Bendi Forklift IV Series B25-442-180D Electric Narrow Aisle Forklift Service Manual – PDF DOWNLOAD

Bendi Forklift IV Series B25-442-180D Electric Narrow Aisle Forklift Service Manual – PDF DOWNLOAD

FILE DETAILS:

Bendi Forklift IV Series B25-442-180D Electric Narrow Aisle Forklift Service Manual – PDF DOWNLOAD

Language : English
Pages :286
Downloadable : Yes
File Type : PDF

B25-4/42-180D B35-4/48-180D
B30-4/42-180D B40-4/48-180D
B45-4/48-180D

TABLE OF CONTENTS:

Bendi Forklift IV Series B25-442-180D Electric Narrow Aisle Forklift Service Manual – PDF DOWNLOAD

Table of Contents 1-i
Using This Manual 2-1
Safety 2-1
Warranty and Parts 2-1
Truck Overview 2-1
Receiving and Inspection 2-1
Operation 2-2
Preventive Maintenance 2-2
Troubleshooting 2-2
Corrective Maintenance 2-2
Mast IPB (illustrated parts breakdown) 2-3
Base IPB (illustrated parts breakdown) 2-3
Appendix, A through Z 2-3
Safety
Precautions 0-1
Safety 0-2
Site Supervision 0-2
Operator 0-3
Seat Belt 0-4
Seat Safety Switch 0-5
Emergency STOP Button0-5
Parking Brake 0-5
Tipping Hazards 0-6
Longitudinal Tipping Can Occur When: 0-6
Lateral Tipping Can Occur When: 0-7
Traveling and Load Handling 0-7
Speed 0-9
Visibility 0-9
ii
Battery Care 0-9
Features0-9
Care0-10
Service Repair 0-11
Side Shifting 0-12
Safety Labels 0-13
General 0-13
Available Options 0-17
Fork Positioner, Non-Side Shifting0-17
Fire Extinguisher 0-18
Rollout Battery Tray 0-18
Additional Publications 0-19
Truck Overview 1-1
Introduction 1-1
Truck Layout 1-3
Overview 1-5
Frame 1-5
Traction Drive 1-5
Brake System1-5
Parking Brake 1-5
Safety Interlock1-5
Electrical System 1-6
Traction 1-6
Main Pump Motor (Lift) 1-6
Power Steering 1-6
Battery 1-6
Hydraulic System 1-7
Steering 1-7
Mast Controls 1-7
Side Shift 1-7
Operator’s Cab 1-8
Driver Controls 1-8
Battery Compartment Access Cover /Latch1-10
Dash Display Panel 1-12
Mast Assemblies 1-13
Technical Specifications 1-16
Bendi Series IV Narrow Aisle Forklift 1-16
Appendix 1-16
Models 1-16
EE Series (Electrical Enclosure)1-16
Cold Storage (Freezer Package)1-16
Available Options 1-16
Fire Extinguisher 1-16
Fork Positioner, Non-Side Shifting1-17
Light and Alarms 1-18
Rollout Battery Tray1-19
Receiving and Inspection 2-1
Receiving Your Truck 2-1
Items Furnished With Your Truck 2-1
Items Required 2-1
Tools and Test Equipment 2-1
To Prepare the Truck 2-2
Charging a Wet Battery 2-2
Using the Hydrometer2-4
To Charge the Battery:2-4
Charging a Dry Battery 2-6
To Charge a Dry-Cell Battery: 2-7
Inspection Check List 2-8
Visual Checks 2-8
Routine Checks 2-9
Replacing the Battery 2-12
To Replace a Battery 2-12
Rollout Battery Tray Option 2-14
Storage, Towing or Shipping 2-14
Truck Storage 2-14
Battery Storage 2-15
Towing the Truck 2-15
To Ship the Truck 2-16
Using Lifting Equipment2-17
Operation 3-1
To Begin Operating 3-2
Understanding Stability 3-2
Capacity3-4
Serial Number Code3-6
Load Center 3-7
Counterweight 3-7
Maximum Fork Height3-8
Determining Weight of the Load3-8
