Operator Manual - Crown Equipment Corporation
Contents
1. e See that the battery cells are filled to the proper level Never use an open flame to check the batteries e Check that the charger is the same voltage and amperage as the battery Read the battery charger instructions e Be sure the charger is turned OFF before connecting the battery to the charger Otherwise a spark could cause the battery to explode Also make sure the truck key switch is turned off and all controls are in neutral Battery Maintenance 28 Warning Labels EACH WARNING LABEL ON YOUR TRUCK IS IMPORTANT Read and obey all of them to protect yourself and others It s the law you must be trained and certified to operate this truck OSHA 1910 178 Rev 1999 You or people around you could be seriously injured or even killed if you don t use this truck correctly Minimum baitery size allowed 000 mm 00 00 in wide 000 mm 00 00 in long Undersize battery can affect truck i ity You could have warnings in the og manual and on thg Stay clear of all Lifting people without ae moving parts a proper platform could cause a fall or other serious injury Platform must be built ified Tilting mast forward when forks are raised and loaded can tip the truck over causing injury or death Do not tilt elevated load forward _ oY unless it is over a stack Falls from docks can _ cause serio CF injury2. accelerator to control how quickly you slow down Plugging will not stop your truck as fast as using the foot brake LOOK WHERE YOU RE GOING Plugging does not hurt your truck Travel in the direction that gives you the best view 19 Traveling amp Plugging Traveling amp Plugging 20 Daily Safety Check CHECK YOUR TRUCK BEFORE STARTING WORK You must make sure your truck is safe to use 1 Walk around your truck and check it over e Check to make sure the battery is charged and vent caps are in place Check water level weekly Don t use an open flame to check the battery e Inspect battery cables and connectors for damage or corrosion e Be certain the battery retainer is properly installed e See that all wheels are in good condition e Check that both forks are secure and not bent cracked or badly worn e Inspect all lift chains for damage e See that the load backrest is in place and secure when required e Look under the truck for signs of leaks e Inspect the seat belt for wear e Turn the key to ON Check the display e Test the horn e Make sure you can read the capacity plate 21 Daily Safety Check 2 Test drive your truck in an uncongested area e Adjust the operator seat and steering wheel to their most comfortable positions e Fasten your seat belt e Try all the hydraulic functions e Check that the steering is easy and smooth e Drive the truck slowly in both directions e Dr
3. or eve You can tip this truck over if you turn too sharply for the conditions seatbelt fastened hq around you Don t risk injury or on and brace your f death in these emergencie You could b e pinned or Falling objects or lowering forks can cause serious injury or death within the operato Stop truck complete before getting off Passengers could be seriously injured There is no safe place for them to ride Slow down when turning DANGER Batteries can produce explosive gas Do not smoke use open flame or create an arc or sparks near this battery Ventilate well when in an enclosed area and when charging crushed by objects intruding or poking into the operator area Look where you are going Inspect your truck before starting work make sure its in good working order This battery contains Sulphuric Acid which causes severe burns Do not get in eyes on skin or Standing or riding on the forks can clothing In case of contact flush immediately and cause a fall You can be seriously thoroughly with water Get medical attention if your mjurgdor kiled X Hold on tight Brace feet All rights reserved under International and Pan American copyright conventions Copyright 2006 Crown Equipment Corp ver stand or ride on forks any reason In case of tip over Follow these instructions 29 Notes Warning Labels 3
4. truck e 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 23 Bea Safe Driver DRIVE CAUTIOUSLY BE ALERT e Adjust the seat and mirror e Fasten your seat belt and pull it snug e Never stick an arm or any part of your body outside the operator area no matter how slow the truck is moving A hand or foot caught between the truck and a fixed object will be crushed or even cut off e Keep your hands on the controls and your feet by the pedals e Travel in the direction that gives you the best view Look where you are going and slow down in congested areas e Slow down for wet or slippery floors Don t run over things e Travel with the forks close to the ground and tilted up Place the load against the load backrest vertical face of the forks e Look where you are going before you change direction of travel e See that you have room to drive and turn Always check for overhead objects e Slow down when making turns e Avoid sudden movement of controls Learn to use them smoothly at a moderate even rate e Check clearances before raising or lowering the forks or load e Be extra careful if you must use your truck in an area where there is a risk of falling objects Continued next page Be a Safe Driver 24 Be a Safe Driver continued WATCH OUT FOR OTHER PEOPLE e Slow down Yield
5. 0
