SAFETY
Control of Hazardous Energy
Control of Hazardous Energy
Lockout/Tagout
For safety and to obey OSHA Regulations, (Standards
- 29 CFR), control of hazardous energy (Lockout/Ta-
gout) - 1910.147, Crown has instructions for the correct
energy control when you do the maintenance on the
truck. Before you do the maintenance on the truck, look
at the applicable sections in this manual for procedures
to follow.
Also, Crown recommends that all technicians wear ap-
plicable protective items when they do the servicing on
Crown equipment. Some examples of these protective
items are:
• Safety glasses
• Work gloves
• Steel-toed shoes.
Battery
Safety Procedures
Wear protective items when you do the maintenance
on the batteries. Some examples of these protective
items are:
– Rubber apron
– Gloves
– Boots
– Full-face shield.
CAUTION
Risk of burns by sulphuric acid.
The battery contains sulphuric acid which could cause
burns when you come in touch with it.
 Do not let the sulphuric acid touch your eyes, skin,
or clothing.
 If you come in touch with the sulphuric acid, flush
the area immediately and fully with clean water and
get medical aid.
• Do not let the battery acid touch the eyes, skin,
clothing, or floor. If the battery acid touches the
eyes, you must flush them immediately with clean
water and get medical aid immediately.
• If the battery acid touches the skin, you must clean
it immediately with clean water and soap.
Crown 2010 PF17919-1 Rev. 10/12
• If you spill the battery acid, use a Battery Spill Kit
(300035) to make the battery acid neutral and clean
it up. Follow the manufacturer directions to use the
kit.
• Keep the vent plugs tightly in position at all times,
but not when you add water or use a hydrometer.
• Do not let flames or sparks near the battery. Gas
made while the battery charges is very explosive.
This gas stays in the cells after you charge the bat-
tery.
• Do not put metal or conductive objects on the bat-
tery because they can cause a short circuit.
• Do not let contamination, solution, or other un-
wanted material into the cells. Contamination will
make the battery acid neutral and will lower the
available battery charge.
• If you must repair the battery, follow the battery
manufacturer instructions for the applicable repair
procedures.
Battery Maintenance
WARNING
Risk of burns by short circuits and high current.
Unapproved handling of tools on batteries can cause
severe injury to you and damage the truck.
 Do maintenance and repair on batteries only if you
are approved for this work.
• Make sure the charger you use has the same volt-
age and amperage as the truck battery. This volt-
age is on the truck data plate.
• Before you connect or disconnect a battery, make
sure the battery charger is OFF. If you do this and
the battery charger is ON, an injury could occur to
you or damage could occur to the battery and the
battery charger.
• Never use a match or lighter. Battery fumes are ex-
plosive.
• Make sure that the battery you use has the same
weight, dimension, amperage, and voltage specifi-
cations as the truck (refer to the truck data plate).
Do not operate a truck without the correct battery.
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SAFETY
Control of Hazardous Energy

Battery Charging

WARNING
Risk of gas explosion.
Battery gases are explosive. Severe injury or death
may result if the battery gas explodes.
 Do not smoke, use an open flame, or make an arc
or sparks around the battery.
 Make sure the area where you charge the battery is
well vented. Use designated areas for charging bat-
teries if they are available.

Consult the battery charger manual or refer to ELEC- Fig. 1 (8251)

TRICAL SYSTEM ► Battery ► Battery Charger for in- Battery Installation
structions on operation and maintenance.

