Crown TSP6000 Operator Manual

This operator manual

has information for all

models of TSP 6000 series

plus some options and

accessories. Some of the

illustrations and information

6000 SERiES

Operator Manual

may not apply to your truck.

The most important component is you.

New Bremen, Ohio 45869 USA © 2005 PF14534-WEB Rev. 11/06 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.

Falling from a platform can cause serious injury or death. Put on

the operator harness and attach tether when elevated and
working with an open side gate or with the narrow front rail
option.

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.

WARNING

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)

All rights reserved under International
and Pan American copyright conventions
Copyright 2005 Crown Equipment Corp.

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

You Must be Trained 2

Protect Yourself

07

Stay clear of all
moving parts.

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

WARNING

Know the Hazards

3 Protect Yourself

WEAR YOUR OPERATOR HARNESS

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

• Use your operator harness and tether when elevated
and working with an open side gate or with the narrow

front rail option. Read the warnings on the harness.

• Check your harness and tether. Replace them if they
have ever been used to stop a fall, or if 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. You could be pinned or
crushed by objects intruding or poking into the operator
area.

DRIVE CAREFULLY

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

Keep 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.

CHECK YOUR LOADS

• Before you pivot a load, make certain it won't intrude
or poke into the operator area. Do not handle long,
wide or unstable loads. Check clearances before using
traverse.

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

• When traveling out of the aisle, keep the forks or load
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.

• Turret Stockpickers 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.

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

USE YOUR TRUCK SAFELY

• Keep hands and feet away from all moving parts such
as the load handler, 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.

• 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.

Protect Yourself 4

Warning
You Must be Trained
Protect Yourself

1
2
3

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.

Contents
What's in it for You?
Your Turret Stockpicker
Turret Truck Parts
Capacity & Load Center
Capacity Plate
Display Panel
Power On & Off
Sit or Stand Operation
Foot Brake
Platform Safety
Traverse & Pivot
Raise & Lower
Steering & Travel
Traveling & Plugging
Wire Guidance Option

11
13
15
17
18
19
21
23
25
27
29
31

5
6
7

QUICK LOCATORS

In addition to the "Contents" page you

9

Center of evenly
distributed load

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.

Load

Center

600mm

(24 in.) Max

SAMPLE

600(24)

600(24)

Truck Weight with Max. Battery

7050(15540)

7050(15540)

E

E

- - - - - - - - -

A1234567

A1234567

1360(3000)

1360(3000)

815(1800)

815(1800)
955(2100)

955(2100)

100(4)

100(4)

9220(363)1180(2600) 600(24)

9220(363)1180(2600) 600(24)

9220(363)

9220(363)
8000(315)

8000(315)

600(24)8000(315)

600(24)8000(315)
865(34)

865(34)
865(34)

865(34)

"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.

Daily Safety Check
Be a Safe Driver
Battery Maintenance
Warning Labels

33
35
39
42

Your Turret Stockpicker

TURRET STOCKPICKERS

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.

• You don't accelerate the same.

HOW TO DRIVE YOUR TRUCK

Put the side gates down. Keep your hands and feet inside
the operator compartment and on the controls. Look in
the direction you're going.

WHEN TO USE THE HARNESS AND TETHER

Wear your harness and attach the tether whenever the
operator compartment is elevated and you have a side
gate open. (The harness may be either a belt or a body
harness, depending on company and state requirements.)

Wear your harness and tether at all times if your truck
has a narrow front rail option.

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

• Occupational Safety and
Health Act (OSHA)

§1910.178 Rev. 1999

• Underwriters Laboratory
(UL) 583

• National Fire Prevention
Association (NFPA) 505

Hands on
controls

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.

7 Your Turret Stockpicker

Side gates
down

Feet on pedals

Your Turret Stockpicker 8

Primary Mast

Overhead Guard
Work Lights

Foot
Brake Pedals

Foot
Presence Pedals

View reflects narrow

front rail option

Operator Display
Panel

Auxiliary Mast
Operator harness

and Tether
Flashing Light

Lowering Valve
(under rear cover)

Side Gate

Battery (inside)

Load Wheel
Fork

Left Hand Controls:
Steering Handle
Override Option
Fork Pivot
Auxiliary(Fork) Raise/Lower
Auto Fork Pivot
Left Armrest Swing
Integrated Hand Sensor

Right Hand Controls:
Travel
Primary (Platform)Raise/Lower
Traverse
Horn
Seat Rotate
Seat Height
Power Disconnect
Right Armrest Swing
Wire Guidance
Integrated Hand Sensor

