Operator Compartment

Sensor System
Kit Installation and
Maintenance
Instructions
for EASi Pacer ® Lift Trucks

Models Kit Part Number

R30, R35, R40, R50 1038530

1046225A Issued: 5/24/05

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.

©2005 The Raymond Corporation.

 OCSS Kit Installation/Maintenance Instructions

General
This document provides installation and maintenance instructions for Raymond Operator
Compartment Sensor Systems (OCSS) designed for EASi Pacer Lift Truck applications.

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 X] referenced in the
installation procedure.

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OCSS Kit Installation/Maintenance Instructions

Component Identification

Item 1 - #1037493 Item 2 - #1037677 Item 3 - #1037454 Item 4 - #1037573

Tractor Cover Assy. Fixture Plate Left Sensor Housing Right Sensor Housing
(not included in kit)

Item 5 - #5-004-013 Item 6 - #5-004-014 Item 7 - Item 8 - #1034758/002

Flathead Socket Screw Flathead Socket Screw #114-020-588/001 Sensor/Harness (JPW1)
Qty. 5 Cable Raceway

Item 9 - #1034757/002 Item 10 - Item 11 - Item 12 - #1037771

Sensor/Harness (JPW2) #1034758/012 #1034757/012 Sensor Gasket Qty. 4
Sensor/Harness (JPW3) Sensor/Harness (JPW4)

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Item 13 - #1037455 Item 14 - #1034865 Item 15 - #1036064 Item 16 - #611-088

Left Sensor Cover Right Sensor Cover Main Harness Plastic Anchor Qty. 6

1031429/004

Item 17 - #611-029 Item 18 - Item 19 - #811-861/006 Item 20 - #811-861/016

Strap Qty. 12 #1031429/004 Flexible Latch Qty. 3 in. Flexible Latch Qty. 3 in.
Expander Module

Item 21 - #1036133 Item 22 -#1046226

Vehicle Manager Cable Owner/Operator Manual Information Sheet

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OCSS Kit Installation/Maintenance Instructions

Tools Required
The following tools are required to install this kit:
• Fixture Plate Part Number 1037677
• drill
• 1/4 inch drill bits
• 3/4 inch drill bit
• cutting fluid for lubricating while drilling
• magnetic-based drill press
• thread locking compound P/N 990-536
• assorted Allen wrenches (standard and metric)
• diagonal cutters for trimming cable ties
• center punch
• hammer
• degreaser/surface cleaner
• laptop computer with Flashware (Version 5.5 or higher)
• metal scribe

Installation
Before installation, operate the truck to confirm it is working correctly.

Disassembly
1. Lower the forks completely. Turn the key switch OFF and disconnect the battery connector.
2. Disconnect all of the connectors at the Vehicle Manager.
3. Disconnect the power cables at the motor controllers.
4. Remove the top cover and the steer compartment cover.

Installation
Cover Assembly and Sensor Housings
1. Make sure the surfaces indicated in Figure 1 are free of damage. Surfaces must be smooth to
allow the sensor housings to sit flush to within 1/8 in. (3 mm) of the surface when installed.
Use a large hammer or Port-A-Power to straighten if necessary.

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 OCSS Kit Installation/Maintenance Instructions

Figure 1: Surface Inspection/Preparation

2. Place Tractor Cover Assembly [Item 1] in position per Figure 2 and set it flush to the frame
(resting on top of floor pad). Align the left side with the steer tire opening. Using the Tractor
Cover Assembly as a template, cut the floor pad to allow it to sit flush to the tractor floor.

FLOOR PAD

Figure 2: Cover Assembly Installation

3. Assemble Fixture [Item 2] to the two Sensor Housings [Items 3 & 4] with six Flathead Socket
Screws [Items 5 & 6] as shown in Figure 3. Do not apply thread locking compound.
NOTE: Retain screws for reuse later.

