ee eet Cee mE This operator manual has information for all models of series R 5700 plus some options | accessories. Some of the strations and information jot apply to your truck. The most important component is you.A WARNING It's the law, you must be trained and certified to operate this truck, (osita §1910,178, Rew. 1999) Read and ob on the truck Head, hands, legs or feet outside the operator area can be rushed whenever the truck is moving. Stay within the ea and stop the truck completely before getting off However, tipovers and falls from docks can cause serious injury or even death, Immediately exit and move away from the truck in these ‘emergencies, You can be trapped or crushed by driving the operator area under racks or other objects. Look where you are going, Inspect your truck before star working order. ng work, make sure is in good and at Truck Labels can be obtained Jon, New Bremen, Ohio 45889 USA, 1 Warning Warning Labels EACH WARNING LABEL ‘A wana 4 A | [ Awannne Warning Labels 42Notes You Must be Trained IT'S THE LAW, YOU MUST BE TRAINED AND CERTIFIED Federal law states that only property t are permitted to operate a powered ind Donot operate this truck in your work plac have been trained and certified by your ery You could be! adequately 41 Notes You Must be Trained 2Protect Yourself Ad Know the Hazards DRIVE CAREFULLY ‘* Keep your hands on the controls and feet on the pedals/pad. Keep your entire body in the operator area. ‘+ Never stick a foot or any part of your body outside + Stay away from the edge of docks and ramps. Make sure dockboards are secure. Check that trailer wheels socked, You could be seriously injured or even Drive ata ‘0 stop safely. Be even more ippery or uneven surfaces. Do not drive over objects on the floor. | LOOK WHERE YOURE DRIVING * Always be alert to the area around you and watch 3 Protect Yourself [AFTERINSTALLING YOUR BATTERY + Replace the battery retainer. ce! fe truck are in the place, S are properly adjusted ) BATTERY SIZE | © Make certain you use the correct size and weight batiery. Never operate a truck that has an. \derweight or undersized batter led. BATTERY RETAINERS Battery Maintenance continues 40Battery Maintenance continued WHEN YOU INSTALL OR CHANGE BATTERIES k OFF. Disconnect the battery. Check weight battery. Never operate \derweight or undersized bat 12 sparks or do damage to the battery. Use an insulator (su lywood) when necessary. to place a battery on, Make sure you adjust the the battery. spreader bar 39 Battery Maintenance continues A Know the Hazards AVOID FALLS AND TIPOVERS you can be crushed o move away from the tru Note: This is not like sit-down rider trucks, where itis = Be extremely cai dockboards and give you time to react in an emergency. * An unloaded truck can tip over also. Be just as careful using an unloaded truck as you are using a foacied one, USE YOUR TRUCK SAFELY Siay clea moving parte. | * Keep your hands and feet away from all moving parts such as masts, chains, forks or wheels. Make sure the ‘overhead guard and load backrest are in place + Never stand on people is with an approved platfor passengers on the truck. There is no safe place for them: ks to the floor, er disconnect. Protect Yourself 4Contents Waring 1 Yourust be Trained 2 Protect Yourself 3 Contents 5 6 Capacity & Load Center fl ° Capacity &Load Center 1" copacityPiate 3 5 switch Panel 18 ower On &OMt 9 Foot Brake a A Know the Hazards Traveling & Plugging 2B Steering & Travel 2s "| BEFORE CHARGING YOUR TRUCK BATTERY ‘Two Types of Steering 6 Never use an open flame to Fork Functions 2» * Make certain the i amperage a Daily Safety Check 3 seer ett i i bite 7 ona and ts « Read the battery charg poe © Be sure the charger is t Battery Maintenance 37 the battery to the charger. Seco 2 a spark which Could cause the battery to exp 5 Contents Battery Maintenance 38Battery Maintenance What's in it for You? WHAT'S INIT FOR YOU? Th r you understan the better and safer some guides to using this manual HH Quick Locators | adkton tthe Ise page headings Ad know the Hazards Ad Know the Hazards how to avoid them, HOW-TO-DRAWINGS, ONCE 0 produces gs that can explode. a that could bum or disfigure you. aoe pictures as wel ge 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 ‘area for all battery + Use protective equipment such as gloves, eve shields, aprons etc. 37 Battery Maintenance What's init