Page 1 Model B40i4 Maintenance Manual LANDOLL CORPORATION 1900 North Street Marysville, Kansas 66508 (785) 562-5381 800-428-5655 ~ WWW.LANDOLL.COM F-581-R1...
Page 3: Table Of Contents
Table of Contents Introduction, Safety and Inspection Before You Begin (Please Read) ..........1-1 Introduction .
Page 4 Daily Inspection ............. . . 2-3 Fuel System Check .
Page 5 Mast Assembly Service ............3-18 Removing the Mast From the Truck .
Page 6 Engine Assembly ............. 3-49 Engine .
Page 7: Introduction, Safety And Inspection
This information is located on the serial number and capacity plate located to the left of the seat. See Figure 1-1. Only Landoll parts are to be used for all repairs.
Page 8: General Maintenance Instructions
• Block the wheels, especially if the forklift is on an are of equal quality parts, that were originally incline. installed on the forklift at the factory. Landoll 4. Before working on the forklift: Replacement Parts Manual is part number F-579.
Page 9: For Your Safety
2. Push and release the manual hand pump 5 to 7 times to build pressure that releases the park brake. 3. The Bendi B40i4 may now be towed a maximum of 200 yards, at a maximum speed of 2 MPH.
Page 10: Towing Vehicle Requirements
• Towing vehicle must have a pull and braking capacity Failure to reset park brakes will result in an greater than 8000 lbs. unsafe condition. The Bendi B40i4 forklift has no • Maximum towing speed should not exceed 2mph. mechanical brakes and stopping is done by hydraulics.
Page 11: Prior To Tilt Cylinder Repair
INTRODUCTION, SAFETY AND INSPECTION Figure 1-4: Blocking Positions Lifting and Blocking the Forklift Prior to Tilt Cylinder Repair • Move forklift to a level area designated for repair.  WARNING • Keep forks empty and low to the ground. • Remove the key. DO NOT place feet or hands in any area through the mast or in forklift pinch points.
Page 12: Mast Removal
Forklift • Mast work to be done in a flat, designated Landoll Corporation recommends that their forklifts NOT area. be cleaned with a power washer. Electrical boards, • NEVER walk under or stand upon forks.
Page 13: Maintenance Introduction
The inspection program designed by Landoll Corporation materials, service must be performed at shorter periodically checks the integrity of Bendi forklift systems intervals.
Page 14 INTRODUCTION, SAFETY AND INSPECTION Operators Daily Checklist Status Landoll / Bendi IC SAFETY & OPERATIONAL CHECKS OK - Yes,No Maintenance Note if Applicable Have a qualified technician correct all problems. If Fuel Odor is detected - DO NOT START TRUCK - REPORT IMMEDIATELY! Forks, Top Clip Retaining Pin and Heel - Condition.
Page 15 INTRODUCTION, SAFETY AND INSPECTION To be performed after 1st 50 hours of truck operation in addition to the required pre-shift daily inspection Technicians 1st 50 Hour Inspection Status Landoll / Bendi IC SAFETY & OPERATIONAL CHECKS Maintenance Note if Applicable OK - Yes,No Have a qualified technician correct all problems.
Page 16 INTRODUCTION, SAFETY AND INSPECTION To be performed after 1st 300 hrs of truck operation in addition to the required pre-shift daily inspection. Technicians 1st 300 Hour Inspection Status Landoll / Bendi IC SAFETY & OPERATIONAL CHECKS Maintenance Note if Applicable OK - Yes,No Have a qualified technician correct all problems.
Page 17 INTRODUCTION, SAFETY AND INSPECTION To be performed each 300 hrs of truck operation in addition to the required pre-shift daily inspection Technicians 300 Hour Inspection Status Landoll / Bendi IC SAFETY & OPERATIONAL CHECKS OK - Yes,No Maintenance Note if Applicable Have a qualified technician correct all problems.
Page 18 INTRODUCTION, SAFETY AND INSPECTION To be performed each 600 hrs of truck operation in addition to the required pre-shift daily inspection Technicians 600 Hour Inspection Status Landoll / Bendi IC Maintenance Note if Applicable SAFETY & OPERATIONAL CHECKS OK - Yes,No Have a qualified technician correct all problems.
Page 19 INTRODUCTION, SAFETY AND INSPECTION To be performed each 1000 hrs of truck operation in addition to the required pre-shift daily inspection Technicians 1000 Hour Inspection Status Landoll / Bendi IC Maintenance Note if Applicable SAFETY & OPERATIONAL CHECKS OK - Yes,No Have a qualified technician correct all problems.
Page 20 To be performed each 2000 hrs of truck operation in addition to the required pre-shift daily inspection. Continued onto page 1-13 for clarity. Technicians 2000 Hour Inspection Status Landoll / Bendi IC SAFETY & OPERATIONAL CHECKS OK (X) Maintenance Note if Applicable Have a qualified technician correct all problems.
Page 21 INTRODUCTION, SAFETY AND INSPECTION Technicians 2000 Hour Inspection Status Landoll / Bendi IC LPG Filter - Change. Air Cleaner Element - Clean. Timing Belt - Replace. Muffler and Exhaust System - Check for leaks and cracks. Alternator and Starter - Clean with compressed air: Check brushes and springs, check power terminals.
