Manual Toyota

Operator Manual Models 5400/5500/5600 High-Level Orderpicker Lift Trucks Your Local Authorized Raymond Sales and Service Center is:

Lift Truck Serial Number:

Installed by (Technician’s Name):

The Raymond Corporation P.O. Box 130 South Canal Street Greene, NY 13778-0130 Phone: 607-656-2311 Fax: 607-656-9005

Publication Number 1031792D 23 Dec 2016

! Printed by the Digital Print Center, The Raymond Corporation, Greene, NY

®

This Operator Manual must remain on the lift truck in the pocket provided. The Owner Manual should remain with the owner, supervisor, or foreman responsible for the operation of this lift truck. If you need a replacement for either manual, contact your local authorized Raymond Sales and Service Center whose name appears on the back cover.

This publication, 1031792D, applies to the Models 5400/5500/5600 High-Level Oderpicker Trucks and to all subsequent releases of this product until otherwise indicated in new editions or bulletins. Changes occur periodically to the information in this publication. To order additional copies of this manual, part number 1031792D, contact your local authorized Raymond Sales and Service Center. If you need assistance with your lift truck, contact your local authorized Raymond Sales and Service Center. To locate your Sales and Service Center, go to www.raymondcorp.com. ©2016 The Raymond Corporation. The following terms are trademarks of The Raymond Corporation: Raymond, Safety On The Move, intellispeed, Maintenance Minder, ACR, and Auto Power Off . All other brand and product names are trademarks or registered trademarks of their respective companies.

Table of Contents Table of Contents

How to Use This Manual . . . . . . . . . . . . . . . . . . ii Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Your Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . 13 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operator Display . . . . . . . . . . . . . . . . . . . . . . . 29 Lift Truck Operation . . . . . . . . . . . . . . . . . . . . 41 Battery Procedures . . . . . . . . . . . . . . . . . . . . . 58 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 61 Selected OSHA Regulations . . . . . . . . . . . . . . . 63 ANSI/ITSDF B56.1. . . . . . . . . . . . . . . . . . . . . . 65 Alphabetical Index. . . . . . . . . . . . . . . . . . . . . . 67

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How to Use This Manual How to Use This Manual

This manual reinforces your training so you can help prevent personal injury and property damage. You should read this entire manual before operating your lift truck.

To Find Information Quickly •

Look it up in the Index at the back of the book.

•

Look it up in the Table of Contents.

•

Look for the section title in the page heading.

Warnings and Cautions You will see two kinds of safety reminders in this manual: WARNING: Warning indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. CAUTION: Caution indicates a potentially hazardous situation, which, if not avoided, could result in minor or moderate injury or in damage to the lift truck or nearby objects. It can also be used to alert against unsafe practices.

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Safety Safety

Training Federal law says you must be trained and authorized to operate this lift truck. Neither this manual nor the Owner Manual is a substitute for training. There is a summary of the training requirements under “Selected OSHA Regulations” on page 63 of this manual. Read and obey all warnings, cautions, and instructions in this manual and on the lift truck. CAUTION: Operate this lift truck slowly in an open area until you understand the controls completely. Raymond builds safe and reliable products. To operate this lift truck safely, you must be properly trained. This manual is intended to remind you of your training so you can help prevent personal injury and property damage. Talk with your supervisor if you have any questions or concerns about operating this lift truck.

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Safety Safety Standards Compliance This lift truck complies with the following standards and regulations in effect on the date the lift truck was built: •

ANSI/ITSDF B56.1, An American National Standards, and trucks with Wire Guidance B56.5

•

Underwriters Laboratories (UL) 583

•

Occupational Safety and Health Administration (OSHA) 29 C.F.R. Section 1910.178

Safety Requirements WARNING: Industrial Equipment Can be Hazardous Powered industrial equipment can be hazardous. This lift truck is not like an automobile. It weighs as much as several automobiles. It does not drive, steer, or stop like an automobile. Lift truck accidents often result from: •

Careless operators

•

Untrained and unauthorized use

•

Poor maintenance

Your lift truck is part of a material handling system that has three parts:

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•

The operator

•

The lift truck

•

The workplace environment

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Safety Safe operation of your lift truck requires: •

Your knowledge, training, skill, and attitude

•

Good lift truck maintenance

•

A safe workplace with an appropriately configured lift truck

Certain optional features enhance the operation of your lift truck in special conditions. See “Options” in the Owner Manual for more information.

Start-Up Safety Do not operate this lift truck until you have checked all systems with the Operator’s Daily Checklist.

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Safety Operating Safely Report any malfunction or unsafe condition to your supervisor immediately. Do not operate the lift truck until the condition is corrected. WARNING: Never place any part of your body between the mast uprights or outside the sidegates while operating the lift truck. Turn the key switch OFF before getting off. Never carry unauthorized personnel. Never let anyone place their feet on either baseleg when the operator platform is elevated.

WARNING: Never let anyone stand or walk under the operator platform or the forks.

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Safety Fall Protection System Do not operate this lift truck unless your personal fall protection system (operator restraining device) is in place. The specific components of the fall protection system to be used are dependent on your weight. The components to be used may consist of a full body harness and self-retracting lanyard, or full body harness and energy absorber. For the proper components to be used for your weight, please see the Fall Protection Table and excerpts of ANSI/ITSDF B56.1 printed in the back of this manual. (See page 65.) Make sure the full body harness is securely fastened to your torso. Then make sure the full body harness is securely fastened to the self-retracting lanyard or energy absorber. The self-retracting lanyard or energy absorber should be fastened to the tether bar on the overhead guard.

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Full Body Harness and Energy Absorber

Full Body Harness and Self-Retracting Lanyard

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Safety Driving Safely If you leave the lift truck unattended, fully lower the platform, turn the key switch OFF, remove the key, and disconnect the battery. Make sure sidegates are placed in their required position. Use only one foot on the deadman pedal. Start, stop, change direction, travel, and brake smoothly. Always look where you are going. Keep a clear view. Travel with the platform as low as possible for floor conditions. Travel at a speed that is safe for conditions. Keep a safe distance from other lift trucks. Keep to the right whenever possible. Do not pass another lift truck going in the same direction at intersections, blind spots, or other dangerous locations. Obey all traffic rules. Yield the right-of-way to pedestrians. Stop the lift truck and sound the horn when you approach intersections or crosswalks, when you exit an aisle, or when you cannot see clearly. Always approach and leave aisles slowly, including guided aisles. Slow down for turns and for uneven, wet, or slippery surfaces that could cause the lift truck to slide or tip. Do not drive over objects on the floor. Do not strike objects or obstructions overhead, such as pipes, sprinkler heads, ducts, lights, elevator gates, or overhead doors. Do not operate this lift truck on any slope or ramp. Keep the lift truck under control at all times. Pay attention to your operating environment.

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Safety Pedestrians Always keep pedestrians safe. Other people in your area or facility might not know how this lift truck works. Always yield the right-of-way to pedestrians. Sound the horn when you approach intersections or crosswalks. WARNING: Never drive this lift truck up close to anyone, especially someone standing next to a solid object like a wall or workbench.

Elevators Check with your supervisor before you use this lift truck in or near an elevator.

Handling Loads Safely Do not overload this lift truck. See the specification plate for capacity. WARNING: Do not handle unstable or loosely stacked loads. If your load shifts, your lift truck could tip over. Use extra care when handling long, high, or wide loads. Watch out for objects sticking out from racks, shelves, and walls. Elevate the operator platform only to do order picking. Watch for obstructions, especially overhead.

