Crown FC4000 Operator Manual

This operator manual

has information for

all models of series

FC plus some options and

accessories. Some of the

illustrations and information

4000 SERiES

Operator Manual

may not apply to your truck.

The most important component is you.

New Bremen, Ohio 45869 USA © 2002 PF12999-WEB Rev. 6/06 Printed in U.S.A.

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

(OSHA § 1910.178, Rev. 1999)

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

Read and obey all warnings and instructions in this Manual*
and on the truck.

Head, arms, hands or legs outside the operator area can
be pinned or crushed whenever the truck is moving. Stay
within the operator area and

stop your truck completely before

getting off.

A dockboard can move or drop while you are on it. Or
you could drive off a dock. Falls from docks or dockboards
can cause serious injury or even death.

Make sure you are

safe.

You can be trapped or crushed by driving the operator
area under racks or other objects.

Look where you are going.

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

STOP

that your employer must train you and certify that you
are qualified to operate this powered industrial truck.

(OSHA §1910.178, Rev. 1999)

Do not operate this truck

been trained and certified by your employer.

You could be killed or seriously injured

adequately trained for lift truck operation!

in your work place until you have

if you are not

1 Warning

All rights reserved under International
and Pan American copyright conventions
Copyright 2001 Crown Equipment Corp.

You Must be Trained 2

Stay clear of all
moving parts.

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

Protect Yourself

Know the Hazards

3 Protect Yourself

WEAR YOUR SEAT BELT

Falling from a truck can cause serious injury or even
death.

• Fasten your seat belt and pull it snug before operating
your truck. Keep it fastened until you leave the truck.

• Stay with your truck. Don't jump from an overturning
or falling sit-down rider truck.
stand-up end control rider trucks, where it is
recommended that the operator exit the truck in these
emergencies.

DRIVE CAREFULLY

• Never stick your foot, hand, head or any part of your
body outside the operator area, no matter how slow
the truck is moving. Anything caught between the truck
and a fixed object will be crushed or even cut off.

• Stay away from the edge of docks and ramps. Make
sure dock boards are secure. Check that trailer wheels
are chocked. You could be seriously injured or even
killed in a fall from a dock or dockboard.

• Keep your truck under control at all times. Drive at a
speed that allows you to stop safely. Be even more
careful on slippery or uneven surfaces. Do not drive
over objects on the floor.

LOOK WHERE YOU'RE DRIVING

• 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.

• Be sure that any equipment added to the truck (terminal,
fan, clipboard, etc.) does not block your vision or
interfere with safe and efficient operation of this truck.

Note:

This is not like

Know the Hazards

AVOID FALLS AND TIPOVERS

Tipovers are very serious accidents. You can be crushed
or even killed by the falling truck if you try to jump clear.
Keep your seatbelt fastened, grip the steering wheel
tightly, brace your feet, and lean away from the direction
of fall. The best way to prevent injury is to know where
you are at all times and follow the rules of safe truck

operation.

• Be extremely careful when working around docks,
dockboards and trailers.

• Use forward tilt only when you have the load in a rack,
over a stack or close to the floor.

• Travel with the load or forks close to the ground and
mast tilted back. Watch for overhead obstructions.
Perform all truck movements smoothly and at a speed
that will give you time to react in an emergency.

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

USE YOUR TRUCK SAFELY

• Keep your hands and feet away from all moving parts
such as masts, chains or wheels. Make sure the load

backrest is in place, when required.

• Never stand on or under the forks, or allow anyone
else to stand on or under them. The only way to lift
people is with an approved platform. Never allow
passengers on the truck. There is no safe place for
them.

• Before you leave your truck:

• Come to a complete stop and lower forks to the floor.

• Shut truck off with the key or power disconnect.

• Apply the parking brake.

Protect Yourself 4

Protect Yourself 4

Know the Hazards

SAMPLE CAPACITY PLATE

The information shown on this

sample plate does not apply to

your truck.