for You? 6Your Narrow-Aisle Truck NARROW-AISLETRUCKS Your narrow-aisle rider truc wads, Lis designs narrower aisles to give maximum storage. ‘YOUR LIFTTRUCK IS NOT AN AUTOMOBILE With a toad it may weigh as much as 3 automobiles, + You don't steer the same, + You don't brake the same. + You don't accelerate the same, FORK FUNCTIONS, STANDARD AND OPTIONAL Raising and Lowering the forks, Tilt (up and down), and Reach (in and out) are standard on the RR and RD AVOID FALLS AND TIPOVERS += Stay away from the edge of docks and ramps. Check that bridgeplates and dockboards are secure. Be certain that either the trailer wheels are chocked or the forks as far as you can and certer the load. Insert the forks as far under the load as you can. Be even more careful wit igh of wide loads. They can bbe less stable. Use iminimum fork tit. to pick up or place a load : ‘When lifting or lowering outside a rack, keep the foad (light and left}, or other options such as Rack Height Select. Your Company has decided which fectures are Paes ene eee needed in your work area and should train you how to ‘+ When moving loads on grades or ramps, drive with use them. ‘your forks pointed upgrade. Without a load, drive with forks downgrade. Slow down, and don’t turn on sredes or ramps. LEAVING YOUR TRUCK * Stop your truck completely before getting off ‘* Lower the forks to the floor. Turn the truck off or push the Power Disconnect button. + Avoid parking on inclines. But if you must, block the wheels of your truck HOWTO DRIVE YOUR TRUCK Your truck is designed with a tilted floorboard and _ padding in the operator area. You drive your trick by r ith your hands on the controls and feet on the pedals'pad, gives you stability. However, controls are located so you can vary your body position for best comfort and visibility GIVE YOUR BODY A BREAK Take advantage of stop arms and legs. Stay bbetter and safer driver. 7 Your Narrow-Aiste Truck Be a Safe Driver continues 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 crosswatk or intersection. + Be careful that you don't pin or crush someone. For example: Never drive your truck toward anyone tanding in front ofa fixed objec + Never allow passengers on your truck, * Keep others away from your truck while you're ing, Don't ever allow anyone on or uncler 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 mechanismn is operating ‘+ Have load backrest vertical (never tilt when elevated). ‘* 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 ed. ‘+ Never transport anyone on the platform from one location to another. 35 Be a Safe Driver continues ional Sate ‘and Health Act (OSHA) §1910.178, Rev. 199 = Undervriters Labs (uly 83 ‘Association (NFP) Your Narrow-Aisle Truck 8Lift Truck Parts 9 Lift Truck Parts Load Backrest Reach Carriage ‘Overhead Guard Fork Mast Operator Cushion Battery Outrigger Load Wheels: Drive Whee! Caster Wheel DRIVE CAUTIOUSLY, BE ALERT * Never stick a foot or any part of your body any part of your body. the truck and off « Stand sideways with your back against Keep your hands on the controls and pedals/pad. * Travel in the direction that gives yc congested areas. + Slow down for wet or slippery floors. Dor are going before you change direction of travel. + See that you have roam to drive ai check for overhead objects. We swing + Slow dows + Avoid sudder them smoothly at * Check clearances bet or load. + Be extra careful if where there isa risk of Be a Safe Driver 34Be a Safe Driver [MAKE SURE YOU ARE READY TO DRIVE less you are trained and The most * Be certain you understand how hazards that go with it. Don't important component . your truck (Load Weight, Load leight). Make certain you use the correct units of measure, is you. Is and shoes are clean and dry, the job, || MAKE SURE YOUR TRUCKIS READY k before using it (see pages 31 and F something is broken, supervisor. Don't use the ‘one. Know takes to stop before you start work, 33 Be a Safe Driver Display Panel Switch Panel Brake Pedal Sensor Pad Entry Bar Floorboard Power Disconnect Operator Cushion Lift Truck Parts 10WHAT IS LOAD CENTER? Load center is the distance from the load! backrest or vertical face of the forks to the center of an ited load, ligane Must REEeaiy Deri anything docsn'tlook or fel right, don't dive the truck. Report the problem to your superv Your truck could tip over, in any directi load is shifted to th container. 