Model AC Series

Maintenance Manual

LANDOLL CORPORATION
1900 North Street
Marysville, Kansas 66508
(785) 562-5381
800-428-5655 ~ [Link]
F-528-0511
 Table of Contents

1 Introduction,Safety,Preventative Maintenance
Before You Begin (Please Read) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
For your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Special Notices and Safety Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Lock Out/Tag Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Battery Care and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Towing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
General Safety Tips: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Towing Vehicle Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Towing a Truck in the Reverse Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Lifting and Blocking the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Mast Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Prior to Tilt Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Prior to Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Inspection Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
General Torque Specifications (Rev. 4/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Torque Specified In Foot Pounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Hydraulic Fitting Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Hydraulic Torque Specified In Foot Pounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
General Bendi AC Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

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2 Tires and Brake Assemblies
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Visual Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Replacing the Drive Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Checking Steer Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Disassembling and Inspecting Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Assembling Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Brake System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Check Service Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Replacing the Brake Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Repairing Brake Caliper Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Disc Brake Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Measuring Rotor Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Check Lateral Run-Out (Warping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Replacing the Brake Rotor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Checking Parking Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Replacing Parking Brake Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Replacing Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Replacing the Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Parking Brake Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Changing Parking Brake Pads or Replacing Parking Brake Caliper . . . . . . . . . . . . . . . . . . 2-10
Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Brake Light/Accelerator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Replacing Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Bench Bleed the Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Check Master Cylinder Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Service Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Floor Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Check Planetary Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Adjusting Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Replacing Accelerator Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Exposing and Maintaining the Traction Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Traction Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Inspecting the Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

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3 Hydraulic Components: Motors and Pumps
Steering Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Change the Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking and Adjusting Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydraulic Steering Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Steer Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Motor(s) Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Power Steering System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Check Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Filling and Air Bleeding the Power Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Replacing the Hydraulic Pump and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Hydraulic Steer Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Checking Steer Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Hydraulic Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Hydraulic Control Valve and Switches Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Spool Section Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Hydraulic Lift Pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Hydraulic Fittings and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Check Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Side Shift Circuit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Check Side Shift circuit performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Steering Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Steering Column (Console) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Steering Orbital Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

4 Electrical System
Steering Column/Dash Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Remove the Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Rocker (On/Off) Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Electrical Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Battery - Safety, Care & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Checking Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Cleaning the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Electrical Static Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
ESD Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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 Electrical Controls and Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Direction Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Check the Return-to-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Replacing a Complete Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
High Current Connections Definition: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Horn Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Removing the horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Check Driver’s Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Truck Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Brake and Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Back Up Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Overhead Guard, Lighting and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

5 Bendi AC Calibration and Programming

Controller Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dash Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Truck Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
1314 Bendi AC Controller Software Program Installation and Operation . . . . . . . . . . . . . . . . . 5-3
USB to Serial Port Adaptor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
1314 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
1314 Update Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Communicating with Bendi AC Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Additional 1314 Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Controller Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Monitoring Default Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Factory Set Parameter Details: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Landoll_TM_S Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Landoll_P_S Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Curtis Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
PROGRAM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Controller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Controller Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Programmer Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

6 Truck Lubrication and Chain Maintenance

Lubricating the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tilt Cylinder Clevis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Main Rotation Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Fork Positioner Lubrication, Non-Side Shifting (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Lubricate Steer Wheel Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

iv
 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Measuring Chain Stretch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Check Primary Lift Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Check Lift Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Checking and Adjusting Degree of Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Adjusting the degree of tilt: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Disconnecting the Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

7 Supplier Provided Documentation

Lift Technologies Mast Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Models 30D/35D/40D/50D/55D/60D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

v
vi
 Chapter 1

Introduction,Safety,Preventative Maintenance

Before You Begin (Please Read)

Introduction
This manual is intended for the service technician who is
seeking information on product maintenance and service
replacement parts. It contains troubleshooting tips and
information on repair which will help the technician solve
problems that may occur.

Operating Instructions
This manual does not contain operating instructions.
Operating instructions are sent with each truck. If the
operators manual is missing on your Bendi AC truck, call
Landoll Corporation to order a replacement.

Service Training
Service Training is available for the forklift technician from
Landoll Corporation. This includes operation, repair,
maintenance, hydraulic system, electrical system and
wire guidance. Contact your regional Landoll service
technician for more information.

Tools Needed
Figure 1-1: Serial Number and Capacity Plate
The tools needed will be the same tools that are often
found in well-equipped service centers, in both SAE and
metric sizes. For example, an assortment of open-end
and box-end wrenches, sockets, as well as Allen and
adjustable wrenches, assorted screwdrivers and
non-marring mallets should be available.

Replacement Parts
When ordering parts that will be used for the repair and
maintenance of your Landoll AC truck, the model and
serial number of the truck being repaired will be required.
This information is located on the serial number and
capacity plate located on the front plate of the battery
box. See Figure 1-1.

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INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

General Maintenance Instructions • Check functions of lift systems, directional control,

speed control, steering, warning devices, brakes and


any attachments if any are used.
CAUTION
6. To avoid fire hazards, have fire protection equipment
• Steel toe shoes and eye protection are present.
required when maintaining or repairing a lift 7. Do not use an open flame to check fluid levels, or for
truck. Ear protection may also be required if leakage of electrolyte and fluids or oil.
the repair facilities are excessively noisy, per
8. Do not use open pans of fuel or flammable cleaning
OSHA standards.
fluids for cleaning parts.
• Keep feet and hands and all other body parts
9. Keep shop well ventilated, clean and dry.
away from all mast areas and pinch points.
10. Brakes, steering mechanisms, control mechanisms,
• Power industrial trucks may become
lift overload devices, guards, and safety devices shall
hazardous if scheduled maintenance is
be inspected regularly and maintained in a safe
neglected.
operating condition.
• Therefore, adequate maintenance facilities,
11. Capacity, operation and maintenance instruction
trained personnel and procedures should be
plates or decals shall be maintained in legible
provided and followed.
condition.
12. All parts of lift mechanisms shall be inspected and
maintained in safe operating condition.
IMPORTANT
13. All hydraulic systems shall be regularly inspected
Maintenance and inspection shall be performed in and maintained in conformance with good practice.
conformance with the following practices: Cylinders, valves, and other similar parts shall be
1. A scheduled planned maintenance, lubrication, and checked to assure that “drift” has not developed to an
inspection system should be followed. A daily check the extent that it would create a hazard.
before each shift is an OSHA requirement. 14. Batteries, motors, controllers, limit switches,
2. Only qualified and authorized personnel shall be protective devices, electrical conductors, and
permitted to inspect, maintain and service the truck. connections shall be maintained in conformance with
3. Before leaving the truck: good practice. Special attention shall be paid to the
condition of electrical insulation.
• Stop the truck.
15. Trucks shall be kept in clean condition to minimize
• Completely lower the mast.
fire hazards and facilitate detection of loose or
• Place directional controls in neutral. defective parts.
• Apply the parking brake. 16. Modifications and additions which affect capacity and
• Turn off the power and disconnect the battery. safe truck operation shall not be performed by the
• Block the wheels, making sure that the truck is NOT customer or user without manufacturers prior written
on an incline. Use chocks or other positive approval. Capacity, operation and maintenance
positioning devices. plates or decals shall not be changed accordingly.
4. Before working on the truck: 17. Care must be taken to assure that all replacement
parts are interchangeable with the original parts and
• Perform a Lock Out/Tag Out operation on the truck.
are of equal quality of parts that were originally
• Raise the drive wheel(s) until it is free of floor and/or installed on the truck at the factory.
disconnect the power sources.
18. Be sure that any optional equipment added to the
• Block inner masts, or chassis before working under truck is positioned so that it does not block the vision
them. of the operator or interfere with safe and efficient
• Operation to check performance of truck or operation of the truck.
attachments shall be conducted in an authorized safe
clearance area.
5. Before starting to operate the truck:
• Be in operating position.
• Apply brake.
• Place directional control in neutral.

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 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

For your Safety

Special Notices and Safety Indicators
The below notices are used throughout this manual for
your reference and protection. Attention required.

NOTICE
Special notice - read and thoroughly understand.

 CAUTION  CAUTION
Proceed with caution. Failure to heed caution Battery Safety Rules:
may cause injury to person or damage product. • Wear protective clothing, rubber apron, boots
gloves, and full-face shield when performing
any maintenance on batteries. DO NOT allow
 WARNING electrolyte to come in contact with eyes, skin,
clothing or floor.
Proceed with caution. Failure to heed warning will • If electrolyte contacts eyes, flush immediately
cause injury to person or damage product. with clean water. OBTAIN MEDICAL
ATTENTION IMMEDIATELY!! Should
electrolyte be spilled on skin, rinse promptly
 DANGER with clean water and soap. A baking soda
solution (one pound to one gallon of water)
Proceed with extreme caution. Failure to heed will neutralize acid spilled on clothing, floor
notice will cause injury or death to person and/or or other surfaces. Apply solution until
damage product. bubbling stops and rinse with clean water.
• Keep battery vent plugs firmly in place at all
times, except when adding water or taking
hydrometer readings.
NOTICE • DO NOT bring any type of flame or spark near
the battery.
Lock Out/Tag Out • DO NOT place any electrically conductive tool
on the battery that could cause a spark. Gas
In the interest of operator safety and in compliance with
formed while the battery is charging is highly
OSHA regulations, guidelines have been developed for
explosive. This gas remains in the cells long
performing service and maintenance on the truck. Before
after charging is complete.
performing service and maintenance on the truck, review
the following sections in this manual for additional • Keep the battery clean. Foreign matter in the
procedures to be followed. electrolyte will result in poor battery
performance.
• Follow the battery manufacturer’s
IMPORTANT instructions concerning maintenance and
repair.
When doing maintenance or repair on the Bendi AC
truck, unless the truck must be on for testing, remove
the key from the Keyswitch. In addition, because it’s
possible to have a duplicate key, remove the main
power fuse and install a commercially available Lock
Out/Tag Out device on the battery connectors. Also,
install a lockout warning reminder on the steering
wheel warning that the truck is not available for use.

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INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Battery Removal and Installation

Battery Care and Charging  CAUTION


BATTERY REMOVAL: When removing the battery,
CAUTION move the truck to an area intended for battery
• Only qualified and experienced personnel care, on a level floor.
should perform maintenance and repair on • Turn the Keyswitch to OFF position and
batteries. remove the key.
• Make certain the charger being used matches • Disconnect battery and lock out the truck as
the voltage and amperage of the truck battery. described in the Lock Out/Tag Out section
This voltage is listed on the truck serial plate. described previously.
See Figure 1-1. • Never remove the battery partially without a
• Before connecting or disconnecting batteries stand in place, roller stand or otherwise.
to the charger, make sure the charger is OFF. • Lower load engagement completely.
Attempts made to do this while the charger is
• It is highly recommended that you not remove
ON, could result in serious injury to the
the battery with a load on the mast, but if you
operator and damage could occur to the
must, use a hoist attached to the mast to
charger with sparks or electrical spikes.
protect against tip over.
• Keep sparks or open flame away the battery
• DO NOT allow any metallic object to come in
or the charging area. BATTERY FUMES ARE
contact with the top of the battery. This may
EXPLOSIVE!!
cause a short circuit when removing or
• NEVER smoke or have an open flame near the transporting the battery. Use an insulator
battery. Gas formed during charging is (such as a piece of plywood) to cover the top
explosive and can cause injury. Consult the of the battery during removal.
charger manufacturer’s manual covering your
charger for operation and maintenance.
• The battery must meet voltage requirements
of the truck.

 CAUTION
BATTERY INSTALLATION: When installing the
IMPORTANT battery, move truck to an area intended for
Insure the battery electrolyte levels are full after battery care. The load forks must be all the way
completeing the charge cycles. Damages may occur down to the floor. Turn key or toggle switch to
if not full. OFF position and put the key in a secure place.

Good Battery Care Recommendations:

• Add approved water only - never add acid.
• Keep electrolyte levels proper.
• Keep Battery top clean and dry.
• Keep flame and metal away from battery top.
• Keep vent caps tightened.
• Cool before charging/operating battery above 115ºF.
• Use only approved correct voltage/current charger.
• Keep battery cover open while charging
• If in doubt, call your local Landoll service technician.

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 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Hydraulic System

 WARNING
• HIGH PRESSURE FLUIDS ARE DANGEROUS! Towing Vehicle Requirements
• High pressure hydraulic oil can puncture the
• Towing vehicle must have a pull and braking capacity
skin and cause severe injury!
greater than 8000 lbs.
• Relieve all pressure from the hydraulic
• Brakes on towed truck will operate, but could operate
system before attempting to work on it.
differently verses an operational truck.
• Make sure all hydraulic lines are tight before
• Maximum towing speed should not exceed 2mph.
starting the system. Leaks in the hydraulic
system can pierce the skin and cause severe • Always tow the truck in the reverse direction.
injury. Any fluid injected into the skin under
high pressure should be considered a
medical emergency despite a normal
appearance of the skin. Medical attention by a
specialist in this area should be administered Towing a Truck in the Reverse
immediately. Direction
• Key must be in the OFF position.
• When attaching towing vehicle to lift truck to be
IMPORTANT towed, a removable pin has been provided on the
When maintenance is to be performed on the rear bottom side of the counter weight, See
hydraulic system, make sure the system hydraulic Figure 1-2. Firmly attach tow device to this pin.
pressure is relieved by:
• Towing device must have a pulling capacity of 8000
• Moving the truck to a level area. lbs.
• Have no load on the forks. • Towed vehicle’s forks should be empty and no higher
• Completely lower the mast, or if the mast is the than 12 in. off the ground.
object of repair, have blocks under the mast. • Be careful. With brakes released, vehicle will roll and
• Relieve all system pressure by moving the steering will be difficult.
hydraulic levers in each direction several times. • Remember that the person on the towed lift has to
turn his head to observe operations.
Towing the Truck
General Safety Tips:

 WARNING
• Have the emergency brake applied when
hooking up the tow chain.
• Release the emergency brake only when
ready to tow the truck.
• Tow the truck under 2 mph or less.
• DO NOT make sharp turns when towing the
truck. The towed truck will be difficult to
steer. USE EXTREME CAUTION and keep the
towed vehicle at a slow, manageable speed. Figure 1-2 Tow Pin
• Forks must be empty and preferably not more
than 12” off the floor.
• The truck can roll easily - USE EXTREME
CARE!

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INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

CRANE

SUPPORT
BLOCKS
OF WOOD

WOOD
BLOCKS TO
PREVENT
TIPBACK
AND ROLL

Figure 1-3: Lifting and Blocking the Truck

Lifting and Blocking the Truck • Remove forks before starting mast repairs.
• NEVER reach through the upright open areas of the
1. Move truck to a level area designated for repair. mast.
2. Keep forks empty and low to the ground. • NEVER maintain or repair the mast without supports
3. Remove the key and place in your pocket. or while anyone is near the truck. (ASME
4. Unhook the battery. B56.1-2000)
5. Attach Lock Out/Tag Out device to the truck. • Raise mast and position blocks under the second
stage mast.
6. Use a jack or hoist with a 8000 lb. minimum lift.
• Using an appropriate set of C-clamps, secure
7. Set the lift on designated hardwood blocks. See
wooden blocks to mast channel.
Figure above for block(s) placement.
• Lower mast until it sits firmly on wooden blocks.
8. Keep the height of the lifted truck to a minimum.
• Disable the truck as described in the Lock Out/Tag
Out section.
Mast Service Precautions • For mast inspection, use only an approved safety
platform or step ladder.
 WARNING • NEVER repair chains, they are to be replaced.
When servicing the mast or sections of the mast, • NEVER replace chain sets with only one chain. All
hardwood blocks (4”X4”, 100 X 100mm minimum) chains are to be replaced in pairs.
should be used to keep individual sections of the
mast from falling. In addition to the wood blocks,
chains should be used to hold the mast sections
from moving, in both the vertical and horizontal
directions.

• Mast work to be done in a flat, designated area.

• NEVER walk under or stand upon forklift forks.

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 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Prior to Tilt Cylinder Repair Cleaning the truck

Landoll Corporation recommends that their fork trucks
 WARNING NOT be cleaned with a power washer. Electrical boards,
circuitry and wiring can be damaged by high pressure
• Steel toed shoes and eye protection are water and soap. Moisture and soap left on components
required when doing maintenance or repair can rust, corrode or leave a residue that can damage
work on a lift truck. everything that it comes in contact with. The preferred
• Do not place feet or hands in any areas method of removing dust is compressed air. For localized
through the mast or in truck pinch points. cleaning, use a non-flammable solvent parts washer and
• Servicing the tilt cylinders requires the use of compressed air after the part or area is cleaned.
an overhead hoist, hoist slings and wheel
blocks. The overhead hoist and slings must
have a rating of 8,000 lb. or greater.
• Do not work under or around a truck that is
not properly secured.
Maintenance Introduction
• Truck repair must be in a level, designated area. Preventative maintenance is an important part of all
• Turn the lift off, pull the key and put it in a secure industrial equipment.
place. A well planned preventative maintenance program is
essential to keeping the working environment safe for the
• Lower the mast completely to the floor.
operator and the longevity of the affected equipment.
• Chock wheels so that the truck cannot move. Regular and planned inspections are the responsibility of
• Attach a sling and hoist to all the top cross braces so both the daily operator and the forklift technician.
the mast sections cannot move.

Prior to Mast Removal

• Move the truck to a level, designated area. Inspection Sheets
• Remove the key and place it in a secure place. The following pages are OSHA (Occupational Safety and
• Perform the Lock Out/Tag Out procedure. Health Administration) required check sheets. These
• Remove the forks. sheets should be copied and the copies used for
maintenance checks on your Bendi AC lift. The pre-shift
• Move all levers back and forth several times to relieve
inspection on your AC lift is an OSHA requirement. It is
internal hydraulic pressure.
the operator’s duty to inspect the lift at each pre-shift and
• Slowly and carefully remove the lift cylinder lines. report all problems to the person in charge of forklift
Use a container to catch oil and an oil absorbent maintenance. Have a qualified mechanic correct all noted
product to absorb any spilled oil. problems.
• Disconnect all wiring (if used) between the mast and
the truck body.
The following pages(pages 1-8 thru 1-16) show daily, 50
• Support the mast using the sling and the overhead hour, 200 hour, 600 hour, 1000 hour and 2000 hour
hoist. suggestive maintenance checks. These should be copied
• Chain the individual sections of mast together at the and the maintenance should be followed by daily
upper cross braces. Chain the lower mast carriage to operator and the forklift technicians.
the lower section of the mast, keeping the sections
from moving when the mast is laid down on the floor.
• Remove all pins holding the tilt cylinders to the mast.
• Remove mast and CAREFULLY place the mast in a
horizontal position.

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INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

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

Operators Daily Checklist Status Landoll / Bendi AC

SAFETY & OPERATIONAL CHECKS OK - Yes, Maintenance Note if
Have a qualified technician correct all problems. No Applicable
Load Backrest Extension Solidly Attached.
Tilt Control-Forward/Reverse Functioning smoothly.
Side Shift Control Functioning smoothly.
Hang-on Attachment Functioning smoothly, securely attached, fittings
attached.
Steering Operation Functioning smoothly.
Accelerator & Brake Pedal Functioning smoothly.
Controls (Turn Power On) - Investigate Unusual noises
Dash Display (Hour Meter, Battery Discharge Indicator, etc) Functioning
Properly.
Horn, Lights, Seat Switch Functioning Properly.
Service and Parking Brake Functioning Properly.
Drive Control-Forward/Reverse Functioning Smoothly.
Battery-Check water/electrolyte level & charge - check level again after
charge.
Battery Discharge Indicator Functioning.
Battery Restraint System - Adjust or Fasten.
Hood and seat latch Functioning properly.
Operator’s Compartment Capacity Plate Attached - Info matches Model,
Serial No. and attachments - Operator’s Manual in Case.
Seat Belt, Buckle, and Retractors Functioning Properly.
Overhead Guard Properly mounted & attached.
Hydraulic Oil, Battery, Brake Fluid - Check levels & look for leaks.
Tires-Check for debris, Torque lug nuts - 225ft-lb.(305 Nm)
Finger Guards attached.
Major Structural Points (Front Rotation, Mast Braces, Overhead Guard) -
Check for cracks.
Hydraulic Cylinders, Pump, Valve-Check for leaks, noise.
Safety Warnings Attached (See Manual for location).

Date Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Battery Fluid Hydraulic Oil

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 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

To be performed after 1st 50 hours of truck operation Fluid specifications found on page 1-17.
in addition to the required pre-shift daily inspection

Operators 1st 50 Hour Inspection Status Landoll / Bendi AC

SAFETY & OPERATIONAL CHECKS OK - Yes,No Maintenance Note if Applicable
Have a qualified technician correct all problems.
Mast chains-Inspect, clean and lubricate.
Power Steering System-Inspect and Fill.
Drive wheels, Re-Torque lug nuts 225 Ft-lbs (305
Nm)).
Gear Box-Drain, flush and refill.
Controller - Check for any faults in “History”.

Date Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Battery Fluid Hydraulic Oil

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INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

To be performed after 1st 200 hrs of truck operation Fluid specifications found on page 1-17.
in addition to the required pre-shift daily inspection
Operators 1st 200 Hour Inspection Status Landoll / Bendi AC
SAFETY & OPERATIONAL CHECKS OK - Yes, No Maintenance Note if Applicable
Have a qualified technician correct all problems.
Mast - Inspect all friction surfaces and check lift chain tension.
Lift and Tilt cylinder - Check to be sure they work together and in unison.
Power Steering Pump - Check Operation.
Brake Pedal - Check for free play.
Parking & Service Brakes - Check for effectivity.
Check Contactor Points & Micro Switches operation.
Control Panel - Clean surface.
Hydraulic Oil Pump - Check Operation.
Switches (interlock, direction, parking/seat, key, pressure/temperature) -
Check operation.
Wires, Connections, Bolts and Nuts - Check.

Date Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Battery Fluid Hydraulic Oil

1-10 F-528-0511 Edition

 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

To be performed each 200 hrs of truck operation in Fluid specifications found on page 1-17.
addition to the required pre-shift daily inspection

Operators 200 Hour Inspection Status Landoll / Bendi AC

SAFETY & OPERATIONAL CHECKS OK - Yes, No Maintenance Note if Applicable
Have a qualified technician correct all problems.
Mast, carriage, or attachment friction surfaces - Clean, inspect for wear or
damage and lubricate.
Lift chains - Clean and lubricate.
Extend mast - Check for excessive wear.
Attachment control - Operational.
Accelerator - Functioning smoothly.
Controls (turn power on); Investigate unusual noises immediately.
Instrument monitors - Functioning.
Parking and service brakes - Functioning smoothly, check pads for
excessive wear.
Hydraulic fluid level - Check and fill.
Exterior of hydraulic Tank and Oil Tank Breather - Clean.
Hydraulic oil and power steering pump - Clean dust from motors.
Hydraulic oil and hydraulic motor - Check Hydraulic motor for rough
operation.
Battery - Thoroughly clean.
Battery box and connectors - Neutralize and clean.
Battery - Check electrolyte level and check again after charging.
Battery - Check structure and electrical conditions.
Traction motors - Clean dust.
Seat belt, buckle, and retractors - Functioning smoothly.
Tires - Check for debris, torque lug nuts - 225 ft. lbs. (305 Nm).
Load wheel bearings - Clean and fill with grease.
Leaks - Hydraulic oil, battery, brake fluid, transmission.
Hydraulic hoses and connections - Check for wear.
Switches (interlock, direction, parking/seat, key, pressure, and
temperature) - Check.
Wire connections and sending units - Check.
Grease fittings - Service.
Tighten Overhead Guard Bolts - 170 fT. lbs. (230 Nm).

Date Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Battery Fluid Hydraulic Oil

1-11
INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

To be performed each 600 hrs of truck operation in Fluid specifications found on page 1-17.
addition to the required pre-shift daily inspection

Operators 600 Hour Inspection Status Landoll / Bendi AC

SAFETY & OPERATIONAL CHECKS OK - Yes, No Maintenance Note if Applicable
Have a qualified technician correct all problems.
Tires - Check for debris; drive tire lug nuts - Torque to 225 ft. lbs. (305
Nm)
Wheel bearings - Clean and fill with grease
Leaks - Hydraulic oil, battery, brake fluid, Complete gear box
Hydraulic hoses and connections - Check for wear
Switches (interlock, direction, parking/seat, key, pressure, and
temperature) - Check
Wire connections and sending units - Check
Grease fittings - Service
Forks, top clip retaining pin and heel - Condition
Mast rollers - No greater clearance than 1/16”
Mast chains - Lube with SAE 40W oil or Bowman Heavy Load Red
grease - Check for wear and stretch
Steering operation - Functioning smoothly; Lubricate steering knob
Brake fluid - Check level
Hydraulic oil filter - Change element and check for proper level - Check
pressures
Battery - Check Electrolyte levels and check for physical damage
Contactor points and Micro Switches - Check operation
Control panel - Clean surface
Operator’s compartment capacity Plate Attached - Information matches
model, serial no., and attachments
Check all connections for proper torque

Date Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Battery Fluid Hydraulic Oil

1-12 F-528-0511 Edition

 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

To be performed each 1000 hrs of truck operation in Continued onto the next page for clarity.
addition to the required pre-shift daily inspection. Fluid specifications found on page 1-17.
Operators 1000 Hour Inspection Status Landoll / Bendi AC
SAFETY & OPERATIONAL CHECKS OK - Yes, No Maintenance Note if Applicable
Have a qualified technician correct all problems.
Mast, carriage, or attachment friction surfaces - Clean, inspect for wear
or damage, and lubricate.
Lift chains - Clean and lubricate.
Extend mast - Check for excessive wear.
Attachment control - Operational.
Accelerator - Functioning smoothly.
Controls (turn power on); Investigate unusual noises immediately.
Instrument monitors - Functioning.
Parking and service brakes - Functioning smoothly, check pads for
excessive wear.
Hydraulic fluid level - Check and fill.
Exterior of hydraulic tank and oil tank breather - Clean.
Hydraulic oil and power steering pump - Clean dust from motors.
Battery - Thoroughly clean.
Battery box and connectors - Neutralize and clean.
Battery - Check electrolyte level.
Battery - Check structure and electrical conditions.
Traction motors - Clean dust.
Seat belt, buckle, and retractors - Functioning smoothly.
Tires - Check for debris, torque lug nuts to 225 ft. lbs. (305Nm).
Wheel bearings - Clean and fill with grease.
Leaks - Hydraulic oil, battery, brake fluid, complete transmission.
Hydraulic hoses and connections - Check for wear.
Switches (interlock, direction, parking/seat, key, pressure, and
temperature) - Check.
Wire connections and sending units - Check.
Grease fittings - Service.
Forks, top clip retaining pin and heel - Condition.
Mast rollers - No greater than 1/16”.
Mast chains - Lube with SAE 40W oil or Bowman Heavy Load Red
grease - Check for wear and stretch.
Steering operation - Functioning smoothly; Lube knob.
Brake fluid - Check level.
Hydraulic oil filter - Change element and check for proper level - Check
pressures.
Battery - Check resistance between truck body and negative/positive
terminal.
Battery rollers - Remove, clean, and repack (optional).
Contactor points and Micro Switches - Check operation.
Control panel - Clean surface.

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INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Operators 1000 Hour Inspection Status Landoll / Bendi AC

Traction motor - Clean commutator.
Check all connections for proper torque.
Power steering system - Fill and air bleed.
Motor - Check that terminal studs and mounting bolts are clean and tight.
Motor - Clean cooling holes of debris or restrictions.
Operator’s compartment capacity plate attached - Check information
matches model, serial number and attachments.

Date Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Battery Fluid Hydraulic Oil

1-14 F-528-0511 Edition

 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

To be performed each 2000 hrs of truck operation in Continued onto the next page for clarity.
addition to the required pre-shift daily inspection. Fluid specifications found on page 1-17.
Operators 2000 Hour Inspection Status Landoll / Bendi AC
SAFETY & OPERATIONAL CHECKS OK - Yes, No Maintenance Note if Applicable
Have a qualified technician correct all problems.
Mast, carriage, or attachment friction surfaces - Clean, inspect for wear
or damage, and lubricate.
Lift chains - Clean and lubricate.
Extend mast - Check for excessive wear
Attachment control - Operational.
Accelerator - Functioning smoothly.
Controls (turn power on); Investigate unusual noises immediately.
Instrument monitors - Functioning.
Parking and service brakes - Functioning smoothly, check pads for
excessive wear.
Hydraulic fluid level - Check and fill.
Exterior of hydraulic tank and oil tank breather - Clean and Check.
Hydraulic oil and power steering pump - Clean dust from motors.
Hydraulic oil, Hydraulic lift pump and power steering pump - Check
commutator surface for roughness.
Battery - Thoroughly clean.
Battery box and connectors - Neutralize and clean.
Battery - Check electrolyte level.
Battery - Check structure and electrical conditions.
Traction motors - Clean dust.
Seat belt, buckle, and retractors - Functioning smoothly.
Tires-Check for debris, torque lug nuts to 225 ft. lbs. (305nM).
Wheel bearings - Clean and fill with grease.
Leaks - Hydraulic oil, battery, brake fluid, complete transmission.
Hydraulic hoses and connections - Check for wear.
Switches (interlock, direction, parking/seat, key, pressure, and
temperature) - Check.
Wire connections and sending units - Check.
Grease fittings - Locate, Check and Service all zerks.
Forks, top clip retaining pin and heel - Condition.
Mast rollers - No greater than 1/16”.
Mast chains - Lube with SAE 40W oil or Bowman Heavy Load Red
grease - Check for wear and stretch.
Steering operation - Functioning smoothly; Lube knob.
Brake fluid - Check level.
Hydraulic oil filter - Change element and check for proper level - Check
pressures.
Battery rollers (optional) - Remove, clean, and repack.
Contactor points and Micro Switches - Check operation
Control panel - Clean surface.
Operator’s compartment capacity plate attached - Check Information
matches model, serial no., and attachments.
Check all connections for proper torque.

1-15
INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Operators 2000 Hour Inspection Status Landoll / Bendi AC

Power steering system - Fill and air bleed.
Motor - Check that terminal studs and mounting bolts are clean and tight.
Motor - Clean cooling holes of debris or restrictions.
Gear box - Drain, flush, and refill.
Hydraulic oil - Change.
Hydraulic reservoir suction screens - Clean with solvent.

Date Inspector: Truck No. Model No. Location Serial No. Shift Hr. Meter Battery Fluid Hydraulic Oil

1-16 F-528-0511 Edition

 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Lubrication Specifications
Name Lubrication Notes
Mast Chain SAE W. oil or Bowman Heavy Load Red Grease Clean and re-oil
Mast Rail Chassis Lube or Kendall Sr-12X. Lube inner side of upright rail
Rotation Bearings Texaco Ref. C&C #880 Use standard lubrication gun
Steering Knob Light weight oil Lightly oil
Battery Rollers (opt.) SAE 30W oil Drain, flush, and refill
Reservoir Cap SAE 30W oil Clean in solvent and re-oil
Hydraulic Reservoir Mobil DTE13 (ISO Grade 32) Drain, flush, and refill
Gear Case Mobilube SHC-630 (ISO Grade 220 Synthetic) Drain, flush, and refill
Master Cylinder Heavy duty brake fluid DOT 3 Check level. Add if necessary
Gear Racks Exposed Gear Lube, Mobil 375 NC Aerosol Spray
Carriage Rollers Texaco Ref. C & C #880 Use standard lubrication gun
Hubs, King Pin, and Tie Rod (Steer Axle) Texaco Ref. C & C #880 Brush or spray on lubricant

Figure 1-4: Lubrication Locations

1-17
INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Fluid Capacities
Item Capacity -Quarts (Liters)
Hydraulic Tank 11.6 gallons (44 liters)
Brake Fluid 0.21 quarts (0.20 liters)
Gear Box 16 oz.