6. 100 4 5 i 7 OF 1360 3000 4825 190 600 24 1430 3150 4370 172 600 24 Serial Number Truck Type 1090 2400 4825 7190 760 30 12345678 E von 1145 2520 4370 172 760 30 f measure Pay attention to e Wei e Load center e Lift height e Position of mast CENTER THE LOAD Your truck could tip over if a load is shifted to the front or side of a pallet or container Make sure your load is evenly distributed and centered over the forks HYDRAULIC OPERATIONS CAN AFFECT STABILITY Capacities shown on your capacity plate are with the mast vertical Be extra careful when tilting a load This also applies to other accessories or attachments your truck may have such as sideshift carton clamp push pull etc Capacity amp Load Center 12 Capacity Plate SAMPLE CAPACITY PLATE The information shown on this sample plate does not apply to your truck S00 SERIES Serial Number 12345678 13 Capacity Plate CAPACITY PLATE INFORMATION The capacity plate is on the overhead guard It contains e Truck serial number e Capacity information load load center and lift height e Truck type a fire safety rating e Truck weight with battery does not include load e Attachment information Cif any READING YOUR CAPACITY PLATE Capacity may be reduced as lift height increases For example On the sample plate 1405kg 3100 Ib can be lifted to 4370mm 172 in But above 4370 172 to 4825
7. 190 capacity is reduced from 1405 3100 to 1360 3000 Capacity is reduced as load center increases For example On the sample plate 1405kg 3100 lb can be lifted if the load center is 600mm 24 in But if the load center is increased to 760mm 30 capacity is reduced from 1405 3100 to 1145 2520 Caution You may not increase capacity if load center is less than shown on your capacity plate 1 4360 3000 4825 190 _600 24 a 1430 3150 4370 172 600 24 46936 Law avai E aY aT ws wave F aY a Wayan AE ER CAM eat BIE 6 Units of measure kg mm b in 3 eee pe with Mast Pa iy O q wy l pyuyV oTUY TUS SY i VU YY 620 4 1145 2520 4370 177 _ 760 30 Note ANSI ITSDF B56 1 requires that all data be shown first in Metric units and then USA units OTHER LIFT HEIGHTS AND LOAD CENTERS Contact Crown for capacities at lift heights or load centers not given on your capacity plate ven must aa sie a Mire E or ES nai into an area restricted to EE or EX trucks ATTACHMENT DATA If an attachment on your truck does not match the information given on your capacity plate don t operate your truck Your capacity plate may be wrong Report the problem to your supervisor Capacity Plate 14 Power On amp Off 15 Power On amp Off KEY UP e Turn the key clockwise to TEST yellow dot Make certain the display is working e Let go of the key and it will return to ON green dot e Tur
8. A 4 S00 SERIES 2e Vv Crow D New Bremen Ohio 45869 USA 2006 PF14704 WEB Printed in U S A You Must be Trained 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 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 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 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 You could be killed or seriously injured if you are not adequately trained for lift truck operation You can be trapped or crushed by objects protruding or poking into the operator area Look where you are going Inspect your truck before starting work make sure it is in good working o
9. afety 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 What s in it for You 6 Your Sit Down Rider SIT DOWN RIDERS Your sit down rider truck lifts and stacks loads It is also BUILT TO STANDARDS designed to move loads over long distances This truck was designed and built to current industry and government YOUR RIDER TRUCK IS NOT AN AUTOMOBILE standards and guidelines For more With a load it may weigh more than 3 automobiles and Ora HON See eon OnNS the steer wheels are in the rear instead of the front e American National Standards Institute ANSI ITSDF B56 1 FORK FUNCTIONS STANDARD AND OPTIONAL reared ae een me Standard fork or hydraulic functions are Raising and a o K E Lowering the forks plus Tilting the mast Accessories S E ES E E such as Sideshift or Carton Clamp may also be included 599 serge ee Your company has decided which features are needed e National Fire Prevention in your work area and should train you how to use them Association NFPA 505 HOW TO DRIVE YOUR TRUCK Sit down fasten your seat belt and pull it snug Adjust the seat and steering wheel to their most comfortable positions Keep your hands on the controls and your entire body inside the operator area Look in the direction you are going Hands on controls Seated Seat Belt Fastened GIVE YOUR BODY A BREAK Ta
10. e 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 a A 07 Stay clear of all moving parts Moving parts can cut or crush hands feet arms or legs Ay Know the Hazards AVOID FALLS AND TIPOVERS Tipovers are very serious accidents You can be crushed or even killed if you try to jump clear of an overturning or falling center control truck Keep your seat belt fastened grip the steering wheel tightly brace your feet and push yourself back between the side restraints The best way to prevent injury is know where you are at all times and follow the rules of safe truck operation e Be extremely careful when working around docks dockboards and trailers e Use forward tilt only when you have the load in a rack over a stack or close to the floor e 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 e An unloaded truck can tip over also Be just as careful using an unloaded truck as you are a loaded one USE YOUR TRUCK SAFELY e Keep your hands and feet away from all moving parts such as chains wheels or mast Make sure the load backrest is in place when required e Never stand on or under the forks or allow anyone else to stand on or under them The only way to l
