Raymond 5400 5500 5600 Orderpicker Lift Truck Parts Manual SN 100 & up – PDF DOWNLOAD

SECTION 1 General Information
Hardware 1-2
Critical 1-14
Recommended 1-31
SECTION 2 Finish & Accessories
Frame, Mechanical Components 2-2
Bumper Installation 2-5
Battery Roller Assembly 2-7
Battery Gate and Roller Assembly 2-9
Finish Instructions 2-11
Mast Guard Assembly 2-22
Floor Pad Installation 2-25
Tether, Mechanical Installation 2-29
SECTION 3 Steering & Controls
Electric Steer Motor Installation 3-2
Steer Motor and Gearbox Assembly 3-6
Electric Steering and Control Components 3-8
Electric Steering Wheel 3-10
SECTION 4 Drive & Brake
Drive Unit and Brake Assembly 4-2
Drive Unit Installation 4-5
Brake Installation 4-7
Brake Assembly 4-9
Deadman Installation 4-11
Deadman Pedal Assembly 4-13
Deadman Brake Pedal Assembly, Standard 4-15
Deadman Brake Pedal Assembly, Optional 4-17
Lower Drive Unit, Heavy Duty 4-19
Lower Drive Unit Assembly, Standard 4-23
Drive Wheel Assembly 4-26
SECTION 5 Electrical Comp & System
Electrical Components 5-2
Fan Installation, Pump Compartment, 36V 5-7
Carriage Electrical Components 5-9
Traction and AC Lift Controller Installation 5-15
Contactor Panel Installation 5-17
Contactor Panel Assembly, Standard 5-19
Contactor Panel Assembly, EE 5-21
Contactor Assembly 5-24
Horn Installation 5-26
Fuse Relay Installation 5-29

Battery Connector and Installation 5-31
Platform, Limit Switch Installation 5-33
Travel, Lift Limit and Decel Switch Installation 5-35
Travel Limit Switch Installation 5-41
Warning Light Installation, Tractor Mount (Standard) 5-44
Warning Light Installation, Mast Mount (Optional) 5-46
Warning Light Assembly (Strobe) 5-48
Warning Lamp (Flashing) 5-50
Heater Assembly, Carriage Card 5-52
Drive Motors 5-55
Drive Motor Assembly W/ Target Plate 5-58
Lift Motors 5-60
Lift Motors, DC 5-62
Lift Motor (Single Stage Pump) (24V) 5-64
Lift Motor, EE (24V) 5-66
Lift Motor 5-68
Control Handle Assembly 5-70
SECTION 6 Hydraulic Components
Lift/Lower Manifold Installation 6-2
Lift/Lower Manifold Installation, with Auxiliary Lift 6-5
Lift/Lower Manifold Assembly 6-7
Manifold Assembly, Lift Select 6-9
Manifold Assembly, Auxiliary Lift 6-11
Lift/Lower Manifold Sub-Assembly, Standard 6-13
Manifold, Lift Select, Auxiliary Lift 6-15
Lift/Lower Valve, Auxiliary Lift 6-17
Flow Sensor Assembly 6-19
Lift Pump and Motor Assembly, AC Lift 6-21
Lift Pump and Motor Assembly (24V, DC) 6-23
Cylinder Assembly, Main Lift, 175 in Diameter (Three Stage Only) 6-26
Cylinder Assembly, Free Lift, 25 in Diameter 6-31
Cylinder Assembly, Free Lift, 25 in Diameter 6-35
Cylinder Assembly, Free Lift, 25 in Diameter 6-39
Lift Cylinder Assembly, 175 in (Two Stage) 6-41
Cylinder Assembly, Auxiliary Lift 6-46
Reservoir Installation 6-48
Reservoir Assembly 6-50
SECTION 7 Mast
Mast Mounting 7-2
Three Stage Mast, Electric Steer 7-4
Elevating Section, Two Stage 7-16
Load Wheels 7-21
Auxiliary Lift Mast 7-23
Over the Mast, Hoses, Cables, and Pulleys (Three Stage) 7-30
System Mechanical, Elevating Section 7-43
Pulley Assembly, Cable, End Cap, Three Stage 7-48
