6M100 MH99719 6m100contl

Chapter 4 CONTROLLERS
1. Outline...................................................................................................... 4-1
2. Main Functions........................................................................................ 4-2
2.1 Instrument Panel ..................................................................................................... 4-3
2.2 VCM (Vehicle Control Module)-1M.......................................................................... 4-3
2.3 ECM (Gasoline Engine Control Module) ................................................................. 4-3
2.4 DCM (Diesel Engine Control Module) ..................................................................... 4-3
2.5 Remote Input/Output Units ...................................................................................... 4-3
2.6 GSE Connector ....................................................................................................... 4-4
3. Service Tool Functions........................................................................... 4-5
3.1 Service Tool Menus................................................................................................. 4-5
3.2 Service Tool Box ..................................................................................................... 4-7
4. Mast Interlock System .......................................................................... 4-18
4.1 Function................................................................................................................. 4-18
4
4.2 VCM-1M Controller, Mast Interlock System Checking Procedure......................... 4-19
4.3 Active Test Inspection Procedure.......................................................................... 4-22
5. Powershift Transmission Driving Interlock System .......................... 4-25
5.1 Function................................................................................................................. 4-25
5.2 Driving Interlock System Checking Procedure for Powershift T/M Trucks ............ 4-26
5.3 Active Test Inspection Procedure.......................................................................... 4-29
6. Seat Belt Warning Lamp....................................................................... 4-31
6.1 Function................................................................................................................. 4-31
6.2 Seat Belt Warning Lamp Checking Procedure ...................................................... 4-31
7. Parking Brake Warning Buzzer and Lamp.......................................... 4-32
7.1 Function................................................................................................................. 4-32
7.2 Parking Brake Warning Buzzer/Lamp Checking Procedure.................................. 4-33
7.3 Parking Brake Warning Buzzer/Lamp Checking Procedure
with Key in OFF Position ....................................................................................... 4-35
8. Harness Codes ...................................................................................... 4-36
9. Controller Details .................................................................................. 4-37
9.1 VCM-1M Controller................................................................................................ 4-37
9.2 Seat Switch/Seat Belt Switch ................................................................................ 4-38
9.3 Parking Brake Switch ............................................................................................ 4-38
9.4 Direction Lever ...................................................................................................... 4-38
9.5 Speed Sensor........................................................................................................ 4-39
9.6 T/M Solenoid ......................................................................................................... 4-40
9.7 Unload Solenoid .................................................................................................... 4-40
9.8 Lift Lock Solenoid .................................................................................................. 4-40
9.9 Warning Buzzer ..................................................................................................... 4-42
9.10 Warning Buzzer Relay........................................................................................... 4-42
9.11 Warning Buzzer Circuit.......................................................................................... 4-43
9.12 Instrument Panel ................................................................................................... 4-43
10. Error Codes and Troubleshootings..................................................... 4-45
10.1 Error Code Display ................................................................................................ 4-45
10.2 Troubleshooting..................................................................................................... 4-46
10.3 Diagnosis Table (F Code)...................................................................................... 4-46
10.4 Error Codes and Troubleshooting ......................................................................... 4-59
11. Locations of Sensors and Switches.................................................... 4-70
CONTROLLERS
Chapter 4 CONTROLLERS
1. Outline
The controllers control the lift truck body and engine.
Controllers are located as shown below.
Instrument panel
Input unit
VCM-1M
(Vehicle control module)
GSE connector
Consult connector
ECM
(Gasoline engine
Output unit control module)
QGS controller
(Diesel truck only) DCM
(Diesel engine
control module)
213486
4-1
CONTROLLERS
2. Main Functions
The controllers connected by a CAN network pass
information between controllers via the network. The
VCM (vehicle control module) controller controls the
vehicle system, and other controllers control the rele-
vant components.
FC model
Instrument Input Output

Armrest FC valve
panel unit unit
Direction HYD ECM / DCM

lever Operating
Lamps VCM-1M Driving
Instrument Parking
switch Engine
Seat Warning
215201
4-2
CONTROLLERS
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.
Refer to “Chapter 3 ELECTRICAL SYSTEM” for other
functions.
2.2 VCM (Vehicle Control Module)-1M

