Crown PE 4500 User Manual

Operator Manual

You could be killed or seriously injured

if you are not

adequately trained for lift truck operation!

It’s the law, you must be trained and certifi ed 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.

1 Warning

All rights reserved under International
and Pan American copyright conventions
Copyright 2006 Crown Equipment Corp.

You Must be Trained

You Must be Trained 2

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 qualifi ed to operate this powered industrial truck.
(OSHA §1910.178, Rev. 1999)

Do not operate this truck

in your work place until you have

been trained and certifi ed by your employer.

LOOK WHERE YOU'RE DRIVING

• You could be pinned or crushed by objects intruding
or poking into the operator area.

• 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

• 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 fl oor.

• Shut the truck off with the key or disconnect the
battery.

• Make certain coast is off.

3 Protect Yourself

Protect Yourself

Know the Hazards

DRIVE CAREFULLY

• When walking, keep to the side of the truck while
traveling power unit fi rst. 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 fi rst, 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 fi xed 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 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 fl oor.

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

Protect Yourself 4

Know the Hazards

Stay clear of all
moving parts.

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

WARNING

Recommended
Walking Path

Warning 1

You Must be Trained 2

Protect Yourself 3

Contents 5

What's in it for You? 6

Your Walkie/Rider Pallet Truck 7

Lift Truck Parts 9

Capacity Plate 11

Display 13

Power On & Off 15

Braking 16

Steering & Travel 17

Power Steering optional 18

Traveling 19

Raising & Lowering 21

Coast Controls optional 22

QuickPick™ Walkalong Control optional 25

Additional Options 27

Daily Safety Check 29

Be a Safe Driver 31

Battery Maintenance 35

Warning Labels 38

Contents

5 Contents

What's in it for You?

What's in it for You? 6

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.

QUICK LOCATORS

In addition to the "Contents" page
you can use page headings to fi nd
topics. Some pages also have a
picture of the truck in the corner
showing features or functions
covered on that page

.

HOW-TO-DRAWINGS

On many pages you will fi nd
pictures as well as text to help you
understand how to use your truck
safely and productively.

"KNOW THE HAZARDS"

Watch for and read these special

blocks. You will fi nd information
about possible safety hazards and
how to avoid them

.

Power On & Off

15 Power On & Off Steering & Travel 16

Know the Hazards

Steering & Travel

KEY SWITCH

Turn the truck on by turning the key
clockwise to ON. Check that all display lights are working.

Turn the truck off by turning the key counterclockwise
to OFF.

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 not cut all power to
the truck.

Don't use the truck if it's not working right. Report the
problem to your supervisor.

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.

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

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.

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 truck and pick stock with it.

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.

HOW TO DRIVE YOUR TRUCK WHILE WALKING
Forks First

When traveling forks fi rst, use both hands to
operate the control handle.

Watch your feet if you change direction of travel.

Power Unit First

When traveling power unit fi rst, stay to one
side of the truck and slightly ahead of the
power unit. Use the hand closest to the truck
to operate the control handle.

Watch your feet.

Stay out of the path of the truck.

Your Walkie/Rider Pallet Truck

7 Your Walkie/Rider Pallet Truck Your Walkie/Rider Pallet Truck 8

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.

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
(Download free from
www.itsdf.org)

• Occupational Safety and Health
Act (OSHA)§1910.178 Rev. 1999

• Underwriters Laboratory (UL) 583

• National Fire Prevention
Association (NFPA) 505

Hand on
grab bar

Hand on

control handle

Feet on
platform

Recommended
Walking Path

Path of
Truck

Lift Truck Parts

9 Lift Truck Parts Lift Truck Parts 10

Control Handle

Power Disconnect

Grab Bar

Coast Control Options

(see pages 22, 23 & 24)

Battery Retainer

Display

Key Switch

Platform

Control Arm

Travel Twist Grip

QuickPick™
Walkalong Control
Buttons (optional)

Lower Button

Raise Button

Reversing Button

Horn Button

QuickCoast

™

Selector

(optional)

(see pages 19, 20 & 23)

Raise Button

Lower Button

High Travel Speed Button

Horn Button

Know the Hazards

Capacity Plate

11 Capacity Plate Capacity Plate 12

SAMPLE CAPACITY PLATE

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

CAPACITY PLATE INFORMATION

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

• Capacity information

• Truck type (a fi re 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.