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Safety When using forks, spread as far apart as load will permit. Before lifting, be sure load is centered and forks are pushed completely under the load. Avoid quick starts, stops, or turns that could shift the load or tip the lift truck. Avoid turns while the platform is elevated with a load. Do not push loads around on the floor. Do not use this lift truck to place pallets into racks or remove pallets from racks. Use this lift truck only for piece-picking and case-picking. Secure allowable pallet or cart to platform and forks. Use only one foot on the deadman pedal.

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Safety Stability Your lift truck is designed to be steady and stable. Stability is affected by: •

Lift truck weight and weight distribution

•

Load weight and height

•

Load position

•

Mast deflection

The lift truck’s specification plate lists maximum loads permitted at various heights. Lift trucks can tip or overturn. This can be caused by: •

Driving, braking, or turning too fast

•

Careless load handling by operator

•

Too much load weight and height

•

Poor floor conditions

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Safety Battery Safety WARNING: • Explosive hydrogen gas forms when a battery is charging. An open flame or spark can cause this gas to explode. Serious personal injury or property damage could occur. This can happen even hours after charging. Ventilate the area to eliminate this hazard. • The battery contains sulfuric acid, which causes burns to skin and clothing. If battery acid contacts your clothing or skin, flush the area immediately with cold water. If battery acid gets on your face or in your eyes, flush the area with cold water immediately and get medical attention. Follow these precautions when working with or around lift truck batteries:

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•

Read, understand, and obey instructions in the battery and battery charger manufacturers’ manuals.

•

Wear personal protective equipment for eyes, face, and skin. This equipment includes goggles or face shield, rubber gloves (with or without arm shields), and a rubber apron. Make sure a shower and eye wash station are nearby.

•

Do not smoke, use open flames, or use devices that produce sparks near charging batteries.

•

The battery must not move more than 0.5 in. (13 mm) side-to-side or front-to-back within the truck battery compartment.

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Safety Warning Decals Read and obey all warning decals on your lift truck. If you have any questions about these warnings, ask your supervisor. If a decal is damaged or missing, report it to your supervisor. Your local authorized Raymond Sales and Service Center will replace it without charge. (See page 12 for location of the numbered warning decals shown below.) 1

2

Remove battery only with mechanism down and load removed. 411-879

3

Drive unit turns automatically. Keep hands clear until battery is disconnected. 411-882

4

5

6

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Safety Location of Warning Decals See page 11 for decals.

5

6

1

2 4

3

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Your Lift Truck Your Lift Truck

Model Definitions The models of the Raymond High-Level Orderpicker are defined as follows: •

Model 5400 is an AC Drive, DC Lift, 24 Volt lift truck

•

Model 5500 is an AC Drive, AC Lift, 24 Volt lift truck

•

Model 5600 is an AC Drive, AC Lift, 36 Volt lift truck

Lift Truck Direction Reference Reference to “left” and “right” assumes you are standing on the operator platform facing the tractor. The operator platform is where you stand to operate the lift truck.

Tractor-First

Right

Left

Operator Area

Operator Platform

Forks-First

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Your Lift Truck Capacity and Rating This lift truck is rated for performance by load center, load weight, and load height (with forks elevated). Load Center is the distance from the front of the operator platform to the center of an evenly distributed load. Load weight includes the weight of the load, container, pallet, and the operator. The truck’s capacity shall be reduced by the operator’s weight in excess of 220 lbs. (100 kg.). Maximum allowed load weight may also decrease as elevated height increases.

Loaded in Lowered Position

Consult the specification plate on your lift truck. Loaded in Lift Position

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Your Lift Truck Specification Plate See the specification plate for lift truck capacity and load center information. The specification plate is located on the upper left side of the operator platform.

CAUTION: Exceeding maximum load weight might damage the lift truck or affect stability. Publication 1031792D

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Controls Controls

Operator Platform The operator platform is where you stand to operate the lift truck.

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Controls WARNING: Keep all parts of your body within the operator area while operating the lift truck. Your head, arms, hands, legs, or feet can be seriously injured if they strike objects outside the operator area while the lift truck is moving. The following pictures show the location of controls and indicators.

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Controls Controls The individual controls work this way: Control

Operator Action

Battery Connector

Lift Truck Response Connect the battery and turn the key switch ON. Lift truck is ready for operation. Pushing the EPO switch IN disables travel, lift/lower circuits, and applies the brake.

Emergency Power Off (EPO) Button

To reactivate the system, pull the EPO switch OUT and turn the key switch ON. Key Switch OFF

Operator Display ON

SelfTest; lift truck is ready for operation Security Start Switch (Optional)

Press and hold the security start switch then turn the key switch to ON.

Lift truck is ready for operation.

Do not step on the deadman pedal.

Security Start Switch

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Controls Control

Operator Action

Lift Truck Response

Round Deadman Pedal 1. Brake is released. 2. Control system is enabled.

Pedal

1. Lift truck slows to a stop. (Brake is applied.) 2. Control system is disabled.

Horn

Press In the event that the carriage must be lowered from the ground, do the following:

Emergency Lowering Valve

NOTE: The operator should remain on the operator platform. • Remove the tractor cover. • Slowly turn the Emergency Lowering Valve (located on the lift/lower manifold) counterclockwise. • After lowering the carriage, turn the valve clockwise to close.

Location of Emergency Lowering Valve

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Controls Control

Operator Action

Lift Truck Response

Directional/Speed Control

Steering Control

Steering Wheel

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Controls Control Steering Direction Indicator

Operator Action

Lift Truck Response Illuminated LED (light-emitting diode) indicates the direction the drive wheel is turned. 10° – 30° to the left.

Illuminated LED indicates the direction the drive wheel is turned. More than 30° to the left.

Illuminated LED indicates the direction the drive wheel is turned. Within 10° (left or right) of center.

Illuminated LED indicates the direction the drive wheel is turned. 10° – 30° to the right.

Illuminated LED indicates the direction the drive wheel is turned. More than 30° to the right.

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Controls Control Auto Steer Centering (for Rail Guidance)

Operator Action

Lift Truck Response

Automatic when the truck senses that it is within the aisle.

Drive wheel is locked in the straight-ahead position.

Switch Press here for Auto Steer Centering. Lift Control Lift

Lower Control Lower

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Controls Control

Operator Action

Lift Truck Response Continues lifting or lowering after limit has been reached.

Lift Limit Bypass (Optional) or Lower Limit Bypass (Optional)

Press and hold button. Lower Decel (Configurable)

None This function is automatic.

Wire Guidance ON/OFF Switch (with optional wire guidance)

Press here for automatic steering.

(Location of Switch)

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Press here for manual steering.

GUIDE WIRE

Truck “locks on” guide wire – steering is automatic.

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Controls Control

Operator Action

Lift Truck Response

Wire Guidance Indicator Lights

Triangles are illuminated. Circular lights within triangles are flashing.

Wire Guidance Switch is ON ( I ). The lift truck is ready for automatic guidance.

Center lights and triangles are illuminated.

Lift truck is locked on the guide wire. You, the operator, can no longer steer.

Rail Guidance Indicator Lights

Triangles are flashing.

Center lights and triangles are illuminated.

Pallet Clamp

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Pallet Clamp

If the rail guidance switch is in MANUAL ( O ) when the lift truck is in the aisle, triangles flash, signaling you to move the rail guidance to AUTO ( I ) (Auto Steer Centering).

