Crown SP4000 Operator Manual

Operator Manual

You could be killed or seriously injured

if you are not

adequately trained for lift truck operation!

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.

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

stop the 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.

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

You Must be Trained

You Must be Trained 2

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

in your work place until you have

been trained and certiﬁ ed by your employer.

WARNING

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 ﬁ xed 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 ﬂ oor.

3 Protect Yourself

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.

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.

Protect Yourself 4

Know the Hazards

Stay clear of all moving parts.

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

WARNING

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 17

Power On & Off 19

Foot Brake 20

Traveling & Plugging 21

Raise & Lower 25

Platform Safety 27

Daily Safety Check 29

Be a Safe Driver 31

Battery Maintenance 35

Warning Labels 40

Contents

5 Contents

What's in it for You?

What's in it for You? 6

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 ﬁ nd 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 ﬁ nd information about possible safety hazards and how to avoid them

HOW-TO-DRAWINGS

On many pages you will ﬁ nd pictures as well as text to help you understand how to use your truck safely and productively.

Capacity & Display Center

11 Capacity & Load Center Capacity & Load Center

Know the Hazards

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, platform or container. Make sure you spread the load evenly as you load a pallet.

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 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.

Center of evenly distributed load

600mm

(24 in.) Max

761-B

series

SAMPLE

Load

Center

4000

STOCKPICKERS

Your Stockpicker is designed mainly for orderpicking. It is not as efﬁ cient 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. (The harness can be either a belt or a body harness.) 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.

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

Your Stockpicker

7 Your Stockpicker

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

Lanyard Fastened

Harness on

Hands on

Controls

Side Gates Down

Foot On

Brake Pedal

Your Stockpicker 8

Fall Protection Devices

Body Belt

Full Body Harness

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

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

Operator Weight kg (lbs.)

Less than 100 kg

(220 lbs.)

100 - 140 kg1)

(220 - 310 lbs.)

141 - 181 kg1)

(311 - 400 lbs.)

XX X X X

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

of 100kg (220 lbs)

2) Self-Retracting Lanyard - shall be rated for the operator's weight.

For operator weight over 140kg (310 lbs) - contact Crown.

Lift Truck Parts

9 Lift Truck Parts Lift Truck Parts 10

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

Display Panel

Override Switch

(optional)

Wire Guidance

(optional)

Spotlight (optional)

Work Light (optional)

Dome Light (optional)

Fan (optional)

Emergency Disconnect

Raise

Lower

Twist Grip

Horn

Key Switch

*See page 7 for Lanyard & Harness information

Know the Hazards

Capacity & Load Center

11 Capacity & Load Center Capacity & Load Center 12

WHAT IS YOUR TRUCK CAPACITY?

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.

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 plus attachments

• Load center

• Lift height

• Operator weight

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.

Center of evenly

distributed load

600mm

(24 in.) Max

Load

Center

*Truck capacity must be reduced by operator weight in excess of 100kg (220 lb)

Load

Center

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

7010(276) 6095(240) 7010(276) 6095(240)

600(24) 600(24) 900(36) 900(36)

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

Truck Weight with Max. Battery

Truck Type

Attachment Data

PLATFORM

Serial Number

Capacity with Mast Vertical

Capacity

4000

SAMPLE

+ 14 hidden pages