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OCSS Kit Installation/Maintenance Instructions

6 6 4

Figure 3: Fixture Assembly

4. Place the Fixture Assembly on top of the Cover Assembly and align the Left Sensor Housing
[Item 3] edge to the operator compartment opening. See Figure 4. Hold the Cover Assembly and
the Fixture Assembly in place.

DRILL LOCATOR HOLE ALIGN EDGES

DRILL LOCATOR HOLE

1
Figure 4: Fixture Placement

5. Mark the locations of the new holes on the tractor with a center punch. See Figure 4. Scribe a
line around the outside edges of the Cover Assembly and the Sensor Housings.
6. Remove the Cover and Fixture Assemblies from the truck.
7. Drill pilot holes through the tractor frame using a 1/4 in. drill.
NOTE: Due to the hardness of the tractor frame steel, several bits may be necessary if they become
dull.
8. Using a magnetic-based drill press fitted with a 3/4 in. bit, re-drill the holes.
NOTE: A magnetic-based drill press will make the drilling effort more accurate and less tiring.
9. Deburr the holes.

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 OCSS Kit Installation/Maintenance Instructions

10. Sand or grind off the paint in the areas scribed in Step 5 to ensure a good weld.

! CAUTION
If there is any doubt that the beams will properly line up, tack weld the
assemblies in place, install the sensors and test the system. If the system tests
OK, remove the sensors and complete the welding process. If the beams are
NOT properly aligned, reposition the sensor housings.

11. Hold the Cover Assembly in position, ensuring the left edge is flush with the wheel opening.
Weld in place with 0.25 in. fillets. See Figure 5.

.25

.25 .25
.25

Figure 5: Welding Cover Assembly

12. Put the Fixture Assembly back in place. Align as indicated in Figure 4 and weld in place with
0.25 in. fillets. See Figure 6.

.25 .25

.25

.25

Figure 6: Welding Sensor Housings

13. Remove the Fixture Plate.

14. Mask, prime, and paint the Cover Assembly, Sensor Housings and truck frame where the paint
was removed.

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OCSS Kit Installation/Maintenance Instructions

Electrical Components
1. Place the Cable Raceway [Item 7] over the drilled hole (adhesive side toward hole). Mark a line to
cut a 20° angle (approx.) on the end so that the top of the raceway conforms with the slope of
the back cover. Also mark the hole on the taped side of the cable raceway through the drilled
3/4 in. hole. See Figure 7.

20° 7 0.75 IN. DIAMETER

TAPED SIDE

7
Clean surface of tractor frame.

Figure 7: Cable Raceway Preparation

2. Cut off the end of the Cable Raceway where it was marked in the previous step. Drill or cut the
3/4 in. hole also marked in the previous step.
3. Clean the area where the Cable Raceway is to be mounted. Remove the tape from the back of
the cable raceway. Align the 3/4 in. hole in the raceway with the 3/4 in. hole in the truck frame
and press into place.
4. Reconnect the cables to the vehicle manager and motor controllers.
5. Install the Sensor Harnesses [Items 8 thru 11] through the 3/4 in. holes. See Figure 8.

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 OCSS Kit Installation/Maintenance Instructions

8
JPW1 7 JPW2

12

6 14

13 11
JPW4

10 JPW3 12
Figure 8: Sensor Harness Installation

6. Place a Sensor Gasket [Item 12] behind each sensor.

7. Hold the sensors in place and install the Sensor Covers [Items 13 & 14] with six Flathead
Socket Screws [Items 5 & 6].
8. Connect the right side Sensor Harnesses and Main Harness [Item 15] connectors (JPW2 &
JPW3). Route the wires on the right side up through the cable raceway and snap the cover in
place. See Figure 9.
NOTE: The connectors will rest inside the raceway.
9. Continue to route the harness over the top of the operator’s compartment back rest. Gently pry
on the top of the backrest and slide the harness behind the backrest.
10. Connect the left side Sensor Harnesses and Main Harness connectors (JPW1 & JPW4).
11. Route the wires on the left side per Figure 9.