If the rail guidance switch is in AUTO ( I ) when the lift truck is in the aisle, the center lights and triangles will be illuminated, telling you the drive wheel is locked straight ahead.

The pallet clamp holds the pallet securely in place while the load is lifting and lowering.

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Controls Control

Operator Action

When releasing the pallet, hold the pallet release pedal in the depressed position before moving the lift truck forward.

Pallet Clamp Release Pedal

Sidegates and Sidegates Power Disconnect (Optional)

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Lift Truck Response

Raise the sidegate to enter/exit the operator platform. Lower the gates before operating the lift truck.

Optional switches prevent lift truck movement until the sidegates are lowered.

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Controls Control

Operator Action

Lift Truck Response

Travel Cut-Out (Optional)

None. This function is automatic.

When the operator platform is elevated above the preset height...

...lift truck travel is prevented. Overhead LED Lights (Optional)

Overhead Light Switch

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Controls Control

Operator Action

Lift Truck Response

Fan (Optional)

Fan Switch

LED Work Area Lights (Optional)

Work Area Light Switc Auxiliary Mast (Optional)

1. Press deadman button.

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2. Press either auxiliary lift button or auxiliary lower button.

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Controls Auto Steer Centering When the key switch is turned ON, and the deadman pedal is depressed, the lift truck automatically centers the steering system. The auto steer centering indicator flashes green while centering, and remains green — indicating straight-ahead travel direction.

Center Steer Indicator

Left Outer Steer LED

Right Outer Steer LED

Fire Extinguisher (Optional) Follow the manufacturer’s operating instructions found on the side of the fire extinguisher. Make sure the fire extinguisher is in place and it is properly charged. If not properly charged, replace it or have it recharged.

Typical Location of Fire Extinguisher

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Operator Display Operator Display

Message Area The Operator Display is located on the operator console. It shows the following: (Also see page 30). •

SelfTest

•

Total hours that the key switch has been turned to ON ( I ) (KH)

•

Total hours on the deadman (HD)

•

Total hours spent lifting (HL)

•

Total miles (TM)

NOTE: To display the hour meters (KH, HD, and HL) and the Total MIles (TM), step off the deadman pedal, then press and hold the horn button while turning the key switch to ON ( I ). The hour meters will continue to scroll until you step on the deadman pedal. •

Clock/calendar

•

Battery state-of-charge (BSOC)

•

Status messages

•

Approximate direction of the drive wheel

•

If the drive wheel is locked in its straight-ahead position (auto steer center for rail guided lift trucks)

•

If there is an over-temperature condition

•

If maintenance is required

The Operator Display may show these options: •

If the wire guidance switch is ON ( I ) or if the lift truck is “locked on” the guide wire.

•

Approximate weight of the load on the forks (with intellispeed™ control system only)

•

Approximate height of the forks (with intellispeed™ control system only)

•

When the lift limit is reached

•

If the sidegates are not lowered.

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Operator Display Steering Direction Indicator

Display

Lift Lower Limit

Over-temperature Indicator Maintenance Required Indicator UP Button ENTER button

Wire Guidance Indicator, Rail Guidance Indicator, or (optional) Auto Steer Centering Indicator for Rail Guidance Operator Display

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DOWN button

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Operator Display Operator Display Selections NOTE: Use the UP ( ) or DOWN ( ) buttons to momentarily view any of the other displays. The Operator Display offers the following two selections: (Both selections can show the same item or they can show two different items. Neither selection can be changed when the lift truck is moving.) 1.

The “Off Deadman” selection is shown whenever the key switch is turned ON ( I ) and you are not depressing the deadman pedal.

2.

The “On Deadman” selection is shown when the key switch is turned ON ( I ) and you are depressing the deadman pedal.

The items available when either “Off Deadman” or “On Deadman” have been selected are time, date, battery state-of-charge (BSOC), weight, and height. To change the “Off Deadman” selection, follow these steps: 1.

Step off the deadman pedal.

2.

While the deadman pedal is still up, use the UP ( DOWN ( ) buttons to scroll through the items.

3.

The last item shown will be the item displayed when the deadman pedal is up.

) or

To change the “On Deadman” selection, follow these steps: 1.

Step on the deadman pedal.

2.

Use the UP ( ) or DOWN ( ) buttons on the Operator Display to scroll through the items.

3.

The last item shown will be the item displayed when the deadman pedal is depressed.

SelfTest SelfTest occurs whenever the key switch is turned ON ( I ). SelfTest checks electrical parts and circuits within the system. If there is a problem, the Operator Display shows a fault code.

Hour Meters and Total Miles Indicator NOTE: To display the hour meters and total miles, press and hold the horn button while the key switch is turned to the ON ( I ) position. Publication 1031792D

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Operator Display Key Switch ON (KH) Records the total number of hours that the lift truck's key switch has been turned to ON ( I ). (This message appears briefly on the Operator Display after the key switch has been turned ON.)

Hours on Deadman (HD) Records the total number of hours that the deadman pedal on the floor of the operator platform has been depressed.

Hours Spent Lifting (HL) Records the total number of hours that the lift pump has run. This is for maintenance information only. This message appears briefly on the Operator Display after Hours on the Deadman (HD).

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Operator Display Total Miles (TM) Records the total number of miles that the lift truck has traveled. This message appears briefly on the Operator Display after Hours Spent Lifting (HL).

758

Shows miles traveled.

Clock Calendar The clock/calendar can be shown on the Operator Display.

8 29 05

To display either the calendar (date) or the clock (time of day) as the default setting, see see page 31 for instructions. Shows Month, Day, and Year.

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Operator Display Fork Height and Load Weight NOTE: Available only on lift trucks equipped with the advanced intellispeed ™ control system. The height of the forks is displayed to the nearest 4 in. (10 centimeters). If the operator's compartment is raised or lowered a total of 315 in. (800 centimeters) without crossing either the upper or lower reference switch, travel speed is reduced to1 mph (1.6 km/h). The weight measurement shows you the approximate total weight of the load on the forks. Do not use this feature as a “scale” to weigh loads. If you want to have the height or the weight displayed as the default, see page 31 for instructions.

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20 in.

Approximate Fork Height

300 lbs.

Approximate Fork Weight

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Operator Display Battery State-of-Charge NOTE: Even though a battery has been fully recharged, it might not display 100% on the Operator Display. The maximum value displayed depends upon the battery's type, age, and condition. Battery State-of-Charge (BSOC) shows the energy that remains in the battery, based on actual voltage readings. The value displayed is the percentage of usable energy. When 0% is displayed, lift is prevented until the battery is either recharged or replaced with a recharged battery.

80%

Battery State-of-Charge

Only a battery with a charge that is significantly different than the old battery causes the display to change. You can select the Battery State-of-Charge to be constantly shown on the Operator Display. (See page 31.) If you just want to check the Battery State-of-Charge (even if another item, such as the clock, is displayed) you can scroll through the display by depressing the UP ( ) or DOWN ( ) buttons.

Status Messages Messages appear on the Operator Display to inform you of certain conditions the system is experiencing. The three types of messages are informational, performance limiting, and fault.

