FL EX Series Explosion Proof Lift Truck Service and Parts Maintenance Manual Landolt Corporation Drexel Division 1900 North Street Marysville, KS 66508 USA Telephon« Fax... Webs: (785) 562-5981 (785) 562-4853, \www.drexltrucks.com ast number: 1420660 -b, 0503NOTICE | Explosion proof - Drexel FL-EX Series lift trucks are designed and constructed to perform in operating environments containing specifically named flammable gases or vapors and combustible dusts. The trucks are inspected and tested to stringent ANSI/UL 583 standard consistent with OSHA 29CFR (Code of Federal Regulations), paragraph 1910.178. Additionally, the trucks are classified by Underwriters Laboratories, Ino. for use in Class 1, Division 1, Group D (operat- ing gas or vapor-air environments) and/or Class Il, Division 1, Group G (operat- ing combustisle dust-air environments) locations as defined in National Electric Code NFPA 70 by National Fire Protection Association. as All items of technical information, advice, know-how, drawings, designs, speciti- cations and other items communicated in this document are confidential and remain the property of Landoll Corporation and shall not be disclosed to a third party, photocopied, reproduced, or translated to another language without the prior written permission of: Landoll Corporation Drexel Division 1900 North Street Marysville, KS 66508 . (785) 562-5381 (785) 562-4853 www.drexeltrucks.com The Landoll Corporation is pleased to provide detailed specifications of its products in this manual, but reserves the right to vary these at its discretion at any time without notice. As the Company's products and services are continu- ously being developed, it is important for customers to check that the informa- tion contained herein includes the latest specifications. This manual is for general guidance only. Landoll Corporation cannot accept any financial or other responsibilty that may be the result of your use of the information contained herein; including direct, indirect, special or consequential damages. All recom- mendations and suggestions issued by or on behalf of the Company in whatever form, are subject to the Company's terms and conditions of sales, a copy of which will be supplied upon request. This document is not part af a contract or license, save insofar as may be expressly agreed. Pert rumba: 14208604, 0505, (© Lando Corprasen, Dretl Division 2008 [AI Rights ReservedUsing this manual Q about this manual sings manus, lh: 1420680 -b 0803 This FL EX * Series Service and Parts Maintenance Manual is a guide to the daily operation and service of your Drexel Explosion Proof Fork Lift Truck. Itis designed to be used as a reference tool in your everyday use of this truck, All brand and product names are the trademarks oftheir respective holders. ‘The manual is divided into several chapters, each chapter dealing with a major function in the care of your truck. The chapters are sepa- rated by individual index tabs and each chapter includes a complete table of contents for ease of location and use. A brief description of each chap- ter follows. Safety ‘Always operate with safety as your number one goal. This chapter must be carefully read, understood and adhered to strictly by all operators and service personnel using the Drexel Explosion Proof lift trucks. Do not use this truck until you have thoroughly read this chapter. Failure to comply could cause risk of death or serious injury to yourself and others. Warranty and Parts A copy of your Limited Warranty and Warranty and Replacement Parts Policies and Procedures guides are found here. ‘Truck overview Chapter 1 offers a brief description of the many functions and fea- tures of your EX Series truck. For example, traction drive, brake systems, electrical and hydraulic systems, the operator's cab, specifications, etc. * FLEX Series includes Drexel Models FL EX-40, and FL.EX-60 If trucks.Q Using this manual Receiving & Inspection Chapter 2 details your responsibilities upon receiving the truck, such as charging the batteries (wet or dry), performing visual inspections and routine checks, battery removal, plus storage, towing or shipping information. Operation Chapter 3 explains the operation of the truck and is divided into three sections. Q__ Basic operation -is a complete guide to the operation of the truck, similar to the Driver's Guide found in the document compartment behind the driver's seat. Theory of operation - is an overview of how the hydraulic and electrical systems work and includes a hydraulic layout diagram and schematic for a standard EX Series truck. A fold-out electrical schematic is be found under the fiap on the inside front cover in this manual. Q Available options - includes operating procedures for the most commonly ordered options, such as, Fire Extinguisher, Lights, etc. When applicable, special customer option operating instruc- tions may also be found here, under separate cover. Always check here, behind the colored slip-sheet, for additional operating information. Preventive maintenance Chapter 4 describes the routine inspections, adjustments and set- tings and lubrication needed to keep your EX Series lift truck in optimum performance and stability, with minimum downtime, Troubleshooting When a problem develops, see this chapter for troubleshooting procedures, in chart form. Troubleshooting procedures are defined as Visible Problems, Audible Problems, or Operational Problems. SX separately excited controller status code trouble- shooting is also found here. Using tne manus hs 1420880 -b a!0aUsing this manual O Once the problem is isolated, see Chapter 6, “Corrective maintenance” for the adjustment and/or repair instructions. Corrective maintenance Chapter 6 details the maintenance procedures for the truck and is divided into four sections. Q Introduction to maintenance procedures - This section must be carefully read and understood before beginning any adjustment or repair to the Drexel Explosion Proof lift truck. Q. Adjustments and/or settings - Instructions on performing ‘the major adjustments andior settings, beyond those explained in the preventive maintenance chapter (4), are explained here. SX controller setup is also included in this section, Q Mechanical repairs - This section is devoted to major mechanical repairs - how to replace andlor repait most major parts and/or assemblies on the truck. Q Electrical control repairs - This section is devoted to major electrical repairs - again, how to replace and/or repair most major parts and/or assemblies on the truck. Mast IPB (ilustrated parts breakdown) Chapter 7 includes a Mast Installation IPB and a Mast Assembly IPB, each having its own Table of Contents. The Mast Installation lists the parts used to install the mast to the truck (interconnecting parts); the Mast Assembly is an internal breakdown of the mast assembly. Base IPB (illusirated parts breakdown) Chapter 8 includes a parts breakdown of the main body (base unit) of the Drexel Lift Truck, such as the drive section, hydraulics and electrics, operator's cab, brakes, steering, etc. Options IPB (iltustrated parts breakdown) Chapter 10 includes a parts breakdown of the most commonly used option features available for all Drexel lift trucks. Using Pe menus, pn: 1420860 -b 08108, 3Q Using this manual Using is manual, pl: 1420880 -> 8sFL EX Series Explosion Proof Lift Truck Chapter: Safety precautions Landolt Corporation Drexel Division 1900 North Street Maryeville, KS 66508 USA, Telephones n.nn-(785) 562-5981 Fax (785) 562-4858 “. warwdrexeltrucks.com Pert number: 1420860 2, 05108, Web:NOTICE! Explosion proof - Drexel FL-EX Series lift trucks are designed and constructed to perform in operating environments containing specifically named flammable gases or vapors and combustible dusts. The trucks are inspected and tested to stringent ANS/UL 83 standard consistent with OSHA 29CFR (Code of Federal Regulations), paragraph 1910.178. Additionally, the trucks are classified by Underwriters Laboratories, Inc. for use in Class 1, Division 1, Group D (operat- ing gas or vapor-air environments) and/or Class Ii, Division 1, Group G (operat- ing combustible dust-air environments) locations as defined in National Electric Code NFPA 70 by National Fire Protection Association. Al items of technical information, advice, know-how, drawings, designs, specifi- cations and other items communicated in this document are confidential and remain the property of Landoll Corporation and shall not be disclosed to a third Party, photocopied, reproduced, or translated fo another language without the prior written permission of: Landoll Corporation Drexel Division 1900 North Street Marysville, KS 66508 USA Telephone: Fax: Web:... (785) 562-5381 (785) 562-4853 .. www. drexeltrucks.com The Landoll Corporation is pleased to provide detailed specifications of its products in this manual, but reserves the right to vary these at its disoretion at any time without notice. As the Company's products and services are continu- ously being developed, it is important for customers to check that the informa- tion contained herein includes the latest specifications. This manual is for general guidance only. Landoll Corporation cannot accept any financial or other responsibility that may be the result of your use of the information contained herein; including direct, indirect, special or consequential damages. All recom- mendations and suggestions issued by or on behalf of the Company in whatever form, are subject to the Company's terms and conditions of sales, a copy of which will be supplied upon request. This document is not part of a contract or license, save insofar as may be expressly agreed, Prt rumber 1420860 b, 0903 © Landal Compra, Drexal Oven 2008 ‘A Rights ReservedOperation Contents Page Safety precautions safety 8.1 Site supervision 35 $.2. Operator .. Seat belt .. Figure 1: Belt release button 3-9 Seat safety switch and brake switch Parking brake .... 8.3. Tipping hazards Longitudinal tipping can occur wher Lateral tipping can occur when: $4. Traveling and load handling .... Figure 2: Capacity plate location S.5 Speed . S.6 Visiblity .. 8.7 Battery Features. Figure 3: Battery bolt-down studs. Care S.8 Service repair $9 Safety labels .. Fire extinguisher In case of a fire .. $.10 Available options. Fork positioner, non-side shifting .. Figure 4: Fork check point “FLE Seres Senic, Safty recaufon, ph: 1420860 +, 05S Safety -3Q Operation Contents - continued Page Safety -4 "FLLDK Sorae Senco, Safety prosautons, ph: 1420660 +, 080sSafety precautions O safety IMPORTANT ! The Drexel FL-EX * Series Explosion Proof ? trucks have been designed for optimum safety of their operators. They are designed to be safe and effective when operating in environments containing specifically named flammable gases or vapors and combustible dusts. Please follow the safety guidelines listed in this section and adher to all Warning, Danger, Caution and Important notes found withi this manual. When the truck is in operation, always keep loose clothing, jewelry, hair and fingers out of the restricted areas (espe- clally pinch areas) as labeled on the truck. This chapter on Safety must be carefully read, understood and adhered to strictly by all operators and service personnel using the Drexel FL-EX Series lift trucks. Do not use this truck until you have thoroughly read this manual. Failure to comply could cause risk of death or serious injury to yourself and others. Drexel SwingMast trucks meet or exceed ASME BS6.1 - Part Ill, Safety for Powered Industrial Trucks. S11 Site supervision Supervision is an essential element in the safe operation of pow- ered industrial lift trucks. The site supervisor must check that the driver's guide is in the seat compartment on the truck at all times. Operators must be trained on the use, maintenance and safety aspects of the FL-EX series trucks under the supervision of a trained and experienced operator. + FLEX Series includes Drexel Models FL40-EX and FL60-EX Explosion Proof Lif Trucks. 