Crown Equipment Walkie Lift Truck WR Series User's Manual
Contents
1. 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 apron etc BATTERY RETAINERS The battery could slide out if battery retainers are not in place Check both sides of the truck BATTERY SIZE Make certain you use the correct size and weight battery Never operate a truck that has an underweight or undersized battery installed BEFORE CONNECTING YOUR BATTERY Be sure the block Crown 77034 is bolted to the back of the battery half of the connector Without that block the Power Disconnect won t work In an emergency you will not be able to cut power to the truck Make certain the truck key switch is turned off and all controls are in the off or neutral position Continued next page Battery Maintenance 28 Battery Maintenance continued Warning Labels li BATTERY CHARGE METER OPTION The lighted bar shows how much charge is left in your battery A flashing light will warn you that the battery is getting low Two flashing lights mean you must have the battery changed or recharged EACH WARNING LABEL ON YOUR TRUCK IS IMPORTANT Read and obey all of them to protect yourself and others Stay clear of all moving parts Moving parts can c2. Additional copies of this Operator Manual and all Truck Labels can be obtained from Crown Equipment Corporation New Bremen Ohio 45869 U S A 2 2 All rights reserved under International and Pan American copyright conventions Copyright 1997 Crown Equipment Corp 1 Warning You Must be Trained 2 Protect Yourself A Know the Hazards h N B SL Recommended 4 Walking Path 3 Protect Yourself LOOK WHERE YOU RE GOING Always be alert to the area around you and watch where you are driving Be careful that you don t get pinned or crushed between the truck and a fixed object such as a wall or post USE YOUR TRUCK CAREFULLY Watch your hands and your feet A foot or hand caught between the truck and a fixed object will be crushed or even cut off Keep to the side of the truck while traveling power unit first Make certain the truck won t hit the back of your leg or foot Don t let the truck run over your foot If traveling forks first keep both hands on the control handle and be careful when changing direction of travel Keep your feet clear of the truck Keep your truck under control at all times Operate at a speed that allows you to stop safely Be even more careful on slippery or uneven surfaces Do not run over objects on the floor Perform all truck movements smoothly and at a speed that will giv
3. HYDRAULIC LEVER OPERATION Move the lever away from the mast toward the control arm and you ll get the action shown by the symbol on the top of the knob Move the lever toward the mast and you ll get the opposite action The farther you move any lever from neutral the faster the forks will move For example Move the Raise Lower lever Tj away from the mast toward the control arm to raise the forks Move the lever toward the mast to lower the forks Or Move the optional Reach lever away from 2 the mast to retract the forks or toward the mast to reach or extend the forks RAISE amp LOWER PUSH BUTTONS OPTION For convenience single speed push buttons may be installed on the control handle Push either the Raise or Lower button until the forks are at the desired height 17 Fork Functions Steering amp Travel 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 A 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 SLOW DOWN FOR SPILLS OR WET FLOORS Powder or liquid spills can cause slippery floo
4. pallet or container Make sure your load is evenly distributed and centered over the HYDRAULIC OPERATIONS CAN AFFECT STABILITY forks Be careful when using reach tilt or other hydraulic operations Remember that any time the forks move the load moves also This can affect stability Perform all operations smoothly This also applies to any attachments your truck may have CENTER THE LOAD Your truck could tip over in any direction if a load is shifted to the front or side of a pallet or container Make certain your load is centered and evenly distributed 11 Capacity amp Load Center Capacity amp Load Center 12 Capacity Plate fe CAPACITY PLATE INFORMATION The capacity plate is on the power unit cover It contains OTHER LIFT HEIGHTS amp LOAD CENTERS Contact Crown for capacities at lift heights or load centers Serial number not given on your capacity plate Capacity information load load center and lift height Truck type a fire safety rating Truck weight with battery does not include load Attachment information if any READING YOUR CAPACITY PLATE Capacity may be reduced as lift height A increases For example On the sample plate 1360kg 3000 Ib can be lifted to 3910mm 154 in But above 3910 154 to Know the Hazards onal 4520 178 capacity is reduced from 1360 3000 to PLATE