Working in Hazardous Environments 3-9
Atmospheric/Electrical 3-9
Chemical Hazards 3-9
Pre-Operation Checklist 3-9
Adjusting the Driver’s Seat 3-10
Seat Belt 3-11
Bendi Series IV Forklift Operator’s Manual
iii
Tilt Steering Column 3-12
Fork Adjustment 3-12
Manual Fork Adjust 3-13
Fork Positioner Option – Automatic 3-13
Driving the Truck 3-14
Practice Session 3-15
The Mast 3-16
Handling the Load 3-18
To Pick Up the Load 3-19
To Deliver a Load 3-22
Fire Extinguisher Option 3-27
In Case of a Fire ! 3-27
Fork Positioner Option 3-28
Hydraulic System 3-29
Power Steering System 3-29
Mast Systems 3-30
Tilt and Shift3-32
Lift and Lower3-32
Electrical Control System 3-33
General 3-33
Dash Displays 3-34
Preventative
Maintenance 4-1
Tables 4-2
Preventative Maintenance Schedule 4-2
Recommended Lubricants 4-3
Overview 4-7
Tools or Equipment Required 4-8
Special Tools Required4-8
Safety Equipment Required 4-8
Floor Access Panel – Removal 4-9
Daily Inspection 4-10
Check Batteries 4-10
To Check the Battery: 4-11
Check Power Steering 4-12
Check Hydraulic Functions 4-12
Check the Return-to-Neutral 4-13
Check Primary Lift Chain 4-13
Inspect Tires 4-14
Chunking (Chipping) or Embedded Objects 4-15
Undercutting and Uneven Wear4-15
Flat-spotting4-16
Bendi Series IV Forklift Operator’s Manual
iv
To Expand Tire Life 4-16
Check Driver’s Seat Switch 4-17
Weekly Inspection 4-18
Check Hydraulic Oil Level 4-18
Check Master Cylinder Fluid Level 4-19
Check Tilt Cylinder Racking 4-20
Tilt Cylinder Racking and Tilt Degree Setting 4-20
Lubricating the Truck 4-23
Front Column Rotation Bearings/Gears 4-24
Tilt Cylinder Clevises4-25
Mast Mounting Pins 4-25
Forks and Side Shifter 4-26
Check Planetary Gear Box 4-26
Check Lift Operation 4-29
Drive Wheel Lug Nuts 4-30
Cooling Fans 4-30
Three Month Inspection 4-31
Check Nuts, Bolts, and Screws 4-31
Change Hydraulic Oil Filter 4-32
Check Service Disc Brakes 4-33
To Check the Brakes4-33
Semi-Annual 4-34
General 4-34
Inspection Check List 4-36
Inspect Electrical Connections 4-36
Fork Inspection 4-36
Replacing Motor Brushes 4-39
Exposing the Motors4-39
Traction Motor Brushes4-41
Pump and Power Steering Motor Brushes 4-42
Annual Inspection 4-43
Change Hydraulic Oil 4-43
Lubricate Front Steer Wheel Bearings 4-45
Inspecting the Bearings, Race and Inner Seal 4-46
Lubricate Steer Wheel Knob 4-47
SRE Controller 4-48
General Practice 4-48
Options 4-49
Fork Positioner Lubrication, Non-Side Shifting 4-49
Rollout Battery Tray 4-50
Troubleshooting 5-1
Preliminary Procedures 5-1
Bendi Series IV Forklift Operator’s Manual
v
Visible Problems 5-2
Spills and Waste Management 5-8
Spills of Sulfuric Acid 5-8
Handling and Storage 5-9
Waste Generation and Disposal 5-9
Recycling locations 5-10
Audible Problems 5-11
Performance Problems 5-14
Pump Problems 5-26
SRE Controller Problems 5-28
Overview 5-28
Corrective Maintenance 6-1
Introduction 6-1
Tools Needed 6-1
Before You Begin 6-2
Lifting the Truck 6-3
Electrical Static Discharge 6-4
Hydraulic Fittings and Hoses 6-4
