Crown 30TS Operator Manual

TSP

SERIES

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.

New Bremen, Ohio 45869 USA © 1997 PF12496-WEB Rev. 6/06 Printed in U.S.A.

The most
important
component
is you.

TSP

SERIES

It’s the law, y ou 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.

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
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 of f 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.

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

STOP

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.

You could be killed or seriously injured if you are not
adequately trained for lift truck operation!

1 Warning

All rights reserved under International
and Pan American copyright conventions
Copyright 1997 Crown Equipment Corp.

You Must be Trained 2

Protect Yourself

07

Stay clear of all
moving parts.

Moving parts can
cut or crush hands,
feet, arms or legs.

WARNING

Know the Hazards

3 Protect Yourself

WEAR YOUR OPERATOR HARNESS

Falls from a platform can cause serious injury or even death.

• Use your operator harness and tether when elevated and
working with an open side gate. Read the warnings on

the harness.

• Check your harness and tether. Replace them if they
have e ver been used to stop a f all, or if damaged or worn.

LOOK WHERE YOU'RE DRIVING

• If you run into things you can be injured. You could
fall from the truck or the load could shift and hit you.
Make certain there is nothing in your path, on the floor
or sticking out of the racks.

• Always be 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.

DRIVE CAREFULLY

• Keep your hands on the controls and feet on the pedals.

Keep your entire body in the operator area. A foot or

hand caught between the truck and a fixed object will
be crushed or even cut off.

• 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.

CHECK YOUR LOADS

Before you pivot a load, make certain it won't intrude or
poke into the operator area. Do not handle long, wide or
unstable loads. Check clearances before using traverse.

Know the Hazards

AVOID FALLS AND TIPOVERS

Tipovers 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. There is no sure way to avoid injury
during a tipover or a drop from a dock.

• Be careful if driving around docks or ramps. Stay away
from the edge. Watch where you're going.

• When traveling out of the aisle, keep the forks or load
close to the ground. Watch for overhead obstructions.
Perform all truck movements smoothly and at a speed
that will give you time to react in an emergency.

• Turret Stockpickers should not be used on ramps or
grades. If you must drive on a grade, travel slowly and
don't turn. If carrying a load, point the forks upgrade.
If unloaded, point the forks downgrade.

• An unloaded truck can also tip over. Be just as careful
using an unloaded truck as you are using a loaded one.

USE YOUR TRUCK SAFELY

• Keep hands and feet away from all moving parts such
as masts or wheels. Don't sit or stand on the side gates.

• Never stand on or under the forks, or allow anyone else
to stand on or under them. Never allow passengers on
the truck. There is no safe place for them.

• Before you leave your truck:

• Come to a complete stop.

• Lower the forks to the floor.

• Shut the truck off with the key or power disconnect.

• Apply the parking brake.

Protect Yourself 4

Capacity & Load Center

11 Capacity & Load Center

Know the Hazards

Capacity & Load Center 12

A1234567

Contents

What's in it for You?

Warning
You Must be Trained
Protect Yourself
Contents
What's in it for You?
Your Turret Stockpicker
Turret Truck Parts
Capacity & Load Center
Capacity Plate
Display Panel
Power On & Off
Sit or Stand Operation
Foot Brake & Parking Brake
Platform Safety
Traverse, Extend & Pivot
Raise & Lower
Steering & Travel
Traveling & Plugging
Wire Guidance Option

11
13
15
17
18
19
21
23
25
27
29
31

1
2
3

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.

5
6
7

QUICK LOCATORS

In addition to the "Contents" page you

9

Center of evenly
distributed load

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.

Units of measure, kg/mm(lb/in)

Truck Weight with Max. Battery

Load

Center

600mm

(24 in.) Max

TSP

SERIES

7050(15540)

Truck Type

Fork Extend / Offset

E

100(4)

Attachment Data

Load

Serial Number

SAMPLE

A1234567

600(24)

Center

Capacity with Mast Vertical

Capacity

9220(363)1180(2600) 600(24)

1360(3000)

600(24)8000(315)

815(1800)

9220(363)

865(34)

955(2100)

865(34)

8000(315)

319-D

"KNOW THE HAZARDS"

W atch 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.