The VCM controller is located at the right side of the
truck body 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 at the left side of the
truck body and controls the engine.
Refer to Engine Service Manual for details.
2.4 DCM (Diesel Engine Control Module)

The DCM controller is located at the left side of the
truck body and controls the diesel engine.
2.5 Remote Input/Output Units

The remote input/output units are installed on the
truck, and detect signals from FC lever to control the
FC control valve.
4-3
CONTROLLERS
2.6 GSE Connector

The GSE connector is required to connect the service
tool and the truck. The GSE connector is located
below the cup holder on the right side of dashboard.
(1) Handpick the upper peripheral rim of cup holder
as shown.
Direction of force
Lift the claw located upper part of cup holder

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

215205
(3) Remove the cup holder, and remove the GSE
connector inside.
GSE connector
215208
4-4
CONTROLLERS
3. Service Tool Functions

3.1 Service Tool Menus
Various functions are displayed in the main menu window.
Menu items
Toolbox 214883
(1) File menu (3) Tool menu

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

in the language menu.
(6) Help menu
Contents: Contents of help menu are displayed.
Topics: This is used to search help topics.
Pop up display: Pop up display of item/button for
screen display.
Version: Version information is displayed.
4-6
CONTROLLERS
3.2 Service Tool Box

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

Monitor window
Discription 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) signal [%]
Accel Switch Joystick (ATT1 lever 1) status
Park brake Switch Joystick (ATT1 lever 1) 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
4-7
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]
4-8
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]
4-9
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
4-10
CONTROLLERS
To select the items, press the display item edit button,

and when the display item screen shows the various
items that are displayed, select items. Hide items Add to show button
OK button
214887
Items to add
214888
Added items
214889
4-11
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 the screen brings up the troubleshooting
information for the error codes.
Troubleshooting manual button 214890
214891
214892
4-12
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 “Read successful” message. If not, “Read error” message is dis-
placed, 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
4-13
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
4-14
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
Setting buttion of time axis
read setting button
214897
Time axis setting screen

Channel setting screen
214898 214899
4-15
CONTROLLERS
214900
4-16
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
4-17
CONTROLLERS
4. Mast Interlock System

4.1 Function
When the 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/
tilt lever is operated.
213488
Instrument panel Operating control lever

Key position of key
Engine Operator Seat Mast interlock
switch 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.
VCM-1M Controller Mast Interlock Function
Interrupts electric current supply to the unload sole-
noid and the lift lock solenoid when the operator is not
seated.
4-18
CONTROLLERS
4.2 VCM-1M 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 to make sure that the mast interlock
indicator lamp is blinking in a few seconds.
Operate the lift lever and make sure that the
213489
fork does not move up and down.
(d) Operate the tilt lever and make sure that the
mast does not tilt forward or backward.
Make sure that nobody is around the lift truck.

VCM-1M Controller, Mast Interlock System Check-
ing Procedure
(1) Connect the service tool to VCM-1M.
(2) Turn the key to the ON position and start the
engine.
(3) Open the service tool input monitor screen.
(4) Sit in the operator's seat and make sure that the
status of seat switch and seat switch timer is ON
in the input monitor screen.
214155
Fig. 1-1 Input monitor screen
(5) Display the output monitor screen from the ser-
vice tool. When the status of Seat Switch timer is
ON, the controller releases the mast interlock and
turns unload output and lift lock output ON. (Fig.
1-2)
The normal lifting and tilting operation can be con-
ducted in this stage.
Check the fork for up and down movement with the
lift lever. Check the mast for forward/backward tilt-
ing with the tilt lever.
214156
Fig. 1-2 Output monitor screen
4-19
CONTROLLERS
(6) Leave the operator's seat. Make sure that seat

switch has turned OFF (Fig 1-3). And then, by the
function of the seat delay counter, Seat switch
timer turns OFF in a few seconds after seat switch
indicates OFF. (Fig. 1-4)
214157
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
4-20
CONTROLLERS
(8) When the mast interlock is activated, the status of

unload output and lift lock output indicates
OFF.(Fig. 1-6)
Move the lift and tilt lever to check that the fork will
not move up and down and the mast will not tilt
forward/backward.
If Seat SW does not indicate ON
Check seat SW for operation, wiring, etc. according to
“Harness codes” of section 8, “VCM-1M controller” of
section 9.1, and “Seat switch/Seat belt switch” of sec-
tion 9.2.
If Unload Solenoid does not indicate ON