Capacity & Load Center 12

Contents

What's in it for You?

Warning
You Must be Trained
Protect Yourself
Contents
What's in it for You?
Your Sit-Down Rider
Lift Truck Parts
Capacity & Load Center
Capacity Plate
Display Panel
Power On & Off
Raise/Lower, Tilt & Accessories
Parking Brake
Service Brake
Traveling & Plugging
Daily Safety Check

11
13
15
17
18
19
20
21
23

1
2
3
5
6
7
9

Capacity & Load Center

4000

SERIES

Truck Weight with Max. Battery

9724

(7788)

Attachment Data

Sideshifter

Serial Number

123456789XX F

WHAT'S IN IT FOR YOU?

The better you understand your truck and how to use it,
the better and safer operator you can be. Here are some
guides to using this manual.

QUICK LOCATORS

In addition to the "Contents" page you
can use page headings to find topics.
Some pages also have a picture of the

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

Capacity with Mast Vertical

(24)

600

Capacity

1745

5230

600

(3850)

(206)

(24)

600

1815

Truck Type

1385
1450

354-001B

(24)

4775

(4000)

(188)

750

(30)

5230

(3050)

(206)

750

(30)

4775

(3200)

(188)

SAMPLE

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.

Be a Safe Driver
Battery Maintenance
Warning Labels

5 Contents

25
29
34

11 Capacity & Load Center

What's in it for You? 6

Your Sit-Down Rider

SIT-DOWN RIDERS

Your sit-down rider truck lifts and stacks loads. It is also
designed to move loads over long distances.

YOUR RIDER TRUCK IS NOT AN AUTOMOBILE

With a load it may weigh more than 4 automobiles, and
the steer wheels are in the rear instead of the front.

FORK FUNCTIONS, STANDARD AND OPTIONAL

Standard fork or hydraulic functions are Raising and
Lowering the forks plus Tilting the mast. Accessories
such as Sideshift or Carton Clamp may also be included.
Your company has decided which features are needed
in your work area and should train you how to use them.

HOW TO DRIVE YOUR TRUCK

Sit down, fasten your seat belt and pull it snug. Adjust
the seat and steering wheel to their most comfortable
positions. Keep your hands on the controls and your
entire body inside the operator area. Look in the direction
you are going.

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

Seated

Seat Belt Fastened

7 Your-Sit Down Rider

Your Sit-Down Rider 8

Lift Truck Parts

Work Lights (optional)

Overhead Guard

Mast

Steering Wheel

Seat

Seatbelt

Emergency Disconnect

Battery Cover Latch

Load Backrest

9 Lift Truck Parts

Hydraulic Levers

Display

Accelerator Pedal

Parking Brake

Key Switch
Service Brake Pedal
Horn

Steering Wheel Tilt Lever

Direction Control

Battery

Steer Wheels

Drive Wheels

Forks

Lift Truck Parts 10

Capacity & Load Center

Know the Hazards

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 load backrest
or vertical face of the fork to the center of an evenly
distributed load.

LOADS MUST BE EVENLY DISTRIBUTED

Your truck could tip over, in any direction, if a
load is shifted to the front or side of a pallet or
container.

SAMPLE CAPACITY PLATE

The information shown on this

sample plate does not apply to

your truck.

4000

SERIES

Truck Weight with Max. Battery

9724

(7788)

Attachment Data

Sideshifter

Serial Number

123456789XX F

Truck Type

354-001B

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

(24)

600

Capacity

1745

(3850)

1815

(4000)

1385

(3050)

1450

(3200)

Capacity with Mast Vertical

5230

(206)

4775

(188)

5230

(206)

4775

(188)

SAMPLE

600
600
750
750

(24)
(24)
(30)
(30)

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

• Position of mast.

CENTER THE LOAD

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

11 Capacity & Load Center

HYDRAULIC OPERATIONS CAN AFFECT STABILITY

Capacities shown on your capacity plate are with the
mast vertical. Be extra careful when tilting a load. (This
also applies to other accessories or attachments your
truck may have, such as sideshift, carton clamp, push­pull, etc.)