Turret Truck Parts 10

Capacity & Load Center

Center of evenly

Load

Center

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 faces 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

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

SAMPLE

600(24)

Truck Weight with Max. Battery

7050(15540)

E

- - - - - - - - -

A1234567

9220(363)1180(2600) 600(24)

1360(3000)

815(1800)

9220(363)

955(2100)

8000(315)

100(4)

600(24)8000(315)
865(34)
865(34)

11 Capacity & Load Center

HYDRAULIC OPERATIONS CAN AFFECT STABILITY

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

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 Plate

CAPACITY PLATE INFORMATION

The capacity plate is on the platform,
above the operator display. 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, 1360kg (3000 lb)
can be lifted to 8000mm (315 in). But above 8000 (315),
to 9220 (363), capacity is reduced from 1360 (3000) to
1180 (2600).

SAMPLE
CAPACITY PLATE

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

TSP

6000

SERIES

Load

SAMPLE

Center

600(24)

557-A

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

Truck Weight with Max. Battery

7050(15540)

Truck Type

E

Attachment Data

- - - - - - - - -

Serial Number

A1234567

Capacity with Mast Vertical

Capacity

1360(3000)

815(1800)
955(2100)

Capacity is reduced as load center increases.

For example: On the sample plate, 1360kg (3000 lb) can
be lifted if the load center is 600mm (24 in). But if the
load center is increased to 865 (34), capacity is reduced
from 1360 (3000) to 955 (2100).

Fork Extend / Offset

100(4)

9220(363)1180(2600) 600(24)

9220(363)
8000(315)

600(24)8000(315)
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/ITSDF 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

Capacity Plate 14

Display Panel

CAPACITY DATA MONITOR (see Caution)

• Fork height limit lights:

how high, or to which lift zone you can raise the load.

• Fork height lights:

lift zone the forks are in. If any of these lights are on, it
means the auxiliary mast is higher than the collapsed
height of the primary mast. Make certain the load and
auxiliary mast will clear any overhead obstructions.

• Overload warning:

the forks are in, the alarm will "beep" and message display
will read . Immediately lower the
load.

Caution:

lights and/or the Capacity Data Monitor is for reference
only. You must always be alert to load center, load
distribution, load height and load weight. You must also
be aware when the load or auxiliary mast extends above
the top of the primary mast, and how much overhead
clearance is needed.

BATTERY CHARGE DISPLAY

The green bars show how much charge is left. A flashing
yellow light means the battery needs to be changed or
recharged.

All information displayed by the fork position

The green bars will light to show

A yellow bar will light to show which

If load is too heavy for the lift zone

DRIVE WHEEL DIRECTION INDICATOR LIGHTS, see page 28

MANUAL STEERING LIGHT, OPTION

Red light means you are in manual steering mode. Take
control of steering tiller.

GUIDANCE LIGHTS, OPTION

Green lights means you are in wire guided mode.

WIRE SIGNAL LIGHTS, OPTION

Amber lights means signal is weak. See message panel.

POWER ON LIGHT

MESSAGE PANEL

The upper half of the message panel is continually
updating fork height, load on forks and battery charge
remaining.

FK HT LOAD BATT
3935mm 1590kg 96%

SAMPLE

MESSAGE

PANEL

CENTER TRAVEL HANDLE

15 Display Panel

SERVICE LIGHT

A yellow light means something needs to be serviced.
Report the trouble to your supervisor, even if the truck
seems to be working OK.

SERVICE & OPTION BUTTONS

See service manual.

The bottom line of the message panel will usually show
time and date. However if truck status or operation
requires your attention, instructions will be displayed
here.

Anytime you hear a beep, or if the truck slows down or
won’t work, check message panel for instructions.

Display Panel 16

Power On & Off

Sit or Stand Operation

KEY SWITCH

• Turn the key clockwise as far as it
will go, to the TEST position. Check that
the alarm and all indicator lights are working.

• Let go of the key and it will return to the ON position.

• Turn the key back to the OFF position to shut the truck
off. Always turn the key to OFF when leaving the truck.

POWER DISCONNECT

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

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

Turn the key switch to OFF and back to TEST to reconnect
the battery.

SIT/STAND OPTION

You can drive while seated, with the seat in one of four
locked positions. Or, with the seat locked in the straight
ahead position, flip the seat up to drive while standing.