Page 22 INTRODUCTION, SAFETY AND INSPECTION To be performed each 4500 hrs of truck operation in addition to the required pre-shift daily inspection. Technicians 4500 Hour Inspection Status Landoll / Bendi IC SAFETY & OPERATIONAL CHECKS OK (X) Maintenance Note if Applicable Have a qualified technician correct all problems.
Page 23: Lubrication Specifications
Engine Coolant GM6277M “Dexcool” *Failure to refill with oil that meets ISO 4406 cleanliness code 15/13/11 may void the warranty. Typical “NEW” oil DOES NOT meet this specification. Contact Landoll Corporation or your lubricant supplier for recommendation. Torque Specifications Component...
Page 24 INTRODUCTION, SAFETY AND INSPECTION General Torque Specifications (rev. 4/97) This chart provides tightening torques for general purpose applications when special torques are not specified on process or drawing. Assembly torques apply to plated nuts and capscrews assembled without supplemental lubrication (in received condition). They do not apply if special graphite moly-disulfide or other extreme pressure lubricants are used.
Page 25 INTRODUCTION, SAFETY AND INSPECTION 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-disulfide or other extreme pressure lubricants are used.
Page 26 INTRODUCTION, SAFETY AND INSPECTION 1-20 F-581-R1...
Page 27: Planned Maintenance
• Overhead crane, appropriate for the weight being factory, (i.e. Loctite Primer and Blue sealant #243 or lifted and/or supported. equivalent Landoll p/n:115627). When these parts are replaced, a non-permanent thread-locking • Grease gun. compound must be reapplied.
Page 28: Preparing For Inspection Or Maintenance
• All fasteners must be replaced with the identical type. and/or other positive forklift-positioning devices. • It is recommended to use only Landoll authorized • If you will be operating the forklift to perform operator replacement parts.
Page 29: Completing Performance Testing
Check the fuel system for leaks and the general condition of parts. When fuel is added to the forklift, follow the procedure for filling the LPG tank as described in the Bendi B40i4 Operator's Manual (F-581-R_). Power Steering Check 1. Sit in the driver’s seat and start the engine.
Page 30: Checking The Battery
(approximately 7-9 turns each direction.) Checking the Battery The battery used on the Bendi B40i4 Series forklift is Figure 2-4: Seat Switch maintenance free. Keep in mind all safety issues, as 1. Start the forklift and release the parking brake.
Page 31 PLANNED MAINTENANCE 11. Install the fill cap, making sure it is tight. 12. Close and latch the access assembly and doors. Figure 2-5: Seat Release 6. Check the fluid level gauge on the right hand side of the tank. See Figure 2-6. Figure 2-6 Oil Gauge 7.
Page 32: Check Engine Oil Level
PLANNED MAINTENANCE Figure 2-7: Engine Compartment Fluid Checks Check Engine Oil Level 11. Close and latch the access assembly and doors. 1. Lower the mast to within a few inches of the ground, then tilt it back completely. 2. Open the engine compartment by releasing the latch just under the driver in the front of the compartment.
Page 33: Check Primary Lift Chain
• To maintain stability and maximum reliability, of the mast See Figure 2-8. you must always replace tires with the type originally supplied, consult your Landoll 3. Set the key switch to “OFF” and remove the key. dealer for ordering information.
Page 34: Flat-Spotting
PLANNED MAINTENANCE separation. Correct such defects as soon as possible. Flat-spotting Flat-spotting occurs when: • The forklift has been sitting idle for some time after heavy use and is usually caused by overheated tires. • The forklift has standing loads (loads left on the forks overnight).
Page 35: 50 Hours Inspection
PLANNED MAINTENANCE 50 Hours Inspection Check Lift Operation Check: Check the lift cylinders to ensure proper sequencing. 1. Mast Chains - Inspect, Clean and Lubricate. 1. Check to see that an unloaded mast will completely lift to full lift height (the relief valve opens). If it will 2.
Page 36: Drive Wheel Lug Nuts
Check these components for drift and leakage. Refer to 3. Side shift completely to the right and hold the control Landoll Corporation and other vendor service information handle in this position for 5 seconds. Check for for specifications. external leaks at the cylinder, fittings, and hoses.
Page 37: Check Tilt Cylinder Racking
PLANNED MAINTENANCE Check Tilt Cylinder Racking 7. Repeat steps 4 and 5 a few times to be sure what type of adjustment is needed.  8. One cylinder may need tightening while the other WARNING needs loosening, or one cylinder may need a minor adjustment.
Page 38 PLANNED MAINTENANCE 19. Remember, both cylinders must dead-head evenly 8. You may have to tilt the mast a number of times and at the same time. Racking will eventually render (repeating Steps 16 through 20) until the adjustment the mast assembly and/or the tilt cylinders defective. is correct.
Page 39 PLANNED MAINTENANCE 2. Set the key switch to “OFF” and remove the key. NOTE 3. Grease bearing fittings at both ends of each tilt Make sure the breather hole is clear of grease and dirt, cylinder and on each side of the forklift until fresh otherwise the hub cap could fall off.