Capacity & Load Center 12

Capacity Plate

CAPACITY PLATE INFORMATION

The capacity plate is on the overhead guard. 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 4775mm (188 in). But above 4775 (188),
to 5230 (206), capacity is reduced from 1815 (4000) to
1745 (3850).

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 750mm (30), capacity is r educed
from 1815 (4000) to 1450 (3200).

Caution:

You may not increase capacity if load center is

less than shown on your capacity plate.

Truck Weight with Max. Battery

9724

(7788)

Attachment Data

4000

SERIES

Sideshifter

Serial Number

123456789XX F

Truck Type

A

B

354-001B

600

SAMPLE
CAPACITY PLATE

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

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

(24)

1745
1815
1385
1450

Capacity with Mast Vertical

Capacity

5230

(3850)

4775

(4000)

5230

(3050)

4775

(3200)

(206)
(188)
(206)
(188)

SAMPLE

600
600
750
750

(24)
(24)
(30)
(30)

OTHER LIFT HEIGHTS AND LOAD CENTERS

Contact Crown for capacities at lift heights or load centers
not given on your capacity plate.

Note:

ANSI B56.1 requires that all data be shown first in

Metric units and then USA units.

Know the Hazards

TRUCK WEIGHT

Dockboards, elevators and some floors have limited
capacity. Check your capacity plate for the weight of
your truck. Remember to add the weight of the load you
have 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.

ATTACHMENT DATA

If an attachment on your truck does not match the
information given on your capacity plate, don't operate
your truck. Your capacity plate may be wrong. Report
the problem to your supervisor.

13 Capacity Plate

Capacity Plate 14

Display Panels

10k

STANDARD DISPLAY
METER DISPLAY

During truck operation, the meter will display battery
charge unless a fault is detected. When the key is turned
off, the meter will display seat hours. The lights below
the display show which mode the meter is in.

BATTERY CHARGE LIGHT

The display shows percent of charge left in the battery.
The display will flash to warn you that the battery is
getting low. Have the battery changed or recharged.

10k LIGHT

Indicates hour meter reading is over 10,000 hours.

HOUR METER LIGHT

When the key is turned off, the display will show total
seat hours.

EVENT CODE LIGHT

The display shows the code for a detected event. The
following events can be corrected by the operator.
For other codes contact your supervisor or service

department.

Standard
Display

-01

-08

What To Do

Sit down. Fasten your seat belt.

Remove foot from accelerator.

Enhanced
Display

OPTIONAL ENHANCED DISPLAY

BATTERY CHARGE DISPLAY

The lighted bars show how much charge is left in your
battery. A flashing bar means the battery must be changed
or recharged.

METER DISPLAY

During truck operation, the display will be blank unless
a fault or other event is detected. When the key is turned
off, the meter will display seat hours.

EVENT CODE LIGHT (SERVICE REQUIRED)

The display shows the code for a detected event which
requires service. Contact your supervisor or service
department.

EVENT CODE LIGHT (OPERATOR CORRECTABLE)

The display shows the code for a detected event which
the operator can correct. See chart on page 15, or
event code label on right lift cylinder.

15 Display Panels

-02/3/6

-05

-05

Return direction control to neutral.

Release parking brake.

Make certain battery retainers are secure.

Check brake fluid pressure.

Display Panels 16

Power On & Off

Raise/Lower, Tilt & Accessories

KEY SWITCH

• Turn the key clockwise to
Check that seat alarm and all indicator lights are working.

• If an alarm does not turn off after the test period, report
the problem to your supervisor.

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

• Turn the key counterclockwise (red dot) to shut the
truck off. Always turn the key to
truck.

POWER DISCONNECT

Pull the Power Disconnect handle up to disconnect the
battery and cut power to the truck.

