Operator Compartment

Sensor System
Kit lnstaflation and
Maintenance
Instructions
for EASi ~ e a c h - ~ o Lift
r p Trucks

Models Kit Part Number

EZ-A/B, ET-A thru E 1034355/001
EZ-C/D 1034355/002

1045885A Issued: 6/22/05

If you need assistance with your lift truck, or to order additional copies of this document, contact your local authorized
Raymond Dealer.

To locate your local authorized Raymond Dealer, go to www.raymondcorp.com.

02005 The Raymond Corporation.

 OCSS Kit Installation/Maintenance Instructions

General
This document provides installation and maintenance instructions for Operator Compartment
Sensor Systems (OCSS) designed for Raymond EASi Reach-Fork Lift Truck applications.
There are two different kits applicable to two groups of EASi Reach-Fork Lift Truck models:
Kit P/N 1034355/001 is used for Models EZ-A, EZ-B and ET-A thru E
Kit P/N 1034355/002 is used for Models EZ-C and EZ-D

CAN I/O Expander Modules

The CAN 1/0 Expander Modules provided in each kit look similar, however, they are different. If the
wrong Expander Module is installed, no harm will come to the equipment, however Code 58 will be
displayed.

Painting Housings
If the housings are to be painted a different color, paint them before installation to prevent
contaminating the sensors.

Thread Locking Compound

Unless otherwise directed, apply thread locking compound P/N 990-536 to all threaded fasteners.

Component Identification
Refer to the "Component Identification" section for item numbers [Item XI referenced in the
installation procedure.
OCSS Kit InstaIlation/Maintenance Instructions

Component Identification

Item 16 - $1035912
Lower Left Cover Lower and Upper Right
 OCSS Kit Installation/Maintenance Instructions

-
Item 27 # 1037426 -
Item 28 #I036063
Flexible Latch Qty. 3 in. Cable, EZA/B and Cable, EZ-C/D only
ET-A thru E only
-

-
Item 29 #611-088 Item 30 - #5-015-007 Item 31 - -
Item 32 # 1045886A
Plastic Anchor Qty.4 HexNutM12 Qty.4 #073-205-006/090 Owner/Operator Manual
Firmware, EZ-A/B and Information Sheet
ET-A thru E only
OCSS Kit Installation/Maintenance Instructions

Tools Required
The following tools are required to install the kit.
drill
1/4 inch drill bits
9/16 inch drill bit
cutting fluid for lubricating while drilling
magnetic-based drill press
thread locking compound P/N 990-536
assorted open end and box wrenches
assorted Allen wrenches (standard and metric)
diagonal cutters for trimming cable ties
center punch
hammer
degreaser/surface cleaner
laptop computer with Flashware for Models E Z C / D
laptop computer with DTIC program and f m w a r e provided in the kit [Item 311 for Models
EZ-A/B and ET-A thru E

Installation
Disassembly
1. Turn the key switch OFF and disconnect the battery connector.

Use extreme care when the lift truck is

jacked up. Keep hands and feet clear
while jacking the lift truck. Support the
jacked up lift truck with solid blocks or
stands. DO NOT rely on the jack alone
to support the lift truck.

2. Jack and block the tractor.

3. Unbolt and remove the counterweight from the truck (it will not be reused).
 OCSS Kit Installation/Maintenance Instructions

Drill Upper Housing Mounting Holes

1. Tape the left and right drill templates [Items 1and 21 in position. See Figure 1.

2. Mark the locations of the new holes on the tractor frame with a center punch.
3. Remove the templates and drill pilot holes through the tractor frame using a 1/4 inch drill.
NOTE:Due to the hardness of the tractor frame steel, several bits may be necessary if they become
dull.

A CAUTION
Do not damage the hoses located in the
motor compartment while drilling the left
tractor holes.

4. Using a magnetic-based drill press fitted with a 9/ 16 inch bit, re-drill the 4 holes.
NOTE:A magnetic-based drill press will make the drilling effort more accurate and less tiring.
OCSS Kit Installation/Maintenance Instructions

Installation of Housings
1. Apply thread locking compound on the short threaded end of the studs [Item 31 and thread
them into the backside of the main housing [Item 41 and upper left housing [Item 51. See
Figure 2.
NOTE:Using jam nuts may make tightening the studs easier.
2. Push the cable clamps [Item 71 in the blind holes in the main housing [Item 41. See Figure 2,
Detail A.