Check the solenoid output according to “Active test
inspection procedure” of section 4.3.
If the solenoid still does not indicate ON after active 214160
test inspection, see “Error codes and Fig. 1-6 Output monitor screen
troubleshootings” of section 10 and check the possible
cause of F-75 and F-79.
If Lift Lock Solenoid does not indicate ON

inspection procedure” of Section 4.3.
If the solenoid still does not indicate ON after active
test inspection, see “Error codes and
troubleshootings” of Section 10 and check the possible
cause of F-77 and F-79.
4-21
CONTROLLERS
4.3 Active Test Inspection Procedure

(1) Connect the service tool and turn the key to the (2) Press the active test button in the service tool
ON position. screen to display the active test screen. (Fig. 1-7)
(DO NOT start the engine.)
Active test flag Write button
Active test
214168
Fig. 1-7 Active test screen
4-22
CONTROLLERS
(3) Put a check mark in the check box of the active

test flag, and press “Write.” (Fig. 1-8) When the Write button
write validity check box is displayed, check “YES.” Check
214169
Fig. 1-8 Active test check screen
(4) Check “OK” when the write completed check box
is displayed. (Fig. 1-9)
214171
Fig. 1-9 Write completed check screen
(5) Put check marks in the check boxes of the unload
solenoid and lift lock valve solenoid, and press
“Write.” (Fig. 1-10)
Write button
Check
(6) Same as above (3), check “YES” when the write
validity check box is displayed, and check “OK”
when the write completed check box is displayed.
214172
4-23
CONTROLLERS
(7) Press the output monitor button in the service tool

screen, and verify the current values of unload
solenoid and lift lock valve solenoid outputs on the
screen. If the values are not 2500 mA or around, cheak current
there is a possibility of error.
214173
(8) After the verification, return the key to OFF posi-
tion to release the active test. (Be sure to turn the
key to the OFF position whenever proceeding with
next procedure.)
If there is an error, see “Error Codes and
Troubleshootings” of Section 10 and check each
item listed as possible causes of trouble of F-75, F-
77 and F-79.
4-24
CONTROLLERS
5. Powershift Transmission 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
Travel Power
electrically activated to shift the forward or reverse Travel
position into the 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
213492
parking brake does 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 con-
dition, 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
position once and then shift it back into the for-
ward or reverse position.
(4) When replacing the operator's seat, be sure to
use Cat genuine seat with operator present
switch.
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 or less.
4-25
CONTROLLERS
5.2 Driving Interlock System Checking Procedure for Powershift T/M Trucks
Travel interlock system (powershift truck)
(1) Raise the forks slightly from the floor.
(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 in the operator's seat and 213489
depress the brake pedal to hold the lift truck.
Return the direction lever to the neutral position,
then place the lever to the forward or reverse
position.
Be sure to check this system on level and hard sur-

face.
Do not park the truck on a grade, in order to prevent
it from traveling by itself.
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
(1) Connect the service tool to VCM-1M controller.
(2) Turn the key in ON position and start the engine.
(3) Open the input monitor screen (VCM-1M) of ser-
vice tool.
(4) Sit in the operator's seat and make sure that the
status of the seat switch and seat switch timer is
ON in the service tool screen. (Fig. 2-1)
214176
4-26
CONTROLLERS
(5) Display the output monitor screen (VCM-1M) from

the service tool.
(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 2000mA or around on the
screen. (Fig. 2-2)
214177
Fig. 2-2 Input/output monitor screen
(7) Leave the operator's seat. Make sure that seat
switch is turned OFF. Then, by the function of the
seat delay counter, Seating flag turns OFF in a
few seconds after seat switch indicates OFF.
(Fig. 2-3 and Fig 2-4)
214178
214179
4-27
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 release the interlock status, sit on the opera-

