Crown Equipment SR 5200 Automobile User Manual

SR
5200 SERiES
This
operator
has
information
all
models
of
Operator Manual
manual
for
series
SR 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
© 2005
PF14590-WEB Rev. 6/06
Printed in U.S.A.
SR
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.
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 2006 Crown Equipment Corp.
1 Warning
You Must be Trained 2
Protect Yourself
Know the Hazards
Know the Hazards
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: End-control rider trucks, such as this SR, are not
like center-control 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.
DRIVE CAREFULLY
• Keep your hands on the controls and feet on the pedals.
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 4400 kg (9700 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.
• 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.
• 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.
• 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.
Stay clear of all
moving parts.
Moving parts can
cut or crush hands,
feet, arms or legs.
07
USE YOUR TRUCK SAFELY
• Keep your hands and feet away from all moving parts
such as masts, chains, forks or wheels. Make sure
the load backrest is 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.
3 Protect Yourself
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 Rider-Reach Truck
7
Lift Truck Parts
9
Capacity & Load Center
11
Capacity Plate
13
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
3680 (8110)
SR
Mast Collapsed Height
4252 (167.4)
Load
Center
5200
Truck Type
E
Attachment Data
SERI ES
Serial Number
Load
Display Panel
15
Center
17
Power On & Off
19
Switch Panel
20
Braking & Horn
21
Traveling & Plugging
23
Steering & Travel
24
Fork Functions
25
Daily Safety Check
29
Be a Safe Driver
31
Battery Maintenance
35
Warning Labels
38
5 Contents
1234567890
Capacity with Mast Vertical
Capacity
1250(2750) 10832(427) 600 (24)
1250(2750) 9152 (360) 600 (24)
2000(4500) 7205 (283) 600 (24)
502-B
Adjusting the Steering & Seat
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"
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.
11 Capacity & Load Center
What's in it for You? 6
Your Rider-Reach Truck
RIDER-REACH TRUCKS
Your rider-reach truck is designed to lift, move and stack
loads.
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 sit the same.
FORK FUNCTIONS, STANDARD AND OPTIONAL
Raising and Lowering the forks, Tilt (fork tips up or down),
Reach (extend or retract the mast), Sideshift (right or
left), and Rack Height Select are standard on the SR
model. Your company may select other options as needed
in your work area, and should train you how to use them.
HOW TO DRIVE YOUR TRUCK
Your truck is equipped with a multi-adjustable seat.
You drive your truck by sitting sideways and leaning back
into the seat. This, along with your hands on the controls
and feet on the pedals or floorboard, 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 Rider-Reach Truck
Sit
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
into seat
Feet on
pedals or
floorboard
Your Rider-Reach Truck 8
Lift Truck Parts
Switch Panel
Steering Wheel
Direction Switch
Display Panel
Power Disconnect
Mast
Adjustable Seat
Battery Release Lever
Load Wheels
Drive Wheel
Horn
Accelerator Pedal
Brake Pedal
Adjustable Steering Column
Power Pedal
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
3680 (8110)
SR
Mast Collapsed Height
4252 (167.4)
5200
Truck Type
E
Attachment Data
SERI ES
Serial Number
Load
Center
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.
1234567890
Capacity with Mast Vertical
Capacity
1250(2750) 10832(427) 600 (24)
1250(2750) 9152 (360) 600 (24)
2000(4500) 7205 (283) 600 (24)
502-B
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. 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 the corner support,
close to the steering wheel. 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, 1210kg (2670 lb) can
be lifted to 9155mm (360 in). But above 9155 (360), to
11435 (450), capacity is reduced from 1210 (2670) to
600 (1325).
SAMPLE
CAPACITY PLATE
The information
shown on this
sample plate
does not apply to
your truck.
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.
Units of measure, kg/mm(lb/in)
Truck Weight with Max. Battery
3680 (8110)
SR
Mast Collapsed Height
4252 (167.4)
Truck Type
E
5200
Attachment Data
SERI ES
Sideshifter-100mm (4 in)
Serial Number
Load
Center
1234567890
Capacity with Mast Vertical
Capacity
1250(2750) 10832(427) 600 (24)
1250(2750) 9152 (360) 600 (24)
2000(4500) 7205 (283) 600 (24)
CAUTION
You may not increase capacity
if load center is less than
shown on your capacity plate.
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. Make certain to use the correct units of
measure. 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.
502-B
13 Capacity Plate
Capacity Plate 14
Display Panel
DRIVE WHEEL DIRECTION INDICATOR
TRAVEL DIRECTION INDICATOR
BATTERY CHARGE DISPLAY
The green bars show how much
charge is left. Have the battery
changed or recharged if the yellow
light is flashing.
