Crown Equipment RR 5200S Series Automobile User Manual

RR 5200S
S
E
R
I
E
Operator Manual
S
This operator manual has
information for all models of
RR5000S series plus some options
and accessories. Some of the
illustrations and information may
not apply to your truck.
The most
important
component
is you.
New Bremen, Ohio 45869 USA
© 2001
PF12905-WEB Rev. 6/06
Printed in U.S.A.
RR 5200S
S
E
R
I
E
S
You Must be Trained
It’s the law, you must be trained and certified to
operate this truck. (OSHA § 1910.178, Rev. 1999)
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.
STOP
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.
Head, arms, hands, legs or feet outside the operator area can be
pinned or crushed whenever the truck is moving. Stay within the
operator area and stop the truck completely before getting off.
However, tipovers and falls from docks can cause serious injury
or even death. Immediately exit and move away from the truck
in these emergencies.
You could be killed or seriously injured if you are not
adequately trained for lift truck operation!
You can be trapped or crushed by driving the operator area under
racks or other objects. Look where you are going.
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 2001 Crown Equipment Corp.
1 Warning
You Must be Trained 2
Protect Yourself
Know the Hazards
Know the Hazards
DRIVE CAREFULLY
• Keep your hands on the controls and feet on the
pedals/pad. Keep your entire body in the operator area.
• Never stick a foot or any part of your body outside the
operator area, no matter how slow the truck is moving.
You cannot stop 3630 kg (8000 pounds) with any part
of your body. A foot or hand caught between the truck
and a fixed object will be crushed or even cut off.
• Stay away from the edge of docks and ramps. Make
sure dockboards are secure. Check that trailer wheels
are chocked. You could be seriously injured or even
killed in a fall from a dock or dockboard.
• Keep your truck under control at all times. Drive at a
speed that allows you to stop safely. Be even more
careful on slippery or uneven surfaces. Do not drive
over objects on the floor.
AVOID FALLS AND TIPOVERS
Falls from docks and tipovers are very serious accidents;
you can be crushed or even killed. Immediately exit and
move away from the truck in these emergencies.
Note: This is not like sit-down rider trucks, where it is
recommended that the operator stay with the truck.
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.
• Travel with the load or forks close to the ground and
tilted back. 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. Be just as careful
using an unloaded truck as you are using a loaded one.
LOOK WHERE YOU'RE DRIVING
• Always be alert to the area around you and watch where
you are driving. You could be pinned or crushed by
objects intruding or poking into the operator area.
USE YOUR TRUCK SAFELY
• Keep your hands and feet away from all moving parts
such as masts, chains, forks or wheels. Make sure the
overhead guard and load backrest are in place.
• 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 allow passengers
on the truck. There is no safe place for them.
• Before you leave your truck:
• Come to a complete stop and lower forks to the floor.
• Shut the truck off with the key or power disconnect.
Stay clear of all
moving parts.
Moving parts can
cut or crush hands,
feet, arms or legs.
07
3 Protect Yourself
Protect Yourself 4
What's in it for You?
Contents
Warning
1
You Must be Trained
2
Protect Yourself
3
Contents
5
What's in it for You?
6
Your Narrow-Aisle Truck
7
Lift Truck Parts
9
Capacity & Load Center
11
Capacity Plate
13
Display Panel
15
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.
Capacity & Load Center
Center of evenly
distributed load
Know the Hazards
600mm
(24in) Max
Units of measure, kg/mm(lb/in)
Truck Weight with Max. Battery
3325(7331)
RR
Mast Collapsed Height
2260(89)
Load
Center
17
Switch Panel
18
Adjusting the Seat & Controls
19
Power On & Off
21
Foot Brake
23
Traveling & Plugging
25
Steering & Travel
27
Two Types of Steering
28
Fork Functions
29
Daily Safety Check
33
Be a Safe Driver
35
Battery Maintenance
39
Warning Labels
42
5 Contents
Truck Type
E
5200
Attachment Data
SERI ES
Sideshifter - 100mm (4 in)
Serial Number
1234-5678
Load
Center
Display Panel Messages
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.
Capacity with Mast Vertical
600(24)
LE
MP
Capacity
1360(3000)
1590(3500)
332-001E
"KNOW THE HAZARDS"
Watch for and read these special blocks.