2 Explosion proof - See inside front cover for regulations and rating specifications, “FLEX Series Serves, Safety precailons, pl: 1420860 +b, 08108 Safety -5Q Safety precautions Safety -6 Only those individuals trained to operate and/or service this truck may do so. Familiarization and driving practice with a new truck must be arranged in a safe area, away from other trucks, obsta- cles and people. The training program must be applied to all new operators, regardless of previous experience. Operator performance must be evaluated to ensure he/she has the proper skills and knowledge to operate the truck. Operators must be re-trained when new equipment is introduced, existing equipment is modified, operating conditions change, or an opera- tor’s performance is determined unsatisfactory. WARNING | DO NOT MAKE MODIFICATIONS OR ADDITIONS TO ELECTRICAL DEVICES. DO NOT TAMPER WITH OR DISCONNECT SAFETY FEATURES OR MODIFY PROTECTIVE GUARDS (SUCH AS, OVERHEAD GUARDS ‘OR LOAD BACKREST EXTENSIONS). DO NOT ADD OR REMOVE STRUCTURAL PARTS. ANY OF THE ABOVE COULD AFFECT TRUCK CAPACITY AND/OR ‘SAFE OPERATION OF THE TRUCK AND IS A SERIOUS SAFETY VIOLATION WHICH COULD CAUSE PERSONAL INJURY, COULD WEAKEN THE CONSTRUCTION OF THE TRUCK, OR COULD AFFECT THE SAFE OPERATION OF THE TRUCK. NO MODIFICATIONS OR ADDITIONS MAY BE MADE TO THIS TRUCK WITHOUT PRIOR WRITTEN PERMISSION FROM: Landoll Corporation Drexel Division 1900 North Street Marysville, KS “66508 U.S.A. Telephone: .. (785) 562-5381 Fax: -1e(785) 562-4853 MODIFICATIONS AND/OR ADDITIONS TO AN EX FORK LIFT TRUCK MUST BE PERFORMED BY THE LANDOLL CORPORATION, EITHER AT THE FACTORY OR IN A NON-VOLATILE SERVICE AREA AND PERFORMED BY AN AUTHORIZED LANDOLL REPRESENTATIVE IN ACCORDANCE WITH ANSI/UL 583 STANDARD. “FL-EX Saree Sarvoe, Sefetypeceutens, wh: 420860 -b, o5098.2 Safety precautions O WARNING ! - continued ALL TRUCK MODIFICATIONS MUST BE EXAMINED, TESTED AND APPROVED BY (IN THE CASE OF THE LANDOLL CORPORATION) UNDERWRITERS LABORATORIES, INC. The truck must be inspected daily for problems or damage risking the safety of the driver, any people in the work area, or possible damage to the truck and the load being moved. When trucks are used on a round-the-clock basis, they must be inspected after each shift. Problems found must be reported and corrected. The truck must be taken out of operation until all repairs have been made and the truck has been reinspected for safety. Operator WARNING ! Check that all directional and operational controls and levers ar their NEUTRAL position, the brakes are set and your seat belt is fa tened before setting the key switch to ON. (See heading ‘Seat belt on page 9.) To avoid personal injury when operating the truck, be extremely careful that NO part of your body (head, feet, arms, legs, fingers) is. outside the operator's cab where it could be subject to injury by aisle supports, other trucks or any obstacle in the area. Know the location of and be especially careful of all pinch points, as Indicated by the WARNING and DANGER labels on the truck. Be especially careful when there are other people or moving or fixed objects in the working area, or when the load reduces visibil- ity. (See heading ‘Visibility’ on page 14.) Never drive a truck up to anyone standing in front of an object. Ensure that people stand clear of the rear swing area before making turns. NEVER LIFT, LOWER OR TRANS- PORT PEOPLE. NEVER ALLOW ANY- ‘ONE ON OR UNDER THE FORKS (OR LOAD). UNDER NO CIRCUMSTANCES ARE THERE TO BE ANY RIDERS ANY- WHERE ON THE TRUCK, OTHER THAN ‘THE OPERATOR Safety -7Q Safety precautions Safety - 8 WARNING} - continued When driving in narrow aisles, make sure there is enough space for the truck and the load, travel at reduced speeds, and where applica- ble, request a helper to guide you safely through the area. a o The operator is responsible for observing all instructions and safety regulations in his or her daily work routine related to the use of this truck. Be careful at cross aisles, doorways and other locations where people may step into the path of travel of the truck. He/she must check the condition of the truck at the start of each work shift. In particular, he/she must check the opera- tion of the steering and brakes; the directional control lever the tit, lit and lower (and shif - optional) joysticks; the condi- tion of the batteries, parking brake, horn, and signaling devices, where applicable. Make sure all access/service panels, doors and covers are installed, closed and latched tight. Do not operate the truck with panels, doors and covers removed, opened or unlatched Keep the truck clean and in good working order. Report any problems or damage risking the safety of the driver and any people in the work area. Problems found must be reported and corrected. The truck must be taken out of operation until all repairs have been made and the truck has been reinspected for safety. Always start, stop, change direction, travel and brake smoothly so as not to shift the load and/or overturn the truck. Do not indulge in stunt driving or horseplay. Drive carefully and slowly onto dock boards and bridge lates. Do not exceed the rated capacity of the dock boards or bridge plates and ensure dock boards or bridge plates are properly secured, either by being anchored or by being equipped with devices that will prevent slipping. Check that dock boards have substantial contact with both the dock and the carrier, preventing them from rocking or sliding. Maintain a safe distance from the edge of ramps, platforms and other similar working surfaces. ‘When leaving the driver's cab, the forks must be lowered to the floor, the mast must be placed in a vertical position, all controls must be ina NEUTRAL, or center position, the park- ing brake must be set and the key switch must be set to the OFF position. “FLEX Soles Service, Seley precautions, ph: 420660 -b, 808Safety precautions O Truck wheels must be blocked if the truck is parked on an incline. Note: A powered industrial truck is considered unattended when the operator is 25 feet (7.6 m) or more away from the truck which sti remains in his/her view... or whenever the operator leaves the truck and it is not in view. Seat belt The driver's seat belt must always be worn when driving this truck. Q First, sit up straight in the driver's seat. Q Pull the belt across you. Do not let it get twisted. WARNING | You can be seriously injured by a twisted belt. In a crash or a tip- cover, the full width of the belt would not be available to take up the Impact forces. Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure. 2 Ifthe belt stops before it reaches the buckle, press the release button on the left side and let it go back all the way and start again, (See Figure 1: ‘Belt release button,’ on page 9.) Figure 1: Belt release button The lap part of the belt must be worn low and snug on the hips, Just touching the thighs. IMPORTANT ! ‘Make sure the release button on the buckle is positioned so you can unbuckle the seat belt quickly in an emergency. “FL-EX Series Sano, Safty precaulons, ph: 1420880 -b, 0513 Safety -9a Safety precautions 8.3 Safety - 10 Seat safety switch and brake switch Ifthe operator leaves the driver's seat, a limit switch is released and the spring-loaded mechanical brake is engaged. The drive and power steering motors are disabled and the parking brake ‘energizes to prevent further truck movement. ‘To continue, you must first sit in the seat to actuate both switches, set the direction control lever in NEUTRAL, then select the direc- tion of travel Parking brake ‘The parking brake lever mechanically activates the brake by pull- ing up on the lever unti it snaps into place, Push down on the lever to release the brake, The parking brake must be set (engaged) when leaving the driver's seat. Tipping hazards WARNING | Lift truck tip-over can cause serious injury or death to the operator or others in the area. Every operator must be thoroughly familiar with the tipping hazards listed in this section and must always avoid any operation of the truck which is likely to result in tipping. All lift trucks that elevate and tilt loads are subject to the risk of tip- ping over, especially when accelerating or when applying the brakes abruptly. Transporting loads off-center also increases the risk of tip-over. Ifa tlp-over occurs, the operator should follow these guidelines: DO NOT JUMP. BRACE YOUR FEET FIRMLY. HOLD ON TIGHT LEAN AWAY FROM THE TIP. “FLEX Series Serco, Seley pecans, ph: 420860 +b, 088Safety precautions O The most likely causes of tip-over are listed beginning on the next page. However, the operator must use good judgement based on proper training and experience to determine turning sharpness and speed for the load being handled and the operating surface (or road) conditions. A truck can tip longitudinally (tipping over the front or rear wheels) or laterally (tipping either to the left or right side). Longitudinal tipping can occur when: o the truck is overloaded o the masts tilted forward excessively, with or without a load. Othe load is raised and brakes are applied while the truck is traveling forward or backward. the load is raised and the truck is accelerated while it is trav- eling forward or backward. the truck is driven forward down a steep incline with a load. Lateral tipping can occur when: Othe truck is turned sharply while traveling rapidly in either direction, with or without a load. An unloaded truck can tip easier than a loaded truck (with the load in the lowered posi- tion). Othe load is raised and the truck is being turned while travel- ing in either direction. the load is raised and the truck is being turned and acceler- ated or braked while traveling forward or backward. Othe truck is turned while traveling on a ramp or other inclined surface. Q alload heavier than the rated truck capacity is lifted, espe- cially when picking up a load. Tipping over in these conditions is made more likely by overload- ing, excessive mast titt, or off-center positioning of the load. Soft tires can also reduce stability. The truck is equipped with tires of a size and hardness that will provide the necessary traction and maintain a proper shape to minimize tipping. "FLEX Savion Senie, Salty precauters, ph: 1420660 -, 803 Safety - 11a Safety precautions Safety - 12 S4 Always replace tires with the type originally supplied by the manu- facturer. (See Figure 2: ‘Capacity plate location,’ on page 13.) The truck can be tipped either longitudinally or laterally if i is driven: Q over objects on the floor or ground, off the edge of a paved surface, into a pothole in a paved surface. off the edge of a loading dock, or off the edge of a loading ramp. (It is important to avoid driving too close to the edge of a dock or ramp). ‘When loading or unloading a highway truck or trailer, make sure the highway truck cannot move away from a dock while loading is in process. Make sure the highway truck or trailer has its brakes applied, engine turned off and, if on an incline, has the wheels blocked. Tipping can also ocour if the truck collides with another truck or other vehicle, or ifthe mast runs into an overhead obstruction. Traveling and load handling Q Observe all trafic regulations. Keep to the right and main- tain a safe distance from the truck ahead based on speed of travel. Keep the truck under contro! at all times. Yield the right of way to other people in the area. Q Slow down and sound the horn at cross aisles and other locations where visibility is obstructed. O Keep a clear view of the path of travel and be alert for other traffic, people and safe clearances. Q Under ail travel conditions, operate the truck at a speed that Permits you to bring the truck to a complete stop in a safe manner. 2 Donot handle unstable loads. Use care when titing forward r backward, when stacking, depositing, or retrieving a load, Never travel with the mast titted forward. Never exceed the truck's maximum lifting capacity. (See Figure 2: ‘Capacity plate location,’ on page 13.) ‘Truck stability and handling may be adversely affected. "FLEW Series Service, Setety precaulers, ph: 1420860 -», 0569,Safety precautions O Figure 2: Capacity plate location Pay particular atten- tion when picking up a load, to ensure the load weight and height requirements are within the trucks capacity. Q Donottransport loads or other items within the driver's cab or other areas of the truck. O Check that the load is properly positioned on the forks before lifting. Spread forks as far apart as the load permits and push com- pletely under the load. Check that forks and loads are cen- tered. Use care if conditions require handling off-center loads. Travel with forks straight ahead, and the mast tilted back- ward 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 overhead. Watch all clear- ances. Q Tita loaded mast slowly. 1D Do not release the lift contro! lever suddenly when lowering loads. This may cause bouncing of the carriage which could dump the load. Q. 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 struc- tures or any moving part of the truck. Q Do not turn when traveling on ramps. When descending ramps, travel forward (forks facing downhill) 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. Safety precsilens, ph: “420660 -5, 051 Safety - 13Q Safety precautions Safety «14 A 8.5 8.6 8.7 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. Always operate the truck at a speed that will permit it to be brought toa stop in a safe manner. WARNING | Careless driving, such as, fast starts or abrupt braking, excessive ‘speed at turns or through cross aisles, sudden stops, or hard turns at high speeds can all lead to serious personal injury and damage to the truck and load. Always drive with safety as your number one goal! Visibility Where visibility is restricted, travel at very slow speed and use the horn frequently. Always ask for a helper to guide you safely through the area when visibility is restricted. Always rotate in the driver's seat to face in the direction you are traveling Battery Features EX serias trucks include, battery retainer bolt-down studs to lock the battery in the compartment and a cutout in the overhead guard for easy battery service. (See Figure 3: ‘Battery disconnect and bolt-down studs,’ on page 15.) eres, Safely preceulhe, pin 1420660 -, 06108Safety precautions 2 Figure 3: Battery disconnect and bolt-down studs Care The truck battery con- tains concentrated sul- furic acid which can cause severe chemi- cal burns. When the battery is charging, It releases hydrogen, a coloriess, odorless and highly explosive gas which can be ignited bya spark. Eliminate all sparks or flames from the charging area. Shorting battery terminals can release enormous amounts of energy, causing sparks or flame, or heating nearby components to dangerous temperatures. The battery is very heavy, and if restraints are not replaced after maintenance, the battery could slide out of the truck causing elec- trical shorts or spilling acid - or it could cause the truck to tip over. The battery is also used as a counterweight. A different size or weight battery could cause the truck to become unstable and tip. Use batteries that meet the weight and size specifications shown on the capacity plate in the operator's cab. WARNING | QQ Always assume the battery Is emitting hydrogen and employ proper safety precautions. O Donot smoke, use an open flame, or create arcs or sparks near the battery. Q. Consult the label on your battery for information on cell-type, ampere-hour capacity, charge rate and normal full-charge voltage. Do not charge the battery at a current greater than 4.5 amp per 100 amp-hours capacity at the end of charge. Packaged with every battery are specific instructions for bat- tery safety, care and use, and a Material Safety Data Sheet (MSDS). Read these documents thoroughly before perform- ing any service to the battery. “FL-BC Sees Seen, Stel pacaton, pl: 4Z0660 0809 Safety - 15Q Safety precautions A WARNING ! A A AN ee eee maintenance and be sure to wear protective clothing and safety glasses when working with battery acid or the battery in general. Neutralize acid spills immediately with Bicarbonate of soda! Hfacid contacts the skin or eyes, wash with water immediately and seek medical help at once. Never place a tool or any metal object on top of the battery where it could possibly touch battery terminals causing a short or serious electrical shock. Use caution when changing battery connectors to ensure that the polarity is not reversed. Keep vent plugs in place and clean at all time: Q. When replacing this battery, use the same type battery as. ‘specified on the truck rating nameplate. Failure to comply could result in an unbalanced condition, resulting in tipping the truck and possible personal injury or loss of life. Be sure to replace, close and/or retighten any battery restraints which have been installed on the truck. S.8 Service repair ee When it becomes necessary to do any service repair or mainte- ance to the truck, itis important to first review the following safety ez guidelines. WARNING | You could be injured and the truck could be damaged if you try to do service work without proper training or equipment. 