Drexel FL40-60 EX Drivers Guide 1417197 05-2006
Drexel FL40-60 EX Drivers Guide 1417197 05-2006
Drexel FL40-60 EX Drivers Guide 1417197 05-2006
SwingMast
Division
Lift Truck
EX Series
DRIVER’S GUIDE
LANDOLL CORPORATION
Landoll Corporation
Drexel Division
1900 North Street
Marysville, KS 66508 U.S.A.
Telephone:.. ............ (785) 562-5381
Fax: ......................... (785) 562-4853
Web:....................... www.drexeltrucks.com
contents page
Safety precautions
safety ...................................................................................................................... 5
1. Site supervision ...................................................................................................... 5
2. Operator .................................................................................................................. 7
3. Tipping hazards .................................................................................................... 11
4. Traveling and load handling .................................................................................. 13
5. Speed ................................................................................................................... 15
6. Visibility ................................................................................................................. 15
7. Battery care .......................................................................................................... 15
8. Service repair ........................................................................................................ 17
9. Safety labels ......................................................................................................... 19
10. Available options ................................................................................................... 21
Overview
truck layout ......................................................................................................... 23
introduction ........................................................................................................... 24
overview ................................................................................................................ 26
1. Driver’s cab .......................................................................................................... 26
2. Lift and tilt, and shift .............................................................................................. 29
3. Mast assemblies ................................................................................................... 29
4. Specifications ........................................................................................................ 30
Operation
to begin operating... ............................................................................................. 31
1. Pre-operation checklist ......................................................................................... 31
2. Adjusting the driver’s seat ..................................................................................... 31
3. Fork adjustment .................................................................................................... 33
driving the truck ................................................................................................... 35
1. Practice session .................................................................................................... 35
the mast ................................................................................................................ 37
1. Practice session .................................................................................................... 37
handling loads ...................................................................................................... 39
1. To pick up the load .............................................................................................. 39
2. To deliver a load ................................................................................................... 43
Appendix
available options................................................................................................... 57
1. Back up alarms ..................................................................................................... 57
2. Fork positioner - non-side shifting ......................................................................... 57
3. Folding forks ......................................................................................................... 58
4. Lift limit interlock ................................................................................................... 59
5. Side shifting option ............................................................................................... 60
6. Strobe light ............................................................................................................ 60
Index
index ...................................................................................................................... 61
safety
IMPORTANT !
1. Site supervision
Supervision is an essential element in the safe operation of
powered industrial lift trucks.
1 “FL EX” Series includes Drexel Models FL40-EX and FL60-EX “Explosion Proof”
lift trucks.
2
“Explosion proof” - See inside front cover for regulations and rating specifications.
WARNING !
Landoll Corporation
Drexel Division
1900 North Street
Marysville, KS 66508 U.S.A.
Telephone: ......(785) 562-5381
Fax: .................(785) 562-4853
WARNING ! - continued
2. Operator
WARNING !
WARNING ! - continued
UNDER NO CIRCUMSTANCES
ARE THERE TO BE ANY RIDERS
ANYWHERE ON THE TRUCK,
OTHER THAN THE OPERATOR.
Seat belt
WARNING !
❑ Push the latch plate into the buckle until it clicks. Pull
up on the latch plate to make sure it is secure.
PU
the belt must be
SH
worn low and
snug on the hips,
just touching the
thighs.
IMPORTANT !
Parking brake
3. Tipping hazards
WARNING !
All lift trucks that elevate and tilt loads are subject to the
risk of tipping over, especially when accelerating or when
applying the brakes abruptly. Transporting loads off-cen-
ter increases the risk of tip-over.
Do not jump........................................
Pay particular
attention when
picking up a load,
to ensure the load
weight and height
requirements are
within the trucks
capacity.
❑ Do not transport
loads or other
items within the
driver’s cab or other areas of the truck.
❑ Check that the load is properly positioned on the
forks before lifting.
❑ Spread forks as far apart as the load permits and
push completely under the load. Check that forks
and loads are centered. Use care if conditions
require handling off-center loads.