5. 1135 2500 TRUCK WEIGHT Dockboards elevators and some floors have limited capacity Check your capacity plate for the weight of your truck Remember to add the weight of the load you have Capacity is reduced as load center B increases For example On the sample plate 1360kg 3000 Ib can The information shown on this sample plate be lifted if the load center is 600mm 24 in But if the i does not apply load center is increased to 685 27 capacity is reduced on the forks Make certain you use the correct units of to your truck from 1360 3000 to 1200 2650 measure Units of measure kg mm b in CAUTION TRUCK TYPE 1790 3945 9 3 Some truck types are not permitted in areas where there TEZI You may not increase capacity if luck load centet ie lace than shown are fire hazards Watch for marked areas For example a ora X p You must not drive a type E or ES truck in an area restricted Attachment Data our capacit late CLAMP ev y pacity p to EE or EX trucks a Serial Number A1234567 o ATTACHMENT DATA ETT i If an attachment on your truck does not match the Capacity 1135 2500 4520 178 600 24 1360 3000 3910 154 600 24 1000 2200 4520 178 685 27 1200 2650 3910 154 685 27 13 Capacity Plate Note ANSI B56 1 requires that all data be shown first in Metric units and then USA units information given here on your capacity plate don t operate your truck Your capacity plate may be
6. AN M ii WA y This operator manual has information for all models of series W and WR plus some options and accessories Some of the illustrations and information may not The most j tant apply to your truck importan component is you cng ll ry New Bremen Ohio 45869 USA 1997 PF12460 WEB Rev 6 06 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 It s the law you must be trained and certified to operate this truck OSHA s 1910 178 Rev 1999 Do not operate this truck in your work place until you have been trained and certified by your employer 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 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 You could be killed or seriously injured if you are not injury or even death Make sure you are safe adequately trained for lift truck operation Inspect your truck before starting work make sure it is in good CS working order
7. Make sure you adjust the spreader bar hooks to fit the battery AFTER INSTALLING YOUR BATTERY Replace the battery retainer Make certain the retainers on both sides of the truck are in place Be sure the block 77034 is bolted to the back of the battery half of the connector Connect the battery Turn the truck ON and check truck operation 27 Battery Maintenance A 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 XXX mm XX XX in wide XXX mm Xx Xx in long Undersize battery can affect truck handling and stability You could have an accident Use U L classified Type EO battery Attach block 77034 to Emergency disconnect Battery Connector lever will not work if block 77034 isn t bolted to the battery half of the connector Never use a battery without the block in place A Know the Hazards 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
8. afe Operator The most important component is you MAKE SURE YOU ARE READY T 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 use 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 nspect 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 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 23 Bea Safe Operator USE CAUTION BE ALERT Watch where you re walking Don t let any part of your body get pinned or crushed between the truck and a fixed object Stay to the side of the truck when traveling power unit first Make sure the truck won t hit your leg or run over your foot When traveling forks first keep both hands on the
9. ances and operate in areas with limited space YOUR LIFT TRUCK IS NOT AN AUTOMOBILE With a load it may weigh more than 2 automobiles You don t steer the same You don t brake the same You don t accelerate the same HOW TO OPERATE YOUR TRUCK Forks First When traveling forks first use both hands to operate the control handle Watch your feet if you change direction of travel Power Unit First When traveling power unit first stay to one side of the truck and slightly ahead of the power unit Use the hand closest to the truck to operate the control handle Watch your feet Stay out of the path of the truck 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 Hand on the control Walk to the side Feet clear of the truck Your Walkie Lift Truck 8 Lift Truck Parts ee 9 Lift Truck Parts Load Backrest Optional on W Reach WR only Mast Fork EEE Hose Reel wr only Control Handle Control Arm Power Disconnect Tilt Lever WR only Reach Leve