PERFORMANCE LEVEL
Access to this setting is determined by your
company.
WRENCH LIGHT
A yellow light means something needs to be fixed.
Report the trouble to your supervisor.
PARKING BRAKE LIGHT
A red light means the parking brake is applied.
STEERING SYSTEM ERROR
Check the message panel.
LOW BRAKE FLUID LEVEL LIGHT
ERROR LIGHT
A yellow light means you have tried to perform an operation
that is not permitted. Check the message display.
MESSAGE PANEL (see page 16)
CAPACITY DATA MONITOR (see page 16)
SERVICE AND OPTION BUTTONS
Your employer will instruct you on the use of these buttons. A PIN may be required.
15 Display Panel
CAPACITY DATA MONITOR (see Caution below)
• 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.
• Lift 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". Check the
message display.
FORKS DOWN LIGHT (see Caution below)
The green fork means the mast is at its minimum collapsed
height. Make certain the load and load backrest will also
clear any overhead obstructions.
MESSAGE PANEL
Anytime you hear a “beep”, or if the truck slows down
or won’t work, check here for instructions, or to identify
the problem area.
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 16
Adjusting the Steering & Seat
BEFORE YOU DRIVE
Adjust the steering wheel and operator
seat to their most comforable positions.
ADJUSTABLE STEERING WHEEL & SEAT
Your SR is equipped with an adjustable steering wheel
and a multi-adjustable seat.
Before using your truck, adjust the steering wheel and
seat to their most comfortable operating positions.
Caution: Do not make any adjustments while the truck
is moving.
ADJUSTING THE STEERING WHEEL
Push the button on the left of the steering column, and
move the steering wheel to the most comfortable
operating position.
Before driving the truck, make certain the steering column
is latched and won’t move.
SEAT ADJUSTMENTS
You can adjust your seat 3 ways for comfort:
• Forward & Back
• Backrest Angle
• Operator Weight
ADJUSTING THE SEAT FORWARD & BACK
Lift the lever on the left side of the seat, and slide the
seat forward or back to the most comfortable operating
position.
Before driving the truck, make certain the seat is latched
and won’t move.
BACKREST ANGLE
Lift the lever at the front of the seat, and move the bottom
of the backrest forward or back to the most comfortable
operating position.
Before driving the truck, make certain the backrest is
latched and won’t move.
OPERATOR WEIGHT
You can adjust the seat suspension for operator weight
between 50 kg (110 lb), and 130 kg (287 lb).
• Don’t sit on the seat while making this adjustment.
• Pull the lever away from the seat as far as it will go,
then release. This resets the lever to 50 kg.
• Pull the lever again until you can read the desired
weight setting on the lever.
17 Adjusting the Tiller & Seat
Adjusting the Steering & Seat 18
Power On & Off
Switch Panel
KEY SWITCH
• To start the truck you must be seated, with both feet
on the floorboard (not on any of the pedals), and all
controls in neutral.
• Turn the key clockwise to ON (green dot). Check that
all display lights are working.
• When leaving the truck, turn the key counterclockwise
to OFF (red dot) to shut the truck off.
USER CODE (PIN number)
A user code (Personal Identification Number) may be
required. Your company will issue it to you and instruct
you on its use.
POWER DISCONNECT
Push the power disconnect button down 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.
Pull the power disconnect button up to reconnect the
battery.
POWER PEDAL
Push the power pedal with your left foot. If you are
properly seated and the key is turned ON, the steering
pump will start running and you can operate the truck.
WORK LIGHT SWITCH (optional)
FLASHING 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, pulling
the raise/lower lever toward you (see page 25).
Caution: Make certain the forks, load and load backrest
will clear all overhead obstructions.
If you remove your foot from the power pedal while
driving, power is cut to all truck operations except for
braking and steering.
19 Power On & Off
Switch Panel 20
Braking & Horn
Know the Hazards
FOOT BRAKE
Step down on the brake pedal to apply the brake. The
harder you step down, the harder the braking will be.
WATCH YOUR FEET
Keep your feet inside the truck and on the pedals at all
times. This truck weighs about 4400 kg (9700 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.
PARKING BRAKE ON
Push the bottom of the parking brake switch to apply
the parking brake.
The red brake icon on the display will light whenever
the parking brake is applied.
Always apply the parking brake when you leave the
truck.
PARKING BRAKE OFF
Push the top of the parking brake switch to release the
parking brake.
HORN
Press the button on the travel-direction switch to sound
the horn. Use it to warn pedestrians and other drivers.
Use your horn when you come to an intersection or a
crosswalk.