1. Be sure you have sufficient knowledge, experience and the proper tools and replacement parts before you attempt any truck maintenance. 2. Be sure to use the proper nuts, bolts and other fasteners. Many are specifically rated; that is, SAE Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc., and must be replaced with the identical type. It is recommended to use only Landoll autho- rized replacement parts. Safety -16 "FLEX Series Servca, Salty pecans, fh: 1420860 -b, 109Safety precautions O WARNING ! Ifyou use the wrong nuts, bolts or other fasteners, parts can later break or loosen. Serious injury could occur. 3. Whenever possible, return the truck to a service area having sufficient lighting, work space and an assortment of tools needed to complete the service. 4, Set the key switch to OFF and set the control lever to NEU- TRAL and set the parking brake. Disconnect the battery. 6. Never place a tool or any metal object on top of the battery where it could possibly touch battery terminals causing a short or serious electrical shook. 7. Make sure all lifting devices and supports, such as, a jack or ‘support stand, are capable of handling the weight of the load being applied. WARNING ! To be certain the truck will not move, place wedges (or blocks of wood) at the front and back of the tires. Ifyou are servicing the brakes or tires, place the block at the front and rear of the tire farthest away from the one being serviced. (That would be the tire on the opposite side of the truck and at the oppo- site end.) 8. _ Always place an appropriate support stand under the truck if it is being lifted, then lower the truck to the stand, having the lift- ing device and stand both supporting the weight of the truck. A DANGER ! fee GETTING UNDER A TRUCK WHEN IT IS LIFTED OR JACKED IS- DANGEROUS AND COULD CAUSE SERIOUS INJURY OR DEATH. NEVER GO UNDER A TRUCK THAT IS SUPPORTED ONLY BY A JACK. 9. Fully open the required truck covers and be sure they are braced to prevent accidental closing. “FLEX Saree Senco, Safty precauton, ph: 1420860 -b, 05108 Safety - 17Q Safety precautions Safety - 18 8.9 Safety labels For operator safety, a number of WARNING, DANGER and CAU- TION plates are attached to the truck, including the CAPACITY nameplate within the driver's cab. WARNING or DANGER plates describe conditions or practices which, ifnot WARNING strictly observed, could Sghemonsaenteeene| result in personal injury or | | Bewetessaerta ea Possible loss of life. ‘Easing ris ectura mariners eben pea CAUTION plates desoribe | |fosSecearumcteatsarvanystgeah™™™ conditions or practices, which ifnot strictly observed | [woaucoweenor paren, or remedied, could result in damage to, or destruction of the equipment or property. CAPACITY plate lists the load weights allowable for various fork heights, battery information, and also lists the truck model number, serial number and other basic truck data. This plate is located in the operator's cab, next to the driver's seat. Fire extinguisher The fire extinguisher should be inspected monthly or more fre- quently if circumstances dictate. The extinguisher should be checked to see that: Q itisnot damaged the discharge outlet is not blocked itis fully charged the seal is not broken oocoo the instruction pamphlet is clearly visible “FLEX Soran Service, Safety preosutons ih: 1420680 +, 0806Safety precautions 0 IMPORTANT ! Dry-powder extinguishers are shipped fully charged. Do not experi- ment with your extinguisher since even a small amount of dis charge could cause it to slowly lose the rest of its pressure, rendering the extinguisher useless. In case of a fire The following directions are for general use only, intended to famil iarize you with the key func s and procedure of the fire extin- guisher. Always check the extinguisher label for specific techniques and starting distances. 4. Have everyone vacate the area immediately. 2. Hold the extinguisher upright and pull the pin. 3. Stand back from the fire the minimum distance indicated on the extinguisher label. 4. Continue to keep the extinguisher upright, compress the han- dles together to discharge while sweeping the extinguisher from side to side over the fire. 5. Move closer to the areas as the fire is extinguished, BUT NOT CLOSE SO AS TO DISPERSE BURNING MATERIAL. 6. When the fire is extinguished, beware of re-ignition. 7. _ Vacate and ventilate the area immediately after use. 8. _ Be equipped to leave the area in the event the fire cannot be controlled immediately. “FLEX Saoe Seon, Stay pact, pl: H20860 0503 Safety - 19Q Safety precautions S.10 & Safety - 20 Daily, check the upper hook engagement, the fasteners, the lower hook engagement and inspect for hydraulic oil leaks. Report any problems to your supervisor and remove the truck from service until the problem Is corrected, Available options Fork positioner, non-side shifting Lift trucks using automatic non-side shifting fork positioners Tequire additional “safety” attention, WARNING | Pay strict attention to all safety labels affixed to the fork posi- tloner and backrest. No riding or standing under any part of the load or on the forks. NEVER reach through the backrest or between the fork posi- tioner mechanism, Q The top of the load must not extend above the top of the back- rest. 2 The load must never exceed the capacity of the fork positioner as stated on the capacity plate affixed within the operator's cab, Figure 4: Fork check points "FLEX Series Serco, Seley precautions, sn: 1420680 -b, 805,FL EX Series Explosion Proof Lift Truck Chapter 1: Truck Overview and Specifications Landolt Corporation Drexel Division 4900 North Street Marysville, KS 66508 USA. “Telephone: nn (785) 562-5981 Fax:.. (785) 562-4853 Web: sn» Wrw.drexelinucks,com art umber: 1420080, 05103NOTICE | LO) Explosion proof - Drexel FL-EX Series lift trucks are designed and constructed s—— to perform in operating environments containing specifically named flammable gases or vapors and combustible dusts. The trucks are inspected and tested to Stringent ANSI/UL 683 standard consistent with OSHA 29CFR (Code of Federal Regulations), paragraph 190.178, Additionally, the trucks are classified by Underwriters Laboratories, Inc, for use in Class 1, Division 1, Group D (operat- ing gas or vapor-air environments) and/or Class Il, Division 1, Group G (operat- ing combustible dust-air environments) locations as defined in National Electric Code NFPA 70 by National Fire Protection Association. All items of technical information, advice, know-how, drawings, designs, specifi- cations and other items communicated in this document are confidential and remain the property of Landoll Corporation and shall not be disclosed to a third Party, photocopied, reproduced, or translated to another language without the prior written permission of: 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 ‘The Landoll Corporation is pleased to provide detailed specifications of its products in this manual, but reserves the right to vary these at its discretion at any time without notice. ‘As the Company's products and services are continu- ously being developed, it is important for customers to cheok that the informa- tion contained herein includes the latest specifications. This manual is for general guidance only. Landoll Corporation cannot accept any financial or other responsibilty that may be the result of your use of the information contained herein; including direct, indirect, special or consequential damages. All recom- mendations and suggestions issued by or on behalf of the Company in whatever form, are subject to the Company's terms and conditions of sales, a copy of which will be supplied upon request. This document is not part of a contract or license, save insofar as may be expressly agreed. Pert umber 1420000 08108, © LandollCorpraion, rex! Dison 2908 ‘AU Rights ReservedTruck overview O Contents Page Truck overview 11 1.2 13 truck layout Figure 1-1: FL EX Overview.. introduction Figure 1-2: Capacity nameplate location... overview 4.3.1 Frame... 4.3.2. Traction drive.. Brake system. Parking brake Interlocks 4.3.3. Electrical system Battery..... 12 volt supply SCR Controlle! 1.3.4 Hydraulic system Steering Mast positioning : Driver's cab Battery connectorifuse box Horn button ... Direction control lever BDI and hour meter sight glass. Emergency pushipull button 1.3.6 Lift and tilt, and shift 1.3.7 Mast assemble Figure 1-9: Mast in collapsed position. Figure 1-10: Mast in free lft position Figure 1-11: Mast fully extended 1.3.8 Fire extinguisher “FLAEK See Serve, Trus over, ih: 1420660 +», 0809 13Q Truck overview Contents - continuea 14 technical specifications Model FL-40-EX. Model FL-60-EX. "FEN Satin Sec, Truck vere, in: 1420660 -b, 05108Truck overview Q 1.1 truck layout Figure 1-1: FLEX Overview Mast Driver's Cab Overhead guard Battery connector conduit Battery compartment Load backrest extension Forks, with brass sheathing Drive axle, tires and wheels © RPnNOaaraBen a Main electrical enclosure 10, Steer axle, tires and wheels 11. Aluminum bumper strip "FL-BNC Serie Senc, Trusevenien, pln 1420880 -b, 08108 15Q Truck overview 1.2 16 introduction This manual provides operating and routine maintenance instructions for Drexel FL-EX * Series Explosion Proof? 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 electrical 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 hazard to the surrounding environment, ‘The “FL-EX” series trucks also offer: Q Four wheel, front drive configuration. SCR controller with hour meter, battery discharg and lift interrupt. Control lever operation for load functions. 36 volt DC battery specifically rated for Class I, Division 1, Group D (operating gas or vapor environments) and Class Il, Division 1, Group G (operating combustible dust environ- ments) applications. Gi Battery restraints and an Anderson type N150 connector (complying to EX application rating). Q Static conductive rubber steer tires and ground straps. Bronze ctad forks and load backrest and aluminum bumper strips around the truck. Q Duplex and triplex mast configurations. 1 Safety interlocks - key switch activation and operator seat safety switches, plus an electrical lockout requiring the con- trol lever to be in the ‘NEUTRAL position before power can berrestored: Two standard models are offered and described in this manual: © Model FL40-EX:having a maximum lift capacity of 4,000 Ibs. at 24” Load Centers (1,815 Kg. at 600 mm L.C.),. Model FL60-EX:having a maximum lift capacity of 6,000 Ibs. at 24” Load Centers (2,721 Kg. at 600 mm L.C.) "FLEX Series includes Drexel Models FL40-EX and FLE0-EX Explosion Proof lit trucks, 2 Explosion proof - See inside front cover for regulations and rating specifications. “FLEX Series Serdee, Tek ovariew, ph 1Az0860 +2, 0609Truck overview Q ‘The FLL-EX Series trucks are the direct resutt of over 20 years’ experience 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 Ill, Safety for Powered Industrial Trucks meeting or exceeding requirements of ANSVUL-583 standard 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. Machine model, serial and option numbers (where applicable) are stamped on the capacity name- plate affixed to the driver's cab, next to the driver's seat. Figure 1-2: Capacity nameplate loca- tion IMPORTANT ! — A FL-EX series truck opera- tors and service personnel must familiarize them- selves with this manual and the FL EX series truck to provide safe and efficient operation. Practice runs in a controlled and safe area, away from obstacles and other personnel, are recommended. Unauthorized driving by untr strictly prohibited. ined or unskilled personnel must be All safety notices in this manual, those found in heading Safety of this manual and the safety regulations or standards valid in your local area must be strictly enforced. “FLEX Serie Sone, Truck evan, pl 1420880 -b, 05/08 47Q Truck overview 1.3 overview 13.1 Frame The frame consists of 3/8” to 1” thick (9.525 mm to 26.4 mm) steel panels welded together to form the backbone of the truck (basic ‘ruck shape). A number of thick rectangular steel shapes (coun- terweights) are welded within the frame to counterbalance the {ruck against the weight of its load. The rear wall of the truck also includes a thick steel plate to add additional counterbalance. Note: The size and weight of the battery is also used as a counterbalance. 