Operator Manual

This operator manual provides essential information for the Crown C-5 Series forklift, including all models, options, and accessories. Some illustrations and information may not apply to your specific truck.

The most important component is you.

Model: PF18349 Rev. 11/12

Published by Crown Equipment Corporation, New Bremen, Ohio 45869 USA. Copyright 2009. Printed in U.S.A.

For additional copies, contact Crown Equipment Corporation or visit https://www.forkliftpdfmanuals.com/

1. You Must be Trained

⚠️ WARNING

It is the law to be trained and certified to operate this truck (OSHA § 1910.178, Rev. 1999). Failure to do so can result in serious injury or death to yourself or others.

Read and obey all warnings and instructions in this manual and on the truck.

Never extend body parts outside the operator area while the truck is moving. Stay within the operator area and stop the truck completely before exiting.

Be aware of dockboard stability and potential falls from docks. Ensure you are safe.

Look where you are going to avoid being trapped or crushed by protruding objects.

Inspect your truck before starting work to ensure it is in good working order.

Federal Law Requirement: Only properly trained and certified operators are permitted to operate a powered industrial truck. Your employer must provide this training and certification.

Do not operate the truck until trained and certified by your employer.

? STOP: You could be killed or seriously injured if not adequately trained.

2. Protect Yourself

Know the Hazards

• WEAR YOUR SEAT BELT: Falling from a truck can cause serious injury or death. Fasten your seat belt and keep it fastened until you leave the truck. Stay with the truck during an overturn; do not jump.
• DRIVE CAREFULLY: Never extend body parts outside the operator area. Stay away from dock edges and ensure dock boards are secure. Keep the truck under control at all times, especially on slippery surfaces. Do not drive over objects.
• LOOK WHERE YOU'RE DRIVING: Be alert to your surroundings to avoid being pinned or crushed by objects. Ensure added equipment does not block vision or interfere with operation.

⚠️ WARNING: Stay clear of all moving parts. Moving parts can cut or crush hands, feet, arms, or legs.

Avoid Falls and Tip-overs

Tip-overs are serious accidents. Keep your seatbelt fastened, grip the steering wheel, brace your feet, and lean away from the direction of fall. Prevention is key.

• Be extremely careful around docks, dockboards, and trailers.
• Use forward tilt only when the load is in a rack, over a stack, or close to the floor.
• Travel with the load or forks close to the ground and mast tilted back. Watch for overhead obstructions. Perform movements smoothly.
• Unloaded trucks can also tip over; be equally careful.

Use Your Truck Safely

• Keep hands and feet away from all moving parts (masts, chains, wheels). Ensure the load backrest is in place.
• Never stand on or under the forks. People can only be lifted with an approved platform.
• Never allow passengers on the truck.
• Before leaving the truck: stop completely, lower forks, shut off the engine, place control in neutral, and apply the parking brake. Chock wheels if on an incline.

3. Contents Overview

This manual is structured to help you understand your truck and use it safely and effectively. Key sections include:

• Warning: Critical safety information.
• You Must be Trained: Legal requirements for operator certification.
• Protect Yourself: Hazards and safety precautions.
• Contents: This overview.
• What's in it for You?: Guidance on using the manual.
• Your Sit-Down Rider: Description of the truck type.
• Lift Truck Parts: Identification of truck components.
• Capacity & Load Center: Understanding load limits and stability.
• Capacity Plate: Information specific to your truck's capacity.
• Display Panel: Indicator lights and their meanings.
• Power On & Off: Procedures for starting and stopping the truck.
• Raise/Lower, Tilt & Accessories: Operation of hydraulic functions.
• Braking: How to use service and parking brakes.
• Traveling: Safe driving practices.
• Daily Safety Check: Pre-operation inspection procedures.
• Be a Safe Driver: Comprehensive safe driving guidelines.
• Fueling, Propane (LPG): Procedures for handling fuel cylinders.
• Notes: Blank pages for your notes.
• Warning Labels: Explanation of important safety labels on the truck.

Quick Locators: Use page headings and corner truck images to find topics.

"Know the Hazards" Blocks: Pay close attention to these sections for safety information.

How-to-Drawings: Visual aids to help understand truck operation.

4. Your Sit-Down Rider

Sit-down rider trucks are designed for lifting, stacking, and moving loads over long distances. Unlike automobiles, their steer wheels are at the rear.

Fork Functions: Standard functions include raising/lowering forks and tilting the mast. Optional accessories like sideshift or carton clamps may be present.

How to Drive: Sit down, fasten your seat belt, adjust the seat and steering wheel for comfort. Keep hands on controls, body inside the operator area, and look in your direction of travel.

Give Your Body a Break: Use stop times to flex arms and legs. Staying alert improves driving.