10. control Be careful when changing direction Keep your feet clear of the truck Travelin 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 Watch out for rough floors Travel with the forks close to the ground plus retracted and tilted back on the WR Place the load against the load backrest or 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 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 Be extra careful if you must use your truck in an area where there is a risk of falling objects Never ride on your truck Continued next page Be a Safe Operator 24 Be a Safe Operator continued it WATCH OUT FOR OTHER PEOPLE Slow down Yield or stop for pedestrians Use your horn when you come to a crosswalk or intersection Be careful that you don t pin or crush someone For example Never drive your truck toward anyone standing in front of a fixed object Never allow anyone to ride on your truck Keep others away from your truck while you re working Don t ever allow anyon
11. e on or under the load or forks Don t let anyone use your truck unless they are trained and certified Watch out for power unit swing 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 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 WHEN LEAVING YOUR TRUCK Lower the forks to the floor Turn the truck off or disconnect the battery Avoid parking on inclines But if you must block the wheels of your truck 25 Bea Safe Operator continued 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 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 With the model WR use minimum fork tilt to pick up or place a load When lifting or
12. e you time to react in an emergency A Know the Hazards AVOID FALLS AND TIPOVERS Tipovers and 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 Be extremely careful when working around docks dockboards and trailers Stay away from the edge of docks and ramps Make sure dockboards are secure Check that trailer wheels are chocked Travel with the load or forks close to the ground and tilted back on the WR Watch for overhead obstructions Perform all truck movements smoothly and at a speed that will give you time to react in an emergency An unloaded truck can tip over also You must be just as careful using an unloaded truck as you are using a loaded one 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 standard on the WR is in place and secure 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 ride on the truck or allow anyone else to ride There is no safe place to sit or stand Before you leave your truck Lower the forks to the floor Shut the truck off with the key or disconnect the battery Protect Yourself 4 Contents Warning You Must be Trained Pro
13. lowering outside a rack keep the load backrest vertical or tilted slightly back Don t take your truck onto an elevator unless you are authorized Check the capacity or load limit and make sure there are no people present Enter forks first and set the brake BE CAREFUL TRAVELING ON RAMPS AND GRADES Stay out of the path of the truck With or without a load drive with the forks pointed downgrade If a load requires that you travel with the forks upgrade be even more careful Operate the controls from the side of the truck Slow down and don t turn on ramps or grades Be a Safe Operator continued 26 Battery Maintenance WHEN YOU INSTALL OR CHANGE A BATTERY Turn the truck OFF Check that all controls are in neutral Make certain you use the correct size and weight battery Never operate a truck that has an underweight or undersized battery installed Use a roller stand to install or remove a battery Make sure the roller stand is the same height as the rollers in the truck s battery compartment Also make sure the roller stand is at least as long as your battery Never let anything metal touch the top of the cells You could cause sparks or do damage to the battery Use an insulator such as plywood when necessary Use an approved spreader bar to place a battery on or remove it from a stand
14. ou 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 See that all wheels are in good condition Check that both forks are secure and not bent cracked or badly worn Inspect lift chains for damage Clean the safety shield and keep it clear Clean the twist grips See that the load backrest is in place and secure if your truck has that option Look under the truck for signs of hydraulic leaks Try the horn Make sure the power disconnect works Check that all controls work smoothly 21 Daily Safety Check 2 Test drive your truck in an uncongested area Try all the hydraulic functions Check the steering Operate the truck slowly in both directions Operate through the full speed range in both forward and reverse Check braking distance 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 use the truck If anything doesn t look work or feel right don t use 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 S
