99729-8C100-04 M

Chapter 4 CONTROLLERS
1. Outline...................................................................................................... 4-1
2. Main Functions........................................................................................ 4-2
2.1 Instrument Panel ..................................................................................................... 4-2
2.2 VCM (Vehicle Control Module)1-M.......................................................................... 4-2
2.3 ECM (Gasoline Engine Control Module) ................................................................. 4-2
2.4 Remote Input/Output Units ...................................................................................... 4-2
2.5 GSE Connector ....................................................................................................... 4-3
3. Service Tool Functions........................................................................... 4-4
3.1 Service Tool Menus................................................................................................. 4-4
3.2 Service Tool Box ..................................................................................................... 4-6
4. Mast Interlock System .......................................................................... 4-19
4.1 Function................................................................................................................. 4-19 4
4.2 VCM1-M Controller, Mast Interlock System Checking Procedure......................... 4-20
4.3 Active Test Inspection Procedure.......................................................................... 4-23
5. Driving Interlock System ...................................................................... 4-26
5.1 Function................................................................................................................. 4-26
5.2 Driving Interlock System Checking Procedure for Powershift T/M Trucks ............ 4-27
5.3 Active Test Inspection Procedure.......................................................................... 4-30
6. Seat Belt Warning Lamp....................................................................... 4-32
6.1 Function................................................................................................................. 4-32
6.2 Seat Belt Warning Lamp Checking Procedure ...................................................... 4-32
7. Parking Brake Warning Buzzer and Lamp.......................................... 4-33
7.1 Function................................................................................................................. 4-33
7.2 Parking Brake Warning Buzzer/Lamp Checking Procedure.................................. 4-34
7.3 Parking Brake Warning Buzzer/Lamp Checking Procedure with Key in
OFF Position.......................................................................................................... 4-36
8. Harness Codes ...................................................................................... 4-37
9. Controller Details .................................................................................. 4-38
9.1 VCM1-M Controller................................................................................................ 4-38
9.2 Seat Switch/Seat Belt Switch ................................................................................ 4-39
9.3 Parking Brake Switch ............................................................................................ 4-39
9.4 Direction Lever ...................................................................................................... 4-39
9.5 Speed Sensor........................................................................................................ 4-40
9.6 T/M Solenoid ......................................................................................................... 4-41
9.7 Unload Solenoid .................................................................................................... 4-41
9.8 Lift Lock Solenoid .................................................................................................. 4-41
9.9 Warning Buzzer ..................................................................................................... 4-43
9.10 Warning Buzzer Relay........................................................................................... 4-43
9.11 Warning Buzzer Circuit.......................................................................................... 4-44
9.12 Instrument Panel ................................................................................................... 4-45
10. Error Codes and Troubleshootings..................................................... 4-46
10.1 Error Code Display ................................................................................................ 4-46
10.2 Diagnosis Table (F Code)...................................................................................... 4-47
10.3 Error Codes and Troubleshooting ......................................................................... 4-61
11. Locations of Sensors and Switches.................................................... 4-71
CONTROLLERS
Chapter 4 CONTROLLERS
1. Outline
The controllers control both the lift truck body and the engine.
Each controller is located as shown below.
Instrument panel
Input unit
VCM-1M
(Vehicle control module)
GSE connector
GLE connector
Output unit
ECM
(Gasoline engine
control module)
217401
4-1
CONTROLLERS
2. Main Functions
Each controller connects into a CAN network, and information is exchanged between controllers via the CAN net-
work. VCM (vehicle control module) controller controls the whole lift truck system, and the other controllers control
relevant components.
FC model
Instrument Input Output

Armrest FC valve
panel unit unit
Direction
lever ECM
Operating
Steering
wheel
VCM-1M
Driving
Lamps
Parking Engine
switch
Instrument
Warning
Seat
215201
Main functions of each controller are as follows:
2.1 Instrument Panel

Instrument panel is located below the steering wheel
and displays the lift truck speed, clock time, and error
codes.
For other functions, refer to the "Chapter 3 ELECTRI-
CAL SYSTEM."
2.2 VCM (Vehicle Control Module)1-M

The VCM controller is located on the right side of the
lift truck and controls the vehicle system (travel/load
interlock, wheel knob deviation correction, etc.)
2.3 ECM (Gasoline Engine Control Module)

The ECM controller is located on the left side of the lift
truck and controls the engine.
Refer to Engine Service Manual for details.
2.4 Remote Input/Output Units

The remote input/output units are installed on the lift
truck, and detect signals from FC lever to control the
FC control valve.
4-2
CONTROLLERS
2.5 GSE Connector

The GSE connector is required to connect the service
tool and the truck. The GSE service tool connector is
located beneath the cup holder on the right side of the
dashboard.
(1) Pick up the cup holder by the rim.
Direction of force
Lift the claw located upper part of cup holder

215204
(2) With the rim of the cup holder raised, push the cup
holder in the direction of the mast.
Direction of force
With claw unhooked, apply force in the direction of mast.

215205
(3) After removing the cup holder, remove the GSE
connector from inside the dash.
GSE connector
215208
4-3
CONTROLLERS
3. Service Tool Functions

3.1 Service Tool Menus
Select functions from the main menu window.
Menu items
Toolbox 214883
(1) File menu (3) Tool menu

Print: allows you to print the screen being dis- Set-up option: allows you to monitor or change
played. setup values.
Exit: allows you to log out. Oscilloscope: allows you to view a graph of input/
(2) View menu output values. The graph data can be stored so
that the graph can be re-displayed by reading the
Input Monitor: allows you to monitor input values.
stored data.
Output Monitor: allows you to monitor output val-
Active Test: Operating conditions can be checked
ues.
automatically with signals being sent out.
Custom Monitor: allows you to monitor customized
Connection change: allows you to change the con-
input/output values.
nection and target controllers.
Fault Status: allows you to monitor the current fault
Firmware Update: allows you to update the firm-
condition.
ware of controller connected.
Fault History: allows you to view past faults.
(4) Communication menu
Setup: allows you to set up communication port,
communication speed and flow control.
4-4
CONTROLLERS
(5) Language menu: allows you to select a language

in the language menu.
(6) Help menu
Contents: allows you to view contents of help
menu.
Topics: allows you to search help topics.
Pop up display: allows you to have a selection of
pop-up display of item name/button name.
Version: allows you to view version information.
4-5
CONTROLLERS
3.2 Service Tool Box

(1) Input Monitor
Monitors input of sensors and switches.
Input monitor button

Monitor window
Description of a monitor item Start recording button Stop recording button Reset values button
214884
Seat Switch Joystick (Tilt 1) status

Seat Switch timer Joystick (Tilt 2) signal [%]
Seat belt Switch Joystick (Tilt 2) status
DC power supply [V] Joystick (ATT1 lever 1) signal [%]
Accel Switch Joystick (ATT1 lever 1) status
Park brake Switch Joystick (ATT1 lever 2) signal [%]
Direction lever F ON/OFF Joystick (ATT1 lever 2) status
Direction lever N ON/OFF Joystick (ATT2 lever 1) signal [%]
Direction lever R ON/OFF Joystick (ATT2 lever 1) status
FNR lever (Forward, Neutral and reverse lever) Joystick (ATT2 lever 2) signal [%]
Joystick (Lift lever 1) signal [%] Joystick (ATT2 lever 2) status
Joystick (Lift lever 1) status 4V-5V changeover Switch
Joystick (Lift lever 2) signal [%] IN-UNIT status(RIO2)
Joystick (Lift lever 2) status Lowering speed Switch ON/OFF
Joystick (Tilt 1) signal [%] Lift operation Switch ON/OFF
4-6
CONTROLLERS
Mast high Switch ON/OFF Handle center Switch ON/OFF

Tilt auto-stop Switch ON/OFF Auto light signal ON/OFF
Tilt operation Switch ON/OFF Coolant low level switch ON/OFF
Tilt angle [V] ON/OFF Air cleaner switch ON/OFF
Weight 0 set Switch ON/OFF Transmission warning switch ON/OFF
Speed [km/h] Fuel warning switch ON/OFF
Speed sensor error [V] Oil temperature switch ON/OFF
Speed limit SW AUX in 2 ON/OFF
Power/Soft mode Switch ON/OFF AUX in 3 ON/OFF
Handle angle [deg] Oil pressure LIFT [Mpa]
Handle angle target [deg] AUX AI [HEX]
Wheel angle [V]
4-7
CONTROLLERS
(2) Output Monitor

Monitors output of sensors and switches.
Output monitor button
214885
Signals monitored are as shown below.

