Crown Boiler AWI195 Boiler User Manual
Contents
1. Move control handle to brake position to stop truck Watch out for people and other trucks e Do not walk in the path of a coasting truck Stay to the side of the truck with your arm extended and keep your feet clear e Watch out for people an e Use coast while traveling power unit first only e Always turn coast off when you finish a coast operation or whenever you leave your vehicle e For QuickCoast equipped trucks when you turn coast off or turn the truck off make certain your body is not in the path of the control handle as it returns to vertical 21 Coast Controls optional continued QuickPick Walkalong Control optional QUICKPICK WALKALONG CONTROL OPTION You can use this option usually along with the coast option see pages 19 20 amp 21 to make it even easier to pick loads Use these options when picking items located close to each other in an aisle usually within 4 bays or about 11 meters 36 feet QUICKPICK WALKALONG CONTROL BUTTONS You can use the QuickPick controls from either side of the truck Place your hand on the end of the control handle closest to you Press both buttons at the same time Your truck will travel power unit first at the maximum walkie speed You have only one travel speed while using the QuickPick option You can control travel speed by releasing and pressing the control buttons occasionally Use the twist grips anytime you need better control of tra2. and the hazards that go with it Don t drive the truck if you com p one nt have any doubts e Know the capacity of your truck Make certain you use the correct units of measure Is you e 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 e Make sure your hands and shoes are clean and dry and your clothing is proper for the job MAKE SURE YOUR TRUCK IS READY e Inspect your truck before using it See pages 25 and 26 If it s not working right or something is broken report the problem to your supervisor Don t use the truck e In an open area test the braking Check at a slow travel speed first then a faster one Know the distance it takes to stop before you start work 27 Bea Safe Driver WHEN RIDING e Never stick a foot or any part of your body outside the operator area no matter how slow the truck is moving You cannot stop 1360 kg 3000 pounds with any part of your body A foot or hand caught between the truck and a fixed object will be crushed or even cut off e Keep your hands on the controls and feet on the platform e Stop your truck completely before getting off WHEN WALKING e Stay to the side of the truck when traveling power unit first Make sure the truck won t hit your leg or run over your foot e When traveling forks first keep both hands on the control Be careful when changing direction Keep yo
3. are in good condition e Clean the twist grips and grab bar e Check that both forks are secure and not bent cracked or badly worn e Look under the truck for signs of hydraulic leaks e Test the horn e Make sure the power disconnect works e Check that all controls work smoothly e See that the load backrest is in place and fastened if your truck has that option 25 Daily Safety Check 2 Test drive your truck in an uncongested area e Test raise and lower operation e Check the steering e Drive the truck slowly in both directions Check the reversing button e Check braking distance in forward and reverse Load size and floor conditions can affect these distances e Drive through the full speed range in both forward and reverse e 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 e Check Coast QuickPick controls and any other options your truck may have If anything doesn t look work 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 Daily Safety Check 26 Be a Safe Driver Th emo st MAKE SURE YOU ARE READY TO DRIVE e Do not use this truck unless you are trained and certified m p or t an t e Be certain you understand how your truck works
4. battery to explode XXX mm nate n wide XXX mm long BATTERY SIZE IS IMPORTANT Undersize battery can affect truck handling and stability You could have Make certain you use the correct size type and weight an accident Use U L classified Type E battery of battery Never operate a truck that has an underweight or undersize battery installed XX XX in All rights reserved under International and Pan American copyright conventions Copyright 2003 Crown Equipment Corp 33 Battery Maintenance continued Warning Labels 34
5. flush immediately Get medical attention if your eyes are affected BATTERY RETAINERS MUST BE IN PLACE The battery could slide out if all retainers are not in place Check that both retainers are installed before operating your truck 107 COAST SELECTOR MUST BE OFF Be sure the coast selector is off and the brake is on before removing or installing a battery Continued next page Battery Maintenance 32 Battery Maintenance continued Warning Labels BATTERY CHARGE METER OPTION The red yellow and three green lights show how much EACH WARNING LABEL ai is ef in your n Mi pear ond ma ON YOUR TRUCK IS IMPORTANT yellow lights remain on the battery is getting low en only the red light remains on and the display reads 20 emer hat ae ETO PRONG or less you must have the battery changed or recharged l At this point you will no longer be able to lift the forks p Avoid being crushed Keep head arms hands legs and feet within the operator area Stop truck completely before getting off However tipovers and f can cause serious injury Immediately exit and Stay clear of all moving parts o Moving parts can cut or crush hands Truck will coast Move tiller to brake position to st if A DANGER 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
