Crown Equipment M Series Automobile User Manual

M
S
E
R
I
E
Operator Manual
S
This operator manual has
information for all models
of series M plus some
options and accessories.
Some of the illustrations
and information may not
The most
apply to your truck.
important
component
is you.
New Bremen, Ohio 45869 USA
© 1997
PF12442- WEB Rev. 6/06
Printed in U.S.A.
M
S
E
R
I
E
S
You Must be Trained
STOP
It’s the law, you must be trained and certified to
operate this truck. (OSHA § 1910.178, Rev. 1999)
IT'S THE LAW, YOU MUST BE TRAINED AND CERTIFIED
Federal law states that only properly trained operators are
permitted to operate a powered industrial truck and that
your employer must train you and certify that you are
qualified to operate this powered industrial truck.
(OSHA §1910.178, Rev. 1999)
Do not operate this truck in your work place until you
have been trained and certified by your employer.
You or others around you can be seriously injured or even killed
if you don't use this truck correctly.
Read and obey all warnings and instructions in this Manual* and
on the truck.
A dockboard can move or drop while you are on it. Or you could
drive off a dock. Falls from docks or dockboards can cause serious
injury or even death. Make sure you are safe.
You could be killed or seriously injured if you are not
adequately trained for lift truck operation!
Inspect your truck before starting work, make sure it is in good
working order.
* Additional copies of this Operator Manual and all Truck Labels can be obtained
from Crown Equipment Corporation, New Bremen, Ohio 45869 U.S.A.
All rights reserved under International
and Pan American copyright conventions
Copyright 1997 Crown Equipment Corp.
1 Warning
You Must be Trained 2
Protect Yourself
Know the Hazards
Know the Hazards
LOOK WHERE YOU'RE GOING
Always be alert to the area around you and watch where
you are walking. Be careful that you don't get pinned or
crushed between the truck and a fixed object such as a
wall or post.
USE YOUR TRUCK CAREFULLY
• Watch your hands and your feet. A foot or hand caught
between the truck and a fixed object will be crushed or
even cut off.
• Keep to the side of the truck while traveling power unit
first. Make certain the truck won't hit the back of your
leg or foot. Don't let the truck run over your foot.
• If traveling forks first, keep both hands on the control
handle and be careful when changing direction of travel.
Keep your feet clear of the truck.
• Keep your truck under control at all times. Operate at
a speed that allows you to stop safely. Be even more
careful on slippery or uneven surfaces. Do not run
over objects on the floor.
• Perform all truck movements smoothly and at a speed
that will give you time to react in an emergency.
AVOID FALLS AND TIPOVERS
Tipovers and falls are very serious accidents, you can be
crushed or even killed. The best way to prevent injury is
to know where you are at all times and follow the rules
of safe truck operation.
• Be extremely careful when working around docks,
dockboards and trailers.
• Stay away from the edge of docks and ramps.
• Make sure dockboards are secure.
• Check that trailer wheels are chocked.
• Travel with the load or forks close to the ground. Watch
for overhead obstructions. Perform all truck movements
smoothly and at a speed that will give you time to react
in an emergency.
• An unloaded truck can tip over also. You must be just
as careful using an unloaded truck as you are using a
loaded one.
WARNING
Stay clear of all
moving parts.
Moving parts can
cut or crush hands,
feet, arms or legs.
07
Recommended
Walking Path
3 Protect Yourself
USE YOUR TRUCK SAFELY
• Keep your hands and feet away from all moving parts
such as masts, chains, forks or wheels.
• Never stand on or under the forks, or allow anyone else
to stand on or under them. The only way to lift people
is with an approved platform. Never ride on the truck or
allow anyone else to ride. There is no safe place to sit
or stand.
• Before you leave your truck:
• Lower the forks to the floor.
• Shut the truck off with the key or disconnect the battery.
Protect Yourself 4
Contents
What's in it for You?
Warning
1
You Must be Trained
2
Protect Yourself
3
Contents
5
What's in it for You?
6
Your Walkie Lift Truck
7
Lift Truck Parts
9
Capacity & Load Center
11
Capacity Plate
13
Power On & Off
15
Braking
16
Raising & Lowering
17
Steering & Travel
18
Traveling
19
Daily Safety Check
21
Be a Safe Operator
23
Battery Maintenance
27
Warning Labels
30
5 Contents
WHAT'S IN IT FOR YOU?
The better you understand your truck and how to use it,
the better and safer operator you can be. Here are some
guides to using this manual.
Traveling
QUICK LOCATORS
In addition to the "Contents" page you
can use page headings to find topics.