Transmission signal N Solenoid output (Tilt valve) status
Transmission solenoid F Solenoid output (ATT1 valve 1) output [mA]
Transmission solenoid R Solenoid output (ATT1 valve 2) output [mA]
Transmission solenoid current [mA] Solenoid output (ATT1 valve) feedback [mA]
Solenoid output (Lift valve 1) output [mA] Solenoid output (ATT1 valve 1) output
Solenoid output (Lift valve 2) output [mA] Solenoid output (ATT1 valve 2) output
Solenoid output (Lift valve) feedback [mA] Solenoid output (ATT1 valve) status
Solenoid output (Lift valve 1) output Solenoid output (ATT2 valve 1) output [mA]
Solenoid output (Lift valve 2) output Solenoid output (ATT2 valve 2) output [mA]
Solenoid output (Lift valve) status Solenoid output (ATT2 valve) feedback [mA]
Solenoid output (Tilt valve 1) output [mA] Solenoid output (ATT2 valve 1) output
Solenoid output (Tilt valve 2) output [mA] Solenoid output (ATT2 valve 2) output
Solenoid output (Tilt valve) feedback [mA] Solenoid output (ATT2 valve) status
Solenoid output (Tilt valve 1) output Solenoid output (ATT3 valve 1) output [mA]
Solenoid output (Tilt valve 2) output Solenoid output (ATT3 valve 2) output [mA]
4-8
CONTROLLERS
Solenoid output (ATT3 valve) feedback [mA] Tiltlock solenoid feedback [mA]
Solenoid output (ATT3 valve 1) output Parking brake alarm
Solenoid output (ATT3 valve 2) output Over load alarm 1
Solenoid output (ATT3 valve) status Over speed alarm
PWM voltage (RIO1) [V] Angle adjust solenoid
PWM voltage (RIO1) Angle adjust tilt lock current [mA]
OUT-UNIT status (RIO1) Auto light OUT
Unload solenoid AUX out 1
Unload solenoid feedback [mA] AUX out 2
Liftlock solenoid AUX out 3
Liftlock solenoid feedback [mA] Limp home
Tiltlock solenoid
(3) Custom Monitor

On custom monitor screen, the user can select monitor items, and the controller reads the value of the selected
items to display.
Custom monitor button
Reset values button
214886
4-9
CONTROLLERS
To select the items, press the display item edit button,

and when the display item screen that shows various
items is displayed, select items. Selection items Add button
OK button
214887
Items to be added
214888
Added items
214889
4-10
CONTROLLERS
(4) Fault Status

Click the fault status button from the menu or toolbox
Fault status button
to display the fault status monitor screen in the main
window. On the fault status monitor screen, the user
can monitor a current fault condition.
Pressing the troubleshooting manual button in the
lower part of screen brings up the troubleshooting
information for the error codes.
Troubleshooting manual button 214890
214891
214892
4-11
CONTROLLERS
(5) Error history

Click fault history button from the menu or toolbox to read past faults stored in the memory of controller. If the read
is successfully completed, the dialog box displays a "Read successful" message. If not, a "Read error" message is
displaced, and the fault history monitor screen will be displayed in the main windows.
Fault history button
214893
When the read is successful When the read is unsuccessful
Success dialog Error dialog

214894 214895
4-12
CONTROLLERS
(6) Set-up option

Click the set-up option button from the menu or toolbox to display the set-up option screen in the main window. On
the set-up option screen, the current monitor set-up values and other set-up values can be updated.
Set-up option button
214896
4-13
CONTROLLERS
(7) Oscilloscope
Click the oscilloscope button from the menu or toolbox to display the oscilloscope screen in the main window. The
oscilloscope screen shows a graph of the specified input/output values. The user can set up two items (CH1 and
CH2) as input/output values to be expressed in the graph. The time axis of the graph is expressed in seconds. The
user also can store the data of the graph being displayed on the screen, and re-display the graph by reading it from
the memory. The graph screen can be printed out on a printer by clicking the printing screen button. Because the
function of this oscilloscope is simple, there will be some amount of lag in the wave pattern and a margin of error.
For an accurate wave pattern, use a dedicated measuring instrument.
Oscilloscope button
Input/output read
Time axis set-up button
setting button
214897
Time axis setting screen

Channel setting screen
214898 214899
4-14
CONTROLLERS
214900
4-15
CONTROLLERS
(8) Active Test

Click the active test button from the menu or toolbox to display the active test screen in the main window.
In active test, signals are sent out to check the operating condition. The active test screen shows the output signal
names on the left side of screen and the monitor items corresponding to the output signals on the right side of
screen.
Active test button
214901
4-16
CONTROLLERS
(9) Connection change

Click the connection change button from the menu or toolbox to display the connection/target change dialog box.
The user can change the connecting controller and target controller in the connection/target change dialog box. To
change the connection, select the controller to be connected to the cable from the selection box of connection. To
change the target, select an appropriate controller from the selection box of target. After the connection and target
are selected, click OK button. Then the change of connection and target controllers will be executed. Click cancel
button if you like it unchanged.
Connection change button
214902
4-17
CONTROLLERS
(10)Firmware Update
Click the firmware update button from the menu or toolbox to display the firmware update screen. The contents dis-
played vary depending on the controller being connected. On firmware update screen, the user selects software
version of controller that is connected, or the user can select a write software, or conduct update. Firmware can be
updated in a setup mode only. Note that updates are available at any time on the controller without entering the
setup mode.
Firmware update button
214903
4-18
CONTROLLERS
4. Mast Interlock System

4.1 Function
When an operator leaves the operator's seat while the
engine is running, the built-in seat switch is activated
to lock the mast. The mast will not move even if the lift
or the tilt lever is operated.
213488
Instrument panel Operating control lever

Operator Seat
Key switch position Engine Mast interlock
occupancy Lift Tilt
indicator lamp
Seated OFF Not active Not active
(OFF) Stop
Not seated OFF Not active Not active
Seated OFF Lowering only Not active
(ON) Stop
Not seated Blink Not active Not active
Seated OFF Active Active
(START) Running
Not seated Blink Not active Not active
Controller Function
Monitors the seat switch and if the operator is not
seated, locks the lift and tilt motions.
VCM1-M Controller Mast Interlock Function
The VCM1-M controller interrupts electric current sup-
ply to the unload solenoid and the lift lock solenoid if
an operator is not seated.
4-19
CONTROLLERS
4.2 VCM1-M Controller, Mast Interlock System Checking Procedure

Mast Interlock System
(a) Raise the forks high enough to see them from
the operator's seat.
(b) Apply the parking brake and place the direction
lever to the neutral position. Then, with the
engine idling (not depressing the accelerator
pedal), half rise from the operator's seat.
(c) Check that the mast interlock indicator lamp
blinks in a few seconds. Operate the lift lever to
check that the forks do not move up and down.
213489
(d) Operate the tilt lever and make sure that the
mast does not tilt forward or backward.
Make sure that sufficient space is available for the lift

truck to move around and that no one or no obstacle is
around the truck.
VCM1-M Controller, Mast Interlock System Check-

ing Procedure
(1) Connect the service tool to the VCM1-M control-
ler.
(2) Turn the key switch to the ON position and start
the engine.
(3) Display the input monitor screen of the service
tool.
(4) While monitoring the input monitor screen, sit in
the operator's seat and make sure that the seat
switch status and the seat switch timer are ON. 214155
(Fig. 1-1) Fig. 1-1 Input monitor screen
(5) Display the service tool output monitor screen.
When the status of the seat switch timer is ON,
the controller unlocks the mast interlock and turns
the unload output and the lift lock output ON. (Fig.
1-2)
You can operate the mast system under this con-
dition.
Operate the lift lever to check that the forks move
up and down, and operate the tilt lever to check
that the mast tilts forward and backward.
214156
Fig. 1-2 Output monitor screen
4-20
CONTROLLERS
(6) Watching the input monitor screen, leave the

operator's seat and check that the seat switch
turns OFF. (Fig 1-3). A few seconds later the seat-
ing flag will turn OFF due to the seat delay counter
function. (Fig. 1-4)
214157
Fig. 1-3 Input monitor screen
214158
(7) Make sure that the mast interlock indicator lamp
on the instrument panel blinks. (Fig. 1-5)
214159
Fig. 1-5 Instrument panel screen
4-21
CONTROLLERS
(8) The unload solenoid output and the lift lock sole-
noid output turn OFF when the mast interlock sys-
tem activates. (Fig. 1-6)
Under this condition, operate the lift lever to check
that the forks do not move up and down, and
operate the tilt lever to check that the mast does
not tilt forward and backward.
If Seat SW does not indicate ON
Check the seat switch operation and wiring connec-
tions by referring to "Harness codes of section 8",
"VCM1-M controller of section 9.1", and "Seat switch/
Seat belt switch of section 9.2."
If Unload Solenoid does not indicate ON
Check the solenoid output by referring to "Active test
inspection procedure of section 4.3." If the solenoid
output does not turn ON even after the active test 214160
inspection, refer to "Error Codes and Troubleshooting Fig. 1-6 Output monitor screen
of Section 10" and check for the possible causes of the
error code F-75 and F-79.
If Lift Lock Solenoid does not indicate ON
output does not turn ON even after the active test
inspection, refer to "Error Codes and Troubleshooting
error code F-77 and F-79.
4-22
CONTROLLERS
4.3 Active Test Inspection Procedure