Daily Safety Check
Be a Safe Driver
Battery Maintenance
Warning Labels

5 Contents

33
35
39
42

What's in it for You? 6

Your Turret Stockpicker

TURRET STOCKPICKERS

Your turret truck is designed to transport, stack and
retrieve loads.

YOUR TURRET TRUCK IS NOT AN AUTOMOBILE

With a load it may weigh more than 6 automobiles.

• You don't steer the same.

• You don't brake the same.

• You don't accelerate the same.

HOW TO DRIVE YOUR TRUCK

Put the side gates down. Keep your hands and feet inside
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
operator compartment is elevated and you have a side gate
open. (The harness may be either a belt or a body harness.)

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.

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

Hands on
controls

Side gates
down

Feet on pedals

7 Your Turret Stockpicker

Your Turret Stockpicker 8

Turret Truck Parts

Work Light
Overhead Guard
Display Panel
Rear View Mirror
Operator Harness

and Tether
Auxiliary Mast

Operator Platform

Primary Mast
Fork
Flashing Light
Power Unit
Lowering Valve

(inside)

Battery
Load Wheel

Service Brake

(sit down)

Interlock Pedals

(sit down)

Service Brake &

Interlock Pedals

(stand up)

Side Gate

Pivot Control

Traverse/Fork

Extend/Retract

Raise/Lower

Steering Handle

Adjustable Seat

Horn

Fork Override

Controls (inside)

Twist Grip/

Palm Switch

Power

Disconnect

9 Turret Truck Parts

Key Switch

Display Panel

Turret Truck Parts 10

Capacity & Load Center

Center of evenly

Load

Center

distributed load

600mm

(24 in.) Max

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 of measure.

WHAT IS LOAD CENTER?

Load center is the distance from the vertical face of the
forks to the center of an evenly distributed load.

LOADS MUST BE CENTERED & EVENLY DISTRIBUTED

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
container.

Know the Hazards

Units of measure, kg/mm(lb/in)

Load

600(24)

319-D

Truck Weight with Max. Battery

7050(15540)

Truck Type

E

Attachment Data

Serial Number

A1234567

Capacity with Mast Vertical

Capacity

9220(363)1180(2600) 600(24)

1360(3000)

815(1800)

9220(363)

955(2100)

8000(315)

Fork Extend / Offset

100(4)

SAMPLE

600(24)8000(315)
865(34)
865(34)

TSP

SERIES

Center

KNOW YOUR LOAD

Do not exceed the capacity shown on your truck's capacity
plate. Be careful when handling long, high or wide loads.
Do not handle unstable loads.

EXCEEDING TRUCK CAPACITY CAN CAUSE AN ACCIDENT

Know the capacity of your truck as shown on your capacity
plate. Make certain you use the correct units of measure.
Pay attention to:

• Weight of load

• Load center

• Lift height

11 Capacity & Load Center

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.

Capacity & Load Center 12

Capacity Plate

CAPACITY PLATE INFORMATION

The capacity plate is by the steering handle.
It contains:

• Truck serial number

• 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 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 PLATE

The information
shown on this sample
plate does not apply
to your truck.

TSP

SERIES

Load

600(24)

Center

319-D

Units of measure, kg/mm(lb/in)

Truck Weight with Max. Battery

7050(15540)

Truck Type

E

Attachment Data

Serial Number

A1234567

Capacity with Mast Vertical

Capacity

1360(3000)

815(1800)
955(2100)

Capacity is reduced as load center increases.

For example: On the sample plate, 1360kg (3000 lb) can
be lifted if the load center is 600mm (24 in). But if the
load center is increased to 865mm (34), capacity is r educed
from 1360 (3000) to 955 (2100).

Fork Extend / Offset

100(4)

SAMPLE

9220(363)1180(2600) 600(24)

9220(363)
8000(315)

600(24)8000(315)
865(34)
865(34)

A

B

CAUTION

You may not increase capacity if load
center is less than shown on your
capacity plate.

Note: ANSI 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.

Know the Hazards

TRUCK WEIGHT

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 on the forks. Make certain
you use the correct units of measure.

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.

13 Capacity Plate

Capacity Plate 14

Display Panel

TRAVERSE/EXTEND LIGHT

Green light on when the forks and auxiliary mast are
in the travel position.

PIVOT LIGHT

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.

PALM/FOOT SWITCH LIGHT

Amber light on when the proper palm switch or foot pedal
is not actuated.