Built to Standards: This truck meets industry and government standards, including ANSI/ITSDF B56.1, OSHA §1910.178, UL 583, and NFPA 505.

5. Lift Truck Parts

This section identifies key components of the lift truck through a diagram:

• Overhead Guard
• Work Lights (optional)
• Mast
• Fuel Tank
• Steering Wheel
• Seat
• Seatbelt
• Load Backrest
• Seat Deck Latch
• Hydraulic Levers
• Accelerator Pedal
• Switch Panel
• Parking Brake
• Service Brake Pedal
• Key Switch
• Steer Wheels
• Drive Wheels
• Forks
• Horn
• Steering Wheel Tilt Lever
• Direction Control
• Display

6. Capacity & Load Center

What is Your Truck Capacity?

Capacity is the maximum load (including pallet/container) that can be lifted to a specific height at a given load center. Refer to your truck's capacity plate and use correct units of measure.

What is Load Center?

Load center is the distance from the load backrest (or fork face) to the center of an evenly distributed load. A common maximum is 600mm (24 inches).

Loads Must Be Evenly Distributed

An unevenly distributed load can cause the truck to tip over. Ensure loads are centered on the forks.

Know Your Load

⚠️ Know the Hazards

Do not exceed the capacity shown on your truck's plate. Be careful with long, high, or wide loads, and avoid unstable loads.

Exceeding Truck Capacity Can Cause an Accident: Pay attention to load weight, load center, lift height, and mast position.

Center the Load

A load shifted to the front or side can cause the truck to tip. Ensure the load is evenly distributed and centered over the forks.

Hydraulic Operations Can Affect Stability

Capacities are rated with the mast vertical. Be extra careful when tilting loads, especially with attachments like sideshift or carton clamps.

Tires Will Affect Capacity and Stability

Cushion and pneumatic tires affect capacity and stability differently. Be cautious when driving different trucks, as capacity may vary.

7. Capacity Plate

Capacity Plate Information

Located on the overhead guard, the capacity plate contains:

• Truck serial number
• Capacity information (load, load center, lift height)
• Truck type (fire safety rating)
• Truck weight
• Attachment information (if any)

Reading Your Capacity Plate

Capacity decreases as lift height (⬆️) or load center (➡️) increases. For example, lifting to a greater height or with the load further from the mast reduces the maximum weight you can lift.

Caution: You cannot increase capacity by moving the load center closer than specified.

Other Lift Heights & Load Centers: Contact Crown for capacities not listed on the plate. Note: ANSI/ITSDF B56.1 requires metric units first, then USA units.

⚠️ Know the Hazards

• Truck Weight: Consider the weight of the truck plus the load when assessing floor or dock capacity.
• Truck Type: Some trucks have fire safety ratings that restrict them from certain areas (e.g., LP trucks in LPS-restricted areas).
• Attachment Data: If an attachment is present, ensure it is listed on the capacity plate. If not, report the discrepancy to your supervisor.

8. Display Panel

The display panel provides operational status and alerts:

• Fuel Lights: Green bars indicate fuel level; amber means low fuel.
• Alternator Light: Symbol indicates charging system needs service.
• Seat Belt Light: Reminds you to fasten your seat belt at Key On.
• Parking Brake Light: Illuminates when the parking brake is applied.
• Coolant Temperature Light: Red light indicates overheating (park and shut off); amber indicates beginning to overheat.
• Transmission Temperature Light: Symbol indicates low engine oil pressure (park and shut off).
• Oil Pressure Light: Symbol indicates charging system needs service.
• Engine Light: Symbol indicates the engine needs service.
• Display Panel Beep: If you hear a beep, check the display for instructions.

(Note: Page 16 is intentionally left blank.)

9. Power On & Off

Key Switch

• Turn clockwise from red dot to yellow dot to start the engine. Check seat alarm and indicator lights.
• Release key; it returns to ON (green dot).
• Turn counterclockwise to OFF (red dot) to shut off. Always turn to OFF when leaving the truck and apply the parking brake.

⚠️ Know the Hazards: Carbon Monoxide Poisoning

Engine exhaust contains odorless carbon monoxide, which can cause unconsciousness or death. Do not operate in unventilated areas.

10. Raise/Lower, Tilt & Accessories

Hydraulic Lever Operation

Levers control truck functions. Pulling a lever towards you (away from mast) performs one action; pushing it away (towards mast) performs the opposite. The farther the lever is moved from neutral, the faster the action.

Example: Pulling the Raise/Lower lever raises the forks; pushing it lowers them.

Lift and Tilt Interlock

Lift and tilt functions are interlocked to prevent lifting higher than 95"-102" if the mast is tilted forward past 2°, or tilting forward past 2° if lifted higher than 95"-102".