Always use the Power Disconnect if the truck isn't working
right. Don't use the truck, and report the problem to
your supervisor immediately.

Push the Power Disconnect handle down, and turn the
key switch to
battery.

OFF

and back to

TEST

(yellow dot).

OFF

when leaving the

TEST

, to reconnect the

Raise/Lower lever
Tilt lever
Accessory levers (optional)

HYDRAULIC LEVER OPERATION

Pull a lever toward you, away from the mast, and you'll
get the action shown by the symbol in the top of the
lever. Push the lever away from you, toward the mast,
and you'll get the opposite action.

The farther you move the lever from neutral, the faster
the action will be.

For example: Pull the Raise/Lower lever toward
you to raise the forks, as shown by the symbol.
Push the lever away from you to lower the forks.

Note:

The left side of each lever has a different shape, to

help you identify them by feel.

17 Power On & Off

Know the Hazards

HYDRAULIC OPERATIONS CAN AFFECT STABILITY

Capacities shown on your capacity plate are for loads
that are centered and level. Be extra careful when tilting
a load. (This also applies to accessories or attachments
your truck may have, such as sideshift, carton clamp,
push-pull, etc.)

Raise/Lower, Tilt & Accessories 18

Parking Brake

?

Service Brake

PARKING BRAKE ON

Press the end of the parking brake rocker
switch nearest the seat to apply the parking brake.

Always put the parking brake on when you leave the
truck. The alarm will sound if the brake is not applied.

PARKING BRAKE OFF

Press the end of the parking brake rocker switch away
from the seat to release the parking brake.

AUTO-PARK BRAKE OPTION

If your truck has this option, the parking brake will be
automatically applied when you leave the seat or if the
key switch is turned

When you sit down on the seat and turn the key ON, the
Auto-Park Brake will release.

OFF

.

SERVICE BRAKE

Step down on the brake pedal to apply the brakes. When
you step down on the brake pedal you still have power
to the drive motors, unless your truck has the traction
cutout option.

LOW BRAKE PRESSURE

If brake pressure is too low, the alarm will sound
( will show on the enhanced display). You will
not be able to drive the truck because the parking brake
will be automatically applied. Notify your supervisor.

Know the Hazards

19 Parking Brake

MAKE SURE YOUR BRAKES WORK

Test the brakes on your truck 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.

Service Brake 20

Traveling & Plugging

BEFORE YOU DRIVE

Adjust the operator seat and steering
wheel to their most comfortable positions.

Fasten your seat belt and pull it snug.

TRAVEL DIRECTION AND SPEED

Move the direction control away from you, toward the
mast, to travel forks first. Move the control toward you,
away from the mast, to travel power unit first (forks
trailing).

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

When you sit down you must place the direction control
in neutral before you select a direction of travel.

OPTIONAL FOOT OPERATED DIRECTION CONTROL

Instead of the hand operated direction control, your
employer may have selected a foot operated control.
Step on the left side of the pedal to travel forks first, or
the right side of the pedal to travel power unit first (forks

trailing).

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 will not

stop your truck as fast as using the foot brake.
Plugging does not hurt your truck.

HORN

Press the center of the steering wheel to blow the horn.
Use it to warn pedestrians and other drivers.

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

Know the Hazards

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.

LOOK WHERE YOU'RE GOING

Travel in the direction that gives you the best view.

POWER UNIT SWING

Be careful turning while traveling forks first. The power
unit will swing wide in the opposite direction. Make
sure you have clearance, and watch out for people in
the area.

PLUGGING VS. BRAKING

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

21 Traveling & Plugging

Traveling & Plugging 22

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.

• 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 a battery.

• Make certain the battery retainer is properly installed.

• See that all wheels are in good condition.

• Make sure all lights are 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.

• Inspect the seat belt for wear.

• Turn the key to
lights are working.

• Test the horn.

• Make sure the power disconnect works.

TEST

. See that the alarm and all indicator

2. Test drive your truck in an uncongested area.

• Adjust the operator seat and steering wheel to their
most comfortable positions.

