Crown FC5200 Operator Manual

Operator Manual

It’s the law, you must be trained and certiﬁ ed 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.

You Must be Trained

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

Federal law states that only properly trained operators are permitted to operate a powered industrial truck and that your employer must train you and certify that you are qualiﬁ ed to operate this powered industrial truck. (OSHA §1910.178, Rev. 1999)

Do not operate this truck

been trained and certiﬁ ed by your employer.

in your work place until you have

Tipovers and falls from docks can cause serious injury or even death. Grip the steering wheel tightly, brace your feet and lean away from the direction of fall.

You can be trapped or crushed by objects protruding or poking into the operator area.

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.

1 Warning

Make sure you are safe.

Look where you are going.

You could be killed or seriously injured

adequately trained for lift truck operation!

if you are not

You Must be Trained 2

Protect Yourself

Know the Hazards

WEAR YOUR SEAT BELT

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

• Fasten your seat belt 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. 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 dockboards are secure. Check that trailer wheels are chocked. You could be seriously injured or even killed in a fall from a dock or dockboard.

Note:

This is not like

Know the Hazards

AVOID FALLS AND TIPOVERS

Tipovers are very serious accidents. You can be crushed or even killed if you try to jump clear of an overturning or falling sit-down truck. Keep your seat belt fastened, grip the steering wheel tightly, brace your feet, and push yourself back between the side restraints. The best way to prevent injury is 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 ﬂ oor.

• Travel with the load or forks close to the ground and 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.

3 Protect Yourself

• 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 operation of this truck

WARNING

Stay clear of all moving parts.

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

USE YOUR TRUCK SAFELY

• Keep your hands and feet away from all moving parts such as chains, wheels or mast. 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, lower forks to the ﬂ oor, and shut the truck off with the key or power disconnect.

Protect Yourself 4

SAMPLE

Contents

What's in it for You?

Warning 1

You Must be Trained 2

Protect Yourself 3

Contents 5

What's in it for You? 6

Your Sit-Down Rider 7

Lift Truck Parts 9

Capacity & Load Center 11

Capacity Plate 13

Power On & Off 15

Braking 16

Display 17

Raise/Lower, Tilt & Accessories 18

Optional Armrest & Controls 19

Traveling & Plugging 23

Daily Safety Check 27

Capacity & Load Center

Center of evenly distributed load

WHAT IS YOUR TRUCK CAPACITY?

Capacity is the load (including pallet or container) that can be lifted to a given height at a given load center. See the capacity plate on your truck. Make certain you use the correct

600mm

units of measure.

(24 in.) Max

Load

Center

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.

Know the Hazards

SAMPLE CAPACITY PLATE

The information shown on this

sample plate does not apply to

your truck.

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.

Truck Weight with Max. Battery

Attachment Data

Sideshifter

Serial Number Truck Type

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.

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, push-pull, etc.)

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

Capacity

786-A

SAMPLE

Capacity with Mast Vertical

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.

Be a Safe Driver 29

Battery Maintenance 33

Notes 35

Warning Labels 38

5 Contents

11 Capacity & Load Center

Capacity & Load

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. 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.

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 (ANSI/ITSDF) B56.1 (Download free from www.itsdf.org)

• Occupational Safety and Health Act (OSHA) §1910.178, Rev. 1999 (Download free from osha.gov)

• Underwriters Laboratory

(UL 583)

• National Fire Prevention

Association (NFPA 505)

Hands-on controls

Seated

Seat Belt Fastened

7 Your Sit-Down Rider

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.

Your Sit-Down Rider 8

Lift Truck Parts

Hydraulic Levers

Travel Direction Switch

Horn

Tilting Mast

Overhead Guard

Seat

Seat Belt

Seat Adjust Lever

Battery Cover Latch

Load Backrest

Battery Disconnect

Power Unit

Battery

Steer Wheels

Hydraulic Levers

Display

Accelerator Pedal

Key Switch

Service Brake Pedal

Horn

Steering Wheel Tilt Lever

Direction Control

Drive Wheels

Forks

9 Lift Truck Parts Lift Truck Parts 10

Capacity & Load Center

Center of evenly distributed load

(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

600mm

correct units of measure.

Know the Hazards

SAMPLE CAPACITY PLATE

The information shown on this sample plate does not

apply to your truck.

Truck Weight with Max. Battery

Attachment Data

Sideshifter

Serial Number

Truck Type

Load

Center

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

Capacity with Mast Vertical

Capacity

SAMPLE

Load

Center

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.

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.

HYDRAULIC OPERATIONS CAN AFFECT STABILITY

11 Capacity & Load Center

Capacity & Load Center 12

+ 14 hidden pages