Crown Equipment Automobile PC 4500 Series User Manual

C
Specifications  
PC 4500 Series  
Center Control  
Pallet Truck  
PC 4500  
Series  
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PC 4500 Series  
Specifications  
1
2
3
4
5
8
9
Manufacturer  
Model  
Crown Equipment Corporation  
PC 4500  
6000/8000  
24 Volts  
Ride  
Load Capacity  
Power  
lb  
Electric  
Operator Type  
Lift Height  
Lift  
Stand-up  
in  
in  
in  
in  
in  
9.25  
6
10 Head Length  
57.31  
22/27  
23/28  
16 Outside Fork Spread  
Standard Tip  
Extended Tip  
17 Speed Travel  
Power Unit First  
Forks First  
6.0  
Empty  
mph  
mph  
mph  
mph  
9.0  
7.0  
6.3  
6.0  
4000 lb  
6000 lb  
8000 lb  
5.7  
5.1  
5.0  
PC 4500 Series  
Standard-Tip Forks  
Extended-Tip Forks  
Nominal Fork Length  
11 Actual Fork Length  
12 Overall Length  
in  
in  
in  
36  
42  
48  
54  
60  
96  
84  
93  
93  
96  
35.75  
93.06  
71.25  
25  
41.75  
99.06  
77.25  
23  
47.75  
53.75  
59.75  
95.75  
83.75  
141.06  
103.25  
17  
95.75  
105.06 111.06 117.06 153.06  
150.31 153.06  
103.25 103.25  
13 Wheelbase  
Forks Raised in  
%
83.25  
21  
89.25  
20  
95.25  
19  
133.25  
13  
14 Grade Clearance  
15 Turning Radius  
17  
17  
Forks Raised in  
81.4  
1895  
1914  
87.4  
1911  
1938  
93.4  
1927  
1962  
99.4  
1943  
1986  
105.4  
1959  
2010  
143.3  
2109  
2174  
113.4  
2092  
2152  
113.4  
2173  
2233  
113.4  
2188  
2248  
7
Truck Weight  
w/o battery  
6000 lb  
8000 lb  
lb  
lb  
Model  
PC 4500-60 and PC 4500-80  
13 x 4.5 x 8 Poly  
Drive Tire  
Casters  
in  
in  
in  
2 - 4 x 2.5 Poly  
Load Wheels  
2 - 3.25 x 6.5 (-302)  
-301 Moderate cut/tear resistance, high capacity. High capacity transport. Not for dock use.  
-302 Highest cut/tear resistance offered. Extremely high capacity, low rolling resistance. Docks, rough floors and floor debris.  
-401 Combines good cut/tear resistance and very high capacity. Use where nothing else works.  
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Technical Information  
PC 4500 Series  
Maximum Battery Size  
13.19" wide x 31.12" long x  
31.62" high  
6. Torsion bar package for  
quick adjustment casters  
7. Tall battery wall (use with  
31.62” tall battery)  
8. 22.5” wide load backrest  
9. 60” or 72” tall load backrest  
10. Battery compartment rollers  
11. Battery retainer interlock  
switches  
12. Quick battery disconnect  
handle (right side only)  
13. Left side battery connector  
(facing power unit door)  
14. Drive tire and load wheel  
options  
15. Toggle switch in lieu of key  
When the high speed pedal is  
engaged, it is approximately flush  
with the platform cushion for  
maximum comfort.  
The Access ™ display offers six  
hour meter readouts and  
odometer. The operator message  
mode can be programmed to  
display model number (default),  
BDI, truck hours, odometer, trip  
odometer or timer. Built-in PIN-  
code (up to 25) capability.  
Batteries  
24-volt, 750 amp hour, 15.2 Kwh  
Min/Max weight 975/1500 lb  
A large back cushion and mold-  
ed urethane platform cushion are  
standard to minimize fatigue  
when the operator is in transport  
position.  
