Crown pc4500 Operator Manual

Operator Manual

PC

You could be killed or seriously injured

if you are not

adequately trained for lift truck operation!

Do not operate this truck

in your work place until you have

been trained and certified by your employer.

You Must be Trained

You Must be Trained 2

STOP

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)

Warning Labels 36

Warning Labels

EACH WARNING LABEL
ON YOUR TRUCK IS IMPORTANT

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

All rights reserved under International
and Pan American copyright conventions
Copyright 2008 Crown Equipment Corp.

1 Warning

All rights reserved under International
and Pan American copyright conventions
Copyright 2008 Crown Equipment Corp.

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.

A dockboard can move or drop while you are on it. Or
you could drive off a dock. Falls from docks or dockboards
can cause serious injury or even death.

Make sure you are

safe.

Inspect your truck before starting work, make sure it is in
good working order.

* Additional copies of this Operator Manual and all Truck Labels can be
obtained from Crown Equipment Corporation, New Bremen, Ohio 45869
U.S.A.

Connect charger
properly or truck
can be damaged.

47

Make certain
charger is plugged
into the battery
connector, not the
truck connector.

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

07

Stay clear of all
moving parts.

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

281

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.

WARNI GN

WAR NI GN

Minimum battery size allowed

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

XXX

mm (XX.XX in.) wide

XXX

mm (XX.XX in.) long

Use U.L. classified Type E battery.

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.

With brake lever off, the
brake is not automatically
applied when the handle
is released.

The truck will coast.

Lift handle to apply brake.

off

brake off

853-A

Objects placed on the operator
platform could affect truck
operation, or cause you to trip
and be injured.

Keep operator platform clear.

870

Know the Hazards

Protect Yourself

3 Protect Yourself

DRIVE CAREFULLY

• When allowing the truck to coast, travel power unit first
only. Do not turn. Keep to the side of the truck. Make
certain the truck won't hit the back of your leg or foot.

Don't let the truck run over your foot.

• When riding, keep your hands on the controls and feet

on the platform. Keep your body within the operator
area.

• Don't put hands or arms over the backrest.

• Never stick a foot or any part of your body outside the
truck, no matter how slow the truck is moving. You
can not stop 4535 kg or 10,000 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.

• Never place objects anywhere on the operator
platform. They would be a trip hazard and could affect
truck speed.

• Stay away from the edge of docks and dockboards.
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 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.

• Perform all truck movements smoothly and at a speed
that will give you time to react in an emergency.

Recommended
Walking Path

Notes 36

Notes

Know the Hazards

Protect Yourself 4

AVOID FALLS

Falls 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. Unless you can safely jump completely
clear of the falling truck, there is no sure way to avoid
injury if you drop from a dock or dockboard.

Be extremely careful when working around docks,
dockboards and trailers.

USE YOUR TRUCK SAFELY

• Keep your hands and feet away from all moving parts
such as forks or wheels.

• 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 disconnect the

battery.

07

Stay clear of all
moving parts.

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

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 objects intruding or poking into the operator area.

When allowing the truck to coast, make certain the
area ahead of you is clear.

Contents

Warning

You Must be Trained

Protect Yourself

Contents

What's in it for You?

Your Rider Pallet Truck

Pallet Truck Parts

Capacity Plate

Display

Power On & Off

Steering & Travel

Coasting

Braking

Raising & Lowering

Traveling & Plugging

Additional Options

Daily Safety Check

Be a Safe Driver

Battery Maintenance

Warning Labels

1

2

3

5

6

7

9

11

13

15

16

17

19

21

23

25

27

29

33

36

Battery Maintenance

31 Battery Maintenance

Know the Hazards

107

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

Battery Maintenance 32

5 Contents

Know the Hazards

Battery Maintenance 34

TRUCK BATTERIES CAN BE DANGEROUS

Your truck battery produces a gas 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.

BATTERY RETAINERS MUST BE IN PLACE

The battery could slide out if retainers are not in place.
Check that both retainers are installed before operating
your truck.

107

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.

What's in it for You? 6

What's in it for You?

QUICK LOCATORS

In addition to the "Contents" page you
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.

"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.

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.

Know the Hazards

107

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

Battery Maintenance 32

Your Rider Pallet Truck

RIDER PALLET TRUCKS

As a rider your pallet truck is designed to move
loads over long distances. You can also use it
as a walk-beside truck when picking stock.