Braking and foot presence pedal operation is not the
same for the two operating positions. See pages 19, 20
& 22.

SEAT ADJUSTMENTS

• Pull the release arm under the right armrest to move
the seat up or down.

• Press the trigger on the front of the right multi-task
handle, and rotate the seat until it locks in one of the
four positions.

SIDE SIT ADVANTAGES

The side facing seat position gives you the best view for
driving power unit first. A faster travel speed is also
available with the seat in this position.

17 Power On & Off

ARMREST ADJUSTMENT

You can swing each armrest to the most comfortable
operating position, or to make it easier to get on or off
the truck.

Press the button on the inside of the armrest to release
and swing the armrest.

Sit or Stand Operation 18

Braking

BRAKE PEDAL BRAKING WHEN SEATED

When seated step down on either of the front pedals to
apply the brake.

PRESENCE PEDAL BRAKING WHEN STANDING

In the standing position only, the brake will be applied
if you remove either foot from a presence pedal.

Note:

When in the seated postion, the truck will coast if

you remove either foot from a presence pedal. You can
stop the truck with the brake pedals or by plugging (see
page 29).

Know the Hazards

19 Braking

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.

SEATED VS STANDING OPERATION

Braking and presence pedal operation is not the same
for the two operating positions. Make certain you
understand all operations and stay alert, especially when
changing operating positions.

Braking 20

Platform Safety

Falling from a raised platform can
cause serious injury or even death.

Attach safety harness
and tether when
elevated and working
with an open side gate
or with narrow front
rail option.

DANGER

21 Platform Safety

KEEP THE SIDE GATES DOWN

• Keep the side gates down unless you are
leaving the truck, or required to pick from the
side. The truck will not operate with a gate up.

• Don’t leave the platform when it is elevated.

• Don't sit or climb on the side gates.

• Keep your entire body in the operator area.

HARNESS AND TETHER

Use your harness and tether whenever you are working
from a raised platform and have a side gate open.

Note:

Trucks equipped with the narrow front rail option
have only a right side gate. The harness and tether must
be worn at all times.

Check the harness, tether, snap hooks and mounting
points daily for wear or breakage. If it doesn't look safe
don't use the truck. Report the problem to your
supervisor.

HAND SENSORS

You must have a hand on each of the multi-task controls
for the following load handling functions to operate:

• Auxiliary raise or lower

• Traverse & extend/retract

• Pivot (manual & auto)
You must have a hand on the right multi-task control for

the following to operate:

• Travel

• Platform raise or lower

FOOT PRESENCE PEDALS

Whether sitting or standing, you must have your feet on
two of the three foot presence pedals to operate the
truck.

Note:

If you remove a foot from one of the presence

pedals while standing, the brake is applied. However if
you remove a foot from one of the presence pedals while
seated, the truck will coast. You must use the brake
pedals or plugging to stop the truck (see pages 19 & 20).

CHECK YOUR DISPLAY

If any truck function doesn't work, your hands or feet may
be out of position, check the message area of the display
for instructions.

Know the Hazards

FALLS CAN KILL

You can reduce the risk of injury by being extra careful
while working on an elevated Turret Stockpicker.

• Put the side gates down and keep your entire body
inside the operator area.

• Always watch where you're going. Running into an
object could cause you to fall.

• Wear your harness and keep your tether fastened when
working with an open side gate, or if your truck has

the narrow front rail option.

Platform Safety 22

Traverse & Pivot

TRAVERSE

Roll the thumb ball to the left to move the carriage or forks
to the left. Roll the ball to the right to move the carriage
or forks to the right.

The farther you move the ball from neutral, the faster the
carriage or forks will move.

Before you traverse a load, make certain it will clear the
platform.

PIVOT (left multi-task handle)

Push the thumb ball to the left to pivot the forks clockwise.
Push the ball to the right to pivot the forks counter
clockwise.

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

AUTO PIVOT

This feature allows you to traverse and pivot at the same
time, keeping the mast and forks within the running lines
of the truck.

Press the trigger on the front of the left multi-task handle.
Then roll the traverse thumb ball in the direction you
want the mast and forks to traverse. The forks will traverse
and pivot automatically.

(right multi-task handle)

OPTIONAL FUNCTIONS (right multi-task handle)

This thumb ball movement is available to control optional
functions such as fork tilt or fork positioner.

Your company must train you how to operate any options.

CHECK YOUR DISPLAY

If any hydraulic function doesn't work, check the message
area of the display for instructions.

