TSP

S E R I E S Operator Manual

This operator manual has

information for all models of

series TSP 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 © 1997 PF12496-WEB Rev. 6/06 Printed in U.S.A.
TSP
S E R I E S
 You Must be Trained

IT'S THE LAW, YOU MUST BE TRAINED AND CERTIFIED

Federal law states that only properly trained operators are

It’s the law, you must be trained and certified to STOP 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.
operate this truck. (OSHA § 1910.178, Rev. 1999) (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.
Do not operate this truck in your work place until you
Read and obey all warnings and instructions in this Manual* and have been trained and certified by your employer.
on the truck.

Falling from a platform can cause serious injury or death. Put on

the operator harness and attach tether before operating 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 You could be killed or seriously injured if you are not
operator area and stop the truck completely before getting off. adequately trained for lift truck operation!
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.

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 1997 Crown Equipment Corp.

1 Warning You Must be Trained 2

Protect Yourself
Know the Hazards Know the Hazards
WEAR YOUR OPERATOR HARNESS AVOID FALLS AND TIPOVERS
Falls from a platform can cause serious injury or even death. Tipovers are very serious accidents, you can be crushed
• Use your operator harness and tether when elevated and or even killed. The best way to prevent injury is to know
working with an open side gate. Read the warnings on where you are at all times and follow the rules of safe
the harness. truck operation. There is no sure way to avoid injury
during a tipover or a drop from a dock.
• Check your harness and tether. Replace them if they
• Be careful if driving around docks or ramps. Stay away
have ever been used to stop a fall, or if damaged or worn.
from the edge. Watch where you're going.
LOOK WHERE YOU'RE DRIVING • When traveling out of the aisle, keep the forks or load
• If you run into things you can be injured. You could close to the ground. Watch for overhead obstructions.
fall from the truck or the load could shift and hit you. Perform all truck movements smoothly and at a speed
Make certain there is nothing in your path, on the floor that will give you time to react in an emergency.
or sticking out of the racks. • Turret Stockpickers should not be used on ramps or
• Always be alert to the area around you and watch where grades. If you must drive on a grade, travel slowly and
you are driving. You could be pinned or crushed by don't turn. If carrying a load, point the forks upgrade.
objects intruding or poking into the operator area. If unloaded, point the forks downgrade.
• An unloaded truck can also tip over. Be just as careful
DRIVE CAREFULLY using an unloaded truck as you are using a loaded one.
• Keep your hands on the controls and feet on the pedals.
Keep your entire body in the operator area. A foot or WARNING USE YOUR TRUCK SAFELY
hand caught between the truck and a fixed object will • Keep hands and feet away from all moving parts such
be crushed or even cut off. Stay clear of all as masts or wheels. Don't sit or stand on the side gates.
moving parts.
• Keep your truck under control at all times. Drive at a Moving parts can • Never stand on or under the forks, or allow anyone else
speed that allows you to stop safely. Be even more cut or crush hands,
feet, arms or legs.
to stand on or under them. Never allow passengers on
careful on slippery or uneven surfaces. Do not drive 07
the truck. There is no safe place for them.
over objects on the floor.
• Before you leave your truck:
CHECK YOUR LOADS • Come to a complete stop.
Before you pivot a load, make certain it won't intrude or • Lower the forks to the floor.
poke into the operator area. Do not handle long, wide or • Shut the truck off with the key or power disconnect.
unstable loads. Check clearances before using traverse. • Apply the parking brake.

3 Protect Yourself Protect Yourself 4

Contents What's in it for You?

Warning 1 WHAT'S IN IT FOR YOU?

2 The better you understand your truck and how to use it,
You Must be Trained
the better and safer operator you can be. Here are some
Protect Yourself 3 guides to using this manual.
Contents 5
What's in it for You? 6
Capacity & Load Center QUICK LOCATORS
Your Turret Stockpicker 7
In addition to the "Contents" page you
Turret Truck Parts 9 can use page headings to find topics.
Capacity & Load Center 11
Center of evenly
distributed load Some pages also have a picture of the
truck in the corner showing features or
Capacity Plate 13 functions covered on that page.
Know the Hazards
Display Panel 15
600mm
TSP
Units of measure, kg/mm(lb/in)
Truck Weight with Max. Battery
7050(15540) "KNOW THE HAZARDS"
Power On & Off 17
Truck Type Fork Extend / Offset
(24 in.) Max SERI ES E 100(4)
Attachment Data

Watch for and read these special blocks.