13.2 Traction drive 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, con- trolled by an SGR motor controller, see heading: “Electrical sys- tem” on page 1-9. Brake system The front drive wheels are equipped with hydraulically-actuated dry disc brakes - typical automotive disc brake system. The brake pedal activates a master cylinder to apply hydraulic pressure to ‘wheel calibers, forcing the brake shoes to press against the wheel. The system is a dedicated system using standard DOT #3 brake fluid and non-asbestos brake shoes. Parking brake The parking brake is hand lever actuated. The parking brake is engaged by pulling up on the lever and disengaged by pushing down. This brake must be engaged when leaving the driver's seat. 18 "FLEX Geis Service, Tusk overview, pl: 420660 2, 5/09Truck overview Interlocks Both a key lock switch (key switch) and a driver's seat switch and mechanical seat brake must be activated before the truck can move. The seat switch and brake are activated when the operator is seated. Also see the Safety chapter in the beginning of this manual. 1.3.3 Electrical system The electrical system consists of the battery, two SCR controllers (one for traction, one for pump), solenoid contactors, interlocks, meters, power cables, and electrical hamesses. The electrical system complies with UL-583 requirements for type E and EE (optional) Electrical Battery-Powered, Industrial Truck construo- tion. Battery A lead-acid battery (36 V) is used to provide drive power, as well as power for the hydraulic system, and power for lights and other auxiliary equipment, For maintenance or emergencies, a battery disconnect switch is provided in the operator's cab. 12 volt supply 12 volts is provided to power the electro-hydraulic solenoid valves, meters/gauges, horn, alarms, options light packages, micro- switches, etc. SCR Controller Two SCR Controllers, one for traction control, and one for pump motor control are used. The controllers convert battery current into electrical pulses, which maintain DC voltage while varying the average current. "FLEX Soros Seven, Truck verve, pin: 1420860 +, 109, 19O Truck overview 1410 The controllers are mounted in the electrical enclosure compart- ment underneath the driver's seat. 13.4 Hydraulic system The hydraulic system Is powered by a variable speed DC electric motor, connected to a tandem hydraulic pump. This system pro- vides power for truck steering and includes primary and secondary circuits for mast tt (forward and backward), pivot (in and out), shift (right-to-left) and lift/ lower (up and down) positioning, ‘System cooling uses convection and conduction of heat from the reservoir, hydraulic tubing and cylinders. ‘A100 mesh (150 micron) suction filter within the reservoir plus an easily accessible return line filter (10 micron rating) are used. Additional information is available in the Operation chapter, head- ing, Theory of operation, beginning on page 3-31. Steering The power assisted steering system operates independently from the main system and consists of a DC electric motor and pump configuration and an orbitrol control valve. The orbitrol valve meters oil to a double-acting, double-ended steer cylinder. Power steering is powered by a permanent magnet DC electric motor, operating at a fixed speed. Mast positioning Mast positioning is controlied by the two dual-function control levers. Hydraulic pressure is provided by a tandem pump driven by a single DC electric motor. Mast movements may be operated individually or together; how- ever, when operated together, the speed of operation is somewhat, slower. “FLEX Sales Seno, Truckoverviaw, ph 1420860 6, 0500Truck overview Q 13.5 Driver’s cab Steering Wheel Accelerator Pedal Brake Pedal Directional Lever Emergency Stop Horn Control Levers Figure 1-3: Driver's cab Q Battery connector lock and fuse box - Both items are provided by the battery manufacturer and vary in design and location. See manufacturer's data for additional information (See Figure 1-4: ‘Battery connector/fuse box.’) Figure 1-4: Battery connector/fuse box Steering wheel - tums the rear wheels left or right. (See Figure 1-3: ‘Driver's cab.’) Horn button - is press down to sound the horn. (See Figure 1-5: Horn button.’) (Also see Fig- ure 1-3: “Driver's cab” on page 1-11.) Figure 1-5: Horn button “FLED Sores Serve, Tusk overta, pin: 1420860», 05108, 11Q Truck overview Q Direction control - selects the direction of travel of the truck (forward or reverse), (See Figure 1-6: ‘Direction control lever.’) Figure 1-6: Direction control lever O Accelerator pedal - is pressed by the driver's right foot to control the speed of the truck. (See Figure 1-3: ‘Driver's cab,’ on page 1-11.) FL EX trucks offer a maximum speed of 4 mph (6.44 kph) loaded. A WARNING ! Driving speed of the truck must be governed by your work environ- ‘ment, such as, slippery floors, cross aisles, slanted driving sur- faces, load size, visibility or other people working in the area. Never travel at speeds with or without a load that could be danger- ous to yourself or others. Also see separate heading Safety, in the beginning of this manual. Brake pedal - when pressed, applies the service brakes bringing the truck to a safe STOP. (See Figure 1-3: ‘Driver's cab,’ on page 1-11.) Q Parking brake - engages the mechanical brake when the ever is pulled upwards. Hourmeter (4-dig- its) - accurately accumulates the active working time (in hours) of the truck. Battery Indicator Figure 1-7: BDI and hour meter sight glass Q Battery discharge indicator (BD!) - is located behind the sight glass in the electrical enclosure, (See Figure 1-7: ‘BDI and hour meter sight glass.) The BDI monitors the capacity (or percentage) of the battery remaining. An LED flashes when the battery drops to 20% of full charge. 112 "FLEX Series Sorc, Truck everiew, ph 1420860 +, 0805Truck overview Q Note: Ifthe battery drops to 20% of full charge, the lift function is dis- abled. 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. Q Emergency push/pull button -is a dual pur- pose button, 1.) powers the truck ON and OFF and 2.) in emergencies, STOPS the truck and all functions. Figure 1-8: Emergency push/pull button Pull up to start the truck. (See Figure 1-8: ‘Emergency pushipull button.’) Push down to immediately shut down the drive and power steering motors and all mast movement, The truck drifts to a STOP. Immediately set the parking brake. To continue, pull up on the button to reset the switch. Use this button: Q to set the truck ON and OFF if a person comes between the truck and a fixed object. in case an accident occurs in case of a short circuit or other electrical problem; for ‘example, if the pump motor is on continuously a O incase of fire, smoke or overheating a a 13.6 Lift and tilt, and shift Lif, tit, (and shift - optional) movements of the mast and forks are accomplished using three function levers. Each lever provides independent movement and each is marked with a graphic icon to represent the function it controls. (Also see heading, “the mast’ on page 37.) 1.3.7 Mast assemblies Various mast assembly configurations can be applied to the EX series trucks to provide both collapsed and extended heights suit- able for most customer requirements. “FLEX Saree Seve, Trek ova, pl 420860 -b, 05/08 4413Q Truck overview 114 The lting capacity of the mast also varies depending on the truck and its application. Load capacities are determined at 24” (609.6 mm) centers, centered on the mast and include all attachments on the carriage. Table 1-2 at the end of this section, lists the dimensions of stan- dard masts available for these trucks. Also check the capacity plate in the operator's compartment for the maximum lifting capa- bilities based on the particular truck and mast combination, (See Figure 1-2: ‘Capacity nameplate location,’ on page 1-7.) The trucks are counterweighted to compensate for all positions of the maximum allowed load, except for a tit forward past the verti- cal position. When very high masts are supplied, interlocks may be provided to block side shift operations at high positions. Masts are engineered to distribute thrust loads evenly between the rollers and rails. Masts move as a unit, providing maximum strength and endurance for the rated load and consists of up to. three pairs of channels or rails (steel beams) rolling one within the other on steel rollers. The outer rails provide guid- ance and support for the mid- dle rails, which in turn guide and suppor the inner rails, The truck forks are mounted on a carriage assembly that runs on rollers within the inner rails. (See Figure 1-9: ‘Mast in collapsed position’) Figure 1-9: Mast in collapsed position OUTER MIDDLE INNER RAL RAL RAL A primary oylinder is sup- ported by the inner rails and hydraulically controlled. As the pri- mary cylinder rod extends, a sheave and chain assembly lift the forklcarriage upward at twice the distance covered by the cylinder rod. This first stage of carriage lift is called free lift. itis the distance of lft available without increasing the overall height of the mast assembly. (See Figure 1- 10: ‘Mast in free lift posi- tion.’) Figure 1-10: Mastin free lift position "FL-DX Saree Service, Truck oventew, ph: 1420660 +b, 0600Truck overview O A secondary cylinder, attached to the outer rails, lis the middle and inner rails progressively via chains, rollers and sheaves. The inner rails are raised at twice the rate of extension of the second- ary cylinder piston. This upward lift continues until the secondary oylinders are fully extended. (See Figure 1- 11: ‘Mast fully extended.’) The hydraulic fluid used to lift the primary cylinder is applied ‘sequentially to the secondary cylinder. When the primary cyl- inder reaches full extension, the secondary cylinder begins to extend Figure 1-11: Mast fully extended ‘The differences in weights being supported by the cylinders, along with the differences in cylinder diameters, ensure that the primary cylinder will be fully extended before the secondary cylinder can begin to move. Consequently, when the mast is raised, it moves through two phases: Free lift, in which only the carriage assembly moves, up to the maximum height allowed by the inner rails. (See Figure 4-10: ‘Mast in free lift position,’ on page 1-14.) Rail extension, in which both the middle and inner rails move, carrying the carriage upward. (See Figure 1-11: ‘Mast fully extended.’) Downward movement of the mast is accomplished by releasing the hydraulic fluid from the oylinders back into the reservoir. The weight of the rails and carriage provides enough pressure to force the fluid from the cylinders. When the secondary cylinder piston is fully contracted, the primary cylinder begins to collapse, forcing its fluid back to the reservoir. ‘The mast is supported by trunnions which allow it to tilt fore and aft. The amount of tit is controlled by two short hydraulic cylinders mounted between the bottom of the mast and the pivot arm. A. mast indicator gauge (pointer) is located on the left side of the mast (as viewed from the front of the truck) to indicate when the carriage/forks are perfectly level with the floor. ‘PLEX’ Series Serve, Tuck overdo, ln: 1420860 -», 0508 415Q Truck overview 1.3.8 Fire extinguisher Adry-powder based fire extinguisher is mounted, using a quick-release bracket, to the right side of the driver's cab. Dry-powder extinguishers help fight Class B and C type fires (cil, gas, grease, electrical, etc.). Fire extinguishers must be inspected monthly and the results recorded on the inspection tag attached to each extinguisher. If your truck is equipped with an extin- guisher, see the Safety, Operation, and Maintenance chapters for proper use and care of the extinguisher. 1.4 technical specifications Model FL-40-EX Model FL-60-EX Landolt Corporation's policy is to continually improve products. We reserve the right to change specifications and design without notice. Technical specifications for the EX series trucks, standard Models FL-40 EX and FL-60 EX and standard mast assemblies are listed ‘on the next two pages. 