Note: Use full engine speed with the inching/brake pedal applied for maximum hydraulic performance.

⚠️ Know the Hazards: Hydraulic Operations Can Affect Stability

Capacities are rated for centered, level loads. Be extra careful when tilting, especially with attachments.

11. Braking

Service Brake

Your truck has either one or two service brake pedals.

• 2 Pedal Option: Left pedal is inching/brake (full depression for braking, partial for controlled travel). Center pedal is for full braking.
• 1 Pedal Option: Large pedal is inching/brake. Partial depression with accelerator provides controlled speed ("inching").

Caution: On inclines, the truck may roll before drive engages.

Note: Use full engine speed with the inching/brake pedal for maximum hydraulic performance.

Parking Brake

• ON: Press the end of the rocker switch nearest the seat. An alarm sounds if not applied when leaving the truck.
• OFF: Press the end of the rocker switch away from the seat.
• Optional Lever: Move lever toward seat to apply; squeeze and move away to release.

⚠️ Know the Hazards: Make Sure Your Brakes Work

Test brakes at the start of each shift. Know your stopping distance. If stopping distance is too long, do not drive the truck and report the issue.

12. Traveling

Before You Drive

Fasten your seat belt and adjust the operator seat and steering wheel.

Travel Direction and Speed

• Direction Control: Away from mast = forks first; toward mast = power unit first (forks trailing).
• Speed: Use the floor accelerator pedal.
• Ensure direction control is in neutral before selecting travel direction.

Note: Use full acceleration with inching/brake pedal for maximum hydraulic performance.

Avoid Truck Damage When Changing Travel Direction

Do not change direction of travel until the truck has slowed to about 5 mph (8 km/h) or less.

Horn

Press the center of the steering wheel to sound the horn. Use it to warn pedestrians and other drivers, especially when leaving aisles or approaching intersections. An optional horn button may be on the rear post.

⚠️ Know the Hazards

• Slow Down for Spills or Wet Floors: Slippery surfaces can cause loss of control. Allow for longer stopping distances. Do not drive over objects.
• Look Where You're Going: Travel in the direction offering the best view. Slow down in congested areas.
• Power Unit Swing: Be careful turning forks first; the power unit swings wide in the opposite direction. Ensure clearance.
• Outdoor Hazards: Exercise extra care on gravel, uneven terrain, or in snow/ice/water.
• Prevent Damage to Truck: Slow to 5 mph (8 km/h) or less before reversing direction.

13. Daily Safety Check

Ensure your truck is safe to use before starting work.

1. Walk Around Your Truck

• Check for propane gas leaks (odor or frost).
• Inspect fuel hoses for damage.
• Inspect fuel valve and other parts.
• Ensure propane cylinder is properly installed and secure.
• Check wheels and tires for good condition.
• Verify all lights are working.
• Check forks for security, damage (bent, cracked, worn).
• Inspect lift chains for damage.
• Look under the truck for oil or coolant leaks.
• Inspect seat belt for wear.
• Turn key to TEST to check display warning alarm and indicator lights.
• Test the horn.

2. Test Drive Your Truck

• Adjust seat and steering wheel for comfort.
• Fasten seat belt.
• Test all hydraulic functions.
• Check steering for smoothness.
• Check braking distance in forward and reverse (load size and floor conditions affect this).
• Drive slowly in both directions.
• Drive through the full speed range.
• Know your stopping distance. If too long, do not drive and report the issue.

If anything seems wrong, do not drive the truck and report it to your supervisor. Use the provided checklist form for service needs.

14. Be a Safe Driver

Make Sure You Are Ready to Drive

• Only use the truck if trained and certified.
• Understand truck operation and hazards. Do not drive if unsure.
• Know your truck's capacity (Load Weight, Load Center, Lift Height) and use correct units.
• Ensure your truck has the correct fire safety type for the area.
• Keep hands, shoes, and clothing clean and dry, and appropriate for the job.

Make Sure Your Truck is Ready

• Inspect the truck before use (see Daily Safety Check). Report any issues to your supervisor and do not use a faulty truck.
• Ensure any added equipment does not block vision or impede operation.
• Test braking in an open area at slow and faster speeds to know stopping distance.

Drive Cautiously, Be Alert

• Fasten seat belt snugly.
• Never extend body parts outside the operator area.
• Keep hands on controls and feet by pedals.
• Travel in the direction offering the best view; slow down in congested areas.
• Slow down for wet or slippery floors; do not run over objects.
• When outdoors, stay away from gravel, uneven terrain, snow, ice, or water.
• Travel with forks close to the floor and mast tilted back. Place load against backrest.
• Look before changing direction. Check for overhead objects.
• Slow down when turning.
• Avoid sudden control movements; use them smoothly.
• Check clearances before raising/lowering forks or loads.
• Be extra careful in areas with falling object risks.