Battery Removal
CAUTION
• Move the truck to an area that is used for battery
maintenance.
• Lower the mast(s) fully.
• Turn the truck OFF and remove the key.
• Disconnect the battery and lockout/tagout the truck.
Refer to SAFETY ► Control of Hazardous Energy
► Lockout/Tagout procedures.
• Do not start to remove the battery from the truck
unless you have a battery roller stand in position.
• If you remove the battery with the mast(s) raised,
use a lift attached to the mast to supply tip over pro-
tection.
• Do not let metal objects touch the top of the battery
cells. This may cause a short circuit when you re-
move the battery.
• Use a non-conductive insulator as a cover on top of
the battery before and during removal.
CAUTION
• Turn the truck OFF and remove the key.
• If the battery was removed with the mast(s) raised,
use a lift attached to the mast to supply tip over pro-
tection.
• Do not metal objects to touch the top of the battery
cells. This may cause a short circuit when you in-
stall or move the battery.
• Use a non-conductive insulator as a cover on the
top of the battery before and during installation.
• Make sure the battery that you use agrees to the
weight, capacity, amperage, and voltage require-
ments of the truck (refer to the truck data plate).
• Do not operate the truck with a battery that does not
agree with the requirements.
Lockout/Tagout Procedures
Lockout/tagout procedures for the truck
Note: A lockout/tagout kit (300037) is available. Refer
to the One Source Catalog.
Note: These procedures let the other personnel know
that the truck is not available for operation.
1. Turn the truck OFF and remove the key.
2. Apply a tag to the multifunction control handle (2)
or the steering tiller (3) with a cable tie to warn oth-
ers that the truck is being serviced.

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 SAFETY
Control of Hazardous Energy

4. Turn and hold the key switch to the start position a

minimum of 10 seconds.
5. Turn the key switch to OFF and remove the key.
6. To verify that the capacitors have discharged,
place a volt meter across the B+ and B- terminals
of ACCESS 2. The voltage should be less than 1
V. Repeat the procedure on ACCESS 3 and AC-
CESS 8. Refer to Figure 3 for RM/RMD 6000S
trucks. Refer to Figure 4 for RM/RMD 6000 trucks.

Fig. 2 (20916)
To do maintenance on the truck (with the
battery in the truck)
1. Disconnect the battery.
2. Remove the primary power fuses.
3. Install a lockout device on the battery connector.

To do maintenance on the truck (with the

battery out of the truck)
1. Remove the primary power fuses.
2. If it is possible, install a lockout device on the truck
battery connector. Or, install a tag with a cable tie
on the truck battery connector to warn others that
the truck is being serviced.

Capacitance

WARNING Fig. 3 (24218)

A charged capacitor could be dangerous. 1 ACCESS 3 B+ and B- Terminals
Uncontrolled discharge of stored electrical energy in 2 ACCESS 2 B+ and B- Terminals
some control modules can cause injury or damage the 3 ACCESS 8 B+ and B- Terminals
truck.
 When you do truck maintenance around the bus
bars and related power cables, first discharge the
capacitors.

Discharge the capacitors

1. Move the truck to a maintenance area that has a
flat and level floor.
2. Chock the wheels. Refer to SAFETY ► Control of
Hazardous Energy ► Lifting and Blocking.
3. Lockout/tagout the truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lockout/Tagout.

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SAFETY
Control of Hazardous Energy

Hydraulic

WARNING
AVOID HIGH PRESSURE FLUIDS
• High pressure fluid can go through the skin and
cause serious injury.
• Release the pressure before you disconnect the hy-
draulic lines.
• Tighten all connections before you apply the pres-
sure.
• Keep your hands and body away from pin holes
which eject high pressure fluids.
• Use a piece of cardboard or paper to examine for
leaks. Do not use your hand.
• High pressure fluid that goes into the skin can be-
come a severe medical emergency even when the
skin looks normal.
• There is a delayed start of pain, and severe tissue
damage may occur.
• You must get medical aid from a specialist who has
had experience with this type of injury.