Torque Specifications
Component Torque
Wheel 225 ft. lbs. (305 Nm.)
Fluid draining and filling plug 16 ft. lbs. (22 Nm.)
Hydraulic braking unit and brake cable 37 ft. lbs. (50 Nm.)
Drive motor with vehicle frame 130 ft. lbs. (176 Nm.)
Hydrostatic Steering Control Unit
Plug and o-ring assy #8 SAE fitting 44-48 ft. lbs. (60-65 Nm.)
Steer 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 Side Shift Mechanism
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.)
Overhead Guard Bolts 170 Ft-lbs ( 230 Nm.)

General Torque Specifications (Rev.

4/97)
This chart below 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-di-sulfide 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.

1-18 F-528-0511 Edition

 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Torque Specified In Foot Pounds

UNC SAE SAE SAE UNF SAE SAE SAE

SIZE Grade 2 Grade 5 Grade 8 SIZE Grade 2 Grade 5 Grade 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 [13] 18 [22] 5/16-24 9 [11] 14 [17] 20 [25]
3/8-16 15 [19] 23 [29] 35 [42] 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] 1010 [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 Nominal
thread Newton-Meters Foot-Pounds Thread Newton-Meters Foot-Pounds
diameter (Standard (Standard Diameter (Standard (Standard
(mm) Torque) Torque) (mm) Torque) Torque
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 [125] 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]

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INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Hydraulic Fitting Torque

Specifications
37 degree JIC, ORS, &ORB (REV. 10/97)
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-di-sulfide 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.

Hydraulic Torque Specified In Foot

Pounds
Parker® Brand Fittings
Dash Size 37 Deg. JIC O-ring (ORS) O-ring boss
-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 58-62
-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

Aeroquip® Brand Fittings

Dash Size 37 Deg. JIC O-ring (ORS) O-ring boss
-4 11-12 10-12 14-16
-5 15-16 --------------- 16-20
-6 18-20 18-20 24-26
-8 38-42 32-35 50-60
-10 57-62 46-50 75-80
-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

1-20 F-528-0511 Edition

 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

General Bendi AC
Troubleshooting Chart
Shown on the following page is a general Bendi AC
troubleshooting chart that will allow the service
technician to diagnose areas of failure, by way of audible,
performance and pump conditions and then proceed to
the proper chapter in this Maintenance Manual for
detailed service.
Condition Cause Suggested Repair
AUDIBLE PROBLEMS
Back up alarm does not sound. Faulty alarm module. • Continuity check alarm module-replace as
needed.
Electrical problem-frayed or • Check related wire harnesses and connectors
broken wires, faulty direction for contact problems, broken wires, etc.
• Examine cable assemblies - tight connections.
control switch or electronics.
• Wire terminal crimps should be secure and
wire stranding must not be frayed or corroded.

Unusual noise when truck is in Rubbing or binding brake pads • Attempt to isolate cause of noise.
motion. in rear wheels (possible frozen • Drive truck slowly having another operator
check for the unusual noise.
caliper).
• Step on brakes lightly to see if brakes are
binding or rubbing excessively - repair or
replace.
Faulty gear box assembly. • Replace if defective.
Singing noise. Insufficient fluid level in gearbox. • Check fluid level. Check and add lubricating oil
as needed.
Faulty motor bearing. • Repair or replace bearing or motor.
Muffled grinding noise. Faulty wheel bearings - could be • Determine if noise is in the front or rear.
insufficient fluid or high
pre-stress or excessive play on
bearings.
Damaged planetary step • Dismount gear box and examine for damage.
gearing - could be insufficient
fluid, excessive play in bearing.
Clicking noise during a turn. Loose or shifting component. • Try to isolate the area of the noise, then check
for loose parts, misalignment, load shifting,etc.
• Check that components are in place and prop-
erly torqued.
Horn does not work. Faulty horn assembly or push • Disconnect horn wires and push button - conti-
button. nuity test horn with leads connected to battery
power.
• Check related wire harnesses and connectors
for contact problems, broken wires, etc.
• Examine cable assemblies for tight connec-
tions.
• Wire terminal crimps should be secure and
wire stranding must not be frayed or corroded.
Blown fuse. • Check fuse.
• Check for electrical shorts in wiring or compo-
nents.
Rubbing noise from the front Faulty wheel bearing or • Dismount suspected wheel and examine bear-
wheels. damaged wheel shaft. ings and shaft.
• Check for foreign material lodged inside wheel
hub - remove and repair and/or replace as
needed.

1-21
INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Condition Cause Suggested Repair

Scraping noise when the mast is Out of alignment. Faulty • Realign and shim mast rails accordingly.
operated hydraulic cylinder - lift, tilt and/or Determine which cylinder is bad-rebuild or
replace. (Seal kits are available for repair)
shift.

PERFORMANCE
PROBLEMS
NO operation! Battery disconnected or • Make sure battery installed is a 48 VDC bat-
insufficient charge. tery.
• Check battery for connection.
• Check battery for full charge.
Emergency STOP (disconnect) • Check push button and if necessary, release
push button is pressed. push button.

• Place the direction switch in NEUTRAL before

Improper start-up sequence.
power on.
• Remember to wait about ten (10) seconds
after power on to allow diagnostic testing.
• Check main power fuses (425 Amp).
Blown fuse. • Check for electrical short, or electrical connec-
tions.
Bad Keyswitch • Check keyswitch fuse
• Possible faulty horn - check horn.
Poor truck performance. Battery undersized. • Refer to capacity plate for battery rating and
install battery with proper ratings.
Undercharged battery. • Return truck to charging station and check
Excessive electrolyte loss. battery characteristics.
• Adjust specific gravity at state of full charge.
Service brakes do not stop the Low fluid level in master cylinder • If low, check for leaking fittings or lines -
truck. reservoir. tighten and/or replace. Add brake fluid and
bleed brakes if needed.
• Also check wheel calipers for leaks -rebuild or
replace.
Worn brake pads. • Check brake pads for wear or defects -always
replace both sides.
Brake pedal linkage adjustment. • Check linkage for loose nuts, broken or
stressed linkage, mis-adjustment - repair and
re-adjust. Reference “Service Brake Linkage”
on page 2-11.
Brake pad contamination. • If the pads are saturated, they must be
replaced.

1-22 F-528-0511 Edition

 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Condition Cause Suggested Repair

Spongy or soft service brake Possible air in brake lines. • Bleed air from brake lines - indicated by bub-
pedal. bles in fluid during fluid bleed, or when check-
ing the master fluid reservoir.
• 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.
Faulty master cylinder. • Examine the brake lines, wheel calipers and
master cylinder for leaks - repair immediately,
then bleed the brakes.
• Also check master cylinder piston for worn
seals. Reference “Master Cylinder” on
page 2-12.
• 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.
Faulty brake caliper. • Check brake caliper for leaks - rebuild or
replace.
Parking brake does not hold the Brake cable system malfunction • Check parking brake linkage for loose nuts,
truck. or out of adjustment. broken or stressed linkage, mis-adjustment -
repair and readjust. See page 2-8.
Steering drifts/wanders or is Improperly sized tires. • Check Identification plate for proper fit and
erratic. replace if not proper size
Low fluid or leaks in power • Check hydraulic fluid level -replenish as nec-
steering system. essary.
• Check all related components for seal or fitting
leaks - repair or replace.
Worn or out-of-adjustment steer • Check motion control valve cartridges for for-
assembly. eign material (these are replaceable car-
tridges and will wear out over time).
• Failed or weak orbital centering spring will
cause the steering to drift - replace accord-
ingly.
• 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.
Insufficient hydraulic pressure. • Check hydraulic pressure of steering relief
valve (2,600 psi).
• Check steering motor for internal or seal leaks,
sticking or mis-adjustment - repair or replace.
Steering potentiometer • Perform dash calibration.
misaligned.
Worn, loose wheel bearings. • Check wheel bearings - replace as needed.
Air in the hydraulic system. • Check the inlet connections to determine
where air is being drawn into the system.
• Internal leaks? Tighten loose connections.
• Bleed hydraulic system.

1-23
INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Condition Cause Suggested Repair

Hard steering effort in one or both Improperly sized tires. • Inspect/correct tire size.
directions. • Vehicle overloaded. NEVER exceed capacity
of the truck.
Vehicle overloaded. • Check capacity nameplate for tire specs.
• Never exceed vehicle capacity. Low hydraulic
fluid.
Low hydraulic fluid. • Check/fill hydraulic oil level, Low flow rate or
fluid pressure.
No and/or low flow rate or fluid • Restriction in fluid return line. Remove line,
clean and/or replace line.
pressure.
• Check pump and priority valve.
• Check hydraulic pressure - 2,600 psi.
Components in steering linkage • Check for steering column, orbital, front rota-
binding or making noise. tion bearing noise.
Drive tires scrubbing. • Check steer pot settings. Adjust or replace.

Lost motion at the steering wheel. Steering wheel loose on column • Check and re-torque the steering wheel lock-
or stripped. ing nut.
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.
Internal Hydraulic Leak • Repair and check hydraulic steer components.
Truck does not turn. Hydraulic pump not activated. • Check that the hydraulic pump/motor is acti-
vated when the operator is on the seat and the
direction is selected.
Truck moves slowly. Battery may be too low. • Check battery charge state and recharge bat-
tery, if necessary. A discharged battery
reduces effective voltage across the traction
motors and control circuits. Slow travel speeds
and erratic contactor operation may result.
Traction motor encoder error. • Verify encoder is operational.
Faulty accelerator switch • Replace accelerator switch module.
module. • If overheating is suspected, turn OFF the
truck, and allow time for the system to cool.
While the truck is cooling, check the following:
Overheated motor or motor • Check motor compartment cooling fan to
controller (thermal cutback). ensure they are operating and clean.
Truck has gone into LOS Mode • Look at dash display to check for errors.
“Loss Of Sensor” also known as Record fault code to determine problem -
Refer to page 5-41, Program Troubleshooting
“Limp Home Mode”
Chart definitions.
Truck does not move. Battery charge state may be too • Check battery charge state & recharge battery
low. if necessary.
• Check dash display for fault condition. Refer to
System fault is present.
controller troubleshooting if fault is present.
See page 5-41.
Faulty direction control lever. • Check that the direction control forward-neu-
tral-reverse control is functioning properly.
Faulty accelerator switch • Repair accelerator switch.
assembly.
Open armature on traction • Repair or replace.
motor.
Creep speed or acceleration Control panel system is • Re-adjust the control panel.
sluggish. mis-adjusted. • Refer to Chapter 5 - Multi-Function operation.

1-24 F-528-0511 Edition

 INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Condition Cause Suggested Repair

Mast lifts slowly - loss of lift speed. Attempting to lift a load in excess • NEVER attempt to lift a load heavier than the
of the truck’s capacity. specified rating of the truck.
Faulty lift pot. • Adjust or replace.
Battery charge state may be too • Check battery charge state and recharge if
low. necessary.
Controller output incorrect. • Check settings.
Insufficient pump or relief valve • Check settings.
pressure setting.
Mechanical damage of the mast. • Repair or replace.
Hydraulic cylinders leaking. • Repair or replace.
Mast drifts downward. Excessive load - attempting to lift • Never exceed truck lift ratings.
loads beyond the capacity of the
truck.

Lift hydraulic cylinders leaking or • Oil may be bypassing between the spool and
binding. body - repair or replace directional control
valve.
Faulty lift control valve. • The spool is not centering properly or is bro-
ken - repair or replace lift control valve.
• Check Chapter 7, for vendor service informa-
tion, where applicable.
Mast does not lift load. Attempting to lift a load in excess • NEVER attempt to lift a load heavier than the
of the truck’s capacity. specified rating of the truck.
Faulty lift pot. • Replace lift pot.

Battery charge state may be low. • Check battery charge state & recharge battery
if necessary.
Low hydraulic oil. • Low levels can cause the cylinder to “cavitate”
and not permit full lift of the mast. Add hydrau-
lic oil.
Faulty hydraulic control valve. • Bent or damage plunger, worn internal seals -
repair or replace as needed.
Insufficient system pressure. • Check hydraulic pressure of system relief
[Link] re-adjusting the pressure relief
valves. Maximum system pressure must not
exceed 2,800 psi. See page 3-7.
• Check valves for seal leaks, sticking or misad-
justment.
• Repair or replace and/or readjust accordingly.
• If problem persists, replace the relief valve car-
tridge.
• Check settings.
Faulty pump. Note: If the pump
• Replace the pump.
were faulty, other mast functions • Determine which cylinder is leaking or binding
would also be affected. - rebuild or replace. Seal kits are available.
Blown fuse. • Check lift pump control fuse.
Mechanical mast damage. • Check mast for damage and signs of misad-
justment.

1-25
INTRODUCTION,SAFETY,PREVENTATIVE MAINTENANCE

Condition Cause Suggested Repair

Mast does not tilt. Inoperative tilt directional control • Repair or replace.
valve.
• Continuity test switch. Replace if defective.
Faulty switch.
• Check settings.
Insufficient pump or relief valve • Adjust pressure.
pressure.
• Follow recommended maintenance schedule.
• Check Chapter 7, for vendor service informa-
tion, where applicable.

Restricted or leaking supply • Locate restriction or replace hose. Tighten fit-

hoses. tings to seal any leaks.
Hydraulic cylinder leaking or • Shift cylinder is leaking or binding-rebuild or
binding. replace. Seal kits are available for most cylin-
ders.
Controller output incorrect. • Check settings via the 1314 software program
in Chapter 5 Calibration and Programming,
page 5-3.
PUMP PROBLEMS
No hydraulic pressure. Pump driven in the wrong • Change the drive direction immediately to pre-
direction of rotation after vent seizure.
• Correct the pump cartridge ring position for
servicing.
each direction of rotation.
Coupling or shaft sheared or • Disassemble the pump and check the shaft
disengaged. and cartridge for damage.
Oil intake line is restricted. • Check all strainers and filters for dirt and
sludge - clean or replace.
• Completely drain the system.
Fluid viscosity too heavy to pick • Add new filtered oil of the proper viscosity.
up prime.
Leaking fluid. Cracked or cut hoses. • Replace. NEVER attempt to patch a hose.
• Tighten and/or replace.
Loose or faulty hose clamps. • Tighten and/or replace. Be careful not to strip
Loose or faulty hydraulic the threads, rendering the fitting defective.
fittings.
Oil seals deteriorated. • Disassemble the unit and replace the oil seals.
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.
Air leaks at the intake or shaft • Check intake lines (hoses and fittings) and
seal. (Oil in reservoir would seals for leaks. Repair all leaks.
possibly be foamy.)
Damaged pump/motor mount. • Repair and/or replace.
Significant loss of speed under Lack of sufficient oil supply. • Check for faulty relief valve and adjust or
replace as required.
load. • Check for and repair worn pump.
High internal motor leakage. • Check for correct oil
Excessive heat source. • Locate excessive heat source, usually a
restriction in the system, correct the condition.
Severely worn or damaged • Disassemble unit and replace worn rotor set,
internal splines. drive link and replace pump.

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 Chapter 2

Tires and Brake Assemblies

Tire Inspection Visual Tire Inspection

1. Inspect the tires for chunking (or chipping),
 WARNING embedded foreign material (wire, rocks, glass, metal,
etc.), cuts, gouges, undercutting or uneven wear.
The truck is equipped with tires of a size and Remove any object that will cause damage.
hardness that provide the necessary traction and 2. Check for loose or missing hardware.
still maintain a proper shape to minimize tipping.
3. Remove any wire strapping or other material that is
To maintain stability and maximum reliability, you
wrapped around the inside of the wheel.
must always replace tires with the type originally
supplied and torqued to specification as listed on 4. Make sure drive wheel nuts are tight. Tighten the
the specification sheet on page 1-18. wheel nuts in a cross pattern to a correct torque
value (225 ft. lbs (305 Nm)).

Chunked tires or Embedded Objects

IMPORTANT
It is recommended to replace worn tires in pairs. IMPORTANT
Treaded drive tires must be replaced when the tread
• Chunking, or chipping is caused by repeatedly
depth is less than 0.0625” (1.6mm) at the deepest
running over objects on a littered floor which can
point.
chip away or produce deep cuts to the rubber
Careful driving habits add additional miles to tire life. surface of the tire. Embedded objects, such as
glass, metal chips, or nails left in a tire, and truck
NOTE overloading cause the same effect.
• Check all wheel nuts after 2 to 5 hours of operation • Sharp, rapid turns at quick speeds, jack-rabbit
when new lift trucks begin operation and on all lift starts and stops and other such bad driving
trucks when the drive wheels have been removed habits can cause the same kind of damage.
and re-installed.
1. Remove any embedded foreign material from the tire
• Tighten the nuts in a cross pattern to the correct as soon as it is noticed. Also remove torn pieces of
torque value shown in the Routine Maintenance tread.
Schedule located in Appendix A of the Bendi AC
2. To avoid overloading, always center the payload on
Operator's Manual (F-522-___).
the truck to equalize the load on all tires. Do not
• When the nuts stay tight for eight hours, the interval dangle the load on the ends of the forks. Also avoid
for checking the torque can be extended to 200 fast cornering, which can cause an overload affect.
hours.
3. If the tires are chunked bad enough to produce a
bouncy ride, replace them.

2-1
TIRES AND BRAKE ASSEMBLIES

Undercutting and Uneven Wear Extending Tire Life

A few simple measures can help increase tire life and
IMPORTANT reduce maintenance (downtime) and cost of operation:
• Undercutting is caused by continuous overloads, 1. Inspect tires regularly and remove embedded objects
rapid, sharp turns, operating on slopes, a faulty immediately.
steer axle, transporting loads with a high center 2. Check that the tires remain centered on the wheels.
of gravity, or transporting off-center loads.
3. Lubricate the truck according to the schedule
• Uneven tire wear is usually the result of provided in Chapter 1, page 1-18; however, avoid
mechanical defects, such as badly adjusted over lubrication.
brakes, misaligned wheels (misaligned steer
axle), or a faulty drive axle. 4. Keep runways clean and maintain floors in good
repair, free from breaks, ruts, cracks and debris.
1. Undercutting causes the rubber to bulge out over the
edge of the steel band, cutting the rubber just above 5. Avoid excessive heat, overloading and standing
the base band. loads.
2. Check that the tires remain centered on the wheels to 6. Regularly check axle alignment and steering.
prevent splitting of the base band and tread 7. Avoid sharp turns and quick starts and stops.
separation. 8. Avoid oil, grease, gasoline and acid. Wipe these
3. Correct defects as soon as possible. compounds off as soon as possible.
9. Do not allow hydraulic oil to drip onto the tires.

Flat-spotting
Replacing the Drive Tires
IMPORTANT
Flat-spotting occurs when:  WARNING
• The truck has been sitting idle for some time after Make sure that replacement drive tires are of the
heavy use and is usually caused by the tires same size and composition as originally supplied
overheating. by Landoll Corporation. Tire composition can
• The truck has standing loads (loads left on the affect braking, capacity, turning and operator
forks overnight). safety. These tires are in interference type,
• Locking the brakes while traveling in either meaning the tires are pressed on and pressed off.
direction on grades (slopes), with or without a Both drive tires must be replaced at the same
load, causing excessive skidding. Polyurethane time to maintain uniform size, performance and
tires are extremely susceptible to this type of stability.
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
 CAUTION
tire structure. Shields which prevent heat from Replacing pressed-on tires should be done only
striking tires directly will often prolong life. by technicians who have been specifically trained
for this procedure and have the specific tools to
2. Avoid standing loads. Solid tires will flat-spot when
perform this job.
loads are left standing on the truck overnight. In
extreme cases, a flat spot develops and the tire
bounces with every revolution. 1. Park the truck at a level, designated work area.
3. If the tires are flat-spotted bad enough to produce a Lower the forks and chock the wheels.
bouncy ride, replace them. 2. Perform a Lock Out/Tag Out procedure as explained
4. Do not indulge in stunt driving or horseplay where on page 1-3.
excessive hard braking is needed, especially on 3. Lift the truck so that the tires are just off the floor.
grades (slopes). 4. Remove the lug nuts and the drive tire assembly from
the drive train.
5. Press existing tire off the hub.
6. Verify that the replacement tire has the same specs
as what Landoll specifies.

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 TIRES AND BRAKE ASSEMBLIES

7. Press replacement tire onto hub. Make sure the

outside of the tire is flush with the hub. NOTE
8. Install tire/hub assembly onto the truck and finger Pre-pack the bearings with grease before replacing.
tighten the lug nuts. Bearing cups and cones as should be replaced as a set.
9. Torque lug nuts to 225 ft. lbs. (300 Nm.)
Assembling Wheel Bearings
1. If bearing cups are replaced, clean hub and press
new bearing cups into hub. See Figure 2-1.
Checking Steer Wheels
2. Pack wheel bearings with grease.
1. First, review Before You Begin beginning on 3. Place outside face of wheel down on bench. Insert
page 1-1. inner bearing and carefully drive seal in until flush
2. With the truck raised and supported, spin each wheel with hub.
and check for noise, rolling resistance and free play. 4. Carefully slide hub, bearing, and seal assembly onto
3. Rock the wheel in and out on the spindle. If there is spindle.
any noticeable movement, the bearings should be
checked and then repacked with grease and/or IMPORTANT
replaced.
Be careful! Avoid damaging grease seal. A damaged
seal must be replaced.
NOTE
5. Insert outer bearing cone and washer. Tighten hex
• The truck is equipped with tires of a size and slot nut against spindle washer.
hardness that provide the necessary traction and still
maintain a proper shape to minimize tipping. To 6. Adjust bearing preload by slowly rotating hub while
maintain stability and maximum reliability, you must tightening hex slot nut until resistance is felt.
always replace tires with the type originally supplied. (Approximately 75 ft./lbs) Back nut off 1/16 of a turn
or until a notch aligns with the spindle cross-hole.
• It is also recommended to replace worn tires in pairs.
Treaded drive tires must be replaced when the tread 7. Readjust if the wheel does not rotate smoothly.
depth is less than 0.0625” (1.6mm) at the deepest 8. Secure nut in place with a new cotter pin.
point. 9. Ensure that the cavity between the two wheel
bearings is filled with grease by injecting grease into
the grease fitting at the top of the steering yoke until
Disassembling and Inspecting grease flows through outer bearing.
Wheel Bearings 10. Apply a thin layer of grease to the hub cap o-ring and
1. First, review Before You Begin on page 1-1. press hub cap into hub.
2. Throughout these instructions, See Figure 2-1. 11. Reinstall wheel and tire assembly.
3. Lift axle and support so that wheels are free to rotate.
4. Measure the tire diameter. If the diameter of the tire SEAL
INNER BEARING
is less than 13”, Landoll recommends that the tire be
O-RING
replaced. HEX SLOT NUT
5. Remove hub cap, 5/32” x 1-1/2” cotter pin, 1-14” hex SPINDLE WASHER
slot nut, spindle washer, and outer bearing cone. OUTER BEARING
6. Slide hub/wheel assembly from spindle. Remove
inner bearing cone and seal from hub.
7. Clean bearing cones and seal. Clean bearing cups
inside hub.
8. Examine for wear or damage. Replace bearing if COTTER PIN
rollers are pitted, rusted, or cracked.
9. Replace bearing cups if cups are cracked or pitted. TIRE/WHEEL ASSY
10. Replace seal if worn or damaged. HUB CAP

Figure 2-1 Wheel Bearing Inspection

2-3
TIRES AND BRAKE ASSEMBLIES

Brake System Check Service Disc Brakes

• The service brakes are hydraulically-actuated, disc
IMPORTANT brakes, similar to an automotive disc brake system.
• Safety must always be paramount when working The brake calipers are installed to the gear box /
on brake system components. motor assembly, on the two rear drive wheels only.
• Parts that are not in perfect working condition • The brakes should be checked every 100 hours of
should not be used. It is recommended to only operation. Normal brake pad life should reach
use genuine Landoll parts. approximately 3,000 hours of operation, but that
figure can vary widely as determined by the operator
• If you are unsure about a procedure, seek and driving conditions. If you are near or beyond this
professional help. time frame, you must inspect the brakes.
• Wear eye protection. If brake fluid comes in • New brake pads are approximately 0.265” (6.7 mm)
contact with eyes, immediately rinse with water thick. Replace them when the pad thickness is
and seek medical attention. 0.0625” (1.588 mm) or less.
• Use only DOT #3 brake fluid.
• Brake fluid will damage paint. Cover all body NOTE
parts and be careful not to spill brake fluid during A few indications of possible brake pad replacement are:
brake maintenance.
• Excess travel of the service brake pedal.
• Brake pads must be replaced on both wheels at
• The truck pulling to one side when the brakes are
the same time. NEVER replace the pads on only
applied.
one wheel to ensure that both sides have equal
braking and to prevent premature wear and • Squealing is heard when you apply the brakes.
uneven braking action. • Drive the truck at creep speed and apply brakes
• Do not use petroleum based solvents to clean lightly, to determine if brakes pads are contacting the
brake parts. Use only brake cleaner or denatured disk (rotor). You should feel a slight pulsating effect
alcohol. as the pads contact the disk.
• Do not use compressed air to blow particles from • If any of the above occurs during brake inspection,
the brake assembly. see “Brake System,” beginning on this page.
• Make sure you strictly adhere to all clearances • The service brake pedal must also have about 1/2”
and torque specifications. (12.7 mm) of the travel remaining when the brakes
are fully applied. If less than 1/2” (12.7 mm) is
• When you are finished working on the brakes,
available, check the pads for wear and replace as
test them carefully under controlled areas before
needed.
releasing truck for operation.
• If the contact surfaces of the rotor show cracks, To Check the Brakes
score marks, deep grooves, a raised lip on the
The brakes are located in the rear end attached to the
outer edge, or signs of overheating or warping,
drive motors.
the rotor must be replaced.
1. First, review Before You Begin on page 1-1.
• If a problem is suspected, do not release or drive
the truck until the problem is corrected. 2. Set the Keyswitch to OFF and remove the key from
the Keyswitch.
3. Place blocks in front of and behind all other wheels
Brake System Overview not being serviced.
4. Perform a Lock Out/Tag Out procedure and
NOTE disconnect the battery.
Braking of the Bendi AC truck is accomplished by using 5. Remove the battery.
the drive motors for restraining the truck, or by putting 6. Remove the battery tray to expose the brake
pressure on the brake pedal. When the accelerator is assembly. See Figure 2-2.
released, the moving motion of the truck is restrained by
7. Remove the 3/8”-24 X 1-1/2” hex headed cap screws
the drive motors, this occurs in both the forward and
securing the brake caliper assemble to the mounting
reverse direction. Stopping the truck can also be done by
plate. Capture the spacers (if used) and keep any
the normal pressing of the brake pedal.
shims separate for each side.

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 TIRES AND BRAKE ASSEMBLIES

8. Check the rotor for scoring, caused by excessively 10. If replacement is needed, always replace pads on
worn brake pads. both sides of the truck. Also see “Changing Brake
9. Check the pad thickness using a 6” scale or Pads”, below, on this page.
micrometer (if the pads are removed). New brake 11. Check brake lines for leaks, Repair leaks
pads are approximately 0.265” (6.7 mm) thick. If the immediately.
pads are 0.0625” (1.588 mm) or less at the thinnest
point they must be replaced.

Brake Rotor

Brake Caliper

Emergency Brake Assembly

Figure 2-2: Brake Assembly

Changing Brake Pads 11. Remove the two outer hex head screws and
hardware to allow pads to be removed from caliper
1. See Figures 2-2 and 2-3 for reference. assembly.
2. Set the Keyswitch to OFF and remove the key from 12. Remove both old disk brake pads.
the Keyswitch.
13. Push the piston into the caliper bore to provide
3. Initiate a Lock Out/Tag Out procedure. clearance between the new brake pads and the rotor
4. Apply the parking brake and disconnect the battery. during assembly.
5. Make sure all the other wheels are securely block so 14. Check the contact surfaces of the brake rotor for
that the truck cannot move. cracks, score marks, deep grooves, a raised lip on
6. Remove the battery. the outer edge, signs of overheating or rotor run-out.
If any of these are preset, the rotor must be replaced.
7. Remove the battery tray.
8. Remove the 3/8”-24 X 1-1/2” hex headed cap screws NOTE
securing the brake caliper assemble to the mounting
plate. Capture the spacers (if used) with and keep If the rotor must be replaced on a Bendi B30 you must
any shims separate for each side. loosen the drive motor and move it out slightly to allow
room to remove the rotor, although on a B40 or larger
9. If preferred, although not necessary, disconnect the
truck moving the motor laterally is not required.
brake lines, using a flare-nut wrench. Plug or cap the
ends to avoid fluid loss and contamination. 15. Also look for the presence of surface glazing, grease
or brake fluid on the brake pad contact surfaces.
10. Be prepared to clean any brake fluid spills. DO NOT
Grease and brake fluid can be removed using
spill brake fluid on caliper housing.
denatured alcohol or brake cleaner. However, if the
shoes become contaminated, they must be replaced.

2-5
TIRES AND BRAKE ASSEMBLIES

16. Check the brake lines for cracking, splits or any 22. Reassemble and check the truck. Connect the
apparent weakness. Replace as needed. battery and check for proper brake operation as
17. Check both brake caliper pistons for signs of fluid follows:
leakage, indicating a seal which must be replaced. • Accelerate the forklift to full speed.
18. Tighten the new brake pads and reassemble the • Apply the brakes to quickly STOP the wheels.
caliper (two outer hex head screws and hardware). • Release the brake pedal after the wheels stop, then
19. Install the brake caliper assembly to it’s brake caliper accelerate again to full speed.
mount. Ensure correct number of shims are installed • Release the accelerator pedal to allow the truck to
between the caliper and the mount. Pads should coast to a stop.
have the same clearance from the disk prior to
• Both wheels should have equal amounts of
actuation of brakes.
resistance.
20. Bleed the brakes if any brake lines have been
• Repeat this procedure two times in forward and
disconnected, making sure to add new fluid.
reverse directions. If the forklift does not perform as
21. Top off the master cylinder with new brake fluid. stated above, reinspect the brake calipers for wear.
Pump the brakes several times to seat the new brake
• Make a few normal stops in forward and reverse to
pads.
allow the brakes to further seat themselves. Do NOT
lock the brakes which could cause tire flat spots.

Figure 2-3: Bleeder screws and Brake Mechanism

Replacing the Brake Caliper to prevent premature wear and uneven braking
action. Whenever a brake caliper is disconnected, it
Assembly is recommended that the entire brake system be
purged of old brake fluid.
IMPORTANT 1. Repeat steps 1 through 8 of section “Changing Brake
Whenever servicing or replacing a caliper assembly, Pads” on page 2-5.
it is recommended to service both sides of the truck 2. Remove brake caliper assembly.

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 TIRES AND BRAKE ASSEMBLIES

3. Install the new caliper assembly in reverse order 8. Install the O-ring seal to the pistons and slide the
making sure the brake pads are properly installed. pistons into the housing bore. Make sure the O-ring
4. Bleed the brakes. seals do not twist as the piston is inserted.
5. It is recommended when replacing a brake caliper 9. Bottom out the piston into the bore, install new brake
assembly, you should purge the entire brake system pads. Reinstall caliper assembly onto caliper bracket.
of used, possibly contaminated fluid. 10. Bleed the brakes.
11. Repeat steps 19 through 20 of the section “Changing
Brake Pads” on page 2-5.

