RAYMOND SERVICE INFORMATION

The Raymond Corporation

Corporate Headquarters
P O Box 130
Greene, New York 13778-0130

RSI OPR-18-005A Model

January 7, 2019 5400, 5500, 5600

SUBJECT: New Carriage Control Card

GENERAL A new Carriage Control Card (CCC) has been released. The new CCC, P/N
INFORMATION: 1275051/003, replaces the previous CCC, P/N 1107833/101, due to part
obsolescence. The new CCC requires software to be loaded with FlashWare. The
CCC also incorporates the Auxiliary card (if equipped).

SERVICE 1. Verify that the FlashWare version on your computer is 7.8 or newer.
INFORMATION: 2. Verify that you have the most current software installed on your computer as
listed on the SAP Portal.
3. Using cable 610-809/W7P, connect the computer to the 9-pin RS-232 port on
the Vehicle Manager (VM). Consult FlashWare Help for proper configuration, if
required.
4. Turn the key switch ON.
5. Establish communication with the vehicle using FlashWare.
6. Save the lift truck FlashWare configuration settings.
7. Check the software in the motor controllers. The motor controller software
should be version 12.115 or newer. Update the software versions if they are
older.
8. Cycle the key switch OFF and ON. The lift truck will go through self-test and be
operational. Re-key the lift truck if it does not complete self-test and sound the
horn. This step could take multiple re-keys.
9. Verify continuity between the fuse relay card ground screw and the lift truck
frame using a digital multi meter. Resistance should be less than 0.5 ohm.
10. Install the new CCC following standard Electrostatic Discharge (ESD) precau-
tions.
Note: If the current CCC has a jumper located in PC3, transfer it from the old
CCC to the new card.
Note: If your lift truck is equipped with an auxiliary card, as shown in Figure 1
below, remove it and connect the cables to the new connection points
shown in Figure 2. Use the CCC schematic, Figure 3, for reference.
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 PC3
Auxiliary Card. Not on
all models.

Figure 1 Old Carriage Control Card 1107833/101

PC3

PC20
PC19

Figure 2 New Carriage Control Card 1275051/003

Figure 3 New Carriage Control Card Schematic

11. Make sure the upper right mounting screw is installed and tightened. This screw
provides a ground path through a capacitor to reduce noise.
12. Connect to FlashWare and then click Other Device Software.
13. Select the CCC and then load with the newest software version. Verify the
newest software version using the Model Number Table in the SAP Portal as
reference.

Service>Software>Software Download>Truck and Component

Software>MODEL NUMBER TABLE

14. Cycle the key switch OFF and ON.

®
Raymond is a registered trademark of The Raymond Corporation RSI OPR-18-005A
2018 The Raymond Corporation. D20055193
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 15. Verify that the lift truck FlashWare configuration settings and lift truck hours are
the same as what was saved in step 6.
16. Enter the Learn menu on the lift truck display and perform a control handle
learn.
17. Check the existing GM software version. If the version is older than 3.4, follow
the steps below to update the Guidance Manager firmware.
a. Observe ESD precautions while performing this procedure. Refer to the
Safety section in the applicable maintenance manual.
b. Turn the key switch to OFF and unplug the battery.
c. Unplug the connections, and remove the Wire Guidance manager from
the vehicle.
d. Remove the Filter Card and the original Guidance Manager firmware.
e. Install the new Guidance Manager firmware, P/N 073-802-083/034,
and re-install the Filter Card. Refer to EPROM/Microprocessor Removal/
Replacement section in the applicable maintenance manual.
f. Re-install the Guidance Manager and connections.
g. Connect the battery, and turn the key switch to ON.
h. Follow the steps in the section Learning Wire Frequency: Software Version
3.4 and Up in the applicable maintenance manual.
18. Update the software in the VM to version 9.3 or newer using FlashWare.
19. Test vehicle operation.

®
Raymond is a registered trademark of The Raymond Corporation RSI OPR-18-005A
2018 The Raymond Corporation. D20055193
1306777/001 Page 3 of 6
 Below are new troubleshooting procedures for trucks equipped with an Auxiliary
mast, with a new CCC installed.