tor's seat and place the direction lever in the Neu-
tral position. Make sure that the status of traveling
interlock indicator (N) lamp has changed from
blink to glow.
214181
Fig. 2-6 Input/output monitor screen
Check seat SW for operation, wiring, etc. according to
“Harness codes” of section 8, “VCM-1M controller” of
section 9.1, and “Seat switch/Seat belt switch” of sec-
tion 9.2.
In case of T/M (F)/(R) Solenoid error

inspection procedure” of section 5.3.
If the solenoid still does not turn ON after active test
inspection, see “Error codes and troubleshootings” of
section 10 and check each item listed as possible
causes of trouble of F-85, F-87 and F-89.
In case of the traveling speed and speed sensor

error
See “Error codes and troubleshootings” of section 10
and check each item listed as possible causes of trou-
ble of F-17 and F-34.
4-28
CONTROLLERS
5.3 Active Test Inspection Procedure
Active test flag Write button

The active test inspection procedure causes the front
wheels to rotate and the lift truck starts to travel at
extremely low speed. To prevent this, block or raise
the front wheels.
(1) Connect the service tool and turn the key to the
ON position. (DO NOT start the engine.)
(2) Press the active test button in the service tool

screen to display the active test screen. (Fig. 2-7)
Active test
214168
(3) Put a check mark in the check box of the active
test flag, and press “Write.” (Fig. 2-8) Write button
Check
214169
(4) When the write validity check box is displayed,
check “YES” (Fig. 2-8), and check “OK” when the
write completed check box is displayed. (Fig. 2-9)
214171
Fig. 2-9 Write completed check screen
4-29
CONTROLLERS
(5) Put a check mark in the check box in the T/M (F)
or T/M (R) solenoid, and press “Write.” (Fig. 2-10)
(6) Same as above (4), check “YES” when the write

validity check box is displayed, and check “OK”
when the write completed check box is displayed.
Do not check ON for both Forward and Backward
statuses at the same time to avoid the risk of dam-
aging the controller.
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 the verification, return the key to OFF posi-
tion to release the active test. (Be sure to turn the
key to the OFF position whenever proceeding with
next procedure.)
If there is a error, see “Error codes and
troubleshootings” of section 10 and check each
item listed as possible causes of trouble of F-85, F-
87 and F-89.
4-30
CONTROLLERS
6. Seat Belt Warning Lamp

6.1 Function
Seat Belt Warning Lamp
Glows when the seat belt is not worn or when the seat Seat belt warning lamp
belt is not properly buckled.
Sends the warning signal to the instrument panel if the
seat belt is not worn.
215106
6.2 Seat Belt Warning Lamp Checking Procedure


engine.
(3) Display the input monitor screen from service tool.
(4) Make sure that Seat Belt Switch indicates OFF

when the seat belt is not worn or the seat belt
buckle is not properly inserted (Fig 3-1). Also
check that the seat belt warning lamp glows. (Fig.
3-3)
214187
(5) Check that the Seat Belt Switch turns ON and the
seat belt warning lamp on the instrument panel
goes out when the seat belt is correctly buckled.
If Seat belt SW does not indicate ON
Check seat belt SW for operation, wiring, etc.
according to “Harness codes” of section 8, “VCM-
1M controller” of section 9.1, and “Seat switch/seat
belt switch” of section 9.2.
Glow
214188
215107
4-31
CONTROLLERS
7. Parking Brake Warning Buzzer and Lamp

7.1 Function
Parking Brake Warning Buzzer and Lamp
(Manual) Parking brake warning lamp
Whether the engine is stopped or running, leaving the
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 lamp for
function.
(2) The buzzer and warning lamp are for reminding 213497
the operator to apply the parking brake when
leaving the lift truck. Be sure to maintain warning (Powershift)
buzzer and lamp so that they are always in Parking brake warning lamp
order.
(3) When and after parking the lift truck:
Park the lift truck in a place with level and hard
surface.
Turn the direction lever to the neutral position.
Lower the forks until the fork tips touch the floor.
Apply the parking brake. 213498
Stop the engine and remove the key.
(4) When replacing the operator's seat, be sure to
use Cat genuine seat with operator presence
switch.
Send warning signal to activate the buzzer when the
operator is not seated in the seat with the parking
brake released and the key is in the ON position.
When the key is in OFF position, the controller does
not activate since the power is not supplied to the con-
troller. In such a case, the buzzer will activate by
releasing the parking brake through the relay circuit.
4-32
CONTROLLERS
7.2 Parking Brake Warning Buzzer/Lamp Checking Procedure


engine. (Keep the parking brake in Lock position.)
(3) Display the input monitor screen from service tool.
(4) Sit in the operator's seat. Make sure the status of