Disc Brake Rotors

IMPORTANT
• Whenever servicing and/or replacing a rotor
assembly, you must service both sides of the
truck to prevent premature wear and uneven
Repairing Brake Caliper Pistons braking action.
• Repeat steps 1 through 6 of preceding section
IMPORTANT “Changing Brake Pads”, beginning on page 2-5.
If the brake caliper piston freezes up or shows signs • Check the rotors for scoring, cracks, deep
of leakage, it must be repaired or replaced. grooves, raised lip on the outer edge, signs of
Whenever servicing or replacing a caliper assembly overheating, rotor run-out or other damage.
or internal parts, you must service both sides of the Rotor run-out should be measured while the rotor
truck to prevent premature wear and uneven braking is installed.
action. • 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
1. Repeat steps 1 through 8 of the section “Changing
calibrated micrometer, calibrated in
Brake Pads” on page 2-5.
ten-thousandths of an inch, to check thickness.
2. Remove the brake caliper assembly from the truck. See Figure 2-4.
3. Restrain the piston in the caliper to stop 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 will eject and cause damage to the piston
or the technician. Stand back from the piston while
air is being applied.
4. Once the piston releases, remove the O-ring seals
and discard. Be careful not to scratch metal surfaces.
Do not use metal tools when removing the seal.
Figure 2-4 Rotor Micrometer
5. Remove both bleeder screws.
6. Inspect the piston and the caliper housing bore for
corrosion, worn plating, scoring, nicks, etc. Crocus
cloth may be used to polish out light corrosion only. If
extensive corrosion exists, the entire brake caliper
assembly must be replaced.
7. Thoroughly wipe out the bore area and clean all
parts, lubricate the pistons, caliper and O-ring seals
with fresh, DOT #3 brake fluid.

2-7
TIRES AND BRAKE ASSEMBLIES

Measuring Rotor Thickness 7. Depending on the model and the amount of

clearance available, you may have to remove one of
the drive motors to remove the rotor from the
IMPORTANT
armature.
• Measure thickness, using a micrometer, at four or
more points on the rotor and make sure all IMPORTANT
measurements are taken at the same distance in
from the outer edge of the rotor. The removal of the drive motor can be done as a
completed assembly. It needs to be slid out just
• Thickness variations of more then 0.0005” (0.013 enough for the rotor to clear.
mm) can cause pedal pulsation and/or vibration
when applying the brakes. A rotor that does not 8. Slide the rotor assembly from the keyed drive shaft
meet these specifications must be replaced. and discard. Do not lose the woodruff key.

IMPORTANT
Check Lateral Run-Out (Warping) When handling the new rotor, protect the finish
1. Raise, jack up, and block both sides of the truck to surfaces from damage, such as nicks, deep
allow the drive wheel to rotate freely, See "Lifting the scratches, dents from dropping, corrosion, oil or
Truck," page 1-6. grease contamination, etc. Damage to the braking
2. Secure the dial indicator to the drive wheel electric surfaces renders the rotor or pads defective.
motor casing so the indicator button contacts the 9. Install the new rotor to the keyed drive shaft. Install,
rotor at about 0.50” (13 mm) from the outer edge of tighten and torque the flange hex nut at 150 Ft-lbs.
the rotor. Set the dial indicator to zero.
3. SLOWLY turn the rotor (wheel/tire) by hand one or NOTE
two complete revolutions and observe the total Make sure there is no grease on the shaft/nut area before
indicated run-out. installing and torquing the nut.
4. If the run-out exceeds 0.0031” (0.08mm), replace the 10. Reassemble in reverse order.
rotor. Do not resurface the rotor - see “Replacing
11. Repeat Steps 11 through 20 of preceding section
Brake Rotor Assemblies,” page 2-8.
“Changing Brake Pads,” on page 2-5.

Replacing the Brake Rotor Parking Brake Assembly

Assemblies The parking brake assembly includes:
1. Repeat Steps 1 through 8 of “Changing Brake Pads”, • Parking Brake Lever
section on page 2-5.
• Parking Brake Switch
2. Remove brake caliper assembly.
• Parking Brake Cable
IMPORTANT • Parking Brake Caliper Assembly
To remove the rotor, you will need a pry bar and a
rubber mallet (dead-blow hammer). DO NOT USE an Parking Brake Lever
unprotected hammer. You will damage the rotor
rendering it unserviceable. NOTE
3. Loosen the flanged hex nut (3/4-16, Grade 8) and The amount of travel of the parking brake lever should
hardware from the motor shaft. DO NOT remove the allow the lever to move from the released position to the
nut from the assembly at this time. brake position, having the brake fully applied before
4. Loosen the bolts mounting holding the motor to the handle travel is at its maximum.
frame enough to move the motor out to allow a gear
puller on the brake rotor. Pry bars can cause
damage.
 CAUTION
Adjusting the parking brake lever too tight will
5. Using the rubber mallet (dead-blow hammer), hit the
overheat brake rotors causing premature wear; or
rotor on the opposite side, driving it towards the
overheat the drive motors, causing failure.
loosened nut.
6. Repeatedly hit the rotor evenly in a circular motion
until it becomes free, then remove the nut.

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 TIRES AND BRAKE ASSEMBLIES

Checking Parking Brake Adjustment 7. Disconnect the clevis end brake cable.
8. Replace with new parking brake lever assembly.
1. Set the Keyswitch to OFF, then remove the key from
the Keyswitch and disconnect the battery. 9. Remove brake linkage and brake switch cam from
old lever assembly and install on the new lever.
2. Block all wheels.
10. Reassemble in reverse order.
3. Raise the right side of the truck until the rear drive
tire clears the floor by no more than 1” (25.4 mm). 11. Adjust park brake. Refer to page 2-10.
4. While sitting on the seat, pull on the parking brake
lever as far as possible using moderate force. The Parking Brake Switch
lever should apply pressure on the right rotor before
The parking brake switch electrically disables the truck
the handle moves to the rear most position. The right
when applied and is connected to the park brake handle.
rear wheel should not turn when turning by hand.
Checking Parking Brake Switch
 CAUTION 1. Set the Keyswitch to OFF and remove the key from
Wear work gloves before reaching into turn the the Keyswitch.
wheel and allow the truck to cool. Various parts 2. Disconnect the battery.
can get extremely hot during operation. 3. Make sure all the other wheels are securely blocked
so that the truck cannot move.
5. Release the parking brake by pushing the button as 4. Remove the hydraulic control valve cover.
the lever is pulled toward you. Then allow handle to 5. Disconnect e-brake cutout switch connector.
move toward the front of the truck. 6. Connect the ohm meter leads to the switch wires.
6. Brake adjustments are done at the rotor. No
adjustments are necessary at the lever. NOTE
The meter should show less than 1 ohm.
IMPORTANT
7. Slowly pull back on the brake lever, the meter reading
DO NOT OVERTIGHTEN. You will separate the cable
must be “OPEN”, indicating the switch is released
from the clevis ends.
before the lever reaches its full locking position.

7. Apply and release the parking brake five or six times IMPORTANT
to stretch (seat) the cable, then double check your If the meter does not read “OPEN”, the switch needs
adjustment. to be replaced (See “Replacing Parking Brake
8. If this fails to properly adjust the park brake, see Switch” on this page).
“Adjusting Parking Brake Caliper”, page 2-9. 8. Disconnect the ohm meter.
9. Reassemble in reverse order.
Replacing Parking Brake Lever
Assembly Replacing Parking Brake Switch
1. First, review “General Maintenance Instructions,” on 1. First, review “General Maintenance Instructions,” on
page 1-2. page 1-2.
2. Set the Keyswitch to OFF, then remove the key from 2. Set key to OFF and place key in a secure place.
the Keyswitch. 3. Apply the parking brake. Perform a Lock Out/Tag Out
3. Perform a Lock Out/Tag Out and disconnect the procedure and disconnect the battery.
battery. 4. Make sure wheels are blocked so that the truck
4. Make sure all the other wheels are securely blocked cannot move.
so that the truck cannot move. 5. Remove the hydraulic control valve cover.
5. Remove floor plates. 6. Disconnect the switch at the Deutsch connector and
6. Remove lower dash cover weldment. release the jam nut on the park brake handle.
7. Remove the jumper harness, if used, from the switch
NOTE and install to the new switch.
The parking brake lever assembly is located to the left of 8. Install the new switch in reverse order.
the hydraulic control valves & to the right of the operator.
9. Connect the switch at the connector.

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TIRES AND BRAKE ASSEMBLIES

NOTE
Parking Brake Caliper Assembly
The parking brake caliper assembly is used for holding
A pin within the handle activates the switch and has no
the forklift in place while unattended, it is activated by
adjustment. It is always activated in the resting position.
pulling the park brake lever.
To check the operation of this switch:
1. Start the truck and release the parking brake. Adjusting Parking Brake Caliper
2. Set the control lever to FORWARD and very slowly 1. First, review “Before You Begin,” page 1-1.
increase motor speed. 2. Set the Keyswitch to OFF, then remove the key from
3. As the truck is moving forward at slow speed, slowly the Keyswitch and disconnect the battery.
pull up on the brake lever. 3. Make sure all the other wheels are securely blocked
4. The truck must immediately slow to a STOP. so that the truck cannot move.
5. If the truck continues moving forward, recheck the 4. Loosen adjustment bolt jam nut.
setting and operation of the switch. 5. Adjust actuator adjustment bolt to desired position.

NOTICE IMPORTANT
DO NOT release or operate the truck if you are in The adjustment should be set so when the park
doubt about the effectiveness of the parking brake lever is screwed all the way out (completely
brake system. Contact your Landoll service counterclockwise) and the lever is pulled to its full
representative for assistance. vertical position, so the caliper holds the wheel.
Refer to “Bendi AC Parts Manual”, F-523.
6. Tighten adjustment bolt jam nut.
7. Reassemble in reverse order.

Replacing the Parking Brake Cable

1. First, review “General Maintenance Instruction,” on
page 1-2.
Changing Parking Brake Pads or
2. Set the Keyswitch to OFF and remove the key from Replacing Parking Brake Caliper
the Keyswitch. 1. First, review “Before You Begin,” page 1-1.
3. Perform a Lock Out/Tag Out procedure. 2. Set the Keyswitch to OFF, then remove the key from
4. Disconnect the battery. the Keyswitch, perform a Lock Out Tag Out
procedure and disconnect the battery.
5. Make sure all the other wheels are securely blocked
so that the truck cannot move. 3. Make sure all the other wheels are securely blocked
6. Remove the hydraulic valve cover to expose the so that the truck cannot move.
parking brake mechanism. 4. Remove 3/8”-16 x 1-1/4” round head square neck
7. Remove the cable from the truck noting how the screws and nuts from park brake bracket. See
cable is positioned. Figure 2-2.

8. At the park lever, pull the pin that connects the cable IMPORTANT
to the park brake linkage.
The parking brake caliper and bracket will be loose
9. At the caliper, remove the bolt that holds the yoke to
when hardware is removed. Remove the parking
the caliper. Remove yoke, tension spring and the two
brake caliper carefully so that the caliper pads,
flat washers, noting placement on the old cable.
backing plate, and actuator pin do not fall.
Replace parts on the new cable positioning yoke in
the same location. 5. Either remove caliper for replacement or replace
brake pads with new ones.
10. Feed the new cable from the parking brake lever to
the wheel motor in the same manner as the one 6. Reassemble in reverse order.
removed, then connect both ends. 7. If needed, adjust caliper. See “Adjusting Parking
11. Adjust the parking brake cable - see “Adjusting Brake Caliper,” on page 2-9.
Parking Brake Caliper,” page 2-9.
12. Reassemble in reverse order.

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 TIRES AND BRAKE ASSEMBLIES

Brake Pedal Assembly • Release the accelerator pedal to allow the truck to
coast to a stop.
• Both wheels should stop at the same time.
Disc Brakes
• Repeat this procedure two times in forward and in
The disc brakes are inherently self-adjusting. NO reverse directions.
adjustments are necessary or provided. Refer to
10. If the forklift does not perform as stated above,
“Changing Brake Pads,” page 2-5.
reinspect the brake calipers for wear.

Brake Pedal
The service brake pedal has about 1" maximum free-play
before any pressure is applied to the brakes, (or before
the pedal moves the master cylinder plunger).
The pedal also has a maximum range of travel of up to
only 0.500” (12.7 mm) before it contacts the positive stop
hex screw, and includes a brake light switch that
energizes the brake STOP lights, where applicable, and 1
has a switch for disengaging traction drive. The brake
light/accelerator switch is factory set to trip just as the
brake pedal begins its downward stroke.

Service Brake Linkage

1. First, review “General Maintenance Instructions,” on
page 1-2.
2. Set the Keyswitch to OFF, remove the key from the
ART #
Keyswitch, perform a Lock Out Tag Out procedure
and disconnect the battery. Figure 2-5: Brake Linkage
3. Before doing any adjustment, check for:
• Low fluid level in the master cylinder reservoir. Brake Light/Accelerator Switch
• Air or leaks in the system
Brake Light/Accelerator Switch Adjustment
• Worn brake pads. See “Changing Brake Pads,”
page 2-5. 1. First, review “Before You Begin,” page 1-1.
• Any of these conditions can affect pedal free-play. 2. Set the Keyswitch to OFF, remove the key from the
Keyswitch, perform the Lock Out/Tag Out procedure
• Proceed to the appropriate heading for repairs.
and disconnect the battery.
4. Remove the left floor plate to expose the brake pedal
3. Slightly loosen both brake switch hex head screws.
linkage and master cylinder, See “Floor Plate
See Figure 2-6.
Removal,” page 2-15.
4. Connect the ohm meter leads to the appropriate
5. Loosen the 5/16” free play adjustment nut on the
switch being tested.
master cylinder push rod. See Figure 2-5.
5. Slowly push down on the brake pedal. Before you
6. Turn the rod clockwise to increase dimension on the
feel pedal resistance, the meter must read one of the
pedal; turn counterclockwise to decrease dimension.
following:
See Figure 2-5. For free play adjustment dimension.
• The meter must show a reading of open at the full
7. Tighten the adjustment lock nut against the brake
upright pedal position for brake lights (2 black wires).
pedal yoke.
• The meter must show a reading of closed (or less
8. Install the left floor plate.
than 1 ohm) at the full upright pedal position for
9. Connect the battery and check for proper brake accelerator switch (2 green wires).
operation as follows:
6. Slide the brake switch forward or backward to locate
• Raise and block the truck off the ground. the switch at this position - to engage as the pedal
• Accelerate the forklift to full speed. begins its downward stroke. See Figure 2-5.
• Apply the brakes to quickly STOP the wheels.
• Release the brake pedal after the wheels stop, then
accelerate again to full speed.

2-11
TIRES AND BRAKE ASSEMBLIES

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 Brake Light Switch Replacement
setting. 1. First, review “Before You Begin,” page 1-1.
8. Disconnect the ohm meter. 2. Set the Keyswitch to OFF and remove the key from
9. Start the truck. the Keyswitch.
10. Apply the brakes while checking that the lights turn 3. Perform Lock Out/Tag Out procedure.
ON and/or the accelerator switch interrupts before 4. Disconnect the battery, block the wheels and release
pressure is applied to the master cylinder. the parking brake.
5. Remove the left floor plate. See “Floor Plate
NOTE Removal,” page 2-15.
To avoid “flat-spotting the tires, do not lock the brakes 6. Unscrew and remove the switch assembly from the
when stopping. brake pedal frame and install the new switch. See
Figure 2-6.
Replacing the linear pot
7. To set the switch see “Accelerator Switch
To replace the linear pot, disconnect the connector to the Adjustment,” on this page.
assembly and remove the 2 bolts holding the assembly
into position and replace the assembly. Calibration is
required through the dashboard calibration procedure.
See page 5-2.

LINEAR
POT

BRAKE
SWITCH

MASTER
CYLINDER

Figure 2-6: Brake Switch Assembly

Master Cylinder 5. Remove lefft floor plate. See “Floor Plate Removal,”
page 2-15.
6. Remove the master cylinder fill cap and rubber
Replacing Master Cylinder diaphragm (two round head screws). See Figure 2-7.
1. First, review “Before You Begin,” page 1-1.
2. Set the Keyswitch to OFF and remove the key from NOTE
the Keyswitch. Note: Siphon out as much fluid as possible. Install and
3. Perform the Lock Out/Tag Out procedure. tighten the fill cap and diaphragm before removing the
4. Apply the parking brake, disconnect the battery and cylinder.
block the wheels.

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 TIRES AND BRAKE ASSEMBLIES

7. Place rags under the brake line connections. Have a 4. Press your finger tightly over the master cylinder
plastic cap or bag handy to cover the end of the line outlet port to prevent air from being drawn back into
to limit fluid spillage. the cylinder when you release the push rod, or feed a
separate line (flexible tubing) from the cylinder port(s)
IMPORTANT and immerse the other end in the container of new
Brake fluid will damage paint. Cover truck body parts brake fluid. Wait several seconds to allow fluid to be
and be careful not to spill fluid during this procedure. drawn from the reservoir to the cylinder bore, then
Wipe up any spilled fluid immediately, then flush the repeat this step. When you push the push rod in
area with clean water. again it will force your finger from the master cylinder
outlet port to expel any trapped air. Place rags under
8. Using a flare-nut wrench, disconnect the brake fluid the brake line fitting to manage any fluid loss.
line at the rear of the cylinder.
5. When only brake fluid is expelled from the master
NOTE cylinder outlet port, hold the push rod in and seal the
master cylinder outlet port with an appropriate
Flare-nut wrenches should be used to prevent rounding threaded plug or plastic cap, then release pressure
off the flats. on the push rod.
9. Carefully pull the brake line away from the cylinder. 6. Fill the master cylinder reservoir and install the filler
Seal or plug the brake line and master cylinder port cap and gasket.
to prevent fluid loss and/or contamination.
10. Disassemble the yoke from the master cylinder crank PUSH IN
plate (one 5/16-18 screw and hardware).
MASTER CYLINDER
11. Remove the two master cylinder mounting bolts and
remove the cylinder from the truck.
12. Remove the reservoir cap and discard any fluid
remaining in the reservoir.
13. Mark the push rod lock nut setting, then remove the
PUSH ROD
yoke and lock nut from the old cylinder and install it to PLUNGER AND
the new cylinder, maintaining the same lock nut RUBBER GROMMET
setting. CYLINDER OUTLET PORT

NOTE Figure 2-7

• The push rod lock nut should be installed so that
when the pedal is completely assembled and Check Master Cylinder Fluid Level
retracted, the yoke to the master cylinder crank plate
hardware is loose. The master cylinder is located below the driver’s left
compartment floor plate.
• Whenever the master cylinder is removed or
replaced, the hydraulic brake system must be bled. 1. Remove the left floor plate. See page 2-15.
The time required to bleed the system can be 2. First clean the reservoir cap to avoid fluid
reduced if the master cylinder is filled with brake fluid contamination, then remove the fill cap and rubber
and bench-bled before installing the cylinder into the gasket. See Figure 2-7.
truck. See “Bench Bleed the Master Cylinder,” below. 3. Additional fluid is needed when the fluid level is
14. Replace the new master cylinder in reverse order. below the FULL line stamped in the master cylinder
housing body.
Bench Bleed the Master Cylinder 4. Add fluid as needed. DO NOT OVER FILL. Use only
DOT3 brake fluid from a clean, sealed source.
1. Support the cylinder in a vise to prevent fluid spillage,
5. Reinstall the reservoir fill cap and rubber gasket.
while allowing you to push the internal piston with the
Tighten only enough to provide a leak-proof seal.
push rod. See Figure 2-7.
6. Note: Do not overtighten. This could crimp, split, or
2. Remove the filler cap and fill the cylinder with DOT 3
damage the seal.
brake fluid.
3. Slowly push in on the rubber boot and cylinder
plunger (push rod) assembly to force air from the
cylinder, then hold the push rod in. See Figure 2-7.

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TIRES AND BRAKE ASSEMBLIES

Bleeding Brakes 4. Block and remove the rear drive wheels.

5. Start with the right wheel (the wheel farthest from the
master cylinder).
NOTE
6. Loosen the bleeder fitting slightly, then tighten it
Bleeding the brake system is necessary to remove any
where it is snug but can be loosened quickly and
air that is trapped when replacing brake lines, brake
easily.
calipers or the master cylinder. To avoid extensive
damage to the system, use only DOT 3 brake fluid. 7. Fit a length of tubing over the bleed screw and
immerse the other end in the container of new brake
 CAUTION fluid. Check that the tubing fits tightly over the
bleeder fitting. See Figure 2-8.
Wear eye protection. If brake fluid comes in 8. Check fluid level in the master cylinder. Fill before
contact with your eyes, immediately rinse them you begin.
with water and seek medical attention. 9. Have someone slowly press on the brake pedal
several times to build pressure in the system, then
hold the pedal down.
NOTE
Check the fluid level often during the bleeding operation IMPORTANT
and add fluid as needed to prevent the level from falling Be careful when handling bleeder screws. Rust may
low enough to allow air bubbles into the master cylinder. cause the fitting to break. Spray the fitting with
Use only new DOT 3 brake fluid from a sealed container. penetrating oil before attempting to loosen. Use a
NEVER use old or used brake fluid. It contains moisture 6-sided wrench instead of a 12-sided wrench.
which will deteriorate the brake system components. 10. Loosen the cylinder bleed screw until fluid starts to
flow. Watch for air bubbles at the immersed end of
IMPORTANT the tube.
It is necessary to bleed both wheels if air has entered 11. When the brake pedal bottoms, tighten the bleed
the system. Air in the brake system can be caused by screw, then release the pedal. DO NOT release
low fluid level or if a brake line has been leaking or pressure on the pedal until the bleed screw is
disconnected. If the brake pedal feels spongy when tightened.
pressed and travels almost to the mechanical stop
12. Repeat Steps 8 through 11 as many times as needed
but regains height when pumped, air has entered the
until the fluid draining in the container is free of air
system. The system must be bled. If no fittings were
bubbles.
recently opened for service, check for leaks that
would have allowed air into the system and repair 13. Fill the master cylinder fluid level and add as needed
leaks before attempting to bleed the system. before bleeding the other side.
14. Check the operation of the brakes. The pedal should
feel solid when depressed, with no softness. If
NOTE necessary, repeat this procedure.
Have an assistant available, as well as a supply of brake
fluid, an empty container, a length of 3/16” (4.763 mm) BLEED SCREWS
clear plastic or vinyl tubing to fit over the cylinder bleeder (USE 6-SIDED
fitting and a six point wrench to open and close the fitting. WRENCH OR
SOCKET)

NOTICE
DO NOT allow fluids to go inside of the brake
caliper and onto the brake pad. It will contaminate
the brake lining and cause failure.

1. First, review “Before You Begin,” page 1-1.

2. Set the Keyswitch to OFF and remove the key from
the Keyswitch.
3. Apply the parking brake, perform a Lock Out/Tag Out Figure 2-8
procedure and disconnect the battery.

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 TIRES AND BRAKE ASSEMBLIES

Service Brake Pedal Assembly Floor Plate Removal

NOTE NOTE
The service brake assembly (brake pedal) includes the The right floor panel provides access to the accelerator
mechanical brake pedal assembly, containing a pivot assembly which is mounted to the underside of the right
bushing. The only normal repair items are the switch, the floor plate. The master cylinder and service brake pedal
pivot bushing, or the brake return spring. and linkage are mounted within the frame well, under the
left floor panel.
Replacing Any Other Hydraulic Brake 1. Thoroughly clean the floor area using a vacuum.
Component 2. Without tearing, pull up the rubber floor mat.
1. First, review “Before You Begin,” on page 1-1. 3. Remove the left floor plate from the truck frame. See
2. Set the Keyswitch to OFF and remove the key from Figure 2-9.
the Keyswitch. 4. Carefully lift the right floor plate. The accelerator
3. Perform Lock Out/Tag Out procedure and disconnect pedal assembly will still be attached to the right floor
the battery. plate.
4. Apply the parking brake.
NOTE
5. Make sure all the other wheels are securely blocked
so that the truck cannot move. The accelerator module electrical harness will restrict
how far the plate can be lifted. To fully remove the plate
6. Remove covers as needed.
you must disconnect the electrical harness.
7. Replace the damaged component and reassemble.
5. Reassemble in reverse order.
8. Make all adjustments needed to insure brakes are
operating correctly.
9. Test the operation of the forklift truck brakes.
Floor
Mat

Right
Floor
Plate Left
Floor
Plate

Accelerator
Module

Figure 2-9 Floor Plate

2-15
TIRES AND BRAKE ASSEMBLIES

Drive Wheel Assembly

 DANGER
Check Planetary Gear Box Getting under a truck when it is lifted or jacked is
dangerous and could cause serious injury or
NOTE death. NEVER go under a truck that is supported
only by a jack.
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 50 hours maximum of 8. To drain, turn the gear box so that one of the drain
operation in order to remove particles worn down during plugs is at the lowest point. If rotating the gear box
the running-in phase. Thereafter, an oil change is only proves difficult, brace a 2” x 4” (5cm x 10cm) block
required once every 2000 hours or yearly, whichever between the wheel studs and rotate. See
comes first. Also, if the truck has been in storage for one Figure 2-10.
year or more, the oil should be changed before placing 9. Place a drain pan capable of storing up to 32 ounces
the truck into operation. (1.0 liter) of fluid under the drain plug.
10. Using a 4 mm Allen key, unscrew the drain/level
 DANGER (position A) and fill (position B) plugs.
• Perform service only in a well-ventilated area. 11. Drain the fluid completely into the drain pan.


• Do not breathe vapors.
CAUTION
• Wear protective goggles, aprons and gloves.
• Avoid contact with skin, eyes and clothes. If truck has just been in operation for a period of
• Failure to observe these precautions may time the oil could be very hot. Use special gloves
result in death or injury. and/or allow the truck to cool before changing the
oil. It is best to drain fluid while the unit is warm,
• If you become dizzy, get fresh air and medical but not HOT! Never drain oil into sewer lines.
help immediately.
• If a solvent contacts your eyes, immediately
treat in accordance with the manufacturer’s 12. Once the fluid has been drained, replace the
recommendations on the container. drain/level plug in position A.

• Do not mix different types of lubricants. 13. Wash the interior of the gear box with cleaning liquid
Always read the label affixed to the fluid as recommended by the lubricant manufacturer.
container for all safety information before use • Put liquid into the gear box through the fill plug and
replace the fill plug.
• Run the gear box for a few minutes at a high speed.
1. Position the truck on a flat surface, set the parking
brake and block the wheels to prevent movement. • Drain the cleaning liquid from the gear box in the
same way as described for draining the oil.
2. Set the Keyswitch to OFF and remove the key from
the Keyswitch. • Clean any contaminants from the magnetic trap and
O-ring seal on the plugs.
3. Perform Lock Out/Tag Out & disconnect the battery.
14. To fill the gear box, turn until the drain/level hole in
4. Raise the vehicle. Use jack stands, or other suitable
position A is about 15º below the horizontal center
supporting device, to support the vehicle.
line of the gear box.
5. Raise the drive wheel(s) to allow the tire to rotate.
15. Fill the gear box with synthetic gear lube through
6. Remove wheel from unit being serviced. position B until fluid flows out from position A. Fluid
7. Thoroughly clean the area around the fill and capacity is approximately 1 pint(16 oz).
drain/level plugs.
NOTE
IMPORTANT DO NOT OVERFILL.
Always place an appropriate support stand under the 16. Install both plugs. Tighten to 25 ft. lbs. (34 Nm).
truck if it is being lifted. Lower the truck to the stand,
17. Wipe off any oil spillage on outside of the gear box.
having both the lifting device and stand supporting
the weight of the truck.

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 TIRES AND BRAKE ASSEMBLIES

18. Turn the gear box a few times to eliminate any air
pockets and recheck fluid level. The oil level should
be checked again after a short driving period. If
necessary, re-fill the oil.

4mm HEX SOCKET

FILL PLUG 5mm HEX
SOCKET BOLT
B
5mm HEX B
SOCKET
BOLT

4mm HEX
5mm HEX SOCKET
SOCKET BOLT FILL o
PLUG 15

5mm HEX
A 4mm HEX SOCKET BOLT
SOCKET A
DRAIN/LEVEL 4mm HEX SOCKET
PLUG DRAIN/LEVEL PLUG

DRAINING THE PLANETARY GEARBOX FILLING THE PLANETARY BOX

Figure 2-10: Draining Gearbox

Accelerator Pedal Assembly Replacing Accelerator Module

1. First, review “Before You Begin,” page 1-1.
NOTE 2. Set the Keyswitch to OFF and remove the key from
The accelerator assembly consists of the linear the Keyswitch.
potentiometer, harness, and accelerator pedal. 3. Apply the parking brake, perform a Lock Out/Tag Out
procedure, disconnect the battery and block all
Adjusting Accelerator Pedal wheels.
1. First, review “Before You Begin,” page 1-1. 4. Remove the floor plates. See “Floor Plate Removal”,
on this page.
2. Set the Keyswitch to OFF and remove the key from
the Keyswitch. 5. Remove the two round head screws (5/16-18 x 1)
and hardware securing the accelerator to the floor
3. Block wheels and perform the Lock Out/Tag Out
panel. See Figure 2-9.
procedure.
6. Disassemble the accelerator from the floor plate and
4. Remove the floor plates.
install the replacement accelerator in its place. See
5. Note: It is recommended to hold the right hand floor Figure 2-9.
plate in a vice while doing this procedure.
7. Loosen the allen headed fastener on the pedal arm
6. Loosen the allen head fastener on the pedal arm so and orient the pedal 90 degrees up. Insert the flat
that it can rotate freely. Rotate the pedal until the part of the arm through the slot, rotate and mate the
pedal touches the rear of the slot. Tighten the accelerator mounting surface to the underside of the
fastener. floor plate. Align with the 5/16" bolts and tighten to
7. Install floor plate assembly back on the forklift. secure the accelerator.
8. Install left hand floor plate. 8. Adjust the pedal, See Adjusting Accelerator Pedal,
9. Refer to Landoll Setup Procedure, located in above.
“Calibration of Steering and Throttle Pot” on page 5-1 9. Re-calibrate the software beginning on page 5-1.
to re-calibrate the throttle pot module.

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TIRES AND BRAKE ASSEMBLIES

Exposing and Maintaining the

Traction Motors
The Bendi AC truck is equipped with a left and a right
traction motor and also a motor that powers the hydraulic
pump. The traction motors have sensors to monitor 4

speed and position. The motors used on the Bendi AC

lifts are AC motors and have no brushes. Motor 1
maintenance consists of keeping the motors clean with
the use of compressed air. 3

To repair and/or replace the traction motors:

1. Set the parking brake and block all wheels not being
serviced.
2. Set the Keyswitch to OFF and remove the key from
the Keyswitch.
3. Disconnect the battery.
4. Perform the Lock Out/Tag Out procedure.
Figure 2-11 Drive Motor Assembly
5. Remove the battery.
6. Remove the battery floor plate to expose the motor
cover.
7. Remove the Brake Caliper and Rotor referencing
“Disc Brake Rotors” on page 2-7. Traction Drive Assemblies
8. Remove the twelve 1/2-20 X 2 hex socket
screws(Item #1) and hardware holding the motor to
the motor mount weldment. See Figure 2-11.
Inspecting the Drive Assembly
9. Support the unit as the mounting bolts are removed. NOTE
10. With the motor supported, rotate the motor to align
The Landoll AC truck has an individual motor that drives
the electrical connecting terminals to the slots
each wheel.
machined in the motor mount weldment.
Before attempting to replace any part of the drive
11. Slide the motor out far enough to install a second
unit, visually inspect the following components:
strap around the motor. This strap is to support the
motor from outside the truck frame. • Check for leaks.
12. Place the assembly on a sturdy work bench. Use • Check all fluid levels.
wood planks to balance and support the assembly • Check for loose, worn or frayed electrical cables.
while on the workbench. • Check tires for gouges, cupping, flat spots and
13. Assemble the new motor by following the preceding excessive wear.
steps in reverse. • Check for any loose bolts or fittings.
14. Tighten and torque the screws. See torque
specifications on page 1-18.

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 Chapter 3

Hydraulic Components: Motors and Pumps

Steering Motor Maintenance

Maintain the hydraulic system, and associated
 CAUTION
components, as required by the various checklists After prolonged truck use, hydraulic oil will
beginning on page 1-8. become hot and can burn skin. Allow hydraulic
oil to cool to a tolerable temperature before per-
Guidelines for hydraulic system maintenance are
forming this procedure.
provided in the following paragraphs.