(1) Connect the service tool and turn the key switch
to the ON position. (DO NOT start the engine.)
(2) Display the active test screen by pressing the
active test button in the service tool. (Fig. 1-7)
Active test flag Write button
Active test
214168
Fig. 1-7 Active test screen
4-23
CONTROLLERS
(3) Check the box of the active test flag, and press
the write button. (Fig. 1-8) Write button
When the write confirmation dialogue box is dis- Check
played, press the YES button.
214169
Fig. 1-8 Active test check screen
(4) When the write completed dialogue box is dis-
played, press the OK button. (Fig. 1-9)
214171
Fig. 1-9 Write completed check screen
(5) Check the box of the unload solenoid and the lift
lock valve solenoid, and press the write button.
(Fig. 1-10)
Write button
Check
(6) When the write confirmation dialogue box is dis-
played, press the YES button same as item (3)
above, and when the write completed dialogue
box is displayed, press the OK button.
214172
4-24
CONTROLLERS
(7) Press the output monitor button on the service

tool screen, and check the electrical current val-
ues of the unload solenoid and the lift lock valve
solenoid. If the values are not close to 2500 mA, a Check current values
defect is suspected. (Fig. 1-11)
214173
(8) After confirmation, turn the key switch to the OFF
position to terminate the active test. Be sure to
turn the key switch to the OFF position before pro-
ceeding to the next operation.
If a defect is found, refer to "Error Codes and Trou-
bleshooting of Section 10" and check for the possi-
ble causes of the error code F-75, F-77, and F-79.
4-25
CONTROLLERS
5. Driving Interlock System

5.1 Function
Powershift Transmission Driving Interlock System
Your lift truck will drive at creep speed when placing
the direction lever to the forward or reverse position
when the engine is idling (not pressing the accelerator
pedal).
In this condition, when the operator leaves the opera-
No No
tor's seat, the operator presence switch of the seat is Power Power
electrically activated to shift the transmission into the Travel Travel
neutral position (the lever itself remains in the forward
or reverse position), and cut off the engine output to
stop the lift truck. In this case, the parking brake does
213492
not synchronize with the driving interlock so that it is
not automatically applied the moment the interlock is
activated. Depending on the condition of the road
(grade, for example), therefore, the lift truck may be
accelerated, instead of being stopped.
(1) Before operating the lift truck, be sure to check

the driving interlock for function.
(2) This interlock system is provided only for risk
reduction in case of a contingency. Always drive
the lift truck correctly with safety in mind.
(3) To restore the lift truck to its normal driving condi-
tion, sit properly in the operator's seat and
depress the brake pedal to hold the lift truck.
Then, return the direction lever to the neutral posi-
tion once and then shift it back into the forward or
reverse position.
(4) When replacing the operator's seat, be sure to
use a Cat genuine seat with the operator pres-
ence switch.
Controller Function
The controller monitors the seat switch and if the oper-
ator is not seated, automatically locks the shift position
in "Neutral" when the speed is 4 km/h (2.5 mph) or
less.
4-26
CONTROLLERS
5.2 Driving Interlock System Checking Procedure for Powershift T/M Trucks
Travel interlock system (powershift truck)
(1) Slightly lift the forks from the ground.
(2) With the engine idling (not pressing on the accel-
erator pedal), place the direction lever to the for-
ward or reverse position, and then half rise from
the operator's seat.
(3) In a few seconds, the lift truck should stop with the
driving interlock indicator lamp blinking.
(4) To restore the lift truck to its normal driving condi-
tion, sit properly on the operator's seat and press 213489
the brake pedal to stop the lift truck. Place the
direction lever to the neutral position once, and
then shift it back into the forward or reverse posi-
tion.
Be sure to check the driving interlock system on level

and hard ground. On grade or ramp, the lift truck
moves due to its own weight.
Make sure that sufficient space is available for the lift
truck to move around and that no one or no obstacle
is around the truck.
Driving Interlock System Checking Procedure for

Powershift T/M trucks
ler.
the engine.
(3) Open the input monitor screen (VCM1-M) of ser-
vice tool.
(4) While sitting in the operator's seat and monitoring
the input monitor screen, make sure the seat
switch and seat switch timer is ON. (Fig. 2-1)
214176
4-27
CONTROLLERS
(5) Display the output monitor screen of the service

tool (VCM1-M).
(6) Place the direction lever in the FORWARD posi-

tion. Make sure that shift lever (F) Input and T/M
control valve (F) output indicate ON and the T/M
control valve current is around 2000 mA on the
screen. (Fig. 2-2)
214177
Fig. 2-2 Input/output monitor screen
(7) Leave the operator's seat. Check that the seat
switch turns OFF on the input monitor screen and
the seat switch timer turns OFF a few seconds
later with the seat delay counter function. (Fig. 2-3
and Fig. 2-4)
214178
214179
4-28
CONTROLLERS
(8) Make sure that the neutral Indicator lamp (N) on

the instrument panel blinks. Blinking of (N) lamp Blink
means that the driving interlock is activated.
(Fig. 2-5)
214180
(9) When the driving interlock is activated, T/M con-
trol valve (F) output does not indicate ON even if
the status of the direction lever (F) input is ON.
(Fig. 2-6)
(10)To unlock the interlock function, sit on the opera-

tor's seat and return the direction lever to the neu-
tral position. At this time, make sure that the
driving interlock indicator lamp (N) changes from
blink to glow.
214181
Fig. 2-6 Input/output monitor screen
tions by referring to "Harness codes of section 8", the
"VCM1-M controller of section 9.1", and the "Seat
switch/Seat belt switch of section 9.2."
In case of T/M (F)/(R) Solenoid error

output does not turn ON even after the active test
inspection, refer to "Error Codes and Troubleshooting
error code F-85, F-87 and F-89.
In case of the traveling speed and speed sensor

error
Refer to "Error Codes and Troubleshooting of Section
10" and check for the possible causes of the error
code F-17 and F-34.
4-29
CONTROLLERS
5.3 Active Test Inspection Procedure
Active test flag Write button

The active test inspection causes the front wheels to
rotate at a creep speed. Before conducting the active
test inspection, be sure to block or raise the front
wheels to prevent the lift truck from moving.
(1) Connect the service tool and turn the key switch
to the ON position. (DO NOT start the engine.)
(2) Display the active test screen by pressing the

active test button in the service tool. (Fig. 2-7)
Active test
214168
(3) Check the box of the active test flag, and press
the write button. (Fig. 2-8) Write button
Check
214169
played, press the YES button. (Fig. 2-8). When
the write completed dialogue box is displayed,
press the OK button. (Fig. 2-9)
214171
Fig. 2-9 Write completed check screen
4-30
CONTROLLERS
(5) Check the box of either T/M solenoid F or T/M

solenoid R, and press the write button. (Fig. 2-10)

played, press the YES button the same as (4)
above, and when the write completed dialogue
box is displayed, press the OK button to complete
the set-up.
Do not check both boxes of T/M solenoid F or T/M
solenoid R to avoid the controller damage.
214182
(7) Press the output monitor button in the service tool
screen to display the output monitor screen (Fig.
2-11), and make sure that the T/M control valve
current is 2 (A) or around on the screen.
214183
(8) After confirmation, turn the key switch to the OFF
position to terminate the active test. Be sure to
turn the key switch to the OFF position before pro-
ceeding to the next operation.
If a defect is found, refer to "Error Codes and Trou-
bleshooting of Section 10" and check for the possi-
ble causes for error codes F-85, F-87, and F-89.
4-31
CONTROLLERS
6. Seat Belt Warning Lamp