CALIBRATION INDICATOR LIGHT

RAISE/LOWER CUTOUT LIGHT

Red light on when forks are at preset raise or lower limits.

LOW SIGNAL STRENGTH LIGHT

Amber light on when signal from guidance wire is low.

SEAT ADJUSTMENT SWITCH

Move seat up or down.

ACCESSORY SWITCHES

Fan, dome light and work lights.

PARKING BRAKE LIGHT

Amber light on when parking brake is applied.

GUIDANCE LIGHTS, OPTION

• Green light on when guidance has control of
steering. Start slowly.

• Red light on when guidance is on but truck is
not on the wire. Steer manually.

BATTERY CHARGE DISPLAY

The green bars show how much charge is left.
Have the battery changed or recharged when you
see a flashing yellow light.

15 Display Panel

Display Panel 16

Power On & Off

Sit or Stand Operation

KEY SWITCH

• Turn the key clockwise as far as it
will go, to the TEST position. Check that
the alarm and all indicator lights are working.

• Let go of the key and it will return to the ON position.

• Turn the key back to the OFF position to shut the truck
off. Always turn the key to OFF when leaving the truck.

POWER DISCONNECT

Push the Power Disconnect button to disconnect the battery
and cut power to the truck. The brake will also be applied.

Always use the Power Disconnect if your truck isn't
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.

SIT/STAND OPTION

You have the choice of putting the seat down to drive your
truck from a seated position, or flip the seat up to drive
from a standing position.

THERE ARE SOME DIFFERENCES

The foot brake and the foot interlock pedals do not work
the same for the two operating positions.

• For instructions on use of the foot brake, see pages 19
and 20.

• For instructions on use of the interlock pedals, see pages
21 and 22.

17 Power On & Off

Sit or Stand Operation 18

Foot Brake & Parking Brake

FOOT BRAKE PEDALS

The platform has foot brake pedals at two
locations. One location is for a seated position
and one is for a standing position. Brake operation
is not the same from the two positions. Be careful.

SEATED POSITION

Press the center pedal on the pedestal to apply the brakes.
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

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.

The floor brake pedals work only while you are standing.
Use the pedestal brake pedal if you operate your truck
from a seated position.

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).

PARKING BRAKE

Move the switch up to apply the parking brake.
The indicator above the switch will light when the
brake is on.

Some service conditions will also set the parking brake.
Always put the parking brake on when you leave the truck.
Move the switch down to release the brake.

Know the Hazards

SEATED BRAKING VS STANDING BRAKING

The brakes do not work the same from the two operating
positions. When seated, you step down on a pedal to
activate the brakes. However when standing, you remove
a foot from a pedal to activate the brakes. Stay alert,
especially when changing operating positions.

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

1

2

Falling from a raised platform can
cause serious injury or even death.

Attach safety belt and
tether when elevated
and working with an
open side gate.

DANGER

KEEP THE SIDE GATES DOWN

• Keep the side gates down unless
you are leaving the truck or picking from
the side. The truck will not operate with a gate up.

• Don't sit or climb on the side gates.

• Keep your entire body in the operator area.

HARNESS AND TETHER

Use your harness and tether whenever you are working
from a raised platform and have a side gate open.

Check the harness, tether, snap hooks and mounting points
daily for wear or breakage. If it doesn't look safe don't
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
grip for the following load handling functions to operate:

• Auxiliary raise or lower

• Traverse

• Extend or retract

• Pivot

INTERLOCK PEDALS

The platform has two sets of foot operated interlock pedals.

1

One set, located on the pedestal, is for seated operation.

2

The second set, on the floor, is for standing operation.
You also use these floor pedals for braking while in the
standing position. (See page 20)

You must have your feet on the correct set of pedals before
you can operate your truck.

CHECK YOUR DISPLAY

If any truck function doesn't work, check the indicator
lights on the console display.

Know the Hazards

FALLS CAN KILL

You can reduce the risk of injury by being extra careful
while working on an elevated Turret Stockpicker.

• Put the side gates down and keep your entire body inside

the operator area.

21 Platform Safety

• W atch 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.

Platform Safety 22

Traverse, Extend & Pivot

TRAVERSE & EXTEND/RETRACT

Move the Traverse, Extend/Retract handle
toward you to move the forks and carriage to the
right. Move the handle away from you to move the
forks and carriage to the left.