❑ Travel with forks straight ahead, and the mast tilted
backward and shifted as far as possible to the right.
❑ Travel with forks or load 8” to 12” (203 mm to
305 mm) above travel surface.
❑ Elevate mast or load only to pick up or deposit a
load. Watch out for obstructions, especially over-
head. Watch all clearances.
❑ Tilt a loaded mast slowly.
❑ Do not release the lift control lever suddenly when
lowering loads. This may cause bouncing of the car-
riage which could dump the load.
❑ Do not allow anyone, under any circumstances, to
walk or stand under the forks or any part of the load.
❑ Never place any part of your body between the mast
structures or any moving part of the truck.
❑ Do not turn when traveling on ramps. When
descending ramps, travel forward (forks facing down-
hill) when empty, and travel backward (forks facing
uphill) when carrying a load.
❑ Use care even when traveling without a load. Avoid
high speeds, sharp turns and abrupt stops.
5. Speed
Travel speed must be chosen according to the situation,
such as, the load being handled, road surface conditions,
visibility, people working in the area, moving and fixed
objects in the area, cross aisles, and so on.
WARNING !
6. Visibility
Where visibility is restricted, travel at very slow speed and
use the horn frequently.
7. Battery care
The truck battery contains concentrated sulfuric acid which
can cause severe chemical burns. When the battery is
charging, it releases hydrogen, a colorless, odorless and
highly explosive gas which can be ignited by a spark. Elim-
inate all sparks or flames from the charging area.
WARNING !
WARNING ! - continued
8. Service repair
When it becomes necessary to do any service repair or
maintenance to the truck, it is important to first review the
following safety guidelines.
WARNING !
WARNING !
4. Set the key switch to OFF and set the control lever to
NEUTRAL and set the parking brake.
WARNING !
DANGER !
9. Fully open the required truck covers and be sure they are
braced to prevent accidental closing.
9. Safety labels
For operator safety, a number of WARNING, DANGER and
CAUTION plates are attached to the truck, including the
CAPACITY nameplate within the driver’s cab.
WARNING or DANGER
plates describe condi-
tions or practices which, !
if not strictly observed,
could result in personal
injury or possible loss of
life.
CAPACITY plate
lists the load weights Division
Fire extinguisher
❑ it is not damaged
❑ the discharge outlet is not blocked
❑ it is fully charged
❑ the seal is not broken
❑ the instruction pamphlet is clearly visible
IMPORTANT !
In case of a fire
WARNING !
truck layout
EX
1. Mast
2. Driver’s Cab
3. Overhead guard
4. Battery connector conduit
5. Battery compartment
6. Load backrest extension
7. Forks
8. Drive axle, tires and wheels
9. Main electrical enclosure
10. Steer axle, tires and wheels
introduction
This manual provides operating and routine maintenance instruc-
tions for Drexel FL-EX 1 * Series Explosion Proof 2 Lift Trucks. FL-
EX series lift trucks are designed to be safe and effective when used
in hazardous areas and are UL 583 approved, EX-rated. All electri-
cal components are contained with enclosures which have been
tested to control sources of ignition in environments containing
explosive mixtures of gasses and dusts without representing a haz-
ard to the surrounding environment.
The FL-EX Series trucks are the direct result of over 20 years’ expe-
rience in designing, manufacturing and distributing world class lift
trucks. Drexel trucks are noted for their exceptional resale value,
low maintenance costs, and our one person - one truck - one move
concept (providing high density storage with value added flexibility).
Drexel trucks meet or exceed AMSE B56.1 - Part III, Safety for Pow-
ered Industrial Trucks and are FMRC approved by meeting or
exceeding requirements of FMRC Class 7820, ANSI/UL-583 stan-
dard for Battery Powered Industrial Trucks, Types E and EE. The
electrical system complies with UL-583 requirements for type E and
type EE (optional) Electrical Battery-Powered, Industrial Truck
construction.