Note:

ANSI/ITSDF B56.1 requires that
all data be shown fi rst in Metric units
and then USA units.

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.

Display

13 Display 14

BATTERY CHARGE DISPLAY

The green bars show how much charge is left.
Have the battery changed or recharged if the yellow
light is fl ashing.

COAST ON INDICATOR

A yellow light means that coast has been selected and the
truck will coast when you let go of the handle.

BATTERY RETAINER LIGHT

A red light means the battery retainer is not properly
installed.

MESSAGE PANEL

Displays truck information such as: hours of operation,
event codes along with instructions, battery charge
and other data.

PERFORMANCE SETTING

Indicates the level that your company has programmed

this truck to operate.

SERVICE & OPTION BUTTONS

See your Service Manual for instructions.

EVENT CODE LIGHT (OPERATOR CORRECTABLE)

The display shows the code for a detected event which the

operator can correct. See the display for instructions.

EVENT CODE LIGHT (SERVICE REQUIRED)

The display shows the code for a detected event which
requires service. Contact your supervisor or service
department.

This page

left blank

intentionally

Power On & Off

15 Power On & Off

Braking

Braking 16

KEY SWITCH

Turn the truck on by turning the key
clockwise to ON. Check that all display lights are working.

Turn the truck off by turning the key counterclockwise
to OFF.

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 not cut all power to
the truck.

Don't use the truck if it's not working right. Report the
problem to your supervisor.

Brake
On

Brake On

Brake Off

Know the Hazards

?

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 22, 23 & 24).

Always check the braking and the position of the coast
selector before you start driving.

WATCH YOUR FEET

While riding, keep your feet on the platform at all times.
This truck can weigh 1360 kg or 3000 pounds unloaded.
You cannot stop or even slow it down with your foot,
or any part of your body, no matter how slow the truck
is moving. A foot or hand caught between the truck
and a wall, or any fi xed object, will be crushed or even
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.

Power Steering optional 18

Power Steering optional

17 Steering & Travel

Steering & Travel

Know the Hazards

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.

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.

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.

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.

POWER STEERING OPTION

This option makes it easier for you to move the
steering handle from side to side.

After you turn the key to ON, the display will show
the following instructions:

1. Steer to Center.

Move the steering handle through the center
position.

Note:

Travel speed will be limited until the handle

is centered.

2. Cycle Reversing Button.

Press the Reversing Button.

The truck is ready for operation.

Right Header Left Header

19 Traveling Traveling 20

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.

Be careful. The reversing button cannot prevent all
injuries.

Know the Hazards

WATCH YOUR FEET AND HANDS

• While riding, keep your feet on the platform and
hands on the controls at all times. This truck weighs
about 1360 kg or 3000 pounds, even without a load.
You cannot stop or even slow it down with your
foot, hand or any part of your body, no matter how
slow the truck is moving. A foot or hand caught
between the truck and a wall, post or any fi xed
object will be crushed or even cut off.

• When walking and traveling power unit fi rst, protect
your legs and feet by staying to the side and keeping
out of the path of the truck.

LOOK WHERE YOU'RE GOING

Driver distractions can cause accidents resulting in
injury or even death.

• Don’t use cell phones or similar devices while
operating the truck.

• Travel in the direction where you have the
best visibility.

• 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
fi xed objects.

• You could also be seriously injured by objects
intruding or poking into the operator area.

Recommended
Walking Path

Coast Controls optional 22

Coast Controls optionalRaising & Lowering

21 Raising & Lowering

Brake
On

Brake On

Coast

COAST, A WALKALONG 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 16).

RAISE

Push either raise button until the forks are at the
desired height.

LOWER

Push either lower button until the forks are at the
desired height.

Coast Controls optional (continued) 2423 Coast Controls optional (continued)

Coast Controls optional (continued)

Know the Hazards

USING COAST REQUIRES EVEN MORE CAUTION

• Automatic braking is disabled when Coast is
activated. Handle must be manually moved to a
brake position.