6. 4000 series Operator Manual New Bremen Ohio 45869 USA 2003 PF14182 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 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 However falls from docks can cause serious injury or even death Immediately exit and move away from the truck in these emergencies 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 All rights reserved under International and Pan American copyright conventions Copyright 2003 Crown Equipment Corp 1 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 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 tr
7. ccupational Safety and Health Act OSHA 1910 178 Rev 1999 e Underwriters Laboratory UL 583 e National Fire Prevention Association NFPA 505 Feet on platform Your Walkie Rider Pallet Truck 8 Lift Truck Parts Control Handle Power Disconnect Grab Bar Coast Control Options see pages 19 20 amp 21 Pw oe Battery Retainer Key Switch on power unit Platform Control Arm 9 Lift Truck Parts Travel Twist Grip QuickPick Walkalong Control Buttons Optional Lower Button Raise Button Reversing Button Horn Button QuickCoast Selector optional see pages 19 20 amp 21 Raise Button Lower Button High Travel Speed Button Horn Button Lift Truck Parts 10 Capacity Plate SAMPLE CAPACITY PLATE The information shown on this sample plate does not apply to your truck Units of measure kg mm b in Max Battery I 1460 3224 p e n am SERIES Serial Number A1234567 11 Capacity Plate CAPACITY PLATE INFORMATION The capacity plate is on the top of the power unit cover It contains e Capacity information e Truck type a fire safety rating e Truck weight does not include load e Grade rating e Battery information e Truck information WHAT IS YOUR TRUCK CAPACITY Capacity is the maximum load that can be lifted or transported with your truck See the capacity plate on your truck Make certain you use the corre
8. ct units of measure Capacity with Eqt ally Distributed Load Truck Data Number Max Grade 1234567890123456 2003 o Battery Weight Hour Rate Min 440 975 Max 680 1500 Truck Weight Less l attery 5 Model Number ine Voltage 780 1724 PW4000XX 240 E This truck as released conforms to the mandatory tole gTintelaicsmem ats m okolomm Mmm OcO i 7 lt 0 EEEO A AOO STe AU ai Battery Type Load Tire Tread Width Max AMP Hr 3 330 712 9 Note ANSI B56 1 requires that all data be shown first in Metric units and then USA units Ai Know thefa ar s ruck ty not permitted in areas where there are gt fire ere Watch o marked areas For example You must not drive a type E or ES truck into an area restricted to EE or EX trucks 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 battery and the load you have on the forks Capacity Plate 12 Power On amp Off 13 Power On amp Off KEY SWITCH Turn the truck on by turning the key to ON green dot Turn the truck off by turning the key to OFF red dot Always turn the key off and make certain coast is off when leaving the truck POWER DISCONNECT Pull up on the battery connector to disconnect the battery and cut all power Always disconnect the battery any time the truck isn t working right The key switch does
9. en more careful on slippery or uneven surfaces Do not drive over objects on the floor e Perform all truck movements smoothly and at a speed that will give you time to react in an emergency Ay Know the Hazards A WARNING Stay clear of all moving parts Moving parts can cut or crush hands feet arms or legs LOOK WHERE YOU RE DRIVING e You could be pinned or crushed by objects intruding or poking into the operator area e Always be alert to the area around you and watch where you are driving AVOID FALLS Falls from docks are very serious accidents you can be crushed or even killed Immediately exit and move away from the truck in these emergencies Note This is not like sit down rider trucks where it is recommended that the operator stay with the truck 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 YOUR TRUCK SAFELY e Keep your hands and feet away from all moving parts such as forks or wheels e Never allow passengers on the truck There is no safe place for them e Before you leave your truck e Come to a complete stop e Lower the forks to the floor e Shut the truck off with the key or disconnect the battery e Make certain coast is off Protect Yourself 4 Contents What s in it for You WHAT S IN IT FOR YOU The better you understand your t
