Académique Documents
Professionnel Documents
Culture Documents
Models 5400/5500/5600
High-Level Orderpicker Lift Trucks
Your Local Authorized Raymond
Sales and Service Center is:
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.
If you need assistance with your lift truck, contact your local authorized
Raymond Sales and Service Center.
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operator Display . . . . . . . . . . . . . . . . . . . . . . . 29
Battery Procedures . . . . . . . . . . . . . . . . . . . . . 58
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 61
ANSI/ITSDF B56.1. . . . . . . . . . . . . . . . . . . . . . 65
Alphabetical Index. . . . . . . . . . . . . . . . . . . . . . 67
Publication 1031792D i
How to Use This Manual
How to Use This Manual
You should read this entire manual before operating your lift
truck.
ii Publication 1031792D
Safety
Safety
Training
Federal law says you must be
trained and authorized to
operate this lift truck.
Publication 1031792D 1
Safety
Safety Standards Compliance
This lift truck complies with the following standards and
regulations in effect on the date the lift truck was built:
Safety Requirements
WARNING: Industrial Equipment Can be Hazardous
• Careless operators
• Untrained and unauthorized use
• Poor maintenance
• The operator
• The lift truck
• The workplace environment
2 Publication 1031792D
Safety
Safe operation of your lift truck requires:
Start-Up Safety
Do not operate this lift truck until you have checked all
systems with the Operator’s Daily Checklist.
Publication 1031792D 3
Safety
Operating Safely
Report any malfunction or unsafe condition to your supervisor
immediately. Do not operate the lift truck until the condition is
corrected.
4 Publication 1031792D
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 Full Body Harness and
absorber. For the proper Energy Absorber
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.)
Publication 1031792D 5
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.
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.
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.
6 Publication 1031792D
Safety
Pedestrians
Always keep pedestrians safe. Other people in your area or
facility might not know how this lift truck works.
Elevators
Check with your supervisor before you use this lift truck in or
near an elevator.
Publication 1031792D 7
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.
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.
8 Publication 1031792D
Safety
Stability
Your lift truck is designed to be steady and stable. Stability is
affected by:
Publication 1031792D 9
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.
10 Publication 1031792D
Safety
Warning Decals
Read and obey all warning decals on your lift truck. If you
have any questions about these warnings, ask your
supervisor.
1 2
Publication 1031792D 11
Safety
Location of Warning Decals
See page 11 for decals.
12 Publication 1031792D
Your Lift Truck
Your Lift Truck
Model Definitions
The models of the Raymond High-Level Orderpicker are
defined as follows:
Operator
Area Operator
Platform
Forks-First
Publication 1031792D 13
Your Lift Truck
Capacity and Rating
This lift truck is rated for
performance by load center, load
weight, and load height (with
forks elevated).
14 Publication 1031792D
Your Lift Truck
Specification Plate
See the specification plate for lift
truck capacity and load center
information.
Publication 1031792D 15
Controls
Controls
Operator Platform
The operator platform is where you stand
to operate the lift truck.
16 Publication 1031792D
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.
Publication 1031792D 17
Controls
Controls
The individual controls work this way:
OFF ON
SelfTest;
lift truck is ready
for operation
Security Start Switch Press and hold the Lift truck is ready
(Optional) security start switch then for operation.
turn the key switch to
ON.
18 Publication 1031792D
Controls
Control Operator Action Lift Truck Response
Round Deadman Pedal
Pedal 1. Brake is released.
2. Control system is
enabled.
Horn
Press
Location of Emergency
Lowering Valve
Publication 1031792D 19
Controls
Control Operator Action Lift Truck Response
Directional/Speed
Control
Steering Control
Steering Wheel
20 Publication 1031792D
Controls
Control Operator Action Lift Truck Response
Steering Direction Illuminated LED
Indicator (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.
Publication 1031792D 21
Controls
Control Operator Action Lift Truck Response
Auto Steer Centering
(for Rail Guidance) Automatic when the truck Drive wheel is locked in
senses that it is within the straight-ahead
the aisle. position.
Switch
Press here for Auto
Steer Centering.
Lift Control
Lift
Lower Control
Lower
22 Publication 1031792D
Controls
Control Operator Action Lift Truck Response
Lift Limit Bypass Continues lifting or
(Optional) lowering after limit has
or been reached.
Lower Limit Bypass
(Optional)
Lower Decel
(Configurable) None
This function
is automatic.
Wire Guidance
ON/OFF Switch
(with optional
wire guidance)
Press here
for
automatic
steering.
Press here
GUIDE
for
WIRE
manual
(Location of Switch)
steering.
Truck “locks on” guide
wire – steering
is automatic.