Seat Switch and Seat Switch timer is ON in the
214155
input monitor screen (Fig. 4-1).
(5) Make sure the parking brake switch indicates ON
in the service tool screen (Fig 4-2). Also make
sure that parking brake warning lamp grows. (Fig.
4-3)
(6) Release the parking brake switch and leave the

operator's seat.
214191
Light
215108
4-33
CONTROLLERS
(7) Make sure that seat switch and parking brake

switch indicate OFF in the service tool screen.
(Fig 4-4 and Fig 4-5)
Also check that the buzzer starts activating as the
warning lamp turns off. (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
4-34
CONTROLLERS
7.3 Parking Brake Warning Buzzer/Lamp Checking Procedure with Key in OFF Position
(1) Place and keep the parking brake lever in lock
position.
Set the direction lever (shift lever) in the neutral
position. Stop the engine and place the key in Release
OFF position. Then, power for VCM-1M controller
and instrument panel is stopped. (Inoperable)
Lock
(2) Make sure that the parking brake warning buzzer
is activated when the parking brake is released.
(This function is not affected by the status of Seat
Switch.)
(3) Make sure that the parking brake warning buzzer
stops when the parking brake lever is shifted to
the lock position. 214196
Fig 4-7 Parking brake lever
When checking the above function, park the truck on

level and solid ground.

Check seat belt SW for operation, wiring, etc. accord-
ing to “Harness codes” of section 8, “VCM-1M control-
ler” of section 9.1, and “Seat switch/seat belt switch” of
Section 9.2.
If Parking Brake Switch does not indicate ON

Check parking brake switch for operation, wiring, etc.
according to “Harness codes” of section 8, “VCM-1M
controller” of section 9.1, and “Parking brake switch” of
section 9.3.
If Warning Buzzer does not indicate ON

Check the warning buzzer output according to “Active
test inspection procedure” of section 4.3. (Fig 4-8)
If the buzzer still does not activate after an active test
inspection, see “Harness codes” of section 8, “VCM-
1M controller” of section 9.1, “Warning buzzer” of sec-
tion 9.9, “Warning buzzer relay” of section 9.10, and
“Warning buzzer circuit” of section 9.11 and check for
wiring and so on.
214197
4-35
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(715) 0.5 W/B
38 CAN 718(716) 0.5 L/R
39 12V 300 1.25 Y
Instrument panel
40 ALT 341 0.5G
41 GND 920 0.5B
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
4-36
CONTROLLERS
9. Controller Details
9.1 VCM-1M Controller
VCM-1M
Controller CN2
CN1
(RIGHT SIDE)
Name plate
214198
Fig. 7-1 Controller location
(1) VCM-1M Controller
VCM CN2 VCM CN1
*1
9 374 343 346 345 642 623 612 609 610 1 9 611 722 723 677 676 1
17 672 671 670 703 702 10 17 10

664 663 662 708 707 613
25 127 603 679 678 18 25 975 600 18
*2 *3 *4 *5
34 866 26 34 26
156 155 865 242 241 976 625 631 628 630 706 705 704 601
*1:A028 FC *4:A087 FC
*2:716 Diesel engine truck *5:A086 FC
*3:715 Diesel engine truck 213503
Fig. 7-2 Controller code allocation (VCM-1M)
4-37
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
Reverse
611 125 461

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
125 Gasoline engine truck(G/W)

126 Diesel engine truck(GY/L)
213507
Fig. 7-5 Direction lever switch
4-38
CONTROLLERS
Light switch/
turn signal lever
Direction lever
Front
Wheel angle sensor
Light switch/
turn signal switch
Shift change switch
Horn contact
214199
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
213509
Fig. 7-7 Speed sensor
4-39
CONTROLLERS
9.6 T/M Solenoid
T/M forward/reverse solenoid
T/M solenoid
0.5 W
( L.H )
670
Forward 0.5 R/B
672
0.5 Y
671
0.5 G
673
( R.H )
Reverse
671 670
673 672
(Gray)
213510
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
4-40
CONTROLLERS
Unloading solenoid connector
Lift lock solenoid connector
214200
Fig. 7-11 MC 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 b2 SOL b3 SOL
(PF relief) 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
Fig. 7-12 FC valve unit
4-41
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
* : 122 ࡮Gasoline
: 124 ࡮Diesel
213516
Fig. 7-14 Warning buzzer relay
4-42
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
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