Some pages also have a picture of the
truck in the corner showing features or
functions covered on that page.
Know the Hazards
"KNOW THE HAZARDS"
Watch for and read these special blocks.
You will find information about
possible safety hazards and how to
avoid them.
HOW-TO-DRAWINGS
On many pages you will find pictures
as well as text to help you understand
how to use your truck safely and
productively.
19 Traveling
What's in it for You? 6
Your Walkie Lift Truck
WALKIE LIFT TRUCKS
Your walkie lift truck can be used to lift, move
and stack loads. It is designed to travel short
distances and operate in areas with limited space.
YOUR LIFT TRUCK IS NOT AN AUTOMOBILE
With a load it may weigh more than an
automobile.
• You don't steer the same.
• You don't brake the same.
HOW TO OPERATE YOUR TRUCK
Forks First
When traveling forks first use both hands to
operate the control handle.
Watch your feet if you change direction of travel.
Path of
Truck
Recommended
Walking Area
BUILT TO STANDARDS
This truck was designed and built
to current industry and government
standards and guidelines. For more
information see the following:
• American National Standards
Institute (ASME) B56.1
• Occupational Safety and Health
Act (OSHA) §1910.178
Rev. 1999
• Underwriters Laboratory
(UL) 583
• National Fire Prevention
Association (NFPA) 505
Hand on
the control
Power Unit First
When traveling power unit first stay to one side
of the truck and slightly ahead of the power unit.
Use the hand closest to the truck to operate the
control handle.
Watch your feet.
Stay out of the path of the truck.
Walk to the side
Feet clear of the truck
7 Your Walkie Lift Truck
Your Walkie Lift Truck
8
Lift Truck Parts
Mast
Fork
Control Handle
Control Arm
Key Switch
Power Disconnect
Raise/Lower Lever
High Travel
Speed Button
Reversing Button
Horn Button
Batteries
Raise Button (Optional)
Load Wheel
Lower Button (Optional)
Power Unit
Twist Grip
9 Lift Truck Parts
Lift Truck Parts 10
Capacity & Load Center
Center of evenly
distributed load
600mm
(24 in.) Max
Load
Center
WHAT IS YOUR TRUCK CAPACITY?
Capacity is the load (including pallet or
container) that can be lifted to a given height
at a given load center. See the capacity plate on
your truck. Make certain you use the correct units
of measure.
WHAT IS LOAD CENTER?
Load center is the distance from the load backrest or
vertical face of the fork to the center of an evenly
distributed load.
Know the Hazards
Units of measure, kg/mm(lb/in)
Truck Weight with Max. Battery
445(980)
M
CLAMP
LE
MP
E
Attachment Data
SERIES
SA
LOADS MUST BE EVENLY DISTRIBUTED
Your truck could tip over, in any direction, if a
load is shifted to the front or side of a pallet or
container.
Truck Type
Serial Number
A1234567
Load
Center
500(20)
Capacity with Mast Vertical
Capacity
905(2000) 3300(130) 600(24)
795(1750) 3300(130) 685(27)
322-D
KNOW YOUR LOAD
Do not exceed the capacity shown on your truck's capacity
plate. Be careful when handling long, high or wide loads.
Do not handle unstable loads.
EXCEEDING TRUCK CAPACITY CAN CAUSE AN ACCIDENT
Know the capacity of your truck as shown on your capacity
plate. Use the correct units of measure. Pay attention to:
• Weight of load
• Load center
• Lift height
CENTER THE LOAD
Your truck could tip over if a load is shifted to the front
or side of a pallet or container. Make sure your load is
evenly distributed and centered over the forks.
11 Capacity & Load Center
Capacity & Load Center 12
Capacity Plate
CAPACITY PLATE INFORMATION
The capacity plate is on the power unit
cover. It contains:
• Serial number
• Capacity information (load, load center and lift height)
• Truck type (a fire safety rating)
• Truck weight with battery (does not include load)
• Attachment information (if any)
READING YOUR CAPACITY PLATE
The capacity plate on the console contains the load,
load center, and lift height ratings for your truck.
For example: On the sample plate, 905kg (2000 lb) can
be lifted to A 3300mm (130 in) at a B 600mm (24 in)
load center.
Capacity is reduced as load center B increases.
For example: On the sample plate, 905kg (2000 lb) can
be lifted if the load center is 600mm (24 in). But if the
load center is increased to 685mm (27 in), capacity is
reduced from 905kg (2000 lb) to 795kg (1750 lb).
SAMPLE
CAPACITY PLATE
The information
shown on this
sample plate does not
apply to your truck.