Page 40 PLANNED MAINTENANCE Figure 2-18: Bearings, Race and Inner Seal 14. Carefully set the wheel over the grease seal and NOTE spindle. Install the outer bearing cone, steel washer and the spindle nut. If the bearings must be replaced, use a standard puller to remove the inner and outer bearing cup (race) from the 15.
Page 41 PLANNED MAINTENANCE 3. Apply 2-3 pumps of the recommended grease to the 6. Reach in between that mast and the front end plate top and bottom ports. (See “Lubrication and apply grease to the two grease fittings in the Specifications” on page 1-17.) lower mast mount.
Page 42: Cooling System
PLANNED MAINTENANCE 4. Before lubricating the positioner rails, wipe off excess Air Filter lubricant and dirt buildup from within the rail channels Check the air filter every 300 hours of operation. Very and dirt from the top and bottom of the rail grooves. dirty conditions will require a daily inspection and 5.
Page 43: Change Engine Oil And Filter
PLANNED MAINTENANCE 600 Hour Inspection Change Hydraulic Oil, Hydraulic Oil Filter and Tank Filter 1. Position the forklift on a flat surface, set the parking brake and block the wheels to prevent movement. 2. Set the key switch to “OFF” and remove the key. 3.
Page 44: Mast Maintenance
PLANNED MAINTENANCE  WARNING • NEVER stand on top of or climb on any part of the mast rails. • NEVER reach through upright open areas. • Wood blocks used for clamping must be square on the ends and not tapered or rounded.
Page 45: Chain Maintenance
Chain stretch can be measured with a Landoll provided 3. Cracked side plates - Replace both chains. chain wear scale - P/N 162280.
Page 46: Fork Inspection
 DANGER exceeds 3º from the original specification, repair or replace the fork. • NEVERoperate your Bendi B40i4 forklift if you suspect the forks are damaged. Report fork Difference in Height Between Fork Tips damage to your supervisor immediately. Check the difference in height between each fork blade, •...
Page 47: Lubricate Steer Wheel Knob
PLANNED MAINTENANCE Fork Marking If the fork marking is not clearly legible, it should be remarked by the fork manufacturer, or their representative, in accordance with paragraph 7.25.2 (ASME B56.1-2000). Measuring Fork Thickness and Distortion Position the forklift on a flat surface, set the parking brake and block the wheels to prevent movement.
Page 48 PLANNED MAINTENANCE 8. Always place an appropriate support stand (or wood blocks) under the forklift, then lower the forklift to the stand, having the lifting device and stand both support the weight of the forklift.  DANGER • Getting under a forklift when it is lifted or jacked is dangerous and could cause serious injury or death.
Page 49: Troubleshooting And Corrective Maintenance
Chapter 3 Troubleshooting and Corrective Maintenance Troubleshooting Troubleshooting Chart procedures are arranged as: Engine Problems This chapter contains troubleshooting procedures to help Hydraulic Problems diagnose and resolve problems. Electrical Problems Once the problem is located you must refer to Audible Problems Corrective Maintenance Section starting onpage 3-16, for Visible Problems repair instructions.
Page 50 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair Inoperative tilt directional control • Repair or replace. Mast does not tilt. valve. • See “Tilt Cylinders” page 3-20. Insufficient pump or relief valve See section “Insufficient pump or pressure. relief valve pressure,” beginning on page 3-4.
Page 51 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair Mast does not lift load. Attempting to lift a load in excess of • NEVER attempt to lift a load the truck’s capacity. heavier than the specified rating of NOTE the truck. All mast warranty is managed by •...
Page 52 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair Cont’d Insufficient system pressure. • Repair or replace and/or re-adjust accordingly. • If problem persists, replace the relief valve cartridge. Improperly sized tires. • Check tire specs described in the Hard steering effort in one or Bendi IC Operator's Manual both directions.
Page 53 Cause Suggested Repair Improperly sized tires. • Check tire specs described in the Steering drifts/wanders, is erratic Bendi B40i4 Operator's Manual or turns too slowly. F-580-R_. • See “Inspect Tires” in Chapter 2, Planned Maintenance, page 2-6. Low fluid or leaks in power steering •...
Page 54 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair Cont’d Insufficient hydraulic pressure at the • Check steering motor for seal pump. leaks, sticking or misadjustment - repair or replace. No hydraulic pressure. Coupling or shaft sheared or • Disassemble the pump and check disengaged.
Page 55: Electrical Problems
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair ELECTRICAL PROBLEMS Frayed or broken wires. This may be caused by improperly • Repair or replace wires and secured wires or harnesses, harnesses and secure properly. allowing pinching or excessive • See “Inspect Electrical movement (vibration).
Page 56: Audible Problems
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair AUDIBLE PROBLEMS Faulty alarm module. • Continuity check alarm module - Back up alarm does not sound. replace as needed. • See “Back Up Alarms,” on page 3-51. • See “Inspect Electrical Frayed or broken wires, faulty Connections,”...