When you do maintenance on the hydraulic system,

Fig. 4 (26407)
1 ACCESS 3 B+ and B- Terminals (below the backpad)
2 ACCESS 2 B+ and B- Terminals (under the console)
3 ACCESS 8 B+ and B- Terminals (under the console)
make sure the hydraulic system is not pressurized by:
• Move the truck to a maintenance area that has a flat
and level floor.
• No load on the forks.
• Fully lower the load engaging means, mast and fork
carriage or, if required for maintenance, block the
mast sections at the appropriate heights as de-
scribed in Lifting and Blocking - Mast in this section.
• Fully retract the reach mechanism or, if required for
maintenance, block extended reach mechanism as
described in Lifting and Blocking - Reach Mecha-
nism of this section.
• Tilt the forks tips all the way down. Do not continue
to request tilt after the fork tips are down to keep
pressure from building up at the tilt cylinder.
• Turn the truck OFF and remove the key.
• Disconnect the battery.
• Lockout/tagout the truck. Refer to SAFETY ► Con-
trol of Hazardous Energy ► Lockout/Tagout.
• Open the manual lower valve to relieve the hydrau-
lic pressure.

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Releasing the Brakes
There are three procedures to release the brakes in a
maintenance situation. Each of the procedures has dif-
ferent degrees of operator control. If the truck will not
move and has to be towed, follow one of the proce-
dures that are shown below to release the brakes.
Note: The preferred procedure to release the brakes is
through the Access 123® UTILITIES Menu.
Access 123 UTILITIES Menu Brake Re-
lease Procedure
This is the preferred procedure to release the brakes in
a maintenance situation. Use this procedure only if the
truck is electronically functional and an operator is on
the truck. Refer to SAFETY ► Control of Hazardous
Energy ► Towing the Truck for the proper towing pro-
cedures.
Note: When tow mode is active, the brakes can be re-
leased and traction will be inhibited. Steering will be ac-
tive.
1. Lower the mast(s) fully.
2. Lockout/tagout the truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lockout/Tagout.
3. Put chocks against the wheels of the truck to pre-
vent unwanted movement of the truck when the
brakes are released.
4. Use ACCESS 1 to enter the UTILITIES Menu and
scroll to the U2 Tow Mode to activate the tow mode
function. Refer to the Access 1 2 3 section for more
information.
5. In order to maintain the brakes in the released po-
sition, the operator must keep his or her feet on
both the upper and lower brake pedals. If the oper-
ator releases either pedal, the brakes will be ap-
plied.
Brake Release Service Tool Procedure
When the Access 123 UTILITIES Menu Brake Release
Procedure cannot be used to release the brakes, the
brake release service tool, part number 127373, is the
next preferred procedure. This procedure cannot be
used if there is an electrical failure in the drive circuit,
the tow circuit or the brake. An operator may be pres-
ent on the truck.
Crown 2010 PF17919-5 Rev. 10/12
SAFETY
Control of Hazardous Energy
WARNING
Use extreme care when you release the brakes when
you use the brake release service tool. The brake
pedal in the operator compartment will have no effect
on braking. The truck will not have traction and there
will be no steering control.
Connect the brake release service tool
1. Lower the mast(s) fully.
2. Lockout/tagout the truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lockout/Tagout.
3. Put chocks against the wheels of the truck to pre-
vent unwanted movement of the truck when the
brakes are released.
4. Disconnect CA609 at the traction motor brake and
connect the brake release service tool to the brake
connector.
5. Connect the battery connector of the brake release
service tool to the battery.
Release the brakes
1. Move the power switch on the brake release ser-
vice tool to ON.
2. Toggle the brake release switch on the brake re-
lease service tool to release the brakes.
3. Remove the wheel chocks and move the truck to a
maintenance area. When you tow the truck, make
sure that you tell all operators and other personnel
about the lack of braking and steering on the truck.
(Refer to Towing Truck in this section for proper
towing procedures.)
Apply the brakes
1. Move the power switch on the brake release ser-
vice tool to OFF.
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SAFETY
Control of Hazardous Energy

Disconnect the brake release service tool 4. Use a spanner wrench, a punch or a screwdriver to
turn the torque adjuster plate. Doing so removes
1. Move the power switch on the brake release ser- the spring preload.
vice tool to OFF.
5. Remove the wheel chocks and move the truck to a
2. Disconnect the battery connector. maintenance area. When you tow the truck, make
3. Disconnect the brake release service tool from the sure that you tell all operators and other personnel
brake connector. about the lack of braking and steering on the truck.
(Refer to Towing Truck in this section for proper
4. Connect CA609 from the primary harness to the towing procedures.)
brake connector.
6. Turn the torque adjuster plate back to its original
position to get the correct spring load and apply the
brake.

