Crown 40TS Operator Manual

TS

SERIES

Operator Manual

This operator manual has

information for all models

of series TS plus some

options and accessories.

Some of the illustrations

and information may not

apply to your truck.

New Bremen, Ohio 45869 USA © 1997 PF12495-WEB Rev. 6/06 Printed in U.S.A.

The most
important
component
is you.

TS

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.

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

Know the Hazards

WARNING

Stay clear of all
moving parts.

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

07

LOOK WHERE YOU'RE DRIVING

• If you run into things you can be injured. You could
fall, 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 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.

USE YOUR TRUCK SAFELY

• Keep hands and feet away from all moving parts such
as masts or wheels.

• 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.

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. Stay away from
the edge. Watch where you're going.

• When you're not stacking or picking loads, travel with
the forks or load close to the ground. Watch for o v erhead
obstructions. Perform all truck movements smoothly
and at a speed that will give you time to react in an
emergency.

• Turret Sideloaders 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. Keep the fork
height below 300 mm or 12 inches.

An unloaded truck can also tip over. You must be just
as careful using an unloaded truck as you are using a
loaded one.

CHECK YOUR LOADS

• Do not handle long, wide or unstable loads.

• Before you pivot a load, make certain it will not intrude
or poke into the operator area.

• Check that the load will clear the operator platform
before using traverse.

3 Protect Yourself

Protect Yourself 4

600mm

(24 in.) Max

Know the Hazards

Capacity & Load Center 12

Center of evenly
distributed load

Load

Center

Know the Hazards

What's in it for You?

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.

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

Truck Weight with Max. Battery

7050(15540)

TS

Truck Type

E

Attachment Data

CLAMP

SAMPLE

180° Traverse Sideshift

-----------

Load

Serial Number

A1234567

Center

Capacity with Mast Vertical

Capacity

7695(303)1450(3200) 600(24)

1815(4000)

600(24)5565(219)

1000(2200)

7695(303)

865(34)

1270(2800)

865(34)

5565(219)

316-D

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.

Your Turret Sideloader

TURRET SIDELOADERS

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.

HOW TO DRIVE YOUR TRUCK

Sit down and latch the door. Keep your hands and feet
inside the operator compartment and on the controls. Look
in the direction you're going.

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

Seated

Hands on
controls

Door latched

7 Your Turret Sideloader

Your Turret Sideloader 8

Turret Truck Parts

Mirror
Overhead Guard
Work Light
Seat
Auxiliary Mast

Operator Platform

Fork
Primary Mast
Flashing Light
Power Unit
Battery

Horn Button

Display Panel

Pivot Handle

Door

Door Latch

Traverse/Sideshift

Handle

Accelerator Pedal

Key switch

Steering Handle

Brake Pedal

Direction Switch

Raise/Lower Handle

Power Disconnect

Fork override

Controls (inside)

9 Turret Truck Parts

Lowering Valve (inside)
Load Wheel

Turret Truck Parts 10

Capacity & Load Center

Load

Center

Center of evenly
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)

Truck Weight with Max. Battery

SAMPLE

Load

316-D

7050(15540)

Truck Type

E

Attachment Data

CLAMP

180° Traverse Sideshift

--------------

Serial Number

A1234567

Capacity with Mast Vertical

Capacity

1815(4000)
1000(2200)
1270(2800)

7695(303)1450(3200) 600(24)

600(24)5565(219)

7695(303)

865(34)
865(34)

5565(219)

TS

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

HYDRAULIC OPERATIONS CAN AFFECT STABILITY

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

11 Capacity & Load Center

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 & 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, 1815kg (4000 lb)
can be lifted to 5565 (219 in). But above 5565 (219), to
7695 (303), capacity is reduced from 1815 (4000) to
1450 (3200).

SAMPLE
CAPACITY PLATE

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

TS

SAMPLE

Load

Center

316-D

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

Truck Weight with Max. Battery

7050(15540)

Truck Type

E

Attachment Data

CLAMP

180° Traverse Sideshift

---------

Serial Number

A1234567

Capacity with Mast Vertical

Capacity

1815(4000)
1000(2200)
1270(2800)

Capacity is reduced as load center increases.

For example: On the sample plate, 1815kg (4000 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 1815 (4000) to 1270 (2800).

7695(303)1450(3200) 600(24)

7695(303)
5565(219)

600(24)5565(219)
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

Traveling & Plugging 26

Capacity Plate 14

Display Panel

DOOR LIGHT

Red light on when operator door is open.

TRAVERSE/SIDESHIFT LIGHT

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

PIVOT LIGHT

Green light on when forks are pivoted to the travel position.

PALM SWITCH LIGHT

Amber light on when proper palm switch is not actuated.

CALIBRATION INDICATOR LIGHT

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.

ACCESSORY SWITCHES

Work lights, dome light and fan.

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.

RAISE/LOWER CUTOUT LIGHT

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

DIRECTION LIGHTS

Green light on to show direction of travel selected.

PARKING BRAKE LIGHT

Amber light on when parking brake is applied.

GUIDANCE LIGHTS, OPTION

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

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

15 Display Panel

• Amber light on when signal from guidance wire is low.