Standard Equipment  
1. 24-volt fused electrical system  
The Access display also includes  
a full featured on-board service  
tool. Proven Access 123  
®
2. Access 123 Comprehensive  
Optional leg cushions are avail-  
able to further reduce fatigue,  
increase comfort and maximize  
productivity.  
System Control  
diagnostics has been extensively  
developed to provide superior  
troubleshooting and service  
ease. The service technician can  
actively view inputs and outputs  
during truck operation. Event  
code history includes the most  
recent event code plus the previ-  
ous 15 codes. No service key,  
laptop or handset required.  
3. Access 123 Display - includes  
BDI with lift lockout (2 re-keys),  
hour meters, event codes,  
Optional width and height load  
backrests can be specified for  
your application. Hip, shoulder and  
elbow clearance are maximized  
when this feature is customized  
to your operators and load sizes.  
PIN-code access and three  
selectable performance levels  
4. e-Gen™ braking system with  
automatic parking brake  
5. Crown manufactured AC  
traction motor  
16. Positive / Negative Accessory  
Cable  
®
17. InfoLink Ready System  
An optional control module is  
available to provide raise, lower  
and horn buttons in the load  
backrest.  
6. Ramp hold  
(InfoLink module sold  
separately)  
7. Standard handle includes  
urethane covered twist grips  
with cams and full width  
Performance tuning is accessed  
through the display to customize  
truck performance for specific  
applications or operator  
18. Travel alarm (requires right  
side battery connector)  
19. Freezer conditioning  
20. Skid Adapter*  
21. Corrosion conditioning*  
22. Shrink Wrap holder*  
23. Strobe Light*  
raise, lower and horn button  
Electrical System  
8. Molded urethane platform  
cushion  
Heavy-duty 24-volt electrical  
system for demanding ware-  
house, dock and transport appli-  
cations. Crown-manufactured  
AC drive motor delivers powerful  
performance and proven reliability  
for long lasting productivity in  
any environment.  
requirements.  
The large Crown-manufactured  
AC drive motor specifically de-  
signed for lift truck applications,  
provides improved acceleration  
and plug reversal contributing to  
greater productivity.  
Anti-slip recommended  
with freezer  
9. Padded back cushion  
10. Preset lift height  
(adjustable)  
24. Second leg cushion (requires  
31.62” tall battery)*  
11. 27.5” wide load backrest  
12. 43.5” tall load backrest  
25. Second level order picking  
platform*  
26. Custom paint color*  
27. Pallet Stop*  
®
InfoPoint  
A lift limit switch shuts the pump  
motor off at full fork elevation.  
Color coded wiring is used for  
ease of service.  
InfoPoint System allows techni-  
cians to troubleshoot without  
complicated schematics, wiring  
diagrams or cumbersome  
service manuals for over 95%  
of repairs. Simplicity is complete  
with InfoPoint Quick Reference  
Guide, color-coded components  
maps and “information nuggets”  
located on the truck.  
®
13. InfoPoint System with Quick  
Reference Guide  
14. Color-coded wiring  
15. Steel power unit doors  
16. Lift-off left and right battery  
retainers  
17. Polyurethane load wheels  
18. Polyurethane drive tire  
19. Quick adjustment casters  
20. Short battery wall (use with  
23.38” tall battery)  
* Extended lead time  
®
Access 123 Comprehensive  
Operator Area and Controls  
The PC 4500 Series incorporates  
an operator compartment designed  
for comfort and productivity.  
System Control with AC  
Traction  
This system provides unmatched  
truck control and system perfor-  
mance in:  
The compartment features  
rounded edges, a large operator  
platform to allow quick entry/exit  
onto the truck and a choice of  
handle options. Dual twist grips  
with soft urethane covering and  
cams improve operator comfort.  
Full width raise, lower and horn  
buttons are employed for easy  
actuation.  
* Traction control  
* Operator interface  
* Diagnostics  
Clearly labeling each component  
and providing an area map  
showing component locations  
helps to minimize downtime.  
A Quick Reference Trouble-  
shooting Guide is supplied with  
each truck showing display  
operation, code definitions,  
and overall component ID of  
the entire truck.  
