PE Operator Manual - Crown Equipment Corporation

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PE4000 SERiESOperator ManualThis operator manual hasinformation for all models ofseries PE 4000 plus someoptions and accessories.Some of the illustrations andinformation may not apply toyour truck.The most important component is you.New Bremen, Ohio 45869 USA 2003PF14182-WEB Rev. 6/06Printed in U.S.A.PE

You Must be TrainedWARNINGIt’s the law, you must be trained and certified to operate thistruck. (OSHA § 1910.178, Rev. 1999)You or others around you can be seriously injured or evenkilled if you don't use this truck correctly.STOPIT'S THE LAW, YOU MUST BE TRAINED AND CERTIFIEDFederal law states that only properly trained operatorsare permitted to operate a powered industrial truck andthat your employer must train you and certify that youare qualified to operate this powered industrial truck.(OSHA §1910.178, Rev. 1999)Do not operate this truck in your work place until you havebeen trained and certified by your employer.Read and obey all warnings and instructions in this Manual*and on the truck.Head, arms, hands, legs or feet outside the operator areacan be pinned or crushed whenever the truck is moving.Stay within the operator area and stop the truck completelybefore getting off.However, falls from docks can cause serious injury oreven death. Immediately exit and move away from thetruck in these emergencies.You could be killed or seriously injured if you are notadequately trained for lift truck operation!Inspect your truck before starting work, make sure it is ingood working order.* Additional copies of this Operator Manual and all Truck Labels can beobtained from Crown Equipment Corporation, New Bremen, Ohio 45869U.S.A.All rights reserved under Internationaland Pan American copyright conventionsCopyright 2003 Crown Equipment Corp.1 WarningYou Must be Trained 2

Protect YourselfKnow the HazardsKnow the HazardsDRIVE CAREFULLY When walking, keep to the side of the truck whiletraveling power unit first. Make certain the truck won'thit the back of your leg or foot. Don't let the truck runover your foot.LOOK WHERE YOU'RE DRIVING You could be pinned or crushed by objects intrudingor poking into the operator area. Always be alert to the area around you and watchwhere you are driving. If traveling forks first, keep both hands on the controlhandle and be careful when changing direction of travel.Keep your feet clear of the truck.RecommendedWalking PathAVOID FALLSFalls from docks are very serious accidents, you can becrushed or even killed. Immediately exit and move awayfrom the truck in these emergencies.Note: This is not like sit-down rider trucks, where it isrecommended that the operator stay with the truck. When riding, keep your hands on the controls and feeton the platform. Keep your body within the operatorarea. While riding, never stick a foot or any part of your bodyoutside the truck, no matter how slow the truck ismoving. This truck weighs about 1360 kg or 3000 pounds,even without a load. You cannot stop or slow it downwith your foot, hand or any part of your body. A footor hand caught between the truck and a fixed objectwill be crushed or even cut off.The best way to prevent injury is to know where you areat all times and follow the rules of safe truck operation.Be extremely careful when working around docks,dockboards and trailers. Stay away from the edge of docks and ramps. Makesure dockboards are secure. Check that trailer wheelsare chocked. You could be seriously injured or evenkilled in a fall from a dock or dockboard. Keep your truck under control at all times. Drive at aspeed that allows you to stop safely. Be even morecareful on slippery or uneven surfaces. Do not driveover objects on the floor. Perform all truck movements smoothly and at a speedthat will give you time to react in an emergency.3 Protect YourselfWARNINGStay clear of allmoving parts.Moving parts cancut or crush hands,feet, arms or legs.07USE YOUR TRUCK SAFELY Keep your hands and feet away from all moving partssuch as forks or wheels. Never allow passengers on the truck. There is no safeplace 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 thebattery. Make certain coast is off.Protect Yourself 4