146 "FLEX Saris Soi, Truckevervion, in 1420080 -b, 08109,SPECIFICATIONS POEeg 1-40/60-ex Explosion-Proof 4,000 Ib. and 6,000 Ib. Capacity | J LANDOLL CORPORATION, Drexel Division 1900 North Street « Marysville, KS 66508 Phone: 785-562-5981 « Fax: 785-562-4853 ‘wwwilandoll.com STANDARD FEATURES Four-wheel configuration - front © Quartz hour meter Static ground steer tires wheel drive; rear whee! steering «Hydrostatic power steering * Cushion rubber drive tires © High visibility mast, 2 or 8 stage © ULE’ labeling © Static ground straps ‘© 36 volt electrical system ‘Designed for ANSI-UL 583, Type EX Brass clad forks and load * Adjustable driver's seat (Class 1, Division 1, Group D and backrest «Safety seat switch, cuts power Class 2, Division 1, Group G) © Overhead guard © Seat belts ‘+ Emergency power disconnect switch + Fire extinguisher ‘© 4.wheel brakes - dual system Type N-180, 3-contact charging Electric horn © Automatic return-to-neutral receptacle, Type EX «Recessed rear tow pin + Independent hand and seat «RF! suppressed to MIL-SDT-461, actuated parking brake (Class 3.) + GE “SOR” controls, © EX rated motors OPTIONAL FEATURES The following Optional Features are the most frequently ordered options that may be “factory installed” to the Models FL-40-EX and/or FL-60-EX Fork Lift Trucks, Strobe warning light Hydraulic attachments, Cable operated hom Electric backup alarm Battery compartment rollers 6,800 Ib (3,084 kg) capacity, FL-60 only Side shifter, 4" (10cm) either side of center, FL-60 only Folding forks RECOMMENDED BATTERY SPECIFICATIONS Battery Type Volts Amp. Hours Nominal Size Flooded orsealed —36V 785 87-118" x 26-1/2" x 25-1/4" (94 x 67 x 64cm) Dealer will select battery size based on the application. ‘* Usage hours will vary with load weight, number of lift cycles, lift height, attachment use and travel distance. ‘* Battery compartment inside dimensions — 87-5/8" x 27-3/8" (96 x 70cm) Battery model 18-85-19 EX, with Anderson Type N- 150, 3 contact charging receptacle - Type EX; ‘weight: 2,475ibs. (1,123kg) minimum; 2,575Ibs. (1,168Kg) maximum (Battery must comply with Landoll “EX* Battery Specification - Drawing number: B-58911.) “Te specteatione contained inthe brochure ae subjctto change at anytime ‘ithaut nati, Atal dnelons ars perfomance data gen heren may var) (ue omanvfecturg lreness. ary speticeton serial yourapotcaon, plese contact your Landal/Orexel Dear. (©2006 ancl Carpraon. Pinto US.SPECIFICATIONS F-40/60-ex Explosion-Proof 4,000 Ib. and 6,000 Ib. Capacity six {e[uinfolplalralsir 39 | 84 | 43 | 96 flow 48 [15°] 12"| 40 | 48 | 85 | Notes CM. 49 |122| 51 [221/13 [99 [21 |109| 91 Bearti21 '102|120/216 * Plus (+) load length. 43 frosy 48 FL-40 LOADED 18% FL-60 FL-40 FL-60 MAST TILT DEGREES) 9° FWO,/4" BACK GRADEABILITY Fay caraciry ar 26" Uc Las. | 4000 6000 sTeeA TIRES IN | 1.2 xerx 11.2" Fy Ka | ieia 2722 om. 41x 15x29 fe] cork size (standars) IN. xarxaz’ | voLTAGE 38 [>] iractass i om, 5x11 x107 fry UrtsPeco ewpTy | s3FPM 53FPM) LOWERING SPEED ewery | s2epM 52 FPM se vor) 15MPM 15 MPM 18MPM 46MPM a LoapeD | a4FPM 25 FPM LoapeD | 58 FPM 58 FPM Fy JOMPM 8 MPM 47MPM_ 17 MPM FY onive nines wv. | terxexresr | save sPeco every | AMPH 4MeH [J (Cushion rubber) om. 49x 20x31 KPH GKPH TRUCK WEIGHT with uss. | 7,700 8.950] MINIMUM BATTERY us, 2478 BATTERY (Minimum) Ka | 3493 4.060] WEIGHT Ka 4428 Mast c i o vi MAST MAX. FORK COLLAPSED FREE LIFT MAX. OVERALL HEIGHT HEIGHT. HEIGHT HEIGHT. iN) (CM) _ (WN) (CM)_(N) (GM) NJ (CMY TRIPLE TRIPLE 188 578 63 210 59 150 236 599 TIPLE 198 503 87 221 63 160 248. 625 TRIPLE 216 549 95 2461 71 180-264 G71 TRIPLE 236 600 103 262 79 201 284 721 RIPLE 149 379° 71 180 48 114 197500 TRIPLE 167 426 77 196 51 190 215 546 TRIPLE 185 470 83 210 57 145 233.592 TRIPLE 198 498 87 221 61 185 244 620 TRIPLE TAIPLE FL6¢ Sa TTSFL EX Series Explosion Proof Lift Truck Chapter 2: Receiving and inspection Landolt Corporation Drexel Division 4900 North Street Marysville, KS 66508 USA. “Telephone: ...-(785) 562-5384 Web? nanan WUNW.drexeltTUCKS. com Pertnumber: 1420660, 05103NOTICE! A () QA\ bxvlosion proof - Drexel! FL-EX Series it rucks are designed and constructed > to perform in operating environments containing specifically named flammable gases or vapors and combustible dusts. The trucks are inspected and tested to stringent ANSV/UL 583 standard consistent with OSHA 29CFR (Code of Federal Regulations), paragraph 1910.178. Additionally, the trucks are classified by Underwriters Laboratories, Inc. for use in Class 1, Division 1, Group D (operat- ing gas or vapor-air environments) and/or Class Il, Division 1, Group G (operat- ing combustible dust-air environments) locations as defined in National Electric Code NFPA 70 by National Fire Protection Association. All items of technical information, advice, know-how, drawings, designs, specifi cations and other items communicated in this document are confidential and remain the property of Landoll Corporation and shall not be disclosed to a third party, photocopied, reproduced, or translated to another language without the prior written permission of: Landoll Corporation Drexel Division 1900 North Street Marysville, KS 66508 USA. Telephone:........ (785) 562-5381 Fax: . (785) 562-4853 Web: . www.drexeltrucks.com ‘The Landoll Corporation is pleased to provide detalled specifications of its products in this manual, but reserves the right to vary these at its discretion at any time without notice. As the Company's products and services are continu- ously being developed, it is important for customers to check that the informa- tion contained herein includes the latest specifications, This manual is for general guidance only. Landoll Corporation cannot accept any financial or other responsibility that may be the result of your use of the information contained herein; including direct, indirect, special or consequential damages. All recom- mendations and suggestions issued by or on behalf of the Company in whatever form, are subject to the Company's terms and conditions of sales, a copy of which will be supplied upon request. This document is not part of a contract or license, save insofar as may be expressly agreed. Pertnumbar 1420800 b, 8/08 {© Landot Corporation, Drexel Dison 2008 ‘AI Rights ReservesTruck overview O Contents Page Receiving and inspection 2.1 receiving your truck 2.1.1. Items furnished with your truck... 2.4.2. Items required... 2.4.3. Tools and test equipment... 2.2 to prepare the truck... 2.2.1 Charging a wet battery .. Using the hydrometer Figure 2-1: Battery charge state using a hydrometer To charge the battery: 2.2.2 Charging a dry batter To charge a dry-cell batte 2.3 inspection check list 2.3.1. Visual checks..... 2.3.2 Routine checks... 2.4 replacing the battery 2.4.1. Disconnect the battery... Figure 2-2: Battery disconnect and retainer latch. 2.4.2. To replace a battery. . Figure 2-3: Removing the Battery 2.5 storage, towing or shipping 2.5.1 Returning the truck to operation... 2.5.2 Towing the truck... 2.8.2. No available at time of, 2.8.2_ publication. Figure 2-4: Ti 2.5.3 To ship the truck.... ports used for towin “FLEX Series Sevies, Recsvng 8 epecton, pl: 1420660 -, 08/08 23Q Truck overview Contents = continued 24 Page "FLEX Safe Sonic, Rcelng & inspect, pin 1420860 -2, 05108Receiving and inspection Q 2.1 receiving your truck Before shipping from the Landoll Corporation, each FL EX Series truck is inspected to make sure the truck you receive is in impeccable condition and equipped per your order. However, we recommend that you: 1 211 21.2 21.3 Inspect the truck for any signs of physical damage during ship- ment. Note any apparent damage on the bill of lading, and request the delivery agent to sign it. Report the damage to your distributor and the shipping company. Verify that the truck configuration and options match your pur- chase order. Report any discrepancies to your distributor. Items furnished with your truck Standard EX series trucks are shipped from the factory with one copy each of the Driver's Guide and Service and Parts Mainte- nance Manual, plus a set of ignition keys attached to the steering column. Items required When the truck is received, a battery approved for use in the truck must be installed. The battery must be replenished from a battery charger at certain intervals. No additional items are required to operate the truck. Tools and test equipment In general, no special tools or test equipment beyond those to be found in a well-equipped service center are required. However, a torque wrench with a capacity of 400 ft. lbs. (542.3 Nm) is required to tighten the bearings on the pivot arm of the pivot shift assembly. “FL-D€ Series Serco, Racoiving& pectin, pin 1420860 -b, 0509, 25Q Receiving and inspection 2.2 to prepare the truck... 26 2.2.1 The ignition key is wired to the steering column. Cut and prop- erly dispose of the wire securing the keys. Check the hydraulic oil level. (See Chapter 4, '4.4.1 Check hydraulic oil level’ on page 4-26.) Check the fluid level in the service brake master cylinder. (See Chapter 4, ‘4.4.3 Check master cylinder fluid level,’ on page 4- 28.) Check the condition of the battery. (See the following head- ings ‘2.2.1: Charging a wet battery’ or 2.2.2: Charging a dry battery.’ Charging a wet battery The truck battery contains concentrated sulfuric acid which can cause severe chemical burns. When the battery is charging, it releases hydrogen, a highly explosive gas which can be ignited by a spark. Shorting battery terminals can release enormous ‘amounts of energy, causing sparks or flame, or heating nearby components to dangerous temperatures. The battery is also very heavy, and if restraints are not replaced after maintenance, the battery could slide out of the truck causing electrical shorts or spilling acid - or it could cause the truck to tip. WARNING | ALWAYS RETURN THE TRUCK TO A NON-VOLITILE SERVICE AREA BEFORE PERFORMING ANY SERVICE. Never connect a battery charger to the EX truck. Always assume the battery is emitting hydrogen and employ proper safety precautions. Q_ Donot smoke, use an open flame, or create arcs or sparks near the battery. Q_ Consult the label on your battery for information on cell-type, ampere-hour capacity, charge rate and normal full-charge voltage. Do not charge the battery at a current greater than 1.5 amp per 100 amp-hours capacity at the end of charge. "FLED Saree Sonic, Racshing & inspect, pin: 1420860 -b, 05/08Receiving and inspection WARNING ! - continued Q Packaged with every battery are specific instructions for bat- tery safety, care and use, and a Material Safety Data Sheet (MSDS). Read these documents thoroughly before perform- ing any service to the battery. Always disconnect the battery before performing any truck maintenance and be sure to wear protective clothing and safety glasses when working with battery acid or the battery in general. Neutralize acid spills immediately with Bicarbonate of soda! Hfacid contacts the skin or eyes, wash with water immediately and seek medical help at once. Never place a tool or any metal object on top of the battery where it could possibly touch battery terminals causing a short or serious electrical shock. Use caution when changing battery connectors to ensure that the polarity is not reversed. Keep vent plugs in place and clean at all times. Q. When replacing this battery, the truck must be equipped with a battery as specified on the rating nameplate. Failure to ‘comply-could result in an unbalanced condition, resulting in tipping the truck and possible personal injury of loss of life. 1 Be sure to replace and retighten any battery restraints which have been installed on the truck. If the truck has been shipped with batteries installed, first remove the batteries from the truck. If the batteries have been shipped with electrolyte installed, check the specific gravity of the electro- Iyte using a hydrometer to determine if a charge is needed. (See Figure 2-1: ‘Battery charge state using a hydrometer,’ on page 2- 8) If the reading is between 1.280 and 1.290, the battery is fully charged. If the reading is near or below 1.150, the battery must be charged as desoribed in section 2.2.1 for a wet battery or in sec- tion 2.2.2 for a dry battery. Using the hydrometer As the battery discharges, the specific gravity of the electrolyte reduces. A hydrometer allows you to check the specific gravity of the cells, thus the charge state of the battery. (See Figure 2-1 ‘Battery charge state using a hydrometer’ on page 2-8.) “FLLEX' Series Senos, Recsving & apectin, pin: 1420660 2, 0508 27Q Receiving and inspection WARNING | A Always disconnect the battery before performing any truck mainte- nance and be sure to wear protective clothing and safety glasses ‘when working with battery acid or the battery in general. 1. Remove a cap from one or two of the cells. Gently squeeze (compress) the bulb of the hydrometer. 2. Insert the tube of the hycrometer into the cell electrolyte. ot 1200 8.G= id i Sony ih Se bulb to allow fiuid to draw into the hydrometer. Enough fluid must enter the hydrome- ter to allow the fioat to move freely. ‘Figure 2-1: Battery charge state using a hydrometer 3. The specific gravity of the electrolyte is read off the scale on the float where it emerges from the fluid. (See Figure 2-1: ‘Battery charge state using a hydrometer.’) Select a different cell each time a measurement is taken and to test more than one cell. 4.” When returning the electrolyte to the battery, ensure that the fluid is returned to the cell it was taken from and be very care- ful not to splash the electrolyte as it is squeezed from the hydrometer. To charge the battery: 1. Remove each vent cap and check electrolyte levels. Ambient temperature should be +77°F (+25°C) to get a proper reading. 2. Do not add water until an accurate level is obtained - cold weather can affect the level. If water must be added, use dis- tiled water only, 28 “FLAEX’ Series Soros, Recovng& Inspection, pln: 1420800 -b, C5102Receiving and inspection 0 Make sure the electrolyte level is at the level indicator. 4. Charge the battery using a constant current charger set to 5% of the six-hour baitery capacity. For example, 55 amps for an 4,100 AH (ampere-hour) battery. CAUTION! Do not charge the battery at a finish current which exceeds the rate on the battery's nameplate. Consult the label on your battery for Information on cell-type, ampere-hour capacity, charge rate and normal full-charge voltage. Do not charge the battery at a current greater than 1.5 amp per 100 amp-hours capacity at the end of charge. 5. Replace the vent caps. They must be secured in place during charging. Ordinarily, the charge should take about 3 to 5 hours to complete. 