• Fasten your seat belt.

• 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.

I

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

problem to your supervisor.

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

23 Daily Safety Check

Daily Safety Check 24

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 23 and

24). If it's not working right, or something is broken,
report the problem to your supervisor. Don't use the
truck.

• Be sure that any equipment added to the truck (terminal,
fan, clipboard, etc.) is positioned so that it does not
block your vision or interfere with safe and efficient
operation of the truck.

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

DRIVE CAUTIOUSLY, BE ALERT

• Fasten your seat belt and pull it snug.

• Never stick an arm or any part of your body outside
the operator area, no matter how slow the truck is
moving. A hand or foot caught between the truck and
a fixed object will be crushed or even cut off.

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

• 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 forks close to the floor and mast
tilted back. Place the load against the load backrest
(vertical face of the forks).

• Look where you are going before you change direction
of travel.

• See that you have room to drive and turn. Always
check for overhead objects.

• Slow down when making turns.

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

• Check clearances before raising or lowering the forks
or load.

• Be extra careful if you must use your truck in an area
where there is a risk of falling objects.

25 Be a Safe Driver

Continued next page...

Be a Safe Driver 26

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 swing.

• 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.

• Have load backrest vertical (never tilt when elevated).

• Make certain truck is in neutral and brake is applied.

• Lift and lower slowly.

• Watch for overhead obstructions.

• Be sure you can see and hear the person being lifted.

• Never transport anyone on the platform from one

location to another.

AVOID FALLS AND TIPOVERS

• Stay with your truck. Don't jump from a moving or
falling sit-down rider truck.

• Stay away from the edge of docks and ramps.

• Check that bridgeplates and dockboards are secure.
Be certain that either the trailer wheels are chocked or
the trailer is locked to the dock. Check capacities. Be
sure your truck, with load, isn't too heavy for where
you are driving.

• Make sure the load you are moving is stable. Spread
the forks as far as you can and center the load. Insert
forks as far under the load as you can. Be even more
careful with long, high or wide loads. They can be less
stable.

• Use forward tilt only when you have the load in a rack,
over a stack or close to the floor. Use minimum fork
tilt to pick up or place a load. When lifting or lowering
outside a rack, keep the load backrest vertical or tilted
back slightly.

• When moving loads on grades or ramps, drive with
your forks pointed upgrade. Without a load, drive with
forks downgrade. Slow down, and don't turn on grades
or ramps.

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.

27 Be a Safe Driver continued

Be a Safe Driver continued 28

Know the Hazards

Capacity & Load Center

11 Capacity & Load Center

Capacity & Load Center 12

Load

Center

Center of evenly
distributed load

24" Max
(600mm)

5230(206)1745(3850) 600(24)

1450(3200)

1385(3050)

1815(4000)

750(30)

750(30)

600(24)4775(188)
5230(206)
4775(188)

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

4685(10324)

Attachment Data

Sideshifter

Truck Type

E

Serial Number

A1234567

000 CL

600(24)

A

B

Center

Load

FC

SERIES

BA

Capacity with Mast Vertical

Truck Wt. as equip., with max. batt.

SAMPLE

QUICK LOCATORS

In addition to the "Contents"

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.

Capacity & Load Center

Battery Maintenance

What's in it for You?

WHEN YOU INSTALL OR CHANGE A BATTERY

• Turn the truck OFF and check that all controls are in
neutral. Disconnect the battery. Tilt the steering wheel
up and raise the battery cover. Remove the side cover
or battery retainer.

• Make certain you use the correct size and weight

ART IN
PROGRESS

QUICK LOCATORS

In addition to the "Contents"

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.

Capacity & Load Center

Battery Maintenance

What's in it for You?

WHEN YOU INSTALL OR
CHANGE A BATTERY

• Turn the truck OFF and check that all controls are in

neutral. Disconnect the battery. Tilt the
steering wheel up and raise the battery cover.
Remove the side cover or battery retainer.