Page 57 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair Muffled grinding noise. Faulty wheel bearings - could • Determine if noise is in the front or be insufficient fluid or high rear. pre-stress or excessive play on • For front - See “Wheel Bearings, bearings.
Page 58 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair Blown horn fuse. •Check for electrical short - in horn Cont’d or electrical connections. Rubbing noise from the front Faulty wheel bearing or damaged • Dismount suspected wheel and wheel shaft. examine bearings and shaft. wheels.
Page 59: Visible Problems
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair VISIBLE PROBLEMS Leaking fluid. Cracked, split, or cut hoses. • Replace. NEVER attempt to patch a hose. • Tighten and/or replace. Be careful not to strip the threads, rendering Loose or faulty hydraulic fittings. the fitting defective.
Page 60 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair Fatigue, age, excessive lifting of Cracked or exceptionally worn • When replacing forks - Forks overweight loads, straightness of forks. must be replaced in pairs. blade and shank, fork angle or • Check straightness of the upper DANGER! height differences between fork tips.
Page 61 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair Loose or faulty hydraulic fittings. • Locate source of leak. Tighten Puddles/leakage in area of rear and/or replace fittings. drive wheels. • Be careful not to strip the threads, rendering the fitting defective. •...
Page 62 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Problem Cause Suggested Repair Loose hose or hydraulic fitting. • Locate source of leak, cylinder, Puddles/leakage near mast. manifold hose, cylinder hoses, etc. Tighten and/or replace fittings. • Be careful not to strip the threads, rendering the fitting defective. •...
Page 63 Bendi IC Operator's Manual F-500. Faulty drive motor bearings causing • Replace complete motor. alignment problems. • Replace. See “Wheel Bearings, Worn steer wheel bearings. Seals, and Races,” on page 3-21. Improper tire durometer. • Replace tire with Landoll recommended spare parts. 3-15...
Page 64: Corrective Maintenance
• It is recommended to always use genuine Landoll Lifting the Truck replacement parts to maintain the overall high quality performance and guarantee maximum 1.
Page 65: Removing Forks
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 3. Install all screws when the floor plate is reinstalled NOTE and make certain the accelerator harness is reconnected to the accelerator. As an alternate method, raise the forks a few inches from the floor and place a block of wood under the fork. Slowly lower the forks.
Page 66: Mast Assembly Service
• Only trained and experienced technicians or or four 6” x 6” x 48” (53 mm x 53 mm x 1,219 mm) solid your Landoll service representative must be planks of wood available for blocking. allowed to service the mast assembly.
Page 67 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 5. Remove the four bolts and hardware holding the 17. Reassemble the mast in reverse order, using your backrest to the mast. Carefully remove the backrest; notes as necessary and the enclosed Mast Service it can be heavy - use adequate lifting apparatus or Manuals.
Page 68 9. To repair the tilt cylinder, replace seals, wiper, and lift cylinder from clevis on mast. Pin is fitted with O-rings, etc. See Landoll LSC Parts Manual P/N threaded hole (3/8-16) to allow for the use of a slide F-575.
Page 69: Wheel Bearings, Seals And Race
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 11. Set the lock nut, insuring that the lock nut is in the 14. Reconnect cylinder rod end to mast, center the same location to maintain the tilt angle on the new cylinder using spacers and shims. cylinder shaft and the same position as on the old 15.
Page 70: Front Axle Assembly
See you must always replace tires with the type page 1-17 for recommended lubricants. originally supplied, Landoll P/N 130741(Load 20. Also apply a thin coat of grease to the spindle at the Wheels) and refer to Sales Order for Drive outer bearing seat and to the inner surfaces of the Wheels Part Number.
Page 71: Articulation Bearing And Seal
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 9. Slowly lower the front axle assembly onto the forks of 11. Remove the 1-8 x 5 hex head cap screws. See the extra forklift. Figure 3-8. Lift the mast up enough to remove the front axle assembly out from underneath the forklift. 10.
Page 72: Stop Block
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 3. Apply the parking brake and block all wheels. 2. Remember to install the bottom spacer before you move the front end weldment back into place. 4. Relieve hydraulic pressure in the system by turning the steering wheel two times to the left, then two 3.
Page 73: Auxiliary Pump - Steer And Lift Circuit
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE The pump supplies fluid to the load sense/fan control valve. This valve controls the flow to the steering circuit based on demand, and the cooling fan according to a signal from the vehicle controller. Excess flow is sent to the mast hydraulic valve for use on mast functions.
Page 74: Drive And Brake Pedals
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 5. Raise the floor panel as far as possible and disconnect the accelerator cable connector from the main harness. 6. Remove the nuts holding the throttle (accelerator) assembly. 7. Recalibrate using the Dash Display. See Chapter 4 for throttle pot calibration.
Page 75: Checking The Park Brake Efficiency
Make no changes to the steering system without first aligning the wheel and shaft splines and pushing consulting qualified Landoll factory service personnel. downward evenly until the nut can be installed. The section below explains the procedures to replace the 5.
Page 76: Remove Right Side Cover
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Figure 3-17: Steering and Column Assembly Remove Right Side Cover 3. Reach inside the steering column and disconnect the appropriate display wire connectors from the main 1. First, review “Before You Begin,” page 1-1. wire harness, then lift the panel out. 2.