 CAUTION Check Hydraulic Oil Level

Do not allow: 1. Lower the mast to within a few inches of the ground,
• Hydraulic fluid level to drop significantly or then tilt it back completely.
allow the reservoir to run dry. This will induce 2. Side shift the mast to the far right and return it to the
air into the system and cause damage to straight forward position (normal carry position).
hydraulic system components. 3. With the Keyswitch OFF, turn the steering wheel left
• Prevent dirt or other foreign matter from and right until it becomes difficult to turn.
entering the hydraulic system; clean filler 4. The fill/dipstick cap is located under the left floor
caps before checking oil level. plate. Remove the left floor plate,
5. First clean the area around the dipstick, then pull
Cylinders and Valves: Check these components for drift dipstick out and wipe clean. Reinsert and then check
and leakage. Refer to Landoll Corporation and other dipstick to determine oil level.
vendor service information for specifications.
Hoses and Tube lines: Check for cracks, hardening, or IMPORTANT
other signs of wear. Reroute any usable hoses that are • It is important that the proper level of oil be
kinked, severely bent, or rest against hot parts. Look for maintained at all times. Failure to check the oil
leaks, especially at couplings and fittings. Replace any level as recommended could cause serious mast
hoses or tube lines that do not meet system flow and function operating problems.
pressure ratings. • The oil level indicated on the dipstick is most
Hydraulic Fluid: Check fluid level and look for air accurate when the oil is at operating temperature
bubbles. Check the filter. See page 1-17 for specifications of 130°F to 176°F (53°C to 93°C).
on recommended lubricants. • Do not overfill. Having the level above the FULL
Other Hydraulic System Components: Visually check line does not allow enough area for expansion
other components to see if they are loosely mounted, when the oil heats during normal operation.
show signs of leaks, or other damage or wear to the 6. Remove the dipstick again, holding the dipstick tip
hydraulics. level and check the oil level. If the oil level is at the
FULL line or between the FULL and ADD lines, the
NOTE
level is correct and no oil is needed. If the oil is at or
The hydraulic pump in your Bendi truck is powered by an below the ADD line, you will need to add oil to bring it
AC non-serviceable motor. The pump supplies hydraulic up to the FULL line (maximum).
pressure for steering and mast lift.
7. Add hydraulic oil as needed. See page 1-17 for
recommended lubricants.

3-1
HYDRAULIC COMPONENTS: MOTORS AND PUMPS

8. If the fluid appears very dirty or dark in color, check

the truck’s maintenance log for the last fluid and filter
Change the Hydraulic Oil Filter
change and service it accordingly.
9. Install dipstick, making sure it is seated. Close  CAUTION
controller compartment and reconnect battery. After prolonged truck use, hydraulic oil will
become hot and can burn skin. Allow hydraulic
Changing Hydraulic Oil oil to cool to a tolerable temperature before per-
forming this procedure.
1. Review “Before You Begin” on page 1-1.
2. Park the truck on a level, designated service area.
1. Park the truck on a level, designated service area,
3. Set the parking brake and block the rear wheels.
set the parking brake and block the wheels.
4. Perform Lock Out/Tag Out procedure.
2. Set the key to OFF and remove the key from the
5. Set the key to OFF and remove the key from the Keyswitch.
Keyswitch.
3. Perform Lock Out/Tag Out procedure.
6. Disconnect the battery.
4. Disconnect the battery.
7. Remove the left floor plate cover. Reference “Floor
5. Remove the operators compartment floor plate, left
Plate Removal” on page 2-15.
side.
8. Open the fill/dipstick cap mounted under floor plate.
6. Using a clean, lint-free cloth, clean the area around
9. The hydraulic reservoir drain plug is located in the the filter element housing and remove the filter
bottom of the truck, underneath the reservoir. See housing cover.
Figure 3-1.
7. Unscrew the hydraulic oil filter cap and remove the
10. Slide a flat collection pan, (minimum 10 gallons (40 old filter, clean and replace See Figures 3-2 and 3-3.
liters)) under the drain plug, then remove the plug.
11. Change the hydraulic filter. See “Change the
Hydraulic Oil Filter” on this page.
12. Clean the magnetic trap on the drain plug of any
contaminants. When the tank is empty, clean and
reinstall the drain plug.
13. Add hydraulic oil. See page 1-17 for recommended
lubricants. DO NOT overfill.
14. Replace the fill/dipstick cap, turn clockwise, and
make sure it is tightened securely.
15. Make sure the drain plug is tight enough to prevent
oil leaks, but do not over tighten. Refer to Torque
Specifications on page 1-17.
16. Remove Lock Out/Tag Out notices and locks.
17. Run lift to check for leaks. Figure 3-2 Hydraulic Oil Filter Cap
18. With the lift OFF and the forks down, check the oil 8. Operate the hydraulic system by running the mast
level on the dipstick and add oil accordingly. functions and observe the filter for oil leaks.
9. Check the hydraulic fluid level and reinstall the
driver’s floor plate.

Figure 3-1Hydraulic Oil Drain Plug Figure 3-3 Hydraulic Oil Filter

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Checking and Adjusting

Hydraulic Pressure
IMPORTANT
 WARNING Do not hold a hydraulic control (bottomed out) for
excessive periods of time. Extreme pressure is
HIGH PRESSURE FLUIDS CAN BE DANGEROUS! applied to the system which can, over periods of
Before continuing with this section, read about time, generate heat, damage oil, and internal
the warnings of pressurized hydraulic oil under components. If the pressure is low and cannot be
“Hydraulic System” on page 1-5. 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
NOTE the proper pressure, replace the relief valve.
For ease of checking hydraulic pressure, Landoll offers a 11. Tighten the relief valve lock nut.
Pressure Check Kit (P.N. 0018152) which includes a 12. Set the key to OFF, remove the key from the
5000 p.s.i. (344.7 bar) gauge, hose and a quick-coupler Keyswitch, and disconnect the battery.
assembly. If you are using your own system, have shop
13. Operate the function controls momentarily to relieve
rags, oil absorbent and a small container ready to collect
system pressure.
any oil spills.
14. Remove the pressure gauge quick-coupler or remove
1. For this test, make sure that the hydraulic tank has
your gauge arrangement.
plenty of oil.
15. Turn the truck on.
2. Set the key to OFF, remove the key from the
Keyswitch and disconnect the battery. 16. Lift and lower the mast a few times to check truck
operation and check the hydraulic system for leaks.
3. Perform the Lock Out/Tag Out procedure.
17. Set the key to OFF and disconnect the battery.
4. Remove the control valve cover, located to the right
of the driver’s seat. 18. Reassemble all covers and panels that were
previously removed.
5. Operate the function levers briefly to relieve any
system pressure.
6. Connect the pressure check kit quick-coupler (female
end) to the test port coupler (male end) on the control
valve. See Figure 3-4.
• If you are not using the pressure check kit, remove
the quick-coupler and install an appropriate fitting to
accept your pressure gauge arrangement.
• Have rags handy to collect any oil leakage.
• Install your 5000 psi (344.7 bar) gauge arrangement
to the tee fitting.
• All parts connected to the gauge port must be
capable of handling up to 5000 p.s.i. (344.7 bar).
• To adjust pressure, the truck (pump) must be running
to create hydraulic pressure. Always pay careful
Pressure
attention when servicing while the truck is running.
To check or set the pressure, you must pull the tilt
Test
lever to dead head the cylinder to build pressure, Port
then set the relief valve.
7. Loosen the relief valve jam nut.
8. Turn the truck on.
9. Adjust the valve stem by turning clockwise to
increase pressure, counterclockwise to decrease
pressure.
10. Release the joystick immediately once the pressure
is set at 2600 psi. (179 bar) Figure 3-4 Hydraulic Pressure Test

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HYDRAULIC COMPONENTS: MOTORS AND PUMPS

Hydraulic Steering Motor Power Steering System Maintenance

Maintenance Guidelines to perform maintenance on the power
steering system is provided in the following paragraphs:
NOTE • Fluid for the hydraulic power steering system comes
from the central hydraulic reservoir.
When performing a hydraulic motor repair, it is important
to have the proper tools and facilities to complete a • Always use a puller to remove the steering wheel. Do
successful rebuild. Make sure the area around the motor, not use a hammer or crow bar.
in the truck, has been thoroughly cleaned and that the • Investigate and immediately correct any play, rattle,
correct replacement parts will be used. Dirt, grease and shimmy, misalignment, or other unusual occurrence
old oil will shorten the pump and steering motor life. in the steering system.
• Report any malfunction or accident that may have
Hydraulic Steer Motor Disassembly damaged a steering system part.
If the hydraulic steering motor is leaking oil from between • Investigate and correct any external leak in the
the sections, but works okay, a simple rebuild kit with steering system, no matter how minor the leak.
replacement o-rings may give adequate repair. A motor • Do not attempt to weld or straighten any broken
with more serious problems will need to be replaced. See steering component. Replace the component with
the F-523 Bendi AC parts book for individual part original equipment only.
numbers and exploded views or contact your nearest
Landoll approved service location for further information.  CAUTION
Prevent dirt or other foreign matter from entering
Parts Inspection the hydraulic system; clean filler caps before
checking oil level.
NOTE
Clean all parts in a non-flammable solvent and dry.
Inspect for wear or damage. Replace worn or damaged Check Power Steering
parts. 1. Sit in the driver’s seat and set the Keyswitch to ON.
2. While applying the service brake, release the parking
Hydraulic Motor(s) Reassembly brake and set the direction control lever to
FORWARD or REVERSE. The power steering pump
1. All parts should be clean and have a light coating of
motor should start running.
hydraulic oil.
3. If the motor does not start, first check that the parking
2. Pay close attention when assembling o-rings, as they
brake is released.
can be pinched.
4. While moving forward or backward slowly (to avoid
3. Insert the hold-down bolts into the pump body and
flat-spotting), verify that the truck turns left and right
hand tighten into the tapped holes in the truck frame.
with a relatively smooth, easy motion.
4. Torque down the mounting bolts. Refer to torque
5. While moving forward or backward slowly, turn the
specification tables on page 1-18.
steering wheel completely to the right (a full
right-hand turn).
Hydraulic Pump Service 6. While moving slowly in either direction, turn the
steering wheel completely to the left
NOTE (counterclockwise) while counting the number of full
The hydraulic lift pump used on the Bendi AC has no revolutions. The steering wheel must complete
serviceable parts and is repaired by replacement only. approximately seven to nine revolutions, 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, set the
direction switch to neutral, and check that the pump
turns off.

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Filling and Air Bleeding the Power Replacing the Hydraulic Pump and
Steering System Motor
Fill and air bleed the power steering system per the 1. For instructions, See Figure 3-5.
schedules shown starting on page 1-7. 2. Remove the key and place in a secure area.
1. Fill the reservoir until it is between the F and E marks 3. Perform the Lock Out Tag/Out procedure.
on the dipstick.
4. Remove the battery.
2. Run the steering through three complete cycles by
5. Remove the battery tray.
turning the steering wheel all the way in one
direction, then all the way the other direction. 6. Move the hydraulic levers back and forth to relieve
pressure from the lines.
3. Check and refill the reservoir after each cycle.
7. Disconnect the suction and pressure hoses from the
4. Add fluid until it is between the F and E marks on the
hydraulic pump, item #1. Place shop rags
dipstick. DO NOT OVERFILL.
underneath the connections to catch hydraulic oil.
8. Mark and disconnect the 2 snap electrical
Hydraulic Components connectors, item #2.
9. Mark and disconnect the 3 heavy gauge electrical
NOTE cables, item #3.
This section explains the following: 10. Insert wooden blocks underneath the counter weight
• Hydraulic Pump closest to the hydraulic motor - right side.
• Steer Motor 11. Hold and steady the counter weight with a floor jack.
• Hydraulic Return Filter 12. Remove the 1-8 x 4 upper counter weight bolt, item
#4. Note: The removal of the bolt is for motor removal
• Hydraulic Control Valve
clearance.
• Servicing the Lift Motor and Pump
13. Remove three 3/8” fasteners, items #5, to allow the
pump and motor assembly to be elevated out of the
Before Servicing Hydraulic Components: frame.
1. First, review “Before You Begin,” page 1-1. 14. Using an overhead hoist, remove the pump and
2. Set the Keyswitch to OFF and remove the key from motor assembly from the truck and place it in the
the Keyswitch. repair area.
3. Apply the parking brake, perform a Lock Out/Tag Out
NOTE
procedure and disconnect the battery.
Assembly is very heavy.
4. Make sure all the other wheels are securely blocked
so that the truck cannot move. 15. Re-assemble in reverse procedure.

3 5
2
Figure 3-5

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HYDRAULIC COMPONENTS: MOTORS AND PUMPS

Hydraulic Steer Motor Replacement NOTE

1. For instructions, See Figure 3-6.
• Power steering pressure is set at 2600 psi ±100 psi
2. Remove the key and place in a secure area. (131 bar, ± 7 bar). A pressure gauge port is provided,
3. Perform the Lock Out/Tag Out procedure. with a “quick-coupler,” (pressure service kit, Landoll
4. Disconnect the battery. p/n: 0018152) for reading the steer pump pressure
when hooked to the pressure relief valve.
5. Release hydraulic pressure in the system by moving
all control levers back and forth and turning the Before you service this valve for possible pressure
steering wheel left and right. problems, make sure there are no leaks in the hydraulic
system and that there is sufficient oil in the tank. Both
6. Remove the front rotation cover and remove the
conditions can contribute to low pressure problems. Also
cover.
see “Power Steering System,” in the Bendi AC Operator's
7. Remove the rotation switch bracket and rotation pot Manual F-522 for additional circuit information.
from the top side of the steering gear assembly - item
#1.
8. Remove the 3/8”-16 x 1 1/4” bolt and pinion retainer Checking Steer Pressure
plate from the steering motor drive shaft - item #2. 1. First, review Before You Begin on page 1-1.
9. Using even pressure from 2 sides, pry up on the 2. Set the Keyswitch to OFF, remove the key from the
steering pinion gear to remove. Keyswitch.
10. Mark and remove all 3 hydraulic lines from the 3. Perform the Lock Out/Tag Out procedure.
steering motor. Keep shop rags near for spills.
4. Remove the floor plates. See “Floor Plate Removal,”
11. Remove the four 1/2” - 20 x 2” bolts that hold the page 2-15.
motor to the frame - item #3. Remove the motor.
5. For ease in checking pressure Landoll Service offers
12. Reassemble the steering motor in reverse order. Item a Pressure Check Kit (p/n: 0018152) which includes
#3 bolts are to be torqued to 90 ft-lbs(122 Nm). a 5,000 psi (344.7 bar) pressure gauge, hose and
13. Item #2 bolt is to be torqued to 40 ft-lbs(55 Nm). quick-coupler). Have shop rags and a small container
14. Re-calibrate with the Bendi AC truck instructions available to collect any oil spills. Refer to Illustration
beginning on page 5-1. shown below.
6. Turn the steering wheel briefly from one side to the
other to relieve system pressure - allow oil to drain.
7. Connect the pressure check kit quick-coupler (female
end) to the coupler (male end) on the pressure test
1 port.
2

Figure 3-7
• If you are not using the pressure check kit, remove
the quick-coupler and install an appropriate fitting to
Figure 3-6 accept your pressure gauge arrangement.

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 HYDRAULIC COMPONENTS: MOTORS AND PUMPS

• Be prepared to collect the oil leakage. Hydraulic Control Valve

• Install your 3,000 psi (207 bar) pressure gauge
arrangement to the fitting. Landoll recommends a
Assembly
5000PSI gauge for accuracy, 3000PSI minimum. The following procedure explains how to replace a valve
8. Turn the truck on. should a sluggish or sticking valve spool be suspect.

 CAUTION
To check pressure, the truck & therefore the
pump, must be running to create hydraulic
pressure. Always use extreme caution when
servicing the truck while it is running.

9. Turn the steering wheel fully to the right and hold the 1
wheel to allow pressure buildup. The pressure
reading must be 2600 psi, ±100 psi (179 bar, ± 7 bar)
maximum.
10. Release the steering wheel.

 CAUTION
Do not turn and hold the steering wheel against
the rotation limit for long periods of time. ART #
Excessive pressure is applied to the circuit which Figure 3-8 Operator Controls
can, over long periods of time, generate heat and
damage internal components. If the pressure is
IMPORTANT
low, check the pump and make sure there are no
leaks in the hydraulic system. If the pressure is If you remove the valve from the truck for servicing
too high or too low, replace the relief valve. (hex head screws and hardware), when reinstalling
the valve be certain to tighten the mounting screws
in a staggered fashion while applying equal pressure
11. Turn the steering wheel from one side to the other, to to all screws. If the screws are not tightened and
check the hydraulic connections for leaks. torqued evenly, you could create a stress crack, thus
12. Check for a pressure reading of 2600 psi ±100 psi internal oil leaks, rendering the valve defective.
(179 bar, ± 7 bar) maximum and then set the
Keyswitch to OFF. NOTE
13. Turn steering wheel to release pressure. • The main hydraulic pump for lift, tilt, pivot, and shift
14. Remove pressure gauge. (mast functions) is a fixed displacement gear pump
15. Replace relief valve if pressure reading is out of (2.008 cu. inch/rev). System pressure must not
specifications. exceed 3,000 psi, ±65 psi (205 bar, ±4 bar)
maximum. Actual pressure is determined by mast
16. Reassemble in reverse order. size, load requirements and lift speed. See reference
chart below:

Bendi AC Pump Speed in RPM’s

Mast Model Lift Speed
35DTriple 1800
35D Quad 1750
40D Triple 1900
45D Quad 2400
50D Triple 2650
55D Triple 2850

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HYDRAULIC COMPONENTS: MOTORS AND PUMPS

15. Remove the lift pot/switch mounts by removing the

• The main pump pressure relief valve is part of the
mounting screws.
hydraulic control valve.
16. Remove the fasteners on the spool actuation end
• A pressure gauge port is provided, with a
and remove the cover plate(s).
“quick-coupler,” (pressure service kit, Landoll p.n.
0018152) for reading the pump pressure on the
hydraulic control valve. The pressure check port on
the forklift is attached to the inlet port on the hydraulic
control valve. See Figure 3-7.

IMPORTANT
• 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,” in the Bendi AC Series
Operator's Manual F-522 for additional circuit
information.

Hydraulic Control Valve and Switches

Removal NOTE
1. First, review Before You Begin on page 1-1. During this time close inspection should be given looking
for leaks between the sections. If there have been
2. Set the Keyswitch to OFF, remove the key from the
sectional leaks, simply unbolt the three bolts that hold the
Keyswitch, perform a Lock Out/Tag Out procedure
sections together, replace the leaking o-ring and tighten
and disconnect the battery.
up the bolts holding the sections together. See “Hydraulic
3. Apply the hand brake and block the wheels. Control Valve” in F-523 Bendi AC parts book.
4. Relieve pressure in the system by moving the 17. Remove the spool and end mechanism from the
hydraulic levers back and forth a few times. bore.
5. Remove the floor plate. 18. Remove the seal, wiper and seal plate from the
6. Remove valve cover. tang/clevis end of the spool. A dental pick can be
7. Inspect the spool actuator end (upper) and the switch used to remove the wiper and o-ring. Use caution to
actuator end (lower) for leakage. Also inspect valve avoid nicking the bore.
for leakage between valve sections. 19. Remove the end mechanism from the cap end of the
8. If leakage is found, the spool seals can be replaced. spool.
If there is leakage within the spools, as determined 20. Remove all foreign material from the spool and seal
by drift in the hydraulic actuator, the valve may need counter bores.
to be replaced. If leakage is found between sections, 21. Lubricate the seal groove bores on the cap and
replace o-ring between the section. tang/clevis ends of the housing.
9. Remove the valve from the truck by first identifying 22. Re-assemble the cap end of the spool with the new
and marking all hoses, disconnecting and plugging seals per the applicable end mechanism repair
all hydraulic tubes. Be prepared to manage spills. instruction and carefully reinsert the spool.
10. Disconnect the lift pot from the truck wiring harness 23. Install the new seal and wiper on the tang/clevis end
and switches from the truck wiring harness at the of the spool using the seal plate to push them in prior
Deutsch connector. to completing the seal plate cap screw installation
11. Remove the push/pull linkage from the spools by and torque.
removing the cotter pins and pulling the pins from the 24. Assemble the switch pot brackets to the other end of
spools. the valve.
12. Remove the bolts holding the valve to the valve 25. Apply grease (NLSI #2 Texaco #880) to actuator end
mounting bracket. prior to assembly of the spool actuator.
13. Place valve on a bench or in a vice. 26. Reassemble valve to truck.
14. Seals can only be removed by removing the spools.

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 HYDRAULIC COMPONENTS: MOTORS AND PUMPS

27. Attach and tighten all hoses. 10. Reassemble pot mount bracket to valve.
28. Operate valve functions and check for leaks. 11. Reinstall valve on truck.
12. Attach and tighten hydraulic hoses.
Spool Section Rebuild 13. Start truck, operate hydraulic system, and check for
leaks.
NOTE 14. Calibrate lift pot input to controller. Refer to page 5-1
The inlet assembly will include an o-ring, and the spool for calibration instructions. This adjustment is actually
sections will include an o-ring, load check poppet and completed through the controller electronically.
load check spring. 15. Reinstall brake assembly.
1. For proper reassembly alignment, lay valve 16. Install floor plates and valve cover.
components on a clean, hard, flat surface.
2. Thread tie rod nuts onto the short threaded end of
each of the individual tie rods with the nuts threaded
up the entire length of the threads.
3. Insert tie rods through tie rod holes of inlet housing,
lay inlet on end with tie rods pointing up and install
o-ring into groove. Special care must be taken to
ensure o-ring has been completely installed in
Sensor
groove.
4. Place first spool section over inlet section with o-ring
groove facing upward and install o-ring into groove.
5. Install load check poppet into load check cavity, nose
first.
6. Once load check poppet has been properly installed,
place load check spring in hollow cavity inside check
poppet. Figure 3-9 Hall Sensor Location

Hydraulic Lift Pot Hydraulic Fittings and Hoses

NOTE 1. First, review Before You Begin on page 1-1.
The hydraulic lift pot is replaced as a complete unit with 2. Set the Keyswitch to OFF and remove the key from
the wiring harness. the Keyswitch.
3. Perform a Lock Out/Tag Out procedure, disconnect
Replacing Lift Pot the battery and block the wheels.
1. First, review Before You Begin on page 1-1. 4. Before disconnecting any hydraulic fittings or hose
2. Set the Keyswitch to OFF and remove the key from assemblies, relieve the system pressure. This is
the Keyswitch. accomplished by turning the steering wheel a few
3. Apply the parking brake, perform a Lock Out/Tag Out times in both directions, and moving the control
procedure, disconnect the battery and block the levers in both directions after the Keyswitch is turned
wheels. OFF.


4. Relieve pressure in the system by turning the
steering wheel two times to the left, then two times to WARNING
the right and move the controls in both directions. • High pressure hydraulic oil leaks can pierce
5. Remove the floor plate to allow removal of the valve the body and cause SEVERE injury to
cover. personnel. Always reduce pressure before
6. Disconnect the lift pot from the main truck harness at opening any hydraulic pressure line.
the Deutsch connector. • Oil spills can cause falls. To avoid injury,
7. Remove the lift pot bracket from the end of valve. make sure all spills are cleaned well with oil
dry/wipes.
8. Remove the two screws holding the lift pot from the
bracket.
9. Install new pot and reassemble the pot to the bracket.

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HYDRAULIC COMPONENTS: MOTORS AND PUMPS

5. Remove the hose coupling from the defective fitting.

Use two wrenches; one wrench to loosen the hose
Side Shift Circuit Maintenance
coupling, and one to prevent the fitting from turning. The following information is provided for authorized ser-
Be prepared to clean up any oil spillage. See vice facilities ONLY.
Figure 3-10. Perform maintenance on the side shift circuit as required
6. Always tag the hoses and fittings for identification. If by the recommended Checklists.
necessary, keep notes and put markings on parts
using a non-destructive marker. Check Side Shift circuit performance
7. Remove the defective fitting and replace with a new 1. Side shift completely to the left and hold the control
fitting. Use two wrenches; one wrench to tighten the handle in this position for 5 seconds. Check for
hose coupling, and one to prevent the fitting from external leaks at the cylinder, fittings, and hoses.
turning.
Side shift completely to the right and hold the control
handle in this position for 5 seconds. Check for external
NOTE leaks at the cylinder, fittings, and hoses.
SAE fittings do not need a thread sealant. They are
straight thread and include an O-ring seal.  CAUTION
• Before you remove any hoses or tubes,
relieve hydraulic system pressure. With the
truck off, operate the truck controls several
times in both directions.
• Check for hydraulic fluid leaks using a piece
of cardboard or wood. Do not use your bare
hands.
• Remember to wear safety glasses.

 DANGER
Hydraulic oil can be under very high pressure. A
pinhole leak is not easily seen and if it pierces
your skin, can cause injury and possible death.

Check the hydraulic system pressure at the control valve

Figure 3-10 Hydraulic Connections fitting. See Figure 3-7. System pressure must not exceed
3000 psi (206 bar).

Check Hydraulic Functions

1. Position the truck on a level, flat surface. Clear area
around the truck.
2. Turn the Keyswitch to the ON position.
3. Make sure your right foot is on the floor of the
operator's compartment and prepared to brake.
4. Pull either joystick to see if hydraulics are working.
The pump must turn OFF immediately as you release
the control lever.
5. If the pump keeps running, see "Hydraulic Control
Valve Assembly" on page 3-7.
6. Visually check cylinders, valves, and hoses for leaks
or other signs of wear.
7. Check hydraulic fluid level.

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 HYDRAULIC COMPONENTS: MOTORS AND PUMPS

Steering Wheel Removal

1. Remove floor plates. See “Floor Plate Removal,”
1. Pry the plastic cover from the steering wheel using page 2-15.
your finger tips. If you cannot grab the cover, you can
2. Remove the lower dash cover weldment. See
start it by carefully using a medium sized flat blade
Figure 3-12.
screw driver and gently prying upwards. DO NOT
force it or the cover may crack. See Figure 3-11. 3. Disconnect the plugs that connect the dash harness
to the main harness and any optional lighting
2. Loosen the steering wheel nut.
harnesses.
3. Pry the steering wheel upwards by wiggling and
4. Relieve hydraulic pressure in the system by turning
pulling straight up. It is important to pull up evenly on
the steering wheel a few times to the left and right.
both sides of the wheel.
5. Also pry (up) the bellows (rubber boot) free of the
NOTE bellows retainer plate. This exposes the mounting
plate for the steering column and the orbital control
If the wheel is difficult to remove, use an automotive-type
unit.
steering wheel puller. Avoid using hammers or pry bars.
4. Install the steering wheel by placing it over the shaft, IMPORTANT
aligning the wheel and shaft splines and pushing
downward evenly until the nut can be installed. Four screws secure the assembly to the orbital
steering mount bracket for stability. Once removed
5. Tighten the nut. the unit is supported by the hydraulic hoses only.
6. Remove the four bolts and hardware securing the
orbital control unit to the steering column.
7. Remove the four bolts and hardware securing the
steering column console to the bellows retainer plate.
See Figure 3-12.
8. With help, lift the steering column upwards to
disengage the shaft from the orbital unit, then
remove the steer column from the truck.
9. When installing the new steer column, you must turn
the steering shaft until it aligns with the orbital unit
and drops into place.
Steering
Knob 10. Continue by reversing the preceding steps making
sure to tighten and torque all mounting screws. See
General Torque, Hydraulic Fitting Torque, and Bendi
AC Special Torque Tables in on page 1-17.
Remove Cover
to Expose Nut
Figure 3-11 Steering Wheel Assembly

Steering Column (Console)

Removal
NOTE
This is a two man operation, due to weight of steering Steering
column (approximately 30 pounds/14 kgs.). If an Column
overhead crane is available, the crane could be strapped Assembly
to the steering wheel for support.
Figure 3-12 Steer Column Assy

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HYDRAULIC COMPONENTS: MOTORS AND PUMPS

Steering Orbital Control Unit NOTE

1. Remove floor plates. See “Floor Plate Removal,” Immediately plug and cap all hose ends and tag each for
page 2-15. identification. Be prepared to clean up any oil spills.
2. Remove the lower dash cover weldment. 6. If the unit is being replaced, or the fittings are
3. Relieve hydraulic pressure in the system by turning defective, notice the placement angle of the hose
the steering wheel a few times to the left and right. fittings then remove them. See Figure 3-13.
4. Tag the port locations of each hydraulic line and 7. Install the new steering orbital control unit to the
fitting, then disconnect the four lines from the unit. steering column by following the preceding steps in
5. Review section “Hydraulic Fittings and Hoses,” on reverse order.
page 3-9. Check oil level in the hydraulic tank and fill as needed.

Figure 3-13: Orbital STeering Control Unit Assembly

NOTE
Immediately plug and cap all hose ends and tag each for
identification. Be prepared to clean up any oil spills.
8. If the unit is being replaced, or the fittings are
defective, notice the placement angle of the hose
fittings then remove them.
9. Install the new steering orbital control unit to the
steering column by following the preceding steps in
reverse order.
10. Check oil level in the hydraulic tank and fill as
needed.

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 Chapter 4

Electrical System

Steering Column/Dash Assembly 7. Reach inside the steering column and disconnect the
appropriate display wire connectors from the main
The following procedures describe access to and wire harness.
replacment of the steering console electrical 8. Install the new display by reversing the above steps.
components, as well as all other electrical components
9. Connect the wire connector to the display and close
on the Bendi AC forklift.
the steering column by reversing the steps outlined in
4 through 8.
The console assembly includes the following and are
accessible by removing the right side steering assembly
cover (black) - screws and hardware:
• Auxiliary power rocker switch (fan, scanner, etc.)
• Headlights (rocker switch, where fitted)
• Standard/Ramp mode (Allows current to increase in
the ramp mode)
• Tilt steering lever DISPLAY
• Keyswitch
A

 CAUTION
Before any maintenance or work is performed on
the electrical system of the truck, perform a Lock
Out/Tag Out procedure, disconnect the battery,
raise the truck and put blocks on the underside of
the truck

Remove the Display Panel

1. First, review Before You Begin page 1-1.
2. Set the Keyswitch to OFF and remove the key from
the Keyswitch.
3. Apply the parking brake, perform a Lock Out/Tag Out
procedure and disconnect the battery. Make sure all
the wheels are securely blocked so that the truck
cannot move.
4. Remove the steering wheel by first removing the B
center boot covering the steering wheel locking nut
and then loosen and remove the steering wheel.
Steering
5. Remove the four large screws and hardware marked Console
(A), See Figure 4-1.
6. Remove the screws and hardware marked (B).
Figure 4-1 Steering Console and Display

4-1
ELECTRICAL SYSTEM

Keyswitch 5. Insert the replacement switch in the slot and

compress the tabs as needed to allow it to insert.
1. Remove the right side cover to expose the internal
6. Connect the cable connector to the wire harness and
components of the steering column as described on
close the steering column by reversing the steps
page 4-1.
outlined in the above section.
2. Unscrew the knurled switch collar ring to separate
the switch from the base plate. See Figure 4-2.
3. Disconnect the wires from the switch terminals noting
how they are connected to ensure proper orientation
when connecting the new switch.
4. Install the Keyswitch by reversing the preceding
steps.