You will find information about
possible safety hazards and how to
avoid them.
PLE
SAM
5030(198)
3935(155)
SA
600(24)
600(24)
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.
11 Capacity & Load Center
Capacity & Load Center 12
What's in it for You? 6
Your Narrow-Aisle Truck
NARROW-AISLE TRUCKS
Your narrow-aisle rider truck lifts, moves and stacks loads.
It is designed to work in warehouses built with narrower
aisles to give maximum storage.
YOUR LIFT TRUCK IS NOT AN AUTOMOBILE
With a load it may weigh more than 3 automobiles.
• You don't steer the same.
• You don't brake the same.
• You don't accelerate the same.
FORK FUNCTIONS, STANDARD AND OPTIONAL
Raising and Lowering the forks, Tilt (up and down), and
Reach (in and out) are standard on the RR and RD models.
Included on all models may also be Sideshift (right and
left), or other options such as Rack Height Select. Your
company has decided which features are needed in your
work area and should train you how to use them.
HOW TO DRIVE YOUR TRUCK
Your truck is designed with a tilted floorboard and padding
in the operator area. Some models include a folding seat.
You drive your truck by standing or sitting sideways and
leaning back against the pads.This, along with your hands
on the controls and feet on the pedals/pad, gives you
stability. The controls are located so you can vary your
body position for best comfort and visibility.
GIVE YOUR BODY A BREAK
Take advantage of stop time. Flex your arms and legs.
Staying alert will help you be a better and safer driver.
7 Your Narrow-Aisle Truck
Stand
sideways
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
Hands on
controls
Lean back
against
cushion
Feet on
pedals/pad
Your Narrow-Aisle Truck 8
Lift Truck Parts
Power Disconnect
Multi-Task Handle
Mast
Overhead Guard
Key Switch
Display Panel
Switch Panel
Steering Tiller
PEDESTAL PEDALS:
Brake Pedal •
Center Brake Pedal •
Sensor Pedal •
Load Backrest
Entry Bar
Operator Cushion
Flip-Down Perch
Folding Seat
(on some models)
Battery
Fork
Load Wheels
FLOOR PEDALS:
Brake Pedal •
* Sensor Pad •
model trucks
* Earlier
are equipped with a
pedal instead of a
sensor pad on the
floorboard.
Drive Wheel
Caster Wheel
9 Lift Truck Parts
Lift Truck Parts 10
Capacity & Load Center
Center of evenly
distributed load
600mm
(24in) 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 forks to the center of an
evenly distributed load.
Know the Hazards
Units of measure, kg/mm(lb/in)
Truck Weight with Max. Battery
3325(7331)
RR
Mast Collapsed Height
Truck Type
2260(89)
E
5200
Attachment Data
SERI ES
Sideshifter - 100mm (4 in)
Serial Number
1234-5678
Load
Center
Capacity with Mast Vertical
600(24)
332-001E
PLE
Capacity
1360(3000)
1590(3500)
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.
LE
P
SAM
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.
5030(198)
3935(155)
SAM
600(24)
600(24)
EXCEEDING TRUCK CAPACITY CAN CAUSE AN ACCIDENT
Know the capacity of your truck as shown on your capacity
plate. Make certain you 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, stable and centered over the forks.
HYDRAULIC OPERATIONS CAN AFFECT STABILITY
Be careful when using reach, tilt, sideshift or other
operations. Remember that anytime the forks move, the
load moves also. This can affect stability. Perform all
hydraulic operations smoothly. (This also applies to any
attachments your truck may have.)
11 Capacity & Load Center
Capacity & Load Center 12
Capacity Plate
CAPACITY PLATE INFORMATION
The capacity plate is on a console in the
operator area. It contains:
• Serial number
• Capacity information (load, load center and lift height)
• Truck type (a fire safety rating)
• Truck weight with max. battery (does not include load)
• Attachment information (if any)
• Mast collapsed height
READING YOUR CAPACITY PLATE
Capacity may be reduced as lift height A increases.
For example: On the sample plate, 2040kg (4500 lb) can
be lifted to 6350mm (250 in). But above 6350 (250), to
7620 (300), capacity is reduced from 2040 (4500) to
1700 (3750).
Capacity is reduced as load center B increases. If you
must handle loads with longer load centers, an additional
capacity plate will show the reduced capacities.