Units of measure, kg/mm(lb/in)
Truck Weight with Max. Battery
445(980)
M
Truck Type
E
Attachment Data
SERIES
CLAMP
Serial Number
Load
A1234567
Center 500(20)
Capacity with Mast Vertical
Capacity
905(2000) 3300(130) 600(24)
795(1750) 3300(130) 685(27)
322-D
13 Capacity Plate
CAUTION
You may not increase capacity if
load center is less than shown on
your capacity plate.
Note: ANSI requires that all data be
shown first in Metric units and then
USA units.
OTHER LIFT HEIGHTS & LOAD CENTERS
Contact Crown for capacities at lift heights or load centers
not given on your capacity plate.
Know the Hazards
TRUCK WEIGHT
Dockboards, elevators and some floors have limited
capacity. Check your capacity plate for the weight of your
truck. Remember to add the weight of the load you have
on the forks. Make certain you use the correct units of
measure.
TRUCK TYPE
Some truck types are not permitted in areas where there
are fire hazards. Watch for marked areas. For example:
You must not operate a type E or ES truck in an area
restricted to EE or EX trucks.
ATTACHMENT DATA
If an attachment on your truck does not match the
information given here on your capacity plate, don't operate
your truck. Your capacity plate may be wrong. Report the
problem to your supervisor, or contact Crown.
Capacity Plate 14
Power On & Off
KEY SWITCH
Turn the key clockwise. Power is ON.
Turn the key counterclockwise. Power is OFF.
Always turn the key off when leaving the truck.
Braking
Brake
On
Brake Off
Brake On
PUSH
DOWN
BRAKING
Move the control handle all the way down or all the way
up to apply the brake.
When you let go of the control handle it will automatically
go to the upper braking position. Check the braking before
you start working.
POWER DISCONNECT
Push the battery connector handle down to disconnect the
battery and cut all power.
Always disconnect the battery any time the truck isn't
working right. The key switch does not cut all power to
the truck.
Don't use the truck if it's not working right. Report the
problem to your supervisor.
Know the Hazards
MAKE SURE YOUR BRAKE WORKS
Test the brake on your truck at the start of each shift.
Know the distance it takes to stop before you start
working.
If at any time the stopping distance is too long for you to
stop safely, don't use the truck. Report any problem to
your supervisor.
15 Power On & Off
Braking 16
Raising & Lowering
RAISE/LOWER
Move the Raise/Lower lever away from the mast,
toward the control arm, to raise the forks. Move the
lever toward the mast to lower the forks.
The farther you move the lever from neutral, the faster
the forks will move.
Steering & Travel
STEERING
You control steering by moving the control handle from side to side.
For example: This picture shows the directions the truck can turn when
the control handle is moved to the approximate position shown.
Travel,
forks first
on
c t i rn
u
fT
RAISE & LOWER PUSH BUTTONS
For convenience, single speed push buttons may be installed
on the control handle. Push either the Raise or Lower
button until the forks are at the desired height.
Di
o re
n
t io rn
u
Di re
of T c
Travel, power
unit first
Know the Hazards
POWER UNIT SWING
Be careful turning while traveling forks first. The power
unit will swing wide in the opposite direction. Make sure
you have clearance, and watch out for people in the area.
SLOW DOWN FOR SPILLS OR WET FLOORS
Powder or liquid spills can cause slippery floors. Slow
down or you could lose control of steering and braking.
Be careful and allow for a longer stopping distance.
Don't run over objects on the floor.
17 Raising & Lowering
Steering & Travel 18
Traveling
TRAVEL
Rotate the top of the twist grip in the direction
you want to travel.
The farther you rotate the grip from the neutral
position, the faster the truck will travel.
HIGH TRAVEL SPEED
For high travel speed, push the high travel speed button
on the control handle and rotate the twist grip to the
maximum travel speed position.
Know the Hazards
REVERSING BUTTON
If you accidentally hit the reversing button while working
in close quarters, the truck will move in the direction of
the forks until the button is released.
Be careful. The reversing button cannot prevent all injuries.
LOOK WHERE YOU'RE GOING
Always be alert to the area around you and watch where
you are walking. You could be pinned or crushed if you
are caught between the truck and walls, racks or other
fixed objects.
WATCH YOUR FEET AND HANDS
A foot or hand caught between the truck and a wall, post
or any fixed object will be crushed or even cut off.
Keep your feet clear of the wheels.
19 Traveling
Traveling 20
Daily Safety Check
CHECK YOUR TRUCK BEFORE STARTING WORK
You must make sure your truck is safe to use.
1. Walk around your truck and check it over.
• Check to make sure the batteries are charged, water
level is OK and vent caps are in place. Don't use an
open flame to check the batteries.