E
PL
M
Load

SA
Serial Number
Load Center 600(24)
A1234567
Center
18
Capacity with Mast Vertical

Sit or Stand Operation

Capacity
1180(2600) 9220(363) 600(24)
1360(3000) 8000(315) 600(24)
815(1800) 9220(363) 865(34)
You will find information about
955(2100) 8000(315) 865(34)
319-D

possible safety hazards and how to

Foot Brake & Parking Brake 19 avoid them.
Platform Safety 21
HOW-TO-DRAWINGS
Traverse, Extend & Pivot 23 On many pages you will find pictures
Raise & Lower 25 as well as text to help you understand
how to use your truck safely and
Steering & Travel 27 productively.
Traveling & Plugging 29
Wire Guidance Option 31
Daily Safety Check 33 11 Capacity & Load Center Capacity & Load Center 12

Be a Safe Driver 35
Battery Maintenance 39
Warning Labels 42

5 Contents What's in it for You? 6

Your Turret Stockpicker

TURRET STOCKPICKERS BUILT TO STANDARDS

Your turret truck is designed to transport, stack and This truck was designed and built to
retrieve loads. current industry and government
standards and guidelines. For more
information see the following:
YOUR TURRET TRUCK IS NOT AN AUTOMOBILE
• American National Standards
With a load it may weigh more than 6 automobiles. Institute (ASME) B56.1
• You don't steer the same. • Occupational Safety and
• You don't brake the same. Health Act (OSHA) §1910.178
• You don't accelerate the same. Rev. 1999
• Underwriters Laboratory
HOW TO DRIVE YOUR TRUCK (UL) 583
Put the side gates down. Keep your hands and feet inside • National Fire Prevention
Association (NFPA) 505
the operator compartment and on the controls. Look in
the direction you're going.

WHEN TO USE THE HARNESS AND TETHER

Wear your harness and attach the tether whenever the Hands on
controls
operator compartment is elevated and you have a side gate
open. (The harness may be either a belt or a body harness.) Side gates
down
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.
Feet on pedals

7 Your Turret Stockpicker Your Turret Stockpicker 8

Turret Truck Parts

Work Light
Overhead Guard Service Brake
(sit down)
Display Panel
Interlock Pedals
Rear View Mirror (sit down)

Operator Harness Service Brake &

and Tether Interlock Pedals
(stand up)
Auxiliary Mast
Side Gate
Pivot Control
Traverse/Fork
Operator Platform Extend/Retract
Raise/Lower
Steering Handle
Primary Mast
Adjustable Seat
Fork
Horn
Flashing Light
Fork Override
Power Unit Controls (inside)
Lowering Valve Twist Grip/
(inside)
Palm Switch
Battery
Power
Load Wheel Disconnect
Key Switch
Display Panel

9 Turret Truck Parts Turret Truck Parts 10

Capacity & Load Center

Center of evenly
distributed load
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. Know the Hazards
See the capacity plate on your truck. Make certain you
use the correct units of measure.
TSP
Units of measure, kg/mm(lb/in)
Truck Weight with Max. Battery KNOW YOUR LOAD
7050(15540)

WHAT IS LOAD CENTER? SERI ES

Truck Type
E
Fork Extend / Offset
100(4) Do not exceed the capacity shown on your truck's capacity
Attachment Data
plate. Be careful when handling long, high or wide loads.

E
PL
Load center is the distance from the vertical face of the

M
Load
Do not handle unstable loads.

SA
600mm Serial Number

(24 in.) Max forks to the center of an evenly distributed load. Center 600(24)
A1234567
Capacity with Mast Vertical
Capacity
1180(2600)
1360(3000)
9220(363)
8000(315)
600(24)
600(24) EXCEEDING TRUCK CAPACITY CAN CAUSE AN ACCIDENT
Load 815(1800)
955(2100)
9220(363)
8000(315)
865(34)
865(34)
Center 319-D
Know the capacity of your truck as shown on your capacity
LOADS MUST BE CENTERED & EVENLY DISTRIBUTED plate. Make certain you use the correct units of measure.
Pay attention to:
Your truck could tip over, in any direction, if a load is
placed or shifted to the front, back or side of a pallet or • Weight of load
container. • Load center
• Lift height

HYDRAULIC OPERATIONS CAN AFFECT STABILITY

Be careful when using operations such as traverse, extend
or pivot. Remember that anytime the forks move, the
load moves also. This can affect stability. Perform all
operations smoothly.