IMPORTANT !
overview
FL-EX series trucks are four-wheeled front loading trucks, having
two load drive wheels in the front and two steerable wheels in the
rear. The traction drive system uses a DC electric motor, controlled
by an SCR motor controller.
1. Driver’s cab
(Also see Figure 7: ‘Driver’s cab’ on page 27.)
❑ Battery connector
latch and fuse box
- Both items are pro-
vided by the battery
manufacturer and
vary in design and
location. See manu- Lock
facturer’s data for
additional informa-
tion. (See Figure 6:
‘Battery connector/ Fuse
fuse box.’) Box
Steering Wheel
Battery Accelerator
Indicator Pedal
Hour
Meter Brake
Pedal
Directional Lever
Emergency Stop
Horn
Control
Levers
Parking
Brake Seat Belt
❑
REVERSE
Accelerator pedal - is pressed by
the driver’s right foot to control the
speed of the truck. (See Figure 7:
‘Driver’s cab.’)
FL-EX trucks offer a maximum speed of 4 mph
(6.44 kph) loaded.
WARNING !
Note: If the battery drops to 20% of full charge, the lift function
is disabled. The operator must return the truck to the charging
station. This prevents a deep discharge of the battery (which
shortens battery life), and also protects the electric motors and
other electrical components from damage caused by low
voltage.
3. Mast assemblies
Various mast assembly configurations can be applied to the
FL-EX series trucks to provide both lowered and extended
heights suitable for most customer requirements. Check
the capacity plate in the driver’s cab for the maximum lifting
capabilities based on the particular truck model and mast
combination.
4. Specifications
See your Service Manual for a complete listing for Model
FL40-EX and FL60-EX technical specifications. (Also see
Figure 5: ‘Capacity nameplate location’ on page 25.)
to begin operating...
WARNING !
Do not operate this truck until this manual has been read
in its entirety, especially the section devoted to SAFETY.
1. Pre-operation checklist
Perform a pre-operation inspection of the FL-EX series lift
truck daily, before beginning your work shift. Report all prob-
lems to your immediate supervisor. (See ‘Routine checks’ on
page 48.)
WARNING !
Adjust the driver’s seat only when the truck is NOT mov-
ing. You could lose control or the sudden movement
could cause you to push a wrong pedal if you attempt to
adjust the seat with the truck moving.
1. Push the lever to one side and slide the seat forward or
backward as needed. Release the lever and try to move
the seat slightly to make sure that it is locked. (See Fig-
ure 12: ‘Driver’s seat adjust,’ on page 32.)
WARNING !
Seat belt
The seat belt must always be worn when driving this truck.
2. Pull the belt across you. Do not let the belt twist.
WARNING !
The lap part of the belt must be worn low and snug on the
hips, just touching the thighs.
WARNING !
3. Fork adjustment
For some loads, it may be necessary to adjust the position of
the forks by moving them sideways on the fork carriage.
WARNING !
WARNING !
As the truck operator, you are responsible for observing all speed
restrictions and traveling in accordance with aisle and work area
conditions. You are responsible for observing all instructions and
safety regulations during your daily work routine related to the use of
this truck. It is your responsibility to thoroughly read this Driver’s
Guide, paying particular attention to the chapter devoted to Safety,
before attempting to operate this lift truck.
1. Practice session
1. Pull the emergency push/pull button UP to start the truck.
WARNING !
the mast
1. Practice session
1. Slowly pull the LIFT lever towards you
to raise the forks. Lift the forks only
one or two feet for practice.
WARNING !
WARNING ! - continued
You should tilt the mast only at the floor level or at the load
level in the rack when depositing or picking up a load. At
any other time, forward tilting could cause the truck to tip
forward or cause the load to slide off the forks causing
serious injury to yourself or anyone in the area.
WARNING !
Too heavy a load may tip the truck, causing injury to the
operator. Unstable loads may fall off, injuring people
nearby.
handling loads
Drexel SwingMast trucks require no more than two movements at a
time to maneuver a load. This ensures that the driver always has
one hand on the wheel, the other hand for one of the levers.