Figure 2: New Housing Assembly

3. Install the harness [Item 91 into the main housing using cable ties, but do not tighten. The
harness is installed correctly when the Molex connectors are on the right side of the main
housing when facing the tractor. Verify wire lengths and position excess harness length in the
main housing. See Figure 2 and Figure 3.
NOTE:When the main housing is installed, the connectors pass through the vent slot on the right
side of the tractor.
 OCSS Kit Installation/Maintenance Instructions

Figure 3: Wiring Harness Routing

4. Apply thread locking compound to the studs and carefully install the main housing [Item 41 to
the tractor.

A CAUTION
Do not allow the harness or sensor
wires to get pinched when installing
the main housing.

5. Mate the main housing to the tractor. Install (do not tighten) two M12 hex nuts and washers
[Items 30 and 211.Slide the main housing sideways to obtain proper contact. See Figure 4.

Contact Points

Figure 4: Main Housing Contact Points

OCSS Kit Installation/Maintenance Instructions

6 . Slide the necessary number of shims [Item 101,[Item 111,and [Item 121 down into the center
section of the main housing to fill the gap between the main housing and the tractor frame. See
Figure 5. The shims are different thicknesses to allow adjustment. Item 10 must be installed
first because it is shorter. Secure them with button head socket screws [Item 131.

Figure 5: Shim, Housing, and Sensor installation

7. Tighten the hardware holding the main housing to the tractor.

NOTE: Do not apply thread locking compound to the screws [Item 141 that secure the sensors.
8. Carefully position the lower sensors in their pockets so that the sensor eyes face each other (the
wire will be at the bottom of the sensor in the pocket). Secure them using two socket
buttonhead screws [Item 141.
9. Place the covers (left [Item 151,right [Item 161)over the sensor assemblies and secure them with
two socket flathead screws. The left cover uses [Item 171;the right cover uses [Item 181.
10. Apply thread locking compound to the studs of the left upper housing and prepare to install it
on the tractor.
11. Carefully position the left upper sensor in the left upper housing pocket, making sure you do
not damage the sensor wire.
 OCSS Kit Installation/Maintenance Instructions

12. Install the left upper housing on the tractor with two M12 hex nuts and washers [Items 30 and
211. See Figure 5.
NOTE:Do not apply thread locking compound to the screws [Item 141 that secure the sensors.
13. Secure the left upper sensor using two socket buttonhead screws [Item 141. Place the cover
[Item 191over the sensor and secure with two socket flathead screws [Item 181.
14. Carefully feed the right wiring harness branch through the uppermost vent slot on the tractor,
making sure you do not damage the connectors or the harness.
15. Feed the right upper sensor into the right upper housing pocket while mating the housing to
the tractor.

A CAUTION
Do not pinch the harness between the
upper housing and the tractor when
tightening it.

16. Install the right upper housing to the tractor with two hex head cap screws [Item 201 and flat
washers [Item 211. Make sure the harness is not pinched.
NOTE:Do not apply thread locking compound to the screws [Item 141that secure the sensors.
17. Secure the right upper sensor using two socket buttonhead screws [Item 141. Place the cover
[Item 161 over the sensor and secure with two socket flathead screws [Item 181.