CENTER THE LOAD

Your truck could tip over if a load is placed or shifted to
the front, back or side of a pallet or container. Make sure
your load is evenly distributed and centered over the
forks.

11 Capacity & Load Center Capacity & Load Center 12

Capacity Plate

CAPACITY PLATE INFORMATION

The capacity plate is by the steering handle. OTHER LIFT HEIGHTS AND LOAD CENTERS
It contains: Contact Crown for capacities at lift heights or load centers
• Truck 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 lb)
can be lifted to 8000 (315 in). But above 8000 (315), to
9220 (363), capacity is reduced from 1360 (3000) to
1180 (2600).
SAMPLE Capacity is reduced as load center B increases.
CAPACITY PLATE For example: On the sample plate, 1360kg (3000 lb) can
The information be lifted if the load center is 600mm (24 in). But if the
shown on this sample
plate does not apply
load center is increased to 865mm (34), capacity is reduced Know the Hazards
to your truck. from 1360 (3000) to 955 (2100).
CAUTION
Units of measure, kg/mm(lb/in) You may not increase capacity if load TRUCK WEIGHT
TSP Truck Weight with Max. Battery
7050(15540) center is less than shown on your Some floors have limited capacity. Check your capacity
Truck Type Fork Extend / Offset capacity plate. plate for the weight of your truck. Remember to add the
SERI ES E 100(4) weight of the load you have on the forks. Make certain
Attachment Data
Note: ANSI B56.1 requires that all data you use the correct units of measure.
E
PL

be shown first in Metric units and then

M

Load
SA

Serial Number
A1234567
USA units. TRUCK TYPE
Center 600(24)
Capacity with Mast Vertical Some truck types are not permitted in areas where there
Capacity
1180(2600) 9220(363) 600(24) are fire hazards. Watch for marked areas. For example:
1360(3000) 8000(315) 600(24) You must not drive a type E or ES truck into an area
815(1800) 9220(363) 865(34)
955(2100) 8000(315) 865(34)
restricted to EE or EX trucks.
319-D

13 Capacity Plate Capacity Plate 14

Display Panel

TRAVERSE/EXTEND LIGHT
Green light on when the forks and auxiliary mast are SEAT ADJUSTMENT SWITCH
in the travel position. Move seat up or down.

ACCESSORY SWITCHES
PIVOT LIGHT Fan, dome light and work lights.
Green light on when the forks are pivoted to the travel
position.

SERVICE LIGHT
Amber light on when something needs to be fixed. Report
the trouble to your supervisor, even if the truck seems to
be working OK.

GATE LIGHT
Red light on when a gate is up. PARKING BRAKE LIGHT
Amber light on when parking brake is applied.
PALM/FOOT SWITCH LIGHT
Amber light on when the proper palm switch or foot pedal GUIDANCE LIGHTS, OPTION
is not actuated. • Green light on when guidance has control of
steering. Start slowly.
CALIBRATION INDICATOR LIGHT • Red light on when guidance is on but truck is
not on the wire. Steer manually.
RAISE/LOWER CUTOUT LIGHT
Red light on when forks are at preset raise or lower limits. BATTERY CHARGE DISPLAY
The green bars show how much charge is left.
LOW SIGNAL STRENGTH LIGHT Have the battery changed or recharged when you
Amber light on when signal from guidance wire is low. see a flashing yellow light.

15 Display Panel Display Panel 16

Power On & Off Sit or Stand Operation

KEY SWITCH SIT/STAND OPTION

• Turn the key clockwise as far as it You have the choice of putting the seat down to drive your
will go, to the TEST position. Check that truck from a seated position, or flip the seat up to drive
the alarm and all indicator lights are working. from a standing position.
• Let go of the key and it will return to the ON position.
THERE ARE SOME DIFFERENCES
• Turn the key back to the OFF position to shut the truck
off. Always turn the key to OFF when leaving the truck. The foot brake and the foot interlock pedals do not work
the same for the two operating positions.
POWER DISCONNECT • For instructions on use of the foot brake, see pages 19
Push the Power Disconnect button to disconnect the battery and 20.
and cut power to the truck. The brake will also be applied. • For instructions on use of the interlock pedals, see pages
Always use the Power Disconnect if your truck isn't 21 and 22.
working right. Don't operate the truck. Report the problem
to your supervisor.
Turn the key switch to OFF and back to TEST to reconnect
the battery.

