Landoll Bendi B40i4 Maintenance Manual Download Page 121

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5-1

Chapter 5

Engine with Fuel System

2.4 Liter GM 4 Cylinder Engine
with GFI LPG Fuel Injection

2.4L LPG ENGINE DESCRIPTION

Specification

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

LPG

Engine Rotation (from the front / fan side)

Clockwise

Compression Ratio

9.6:1

Main bearing caps

2 bolt

Cam Drive

20 mm Toothed Belt

Valve train Configuration

SOHC / 2V

Valve Rocker

End pivot rocker / radiused cam follower

Valve Lifter / Lash Adjuster

Hydraulic lash adjusters in head

Crankcase Ventilation

Foul Air System with PCV

Oil Pan Capacity (excludes filter volume)

4.3L

LPG fuel system pressure

0.88 bar

Balancer/Pulley

Yes with 6 groove Poly V

Oil Level Indicator (Dipstick)

Yes

Oil Filter - screw into / location

Oil pump Assy/frnt of eng

Ventilation / PCV system

“Foul Air” System

- cam housing to intake plumbing

Yes (includes PCV)

- crankcase to cam housing plumbing

Yes

Water pump

Yes

Cooling - t/stat (start to open/full open)

82/97oC

Intake Manifold

Aluminum PFI Style

Exhaust Manifold

Cast iron with heat shield Dual channel

Summary of Contents for Bendi B40i4

Page 1: ...F 581 R1 LANDOLL CORPORATION 1900 North Street Marysville Kansas 66508 785 562 5381 800 428 5655 WWW LANDOLL COM Model B40i4 Maintenance Manual...

Page 2: ......

Page 3: ...3 Towing Vehicle Requirements 1 4 Towing a Truck in the Reverse Direction 1 4 Lifting and Blocking the Truck 1 5 Prior to Tilt Cylinder Repair 1 5 Mast Removal 1 6 Cleaning Inspecting the Truck 1 6 M...

Page 4: ...2 10 Tilt Cylinder Racking and Tilt Degree Settings 2 10 Lubricating the Truck 2 11 Cooling System 2 15 Air Filter 2 15 Change Engine Oil and Filter 2 16 600 Hour Inspection 2 16 Change Hydraulic Oil...

Page 5: ...sole Assembly 3 27 Steering Wheel 3 27 Remove Right Side Cover 3 28 Display 3 28 Key Switch 3 28 Option Rocker On Off Switches 3 29 Steering Column Console 3 29 Orbital Steer Unit 3 30 Load Sense Stee...

Page 6: ...l Injection 5 1 2 4L LPG Engine GM Service Notes 5 2 2 4L LPG Engine System Operation Overview 5 2 2 4L LPG Engine System Operation 5 3 Fuel Gauge Quick Troubleshooting Guide 5 7 2 4L LPG Engine Quick...

Page 7: ...hat 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 s...

Page 8: ...plates or decals shall be maintained in legible condition See Figure 1 1 11 All parts of lift mechanisms shall be inspected and maintained in safe operating condition 12 All hydraulic systems shall b...

Page 9: ...alve by pulling up on the handle rotate the handle 90 and allow the cross pin to fall into place 2 Push and release the manual hand pump 5 to 7 times to build pressure that releases the park brake 3 T...

Page 10: ...e will roll and steering will be difficult Keep towing speed below 2 mph Remember that the person on the towed lift has to turn his head to observe operations Figure 1 3 Tow Pin Failure to reset park...

Page 11: ...Repair WARNING Forklift repair must be in a level designated area Lower the mast completely to the floor Turn the forklift OFF pull the key and observe Lockout Tagout procedures Chock wheels so that t...

Page 12: ...leaning solvent to come in contact with rubber parts or rubber insulation such as electrical wiring seals etc to avoid quicker corrosion IMPORTANT Cleaning solvents can be TOXIC and FLAMMABLE Pay part...

Page 13: ...300 Hour Inspection Checklist 600 Hour Inspection Checklist 2000 Hour Inspection Checklist Except for the Operator s Daily Checklist these tasks are usually performed by a service and maintenance faci...

