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.