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Operator Display Informational Messages An informational message does not restrict or limit lift truck performance. An example of an informational message is Battery State-of-Charge (BSOC). When you first turn the lift truck ON ( I ), the Operator Display shows: . . ..Selftest. . . Please complete daily check list. . . then fasten harness If you request a disabled function, a message describing how to enable the function scrolls across the Operator Display. The following table shows examples of operator display messages and the correct operator response. Operator Display Message Eight blank spaces --------

Guidance not learned

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Reason

Operator Response

You have not entered the Enter it. (See page 46 for password or (optional) instructions.) electronic key. The wire guidance switch Have authorized technician is in AUTO, but the wire run LEARN for the wire guidance parameters guidance system. have not been learned.

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Operator Display Performance Limiting Messages Any reduction in lift truck performance is indicated by a corresponding performance limit message. (Messages are continuously displayed until the cause of the limitation is removed. Operator Display Message SelfTest

Meaning Power ON SelfTest (POST).

Performance Limit 0 mph (0 km/h)

Initialize to allow full Lower reference switch is speed travel. (typically 24 in. [600 mm]) not sensed.

2.5 mph (4.0 km/h) below the upper reference switch. 1 mph (1.6 km/h) above the upper reference switch.

Aligning 1

Wire guidance switch is in AUTO. Lift truck senses guide wire and is trying to acquire it.

Seeking 1

Wire guidance switch is in AUTO. Lift truck has not sensed the guide wire.

Speed is limited to the configurable acquire speed when driving tractor-first. When driving forks-first, speed is limited to 1 mph (1.6 km/h).

Speed limited due to unknown height... lower to reference switch. 3

Lift system does not recognize elevated height.

1 mph (1.6 km/h)

Speed limited due to the steer angle.

Steer angle is greater than 10° and the operator platform is above 24 in. (600 mm) but below 60 in. (1524 mm).

2.5 mph (4.0 km/h)

Steer angle is greater than 10° and the operator platform is between 60 in. (1524 mm) and 150 in. (3810 mm).

1 mph (1.6 km/h)

Steer angle is greater than 10° and the operator platform is higher than 150 in. (3810 mm).

0 mph (0 km/h)

Sidegates are up when requesting travel, lift, or lower.

0 mph (0 km/h). Lift and lower are disabled.

Lower sidegates to resume operation. 2

1 = Wire Guidance lift trucks 2 = Optional 3 = Lift trucks with intellispeed™ Control System

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Operator Display Operator Display Message

Meaning

Performance Limit

Lower inhibited or press and hold bypass to continue lowering. 2

Lower limit is reached.

Lowering system is shut down

EPO depressed

EMERGENCY POWER OFF Total shutdown switch is detected down.

Release control handle to resume operation.

Throttle moved before deadman was depressed.

0 mph (0 km/h)

Press bypass switch to continue lifting. 2

Upper limit reached.

Lift system is shut down

1 = Wire Guidance lift trucks 2 = Optional 3 = Lift trucks with intellispeed™ Control System

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Operator Display Fault Codes If a fault occurs, travel and/or lift functions may be disabled. The Operator Display presents the fault code and associated message. The wrench icon and/or the thermometer icon on the Operator Display flashes. A fault code has a higher priority than other functions, such as hours or battery condition. Therefore, the Operator Display shows a fault code before it shows the battery condition. The fault is shown first by a two character code, followed by a message. The code and message repeat continually until reset.

Code 2A

Thermometer Icon

Code 43

Example of a fault code:

Code 42 inform service

Wrench Icon

Depending on the problem, the lift truck not only visually shows that a problem exists, but it might also sound a tone. (See Audible Alarm on page 40.) The tone and sound pattern vary, depending on the type of problem sensed by the system. Fault codes limit or disable the ACR system until the problem is corrected. If a fault code appears, first try to clear it by turning the key switch OFF ( O ) and ON ( I ) several times. If this does not clear the code, then contact an authorized service technician to correct the problem. Do not operate this lift truck before correcting the problem.

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Operator Display Audible Alarm The audible alarm is automatic. Type of Alarm Sound

What the Sound Means

One Ping

A prompt for the operator when the lift truck is in the Configure Mode.

Low/Hi/Low Tone 2

Sidegate (equipped with interlock switch) is up.

Hi/Low Tone 1,2

Total shutdown. Lift or lower system shutdown. Traction system derating or shutting down.

A Descending Scale

Incorrect password.

One Beep

Either the UP (s), DOWN (t), or ENTER button on the Operator Display has been pushed. The operator carriage has crossed the 24 in. (600 mm) switch.

1 = If the lift truck is in a shutdown condition, the tones repeat only three times. 2 = While the alarm is sounding, a message describing the performance limitation or fault usually scrolls across the Operator Display. T

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Lift Truck Operation Lift Truck Operation

Training Federal law says you must be trained and authorized to operate this lift truck. This manual is not a substitute for training. There is a summary of the training requirements under “Selected OSHA Regulations” on page 63 of this manual. WARNING: Do not use this lift truck unless you have been trained and authorized to do so. Read and obey all safety warnings and cautions. Operate this lift truck slowly in an open area until you understand the controls completely.

Operator’s Daily Checklist At the start of your shift, check the two lists of items on the following pages. Federal law requires daily checks. Report any malfunction or unsafe condition to your supervisor. Do not operate this lift truck until it is repaired.

✓✓

To help you inspect this lift truck, make copies of the single sheet version of the Operator’s Daily Checklist included with this manual.

A pre-printed bulk Operator’s Daily Checklist is also available through your local authorized Raymond Sales and Service Center.

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Lift Truck Operation Daily Record (Perform these checks at the start of each shift) Model:

Serial Number:

Operator:

Shift Number:

Truck Number:

Date:

Mark Each Box OK or R/A (Repair/Adjust)

Visual Inspection: Key Switch Turned OFF ( O ) V-1

Mark

BATTERY • Charged/correct voltage, no leakage • Correct weight (see specification plate on truck) • Installed correctly; battery gates secure; battery moves less than 0.5 in. (13 mm) in any direction • Battery connector in good condition and attached correctly to truck connector

V-2

TRACTOR, MAST, AND FORKS • No cracks in welds, baselegs, forks, overhead guard, or frame • Mast guard (glass or mesh) in good condition, with no damage; clear view • Forks not bent

V-3

WHEELS AND TIRES • No gouges, chunking, other damage, or flat spots • No bond failures of drive tire to wheel • Sufficient tread remaining

V-4

LIFT/LOWER SYSTEM • No damage to hoses, chains, or limit switches • No leaks; also check floor under lift truck for any dripping fluid • Lift chains in good condition and lubricated correctly • Hydraulic fluid level, at room temperature, with carriage completely lowered, should be visible to the fill line on the reservoir.

