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
Publication 1031792D i
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.
ii Publication 1031792D
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.
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:
• 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:
• The operator
• The lift truck
• The workplace environment
2 Publication 1031792D
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.
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.
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.)
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 Full Body Harness and
self-retracting lanyard or Self-Retracting Lanyard
energy absorber should be
fastened to the tether bar on
the overhead guard.
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.
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.
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.
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
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:
• 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.
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
Drive unit turns automatically.

Keep hands clear until battery
is disconnected.
411-882
Safety
Location of Warning Decals
See page 11 for decals.
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” Tractor-First
assumes you are standing on the
operator platform facing the
tractor.
The operator platform is where Left Right

you stand to operate the lift
truck.
Operator
Area Operator
Platform
Forks-First
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.
Loaded in Lowered Position
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.
Consult the specification plate on

your lift truck.
Loaded in Lift Position
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.
Controls
Controls
Operator Platform
The operator platform is where you stand
to operate the lift truck.
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.
Controls
Controls
The individual controls work this way:
Control Operator Action Lift Truck Response

Battery Connector
Connect the battery
and turn the key
switch ON.
Lift truck is ready

for operation.
Emergency Power Off Pushing the EPO switch
(EPO) Button IN disables travel,
lift/lower circuits, and
applies the brake.
To reactivate the system,

pull the EPO switch
OUT and turn the key
switch ON.
Key Switch Operator Display
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.
Do not step on the

deadman pedal.
Security Start Switch
Controls
Round Deadman Pedal
Pedal 1. Brake is released.
2. Control system is
enabled.
1. Lift truck slows to a

stop. (Brake is
applied.)
2. Control system is
disabled.
Horn
Press
Emergency In the event that the

Lowering Valve carriage must be lowered
from the ground, do the
following:
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
Controls
Directional/Speed
Control
Steering Control
Steering Wheel
Controls
Steering Direction Illuminated LED
Indicator (light-emitting diode)
indicates the direction
the drive wheel is turned.
10° – 30° to the left.
Illuminated LED
More than 30° to the left.
Illuminated LED
Within 10° (left or right)
of center.
Illuminated LED
10° – 30° to the right.
Illuminated LED
More than 30° to
the right.
Controls
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
Controls
Lift Limit Bypass Continues lifting or
(Optional) lowering after limit has
or been reached.
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.
Press here
GUIDE
for
WIRE
manual
(Location of Switch)
steering.
Truck “locks on” guide
wire – steering
is automatic.
Controls
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.
Center lights and triangles Lift truck is locked on the

are illuminated. guide wire. You, the
operator, can no
longer steer.
Rail Guidance If the rail guidance

Triangles are flashing.
Indicator Lights 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

Center lights and triangles switch is in AUTO ( I )
are illuminated. 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.
Pallet Clamp Pallet Clamp The pallet clamp holds

the pallet securely in
place while the load is
lifting and lowering.
Controls
Pallet Clamp When releasing the
Release Pedal pallet, hold the pallet
release pedal in the
depressed position before
moving the lift truck
forward.
Sidegates Raise the sidegate to Optional switches

and Sidegates Power enter/exit the operator prevent lift truck
Disconnect (Optional) platform. Lower the gates movement until the
before operating the lift sidegates are lowered.
truck.
Controls
Travel Cut-Out None. This function When the operator
(Optional) is automatic. platform is elevated
above the preset height...
...lift truck travel is

prevented.
Overhead LED Lights
(Optional)
Overhead Light Switch
Controls
Fan
(Optional)
Fan Switch
LED Work Area Lights

(Optional)
Work Area Light Switc
Auxiliary Mast
(Optional)
1. Press
2. Press
deadman either
button.
auxiliary lift
button or
auxiliary
lower button.
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.
Left Outer Right Outer

Steer LED 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
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.
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
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 ( ) or
DOWN ( ) buttons to scroll through the items.
3. The last item shown will be the item displayed when the
deadman pedal is up.
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.
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).
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).
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.
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 20 in.
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). Approximate Fork Height
The weight measurement shows

you the approximate total weight 300 lbs.
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 Approximate Fork Weight
instructions.
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 80%
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 Battery State-of-Charge
either recharged or replaced with
a recharged battery.
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.
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 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.
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
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
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.
The fault is shown first by a two Code 43

character code, followed by a
message. The code and message
repeat continually until reset.
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.
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
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.
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 ) Mark