Test I41 - Aux Mast Lift Switch S32

This test monitors the state of the auxiliary lift switch (S32). This switch causes the
auxiliary mast to lift. This test displays what the CCC is reading from the switch.

S31 (Aux lift left-hand deadman) must also be pressed during this test. The S31
switch circuit must be functional.

Run Test:

You should see:

Aux Mast Lift Switch Operator Display

Out Off

Pressed On

If results do not match the preceding table, the test has failed. Perform diagnosis
and repair.

Diagnosis and Repair

Action/ (+) (-) Expected Step Step

Step
Meter Setting Lead Lead Results Passed Failed

1 JPC19 PC19-1 PC19-3 6-13V Perform Replace

Disconnected/ Step 2 CCC
DCV

2 JPC19 JPC19-1 JPC19-3 Approx. Replace Perform

Connected/ 0.0V CCC Step 3
DCV/S31 and
S32 Activated

3 S32 Activated/ S32-1 S32-2 0.1 ohm Perform Replace

ohms Step 4 S32

4 ohms S32-2 S31-1 0.1 ohm Perform T/S

Step 5 wiring
from
S31 to
S32

5 S31 Activated/ S31-2 S31-1 0.1 ohm T/S Replace

ohms wiring S31
from
CCC to
S31

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Raymond is a registered trademark of The Raymond Corporation RSI OPR-18-005A
2018 The Raymond Corporation. D20055193
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 Test I42 - Aux Mast Lower Switch S33 (Option)

This test monitors the state of the auxiliary lower switch (S33). This switch causes the
auxiliary mast to lower. This test displays what the CCC is reading from the switch.

Note: Switch S31 (Aux lift left-hand deadman) must also be pressed during this
test. The S31 switch circuit must be functional.

Run Test:

You should see:

Aux Mast Lift Switch Operator Display

Out Off

Pressed On

If results do not match the preceding table, the test has failed. Perform diagnosis
and repair.

Diagnosis and Repair

Action/
(+) (-) Expected Step Step
Step Meter
Lead Lead Results Passed Failed
Setting

1 JPC19 PC19-2 PC19-3 6-13V Perform Replace

Disconnected/ Step 2 CCC
DCV

2 JPC19 JPC19-2 JPC19-3 Approx. Replace Perform

Connected/ CCC Step 3
0.0V
DCV/S31 and
S33 Activated

3 S33 Activated S32-1 S33-2 0.1 ohm Perform Replace

/ohms Step 4 S33

4 ohms S33-1 S31-1 0.1 ohm Perform T/S wiring

Step 5 from S31
to S33

5 S31 Activated S31-2 S31-1 0.1 ohm T/S wiring Replace

/ohms from CCC S31
to S31

®
Raymond is a registered trademark of The Raymond Corporation RSI OPR-18-005A
2018 The Raymond Corporation. D20055193
1306777/001 Page 5 of 6
 Test I44 - Aux Limit Switch S34

This test monitors the state of the auxiliary limit switch (S34). This switch causes the
auxiliary mast to decelerate before reaching the stops. This test displays what the
CCC is reading from the switch.

Run Test:

You should see:

Aux Limit Switch Operator Display

Switch Activated Belw

Switch Not Activated Abve

If results do not match the preceding table, the test has failed. Perform diagnosis
and repair.

Diagnosis and Repair

Action/
(+) (-) Expected Step Step
Step Meter
Lead Lead Results Passed Failed
Setting

1 JPC20 PC20-2 PC20-3 12V Perform Replace

Disconnected/ step 2 CCC
DCV

2 S34/DCV S34-3 S34-1 Perform T/S

step 3 wiring
from S34
to CCC

3 S34/ohms S34-2 S34-1 Switch T/S Replace

Engaged wiring S34
0.1ohm\ from
Disengaged S34-2 to
Open CCC

PARTS Now available through the Parts Distribution Center.

AVAILABILITY:

FILING File this notice in Maintenance Manual 1031794D next to pages 6-88, 6-89, 6-92
INSTRUCTIONS: and 7-82.

®
Raymond is a registered trademark of The Raymond Corporation RSI OPR-18-005A
2018 The Raymond Corporation. D20055193
1306777/001 Page 6 of 6