6.1 Function
Seat Belt Warning Lamp
This lamp glows when the seat belt is not worn or not Seat belt warning lamp
buckled properly.
Controller Function
The controller sends a warning signal to the instru-
ment panel if the seat belt is not fastened.
215106
6.2 Seat Belt Warning Lamp Checking Procedure

ler.
the engine.
tool.
(4) Make sure that the seat switch status is ON, on

the input monitor screen when the seat belt is not
worn or not buckled properly. (Fig. 3-1) Also check
that the seat belt warning lamp glows on the
instrument panel. (Fig 3-3)
214187
(5) Make sure that the seat belt switch turns ON on
the input monitor screen and the seat belt warning
lamp on the instrument panel goes out when the
seat belt is properly fastened. (Fig. 3-2)
If Seat belt SW does not indicate ON
Check the seat switch operation and wiring con-
nections by referring to "Harness codes of section
8", the "VCM1-M controller of section 9.1", and the
"Seat switch/Seat belt switch of section 9.2."
Glow
214188
215107
4-32
CONTROLLERS
7. Parking Brake Warning Buzzer and Lamp

7.1 Function
Parking Brake Warning Buzzer and Lamp
(FC Model) Parking brake warning lamp
Whether the engine is stopped or running, leaving the
(Powershift)
operator's seat with the parking brake released acti-
vates the operator presence switch which activates the
warning buzzer.
(1) Before operating the lift truck, be sure to check

the parking brake warning buzzer and the warning
lamp are functioning properly.
217333
(2) The warning buzzer and the warning lamp remind
an operator of locking the parking brake lever
before leaving the lift truck. Be sure to maintain (MC Model)
Parking brake warning lamp
the warning buzzer and the warning lamp so that (Powershift)
they function properly.
(3) When and after parking the lift truck:
Park the lift truck on level and hard ground.
Turn the direction lever to the neutral position.
Lower the forks until the fork tips touch the floor.
Apply the parking brake.
217334
Stop the engine and remove the key.
(4) When replacing the operator's seat with a new
one, be sure to use the Cat genuine seat with an
operator presence switch.
Controller Function
The controller turns the warning buzzer output ON
when the operator is not seated and leaves the park-
ing brake switch released while the key lever is in the
ON position. (the warning buzzer activates.)While the
key switch is in the OFF position, the controller does
not activate since the power to the controller turns
OFF. In this case, the relay circuit causes the warning
buzzer to activate.
4-33
CONTROLLERS
7.2 Parking Brake Warning Buzzer/Lamp Checking Procedure

ler.
the engine. (Leave the parking brake engaged.)
tool.
(4) Sit on the operator's seat and make sure that the
seat switch and the seat switch timer are ON on
the input monitor screen. (Fig. 4-1)
214155
(5) Make sure the parking brake switch turns ON, on
the input monitor screen. (Fig. 4-2) Also check
that the parking brake warning lamp glows on the
instrument panel. (Fig. 4-3)
(6) Release the parking brake and leave the opera-

tor's seat.
214191
Glow
215108
4-34
CONTROLLERS
(7) Make sure that the seat switch and the parking
brake switch turn OFF on the input monitor
screen. (Fig 4-4 and Fig 4-5)
Also check that the parking brake warning lamp
on the instrument panel goes out and the warning
buzzer activates. (Fig. 4-6)
(8) Apply the parking brake. Make sure that the park-
ing brake warning lamp in the instrument panel
glows and the buzzer stops.
214158
214194
Turn off
215109
4-35
CONTROLLERS
7.3 Parking Brake Warning Buzzer/Lamp Checking Procedure with Key in OFF Position
(1) Lock the parking brake and keep it locked. Place
the direction lever to the neutral position, and turn
the key switch to the OFF position to stop the
engine. This turns off the power to the VCM1-M Release
controller and the instrument panel.
(2) Make sure that the parking brake warning buzzer Lock
activates when the parking brake is released.
(This function is not affected by the seat switch
status.)
(3) Make sure that the parking brake warning buzzer
deactivates when the parking brake is shifted to
the locked position. (Fig. 4-7)
214196
Fig 4-7 Parking brake lever
Be sure to park the lift truck on level and hard ground
before checking this function.

If Parking Brake Switch does not indicate ON
If Warning Buzzer does not indicate ON
Check the warning buzzer output by referring to
"Active test inspection procedure of section 4.3." (Fig.
4-8)
If the warning buzzer does not activate even after the
active test inspection, check the wiring connections by
referring to "Harness codes of section 8," the "VCM1-
M controller of section 9.1", "Warning buzzer of section
9.9", "Warning buzzer relay of section 9.10", and the
"Warning buzzer circuit of section 9.11."
214197
4-36
CONTROLLERS
8. Harness Codes
Explanation Wire number Remark
1 Seat Switch 610 0.5 L/Y
2 Seat Belt Switch 609 0.5 G/W
3 Seat Switch GND 966 0.5 B
4 Parking Brake Switch N.O 373 0.5 W/L
5 Parking Brake Switch N.O 349 0.5 L
6 Parking Brake Switch GND 949 0.5 B
9 FNR Direction Lever 1 125 0.5 G/W
10 FNR Direction Lever 2 921 0.5 B
11 FNR Direction Lever 3 611 0.5 BR
12 FNR Direction Lever 4 922 0.5 B
13 FNR Direction Lever 5 461 0.5 L/W
14 Speed Sensor + 702 0.5 G
15 Speed Sensor 703 0.5 G/B
16 Forward Solenoid 670 0.5 W
17 Forward Solenoid RET 672 0.5 R/B
18 Backward Solenoid 671 0.5 Y
19 Backward Solenoid RET 673 0.5 G
20 Unload Solenoid 630 0.5 R/W
21 Unload Solenoid RET 631 0.5 G/W
22 Lift lock Solenoid 628 0.5 L/Y
23 Lift Lock Solenoid RET 629 0.5 G/W
24 Warning Buzzer 371 (625) 0.5 Y
25 Warning Buzzer +12V 370 0.5 G
26 Warning Buzzer Relay Contact a 373 0.5 W/L
27 Warning Buzzer Relay Contact c 371 0.5 Y
28 Warning Buzzer Relay +12V 372 0.5 L/Y
29 Warning Buzzer Relay 0V 906 0.5 B
30 Fuel Gauge FUEL 302 0.5 BR
31 Brake Lamp PKB 349 0.5 L
32 Oil Pressure OIL 342 0.5 W/Y
33 Water Temperature TEMP 301 0.5 Y/R
37 CAN 717 0.5 W/B
38 CAN 718 0.5 L/R
39 12V 300 1.25 Y
Instrument panel
40 ALT 341 0.5 G
41 GND 920 0.5 B
42 Speedometer SP 303 0.5 Y/G
43 Speed alarm RL1 308 0.5 GY
44 Speed alarm RL2 309 0.5 Y/L
45 Continuous Power BAT 360 0.5 W/L
46 Brake Fluid Level Sensor BFS 348 0.5 G
4-37
CONTROLLERS
9. Controller Details
9.1 VCM1-M Controller
VCM1-M CN2
CN1
Controller (Gray connector)
(White connector)
(RIGHT SIDE)
Name plate
214198
Fig. 7-1 Controller location
(1) VCM1-M Controller
VCM CN2 VCM CN1
9 374 343 346 345 642 623 612 609 610 1 9 611 722 723 677 676 1
17 672 671 670 711 710 709 703 702 10 17 664 663 662 708 707 613 10
25 127 603 679 678 700 18 25 975 618 617 616 970 615 600 18
34 156 155 865 242 241 866 26 34 976 625 631 628 630 706 705 704 601 26
213503
Fig. 7-2 Controller code allocation (VCM1-M)
4-38
CONTROLLERS
9.2 Seat Switch/Seat Belt Switch
(White)
610 966 609
Seat belt 610

0.5 L/Y
0.5 B
966
0.5 GW
609
Seat switch
213505
Fig. 7-3 Seat switch
9.3 Parking Brake Switch
Parking brake switch
0.5 W/L
(Release) 373
0.5 B
949
349 0.5 L
(Lock)
(Black)
373 949 349
213506
Fig 7-4 Parking brake switch
9.4 Direction Lever