V-5

CONTROL HANDLE AND DEADMAN PEDAL • Moves smoothly without binding • Returns to neutral when released; deadman pedal returns when released

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Lift Truck Operation Visual Inspection: Key Switch Turned OFF ( O ) V-6

Mark

GUARDS, COVERS, DECALS, AND FALL PROTECTION • All guards and covers installed correctly and securely • Warning and safety decals in place and readable • Self-retracting lanyard with full body harness or energy absorber with full body harness is not frayed and/or damaged

V-7

OTHER • Static strap (under lift truck) in good condition • Ventilation slots clean and clear of debris • No water or ice build-up in tractor or on the operator platform floor, deadman pedal, or controls • All plugs, terminals, cables, and receptacles in good condition • Fire extinguisher (if included) is charged correctly and mounted correctly/ securely on lift truck • Examine lift truck for loose or missing hardware • Check rail guidance rollers on rail guided vehicles for damage

Operational Inspection: Key Switch Turned ON ( I ) O-1

Mark

SELFTEST • SelfTest passes without fault code

O-2

HOUR METER(S) AND * TOTAL MILES INDICATOR • Records hours of lift truck operation, hours spent lifting, and total miles traveled [Record hour meter readings on page 44]

* If applicable

O-3

STEERING • Smooth, without binding or excess play

0-4

HORN • Sounds when you press the button

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Lift Truck Operation Operational Inspection: Key Switch Turned ON ( I ) 0-5

Mark

DIRECTIONAL/SPEED CONTROL • Lift truck motion is smooth and responds to commands through all speed ranges • Controls speed and direction correctly • Plugging operates correctly • Speed limits function correctly

O-6

STOPPING/DEADMAN CIRCUIT/BRAKE • Traveling in an open area at 2 to 3 mph (3.2 to 4.8 km/h), the empty lift truck should stop in 2 to 4 ft. (0.6 to 1.2 m). In normal operation, with a rated load and traveling at maximum speed, the lift truck should stop in approximately 1.5 lift truck lengths. • Lift truck does not travel when deadman pedal is up

O-7

LIFT/LOWER SYSTEM • All controls perform their functions correctly and smoothly

O-8

EMERGENCY POWER OFF (EPO) BUTTON • Disables travel and lift/lower functions when pressed

O-9

SAFETY • All warning and working lights operate correctly • All limit switches operate correctly

COMMENTS:

Hour Meter Readings KH:

HD:

HL:

TM:

Time to Service:

Total:

Operator’s/Supervisor’s Initials/Signature

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Lift Truck Operation To Start the Lift Truck CAUTION: Make sure you complete both parts of the Operator's Daily Checklist before you operate this lift truck. Connect the battery to the lift truck. Install the battery side covers. Step onto the operator platform. WARNING: Never place any part of your body between the mast uprights or outside the sidegates while operating the lift truck. Turn the key switch OFF before getting off. Make sure the EPO button is out. NOTE: Make sure batteries cannot move more than 0.5 in. (13 mm) in any horizontal direction. Shim or block to restrain them. If you want to see the Hour Meters and Total Miles Indicator, depress and hold the horn button before you turn the key switch ON ( I ). The hour meters consist of the Key-On Hours (KH), Hours on the Deadman (HD), and Hours Spent Lifting (HL). The Total Miles (TM) indicator follows the hour meters. Turn the key switch to ON ( I ). NOTE: If your lift truck is equipped with the Security Start Switch, see page 18. During start-up, a system SelfTest occurs. Contactors cycle (click) and the horn briefly sounds (this is normal). If the system finds a fault during SelfTest, the Operator Display shows a fault code. Do not operate the lift truck until the problem is corrected. Depress the deadman pedal. Make sure the forks are elevated slightly so they do not scrape the floor.

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Lift Truck Operation If this lift truck has the optional Electronic Key, enter the code as follows: 1.

Note that one of the eight segments on the Operator Display is blinking. This is the active segment. To move the active segment to the right or left, hold down the ENTER button and press either the UP ( ) or DOWN ( ) button.

2.

When the desired segment is active, release the ENTER button. Move UP ( ) through the numbers, and then letters as shown below by pressing the UP ( ) button.

3.

If you need to move DOWN ( ) through the letters, and then numbers as shown below, press the DOWN ( ) button.

4.

When the letter or number you want is shown in the segment, stop pressing the UP ( ) or DOWN ( ) buttons.

5.

Enter the rest of the password by repeating Steps 1, 2, and 3 as necessary.

6.

When the correct Electronic Key Personal Identification Number is shown on the Operator Display, press the ENTER button.

NOTE: If the Electronic Key Code is not correct, the lift truck's alarm sounds a downward scale. The Operator Display shows Invalid code try again. The incorrect Electronic Key Personal Identification Number reappears on the Operator Display. Enter the correct Electronic Key Personal Identification Number. 7.

Ensure the lift truck passes SelfTest.

8.

Ensure the battery is adequately charged. (See the Battery State-of-Charge [BSOC] on the Operator Display.)

9.

Depress the deadman pedal.

10. Use one hand to steer the lift truck. Use the other hand to control the travel and lift and lower functions. NOTE: Travel slowly until you know the lift truck's path. Ensure the brake functions properly. To check brake, lift your foot off the round deadman pedal. Check operation of the plugging system by plugging the lift truck to a stop. (See page 49.) 46

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Lift Truck Operation Lift Truck Travel CAUTION: Obey all the rules under “Driving Safely” on page 6. Step on the deadman pedal with only one foot.

Move the control handle in the direction you want to go. The farther you move the handle from neutral, the faster the lift truck will go. Drive at a speed that is safe for conditions.

WARNING: Do not handle unstable or loosely stacked loads. If your load shifts, your lift truck could tip over. Use extra care when handling long, high, or wide loads. Watch out for objects sticking out from racks, shelves, and walls. Stop and sound the horn when you approach intersections or crosswalks and when you exit an aisle.

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Lift Truck Operation Steering You can drive your lift truck either forks-first or tractor-first. CAUTION: Your lift truck does not steer like an automobile. When you turn the lift truck steering wheel, the tractor pivots out. Make sure you have enough room for the tractor to pivot when turning. If you are not sure of the steering direction, begin driving in an open area slowly until you are sure of the lift truck's direction of travel. Also, refer to page 20 for Steering Control information and page 21 for Steer Indicator information.

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Lift Truck Operation To Slow Your Speed To slow your speed, 1.

Move the control handle through neutral to the direction opposite your current direction of travel. This action is called “plugging.” The farther you move the control in the opposite direction of travel, the faster you slow down.

2.

When the lift truck slows to the desired speed, move the control back through neutral to the direction you are moving and far enough to maintain your speed.

CAUTION: Slow down for turns and for uneven, wet, or slippery surfaces.

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Lift Truck Operation To Reverse Direction To reverse direction,

50

1.

Move the control handle through neutral to the direction opposite your current direction of travel. This action is called “plugging.” The farther you move the control in the opposite direction, the faster you slow down.

2.

Hold the handle in this position and the lift truck slows, stops, and starts moving in the opposite direction.

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Lift Truck Operation To Stop the Lift Truck (Normal Operation) To stop the lift truck normally, 1.

Move the control handle through neutral to the direction opposite your current direction of travel. This action is called “plugging.” The farther you move the control in the opposite direction of travel, the faster you slow down.

2.

When the lift truck stops, release the control handle and lift your foot off the deadman pedal. Releasing the deadman pedal disables travel and applies the parking brake.

Stop the lift truck and sound the horn when you approach intersections or crosswalks, when you exit an aisle, or when you cannot see clearly.

To Stop the Lift Truck (Emergency) To stop the lift truck in an emergency, lift your foot off the deadman pedal immediately. This stops the lift truck in the shortest possible distance.

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Lift Truck Operation Entering an Aisle To enter an aisle follow these steps:

52

1.

Center the load (from side to side) in the aisle in which you are traveling.

2.

Turn the steering wheel to pivot the lift truck on the load wheel nearest the corner being turned.

3.

As the rear of the lift truck swings toward the center of the aisle, gradually begin returning the drive wheel to the straight-ahead position.

4.

When the lift truck is aligned with the aisle entrance, proceed into the aisle.