17 Power On & Off Sit or Stand Operation 18

Foot Brake & Parking Brake

FOOT BRAKE PEDALS PARKING BRAKE

The platform has foot brake pedals at two Move the switch up to apply the parking brake.
locations. One location is for a seated position The indicator above the switch will light when the
and one is for a standing position. Brake operation brake is on.
is not the same from the two positions. Be careful. Some service conditions will also set the parking brake.
Always put the parking brake on when you leave the truck.
SEATED POSITION
Press the center pedal on the pedestal to apply the brakes. Move the switch down to release the brake.
The pedestal brake pedal works only while you are seated.
Use the floor brake pedals if you operate your truck from
a standing position.

STANDING POSITION Know the Hazards

Lift or remove your foot from either of the floor brake
pedals to apply the brakes. Both of the floor pedals must
be down for the truck to operate. SEATED BRAKING VS STANDING BRAKING
The brakes do not work the same from the two operating
The floor brake pedals work only while you are standing.
positions. When seated, you step down on a pedal to
Use the pedestal brake pedal if you operate your truck
activate the brakes. However when standing, you remove
from a seated position.
a foot from a pedal to activate the brakes. Stay alert,
especially when changing operating positions.
Note: Whenever you apply the brakes, power is cut to the
drive motors, so you cannot stop or slow your truck down
by using plugging (see page 29). MAKE SURE YOUR BRAKES WORK
Test your brakes at the start of each shift. Know the
distance it takes to stop before you start working. If the
stopping distance is too long for you to stop safely, don't
drive the truck. Report any problem to your supervisor.

19 Foot Brake & Parking Brake Foot Brake & Parking Brake 20
Platform Safety

KEEP THE SIDE GATES DOWN 1 INTERLOCK PEDALS

• Keep the side gates down unless The platform has two sets of foot operated interlock pedals.
you are leaving the truck or picking from 1 One set, located on the pedestal, is for seated operation.
the side. The truck will not operate with a gate up. 2 The second set, on the floor, is for standing operation.
• Don't sit or climb on the side gates. You also use these floor pedals for braking while in the
• Keep your entire body in the operator area. standing position. (See page 20)
You must have your feet on the correct set of pedals before
HARNESS AND TETHER you can operate your truck.
2
Use your harness and tether whenever you are working
from a raised platform and have a side gate open. CHECK YOUR DISPLAY
Check the harness, tether, snap hooks and mounting points If any truck function doesn't work, check the indicator
daily for wear or breakage. If it doesn't look safe don't lights on the console display.
use the truck. Report the problem to your supervisor.

PALM SWITCH
The travel twist grip has an interlock switch built into the
top of it.
You must have your hand, or palm, on the top of the twist
Know the Hazards
grip for the following load handling functions to operate:
• Auxiliary raise or lower FALLS CAN KILL
DANGER
• Traverse Falling from a raised platform can
You can reduce the risk of injury by being extra careful
• Extend or retract cause serious injury or even death. while working on an elevated Turret Stockpicker.
• Pivot Attach safety belt and • Put the side gates down and keep your entire body inside
tether when elevated the operator area.
and working with an
open side gate. • Watch where you're going. Running into an object could
cause you to fall.
• Wear your harness and keep your tether fastened when
working with an open side gate.

21 Platform Safety Platform Safety 22

Traverse, Extend & Pivot

TRAVERSE & EXTEND/RETRACT CHECK YOUR DISPLAY

Move the Traverse, Extend/Retract handle If any hydraulic function doesn't work, check the indicator
toward you to move the forks and carriage to the lights on the console display.
right. Move the handle away from you to move the • The gates must be down.
forks and carriage to the left.
• The palm interlock switch must be actuated.
The farther you move the handle the
faster the carriage, or forks, will move. • The proper set of foot interlock pedals must be actuated.
Make sure the load will clear the • Some service conditions may also prevent you from
platform. operating your truck.

PIVOT
Move the Pivot handle toward you to
pivot the forks counter clockwise. Move
the handle away from you to pivot the
forks clockwise.
The farther you move the handle the
faster the forks will pivot.
Before you pivot a load, make certain it will not poke or
intrude into the operator area.

