Crown TR 4500 Operator Manual for Tractor Trailer

Crown TR 4500 Operator Manual for Tractor Trailer
Operator Manual
Power Steer
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 on or off.
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 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 2008 Crown Equipment Corp.
1Warning
You Must be Trained 2
Protect Yourself
Know the Hazards
DRIVE CAREFULLY
• When allowing the truck to coast, travel power unit
first only. Do not turn. Keep to the side of the truck.
Make certain the truck won't hit the back of your leg
or foot. Don't let the truck run over your foot.
• When riding, keep your hands on the controls and
feet on the platform. Keep your body within the
operator area.
• Don't put hands or arms over the backrest.
• Never stick a foot or any part of your body outside
the truck, no matter how slow the truck is moving.
You cannot stop 900 kg or (2,000 lbs) 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.
• Never place objects anywhere on the operator
platform. They would be a trip hazard and could
affect truck speed.
• 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.
• Perform all truck movements smoothly and at a
speed that will give you time to react in
an emergency.
3 Protect Yourself
Know the Hazards
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 fixed objects, or by objects intruding or
poking into the operator area.
When allowing the truck to coast, make certain the
area ahead of you is clear.
AVOID FALLS
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. Unless you can safely
jump completely clear of the falling truck, there is no
sure way to avoid injury if you drop from a dock or
dockboard.
Be extremely careful when working around docks,
dockboards and trailers.
WARNING
Stay clear of all
moving parts.
Moving parts can
cut or crush hands,
feet, arms or legs.
USE YOUR TRUCK SAFELY
• Keep your hands and feet away from all moving parts such as coupler or wheels.
• Never allow passengers anywhere on the truck.
There is no safe place for them.
• Before you leave your truck:
• Come to a complete stop.
• Shut the truck off with the key or disconnect the battery.
• Make certain the brake is applied and the truck will not coast.
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 Tow Tractor 7
Tow Tractor Parts 9
Capacity Plate
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.
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.
11
Display13
Power On & Off 14
Steering & Travel 15
Know the Hazards
DANGER
Coasting17
Braking 19
Traveling & Plugging
21
Daily Safety Check
25
Be a Safe Driver
27
Battery Maintenance
31
Warning Labels
34
5Contents
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.
"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.
31
What's in it for You? 6
Your Rider Tow Tractor
RIDER TOW TRACTOR
As a rider your truck to is designed to tow loads over
long distances. You can also use it as a walk-beside
truck when picking stock.
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.
YOUR TOW TRACTOR IS NOT AN AUTOMOBILE
It may weigh more than an automobile, even without
a load.
• You don't steer the same.
• You don't brake the same.
• You don't accelerate the same.
HOW TO DRIVE WHEN COASTING
• Travel power unit first only. Do not turn. Stay
to one side of the truck. Use the hand closest to the
truck to operate the control handle.
• Watch your feet. Stay out of the path of the truck.
• Make certain the area ahead of you is clear.
HOW TO DRIVE YOUR TRUCK WHILE RIDING
Keep both feet on the platform. Place both hands on
the control handle. Keep your entire body within
the operator area.
BUILT TO STANDARDS
Hands on
controls
Lean against
the backrest
This truck was designed and
built to current industry and
government standards and
guidelines. For more
information see the following:
• American National Standards
Institute (ANSI/ITSDF B56.1)
• Occupational Safety and
Health Act (OSHA)
§1910.178, Rev. 1999
• Underwriters Laboratory
(UL 583)
• National Fire Prevention
Association (NFPA 505)
Feet on
platform
7 Your Rider Tow Tractor
Your Rider Tow Tractor 8
Tow Tractor Parts
Control Handle
Hand Holds
Key Switch
(On power unit)
Power Disconnect
Horn Button (underside, hidden in view)
Travel Speed Switch
Platform
Battery Retainer
Forward/Reverse Rockers
Brake Button
Forward/Reverse Rockers
Horn Button (underside, hidden in view)
9 Tow Tractor Parts
Tow Tractor Parts 10
Capacity Plate
CAPACITY PLATE INFORMATION
The capacity plate is on the top of the
power unit cover. It contains:
• Capacity information
• Truck type (a fire safety rating)
• Truck weight
• Maximum grade rating
• Battery information
• Truck information
SAMPLE CAPACITY PLATE
The information
shown on this sample
plate does not apply
to your truck.
WHAT IS YOUR TRUCK CAPACITY?