21 Braking & Horn
?
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.
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.
Braking & Horn 22
Traveling & Plugging
Steering & Travel
TRAVEL DIRECTION AND SPEED
Move the direction control toward the mast
to travel forks first. Move the control away from
the mast to travel power unit first (forks trailing).
STEERING AND DRIVING
Steering is not the same in both directions. Be careful.
Drive slowly until you get used to all the controls.
When you sit down in the seat, the direction control must
be placed in neutral before you select a travel position.
While the truck is moving, in either direction, select the
opposite direction of travel. Use the accelerator to
control how quickly you slow down. Plugging will not
stop your truck as fast as using the foot brake.
Travel, power
unit first
ur t i o n
n
re
Di o f
Travel,
forks first
2
io
n
rn
Di r
of
n
t io
ec u r n
T
Travel, power
unit first
D i re
of T ct
u
Plugging does not hurt your truck.
1
ec
Dir f T
o
PLUGGING
Plugging is another way to slow down or stop your truck.
c
Tu t i o n
rn
TRUCKS THAT LOOK ALIKE CAN BE DIFFERENT
This style truck can be built with one of two different
types of steering(see below).
Step down on the accelerator to control travel speed.
The farther you push it down, the faster the truck will
go.
Travel,
forks first
REAR DIRECTIONAL STEERING
(Also called Reverse Steering.)
Shows direction truck will turn
when steering handle is turned
clockwise.
FRONT DIRECTIONAL STEERING
(Also called Forward Steering.)
Shows direction truck will turn
when steering handle is turned
clockwise.
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.
Caution: If you ever drive a different SR Series truck, be
careful. The steering may be different.
23 Traveling & Plugging
Steering & Travel 24
Fork Functions
RACK HEIGHT SELECT OPTION
This option allows a truck to be programed so the forks will stop at a
selected height.
FORK FUNCTIONS
Standard fork functions include:
Raising and Lowering the forks, Tilt (fork tips up or down),
Reach (extend or retract the mast), Sideshift (right or
left), and Rack Height Select which allows the truck to
be programmed so the forks will stop at selected heights.
Your employer will instruct you how to use the service and option
buttons to access this option. A PIN may be required.
Make certain the path of the forks is clear. Pull the raise/lower lever
toward you. The forks will stop and there will be a one second “beep”
when they reach the programmed height. Check to make certain the
forks are at the correct position before entering the rack or pallet.
Your company may select additional optional fork
functions for your truck.
RAISE/LOWER
Pull the raise/lower lever toward you to raise the forks.
Push the lever away from you to lower the forks.
The farther you move the lever away from neutral, in
either direction, the faster the forks will move.
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.
RAISE CUTOUT OPTION
Your truck may be equipped with an automatic cutout
to prevent you from raising the forks into restricted areas.
Check that the forks are at the proper position to enter
the pallet, or that the pallet will clear the rack beam.
See page 20 for using the optional Raise Cutout Override
Switch.
Caution: Make certain the forks, load and load backrest
will clear all overhead obstructions.
WARNI NG
WATCH OUT FOR THE MOVING MAST
Any part of a body caught between the moving mast
and the truck could be pinned or crushed.
Stay completely out of this area at all times. Never allow
anyone else to be in this area.
Moving mast can pin or crush
your head, hands, or arms.
Stay completely out of this
area at all times.
25 Fork Functions
Fork Functions 26
Fork Functions continued
TILT UP & DOWN
Pull the tilt lever toward you to tilt the fork tips up. Push
the lever away from you to tilt the fork tips down.
REACH/RETRACT
Push the reach lever away from you to reach (extend)
the mast. Pull the lever toward you to retract the mast.
The farther you move the lever away from neutral, in
either direction, the faster the forks will move.
The farther you move the lever away from neutral, in
either direction, the faster the forks will move.
TILT POSITION ASSIST OPTION
If your truck is equipped with this option, and it is turned
on, the forks will stop at the programed tilt position.
To tilt farther, repeat the tilt lever motion.
SIDESHIFT
Pull the sideshift lever toward you to move the forks to
the right. Push the lever to move the forks to the left.
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.
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.
27 Fork Functions continued
Fork Functions continued 28
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.
• 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 is in place and fastened.
• Look under the truck for signs of hydraulic leaks.
• Turn the key to ON (green dot). See that all display
lights are working.
• Test the horn.
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.
• Make sure the power disconnect works.
29 Daily Safety Check
Daily Safety Check 30
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 29 and
30). 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 4400 kg (9700 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 or floorboard.
• 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...
31 Be a Safe Driver
Be a Safe Driver 32
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.