OVERRIDE SWITCHES
Traverse and Extend/Retract override switches are located
under the right-hand console. Use these switches to get
the forks out of the rack in case of electrical malfunction.
Traverse Override
Actuate the Traverse override switch while moving the
Traverse & Extend/Retract handle.
Extend/Retract Override
Actuate both the Traverse and the Extend/Retract override
switchs while moving the Traverse & Extend/Retract handle.

23 Traverse, Extend & Pivot Traverse, Extend & Pivot 24

Raise & Lower

RAISE & LOWER RAISE/LOWER CUTOUT (optional)

Primary raise and lower lets you move Your truck may be equipped with automatic cutout of raise
the entire operator platform, and forks, up or and lower at selected heights.
down on the primary mast. If Raise or Lower stops and the red fork symbol on the
Auxiliary raise and lower lets you move just display is lit, you are at a raise or lower cutout height.
the forks up or down on the auxiliary mast. To travel past the cutout height, push the Cutout Override
Note: Emergency manual lowering valve button while, at the same time, moving the Raise/Lower
located behind power unit door. handle.
Be very careful and watch that you don't raise, lower or
Primary Raise/Lower
drive into obstructions when using the Cutout Override.
Move the Raise/Lower handle toward
you to raise the platform and forks.
Move the handle away from you to
lower the platform and the forks.
The farther you move the handle the
faster the platform will raise or lower.

Auxiliary Raise/Lower
Press the button in the side of the handle
and move the handle toward you to Know the Hazards
raise only the forks. Press the button
and move the handle away from you RAISE/LOWER CUTOUT OVERRIDE
to lower only the forks.
Using the Cutout Override allows you to travel, or raise
The farther you move the handle the the platform, into areas where there are obstructions and
faster the forks will raise or lower. hazards such as pipes, ducts, conduits, low ceilings etc.
Hitting any obstruction could tip the truck over, causing
serious injury or even death.
Watch out for obstructions anytime you're operating your
truck. Be even more careful when using Cutout Override.

25 Raise & Lower Raise & Lower 26

Steering & Travel

LIFT TRUCKS ARE NOT LIKE AUTOMOBILES STEER/DRIVE WHEEL DIRECTION DISPLAY
Your lift truck does not steer or drive like The indicator lights show you whether the drive wheel is
an automobile. Be sure you are trained to straight (within 5 degrees), or turned either right or left.
operate this truck. Even then, drive slowly until
you get use to the steering and all other controls.

STEERING AND DRIVING

You will need to drive your truck both in the direction of
the forks (forks first) and also away from the forks (power
unit first or forks trailing). Steering is not the same in
both directions.

Know the Hazards

Travel, power Travel,
n Di forks first
unit first io of r POWER UNIT SWING
rn

ec rn
of T ct
Di re

t io
u

Tu Be careful turning while traveling forks first. The power

n
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

This shows the direction your truck will turn, when you turn the steering handle clockwise. 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.

27 Steering & Travel Steering & Travel 28

Traveling & Plugging

TRAVEL TRAVEL POSITION OF FORKS & CARRIAGE

Rotate the top of the twist grip in the Before traveling at full speed, you must pivot the forks
direction you want to travel. and sideshift the carriage so they do not extend past the
The farther you rotate the grip from the neutral sides of the truck. The pivot and traverse indicators will
position, the faster the truck will travel. light when the forks and carriage are properly positioned
(see pages 15 & 16).
You must also make certain that the load does not extend
past the sides of the truck.
PLUGGING
Plugging is another way to slow down or stop your truck. CHECK YOUR DISPLAY
While the truck is moving, in either direction, rotate the
twist grip through neutral to the opposite direction of travel. If your truck won't travel, or operates at a reduced speed,
Use the twist grip to control how quickly you slow down. check the indicator lights on the console display.
Plugging will not hurt your truck.

HORN
Press the horn button to blow the horn. Use it to warn
Know the Hazards
pedestrians and other drivers.
Use your horn when you leave the aisle or come to an LOOK WHERE YOU'RE GOING
intersection or crosswalk. Travel in the direction where you have the best visibility.

PLUGGING VS. BRAKING

Of the two, the foot brakes are designed to stop the truck
in the shortest distance. Use the foot brakes in an
emergency, on ramps or in busy areas.

YOU CAN'T HAVE BOTH

Plugging works only when the brakes are off. When the
brakes are applied, power is cut to the drive motors and
you will not be able to plug.