Installation of CAN 1/0 Expander Module

1. Install the expander module ([Item 221 - EZA/B and ET-A thru E. [Item 231 - EZC/D) in the
tractor compartment. See Figure 6 for Models EZ-A/B and ET-A thru E or Figure 7 for Models
EZ-C/D. Secure the expander module with Items 2 4 and 25.
2. Run the cable [27] down to the sensor cable connectors. See Figure 8.
3. Make connections to the sensor cable connectors a s shown in Figure 8. Secure the harness to
the truck using the plastic anchors [29]and cable ties [Item 81.
NOTE:Clean the surface to promote adhesion of plastic anchors.
4. On Models EZ-A, EZ-B and ET-A thru E, route the other expander module cable [Item 261 to
the System Card a t JS9. See Figure 6. On Models EZC/D, route the cable [Item 281 to the
Vehicle Manager a t J C 1. See Figure 7.
OCSS Kit Installation/Maintenance Instructions

I 'I I
VlEW A-A
-
Figure 6: Expander Module Location and Cable EZ-A/B, ETA thru E

VlEW A-B

Figure 7: Expander Module Location and Cable - EZ-C/D

 OCSS Kit Installation/Maintenance Instructions

Figure 8: Cable Connections

Installation of Firmware/Software
Models EZ-A, EZ-B and ET-Athru E
Remove old firmware. Install new firmware [Item 311.Refer to "Firmware Replacement" in the
Component Procedures section of Maintenance Manual PDMM-0080.
NOTE:Firmware P/N 073-205-006/090 [Item 311 is intended for trucks equipped with the OCSS
only.
Models EZ-C/D
Download the new software version from the iNet.

Test System
Connect the battery connector and turn the key switch ON. Check truck for proper operation:
With the sensors obstructed and the truck at rest with the deadman pedal depressed, the
message "Entrance Beam Blocked" should be displayed and a n alarm tone should sound.
Moving the control handle should cause the truck to travel 1 mph.
When the sensor obstruction is cleared, the truck will travel at the reduced speed until the
control handle is moved to neutral and the truck comes to a complete stop. When the operator
attempts to travel again, the truck should then travel a t requested speed.
If the truck is traveling and the sensor beam becomes obstructed, the truck should plug to a
stop, the message "Entrance Beam Blocked" should be displayed and an alarm tone should
sound.
When the sensor obstruction is cleared and the control handle is returned to neutral and the
truck comes to a complete stop, the truck should then travel at requested speed.
OCSS Kit Installation/Maintenance Instructions

Retain this document with the applicable Maintenance Manual for the truck that the system was
installed on. Unless otherwise directed, refer to this document for OCSS troubleshooting,
maintenance, and parts information. -
An OCSS Owner/Operator Information Sheet [Item 321 is provided with each kit. For convenience,
it can be kept in the Owner/Operator Manual of the truck that the system was installed on.

Maintenance
Periodically clean sensor eyes with a cotton-tipped swab.

Troubleshooting

Code 58
Comparl
Code Tit
ommunication Failure
nication has been received from the OCSS
Reason

-
AlarmL Sounds
Opera
1 PC Conlractor

,,,dntactor
Lift (E
- -
erformance Limits

stem

Test I15 - Lower Beam Test (EZA/B and ET-A thru E)

 OCSS Kit Installation/Maintenance Instructions

Code 8A
-
Code Title -
Code 8A Operator compartment Sensor System Failure
Rea The V?A senses the beams are ON with the deadman pedal UP.
-
S Y S Lnespunsr:
~ ~
-
A

P Yes
-
Dis
GVGLULUL Code 8A. Inform Service.
-
'1 :Contactor Energized
-
Eu uu..la Energized
-
I Energized
-
Performance Limits
-
'I 1 mph speed limit
-
Auxiliary System No limits
-
I No limits
-
How to clea Cycle the key switch.
-
Test I14 - Upper Beam Test (EZ-A/B and ET-A thru E)
Test I80 - Upper Beam Test (EZ-C/D)
Tesrs ro xu
Test I15 - Lower Beam Test (EZ-A/B and ET-A thru E)
C
Test I81 - Lower Beam Test (EZ-C/D)
OCSS Kit lnstaIlation/Maintenance Instructions

UPPER BEAM TESTS

-
Test 114 EZ-A/B and ET-A thru E
Test 180 - EZ-C/D
This test veflies the upper beam is working properly.
NOTE:
This test must be run in Maintenance Mode. Refer to "Using Maintenance Mode" in the
Maintenance Manual.

Run Test
Make sure the beam is not blocked. The Operator Display shows the state of the beam:

Pedal
Down

If results do not match the preceding table, the test has failed. Perform Diagnosis and Repair.