Publication 1031792D 23
Controls
Control Operator Action Lift Truck Response
Wire Guidance Triangles are illuminated. Wire Guidance Switch is
Indicator Lights Circular lights within ON ( I ). The lift truck is
triangles are flashing. ready for automatic
guidance.
24 Publication 1031792D
Controls
Control Operator Action Lift Truck Response
Pallet Clamp When releasing the
Release Pedal pallet, hold the pallet
release pedal in the
depressed position before
moving the lift truck
forward.
Publication 1031792D 25
Controls
Control Operator Action Lift Truck Response
Travel Cut-Out None. This function When the operator
(Optional) is automatic. platform is elevated
above the preset height...
26 Publication 1031792D
Controls
Control Operator Action Lift Truck Response
Fan
(Optional)
Fan Switch
Auxiliary Mast
(Optional)
1. Press
2. Press
deadman either
button.
auxiliary lift
button or
auxiliary
lower button.
Publication 1031792D 27
Controls
Auto Steer Centering
When the key switch is turned ON, Center Steer
and the deadman pedal is depressed, Indicator
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.
Typical Location of
Fire Extinguisher
28 Publication 1031792D
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
Publication 1031792D 29
Operator Display
Steering Display Lift Lower Over-temperature
Direction Limit Indicator
Indicator
Maintenance
Required
Indicator
UP
Button
Wire ENTER
Guidance button
Indicator, Rail
Guidance
Indicator, or
(optional) Auto
Steer
Centering
Indicator for
Rail Guidance DOWN
button
Operator Display
30 Publication 1031792D
Operator Display
Operator Display Selections
NOTE: Use the UP ( ) or DOWN ( ) buttons to momentarily
view any of the other displays.
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.
Publication 1031792D 31
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.)
32 Publication 1031792D
Operator Display
Total Miles (TM)
Records the total number of miles
that the lift truck has traveled. 758
This message appears briefly on
the Operator Display after Hours
Spent Lifting (HL).
Clock Calendar
The clock/calendar can be shown
on the Operator Display. 8 29 05
Publication 1031792D 33
Operator Display
Fork Height and Load Weight
NOTE: Available only on lift trucks equipped with the
advanced intellispeed ™ control system.
34 Publication 1031792D
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.
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.
Publication 1031792D 35
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:
Operator Operator
Display Message Reason Response
Eight blank spaces You have not entered the Enter it. (See page 46 for
-------- password or (optional) instructions.)
electronic key.
Guidance not learned 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.
36 Publication 1031792D
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
Meaning Performance Limit
Message
SelfTest Power ON SelfTest (POST). 0 mph
(0 km/h)
Initialize to allow full Lower reference switch is 2.5 mph (4.0 km/h) below
speed travel. (typically 24 in. [600 mm]) the upper reference switch.
not sensed. 1 mph (1.6 km/h) above
the upper reference switch.
Aligning 1 Wire guidance switch is in Speed is limited to the
AUTO. Lift truck senses configurable acquire speed
guide wire and is trying to when driving tractor-first.
acquire it. When driving forks-first,
Seeking 1 Wire guidance switch is in speed is limited to 1 mph
AUTO. Lift truck has not (1.6 km/h).
sensed the guide wire.
Speed limited due to Lift system does not 1 mph (1.6 km/h)
unknown height... recognize elevated height.
lower to reference
switch. 3
Speed limited due to Steer angle is greater than 2.5 mph (4.0 km/h)
the steer angle. 10° and the operator
platform is above 24 in.
(600 mm) but below
60 in. (1524 mm).
Steer angle is greater than 1 mph (1.6 km/h)
10° and the operator
platform is between
60 in. (1524 mm) and
150 in. (3810 mm).
Steer angle is greater than 0 mph (0 km/h)
10° and the operator
platform is higher than
150 in. (3810 mm).
Lower sidegates to Sidegates are up when 0 mph (0 km/h). Lift and
resume operation. 2 requesting travel, lift, or lower are disabled.
lower.
1 = Wire Guidance lift trucks
2 = Optional
3 = Lift trucks with intellispeed™ Control System
Publication 1031792D 37
Operator Display
Operator Display
Meaning Performance Limit
Message
Lower inhibited or Lower limit is reached. Lowering system is shut
press and hold down
bypass to continue
lowering. 2
EPO depressed EMERGENCY POWER OFF Total shutdown
switch is detected down.
Release control Throttle moved before 0 mph (0 km/h)
handle to resume deadman was depressed.
operation.