29 Traveling & Plugging Traveling & Plugging 30

Wire Guidance Option

Guidance Wire ACQUIRING THE WIRE FOR MANUAL STEERING

Push the wire guidance switch to ON as Take control of steering, push the guidance switch to OFF.
30° MAX you near a guided aisle. Approach the wire Note: Whenever guidance is OFF, the red light on the
at an angle of 30° or less. Drive slowly and center display will flash and the alarm will "beep", at a slow rate,
the truck over the wire. When you hear a "beep" and the to remind you that you are in manual steering.
red light turns off, begin guided driving. Start Slowly.
When the truck senses a guidance wire, the rate of both
the "beeping" and the flashing will speed up, to notify you
WHEN DRIVING ON THE WIRE that a wire is near. To acquire the wire, see page 31.
• Watch where you're going. Make sure your path is clear.
• Always be alert for "beeps" from the alarm or changes END OF AISLE CONTROL OPTION
in the indicator lights that signal changes in guidance With this feature, your truck will either slow down or stop
status. automatically when it comes to the end of an aisle. You
will hear a "beep", and the indicator light will turn on.
• Start slowly after changing direction of travel. Be sure
the truck is following the wire. If the truck stops: let up on the accelerator, press the
override button and resume travel.
AUTOMATIC SLOW DOWN
While traveling on guidance, your truck may slow down
automatically for certain conditions.
• Low signal strength from the wire.
Know the Hazards
• Truck deviates slightly from the wire.
STAY ALERT
• End of Aisle Control (optional) is activated.
You must be just as careful and alert while driving on
guidance as you are when driving with manual steering.
AUTOMATIC STOP
• Start slowly and look where you're going.
Your truck may stop automatically for certain conditions.
• Always be prepared to steer manually.
• Signal strength from the wire is lost or is too low. • Make sure there is nothing in your path, on the floor or
• Truck deviates too far from the wire. sticking out of the racks.
• End of Aisle Control (optional) is activated. LISTEN FOR THE "BEEP", CHECK THE DISPLAY
• Take control of the steering any time the red light is on.
• Check the display if you hear a "beep".

31 Wire Guidance Option Wire Guidance Option 32

Daily Safety Check

CHECK YOUR TRUCK BEFORE STARTING WORK 2. Test drive your truck in an uncongested area.
You must make sure your truck is safe to use. • Try all the hydraulic functions.
• Check that the steering is easy and smooth.
1. Walk around your truck and check it over.
• Inspect your harness, tether, snap hooks and mounting • Drive the truck slowly in both directions.
points. Have them replaced if they look damaged or • Drive through the full speed range in both forward
worn, or have ever been used to stop a fall. and reverse.
• Clean the safety shields and keep them clear. • Check braking and plugging distances in forward and
• Check to make sure the battery is charged, water level reverse. Load size and floor conditions can affect these
is OK and vent caps are in place. Don't use an open distances.
flame to check the battery. • Know the distance it takes to stop before you start
• Make certain the battery retainer and side cover are working. If the braking distance is too long to stop
properly installed. safely, don't drive the truck.
• See that all wheels are in good condition. • Check wire guidance operation.
• Make sure the flashing light is working. If anything doesn't look or feel right, don't drive the truck.
• Check that both forks are secure and not bent, cracked Report the problem.
or badly worn.
You can get checklist forms from your Crown dealer
• Inspect all lift chains for damage.
(part no. OF-3772). Used properly, this checklist can alert
• Look under the truck for signs of hydraulic leaks. service people to needed repairs.
• Adjust the operator seat to the most comfortable position.
Turn the rear view mirror to the best viewing position.
• Turn the key to TEST. See that the alarm and all indicator
lights are working.
• Test the horn.
• Make sure the power disconnect works.