11. e moving is stable Spread forks as far as you can and center the load Insert forks as far under the load as you can Be even more careful with long high or wide loads They can be less stable e Use forward tilt only when you have the load in a rack over a stack or close to the floor Use minimum fork tilt to pick up or place a load When lifting or lowering outside a rack keep the mast vertical or tilted back slightly e When moving loads on grades or ramps drive with forks pointed upgrade Without a load drive with forks downgrade Slow down Don t turn on grades or ramps Don t raise the mast while on a grade or ramp LEAVING YOUR TRUCK e Stop your truck completely before getting off e Lower the forks to the floor Turn the truck off or disconnect the battery e Avoid parking on inclines But if you must block the wheels of your truck Be a Safe Driver continued 26 A Ni j WHEN YOU INSTALL OR CHANGE A BATTERY e Turn the truck OFF and check that all controls are in neutral Disconnect the battery Tilt the steering wheel up and raise the battery cover Remove the side cover and battery retainer e Make certain you use the correct size and weight battery Never operate a truck that has an underweight or undersized battery installed e 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 your truck s battery compartment Als
12. en bars show how much reei is left Have the battery changed or recharged if the yellow light is flashing MESSAGE DISPLAY Displays truck information such as hours of operation event codes along with instructions battery charge and other data BATTERY RETAINER LIGHT OPTION A red light will come on if the battery retainer is not properly installed BATTERY o GATE OPEN displayed BOO PERFORMA oP SERVICE amp OPTION BUTTONS See Service Manual for instructions PERFORMANCE SETTING Indicates the level that your company has programmed this truck to operate at EVENT LIGHT OPERATOR CORRECTABLE A yellow light will come on when there is a detected event which the operator can correct See the message display for instructions SERVICE LIGHT SERVICE REQUIRED A yellow light will come on when there is a detected event which requires service Contact your supervisor or service department Braking SERVICE BRAKE Step down on the brake pedal to apply the brakes The harder you step down the harder the braking will be PARKING BRAKE The parking brake is automatically applied after the truck comes to a stop Avoid parking on inclines But if you must block the wheels of your truck Step down firmly on the service brake pedal to release the parking brake AKnowthe nazaras A A d dl to your supervisor AVOID PARKING ON INCLINES Block the wheels of your truck if you must park on an incli
13. ift people is with an approved platform Never allow passengers on the truck There is no safe place for them e Before you leave your truck Come to a complete stop lower forks to the floor and shut the truck off with the key or power disconnect Protect Yourself 4 Contents Warning You Must be Trained Protect Yourself Contents What s in it for You Your Sit Down Rider Lift Truck Parts Capacity amp Load Center Capacity Plate Power On amp Off Raise Lower Tilt amp Accessories Display Braking Traveling amp Plugging Daily Safety Check Be a Safe Driver Battery Maintenance Notes Warning Labels 5 Contents O N AHA UU W N UJ Capacity amp Load Center M s 11 Capacity amp Load Center What s in it for You Capacity amp Loa 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 KNOW THE HAZARDS Watch for and read these special blocks You will find information about possible s
14. ive through the full speed range in both forward and reverse e Check braking and plugging distances in forward and reverse Load size and floor conditions can affect these distances e 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 22 Be a Safe Driver MAKE SURE YOU ARE READY TO DRIVE e Do not use this truck unless you are trained and certified e Be certain you understand how your truck works and the hazards that go with it Don t drive the truck if you im por tant have any doubts e Know the capacity of your truck Load Weight Load com po ne nt Center and Lift Height Make certain you use the correct units of measure The most j s VOU e Some trucks are not allowed in areas where there are y j fire hazards Be certain your truck is the correct fire safety type for the area e Make sure your hands and shoes are clean and dry and your clothing is proper for the job MAKE SURE YOUR TRUCK IS READY e Inspect your truck before using it see pages 21 and 22 If it s not working right or something is broken report the problem to your supervisor Don t use the
15. ke advantage of stop time Flex your arms and legs Staying alert will help you be a better and safer driver 7 Your Sit Down Rider Your Sit Down Rider 8 Lift Truck Parts 9 Lift Truck Parts Hydraulic Levers Display Accelerator Pedal Key Switch Service Brake Pedal Horn Steering Wheel Tilt Lever Direction Control Steer Wheels Tilting Mast Overhead Guard Seat Seat Belt Seat Adjust Lever Battery Cover Latch Load Backrest Power Unit Battery Disconnect Battery Drive Wheels Forks Lift Truck Parts 10 Capacity amp Load Center Center of evenly 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 distributed load 600mm 24 in Max of measure sow Center WHAT IS LOAD CENTER distributed load container 11 Capacity amp Load Center Load center is the distance from the load backrest or vertical face of the fork to the center of an evenly 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 of 3 Truck Weight with Max Battery Load Units of measure kg mm b in t 3290 7250 i e Capacity with Mast Vertical N Attachment Data J Center KOCE A N a Sideshifter