V-1 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
Visual Inspection: Key Switch Turned OFF ( O ) Mark
V-6 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 ) Mark

O-1 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
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
• 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
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.
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.)
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.
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.
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.
To Reverse Direction
To reverse direction,

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

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.
Entering an Aisle
To enter an aisle follow these steps:
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.
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
Guide
your local authorized Raymond Wire
Sales and Service Center
service representative.)
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.
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.
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.
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:
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.
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, double-
faced 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
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.
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.
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.
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.
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.
Battery discharges quickly or Even though a battery has been fully

does not indicate a full charge recharged, it may not display 100% on the
after charging. 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 Contact the Service Department.
travel, lift, or lower function).
Received a fault code. Do not operate the lift truck until the
problem is corrected.
Troubleshooting
Tractor Cover Removal and
Installation
To remove the tractor covers do the
following:
1. 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 Top Cover Removal
up and pull it off. This releases
the front tractor cover.
2. 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. Tractor Cover
2. Position the top cover over the Removal/Installation
latches and push down.
Top Cover Installation
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)
• 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)
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.
ANSI/ITSDF B56.1
Table 1. Personal Fall Protection System Configurations

Operator Weight (pounds/kilograms)
220 - 310 lbs. 311 - 400 lbs. >400 lbs.

Fall Protection / <220 lbs.
[1] [1] [1]
Prevention Device (<100 kg)
(100 - 140 kg) (141 - 181 kg) (>181 kg)
Full Body Harness X X X X X

Energy Absorber -
max total length X X
(6 ft.) Contact Lift
Self-Retracting Truck
X X X [2] Manufacturer
Lanyard
Maximum Arresting 1800 1800 1800 1800 1800
Force Permitted
(8000) (8000) (8000) (8000) (8000)
(lbs./N)
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.
Reprinted from ANSI/ITSDF B56.1-2012 by permission of ITSDF. All

rights reserved.
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
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
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
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
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
Alphabetical Index
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
!
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Operator Manual

Lift Truck Serial Number:

Installed by (Technician’s Name):

The Raymond Corporation

The Owner Manual should remain with the owner, supervisor, or

If you need a replacement for either manual, contact your local

This publication, 1031792D, applies to the Models 5400/5500/5600

To order additional copies of this manual, part number 1031792D, contact

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,

How to Use This Manual . . . . . . . . . . . . . . . . . . ii

Your Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . 13

Lift Truck Operation . . . . . . . . . . . . . . . . . . . . 41

Selected OSHA Regulations . . . . . . . . . . . . . . . 63

This manual reinforces your training so you can help prevent

To Find Information Quickly

Warnings and Cautions

WARNING: Warning indicates a potentially hazardous

CAUTION: Caution indicates a potentially hazardous

Neither this manual nor the

There is a summary of the training

Read and obey all warnings, cautions, and instructions in this

CAUTION: Operate this lift truck slowly in an open area

Raymond builds safe and reliable products. To operate this lift

Talk with your supervisor if you have any questions or

• ANSI/ITSDF B56.1, An American National Standards, and

Powered industrial equipment can be hazardous. This lift

Lift truck accidents often result from:

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

• Your knowledge, training, skill, and attitude

See “Options” in the Owner Manual for more information.

WARNING: Never place any part of your

Never carry unauthorized personnel.

Never let anyone place their feet on either

WARNING: Never let anyone

Make sure the full body

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

Obey all traffic rules. Yield the right-of-way to pedestrians.

Always approach and leave aisles slowly, including guided

Do not strike objects or obstructions overhead, such as pipes,

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.

Always yield the right-of-way to pedestrians.

Sound the horn when you approach intersections or

WARNING: Never drive this lift

Handling Loads Safely

WARNING: Do not handle

Elevate the operator platform only to

Avoid turns while the platform is elevated with a load.

Do not push loads around on the floor.

Secure allowable pallet or cart to platform and forks.

Use only one foot on the deadman pedal.

• Lift truck weight and weight distribution

The lift truck’s specification plate lists maximum loads