Direction lever (shift lever)
(White)
921 922
611 125 461

Reverse
Forward
Neutral
0.5 G/W
125
5 4 3 2 1
0.5 B
921
0.5 BR
611
0.5 B
922
0.5 L /W
461
213507
Fig. 7-5 Direction lever switch
4-39
CONTROLLERS
Light switch/
turn signal lever
Direction lever
Front
Light switch/
turn signal switch
Shift change switch
Horn contact
217343
Fig. 7-6 Direction lever
9.5 Speed Sensor

Transmission (Right side)
Speed sensor
0.5 G
702
0.5 G / B
703
(Black)
702 703
Speed sensor
217097
Fig. 7-7 Speed sensor
4-40
CONTROLLERS
9.6 T/M Solenoid
T/M forward/reverse solenoid

T/M solenoid
0.5 W
670
( F)
Forward 0.5 R/B

672
0.5 Y
671
0.5 G
673
(R)
Reverse
671 670
673 672
(Gray)
217098
Fig. 7-8 T/M solenoid
9.7 Unload Solenoid
Unload solenoid
0.5 R/W
630
0.5 G/W
631
630 631
(Black)
213511
Fig. 7-9 Unload solenoid
9.8 Lift Lock Solenoid
Lift lock solenoid
0.5 L/Y
628
0.5 G/W
629
628 629
(Black)
213512
Fig. 7-10 Lift lock solenoid
4-41
CONTROLLERS
Unloading solenoid connector
Lift lock solenoid connector
214200
Fig. 7-11 MC control valve unit (with lift lock valve)
Unload valve Emergency shut-off valve

Unload valve solenoid (lift lock)
solenoid
Tilt valve assembly
(Main relief)
b1 SOL
(PF relief)
b2 SOL b3 SOL
Emergency shut-off valve
Inlet valve (attachment)
assembly Attachment valve assembly
End cover assembly
B2 B3
A2 A3
From
hydraulic tank
(oil intake port) To hydraulic tank
a3 SOL
(oil return port)
(To lift cylinder) a2 SOL
a1 SOL
214201
Fig. 7-12 FC control valve unit
4-42
CONTROLLERS
9.9 Warning Buzzer
Warning buzzer
371 0.5 Y
0.5 G
370
(White) Notice: In VCM controller connector,

370
the line No.371 becomes 625.
371 (branched by harness)
213515
Fig. 7-13 Warning buzzer
9.10 Warning Buzzer Relay
Warning buzzer relay

0.5 W / L
373
0.5 Y
371
0.5 B
906
0.5 L / Y
372
(Black)
(Blue) Relay box 1
200 401 400 906 603 122 902 467
207 371 373 372 208 904 121 460 125
213516
Fig. 7-14 Warning buzzer relay
4-43
CONTROLLERS
9.11 Warning Buzzer Circuit
Fuse box
+ 12 V (Continuous)
5 W/R
115 Key switch (Relay ON with key
5 W/L
116 in ON position)
F13 10A 1.25 L / Y Warning buzzer ( + 12 V )
130
F2 10A 0.85 G Warning buzzer ( + 12 V )
430
Warning buzzer
VCM Controller
371 0.5 Y 625
0.5 G
370
Warning buzzer relay

373 0.5 W / L
371 0.5 Y
372 0.5 L / Y
0.5 B
906 * Buzzer activates with
(0V) parking brake released
Parking brake switch
(Release) and key in OFF position.
373 0.5 W / L
949 0.5 B
0.5 L (To instrument panel) (0V)
349
(Lock)
213517
Fig. 7-15 Warning buzzer circuit
4-44
CONTROLLERS
9.12 Instrument Panel

Torque converter oil temperature Engine oil pressure warning lamp
warning lamp (Powershift) Engine check lamp (Electronic
Multi-purpose warning lamp gasoline engine model)
Battery charge warning lamp Glow pilot lamp (Diesel engine model)
Seat belt warning lamp
Parking brake warning Mast interlock indicator lamp
lamp
Cursor buttons
Main display Enter/display switch button

Water temperature gauge
217364
Fig. 7-16 Instrument panel
GASOLINE ENGINE TRUCK

CAN H
CAN L
TEMP
ALT L
FUEL
GND
GND
OPS
PKB
BFS
BAT
RL1
RL2
IGN
SP
G045
360
348
302
349
342
301
0.5W/B 717
0.5L/R 718
300
341
920
303
308
309
0.5R/W
0.5W/Y
0.5Y/G
0.5Y/R
0.5OR
0.5Y/L
0.5GY
0.5BR
HARNESS M/P
360 301 302 A038

0.5G
0.5Y
0.5B
0.5B
0.5L
349 348 342 A040 A039

(WHITE)
300 341
920 718 717 303 230
(BLACK)
A040
A039
A038
360
348
302
349
342
301
341
920
303
308
309
230
717
718
300
308 309
0.5W/B
0.5L/W
0.5W/L
0.5G/B
0.5Y/G
0.5Y/R
0.5R/B
0.5L/G
0.5Y/B
0.5L/R
0.5Y/L
0.5GY
0.85G
1.25Y
1.25B
0.5G
0.5Y
0.5L
(BLACK)
214875
Fig. 7-17 Instrument panel circuit (gasoline-engine model only)
4-45
CONTROLLERS
10.Error Codes and Troubleshootings

10.1 Error Code Display
Error Code Display
This displays all of the error codes detected by the
VCM.
Troubleshooting
Display the fault status screen by clicking the fault sta-
tus button either from the monitor menu or toolbox.
When the screen is displayed, press the troubleshoot-
ing button on the bottom right of the screen to display
a list of error codes and their descriptions.
Example: Error code 34 (Speed sensor error)

Probable causes
(1) Connector contact bad
(2) Harness bad
(3) Speed sensor bad
(4) Controller bad 215110
Check items
(1) Connector connection check
(2) Harness connection check
(3) Sensor connection check
215111
4-46
CONTROLLERS
10.2 Diagnosis Table (F Code)

10.2.1 Error Code Table
Error descriptions
Diagnosis Lift lever neutral error (F10) Error name and error code
Input signal < 2.3V F10

Error logic
Logic conditions Input signal < 2.7V (with the
conditions
key in ON position)
A
A F F
B
Error occurs with condition A Error occurs with condition A
Recovers automatically when the lever

Recovery Error recovery condition
is placed in neutral.
Action
Turn OFF all solenoid outputs of oper-
Actions to be taken when errors occur
ating functions.
LED blink pattern C See "LED light emitting pattern" on page 4-61.
Diagnosis VCM Memory error (F01)

Logic conditions
EEPROM Sum check value
Controller type unmatched F01
(with the key in ON position)
Recovery Turn on power again.

Action Stop the operation of controller (excluding GSE and CAN communication)
LED blink pattern B
Diagnosis VCM Battery voltage fault (F02)

Logic conditions
Power supply voltage is 7V or less
Power supply voltage is 21V or more F02
(1-second continuity)
Recovery Recovers automatically

Action Turn OFF the all solenoid outputs.
LED blink pattern B
4-47
CONTROLLERS
Diagnosis VCM communication error (F03)

Logic conditions
CAN transmission from VCM1-M is impractical.
F03

Action Error indication only, the operation continues.
LED blink pattern B
Diagnosis ECM communication error (F04)

Logic conditions
CAN receiving from ECM is impractical.
F04

Action Activates with default values of ECM incoming data.
LED blink pattern B
Diagnosis DCM communication error (F05)

Logic conditions
CAN receiving from DCM is impractical.
F05

Action Activates with default values of DCM incoming data.
LED blink pattern B
Diagnosis OCM communication error (F06)

Logic conditions
CAN receiving from OCM is impractical.
F06

Action Activates with default values of OCM incoming data.
LED blink pattern B
Diagnosis MP communication error (F07)

Logic conditions
CAN receiving from instrument panel is impracti-
cal. F07

Action Activates with default values of instrument panel incoming data.
LED blink pattern B
4-48
CONTROLLERS
Diagnosis TMS communication error (F08)

Logic conditions
CAN receiving from TMS is impractical.
F08

Action Activates with default values of TMS incoming data.
LED blink pattern B
Diagnosis Lift lever neutral error (F10)

Logic conditions
Lift lever open angle is 20% or more.
F10
Recovery Recovers automatically when the lever is placed in neutral.