11 Capacity & Load Center Daily Safety Check 32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. the battery is charged, water level is aps are in place, Don't use an open the battery battery retainers on both sides of the stalled and adjusted, good condition, ® See that the load backrest and overhead guard are in place ‘and fastened, * Look under the truck for signs of hydraulic leaks, ‘Turn the key to TEST (yellow dot). See that all display lights are working, + Test the horn, + Make sure the power disconnect works, Safety Check CENTERTHELOAD “hh Know the Hazards Koow 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 lof measure. Pay attention to * Weight of load * Load center eight outed, stable and centered over the forks. HYDRAULIC OPERATIONS CAN AFFECT STABILITY It, sideshift or other Be careful when using reach, ions, Remember that Capacity & Load Center 12Capacity Plate ‘CAPACITY PLATE INFORMATION D ison a console in the tains: reachmerract fy Sy Roll the thumb bell away from you to reach (extend) the forks, Rol the ball toward you to retract the forks. ‘The farther you move the ball from neut forks will move, READING YOUR CAPACITY PLATE penn Capacity may be reduced as lift height @ increases. 1590kg (3500 1b) can wove 3935 (155), to 5030 (198), capacity is reduced from 1590 (3500) 10 1360 (3000) laway from you to sk ball toward you to shift t \e forks to he Capacity is reduced as load center @ increases. IF you must handle loads with longer load centers, an tester the nal capacity plate will show the reduced capacities. CAUTION -ase capacity if load ian shown on your capacity plate. ‘CHECK FORK AND PALLET POSITION The fork position will vary depending on whether the forks are loaded or unloaded. Make certain the forks are at the correct tilt position and ‘enter a pallet, or that the palllet and load | will clear the rack bearns. ITSDF 856.1 requires that al data bes! and then USA units. 13 Capacity Plate ¥ Fork Functions continues 30Fork Functions continued THUMB BALL THT UP & DOWN Roll the thumb ball down to truck is e will go to the programmer ‘chosen by your company for this truck, ye in neutral, press and hold the Hask handle. Then rall Always check to see that the forks are at the correct tilt position and iift height to enter a pallet, or that the and load will clear the rack beams. Be just as careful when using programmed funs when operating the truck manually. 5 a5 29 Fork Functions continued ‘OTHER LIFT HEIGHTS & LOAD CENTERS Contact Crown for capacities at lift heights or load centers not given on your capacity plate. A Know the Hazards ‘TRUCK WEIGHT Dockboards, elevators and Check your capaci TRUCKTYPE Some truck types are not permitted in areas where hazards. Watch for marked areas. For sst not drive a type E or ES truck into an area restricted to EE or EX trucks. ATTACHMENT DATA, your truck does operate wrong. lowered below the top of the mast. Capacity Plate 14Display Panel - ENTER OR RETURN BUTTON Use to navigate in and out of menus and select NAVIGATION BUTTONS: Up, Down, Left and Right Arrows are used to scroll through menus. FORKS DOWN LIGHT (see Caution) ihe green fork means the mast is at its minimum collapsed height. Make certain the ‘cad will clear overhead obstructions CAPACITY DATA MONITOR (see Caution) +Forkhelghtlights:A yellow fork wi 0 show wk { any of these lights are on, it means the load backrest is higher height of the mast, Make certain the load ancl load backrest will clear any oasiructions above you The lash anc alae wi speed (24 kr, 1.5 MPH) collapsed height of the mast. you can raise the load Overload warning: If load! is too heavy fo layed bby the fork positio itor is for reference only. You must always be alert to load center tion, load height and load weight. You must also be aware when the ioad or rest extends above the top of the mest, and how werhead clearance 15 Display Panel RACK HEIGHT SELECT OPTION ‘This option allows a truck to be programmed so the forks will stop at a selected height 1. Press the UP or DOWN ARROW button until the 2, Select the RIGHT ARROW to enter rack select mode, 3. Press the switch on the back of the multi-task handle to scroll through the fift heights that have been 10 the truck. The message display wi either millimeters or in tber for the height. raising or lowering, press and release the switch to select the next prograramed rack height. 