Figure 4-3

Figure 4-2

Electrical Contactors
Rocker (On/Off) Switches
NOTE  CAUTION
Rocker switches are also used to control various light Before any maintenance or work is performed on
packages and accessories. the electrical system of the truck, perform a Lock
1. Repeat preceding section Keyswitch removal. Out/Tag Out procedure, disconnect the battery,
raise the truck and put blocks on the underside of
2. Reach inside the steering column and disconnect the
the truck
appropriate accessory switch connector from the
main wire harness.
3. The accessory on/off rocker switches are held by Inspecting the Contacts
plastic tabs. Compress the tabs on one side at a time
to release the switch body, then push up and lift out NOTE
of the slot. See Figure 4-3. Contactors are set at the factory and should not require
any adjustment. During the life of the contactor, they may
NOTE become discolored, blacken or corroded. Cleaning or
Be careful when compressing and pushing the switch in maintenance is not necessary. Replacement is
or out. The tabs could break off if the procedure is not recommended instead of maintenance. If one contactor
done carefully and evenly on all sides. is due for replacement, it is recommended that they are
all replaced as a set.
4. Detach the wires from the defective switch, noting the
connection arrangement for when installing the new
rocker switch.

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 ELECTRICAL SYSTEM

Battery - Safety, Care & IMPORTANT

Replacement • If any repairs to the battery are needed, follow the
instructions given by the battery manufacturer.
Battery Safety - Duplicate of Safety
• Do not lay metallic items or tools on the battery.
Notices Shown in Chapter 1. Arcing or an explosion may result.

 WARNING
• Battery gas is explosive. Keep all flame and
arcing away from the battery.
• Forklift batteries give off explosive gasses • Keep the battery clean. Impurities can weaken
during use. and eventually discharge the battery.
• Do not smoke, strike a welding arc, or create • Keep battery vent plugs firmly in place, except
any flame while using, working in the area or when checking or charging the battery.
maintaining a forklift.
• Charge the forklift battery in a designated Checking Batteries
area with adequate ventilation.
• Batteries contain sulfuric acid which can NOTE
severe skin and eye burns. Avoid sulfuric acid
The electrolyte fluid level of the battery should be
contact to all parts of the body, period.
checked after each charge of the battery. The optimum
• In case of contact, flush immediately and level of the electrolyte should be about 1/2” (13 mm) over
thoroughly with clean water. If the eyes have the top of the plates or just below the bottom the lowest
been affected, get medical attention. part of the lip of the battery filler vent hole. If low, add
distilled water OR the solution recommended by the
battery manufacturer. Do not overfill.
IMPORTANT For increased battery life reference Battery Care
Keep all areas of the battery and the battery cables page 1-4 and check daily the specific gravity readings.
clean. Dirt or corrosion in these areas can drain the Since the water must be mixed with the electrolyte for an
battery or cause erratic performance. Battery accurate reading, do not check the gravity readings right
corrosion can also cause a voltage drop to the after adding water. Unless the electrolyte is below the top
electrical components on the truck. level of the plates, do not add water right before the
battery is scheduled to be charged. Normal full charged
specific gravity should be between 1.265 and 1.285.
Battery Safety
IMPORTANT
 CAUTION • Always assume the battery is emitting hydrogen
• Wear protective clothing when working and practice proper safety precautions.
around batteries, including rubber aprons, • Do not smoke, use an open flame, or create arcs
gloves, boots, eye goggles and face shields. or sparks near the battery.
• Do not allow body to become in contact with • Packaged with every battery are specific
battery electrolyte. If contact with electrolyte instructions for battery safety, care and use, plus
is made, wash affected areas immediately. In a Material Safety Data Sheet (MSDS). Read these
case of contact with eyes, flush immediately documents thoroughly before servicing the
with clean water and get medical attention. battery.
• A baking soda solution (one pound baking • Always disconnect the battery before performing
soda to one gallon of water) will neutralize any kind of service.
electrolyte acid spilled on clothing, the floor • Do not lay objects on the battery as they may
or most other surfaces. Apply the solution cause a short circuit. Shorting battery terminals
until the bubbling stops and rinse with clean can release enormous amounts of energy,
water. causing electrical shock, sparks or flame, or
heating nearby components to dangerous
temperatures.
• Use caution when changing battery connectors
to ensure that correct polarity is maintained.

4-3
ELECTRICAL SYSTEM

• Truck batteries contain concentrated sulfuric

acid which can cause severe chemical burns.  CAUTION
When adding water to the battery, wear rubber
gloves, protective clothing and safety glasses or • Never smoke or bring an open flame near a
full-face shield. Use a plastic container or an charging or idle battery. Gas from a battery is
automatic cell filler to prevent container highly explosive and can cause serious
breakage. injury.
• Neutralize acid spills immediately with • Avoid over filling as it will cause overflow
Bicarbonate of Soda. If acid contacts the skin or (flooding) of the electrolyte, resulting in loss
eyes, wash with water immediately and seek of electrolyte, battery tray corrosion, ground
medical help at once. paths and loss of capacity or working ability.
• Keep vent plugs in place, fully tightened and • Connecting the charger cable to the truck
clean at all times. cable can cause damage to the forklift.
• Be sure to replace and retighten any battery
restraints which have been installed on the truck.
IMPORTANT
1. Park the truck at the designated charge area with
Battery Care forks down and key OFF.
• Only charge the battery in the designated area. 2. Make sure charger is in the OFF position.
• Make sure that the charger being used matches the Connect the battery to the charger and make
voltage and amperage of the truck battery. certain cables are firmly connected.
• Before connecting and disconnecting the battery 3. Turn the charger on and set the timer, if
charger to the battery, make sure the charger is OFF. equipped. For an overnight fill, set charger to
Connecting or disconnecting the charger when it is NORMAL.
ON, could damage the charger or cause an arc. 4. View the charger gauge to be positive of charge.
5. Check and fill the batteries after charging.
• Before charging, make sure the electrolyte covers the
top of the battery plates.
Removing the Battery From Charger
• Before connecting the battery cable to the truck’s
1. Make sure the charger is off and disconnect the
receptacle, make sure the key to the truck is off and
charger cables from the battery with a straight pulling
that the controls are in the off position.
motion. Store the charging cables appropriately.
• Make sure the battery terminals and cables are
2. Check the battery for the appropriate electrolyte level
cleaned of corrosion regularly. Clean battery
and measure specific gravity.
terminals are important not only to the operation of
the lift, but for proper battery charging.
• Make certain that the battery used meets weight and
size requirements of the truck. NEVER operate the
truck with an undersized battery. Reference data Cleaning the Battery
plate information for this information.
When properly maintained, the battery will remain rela-
tively clean and dry. It may be necessary to clean the top
Charging the Battery of the battery. Occasionally it may be necessary to
remove excessive electrolyte. If this happens, remove the
NOTE battery from the truck and clean with a solution of baking
Charging time and requirements will vary with the battery soda and water. (one pound baking soda to 1 gallon of
size and condition. Whenever the truck needs to be water) Rinse the battery off with water and allow to air
troubleshot, the battery must be fully charged. dry.

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 ELECTRICAL SYSTEM

Battery Removal Electrical Static Discharge

 CAUTION IMPORTANT
• Normal precautions concerning the handling of
Don’t allow metallic objects to be on top or near electronic components are applicable in order to
the battery. A short could cause an electrical arc minimize the risk of damage to these devices by
and personal injury may result. When moving the Electrical Static Discharge. Avoid contact with
battery, keep the top of the battery covered with the pins of these devices and insure that when
an insulator, such as a piece of plywood or tarp. they are removed from a printed circuit board
(PCB), the pins are strapped together with
Rollout Battery Removal - optional conductive tape. Immediately place the PCB in
static-free bubble wrap or an ESD bag.
1. Remove the safety retainer bar, deactivating the
safety switch. • smocks over normal clothing must be worn to
discharge high voltage potentials caused by
2. Position battery roll out stand next to the truck and
friction during normal wear.
align the stand with the path of the battery.
• Use a grounding wrist band to protect
3. Roll the battery onto the stand.
microprocessors and all electronic components
from static electricity and always touch a metal
Battery Installation surface (other than the truck) before touching a
1. Change and charge batteries in accordance with PCB. These precautions are especially necessary
ANSI/NFPA 505. with respect to microprocessor devices, found
on the hydraulic control PCB’s of this truck.
2. Check to be sure the key is off.
3. Open the right hand door.
4. If using a rollout stand, position the battery stand
ESD Strap
next to the truck. Align stand with battery Shown to the right is the ESD(Electrical Static Discharge)
compartment. Battery roller stand should be at the Strap which will be installed just behind the front steering
same height as the truck. assembly. See Figure 4-5. This device will drain all static
5. Push battery into the truck’s battery compartment or electricity build up that may occur on the Bendi AC forklift.
lower if using a hoist.
6. Install the rollout battery arm bar, or the truck will not
operate. See Figure 4-4.
7. Connect the battery.

Figure 4-4 Rollout Battery Arm Bar

Figure 4-5 ESD Strap Location

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ELECTRICAL SYSTEM

Electrical Controls and Levers

Direction Control Lever
Check the Return-to-Neutral
NOTE 1. Sit in the driver’s seat, and turn the Keyswitch ON.
The directional control lever (forward-neutral-reverse) is 2. Set the direction control lever to FORWARD.
located on the battery cover. Each assembly is available 3. Slowly move the truck forward, then slowly lift
as a complete unit. yourself off the seat, the truck should come to a stop.
Replacing Direction Control Lever 4. Turn the Keyswitch OFF, then back on again.
5. Press on the accelerator pedal.
1. First, review “Before You Begin,” page 1-1.
6. The truck must not move.
2. Set the Keyswitch to OFF and remove the key from
the Keyswitch. 7. If the truck does not move, take your foot off the
accelerator pedal. Place the directional control lever
3. Apply the parking brake, perform a Lock Out/Tag Out
in NEUTRAL then back to FORWARD again.
procedure and disconnect the battery.
8. Slowly push on the accelerator pedal. The truck
4. Make sure all the other wheels are securely blocked
should move forward. If it does not move, Refer to
so that the truck cannot move.
Programming Troubleshooting Chart and 1314
5. Raise the battery cover. Monitoring Function starting at page 5-1.
6. Remove the directional control lever wires from the 9. Repeat preceding Steps 1 through 6, but instead of
contact blocks on the main harness. turning the Keyswitch OFF in Step 4, lift yourself from
7. Replace in reverse order. the driver’s seat for 5 seconds to allow the switch
8. Test for proper operation. interlock to release. The truck must react as stated in
Steps 4 through 8.

Figure 4-6: Control Panel Wiring

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 ELECTRICAL SYSTEM

Replacing a Complete Control 7. Remove mounting hardware that secures the

assembly to the truck and remove the panel or single
Panel component from the truck.
1. First, review “Before You Begin,” page 1-1. 8. Reassemble in reverse order. All cables installed on
2. Set the Keyswitch to OFF and remove the key from the motor controllers must use Landoll approved
the Keyswitch. fasteners. Refer to the Bendi AC Parts Manual for
replacement parts, F-523.
3. Apply the parking brake, perform a Lock Out/Tag Out
procedure and disconnect the battery. 9. Tighten cables connected to the high current
terminals, identified on the controller housing as B+,
4. Make sure all the other wheels are securely blocked B-, U, V and W to 90 +/- 1- in-lbs (10.2 +/- 1.1 Nm).
so that the truck cannot move. See Figure 4-7. - for high current cables.
5. Remove the rear control compartment cover.
6. Mark and remove all cables connected to high NOTE
current terminals of the panel and disconnect the After replacing the controller it must be reprogrammed.
main harness. See Figure 4-6. See Chapter 5 “Calibration and Programming”.

Figure 4-7

High Current Connections Definition: U = Motor phase U.

V = Motor phase V.
B+ = Positive Battery to Controller.
B- = Negative Battery to COntroller. W = Motor phase W.

Figure 4-8 Controller Panel

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ELECTRICAL SYSTEM

Horn Service Check Driver’s Seat Switch

This procedure checks the physical mechanics
NOTE (actuation) of the driver’s seat switch only. The switch is
The horn button is located to the right of the direction part of the seat.
control lever. 1. Start the truck and release the parking brake.
2. The seat switch and actuator are internal to the seat
Removing the horn cushion, located on the under side of the seat
cushion between the cushion and the bottom plate.
1. Turn the Keyswitch OFF, remove the key, perform
3. Set the direction control lever in either FORWARD or
Lock Out/Tag Out procedure and disconnect battery.
REVERSE and slowly apply acceleration. As the
2. Remove front rotation cover plate. truck begins to slowly move in either direction, lift
3. Disconnect the electrical wires. yourself from the driver’s seat just enough to release
4. Remove the hex screws and hardware to separate the switch in the seat cushion.
the horn from the frame. 4. The truck will not come to an immediate stop. You
5. Install the new horn by reversing the preceding steps. should lose forward direction (or reverse). The truck
will coast unless you use you brakes.
6. Connect the battery and test the horn.
5. If the truck continues, see “Seat Switch,” previously
on this page or refer to Troubleshooting the Controller
- Chapter 5.
Seat Assembly
DRIVER’S SEAT
Seat Switch (VINYL OR
CLOTH)
The driver's seat micro switch and cable assembly are
HIP
mounted to the bottom of the seat cushion. See RESTRAINT
Figure 4-9.
SEAT CUSHION
Replacing the Switch and Cable WEIGHT ADJUST
KNOB
1. First, review Before You Begin page 1-1.
2. Set the Keyswitch to OFF and remove the key from
the Keyswitch.
3. Apply the parking brake, perform a Lock Out/Tag Out SLIDE
procedure, disconnect the battery and block all RAILS LIMIT SWITCH
wheels. AND CABLE

4. Remove the hardware securing the front portion of Figure 4-9 Seat Switch Assy
the seat slide rails to the cover. Then loosen the back
two sets of hardware.
5. Raise the front of the seat up to expose the switch
and cable mounting.
6. Have a helper disconnect the switch cable from the
main harness, then unscrew the switch assembly.
7. Install the new switch and cable by performing the
preceding steps in reverse order.
8. Before placing the truck back into operation, test it to
be sure the switch functions properly.

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 ELECTRICAL SYSTEM

Truck Lighting Overhead Guard, Lighting and

Trucks equipped with optional lighting, flashing or spot Alarms
lights may contain replaceable bulbs or the housing may
Trucks equipped with optional LED flood / headlights, tail
be replaced as a whole. Lighting replacement varies
and stop lights, flashing or spot lights (strobe lights), etc.
according to the manufacturer.
do not contain replaceable bulbs. Bulb replacement must
be done as a complete assembly.
Headlights
These lights have non-replaceable elements and are
replaced as an entire unit.

Brake and Tail Lights

1. First, review Before You Begin on page 1-1.
2. Set the Keyswitch to OFF and remove the key from
the Keyswitch.
3. Perform the Lock Out/Tag Out procedure.
4. Apply the parking brake and disconnect the battery.
5. The complete LED light assembly must be replaced
to repair a faulty light assembly.
6. Pull off the complete LED light assembly. Exercise
care to avoid breaking the LED assembly.
7. Disconnect the wire connector and remove the
bracket that is attached to the overhead guard.
8. If shielding or guard covers are involved, make
certain that the guard is replaced after the repair.
Reassemble in reverse order.

Back Up Alarms Figure 4-10 Overhead Guard Electrical

1. First, review Before You Begin on page 1-1.
2. Set the Keyswitch to OFF and remove the key from
the Keyswitch.
3. Perform the Lock Out/Tag Out procedure.
4. Apply the parking brake and disconnect the battery.
5. To access the alarm assembly, raise the seat base as
it is located under the arm rest.
6. To replace the alarm assembly, disconnect the wire
connector and remove the mounting hardware
holding the alarm to the mounting bracket.

4-9
ELECTRICAL SYSTEM

Figure 4-11: Controller Fuses

Fuses
Shown above are the location of the Bendi AC System
and Controller fuses. See Figure 4-11. Exact size and
amperage rating must but be retained when replacing.

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 Chapter 5

Bendi AC Calibration and Programming

Controller Theory of Operation Dash Display Parameters

The Bendi AC truck uses Curtis controllers that convert The following parameters can be adjusted through
DC battery power to 3-phase AC power by precisely the dash display:
controlling the induction drive for high bandwidth, • Maintenance Monitor - Used to set the hour meter
efficiency and low ripple torque generation. The Dual value at which the operator will be alerted that
Drive feature of Curtis controllers allow 2 controllers to service is required, NXT SVC DUE. When the truck
work in vehicles with dual fixed axle drive motors, a meets or exceeds the value entered in this section,
steered wheel or axle, and an analog steer-angle sensor. “SERVICE DUE” will be shown on the display. If this
The 2 controllers should be the same size and model. feature is not desired, set the value to the factory
Different models of controllers cannot be mixed. The 2 default of 99900 hrs. Use the Up/Down arrows to
controllers control motor speed on the inner and outer manipulate the values by the hundreds.
wheels during turns, as well as vehicle speed and
• Steer Potentiometer(POT) Setup - Used to calibrate
acceleration while turning. Current is automatically
the steering position potentiometer.
balanced between the 2 traction motors when driving
straight, and a limited operating strategy (LOS) allows • Accelerator Potentiometer(POT) Setup - Used to
limp-home in case of a steer angle sensor, single motor calibrate the accelerator potentiometer.
or controller failure. • Lift Potentiometer(POT) Setup - Used to calibrate the
The Display is shown here for reference: lift potentiometer.
Button #1 “Enter Key” - Used to Enter the Calibration • Brake Potentiometer(POT) Setup - Used to calibrate
Mode and to make selections after they are located. the brake potentiometer.
Display directions: • Lift Lockout Setup - This parameter allows for
adjustment of the battery capacity percentage where
You must hold the enter button down until the change has
lift lockout is initiated.
been accepted.
Button #2 “Up Key” - Used to move “Up” through the IMPORTANT
selections.
When replacing the steering, brake, acceleration or
Button #3 “Down Key” - Used to move “Down” through lift potentiometer maintenance has been performed,
the selections. re-calibration of the Bendi AC is required.

Truck Calibration
Truck calibration is performed by activating the Keyswitch
and performing the following procedure:
Follow the flow chart, See Figure 5-1.
1. At the Main Screen, press and hold the ENTER
button for approximately 5 seconds. This will open
the main menu. “TRUCK SETUP”.
2. An “Asterisk” will show your selection - Use the
Up/Down arrows to move to the next selection.
1 2 3 Hold down ENTER to select.

5-1
BENDI AC CALIBRATION AND PROGRAMMING

3. Truck Setup now will display the password screen. 11. LIFT/LOCKOUT SETUP: Select LIFT LOCKOUT
4. To enter the password, use the Up/Down arrows to from the truck setup menu and press enter. Press
manipulate the value to the desired digit and press ENTER again to begin editing.
ENTER. Repeat this process for each digit. After • Use the Up/Down arrows to manipulate the value to
entering the correct password, the truck setup menu the desired percentage and press enter to store the
will be displayed. new value. This completes the LIFT/LOCKOUT.

NOTE
Main Menu
The default password is: 4 2 3 1. * TRUCK SETUP
5. If use of Maintenance Monitor is desired, navigate to LCD CONTRAST
“MAINT MONITOR” selection and adjust the Service EXIT
Due Hour Meter value as you require.
* PASSWORD ****
6. When (*) is to the right of “Steer Pot Setup”, press EXIT
ENTER. “Password Ok”
7. STEER POT SETUP: Hold down ENTER, which will * LCD CONTRAST
display the Steer Pot menu. ADJUST CONTRAST
EXIT
• The astericks moves to the right indicating your
selection. (The location of (*) defines current stage of
calibration) * MAINT. MONITOR
• Steer truck fully left and press ENTER. Turn Steer to STEER POT SETUP
ACCEL POT SETUP
straight selection and hit ENTER. Steer the truck to LIFT POT SETUP
the right position & press ENTER. BRAKE POT SETUP
• This completes the STEER POT SETUP. LIFT LOCKOUT SETUP
EXIT
8. ACCEL POT SETUP: Navigate to ACCEL POT
SETUP on the main menu and press enter. Press VEHICLE HRS *
NXT SVC DUE Maint. Monitor
ENTER again to begin calibration. EXIT Sub-Menu
• ACCEL ZERO calibration - Ensure the foot pedal is in STEER FULL LEFT *
the up position and press ENTER. STEER CENTER
Steer Pot Setup
• ACCEL FULL - Press the pedal to the floor and press STEER FULL RIGHT
Sub-Menu
STEER POT= VDC
ENTER. Monitor the accelerator pot voltage on the EXIT
screen; ensure this value is changing with movement
ACCELERATOR ZERO *
of the pedal between .1VDC and 5.2VDC. This
ACCELERATOR FULL Accel Pot Setup
completes the ACCELERATOR POT SETUP. ACCEL. POT= VDC Sub-Menu
9. LIFT POT SETUP: Select LIFT POT SETUP from the EXIT
truck setup menu and press ENTER. Press ENTER LIFT LEVER ZERO *
again to begin calibration. LIFT LEVER FULL Lift Pot Setup
LIFT POT= VDC Sub-Menu
• LIFT LEVER ZERO - Ensure the lift lever is in the EXIT
neutral position and press ENTER.
BRAKE PEDAL ZERO *
• LIFT LEVER FULL - Pull the lift lever back completely BRAKE PEDAL FULL Brake Pot Setup
and press ENTER. Monitor the lift pot voltage on the BRAKE POT= VDC Sub-Menu
screen; ensure this value is changing with movement EXIT
of the lever between .1VDC & 5.2V. LIFT LOCKOUT % *
10. BRAKE POT SETUP: Select BRAKE POT SETUP EXIT
from the truck setup menu and press ENTER. Press Figure 5-1 Truck Calibration Flow Chart
ENTER again to begin calibration.
• BRAKE PEDAL ZERO - Ensure the brake pedal is in
the up position and press ENTER.
• BRAKE PEDAL FULL - Press the brake pedal to the
floor and press ENTER. Monitor the brake pot
voltage on the screen; ensure this value is changing
with movement of the pedal between .1VDC and
5.1VDC. This completes the BRAKE POT SETUP.

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 BENDI AC CALIBRATION AND PROGRAMMING

1314 Bendi AC Controller NOTE

Software Program Installation The Belkin F5U509 is a recommended model, although
and Operation other suppliers of this type of adapter are available at
many computer cable suppliers. Refer to picture shown in
The 1314 Controller Software is used to manipulate, the previous column.
monitor and diagnose the Bendi AC Forklift performance
If your laptop is equipped with a serial port you may
and functions.
connect the Bendi controller directly to your laptop with
The following sections will guide you through the the supplied 1309 Curtis interface cable. See Figure 5-3.
installation of the 1314 Controller Programming Station
and explain the software program functionality.

USB to Serial Port Adaptor Cable

Depending on the configuration of your laptop, an
interface cable may be needed for the software transfer
between the laptop and the Bendi controllers. A 9-pin
Serial to USB port adapter is needed. See Figure 5-2.

Figure 5-3 Controller Dongle

See Figure 5-4. Shown here is the Serial to USB adaptor
cable connected to the Curtis 1309 interface cable that is
to be connected between the forklift controller and your
Figure 5-2 Serial to USB Adapter
laptop computer. Reference Figure 5-5 on page 5-4 for
truck cable connector(s) locations.

Figure 5-4: Serial Adaptor + 1309 Interface Cable

5-3
BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-5: Cable Connections

1314 Installation Procedure

Follow the installation instructions below:

Figure 5-6: Start - Steps 1 & 2

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-7: Steps 3 & 4

Figure 5-8: Step 5

5-5
BENDI AC CALIBRATION AND PROGRAMMING

1314 Update Procedure

NOTE
This procedure must be completed before using the
software, on every installation of the software. See
Figure 5-9.

Figure 5-9: Update Procedure

Communicating with Bendi AC

Controllers

Figure 5-10: Communicating with the Controllers - Step 1

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-11: Steps 2 & 3

Figure 5-12: Steps 4 thru 6

5-7
BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-13: Steps 7 & 8

Additional 1314 Controller

Features

Figure 5-14: Fault Monitor

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-15: Fault History

IMPORTANT
After successfully re-flashing a controller, make sure
to clear the fault history of all comments.

Controller Fault History

The 1314 programmer can be used to access the
controller’s fault history file. The programmer will read out
all the faults the controller has experienced since the last
time the fault history file was cleared. Faults such as
contactor faults may be the result of loose wires; Figure 5-16 System Connect Selection
contactor wiring should be carefully checked. Faults such
as over temperature may be caused by operator habits or
by overloading. After a problem has been diagnosed and
corrected, it is a good idea to clear the fault history file.
This allows the controller to accumulate a new file of
faults. By checking the new fault history file at a later date
you can readily determine whether the problem was
indeed fixed.

You may now begin to manipulate, monitor and diagnose

the forklift performance and functionality.
See Figures 5-16 and 5-17. “Connect” to check software
“Revision” Levels and only if required change forklift
“Settings” and “Monitor” functionality.

5-9
BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-17: Devices Info

Figure 5-18: Software Revisions

IMPORTANT
See Figure 5-18. Contact Landoll for Current
Software Revision.

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 BENDI AC CALIBRATION AND PROGRAMMING

NOTE
See Figures 5-19 thru 5-58. After successfully
connecting to the controller, proceed through the
instructed menu’s and sub-menu’s to review all
parameters.

Figure 5-19: 1314 Parameters

Figure 5-20: HPD Sequencing Delay - 1 of 2

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BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-21: HPD Sequencing Delay - 2 of 2

Figure 5-22: Steering Off Delay

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-23: Lift Lockout Level

Figure 5-24: Rabbit Fwd Max Speed

5-13
BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-25: Turtle Fwd Max Speed

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-26: Rabbit Rev Max Speed

Figure 5-27: Turtle Rev Max Speed

5-15
BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-28: Set Total HM

Figure 5-29: 10s of Hours

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-30: Remaining HRs in Mins

Figure 5-31: Next Service Due

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BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-32: 1 - Speed Mode

5-18 F-528-0511 Edition

 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-33: Full Accel Rate HS

See Figure 5-33. Full Accel Rate HS: The rate of which See Figure 5-34. Full Accel Rate LS: The rate of speed
speed command increases when full throttle is applied at command increases when full throttle is applied at low
high speeds. speeds.

Figure 5-34: Full Accel Rate LS

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BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-35: Low Accel Rate

See Figure 5-35. Low Accel Rate: Sets the rate at See Figure 5-36. Neutral Decel Rate HS: Sets the rate
which the speed command increases when a small that slows down the vehicle when the throttle is release to
amount of throttle is applied. Typically adjusts low speed neutral at high vehicle speeds.
control.

Figure 5-36: Neutral Decel Rate HS

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-37: Neutral Decel Rate LS

See Figure 5-37. Neutral Decel Rate LS: Sets the rate See Figure 5-38. Full Brake Rate HS: Sets the rate at
that slows down the vehicle when the throttle is released which the vehicle slows down from the high speeds when
to neutral at slow vehicle speeds. full brake is applied or when full throttle is applied in the
opposite direction.

Figure 5-38: Full Brake Rate HS

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BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-39: Full Brake Rate LS

See Figure 5-39. Full Brake Rate LS: Sets the rate at See Figure 5-40. Low Brake Rate: Sets the rate at
which the vehicle slows down from slow speeds when full which the vehicle slows down at all speeds when a small
brake is applied or when full throttle is applied in the amount of brake is applied or a small amount of throttle is
opposite direction. applied in the opposite direction.

Figure 5-40: Low Brake Rate

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-41: Partial Decel Rate

See Figure 5-41. Partial Decel Rate: Sets the rate that See Figure 5-42. HS(High Speed): Sets the percentage
is used to slow down the vehicle when the throttle is of the Typical Max Speed above which the “HS”
reduced without being released to neutral. parameters will be used.

Figure 5-42: HS(High Speed)

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BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-43: LS(Low Speed)

See Figure 5-43. LS(Low Speed): Sets the percentage See Figure 5-44. Reversal Soften: Larger values create
of the Typical Max Speed below which the “LS” a softer reversal from regen braking to drive when near
parameters will be used. zero speed.

Figure 5-44: Reversal Soften

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-45: Max Speed Accel

See Figure 5-45. Max Speed Accel: This parameter See Figure 5-46. Max Speed Decel: This parameter
controls the rate at which the maximum speed setpoint is controls the rate at which the maximum speed set point is
allowed to change when the value of Max Speed is allowed to change when the value of Max Speed is
raised. lowered.

Figure 5-46: Max Speed Decel

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BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-47: Forward Deadband

Figure 5-48: Forward Max

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-49: Brake Deadband

Figure 5-50: Brake Max

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BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-51: Reset Volts Per Cell

Figure 5-52: Full Volts Per Cell

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-53: Empty Volts Per Cell

Figure 5-54: Discharge Time

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BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-55: BDI Reset Percent

Figure 5-56: Steer Pot Min

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-57: Steer Pot Zero

Figure 5-58: Steer Pot Max

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BENDI AC CALIBRATION AND PROGRAMMING

Monitoring Default Parameters

Figure 5-59: Monitor Menu

Figure 5-60: Device Monitor

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 BENDI AC CALIBRATION AND PROGRAMMING

Factory Set Parameter Details:

“Throttle Pedal Switch” - safety switch on accelerator
“LIft Cutout Flag” “on” when in Lift Lock Out.
that disables/enables throttle command.
“Steer Pump Speed Flag” “on” when in forward or
“Forward Switch” is “on” when in Forward.
reverse AND driver is on the seat.
“Reverse Switch” is “on” when in Reverse.
“Seat Switch” “on” when operator is on seat.
“Main Cont Driver PWM” - 100% setting to pull in
“Battery Roll Out Switch” - Optional Feature - check to
contactor and 80% to hold contactor.
see if jumper is in place on battery roll out connector.
“Motor Temp Sensor Analog” - Linear Thermocouple
“Mode Switch” in Turtle mode is “off” and in Rabbit
reading.
mode is “on”

Figure 5-61: Factory Set Inputs

Figure 5-62: Factory Set Outputs

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BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-63: Battery Parameters

Figure 5-64: Motor Parameters

Figure 5-65: Controller Parameters

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 BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-66 Cutback Parameters

Figure 5-67: Vehicle Parameters

Figure 5-68: CAN Status Parameters

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BENDI AC CALIBRATION AND PROGRAMMING

Figure 5-69: System Fault Monitor

IMPORTANT
After successfully reflashing a controller, make sure
to clear the fault history of all comments.

Landoll_TM_S Parameters
Explanation of controller parameters are shown below in
the following tables. Slave parameters are not adjustable.

DESCRIPTION Unit Value Min Max Text Description

Landoll Traction
HPD Sequencing Delay Sec 2 0 5 Sets amount of time an operator can be off seat
before SRO enables.
Steer Cont PWM % 100 0 100 Sets the voltage to the steer contactor.
Steering Off Delay Sec 10 0 30 Time that the pump continues to run after operator
leaves seat.
Lift Lockout Level % 0 0 99 Determines battery percentage before LOS
engages.
Multimode Functions
Rabbit Fwd Max Speed % 100 0 100 Sets maximum speed of vehicle in rabbit mode.
Turtle Fwd Max Speed % 15 0 100 Sets maximum speed of vehicle in turtle mode.
Rabbit Rev Max Speed % 90 0 100 Sets maximum speed of vehicle in rabbit mode.
Turtle Rev Max Speed % 15 0 100 Sets maximum speed of vehicle in turtle mode.
HourMeter
Set Total HM 0 0 1 Set to 1 to write 10s of hours and remaining hours in
minutes to controllers.
10s of Hours 0 0 20000 Sets 10s of hours. (I.E. 90=900 hours)
Remaining HRs in min. 0 0 600 Sets remaining hours in minutes. (I.E. 60=1hour)
Maintenance Due
Next Service Due When hour meter = next service due, maintenance
due will be displayed on dash.
Speed Mode
Response
Sec 0.1 3.0 30.0 Sets the rate at which the speed command
Full Accel Rate HS increases when full throttle is applied at high vehicle
speeds. Larger values represent slower response.
Sec 0.1 3.0 30.0 Sets the rate at which the speed command
Full Accel Rate LS increases when full throttle is applied at low vehicle
speeds. Larger values represent slower response.