• The gates must be down.

• The hand sensors and foot-presence pedals must be
actuated.

• Some service conditions may also prevent you from
operating your truck.

EMERGENCY TRAVERSE

If there is a problem with traverse, you can have someone
on the floor assist you by using the power unit emergency
traverse switch. The switch is located under the rear
power unit cover, on the right side of the truck.

• To traverse out of the rack

Locate the platform emergency traverse switch in the
left hand storage area.

Press this switch while your assistant on the floor is
pressing the power unit switch. The forks will traverse
out of the rack. Either of you can stop the movement by
releasing your switch.

23 Traverse & Pivot

• To traverse into the rack

Press the platform switch twice to traverse into the rack.

Traverse & Pivot 24

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.

Primary Raise & Lower (right multi-task handle)

Move the right multi-task handle to the right to
raise the platform and forks. Move the handle
to the left to lower the platform and forks.

The farther you move the multi-task handle
from the neutral position, the faster the
platform will raise or lower.

Auxiliary Raise & Lower (left multi-task handle)

Roll the thumb ball up to raise only the forks,
Roll the ball down to lower only the forks.

The farther you move the ball from the
neutral position, the faster the forks will
raise or lower.

RAISE & LOWER CUTOUT (optional)

Your truck may be equipped with automatic cutout of
raise or lower at selected heights.

To travel past the cutout height, push the Override button
while, at the same time, moving the Raise/Lower control.

Be very careful and watch that you don't raise, lower or
drive into 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.

25 Raise & Lower

EMERGENCY LOWERING

If there is a problem with primary lowering, you can have
someone on the floor lower the platform by using the
emergency manual lowering valve. The valve is located
under the rear power unit cover, on the right side of the
truck. Do not lower if slack or broken chain is indicated.

You must first make certain the forks are traversed clear
of the rack. See page 24 for emergency traverse.

Hitting any obstruction could tip the truck over, causing
serious injury or even death.

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

EMERGENCY LOWERING AND TRAVERSE

Keep all body members within the operator compartment
while performing any emergency operations.

Raise & Lower 26

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
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
(power unit first or forks trailing). Steering is not the
same in both directions.

t

i

o

n

Travel,

forks first

n

o

i

t

n

c

r

e

u

r

T

i

f

D

o

D

i

r

e

o

c

f

T

u

r

n

This shows the direction your
truck will turn, when you turn
the steering handle clockwise.

DRIVE WHEEL DIRECTION INDICATOR LIGHTS

The green light in the center shows you that the drive
wheel is straight (within 1 degree).

The yellow lights to either side show the approximate
position of the drive wheel while turning.

Know the Hazards

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.

27 Steering & Travel

ADJUSTABLE MIRROR

Place the mirror in a position that allows you to see along
the side of the truck and into the aisle behind you.

When adjusting the mirror, keep in mind all seated and
standing positions you normally use.

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 28

Traveling & Plugging

TRAVEL, FORKS FIRST

Push the right multi-task handle away from you to travel
in the direction of the forks (forks first).

The farther you push the handle from the neutral position,
the faster the truck will travel.

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.

You must also make certain that the load does not extend
past the sides of the truck.

TRAVEL, POWER UNIT FIRST

Pull the right multi-task handle toward you to travel in
the direction of the power unit (power unit first).

The farther you pull the handle from the neutral position,
the faster the truck will travel.

PLUGGING

Plugging is another way to slow down or stop your truck.
While the truck is moving, pull or push the multi-task

handle through neutral to the opposite direction of travel.
Plugging will not hurt your truck.

HORN (right multi-task control)

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.

CHECK YOUR DISPLAY

If your truck won't travel, or operates at a reduced speed,
check the message panel 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 brakes are designed to stop the truck in
the shortest distance. Use the brakes in an emergency
or in busy areas.

29 Traveling & Plugging

Traveling & Plugging 30

Wire Guidance Option

Guidance Wire

30° MAX

ACQUIRING THE WIRE

Toggle the wire guidance switch 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, the truck takes control of steering. Start slowly.

WHEN DRIVING ON THE WIRE

• Always watch where you're going. Make sure your
path is clear.

• Always be alert for "beeps" from the alarm, messages
on the display, or 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.

FOR MANUAL STEERING

Take control of the steering handle, toggle the guidance
switch OFF.

Note:

Whenever guidance is OFF, the red light on the

display will be on, and the alarm will "beep" to remind
you that you are in manual steering.