6. During the initial charge the volume of electrolyte decreases through electrolysis and evaporation. Water approved for use in lead-acid storage batteries should be added if the electrolyte level falls below the level indicator. Ifthe cell temperature rises higher than +110°F (+61.2°C), either reduce the charging current to 1/2 (half) the original value or stop charging until the temperature falls below +110°F (#61.2°C). If you reduce the charging current, extend the charging time accordingly 7. Continue charging until the cells gas freely and the specific gravity remains constant over a three-hour period. At the end of the charge period the cell voltages rise to about 2.55 volts and the specific gravity rises to about 1.280, corrected to 77° F. (See Table 1: ‘Specific gravity corrections for electrolyte temperature,’ on page 2-10.) 8. When charging is complete, REPLACE the vented cell caps on the battery. 9. Connect battery cables and install battery in truck. “FL-BE Series See, Recshing &inspestn, pln: 1420860 ->, 0508 29Q Receiving and inspection Table 1: Specific gravity corrections for electrolyte temperature [ene TT eeireeton’ Fema e 1] corec 30-41 ‘or-i0s | +0008 2.44 tos-ios | +0000 45-47 107-109 40.010 4850 wore — | soon 51-53 visits | soot 8456 sete | soos 5780 visa | 0014 61-63 wzzi2s | 40016 64-66 v25127 | 0018 ore vze180 | 0017 70-72 ssi133 | 0018 7378 ieuie | soot 7678 s799 | +0020 7031 woz — | +0021 a2 vas | +0002 85-07 sea | +0008 6-01 wots: | 40024 92.04 szise | 40026 95497 156-187 | 0028 36-100 ‘se-160 | 0027 2.2.2 Charging a dry battery The truck battery contains concentrated sulfuric acid which can cause severe chemical burns. When the battery is charging, it releases hydrogen, a highly explosive gas which can be ignited by a spark. Shorting battery terminals can release enormous amounts of energy, causing sparks or flame, or heating nearby components to dangerous temperatures. The battery is also very heavy, and if restraints are not replaced after maintenance, the battery could slide out of the truck causing electrical shorts or acid to spill - or it could cause the truck to tip. WARNING | ALWAYS RETURN THE TRUCK TO A NON-VOLITILE SERVICE AREA BEFORE PERFORMING ANY SERVICE. Always assume the battery is emitting hydrogen and employ proper safety precautions. 2 Donot smoke, use an open flame, or create arcs or sparks near the battery. 2-10 "FLED Saree Serie, Receiving Inspection, pn 1420880 -b, 08108Receiving and inspection O WARNING! - continued A Consult the label on your battery for information on cell-type, ampere-hour capacity, charge rate and normal full-charge voltage. Do not charge the battery at a current greater than 4.5 amp per 100 amp-hours capacity at the end of charge. Packaged with every battery are specific instructions for bat- tery safety, care and use, and a Material Safety Data Sheet (MSDS). Read these documents thoroughly before perform- ing any service to the battery. Always disconnect the battery before performing any truck maintenance and be sure to wear protective clothing and safety glasses when working with battery acid or the battery in general. CO Neutralize acid spills immediately with bicarbonate of soda! Ifacid contacts the skin or eyes, wash with water immediately and seek medical help at once. Never place a tool or any metal object on top of the battery where it could possibly touch battery terminals causing a short or serious electrical shock. Q._ Use caution when changing battery connectors to ensure that the polarity is not reversed. Keop vent plugs in place and clean at all times. When replacing the battery, the truck must be equipped with a battery as specified on the rating nameplate. Failure to com- ply could result in an unbalanced condition, resulting in tip- ping the truck and possible personal injury or loss of life. Be sure to replace and retighten any battery restraints which have been installed on the truck. o To charge a dry-cell battery: 1. Remove and discard plastic film seals from each cell vent hole (if present). 2. _ Fillthe cells to the level indicator using dilute battery grade sul- furic acid with a specific gravity between 1.260 and 1.270 cor- rected to +77° F (+25° C). The temperature of the electrolyte should be no higher than 90° F (50° C). "FLEX Smee Soon, Recshing &Inspectn, pln 1420880 -b, 0508 2-14Q Receiving and inspection 10, 2412 Allow the cells to soak for 2 to 3 hours after filing. The electro- lyte level may drop slightly because of absorption into the plates and separators. If it does, add more electrolyte to restore the level. Charge the battery, using a constant current charger set to 5% of the sicchour battery capacity. For example, 55 amps for an 1,100 AH (ampere-hour) battery. The time required for an ini= tial charge is approximately 8 hours. During the initial charge the volume of electrolyte decreases through electrolysis and evaporation. Water approved for use in lead-acid storage batteries should be added ifthe electrolyte level falis below the level indicator. If the cell temperature rises higher than +110° F (+61.2° C) elther reduce the charging current to half the original value or stop charging until the temperature falls below +110°F (+61,2° C). If you reduce the charging current, extend the charging time accordingly. Continue charging until the cells gas freely and the specific gravity remains constant over a three-hour period. At the end of the charge period the cell vottages rise to about 2.55 volts and the specific gravity rises to about 1.280, corrected to 77° F. (See Table 1: ‘Specific gravity corrections for electrolyte temperature,’ on page 2-10.) Ifthe specific gravity exceeds 1.290 after charging, dilute with distilled water and continue to charge for two more hours. If the specific gravity is below 1.280 after charging, add elec- trolyte with a specific gravity of 1.400 until the battery has a specific gravity between 1.280 and 1.290, Then resume charging for another two hours. When charging is complete, REPLACE the vented cell caps on the battery. Connect battery cables and install battery in truck. “FLEX Sores Service, Reeling &nspecton, ph: 1420600 +, 0809,Receiving and inspection 0 2.3 inspection check lis 1, Before releasing the truck for use, prepare a log book or log sheet 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 and date the service was performed). Permanent logs serve as a checklist to show maintenance and repair history and to record whether faults have been cor- rected. 2. Perform inspections with the truck key switch set to off, the control lever in the NEUTRAL position and all brakes set (ACTIVATED). 3. _ Always pay strict attention to all WARNING, DANGER and CAUTION nameplates affixed to the truck and thoroughly read the “Safety” chapter of this manual. 4. Ifyou notice or suspect a problem, immediately report it to your supervisor, record it in the truck log book and have it checked and/or repaired before releasing the truck for use. 2.3.1 Visual checks Many problems can be spotted by a simple visual inspection of the ‘ruck; such as, oll leaks, damaged tires, cracks in welds or forks, damaged covers, etc. However, dirt, grease, oll and debris can mask some problems. If possible, the truck should be washed on a regular basis. To remove stubborn grease accumulations, a grease-dissolving sol- vent may be needed. Make sure the solvent is not harmful to painted surfaces. After high-pressure washing, lubricate all unprotected grease fit- tings and metal-to-metal surfaces, located outside the truck. (See Chapter 4, ‘4.5.2 Lubricating the truck,’ on page 4-38.) “FLAN Series Sanca,Receing & pecton, pl: 1420660 -b, 05103 2-413Q Receiving and inspection 2.3.2 214 WARNING ! Grease solvents are often toxic and may be flammable. Use only In accordance with the solvent manufacturer's recommendations sup- plied with the solvent. For example, use only in a well-ventilated area and do not breathe vapors. Wear protective goggles, aprons, and gloves. Avoid con- tact with skin, eyes and clothes. Keep away from heat and flame. Do not smoke when using solvents or in the area where solvents are stored. Failure to observe these precautions may result in death or injury. Ifyou become dizzy while using cleaning solvents, get fresh alr and ‘medical help immediately. If solvent contacts your eyes, immedi: ately treat in accordance with the manufacturer's recommendations on the container. Always read the label affixed to the solvent container for all safety information before use, Routine checks With the truck key switch in the off position, perform a walk-around inspection. Check for obvious damage that would require a more detailed inspection. If any of the following are apparent during your walk-around, record it in the log book and immediately notify your supervisor. For most cases, do not release the truck for use until repairs are made. Battery bolt down - ‘Check that the battery boit-down is in position and tightened fully whenever a battery is installed in the truck, Brake, Parking - Drive forward slowly while steadily applying (pulling up) the parking brake lever. The truck should stop ‘smoothly without noticeable side pull or vibration. Any problems with the brake system must be repaired imme- diately. Do not use the truck. Brake pedal - Check the operation of the brake pedal for smooth, firm, unobstructed movement when pressed and released. Any problems with the brake system must be repaired imme- diately by service. Do not use the truck. "FLEX Seis Sens, Recelng A lnssecton, nh: 1420880 -b, 0809,Receiving and inspection Brake, service - With the key emergency button set to ON, drive forward slowly while steadily applying the brake pedal. The truck should stop smoothly without noticeable side pull or vibration. Any problems with the brake system must be repaired imme- diately. Do not use the truck. Driver’s seat - Check the seat covering for rips or cuts. Check seat belt straps for worn or frayed areas or cuts. Check that the seat belt is firmly attached and that the buckle is not damaged. Check that the seat belt works properly. Mechanical brake - To check the seat spring-loaded mechanical brake itis recommended to carry a load close to the rated capacity of the truck. While driving the truck down an approximate 15% grade and with a load, apply the service brakes and STOP the truck on the grade. Q While holding pressure on the foot brake pedal, lift your- self from the driver's seat enough to release the spring- loaded mechanical brake switch. Slowly release pressure on the foot brake pedal. A WARNING ! BE ALE! IF THE MECHANICAL BRAKE IS DEFECTIVE OR OUT OF ADJUSTMENT, THE TRUCK WILL BEGIN TO MOVE FORWARD. YOU MUST IMMEDIATELY PRESS THE FOOT BRAKE PEDAL TO ‘STOP THE TRUCK AND RETURN THE TRUCK TO SERVICE FOR IMMEDIATE REPAIR. The truck should hold on the grade with the rated load in a carry position on the forks. Q Ifthe truck moves forward, it must be removed from operation and the brake mechanism must be repaired, Seat limit switch interlock - includes a safety interlock that shuts down the drive and power steering motors and dis- ables the direction control (resets to NEUTRAL) bringing the truck to a smooth STOP. The mast remains operable. Inspect the seat safety limit switch, located under the back portion of the seat. The limit switch plunger must move up and down freely and a click is heard as the switch is actu- ated. “FLEX Saree Senn, Rezshing &ingpesin, pln: 1420860 -b, 05108 245Q Receiving and inspection 4 246 ‘To check the safety interlock, Q Sit in the driver's seat, set the emergency button to ON and reléase the parking brake. Q Set the control lever to FORWARD and slowly increase ‘motor speed until the truck begins to move, Lift yourself from the seat far enough to release the seat switch. The truck must immediately slow to a STOP, and power steering is disabled. Q Ifthe truck continued moving forward, it must be removed from operation and the seat switch must be replaced. Fasteners, damaged - Check for loose or missing screws and nuts. Tighten and/or have service replace as needed. Horn, Lights, etc. (optional) - Check for proper on/off operation and that the hom sounds when cover is pressed. Hourmeter/Battery discharge indicator (BDI) - Inspect these gauges for damaged or malfunction. These require the key switch to be ON and can be checked prior to beginning your daily work routine. Hydraulic lines, loose fittings - Check underneath the truck for evidence of fluid leaks. Look for hydraulic hose wear, dam- age and leaks. Make sure clamps and fittings are tight. If leaks are found, have service repair all leaks immediately and cheok the hydraulic fluid level. Do not use the truck Hydraulic oil level - Check the oil level weekly. Low oll can cause operational problems. See your Service Manual, Chapter 2 "Preventive maintenance” and check the oil level Mast operation - With the key switch set to ON, raise the mast. Check that the primary oylinder extends fully and that the lift carriage raises to the top of the inner rails before the second- ary cylinders begin to move. WARNING | Never place your head, hands, arms or feet in the mast areal When the lift carriage reaches the top of the inner rails, the ‘secondary cylinders and middle rails begin lifting. Check to make sure the rails travel smoothly and that there is no chat- ter or visible binding. "PLDC Sarin Senos, Resehing & Inspection, ph: 1420860 -b, C58Receiving and inspection O With the mast fully extended, begin lowering the mast. The secondary cylinders and middle rails fully lower first, fol- lowed by the primary cylinder and the lift carriage. Check for ‘smooth travel with no chattering or visible binding, If there is noticeable chatter or binding, immediately notify your immediate supervisor or service personnel. DO NOT attempt to repair the mast or operate the truck until the prob- lem is corrected. i, WARNING | Ifthe