ContentsWhat's in it for You?Warning1You Must be Trained2Protect Yourself3WHAT'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 someguides to using this manual.PowerControlsOn & Off optional (continued)CoastContents5What's in it for You?6Your Walkie/Rider Pallet Truck7KEY SWITCHTurn the truck on by turning the key to ON (green dot).Lift Truck Parts9Turn the truck off by turning the key to OFF (red dot).Capacity Plate11Power On & Off13Steering & Travel14Braking15Raising & Lowering16Traveling17 Walkalong Control optionaloptionalQuickPick Always turn the key off and make certain coast is offwhen leaving the truck.HOW-TO-DRAWINGSOn many pages you will find picturesas well as text to help you understandhow to use your truck safely andproductively.POWER DISCONNECTPull up on the battery connector to disconnect the batteryand cut all power.Know the HazardsAlways disconnect the battery any time the truck isn'tWARNI NGTruck will coastif handle stays in driveposition when released.Move control handle tobrake position to stop truck.working right. The key switch does not cut all power tothe truck.Don't use the truck if it's not working right. Report theproblem to your supervisor.Know thethe HazardsHazardsKnowCoast Controls optional19QuickPick Walkalong Control optional 22Additional Options23Daily Safety Check25Be a Safe Driver27Battery Maintenance31Warning Labels345 Contents13 CoastPowerControlsOn & Offoptional (continued)21QUICK LOCATORSIn addition to the "Contents" page youcan use page headings to find topics.Some pages also have a picture of thetruck in the corner showing featuresor functions covered on that page."KNOW THE HAZARDS"Watch for and read these specialblocks. You will find information aboutpossible safety hazards and how toavoid them.QuickPick WalkalongWalkalong ControlControl optionaloptional 2222QuickPickWhat's in it for You? 6

Your Walkie/Rider Pallet TruckWALKIE/RIDER PALLET TRUCKSAs a rider your pallet truck is designed to moveloads over long distances. You can also use itas a walkalong truck and pick stock with it.HOW TO DRIVE YOUR TRUCK WHILE RIDINGKeep both feet on the platform. Place one hand onthe control handle and the other on the grab bar.Keep your entire body within the operator area.YOUR PALLET TRUCK IS NOT AN AUTOMOBILEWith a load it may weigh more than 3automobiles. You don't steer the same. You don't brake the same. You don't accelerate the same.GIVE YOUR BODY A BREAKTake advantage of stop time. Get off the truck andflex your arms and legs. Staying alert will help yoube a better and safer driver.HOW TO DRIVE YOUR TRUCK WHILE WALKINGForks FirstWhen traveling forks first, use both hands tooperate the control handle.Watch your feet if you change direction oftravel.Path ofTruckRecommendedWalking AreaPower Unit FirstWhen traveling power unit first, stay to oneside of the truck and slightly ahead of thepower unit. Use the hand closest to the truckto operate the control handle.Hand ongrab barHand oncontrol handleWatch your feet.Stay out of the path of the truck.Feet onplatform7 Your Walkie/Rider Pallet TruckBUILT TO STANDARDSThis truck was designed and builtto current industry and governmentstandards and guidelines. For moreinformation see the following: American National StandardsInstitute (ASME) B56.1 Occupational Safety and HealthAct (OSHA)§1910.178 Rev. 1999 Underwriters Laboratory (UL) 583 National Fire PreventionAssociation (NFPA) 505Your Walkie/Rider Pallet Truck8

Lift Truck PartsControl HandlePower DisconnectGrab BarCoast Control Options(see pages 19, 20 & 21)Travel Twist GripQuickPick Walkalong ControlButtons (Optional)Lower ButtonRaise ButtonReversing ButtonHorn ButtonQuickCoast Selector(optional)(see pages 19, 20 & 21)Raise ButtonBattery RetainerKey Switch(on power unit)PlatformLower ButtonHigh Travel Speed ButtonHorn ButtonControl Arm9 Lift Truck PartsLift Truck Parts 10

Capacity PlateCAPACITY PLATE INFORMATIONThe capacity plate is on the top ofthe power unit cover. It contains: Capacity information Truck type (a fire safety rating) Truck weight (does not include load) Grade rating Battery information Truck informationUnits of measure, kg/mm(lb/in)Capacity with Equally Distributed Load2720(6000)1460(3224)SERI ESTruck Weight Less Battery 5%780(1724)Serial NumberA1234567Truck Data Number1234567890123456Battery WeightMin 440(975)Model NumberTruck Weight with Max. Battery4000Know the HazardsWHAT IS YOUR TRUCK CAPACITY?Capacity is the maximum load that can be lifted ortransported with your truck. See the capacity plateon your truck. Make certain you use the correct unitsof measure.SAMPLE CAPACITY PLATEThe informationshown on this sampleplate does not applyto your truck.2003Max 680(1500)EBattery TypeE%Hour RateD.C. Voltage24PW4000XXTruck TypeMax. GradeKNOW YOUR LOADDo not exceed the capacity shown on your truck's capacityplate. Make certain you use the correct units of measure.Be careful when handling long, high or wide loads. Do nothandle unstable loads.Load Tire Tread Width330(12.9)Max. AMP Hr.This truck as released conforms to the mandatory requirements of ASME B56.1 Crown Equipment Corporation New Bremen, Ohio 45869 USA411-CNote: ANSI B56.1 requires that alldata be shown first in Metric unitsand then USA units.11 Capacity PlateTRUCK TYPESome truck types are not permitted in areas where thereare fire hazards. Watch for marked areas. For example:You must not drive a type E or ES truck into an area restrictedto EE or EX trucks.TRUCK WEIGHTDockboards, elevators and some floors have limitedcapacity. Check your capacity plate for the weight of yourtruck. Remember to add the weight of the battery and theload you have on the forks.Capacity Plate 12