Page 77: Option Rocker (On/Off) Switches
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Close the steering column by reversing the steps outlined in section “Remove Right Side Cover,” on this page. Figure 3-19: Rocker Switch Figure 3-18: Key Switch Option Rocker (On/Off) Switches Optional rocker switches are also used to control various light packages, or other accessories.
Page 78: Orbital Steer Unit
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 4. Also pry (up) the bellows (rubber boot) free of the 7. Remove the four bolts and hardware securing the bellows retainer plate. This exposes the mounting steering column (console) to the bellows retainer plate for the steering column and the orbital control plate.
Page 79: Steering Counterbalance Valve
Both that there are no oil leaks. conditions can contribute to low pressure problems. Also hydraulic oil should be at warm operating temperature. Also see "Mast Systems," in the Bendi B40i4 Operator's Manual F-580 for additional circuit information. 3-31...
Page 80 2. Set the key switch to “OFF”, remove the key from the ignition switch and disconnect the battery. 3. For ease in checking pressure Landoll Service offers a Pressure Check Kit (p/n: 0018152) which includes a 3,000 psi (21 MPa) pressure gauge, hose and quick-coupler.
Page 81: Steer System Relief Valve
10. If a valve is being replaced, remove the hydraulic The Bendi B40i4 is equipped with a load sense power fittings from the defective valve and note how the steering system. This system only uses the fluid that is fittings are arranged.
Page 82: Hydrostatic Pump
(male end) on the control valve. be done to the hydrostatic drive. The entire unit must 7. Start the truck. be replaced. If the Bendi B40i4 is exhibiting diminished gradibility or reduced top speed, then one ...
Page 83: To Remove And Replace The Hydrostatic Pump
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Figure 3-25: Charge Pressure Test Port To Remove and Replace the 10. Remove mounting hardware from pump to bell housing. Hydrostatic Pump 11. Start to raise winch while prying shaft away from bell 1. First, review “Before You Begin,” page 1-1. housing coupler.
Page 84: To Remove And Replace Hydrostatic Pump Manifold
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Hydrostatic Drive Motor 2. Connect 600 psi gauge, Landoll p/n 133929, to the front (right) pump test port. Assembly Make sure everything is connected before proceeding as you will be energizing the hydraulic To Remove Drive Wheels system.
Page 85: Hydrostatic Drive Motors - Rear
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 7. Using an overhead crane and adequate lifting Hydrostatic Drive Motors - Rear apparatus, remove the wheel. The wheel and tire This section explains servicing the hydrostatic drive unit. weigh approximately 100 lbs(45.4 kg.). 1. First, review “Before You Begin,” page 1-1. 8.
Page 86: Brake Service And Repair
Brake Service and Repair NOTE A cover will be required. It is destroyed in the removal Figure 3-30: Extract O-Ring process. The Landoll P/N of the cover and seal is 4. Extract and discard the O-ring, item 143. See 154199. Figure 3-30.
Page 87 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 8. Press and pliers. See Figures 6506 and 6507. NOTE If you use a bearing press do not place the bearing support on the studs. 9. Extract the spring washer, item 108. See Figure 3-32. 10. Extract the brake piston, item 107. See Figure 3-33. 11.
Page 88: Reassembly
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Figure 3-37: Remove Shims and Brake Discs Figure 3-39: Correct Chamfering 1. Coat with anti-oxidizing grease, Mobil XHP222 or equivalent, the grooves, the top of the piston, the spring washer, the snap ring and the piston seal contact surface in the brake housing.
Page 89 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE NOTE DO NOT file or emery the mating surface. The finish must be maintained. 6. Wipe the mating face with a lint free moist cloth, rubbing the valve cover from inside to outside. See Figure 3-41. 7.
Page 90 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Figure 3-44: Apply Loctite to Brake Housing Face Figure 3-45: Loctite Only on the Median Line IMPORTANT The following steps must be acheived in 10 minutes maximum, after the glue is applied. 13. Position the parts to be assembled by installing some new bolts.
Page 91 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 18. Install the torque reduction shims, item 115, according to the version. See Figure 3-50. 19. Oil the new discs with hydraulic fluid. Figure 3-47: Install 6 Bearings on Cover 16. Install a new O-ring, item 045, in the cover, item 041. See Figure 3-48.
Page 92 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Figure 3-50: Install New Shims 21. The last brake disc must be an external disc, item 103. Table 3-1: Component Descriptions Rep. Item Description Brake housing Mounting screw External brake disc Internal brake disc Shims Figure 3-51: Install Brake Discs External then Internal Alternately 20.
Page 93 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Table 3-1: Component Descriptions Rep. Item Description Brake piston O-ring Brake piston Spring washer Snap ring Tourque reduction shim Brake cover Plug Figure 3-53: Install Brake Piston O-ring 22. Coat the piston seal contact surface in the brake housing with anti-oxidizing grease - Mobil XHP222 or equivalent.