Page 14: ...properly Drive Control Forward Reverse functioning smooth Engine Air Cleaner Squeeze rubber dirt trap Clean and check Engine Belt Check for wear Battery Check for cracks and electrolyte level Hood an...

Page 15: ...AL CHECKS Have a qualified technician correct all problems OK Yes No Maintenance Note if Applicable Mast chains Inspect clean and lubricate Power Steering Check Operation Inspect and Fill Drive wheels...

Page 16: ...tension inspect clean and lubricate Lift and Tilt cylinder Check to be sure they work together and in unison Power Steering Check operation inspect and fill Parking Brakes Check for effectivity Engine...

Page 17: ...s Check for cracks and leaks Exterior of hydraulic Tank and Oil Tank Breather Clean Engine Compartment Clean Engine Oil and Filter Replace Alternator and Starter Clean with compressed air Check brushe...

Page 18: ...arking seat key pressure and temperature Check Wire connections and sending units Check Grease fittings Service Forks top clip retaining pin and heel Condition Load rollers No greater clearance than 1...

Page 19: ...tion Technicians 1000 Hour Inspection Status Landoll Bendi IC SAFETY OPERATIONAL CHECKS Have a qualified technician correct all problems OK Yes No Maintenance Note if Applicable Spark Plugs Wires Repl...

Page 20: ...er Clean Hydraulic oil and power steering Clean dust from motors Leaks Hydraulic oil battery brake fluid transmission Hydraulic hoses and connections Check for wear Hydraulic oil filter Change element...

Page 21: ...ernator and Starter Clean with compressed air Check brushes and springs check power terminals Radiator Use compressed air to clean fins check for correct cap and tighten check hoses and clamps drain f...

Page 22: ...equired pre shift daily inspection Technicians 4500 Hour Inspection Status Landoll Bendi IC SAFETY OPERATIONAL CHECKS Have a qualified technician correct all problems OK X Maintenance Note if Applicab...

Page 23: ...may void the warranty Typical NEW oil DOES NOT meet this specification Contact Landoll Corporation or your lubricant supplier for recommendation Component Torque Drive motor with vehicle frame 130 ft...

Page 24: ...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 32...

Page 25: ...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...

Page 26: ...1 20 F 581 R1 INTRODUCTION SAFETY AND INSPECTION...

Page 27: ...pecial Tools Required The following special tools may be required Angle wrenches IMPORTANT Read and comply with all applicable SAFETY precautions when servicing this forklift See the Safety Chapter 1...

Page 28: ...e condition Performance Testing NOTE Make sure all accessories are off before continuing Make sure you are in the operator s seat 1 Make sure your right foot is on the floor of the operator s compartm...

Page 29: ...nspection of the entire forklift for any defect Visual check for any engine oil or hydraulic fluid leaks Radiator overflow level check Check that all controls and gauges work properly A complete Daily...

Page 30: ...Seat Switch This procedure checks the physical mechanics actuation of the driver s seat switch only The switch is part of the seat See figure below Figure 2 4 Seat Switch 1 Start the forklift and rele...

Page 31: ...ntained at all times Failure to check the oil level as recommended could cause serious mast function operating problems 8 Add hydraulic oil as needed See page 1 17 for recommended lubricants 9 DO NOT...

Page 32: ...he area around the engine fill cap then open the cap turn counterclockwise See Figure 2 7 IMPORTANT It is important that the proper level of oil be maintained at all times Failure to check the oil lev...

Page 33: ...s in a cross pattern to a correct torque value of 225 ft lbs 300 Nm 6 Squeaking or friction noises coming from the tires during operation may be caused by separation of the tire layers 7 Separation is...

Page 34: ...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 o...

Page 35: ...g bolts 7 Master cylinder clevis and mounting bolts 8 All hydraulic pump and motor mounting bolts 9 Hydraulic cylinder clevises 10 Overhead guard mounting bolts Check Lift Operation Check the lift cyl...