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
3325(7331)
RR
Mast Collapsed Height
2260(89)
5200
PLE
SERI ES
SAM
Load
Center
600(24)
Truck Type
E
CAUTION
You may not increase capacity if load
center is less than shown on your
capacity plate.
Attachment Data
Sideshifter - 100mm (4 in)
Serial Number
1234-5678
Capacity with Mast Vertical
Capacity
1700(3750)
2040(4500)
332-001E
13 Capacity Plate
7620(300)
6350(250)
600(24)
600(24)
Note: ANSI B56.1 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.
TRUCK TYPE
Some truck types are not permitted in areas where there
are fire hazards. Watch for marked areas. For example:
You must not drive a type E or ES truck into 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.
MAST COLLAPSED HEIGHT
Some work areas may have overhead obstructions. Mast
Collapsed Height is the minimum height your truck can
clear, providing the backrest and load are lowered below
the top of the mast.
Capacity Plate 14
Display Panel with options
Display Panel standard
ADDITIONAL SERVICE BUTTONS
See your Service Manual for
instructions.
SERVICE AND OPTION BUTTONS
See your Service Manual for
instructions.
WRENCH LIGHT
A yellow light means something needs to be fixed. Report
the trouble to your supervisor.
STANDARD MESSAGE DISPLAY
See page 17 for typical messages.
ERROR LIGHT
A yellow light means you have tried to perform an operation
that is not permitted. Check the message display.
BATTERY CHARGE DISPLAY
The green bars show how much charge is left. Have the
battery changed or recharged if the yellow light is flashing.
FORK HEIGHT LIGHT (see Caution)
A yellow light means the load backrest is higher than the
collapsed height of the mast. Make certain the load and
load backrest will clear any obstructions above you.
The yellow light will flash and alarm will "beep" if you
travel faster than the load positioning speed (2.4 kmph,
1.5 MPH) while the load backrest is above the collapsed
height of the mast.
15 Display Panel standard
EXPANDED MESSAGE DISPLAY
See page 17 for typical messages.
FORKS DOWN LIGHT (see Caution)
The green light means the mast is at its minimum collapsed
height. Make certain the load and load backrest will also
clear any overhead obstructions.
CAPACITY DATA MONITOR (see Caution)
• Fork height lights: A yellow fork will light to show
which lift zone the forks are in. If any of these lights are
on, it means the load backrest is higher than the collapsed
height of the mast. Make certain the load and load backrest
will clear any obstructions above you.
The yellow light will flash and alarm will "beep" if you
travel faster than the load positioning speed (2.4 kmph,
1.5 MPH) while the load backrest is above the collapsed
height of the mast.
• Fork height lights: The green bars will light to show
how high, or to which lift zone you can raise a load.
• Overload warning: If the load is too heavy for the lift
zone the forks are in, the alarm will "beep" and the message
display will read CHECK LOAD
.
Caution: All information displayed by the fork position lights and/or the Capacity Data
Monitor is for reference only. You must always be alert to load center, load distribution,
load height and load weight. You must also be aware when the load or load backrest
extends above the top of the mast, and how much overhead clearance is needed.
Display Panel with options 16
Display Panel Messages
Switch Panel
AUDIO ALARM
Anytime you hear a "beep", something is wrong. Check the message display.
MESSAGE DISPLAY FOR STANDARD TRUCK
If your truck slows down or won't work, check the message display for instructions.
Standard
Message Display
What To Do
Optional Expanded
Message display
TEST
Check that the alarm, message display
and all lights are working.
LAMP TEST
FOOT
Both feet must be on the correct pedals/pad.
LEFT OR RIGHT PEDAL
HAND
Return the multi-task control handle to
neutral.
CENTER HANDLE
ENT
Remove your foot from the entry bar.
ENTRY BAR
DOOR
Make sure battery retainer is in place
and secure.
BATTERY DOOR
----
Enter your user code (PIN number).
USER CODE: / - - -
RCUT
Forks are at cutout height. Use the cutout
override switch to continue raising.
RAISE CUTOUT
CTR
During start-up, briefly move left foot
to the Center Brake Pedal.
CENTER PEDAL
DOME LIGHT SWITCH
FAN SWITCH (optional)
WORK LIGHT SWITCH (optional)
RAISE CUTOUT OVERRIDE SWITCH (optional)
Your truck may be equipped with automatic cutout of raise
at selected lift heights.