Page 94 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 32. Install the proper shimming, item 105, on the last disc, the thickest shim towards the brake piston. See Figure 3-59. Figure 3-59: Install Shims on Last Disc, Thickest First Figure 3-56: Measure PBrake Piston Stroke with Dial NOTE Gauge Minimize the number of shims of thickness .0079”...
Page 95 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Figure 3-61: Apply 15,740 lbs to Install Snap Ring Figure 3-64: Click Into Place NOTE Make sure that the outer edge of the brake cover is engaged in the groove. 39. Install a new plug, item 142. 40.
Page 96: Seat Assembly/Horn
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Seat Assembly/Horn Horn and Direction Control • The horn push button and directional control switch Seat Switch (forward-neutral-reverse) are located on the driver’s arm rest panel. Each assembly is available as a The driver’s seat micro switch and cable assembly are complete unit only.
Page 97: Engine Assembly
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Direction Control Switch 1. Set the key switch to “OFF” and remove key. 2. Remove the switch locknut cap. See Figure 3-67. 3. Open the top cover to the locked position. 4. Note wire color and connection terminals and tag for identification.
Page 98: Radiator/Oil Cooler
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Figure 3-70: Powertrain Assembly Radiator/Oil Cooler 9. Replace radiator and reinstall in reverse order. NOTE You may notice that when you turn the truck “OFF” the fan momentarily runs at full speed. This is completely normal. 1.
Page 99: Overhead Guard/Lighting/Alarms
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE Overhead Guard/Lighting/Alarms Trucks equipped with optional flood / headlights, tail and stop lights, flashing or spot lights (strobe lights), etc. contain non-replaceable bulbs. The truck is equipped with LED bulbs and replacement varies according to manufacturer, but usually the unit gets replaced as a one assembly.
Page 100 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE 3-52 F-581-R1...
Page 101: Calibration And Programming
Getting Started Using Plus 1 Software NOTE Landoll recommends steps 1 thru 3 be completed at the dealership and not at the customer location. If problems arise when loading the Plus 1 software, you may need to consult the factory.
Page 102 CALIBRATION AND PROGRAMMING Figure 4-2: Computer Interface Cables 5. You are now ready to begin monitoring and operating the forklift functions and parameters. 6. Follow the screens shots provided below to navigate through the Plus 1 capabilities and forklift forklift performance checks.
Page 103: Ecu Downloading And Type
CALIBRATION AND PROGRAMMING ECU Downloading and Type The Plus 1 software package is segregated into two basic operational sections. See Figure 4-5. ECU screens are shown here in the next 2 illustrations to • The first section of the software is a monitoring check the revisions of software and application along with “Log Function”, which allows the user to monitor downloading the appropriate software.
Page 104: Log Functions
CALIBRATION AND PROGRAMMING Log Functions Figure 4-7: Main Inputs Screen Main Inputs 0,3-CP_BRAKE_SW – On when stop pedal is depressed, Off when stop pedal is in neutral position. The “MAIN INPUTS” screen shot provides monitored This signal is provided by a pressure transducer. parameters for the Plus 1 functions.
Page 105 CALIBRATION AND PROGRAMMING 0,3-CP_Steer_RPM_Percent – Displays the 0,3-CP_Brk_CMD – Displays amount of Brake mapped steer angle as a percent of RPM. command “driven by direction and amount commanded is said direction. 0,3-CP_LoadRamp - unused. 0,3-CP_Rev_EDC - Displays current supplied to coil 0,3-CP_Propel_Command –...
Page 106 CALIBRATION AND PROGRAMMING Figure 4-8: Input Screen Input Screen 0,3-CP_TransFilter_SW - If trans filter is plugged/clogged TrnasFilter_switch icon will be “INPUTS SCREEN” showing added functions monitored. true/on. Below is provided a definitions list for forklift 0,3-CP_Steer_Pot - Represents steer angle scaled parameters: See Figure 4-8.
Page 107 CALIBRATION AND PROGRAMMING Figure 4-9: Faults Screen “FAULTS SCREEN” showing added functions monitored 0,3-CP_Steer_Flt – Displays status of accel pot, Off = systems ok, On = Pot shorted, open, or faulty. Below is provided a definitions list for forklift parameters: See Figure 4-9. 0,3-CP_Steer_mV –...
Page 108 CALIBRATION AND PROGRAMMING Figure 4-10: Engine Screen Engine Screen 0,3-CP_LoadRamp - Filtered Load PID 0,3-CP_LoadPropel - Final result of propel The “ENGINE” screen shot provides featured parameters command (filtered using time ramps and PID for load for the Plus 1 functions. See Figure 4-10. percentage) Below is provided a definitions list for forklift 0,3-CP_PROPEL_RAMP...
Page 109 CALIBRATION AND PROGRAMMING Figure 4-12: Pumps Screen Pumps Screen 0,3-MinPumpFWD – Defines the min current supplied to the forward direction coil. The “PUMPS” screen shot provides featured parameters 0,3-MaxPumpREV – Defines the max current for the Plus 1 functions. See Figure 4-12. supplied to the reverse direction coil.
Page 110 CALIBRATION AND PROGRAMMING 0,3-RampDownNFWD - Sets the decel rate when 0,3-Min_Pump – Pre defined in software, for selecting neutral. The lower the value the more reference only. aggressive. 0,3-RampDownDRev – Sets the decel rate when changing direction. “Reverse to forward”. The lower the value the more aggressive.