Page 36: ...check side shift circuit performance 1 Side shift completely to the left and hold the control handle in this position for 5 seconds 2 Check for external leaks at the cylinder fittings and hoses 3 Side...

Page 37: ...th level surface 10 Tilt the mast back its full stroke 11 Place a tilt gauge against the rear outer mast rail on the right side of the forklift See Figure 2 13 12 The gauge must read between 3 0 and 3...

Page 38: ...parking brake 2 Certain grease fittings may include protective plastic caps remove them before applying grease Remember to replace the caps when you are finished 3 In the following illustrations the l...

Page 39: ...the front axle weldment plate until fresh grease is seen 9 Wipe off excess grease and replace the hub cap using a rubber mallet NOTE Make sure the breather hole is clear of grease and dirt otherwise t...

Page 40: ...g cup race is fully seated bottomed out against the shoulder in the rim bore 13 Install the inner bearing cone into the wheel rim 14 Carefully set the wheel over the grease seal and spindle Install th...

Page 41: ...e lower mast mount An extension to the grease gun may be required 7 Wipe off any excess grease Figure 2 20 Mast Mounting Pin Grease Point Forks and Side Shifter 1 See Figure 2 21 2 Start the forklift...

Page 42: ...ture of Dexcool and water Check the radiator fins Clean the radiator with compressed air water as needed Air Filter Check the air filter every 300 hours of operation Very dirty conditions will require...

Page 43: ...oving either filter assembly clean the area to avoid contamination 5 Reach in and spin off the hydrostat charge hydraulic oil filter assembly Figure 2 7 on page 2 5 6 Remove the filter canister and ta...

Page 44: ...manufacturer s mast service manual 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 forklift control handles per ASME B...

Page 45: ...pressure to force the lubricant thoroughly into the chain links 1 Avoid removal or contamination of this factory applied lubricant 2 DO NOT wash sand blast etch steam clean or paint the chains Chain A...

Page 46: ...fork Difference in Height Between Fork Tips Check the difference in height between each fork blade measured at the tip with the fork mounted on the fork carrier If the difference in tip heights exceed...

Page 47: ...elevation of each fork tip If the difference is more than 3 4 19 1 mm replace the forks See Figure 2 30 9 Check the forks for cracks paying close attention to the heel portion of the forks If any crac...

Page 48: ...jack stand or lift blocks and lower forklift back to level surface 15 Add hydraulic oil See page 1 17 for recommended lubricants and fluid capacities 16 Also see Check Hydraulic Oil Level page 2 4 NOT...

Page 49: ...rk plugs wires coil No acceleration Drive pedal out of calibration See Throttle Pot Setup on page 4 17 and recalibrate Runs Rough and or Sluggish Refer to Chapter 5 for engine and fuel system service...

Page 50: ...s leaking or binding Air in cylinder Faulty lift control valve See Mast does not lift load on page 3 4 Determine which cylinder is leaking or binding rebuild or replace See Mast does not lift load on...

Page 51: ...anned Maintenance page 2 8 Check reservoir oil level Replenish as needed See Check Hydraulic Oil Level in the Bendi IC Planned Maintenance page 2 4 Bent or damaged spool worn internal seals repair or...

Page 52: ...Check Hydraulic Oil Level on page 2 4 Planned Maintenance Restriction in fluid return line Remove line clean and or replace line Check pump See Auxiliary Pump Steer and Lift Circuit page 3 25 Check hy...

Page 53: ...eal or fitting leaks repair or replace Check the inlet connections to determine where air is being drawn into the system Tighten loose connections Bleed hydraulic system Check wheel bearings replace a...

Page 54: ...aintenance Leaking fluid Cracked or cut hoses where applicable Loose or faulty hydraulic fittings Oil seals deteriorated Replace the defective hose NEVER attempt to patch or splice a hose Tighten and...

Page 55: ...ken wires blown fuse faulty switch or electronics Check related wire harnesses and connectors for contact problems broken wires check fuse etc Continuity check on off switches replace as needed See In...