To raise past the cutout height, push the optional Raise
Cutout Override switch while, at the same time, lifting the
multi-task control handle (see page 29).
Caution: Make certain the load and load backrest will
clear all overhead obstructions.
ADDITIONAL MESSAGES FOR CAPACITY DATA MONITOR OPTION
If your truck has this option, the following messages can also be displayed.
Load is too heavy for the lift zone you
are operating in.
CHECK LOAD
Make sure the forks are not tilted all the
way up or down. If the problem continues,
notify your service department or supervisor.
MONITOR DISABLED
17 Display Panel Messages
Switch Panel 18
Adjusting the Seat & Controls
ADJUSTABLE SEAT & CONTROLS
Some models of the RR 5000S Series are equipped with
a folding seat, flip-down perch and adjustable controls.
Before using your truck, adjust the controls, backrest and
seat to their most comfortable operating positions.
Caution: Do not make any adjustments while the truck
is moving.
ADJUSTING THE STEERING TILLER HEIGHT
Push the yellow button to the right of the steering column,
and move the steering tiller to the most comfortable
operating position.
FLIP-DOWN PERCH
Flip the perch down to the horizontal position for extra
support in the standing position.
Flip the perch up to the vertical position when it is not
needed.
FOLDING SEAT
Lift the front edge of the seat up until it latches in the
horizontal position.
Squeeze the handle under the front of the seat to lower
the seat to the vertical position.
ADJUSTING THE MULTI-TASK CONTROL AND SEAT HEIGHT
Push down on the Orange lever next to the seat, and raise
or lower the backrest, armrest and seat unit to the most
comfortable operating position.
19 Adjusting the Seat & Controls
Adjusting the Seat & Controls 20
Power On & Off
KEY SWITCH
• To start the truck, turn the key clockwise to TEST
(yellow dot). Check that all display lights are working.
• Let go of the key and it will return to ON (green dot).
You must step on the center brake pedal on the pedestal
with your left foot. This allows the truck electronics to
check brake pedal operation before you drive the truck.
• When leaving the truck, turn the key counterclockwise
to OFF (red dot) to shut the truck off.
FOOT PEDALS/PAD
Place your right foot on either the pedestal sensor pedal
or the floorboard sensor pad*. Place your left foot on one
of the left brake pedals. If the key is turned ON, the
steering pump will start running and you can operate the
truck.
model trucks are equipped with a pedal instead
*of Earlier
a sensor pad on the floorboard.
USER CODE (PIN number)
You may have to enter a user code (Personal Identification
Number) before you can use the truck. Check the message
display if the truck doesn't operate.
ENTRY BAR
Always keep your feet in the operator area and clear of
the entry bar.
If you put your foot on the entry bar while traveling, the
alarm will sound and the truck will slow to a stop.
POWER DISCONNECT
Push the Power Disconnect button to cut power to the truck.
Use the Power Disconnect to shut the truck down any time
it isn't working right. Don't use the truck if it's not working
right. Report the problem to your supervisor.
Turn the key switch to OFF and back to ON to reconnect
the battery and reset the Power Disconnect button.
21 Power On & Off
Power On & Off 22
Foot Brake
BRAKE OFF
Step all the way down on either the floor brake pedal or
the left pedestal brake pedal. The brakes are now "off".
Know the Hazards
WATCH YOUR FEET
Keep your feet inside the truck and on the pedals/pad at
all times. This truck weighs about 3630 kg (8000 pounds)
even without a load on the forks. You cannot stop or
even slow down that much weight with your foot or any
part of your body, no matter how slow the truck is
moving.
A foot or hand caught between the truck and a wall, post
or any fixed object will be crushed or even cut off.
BRAKE ON
• Floor Brake Pedal
When operating with both feet on the floorboard, lift your
heel or move your foot off the floor brake pedal to apply
the brakes. Keep a part of your foot in contact with the
floorboard.
• Center Pedestal Brake Pedal
When operating with either foot on the pedestal, step on
the center pedestal brake pedal to apply the brakes.
23 Foot Brake
KEEP YOUR BALANCE WHILE STANDING
Put your hands on the controls and keep your feet on
either the floorboard or the pedestal. This, along with
leaning back against the cushion, gives you better
stability.