mast does not raise or lower properly or shows signs of bind- ing it may release or stop suddenly or move with a jerky motion and allow the load or carriage to drop. This could result in death or serious injury to the operator or nearby persons and/or damage the load. Overhead Guard - Check the overhead guard and make sure that itis firmly attached to the truck and that all fasteners are secured. Rust or corrosion - Check the truck frame, side and floor pan- els for rust and corrosion. Clean rusty or corroded areas and repaint if applicable. Apply a thin coat of oil to any bare metal surface. Safety decals, data plates, etc. - Check for damage and miss- ing decals. Check that the decals are legible. Clean and/or replace as needed. Static discharge strap - make sure the static discharge straps (2) are dragging (touching) the ground. Both straps are located on the front of the truck, between the front wheels. Tires and wheels - Check tires for cuts or chunking, oil slicks, ‘embedded foreign material or excessive wear. Check wheels for missing lug nuts. Repair and/or have service replace immediately. Do not use the truck, Welds, cracked or broken - Check for damage and reliability. Clean and repair as necessary. Wires or connectors, damaged - Look for cracked or broken insulation, bare wires showing, loose or broken connectors. if electrical problems are found, have service make repairs immediately. Do not use the truck Remember, a complete service manual is included with your FL- EX series truck containing additional service procedures that must be periodically performed by a trained service technician or your authorized Landoll Service Representative. "FAB Satos Service, Receling Snepecton, pi: 1420860 +, 0609, 217Q Receiving and inspection 2.4 replacing the battery 2418 Replacing the battery requires lift and support apparatus capable of sup- porting the weight and size of the battery (minimum 3,000 Ibs./1,361 kgs.) Check the capacity plate for battery information. (See Safety chapter, “Figure 2: Capacity plate location,” on page 13 for more information.) 2.4.1 Disconnect the battery Before you begin, see the Safety chapter, “S,7 Battery,” beginning on page 14. A CAUTION | Caution should be used to assure that the polarity to the vehicle is not reversed when the battery is installed or serviced or when the connector is removed. Before you remove the battery or battery connections, the cables should be tagged as to positive and nega- tive polarity. If you have any doubt, check the polarity with a meter. 1. Return the truck to your service changing station (area). 2. Set the key switch to OFF and place the key in your pocket. jattery Connector Latch rs i 3. Unlock the retainer latch and pull the battery con- nector straight out. (See Fig- ure 2-2: ‘Bat- terydisconnect and retainer latch.’) Figure 2-2: Battery disconnect and retainer Intch 4. As the connector is released, the battery retainer latch lifts. "FLEX Series Seria, Receiving &Inapecton, pln 1420860 -b, 0569Receiving and inspection Q 2.4.2 To replace a battery Before you begin, see the Safety chapter, “S.7 Battery,” beginning on page 14. 4. Return the truck to your service changing station (area). 2. Set the key switch to OFF and place the key in your pocket. 3. Disconnect the battery. See section 2.4.1, “Disconnect the battery.” 4, Place blocks in front of and behind all wheels. Remove the battery hold-down retainer bolts, one located on each side of the battery compartment. Use a wrench to unscrew the two hex head bolts from each retainer. (See Fig- ure 2-3: ‘Removing the Battery’) ae : ‘Figure 2-3: Removing the Battery 6. Attach a spreader bar with chains and hooks to an appropriate overhead crane capable of lifting the weight of the battery (minimum 3,000 lbs./1,3061 kgs.). (See Figure 2-2: ‘Battery disconnect and retainer latch.’) Check the battery nameplate for specifications. Also see Safety chapter, “Figure 2: Capacity plate location,” on page 13. "PLB Saree Seven, Recehng& spect, pln: 1420660 2, 0509, 2419Receiving ani inspection Q CAUTION | Do not allow lifting apparatus to contact the battery terminals. A serious arch or short could occur through the battery tray or spreader bar. 7. Attach the spreader bar chain hooks to the lifting eyes on each side of the battery. (See Figure 2-3: ‘Removing the Battery’) 8. _ Raise the battery to a height clearing the compartment side walls and remove the battery from either side of the truck. 9. Immediately lower the battery to the ground. 10, Check the condition of the plywood floor in the battery com- partment. Replace as needed. 11. When installing the new battery, it must comply with the requirements for weight and capacity as shown on the manu- facturer’s nameplate. Also see Safety chapter, “Figure 2: Capacity plate location,” on page 13. 12. Install and secure the battery retainers on each side of the bat- tery and torque the lock nuts accordingly. (See Chapter 4, ‘Table 3: English torque specifications,’ on page 4-13.) 2.5 storage, towing or shipping For long-term storage, the truck battery should be removed and stored where it can be periodically checked and recharged every three months, The truck should be stored indoors within a temperature range of +35° F (2° ©) to +115 F (46° C) and a relative humidity of 90%. The truck should be raised with the tires at least 2" (51 mm) off the floor and the frame set on large wooden blocks. Hard polyester tires, over long Periods of time can develop flat spots that may not return to normal when the truck is returned to service, rendering the tires defective. If the truck must be stored outside, it must be covered securely with a tar- Paulin. Continued exposure to sunlight will cause deterioration of rubber tires, gaskets and hoses, as well as vinyl seat coverings, etc. “FLEX Series Serco, Recelvng& nepacton, pin 1420860 -, 0809, 2-20Receiving and inspection Q Batteries must be stored indoors within a temperature range of +35° F (2° C) and a maximum humidity range of 90%. Batteries are shipped charged and dry, with the electrolyte separate. {f the batteries are not activated within one year, they will become sulfated. 2.5.1 Returning the truck to operation IF the truck is out of operation for several months or more, it must undergo the same maintenance procedures that apply for 500 hours of use. (See Table 1, ‘Preventive maintenance schedule,’ on page 4-7.) Thereafter, normal daily maintenance and inspeo- tion is sufficient. 2.5.2 Towing the truck A WARNING ! Make sure the towing equipment is capable of handling the ‘weight of the truck being towed. Also see Safety chapter, “Figure 2: Capacity plate location,” on page 13. Never lift a truck using straps, chains or hoists of any type. Q_ Never connect lifting equipment to the operator's compart- ment overhead guards. Never tow a truck that is carrying a load. Never use the truck to tow materials. Never connect towing equipment to the mast. Ifthe truck breaks down and cannot be repaired at that loca- tion, it may be towed by attaching a suit- able hook and chain to the side slots located in the cutout at the lower rear of the truck. (See Fig- ure 2-4: Tie-down ports used for tow- ing.’) Figure 2-4: Tie-down ports used for towing "FLEX Serie Sonics, ReceNng inepecton, pln: 1420860 -b 05/8 2-24Q Receiving and inspection 2-22 ff & J 2.5.3 3. Notes: The use of ridged bar for towing provides better control and stability over the towed vehicle. For better traction, tis recommended to partially load the vehicle doing the towing. Carefully and slowly tow the EX to your service bay avoiding inclines wherever possible. To ship the truck Set the mast to its forward position (straight ahead), Remove the battery. Scrape away and wipe clean any wet residue or corrosive deposits left by the battery. IMPORTANT | (See Safety chapter, “S.7 Battery.” on page 14 for more information.) Connect a battery to the truck disconnect using long jumper cables and back the truck onto its carrier so that the forks are Pointed away from the forward direction of motion. (This is usually accomplished by connecting the cables to a battery being carried by a nurse truck and carefully driving both trucks close to the carrier.) Set the mast to its forward (level) position and lower the forks to the bottom of the mast - align the mast indicator pointer located on the left side of the mast, as viewed from the front of the truck. Disconnect the jumper cables from the truck and set the park- ing brake as firmly as possible. Set wedges against the front and rear tires and fasten them to the floor of the carrier. If the carrier is equipped with rings or receptacles for chains or wire rope, support the truck as firmly ible. IMPORTANT ! Do not run chain or wire over the battery cover or any other sheet metal surface. Use padding as necessary to protect the truck finish from chain or wire. "FLX Saris Servic, Recehing& Inspection, pin: 1420680 -b, 05108FL EX Series Explosion Proof Lift Truck Chapter 3: Operation me DR=X=L- Landolt Corporation Drexel Division 1900 North Street Marysville, KS 68508 USA Teleph (785) 562-5381 Fe (785) 562-4853 “. Wuw.drexelirucks.com We Partnumber: 1420060, 05108A NOTICE! Explosion proof - Drexel FL-EX Series lift trucks are designed and constructed to perform in operating environments containing specifically named flammable gases or vapors and combustible dusts. The trucks are inspected and tested to stringent ANSI/UL 883 standard consistent with OSHA 29CFR (Code of Federal Regulations), paragraph 1910.178. Additionally, the trucks are classified by Underwriters Laboratories, Inc. for use in Class 1, Division 1, Group D (operat- ing gas or vapor-air environments) and/or Class I, Division 1, Group G (operat- ing combustible dust-air environments) locations as defined in National Electric Code NFPA 70 by National Fire Protection Association. Al tems of technical information, advice, know-how, drawings, designs, speciti- cations and other items communicated in this document are confidential and remain the property of Landoll Corporation and shall not be disclosed to a third party, photocopied, reproduced, or translated to another language without the prior written permission of: Landoll Corporation Drexel Division 1900 North Street Marysville, KS 66508 US) Telephone: (785) 562-5381 Fax: (785) 562-4853 Web: www.drexeltrucks.com The Landoll Corporation is pleased to provide detailed specifications of its. products in this manual, but reserves the right to vary these at its discretion at any time without notice. As the Company's products and services are continu- ously being developes, it is important for customers to check that the informa- tion contained herein includes the latest specifications. This manual is for general guidance only. Landoll Corporation cannot accept any financial or other responsibility that may be the result of your use of the information contained herein; including direct, indirect, special or consequential damages. All recom- mendations and suggestions issued by or on behalf of the Company in whatever form, are subject to the Company's terms and conditions of sales, a copy of which will be supplied upon request. This document is not part of a contract or license, save insofar as may be expressly agreed. Pectrumber 1420860 -b, 8108 ‘Landa Corporation, roel Dhlon 2008, ‘AE Righls ReservedOperation O Contents Page Basic operation 3.1 3.2 3.3 3.4 to begin operating. 2 & 3.1.1 Pre-operation checklist.. 3.1.2 Adjusting the driver's seat Figure 3-1: Driver's seat adjust Seat belt Figure 3-2: Belt release button 3.1.3 Fork adjustment. Manual fork adjus Figure 3-3: Unlocking the forks Figure 3-4: Locking the forks Fork positioner option - automatic a eeee SE EEE bush 555 driving the truck 3.2.1 Practice session .... the mast 3.3.1. Practice session Figure 3-5: Lift lever ico Figure 3-6: Tilt lever ico Side shift option. Figure 3-7: Shift lever icon handling loads 3.4.1. To pick up the load... Figure 3-8: Normal driving posi Figure 3-9: Aligning the truck to the palit opening Figure 3-10: Inserting the forks into the pallet. 3-14 Figure 3-11: Tilting the load. Figure 3-12: Retrieving the load. “FLEW Suen Senice, Operation, pl: {420880 -b, 0818 33Q Operation Contents - continued Page 3.4 handling loads - continued 3.4.2. To deliver a load Figure 3-13: Tilting the load Figure 3-14: Aligning the load to the Figure 3-15: Delivering the load.. Figure 3-16: Positioning load for stacking. Figure 3-17: Backing out... Appendix 3.5 available options 3.5.1. Back up alarms Figure 3-18: Back up alarm. 3.5.2. Fork positioner - non-side shiftin Figure 3-19: Fork positioner layout and setting Figure 3-20: Fork positioner leve 3.5.3. Folding forks 3-4 "FLEX Serie Servic Operation, ph: 1420600 -b, 0600Basic operation O 3.1 to begin operating. WARNING | fs (1) ‘The FL-EX series lift trucks are heavy and powerful machines, capa- ble of causing injury or death to its operator and nearby people if they are improperly or carelessly operated. Only those individuals trained by an experienced instructor may operate and/or service these trucks. Practice runs in a controlled and safe area, away from other people and obstacles, are recommended. Unauthorized driv- ing by untrained or unskilled people must be strictly prohibited. Do not operate this truck until this manual has been read in its entirety, especially the section devoted to SAFETY. 3.1.1 Pre-operation checklist Perform a pre-operation inspection of the FL-EX series lift truck daily, before beginning your work shift. Report all problems to your immediate supervisor. (See Receiving and inspection, Chap- ter 2.3.2, ‘Routine checks,’ on page 2-14.) 3.1.2 Adjusting the driver’s seat A WARNING | Adjust the driver's seat only when the truck is NOT moving. 