4. Make certain the path of the forks isch hold the m there will be a one second beep when they reach t programmed height. Check to make cestain the forks are atthe correct position before entering the rack or pallet. (CHECK THE PATH OF THE FORKS Be just as careful raising the forks with the rack height select option as when using manual raise, Make certain the path of the forks f var and free of obstacles, Check that the forks @ the pallet, or that the ps tthe jet will clear the rack hear Fork Functions 28Fork Functions 27 Fork Functions i ri ‘Standard fork functions include Raising and Low re forks, h (extend and retract). ‘Some optional fork functions your truck may equipped with are Sideshift (right or left), Rack Height Select which allows the truck to be programmed so the forks will stop at selected heights, and Tilt Position Assist to tit the forks to a programmed position Cup and down), and RaiseLower oy ey Life the multi-task handle up to raise the forks, Push down on the handle to lower the forks, ‘The f task handle from neutral, move, you move the mul ie faster the forks wi RAISE CUTOUT OPTION Your truck may be equipped with an automatic cutout to prevent you from he forks into restricted areas. I raise stops, check the message displ: are at a raise cutout height. See page 18 for using the optional Raise Cutout Override Switch. MESSAGE PANEL ‘The upper half of the message panel shows percent of charge remaining in the battery, and indicators relating to truck operation and service. Fa} sence ested. Contact you superior or see department © operator aie. see bottom ine ornstuctions [BH ricco atta backrest above collapsed neigh te ae @ ve whee! tection nd argent GB tection contro! incicator Contre truck to operate. if Indicates energy is being retumed to the battery. a _ Faroe __ 3S) 198! S =) CENTER TRAVEL HANDLE ‘The bottom line of the message panel is usuaily blank. However if anything requires your attention, instructions will be displayed here Anytime you hear a beep, or if the truck slows down or won message panel for instructions. ‘This line of the message panel shows selective truck information, when requested using the Service & Option Buttons. See your Service Man work, check Display Panel 16Two Types of Steering ) 1ed clockwise. This page left blank intentionally. 9.) 2 Stowe crecton suck ied clockwise. Two Types of Steering 26Steering & Travel ions, Be careful. Drive slowly until you get used to al controls, is truck is designed to slow down wher Caution: RR Modets 5200, and earlier, dom ‘TRUCKS THAT LOOK ALIKE CAN BE DIFFERENT ] POWER UNIT SWING ‘eful tuming while traveling forks first area. ‘SLOW DOWN FOR SPILLS OR WET FLOORS Powder of liquid spills can cause slippery floors. Siow ‘down or you could lase control of steering and braking Be careful and allow for a longer stopping distance. Don't run over objects on the floor. 25 Steering & Travel Switch Panel DOME LIGHT SWITCH WORK LIGHT SWITCH (optional) RAISE CUTOUT OVERRIDE SWITCH (opt Your truck may be equipped wi Switch Panel 18Power On & Off | Key SWITCH * To start the USER CODE (PIN number} ave to enter a user code (Personal ion Number) before you can use the truck. truck doesn't operate HORN Press the button on the multi-task handle to sound Use you crosswalk, ruck is ready for operation ENTRY BAR A Know the Hazards PLUGGING VS. BRAKING Of the two, the foot brake is designed truck in the shortest distance. Use the foot brake in an ‘emergency, on ramps or in busy areas. 19 Power On & Off Traveling & Plugging 24Traveling & Plugging ‘ POWER DISCONNECT Push the Power Disconnect button to cut power to the truck travel ‘TRAVEL, FORKS FIRST 23 Traveling & Plugging Power On & Off 20Foot Brake A Know the Hazards WATCH YOUR FEET Keep your feet inside the truck and on the pedals‘pad es. This truck weighs about 3630 kg or (80 load on the forks. You canni The brake is now “oft ar even slow dot any part of your bo moving A foot or hand caught betweer post or any fixed object will be crushed or even cut off. BRAKE ON, brake. Keep a part of yo sorboard, C KEEP YOUR BALANCE the cushion, gives you [MAKE SURE YOUR BRAKE WORKS bbrake on your truck at the start of each shift ne distance it takes {0 stop before you start working. any time the stopping distance is too long for you jon't drive the truck. Report any prob- Jem to your supervisor. 21 Foot Brake Foot Brake 22