Crown SP 3500 Series, SP 4000 Series Operator's Manual

Operator Manual

WARNING

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.

Falling from a platform can cause serious injury or death.

Put on the operator harness and attach lanyard 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

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.

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.

stop the truck completely

Make sure you are safe.

1 Warning

All rights reserved under International
and Pan American copyright conventions
Copyright 2007 Crown Equipment Corp.

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 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

You Must be Trained 2

Protect Yourself

Know the Hazards

WEAR YOUR OPERATOR HARNESS

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

• Put on your operator harness and attach the lanyard
before operating your truck. Read the warnings on
the harness.

• Check your harness and lanyard daily. Have them
replaced if they have ever been used to stop a fall,
or if they look 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.

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

WARNING

Stay clear of all
moving parts.

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

3 Protect Yourself

USE YOUR TRUCK SAFELY

• Make sure your pallet, cart or fork mounted platform
is secure and won't slide or tip.

• 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.

• Come to a complete stop before you leave your
truck. Lower the forks to the floor and shut the truck
off with the key switch.

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 or
dockboard.

• Be extremely careful when working around docks
and dockboards. Stay away from the edge.

• When you're not picking, travel with the load or forks
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.

• Stockpickers 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, point the forks
upgrade. If unloaded, point the forks downgrade.
Keep the fork height below 300mm (12inches).

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

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.

Protect Yourself 4

Contents

Capacity & Display Center

11 Capacity & Load Center

Warning 1

You Must be Trained 2

Protect Yourself 3

Contents 5

What's in it for You? 6

Your Stockpicker 7

Lift Truck Parts 9

Capacity & Load Center 11

Capacity Plate 13

Display Panel Standard 15

Driving on Wire Guidance 19

Power On & Off 21

Foot Brake 22

Traveling & Plugging 23

Raise & Lower 25

Platform Safety 27

Daily Safety Check 29

Be a Safe Driver 31

Battery Maintenance 35

Warning Labels 40

Load

Center

Center of evenly

WHAT IS YOUR TRUCK CAPACITY?

distributed load

Capacity is the load (including pallet, cart,
container etc.) 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

WHAT IS LOAD CENTER?

Load center is the distance from the end of the
operator platform 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 placed or shifted to the front, back or
side of a pallet, cart, platform or container.
Make sure you spread the load evenly as you
load a pallet.

5 Contents

What's in it for You?

Capacity & Load Center

8563-A

Serial Number

SP

4000

SERIES

Truck Type

Attachment Data

Capacity with Mast Vertical

Truck Weight, Less Load, with Max. Battery,
and Attachment 5

kg(lb)

Capacity

kg (lb) mm (in)

mm (in)

*

Truck capacity must be reduced by operator

weight in excess of 100kg (220 lb)

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 truck in the corner
showing features or functions
covered on that page.

"KNOW THE HAZARDS"

Know the Hazards

KNOW YOUR LOAD

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

SAMPLE

wide loads. Do not handle unstable loads.

600(24)

EXCEEDING TRUCK CAPACITY CAN CAUSE AN ACCIDENT

900(36)
900(36)

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 plus attachments

• Load center

• Lift height

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.

600(24)

3715 (8193)

E

Platform

12345678

1125(2500)
1350(3000)
750(1650)
900(2000)

7010(276) 600(24)
6095(240)
7010(276)
6095(240)

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.

What's in it for You? 6

Your Stockpicker

STOCKPICKERS

Your Stockpicker is designed mainly for orderpicking.
It is not as efficient as other type trucks if it is used to
transport or stack loads.

YOUR LIFT TRUCK IS NOT AN AUTOMOBILE

With a load it may weigh more than 2 automobiles.

• You don't brake the same.

• You don't accelerate the same.

HOW TO DRIVE YOUR TRUCK

Wear your harness and attach the self-retracting
lanyard or energy absorber. See chart below

Put the side gates down. Make sure the pallet, cart or
platform is secure. Put your left hand on the steering
wheel, right hand on the speed control and one foot
on the brake pedal. Look in the direction you're going.

7 Your Stockpicker

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.

FALL PROTECTION / PREVENTION SELECTION CHART

Operator Weight kg (lbs.)

Fall Protection Devices

Full Body Harness

Energy Absorber - max total length 1.8m (6ft)

Self-Retracting Lanyard - max total length 2.4m (8ft)

1) Truck capacity shall be reduced by the operator(s) weight in excess

of 100kg (220 lbs)

2) Energy Absorbing Lanyard is prohibited by CAL-OSHA in the state of

California.

3) All components of the fall protection system shall be rated for the

operator's weight.

< 141 kg

(<311 lbs.)1

X

X

X X

2

X

X

1

141-181 kg1

(311 - 400 lbs.)

X X X X

X

X X

1

(>400 lbs.)

X

3

X

X

>181 kg1

Contact

Crown

2)

X

1

Lanyard Fastened

Harness on

Hands on

Controls

Side Gates Down

Foot On

Brake Pedal

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

Your Stockpicker 8

Lift Truck Parts

Display Panel

Override Switch

(optional)

Wire Guidance

(optional)

Spotlight (optional)

Work Light (optional)

Dome Light (optional)

Fan (optional)

Emergency Disconnect

Raise

9 Lift Truck Parts

Lower

Twist Grip

Horn

Key Switch

Lanyard

Control Module

Display Panel

Steering Wheel

Pallet Grab

Release Handle

Operator Harness*

Lowering Valve

(inside)

Side Gates

Pallet Grab

Foot Pedal

Brake Pedal

Platform

Pallet Grab

*See page 7 for Lanyard & Harness information

Lift 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, cart,
container etc.) 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 end of the
operator platform 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 placed or shifted to the front, back or
side of a pallet, cart, fork mounted platform or
container. Make sure you spread the load evenly
as you load a pallet.

11 Capacity & Load Center