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 back- ward as needed. Release the lever and try to move the seat slightly to make sure that itis locked. (See Figure 3-1: Driver's seat adjust,’ on page 3-6) WARNING | Ifthe seat is not locked, it could slide forward in a sudden stop or crash which could cause injury to the driver. "AL-BX Sai Sendce, Beslecperton in: 14208600, 0509 35Q Basic operation Figure 3-1: Driver’s seat adjust 2. Fasten the seat belt - see heading Seat Belt which fol- lows. 3. To dismount, release the seat belt and dismount using the side panel step. Seat belt ‘The seat belt must always be worn when driving this truck. 1. First, sit up straight in the driver's seat. 2, Pull the belt across you. Do not let it get twisted. I WARNING | I \, JARN = ‘You can be seriously injured by a twisted belt. In a crash or a tip- over, the full width of the belt would not be available to take up the Impact forces. 3. Push the latch plate into the buckle until it clicks. Pull up on the latch piate to make sure it is secure. 4, Ifthe belt stops before it reaches the buckle, press the release button on the left side and let it go back all the way and start again. (See Figure 3-2: ‘Belt release button.’) Figure 3-2: Belt release button The lap part of the belt must be worn low and snug on the hips, just touching the thighs. \ WARNING | /\, cS Make sure the release button on the buckle is positioned so you could unbuckle the seat belt quickly in an emergency. 3-6 "FLEX Sees Senco, Basle opertn, pin: 1420800-6, 0809Basic operation O 3.1.3 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 | Review heading Safety with regards to fork positioners for proper safety precautions when adjusting the location of the forks on the carriage. Before you begin, raise the forks to about waist high to protect your back from possible awkward bending while moving heavy objects. Make certain the truck key switch Is in the OFF position and that the parking brake is set. ‘The forks must be set equal distance from the center of the fork car- riage. Setting them too far to the left or right could cause a load to unbalance and tip the truck. Be sure the forks do not extend beyond any load, causing damage or tipping of other adjacent loads or materials behind the load being moved. Manual fork adjust 4. The forks are locked in position by a spring-loaded latch. To release them, reach behind the top of each fork, and pull the tip of the latch upward. (See Figure 3-3: ‘Unlocking the forks.’) Figure 3-3: Unlocking the forks 2. Slide the forks in the desired direction, using your hand to push at the top, and your foot to push against the tines at the bottom. A stubborn fork may be dislodged by alternating a push at the top and at the bottom. WARNING | Never pull a fork towards you as this places your hands in a possl- ble pinch position which could cause serious injury. Always push the fork away from your body. “FLEX Seres Senos, Basle operation, ph: 1420600, 05108 37Q Basic operation When the fork is in position, push the latch down. If neces- sary, push the fork a little more to make sure the pin falls into a notch at the top of the carriage bar locking the fork in position. Figure 3-4: Locking the forks Fork positioner option - automatic Automatic fork positioners are an option on FL-EX series trucks. If your truck includes a fork positioner, see the Appendix section of this manual, heading Fork positioner for more information. 3.2. driving the truck ad WARNING! Only those individuals trained by an experienced instructor or oper- ator may operate andlor service this truck. Familiarization and driv- ing practice with a new truck must be arranged in a safe and protected area, away from other personnel and obstacles. Check that all directional and operational controls and levers are in the NEUTRAL, or center position, the brakes are set and your seat belt is fastened before setting the key switch to on. (See ‘Seat belt’ on page 3-6.) To avold personal injury when operating the truck, be extremely careful that NO part of your body (head, feet, arms, legs, fingers) is outside the operator's compartment where it could be subject to injury by aisle supports, other trucks, the mast raising or lowering, or any obstacle in the area. As the truck operator, you are responsible for observing all speed restric- tions and traveling in accordance with aisle and work area conditions. You are responsible for observing all instructions and safety regulations during your dally work routine related to the use of this truck. "FLEX Soles Sonica, Besi operation pit: 1420880-b, 08108Basic operation Itis your responsibility to thoroughly read this Driver's Guide, paying par- ticular attention to the chapter devoted to Safety, before attempting to operate this lft truck, Under normal driving conditions, speed must be chosen according to the situation, such as, surface conditions, visibility, people working in the area, moving and fixed objects in the area, cross aisles, etc. Where visi- bility is a problem, always travel at very slow speed and ask for a helper to guide you through the area. Always rotate in your seat to face in the direction your are traveling. 3.2.1 Practice session 4. Pull the emergency pushipull button UP to start the truck. 2. Release the hand parking brake. 3. Move the directional control lever to the FORWARD position. Note: If you push the emergency button down (OFF position) or leave your driver's seat while the truck is in a drive mode, the truck automati- cally reverts to the NEUTRAL mode and the mechanical brake is applied to immediately STOP the truck. The directional control lever must then be retumed to NEUTRAL, before selecting the desired driv- ing direction, 4, — Slowly press the accelerator pedal. The truck begins to move in the selected direction. Pressing the pedal produces the same effect as in an automobile; the further the pedal is pressed, the faster the speed of travel. Steer the truck in a straight path while traveling at a SLOW speed, Practice in a straight path and at slow speed until you are thoroughly comfortable with the action and feel of the truck. 6. Tum right at @ slow speed. Although the truck includes power steering, you must manually return the wheel to the straight- ahead or center position. 7. Tur left at a slow speed. 8. _ Bring the truck to a full and smooth stop. "FLEX Series Sonic, Baslcperton, pin 1420860, 0508 3-9Q Basic operation 9. 10. WARNING ! Careless driving, such as, fast starts or abrupt braking, excessive ‘speed at turns or through cross aisles, sudden stops, or hard turns at high speeds can all lead to serious injury and damage to the, truck and load. Do not indulge in stunt driving or horseplay. Always drive with safety as your number one goal. Now move the directional control iever to the REVERSE posi- tion and repeat steps 4 through 8, at reduced speed, Note: As an option, an audible alarm may be added to sound (beep) while you are traveling in reverse or anytime a direction of travel is selected Continue practicing until you are comfortable with forward and reverse driving at slow speed. When you feel you have mas tered driving the truck, proceed to the next heading ‘the mast.” 3.3 the mast 3.3.1 3-10 Practice session Slowly pull the LIFT lever towards you to. raise the forks. Lift the forks only one or two feet for practice. Figure 3-5: Lift ever icon Push the LIFT lever away to lower the forks. Push the TILT lever forward to tilt the mast forward, as shown in the bottom portion of the icon. Figure 3-6: Tilt lever icon Pull the TILT lever back to move the mast back, or to return the forks to their horizontal position, Practice tiling the mast slowly by feathering in the desired direction. Feathering is the process of maving the lever ever so slowiy in the required direction to “very slowly” move the load into position. "FL-DK Saves Saree, Basle cperatn, pn: 1420880-2, 0509Basic operation WARNING ! Avoid jerky movements of the mast, especially when the load is ralsed. Jerky movements with the mast raised could tip the truck or allow the load to slip from the forks, causing serious injury and/or damage. 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. 6. Tilting @ loaded mast forward should be done slowly by feath- ering the tit lever. Rapid tilting might jostle a load off the forks prematurely. Side shift option The side shift option allows the carriage (forks) to be moved approximately 4” (102 mm) from center to either side. Make sure the area to the right or left of the truck is clear. Push the SHIFT lever forward to shift the forks up to 4* (102 mm) from center to the driver's left, Figure 3-7: Shift lever icon Pull the SHIFT lever back to shift the forks up to 4” (102 mm) from center to the driver's right. When you are thoroughly familiar with all of the control move- ments of the levers, practice depositing and retrieving a load under the supervision of an experienced instructor or operator. WARNING! NEVER handle loads in excess of the specified rating on the capac- ity plate located in the driver’s cab. Do not handle unstable or loosely stacked loads. Too heavy a load may tip the truck, causing injury to the operator. Unstable loads may fall off, injuring people nearby. “FLIDE Sarlos Senco, Basic cperatn, pln: 1420800 -b, 05103 314Q Basic operation 3.4 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. J WARNING | Unless you are moving the load immediately to another nearby loca- tion that is on the same side of the aisle, you must lower the load to about 12" (305 mm) from the floor. Lowering the mast improves driver visibility, and improves the st bility of the truck by reducing the possibility of personal injury or damage to the load if it were to slip from the forks. 3.4.1, To pick up the load 1. With the forks lowered (normal driving position), and the mast shifted to the center of the truck (if shift option is included), ‘somewhat center the truck in the aisle, then drive to the rack location. (See Figure 3-8: ‘Normal driving position.’) Figure 3-8: Normal driving position 2, When near the pallet (rack location), turn the steering wheel and center the forks to the pallet opening. (See Figure 3-9: ‘Aligning the truck to the pallet opening.’) le operator, ph: 1420080, 0509"FL-BC Saris Sonic Basic operation pln 1420680-b, 0509 Basic operation Q Figure 3-9: Aligning the truck to the pallet opening. 3. As you slowly approach the rack, raise the forks to the required level of the load, 4, Carefully turn and drive forward as needed to align the right fork to the opening in the pallet. Make sure you do not strike any racks or objects on either side of the load 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. 5. _ Bring the truck to a smooth stop when centered in front of the pallet or rack. (See Figure 3-9: ‘Aligning the truck to the pallet opening.’) IMPORTANT ! When handling loads, it is always important to position the forks with respect to the center of gravity of the load to mal balance when the load is lifted. aneven 6. Adjust the fork spread to accommodate the center of the load. (See ‘Fork adjustment’ on page 3-7.) 7. Gradually drive forward, inserting the forks all the way into the pallet. (See Figure 3-10: ‘Inserting the forks into the pallet,’ on page 3-14.) 343Q Basic operation 344 10. Figure 3-10: Inserting the forks into the pallet Note: Be sure the forks do not extend beyond the load, causing dam- ‘age or tipping of other adjacent loads or materials behind the load being moved. 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. Also make sure the load is centered and appears balanced before you move it any distance. Tilt the mast back to make sure the load will not side off the forks. (See Figure 3-11: Tilting the load,’) ‘Figure 3-11: Tilting the load You may have to wait until the load has been withdrawn somewhat before you can tit it completely without striking any cross members above it. 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 3-12: ‘Retrieving the load,’ on page 3-16.) “FLEX Sete Senco, cope, ln 14208008, 0808Basic operation O " 12. "AL-DC Sores Sarco, Bosc operon pl: 1420600 b, Figure 3-12: Retrieving the load ‘When you are sure the pallet clears the rack completely, con- tinue backing out until the load is completely away from the rack. ‘As soon as possible, lower the forks to about 6” to 12" (152 mm - 305 mm) from the floor, (See Figure 3-8: Normal driving position.) WARNING ! Lowering the mast improves driver visibility, and improves the sta- bility of the truck by reducing the possibility of personal injury or damage to the load if it were to slip from the forks. To deliver a load 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. Always tilt the mast back slightly to make sure the load will not slide off the forks. (See Figure 3-13: Tilting the load,’ on page 3-16.) 503 345Q Basic operation Figure 3-43: Tilting the load 3. With the load centered and the forks lowered (normal driving position), ‘somewhat center the truck in the aisle, then drive to the rack opening. 4. Asyou approach the opening, turn the steering wheel to rotate the load into the rack opening. (See Figure 3-14: ‘Aligning the load to the rack open- ing.) Figure 3-14: Aligning the load to the rack opening 5. Ralse the load to the proper height making sure you do not strike any cross members that may be above it. 6. Gradually drive forward, inserting the load all the way into the opening. (See Figure 3-16: ‘Delivering the load,’ on page 3- 17) A WARNING | Be careful that the load does not hit the side of the rack as itis 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. 3-46 “FL-EX Sotas Sorc, Besi operation pin: 1420660», 508