POWER
SWITCH
WARNI NG
Truck does not have
brakes, travel control
or power steering
when Brake Release
Tool is being used.
WARNING
If you do not return the adjuster plate to its original po-
sition the truck to have no braking.
To prepare for towing:
1. Move power switch to OFF .
2. Disconnect battery from truck
and connect to brake release
tool.
3. Connect brake release tool to
traction brake.
4. Move power switch to ON.

7. Coat the top surface of the adjuster plate with a thin

Warn the towing 5. Press and release the brake
release switch. Truck is ready
vehicle that an to be towed.
accident could
happen and to use BRAKE To remove brake release tool:
extreme caution. RELEASE
SWITCH 1. Move power switch to OFF .

layer of lubricant to reduce likelihood of bending

2. Disconnect battery from brake
release tool.
3. Disconnect brake release tool
from traction brake.
Check to see that traction
brake is applied.

BRAKE RELEASE TOOL

286-C
the compression springs.
8. Refer to Torque Gap Adjustment in the Brake sec-
tion of this manual for factory settings.

Towing Truck
Refer to the following guidelines when you tow the
truck:
Fig. 5 (8255)
Mechanical Brake Release Procedure Towing by Pulling in Power Unit First Di-
rection
If the truck cannot be electrically released by one of the
above procedures, release the brake mechanically. This method is used only when steering is available.

WARNING WARNING
Use extreme care when you release the brakes when • The towed truck must always have three contact
you use the manual brake release procedure. The points with the floor and towing device.
brake pedal in the operator compartment will have no • The maximum travel speed while you tow the truck
effect on braking. The truck will not have traction and is 3.2 km/h (2 mph).
there will be no steering control. An operator is not re-
• Do not make sharp turns when you lift and tow the
quired on the truck.
truck.

1. Lower the mast(s) fully.

2. Lockout/tagout the truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lockout/Tagout.
3. Put chocks against the wheels of the truck to pre-
vent unwanted movement of the truck when the
brakes are released.