Capacity of your truck is shown as Normal Drawbar
Pull. (For normal conditions, 225N or 50lbs of
drawbar pull is required to tow 905kg or 2000 lbs).
See the capacity plate on your truck.
KNOW YOUR LOAD
Do not exceed the capacity (normal drawbar pull) shown
on your truck's capacity plate. Make certain you use the
correct units of measure. Do not tow unstable loads.
TR4540-200
Note: ANSI B56.1 requires that
all data be shown first in Metric
units and then USA units.
11 Capacity Plate
Know the Hazards
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.
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 battery and the
load you are towing.
Capacity Plate 12
Power On & Off
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.
MESSAGE PANEL
Displays truck information such as: hours of operation,
event codes along with instructions, battery charge
and other data.
PERFORMANCE SETTING
Indicates the level that your company has
programmed this truck to operate at.
ENTER OR RETURN BUTTON
Use to navigate in and out of menus and select
inputs.
KEY SWITCH
Turn the truck on by turning the key clockwise to ON.
Check that all display lights are working.
Turn the truck off by turning the key counterclockwise
to OFF.
Always turn the key off when leaving the truck.
POWER DISCONNECT
Pull up on the battery connector, or the optional handle,
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.
NAVIGATION BUTTONS
Up, Down. Left and Right Arrows are used to
scroll through menus.
EVENT CODE LIGHT (OPERATOR CORRECTABLE)
The display light shows a detected event which the
operator can correct. See the display for instructions.
EVENT CODE LIGHT (SERVICE REQUIRED)
The display shows the code for a detected event
which requires service. Contact your supervisor or
service department.
13Display
Power On & Off 14
Steering & Travel
Dire
of T c
Travel,
coupler first
n
tio n
ur
n
tio n
ur
Dire
of T c
Travel, power
unit first
STEERING WHILE WALKING OR COASTING
Anytime the operator is off the platform, steering is
reduced to 15º each way of center.
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.
STEERING AT HIGH TRAVEL SPEED
When the travel speed switch is in the
high travel speed position ( ), steering
is set to 60˚ each way of center for smooth
operation at higher travel speeds.
Know the Hazards
POWER UNIT SWING
Be careful turning while traveling coupler end first.
The power unit will swing wide in the opposite
direction. Make sure you have clearance, and watch
out for people in the area.
Keep your hands and feet in the operator area.
Warning: Never place objects anywhere on the operator
platform. They would be a trip hazard and could
affect truck speed and steering.
STEERING AT MANEUVER SPEED
When the travel speed switch is in the
low travel speed position ( ), 90˚ of
steering each way of center is available
for maneuvering in confined spaces.
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.
15 Steering & Travel
Steering & Travel 16
Coasting
WHEN WALKING OR COASTING
• Travel power unit first only. Do not turn.
COASTING
Coasting can make it easier for you to pick
loads while walking to the side of the truck.
The ability to coast is standard. The coasting
distance can be adjusted by your service personnel.
• Stay to the side of the truck and load. Keep your arm extended to give
maximum clearance between you and the truck or load. Keep your feet clear.
When you let go of the forward and reverse rocker the
brake is partially applied to allow the truck to coast to
a controlled stop.
• Make sure the area ahead of you is clear.
Note: When you are off the platform, travel
is always in low speed, and steering is
reduced to +/- 15 degrees.
However you can apply the brake by pressing the
brake button on the control handle.
Be even more careful when allowing the truck to coast.
Make sure you understand the possible hazards. Don't
place yourself or others at risk.
When moving from the riding position to the walk
beside or coast position, stop your truck completely
before getting off.
Never get on or off the truck while it is moving.
WHEN RIDING
Stop your truck before getting on or off.
Know the Hazards
COASTING REQUIRES EVEN MORE CAUTION
• Floors must be level and free of obstacles.
• Never allow the truck to coast into a cross aisle.
• Do not coast in pedestrian walkways.
• Watch out for people and other trucks.
• Do not walk in the path of a coasting truck. Stay to the side of the truck and load. Keep your
arm extended and your feet clear.
• When coasting, travel power unit first only. Do not turn.
• Always stop your truck before getting on or off.
17Coasting
Coasting 18
Braking
BRAKING
To apply the brake, press the brake button on the end
of the control handle. The truck will continue to brake
to a stop even if the brake button is released.
PARKING BRAKE
The parking brake is automatically applied when the
key switch is turned off, the battery is disconnected or
after the truck comes to a stop.
The parking brake is released when the Forward/
Reverse rocker is moved in the direction of travel.