YOUR PALLET TRUCK IS NOT AN AUTOMOBILE

With a load it may weigh more than
3 automobiles.

• You don't steer the same.

• You don't brake the same.

• You don't accelerate the same.

7 Your Rider Pallet Truck

HOW TO DRIVE WHEN COASTING

• Travel power unit first only. Do not turn. Stay
to one side of the truck. Use the hand closest to
the truck to operate the control handle.

• Watch your feet. Stay out of the path of the truck.

• Make certain the area ahead of you is clear.

HOW TO DRIVE YOUR TRUCK WHILE RIDING

Keep both feet on the platform. Place both hands
on the control handle and lean against the backrest.
Keep your entire body within the operator area.

Path of
Truck

Recommended
Walking Path

Be a Safe Driver continued 32

AVOID FALLS

• 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 trailer is locked to the dock. 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. Center
the load. Be even more careful with long, high or wide
loads. They can be less stable.

• 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 come to a
complete stop.

BE CAREFUL TRAVELING ON RAMPS AND GRADES

• Always operate your truck from the rider position when
traveling on a grade.

• With a load, drive with the forks pointed upgrade.

• Without a load, drive with forks downgrade.

Slow down and don't turn on ramps or grades.

HOW TO DRIVE YOUR TRUCK FORKS FIRST

Keep both feet on the platform. Place one hand on
the backrest and the other on the control handle
while leaning against the backrest. Keep your entire
body within the operator area.

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)

Feet on

platform

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.

Your Rider Pallet Truck 8

Lean against

the backrest

Pallet Truck Parts

9 Pallet Truck Parts

High Speed Switch

(On platform)

Platform

Battery Retainer

Control Arm

Brake Lever

(Standard handle only)

Key Switch

(On power unit)

Control Handle

Power Disconnect

Be a Safe Driver 30

Continued next page...

Recommended

Walking Path

WHEN USING COAST

• Travel power unit first only. Do not turn.

• Keep to the side of the truck. Make certain the truck
won't hit the back of your leg or foot. Don't let the
truck run over your foot.

• Be certain the area ahead of you is clear.

WHEN RIDING

• Never stick a foot or any part of your body outside the
operator area, no matter how slow the truck is moving.

• Don't put your hands or arms over the backrest. Keep
your hands on the controls and feet on the platform.

• Stop your truck completely before getting off.

DRIVE CAUTIOUSLY, BE ALERT

• Look where you are going. Don't let your hands or

feet get pinned or crushed.

• Travel in the direction that gives you the best view.
Slow down in congested areas.

• Slow down for wet or slippery floors. Don't run over
things.

• Look where you are going before you change direction
of travel.

• See that you have room to drive and turn. Watch out
for power unit swing. Slow down when making turns.

• Avoid sudden movement of controls. Learn to use
them smoothly at a moderate, even rate.

• Be extra careful if you must use your truck in an area
where there is a risk of falling objects.

Pallet Truck Parts 10

Standard Control Handle

Lower Button

Raise Button

Travel Twist Grip

Horn Button

"T" Control Handle (Optional)

Lower Button

Raise Button

Hand Brake Lever

Travel Twist Grip

Horn Button

SAMPLE CAPACITY PLATE

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

Note: ANSI B56.1 requires that all

data be shown first in Metric units
and then USA units.

Capacity Plate

11 Capacity Plate

CAPACITY PLATE INFORMATION

The capacity plate is on the top of
the power unit cover. It contains:

• Capacity information

• Truck type (a fire safety rating)

• Truck weight (does not include load)

• Grade rating

• Battery information

• 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 correct units
of measure.

Daily Safety Check 28

2. Test drive your truck in an uncongested area.

• Try all the hydraulic functions.

• Check the steering.

• Drive the truck slowly in both directions.

• Check braking distance in both directions. Load size
and floor conditions can affect these distances.

• Drive through the full speed range in both directions.

• 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 parking brake operation.

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. OF3772). Used properly, this checklist can alert
service people to needed repairs.

Know the Hazards

Capacity Plate 12

KNOW YOUR LOAD

Do not exceed the capacity shown on your truck's capacity
plate. Make certain you use the correct units of measure.
Be careful when handling long, high or wide loads. Do not
handle unstable loads.

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.

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.