15. r wr only Raise Lower Lever Key Switch Battery Power Unit Load Wheels Twist Grip Lower Button optional Raise Button optional Horn Button Reversing Button High Travel Speed Button Lift Truck Parts 10 H Capacity amp Load Center iN WHAT IS YOUR TRUCK CAPACITY E a Capacity is the load including pallet or l Genter ofevenly container that can be lifted to a given height A Know the Hazards dm at a given load center See the capacity plate on your truck Make certain you use the correct units KNOW YOUR LOAD of measure ma Do not exceed the capacity shown on your truck s capacity 24 Max WHAT IS LOAD CENTER plate Be careful when handling long high or wide loads si Load center is the distance from the load backrest or Do not handle unstable loads Center vertical face of the fork to the center of an evenly Be distributed load S S i g a EXCEEDING TRUCK CAPACITY CAN CAUSE AN ACCIDENT a e a Know the capacity of your truck as shown on your capacity plate Use the correct units of measure Pay attention to e Weight of load LOADS MUST BE EVENLY DISTRIBUTED Load eonte Your truck could tip over if a load is shifted to the Lift height front or side of a
16. rs 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 Steering amp Travel 18 Traveling 19 Traveling TRAVEL Rotate the top of the twist grip in the direction you want to travel The farther you rotate the grip from the neutral position the faster the truck will travel HIGH TRAVEL SPEED For high travel speed push the high travel speed button and rotate the twist grip to the maximum travel speed position REVERSING BUTTON If you accidentally hit the reversing button while working in close quarters the truck will move in the direction of the forks until the button is released Be careful The reversing button cannot prevent all injuries A Know the Hazards LOOK WHERE YOU RE GOING Always be alert to the area around you and watch where you are walking You could be pinned or crushed if you are caught between the truck and walls racks or other fixed objects WATCH YOUR FEET AND HANDS A foot or hand caught between the truck and a wall post or any fixed object will be crushed or even cut off Keep your feet clear of the wheels Traveling 20 Daily Safety Check n CHECK YOUR TRUCK BEFORE STARTING WORK Y
17. tect Yourself Contents What s in it for You Your Walkie Lift Truck Lift Truck Parts Capacity amp Load Center Capacity Plate Power On amp Off Braking Fork Functions Steering amp Travel Traveling Daily Safety Check Be a Safe Operator Battery Maintenance Warning Labels 5 Contents D nN OO Gi W N GJ N M M C N Q CO N OO CI C Traveling 19 Traveling What s in it for You A Know the Hazards 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 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 What s in it for You 6 Your Walkie Lift Truck Recommended Walking Area 7 Your Walkie Lift Truck WALKIE LIFT TRUCKS Your walkie lift truck can be used to lift move and stack loads It is designed to travel short dist
18. ut or crush hand Connect charger OSHA 1910 178 Rev 1999 You or people around you could bi Riding on this and in the operator manual truck could Inspect your truck before starting work make sure it is in good working order cause serious injury No Riding Minimum battery size allowed ey XXX mm XX XX in o DANGER Undersize battery can affect handling and stability You cd an accident Use U L classified Type EO Attach block 77034 to Emergency disconnect Battery Connector lever will not work if block 77034 isn t bolted to the battery half of the connector use a battery it the block in E Batteries can produce explosive gas Do not smoke use open flame or create an arc or sparks near this battery Ventilate well when in an enclosed area and when charging This battery contains Sulfuric Acid which causes severe burns Do not get in eyes on skin or clothing In case of contact flush immediately and thoroughly with water Get medical attention if your eyes are affected All rights reserved under International and Pan American copyright conventions Copyright 1997 Crown Equipment Corp 29 Battery Maintenance continued Warning Labels 30
19. wrong Report the problem to your supervisor Capacity Plate 14 Power On amp Off 15 Power On amp Off KEY SWITCH Turn the key clockwise Power is ON Turn the key counterclockwise Power is OFF Always turn the key off when leaving the truck POWER DISCONNECT Push the battery connector handle down 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 Braking Brake Off Brake On MEN 4 BRAKING Move the control handle all the way down or all the way up to apply the brake When you let go of the control handle it will automatically go to the upper braking position Check braking before you start working A 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 use the truck Report any problem to your supervisor Braking 16 Fork Functions A Tilt lever WR only Reach lever WR only Raise Lower lever standard
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