Diagnosis and Repair

Remove sensor housing covers. Turn key switch ON and verify LEDs are illuminated a s follows:

Deadman Pedal
LED Status
Position *i9 .
,. x "57 y 1 cu
%

Receiver Up or Down Green ON + 12V present a t RCVR- 1

(3 wires) Down Yellow ON Receiver is receiving light beam (properly aligned)
Emitter
(2 wires)
Down Green ON + 12V present a t EMTR-1

If the LEDs do not illuminate a s described above, Troubleshoot US] a s follows:

PI
Action/
Met:er Scale I ' .'sad (-1 Lead
I ~bected I Step Pa - ep Failc '
'

-
FadIt: All LEDS noLilluminat
I
DM down, JPXl
Replace Expander
1 disconnected/ PX1-1 PXl-4 Step
Module
Voltage
- 13V Replace harness
DM down, JPS9 TS VM/Syston Card
2 disconnected/ JS9-9 JS9-8 Expander (refer to Maintenance
Module & System
Voltage
Card/VM
 OCSS Kit Installation/Maintenance Instructions

Upper Beam Diagnosis and Repair continued -

Meter Sicale I'
IR1
-
Fault: EMITTER Green LED not
r
ated

DM down. JPX2

Fault: R I LED nc

Replace Receiver

Clean Emitter eye

OCSS Kit Installation/Maintenance Instructions

LOWER BEAM TESTS

-
Test 115 EZ-A/B and ET-A thru E
Test I81 EZ-C/D -
This test verifies the lower beam is working properly.
NOTE:This test must be run in Maintenance Mode. Refer to "Using Maintenance Mode" in the
Maintenance Manual.

Run Test
Make sure the beam is not blocked. The Operator Display shows the state of the beam:

Pedal

If results do not match the preceding table, the test has failed. Perform Diagnosis and Repair.

Diagnosis and Repair

Remove sensor housing covers. Turn key switch ON and verify LEDs are illuminated a s follows:

Deadman Pedal
LED Status
Position
Receiver Up or Down Green ON + 12V present at RCVR-2
(3wires) Down Yellow ON Receiver is receiving light beam (properly aligned)
Emitter
(2 wires)
Down Green ON +12V present at EMTR-2

If the LEDs do not illuminate a s described above. Troubleshoot (TS) as follows:

Step
<- 5
Action/
(+) Lead (-) Lead
Expected I Step P a - - - * "tep Faill- '
M, ter Scale,
- I
Fau CDS not !Uluminated
I
Deadman pedal
down, JPXl Replace Expander
PX1-1 PX1-4 Step 2,
disconnected/ Module
Voltage
10.7 - 13V
Deadman pedal harness
TS VM/System Card
down. JPS9 Expander
JS9-9 JS9-8 (refer to Maintenance
disconnected/ Module & System
Voltage Card/VM
 OCSS Kit Installation/Maintenance Instructions

-
Lower Beam Diagnosis and Repair continued

Meter Sicale I'

- Green LED not

Replace Receiver

Replace Expander

JPW4 & JPX2

between Expander
Module and Receiver

I
OCSS Kit Installation/Maintenance Instructions

Schematics

CAN 110 EXPANDER I

MODULE

Ill - -
PHOTO BEAM UPPER
,
,
' I
+ I 2 VP
DOUT-0

+ I 2 VP
H
DOUT- I

DIN-I
+ I 2 VP
DGND

DIN-0
+ I 2 VP
DGND

Figure 9: Models EZ-A, EZ-8 and ETA fhru E

C A N 110 E X P A N D E R
MODULE
RCVR- I
+ I 2 VP

DOUT-0
PHOTO BEAM UPPER
RCVR-2
H

PHOTO BEAM LOWER

j\PW4-3 JPX2-7
DIN-I
JeW4-I JpX2-3
+ , 2 vp
J\PW4-4 JP'X2-8
DGND

J>PW2-2 JPX2-2
DIN-O
J\PW2-I JPX2-I
+12VP
JPW24 JX2-6
>& DGND

Figure 10: Models EZ-C and EZ-D