Page 111 CALIBRATION AND PROGRAMMING 0,3-RPM_RampUp - Pre defined in software, for 0,3-RPM_PER_X6 – Pre defined in software, for reference only reference only. 0,3-RPM_RampDown - Pre defined in software, for 0,3-RPM_PER_Y1 – Value sets the added percent of reference only. change required for lift while in motion. 0,3-RPM_PER_Y2 –...
Page 112 CALIBRATION AND PROGRAMMING Figure 4-15: Lift Screen Lift Screen 0,3-Lower_Valve_Enable - Enables control of secondary lowering valve that bypasses the lift lower The “LIFT” screen shot provides featured parameters for spool valve. the Plus 1 functions. See Figure 4-15. 0,3-LiftCenDB –...
Page 113 CALIBRATION AND PROGRAMMING Engine Load Screen The “ENGINE LOAD” screen shot provides featured parameters for the Plus 1 functions. See Figure 4-18. Below is provided a definitions list for forklift Figure 4-16: Defaults Screen parameters: See Figure 4-18. 0,3-Load_DB – Pre defined in software, for reference Defaults Screen only The “Defaults”...
Page 114 CALIBRATION AND PROGRAMMING 0,3-PID_Off_Value – Pre defined in software, for reference only. Figure 4-19: Calibration Screen Calibration Screen 0,3-PedalMinHi - This value is for fault detection during calibration. Default value = 1500, If the pot The “CALIBRATION” screen shot provides featured returns a voltage higher than this value during parameters for the Plus 1 functions.
Page 115 CALIBRATION AND PROGRAMMING 0,3-SteerMaxLow – This value is for fault detection Steer Profile Screen during calibration. Default value = 3000, If the pot The “STEER PROFILE” screen shot provides featured returns a voltage below this value during calibration, parameters for the Plus 1 functions. See Figure 4-20. calibration will be unsuccessful.
Page 116: Dash Display Calibration And Operation
CALIBRATION AND PROGRAMMING Figure 4-21: Fan Screen Fan Screen Before starting to operate the forklift, for safe forklift operation, monitoring and performance testing: The “FAN” screen shot provides featured parameters for • Be in a safe operating position. the Plus 1 functions. See Figure 4-21. •...
Page 117 CALIBRATION AND PROGRAMMING Figure 4-25: Sub Menu Screen When a “Service Required”warning indication is given press the “ENG FLT” button located at the bottom of the display, See Figure 4-25. Obtain the SPN# fault information from the display as shown, which can be used in correlation with the Diagnostic Trouble Charts provided on starting on page 5-12.
Page 118 CALIBRATION AND PROGRAMMING IMPORTANT At any time, with any of the three “SET STEER”, “SET PEDAL” and/or “SET LIFT” settings if you require direction or assistance, select the “HELP” button and the steps required to complete that section of calibration will appear on the screen. See Figure 4-29.
Page 119 CALIBRATION AND PROGRAMMING Press “NEXT”” to proceed to “SETUP SCREEN 2” which will allow you to calibrate the drive pedal and Tilt Lever functions. See Figures 4-31, 4-32 and 4-33. Figure 4-31: Setup Screen Two Figure 4-32: Acceleration Pedal Setup Screen Figure 4-33: Lift Lever Setup Screen 4-19...
Page 120 CALIBRATION AND PROGRAMMING 4-20 F-581-R1...
Page 121: Engine With Fuel System
Chapter 5 Engine with Fuel System 2.4 Liter GM 4 Cylinder Engine with GFI LPG Fuel Injection Specification 2.4L LPG ENGINE DESCRIPTION ENGINE CONFIGURATION 2.4L L4 Displacement 2,405 cc (147 cid) Bore spacing (mm) 93.0 Bore x Stroke (mm) 87.5 x 100 Firing Order 1-3-4-2 Fuel Type...
Page 122: 2.4L Lpg Engine Gm Service Notes
ENGINE WITH FUEL SYSTEM Specification 2.4L LPG ENGINE DESCRIPTION IGNITION Spark Plugs Conventional J-gap (.035") DIS Coil pack Mounted Side of Head Plug Wires & retainers PERFORMANCE Idle/Max Speed 1000 / 2700 rpm Peak Torque 180 Nm (133 ft.-lbs) Power 50 kW (67 hp) 2.4L LPG Engine GM Service Notes Component...
Page 123 ENGINE WITH FUEL SYSTEM 2.4L LPG Engine System Operation The manufacturer of record for the 2.4L engine, fuel and emissions system is GFI. The key components of the 2.4L engine system are the propane vaporizer, the electronic throttle, the engine control unit (ECU), the injector driver module, the fuel rail, the propane injectors, the oxygen sensor and the catalytic converter.
Page 124 ENGINE WITH FUEL SYSTEM Electronic Throttle S3000 Engine Control Unit (S3000) The electronic throttle plate is commanded to open by the The S3000 ECU is the command and control unit for the ECU. A servo motor on the throttle opens the throttle 2.4 liter LPG engine.