15. Be a Safe Driver continued

Watch Out for Other People

• Always look in the direction of travel.
• Slow down, yield, or stop for pedestrians. Use horn at crosswalks/intersections.
• Do not pin or crush people; never drive towards someone in front of a fixed object.
• Watch for power unit swing.
• Never allow passengers.
• Keep others away from your truck while working.
• Do not let untrained individuals use your truck.
• Never lift people with forks unless using an approved platform and extreme caution. This includes using a secure platform, ensuring the lifting mechanism is proper, keeping the load backrest vertical, truck in neutral with brake applied, lifting/lowering slowly, watching for obstructions, ensuring visibility, and not transporting people from location to location.

Avoid Falls and Tip-overs

• Stay with your truck during an overturn; do not jump.
• Stay away from dock and ramp edges.
• Ensure bridgeplates and dockboards are secure. Chock trailer wheels or lock the trailer to the dock. Check capacities.
• Ensure loads are stable, spread forks wide, center the load, and insert forks fully. Be more careful with long, high, or wide loads.
• Use forward tilt only for racks, stacks, or close to the floor. Use minimum tilt for pickup/placement. Keep load backrest vertical or slightly back when lifting/lowering outside a rack.
• When moving loads on grades/ramps, drive with forks upgrade. Without a load, drive downgrade. Slow down and do not turn on grades/ramps.

Leaving Your Truck

• Stop completely before exiting.
• Lower forks, shut off engine, apply parking brake.
• Avoid parking on inclines; if necessary, block wheels.
• Never park on a dockboard.

16. Fueling, Propane (LPG)

Before You Remove the LPG Cylinder

1. Set parking brake and chock wheels if on an incline.
2. While engine is running, close cylinder fuel supply valve (clockwise).
3. After engine stops, turn ignition OFF and disconnect fuel hose.

Swing-Down Tank Mount

1. Push release lever on the mount.
2. Lower tank firmly.
3. Release tank strap and remove cylinder.

Caution: Do not operate truck with tank in lowered position.

When You Install a LPG Cylinder

1. Place correct size/type cylinder onto mount; ensure locating pin fits through collar.
2. Tighten tank clamp, ensuring fingers are clear. Return mount to upright position if applicable.
3. Attach fuel hose and open supply valve SLOWLY to equalize pressure and prevent excess flow valve closure.
4. Check for leakage. If suspected, close valve and contact supervisor.

⚠️ Know the Hazards

? DANGER: Flammable LP Gas

Propane gas can cause fire or explosion. Do not install, remove, refill, or service cylinders unless trained and authorized. Never smoke or use open flames near propane. See mounting bracket for allowable cylinder size. If gas odor or frost is detected, turn off engine, close valve, and contact supervisor.

Propane Cylinders Can Be Dangerous:

• Do not attempt cylinder service unless trained and authorized.
• Never smoke or use open flames around propane.
• Your company should provide a ventilated area for servicing and storage.
• Disconnect the truck battery before servicing the fuel system.
• Wear proper personal protection equipment.
• Cylinders are heavy; ask for help.
• Cylinders must not extend outside the truck.
• Turn off the fuel valve when the truck is not in use.
• If gas odor or frost is detected, turn off engine, close valve, and contact supervisor.
• Use fuel meeting National Gas Processors Association "HD-5" specification.
• For exchangeable/removable cylinders, remove cylinder before refueling. Follow NFPA 58, 8.1.2.10.
• Consult NFPA Pamphlet 58 for more information on safe handling and storage.

17. Notes

This section is provided for your notes.

18. Warning Labels

Each warning label on your truck is important for protecting yourself and others. Read and obey all labels.

Key warnings include:

• Flammable LP Gas: Danger of fire/explosion; requires training.
• No Passengers: Passengers can be seriously injured; no safe place for them.
• Lifting People: Requires proper platform and adherence to OSHA/ANSI standards.
• Propane Danger: Fire/explosion risk; requires training and authorization.
• Moving Parts: Stay clear; can cut or crush.
• Tip-over Risk: Slow down when turning; don't jump.
• Falling Objects/Forks: Never stand under forks; block them during service.
• Tilting Mast Forward: Risk of tip-over with raised loads; do not tilt forward unless over a stack.
• Training Required: It is the law to be trained and certified (OSHA § 1910.178).
• Avoid Being Crushed: Keep body parts within operator area; stop truck before exiting.
• Falls from Docks: Serious injury/death risk; keep seat belt fastened, hold on, brace feet.
• Pinned/Crushed by Objects: Look where you are going.
• Inspection: Inspect truck before starting work.

Additional copies of manuals and labels can be obtained from Crown Equipment Corp., New Bremen, OH 45869.