WARNING !
Note: If your truck is equipped with the shift option, you can
shift the forks to the left or right to assist with the alignment.
IMPORTANT !
Note: Be sure the forks do not extend beyond the load, caus-
ing damage or tipping of other adjacent loads or materials
behind the load being moved.
8. Raise the load above the rack about 2” (51 mm) to clear
the rack horizontal members. Be careful of any cross
members above the load.
10. Check your travel path, then very slowly move the truck
in reverse, at the same time turning the wheel to pivot the
load (approximately 45°) and to rotate it out of the rack
area, or drive straight back until the load clears the rack.
(See Figure 23: ‘Retrieving the load.’)
11. When you are sure the pallet clears the rack completely,
continue backing out until the load is completely away
from the rack.
WARNING !
2. To deliver a load
1. When transporting a load, travel with the forks 6” to 12”
(152 mm - 305 mm) maximum from the floor and travel at
reduced speed, comparable to your work environment.
6. Gradually drive forward, inserting the load all the way into
the opening. (See Figure 26: ‘Delivering the load.’)
WARNING !
Be careful that the load does not hit the side of the rack as
it is inserted. You may have to move the truck forward or
backward to help provide clearance for the load to swing
into the rack. Also make sure the load is a few inches
above the bottom rail of the rack and that it does not strike
any cross members above.
Note: If your truck is equipped with the shift option, you can
shift the forks to the left or right to assist with the alignment.
Do not lower them so far that they strike the bottom of the
pallet or a cross member below the load.
9. Check your travel path, then very slowly move the truck
in reverse, at the same time turning the wheel (approxi-
mately 45°) to rotate the forks out of the rack area. (See
Figure 28: ‘Backing out.’)
10. Be careful that the forks do not hit the side of the rack or
pallet as they emerge.
11. When you are sure the pallet clears the rack completely,
continue backing out until the load is completely away
from the rack.
WARNING !
general
This section provides general information about the inspection and
care of your Drexel FL-EX Lift Truck. Detailed inspection and ser-
vice work must be performed by your trained service personnel or
an authorized Landoll Service Representative. A separate Service
Manual, supplied with every truck, details preventive maintenance
schedules and troubleshooting procedures and should be kept on
file with your immediate supervisor or in your service department.
Keep a log for each truck at your site, listing all services, repairs and
adjustments performed, as well as equipment or operation problems
and when they are performed (hour meter reading). Permanent logs
serve as a checklist to show maintenance and repair history and to
record whether problems have been corrected.
1. Visual checks
Many problems can be spotted by a simple visual inspec-
tion of the truck; such as, oil leaks, damaged tires, cracks in
welds or forks, damaged covers, etc.
However, dirt, grease, oil and debris can mask some prob-
lems. If possible, the truck should be washed on a regular
basis. To remove stubborn grease, a grease-dissolving sol-
vent may be required. Make sure the solvent is not harmful
to painted surfaces.
WARNING !
2. Routine checks
With the truck emergency switch set to OFF, perform a
walk-around inspection. Check for obvious damage that
would require more detailed inspection. If any of the follow-
ing is apparent during your walk-around, record it in the log
book for the truck and immediately notify your supervisor
and/or service personnel.
WARNING !
CAUTION !
Note: Inertia may cause the mast to drift upwards a few addi-
tional inches (millimeters) before it actually stops.
If the interlock is
not working
Lift Limit
properly, repair Switch
and/or have ser-
vice replace
immediately.
Flag
Do not use the
truck.
Mast operation -
With the key
switch set to
ON, raise the
mast. Check Front Of Truck
that the primary
cylinder extends
fully and that the lift carriage raises to the top of the
inner rails before the secondary cylinders begin to
move.
WARNING !
Never place your head, hands, arms or feet in the mast area!
WARNING !
WARNING !
Note: It is recommended to
partially load the truck doing
the towing for better traction.