• Floors must be level and free of obstacles.

• Never allow the truck to coast into a cross aisle.

• Do not use coast in pedestrian walkways.

• Watch out for people and other trucks.

• 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.

• Use coast while traveling power unit first only.

• Always turn coast off when you finish a coast
operation, or whenever you leave your vehicle.

• 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.

Brake
On

Brake On

Coast

OPTION 2, Electronic QuickCoastTM SELECTOR

COAST ON

Move the control handle to the coast position and
press the coast selector button on the back of the grab
bar, opposite the raise/lower switches. The “no-brake”
symbol on the display 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 16).

WHEN USING COAST

• Travel power unit fi rst only.

• Don't get in the path of the
truck and watch your feet.

• Stay to the side of the truck.
Keep your arm extended
to give maximum clearance
between you and the truck.

Recommended
Walking Path

Travel,
power unit
fi rst

Truck will coast

if handle stays in drive
position when released.

Move control handle to
brake position to stop truck.

WARNING

Truck will coast

if handle stays in drive
position when released.

Move control handle to
brake position to stop truck.

WARNING

QuickPick™ Walkalong Control optional 2625 QuickPick™ Walkalong Control optional

QuickPick

™

Walkalong Control optional

QUICKPICK

TM

WALKALONG CONTROL OPTION

You can use this option,
usually along with the coast option
(see pages 22, 23 & 24), 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 fi rst. 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
travel speed or steering.

Know the Hazards

USE THE QUICKPICK

TM

WALKALONG CONTROL CAREFULLY

• Don't let the truck speed exceed your walking speed.

• Limit use of the QuickPick controls to moving the
truck between picks in clear aisles.

• Use the twist grips if you need better control of travel
speed or steering.

• Use only on level surfaces.

• Watch out for people and other trucks.

Additional Options 2827 Additional Options

Additional Options

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.

Know the Hazards

WORK ASSISTTM 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 obstructions.

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.

PROTECT YOUR HANDS AND ARMS

Loads can shift and fall against the backrest. Keep your
hands and arms on the power unit side of the backrest.

Do not use the work assist tube as a handhold. Keep
one hand on the grab bar while riding.

WATCH FOR OTHER WORK ASSIST HAZARDS

Make certain the work assist tube will clear all
doorways, lighting, racks and other surrounding
obstructions.

Be sure any additions to the work assist tube will not
interfere with control handle movement.

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.

Daily Safety Check 3029 Daily Safety Check

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.

• Check to make sure the battery is charged, water
level is OK and vent caps are in place. Don't use an
open fl ame to check the battery.

• Make certain the battery retainers on both sides of
the truck are properly installed.

• See that all wheels are in good condition.

• Clean the twist grips and grab bar.

• Check that both forks are secure and not bent,
cracked or badly worn.

• Look under the truck for signs of hydraulic leaks.

• Test the horn.

• Make sure the power disconnect works.

• Check that all controls work smoothly.

• See that the load backrest is in place and fastened if
your truck has that option.

2. Test drive your truck in an uncongested area.

• Test raise and lower operation.

• Check the steering.

• Drive the truck slowly in both directions. Check the
reversing button.

• Check braking distance in forward and reverse. Load
size and fl oor conditions can affect these distances.

• Drive through the full speed range in both forward
and reverse.

• 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 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.

Be a Safe Driver 3231 Be a Safe Driver

Be a Safe Driver

MAKE SURE YOU ARE READY TO DRIVE

• Do not use this truck unless you are trained
and certifi ed.

• 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. Make certain you
use the correct units of measure.

• Some trucks are not allowed in areas where there are
fi re hazards. Be certain your truck is the correct fi re
safety type for the area.

• Make sure your hands and shoes are clean and dry,
and your clothing is proper for the job.

MAKE SURE YOUR TRUCK IS READY

• Inspect your truck before using it (see pages 29 and

30). If it's not working right, or something is broken,
report the problem to your supervisor. Don't use the
truck.

• In an open area, test the braking. Check at a slow
travel speed fi rst, then a faster one. Know the
distance it takes to stop before you start work.

WHEN RIDING

• 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 fi xed object will be crushed
or even cut off.

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

• Stop your truck completely before getting off.