ART IN
PROGRESS

QUICK LOCATORS

In addition to the "Contents" page you can

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.

Capacity & Load Center

Battery Maintenance

What's in

WHEN YOU INSTALL OR CHANGE A BATTERY

• Turn the truck OFF and check that all controls are in
neutral. Disconnect the battery. Tilt the steering wheel
up and raise the battery cover. Remove the side cover
or battery retainer.

• Make certain you use the correct size and weight

ART IN
PROGRESS

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.

Use U.L. classified Type EO battery.

Battery Maintenance

29 Battery Maintenance

WHEN YOU INSTALL OR CHANGE A BATTERY

• Turn the truck

OFF

and check that all controls are in
neutral. Disconnect the battery. Tilt the steering wheel
up and raise the battery cover. Remove the full side
cover or short battery retainer.

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

• If you use a roller stand to install or remove a battery,

make sure the roller stand is the same height as the

rollers in your truck's battery compartment. Also make
sure the roller stand is at least as long as the battery.

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

• Use an approved spreader bar to move a battery to, or

from, the battery compartment or stand. Make sure

you adjust the spreader bar hooks to fit the battery.

AFTER INSTALLING YOUR BATTERY

• Replace the full side cover or short battery retainer.

• Lower and latch the battery cover.

• Connect the battery.

• Return the steering wheel to a comfortable position.
Turn the truck ON and check truck operation.

Know the Hazards

TRUCK BATTERIES CAN BE DANGEROUS

DANGER

WARNING

Your truck battery produces gas that can explode.
It also contains acid that could burn or disfigure you.

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

• 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. when working on batteries.

BATTERY RETAINER MUST BE IN PLACE

The battery could slide out if the retainer is not in place.
Check that the retainer is installed and secure, and battery
cover is latched.

BATTERY SIZE AND WEIGHT IS IMPORTANT

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

BEFORE CHARGING YOUR TRUCK BATTERY

• See that the battery cells are filled to the proper level.

Never use an open flame to check the batteries.

• Check that the charger is the same voltage and
amperage as the battery. Read the battery charger
instructions.

• Be sure the charger is turned
the battery to the charger. Otherwise a spark could
cause the battery to explode. Also, make sure the
truck key switch is turned
neutral.

OFF

before connecting

OFF

and all controls are in

Battery Maintenance 30

Notes

Notes

31 Notes

Notes 32

Notes

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.

Lifting people without
a proper platform could
cause a fall or other
serious injury.

Platform must be built
and used as specified
in OSHA 1910.178 and
ANSI-B56.1.

Stay clear of all
moving parts.

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

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

No Passengers.

Tilting mast forward when forks
are raised and loaded can tip the
truck over causing injury or death.

Do not tilt elevated load forward
unless it is over a stack.

Slow down when turning.

You can tip this truck over if you

turn too sharply for the conditions
around you. Don't risk injury or
death.

Buckle seatbelt

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.

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.

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.

In case of
tip-over

Follow these
instructions:

Hold on tight Brace feet

Don't jump!

Warning Labels

WARNI GN

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

(OSHA § 1910.178, Rev. 1999)

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

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

Avoid being
crushed.

Keep head,
arms,hands,
legs, and feet

within the operator area.

Stop truck completely
before getting off.

Falls from
docks can
cause serious
injury or even
death. Keep

seatbelt fastened, hold
on, and brace your feet
in these emergencies.

You could be
pinned or
crushed by

objects
intruding or poking
into the operator area.

Look where you are
going.

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

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

WARNI GN

WARNI GN

WARNING

WARNI GN

EACH WARNING LABEL
ON YOUR TRUCK IS IMPORTANT

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

WARNING

WARNING

WARNI GN

33 Notes

DANGER

All rights reserved under International
and Pan American copyright conventions
Copyright 2001 Crown Equipment Corp.

Warning Labels 34