Power On & OffSteering & TravelKEY SWITCHTurn the truck on by turning the key to ON (green dot).STEERINGYou control steering by moving the control handle from side to side.Turn the truck off by turning the key to OFF (red dot).For example: This picture shows the directions the truck can turn whenthe control handle is moved to the approximate position shown.Always turn the key off and make certain coast is offwhen leaving the truck.Always disconnect the battery any time the truck isn'tworking right. The key switch does not cut all power tothe truck.Don't use the truck if it's not working right. Report theproblem to your supervisor.Travel,forks firstnt ioec Tur nfPOWER DISCONNECTPull up on the battery connector to disconnect the batteryand cut all power.Dio ronrnDi reo f T ct iuTravel, powerunit firstKnow the HazardsPOWER UNIT SWINGBe careful turning while traveling forks first. The powerunit will swing wide in the opposite direction. Make sureyou have clearance, and watch out for people in the area.SLOW DOWN FOR SPILLS OR WET FLOORSPowder or liquid spills can cause slippery floors. Slowdown 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.13 Power On & OffSteering & Travel 14

Raising & LoweringBrakingBrakeOnBrake OffBrake OnBRAKINGTo apply the brake, move the control handleeither down or up to one of the braking positions.RAISEPush either raise button until the forks are at the desiredheight.Braking is different if you use the coast feature (seepages 19, 20 & 21).Always check the braking and the position of the coastselector before you start driving.LOWERPush either lower button until the forks are at the desiredheight.Know the Hazards?15 BrakingWATCH YOUR FEETWhile 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 truckis moving. A foot or hand caught between the truckand a wall, or any fixed object, will be crushed or evencut off.MAKE SURE YOUR BRAKE WORKSTest the brake on your truck at the start of each shift.Know the distance it takes to stop before you startworking.If at any time the stopping distance is too long for youto stop safely, don't drive the truck. Report any problemto your supervisor.Raising & Lowering 16

TravelingKnow the HazardsTRAVELRotate the top of the twist grip in the directionyou want to travel.WATCH YOUR FEET AND HANDS While riding, keep your feet on the platform and handson the controls at all times. This truck weighs about1360 kg or 3000 pounds, even without a load. Youcannot stop or even slow it down with your foot, handor any part of your body, no matter how slow thetruck is moving. A foot or hand caught between thetruck and a wall, post or any fixed object will becrushed or even cut off.The farther you rotate the grip from the neutral position,the faster the truck will travel.ONE TOUCH HIGH TRAVEL SPEEDFor high travel speed while riding the truck, rotate thetwist grip, then press and release the high travel speedbutton on the grab bar. Rotate the twist grip to themaximum travel speed position. When walking and traveling power unit first, protectyour legs and feet by staying to the side and keepingout of the path of the truck.When the twist grip is returned to neutral, the speedcontrol will reset to standard operation.HIGH TRAVEL SPEED WITHOUT ONE TOUCHRotate the twist grip, then push and hold the high travelspeed button on the grab bar. Rotate the twist grip tothe maximum travel speed position.When the twist grip is returned to neutral, the speedcontrol will reset to standard operation.REVERSING BUTTONIf you accidentally hit the reversing button while workingin close quarters, the truck will move in the direction ofthe forks until the button is released.Be careful. The reversing button cannot prevent allinjuries.17 TravelingRecommendedWalking PathLOOK WHERE YOU'RE DRIVINGAlways be alert to the area around you and watch whereyou are driving. You could be pinned or crushed bydriving into walls or racks or other fixed objects.You could also be seriously injured by objects intrudingor poking into the operator area.Traveling 18