Fuel gauge Water temperature gauge
214202
Fig. 7-16 Instrument panel
4-43
4-44
CONTROLLERS
0.5W/L 0.5R/W 360 BAT

0.5W/L 0.5R/W 360 BAT 0.5G 0.5OR 348 BFS
0.5G 0.5OR 348 BFS 0.5Y/B
0.5Y/B 0.5BR 302 FUEL 0.5L 0.5L PKB
0.5L 0.5L PKB 349
349 0.5Y 0.5W/Y 342 OPS
0.5Y 0.5W/Y 342 OPS 0.5Y/R 0.5Y/R 301 TEMP
0.5Y/R 0.5Y/R 301 TEMP
0.5W 344 GLOW 0.5W/B 717 CAN H
0.5W 0.5W/B 715 CAN H 0.5L/R 718 CAN L
0.5R/B 0.5L/R 716 CAN L 0.5W/B 0.5Y IGN
0.5W/B 0.5Y ING 300
300 0.5L/R
0.5L/R 0.5R ALT R 1.25Y 0.5G ALT L
DIESEL ENGINE TRUCK

102 341
1.25Y 0.5G 341 ALT L 0.85G 0.5B GND
0.85R 0.5B GND 920
1.25B
GASOLINE ENGINE TRUCK
920
0.85G 0.5Y/G 0.5B
1.25B 0.5B G045 GND
G045 GND 0.5GY 308 RL1
0.5Y/G 0.5GY 308 RL1 0.5Y/L 309 RL2
0.5Y/L 309 RL2 0.5GY
0.5GY 719 0.5Y/L
0.5Y/L 719
1
14
14
360 920
360 920
Fig. 7-18 Instrument panel circuit (diesel-engine model only)

301 302 342 348 349 308 309
301 302 342 348 349 308 309

Fig. 7-17 Instrument panel circuit (gasoline-engine model only)
G045
G045
341
718 717
13
26
13
26
390
341 344 102 390
719 716 715 719
215206
214875
CONTROLLERS
10.Error Codes and Troubleshootings

10.1 Error Code Display
Error Code Display
All the error codes detected by VCM are displayed.
Troubleshooting
Press the fault status button from the monitor menu or
toolbox to display the fault status screen, and the
screen is displayed, press the troubleshooting button
on the lower part of screen to display error codes and
their descriptions.
Example: Error code 34 (Speed sensor error)

Probable cause
(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
4-45
CONTROLLERS
10.2 Troubleshooting
10.3 Diagnosis Table (F Code)
10.3.1 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 F٤٤ F٤٤
B
Error ocurrs with condition A Error ocurrs 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” of “10.3.2 LED blink pattern.”
Diagnosis VCM Memory error (F01)

Logic conditions EEPROM Sum check value
F01
Controller type unmatched
(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
F02
Power supply voltage is 21V or more
(1 second's continuity)
Recovery Recovers automatically
Action Turn OFF the all solenoid outputs.
LED blink pattern B
4-46
CONTROLLERS
Diagnosis VCM communication error (F03)

Logic conditions
CAN transmission from VCM-1M 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-
F07
cal. (2 second's continuity)

Action Activates with default values of instrument panel incoming data.
LED blink pattern B
4-47
CONTROLLERS
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

Logic conditions
F14

LED blink pattern C
4-48
CONTROLLERS
Diagnosis Shift lever error (F16)

Logic conditions
Shift lever overlap input (1800 msec continuity) F16

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

Logic conditions
Speed > 30km/h (400 msec 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 msec 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
Diagnosis Att1 lever error (F24)