?
MAKE SURE YOUR BRAKES WORK
Test the brakes 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 drive the truck. Report any problem to
your supervisor.
Foot Brake 24
Traveling & Plugging
TRAVEL, POWER UNIT FIRST
Pull the multi-task handle toward you to travel
in the direction of the power unit (power unit
first).
The farther you pull the handle from the
neutral position, the faster the truck will
travel.
TRAVEL, FORKS FIRST
Push the multi-task handle away from you
to travel in the direction of the forks (forks
first).
The farther you push the handle from the
neutral position, the faster the truck will
travel.
PLUGGING
Plugging is another way to slow down or
stop your truck.
While the truck is moving, in either direction,
pull or push the multi-task handle through
neutral to the opposite direction of travel.
Plugging will not hurt your truck.
Pull the
multi-function
control
Travel,
power unit first
Travel,
forks first
Push the
multi-function
control
HORN
Press the button on the multi-task handle to sound the
horn. Use it to warn pedestrians and other drivers.
Use your horn when you come to an intersection or a
crosswalk.
Know the Hazards
PLUGGING VS. BRAKING
Of the two, the foot brake is designed to stop the truck in
the shortest distance. Use the foot brake in an emergency,
on ramps or in busy areas.
25 Traveling & Plugging
Traveling & Plugging 26
1
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.
27 Steering & Travel
2
ur t i o n
n
re
Di o f
Travel,
forks first
FRONT DIRECTIONAL STEERING (Sometimes called Forward Steering.)
Shows direction truck will turn when steering handle is turned clockwise.
Travel, power
unit first
i on
rn
Di
of r
Travel,
forks first
n
t io
ec ur n
T
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.
Travel, power
unit first
ec
Di r f T
o
TRUCKS THAT LOOK ALIKE CAN BE DIFFERENT
This style truck can be built with one of two different types
of steering. Your company has selected the type which is
best for your work area.
Caution: If you ever drive a different RR Series truck, be
careful. The steering may be different (see page 28).
REAR DIRECTIONAL STEERING (Sometimes called Reverse Steering.)
Shows direction truck will turn when steering handle is turned clockwise.
c
Tu t i o n
rn
STEERING AND DRIVING
You will need to drive your truck in
both the direction of the forks (forks first)
and also in the direction of the power unit
(power unit first or forks trailing). Steering is not
the same in both directions. Be careful. Drive slowly
until you get used to all the controls.
Two Types of Steering
D i re
of T ct
u
Steering & Travel
Two Types of Steering 28
Fork Functions
FORK FUNCTIONS
Standard fork functions include
Raising and Lowering the forks, Tilt (up and down),
and Reach (extend and retract).
1
Some optional fork functions your truck may be equipped
with are Sideshift (right or left), Rack Height Select which
allows the truck to be programmed so the forks will stop
at selected heights, and Tilt Position Assist to tilt the forks
to a programmed position.
RAISE/LOWER
Lift the multi-task handle up to raise the forks. Push down
on the handle to lower the forks.
The farther you move the multi-task handle from neutral,
the faster the forks will move.
RAISE CUTOUT OPTION
Your truck may be equipped with an automatic cutout to
prevent you from raising the forks into restricted areas.
RCUT
If raise stops, check the message display.
or
will show on the display if you
RAISE CUTOUT
are at a raise cutout height. See page 18 for using the
optional Raise Cutout Override Switch.
2
3
RACK HEIGHT SELECT OPTION
This option allows a truck to be programed so the forks
will stop at a selected height.
1. Press the UP ARROW button on the right side of the
display panel to activate the rack select option. The
message display will show R A C K S E L E C T
if at
least one lift height has been programed into the truck,
and your truck is equipped with this option.
2. Press the switch on the back of the multi-task handle
to scroll through the lift heights that have been programed
into the truck. The message display will show the height
in either millimeters or inches, along with the label
number for the height.
3. Make certain the path of the forks is clear. Lift and
hold the multi-task handle. The forks will stop and
there will be a one second beep when they reach the
programed height. Check to make certain the forks are
at the correct position before entering the rack or pallet.
Know the Hazards
CHECK THE PATH OF THE FORKS
Be just as careful raising the forks with the rack height
select option as when using manual raise. Make certain
the path of the forks is clear and free of obstacles.