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Prepare Truck for Towing:
• Forks must be empty and no more than 305 mm (12
in) off the floor. Tilt the forks back and center the
sideshifter.
• Use care when you use this procedure to tow the
truck. With the brakes released on uneven sur-
faces, the vehicle will roll.
• Provide a safe distance for the truck to coast to a
stop.
• Too much acceleration by the towing vehicle, or
drag caused by a towed vehicle (i.e., brake drag,
drive unit drag, wheel drag, etc.) will increase the
requirements to pull or push a vehicle.
• Release the brakes. Refer to SAFETY ► Control of
Hazardous Energy ► Releasing the Brakes.
• The operator can be on the towed truck if the steer-
ing works.
Towing Device Requirements:
• The towing device must have pulling and braking
capacity of more than 3900 kg (8600 lb).
• Firmly attach the tow device to the rear, lower por-
tion of the truck power unit skirt, within ± 51 mm (2
in) of the truck center.
• Attach the tow device to the truck so it will not be-
come loose or disengage while you tow the truck.
Towing Guidelines:
• The maximum travel speed while you tow the truck
is 3.2 km/h (2 mph).
Towing by Pulling in the Forks First Direc-
tion
WARNING
Towing by pulling in the forks first direction is not rec-
ommended.
Towing by Lifting Truck and Pulling in
Power Unit First Direction
This towing method is used when steering is not avail-
able.
Crown 2010 PF17919-7 Rev. 10/12
SAFETY
Control of Hazardous Energy
WARNING
• Do not lift the towed truck more than 51 mm (2 in)
off the floor.
• The towed truck must always have three contact
points with the floor and towing device.
• The maximum travel speed while you tow the truck
is 3.2 km/h (2 mph).
• Do not make sharp turns when you lift and tow the
truck.
Prepare Truck for Towing:
• Forks must be empty and no more than 305 mm (12
in) off the floor. Tilt the forks back and center the
sideshifter.
• Turn the truck OFF.
Towing Device Requirements:
• For trucks with lift heights of 10,160 mm (400 in)
and below, the towing device must have a minimum
lifting capacity of 2722 kg (6000 lb) at the lift posi-
tion at the rear of the power unit skirt.
• For trucks with lift heights above 10,160 mm (400
in), the towing device must have a minimum lifting
capacity of 2950 kg (6500 lb) at the lift position at
the rear of the power unit skirt.
• The towing device must have pulling, pushing and
braking capacity greater than 3900 kg (8600 lb).
• Make sure that you use a stem or ball that is capa-
ble of the stated pulling, pushing, braking capacity
and of such a design as to prevent disengagement
during the towing operation.
• Firmly attach the tow device to the rear, lower por-
tion of the truck power unit skirt, within ± 51 mm (±
2 in) of the truck center.
Towing Guidelines:
WARNING
The truck will be difficult to maneuver. Use extreme
caution.
• The maximum travel speed while you tow the truck
is 3.2 km/h (2 mph).
• No operator should be on the truck while it is being
towed.
• Operator actions: see WARNINGS above.
MA-1460-106
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SAFETY
Control of Hazardous Energy

Towing by Lifting Truck and Pulling in the Equipment Capacities Required:

Forks First Direction • Hydraulic jack capacity: 3620 kg (8000 lb)
– Crown part number: 122599
– Collapsed height minimum: 60 mm (2.25 in)
WARNING – Raised height maximum: 400 mm (16 in)
Towing by lifting truck and pulling in the forks first direc- • Jack stand capacity: 4500 kg (10000 lb)
tion is not recommended. – Commercially available.

Lifting and Blocking

• Move the truck to a maintenance area that has a flat
and level floor.
• No load on the forks.
• Lockout/tagout the truck. Refer to SAFETY ► Con-
trol of Hazardous Energy ► Lockout/Tagout.
WARNING
Truck stability decreases dramatically if the load
wheels are raised more than 13 mm (0.5 in). Attach a
sling and an overhead lifting device to all cross mem-
bers of the mast so the truck does not tip over when
you raise the side of the truck.

Note: RM/RMD 6000S truck shown.

Fig. 6 (24077-01)
1 Lower the forks completely and move them towards the
center of the truck
2 Chock the load wheels under the outriggers with 4 x 4
hardwood blocks

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 SAFETY
Control of Hazardous Energy

channels. The block lengths detailed below allow

blocking at the proper height for reach carriage re-
moval. Depending upon required service, the mast
may be blocked at different heights than below, al-
though in all cases, the third stage mast column must
touch the longer blocks before the second stage mast
column touches the shorter blocks.
1. Move the truck to a maintenance area that has a
flat and level floor.
2. Chock the wheels of truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lifting and Block-
ing.
3. Cut two hardwood blocks to a length of 521 mm
(20.5 in) and two hardwood blocks to a length of
1130 mm (44.5 in). Use these blocks to block the
second and third stage masts respectively.
4. Measure from the floor to find the necessary height
of the notch (1) to be cut in the longer blocks. Cut
a notch into one end of each of the 1130 mm (44.5
in) blocks. This notch allows for clearance of the
base of the truck mainframe. Refer to Figure 8.