• See that all wheels are in good condition.
• Check that both forks are secure and not bent, cracked
or badly worn.
• Inspect lift chains for damage.
• Clean the safety shield and keep it clear. Clean the
twist grips.
• See that the load backrest is in place and secure, if
your truck has that option.
• Look under the truck for signs of hydraulic leaks.
• Try the horn.
• Make sure the power disconnect works.
• Check that all controls work smoothly.
21 Daily Safety Check
2. Test your truck in an uncongested area.
• Try all the hydraulic functions.
• Check the steering.
• Operate the truck slowly in both directions.
• Operate through the full speed range in both forward
and reverse.
• Check braking distance in forward and reverse. Load
size and floor conditions can affect these distances.
• Know the distance it takes to stop before you start
working. If the braking distance is too long to stop
safely, don't use the truck.
If anything doesn't look, work or feel right, don't use the
truck. Report the problem to your supervisor.
You can get checklist forms from your Crown dealer
(part no. OF-3772). Used properly, this checklist can alert
service people to needed repairs.
Daily Safety Check 22
Be a Safe Operator
The most
important
component
is you.
MAKE SURE YOU ARE READY
• Do not use this truck unless you are trained
and certified.
• Be certain you understand how your truck works and
the hazards that go with it. Don't use the truck if you
have any doubts.
• Know the capacity of your truck. Make certain you use
the correct units of measure.
• Some trucks are not allowed in areas where there are
fire hazards. Be certain your truck is the correct fire
safety type for the area.
• Make sure your hands and shoes are clean and dry, and
your clothing is proper for the job.
MAKE SURE YOUR TRUCK IS READY
• Inspect your truck before using it (see pages 21 and 22).
If it's not working right, or something is broken, report
the problem to your supervisor. Don't use the truck.
• In an open area, test the braking. Check at a slow travel
speed first, then a faster one. Know the distance it takes
to stop before you start work.
Recommended
Walking Path
USE CAUTION, BE ALERT
• Watch where you're walking. Don't let any part of your
body get pinned or crushed between the truck and a
fixed object.
• Stay to the side of the truck when traveling power unit
first. Make sure the truck won't hit your leg or run over
your foot.
• When traveling forks first keep both hands on the control.
Be careful when changing direction. Keep your feet
clear of the truck.
• Travel in the direction that gives you the best view. Look
where you are going and slow down in congested areas.
• Slow down for wet or slippery floors. Don't run over
things. Watch out for rough floors.
• Travel with the forks close to the ground. Place the load
against the load backrest or vertical face of the forks.
• Look where you are going before you change direction
of travel.
• See that you have room to turn. Watch out for power
unit swing.
• Slow down when making turns.
• Avoid sudden movement of controls. Learn to use them
smoothly at a moderate, even rate.
• Check clearances before raising or lowering the forks
or load.
• Be extra careful if you must use your truck in an area
where there is a risk of falling objects.
• Never ride on your truck.
Continued next page...
23 Be a Safe Operator
Be a Safe Operator
24
Be a Safe Operator continued
WATCH OUT FOR OTHER PEOPLE
• Slow down. Yield or stop for pedestrians.
Use your horn when you come to a crosswalk
or intersection.
• Be careful that you don't pin or crush someone.
For example: Never move your truck toward anyone
standing in front of a fixed object.
• Never allow anyone to ride on your truck.
• Keep others away from your truck while you're working.
Don't ever allow anyone on or under the load or forks.
• Don't let anyone use your truck unless they are trained
and certified.
• Never lift anyone with the forks unless they are using
an approved platform. Even then use extreme caution:
• Use a securely attached and approved safety platform.
• Make certain lifting mechanism is operating properly.
• Make certain truck is in neutral and brake is applied.
• Lift and lower slowly.
• Watch for overhead obstructions.
• Be sure you can see and hear the person being lifted.
• Never transport anyone on the platform from one
location to another.
WHEN LEAVING YOUR TRUCK
• Lower the forks to the floor. Turn the truck off or
disconnect the battery.
• Avoid parking on inclines. But if you must, block the
wheels of your truck.
25 Be a Safe Operator
continued
AVOID FALLS
• Stay away from the edge of docks and ramps.
• Check that bridgeplates and dockboards are secure. Be
certain that either the trailer wheels are chocked or the
trailer is locked to the dock. Check capacities. Be sure
your truck, with load, isn't too heavy for where you are
operating.
• Make sure the load you are moving is stable. Spread
the forks as far as you can and center the load. Insert
the forks as far under the load as you can. Be even more
careful with long, high or wide loads. They can be less
stable.