Check that the forks are at the proper position to enter
the pallet, or that the pallet will clear the rack beam..
29 Fork Functions
Fork Functions 30
Fork Functions continued
THUMB BALL
All hydraulic fork functions, other than
raise & lower, are controlled by the multi-task thumb ball.
TILT UP & DOWN
Roll the thumb ball up to tilt the fork tips up. Roll the
ball down to tilt the fork tips down.
TILT POSITION ASSIST OPTION
With the thumb ball in neutral, press and hold the switch
on the back of the multi-task handle. Then roll the thumb
ball either up or down.
If your truck is equipped with this option, the forks will
go to the programed tilt position chosen by your company
for this truck.
FORK POSITION WILL VARY DEPENDING ON LOAD
The tilt of the forks and raised height of the forks will
change depending on how much load is on the forks.
Always check to see that the forks are at the correct tilt
position and lift height to enter a pallet, or that the pallet
and load will clear the rack beams.
Be just as careful when using programmed functions as
when operating the truck manually.
31 Fork Functions continued
REACH/RETRACT
Roll the thumb ball away from you to reach (extend) the
forks. Roll the ball toward you to retract the forks.
The farther you move the ball from neutral the faster the
forks will move.
This motion of the thumb ball will have a second function
if your truck has a sideshift option.
SIDESHIFT OPTION
With the thumb ball in neutral, press and hold the switch
on the back of the multi-task handle. Then roll the ball
away from you to shift the forks to the left (away from
you). Roll the ball toward you to shift the forks to the
right (toward you).
The farther you move the ball from neutral the faster the
forks will move.
Know the Hazards
CHECK FORK AND PALLET POSITION
The fork position will vary depending on whether the
forks are loaded or unloaded.
Make certain the forks are at the correct tilt position and
lift height to enter a pallet, or that the pallet and load will
clear the rack beams.
Fork Functions continued 32
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 battery is charged, water level
is OK and vent caps are in place. Don't use an open
flame to check the battery.
• Make certain the battery retainer is properly installed
and adjusted.
• See that all wheels are in good condition.
• Clean the safety glass.
• Check that both forks are secure and not bent, cracked
or badly worn.
• Inspect lift chains for damage.
• See that the load backrest and overhead guard are in
place and fastened.
• Look under the truck for signs of hydraulic leaks.
• Turn the key to TEST (yellow dot). See that all display
lights are working.
• Test the horn.
• Make sure the power disconnect works.
33 Daily Safety Check
2. Test drive your truck in an uncongested area.
• Try all the hydraulic functions.
• Check that the steering is easy and smooth.
• Drive the truck slowly in both directions.
• Drive through the full speed range in both forward
and reverse.
• Check braking and plugging distances 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 drive the truck.
If anything doesn't look or feel right, don't drive 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 34
Be a Safe Driver
The most
important
component
is you.
?
MAKE SURE YOU ARE READY TO DRIVE
• 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 drive the truck if you
have any doubts.
• Know the capacity of your truck (Load Weight, Load
Center and Lift Height). Make certain to 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 33 and 34).
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 brakes and plugging. Check at
a slow travel speed first, then a faster one. Know the
distance it takes to stop before you start work.
DRIVE CAUTIOUSLY, BE ALERT
• Never stick a foot or any part of your body outside the
operator area, no matter how slow the truck is moving.
You cannot stop 3680 kg (8000 pounds) with any part
of your body. A foot or hand caught between the truck
and a fixed object will be crushed or even cut off.
• Keep your hands on the controls and your feet on the
pedals/pad.
• 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.
• Travel with the forks close to the ground, retracted and
tilted up. Place the load against the load backrest
(vertical face of the forks).
• Look where you are going before you change direction
of travel.
• See that you have room to drive and turn. Always check
for overhead objects. 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.
Continued next page...
35 Be a Safe Driver
Be a Safe Driver 36
Be a Safe Driver 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 drive your truck toward anyone
standing in front of a fixed object.
• Never allow passengers 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.
• Have load backrest vertical (never tilt when elevated).
• 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.
37 Be a Safe Driver continued
AVOID FALLS AND TIPOVERS
• 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
driving.
• 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.