21. 175 amp battery connector  
22. Key switch  
23. Horn  
Crown technology provides  
a closed-loop traction control  
system which maintains speed  
throughout the battery charge  
and provides optimum accelera-  
tion and speed as the load on  
the forks increases.  
Optional Equipment  
1. “T”-type control handle  
includes urethane covered  
twist grips with cams, full  
width raise, lower and horn  
buttons with automatic park  
brake  
2. Molded urethane leg cushion  
3. Raise, lower and horn control  
module on load backrest  
In low level order picking applica-  
tions, where walking through the  
compartment is common, the  
larger compartment, low profile  
high speed pedal, rounded edges  
and optional load backrest widths  
and heights improve order picking  
efficiency. Preset lift height pro-  
vides operators with a consistent  
platform step height and is ad-  
justable to individual operator  
preference for improved comfort  
and productivity.  
Access controller has full-time  
management control of traction  
and other system inputs and  
outputs. Access 123 technology  
simplifies the system by reducing  
componentry including contac-  
tors, relays and other hard-wired  
components. The Access 123  
system is covered by a 3 year /  
6000 hour supplemental warranty.  
4. Storage tray and bin in load  
backrest  
5. Storage module on battery  
(23.28” high battery only)  
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Technical Information  
PC 4500 Series  
Hydraulics  
Extended-tip fork design has  
totally enclosed tip, with full length  
convex bottom surface creating  
an entry ramp. Ramp design  
helps fork glide over bottom  
boards of pallet and keeps welded  
edges from touching bottom  
boards of pallet.  
e-GEN Braking System  
Heavy-duty pump, motor, reservoir  
and control are assembled into  
one unit. A centrally located lift  
cylinder, mounted vertically,  
is equipped with long-life  
Variable regenerative motor  
braking is optimized and virtually  
eliminates brake maintenance.  
Other Options  
1. Audible travel alarm  
2. Flashing lights  
While moving, e-GEN braking is  
applied if the operator moves the  
standard handle into the brake  
zone, activates brake levers on  
“T” handle, removes travel input  
request or reverses direction.  
Safety considerations and dangers  
associated with audible travel  
alarms and flashing lights include:  
polyurethane packings. A  
pressure compensating flow  
control valve is an integral part  
of the valve block and regulates  
lowering speed. Overload valve  
protects hydraulic components.  
Abrasion resistant steel entry/exit  
slides on both sides of each fork  
have convex bottom surfaces to  
prevent snagging as forks move  
over bottom boards of pallet.  
One-piece design with radiused  
edges are welded away from  
contact point of slide.  
• Multiple alarms and/or lights  
can cause confusion.  
• Workers ignore the alarms  
and/or lights after day-in and  
day-out exposure.  
The closed loop Access 123  
traction control will keep the  
truck static until a travel input is  
requested, even when operating  
on a grade.  
Drive Unit  
All gear drive from drive motor to  
drive wheel axle. Crown-manu-  
factured gears are hard finished  
and dual machined for high quality.  
Drive tire axle is mounted in the  
drive unit on both sides for maxi-  
mum strength in rough floor or  
docking applications. Drive unit is  
top and bottom mounted. Top  
mount is a large, tapered roller  
bearing for vertical or horizontal  
forces. Bottom mount has four  
shock mounted rollers on drive  
unit running in a hardened steel  
roller race. Gear train runs in oil-  
filled, sealed housing.  
• Operator may transfer the  
responsibility for “looking out”  
to the pedestrians.  
Automatic electric parking brake  
activates when the truck has  
been stationary for four seconds,  
the truck is keyed off or the bat-  
tery has been disconnected.  
Exit roller design prevents load  
wheel from dropping after cross-  
ing bottom board. The 4" wide,  
steel exit roller is positioned di-  
rectly behind the load wheel  
to keep the fork rolling. The  
• Annoys operators and  
pedestrians.  