16. n key counterclockwise to OFF red dot to shut the truck off Always turn key to OFF when leaving truck TO BEGIN TRAVEL AFTER KEY UP e Place direction control in neutral e Step down firmly on the service brake pedal then release POWER DISCONNECT Pull the battery connector up to disconnect the battery and 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 Raise Lower Tilt amp Accessories Raise Lower lever standard Tilt lever standard Accessory lever optional HYDRAULIC LEVER OPERATION Pull the lever toward you away from the mast and you ll get the action shown by the symbol in the top of the lever Push the lever away from you toward the mast and you ll get the opposite action The farther you move the handle from neutral the faster the action will be w For example Pull the Raise Lower lever toward is t you to raise the forks as shown by the symbol Push the lever away from you to lower the forks Note The left side of each lever has a different shape to help you identify the lever by feel also applies to other accessories or attachments your truck may have such as sideshift carton clamp push pull etc Ai Raise Lower Tilt amp Accessories 16 17 Display Cnown BATTERY CHARGE STATUS The gre
17. ne Braking 18 Traveling amp Plugging BEFORE YOU DRIVE Adjust the operator seat and steering wheel to their most comfortable positions HORN Press the center of the steering wheel to sound the horn Use it to warn pedestrians and other drivers Fasten your seat belt and pull it snug Use your horn when you leave an aisle or come to a TO BEGIN TRAVEL AFTER KEY UP crosswalk or intersection e Place direction control in neutral e Step down firmly on the service brake pedal then release TRAVEL DIRECTION AND SPEED 7 a A 7 4 J Move the direction control lever away from you toward the mast to travel forks first Move the control toward you away from the mast to travel power unit first forks trailing Use the accelerator on the floor to control travel speed The farther you push it down the faster the truck will go If the truck will not move check the message display e RETURN TO NEUTRAL means the direction control must be put in neutral e DEPRESS BRAKE PEDAL means the brake pedal must be depressed firmly to release the parking brake 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 PLUGGING Plugging is another way to slow down or stop your truck While the truck is moving in either direction select the opposite direction of travel Use the
18. o make sure the roller stand is at least as long as the battery e 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 e Use an approved spreader bar to move a battery to or from the battery compartment or stand Make sure you adjust the spreader bar hooks to fit the battery AFTER INSTALLING YOUR BATTERY e Replace the battery retainer and side cover e Lower and latch the battery cover e Connect the battery e Return the steering wheel to a comfortable position Turn the truck ON and check truck operation 27 Battery Maintenance DANGER 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 Minimum battery size allowed 000 mm 00 00 in wide 000 mm 00 00 in long Undersize battery can affect truck handling and stability You could have an accident Use U L classified Type EO battery BATTERY SIZE AND WEIGHT IS IMPORTANT Make certain you use the correct size and weight battery Never operate a truck that has an underweight or undersized battery installed BEFORE CHARGING YOUR TRUCK BATTERY
19. or stop for pedestrians Use your horn when you come to a crosswalk or Intersection e 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 e Watch out for power unit swing e Never allow passengers on your truck e Keep others away from your truck while you re working Don t ever allow anyone on or under the load or forks e Don t let anyone use your truck unless they are trained and certified e Never lift anyone with the forks unless they are using an approved platform Even then use extreme caution e Use a securely attached and approved safety platform e Make certain lifting mechanism is operating properly e Have mast vertical never tilt when elevated e Make certain direction control lever is in neutral e Lift and lower slowly e Watch for overhead obstructions e Be sure you can see and hear the person being lifted e Never transport anyone on the platform from one location to another 25 Bea Safe Driver continued AVOID FALLS AND TIPOVERS e Stay with your truck Don t jump from a moving or falling sit down truck e Stay away from the edge of docks and ramps e 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 e Make sure the load you ar
20. rder 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 Ay Know the Hazards 3 Protect Yourself WEAR YOUR SEAT BELT Falling from a truck can cause serious injury or even death e Fasten your seat belt and pull it snug before operating your truck Keep it fastened until you leave the truck e Stay with your truck Don t jump from an overturning or falling center control rider truck Note This is not like end control rider trucks where it is recommended that the operator exit the truck in these emergencies DRIVE CAREFULLY e Never stick your foot hand head or any part of your body outside the operator area no matter how slow the truck is moving Anything caught between the truck and a fixed object will be crushed or even cut off e 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 e 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 LOOK WHERE YOU RE DRIVING e Always b
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