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Lift Truck Operation Wire Guidance (Optional) —Acquiring the Guide Wire When the wire guidance switch is ON ( I ), you control the same functions as when the wire guidance switch is OFF ( O ), except for the steering. When the lift truck is locked on the guide wire, you cannot control the steering. It is now automatic. NOTE: Review the Start-up procedure on page 45. Although it is possible to acquire the guide wire when driving in the forks-first position, acquiring the guide wire tractor-first is the recommended method. To acquire the guide wire follow these steps: 1.

Drive the lift truck tractor-first towards the entrance to the aisle. Begin slowing down as you are approaching the guide wire.

2.

As the lift truck approaches the guide wire, slow it down to below its acquire speed. (This speed is configurable; contact your local authorized Raymond Sales and Service Center service representative.)

Guide Wire

3.

Turn the wire guidance switch to ON ( I ) when the lift truck is finding the guide wire. The two triangular green wire guidance lights come on and an alarm sounds. Continue to drive the lift truck so that it is centered over the guide wire. When the lift truck senses the guide wire, the alarm stops and steering becomes automatic.

4.

Continue driving the lift truck along the wire until the two triangular green lights and the three yellow lights stay illuminated. The lift truck is now locked on the guide wire. You can now drive it at its full rated speed.

See page 55 for End-of-Aisle Slowdown if your lift truck has this optional feature installed.

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Lift Truck Operation Rail Guidance (Optional) To enter a rail guided aisle follow these steps: 1.

Slowly drive the lift truck tractor-first so that it approaches the centerline of the aisle. Slow the lift truck down to 1 mph (1.6 km/h) or less.

2.

Steer the lift truck so that it is in-line with the aisle.

3.

Slowly drive the lift truck forward. Watch the lift truck's rail guidance to ensure that both rail guidances are properly aligned with the guided aisle.

4.

When the lift truck's rail guidance is between the rails, you can drive the lift truck at its full rated speed.

5.

If this lift truck has the optional aisle-steer centering: a. You can lock the drive wheel in its straight-ahead position by moving the auto-steer center switch to ON ( I ). b. Turn the auto-steer centering switch to OFF ( O ) as the lift truck leaves the aisle. The horn will beep and steering will return to MANUAL. You must now steer the lift truck.

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Lift Truck Operation End-of-Aisle Slowdown (Optional) This is an optional feature on lift trucks that are equipped with either the wire-guidance or rail-guidance system. When active the system allows full speed while the lift truck is in the aisle. The system when active will decelerate the truck when it approaches the end of an aisle and either slow or plug to a stop depending on the selected configuration. The operator may, however, override the end-of-aisle slowdown with more aggressive plugging. As the truck exits an aisle, the lift truck is limited to the selected end-of-aisle speed until the throttle control is returned to neutral.

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Lift Truck Operation Parking WARNING: Never park this lift truck on a ramp or slope.

WARNING: Do not park this lift truck in a cold storage area overnight. To park this lift truck:

56

1.

Stop the lift truck.

2.

Lower the operator platform completely.

3.

Turn the key switch counterclockwise to OFF ( O ).

4.

Remove the key.

5.

If you leave this lift truck unattended, disconnect the battery connector.

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Lift Truck Operation Use of Pallets on Raymond Operator-up Lift Trucks When a pallet is used for order picking, it is not a work platform but rather a place to temporarily set materials being retrieved or stored. When placing material on a pallet, it is often necessary to place one foot on the pallet to reach the back surface.

Allowable pallet types: NOTE: Make sure that all pallets are in good repair, doublefaced with a center stringer, and do not contain undersized stringers or boards. •

Double-faced pallets with a center stringer that lets the pallet clamp securely fasten the pallet to the platform

•

Pallets that are in good repair, having no broken or missing boards and no loose connections or fasteners between pallet components

•

Wood or plastic pallets that conform to the above

Operator procedures: •

Use the pallet clamp to securely fasten the pallet to the lift truck

•

Use the personal fall protection system in accordance with safety guidelines (see page 5)

•

When stepping on the pallet, place one foot on the portion of the pallet located between the forks, not on the edge of the pallet

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Battery Procedures Battery Procedures

These procedures do not replace information that comes with the battery and battery charger. Read the manuals for your battery and charger. Tell your supervisor if you have concerns or questions about battery safety or procedures.

Battery Safety WARNING: • Explosive hydrogen gas forms when a battery is charging. An open flame or spark can cause this gas to explode. Serious personal injury or property damage could occur. This can happen even hours after charging. Ventilate the area to eliminate this hazard. • The battery contains sulfuric acid, which causes burns to skin and clothing. If battery acid contacts your clothing or skin, flush the area immediately with cold water. If battery acid gets in your face or eyes, flush the area with cold water immediately and get medical attention.

58

1.

Read, understand, and obey instructions in the battery and battery charger manufacturers’ manuals.

2.

Wear personal protective equipment for eyes, face, and skin. This equipment includes goggles or face shield, rubber gloves (with or without arm shields), and a rubber apron. Make sure a shower and eye wash station are nearby.

3.

Do not smoke, use open flames, or use devices that produce sparks.

4.

Ventilate the battery charging area.

5.

Do not remove the battery cable at the battery terminal.

6.

Never lay tools or metal objects on top of the battery. A short circuit could cause the battery to explode.

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Battery Procedures 7.

Keep batteries, filler plugs, terminals, cables, and connectors clean and in good condition.

8.

Keep filler plugs firmly in place except when checking the battery or adding water to the cells.

9.

Make sure the vent holes in the filler plugs are open.

10. Do not let cleaning solution, dirt, or any foreign matter enter the cells. 11. Charge batteries at specified intervals. Do not overcharge.

To Install the Battery NOTE: Before installing a battery in a lift truck, always make sure that it is fully charged. 1.

Remove the battery gate closest to the battery connector.

2.

Make sure that the other battery gate is secure.

3.

Using a battery stand or equivalent material handling equipment, slide the battery into the open side of the battery compartment.

CAUTION: Do not jam or cut the battery cables during installation. This could cause a short circuit that could result in a fire or a battery explosion. 4.

Make sure the battery cable is in the correct position to connect to the lift truck connector.

5.

Make sure the battery cannot move more than 0.5 inch (13 mm) front-to-back or side-to-side.

6.

Install the battery gate. Make sure both battery gates are secure.

NOTE: Make sure the key switch is in the OFF position before connecting the battery. 7.

Connect the battery connector/cables to the connector for the lift truck.

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Battery Procedures To Remove the Battery CAUTION: When you remove a battery from a lift truck, always use a battery stand or similar equipment. 1.

Lower the operator platform fully and remove any load.

2.

Turn the key switch to OFF.

3.

Disconnect the battery connector/cables from the lift truck.

4.

Remove the battery gate closest to the battery connector.

5.

Use the correct equipment to slide the battery out of the open end of the battery compartment.

6.

Store the battery safely after you remove it.

Battery History Record Keep a history record for each lift truck battery. Good batteries give best performance and lowest operating cost. Battery records help you identify batteries with the following problems: •

Overcharging

•

Undercharging

•

Over-discharging

•

Excessive water consumption

•

Excessive dirt and corrosion

•

Worn-out batteries

•

Excessive current consumption by lift trucks

Keep a separate record for each battery. Your battery manufacturer can provide maintenance record sheets.

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Troubleshooting Troubleshooting

If you have a problem with your lift truck, use the table below to decide what to do. Do not try to service this lift truck unless you are properly trained and authorized to do so. Contact your Service Department or local authorized Raymond Sales and Service Center listed on the back of this manual.