Action Turn OFF the all solenoid outputs of operating functions.
Turn OFF the unload solenoid.
LED blink pattern C
Diagnosis Tilt lever neutral error (F11)

Logic conditions
Tilt lever open angle is 20% or more.
F11

LED blink pattern C
Diagnosis Att1 lever neutral error (F12)

Logic conditions
Att1 lever open angle is 20% or more.
F12

LED blink pattern C

Logic conditions
F13

LED blink pattern C
4-49
CONTROLLERS

Logic conditions
F14

LED blink pattern C
Diagnosis Shift lever error (F16)

Logic conditions
Shift lever overlap input (1800-millisecond continu-
F16
ity)

Action Turn OFF the T/M forward and backward solenoids.
LED blink pattern C
Diagnosis Speed error (F17)

Logic conditions
Speed > 30km/h (400-millisecond continuity) F17

Action With T/M shift lock control, neglect of speed.
Speed of 0km/h is transmitted to other controllers.
LED blink pattern C
Diagnosis Lift lever error (F20)

Logic conditions
CAN receiving abnormal flag from input unit F20

Action Turn OFF the lift solenoid output.
(Before 400-millisecond continuity, set the current command value to 0mA)
LED blink pattern D
Diagnosis Tilt lever error (F22)

Logic conditions

Action Turn OFF the tilt solenoid output.
LED blink pattern D
4-50
CONTROLLERS
Diagnosis Att1 lever error (F24)

Logic conditions

Action Turn OFF the Att1 solenoid output.
LED blink pattern D

Logic conditions

LED blink pattern D

Logic conditions

LED blink pattern D
Diagnosis Joystick lever error (F29)

Logic conditions
Error of both lever signals (primary and secondary) F29

Action Indication only
LED blink pattern D
4-51
CONTROLLERS
Diagnosis Sensor battery error (F31)

Logic conditions
Sensor battery is 2.5V or less
F31
(20-millisecond continuity)

Action Photoelectronic sensor: keeps the status before error occurs.
12V DC power: not considered as an error.
Wheel angle sensor: No knob deviation correction control by not considering as an error.
Tilt angle sensor, Oil pressure sensor [lift]: No tilt auto-stop control by not considering as an error.
Speed sensor: not considered as an error. Speed value is effective. No error detection in current
break, short or leaks of solenoid [unload/lift lock], T/M control valve [F/R], Knob position solenoid/
tilt lock solenoid.
(Solenoid outputs remains the status before error occurs.)
LED blink pattern B
Diagnosis Oil pressure sensor (lift) error (F32)

Logic conditions
Input signal is 0.1V or less
Input signal is 4.9V or more F32

Action No tilt action with the load indication OFF and the tilt auto-stop SW ON.
LED blink pattern D
Diagnosis Speed sensor error (F34)

Logic conditions

Action With T/M shift lock control, neglect of speed.
On the lift trucks with ECM, maximum speed limit value plus 1km/h is transmitted.
On non-electric control engine, 0km/h is transmitted.
LED blink pattern D
Diagnosis Wheel sensor error (F36)

Logic conditions
Input signal is 0.27V or less (10 degrees)
Input signal is 4.72V or more (170 degrees) F36

Action No knob deviation correction control
LED blink pattern D
Diagnosis Wheel sensor error (F38)

Logic conditions

Action No tilt action with the tilt auto-stop ON.
LED blink pattern D
4-52
CONTROLLERS
Diagnosis Steering error (F40)

Logic conditions
Changes continue 2-second to wheel angle sensor
only. F40
Handle (steering wheel) angle sensor input error

Action No knob deviation correction control
LED blink pattern D
Diagnosis RI01 error (F41)

Logic conditions
CAN receiving abnormal flag from output unit F41

LED blink pattern B
Diagnosis RI01 PWM power error (F44)

Logic conditions

LED blink pattern B
Diagnosis RI01 communication error (F45)

Logic conditions
CAN receiving from output unit is impractical.
F45

Action Activates with default values of output unit incoming data.
LED blink pattern B
Diagnosis RI02 error (F46)

Logic conditions

LED blink pattern B
4-53
CONTROLLERS
Diagnosis RI02 communication error (F49)

Logic conditions
CAN receiving from input unit is impractical.
F49

Action Activates with default values of output unit incoming data.
LED blink pattern B
Diagnosis Lift up solenoid error (F50)

Logic conditions

Action Set the lift current command value to 0mA.
LED blink pattern E
Diagnosis Lift down solenoid error (F52)

Logic conditions

LED blink pattern E
Diagnosis Lift solenoid leak (F54)

Logic conditions

Action Set the current command value to 0mA and turn OFF unload solenoid of all operating functions.
LED blink pattern E
Diagnosis Tilt forward solenoid error (F55)

Logic conditions

LED blink pattern E
4-54
CONTROLLERS
Diagnosis Tilt backward solenoid error (F57)

Logic conditions

LED blink pattern E
Diagnosis Tilt solenoid leak (F59)

Logic conditions

LED blink pattern E
Diagnosis Att1A solenoid error (F60)

Logic conditions

Action Set Att1 current command value to 0mA.
LED blink pattern E
Diagnosis Att1B solenoid error (F62)

logic conditions

LED blink pattern E
Diagnosis Att1 solenoid leak (F64)

Logic conditions

LED blink pattern E
4-55
CONTROLLERS

Logic conditions

LED blink pattern E

logic conditions

LED blink pattern E

Logic conditions

LED blink pattern E

Logic conditions

LED blink pattern E

Logic conditions

LED blink pattern E
4-56
CONTROLLERS
Diagnosis Hour meter GAP error (F73)

Logic conditions
Difference of hour meter between instrument panel
F73
and VCM is 24 hours or more
Recovery Using service tool, reset #186 M/P hour meter to zero.
Action Sends zero from VCM as VCM hour meter value.
No overwrite of VCM hour meter.
LED blink pattern E

Logic conditions

LED blink pattern E
Diagnosis Unload solenoid error (F75)

Logic conditions
Current value 160mA (1800-millisecond conti-
nuity) F75
Input signal 2.4A (200-millisecond continuity)

Action Turn OFF the unload solenoid output.
LED blink pattern E
Diagnosis Lift lock valve error (F77)

Logic conditions Current value is 160mA or less
F77
Current value is 3.4A or more
Action Turn OFF the Lift lock valve output.
LED blink pattern E
Diagnosis Unload solenoid leak (F79)

Logic conditions
Current value is 500mA or more with output OFF
F79

LED blink pattern E
4-57
CONTROLLERS
Diagnosis Knob position solenoid error (F80)

Logic conditions Current value is 160mA or less (400-millisecond
continuity)
F80
Current value is 3.54A or more (200-millisecond
continuity)
Action Set knob position solenoid error output to OFF.
LED blink pattern E
Diagnosis VCM tilt lock valve error (F82)

Logic conditions Current value is 160mA or less
F82
Current value is 2.88A or more
Action Set tilt lock valve output to OFF.
LED blink pattern E
Diagnosis Knob position solenoid leak (F84)

Logic conditions
F84

Action Set knob position solenoid error output to OFF.
LED blink pattern E
Diagnosis T/M forward solenoid error (F85)

continuity)
F85
continuity)
Action Turn OFF the T/M forward solenoid output.
LED blink pattern E
Diagnosis T/M backward solenoid error (F87)

continuity)
F87
continuity)
Action Turn OFF the T/M backward solenoid output.
LED blink pattern E
4-58
CONTROLLERS
Diagnosis T/M solenoid leak (F89)

Logic conditions
F89

Action Turn OFF the T/M forward and backward solenoids.
LED blink pattern E
4-59
CONTROLLERS
10.2.2 LED blink pattern

When error codes cannot be identified due to instrument panel failure etc., or due to a VCM1-M communication cir-
cuit problem, GSE cable damage, or no presence of GSE, error codes can be identified, to some extent, by the LED
blink pattern of the VCM1-M controller.
*When checking, place the key switch in the ON position.
LED blink
LED blinking
pattern
Lit 1.2 1.2 (sec.)

A
OFF 1.2 1.2
Lit 1.2 0.3 (sec.)

B
OFF 0.6 2.7
Lit 1.2 0.3 0.3 (sec.)

C
OFF 0.6 0.6 1.8
Lit 1.2 0.3 0.3 0.3 (sec.)