• Watch out for power un it swing.
• 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.
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 and before getting off.
• Lower the forks to the floor.
• Apply the parking brake.
• Turn the truck off or push the Power Disconnect button.
• Avoid parking on inclines. But if you must, block the
wheels of your truck.
33 Be a Safe Driver continued
Be a Safe Driver continued 34
Battery Maintenance
Know the Hazards
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
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.
REMOVING THE BATTERY FOR SERVICE
• Retract the mast all the way, and lower the forks.
• Push down on the battery lever. The battery is now
connected to the mast.
• Fully extend the mast. The battery will move with the
mast.
• Switch off the truck and remove the key.
• Disconnect the battery from the truck.
CHARGING YOUR BATTERY
• Connect the battery to the proper charger.
• Follow the directions on the battery and the battery
charger.
• 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.
WARNING
Minimum battery size allowed
XXX mm (XX.XX in.) wide
XXX mm (XX.XX in.) long
BATTERY SIZE
Use the correct size and weight battery. Never operate
a truck with an underweight or undersized battery
installed.
Undersize battery can affect truck
handling and stability. You could have
an accident.
Use U.L. classified Type EO battery.
Continued next page...
35 Battery Maintenance
Battery Maintenance 36
Battery Maintenance continued
CHANGING YOUR BATTERY
• Loosen the battery retainer clamp. Lift and remove the
retainer.
• Never let anything metal touch the top of the cells.
You could cause a spark or do damage to the battery.
Use an insulator (such as plywood) when necessary.
• If you 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.
• Use an approved spreader bar to place a battery on,
or remove it from, the truck or a stand. Make sure you
adjust the spreader bar hooks to fit the battery.
• When replacing the battery, make certain you use the
correct size and weight battery. Never operate a truck
that has an underweight or undersized battery installed.
• Replace the battery retainer and tighten the retainer
clamp.
RETURNING YOUR BATTERY
• Connect the battery to the truck.
• Fully retract the mast, moving the battery into the
battery compartment. You should hear the battery
latch unhook.
• Extend the mast and make certain the battery remains
in the battery compartment.
Warning Labels
EACH WARNING LABEL
ON YOUR TRUCK IS IMPORTANT
Read and obey all of them to protect
yourself and others.
WARNING
It’s the law,
you must be
trained and
certified to
operate this
truck.
(OSHA § 1910.178, Rev. 1999)
CAUTION
Connect charger
properly or truck
can be damaged.
You or people around
you could be seriously
injured or even killed if Make certain
you don't use this truck charger is plugged
into the battery
correctly.
connector, not the
Obey all instructions & truck connector.
warnings in the operator
WARNING
manual and on the truck.
Stay clear of all
Avoid being
moving parts. WARNING
crushed.
Keep head,
Moving parts canLifting people without
cut or crush hands,
arms, hands,
a proper platform can
WARNING
feet, arms or legs.cause a fall and
legs, and feet
serious injury.
within the operator area.
Platform must be built
WARNING
Stop truck completely
and used as specified
before getting off.
in OSHA 1910.178
WARNING
and ANSI-B56.1.
However,
tipovers and
falls from docks
can cause
Moving mast can pin or crush
WARNING
your head, hands, or arms.
serious injury or even
Stay
completely
death. Immediately exit
Standing or riding on the forks can Minimum battery
size
allowed out of this
cause a fall. You can be seriously
area at all times.
and move away from
XXX mm (XX.XX in.) wide
injured or killed.
XXX mm (XX.XX in.) long
the truck in these
Falling objects or lowering forks can
Never stand or ride on forks
Undersize battery can affect truck
emergencies. cause serious injury or death.
for any reason.
handling and stability. You could have
Never stand under the forks.
an accident.
You can be
Use U.L. classified Type EO battery.
While servicing, block the forks so
trapped
theyor
won't fall.
crushed by
Batteries can produce explosive gas. Do not
objects
smoke, use open flame, or create an arc or sparks
protruding into the
near this battery. Ventilate well when in an enclosed
area and when charging.
operator area. Look
where you are going.
This battery contains Sulfuric Acid which causes
severe burns. Do not get in eyes, on skin, or clothing.
Inspect your truck before
In case of contact, flush immediately and thoroughly
with water. Get medical attention if your eyes are
starting work, make sure
affected.
it’s in good working order.
* Additional copies of the
Operators Manual and Truck
Labels can be obtained from:
Crown Equipment Corp.
New Bremen, OH 45869
20
549-A
All rights reserved under International
and Pan American copyright conventions
Copyright 2006 Crown Equipment Corp.
37 Battery Maintenance continued
Warning Labels 38
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