WHEN WALKING

• Stay to the side of the truck when traveling power
unit fi rst. Make sure the truck won't hit your leg or
run over your foot.

• When traveling forks fi rst, keep both hands on the
control. Be careful when changing direction. Keep
your feet clear of the truck.

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 fl oors. 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.

Continued next page...

The most

important

component

is you.

?

Be a Safe Driver continued 3433 Be a Safe Driver continued

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 fi xed object.

• Never allow passengers on your truck.

• Keep others away from your truck while you're
working. Don't ever allow anyone to ride on the load
or forks.

• Don't let anyone use your truck unless they are
trained and certifi ed.

• Don't use the coast option if there are people in
the aisle.

WHEN LEAVING YOUR TRUCK

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

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

• Make sure coast is off.

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
fi rst and set the brake.

BE CAREFUL TRAVELING ON RAMPS AND GRADES
When Riding

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

• Without a load, drive with forks downgrade.

When Walking

• Stay out of the path of the truck.

• With or without a load, drive with the forks pointed
downgrade.

• 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.

Forks pointed upgrade

Forks pointed downgrade

Battery Maintenance 3635 Battery Maintenance

Battery Maintenance

WHEN YOU INSTALL OR CHANGE BATTERIES

• Turn the truck OFF. Be sure the coast selector is off
and the brake is applied.

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

• 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 a battery in,
or remove it from, the battery compartment or a
stand. Make sure you adjust the spreader bar hooks
to fi t the battery.

USING A ROLLER STAND

• 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

• Replace the battery retainers. Make certain the
retainers on both sides of the truck are in place.

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

Know the Hazards

Note: DELAY ON LIFT

When the battery is connected to the truck, there is
approximately a 10 second delay before lift is available.

TRUCK BATTERIES CAN BE DANGEROUS

Your truck battery produces fumes that can explode.
It also contains acid that could burn or disfi gure 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 fl ame 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 all retainers are not in
place. Check that both retainers are installed before
operating your truck.

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...

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

Warning Labels

Warning Labels 3837 Battery Maintenance continued

Battery Maintenance continued

Know the Hazards

BEFORE CHARGING YOUR TRUCK BATTERY

• Turn the truck OFF. Be sure the coast selector is off
and the brake is applied.

• Charge the battery only in areas designated for that
use.

• See that the battery cells are fi lled to the proper
level. Never use an open fl ame to check the battery.

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

• Read the battery charger instructions.

• Be sure the charger is turned OFF before connecting
the battery to the charger. Otherwise you might
create a spark which could cause the battery to
explode.

BATTERY SIZE IS IMPORTANT

Make certain you use the correct size, type and weight
of battery. Never operate a truck that has an
underweight or undersize battery installed.

EACH WARNING LABEL
ON YOU 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 2006 Crown Equipment Corp.

Minimum battery size allowed

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

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

an accident.
Use U.L. classified Type E battery.

WARNING

280

WARNING

Avoid being crushed. Keep head,

arms, hands, legs, and feet within the
operator area. Stop 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.

07

Truck will coast

Move tiller to brake
position to stop truck.

Stay clear of all
moving parts.

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

47

WARNING

WARNING

CAUTION

Connect charger
properly or truck
can be damaged.

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

20

DANGER

Batteries can produce explosive gas. Do not

smoke, use open fl ame, 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, fl ush immediately and
thoroughly with water. Get medical attention if your
eyes are affected.

WARNING

Minimum battery size allowed

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

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

Use U.L. classifi ed Type E battery

04

WARNING

It's the law, you must be
trained and certifi ed 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 & instructions on the
truck and in the operator manual and
on the truck.

* Additional copies of the Operators Manual
and Truck Labels can be obtained from Crown
Equipment Corp., New Bremen, OH 45869

Truck will coast

if handle stays in drive position
when released.

Move control handle to
brake position to stop truck.

WARNING

New Bremen, Ohio 45869 USA © 2009 PF14692 Rev. 6/14 Printed in U.S.A.

The most important component is you.

4500 SERIES

This operator manual has

information for all models of

series PE 4500 plus some

options and accessories.

Some of the illustrations and

information may not apply

to your truck.