Page 56: ...hould be secure and wire stranding must not be frayed or corroded Check wiring to relay See Intermittent electrical problems on page 3 8 Unusual noise when truck is in motion Faulty Hydraulic Wheel mo...

Page 57: ...and properly torqued See Appendix B in the Bendi IC Operator s Manual F 500 Pump making noise Pump intake partially blocked Air leaks at the intake or shaft seal Oil in reservoir could possibly look...

Page 58: ...dged inside wheel hub remove and repair and or replace as needed Scraping noise when the mast is operated NOTE All mast warranty is done by Lift tek if applicable Please call 888 liftek Out of alignme...

Page 59: ...ic fittings Pump or motor oil seals rings gaskets etc deteriorated by excessive heat or corrosion Replace NEVER attempt to patch a hose Tighten and or replace Be careful not to strip the threads rende...

Page 60: ...ASME B56 1 2000 except that the test load must be 2 5 times the rated capacity marked on the fork When replacing forks Forks must be replaced in pairs Check straightness of the upper face of each bla...

Page 61: ...e 3 35 Also see Pump Problems on page 3 9 Check appropriate vendor service information where applicable Grease blotches around front steer wheels especially on inside of wheel rim Faulty grease seal i...

Page 62: ...tions in Chapter 2 Planned Maintenance Make sure wires do not come in contact with any moving parts or are not pinched in access doors or cover panels Scraping marks on the mast Rail misalignment Real...

Page 63: ...r See Inspect Tires in Chapter 2 Planned Maintenance NEVER lift loads in excess of what is recorded on the capacity nameplate in the Bendi IC Operator s Manual F 500 Excessive overloading or improper...

Page 64: ...attery where it could possibly touch battery terminals causing a short or serious electrical shock Lifting the Truck 1 Always place an appropriate support stand or blocks of wood 8 square 204 mm squar...

Page 65: ...r for repair Never try to repair surface cracks or wear by welding the fork If you need to reset a fork make sure it is heat treated before it is returned to service Load Testing Forks The following i...

Page 66: ...least three 3 tons and have three or four 6 x 6 x 48 53 mm x 53 mm x 1 219 mm solid planks of wood available for blocking 1 Thoroughly steam clean the mast removing all dirt debris and grease 2 Record...

Page 67: ...dware See Figure 3 6 13 Remove the wedged block of wood between the mast and front mounting plate Slowly slide the mast backwards 14 Raise the mast enough to release the trunnion pins from their suppo...

Page 68: ...emove pin and lift cylinder from clevis on mast Pin is fitted with threaded hole 3 8 16 to allow for the use of a slide hammer for pin removal 4 DO NOT lose the cylinder spacers and note how many spac...

Page 69: ...from the ignition switch 4 Apply the parking brake and disconnect the battery 5 Make sure all the wheels are securely blocked so that the truck cannot move 6 Lift and support the truck so that the whe...

Page 70: ...tions 27 Loosen the nut 1 2 turn no more then tighten the nut again and torque as needed 28 Insert a new cotter pin Back off the nut slightly as needed to align the notches to the hole in the spindle...

Page 71: ...t your work bench remove the bearing from the block 8 When reassembling this bearing is a maintenance free dry bearing No grease is needed during assembly be certain the O ring seals are properly inst...

Page 72: ...uator you must align all parts The overhead crane may have to be adjusted a fraction of an inch to allow the actuator to slide in place 2 Remember to install the bottom spacer before you move the fron...

Page 73: ...pplies 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...

Page 74: ...lerator assembly 7 Recalibrate using the Dash Display See Chapter 4 for throttle pot calibration Figure 3 15 Drive Pedal Stop Pedal Park Brake Assembly Spring Applied Hydraulically Released Brakes The...

Page 75: ...n page 1 1 3 Set the key switch to OFF and remove the key from the ignition switch 4 Apply the parking brake and disconnect the battery 5 Make sure the other wheels are securely blocked so that the tr...

Page 76: ...our screws securing the dash panel to the steering console 3 Reach inside the steering column and disconnect the appropriate display wire connectors from the main wire harness then lift the panel out...