Fig. 7 (24078)
1 Raise forks 70 to 150 mm (3 - 6 in) from floor
2 Chock both load wheels
3 Set jack stand as required - Not to exceed 400 mm (16 in)

Mast and Fork Carriage

Blocking Masts

WARNING
Always block both mast rails of each mast stage to
maintain stability. The third stage must always contact
the blocks first.
Note: RM/RMD 6000S truck shown.
Note: Use 50 x 100 mm (2 x 4 in) or larger hardwood
blocks of the appropriate length to support the mast
Fig. 8 (24080)
5. With the battery connected and the truck ON, raise
the mast until the bottom of the third stage is
slightly higher than 1130 mm (44.5 in) from the
floor.
6. Put a shorter block (1) on each side of the first
stage mast (between the second stage mast and
the mainframe). Refer to Figure 9.

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SAFETY
Control of Hazardous Energy

Fig. 9 (24079) Fig. 10 (24219)

7. Put a notched longer block (2) on each side of the
second stage mast (between the third stage mast
and the floor) as shown in Figure 8. Slowly lower
the mast until the third stage mast touches the lon-
ger outside blocks.
CAUTION
9. If the reach mechanism will not be removed, lower
the fork carriage until the carriage is on the stops
or put a block below each side of the carriage and
lower it until the weight is on the block (1). This re-
moves the load from the primary cylinder and is
necessary for removal of the primary cylinder and
the primary cylinder lift chains. Clamp the blocks in
place. Refer to Figure 11.

It is very important that the third stage mast touches the

longer blocks before the second stage touches the
shorter blocks. If the third stage mast does not touch
first, remove and shorten the second stage blocks by
12 mm (0.5 in) until the third stage touches first.

8. Clamp or band all the blocks to the mast. If the

reach mechanism is to be removed, banding (1)
must be used (as opposed to clamping) to let the
reach carriage to be lowered past the blocks and
the banding. Refer to Figure 10.

Fig. 11 (24081)
10. Turn the truck OFF and disconnect the battery.
11. Lockout/tagout the truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lockout/Tagout.

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Reach Mechanism
1. Move the truck to a maintenance area that has a
flat and level floor.
2. No load on the forks.
3. Chock the wheels of truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lifting and Block-
ing.
4. Extend the reach assembly.
5. Clamp a 50 x 100 mm (2 x 4 in) hardwood block (1)
in the right channel of the reach support assembly
below the roller. Refer to Figure 12.
Fig. 12 (24082)
6. If you are removing the tilt cylinder, use a different
form of blocking. Put a 75 x 75 mm (3 x 3 in) hard-
wood block (1) through the reach mechanism as
shown in Figure 13. Make sure that the block ex-
tends past the outer arms.
Crown 2010 PF17919-11 Rev. 10/12
SAFETY
Control of Hazardous Energy
Fig. 13 (24221)
7. Release the hydraulic pressure from the reach cir-
cuit by retracting the carriage until the roller is on
the block. To prevent pressure from collecting at
the reach cylinder, do not continue to request re-
tract after carriage roller touches the block.
8. If the mast is staged, refer to Mast in this section
for blocking instructions.
9. Lockout/tagout the truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lockout/Tagout.
Tilt
1. Move the truck to a maintenance area that has a
flat and level floor.
2. No load on the forks.
3. Chock the wheels of truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lifting and Block-
ing.
4. Tilt the forks down so the weight of carriage is not
on the tilt cylinder. Do not continue to request tilt
after weight is supported.
5. Fully retract the reach mechanism.
6. Lockout/tagout the truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lockout/Tagout.
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SAFETY
Control of Hazardous Energy

Mast Removal

WARNING
Avoid serious injury. Do not remove the lifting bracket.
The parts are spring loaded when the mast is horizon-
tal.

Trucks are equipped from the factory with a lift bracket

(Crown part number 149650-001) and six screws
(Crown part number 060019-081). The bracket at-
taches to the mast at the six threaded holes (1) at the
top of the mast. Attach the bracket to the mast and use
it to remove or tilt the mast. Refer to Figure 14.

Fig. 14 (24231)

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