GUIDANCE SWITCH, OPTION

Display Panel 16

Power On & Off

Foot Brake & Parking Brake

KEY SWITCH

• Turn the key sideways to TEST (yellow dot).
Check that the alarm and all indicator lights are working.

• Let go of the key and it will return to ON (green dot).

• Turn the key vertical (red dot) to shut the truck off.
Always turn the key to OFF when leaving the truck.

POWER DISCONNECT

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

Always use the Power Disconnect if the truck isn't working
right. Don't use the truck. Report the problem to your
supervisor.

Pull up on the Power Disconnect knob and turn the key
switch to OFF and back to TEST to reconnect the battery.

FOOT BRAKE ON

Step down on the brake pedal to apply the brake. This
also cuts power to the drive motors.
Note: Slowing or stopping the truck by plugging (see page

25), requires power to the drive motors. If you have your
foot on the brake pedal, plugging will not work.

PARKING BRAKE

Move the switch up to apply the parking brake. The
indicator above the switch will light when the brake is on.
Always put the parking brake on when you leave the truck.

Some service conditions will also set the parking brake.
Move the switch down to release brake.

Know the Hazards

17 Power On & Off

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.

Foot Brake & Parking Brake 18

Platform Safety

Traverse/Sideshift & Pivot

ELECTRICAL INTERLOCKS

The seat and operator door have interlock
switches built in. You must be seated and have
the door latched before you can operate your truck.

PALM SWITCHES

Interlock, or "palm", switches are also built into the tops
of the Raise/Lower and Traverse/Sideshift handles.

You must have your hand, or palm, on the top of the
Traverse/Sideshift handle while you raise or lower.
Likewise you must have your hand on the top of the
Raise/Lower handle while you traverse, sideshift or pivot.

Note: You must be seated before pressing either palm
switch.

CHECK YOUR DISPLAY

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

TRAVERSE/SIDESHIFT

Move the Traverse/Sideshift 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
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 pivoting a load, make certain
it will not poke or intrude into the
operator area.

OVERRIDE SWITCHES

Sideshift and Traverse/Pivot override switches are located
under the right armrest. Use these switches to get the
forks out of the rack in case of electrical malfunction.

19 Platform Safety

Traverse or Pivot Override

Actuate the Traverse/Pivot override switch while moving
either the Traverse/Sideshift handle or the Pivot handle.

Sideshift Override

Actuate both the Sideshift and the Traverse/Pivot override
switchs while moving the Traverse/Sideshift handle.

Traverse/Sideshift & Pivot 20

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 end 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

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 and, at the same time, move the Raise/Lower handle.

Be very careful and watch that you don't raise, lower or
drive into overhead 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.
Hitting any obstruction could tip the truck over, causing
serious injury or even death.

21 Raise & Lower

Watch out for obstructions anytime you're operating your
truck. Be even more careful when using Cutout Override.

Raise & Lower 22

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

n

Travel,

forks first

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.

23 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 24

Steering & Travel 24

Traveling & Plugging

TRAVEL DIRECTION AND SPEED

Press the top of the direction switch to
travel in the direction of the forks (forks first).
Press the bottom of the switch to travel power unit
first (forks trailing). Check the direction indicators on the
console display (see pages 15 & 16).

Use the accelerator on the floor to control travel speed.
The farther you push it down, the faster the truck will go.

The truck will not travel when the direction switch is in
the center (neutral) position.

PLUGGING

Plugging is another way to slow down or stop your truck.
While the truck is moving, in either direction, select the
opposite direction of travel. Use the accelerator to control
how quickly you slow down.

Plugging does 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.

PLUGGING VS. BRAKING

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

25 Traveling & Plugging

YOU CAN'T HAVE BOTH

Plugging works only when the brake is off. When you
step on the brake pedal, power is cut to the drive motors
and you will not be able to plug.

Traveling & Plugging 26

Traveling & Plugging 26

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.

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 s teering.

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 27.

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

• 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.

• End of Aisle Control (optional) is activated.

27 Wire Guidance Option

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.

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 28

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.

• 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.

• Turn the key to TEST . See that the alarm and all indicator
lights are working. Try the horn.

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.

• Make sure the power disconnect works.

29 Daily Safety Check

Daily Safety Check 30

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 29 and 30).

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

• 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.

• Travel in 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.

• 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/Sideshift or Pivot.

• Avoid sudden movement of controls. Learn to use them
smoothly at a moderate, even rate.

31 Be a Safe Driver

• 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 32

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 300 mm (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. Apply the parking brake.

• Avoid parking on inclines. But if you must, block the
wheels of your truck.

33 Be a Safe Driver continued

Be a Safe Driver continued 34

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.

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 an ything metal touch the top of the cells. Y ou
could cause sparks or do damage to the batteries. Use
an insulator (such as plywood) when necessary.

• 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.

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.

35 Battery Maintenance

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 36

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

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

281

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.

WARNI GN

43

CAU

T

I N

O

WARNIGN

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.

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

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.

45

Moving beam can pin or crush
your head, hands or arms.

Stay completely within the
operator area at all times.

WARNI GN

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

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.

37 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 38