Page 77: ...The wings tabs could break off if the procedure is not done evenly on all sides 4 Detach the wires from the defective switch noting the connection arrangement for installing the new rocker switch 5 I...

Page 78: ...eral Torque page 1 17 Figure 3 21 Steering Hydaulic Lines Orbital Steer Unit 1 Repeat Steps 1 through 5 of preceding section Steering Column Console beginning on page 3 27 2 Tag the port locations of...

Page 79: ...ll functions are operating properly and that there are no oil leaks Hydraulic Control Valve Assembly General Individual directional control pressure valve assemblies and gauge ports for psi readings a...

Page 80: ...essure counterclockwise to decrease pressure See Figure 3 23 13 Release the control lever immediately once the pressure is set 2 600 psi 65 psi 0 psi 18 MPa 0 45 0 MPa minimum up to 3 000 psi 21 MPa 0...

Page 81: ...erly seated before sealing the parts together Disconnect hoses at the fittings and immediately plug cap all lines Have shop rags handy to manage spills Remove the fittings from the defective valve and...

Page 82: ...g wheel from one side to check the hydraulic connections for leaks 15 With pressure set at 1900 psi 65 psi 18 MPa 0 3 MPa maximum set the key switch to OFF Hydrostatic Pump Charge Pressure Check NOTE...

Page 83: ...identification Have shop rags ready to manage spills 8 Remove case drain check port and suction line hose assembly 9 Place hand winch between overhead guard and center of pump Put slight tension on pu...

Page 84: ...nifold 10 Install new Landoll P N 168279 O rings lubricated with new clean hydraulic oil 11 Re install manifold to the hydrostat and start all 8 bolts 12 Snug all bolts in a criss cross pattern workin...

Page 85: ...pply the parking brake 4 Make sure all wheels are securely blocked so that the truck cannot move 5 Raise the side of the truck being serviced 6 to 8 15 20 cm off the floor surface and support the truc...

Page 86: ...vice and Repair NOTE A cover will be required It is destroyed in the removal process The Landoll P N of the cover and seal is 154199 1 Remove the motor The hydrostatic drive motor assembly is very hea...

Page 87: ...washer item 108 See Figure 3 32 10 Extract the brake piston item 107 See Figure 3 33 11 Discard the O ring item 106 See Figure 3 34 12 Remove and discard the bolts item s 102 See Figure 3 35 13 Remove...

Page 88: ...e 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 brak...

Page 89: ...g Wait 2 minutes See Figure 3 42 IMPORTANT DO NOT apply any activator on the shaft 10 Install the new O ring item 045 and if the motor is dual displacement install the new O ring item 057 See Figure 3...

Page 90: ...e is applied 13 Position the parts to be assembled by installing some new bolts See Figure 3 46 14 Install and torque 63 ft lbs 85 Nm all new bolts item 102 See Figure 3 35 IMPORTANT The glued connect...

Page 91: ...48 17 Install the brake housing item 101 on the cover item 041 Take care to place the housings in front of the balls item 123 See Figure 3 49 18 Install the torque reduction shims item 115 according t...

Page 92: ...lternately 20 Start by installing one external brake disc item 103 then one internal brake disc item 104 then alternately 103 and 104 etc 21 The last brake disc must be an external disc item 103 Table...

Page 93: ...00N of compressive force to install the snap ring See Figure 3 55 Figure 3 52 Install New O Ring V Figure 3 53 Install Brake Piston Figure 3 54 Install Spring Washer Figure 3 55 Apply 15 740 lbs to Sn...

Page 94: ...brake piston item 107 and the spring washer item 108 See Figure 3 60 34 Apply the compressive force of 15740 lbs 70000N to install the snap ring item 109 and release the compressive force See Figure 3...

Page 95: ...e 3 63 Install New Cover 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 Install the motor IMPORTANT Wait...

Page 96: ...itch and cable by performing the preceding steps in reverse order 10 Before placing the truck back into operation test it to be sure the switch functions properly See Check Driver s Seat Switch on pag...