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OCSS Kit Installation/Maintenance Instructions

15 15

16 17

Figure 9: Harness Routing

12. Apply Plastic Cable Anchors [Item 16] to clean truck frame surfaces. Secure the harnesses with
Straps [Item 17]. See Figure 9.
13. Clean the tractor frame where the Expander Module [Item 18] is to be mounted. Install the
Expander Module using the supplied Flexible Latch Fasteners [Items 19 & 20]. See Figure 10.

SEE DETAIL A

21
18
19
20

DETAIL A
ROTATED FOR CLARITY

Figure 10: Expander Module Installation

14. Connect the Main Harness to JPX2 on the Expander Module.

15. Connect the Vehicle Manager Cable [Item 21] to JPX1 on the Expander Module and JPC1 on the
Vehicle Manager.

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 OCSS Kit Installation/Maintenance Instructions

Installation of Software
1. Download software version 5.5 from the iNet.
2. Connect the battery and hook up the laptop to the Vehicle Manager.
3. Using Flashware, flash the truck with version 5.8 software.
4. Enable the OCSS option and save the changes to the truck.
5. Turn the key switch OFF and disconnect the battery connector.

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 an 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 at 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.

Documentation/Manuals
Retain this document with your EASi Pacer Maintenance Manual. Unless otherwise directed, refer
to this document for OCSS troubleshooting, maintenance, and parts information.
An OCSS Owner/Operator Information Sheet [Item 22] 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.
NOTE: French and Spanish versions of the OCSS Owner/Operator Information Sheet will be
provided as necessary.

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

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OCSS Kit Installation/Maintenance Instructions

Troubleshooting

Code 58
Code 58 - Operator Compartment Sensor System CAN
Code Title
Communication Failure

No communication has been received from the OCSS

Reason
controller.

System Response

Alarm Sounds Yes

Operator Display Code 58. Inform Service.

Travel PC Contactor Energized

PC Contactor Energized

Lift (P) Contactor Energized

Performance Limits

Travel System 1 mph speed limit

Auxiliary System No limits

Lift/Lower System No limits

How to Clear Cycle the key switch.

Test I80 - Upper Beam Test

Tests to Run
Test I81 - Lower Beam Test

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 OCSS Kit Installation/Maintenance Instructions

Code 8A
Code Title Code 8A - Operator Compartment Sensor System Failure

Reason The VM senses the beams are ON with the deadman pedal UP.

System Response

Alarm Sounds Yes

Operator Display Code 8A. Inform Service.

Travel PC Contactor Energized

PC Contactor Energized

Lift (P) Contactor Energized

Performance Limits

Travel System 1 mph speed limit

Auxiliary System No limits

Lift/Lower System No limits

How to Clear Cycle the key switch.

Test I80 - Upper Beam Test

Tests to Run
Test I81 - Lower Beam Test

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OCSS Kit Installation/Maintenance Instructions

Test I80 - UPPER BEAM

This test verifies 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:

Deadman Pedal Display

Down ON
Up OFF

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 as follows:

Deadman Pedal
LED Status
Position
Receiver Up or Down Green ON +12V present at RCVR_1
(3 wires) Down Yellow ON Receiver is receiving light beam (properly aligned)
Emitter
Down Green ON +12V present at EMTR_1
(2 wires)

If the LEDs do not illuminate as described above, Troubleshoot (TS) as follows:

Action/ Expected
Step Meter Scale
(+) Lead (–) Lead Results
Step Passed Step Failed

Fault: All LEDS not illuminated

DM down, JPX1
Replace Expander
1 disconnected/ PX1-1 PX1-4 Step 2
Module
Voltage
10.7 – 13V
DM down, JPC1 Replace harness
TS VM (refer to
2 disconnected/ JC1-9 JC1-5 between Expander
Maintenance Manual)
Voltage Module & VM

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 OCSS Kit Installation/Maintenance Instructions

Upper Beam Diagnosis and Repair - continued

Action/ Expected
Step Meter Scale
(+) Lead (–) Lead Results
Step Passed Step Failed