33 Daily Safety Check Daily Safety Check 34

Be a Safe Driver

DRIVE CAUTIOUSLY, BE ALERT

The most MAKE SURE YOU ARE READY TO DRIVE
• Do not use this truck unless you are trained • Wear your harness and have the tether fastened when
and certified. elevated and working with an open side gate.
important • Be certain you understand how your truck works and • Never stick an arm, foot or any part of your body outside
the hazards that go with it. Don't drive the truck if you the operator area, no matter how slow the truck is
component have any doubts. moving. A hand or foot caught between the truck and
a fixed object will be crushed or even cut off.
• Know the capacity of your truck (Load Weight, Load
• Keep your hands on the controls and feet on the pedals.
is you. Center and Lift Height). Make certain you use the
correct units of measure. • Travel in the direction that gives you the best view.
• Some trucks are not allowed in areas where there are Look where you're going, slow down in congested areas.
fire hazards. Be certain your truck is the correct fire • Slow down for slippery floors. Don't run over things.
safety type for the area.
• Travel with the platform close to the ground when
• Make sure your hands and shoes are clean and dry, and outside of an aisle. Place the load against the vertical
your clothing is proper for the job. face of the forks.
• Be certain forks and load are in the travel position.
MAKE SURE YOUR TRUCK IS READY

?
• Inspect your truck before using it (see pages 33 and 34). • Look where you are going before you change direction
If it's not working right, or something is broken, report of travel. Slow down when making turns.
the problem. Don't use the truck. • See that you have room to drive and turn. Check for
• In an open area, test the braking and plugging. Check overhead objects. Watch out for power unit and fork
at a slow travel speed first, then a faster one. Know (load) swing.
the distance it takes to stop before you start work. • Make certain the load will clear the operator platform
before you use Traverse, Extend/Retract or Pivot.
• Avoid sudden movement of controls. Learn to use them
smoothly at a moderate, even rate.
• Check clearances before raising or lowering the forks
or load. Watch for overhead obstructions.
• Be extra careful if you must use your truck in an area
where there is a risk of falling objects.
Continued next page...

35 Be a Safe Driver Be a Safe Driver 36

Be a Safe Driver continued

WATCH OUT FOR OTHER PEOPLE AVOID FALLS AND TIPOVERS

• Slow down. Yield or stop for pedestrians. • Be extremely careful when working around docks or
Use your horn when you come to a crosswalk ramps. Stay away from the edge.
or intersection. • Check capacities. Be sure your truck, with load, isn't
• Be careful that you don't pin or crush someone. too heavy for where you are driving.
For example: Never drive your truck toward anyone • Make sure the load you are moving is stable. Spread
standing in front of a fixed object. the forks as far as you can and center the load. Insert
• Watch out for power unit and fork (load) swing when the forks as far under the load as you can.
turning. • Watch out for overhead obstructions.
• Never allow passengers on your truck. • Turret trucks should not be used on ramps or grades.
• Keep others away from your truck while you're working. If you must drive on a grade, travel slowly and never
Don't ever allow anyone on or under the load or forks. turn the truck. If carrying a load, travel with forks
upgrade. If unloaded, travel with forks downgrade.
• Don't let anyone use your truck unless they are trained
Keep the fork height below 300mm (12 inches).
and certified.
• Never lift anyone with the forks unless they are using LEAVING YOUR TRUCK
an approved platform. Even then use extreme caution: • Stop your truck completely before getting off.
• Use a securely attached and approved safety platform.
• Lower the forks to the floor. Turn the truck off or
• Make certain lifting mechanism is operating properly. disconnect the battery.
• Make certain truck is in neutral and brake is applied.
• Avoid parking on inclines. But if you must, block the
• Lift and lower slowly. wheels of your truck.
• Watch for overhead obstructions.
• Be sure you can see and hear the person being lifted.
• Never transport anyone on a safety platform from one
location to another.

37 Be a Safe Driver continued Be a Safe Driver continued 38

Battery Maintenance

WHEN YOU INSTALL

OR CHANGE BATTERIES
• Turn the truck OFF. Make sure the
parking brake is applied and all other controls
Know the Hazards
are in neutral. Disconnect the batteries.
• Make certain you use the correct size and weight batteries. TRUCK BATTERIES CAN BE DANGEROUS
Never operate a truck that has underweight or
DANGER Your truck batteries produce fumes that can explode.
undersized batteries installed. They also contain acid that could burn or disfigure you.
• Use a roller stand to install or remove batteries. Make • Do not try to install, remove, charge or service your
sure the roller stand is the same height as the rollers in truck batteries unless you are trained and authorized.
the truck's battery compartment. Also be certain the • Never smoke or use an open flame around batteries.
roller stand is at least as long as your batteries. Batteries produce explosive gas.
Do not smoke, use open flame, or
• Your company should provide an area where it is safe
• Never let anything metal touch the top of the cells. You create an arc or sparks near this to work on batteries. Use that area for all battery work.
battery. Ventilate well in enclosed
could cause sparks or do damage to the batteries. Use areas and when charging. • Use protective equipment such as gloves, eye shields,
an insulator (such as plywood) when necessary. Batteries contain Sulfuric Acid which aprons etc.
causes severe burns. Do not get in
eyes, on skin, or clothing. In case of
• Use an approved spreader bar to place the batteries on, contact, flush immediately. Get medical
or remove them from a stand. Make sure you attention if your eyes are affected.
107
adjust the spreader bar hooks to fit the batteries.