Problem

Procedure

Nothing happens when the key switch is turned ON.

Is the battery connected? Check the battery. Contact the Service Department.

Battery discharges quickly or does not indicate a full charge after charging.

Even though a battery has been fully recharged, it may not display 100% on the Operator Display. The maximum value displayed depends upon the battery’s type, age, and condition. Try another battery. If the same problem happens again, contact the Service Department.

Any system malfunction (no travel, lift, or lower function).

Contact the Service Department.

Received a fault code.

Do not operate the lift truck until the problem is corrected.

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Troubleshooting Tractor Cover Removal and Installation To remove the tractor covers do the following: 1.

2.

Place your fingers under the center front edge of the top cover, then walk your fingers around to either the right or left side of the cover. Snap the cover up and pull it off. This releases the front tractor cover.

Top Cover Removal

Pull out the tractor cover from the top.

To install the tractor covers do the following: 1.

Position the bottom of the cover inside the bumper and push it in from the top.

2.

Position the top cover over the latches and push down.

Tractor Cover Removal/Installation

Top Cover Installation

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Selected OSHA Regulations Selected OSHA Regulations

The use of forklift trucks in the workplace is governed by various regulations. In the United States, the Federal Occupational Safety and Health Administration (OSHA) has issued regulations which cover the majority of workplaces. In addition, several states have implemented regulations which apply instead of the Federal regulations. Check with your local OSHA office or provincial Labor Bureau to confirm which regulations govern your workplace. Because of their wide applicability, this section of your manual lists several parts of the Federal OSHA regulations that might be of particular importance to your workplace. The full text of the Federal regulations can be found in the Code of Federal Regulations at 29 CFR Section 1910.178. The following citations are followed by a reference to the appropriate subparagraph of the regulations. •

Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation and maintenance instruction plates, tags or decals shall be changed accordingly. (a) (3)

•

The user shall see that all nameplates and markings are in place and are maintained in a legible condition. (a) (6)

•

The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph. (l) (1) (i)

•

Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the training required by this paragraph. (l) (1) (ii)

•

Trainees may operate a powered industrial truck only under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence and where such operation does not endanger the trainee or other employees. (l) (2) (i) (A) (B)

•

Training shall consist of a combination of formal instruction (e.g. lecture, discussion, interactive computer learning, videotape, written material), practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator’s performance in the workplace. (l) (2) (B) (ii) [Editorial Note: For required training program content, refer to (l) (3) (i) (A-M) and (l) (3) (ii) (A-I).]

•

Refresher training, including an evaluation of the effectiveness of that training, shall be conducted as required by paragraph (l) (4) (ii) to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely. (l) (4) (i)

•

An evaluation of each powered industrial truck operator’s performance shall be conducted at least once every three years. (l) (4) (iii)

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Selected OSHA Regulations

64

•

The employer shall certify that each operator has been trained and evaluated as required by this paragraph (l). The certification shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation. (l) (6)

•

The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck. (m) (4)

•

Brakes shall be set and wheel blocks shall be in place to prevent movement of trucks, trailers or railroad cars while loading or unloading. Fixed jacks may be necessary to support a semitrailer when the trailer is not coupled to a tractor. The flooring of trucks, trailers, and railroad cars shall be checked for breaks and weakness before they are driven onto. (m) (7)

•

Only approved industrial trucks shall be used in hazardous locations. (m) (11)

•

All traffic regulations shall be observed, including authorized plant speed limits. A safe distance shall be maintained approximately three truck lengths from the truck ahead, and the truck shall be kept under control at all times. (n) (1)

•

The driver shall be required to slow down and sound the horn at cross aisles and other locations where vision is obstructed. If the load being carried obstructs forward view, the driver shall be required to travel with the load trailing. (n) (4)

•

Under all travel conditions the truck shall be operated at a speed that permits it to be brought to a stop in a safe manner. (n) (8)

•

Stunt driving and horseplay shall not be permitted. (n) (9)

•

If at any time a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck shall be taken out of service until it has been restored to safe operating condition. (p) (1)

•

Any power-operated industrial truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel. (q) (1)

•

All parts of any such industrial truck requiring replacement shall be replaced only by parts equivalent as to safety with those used in the original design. (q) (5)

•

Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the truck. Such examination shall be made at least daily. Where powered industrial trucks are used on a round-the-clock basis, they shall be examined after each shift. Defects when found shall be immediately reported and corrected. (q) (7)

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ANSI/ITSDF B56.1 ANSI/ITSDF B56.1

The American National, ANSI/ITSDF B56.1 Safety Standard, is addressed to both the manufacturer and user of forklifts. This section of the manual lists several sections of the standard. The full text of the standard, which provides additional information regarding the use and design of forklifts is available at www.itsdf.org or from: ITSDF 1750 K STREET NW, SUITE 460 WASHINGTON, DC 20009 4.17 Elevating Personnel 4.17.1 Only operator-up high lift trucks have been designed to lift personnel. On these trucks the requirements of paragraph 4.17.2 shall be met for the protection of personnel. If a work platform is used on trucks designed and intended for handling materials, the requirements of paras. 4.17.2 and 4.17.3 shall be met for the protection of personnel. 4.17.2 Whenever a truck is used to elevate personnel, the following precautions for the protection of personnel shall be taken: (a) Comply with the design requirements in para 7.37 of this Standard. (b) Provide protection for personnel in their normal working position on the platform from moving parts of the truck that represent a hazard. (c) Make sure required fall restraint means, such as guardrails and/or personal fall protection systems, are in place and properly used (see 7.37.1(d)(1). For personal fall protection system configurations, see Table 1 on page 66. (d) Be certain that the lifting mechanism is operating smoothly throughout its entire lift height, both empty and loaded, and that all lift limiting devices and latches, if provided, are functional. (e) Provide overhead protection as indicated to be necessary by the operating conditions. (f) All components of the personal fall protection system shall be inspected and maintained in accordance with the schedule and requirements found in Section 6 of ANSI/ASSE Z359.1-2007 Safety Requirements for Personal Fall Arrest Systems, Subsystems and Components.

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ANSI/ITSDF B56.1 Table 1. Personal Fall Protection System Configurations Operator Weight (pounds/kilograms) Fall Protection / Prevention Device

<220 lbs. (<100 kg)

Full Body Harness

X

Energy Absorber max total length (6 ft.) Self-Retracting Lanyard Maximum Arresting Force Permitted (lbs./N)

Notes: [1] [2]

220 - 310 lbs. [1] (100 - 140 kg)

X

X

X

X

X 1800 (8000)

1800 (8000)

1800 (8000)

X

311 - 400 lbs. [1] (141 - 181 kg)

>400 lbs. [1] (>181 kg)

X

X

X [2]

1800 (8000)

1800 (8000)

Contact Lift Truck Manufacturer

Truck capacity shall be reduced by the operator(s) weight in excess of 220 lbs. (100 kg). Self-Retracting Lanyard - shall be rated for the operator’s weight. Contact the truck manufacturer.

Reprinted from ANSI/ITSDF B56.1-2012 by permission of ITSDF. All rights reserved.