D
OFF 0.6 0.6 0.6 0.9
Lit 1.2 0.3 0.3 0.3 0.3 (sec.)

E
OFF 0.6 0.3 0.3 0.3 0.9
Lit
F
OFF (LED remains in a solid lit state or OFF.)
4-60
CONTROLLERS
10.3 Error Codes and Troubleshooting

Error
Description Probable cause Check item
code
F-01
Memory check error 1. Controller bad
D-51
1. Connector contact bad 1. Connector connection check
F-02
Battery voltage fault 2. Harness bad 2. Harness connection check
D-52
3. Controller bad
F-03
D-53 2. Harness bad 2. Harness connection check
VCM communication error
E-03 3. VCM Controller bad 3. Communication line check
L-03
4. Controller bad
F-04
ECM communication error
E-04 3. ECM Controller bad 3. Communication line check
L-04
4. Controller bad
F-06
OCM communication error 2. Harness bad 2. Harness connection check
S-06
3. OCM Controller bad 3. Communication line check
F-07
MP communication error
E-07 3. Instrument panel bad 3. Communication line check
L-07
4. Controller bad
F-08 1. Connector contact bad 1. Connector connection check
E-08 TMS communication error
P-08 3. TMS Controller bad 3. Communication line check
L-08 4. Controller bad
2. Harness bad 2. Harness connection check
F-10 Lift lever neutral error
3. Lift lever bad 3. Lever connection check
4. Controller bad
F-11 Tilt lever neutral error
3. Tilt lever bad 3. Lever connection check
4. Controller bad
F-12 Att1 lever neutral error
3. Att1 lever bad 3. Lever connection check
4. Controller bad
4. Controller bad
4. Controller bad
4-61
CONTROLLERS
Error
code
F-16 Shift lever error
3. Shift lever bad 3. Shift lever check
4. Controller bad
F-17 Speed error
3. Speed sensor bad 3. Sensor connection check
4. Controller bad
F-20 Lift lever error
3. Lift lever bad 3. Lever connection check
4. Controller bad
F-22 Tilt lever error
3. Tilt lever bad 3. Lever connection check
4. Controller bad
F-24 Att1 lever error
4. Controller bad
4. Controller bad
4. Controller bad
1. Joystick lever bad 1, Check if any other errors is present
(e.g.: F20, F22, F24, F26, F28)
F-29 Joystick lever error
2. Input unit bad 2. Input unit check
1. Wheel sensor bad 1. Wheel sensor check
F-31 Sensor battery error 2. VCM bad 2. VCM check
F-34 Speed sensor error
3. Speed sensor bad 3. Sensor connection check
4. Controller bad
F-36 Wheel sensor error 3. Wheel sensor bad 3. Sensor connection check
4. Joint and link bad 4. Joint and link check
5. Controller bad
4-62
CONTROLLERS
Error
code
1. Connector contact bad 1. Link connection and damage check
2. Connector connection check
F-38 Tilt sensor error 2. Harness bad 3. Harness connection check
3. Tilt sensor bad 4. Sensor connection check
4. Controller bad
F-40 Steering error
3. Wheel sensor bad 3. Sensor connection check
4. Controller bad
F-41 Output unit fault 1. Output unit bad 1. Output unit check
1. Power shortage 1. Battery voltage check
2. Output unit bad 2. Output unit check
F-44 Output unit PWM power error
3. VCM bad 3. VCM check
4. Harness bad 4. Harness check
1. Output unit bad 1. Output unit check
F-45 Output unit communication error 2. VCM bad 2. VCM check
F-46 Input unit fault 1. Input unit bad 1. Input unit check
1. Input unit bad 1. Input unit check
F-49 Input unit communication error 2. VCM bad 2. VCM check
2. Diode bad 2. Diode connection check
F-50 Lift up solenoid error 3. Harness bad 3. Harness connection check
4. Lift UP solenoid error 4. Lift UP sol connection check
5. Controller bad
F-52 Lift down solenoid error 3. Harness bad 3. Harness connection check
4. Lift Down solenoid error 4. Lift Down sol connection check
5. Controller bad
F-54 Lift solenoid leak 3. Harness bad 3. Harness connection check
4. Lift solenoid bad 4. Lift solenoid connection check
5. Controller bad
F-55 Tilt forward solenoid error 3. Harness bad 3. Harness connection check
4. Tilt FW solenoid bad 4. Tilt FW sol connection check
5. Controller bad
F-57 Tilt backward solenoid error 3. Harness bad 3. Harness connection check
4. Tilt BW solenoid bad 4. Tilt BW sol connection check
5. Controller bad
4-63
CONTROLLERS
Error
code
F-59 Tilt solenoid leak 3. Harness bad 3. Harness connection check
4. Tilt solenoid bad 4. Tilt sol connection check
5. Controller bad
F-60 Att1A solenoid error 3. Harness bad 3. Harness connection check
4. Att1A sol bad 4. Att1A sol connection check
5. Controller bad
F-62 Att1B solenoid error 3. Harness bad 3. Harness connection check
4. Att1B sol bad 4. Att1B sol connection check
5. Controller bad
F-64 Att1 solenoid leak 3. Harness bad 3. Harness connection check
4. Att1 sol bad 4. Att1 sol connection check
5. Controller bad
5. Controller bad
F-67 Att2B solenoid error 3. Harness bad 3. Harness connection check
4. Att2B sol bad 4. Att2B sol connection check
5. Controller bad
5. Controller bad
5. Controller bad
F-72 Att3b solenoid error 3. Harness bad 3. Harness connection check
4. Att3B sd bad 4. Att3B sol connection check
5. Controller bad
4-64
CONTROLLERS
Error
code
1. Hour meter time difference between 1. Connect service tool and zero reset
F-73 Hour meter gap error
VCM and instrument panel #197 M/P hour-meter
5. Controller bad
F-75 Unload solenoid error 3. Harness bad 3. Harness connection check
4. Unload solenoid error 4. Unload sol connection check
5. Controller bad
F-77 Lift lock solenoid error 3. Harness bad 3. Harness connection check
4. Lift lock sol bad 4. Lift lock sol connection check
5. Controller bad
F-79 Unload solenoid leak 3. Harness bad 3. Harness connection check
4. Unload solenoid error 4. Unload sol connection check
5. Controller bad
F-80 Knob position solenoid error 3. Harness bad 3. Harness connection check
4. Knob pos sol bad 4. Knob pos sol connection check
5. Controller bad
F-82 Tilt lock solenoid error 3. Harness bad 3. Harness connection check
4. Tilt lock sol bad 4. Tilt sol connection check
5. Controller bad
F-84 Knob position solenoid leak 3. Harness bad 3. Harness connection check
4. Knob pos sol bad 4. Knob pos sol connection check
5. Controller bad
F-85 T/M FW solenoid error 3. Harness bad 3. Harness connection check
4. T/M FW sol bad 4. T/M FW sol connection check
5. Controller bad
4-65
CONTROLLERS
Error
code
F-87 T/M BW solenoid error 3. Harness bad 3. Harness connection check
4. T/M BW sol bad 4. T/M BW sol connection check
5. Controller bad
F-89 T/M solenoid leak 3. Harness bad 3. Harness connection check
4. T/M sol bad 4. T/M sol connection check
5. Controller bad
1. When air flow meter output current of
0.5V or less (break or short) contin-
ues for a length of time while engine
is running.
E-21 Air flow meter fault 2. When air flow meter output current of
4.9V or more (break or short) contin-
ues for a length of time with the
engine stopped (key SW in ON posi-
tion)
1. When water temperature sensor out-
put voltage of 0.06V or less (break or
short) continues for a length of time.
E-22 Water temperature sensor fault
2. When water temperature sensor out-
put voltage of 4.8V or more (break or
short) continues for a length of time.
1. When throttle sensor 2 output voltage
of 0.3V or less (break) continues for a
length of time.
of 4.8V or more (short) continues for
a length of time.
of 0.3V or less (break) continues for a
length of time.
E-23 Throttle sensor fault
of 4.8V or more (short) continues for
a length of time.
5. When throttle min position learning is
abnormally small.
6. When throttle valve closed position
learning is impossible
7. When there is an error on correlation
between throttle sensors 1 and 2.
4-66
CONTROLLERS
Error
code
1. When accelerator sensor 1 output
voltage of 0.15V or less (break) con-
tinues for a length of time.
voltage of 5V or more (short) contin-
ues for a length of time.
E-24 Accelerator sensor fault voltage of 0.15V or less (break) con-
tinues for a length of time
voltage of 5V or more (short) contin-
ues for a length of time.
between accelerator sensors 1 and
2.
1. When O2 sensor output voltage is
higher than the normal voltage (1.4V
E-25 O2 sensor fault or more).
2. When break of O2 sensor signal line
occurs.
1. When O2 sensor heater control volt-
age of 1.2V or less (break or short)
continues for a length of time.
E-26 O2 sensor heater fault
2. When O2 sensor heater control volt-
age of 4.7V or more (short) continues
for a length of time.
1. When POS signal is not detected for
a length of time when the engine
being started or running (during
PHASE signal input).
E-27 POS sensor fault
2. When abnormal POS signal wave is
detected for a length of time when
the engine is running (during PHASE
signal input)
1. When PHASE signal is not detected
for a length of time when the engine
is being started.
2. When PHASE signal is not detected
for a length of time when the engine
E-28 Phase sensor fault
is running (during POS signal input).
3. When abnormal PHASE signal wave
is detected for a length of time when
the engine is running (during POS
signal input)
1. ECCS C/U self shutoff does not acti-
E-29 Self shutdown system fault
vate properly.
1. CPU or circuit of ECCS C/U has
problem.
2. ECCS C/U are not supplied with
E-30 ECCS C/U system fault power.
3. When sensor battery of 5.6V or
more, or 4.6V or less continues for a
length of time.
4-67
CONTROLLERS
Error
code
1. When a short-circuit fault in throttle
motor power system occurs.
2. When a break fault in throttle motor
power system occurs.
3. When a short-circuit fault in throttle
motor signal system.
4. When target throttle valve open angle
is abnormal.
E-31 Throttle control fault
5. When electronic control throttle valve
does not function properly due to
mechanical malfunction.
between target throttle open angle
and actual angle.
2. When overcurrent flows in the throttle
motor control system.
1. When water sensor output voltage of
0.35V or less continues for a length
E-32 Over heat (STEP 1) of time
(when water temperature sensor is
normal).
1. When water sensor output voltage of
0.35V or less continues for a length
E-33 Over heat (STEP 2) of time
(when water temperature sensor is
normal).
1. When there is no generation of igni-
E-34 Ignition system fault tion signal continuously when the
engine is running.
1. When abnormal current is applied to
the LPG injector 1 (within injection
range)
E-35 LPG Injector system fault
2. When abnormal current is applied to
the LPG injector 2 (non injection
range)
1.When a short-circuit of LPG fuel pres-
E-36 Fuel pressure sensor fault
sure sensor occurs.
E-37 LPG fuel temperature sensor fault
1. When a short-circuit of LPG fuel
pressure sensor occurs.
E-38 LPG vaporizer fuel pressure 2. When abnormal rise of LPG fuel
pressure in fuel pipe from LPG VAPO
to injector continues a length of time.
E-39 Mast height switch fault
E-40 Oil pressure sensor fault
1. When break or short-circuit of stop
E-41 Stop lamp switch fault
lamp occurs.
P-03 VCM communication error
3. VCM Controller bad 3. Communication line check
4. Controller bad
P-06 OCM communication error
4-68
CONTROLLERS
Error
code
1. Controller bad
S-01 VCM communication error
2. Setting data bad 2. Setting data check
S-02 OCM battery error
3. Battery voltage decrease 3. Battery check
4. Controller bad
S-03 VCM communication error
3. VCM Controller bad 3. Communication line check
4. Controller bad
S-04 ECM communication error
3. ECM Controller bad 3. Communication line check
4. Controller bad
S-05 DCM communication error
3. ECM Controller bad 3. Communication line check
4. Controller bad
S-06 OCM communication error 2. Harness bad 2. Harness connection check
3. OCM Controller bad 3. Communication line check
S-07 MP communication error
3. Instrument panel bad 3. Communication line check
4. Controller bad
S-08 TMS communication error
3. TMS bad 3. Communication line check
4. Controller bad
S-10 APS1 input error
3. Accelerator position sensor bad 3. Accelerator position sensor check
4. Controller bad
S-11 APS2 input error
4. Controller bad
S-13 APS1/APS2 correlation error
4. Controller bad
S-14 Idle switch error 2. Harness bad 2. Harness connection check
3. Idle switch bad 3. Idle switch check
4-69
CONTROLLERS
Error
code
S-40 Service brake solenoid error
4. Service brake solenoid bad 4. Service brake solenoid connection
check
5. Controller bad
S-41 Service brake solenoid leak error
4. Service brake solenoid bad 4. Service brake solenoid connection
check
5. Controller bad
S-42 Parking brake solenoid error
4. Parking brake solenoid bad 4. Parking brake solenoid connection
check
5. Controller bad
S-43 Parking brake solenoid leak error
4. Parking brake solenoid bad 4. Parking brake solenoid connection
check
5. Controller bad
4-70
CONTROLLERS
11.Locations of Sensors and Switches
Selector switch between fourth Fore-and-aft adjustment