Coast Controls optionalBrakeOnCOAST, A WALKALONG CONTROL OPTIONBrakeOnCoastBrake OnYou can use one of two optional coast controls to makeit easier to pick loads while walking short distances withthe truck. This feature allows the truck to coast whenyou let go of the control handle. However you can applythe brake by moving the control handle to one of thebrake positions.CoastBrake OnBe even more careful when using coast. Make sure youunderstand the possible hazards. Don't place yourselfor others at risk.OPTION 2, ELECTRONIC QuickCoastTM SELECTORCOAST ONMove the control handle to the coast position and pressthe coast selector button on the back of the grab bar,opposite the raise/lower switches. The “no-brake” symbolat the base of the control handle will light and a single“beep” will sound to warn that the truck is in the coastmode.High travel speed is not available while coast is engaged.OPTION 1, MANUAL COAST SELECTORCOAST ONMove the control handle to the coast position and shiftthe coast selector lever toward the control arm.With coast on, the truck will coast when you let go ofthe control handle. You must move the handle to a brakeposition to apply the brake. A “beep” will continue tosound as long as the handle is in the brake position.With coast on, the truck will coast when you let go ofthe control handle. You must move the handle to a brakeposition to apply the brake.COAST OFFMove the control handle down and shift the coast selectoraway from the control arm.When coast is disabled, braking will return to standardoperation (see page 15).Truck will coastif handle stays in driveposition when released.Move control handle tobrake position to stop truck.COAST OFFTo turn coast off, either press the high travel speed buttonon the grab bar, turn the key switch to OFF, or disconnectthe battery. The “no-brake” symbol will go out, and thecontrol handle will return to vertical.If you accidentally hit the reversing button when thehandle is in the coast position, coast is also disabled.When coast is disabled, braking will return to standardoperation (see page 15).Continued next page.19 Coast Controls optionalCoast Controls optional 20

Coast Controls optional (continued)WHEN USING COAST Travel power unit first only.Travel,power unitfirst Don't get in the path of the truck.QuickPick Walkalong Control optionalQUICKPICKTM WALKALONG CONTROL OPTIONYou can use this option, usually along with thecoast option (see pages 19, 20 & 21), to make it eveneasier to pick loads.Use these options when picking items locatedclose to each other in an aisle, usually within4 bays or about 11 meters (36 feet). Watch your feet. Stay to the side of the truck. Keep yourarm extended to give maximum clearancebetween you and the truck.RecommendedWalking AreaKnow the HazardsTruck will coastif handle stays in driveposition when released.Move control handle tobrake position to stop truck.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 theside of the truck with your arm extended and keep yourfeet 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 coastoff or turn the truck off, make certain your body is notin the path of the control handle as it returns to vertical.21 Coast Controls optional (continued)QUICKPICK WALKALONG CONTROL BUTTONSYou can use the QuickPick controls from eitherside of the truck. Place your hand on the end of thecontrol handle closest to you. Press both buttons atthe same time.Your truck will travel power unit first at the maximumwalkie speed. You have only one travel speed whileusing the QuickPick option.You can control travel speed by releasing and pressingthe control buttons occasionally.Use the twist grips anytime you need better control oftravel speed or steering.Know the HazardsUSE THE QUICKPICK WALKALONG CONTROL CAREFULLY Don't let the truck speed exceed your walking speed. Limit use of the QuickPick controls to moving the truckbetween picks in clear aisles. Use the twist grips if you need better control of travelspeed or steering.QuickPick Walkalong Control optional 22

Additional OptionsWORK ASSIST TUBE OPTIONThis feature provides a location for attaching work assistoptions such as: lights, fan, clipboard etc.LOAD BACKREST OPTIONYour company may have ordereda load backrest if you must handle loadsthat are unstable or not secured.While traveling, be sure that the work assist tube willclear doorways and other surrounding obstructions.Don't place your hand or arm over the backrest. It couldbe pinned or crushed by the load.The work assist tube does not have a gripping surface,nor is it located to serve as a handhold. Always keepone hand on the grab bar while riding.There are three types of backrest.PIVOTING TYPELift up on the handle and swing the backrest forward ifyou need to service the battery. When you return thebackrest to the upright position, make sure the handle isall the way down and the backrest can't swing forward.LIFT-OFF TYPEYou can remove or install this backrest as required.Note: Use a hoist if the backrest is heavy.BOLT-ON TYPENeed not be removed to change the battery.Make certain any options fastened to the work assisttube do not interfere with operation of the control handle.K

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

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