• Don't take your truck onto an elevator unless you are
authorized. Check the capacity or load limit and make
sure there are no people present. Enter load first and
set the brake.
BE CAREFUL TRAVELING ON RAMPS AND GRADES
• Stay out of the path of the truck.
• With or without a load, travel with the forks pointed
downgrade.
• If a load requires that you travel with the forks upgrade,
be even more careful. Operate the controls from the
side of the truck.
• Slow down and don't turn on ramps or grades.
Be a Safe Operator
continued
26
Battery Maintenance
BATTERIES
Your truck has four automotive style batteries.
You must check your batteries daily.
Know the Hazards
CHARGERS
Your truck will have either a built-in charger or an optional
bench type charger. The built-in charger must be plugged
into an AC electrical outlet before charging. Make certain
the charger and the AC outlet are the same voltage.
Follow the directions on your charger.
DANGER
Batteries can produce explosive gas. Do not
smoke, use open flame, or create an arc or sparks
near this battery. Ventilate well when in an enclosed
area and when charging.
This battery contains Sulfuric Acid which causes
severe burns. Do not get in eyes, on skin, or clothing.
In case of contact, flush immediately and thoroughly
with water. Get medical attention if your eyes are
affected.
20
BATTERY CHARGE METER OPTION
The lighted bar shows how much charge is left in your
battery. A flashing light will warn you that the battery is
getting low. Two flashing lights mean you must have the
battery changed or recharged.
27 Battery Maintenance
BATTERIES CAN BE DANGEROUS
Your truck batteries produce fumes that can explode.
They also contain acid that could burn or disfigure you.
• Never smoke or use an open flame around batteries.
• Do not try to install, remove, charge or service your
truck batteries unless you are trained and authorized.
• Your company should provide an area where it is safe
to work on batteries. Use that area for all battery work.
• Use protective equipment such as gloves, eye shields,
aprons, etc.
• See that the battery cells are filled to the proper level.
Never use an open flame to check the battery.
• For a built-in charger, make certain the AC outlet is the
same voltage as your charger.
• Read and follow the battery charger instructions.
• Be sure the charger is turned OFF before connecting
the batteries to the charger. Otherwise you might create
a spark which could cause a battery to explode.
• Make sure the truck key switch is turned OFF and all
controls are in the off or neutral position.
• Leave battery door open while charging.
• Avoid using extension cords. But if you must, follow
the recommendations on your battery charger.
Battery Maintenance 28
Notes
Warning Labels
EACH WARNING LABEL
ON YOUR TRUCK IS IMPORTANT
Read and obey all of them to protect
yourself and others.
CAUTI ON
To avoid damage to truck:
• Power unit door must be left open while charging.
• Check that line voltage is same as rated voltage of charger.
• Ammeter will show a high rate of charge if batteries are low, and
will drop to a low rate as the batteries become fully charged.
• Extension cord, if used, must have correct plugs and meet
minimum AWG size on chart.
WARNI NG
RECOMMENDED CHARGING TIME
Specific Gravity
1.260
1.250
1.230
1.210
1.190
1.170
1.150
1.130
Charge Time
0
4
6
8
10
12
14
16
MINIMUM AWG FOR EXTENSION CORD SIZE TO
BATTERY CHARGER
% of Charge
100%
75%
50%
25%
AWG Cord Size
AC Input Rating, Amps.
Equal to or
greater than
but less
than
0
2
3
4
2
3
4
5
It’s the law, you must be trained
and
certified
to operate this truck.
18
16
Length of Cord
15m(50') 30m(100') 45m(150')
18
18
18
16
WARNI NG
(OSHA
§ 1910.178,
Rev. 1999)
16
14
16
14
14 or people
12
You
around you could be
60
seriously injured
or even killed if you
don't use this truck correctly.
Obey all warnings and instructions on the truck
Riding on this
and in the operator manual*.
truck couldInspect your truck before starting work, make
sure it is in good working order.
cause serious
* Additional copies of the Operators Manual and Truck
injury.
Labels can be obtained from Crown Equipment Corp.,
New Bremen, OH 45869 U.S.A.
No Riding.
DANGER
04
36
Batteries can produce explosive gas. Do not
smoke, use open flame, or create an arc or sparks
near this battery. Ventilate well when in an enclosed
area and when charging.
This battery contains Sulfuric Acid which causes
severe burns. Do not get in eyes, on skin, or clothing.
In case of contact, flush immediately and thoroughly
with water. Get medical attention if your eyes are
affected.
20
All rights reserved under International
and Pan American copyright conventions
Copyright 1997 Crown Equipment Corp.
29 Notes
Warning Labels 30
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