Logic conditions

Action Turn OFF the Att1 solenoid output.
LED blink pattern D
4-49
CONTROLLERS

Logic conditions

LED blink pattern D

Logic conditions

LED blink pattern D
Diagnosis Joystick double error (F29)

Logic conditions
Error of both levers (primary and secondary) F29

Action Indication only
LED blink pattern D
Diagnosis Sensor voltage error (F31)

Logic conditions
Sensor voltage is 2.5V or less
F31
(20 msec 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
4-50
CONTROLLERS
Diagnosis Oil pressure sensor (lift) error (F32)

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

F34
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)
F36
Input signal is 4.72Vor more (170 degrees)
Action No knob deviation correction control
LED blink pattern D
Diagnosis Tilt angle sensor error (F38)

F38
Action No tilt action with the tilt auto-stop ON.
LED blink pattern D
Diagnosis Steering error (F40)

Logic conditions Changes continue 2 seconds to wheel angle
sensor only.
F40
Handle (steering wheel) angle sensor input error
Action No knob deviation correction control
LED blink pattern D
4-51
CONTROLLERS
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
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
4-52
CONTROLLERS
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
Diagnosis Tilt backward solenoid error (F57)

Logic conditions

LED blink pattern E
4-53
CONTROLLERS
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

Logic conditions

LED blink pattern E
4-54
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
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, #252. Hour meter update.

Action Sends zero from VCM as VCM hour meter value.
No overwrite of VCM hour meter.
LED blink pattern E
4-55
CONTROLLERS

Logic conditions

LED blink pattern E
Diagnosis Unload solenoid error (F75)

Logic conditions
Current value ҇160mA (1800 msec continuity)
F75
Current value ҈2.4A (200 msec continuity)

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

Logic conditions Current value is 160mA or less
F77
Current value is 4.8A 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
Diagnosis Knob position solenoid error (F80)

F80
Action Set knob position solenoid error output to OFF.
LED blink pattern E
4-56
CONTROLLERS
Diagnosis Tilt lock valve error (F82)

F82
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)

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

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

Logic conditions
F89

Action Turn OFF the T/M forward and backward solenoids.
LED blink pattern E
4-57
CONTROLLERS
10.3.2 LED blink pattern