This page
left blank
Intentionally.
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 drive the truck Report any
problem to your supervisor.
SIMILAR LOOKING TRUCKS CAN BE DIFFERENT
Your company has selected the options which are best
for your work area.
If you ever drive a different truck, even one that looks
just like yours, be careful. It may not have the same
controls, functions, or options.
19Braking
Braking 20
Traveling & Plugging
HORN
Push the switch on the underside of either grip to
sound the horn. Use it to warn pedestrians and
other drivers.
TRAVEL
Move the Forward/Reverse rocker.
in the direction you want to travel.
Use your horn when you come to an intersection or
a crosswalk.
The farther you move the rocker from the neutral
position, the faster the truck will move.
HIGH TRAVEL SPEED
For high travel speed, turn the travel speed switch to
the high speed position (
), and move the Forward/
Reverse rocker to the maximum travel speed position.
Steering performance is set at 60˚ each way of center
for smooth operation at higher speeds.
MANEUVERING SPEED
For maneuvering and traveling in congested areas, turn
the travel speed switch to the low speed position ( ).
The display message panel will show
90˚ of steering each way of center is available for
maneuvering in confined areas.
.
PLUGGING
Plugging is another way to slow down your truck.
While the truck is moving, in either direction, move
either Forward/Reverse rocker through neutral to the
opposite direction of travel.
Plugging will not hurt your truck.
21 Traveling & Plugging
Know the Hazards
WATCH YOUR FEET AND HANDS
• While riding, keep your feet on the platform and
hands on the controls at all times. This truck
weighs over 900kg or (2000 lbs.). You cannot stop
or even slow it down with your foot, hand or any part
of your body, no matter how slow the truck is moving.
• When coasting, keep out of the path of the truck
and load. Travel power unit first only. Do not turn.
LOOK WHERE YOU'RE GOING
• Always be alert to the area around you and watch where you are driving.
• Any part of your body caught between the truck or load, and any fixed object, can be crushed.
• You could also be seriously injured by objects
intruding or poking into the operator area.
• Don’t put hands or arms over the backrest.
BRAKING VS. PLUGGING
Of the two, braking is designed to stop the truck in the
shortest distance. Use braking in an emergency, on
ramps or in busy areas.
Traveling & Plugging 22
This page
left blank
Intentionally.
Know the Hazards
SIMILAR LOOKING TRUCKS CAN BE DIFFERENT
Your company has selected the options which are
best for your work area.
If you ever drive a different tractor, even one that
looks just like yours, be careful. It may not have the
same control handle, functions, or other options.
Operation and performance may vary.
23
24
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.
2. Test drive your truck in an uncongested area.
•To check power steering: Turn the truck on. Step onto the platform. Steering should be difficult for a second and then become easier.
•Check to make sure the battery is charged.
•Drive the truck slowly in both directions.
•After checking water level, be sure vent caps are in
place. Don't use an open flame to check the battery.
•Check braking distance in both directions. Load size
and floor conditions can affect these distances.
•Drive through the full speed range in both directions.
•Make certain the battery retainers on both sides of the
truck are properly installed.
•See that all wheels are in good condition.
•Clean the control handle and hand holds.
•Make certain there are no objects placed
anywhere on the operator platform.
•Be sure the coupler is working properly.
•Look under the truck for signs of oil leaks.
•Try the horn.
•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.
•Check parking brake operation.
If anything doesn't look, work 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. OF3772). Used properly, this checklist can alert
service people to needed repairs.
•Make sure the power disconnect works.
•Check that all controls work smoothly.
25 Daily Safety Check
Daily Safety Check 26
Be a Save Driver
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. 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 25
and 26). 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.
• Make certain there are no objects stored anywhere
on the operator platform. They would be a trip
hazard and could affect truck speed and steering.
WHEN COASTING
•Travel power unit first only. Do not turn.
•Stay to the side of the truck and load. Keep your
feet clear.
•Be certain the area ahead of you is clear.
WHEN RIDING
• Never stick a foot or any part of your body outside the operator area, no matter how slow the truck is
moving.
• Don't put your hands or arms over the backrest.
Keep your hands on the controls and feet on the
platform.
• Never ride on any part of the truck other than the
operator platform.
• Stop your truck before getting on or off.
DRIVE CAUTIOUSLY, BE ALERT
• Look where you are going. Don't let any part of your
body get pinned or crushed. Don’t get caught
between the truck, or load, and a fixed object.