Page 97: ...ocation Horn Removal The horn 12VDC is removed by 1 Set the key switch to OFF and remove key from the ignition switch 2 Disconnect the battery 3 Remove front rotation cover to expose the horn See Figu...

Page 98: ...ou Begin page 1 1 2 Set the key switch to OFF and remove key from the ignition switch 3 Apply the parking brake disconnect the battery and block the wheels 4 Remove back cover 5 Remove muffler 6 Drain...

Page 99: ...lly the unit gets replaced as a one assembly See Figure 3 72 Additional options can include backup alarms Figure 3 72 Overhead Guard Assembly Back Up Alarms Two types of back up alarm are offered audi...

Page 100: ...3 52 F 581 R1 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE...

Page 101: ...loading the Plus 1 software you may need to consult the factory 1 Install the Plus 1 program by following the software installation instructions provided at Landoll com 2 Attach cable to the availabl...

Page 102: ...screens shots provided below to navigate through the Plus 1 capabilities and forklift forklift performance checks IMPORTANT The status is provided at the bottom of the computer screen See Figure 4 3...

Page 103: ...where parameters can be manipulated as applicable Follow the screens shots of the Plus 1 provided in the upcoming pages Also shown below you will notice in the right side column the REV control numbe...

Page 104: ...switch I Reverse direction switch J Drive pedal switch 1 0 3 CP_BRAKE_SW On when stop pedal is depressed Off when stop pedal is in neutral position This signal is provided by a pressure transducer 2...

Page 105: ...l engine temperature Transmitted from the GFI ECM 25 0 3 CP_EngFanCmd Displays Fan command based on min max temperature scaled from 0 to 100 26 0 3 CP_FORWARD_SW Displays the state of the direction Sw...

Page 106: ...Off when reverse is not selected 4 0 3 CP_Seat_SW On when operator is present Off when operator is not present 5 0 3 CP_Tilt_SW Displays status of tilt command On when tilt lever is manipulated in eit...

Page 107: ...al_mV Displays pot wiper voltage 8 0 3 CP_REV_EDC_FLT Displays status of valve coil Off systems ok On coil shorted open or faulty 9 0 3 CP_FWD_EDC_FLT Displays status of valve coil Off systems ok On c...

Page 108: ...e Lift RPM Tilt RPM shift RPM and throttle command This will be the actual commanded RPM to the Engine 6 0 3 CP_Eng_RPM Displays the actual engine RPM in real time 7 0 3 CP_PctLoad_Avg Displays the Av...

Page 109: ...tual and commanded Propel command 5 0 3 MaxPumpFWD Defines the max current supplied to the forward direction coil 6 0 3 MinPumpFWD Defines the min current supplied to the forward direction coil 7 0 3...

Page 110: ...e defined in software for reference only 26 0 3 Pedal_Profile_X6 Pre defined in software for reference only 27 0 3 Pedal_Profile_Y1 Pre defined in software for reference only 28 0 3 Pedal_Profile_Y2 V...

Page 111: ...only 4 0 3 RPM_PER_X2 Pre defined in software for reference only 5 0 3 RPM_PER_X3 Pre defined in software for reference only 6 0 3 RPM_PER_X4 Pre defined in software for reference only 7 0 3 RPM_PER_...

Page 112: ...e faster lift 11 0 3 LiftPot_Y5 Value sets RPM commanded to engine Higher value faster lift 12 0 3 LiftPot_Y6 Value sets RPM commanded to engine Higher value faster lift 13 0 3 Lower_Valve_Enable Enab...

Page 113: ...in software for reference only 4 0 3 Load_DGAIN Pre defined in software for reference only 5 0 3 Load_T1 Pre defined in software for reference only 6 0 3 LOAD_RPM_X1 Pre defined in software for refere...

Page 114: ...cessful Pedal fully depressed 3 0 3 PedalMaxCal This is the actual value of the accel pot fully depressed based on last calibration Pedal fully depressed 4 0 3 PedalMinHi This value is for fault detec...

Page 115: ...rMinLow This value is for fault detection during calibration Default value 250 If the pot returns a voltage below this value during calibration calibration will be unsuccessful Steer full right 15 0 3...