Dimensions and performance  
data given may vary due to manu-  
facturing tolerances. Performance  
is based on an average size vehicle  
and is affected by weight, condi-  
tion of truck, how it is equipped  
and the conditions of the operating  
area. Crown products and speci-  
fications are subject to change  
without notice.  
.
entry/exit slide design also assists  
in trouble-free pallet entry/exit.  
Pallet Planning Guide  
On standard-tip fork models, the  
load wheel will drop in the second  
opening of the pallet when “A” or  
“B” dimension equals the nominal  
fork length. On extended-tip fork  
models, the load wheel will drop  
in the first opening of the second  
pallet. On models with a single  
load wheel, the “C” dimension  
should be 6" maximum and the  
“D” dimension should be 14" mini-  
mum. On models with tandem  
load wheels, the “C” dimension  
should be 6" maximum and the  
“D” dimension should be 17"  
minimum. Customers that need  
tandem load wheel trucks, but  
use pallets with smaller openings,  
may be accommodated if the  
maximum lift height of the truck is  
reduced. Contact your Crown  
dealer for details.  
Fork adjustment is done at the toe  
with no need to remove a cover  
plate. Fork heel height adjustment  
is done quickly without removing  
battery. Quick and easy fork  
adjustment promotes servicing of  
fork assembly to keep pallet  
entry/exit productive.  
Caster System  
Standard on the PC 4500 Series  
are the quick adjustment casters.  
These casters adjust quickly to  
enable braking, traction, steer  
effort and stability to be  
Pull rod design incorporates a  
replaceable “tenon” design for  
fast servicing of pull rod while still  
in the truck.  
“balanced” based on your  
specific application. This system  
can also increase drive tire life by  
as much as 60% by permitting  
more tire wear. The optional  
torsion bar suspension is avail-  
able to maximize stability on tall,  
unwieldy and less stable loads.  
Power Unit Structure  
Heavy gage steel is used in the  
power unit structure and skirt.  
Rugged steel power unit doors  
protects electronic components  
and swing open providing  
Fork Assembly  
excellent access. Doors also can  
be lifted off if desired. Door bolts  
have exclusive convex design  
that mate with concave door  
holes for fast reinstallation of bolts.  
Crown provides an exclusive  
5 year Supplemental Guarantee  
on the Power Unit and Fork  
Weldment structures.  
Fork width - 9.12" on standard-  
tip fork models, 10" on extended-  
tip fork models. Fork spread - 22"  
and 27" standard on standard-tip  
models. 23"- 26" spread available  
in one-inch increments. 23" and  
28" standard on models with  
extended-tip models. Fork spreads  
from 24"- 27" available in one-  
inch increments. Fork lengths -  
36, 42, 48, 54, 60 and 96" with  
standard tip; 84, 93, and 96"  
forks available with extended-tip  
design for shorter wheelbase.  
B
A
A
C
C
D
D
First  
Second  
Opening  
Opening  
To facilitate pallet entry/exit  
Crown has engineered several  
features into their fork assembly.  
Standard-tip forks have pallet  
entry rollers to lift fork over bottom  
board of pallet. Rollers are made  
of high molecular weight polyeth-  
ylene with .75" axle and roll pin.  
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Crown Equipment Corporation  
New Bremen, Ohio 45869 USA  
Tel 419-629-2311  
C
Fax 419-629-3796  
crown.com  
Because Crown is continually improving its products,  
specifications are subject to change without notice.  
You can count on Crown to build lift trucks  
designed for safe operation, but that’s  
only part of the safety equation. Crown  
encourages safe operating practices through  
ongoing operator training, safety-focused  
supervision, maintenance and a safe working  
environment. Go to crown.com and view our  
safety section to learn more.  
Crown, the Crown logo, the color beige, the  
Momentum symbol, Access 123, e-GEN, InfoPoint,  
and InfoLink are trademarks of Crown Equipment  
Corporation.  
Copyright 2008 Crown Equipment Corporation  
SF18004 8/08  
Printed in U.S.A.  
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