• Use minimum fork tilt to pick up or place a load. When
lifting or lowering outside a rack, keep the load backrest
vertical or tilted back slightly.
• When moving loads on grades or ramps, drive with
your forks pointed upgrade. Without a load, drive
with forks downgrade. Slow down, and don't turn on
grades or ramps.
LEAVING YOUR TRUCK
• Stop your truck completely before getting off.
• Lower the forks to the floor. Turn the truck off or push
the Power Disconnect button.
• Avoid parking on inclines. But if you must, block the
wheels of your truck.
Be a Safe Driver continued 38
Battery Maintenance
Know the Hazards
WHEN YOU INSTALL OR CHANGE BATTERIES
• Turn the truck OFF. Disconnect the battery.
Check that all controls are in neutral.
• Make certain you use the correct size and weight battery.
Never operate a truck that has an underweight or
undersized battery installed.
• Use a roller stand to install or remove a battery. Make
sure the roller stand is the same height as the rollers in
the truck's battery compartment. Also make sure the
roller stand is at least as long as your battery.
• Never let anything metal touch the top of the cells. You
could cause sparks or do damage to the battery. Use an
insulator (such as plywood) when necessary.
• Use an approved spreader bar to place a battery on, or
to remove it from a stand. Make sure you adjust the
spreader bar hooks to fit the battery.
AFTER INSTALLING YOUR BATTERY
• Replace the battery retainer.
• Make certain the battery retainer is properly adjusted to
prevent the battery from shifting.
• Connect the battery. Turn the truck ON and check
truck operation.
Batteries produce explosive gas.
Do not smoke, use open flame, or
create an arc or sparks near this
battery. Ventilate well in enclosed
areas and when charging.
Batteries contain Sulfuric Acid which
causes severe burns. Do not get in
eyes, on skin, or clothing. In case of
contact, flush immediately. Get medical
attention if your eyes are affected.
107
WARNING
Minimum battery size allowed
XXX mm (XX.XX in.) wide
XXX mm (XX.XX in.) long
Undersize battery can affect truck
handling and stability. You could have
an accident.
Use U.L. classified Type EO battery.
39 Battery Maintenance
TRUCK BATTERIES CAN BE DANGEROUS
Your truck battery produces fumes that can explode.
It also contains acid that could burn or disfigure you.
• Do not try to install, remove, charge or service your
truck battery unless you are trained and authorized.
• Never smoke or use an open flame around batteries.
• 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.
BEFORE CHARGING YOUR TRUCK BATTERY
• See that the battery cells are filled to the proper level.
Never use an open flame to check the battery.
• Read the battery charger instructions and make certain
the charger is the same voltage and amperage as your
battery.
• Be sure the charger is turned OFF before connecting the
battery to the charger. Otherwise you might create a
spark which could cause the battery to explode.
BATTERY SIZE
Use the correct size and weight battery. Never operate a
truck with an underweight or undersized battery installed.
BATTERY RETAINERS
The battery could slide out if retainers are not in place.
Check both sides of the truck.
Truck operation can be affected if the battery is able to
shift. Make certain the battery retainers are properly
adjusted.
Battery Maintenance 40
Notes
Warning Labels
EACH WARNING LABEL
ON YOUR TRUCK IS IMPORTANT
Read and obey all of them to protect
yourself and others.
WARNI NG
Connect charger
properly or truck
can be damaged.
Make certain
charger is plugged
into the battery
connector, not the
truck connector.
Stay clear of all
moving parts.
Lifting people without
Moving parts cana proper platform can
cause a fall and
cut or crush hands,
serious injury.
feet, arms or legs.
Platform must be built
and used as specified
in OSHA 1910.178
and ANSI-B56.1.
WARNI NG
Minimum battery size allowed
Standing or riding on the forks can
cause a fall. You can be seriously
injured or killed.
Falling objects or lowering forks can
cause serious injury or death.
Never stand under the forks.
XXX mm (XX.XX in.) wide
XXX mm (XX.XX in.) long
Undersize battery can affect truck
handling and stability. You could have
Never stand or ride on forksan accident.
for any reason.
Use U.L. classified Type EO battery.
While servicing, block the forks so
they won't fall.
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
169
All rights reserved under International
and Pan American copyright conventions
Copyright 2001 Crown Equipment Corp.
41 Notes
Warning Labels 42