Tow Pin
Also, the power steering on the
disabled truck does not oper-
ate when the power steer
motor is not running, which
makes the steering wheel diffi-
cult to turn.
driver’s log
driver’s log
available options
1. Back up alarms
The back up alarm beeps continu-
ously for as long as the truck is in
reverse. (See Figure 32: ‘Back up
alarm.’)
Backrest
Forks
Positioner
3. Folding forks
For the convenience of truck stor-
age and/or transport, folding
forks are available. (See Figure
35: ‘Folding forks.’)
WARNING !
working in areas
having low ceil-
ing heights.
WARNING !
IMPORTANT !
6. Strobe light
Strobe light
packages
are designed Strobe
Light
to warn oth-
ers that the
EX truck is in
the area. The
strobe light
also includes EX
a blackout
for operator
protection.
index
A D - continued
Aisle space ............................................. 8 Driver’s seat - continued
Alarm .................................................... 57 Seat belt ........................................ 9, 32
Back up .......................................36, 57 Important ! ..................................... 10
Align the load ........................................40 Release button .................. 10, 32, 33
Warning ! ................................. 32, 33
B Warning ! ...................................... 9, 31
Battery ........................................ 8, 15, 26 Driving the truck ......................... 8, 35–37
Care ............................................15–17 Important ! ......................................... 25
Connector latch ................................. 48 Practice session ................................ 35
Connector lock ..................................26 Emergency button ......................... 35
Discharge indicator (BDI) .................. 28 Speed ............................................... 15
Fuse box ........................................... 26 Training ............................................. 35
Hold-down hardware ......................... 49 Warning ! .................................... 35, 36
Warning ! ....................................16, 17
Brakes .................................................. 26 E
Driver’s seat switch, mechanical .10, 50 Emergency stop ............................. 28, 29
Parking .............................. 7, 10, 35, 49 Uses .................................................. 29
Service ........................ 8, 11, 12, 18, 49
F
C Feathering ............................................ 37
Cab, driver’s ............................... 9, 26–29 Fire extinguisher ................................... 20
Accelerator ........................................27 Dry powder ....................................... 20
Battery discharge (BDI) ..................... 28 Important ! ......................................... 20
Brake, Service ..................................28 In case of fire .................................... 20
Direction control ................................ 27 Fork positioner, non-side shifting ......... 57
Emergency button .............................28 Daily checks ...................................... 21
Fuse box, battery .............................. 26 Folding .............................................. 58
Horn .................................................. 27 Setting ............................................... 58
Hourmeter ......................................... 28 Warning ! .......................................... 58
Key switch ......................................... 26 Forks .................................................... 33
Service brake .................................... 28 Automatic .......................................... 34
Steering wheel ..................................27 Centering .......................................... 40
Unattended ......................................... 9 Manual adjust ................................... 34
Checklist, pre-operation ........................ 31 Warning ! .......................................... 33
D H
Direction control ............... 7, 8, 10, 27, 35, Handling loads ................................ 39–46
36, 50, 54 Deliver a load .............................. 43–46
Driver’s log ............................................ 55 Pick up a load ............................. 39–43
Driver’s seat .......................... 9, 31, 32, 49 Traveling ..................................... 39, 43
Lever, adjust ..................................... 31 Warning ! ........................ 39, 43, 44, 46
L M - continued
Labels .................................................. 19 Maintenance - continued
Capacity ........................................... 19 Visual checks ................................... 47
Caution ............................................. 19 Grease .......................................... 48
Warning ............................................ 19 Warning ! .................................... 50, 52
Lever .................................................... 29 Mast ............................................... 37–38
Feathering ........................................ 37 Configuration .................................... 29
Forks ................................................ 58 Practice session ............................... 37
Lift ............................................... 14, 37 Servicing ........................................... 52
Side shift, optional ............................ 38 Warning ! .................................... 37, 38
Tilt ........................................... 8, 37, 38 Models
Lift limit ..................................... 22, 52, 59 FL40-EX (4,000 lbs.) ........................ 24
Important ! ........................................ 59 FL60-EX (6,000 lbs.) ........................ 25