When error codes cannot be identified due to instrument panel failure, etc., or due to a VCM-1M 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 VCM-1M 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.)
4-58
CONTROLLERS
10.4 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 2. Harness bad 2. Harness connection check
D-53 VCM communication error
E-03 3. VCM Controller bad 3. Communication line check
4. Controller bad
D-54 ECM communication error
E-04 3. ECM Controller bad 3. Communication line check
4. Controller bad
D-55 DCM communication error
E-05 3. ECM Controller bad 3. Communication line check
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
D-57 MP communication error
E-07 3. Instrument panel bad 3. Communication line check
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
3. Att3 lever bad 3. Lever connection check
4. Controller bad
4-59
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
3. Att3 lever bad 3. Lever connection check
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 double error
2. Input unit bad 2. Input unit check
1. Wheel sensor bad 1. Wheel sensor check
F-31 Sensor voltage 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
4-60
CONTROLLERS
Error
code
1. Link connection and damage check
1. Connector contact bad
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
4-61
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
4-62
CONTROLLERS
Error
code
1. Hour meter time difference between 1. Connect service tool and #252.
F-73 Hour meter gap error
VCM and instrument panel Hour meter update.
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
4. Knob position solenoid bad 4. Knob position solenoid 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
4. Knob position solenoid bad 4. Knob position solenoid 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
4-63
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
D-61 Engine overrun
3. Engine revolution sensor bad 3. Sensor connection check
4. Controller bad
D-62 Engine revolution pulse error
4. Controller bad
D-63 Over heat (STEP 1)
3. Temp sensor bad 3. Sensor connection check
4. Controller bad
D-64 Over heat (STEP 2)
3. Temp sensor bad 3. Sensor connection check
4. Controller bad
D-71 Accelerator sensor error
3. Accelerator sensor bad 3. Sensor connection check
4. Controller bad
D-73 Engine revolution sensor error
4. Controller bad
D-75 Idle switch fault
3. Idle switch bad 3. Idle switch check
4. Controller bad
D-76 Throttle min position error
3. Throttle min switch bad 3. Throttle min switch check
4. Controller bad
D-77 Throttle max position error
3. Throttle max switch bad 3. Throttle max switch check
4. Controller bad
4-64
CONTROLLERS
Error
code
D-78 Throttle origin position error 2. Harness bad 2. Harness connection check
3. Controller bad
D-79 Throttle min switch fault
3. Throttle min switch bad 3. Throttle min switch check
4. Controller bad
D-91 Throttle motor fault
3. Throttle motor bad 3. Throttle motor check
4. Controller bad
1. When air flow meter output current of
0.5V or less (break or short) continues
for a length of time while engine is run-
ning.
E-21 Air flow meter fault
2. When air flow meter output current of
4.9V or more (break or short) continues
for a length of time with the engine
stopped (key SW in ON position)
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.
4-65
CONTROLLERS
Error
code
1. When accelerator sensor 1 output
voltage of 0.15V or less (break) contin-
ues for a length of time.
voltage of 5V or more (short) continues
for a length of time.
E-24 Accelerator sensor fault
voltage of 0.15V or less (break) contin-
ues for a length of time
voltage of 5V or more (short) continues
between accelerator sensors 1 and 2.
1. When O2 sensor output voltage is
higher than the normal voltage (1.4V or
E-25 O2 sensor fault more).
2. When break of O2 sensor signal line
occurs.
1. When O2 sensor heater control volt-
age of 0.12V 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
1. When POS signal is not detected for
a length of time when the engine being
started or running (during PHASE sig-
nal 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 is
E-28 Phase sensor fault
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.
4-66
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
E-31 Throttle control fault is abnormal.
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
0.6V or less continues for a length of
E-32 Over heat (STEP 1) time
(when water temperature sensor is nor-
mal).
1. When water sensor output voltage of
0.35V or less continues for a length of
E-33 Over heat (STEP 2) time
(when water temperature sensor is nor-
mal).
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
E-35 LPG Injector system fault range)
2. When abnormal current is applied to
the LPG injector 1 (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
1. Controller bad
S-01 VCM communication error
2. Setting data bad 2. Setting data check
4-67
CONTROLLERS
Error
code
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. DCM 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-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
S-40 Service brake solenoid error
4. Service brake solenoid bad 4. Service brake solenoid connection
check
5. Controller bad
4-68
CONTROLLERS
Error
code
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
4-69
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
Shift lever
connector Oil temperature sensor
Shift lever Transmission
(for powershift truck) (right side)
213520
4-70
CONTROLLERS
Attachment 1B
Tilt, Forward
Lift, Lowering Attachment 2B
Attachment 3B
Attachment 3A
Tilt, Backward Attachment 2A
Lift, Lifting Attachment 1A
Control valve (for FC truck)
Solenoid valves
Unloading solenoid connector
Lift lock solenoid connector
Control valve
(for MC truck)
213524
4-71
CONTROLLERS
T/M forward/reverse solenoid
Transmission
(for Powershift truck) 213527
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
4-72

6M100 MH99719 6m100contl

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Chapter 4 CONTROLLERS

Instrument Input Output

Direction HYD ECM / DCM

Lamps VCM-1M Driving

Main functions of each controller are as follows:

2.1 Instrument Panel

2.2 VCM (Vehicle Control Module)-1M

2.3 ECM (Gasoline Engine Control Module)

2.4 DCM (Diesel Engine Control Module)

2.5 Remote Input/Output Units

2.6 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: The user can 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

4. Mast Interlock System

Instrument panel Operating control lever

4.2 VCM-1M Controller, Mast Interlock System Checking Procedure

Make sure that nobody is around the lift truck.

(6) Leave the operator's seat. Make sure that seat

(8) When the mast interlock is activated, the status of

If Unload Solenoid does not indicate ON

If Lift Lock Solenoid does not indicate ON

4.3 Active Test Inspection Procedure

Active test flag Write button

(3) Put a check mark in the check box of the active

(7) Press the output monitor button in the service tool

5. Powershift Transmission Driving Interlock System

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

Be sure to check this system on level and hard sur-

Driving Interlock System Checking Procedure for

(5) Display the output monitor screen (VCM-1M) from

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

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

(10)To release the interlock status, 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) Press the active test button in the service tool