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 BENDI AC CALIBRATION AND PROGRAMMING

DESCRIPTION Unit Value Min Max Text Description

Sec 0.1 10.0 30.0 Sets the rate at which the speed command
Low Accel Rate increases when a small amount of throttle is applied.
Typically adjusted to affect low speed control.
Sec 0.1 7.0 30.0 Sets the rate slows down the vehicle when the
Neutral Decel LS throttle is released to neutral at high vehicle speeds.
Larger values represent slower response.
Sec 0.1 2.5 30.0 Sets the rate that slows down the vehicle when the
Neutral Decel Rate HS throttle is released to neutral at slow vehicle speeds.
Larger values represent slower response.
Sec 0.1 1.0 30.0 Sets the rate at which the vehicle slows down from
high speeds when full brake is applied or when full
Full Brake Rate HS
throttle is applied in the opposite direction. Larger
values represent slower response.
Sec 0.1 2.5 30.0 Sets the rate at which the vehicle slows down from
low speeds when full brake is applied or when full
Full Brake Rate LS
throttle is applied in the opposite direction. Larger
values represent slower response.
Sec 0.1 6.0 30.0 Sets the rate at which the vehicle slows down at all
speeds when a small amount of brake is applied or a
small amount of throttle is applied in the opposite
Low break Rate
direction. Larger values gives a slower response

.
Fine Tuning
Sec 0.1 30.0 30.0 Sets the rate that is used to slow down the vehicle
Partial Decel Rate when the throttle is reduced without being released
to neutral. Larger values represent slower response.
Sec 0 70 100 Sets the percentage of the Typical Max Speed
HS (High Speed)
above which parameters will be used.
Sec 0 30 100 Sets the percentage of the Typical Max Speed below
LS (Low Speed)
which the “LS” parameters will be used.
Sec 0 20 100 Larger values create a softer reversal from regen
braking to drive when near zero speed. This helps
Reversal Soften
soften the transition when the regen and drive
current limits are set to different values.
Sec .1 1.0 30.0 In some applications, the Max Speed value is
changed frequently through VCL or over the CAN
bus. The Max Speed Accel parameter controls the
rate at which the maximum speed setpoint is
allowed to change when the value of Max Speed is
raised. The rate set by this parameter is the time to
Max Speed Accel
ramp from 0 rpm to Typical Max Speed rpm. For
example, suppose Max Speed is raised from 1000
rpm to 4000 rpm. If Typical Max Speed is 5000 rpm,
and the rate is 10.0 seconds, it will take 10.0 *
(4000–1000) / 5000 = 6.0 seconds to ramp from
1000 rpm to 4000 rpm.
Sec 0.1 10 30 This parameter works like the Max Speed Accel
parameter, except that it controls the rate at which
the maximum speed setpoint is allowed to change
when the value of Max Speed is lowered. For
Max Speed Decel example, suppose you change Max Speed from
4500 rpm to 2500 rpm. If Typical Max Speed is 5000
rpm, and the rate is 5.0 seconds, it will take 5.0
(4500–2500) / 5000 = 2.0 seconds to ramp from
4500 rpm to 2500 rpm.
Throttle

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BENDI AC CALIBRATION AND PROGRAMMING

DESCRIPTION Unit Value Min Max Text Description

Forward Deadband Volt Auto set 0 5 Defines the wiper voltage at the throttle deadband
during threshold. Increasing the throttle deadband setting
calibrati will increase the neutral range. This parameter is
on. especially useful with throttle assemblies that do not
reliably return to a well-defined neutral point,
because it allows the deadband to be defined wide
enough to ensure that the controller goes into
neutral when the throttle mechanism is released.
Forward Max Volt Auto set 0 5 Defines the wiper voltage required to produce 100%
during controller output. Decreasing the throttle max
calibrati setting reduces the wiper voltage and therefore the
on. full stroke necessary to produce full controller
output. This parameter allows reduced-range throttle
assemblies to be accommodated.
Reverse Deadband Volt 10 2 125 The four Throttle Reverse parameters are the same
as their Throttle Forward counterparts, and apply
when the throttle direction is reversed.
Reverse Max Volt 3 0 5 Same as above.
Brake
Brake Deadband ms 48 40 2000 The four Brake throttle adjustment parameters are
the same as their Drive throttle counterparts
Brake Max ms 200 0 800 Same as above.
Battery
Reset Volts Per Cell Volt 2.09 0.9 3 The value of this parameter is a percentage of the
Nominal Voltage setting. The User Undervoltage
parameter can be used to adjust the undervoltage
threshold, which is the voltage at which the
controller will cut back drive current to prevent
damage to the electrical system. Typically this
parameter is changed only when the controller is
being used in an application at the high end of the
controller’s range: such as a 24–36V controller
being used in a system with a 36V battery pack. In
this case, the undervoltage threshold can be
lowered by setting the User Undervoltage to a lower
value. The undervoltage threshold can never be
lowered below the controller’s power base minimum
voltage rating.
Full Volts Per Cell Volt 2.04 0.9 3 The reset voltage level is checked only once, when
KSI is first turned on. Note that the BDI Reset
Percent parameter also influences the algorithm that
determines whether BDI Percentage is reset to
100%. Reset Volts Per Cell should always be set
higher than Full Volts Per Cell. Reset Voltage Level
= Reset Volts Per Cell × number of cells in the
battery pack
Empty Volts Per Cell Volt 1.71 0.9 3 The full voltage level sets the Keyswitch Voltage that
is considered to be 100% state-of-charge; when a
loaded battery drops below this voltage, it begins to
lose charge. Keyswitch Voltage is viewable in the
1311 menu Monitor » Battery. Full Voltage Level =
Full Volts Per Cell × number of cells in the battery
pack.

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 BENDI AC CALIBRATION AND PROGRAMMING

DESCRIPTION Unit Value Min Max Text Description

Discharge Time Min 60 0 600 Sets the minimum time for the BDI algorithm to
count down the BDI Percentage from 100% to 0%.
The BDI algorithm integrates the time the filtered
keyswitch voltage is below the state of charge
voltage level. When that cumulative time exceeds
the Discharge Time / 100, the BDI Percentage is
decremented by one percentage point and a new
state of charge voltage level is calculated. State of
Charge Level = ((Full Voltage Level - Empty Voltage
Level) × BDI Percentage / 100) + Empty Voltage
Level.
BDI Reset Percent % 75 0 100 When a battery has a high BDI percentage, its float
voltage at KSI On can sometimes cause false
resets. The BDI Reset Percent parameter addresses
this problem by allowing the user to define a BDI
Percentage value above which the BDI Percentage
variable will not reset. When KSI is first powered on,
the BDI Percentage variable will reset to 100% only
if ((Keyswitch Voltage > Reset Voltage Level) and
(BDI Percentage < BDI Reset Percent)).
Dual Drive
Master
Steer Pot Min Volt 1.12 0 5 Set Steer Pot Min to the voltage on the steering pot
when steering as far as possible clockwise.
Determine the value by reading the voltage on the
pot when steering CW to the maximum position.
Steer Pot Zero Volt Set Steer Pot Zero to the voltage on the steering pot
when steering straight ahead. Determine the value
by reading the voltage on the pot when steering
straight.
Steer Pot Max Volt 4.77 0 5 Set Steer Pot Max to the voltage on the steering pot
when steering as far as possible counterclockwise.
Determine the value by reading the voltage on the
pot when steering CCW to the maximum position.

Landoll_P_S Parameters
DESCRIPTION Unit Value Min Max Text Description
Landoll Pump
Pump Speeds
Max Total Speed rpm 2600 1000 5000 Max Pump motor RPM
Sideshift Speed rpm 900 0 5000 Sideshift maximum motor RPM
Tilt Speed rpm 900 0 5000 Tilt maximum motor RPM
Lift Speed rpm See p. 0 5000 Lift maximum motor RPM
5-38.
Steer Speed rpm 850 0 5000 Steer maximum motor RPM
Seat Hydraulics Enable 0 0 1 When off, hydraulics can be operated without
operator on seat.
On: Can be operated regardless of seat switch.
Throttle

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BENDI AC CALIBRATION AND PROGRAMMING

DESCRIPTION Unit Value Min Max Text Description

Lift Deadband Volt 2.72 0 5 Defines the wiper voltage at the throttle deadband
threshold. Increasing the throttle deadband setting
will increase the neutral range. This parameter is
especially useful with throttle assemblies that do not
reliably return to a well-defined neutral point,
because it allows the deadband to be defined wide
enough to ensure that the controller goes into
neutral when the throttle mechanism is released.
Lift Max Volt 3.8 0 5 Defines the wiper voltage required to produce 100%
controller output. Decreasing the throttle max
setting reduces the wiper voltage and therefore the
full stroke necessary to produce full controller
output. This parameter allows reduced-range
throttle assemblies to be accommodated.

Curtis Controller See Figure 5-70. For illustration, see photo or refer to
Controller panel shown on page 4-7 for the left, pump
Troubleshooting and right controllers, the interconnect cables and the
LED lights.
IMPORTANT
The following troubleshooting chart provides
information on the Curtis controller faults:
• • Fault code
• • Fault name displayed on the dash display.
• • The effect of the fault
• • Possible causes of the fault
• • Fault set conditions
• • Fault clear conditions

NOTE
Whenever a fault is encountered and no wiring or vehicle
fault can be found, shut off KSI(Key Switch Interrupt) and
turn it back on to see if the fault clears. If it does not, shut
off Keyswitch Interrupt (KSI) and remove the 35-pin
connector. Check the connector for corrosion, damage or
unseated terminals. If necessary, clean the pins and
re-insert them. Figure 5-70 LED Status
TYPES OF LED DISPLAY
DISPLAY STATUS
Neither LED Controller is not powered on; or vehicle
illuminated has dead battery; or severe damage.
Yellow LED flashing Controller is operating normally.
Yellow and red Controller is in Flash program mode.
LED’s both on solid
Red LED on solid Watchdog failure or no software
loaded. Cycle KSI to restart, and if
necessary load software.
Red LED and yellow Controller has detected a fault. 2-digit
LED flashing code flashed by yellow LED identifies
alternately the specific fault; one or two flashes by
red LED indicate whether first or
second code digit will follow.

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 BENDI AC CALIBRATION AND PROGRAMMING

PROGRAM TROUBLESHOOTING CHART

C
O
D PROGRAMMER LCD
E DISPLAY T P POSSIBLE CAUSE SET/CLEAR CONDITIONS
12 Controller Overcurrent X X 1. External short of phase U,V, or W motor Set: Phase current exceeded the
ShutdownMotor; connections. current measurement limit.
ShutdownMainContactor; 2. Motor parameters are mis-tuned. Clear: Cycle KSI.
ShutdownEMBrake; 3. Controller defective.
ShutdownThrottle;
FullBrake;
ShutdownPump.
13 Current Sensor Fault X X 1. Leakage to vehicle frame from phase U, Set: Controller current sensors have
ShutdownMotor; V, or W (short in motor stator). invalid offset reading.
ShutdownMainContactor; 2. Controller defective. Clear: Cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
FullBrake;
ShutdownPump.
14 Precharge Failed X X 1. See Monitor menu » Battery: Capacitor Set: Precharge failed to charge the
ShutdownMotor; Voltage. capacitor bank to the KSI voltage.
ShutdownMainContactor; 2. External load on capacitor bank (B+ Clear: Cycle Interlock input or use VCL
ShutdownEMBrake; connection terminal) that prevents the function Precharge().
ShutdownThrottle; capacitor bank from charging.
Full Brake;
ShutdownPump.
15 Controller Severe X X 1. See Monitor menu » Controller: Set: Heatsink temperature below
Undertemp ShutdownMotor; Temperature. -40°C.
ShutdownMainContactor; 2. Controller is operating in an extreme Clear: Bring heatsink temperature
ShutdownEMBrake; environment. above -40°C, and cycle interlock or
ShutdownThrottle; KSI.
FullBrake;
ShutdownPump.
16 Controller Severe Overtemp X X 1. See Monitor menu » Controller: Set: Heatsink temperature above
ShutdownMotor; Temperature. +95°C.
ShutdownMainContactor; 2. Controller is operating in an extreme Clear: Bring heatsink temperature
ShutdownEMBrake; environment. below +95°C, and cycle interlock or
ShutdownThrottle; 3. Excessive load on vehicle. KSI.
FullBrake; 4. Improper mounting of controller.
ShutdownPump.
17 Severe Undervoltage X X 1. Battery Menu parameters are Set: Capacitor bank voltage dropped
Reduced drive torque. misadjusted. 2. Non-controller system drain below the Severe Undervoltage limit
on battery. (see page 55) with FET bridge
3. Battery resistance too high. enabled.
4. Battery disconnected while driving. Clear: Bring capacitor voltage above
5. See Monitor menu » Battery: Capacitor Severe Undervoltage limit.
Voltage.
6. Blown B+ fuse or main contactor did not
close.
18 Severe Overvoltage X X 1. See Monitor menu » Battery: Capacitor Set: Capacitor bank voltage exceeded
ShutdownMotor; Voltage. the Severe Overvoltage limit (see page
ShutdownMainContactor; 2. Battery menu parameters are 55) with FET bridge enabled.
ShutdownEMBrake; misadjusted. Clear: Bring capacitor voltage below
ShutdownThrottle; 3. Battery resistance too high for given Severe Overvoltage limit, and then
FullBrake; regen current. cycle KSI.
ShutdownPump. 4. Battery disconnected while regen
braking.

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BENDI AC CALIBRATION AND PROGRAMMING

C
O
D PROGRAMMER LCD
E DISPLAY T P POSSIBLE CAUSE SET/CLEAR CONDITIONS
22 Controller Overtemp X X 1. See Monitor menu » Controller: Set: Heat sink temperature exceeded
Cutback Temperature. 85°C.
Reduced drive and brake 2. Controller is performance-limited at this Clear: Bring heat sink temperature
torque. temperature. 3. Controller is operating in an below 85°C.
extreme setting.
4. Excessive load on vehicle.
5. Improper mounting of controller
23 Undervoltage Cutback X X 1. Normal operation. Fault shows that the Set: Capacitor bank voltage dropped
Reduced drive torque. batteries need recharging. Controller is below the Undervoltage limit (see page
performance limited at this voltage. 2. 55) with the FET bridge enabled.
Battery parameters are misadjusted. 3. Clear: Bring capacitor voltage above
Non-controller system drain on battery. 4. the undervoltage limit.
Battery resistance too high. 5. Battery
disconnected while driving. 6. See Monitor
menu » Battery: Capacitor Voltage. 7.
Blown B+ fuse or main contactor did not
close.
24 Overvoltage Cutback X X 1. Normal operation. Fault shows that regen Set: Capacitor bank voltage exceeded
Reduced brake torque. braking currents elevated the battery the Overvoltage limit (see page 55)
voltage during regen braking. Controller is with the FET bridge enabled.
performance limited at this voltage. Clear: Bring capacitor voltage below
2. Battery parameters are misadjusted. 3. the
Battery resistance too high for given regen Overvoltage limit.
current.
4. Battery disconnected while regen
braking. 5. See Monitor menu » Battery:
Capacitor Voltage.
25 +5V Supply Failure X X 1. External load impedance on the +5V Set: +5V supply (pin 26) outside the
None, unless a fault action is supply (pin 26) is too low. +5V±10% range.
programmed in VCL. 2. See Monitor menu » outputs: 5 Volts and Clear: Bring voltage within range.
Ext Supply Current.

28 Motor Temp Hot Cutback X X 1. Motor temperature is at or above the Set: Motor temperature is at or above
Reduced drive torque. programmed Temperature Hot setting, and the Temperature Hot parameter setting.
the requested current is being cut back. 2.
Motor Temp Control Menu parameters are Clear: Bring the motor temperature
mis-tuned. 3. See Monitor menu » Motor: within range.
Temperature and » Inputs: Analog2. 4. If the
application doesn’t use a motor thermistor,
Temp Compensation and Temp Cutback
should be programmed Off.
29 Motor Temp Sensor Fault X X 1. Motor thermistor is not connected Set: Motor thermistor input (pin 8) is at
MaxSpeed reduced (LOS, properly. 2. If the application doesn’t use a the voltage rail (0 or 10V).
Limited Operating Strategy), motor and motor thermistor, Motor Temp Clear: Bring the motor thermistor input
and motor temperature Sensor Enable should be programmed Off. voltage within range.
cutback disabled. 3. See Monitor menu » Motor: Temperature
and » Inputs: Analog2.
31 Coil1 Driver Open/Short X X 1. Open or short on driver load. Set: Main contactor driver (pin 6) is
ShutdownDriver1. 2. Dirty connector pins. either open or shorted. This fault can
3. Bad crimps or faulty wiring. be set only when Main Enable = Off.
Clear: Correct open or short, and cycle
driver.

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 BENDI AC CALIBRATION AND PROGRAMMING

C
O
D PROGRAMMER LCD
E DISPLAY T P POSSIBLE CAUSE SET/CLEAR CONDITIONS
36 Encoder Fault X X 1. MotorCoil3 Driver Open/Short Set: Motor encoder phase failure
ShutdownEMBrake. ShutdownDriver3. detected.
encoder failure. Clear: Cycle KSI.
2. Bad crimps or faulty wiring.
3. See Monitor menu » Motor:
Motor RPM.
37 Motor Open X X 1. Motor phase is open. Set: Motor phase U, V, or W detected
ShutdownMotor; 2. Bad crimps or faulty wiring. open.
ShutdownMainContactor; Clear: Cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
FullBrake;
ShutdownPump.
38 Main Contactor Welded X X 1. Main contactor tips are welded closed. 2. Set: Just prior to the main contactor
ShutdownMotor; Motor phase U or V is disconnected or closing, the capacitor bank voltage (B+
ShutdownMainContactor; open. connection terminal) was loaded for a
ShutdownEMBrake; 3. An alternate voltage path (such as an short time and the voltage did not
ShutdownThrottle; external precharge resistor) is providing a discharge.
FullBrake; current to the capacitor bank (B+ connection Clear: Cycle KSI
ShutdownPump. terminal).
39 Main Contactor Didn’t close X X 1. Maincontactor did not close. Set: With the main contactor
ShutdownMotor; 2. Main contactor tips are oxidized, burned, commanded closed, the capacitor bank
ShutdownMainContactor; or not making good contact. voltage (B+ connection terminal) did
Shutdown EMBrake; 3. External load on capacitor bank (B+ not charge to B+.
ShutdownThrottle; connection terminal) that prevents capacitor Clear: Cycle KSI.
Fullbrake; bank from charging.
ShutdownPump 4. Blown B+ fuse.
41 Throttle Wiper High X X 1. See Monitor menu >> Inputs: Throttle Pot. Set: Throttle pot wiper (pin 16) voltage
ShutdownThrottle. is higher than the high fault threshold
2. Throttle pot wiper voltage too high. (can be changed with the VCL function
SETUP POT FAULTS)
Clear: Bring throttle pot wiper voltage
above the fault threshold.
42 Throttle Wiper Low X X 1. See Monitor menu >> Inputs: ThrottlePot. Set: Throttle pot wiper (pin 16) voltage
ShutdownThrottle; 2. Throttle pot wiper voltage too high. is higher than the high fault threshold
(can be changed with the VCL function
Setup_Pot_Faults). Clear: Bring throttle
pot wiper voltage below the fault
threshold.

43 Pot2 Wiper High X Refer to Curtis Return Controller to Landoll

FullBrake. Corporation for evaluation.

44 Pot2 Wiper Low X Refer to Curtis Return Controller to Landoll

FullBrake. Corporation for evaluation.

45 Pot Low Overcurrent X X 1. See Monitor menu >> Outputs: Pot Low. Set: Pot low (pin 18) current exceeds
ShutdownThrottle. 2. Combined pot resistance connected to 10mA.
FullBrake pot low is too low. Clear: Clear pot low overcurent
ShutdownSteer condition and cycle KSI.

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BENDI AC CALIBRATION AND PROGRAMMING

C
O
D PROGRAMMER LCD
E DISPLAY T P POSSIBLE CAUSE SET/CLEAR CONDITIONS
46 EEPROM Failure X X 1. Failure to write to EEPROM memory. This Set: Controller operating system tried
ShutdownMotor; can be caused by EEPROM memory writes to write to EEPROM memory and
ShutdownMainContactor; initiated by VCL, by the CAN bus, by failed.
Shutdown EMBrake; adjusting parameters with the programmer, Clear: Download the correct software
ShutdownThrottle; or by loading new software into the (OS) and matching parameter default
ShutdownInterlock;Shutdown controller. settings into the controller and cycle
Driver1 KSI.
ShutdownDriver2;Shutdowndr
iver3;
ShutdownDriver4;ShutdownP
D; Fullbrake; ShutdownPump;
TrimDisable;SevereDual;
ShutdownSteer; LOSDual
47 HPD/Sequecing Fault. 1. KSI, interlock, direction, and throttle Set: HPD (High Pedal Disable) or
Shutdown Throttle inputs applied in incorrect sequence. sequencing fault caused by incorrect
2. Bad crimp, faulty wiring or KSI switch. sequence if KSI, interlock, direction
See Monitor menu>>Inputs. and throttle inputs.
Clear: Reapply correct input sequence.
49 Parameter Change Fault X X [Link] is a safety fault caused by a change Set: Adjustment of a parameter setting
ShutdownMotor; in certain parameter settings so that the that requires cycling of KSI.
ShutdownEMBrake; vehicle will not operate until KSI is cycled. Clear: Cycle KSI.
Shutdown Throttle; For example, if a user changes the Throttle
Fullbrake; Type, this fault will appear and require
ShutdownPump cycling KSI before the vehicle can operate.
52 Battery Rollout Switch Return Controller to Landoll
Fault in Left traction controller. Corporation for evaluation.
68 VCL Run Time Error X X [Link] code encountered a runtime VCL Set: Runtime VCL code error condition.
ShutdownMotor; error. Clear: Edit VCL application software to
ShutdownMainContactor; 2. See Monitor menu>>Controller:VCL Error fix this error condition; flash the new
ShutdownEMBrake; Module and VCL Error. This error can then compiled software and matching
ShutdownThrottle; be compared to the runtime VCL module ID parameter defaults; cycle KSI.
ShutdownInterlock; and error code definitions found in the
ShutdownDriver1; specific OS system information file.
ShutdownDriver2;
ShutdownDriver3:
ShutdownDriver4;
ShutdownPD; FullBrake;
ShutdownPump.
ShutdownPump: TrimDisable;
SevereDual; ShutdownSteer;
LOSDual.
69 External Supply Out of X X 1. External load on the 5V and 12V supplies Set: The external supply current
Range draws either too much or too little current. (combined current used by the 5V
None, unless a fault action is 2. Fault Checking Menu parameters Ext supply [pin 26} and 12V supply {pin
programmed in VCL; Supply Max and Ext Supply Min are 25}) is either greater than the upper
mistuned. current threshold or lower than the low
3. See Monitor menu>>Outputs: Ext Supply current threshold. The two thresholds
Current. are defined by the External Supply Max
and External Supply Min parameter
settings.
Clear: Bring the external supply current
within range.

5-44 F-528-0511 Edition

 BENDI AC CALIBRATION AND PROGRAMMING

C
O
D PROGRAMMER LCD
E DISPLAY T P POSSIBLE CAUSE SET/CLEAR CONDITIONS
71 OS General X X [Link] Controller fault. Set: Internal controller fault detected.
ShutdownMotor; Clear: Cycle KSI.
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;ShutdownD
river2;
ShutdownDriver3;ShutdownD
river4; ShutdownPD;
FullBrake:Shutdown Pump;
TrimDisable;
SevereDual;Shutdown Steer;
LOSDual
72 PDO TImeout X X Time between CAN OPDO messages Set: Time between CAN PDO
Shutdown Interlock; received exceeded the PDO Timeout messages received exceeded the PDO
CAN NMT State set to Period. Timeout Period.
Pre-operational Clear: Cycle KSI or receive CAN NMT
message
73 Stall Detected X X 1. Stalled motor. Set: No motor encoder movement
ShutdownMotor; 2. Motor encoder failure. detected.
SevereDual; 3. Bad crimps or faulty wiring. Clear: Either cycle KSI, or detect valid
ShutdownEMBrake; 4. Problems with power supply for the motor motor encoder signals while operating
Control Mode changed to encoder. in LOS mode and return Throttle
LOS (Limited Operating 5. See Monitor menu>>Motor: Motor RPM. Command=) and Motor RPM=0.
Strategy)
74 Fault On other Traction X X 1. A fault is active on the other traction Set: In a Dual Drive traction system,
Controller controller. any fault in the other traction controller
For information on this fault, will cause this fault to be set.
plug the programmer into the Clear: Clear all the active faults in the
other controller. other traction controller.

5-45
BENDI AC CALIBRATION AND PROGRAMMING

C
O
D PROGRAMMER LCD
E DISPLAY T P POSSIBLE CAUSE SET/CLEAR CONDITIONS
75 Dual Severe Fault X X 1. Both taction controllers have active Set: A severe fault in each traction
ShutdownMotor; severe faults and therefore both will be controller will cause this fault to be set.
ShutdownMainContactor disabled. Clear: Correct the severe fault(s) in
ShutdownEMBrake; either controller to clear the Dual
Shutdown Throttle; FullBrake; Severe Fault; of course, you will want to
Shutdown Pump Other clear all faults on both controllers.
controller: Same effects as
this controller.
91 VCL/OS Mismatch [Link] VCL software in the controller does Set: VCL and OS software do not mach
ShutdownMotor; not match the OS software in the controller. when KSI cycles, a check is made to
ShutdownMainContactor; verify that they match and a fault is
ShutdownEMBrake; issued when they don’t.
ShutdownThrottle; Clear: Download the correct VCL and
ShutdownInterlock; OS software into the computer.
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD; FullBrake;
ShutdownPump
91 VCL/OS Mismatch [Link] VCL software in the controller does Set: VCL and OS software do not mach
ShutdownMotor; not match the OS software in the controller. when KSI cycles, a check is made to
ShutdownMainContactor; verify that they match and a fault is
ShutdownEMBrake; issued when they don’t.
ShutdownThrottle; Clear: Download the correct VCL and
ShutdownInterlock; OS software into the computer.
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD; FullBrake;
ShutdownPump
93 Encoder LOS 1. Limited Operating Strategy (LOS) control Set: Encoder Fault (Code 36) or Stall
(LimitedOperatingStrategy). mode has been activated, as a result of Detect Fault (Code 73) was activated,
Enter LOS control mode. either an Encoder Fault (Code 36) or a Stall and Brake or Interlock has been
Detect Fault (Code 73). applied to activate LOS control mode,
2. Motor encoder failure. allowing limited motor control. Clear:
[Link] crimps or faulty wiring. Cycle KSI or, if LOS mode was
4. Vehicle is stalled. activated by the Stall Fault, clear by
ensuring encoder senses proper
operation, Motor RPM=0, and Throttle
Command=0.
98 Illegal Model Number X X 1. Model_Number variable contains illegal Set: Illegal Model_Number variable;
ShutdownMotor; value (not 1234, 1236, 1238, or 1298). when KSI cycles, a check is made to
ShutdownMainContactor; 2. Software and hardware do not match. confirm a legal Model_Number, and a
ShutdownEMBrake; 3. Controller defective. fault is issued if one is not found.
ShutdownThrottle; Clear: Download appropriate software
FullBrake; for your controller model.
ShutdownPump.
99 Dualmotor Parameter X 1. Dual Motor Enable parameter set On and Set: When the Dual Drive software is
Mismatch Control Mode Select parameter not set to 1 enabled, the controller must be set to
ShutdownMotor; (Speed Mode Express) or 2 (Speed Mode). either Speed Mode Express or Speed
ShutdownMainContactor; Mode; otherwise this fault is set.
ShutdownEMBrake; Clear: Adjust parameters to
ShutdownThrottle; appropriate values for your application
FullBrake; and cycle KSI.
ShutdownPump.

5-46 F-528-0511 Edition

 BENDI AC CALIBRATION AND PROGRAMMING

Controller Maintenance Programmer Menus

There are no user serviceable parts in the Curtis The programmers have six menus, which in turn lead to
1234/36/38 controllers. No attempt should be made to nested submenus.
open, repair, or modify the controller. Modifying the • Program — provides access to the programmable
controller will void the warranty. It is recommended that parameters.
the controller and connection be kept clean and dry and
• Monitor — presents real-time values during vehicle
that the controller’s fault history file be checked and
operation; these include all inputs and outputs, as
cleared during service.
well as the mapped throttle values and conditioned
throttle requests.
Controller Cleaning • Faults — presents diagnostic information and also a
means to clear the fault history file.
Periodically cleaning the controller exterior will help
protect it against corrosion and possible electrical • Functions — provides access to the
problems created by dirt that is part of the operating controller-cloning commands and to the “reset”
environment and that normally exists in battery powered command.
systems. When working around any battery powered • Information — displays data about the host
system, proper safety precautions should be taken. controller, model and serial numbers, date of
These include, but are not limited to: proper training, manufacture, hardware and software revisions, and
wearing eye protection, and avoiding loose clothing and itemization of other devices that may be associated
jewelry. with the controller’s operation.
• Programmer Setup — displays data about the
IMPORTANT programmer: model and serial numbers, and date of
Never use a pressure washer to clean the controller. manufacture.
Use the following cleaning procedure for routine
maintenance:
1. Remove power by disconnecting the battery.
2. Discharge the capacitors in the controller by
connecting a load across the controller’s B+ and B
terminals.
3. Remove any dirt or corrosion from the power and
signal connector areas. The controller should be
wiped clean with a moist rag. Dry it before
reconnecting the battery.
4. Make sure the connections are tight.

5-47
BENDI AC CALIBRATION AND PROGRAMMING

5-48 F-528-0511 Edition

 Chapter 6

Truck Lubrication and Chain Maintenance

Lubricating the Truck Tilt Cylinder Clevis

1. Before lubricating the truck, lower the forks, set the 1. Start the truck and pivot the mast straight forward to
Keyswitch to the OFF position, and set the parking the normal carry position.
brake. 2. Set the Keyswitch to OFF and remove the key from
2. Certain grease fittings may include protective plastic the Keyswitch.
caps. Remove them before applying grease. 3. Grease clevis fitting on the end of tilt cylinder until
Remember to replace the caps when you are fresh grease is squeezed from the clevis. See
finished. Figure 6-4.
3. In the following procedures, the location of grease 4. Wipe off excess grease.
fittings or surfaces to be greased are by either a
grease-gun or brush respectively. Main Rotation Bearings
4. Make sure all grease fittings are wiped clean before
lubricating. If any of the fittings are corroded or 1. Start the truck and pivot the mast straight forward to
blocked, replace them. Before brush-applying grease the normal carry position.
to bearing pad surfaces, wipe out the channel to 2. Set the Keyswitch to OFF and remove the key from
remove any foreign matter that may have the Keyswitch.
accumulated since your last lubrication. 3. Grease the upper and lower front rotation bearing
5. High pressure washing the forklift is not fittings until fresh grease is squeezed from the lower
recommended but if unavoidable, lubricate all bearing. See Figure 6-1.
unprotected grease fittings and metal-to-metal
surfaces, located outside the truck.

NOTE
Keep high pressure wash away from all electronic wiring
and semiconductor components.
6. Lubrication frequency can be recorded from the
running hours read on the hour meter in the driver’s
compartment.
7. See Table in Chapter 1 page 1-17 for recommended
lubricants.

 WARNING
Do not service the truck and/or mast area while
the Keyswitch is ON. If a control, steering wheel
or accelerator pedal is accidentally moved Figure 6-1: Steering Grease Points
serious injury could occur. 4. Wipe off excess grease at the lower bearing.