Press bypass switch Upper limit reached. Lift system is shut down
to continue lifting. 2
1 = Wire Guidance lift trucks
2 = Optional
3 = Lift trucks with intellispeed™ Control System
38 Publication 1031792D
Operator Display
Fault Codes
If a fault occurs, travel and/or lift
functions may be disabled. The Code 2A
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 Thermometer Icon
Operator Display shows a fault
code before it shows the battery
condition.
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.
Publication 1031792D 39
Operator Display
Audible Alarm
The audible alarm is automatic.
40 Publication 1031792D
Lift Truck Operation
Lift Truck Operation
Training
Federal law says you must be
trained and authorized to
operate this lift truck.
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.
✓✓
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.
Publication 1031792D 41
Lift Truck Operation
Daily Record (Perform these checks at the start of each shift)
Model: Serial Number: Operator:
• Installed correctly; battery gates secure; battery moves less than 0.5 in. (13 mm)
in any direction
• Mast guard (glass or mesh) in good condition, with no damage; clear view
• No leaks; also check floor under lift truck for any dripping fluid
42 Publication 1031792D
Lift Truck Operation
Visual Inspection: Key Switch Turned OFF ( O ) Mark
V-6 GUARDS, COVERS, DECALS, AND FALL PROTECTION
• Self-retracting lanyard with full body harness or energy absorber with full body
harness is not frayed and/or damaged
V-7 OTHER
• Records hours of lift truck operation, hours spent lifting, and total miles
traveled
* If applicable
O-3 STEERING
0-4 HORN
Publication 1031792D 43
Lift Truck Operation
Operational Inspection: Key Switch Turned ON ( I ) Mark
0-5 DIRECTIONAL/SPEED CONTROL
• Lift truck motion is smooth and responds to commands through all speed
ranges
• 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.
O-9 SAFETY
COMMENTS:
Operator’s/Supervisor’s Initials/Signature
44 Publication 1031792D
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.
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.
Make sure the forks are elevated slightly so they do not scrape
the floor.
Publication 1031792D 45
Lift Truck Operation
If this lift truck has the optional Electronic Key, enter the code
as follows:
Publication 1031792D 47
Lift Truck Operation
Steering
You can drive your lift truck either forks-first or tractor-first.
48 Publication 1031792D
Lift Truck Operation
To Slow Your Speed
To slow your speed,
Publication 1031792D 49
Lift Truck Operation
To Reverse Direction
To reverse direction,
50 Publication 1031792D
Lift Truck Operation
To Stop the Lift Truck
(Normal Operation)
To stop the lift truck normally,
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.
Publication 1031792D 51
Lift Truck Operation
Entering an Aisle
To enter an aisle follow these steps:
52 Publication 1031792D
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.
Publication 1031792D 53
Lift Truck Operation
Rail Guidance (Optional)
To enter a rail guided aisle follow these steps:
54 Publication 1031792D
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.
Publication 1031792D 55
Lift Truck Operation
Parking
WARNING: Never park this lift truck on a ramp or slope.
56 Publication 1031792D
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.
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
Publication 1031792D 57
Battery Procedures
Battery 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.
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.
58 Publication 1031792D
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.
Publication 1031792D 59
Battery Procedures
To Remove the Battery
CAUTION: When you remove a battery from a lift truck,
always use a battery stand or similar equipment.
• Overcharging
• Undercharging
• Over-discharging
• Excessive water consumption
• Excessive dirt and corrosion
• Worn-out batteries
• Excessive current consumption by lift trucks
60 Publication 1031792D
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 Is the battery connected? Check the battery.
switch is turned ON. Contact the Service Department.
Received a fault code. Do not operate the lift truck until the
problem is corrected.
Publication 1031792D 61
Troubleshooting
Tractor Cover Removal and
Installation
To remove the tractor covers do the
following:
62 Publication 1031792D
Selected OSHA Regulations
Selected OSHA 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)
Publication 1031792D 63
Selected OSHA Regulations
• 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)
64 Publication 1031792D
ANSI/ITSDF B56.1
ANSI/ITSDF B56.1
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.
(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.
(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.
Publication 1031792D 65
ANSI/ITSDF B56.1
Notes:
[1] Truck capacity shall be reduced by the operator(s) weight in excess of 220 lbs. (100 kg).
[2] Self-Retracting Lanyard - shall be rated for the operator’s weight. Contact the truck
manufacturer.
66 Publication 1031792D
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
Publication 1031792D 67
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
68 Publication 1031792D
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
Publication 1031792D 69
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
70 Publication 1031792D
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
Publication 1031792D 71
Alphabetical Index
72 Publication 1031792D
Operator Manual
Models 5400/5500/5600
High-Level Orderpicker Lift Trucks
Your Local Authorized Raymond
Sales and Service Center is:
Publication Number
1031792D
23 Dec 2016
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