The farther you move the handle the
faster the carriage, or forks, will move.

Make sure the load will clear the
platform.

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.

CHECK YOUR DISPLAY

If any hydraulic function doesn't work, check the indicator
lights on the console display.

• The gates must be down.

• The palm interlock switch must be actuated.

• The proper set of foot interlock pedals must be actuated.

• Some service conditions may also prevent you from
operating your truck.

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

Primary raise and lower lets you move
the entire operator platform, and forks, up or
down on the primary mast.

Auxiliary raise and lower lets you move just
the forks up or down on the auxiliary mast.

Note: Emergency manual lowering valve

located behind power unit door.

Primary Raise/Lower

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
raise only the forks. Press the button
and move the handle away from you
to lower only the forks.

The farther you move the handle the
faster the forks will raise or lower.

RAISE/LOWER CUTOUT (optional)

Your truck may be equipped with automatic cutout of raise
and lower at selected heights.

If Raise or Lower stops and the red fork symbol on the
display is lit, you are at a raise or lower cutout height.

To travel past the cutout height, push the Cutout Override
button while, at the same time, moving the Raise/Lower
handle.

Be very careful and watch that you don't raise, lower or
drive into obstructions when using the Cutout Override.

Know the Hazards

RAISE/LOWER CUTOUT OVERRIDE

Using the Cutout Override allows you to travel, or raise
the platform, into areas where there are obstructions and
hazards such as pipes, ducts, conduits, low ceilings etc.

25 Raise & Lower

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.

Raise & Lower 26

Steering & Travel

Travel, power
unit first

LIFT TRUCKS ARE NOT LIKE AUTOMOBILES

Your lift truck does not steer or drive like
an automobile. Be sure you are trained to

STEER/DRIVE WHEEL DIRECTION DISPLAY

The indicator lights show you whether the drive wheel is
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 (po wer
unit first or forks trailing). Steering is not the same in
both directions.

Know the Hazards

n

o

i

t

n

c

r

e

u

r

T

i

f

D

o

D

i

r

e

o

c

f

t

T

i

u

o

r

n

forks first

n

Travel,

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.

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

27 Steering & Travel

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.

Steering & Travel 28

Traveling & Plugging

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.

PLUGGING

Plugging is another way to slow down or stop your truck.
While the truck is moving, in either direction, rotate the
twist grip through neutral to the opposite directio n of travel .
Use the twist grip to control how quickly you slow down.

Plugging will not hurt your truck.

HORN

Press the horn button to blow the horn. Use it to warn
pedestrians and other drivers.

Use your horn when you leave the aisle or come to an
intersection or crosswalk.

TRAVEL POSITION OF FORKS & CARRIAGE

Before traveling at full speed, you must pivot the forks
and sideshift the carriage so they do not extend past the
sides of the truck. The pivot and traverse indicators will
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.

CHECK YOUR DISPLAY

If your truck won't travel, or operates at a reduced speed,
check the indicator lights on the console display.

Know the Hazards

LOOK WHERE YOU'RE GOING

Travel in the direction where you have the best visibility.

29 Traveling & Plugging

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.

Traveling & Plugging 30

Wire Guidance Option

Guidance Wire

30° MAX

ACQUIRING THE WIRE

Push the wire guidance switch to ON as
you near a guided aisle. Approach the wire
at an angle of 30° or less. Drive slowly and center
the truck over the wire. When you hear a "beep" and the
red light turns off, begin guided driving. Start Slowly.

WHEN DRIVING ON THE WIRE

• Watch where you're going. Make sure your path is clear.

• Always be alert for "beeps" from the alarm or changes
in the indicator lights that signal changes in guidance
status.

• Start slowly after changing direction of travel. Be sure
the truck is following the wire.

AUTOMATIC SLOW DOWN

While traveling on guidance, your truck may slow down
automatically for certain conditions.

• Low signal strength from the wire.

• Truck deviates slightly from the wire.

• End of Aisle Control (optional) is activated.

AUTOMATIC STOP

Your truck may stop automatically for certain conditions.

• Signal strength from the wire is lost or is too low.

• Truck deviates too far from the wire.

FOR MANUAL STEERING

T ake control of steering, push the guidance switch to OFF.
Note: Whenever guidance is OFF, the red light on the

display will flash and the alarm will "beep", at a slow rate,
to remind you that you are in manual steering.