Cleaning and Inspection 6-5
Brake System 6-6
Disc Brakes 6-6
Brake Pedal 6-6
Service Brake Linkage6-6
Brake Cut-off and Light Switch 6-8
Parking Brake Handle 6-8
Adjust the Parking Brake Handle 6-9
Adjust Parking Brake Caliper6-10
Mast Lift Chains 6-10
Inspect Lift Chains 6-10
Chain and Roller Adjustment 6-10
Main Pump Relief Valve 6-11
General 6-11
To Check and/or Adjust Pressure 6-11
Steer Pump Relief Valve 6-14
General 6-14
To Check and/or Adjust Pressure 6-15
Front Rotation Pot 6-16
General 6-16
To Adjust and/or Replace6-17
SRE Control Adjust 6-17
General 6-17
Set up 6-18
Bendi Series IV Forklift Operator’s Manual
vi
Brake System – Repair 6-19
Changing Brakes 6-20
To Change Brake Pads 6-20
Replace the Brake Caliper Assembly 6-23
Caliper Pistons 6-24
Disc Brake Rotors 6-25
Measure Thickness 6-25
Check Lateral Run-Out (Warping) 6-25
Replace Brake Rotor Assemblies6-26
Master Cylinder 6-27
To Remove the Old Cylinder 6-27
Bench Bleed the Master Cylinder6-29
To Install the New Cylinder 6-30
Rigid Brake Line 6-30
To Replace a Damaged Line 6-31
Bleeding Brakes 6-32
Parking Brake Assembly 6-34
Continuity test6-34
Replace Micro Switch 6-35
Replacing the Brake Cable6-35
Service Brake Pedal Assembly 6-37
Brake Warning Switch 6-37
Brake Pedal6-37
Removing Forks 6-38
Steer (Load) Wheels 6-39
To Check 6-39
Wheel Bearings, Seals and Race 6-39
Replacing Tires/Wheels 6-41
Drive Wheels 6-41
Steer (Load) Wheels 6-42
Console Assembly 6-42
Remove Left Side Cover 6-43
Display or Cable 6-44
Key Switch 6-45
Option Rocker (On/Off) Switches 6-45
Circuit Breaker Panel 6-46
Steering Assembly 6-46
Steering Wheel 6-47
Steering Column (Console) 6-47
Orbital Steer Unit 6-49
To Service the Orbital Control Unit 6-49
Steering Motor or Support Bearing 6-50
Bendi Series IV Forklift Operator’s Manual
vii
Hints6-51
To Service the Motor6-51
Steer Pump and Motor 6-52
To Replace the Pump and/or Motor6-53
To Service the Steer Pump6-55
Lift Circuit 6-56
To Replace the Pump and/or Motor6-56
To Service the Lift Pump6-59
Traction Drive – Rear 6-60
To Begin… 6-60
To Replace Gear Unit / Motor 6-60
Hydraulic Valve Assemblies 6-63
Steer Control Valve 6-63
Hydraulic Control Valve and Switches 6-64
Hydraulic Lift Pot 6-66
General 6-66
To Adjust and/or Replace6-66
Linear Accelerator Module 6-67
Module and Cable Assembly 6-67
Pedal Spring 6-69
Seat Switch 6-69
Replace the Switch and Cable 6-70
Front End Assembly 6-70
To Begin… 6-72
Rotation Seals, Bearings or Spur Gear 6-72
To Remove Spur Gear Only6-73
Rotation Seals and Bearings 6-75
Hints for reassembly6-76
The Mast 6-76
Removing the Mast From the Truck 6-77
Tilt Cylinders 6-80
Sideshifter 6-82
Articulation Bearing and Seal 6-83
Stop Block 6-84
Horn and Direction Control 6-85
Horn/Horn Pushbutton 6-85
Direction Control Switch 6-86
Fans 6-87
To Replace a Fan 6-87
Options 6-88
Lights 6-89
Back Up Alarms 6-89
Appendix A – H 7-91
Appendix I – P 8-93
Appendix Q – Z 9-95

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