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Alphabetical Index Alphabetical Index

A Accidents, Causes 2 Aisles 6, 52 Allowable Pallet Types 57 American National Standards 2 American National Standards Institute 2 ANSI/ITSDF B56.1 Compliance 2, 65 to 66 ANSI/ITSDF B56.5 Compliance 2 Audible Alarm 40 Auto Steer Centering 28 Auxiliary Mast (Optional) 27

B Battery 58 to 60 Acid, Washing 10, 58 Cables, Caution 59 Charge 35 Connector 18 History Record 60 Hydrogen Gas 10, 58 Installing 59 Personal Protective Equipment 10, 58 Removing 60 Safety 10, 58 State-of-Charge 35 Sulfuric Acid 10, 58 Warning 10, 58

C Calendar/Clock Display as Default 31 Capacity and Rating 14 Cautions Battery Cables 59 Definition ii Driving Safely 47 Intersections 51 Operate Slowly While Learning 1 Removing Battery 60 Slow Down 49 Steering 48 Stop and Sound the Horn 51 See also Safety Checklist, Operator’s Daily 41 to 45 Clock/Calendar Display as Default 31 Compliance, Safety Standards 2 Controls Auto Steer Centering 28 Auto Steer Centering (for Rail Guidance) 22 Auxiliary Mast (Optional) 27 Battery Connector 18 Controls and Indicators 18 Cut-Out (Optional) 26 Deadman Pedal, Round 19 Directional/Speed Control 20

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Alphabetical Index Emergency Lowering Valve 19 Emergency Power Off (EPO) Button 18 Fall Protection System 5 Fan (Optional) 27 Fire Extinguisher (Optional) 28 Guidance Indicator Lights 24 Horn 19 Key Switch 18 LED Work Area Lights (Optional) 27 Lift Control 22 Lift Limit Bypass (Optional) 23 Lower Control 22 Lower Decel (Optional) 23 Lower Limit Bypass (Optional) 23 Overhead LED Lights (Optional) 26 Pallet Clamp 24 Pallet Clamp Release Pedal 25 Security Start Switch (Optional) 18 Sidegates (Optional) 25 Sidegates Power Disconnect (Optional) 25 Steering Control 20 Steering Direction Indicator 21 Wire Guidance ON/OFF Switch 23

D Deadman Pedal, Round 19 Emergency Stop 51 Decals, Location of Warning 12 Decals, Warning 11, 12 Double Rail Systems 54 Driving Safely 6

E Elevators, Safety 7 Emergency Lowering Valve 19 Emergency Power Off (EPO) Button 18 Emergency Stop 51 End-of-Aisle Slowdown (Optional) 55 Energy Absorber (with Full Body Harness) 5 EPO Button 18

F Fall Protection System Energy Absorber, Full Body Harness 5 Self-Retracting Lanyard, Full Body Harness 5 Fan (Optional) 27 Fault Codes 39 Fire Extinguisher (Optional) 28 Fork Carriage Safety 4, 6 Warning 4 Fork Height and Load Weight 34 Full Body Harness 5

H Handling Loads Safely 7 Harness, Full Body 5

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Alphabetical Index Horn 6, 7, 19, 20, 47 Hour Meters and Total Miles Indicator 31 Hours Key Switch (KH) ON 32 Hours on Deadman (HD) 32, 45 Hours Spent Lifting (HL) 32

I Informational Messages 36 intellispeed™ Control System 34, 37

K Key Switch 18 Key Switch ON (KH) 32

L Law, Federal 1, 2, 41, 63 LED Work Area Lights (Optional) 27 Left Direction 13 Lift Control 22, 23 Lift Truck Operation 41 to 57 Load Capacity 14, 15 Load Center 14, 15 Load Handling Safety/Warning 7 Load Weight 14 Location of Controls and Indicators 18 Location of Warning Decals 12 Lower Control 22, 23 Lower Limit Bypass (Optional) 23

M Model Definition Model 5400 13 Model 5500 13 Model 5600 13

O Objects Sticking Out, Warning 7, 47 Obstructions, Warning 7, 47 Occupational Safety and Health Administration 2 Off Deadman Selection 31 On Deadman Selection 31 Operation, Lift Truck 41 to 57 Aisle 52 Parking 56 Plugging 50 Reverse Direction 50 Slowing Your Speed 49 Starting the Lift Truck 45 Steering 48 Stop the Lift Truck (Emergency) 51 Stop the Lift Truck (Normal) 51 Travel 47 Operator Display 29 to 40 Message Area 29 Operator Platform 16 Warning 17

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Alphabetical Index Operator’s Daily Checklist 41 to 45 Operational Inspection 43 Visual Inspection 42 Orientation, Left and Right 13 OSHA Compliance 2 Overhead Hazards 6 Overhead LED Lights (Optional) 26 Overturn or Tip 9

P Pallet Clamp 24 Pallet Clamp Release Pedal 25 Pallets, Use of 57 Parking 56 Cold Storage 56 No Ramps 56 Safety 6 Warning 56 Passengers 4 Pedestrians Safety 6, 7 Warning 7 Performance Limiting Messages 37 Personal Protective Equipment (Battery) 10, 58 Plugging 50

R Racks Warning 7, 47 Rail Guidance (Optional) 54 Rail Guidance Indicator Lights 24 Rating and Capacity 14 Reverse Direction 50 Right Direction 13 Round Deadman Pedal 19

S Safety 1 to 13 Accidents, Causes 2 Battery 10, 58 Driving Safely 6 Elevators 7 Forks 6 Handling Loads 7 Horn 6, 7 Parking 6 Passengers 4 Pedestrians 6, 7 See Also Cautions and Warnings Stability 9 Standards Compliance 2 Tipovers 4, 45 Under Forks 4 Warning Decals 11, 12 Safety Standards 2 Security Start Switch (Optional) 18 Self-Retracting Lanyard (with Full Body Harness) 5 SelfTest 31, 45

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Alphabetical Index Sidegates (Optional) 25 Sidegates Power Disconnect (Optional) 25 Slowing Your Speed 49 Specification Plate 15 Stability 9 Start Switch, Security (Optional) 18 Starting the Lift Truck 45 Status Messages 35 Steering Caution 48 Control 20 Steering Direction Indicator 21 Steering the Lift Truck 48 Stop the Lift Truck Emergency 51 Normal 51 Switch, Key 18

T Tip or Overturn 9 Total Miles (TM) 33 Tractor Covers 62 Training 1, 41 Warning 41 Travel 47 Travel Cut-Out (Optional) 26 Troubleshooting 61

U UL 583 Compliance 2 Underwriters Laboratories 2 Unstable Loads 7, 47 Use of Pallets 57

W Warning Decals 11, 12 Warnings Battery Acid and Gas 10, 58 Definition ii Fork Carriage 4 Industrial Equipment Can Be Hazardous 2 Objects Sticking Out 7, 47 Obstructions 7, 47 Operator Platform 17 Operator Platform and Forks 4 Parking 56 Pedestrians 7 Racks 7, 47 Training 41 Unstable Loads 7, 47 See also Safety Wire Guidance (Optional) —Acquiring the Guide Wire 53 Wire Guidance Indicator Lights 24 Wire Guidance ON/OFF Switch 23

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Operator Manual Models 5400/5500/5600 High-Level Orderpicker Lift Trucks Your Local Authorized Raymond Sales and Service Center is:

Lift Truck Serial Number:

Installed by (Technician’s Name):

The Raymond Corporation P.O. Box 130 South Canal Street Greene, NY 13778-0130 Phone: 607-656-2311 Fax: 607-656-9005

Publication Number 1031792D 23 Dec 2016

! Printed by the Digital Print Center, The Raymond Corporation, Greene, NY

®