When the truck senses a guidance wire, the rate of both
the "beeping" and the flashing will speed up, to notify you
that a wire is near. To acquire the wire, see page 31.

END OF AISLE CONTROL OPTION

With this feature, your truck will either slow down or stop
automatically when it comes to the end of an aisle. You
will hear a "beep", and the indicator light will turn on.

If the truck stops: let up on the accelerator, press the
override button and resume travel.

Know the Hazards

STAY ALERT

You must be just as careful and alert while driving on
guidance as you are when driving with manual steering.

• Start slowly and look where you're going.

• Always be prepared to steer manually.

• Make sure there is nothing in your path, on the floor or
sticking out of the racks.

• End of Aisle Control (optional) is activated.

31 Wire Guidance Option

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".

Wire Guidance Option 32

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.

• Inspect your harness, tether, snap hooks and mounting
points. Have them replaced if they look damaged or
worn, or have ever been used to stop a fall.

• Clean the safety shields and keep them clear.

• 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.

• Make certain the battery retainer and side cover are
properly installed.

• See that all wheels are in good condition.

• Make sure the flashing light is working.

• Check that both forks are secure and not bent, cracked
or badly worn.

• Inspect all lift chains for damage.

• Look under the truck for signs of hydraulic leaks.

• Adjust the operator seat to the most comfortable position.
Turn the rear view mirror to the best viewing position.

2. Test drive your truck in an uncongested area.

• Try all the hydraulic functions.

• Check that the steering is easy and smooth.

• Drive the truck slowly in both directions.

• Drive through the full speed range in both forward
and reverse.

• Check braking and plugging distances 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 drive the truck.

• Check wire guidance operation.

If anything doesn't look or feel right, don't drive the truck.
Report the problem.

You can get checklist forms from your Crown dealer
(part no. OF-3772). Used properly, this checklist can alert
service people to needed repairs.

• 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

The most

important

component

is you.

?

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 (Load Weight, Load
Center and Lift Height). 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 33 and 34).

If it's not working right, or something is broken, report

the problem. Don't use the truck.

• In an open area, test the braking and plugging. Check
at a slow travel speed first, then a faster one. Know
the distance it takes to stop before you start work.

DRIVE CAUTIOUSLY, BE ALERT

• Wear your harness and have the tether fastened when
elevated and working with an open side gate.

• Never stick an arm, foot 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.

• Keep your hands on the controls and feet on the pedals.

• Travel in the direction that gives you the best view.
Look where you're going, slow down in congested areas.

• Slow down for slippery floors. Don't run over things.

• Travel with the platform close to the ground when
outside of an aisle. Place the load against the vertical
face of the forks.

• Be certain forks and load are in the travel position.

• Look where you are going before you change direction
of travel. Slow down when making turns.

• See that you have room to drive and turn. Check for
overhead objects. Watch out for power unit and fork
(load) swing.

• Make certain the load will clear the operator platform
before you use Traverse, Extend/Retract or Pivot.

35 Be a Safe Driver

• 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...

Be a Safe Driver 36

Be a Safe 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.

• Watch out for power unit and fork (load) swing when
turning.

• Never allow passengers on your truck.

• Keep others away from your truck while you're working.

Don't ever allow anyone on or under the load or forks.

• Don't let anyone use your truck unless they are trained
and certified.

• 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 a safety platform from one

location to another.

AVOID FALLS AND TIPOVERS

• Be extremely careful when working around docks or
ramps. Stay away from the edge.

• 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.

• Watch out for overhead obstructions.

• Turret trucks should not be used on ramps or grades.
If you must drive on a grade, travel slowly and never
turn the truck. If carrying a load, travel with forks
upgrade. If unloaded, travel with forks downgrade.
Keep the fork height below 300mm (12 inches).

LEAVING YOUR TRUCK

• Stop your truck completely before getting off.

• 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.

37 Be a Safe Driver continued

Be a Safe Driver continued 38

Battery Maintenance

107

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.

DANGER

Minimum battery size allowed

Undersize battery can affect truck
handling and stability. You could have
an accident.

XXX mm (XX.XX in.) wide
XXX mm (XX.XX in.) long

Use U.L. classified Type EO battery.