• Travel in the direction that gives you the best view.
Slow down in congested areas.
• Slow down for wet or slippery floors. Don't run over
things.
• Look where you are going before you change
direction of travel.
• Avoid sudden movement of controls. Learn to use
them smoothly at a moderate, even rate.
• Be extra careful if you must use your truck in an
area where there is a risk of falling objects.
Continued on next page...
27 Be a Safe Driver
Be a Safe Driver 28
Right
Be
a Safe
Header
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
•Be even more careful moving a wide load. Make
certain you or someone around you doesn’t get
pinned or crushed. Have a helper or “spotter” assist
you.
•Keep others away from your truck while you're
working. Don't ever allow anyone to ride on
anything being towed.
•Don't let anyone use your truck unless they are
trained and certified.
•Don't allow the truck to coast in a congested area or
if there are people in the aisle.
•Watch out for power unit swing. Slow down when
making turns.
•Never allow passengers on your truck.
Left Header
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 driving.
•Make sure the load you are towing is stable.
•Don't drive 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 come to a complete stop.
BE CAREFUL TRAVELING ON RAMPS AND GRADES
• Always operate your truck from the rider position
when traveling on a grade.
• With or without a towed load, going upgrade or
downgrade, always travel power unit first.
Slow down and don't turn on ramps or grades.
WHEN LEAVING YOUR TRUCK
• Turn the truck off or disconnect the battery.
• Apply the parking brake and make certain the truck
will not coast.
• Avoid parking on inclines. But if you must, make sure you apply the parking brake and block the wheels of your truck.
29 Be a Safe Driver continued
Be a Safe Driver continued 30
Battery Maintenance
WHEN YOU INSTALL OR CHANGE BATTERIES
• Turn the truck OFF. Brake applies automatically when truck is turned OFF. Check that all controls are
in neutral and disconnect the battery. Press the button on the side of the steer column and pivot the handle out of the way before removing the battery.
• Make certain you use the correct size and weight battery. Never operate a truck that has an underweight or undersize battery installed.
• Never let anything metal touch the top of the cells. You could cause sparks or do damage to the battery. Use an an insulator (such as plywood) when necessary.
• Use an approved spreader bar to place a battery in, or remove it from, the battery compartment or a stand. Make sure you adjust the spreader bar hooks to fit the battery.
USING A ROLLER STAND
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.
AFTER INSTALLING YOUR BATTERY
• Replace the battery retainers. Make certain the retainers on both sides of the truck are in place.
• Connect the battery. Turn the truck ON and check
truck operation.
31 Battery Maintenance
Know the Hazards
DANGER
TRUCK BATTERIES CAN BE DANGEROUS
Your truck battery produces gas 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.
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.
• 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.
BATTERY RETAINERS MUST BE IN PLACE
The battery could slide out if retainers are not in place.
Check that both retainers are installed before operating
your truck.
Battery Maintenance 32
Right Header
Battery
Maintenance continued
Left
Header
Warning
Labels
EACH WARNING LABEL
ON YOUR TRUCK IS IMPORTANT
Read and obey all of them to protect
yourself and others.
BEFORE CHARGING YOUR TRUCK BATTERY
• Charge the battery only in areas designated for
that use.
• Make sure the truck key switch is turned off and all other controls are in the off or neutral position.
• See that the battery cells are filled to the proper
level.
Never use an open flame to check the battery.
• Make certain the charger is the same voltage and
amperage as your battery.
• Read the battery charger instructions.
• 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 IS IMPORTANT
Make certain you use the correct size, type and weight of
battery. Never operate a truck that has an underweight
or undersize battery installed.
0Protect
33
Battery Maintenance continued
WARNING
Stay clear of all
moving parts.
Moving parts can
cut or crush hands,
feet, arms or legs.
DANGER
Propane gas can cause a fire or even an explosion.
Do not try to install, remove, refill or service a propane
cylinder unless you are trained and authorized.
Never smoke or have an open flame around propane.
See mounting bracket for allowable cylinder size.
Locating pin must fit through hole in cylinder collar to
maintain proper position.
If gas odor is detected or frost appears, turn off engine,
close cylinder valve and contact supervisor or service
department.
971-A
All rights reserved under International
and Pan American copyright conventions
Copyright 2008 Crown Equipment Corp.
Protect 34
0
Warning Labels
4500 SERIES
This operator manual
has
information
for
all models of series
TR
4500
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
© 2011
PF18783 Rev. 03/12 Printed in U.S.A.
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