10. he back of the grab bar opposite the raise lower switches The no orake symbol at the base of the control handle will light and a single beep will sound to warn that the truck is in the coast mode With coast on the truck will coast when you let go of the control handle You must move the handle to a brake position to apply the brake A beep will continue to sound as long as the handle is in the brake position COAST OFF To turn coast off either press the high travel speed button on the grab bar turn the key switch to OFF or disconnect the battery The no brake symbol will go out and the control handle will return to vertical If you accidentally hit the reversing button when the handle is in the coast position coast is also disabled When coast is disabled braking will return to standard operation see page 15 Continued next page Coast Controls optiona 20 000000000 o00000000000 e 0000000000 000000000000 00000000000 o000000000 D oo0oo0000000 oooo0o0000 0000000 000000 ae e Travel power unit first only o0000 o00000 see 7 e Don t get in the path of the truck 00000000000 000000000000 e0000000000 e 0000000000 000000000 e Watch your feet e Stay to the side of the truck Keep your arm extended to give maximum clearance between you and the truck Recommended Walking Area Truck will coast O gt if handle stays in drive position when released
11. not cut all power to the truck Don t use the truck if it s not working right Report the problem to your supervisor Steering amp Travel STEERING You control steering by moving the control handle from side to side For example This picture shows the directions the truck can turn when the control handle is moved to the approximate position shown 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 amp Travel 14 Braking Brake AC oN Brake Off N Brake On x 15 Braking BRAKING To apply the brake move the control handle either down or up to one of the braking positions Braking is different if you use the coast feature see pages 19 20 amp 21 Always check the braking and the position of the coast selector before you start driving SIIILLLIAA d a wall cut off MAKE SURE YOUR BRAKE WORKS Test the brake on your truck at the start of each shift Know the distance it takes to stop before you start working If at any time the stopping distance is too long for you to stop safely don t drive the truck Report any problem to your supervisor Raising amp Lowering RAISE Push either raise button until the forks are at the desired height LOWER Push either lower bu
12. of your truck e Make sure coast Is off 29 Be a Safe Driver continued d S Forks pointed upgrade Forks pointed downgrade AVOID FALLS e Stay away from the edge of docks and ramps e 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 e Make sure the load you are moving is stable Center the load Be even more careful with long high or wide loads They can be less stable e Don t drive onto an elevator unless you are authorized Check the capacity or load limit and make sure there are no people present Enter load first and set the brake BE CAREFUL TRAVELING ON RAMPS AND GRADES When Riding e With a load drive with the forks pointed upgrade e Without a load drive with forks downgrade When Walking e Stay out of the path of the truck e With or without a load drive with the forks pointed downgrade e If a load requires that you travel with the forks upgrade be even more careful Operate the controls from the side of the truck Slow down and don t turn on ramps or grades Be a Safe Driver continued 30 WHEN YOU INSTALL OR CHANGE BATTERIES e Turn the truck OFF Be sure the coast selector is off and the brake is applied e Make certain you use the correct size and weight battery Never operate a truck
13. ruck and how to use it the better and safer operator you can be Here are some meting suides to using this manual You Must be Trained 2 Protect Yourself 3 QUICK LOCATORS Contents 5 Pa QuickPick Walkalong Control optiona In addition to the Contents page you What s in it for You 6 can use page headings to find topics E Some pages also have a picture of the Your Walkie Rider Pallet Truck 7 truck in the corner showing features Lift Truck Parts 9 or functions covered on that page Capacity Plate 11 HOW TO DRAWINGS Power On amp Off 13 On many pages you will find pictures l as well as text to help you understand Steering amp Travel 14 how to use your truck safely and Braking 15 sop TERS POCNE Raising amp Lowering 16 A mK KNOW THE HAZARDS Traveling 17 m nN ene Watch for and read these special Coast Controls optional 19 i vo l Ak now the Haz afd is Z 14 VLA Z 14 4 14 blocks You will find information about possible safety hazards and how to QuickPick Walkalong Control optional 22 avoid them Additional Options 23 rm Daily Safety Check 25 Be a Safe Driver 4 21 Coast Controls optional continued QuickPick Walkalong Con Battery Maintenance 31 Warning Labels 34 5 Contents What s in it for You 6 Your Walkie Rider Pallet Truck WALKIE RIDER PALLET TRUCKS As a rider your pallet truck is designed to move loads over long distances You can also use it as a Walkalong t
14. ruck and pick stock with it YOUR PALLET TRUCK IS NOT AN AUTOMOBILE With a load it may weigh more than 3 automobiles e You don t steer the same e You don t brake the same e You don t accelerate the same HOW TO DRIVE YOUR TRUCK WHILE WALKING Forks First When traveling forks first use both hands to operate the control handle Watch your feet if you change direction of travel Power Unit First When traveling power unit first stay to one side of the truck and slightly ahead of the power unit Use the hand closest to the truck Fecamneided to operate the control handle Walking Area Watch your feet Stay out of the path of the truck 7 Your Walkie Rider Pallet Truck HOW TO DRIVE YOUR TRUCK WHILE RIDING Keep both feet on the platform Place one hand on the control handle and the other on the grab bar Keep your entire body within the operator area GIVE YOUR BODY A BREAK Take advantage of stop time Get off the truck and flex your arms and legs Staying alert will help you be a better and safer driver Hand on grab bar BUILT TO STANDARDS Hand on This truck was designed and built control handle to current industry and government standards and guidelines For more information see the following e American National Standards Institute ASME B56 1 e O