Lights Modifications .......................................... 6
Strobe ............................................... 60
N
M Nameplate
Maintenance .................................. 47–53 Capacity ............................... 13, 19, 38
Caution ! ........................................... 51 Model, serial and option ................... 25
Driver’s log ........................................ 47
Inspection ......................................... 47 O
Procedures ....................................... 47 Operating your truck ...................... 31–46
Routine checks ........................... 48–53 Warning ! .......................................... 31
Battery connector latch ................. 48
Battery discharge (BDI) ................. 51 P
Battery hold-down studs ............... 49 Pedals
Brake pedal ................................... 49 Accelerator ................................. 27, 36
Brakes, parking ............................. 49 Parking ............................................. 28
Brakes, service ............................. 49 Service ............................................. 28
Cracked welds .............................. 53 Practice session
Decals and plates ......................... 53 Driving ........................................ 35–37
Driver’s seat .................................. 49 Mast ............................................ 37–38
Brake, mechanical ..................... 50
Limit switch ................................ 50 R
Fasteners ...................................... 51 Responsibilities
Ground strap ................................. 53 Operator ..................... 7–10, 35, 47–54
Horn .............................................. 51 Service ............................................. 47
Hourmeter ..................................... 51 Supervision ..................................... 5–7
Hydraulic lines and fittings ............ 51 Routine checks. See Maintenance
Inspection ....................................... 7
Lift limit interlock ........................... 52 S
Lights ............................................ 51 Safety ............................................... 5–22
Mast .............................................. 52 Battery. See Battery
Oil level ......................................... 51 Capacity plate ............................. 13, 14
Overhead guard ............................ 53 Fire extinguisher ............................... 20
Rust and corrosion ........................ 53 In case of fire ................................ 20
Tires .............................................. 53 Fork positioner, non-side shifting ..... 21
Wires and connectors ................... 49 Warning ! ...................................... 21
S - continued T
Safety - continued Tipping hazards. See Safety
Forks ................................................. 14 Tires ............................................... 12, 53
Important ! ........................................... 5 Towing the truck ................................... 54
Load handling .............................13–15 Warning ! .......................................... 54
Modifications ....................................... 6 Training program .................................... 6
Operator .............................................. 7 Evaluation ........................................... 6
Riders, transport ................................. 7 Traveling. See Safety
Riders, transporting ............................. 8 Truck overview ..................................... 23
Seat belt. See Driver’s seat
Service repair .................................... 17 V
Danger ! ........................................18 Ventilation ............................................. 48
Warning ! .................................17, 18 Visibility. See Safety
Speed. See Speed Visual checks. See Maintenance
Supervision ......................................... 5
Tipping hazards ..........................11–13
Causes .......................................... 11
Driving surface .............................. 12
Guidelines ..................................... 11
Lateral ........................................... 12
Longitudinal ................................... 11
Tires .............................................. 12
Warning ! ....................................... 11
Traveling .....................................13–14
Visibility .............................................15
Warning ! ....................................6, 7, 8
Seat belt. See Driver’s seat
Service repair .................................17–19
Side shift, optional ....................38, 40, 45
Lever ................................................. 38
Side shifting .......................................... 60
Control lever ..................................... 60
Specifications
Explosion proof ................................. 24
FL-EX series ..................................... 30
Models ........................................24, 25
Overview ........................................... 24
Rating ........................................... 5, 25
Speed .............................................15, 27
Warning ! ....................................15, 28
Switch
Battery connector lock ...................... 26
Driver’s seat ...................................... 10
Seat, safety ....................................... 26
Landoll Corporation
Drexel Division Additional copies of this Driver's Guide
1900 North Street may be purchased from your authorized
Marysville, KS 66508 U.S.A. Landoll Dealer.
Telephone: ................... 785-562-5381
Fax: .............................. 785-562-4853 Driver's Guide p/n:1417197, -c 05/03
Web: ............... www.drexeltrucks.com