AFTER INSTALLING BATTERIES BATTERY RETAINER

• Replace the battery retainer and side cover. The batteries could slide out if the retainer is not in place.
Check before you operate your truck.
• Connect the batteries. Turn the truck ON and check
truck operation.
BATTERY SIZE
WARNING
Make certain you use the correct size and weight batteries.
Minimum battery size allowed
XXX mm (XX.XX in.) wide
Never operate a truck that has underweight or undersized
XXX mm (XX.XX in.) long batteries installed.
Undersize battery can affect truck
handling and stability. You could have
an accident.
Use U.L. classified Type EO battery.

Continued next page...

39 Battery Maintenance Battery Maintenance 40

Battery Maintenance continued Warning Labels

WARNI NG EACH WARNING LABEL

WARNI NG ON YOUR TRUCK IS IMPORTANT
Stay clear of all
moving parts. Read and obey all of them to protect
Moving parts can
cut or crush hands,
feet, arms or legs.
yourself and others.
Standing or riding on the forks can
07 cause a fall. You can be seriously
injured or killed.
WARNI NGNever stand or ride on forks
for any reason.
09 WARNI NG
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
WARNING Falling objects or lowering forks can
cause serious injury or death. CAUTION
don't use this truck correctly.
Never stand under the forks. Obey all warnings and instructions on the truck
Avoid being crushed. and in the operator manual*.
Keep head, servicing, block the forks soWARNI NG
arms,
While
they won't fall.
hands, legs, and feet 10
Inspect your truck before starting work, make
Minimum battery sure it size
is inallowed
good working order.
within the operator
area. XXX mm (XX.XX in.) wide
XXX mm*(XX Additional WARNI NG
copies of the Operators Manual and Truck
.XX in.) long
Stop truck completely Labels
Undersize battery can can
affectbe obtained from Crown Equipment Corp.,
truck
before getting off. New Bremen,
handling and stability. You couldOHhave
45869 U.S.A. Truck does not automatically slow
43
an accident.
down at end of aisles.
Tipovers and falls from
WARNI NG
Use U.L. classified Type EO battery. 04

There are blind spots not covered

docks can cause WARNI
Cross traffic N Gnot stop.
does

Know the Hazards serious injurybyorthe mirror.

even
death.
Slow Down, look out for people
You could hit someone not visible Unsafe loads
and can swing
other or fall
trucks.
in the
Make sure you aremirror.
safe.
into
Don't drive with the mirror, look
the operator area causing DANGE R
serious injury.
88

in direction of travel. High voltage can cause electric

264 Never operate the truck with
41
shock or burn.
WARNI NG a load that is off-center,
BEFORE CHARGING YOUR TRUCK BATTERIES Passengers could be
oversize, or unstable.
44 DANGE R
Serious injury or death could occur.

Disconnect battery(s) and consult

• Charge the batteries in designated areas only. seriously injured. There
is no safe place for them.
Falling from a raised platform can Electrical Section of Service Manual
before working on truck.
cause serious injury or even death.
• See that the battery cells are filled to the proper level. No Passengers.
Attach safety belt and
19

DANGER
tether when elevated
Never use an open flame to check the batteries. 77

and working with an

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
open side gate. area and when charging.
• Make certain the chargers are the same voltage and This battery contains Sulfuric Acid which causes
severe burns. Do not get in eyes, on skin, or clothing.

amperage as your batteries. In case of contact, flush immediately and thoroughly

with water. Get medical attention if your eyes are
affected.

• Read the battery charger instructions. 20

• Be sure chargers are turned off before connecting

batteries to them. Otherwise you might create a spark
which could cause a battery to explode. Also, make
sure the truck key switch is turned off and all controls
are in the neutral position. All rights reserved under International
and Pan American copyright conventions
Copyright 1997 Crown Equipment Corp.

41 Battery Maintenance continued Warning Labels 42