15. that has an underweight or undersize battery installed e 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 e Use an approved spreader bar to place a battery in or remove it from the battery compartment or a stand Make sure you adjust the spreader bar hooks to fit the battery USING A ROLLER STAND e 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 the truck s battery compartment Also make sure the roller stand is at least as long as your battery AFTER INSTALLING YOUR BATTERY e Replace the battery retainers Make certain the retainers on both sides of the truck are in place e Connect the battery Turn the truck ON and check truck operation 31 Battery Maintenance Note DELAY ON LIFT When the battery is connected to the truck there is approximately a 10 second delay before lift is available bah DANGER 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 to work on batteries Use that area for all battery work e Use protective equipment such as gloves eye shields aprons etc Batteries contain Sulfuric Acid which causes severe burns Do not get in eyes on skin or clothing In case of contact
16. tton until the forks are at the desired height Raising amp Lowering 16 Traveling 17 Traveling TRAVEL Rotate the top of the twist grip in the direction you want to travel The farther you rotate the grip from the neutral position the faster the truck will travel ONE TOUCH HIGH TRAVEL SPEED For high travel speed while riding the truck rotate the twist grip then press and release the high travel speed button on the grab bar Rotate the twist grip to the maximum travel speed position When the twist grip is returned to neutral the speed control will reset to standard operation HIGH TRAVEL SPEED WITHOUT ONE TOUCH Rotate the twist grip then push and hold the high travel speed button on the grab bar Rotate the twist grip to the maximum travel speed position When the twist grip is returned to neutral the speed control will reset to standard operation REVERSING BUTTON If you accidentally hit the reversing button while working in close quarters the truck will move in the direction of the forks until the button is released Be careful The reversing button cannot prevent all injuries MMoowthe Hazards A A AAAA Recommended Walking Path 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 driving into walls or racks or other fixed objects You could also be seriously inj
17. uck in your work place until you have been trained and certified by your employer You could be killed or seriously injured if you are not adequately trained for lift truck operation You Must be Trained 2 Protect Yourself Recommended Walking Path 3 Protect Yourself Ay Know the Hazards DRIVE CAREFULLY e When walking keep to the side of the truck while traveling power unit first Make certain the truck won t hit the back of your leg or foot Don t let the truck run over your foot If traveling forks first keep both hands on the control handle and be careful when changing direction of travel Keep your feet clear of the truck When riding keep your hands on the controls and feet on the platform Keep your body within the operator area While riding never stick a foot or any part of your body outside the truck no matter how slow the truck is moving This truck weighs about 1360 kg or 3000 pounds even without a load You cannot stop or slow it down with your foot hand or any part of your body A foot or hand 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 Keep your truck under control at all times Drive ata speed that allows you to stop safely Be ev
18. uctions The work assist tube does not have a gripping surface nor is it located to serve as a handhold Always keep one hand on the grab bar while riding Make certain any options fastened to the work assist tube do not interfere with operation of the control handle AKnowthe hazards AA AAA Watch For Obstructions Make certain this tube will clear doorways and any surrounding obstructions Make certain the work assist tube will clear all doorways lighting racks and other surrounding obstructions This Tube Not A Handhold Keep your hands in the proper operating position while riding Be sure any additions to the work assist tube will not interfere with control handle movement Handle Must Move Freely Do not add any SIMILAR LOOKING TRUCKS CAN BE DIFFERENT If you ever drive a different truck even one that looks just like yours be careful It may not have the same options device that will interfere with movement of the control handle 478 A Additional Options 24 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 e 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 e Make certain the battery retainers on both sides of the truck are properly installed e See that all wheels