Page 125 ENGINE WITH FUEL SYSTEM MAP Sensor and MAT Sensor The MAP/MAT sensors are combined into one unit that is fitted into a port in the intake manifold to allow it to read MAT and MAP. The MAT portion of the sensor is a negative coefficient thermistor.
Page 126 ENGINE WITH FUEL SYSTEM The O2 sensor place and should not be touching the top of the injectors as this can affect their performance. The propane The O2 sensors used in this engine are “planar” type injectors are a pulse width modulated injector. The sensors and require a small pumping current, supplied by greater the on time, or duty cycle, the more fuel will flow.
Page 127: Fuel Gauge Quick Troubleshooting Guide
ENGINE WITH FUEL SYSTEM Fuel Gauge Quick Troubleshooting Guide Shown below are common fuel gauge7 faults and possible related causes as well as helpful remedies: Fault Cause Remedy No Operation / Display Possible: Sonatic® FLT not properly connected. > Switch ignition on, check fuse and (e.g.
Page 128 ENGINE WITH FUEL SYSTEM Fault Cause Remedy Pointer in gauge fluctuates > Re-couple Sonatic® FLT to continuously in first quarter: cylinder, switch ignition on again. (Between 0.5V and 1.5V in No LPG cylinder fitted. > Place full LPG cylinder into bracket. 0.25Hz) Maximum forklift limit exceeded.
Page 129 ENGINE WITH FUEL SYSTEM Figure 5-10: Fuel System Troubleshooting...
Page 130: L Lpg Engine Quick Trouble Shooting Guide
ENGINE WITH FUEL SYSTEM 2.4L LPG Engine Quick Trouble • - pin A should be zero (or very low voltage) 3. Turn Key “ON” Shooting Guide • - pin A should rise to battery voltage • - pin D should drop to zero (or very low voltage) First Check For DTC Faults 4.
Page 131: If The Engine Cranks But Will Not Start Or Runs Poorly, With No Dtc's
ENGINE WITH FUEL SYSTEM Description Redundant μ throttle a/d conversion failure 522695 Redundant μ general a/d conversion failure 522692 Redundant μWatchdog failure 522699 Redundant μ SPI Bus failure 522690 Redundant μ Clock failure 522698 Redundant μ Sanity check failure 522691 Battery voltage Low 524260 5 Volt Power Supply 2 Out of Spec...
Page 132: Dtc Codes
ENGINE WITH FUEL SYSTEM Is LPG vaporizer Lock-Off opening? heat shield and then through the spring to ground. It has also been noticed that it is very difficult to determine if the The LPG lock-off can be checked for activation with a iron bar (or other metal which is attracted to a magnet), clip at the end of the plug wire is truly snapped on the by holding it close but not touching the solenoid tower of...
Page 133 ENGINE WITH FUEL SYSTEM 5-13...
Page 134 ENGINE WITH FUEL SYSTEM 5-14 F-581-R1...
Page 135: Getting Started Using Kvaser(S3000) Engine Diagnostics Software
ENGINE WITH FUEL SYSTEM Getting Started Using Kvaser(S3000) 2. Start Kvaser software only. 3. Attach cable to the available USB computer port. Engine Diagnostics Software If steps 1 thru 3 are ok, proceed to hook up the computer interface cable to the forklift with the cable marked IMPORTANT “Engine J1939”.
Page 136 ENGINE WITH FUEL SYSTEM • Place the forklift in a safe operating position and  CAUTION location. • Apply parking brake. While Testing you will be operating many • Place directional control in neutral. functions of the forklift and it is imperative that you position the forklift in an area without •...
Page 137 ENGINE WITH FUEL SYSTEM The provided S3000, SAX500 tabs, along with the VSM Diagnostics Function Tab and TCM tabs are provided to display all function settings Within this function “Active” or “Historic” engine faults will within the software. The settings shown are for reference be recorded with SPN fault codes and descriptions.
Page 138 ENGINE WITH FUEL SYSTEM Plot/Plot Choices Function Tab Pedal position and engine speed have been selected as an example. The record function is also available to The “Plot”, Figure 5-18, allows you to monitor and graph record graphs created, in a tab limited format. a plot of engine performance.
Page 139: Gm Engine Supplier Provided Documentation
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. 2.4 Liter GM 4 Cylinder Engine with GFI LPG Fuel Injection Table of Contents - page 3 •...
Page 140 GM ENGINE SUPPLIER PROVIDED DOCUMENTATION F-581-R1...
Page 141 Document Control Revision Log: Date Revision Improvement(s) Description and Comments 01/26/11 F-581-R1 Initial Release 11/01/16 F-581-R1 Hydraulic fluid change - Joshua nn/nn/nn...
Page 142 Equipment from Landoll Corporation is built to exacting standards ensured by ISO 9001 registration at all Landoll manufacturing facilities. Model B40i4 Maintenance Manual Re-Order Part Number F-581-R1 LANDOLL CORPORATION 1900 North Street Marysville, Kansas 66508 (785) 562-5381 800-428-5655 ~ WWW.LANDOLL.COM Copyright 2016.

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