When the truck senses a guidance wire, the red light will
flash and the "beeping" will speed up, to notify you that
the truck senses a wire. To acquire the wire, see
page 31.

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: return the travel control to neutral,
press the override button and resume travel.

Know the Hazards

• Truck deviates slightly from the wire.

• 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.

• Acquiring the wire at an angle greater than 30°.

• Truck deviates too far from the wire.

• End of Aisle Control (optional) is activated.

31 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 32

Daily Safety Check

CHECK YOUR TRUCK BEFORE STARTING WORK

You must make sure your truck is safe to use.

2. Test drive your truck in an uncongested area.

• Try all the hydraulic functions.

• Check that the steering is easy and smooth.

1. Walk around your truck and check it over.

• Inspect your harness, tether, snap hooks and mounting
points. Have them replaced if they look damaged
or worn, or have ever been used to stop a fall.

• 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.

• 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 local Crown dealer
(part no. OF3772). Used properly, this checklist can alert
service people to needed repairs.

• Test the horn.

• Make sure the power disconnect works.

33 Daily Safety Check

Daily Safety Check 34

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.

DRIVE CAUTIOUSLY, BE ALERT

• Wear your harness and have the tether fastened when
elevated, working with an open side gate, or with the
narrow front rail option.

• 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 and feet on the pedals.

• Travel in the direction that gives you the best view.
Look where you're going, slow down in congested
areas.

• Slow down for 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.

?

35 Be a Safe Driver

MAKE SURE YOUR TRUCK IS READY

• Inspect your truck before using it (see pages 33 and

34). 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.

• 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, Extend/Retract or Pivot.

• 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. 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 36

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 300mm (12 inches).

• Stop your truck completely before getting off.

• Lower the forks to the floor. Turn the truck off or
disconnect the battery.

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

37 Be a Safe Driver continued

Be a Safe Driver continued 38

Battery Maintenance

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.

DANGER

Minimum battery size allowed

Undersize battery can affect truck
handling and stability. You could have
an accident.

000 mm (00.00 in.) wide
000 mm (00.00 in.) long

Use U.L. classified Type EO battery.

WHEN YOU INSTALL OR CHANGE THE BATTERY

• Turn the truck OFF. Make sure all controls are in neutral.
Disconnect the battery.

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

• Use a roller stand to install or remove the battery. 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 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 place the battery on,
or remove it from a stand. Make sure you adjust the
spreader bar hooks to fit the battery.

Know the Hazards

TRUCK BATTERIES CAN BE DANGEROUS

Your truck battery produces fumes 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.

39 Battery Maintenance

AFTER INSTALLING THE BATTERY

• Replace the battery retainer and side cover.

• Connect the battery. Turn the truck ON and check
truck operation.

WARNING

BATTERY RETAINER

The battery 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 battery.
Never operate a truck that has underweight or undersized
battery installed.

Continued next page...

Battery Maintenance 40

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

264

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.

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

43

CAUTION

WARNI GN

Minimum battery size allowed

Undersize battery can affect truck
handling and stability. You could have
an accident.

000 mm (00.00 in.) wide
000 mm (00.00 in.) long

Use U.L. classified Type EO battery.

41

There are blind spots not covered
by the mirror.

You could hit someone not visible
in the mirror.

Don't drive with the mirror, look
in direction of travel.

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.

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

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

No Passengers.

WARNI GN

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

568-A

Attach safety harness and tether when
elevated and working with an open side
gate or with narrow front gate option.

Falling from a raised platform can cause
serious injury or even death.

DANGER

Know the Hazards

Warning Labels

EACH WARNING LABEL
ON YOUR TRUCK IS IMPORTANT

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

WARNING

WARNING

Keep all body parts within
the operator compartment
while performing any
emergency operations.

Emergency Traverse Switch

• To traverse out of the rack,

press this switch while your
assistant on the floor presses
the power unit traverse switch.
Release the switch to stop
movement.

• To traverse into the rack,
press this switch a second
time.

41 Battery Maintenance continued

BEFORE CHARGING YOUR TRUCK BATTERY

• Charge the battery in designated areas only.

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

Never use an open flame to check the battery.

• Make certain the charger is the same voltage and
amperage as your battery.

• Read the battery charger instructions.

• Be sure charger is turned off before connecting the
battery to it. Otherwise you might create a spark
which could cause the 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 2005 Crown Equipment Corp.

Warning Labels 42