WHEN YOU INSTALL
OR CHANGE BATTERIES

• Turn the truck OFF. Make sure the
parking brake is applied and all other controls
are in neutral. Disconnect the batteries.

• Make certain you use the correct size and weight batteries.
Never operate a truck that has underweight or

undersized batteries installed.

• Use a roller stand to install or remove batteries. Make
sure the roller stand is the same height as the rollers in
the truck's battery compartment. Also be certain the
roller stand is at least as long as your batteries.

• Never let anything metal touch the top of the cells. You
could cause sparks or do damage to the batteries. Use
an insulator (such as plywood) when necessary.

Know the Hazards

TRUCK BATTERIES CAN BE DANGEROUS

Your truck batteries produce fumes that can explode.
They also contain acid that could burn or disfigure you.

• Do not try to install, remove, charge or service your
truck batteries unless you are trained and authorized.

• 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.

39 Battery Maintenance

• Use an approved spreader bar to place the batteries on,
or remove them from a stand. Make sure you
adjust the spreader bar hooks to fit the batteries.

AFTER INSTALLING BATTERIES

• Replace the battery retainer and side cover.

• Connect the batteries. Turn the truck ON and check
truck operation.

WARNING

BATTERY RETAINER

The batteries could slide out if the retainer is not in place.
Check before you operate your truck.

BATTERY SIZE

Make certain you use the correct size and weight batteries.
Never operate a truck that has underweight or undersized
batteries installed.

Continued next page...

Battery Maintenance 40

07

Stay clear of all
moving parts.

Moving parts can
cut or crush hands,
feet, arms or legs.

WARNI GN

09

Standing or riding on the forks can
cause a fall. You can be seriously
injured or killed.

Never stand or ride on forks
for any reason.

WARNI GN

Falling objects or lowering forks can
cause serious injury or death.

Never stand under the forks.

While servicing, block the forks so
they won't fall.

10

WARNI GN

264

Avoid being crushed.

Keep head, arms,
hands, legs, and feet
within the operator
area.

Stop truck completely
before getting off.

Tipovers and falls from
docks can cause
serious injury or even
death.

Make sure you are
safe.

04

It’s the law, you must be trained
and certified to operate this truck.

(OSHA § 1910.178, Rev. 1999)

* Additional copies of the Operators Manual and Truck
Labels can be obtained from Crown Equipment Corp.,
New Bremen, OH 45869 U.S.A.

You or people around you could be
seriously injured or even killed if you
don't use this truck correctly.

Obey all warnings and instructions on the truck
and in the operator manual*.

Inspect your truck before starting work, make
sure it is in good working order.

WARNI GN

43

CAUTION

WARNI GN

Minimum battery size allowed

Undersize battery can affect truck
handling and stability. You could have
an accident.

XXX mm (XX.XX in.) wide
XXX mm (XX.XX in.) long

Use U.L. classified Type EO battery.

41

There are blind spots not covered
by the mirror.

You could hit someone not visible
in the mirror.

Don't drive with the mirror, look
in direction of travel.

WARNI GN

88

WARNI GN

Truck does not automatically slow
down at end of aisles.

Cross traffic does not stop.
Slow Down, look out for people

and other trucks.

44

Unsafe loads can swing or fall
into the operator area causing
serious injury.

Never operate the truck with
a load that is off-center,
oversize, or unstable.

WARNI GN

77

Passengers could be
seriously injured. There
is no safe place for them.

No Passengers.

WARNI GN

DANGER

19

Disconnect battery(s) and consult
Electrical Section of Service Manual
before working on truck.

Serious injury or death could occur.

High voltage can cause electric
shock or burn.

20

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.

DANGER

DANGER

Falling from a raised platform can
cause serious injury or even death.

Attach safety belt and
tether when elevated
and working with an
open side gate.

Battery Maintenance continued

Know the Hazards

Warning Labels

EACH WARNING LABEL
ON YOUR TRUCK IS IMPORTANT

Read and obey all of them to protect
yourself and others.

WARNING

41 Battery Maintenance continued

BEFORE CHARGING YOUR TRUCK BATTERIES

• Charge the batteries in designated areas only.

• See that the battery cells are filled to the proper level.
Never use an open flame to check the batteries.

• Make certain the chargers are the same voltage and
amperage as your batteries.

• Read the battery charger instructions.

• 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.

Warning Labels 42