Page 116: ...to operate the forklift for safe forklift operation monitoring and performance testing Be in a safe operating position Apply parking brake Place directional control in neutral To operate the forklift...

Page 117: ...5 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...

Page 118: ...ng is calibrated press NEXT to proceed to SETUP SCREEN 2 which will allow you to calibrate the drive pedal and tilt lever functions See Figure 4 28 IMPORTANT At any time with any of the three SET STEE...

Page 119: ...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...

Page 120: ...4 20 F 581 R1 CALIBRATION AND PROGRAMMING...

Page 121: ...lve Rocker End pivot rocker radiused cam follower Valve Lifter Lash Adjuster Hydraulic lash adjusters in head Crankcase Ventilation Foul Air System with PCV Oil Pan Capacity excludes filter volume 4 3...

Page 122: ...s a signal one per camshaft revolution or once every 2 engine revolutions The ECU then monitors the Oxygen sensor to make corrections for minor errors in the fueling The ECU has the capability of both...

Page 123: ...uel storage cylinder to the vaporizer through an integral liquid fuel filter Fuel Shutoff Solenoid This solenoid is a normally closed valve on the vaporizer controlled by the engine ECU allows the fue...

Page 124: ...s and controls outputs to achieve the desired engine performance The ECU also monitors the various input and output components as well as it s own internal functioning for failures and then alerts the...

Page 125: ...stroke The engine will run without this signal but will have throttle tip hesitation problems Figure 5 6 CAM Sensor Location Crank Sensor The crank position sensor is a reluctor sensor that is trigge...

Page 126: ...0 45 indicates a fuel lean mixture The ECU uses this information to swing the fuel rich and lean at 2 to 10 times a second to supply the catalyst with the optimum mixture for emissions reduction The...

Page 127: ...der cannot be displayed Incorrect display value LPG cylinder with similar filing level to previous one has been installed Maximum forklift tilt limit exceeded when ignition switch is on LPG cylinder p...

Page 128: ...g continuously over entire range Between 0 5V and 4 5V in 0 25Hz Calibration connection is open Close connection and re calibrate Forklift stops even though gauge is indicating a fill level LPG cylind...

Page 129: ...ENGINE WITH FUEL SYSTEM 5 9 Figure 5 10 Fuel System Troubleshooting...

Page 130: ...fuses 5 If you do not see voltage on pin D then the coil may be bad in the relay replace or the power latch relay circuit may be shorted to ground or the ECU is already on 6 If when key is turned ON...

Page 131: ...the engine block and crank the engine or other suitable ground you should see a spark between the spark plug tip and the ground electrode Be sure there is no petrol or LPG about when you do this test...

Page 132: ...injector at a time and see if there is a drop in rpm as each injector in turn is disabled the rpm needs to be above idle since if the forklift is on idle the idle governor will try to keep the rpm co...

Page 133: ...ENGINE WITH FUEL SYSTEM 5 13...

Page 134: ...5 14 F 581 R1 ENGINE WITH FUEL SYSTEM...

Page 135: ...y need to consult the factory 1 Install the Kvaser program by following the software installation instructions with the CD 2 Start Kvaser software only 3 Attach cable to the available USB computer por...

Page 136: ...rked at the bottom left hand corner of the Main Monitor screen you will find the Injectors Tab After you select this tab you will see a list of all injectors See Figure 5 15 By selecting any number of...

Page 137: ...f corrections have not been made Active faults will return All faults may be saved to a Tab Limited Excel file for future use Faults can also be cleared here Figure 5 16 Diagnostics Tab TSC1 Function...

Page 138: ...e Figure 5 19 is provided to show options available within this functionality that can be plotted on the graph in any combination required Figure 5 18 Plot Screen Pedal position and engine speed have...

Page 139: ...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...

Page 140: ...6 2 F 581 R1 GM ENGINE SUPPLIER PROVIDED DOCUMENTATION...

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 F...

Page 142: ...ring 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 F 581 R1 Copyright...

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