and fifth attachment (optional) stopper knob
Emergency stop button
Up-and-down adjustment
Attachment stopper knob
Lift lever
2 lever
Tilt lever
Attachment 1 lever
VCM-1M
(body right side) FC Lever box
Shift lever
Speed sensor
Shift lever
connector
Shift lever Oil temperature sensor

(for powershift truck) Transmission
(right side)
217100
4-71
CONTROLLERS
Attachment 1B
Tilt, Forward
Lift, Lowering Attachment 2B
Attachment 3B
Tire angle sensor
Attachment 3A
Tilt, Backward Attachment 2A
Lift, Lifting Attachment 1A Rear axle
(right side)
Control valve (for FC truck)
Solenoid valves
Unloading solenoid connector
Lift lock solenoid connector
Control valve
(for MC truck)
213524
4-72
CONTROLLERS
T/M forward/reverse solenoid
Transmission
(for Powershift truck)
217101
Others (option)
Lift pressure sensor and
Sensor name Tilt angle sensor and connector Tiltlock solenoid and connector
connector
Between control valve and tilt Between control valve and lift
Location Tilt cylinder pin
cylinder cylinder
4-73

99729-8C100-04 M

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Chapter 4 CONTROLLERS

Instrument Input Output

Main functions of each controller are as follows:

2.1 Instrument Panel

2.2 VCM (Vehicle Control Module)1-M

2.3 ECM (Gasoline Engine Control Module)

2.4 Remote Input/Output Units

2.5 GSE Connector

Lift the claw located upper part of cup holder

With claw unhooked, apply force in the direction of mast.

3. Service Tool Functions

(1) File menu (3) Tool menu

(5) Language menu: allows you to select a language

3.2 Service Tool Box

Input monitor button

Seat Switch Joystick (Tilt 1) status

Mast high Switch ON/OFF Handle center Switch ON/OFF

(2) Output Monitor

Output monitor button

Signals monitored are as shown below.

(3) Custom Monitor

Custom monitor button

Reset values button

To select the items, press the display item edit button,

(4) Fault Status

Troubleshooting manual button 214890

(5) Error history

Fault history button

When the read is successful When the read is unsuccessful

Success dialog Error dialog

(6) Set-up option

Set-up option button

Time axis setting screen

(8) Active Test

Active test button

(9) Connection change

Connection change button

Firmware update button

4. Mast Interlock System

Instrument panel Operating control lever

4.2 VCM1-M Controller, Mast Interlock System Checking Procedure

Make sure that sufficient space is available for the lift

VCM1-M Controller, Mast Interlock System Check-

(6) Watching the input monitor screen, leave the

4.3 Active Test Inspection Procedure

Active test flag Write button

(7) Press the output monitor button on the service

5. Driving Interlock System

(1) Before operating the lift truck, be sure to check

Be sure to check the driving interlock system on level

Driving Interlock System Checking Procedure for

(5) Display the output monitor screen of the service

(6) Place the direction lever in the FORWARD posi-

(8) Make sure that the neutral Indicator lamp (N) on

(10)To unlock the interlock function, sit on the opera-

In case of T/M (F)/(R) Solenoid error

In case of the traveling speed and speed sensor

5.3 Active Test Inspection Procedure

Active test flag Write button

(2) Display the active test screen by pressing the

(5) Check the box of either T/M solenoid F or T/M

(6) When the write confirmation dialogue box is dis-

6. Seat Belt Warning Lamp