Pulley Assembly, Hose 7-50
Pulley Assembly, Cable, Bottom 7-52
Pulley Assembly, Cable 7-54
Bumper Assembly 7-56
Fork Assembly, Standard 7-58
Fork Assembly, Extended Lift, 175 in X 5 in, Heat Treated 7-60
Fork Assembly, Tubular 7-62
Fork Assembly, Auxiliary Lift 7-64
SECTION 8 Options & Kits
Pallet Clamp Assembly, 125 in to 225 in 8-3
Pallet Clamp Installation 8-9
Pallet Clamp, Jaws Assembly 8-13
Pallet Clamp Assembly 8-15
Pallet Assembly, Clamp and Cable 8-17
Pallet Clamp, Pedal Assembly, 125 in to 500 in 8-19
Pallet Clamp Assembly 8-22
Pallet Clamp, Weldment 8-24
Sidegate Installation 8-26
Sidegates, Heavy Duty (Optional) 8-28
Full Retractable Sidegate Installation 8-30
Mechanical Sidegates – Bar, Installation 8-33
Gate, Mechanical, Fixed Installation 8-35
Platform Extension 8-37
Guide Roller Installation, 25 in Wheel 8-40
Carriage Alteration and Hardware 8-44
Guide Roller Assembly 8-46
Guide Roller Installation, 325 in Wheel 8-48
Guide Roller Assembly 8-56
Roller Switch Assembly 8-58
Guide Roller Assembly, Heavy Duty 8-60
Guide Roller Assembly With 5700 in Base Legs 8-65
Guide Roller Assembly (Furniture Picker) 8-67
Cart Latch Assembly 8-70
Wire Guidance Installation 8-72
Guidance Control Assembly 8-74
Wire Guidance Sensor, Tractor End 8-76
Wire Guidance Sensor, Load End 8-78
End-of-Aisle Slowdown 8-80
Operator Compartment, Lights and Fan 8-82
Light Assembly, LED, Overhead 8-86
Overhead Fluorescent Light Assembly 8-90
Lights and Fan, Operator Compartment (Cold Storage) 8-92
Bin Lights Installation 8-95
Bin Light Assembly 8-97
Working Light Installation, LED 8-99
Working Light Assembly, LED 8-101
Auxiliary Power Hookup 8-103
Auxiliary Power Hookup (6 AMP and 10 AMP) 8-105
Auxiliary Power (100 Amp) 8-108
Motion Alarm Installation 8-114
Cooling Fan Installation 8-116
Operator Cooling Fan Installation 8-120
Operator Cooling Fan Assembly 8-122
Fire Extinguisher 8-124
Battery Guide 8-126
Slack Switch Installation 8-128
Accessory Installation 8-130
RF Terminal Mounting 8-132
Security Start Switch Installation 8-134
iPort and iWarehouse Installation 8-136
Outrigger Installation (Contact Technical Support) 8-138
Mechanical Guide Rollers, Installation 8-139
Outrigger Installation (With Wheels) 8-143
Battery Gate Interlocks, Installation 8-145
Cart Latch Installation 8-147
Cart Latch Installation 8-149
Auxiliary Light, Mast Mounted 8-151
iWarehouse RED 8-154
Carriage, Catwalk, Installation 8-156
Catwalk, Chain Installation 8-158
Mechanical Stop, Installation 8-160
Overhead Guard, Plexiglass 8-162
Sidegate Covers 8-164
Terminal Strip Install (On-Board Power Hookup) 8-166
IC Converter, Inverter Installation 8-168
Plug Installation 8-170
SB175 Installation 8-172
SB350 Installation 8-174
Inverter Installation 8-176
Switch, Emergency Power Off, Installation 8-178
Switch, Emergency Power Off, Installation 8-180
Switch Installation 8-182
Battery Spacer, Installation 8-184
©The Raymond Corporation – 1062278 Generated Sep 30, 2015 iv
APPENDIX A Alphabetical Parts Index
APPENDIX B Numerical Parts Index