6-1
TRUCK LUBRICATION AND CHAIN MAINTENANCE

Fork Positioner Lubrication, Non-Side

Shifting (Option)
1. Start the truck and position the mast straight ahead.
Chain Lubrication
Caution

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

the Keyswitch.  CAUTION
3. Before lubricating the positioner rails, wipe off excess The chains must be coated with a film of lubricant
lubricant and dirt buildup from within the rail channels at all times.
and dirt from the top and bottom of the rail grooves.
4. Using a brush, lubricate the top surface on the fork
• Lubricate the chains as required by the Hourly
rails, including a thin film on the front face of both
Checklists beginning on page 1-8.
rails. See Figure 6-2.
• Use lubricant listed on the Lubrication Chart located
on page 1-17.
• Each pair of chains has been factory-lubricated using
heat and pressure to force the lubricant thoroughly
into the chain links. Avoid removal or contamination
of this factory applied lubricant. Do not wash, sand
blast, etch, steam clean, or paint the chains.

Chain Adjustment
The chain must be adjusted so each strand is under
equal tension for proper load distribution and mast
operation.
To determine whether the chains are properly
adjusted:
1. Remove load from forks.
2. Extend the mast to put the chains under tension.
3. Press the center of a strand of chain with your thumb,
Figure 6-2: Fork Rail then press at the same place on the other chain of
the pair.
5. Wipe off excess grease.
4. Each chain in a pair should have equal “give”. If
tension is not equal, adjust them as described in the
Lubricate Steer Wheel Knob manufacturer’s mast service manual, Chapter 7.

Measuring Chain Stretch

If the chains stretch beyond the recommended amount,
they should be replaced in pairs. Chain stretch can be
measured with a Chain Wear Scale, Landoll P/N162280.
The scale indicates whether the distance between two
chain links is within tolerance. Compare a stretched
chain, to a new chain. See Chapter 7, Figure 52.
Measure the chains according to the instructions printed
on the chain wear scale, without load on the carriage.
• To check the free lift chains, raise the carriage 1 ft.
(30 cm) off the ground to put tension on the chains.
• To check the main lift chains, raise the mast until the
inner upright starts to extend putting tension on the
1. While the truck is stationary and with the Keyswitch chains.
OFF, apply a drop or two of light machine oil where
the knob meets the steering wheel.
2. Spin the knob a few times and wipe off excess oil.

6-2 F-528-0511 Edition

 TRUCK LUBRICATION AND CHAIN MAINTENANCE

Check Primary Lift Chain Checking and Adjusting Degree of Tilt

1. Park the truck on a flat, level surface, with the parking 1. To check degree of tilt, be certain the truck is on a
brake engaged. smooth, level surface.
2. Set the mast in the center of the truck, facing straight 2. Tilt the mast back its full stroke. Place the tilt gauge
ahead, level to the floor and empty (unloaded). against the rear outer mast rail on the right side of
Check the fork level gauge on the left side of the the truck.
mast. 3. If equipped with a mast that has a fork height greater
3. Set the Keyswitch to OFF and remove the key from than 240”, available tilt is limited to 1 degree forward
the Keyswitch. and 2.1 degrees back. The standard tilt is 3 degrees
4. Measure the distance from the floor to the bottom forward and 3.1 degrees back for masts of 239” or
heel of each fork tine. Measurement must be 1/8” lower. When testing a standard truck equipped with a
(3.175 mm) minimum to 1/4” (6.35 mm) maximum. mast gauge, the gauge must read between 3.0 and
3.1 degrees, while the taller mast must read between
5. If it is not within 1/8” to 1/4” (3.175 mm to 6.35 mm),
2.0 and 2.1 degrees of rear tilt.
adjust the primary lift chain accordingly. See Chain
Adjustment on page 6-2.
Adjusting the degree of tilt:
1. Tilt the mast fully forward.
2. Set the Keyswitch to OFF and remove the key from
the Keyswitch.

 CAUTION
Do not service the tilt cylinder while the
Keyswitch is ON. If a control, steering wheel or
accelerator pedal is accidentally moved, you
1/8" - 1/4"
could be caught between the mast and the truck,
causing serious injury.
Figure 6-3
3. Loosen the tilt cylinder adjuster bolt. See Figure 6-4.
Check Lift Operation
1. Check the lift cylinders to ensure proper sequencing.
If adjustment is needed, see Chain Adjustment on
page 6-2.
2. Check to see that an unloaded mast will completely
lift to full lift height (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.
5. Look for signs of galling where the rollers contact the
rail. Galling is indicated by track marks in the rails Figure 6-4: Tilt Cylinder Adjustment
that are 1/4” to 1/2” (6.35 mm to 12.7 mm) wide
4. Continue to loosen the tilt cylinder adjuster bolt until
running up the rail. Normal track marks are no more
there is no bolt pressure on the tilt cylinder clevis.
than 1/4” (6.35 mm) wide.
5. Place the tilt gauge against the rear outer mast rail
6. If galling is detected, adjust the rollers for the proper
on the right side of the truck, about 6” (152 mm)
clearance over the full length of the mast rails. See
above the mast cross member.
“Inspection Check List,” page 1-7.

6-3
TRUCK LUBRICATION AND CHAIN MAINTENANCE

Disconnecting the Tilt Cylinder

 CAUTION
NEVER exceed 3.0° to 3.1° rear tilt for 239” or
shorter masts. Never exceed 2.0° to 2.1° rear tile
 WARNING
for 240” or taller masts. Actual rear tilt in excess • Steel toed shoes and eye protection are
of recommended tilt can cause the truck to required when doing maintenance or repair
become unstable under certain conditions. work on a lift truck.
• Do not place feet or hands in any areas
6. Relieve the hydraulic pressure on the tilt cylinder. through the mast or in truck pinch points.
Rotate the tilt cylinder rod, using a 1-3/4 open end • Servicing the tilt cylinders requires the use of
wrench on the tilt cylinder rod. Looking at the rod end an overhead hoist, hoist slings and wheel
of the cylinder turn clockwise to shorten the rear tilt blocks. The overhead hoist and slings must
or counterclockwise to increase the rear tilt. It is best have a rating of 8,000 lb. or greater.
to turn the rod only a 1/2 turn at a time. • Do not work under or around a truck that is
7. You may have to tilt the mast a number of times, not properly secured.
repeating steps 4 thru 9, until the adjustment is • The battery must be disconnected or
correct and both tilt cylinders are adjusted identically. removed from the truck.
8. When the adjustment is complete, reinsert the key
and turn to the ON position. Using the tilt cylinder
1. Truck repair must be in a level, designated area.
lever, tilt the mast back to its full stroke.
2. Turn the lift off, pull the key and put it in a secure
9. Check functionality that mast does not twist when run
place.
to full forward or full rear tilt, and that there is no
interference with hoses and wiring. 3. Lower the mast completely to the floor.
10. Tighten and torque the tilt cylinder adjuster bolt 4. Chock the wheels so that the truck cannot move.
against the cylinder clevis. See General Torque, 5. Attach a sling and hoist to all the top cross braces so
Hydraulic Fitting Torque, and Bendi AC Special the mast sections cannot move.
Torque Tables on page 1-17. 6. Lift the mast gently until all pressure is removed from
the tilt cylinders and remove cylinder(s) retaining
bolt(s) as required. See Figure 6-4.
7. Pull cylinder pins and disconnect cylinders.
8. Replace in reverse order.

6-4 F-528-0511 Edition

 Chapter 7

Supplier Provided Documentation

Disclaimer:
The documentation provided here within
Chapter 7, “Supplier Provided
Documentation”, has been appended to
this Landoll Maintenance Manual for
reference only.
The specific contents of this information
is not the responsibility of Landoll
Corporation or any of it’s affiliates.

Lift Technologies Mast Service

Manual
Models 30D/35D/40D/50D/55D/60D
Table of Contents - page 4
Proceed to the above “Table of Contents” starting on
page 4, to the Mast Installation, Periodic Maintenance,
Troubleshooting and Service instructions as required.

7-1
SUPPLIER PROVIDED DOCUMENTATION

7-2 F-528-0511 Edition

Mast Service Chapter
30D/35D/40D/50D/55D/60D
Full Free Lift 3-Stage Mast - MT

Manual Part Number 687250 R3

Lift Technologies, Inc. 2005

Contents
Page
INTRODUCTION, Section 1 4
Introduction 4
Special Definitions 4
INSTALLATION INSTRUCTIONS, Section 2 5
Truck System Requirements 5
Mounting Bracket Installation 5
Mast Installation 6
Inspection and Adjustments 7
Chain Inspection and Tension 7
Main Lift Chain Adjustment 7
Free Lift Chain Adjustment 7
Free Lift Cylinder Supply Hose Tracking Adjustment 8
Upright Rail Lubrication 8
Cylinder Bleeding 8
Mast Skewing 8
Internal Reeving Installation 9
PERIODIC MAINTENANCE, Section 3 16
TROUBLESHOOTING, Section 4 17
SERVICE, Section 5 18
Mast Removal 18
Cylinders 19
2000 PSI Main Lift Cylinder Description 19
2600 PSI Main Lift Cylinder Description 20
Free Lift Cylinder Description 21
Cylinder Operation 22
Main Lift Cylinder Removal- Mast on Floor 24
Free Lift Cylinder Removal- Mast on Floor 25
Free Lift Cylinder Removal- Mast on Truck 26
Main Lift Cylinder Service 27
Free Lift Cylinder Service 28
Piston Removal 29
2600 PSI Cylinder Bleeding 29
Valve 29
Valve Cartridge Service 29
Carriage 30
Description 30
Carriage Removal- Mast on Truck 31
Carriage Removal- Mast on Floor 32
Carriage Inspection 33
Mast Uprights 34
Upright Description 34
Upright Operation 35
Upright Disassembly 36
Upright Inspection 37
Upright Reassembly 38
Mast Skewing 41
Chains 42
Inspection and Tension 42
Measuring Chain Stretch 43
Main Lift Chain Adjustment 43
Free Lift Chain Adjustment 43
Main Lift Chain Service 44
Free Lift Chain Service 44
Section 1 Introduction
1.1
Introduction
This manual provides the installation instruction, periodic
maintenance, troubleshooting and service procedures for
the Lift Tek Series masts.
XXXXXX
In any communication about the mast, refer to the mast XXXX OR XXXXXX
XXXXXX
serial number stamped in the nameplate. If the nameplate XXXX

is missing, these numbers are also stamped on the Stamped

left-hand upper cheekplate. See Figure 1. Serial
Numbers

WARNING: Do not install a Lift Tek Mast XXXXXX

XXXX

on a truck with a capacity greater than the

truck rated capacities shown below
[Link]

TRUCK CAP ACITY AT 24IN. Example:

(610 mm) LOAD CENTER
55D–MT–001–00025–M
30D 35D 40D 50D 55D 60D
3000 lbs. 3500 lbs. 4000 lbs. 5000 lbs. 5500 lbs. 6000 lbs. Figure 1. Serial Mast Number Location
(1361 kg) (1585 kg) (1812 kg) (2268 kg) (2491kg) (2718 kg)

Modifications and additions which affect capacity or safe

operation shall not be performed without prior written
approval from Lift Technologies per ANSI B56. 1.
1.2
Special Definitions
WARNING
A statement preceded by WARNING is information
that should be acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
CAUTION
A statement preceded by CAUTION is information that
should be acted upon to prevent machine damage.
IMPORTANT
A statement preceded by IMPORTANT that
possesses special significance.
NOTE
A statement preceded by NOTE is information that is handy
to know and may make your job easier.

4 687250 R3
Section 2 Installation Instructions
2.1 Truck System
Requirements
To achieve maximum lifting capacity of the mast, the
truck relief valve should be set to relieve at the pressure
indicated in the chart below. This chart also indicates the
hose fitting size to use between the truck control valve
and masts valve.

Lift Tek Relief Hose Fitting*

Mast Pressure Size Size
30D/35D/40D 2000 psi No. 8 min. No. 8 min.
30D/35D/40D 2600 psi No. 6 min. No. 6 min.
50D/55D/60D 2600 psi No. 8 min. 13/32 in. Orifice
* Valve inlet port is 3/4 in. SAE O-ring. See Figure 2.
[Link]
WARNING: For proper truck stability or to
prevent interference, tilt restriction may be
required. Contact the truck manufacturer.
IMPORTANT: Lift Tek Masts are compatible with SAE 10W
petroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104
Valve Inlet Port
B only. Use of synthetic or aqueous base hydraulic oil is not 3/4 in. SAE O-ring
recommended. If fire resistant hydraulic oil must be used,
FigFigure 2. Valve inlet Port.
contact Lift Tek.

2.2
Mounting Bracket
Installation Truck Cowl
A
B
1 If it is necessary to install mounting brackets and cross-
members to fit your lift truck, consult with the nearest C
D
Lift Tek Service Department listed on the back cover.
You must supply dimensions A through F shown in
Figure 3. Failure to install the correct brackets and cross- Front View
members can result in mast structural failure, bodily injury
and loss of warranty.
Tilt Cylinders
WARNING: Failure to install the correct
brackets and crossmembers can result in
mast structural failure, bodily injury and
loss of warranty.

Side View
[Link]

Figure 3. Determining Mounting Bracket Location.

5 687250 R3
Section 2 Installation Instructions
2.3
Mast Installation
1 1. Raise and block the front end of the truck 1ft. (30 cm) per
ANSI B56.1 or drive the truck over a service pit.

2. Install the bearings to lower the axle mounts.

3. Lubricate the bearing surfaces of the lower axle and tilt

cylinder mounting brackets with chassis grease.

4. Lift the mast using an overhead hoist with chain hooks

attached to the cheekplate lifting holes. Position the mast
by lowering the axle mounts on the truck axle. Install the
mount caps and capscrews. Tighten the capscrews to the
truck manufacturer’s torque specifications.
IMPORTANT: Prior to connecting the tilt cylinders to the
mast, make sure the cylinders “bottom” evenly. Adjust the tilt
cylinders to prevent the mast from “racking” during tilting.
Refer to your truck service manual for procedures.
4
5. Connect the lift truck hose to the mast valve.
6. Connect the tilt cylinders to the mast anchor brackets.
Tighten the pin capscrews to the truck manufacturer’s
torque specifications.

NOTE: Use as few fittings as possible and always use 45o

fittings instead of 90o fittings. Keep the hose lengths to a
minimum. Avoid sharp bends or pinch points when routing
the hose.
50D MAST

Contact Lift Tek if

additional fittings are
required. See back cover.

5 6

4 [Link]

2 3
FiFigure 4. Mast Installation.
6 687250 R3
 Section 2 Installation Instructions
2.4
Inspection and
Adjustments
2.4-1 Chain Inspection and
Tension
The hoist Chains have been factory lubricated using heat and
*3 in. *5 in.
pressure to force the lubricant thoroughly into the chain links. Underclearance Underclearance
Avoid removal or contamination of this factory applied
lubricant. Do not wash, sand blast, etch, steam clean, or
Outer Upright
paint the chains for internal mast installation. and Carriage
Flush Outer
Upright
The chains must be adjusted with equal tension to ensure
proper load distribution and mast operation. To determine Carriage 2 in.
Below Outer
equal tension, extend the unload mast to put the chains Upright
under tension. Press the center of a strand of chain with your [Link]

thumb, then press at the same place on the other chain of the NOTE: Underclearance is based on mast
pair. Each chain in a pair should have equal “give”. If they production series, actual mast
do not have equal tension, preform the hoist chain adjust- underclearance may vary by truck
model.
ments described in Section 5.6-3 and 5.6-4.

Figure 5. Upright and Carriage Position.

2.4-2 Main Lift Chain Adjustment
SEE SECTION 5.6-4.

2.4-3 Free Lift Chain adjustment

SEE SECTION 5.6-6.

7 687250 R3
Section 2 Installation Instructions
2.4-4 Free lift Cylinder Supply
Hose Tracking Adjustment
Make sure the cylinder supply hose is not twisted and travels
evenly in the hose guide. Check the hose to be sure it is not
scuffing. Adjust the hose by loosening the hose end
connection at the valve and twist the hose. Tighten the hose
end while holding the hose in place. See Figure 10. Tension
on the hose can be adjusted by using a different set of
bracket holes. Use the holes that place a small amount of
tension on the hose. Adjust
Hose
End

Mast
Valve

[Link]

Figure 6. Free Lift Cylinder Supply Hose Adjustment.

2.4-5 Upright Rail Lubrication
Lubricate the full length of each upright rail with chassis lube
Upright
or Kendall SR-12X as shown in Figure 6. Rails

2.4-6 Cylinder Bleeding

SEE SECTION 5.2-11.

2.4-7 Mast Skewing

Check for mast skewing as described in Section 5.5-6. [Link]

LUBRICATE ONLY WHERE INDICATED

BY THE HEAVY LINE FOR THE FULL
LENGTH OF EACH UPRIGHT

Figure 7. Channel lubrication.

8 687250 R3
Section 2 Installation Instructions
2.5
Internal Reeving - Hi-Vis
Installation 30D/35D/40D and 50D
1. Install the shafts, sheaves and hose guards to the
crosshead center plate. Leave the capscrew and nut
finger tight to allow hose installation.

[Link]

2. Install the carriage bracket to the tabs between the Figure 8 . Crosshead Assembly.
carriage sideplates. Leave the capscrews finger tight.

3. Install fittings to bracket.

* Single Function - Install the fittings to the left or right
side location. Tighten the fittings finger tight.
* Double Function - Install the fittings to the left and right
side location. Tighten the fittings finger tight.

OR 3

SINGLE DOUBLE
FUNCTION FUNCTION 2
[Link]
Figure 8. Carriage Bracket Assembly.

[Link]
Figure 9. Carriage bracket Installation.
9 687250 R3
Section 2 Installation Instructions
Internal Reeving - Hi-Vis
Installation 30D/35D/40D and 50D
4. Install the brackets, hose clamps and sheaves to the
uprights. Tighten the bracket capscrews to a torque of
38 ft.- lbs. (51 Nm).

5. Completely lower the carriage. Route the hoses down

behind the top carriage bar to the carriage bracket
fittings. Connect the hoses fittings to the carriage fittings
and tighten.

6. Loosen the crosshead coverplate capscrew. Route the

hoses up over the crosshead sheaves. Orient the hoses
with the natural curve over the sheaves.

7. Route the hoses down between the free lift cylinder and
middle inner crossmember to the bracket behind the free
lift cylinder. The hoses route through the wire loop then
2 Hose 4 Hose
underneath the lower inner crossmember. Assemble the Sheave Sheave Outer
Upright
clamp and hoses, then pull down on the hoses with 80
4
lbs. force to remove slack. Tighten the clamp capscrews
to a torque of 8 ft.-lbs (11Nm).

Inner Intermediate
Upright Upright 4

[Link]

4
Figure 10. Bracket Installation.

10 687250 R3
Section 2 Installation Instructions
Internal Reeving - Hi-Vis
Installation 30D/35D/40D and 50D 9

9
Upper
Bracket

6 10
Center
SINGLE DOUBLE Bracket
FUNCTION FUNCTION

5 7
Carriage
Bracket
Fittings
7

SINGLE
FUNCTION
SINGLE
FUNCTION

5 7 7 DOUBLE
DOUBLE FUNCTION
FUNCTION (Typical all clamps)

[Link]
Figure 11. Hose Routing.

8. Route the hoses under the lower inner crossmember

to loop up to the lower hose bracket. Install the hose clamps
leaving the capscrews finger tight. Align the hoses under
the crossmember and into the clamp. Tighten the clamp
11
capscrews to a torque of 8 ft.-lbs. (11Nm).

9. Route the hoses up to and over the upper hose sheaves and
then down to the upper hose bracket. Assemble the
clamp and hoses to the upper bracket leaving the
capscrews finger tight. Starting with the outer hose, pull
down on the hoses with 80 lbs. of force to remove slack,
then tighten the clamp capscrews to a torque of 8 ft.-lbs. (11Nm).

10. Attach the hose ends to the center hose bracket aligning
the hoses with their natural curve. Tighten the clamp
capscrews to a torque of 8 ft.-lbs. (11Nm.)

11. Attach the left hand cylinder supply hose and clamp to the
outer upright center crossmember. Tighten the clamp [Link]

capscrew to a torque of 8 ft.-lbs. (11Nm.) Figure 12. Main Lift Hose.

11 687250 R3
Section 2 Installation Instructions
Internal Reeving - Hi-Vis
Installation 30D/35D/40D and 50D
12. Tighten the crosshead coverplate capscrew to a torque of
51 ft.-lbs. (70Nm.).

13. Tighten the carriage bracket capscrews to a torque of 46

ft.-lbs. (63 Nm.)

14. Raise and lower the mast slowly through several cycles
checking for proper hose alignment, clearances and hose
tracking.

12

Crosshead
Coverplates

13

[Link]

Figure 13. Crosshead Assembly.

12 687250 R3
Section 2 Installation Instructions
Internal Reeving - Std-Vis
Installation 55D/60D
1. Install the reeving brackets to the crosshead. Tighten
the capscrews to a torques of 12 ft.-lbs. (17Nm.).

2. Install the rollers and hose guards to the crosshead

reeving bracket. Leave the nut finger tight to allow
hose installation.
2
2

[Link]

Figure 14. Center Crosshead Sheaves.

3. Double Function Internal Reeving - Install the

sheaves to the crosshead chain shafts. Leave the
capscrews finger tight to allow for hose installation.

[Link]

Figure 15. Outer Crosshead Sheaves.

13 687250 R3
Section 2 Installation Instructions
Internal Reeving - Std-Vis
Installation 55D/60D Single Function
1. Install the carriage bracket to the tabs on the carriage
side plates. Tighten the nuts to a torque of 38 ft.-lbs. (51Nm.)

2. Install the bulkhead and 900 fitting to the middle two

holes in the carriage bracket.

3. Install the hoses to the carriage bracket fittings. Leave

the fittings loose. 8

4. Route the hoses up and over the rollers on the center of

the crosshead. Tighten the hose guard capscrew to a
torque of 38 ft.-lbs. (51Nm.). 7
WARNING: Chain and block the uprights
and carriage to secure for step 5. -

5. Install spacers to the inner crossmember backside tabs.

6. Raise the carriage approximately 8 ft. (240cm). route

the hoses downward on the front side of all the cross-
members, then under the tab on the front side of the cylinder
support. Feed the hoses backward under the cross-
member, around the casting guide upward under the 4
back side. 9,12
7. Pull the hose ends to remove hose slack.
4 11
8. Remove the existing capscrews from the main lift chain
shafts. Install the hose, sheaves, shafts and spacers to
the main lift chain shafts. Tighten the capscrews to a
torque of 58 ft.-lbs. (79Nm.). Make sure the sheaves 10
rotate freely.

9. Attach the hoses to the brackets and fittings. Leave the

fittings loose on the bracket.
4
Tab

Cylinder
Support

Front

Figure 16. Hose Routing.

1 Crossmember
8 5
10. Install the hose clamps to the hoses half way between the 2
crosshead and lower crossmember.

11. Pull down on the hoses to remove slack and stretch 3,12 Back
hoses one inch. Install the brackets on the front side of the Side
crossmember using the next hole down. Tighten the Tab
Casting
capscrew to a torque of 38 ft.-lbs. (51 Nm.). Guide
12. Raise and lower the mast several times to make sure the
hoses are tracking correctly. Use the white line on the
hose to detect twisting. Adjust the hose ends if re-
quired. Tighten fittings making sure they do not twist. Back
[Link]

14 687250 R3
Section 2 Installation Instructions
Internal Reeving - Std-Vis
Installation 55D/60D Double Function
1. Install the carriage bracket to the tabs on the carriage
side plates. Tighten the nuts to a torque of 38 ft.-lbs.
(51Nm.).

2. Install the bulkhead and 900 fitting to the holes in the

carriage bracket.
7
3. Install the hoses to the carriage bracket fittings. Leave
the fittings loose.

4. Route the hoses up and over the rollers on the cross-

head. Tighten the sheave capscrews to a torque of 6
38 ft.-lbs. (51Nm.). 0
WARNING: Chain and block the uprights
and carriage to secure for step 5.

5. Raise the carriage approximately 8 ft. (240 cm). Route

the hoses downward on the front side of all crossmem-
bers, then under the tab on the front side of the cylinder
support. Feed the hoses backward under the cross-
member, around the casting guide upward under the 8, 11
back side tabs. 4

6. Pull the hose ends to remove slack. 10

7. Remove the existing capscrew from the main lift chain

shafts. Install the hoses, sheaves, shaft and spacers to 4
the main lift chain shafts. Tighten the capscrew to a
torque of 58 ft.-lbs. (79Nm.). Make sure the sheaves
rotate freely. 9

8. Attach the hoses to the brackets and fittings. Leave the

fittings loose on the bracket
4
Tab

Cylinder
Support 3, 11

Front

Figure 17. Hose Routing.

Crossmember
9. Install the hose clamp to the two center hoses half way 5
between the crosshead and lower crossmember. 2

10. Pull down on the hoses to remove slack and stretch 1

the hoses one inch. Install the brackets on the front side of the Back
crossmember using the next hole down. Tighten the Side
capscrew to a torque of 38 ft.-lbs. (51Nm.). Tab
Casting
11. Raise and lower the mast several times to make sure the Guide
hoses are tracking correctly. Use the white line on the
hose to detect twisting. Adjust the hose ends if re-
quired. Tighten the fittings making sure they do not
twist. Back
[Link]

15 687250 R3
Section 3 Periodic Maintenance
3.1
Periodic Maintenance
For proper operation and an extended service life, your
Lift Tek Mast should be inspected and serviced regularly
as part of your normal lift truck maintenance schedule accord-
ing to the following outlines and ANSI B56.1 procedures.

The recommended intervals are for masts operating under

normal conditions. If the mast is operating in severe conditions
or corrosive atmospheres, the inspections should be per-
formed more frequently.
WARNING: Never work on the mast with a load
on the forks or attachment, in the raised position
without supports or while anyone is near the lift
truck control handles per ANSI B56.1
3.1-1 Daily Inspection
Perform the following at the beginning of each work shift:

1. Extend the carriage a few inches off the ground and make
sure the chains are under equal tension. Refer to Section
5.6-3 and 5.6-6 for chain adjustment.

2. Extend the mast to its fullest height to make sure the mast rails
and carriage extend freely without binding.

3. While the mast is extended, inspect the upright rails for

proper lubrication. Refer to Section 2.4-5 Step for rail
lubrication.

4. Make sure the internal reeving hoses (if equipped) travel

evenly in the hose guides. Adjust the hose ends if re-
quired. Tighten the fittings making sure they do not twist.

100 Hour Inspection

After each 100 hours of lift truck operation, and in addition to
the daily inspection:
1. Inspect and lubricate the full length of the chains with SAE
40 wt. oil or Bowman Heavy Load Red Grease.
CAUTION: The chains must be coated with a film of lubricant
at all times.

500 Hour Inspection

After each 500 hours of lift truck operation, and in addition to
the Daily and 100 Hour Inspection:
1. Each pair of load rollers on the uprights and carriage
should be shimmed so that a total side to side clearance
no greater than 1/16 in. (1.5 mm) occurs at the tightest
point throughout the travel of the member. Pry between
the upright and load roller so that the opposite load roller
is tight against the upright. Measure the clearance for the
pair of rollers at XXX shown. See Figure 18.

2. Check the chains for wear and stretch. Refer to Section

5.6-1 for complete chain inspection. Figure 18. Load Roller Clearances.
16 687250 R3
Section 4 Troubleshooting
The following table lists problems that may be encountered on your Lift Tek Mast, the probable causes and rec-
ommended corrective action that should be taken to restore the mast to normal operating condition.

PROBLEM PROBABLE CAUSE SOLUTION

Cylinders don’t lift load or
won't move
Empty a) Plugged inlet hose a) Unplug hose or replace.
b) Insufficient oil. b) Check the truck hydraulic system for
correct oil level in tank, defective pump or
pump drive, leaks in the lines or
disconnect control valve linkage. Repair
or replace as necessary.
c) Bent or jammed plunger. c) Repair or replace as necessary.
WARNING: Extreme care should be used when working on a unit
when the carriage (with or without a load) is in the raised position.
Loaded a) Plugged piston check valve. a) Unplug check valve or replace.
b) Truck relief valve setting low. b) Raise truck relief setting to specified level.
c) Over capacity. c) Reduce load to specified capacity.
d) Mechanical bind due to bent plunger d) Remove mechanical bind by
or bad rollers. replacing/freeing plunger and rollers.
WARNING: Extreme care should be used when working on a unit
when the carriage (with or without a load) is in the raised position.
Cylinders drift- a) External leak in pressure line. a) Tighten or replace as necessary.
b) Truck valve defective-cycle to full b) Repair or replace truck valve.
lift height to verify.
c) External leaks at retainer. c) Replace all cylinder seals.
d) Piston check valve leaking. d) Replace check valve.
Spongy or jerky action- a) Sticky or defective truck relief valve. a) remove and check the truck relief valve. If
contaminated oil caused the malfunction,
drain and flush the system, change the
filter and refill with fresh oil.
WARNING: Extreme care should be used when working on a unit
when the carriage (with or without a load) is in the raised position.
b) Bent or damaged cylinder plunger. b) Disassemble, check and repair cylinder
assembly.
WARNING: Extreme care should be used when working on a unit
when the carriage (with or without a load) is in the raised position.
c) Load rollers not properly adjusted c) Adjust or repair as necessary.
or defective.
WARNING: Extreme care should be used when working on a unit
when the carriage (with or without a load) is in the raised position.
d) Mast channels improperly lubricated. d) Lubricate mast.
WARNING: Extreme care should be used when working on a unit
when the carriage (with or without a load) is in the raised position.
e) Low Battery charge. e) Charge battery.
f) Low pump volume. f) Install accumulator.
g) Low oil level. g) Fill oil reservoir.
h) Insufficient hydraulic tank capacity h) Install larger tank baffles
or baffles.
Other. Contact Lift Technologies

17 687250 R3
Section 5 Service
5.1
Mast Removal
1. Raise and block the front end of the truck 1ft. (30cm) or
drive the truck over a service pit.

2. Disconnect the lift truck supply hose from the mast

valve. Plug the hose end and cap the valve fitting.
WARNING: Do not stand on or near the mast
while suspended by the hoist.
3. Attach overhead hoist with lifting strap routed under
all upper crossmembers. Take up slack in the strap. 3 6
4. Disconnect the tilt cylinders from the mast anchor
brackets. For reassembly, tighten the pin capscrews to
the truck manufacturer’s torque specifications.

5. Disconnect the mast lower mounts. For reassembly,

tighten the capscrews to the truck manufacturer’s
torque specifications.

6. Lift away the mast.

7. For mast installation, refer to Section 2.1.

WARNING: Do not stand the mast upright

unless it is chained to a support.

50D MAST

2 4

5 [Link]

Figure 19. Mast Removal

18 687250 R3
 Section 5 Service
5.2
Cylinders
5.2-1 2000 PSI Main Lift Cylinder
Description
The main lift cylinders are single stage piston type cylin-
ders. They consist of a shell and a telescoping plunger/ Retainer
piston assembly. During extension oil pressure is acting
against the full piston area. The truck hoist control valve Bleed
holds the cylinder in place once extension has stopped. Screw

The shell is internally threaded at the top end to hold the

retainer. The retainer seals provide a high-pressure
hydraulic seal against the plunger. The retainer also limits
the upward stroke of the plunger.

A piston is attached to the bottom end of the plunger. The Shell

piston seal provides a high-pressure hydraulic seal against
the shell. A check valve is located in the bottom of the
piston. The check valve allows residual oil between the
shell and plunger to escape when the cylinder is extending.

A hydraulic fuse/cushion valve is located in the cylinder

port. In case of a hose failure between the lowering control
valve and cylinders, the fuse limits the lowering speed of the
cylinder. The valve also cushions the piston when the
cylinder nears the fully lowered position.

Plunger/
Piston
Assembly

Check Valve
(free flowing
direction of arrow)

Hydraulic Fuse /
Cushion Valve

[Link]

Figure 20. 2000 PSI Cylinder

19 687250 R3
Section 5 Service
5.2-2
2600 PSI Main Lift Cylinder
Description
The main lift cylinders are a single stage displacement type
cylinders. They consist of a shell and a telescoping
plunger/piston assembly. During extension the oil pressure Retainer
is acting against the plunger outer diameter due to the
internal porting through the piston. The piston seals do not Bleed
affect cylinder extension. The truck hoist control valve Screw
holds the cylinders in place once extension has stopped.