Fault: EMITTER - Green LED not illuminated

DM down, JPW1
Replace Emitter
1 disconnected/ JW1-1 JW1-2 Step 2
harness
Voltage
10.7 – 13V Replace harness
DM down, JPX2
between Expander Replace Expander
2 disconnected/ JX2-4 JX2-9
Module and Emitter Module
Voltage
harness

Fault: RECEIVER - Green LED not illuminated

DM up, JPW2
Replace Receiver
1 disconnected/ JW2-1 JW2-4 Step 2
harness
Voltage
10.7 – 13V Replace harness
DM up, JPX2
between Expander Replace Expander
2 disconnected/ JX2-1 JX2-6
Module and Receiver Module
Voltage
harness

Fault: RECEIVER - Yellow LED not illuminated

Replace harness
JPW2 & JPX2
0 Ohms between Expander
1 disconnected/ JW2-2 PX2-2 Step 2
(continuity) Module and Receiver
Ohms
harness

Make sure Emitter is not obscured (dirty) and is Clean Emitter eye
2 Step 3
aligned properly and/or align properly

JPX2
Replace Receiver Replace Expander
3 disconnected/ JX2-2 JX2-6 10.7 – 13V
harness Module
Voltage

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OCSS Kit Installation/Maintenance Instructions

Test I81 - LOWER BEAM

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:

Deadman Pedal Display

Down ON
Up OFF

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 as follows:

Deadman Pedal
LED Status
Position
Receiver Up or Down Green ON +12V present at RCVR_2
(3 wires) Down Yellow ON Receiver is receiving light beam (properly aligned)
Emitter
Down Green ON +12V present at EMTR_2
(2 wires)

If the LEDs do not illuminate as described above, TroubleShoot (TS) as follows:

Action/ Expected
Step Meter Scale
(+) Lead (–) Lead Results
Step Passed Step Failed

Fault: All LEDS not illuminated

Deadman pedal
down, JPX1 Replace Expander
1 PX1-1 PX1-4 Step 2
disconnected/ Module
Voltage
10.7 – 13V
Deadman pedal
Replace harness
down, JPC1 TS VM (refer to
2 JC1-9 JC1-5 between Expander
disconnected/ Maintenance Manual)
Module & VM
Voltage

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 OCSS Kit Installation/Maintenance Instructions

Lower Beam Diagnosis and Repair - continued

Action/ Expected
Step Meter Scale
(+) Lead (–) Lead Results
Step Passed Step Failed

Fault: EMITTER - Green LED not illuminated

Deadman pedal
down, JPW3 Replace Emitter
1 JW3-1 JW3-2 Step 2
disconnected/ harness
Voltage
10.7 – 13V
Deadman pedal Replace harness
down, JPX2 between Expander Replace Expander
2 JX2-5 JX2-10
disconnected/ Module and Emitter Module
Voltage harness

Fault: RECEIVER - Green LED not illuminated

Deadman pedal
up, JPW4 Replace Receiver
1 JW4-1 JW4-4 Step 2
disconnected/ harness
Voltage
10.7 – 13V
Deadman pedal Replace harness
up, JPX2 between Expander Replace Expander
2 JX2-3 JX2-8
disconnected/ Module and Receiver Module
Voltage harness

Fault: RECEIVER - Yellow LED not illuminated

Replace harness
JPW4 & JPX2
0 Ohms between Expander
1 disconnected/ JW4-3 PX2-7 Step 2
(continuity) Module and Receiver
Ohms
harness

Make sure Emitter is not obscured (dirty) and is Clean Emitter eye
2 Step 3
aligned properly and/or align properly

JPX2
Replace Receiver Replace Expander
3 disconnected/ JX2-7 JX2-8 10.7 – 13V
harness Module
Voltage

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OCSS Kit Installation/Maintenance Instructions

Schematic
10

Figure 11: OCSS Schematic for EASi Pacer

20 1046225A