19. ur feet clear of the truck DRIVE CAUTIOUSLY BE ALERT e Look where you are going Don t let your hands or feet get pinned or crushed e Travel in the direction that gives you the best view Slow down in congested areas e Slow down for wet or slippery floors Don t run over things e Look where you are going before you change direction of travel e See that you have room to drive and turn Watch out for power unit swing Slow down when making turns e Avoid sudden movement of controls Learn to use them smoothly at a moderate even rate e 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 28 Be a Safe Driver continued WATCH OUT FOR OTHER PEOPLE e Slow down Yield or stop for pedestrians Use your horn when you come to a crosswalk or intersection e 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 e Never allow passengers on your truck e Keep others away from your truck while you re working Don t ever allow anyone to ride on the load or forks e Don t let anyone use your truck unless they are trained and certified e Don t use the coast option if there are people in the aisle WHEN LEAVING YOUR TRUCK e Lower the forks Turn the truck off or disconnect the battery e Avoid parking on inclines But if you must block the wheels
20. ured by objects intruding or poking into the operator area Traveling 18 Coast Controls optional A Brake ON Coast Brake On COAST AWALKALONG CONTROL OPTION You can use one of two optional coast controls to make it easier to pick loads while walking short distances with the truck This feature allows the truck to coast when you let go of the control handle However you can apply the brake by moving the control handle to one of the brake positions Be even more careful when using coast Make sure you understand the possible hazards Don t place yourself or others at risk High travel speed is not available while coast is engaged OPTION 1 MANUAL COAST SELECTOR COAST ON Move the control handle to the coast position and shift the coast selector lever toward the control arm With coast on the truck will coast when you let go of the control handle You must move the handle to a brake position to apply the brake COAST OFF Move the control handle down and shift the coast selector away from the control arm When coast is disabled braking will return to standard operation see page 15 19 Coast Controls optional Truck will coast O gt if handle stays in drive position when released Move control handle to brake position to stop truck OPTION 2 ELECTRONIC QuickCoast SELECTOR COAST ON Move the control handle to the coast position and press the coast selector button on t
21. vel speed or steering ar MMM LLNS e Limit u between picks in clear aisles e Use the twist grips if you need better control of travel speed or steering QuickPick Walkalong Control optiona 22 Additional Options ls a f a CF 7 a i FZ 7 Z 4 gt VN 4 F NEV L ym aw N _V LOAD BACKREST OPTION Your company may have ordered a load backrest if you must handle loads that are unstable or not secured Don t place your hand or arm over the backrest It could be pinned or crushed by the load There are three types of backrest PIVOTING TYPE Lift up on the handle and swing the backrest forward if you need to service the battery When you return the backrest to the upright position make sure the handle is all the way down and the backrest can t swing forward LIFT OFF TYPE You can remove or install this backrest as required Note Use a hoist if the backrest is heavy BOLT ON TYPE Need not be removed to change the battery SKID ADAPTOR OPTION Lift the skid adaptor until you can move it forward and lower it to the forks Make certain the skid adaptor is secure when you return it to the upright position 23 Additional Options WORK ASSIST TUBE OPTION This feature provides a location for attaching work assist options such as lights fan clipboard etc While traveling be sure that the work assist tube will clear doorways and other surrounding obstr
22. when charging Connect charger properly or truck can be damaged Make certain charger is pluggeq into the battery connector not the truck connector This battery contains Sulfuric Acid which causes severe burns Do not get in eyes on maa or encase In case of contact flush immedia with water Get medical at affected imum battery size allowed XX mm XX XX in wide XX mm XX XxX in long ersize battery can affect truck dling and stability You could have ccident 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 warnings and instructions on the truck and in the operator manual Truck will coast O gt if handle stays in drive Inspect your truck before starting work make position when released sure it is in good working order Make certain the charger is the same voltage and TE as your oi e Read the battery charger instructions Move control handle to Additional copies of the Operators Manual and Truck brake position to stop truck Labels can be obtained from Crown Equipment Corp New Bremen OH 45869 U S A e Be sure the charger is turned OFF before connecting the battery to the charger Otherwise you might create Minimum baten size dioded a spark which could cause the
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