The shell is internally threaded at the top end to hold the

retainer. The retainer seals provide a high-pressure hy-
draulic seal against the plunger. The retainer also limits the
upward stroke of the plunger.
Shell
A piston is attached to the bottom end of the plunger. The
piston seal provides a high-pressure hydraulic seal against
the shell that engages the cushion valve when the cylinder
is fully lowered.

A hydraulic fuse/cushion is located in the cylinder

port. In case of a hose failure between the lowering control
valve and cylinders, the fuse limits the lowering speed of
the cylinder. The valve also cushions the piston when the
cylinder nears the fully lowered position.

Plunger/
Piston
Assembly

Hydraulic Fuse /
Cushion Valve

[Link]

Figure 21. 2600 PSI Cylinder

20 687250 R3
Section 5 Service
5.2-3 Free Lift Cylinder Description
The 2000 and 2600 psi free lift cylinders are single stage
piston type cylinders. They consist of a shell and a plunger/
piston assembly. During extension the oil pressure is acting
against the full piston area. The truck hoist control valve
holds the cylinder in place once extension has stopped.

The shell is internally threaded at the top end to hold the re-
tainer. The retainer seal provide a high-pressure hydraulic
seal against the plunger. The retainer also limits the upward
stroke of the plunger. Retainer

A piston is attached to the bottom end of the plunger. The

piston seal provides a high-pressure hydraulic seal against
the shell. A check valve is located in the bottom on the pis-
ton. The check valve allows residual oil between the shell
and plunger to escape when the cylinder is extending.

A hydraulic fuse/cushion valve is located in the cylinder port.

In case of a hose failure between the lowering control valve
and cylinder, the fuse limits the lowering speed of the cylin-
der.

Shell

Piston/Plunger
Assembly

Check Valve
(free flow in
direction of arrow)

Hydraulic Fuse
Assembly

[Link]

Figure 22. Free Lift Cylinder

21 687250 R3
Section 5 Service
5.2-4
Cylinder Operation
Cylinders Raising
1. When the truck hoist control valve is actuated, oil enters
the lowering control valve through the inlet port and
flows unrestricted through the lowering control car-
tridge.
2. Oil flows to the cylinder inlet ports. Due to the larger
bore diameter of the free lift cylinder compared to both
main lift cylinders, the free lift cylinder will raise com-
pletely before the main lift cylinders raise.
3. Oil flows through the free lift cylinder hydraulic fuse/
cushion valve to the bottom of the piston. Lifting force
is created against the bottom of the piston causing the
plunger to raise. Oil in the area between the plunger
and shell is allowed to escape through the check valve
in the piston as the plunger raises to the end of its
stroke.
4. 2000 PSI Piston Type Main Lift-Cylinders- Oil flows
through the hydraulic fuse/cushion valve to the bottom
of the piston. Lifting force is created against the bottom
of the piston causing the plunger to raise. Oil in the
area between the plunger and shell is allowed to
escape through the check valve in the piston as the
plunger raises.
2600 PSI Displacement Type Main Lift Cylinders- Oil
flows through the hydraulic fuse/cushion valve to the
piston. The piston is internally ported to allow oil flow to
the area between the plunger and shell. Lifting force is
created that acts on the diameter of the plunger
causing the plunger to raise.
5. When oil flow from the truck hoist control valve is
discontinued, the cylinders are held in position by the
closed center spool of the truck valve.

Cylinders Lowering
1. When the truck hoist control valve is actuated, the main
lift then free lift cylinder plungers lower, forcing oil out
through the hydraulic fuse/cushion valves.
NOTE: The restriction setting of each hydraulic fuse is
lower (allows more oil flow) than the setting of the
lowering control valve. The hydraulic fuses restrict flow
only in the instance of a lowering control valve or hose
failure.
2. Oil flows to the lowering control valve where it is re-
stricted at a controlled speed determined by the load
being handled.
3. As the main lift cylinder pistons lower over the spear in
the bottom of the shell, a high pressure area is devel-
oped between the piston and shell which engages the
cushion valve to restrict flow. This slows the piston/
plunger just prior to bottoming providing a smooth
transition to the free lift cylinder lowering.

22 687250 R3
Section 5 Service
Triple Mast (MT) Hydraulic Schematic

Main Lift Cylinder Main Lift Cylinder

Free Lift Cylinder

Shell

Shell

Plunger
Plunger

Check Valve
Not used in Main Lift Ckeck
2600 psi cylinders Valve

Piston Piston

Hydraulic Fuse/
Cushion Valve

Lowering
Control Valve

Inlet Port

To Truck Valve

Figure 23. Cylinder Operation

23 687250 R3
Section 5 Service
5.2-5 Main Lift Cylinder Removal-
Mast on Floor
1. Remove the mast from the truck as described in
Section 5.1

2. Lay the mast down on wooden blocks as shown. Block

under the outer upright so the inner upright will be free
to move. The carriage must be positioned between the
blocks and free to move.

3. Disconnect the cylinder supply hoses from the cylinder

inlet ports. Remove the special long fittings from the
cylinder ports and install plug fittings. NOTE: Each
fitting holds a compressed spring in place.

4. Remove the snap rings fastening the cylinder rods to

the intermediate upright.

5. Pull the inner and intermediate upright outward 2 ft.

(60 cm).

6. Lift the cylinder from the base mount and angle inward
to remove through the gap at the top of the uprights.

7. Note the number of shims (if equipped) on each

cylinder rod.
6
8. For reassembly, reverse the above procedures except
as follows:
WARNING: Main lift cylinders must be bled to
remove trapped air prior to returning the mast
to operation. Refer to Section 5.2-11.
3
7

7
6
4

[Link]
Figure 24. Cylinder Removal.

24 687250 R3
Section 5 Service
5.2-6 Free Lift Cylinder Removal-
Mast on Floor
1. Remove the mast from the truck as described in
Section 5.1.

2. Lay the mast down as shown.

3. Roll the carriage toward the center of the cylinder to

slacken the chains and internal reeving hoses (if
equipped).

4. Disconnect the hose from the cylinder 45o fitting. Cap

the fitting and plug the hose.

5. Remove the chain guards from the crosshead. For

reassembly, tighten the capscrews to a torque of 48-52
ft.-lbs. (65-70 Nm).

6. Remove the snap ring fastening the crosshead to the

cylinder rod.

7. Pull the crosshead with chains and hoses (if equipped)

off the cylinder rod.

8. Remove the cylinder strap.

9. Remove the cylinder from the mast.

10. For reassembly, reverse the above procedures.

Figure 25. Cylinder Removal.

25 687250 R3
Section 5 Service
5.2-7 Free Lift Cylinder Removal-
Mast on Truck
1. Completely lower the carriage. Remove forks or
attachment if equipped. Make sure the free lift cylinder
is completely retracted. Attach an overhead hoist to
the top carriage bar.
WARNING: The carriage must be supported
by a block while removing the cylinder to
avoid possible injury.
2. Raise the carriage to the center of the cylinder to
slacken the chains and internal reeving hoses (if
equipped). Block the carriage in place using a 4 X 4 X
24 in. (10 X 10 X 60 cm) wood block between the lower
carriage bar and the floor.

3. Remove the cylinder strap.

4. Remove the chain guards from the crosshead. For

reassembly, tighten the capscrews to a torque of 48-52
ft.-lbs. (65-70 Nm).

5. Remove the snap ring fastening the crosshead to the

cylinder rod.

6. Pull the crosshead with chains and hoses (if equipped)

off the cylinder rod and lay over upper carriage bar.

7. Pry the cylinder up out of the support casting to gain

access to the cylinder hose fitting. Remove the hose
from the 45o fitting. Cap the fitting and plug the hose.

8. Remove the cylinder from the mast from the top.

9. For reassembly, reverse the above procedures.

Figure 26. Cylinder Removal.

26 687250 R3
 Section 5 Service
5.2-8 Main Lift Cylinder Service
1. Remove the cylinder from the mast as described in
Section 5.2-5.

2. Use a claw type spanner wrench

to remove the retainer. See Figure 27.

3. Remove the plunger/piston assembly from the shell.

4. Remove the Hydraulic Fuse/Lowering Cushion compo-

nents.
[Link]
5. Inspect all components for nicks or burrs. Minor nicks
or burrs can be removed with 400 grit emery cloth. Figure 27. Claw Type Spanner Wrench..
NOTE: Minor nicks are those that will not bypass oil
when under pressure. If they cannot be removed with
emery cloth, replace the part. If the piston requires re-
placing, refer to Section 5.2-10.

6. Replace the retainer and piston seals, back-up rings

O-rings and bearing. Lubricate the new seals with
petroleum jelly prior to installation. Note the correct
seal directions . The cylinder will not operate correctly
if the seals are installed backwards.

7. 2000 PSI CYLINDERS- When replacing the piston

check valve O-ring, make sure the check valve is
reinstalled with the arrow pointed in the correct
direction.

8. Install the plunger retainer on the plunger. Install the

plunger/piston assembly into the cylinder shell.
Tighten the retainer to the torque value listed below
using the claw spanner wrench and a strap wrench.

30D/35D/40D- 95-125 ft.-lbs. (129-169 Nm)

50D/55D/60D- 225-250 ft.-lbs. (305-340 Nm)

Figure 28. Cylinder Service.

27 687250 R3
Section 5 Service
5.2-9 Free Lift Cylinder Service
1. Remove the cylinder from the mast as described in
Section 5.2-6 or 5.2-7.

2. Use a claw type spanner wrench

to remove the retainer. See Figure 29.

3. Remove the plunger/piston assembly from the shell.

[Link]

4. Remove the Hydraulic Fuse/Lowering Cushion compo- Figure 29. Claw Type Spanner Wrench..
nents.

5. Inspect all components for nicks or burrs. Minor nicks

or burrs can be removed with 400 grit emery cloth.
NOTE: Minor nicks are those that will not bypass oil
when under pressure. If they cannot be removed with
emery cloth, replace the part. If the piston requires
replacing, refer to Section 5.2-10.

6. Replace the retainer and piston seals, back-up rings,

O-rings and bearing. Lubricate the new seals with
petroleum jelly prior to installation. Note the correct
seal directions. The cylinder will not operate correctly
if the seals are installed backwards.

7. When replacing the piston check valve O-ring, make

sure the check valve is reinstalled with the arrow
pointed in the correct direction.

8. Install the plunger retainer on the plunger. Install the

plunger/piston assembly into the cylinder shell. Pour
1/2 cup (120 ml) hydraulic oil into the cylinder cavity
between the shell and rod. Tighten the retainer to a
torque of 275-300 ft.-lbs. (375-405 Nm) using the claw
spanner wrench and a strap wrench.

Figure 30. Cylinder Service.

28 687250 R3
 Section 5 Service
5.2-10
Piston Removal
1. Remove the plunger/piston assembly from the cylinder
shell as described in Section 5.2-8 or 5.2-9.
2. Use a strap wrench and 400
grit emery cloth to secure the plunger while turning the
piston with a pin type spanner wrench
. 3. Turn the piston until the snap wire end is visible through
the hole. Use a screwdriver to start the wire end out the
hole. Turn the piston to feed the wire out.
4. Pull the piston from the plunger.
5. For reassembly, reverse the above procedures except
as follows:
[Link]
*Install a new snap wire when installing the piston.

5.2-11 Cylinder Bleeding Figure 31. Piston Removal.

WARNING: The cylinders must be bled to

remove air. Air in the cylinders will compress
on the first extension which could rupture the
cylinders causing serious bodily injury and
property damage.
1 After repair, the cylinders may have air trapped in them that
must removed. To bleed air do the following:

1. Without a load extend the free lift cylinder and con-

tinue to extend the main lift cylinders to 90% of full
stroke. Retract all cylinders completely. Repeat
three times.

2. Extend the cylinders without a load at 50% full engine

speed then build to full system pressure at the end of
the main lift cylinder stroke. Electric trucks - limit the
control valve movement to achieve 50% speed.
Retract all cylinders. Repeat four times.
3
3. Cycle the mast with a half load (50% mast rated
capacity) through full cylinder extension several times.
The cylinders should extend smoothly. Repeat the
2
steps if cylinder extension is not smooth.

5.3
Valve
5.3-1 Valve Cartridge Service
1. Completely lower the mast.
2. Remove the truck supply hose from the valve car-
tridge. See Figure 32. Plug the hose.
3. Remove the valve cartridge from the valve. Note the [Link]
stamped part no. on the Cartridge for ordering a
replacement. Figure 32. Valve Cartridge Service.
WARNING: Replacing the valve cartridge with
a different part no. cartridge may cause the
mast to malfunction.
4. For reassembly, reverse the above procedures.
29 687250 R3
Section 5 Service
5.4
Carriage
5.4-1 Description
The carriage shown below is the structure that hook-type
forks or attachments are attached. The carriage travels
within the rails of the mast inner upright on four (or six
optional) shim adjustable rollers. The rollers are held in
the uprights*. All load rollers are interchangeable. There are
four side thrust rollers to transfer carriage side loading to the
inner rails. These rollers are eccentrically adjustable. A
pair of chain anchors are used to connect the carriage
chains to the carriage.

*Except on 6 roller carriages where the top roller extends past

the top of the mast inner upright at full extention and are held in
place by a retainer plate. Carriage
Weldment

Pin Cotter
Pin

Chain
Side
Anchor
Thrust
Rollers

Shim
Load
Rollers

Cotter
Pin
Jam
Nut
Chain
Anchor
Nut

Figure 33. Carriage Service.

[Link]

IMPORTANT: The chain anchor

nuts must be installed as shown
for correct operation.

30 687250 R3
Section 5 Service
5.4-2 Carriage Removal-Mast on Truck
1. Raise the mast high enough to place a 20 in. (50 cm)
1 long, 4X4 in. (10 X 10cm) wood block between the
intermediate lower crossmember and the ground. Lower
the carriage to be even with the bottom of the inner
upright

2. Attach an overhead hoist to the carriage. Raise the

carriage to slacken the carriage chains.

3. Remove the chain anchor nuts. Note the location of

the double nuts for reassembly. Inner Upright

4. Disconnect the internal reeving hoses from the

carriage fittings (if equipped). Plug the hose ends.
Intermediate
5. Using the overhead hoist, lower the carriage to the Upright
bottom of the mast to remove. Outer Upright

6. Note the number of shims behind each load roller for

reassembly. 2
7. For reassembly, reverse the above procedures except
as follows:

*inspect the carriage as described in Section 5.4-4.

*Lubricate the inner upright rails with chassis lube or

Kendall SR-12X.
See Figure 34. 2
*Assemble shims and load rollers on the stub shafts.
The shims should be installed to provide a total side
to side clearance no looser than 1/16 in. (1.5 cm) at
the tightest point throughout the travel of the car-
4
raige. Use an equal amount of shims side to side.

*Adjust the carriage side thrust rollers for unrestricted

clearance along the travel of the carriage. The 5
rollers have eccentric mount bases. Turn the base
of the roller toward the upright rail to decrease clear-
ance. See Figure 28. Tighten the capscrews to a
torque of 70-80 ft.-lbs. (95-110 Nm). 3
*Check and adjust the free lift chains as described in
Section 5.6-4 and 5.6-6.

Figure 35. Carriage Removal.

Figure [Link] Lubrication and Carriage Side Thrust Rollers.
31 687250 R3
Section 5 Service
5.4-3
Carriage Removal-
Mast on Floor
1. Remove mast from truck as described in Section 5.1.

2. Remove chain anchor nuts. Note location of double

nuts for reassembly. Remove the chain anchors.

3. Disconnect the internal reeving hoses for the carriage

fittings (if equipped). Plug the hose ends.

4. Roll the carriage tot he bottom of the mast.

5. Attach an overhead hoist to the carriage for bars.

Remove the carriage through the bottom of the mast.

6. Note the number of shims located behind each load

roller for reassembly.

Figure 36. Rail Lubrication.

7. For Reassembly, reverse the above procedures except

as follows:

*inspect the carriage as described in Section 5.4-4.

*Lubricate the inner upright rails with chassis lube or

Kendall SR-12X . See Figure 37. Carriage Removal.
Figure 38.

*Assemble shims and load rollers on the carriage stub

shafts. The shims should be installed to provide a
total side to side clearance no looser than 1/16 in.
(1.5 mm) at the tightest point throughout the travel of
the carriage. Use an equal amount of shims side to
side.

*Adjust the carriage side thrust rollers for unrestricted

clearance along the travel of the carriage. The rollers
have eccentric mount bases. Turn base of rollers
toward the upright rail to decrease clearance.
Tighten to a torque of 70-80 ft.-lbs. (96-110 Nm).

*Check and adjust the free lift chains as described in Figure 38. Carriage Side Thrust Rollers.
Section 5.6-4 and 5.6-6.
32 687250 R3
Section 5 Service
5.4-4
Carriage Inspection
1. Inspect the rollers for excessive wear or damage.
Rollers with visible flat spots or cracks should be re-
placed.

2. Inspect the roller bearings by turning the rollers on their

shafts. Rollers with roughness or noticeable restrictions
to turning should be replaced.

3. Inspect all welds between the carriage side plates and

the carriage fork bars. If any welds are cracked,
replace the carriage.

4. Inspect the roller stub shafts. If they are damaged or if

there are cracks at the base of the stub shafts, the
carriage must be replaced or repaired. Contact
Lift Tek for repair procedures.
Carriage
Weldment

Pin Cotter
Pin

Chain
Side
Anchor
Thrust
Rollers

Shim
Load
Rollers

Cotter
Pin
Jam
Nut
Chain
Anchor
Nut

Figure 39. Carriage . [Link]

IMPORTANT: The chain anchor

nuts must be installed as shown
for correct operation.

33 687250 R3
Section 5 Service
5.5
Mast Uprights
5.5-1 Upright Description

Outer Upright Assembly

The outer upright assembly is mounted to the truck. A pair
of shim adjustable load rollers are attached to stub shafts
located near the top of the upright. A pair of adjustable
hoist chain anchors are located on the top crossmember.

Intermediate Upright Assembly

The intermediate upright assembly telescopes within the
outer upright assembly. A pair of shim adjustable load
rollers are attached to stub shafts located at the top and
bottom of the upright. A pair of chain sheaves are located
near the top of the upright to provide a rolling surface for
the main lift chains.

Inner Upright Assembly

The inner upright assembly telescopes within the intermedi-
ate upright assembly. A pair of shim adjustable load rollers
are attached to stub shafts located at the bottom of the
upright. The free lift chain anchors are attached to the
center crossmember. The free lift cylinder rests on a cradle
which is integral with the lower crossmember.

Figure 40. Mast Uprights .

34 687250 R3
 Section 5 Service
5.5-2
Upright Operation

Fully Lowered
The main Lift chains are anchored to the outer upright top
crossmember then travel over the intermediate upright chain
sheaves and attach to the inner upright anchors.

The free lift chains are anchored to the inner upright center
crossmember then travel over the free lift cylinder chain
sheaves and attach to the carriage chain anchors.

Free Lift
Actuating the truck hoist valve causes the free lift cylinder to
raise which draws the carriage to the top of the inner
upright.

Full Extension
When the free Lift cylinder reaches the end of its stroke the
main lift cylinders begin to rise. The extension of the
cylinders causes the intermediate and inner uprights to
raise.

Lowering
The main lift cylinders lower at the same time. Once the main
lift cylinder have nottomed out, the free lift cylinder begins to
lower resulting in a smooth lowering of the carriage.

Figure 41. Upright Operation .

35 687250 R3
Section 5 Service
5.5-3 Upright Disassembly
1. Remove the mast assembly from the truck as de-
scribed in Section 5.1.

2. Remove the main lift cylinders from the mast as de-

scribed in Section 5.2-5.

3. Turn the mast over.

4. Remove the free lift cylinder from the mast as de-

scribed in Section 5.2-6.

5. Remove the carriage from the mast as described in

Section 5.4-3.

6. Remove the internal hose reeving sheave and hoses (if

equipped).

7. Remove the pins fastening the main

lift chains to the inner upright
chain anchors. Pull the main lift
chains back through the chain
sheaves.

CAUTION: The chain anchor nuts should be used one time

only and be replaced after removal.

8. Remove the main lift chain anchors (long anchors)

from the inner upright lower back side. Tag the
anchors for reassembly.
Figure 42. Upright Disassembly .
9. Remove the pins fastening the free lift chains to the
inner upright chain anchors.

10. Remove the free lift cylinder supply hose and sheave.
Remove the main lift chain sheaves.

11. Roll the inner upright downward to expose the inner

and intermediate upright load rollers. Remove the load
rollers. Note the number of shims behind each load
roller.

12. Attach an overhead hoist to the inner upright. Remove

the inner upright through the top of the intermediate
upright.
36 687250 R3
Section 5 Service
5.5-3
Upright Disassembly
(Continued)
CAUTION: The chain anchor nuts should be used one
time only and be replaced after removal.

13. Remove the main lift chain anchors (long anchors) and
chains from the outer upright crossmember. Tag the
anchors for reassembly.

14. Roll the inner upright downward to expose the interme-

diate and outer upright load rollers. Remove the load
rollers. Note the number of shims behind each load
roller.

15. Attach an overhead hoist to the intermediate upright.

Remove the intermediate upright through the top of the
outer upright.

Figure 43. Upright Disassembly .

5.5-4 Upright Inspection

1. Inspect the load rollers for excessive wear or damage.
Rollers with visible flat spots or cracks should be
replaced. See Figure 44.

2. Inspect the load roller bearings by turning the rollers on

their shafts. Rollers with roughness or noticeable
restrictions to turning should be replaced.

3. Inspect the load roller stub shafts. If they are damaged

or have cracks at the base, the upright mast must be re-
placed or repaired.

4. Inspect the outer and intermediate upright thrust plugs.

If the wear surface is worn to less than 1/16 in. (1.5 mm),
they should be replaced. [Link]

5. Inspect the hoist chains as described in Section

Figure 44. Upright Inspection .
5.6-1.
37 687250 R3
Section 5 Service
5.5-5
Upright Reassembly
1. Lubricate the outer upright rails with chassis lube or
Kendall SR-12X. See Figure 45.
Upright
Rail
2. Attach an overhead hoist to the intermediate upright.
Install the intermediate uptight through the top of the
outer upright.

3. Install the thrust plugs to the uprights.

4. Assemble shims and load rollers to the outer upright 11 5

and lower intermediate upright stub shafts. The shims
should be installed to provide a total side to side
clearance no looser than 1/16 in. (1.5 mm) at the [Link]
tightest point throughout the travel in the upright. Use
an equal amount of shims side to side. NOTE: Roll
Lubricate only where indicated
the upright past the thrust plugs before checking roller by the heavy lines for the full
clearances. length of each upright

5. Lubricate the intermediate upright rails with chassis

lube or Kendall SR-12X. See Figure 40.
Figure 45. Rail Lubrication

Figure 46. Mast Reassembly

38 687250 R3
Section 5 Service
5.5-5
Upright Reassembly
(Continued)
5. Attach an overhead hoist to the inner upright. Install
the inner upright through the top of the intermediate
upright.

6. Assemble shims and load rollers to the intermediate

upright top and inner upright lower stub shafts. The
shims should be installed to provide a total side
clearance no loosest than 1/16 in. (1.5 mm) at the
tightest point throughout the travel in the upright. Use
an equal amount of shims side to side. NOTE: Roll
the upright past the thrust plugs before checking roller
clearances.

7. Install the chain sheave and free lift hose sheave to the
intermediate upright. Tighten the capscrew to a
torque of 26-30 ft.-lbs. (35-40 Nm).

8. Install the main lift chain anchors (long anchors) and

chains to the outer upright crossmember.

Figure 47. Mast Reassembly

39 687250 R3
Section 5 Service
5.5-5
Upright Reassembly
(Continued)
9. Install the chain anchors (long anchors) to the back
side of the inner upright lower crossmember.

10. Pull the main lift chains over the chain sheaves and
attach to the lower inner upright chain anchors.

11. Install the free lift chain anchors (short anchors) and
chains to the inner upright center crossmember.

12. Install the free lift cylinder supply hose through the hole
in the outer upright top crossmember and over the
sheave on the intermediate top upright.

13. Install the carriage as described in Section 4.5-3.

14. Install the free lift cylinder as described in Section

5.2-6.

15. Install the internal reeving sheave and hoses (if

equipped) as described in Section 2.4.

16. Turn the mast over.

17. Install the main lift cylinders as described in Section

5.2-5.

18. Install the mast to the truck as described in Section 5.1.

19. Adjust the main lift and free lift chains as described in
Sections 5.6-3 and 5.6-4. Check for mast skewing as
described in Section 5.5-6.

Figure 48. Upright Reassembly.

40 687250 R3
Section 5 Service
5.5-6 Mast Skewing WARNING: The intermediate upright must be
1. Extend the mast to the full lift height. supported by angle iron to avoid possible injury.

*If the mast kicks to the right at full extension, a shim

(part no. 200524) needs to be installed to the right
hand main lift cylinder rod.
1
*If the mast kicks to the left at full extension, a shim
(part no. 200524) needs to be installed to the left
hand main lift cylinder rod.

2. Place a 6 in. (15 cm) long, 2 X 2 in. (5 X 5 cm) angle

iron between the top of the main lift cylinder and the
crossmember. See Figure 45. Lower the crossmember onto the
angle iron.
3
3. Remove the snap ring from the cylinder to be adjusted.
Freelift
Open the truck valve to allow the center (free lift)
Cylinder
cylinder to fully retract. Tap the main lift cylinder rod
down past the crossmember to install the shim.
4 1 1
4. Slowly hydraulically power the main lift cylinder back
into the crossmember and reinstall the snap ring.
5
5. Repeat steps through until skewing is removed.

Left Hand Right Hand

Snap Ring Main Lift Main Lift
3 Cylinder Cylinder
Intermediate
Upright

Outer Shim
Upright

2
Angle Iron

Three Stage
Mast shown

[Link]
[Link]

Figure [Link] Installation. Figure [Link] Upright.

41 687250 R3
Section 5 Service
5.6
Chains
5.6-1 Inspection and Tension
Each pair of chains has been factory-lubricated using heat
and pressure to force the lubricant thoroughly into the chain
links. Avoid removal or contamination of this factory
applied lubricant. Do not wash, sand blast, etch, steam
clean, or paint the chains on initial mast installation.
CRACKED SIDE PLATES
The chains must be adjusted with equal tension to ensure
proper load distribution and mast operation. To determine
equal tension, extend the unloaded mast to put the chains
under tension. Press the center of a strand of chain with
your thumb, then press at the same place on the other
chain of the pair. Each chain in a pair should have equal
“give”. If tension is not equal, adjust the chains as de-
scribed in Chain Adjustment.

Inspect the chains. If inspection reveals that one strand of

a pair of chains requires replacement, both strands of the
pair should be replaced.

*Check for rust and corrosion. TIGHT PIN JOINTS

*Check for cracked side plates. If you find cracked side

plates, replace both strands of chain.

*Check for tight joints. If tight joints are caused by rust or

corrosion, loosen them with SAE 40 wt. oil or penetrating
oil. If they cannot be loosened, or if the tight joints are
caused by bent pins or plates or by peened plate edge,
replace both strands of the chain.

*Check for protruding or turned pins. Replace both

strands of the chain. PEENED PLATE EDGES

*Check for chain side wear. If pins and outside plates

show signs of wear, check for misalignment os sheaves,
anchors or other components. Correct the misalignment.
If wear is excessive, replace both strands of chain.

*Check for worn, broken or misaligned chain anchors.

Replace or adjust as required.
PROTRUDING PINS
*Lubricate the full length of the chains with SAE 40 wt. oil
or Bowman Heavy Load Red Grease.

[Link]

TURNED PINS

Figure [Link] Inspection.

42 687250 R3
Section 5 Service
5.6-2
Measuring Chain Stretch
Regular inspection and lubrication of the chains will
increase their service life and reduce downtime.

A
A
If the chains stretch beyond the recommended amount,
they should be replaced in pairs. Chain stretch can be Chain
measured with chain wear scale. Measure Wear
the chains according to the instructions printed on the chain Scale
wear scale, without a load on the carriage.

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

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

Main Lift Chain Adjustment

5.6-3 The main lift chains should be adjusted so that when the

A
A
[Link]
unloaded mast is fully lowered, the uprights are positioned New Chain Stretched Chain
as shown in figure 53.
Figure [Link] Chain Stretch.
1. Adjust one chain to achieve the correct upright position
when fully lowered. See Figure 55.
*3 in. *5 in.
Underclearance Underclearance
2. Adjust the other chain to achieve equal chain tension.
Tighten the nuts together to a torque of 50-70 ft.-lbs.
(98-96 Nm).
Outer Upright
3. Raise and lower the mast several times to confirm the and Carriage
Flush Outer
adjustments. Upright

Free Lift Chain Adjustment Carriage 2 in.

Below Outer
5.6-4 The free lift chains should be adjusted so that when the Upright
unloaded mast is fully lowered, the upright channels and [Link]

carriage are positioned as shown in Figure 53.

NOTE: Underclearance is based on mast
production series, actual mast
1. Locate the threaded chain anchors on the front side of
the inner upright crossmember on each side of the underclearance may vary by truck
cylinder. Adjust one chain to achieve the correct model.
upright position when fully lowered. See Figure 54.
Figure [Link] and Carriage Position.
2. Adjust the other chain to achieve equal chain tension.
Tighten the nuts together to a torque of 50-70 ft.-lbs.
(68095 Nm).

3. Raise and lower the mast several times to confirm the

adjustments.

Free Lift
Cylinder

Cylinder
Strap
Main Lift Chain
Free Lift Adjusting Nuts [Link]
Adjusting
Nuts

[Link] Figure [Link] Lift Chains.

Figure [Link] Lift Chains.
43 687250 R3
Section 5 Service
5.6-5 Main Lift Chain Service
WARNING: The intermediate upright must be
supported by a block to avoid possible injury.

1. Raise the inner upright 3 ft. (90 cm). Place a 3 ft. (90
cm) block under the free lift cylinder support casting,
then lower the cylinder support onto the block. The
main lift chains should be slack. See Figure 51.

2. Remove the cotter pins and pins from the chain

anchors. Remove the chains.
Thin
3. Inspect the chain anchors for cracks. Replace as Jam
required. Nut

4. For reassembly, reverse the above procedures. Adjust [Link]

the chains as described in Section 5.6-3.

Figure [Link] Chains.

5.6-6 Free Lift Chain Service

WARNING: The carriage must be supported
by a block to avoid possible injury.

1. Raise the carriage 12 in. (30 cm). Place a 12 in. (30

cm) block under the carriage, then lower the carriage
onto the block. The free lift chains should be slack.
See Figure 52.

2. Remove the cotter pins and pins from the chain

anchors. Remove the chains.

3. Inspect the chain anchors for cracks. Replace as

required.

4. For reassembly, reverse the above procedures. Adjust

the chains as described in Section 5.6-4.
Thin
Jam
Nut

Figure [Link] Lift Chains.

44 687250 R3
Document Control Revision Log:
Date Revision Improvement(s) Description and Comments
10/4/2010 F-528-1010 Initial Release
5/20/2011 F-528-0511 Formatting Updates
nn/nn/nn F-

1-1
 Equipment from Landoll Corporation is built to exacting
standards ensured by ISO 9001:2008 registration at all
Landoll manufacturing facilities.

Bendi AC
Maintenance Manual

Re-Order Part Number F-528-0511

LANDOLL CORPORATION
1900 North Street
Marysville, Kansas 66508
(785) 562-5381
800-428-5655 ~ [Link]

Copyright 2011. Landoll Corporation - Author Tech Comm Zeke

"All rights reserved, including the right to reproduce this material or portions thereof in any form"

F-528-0511