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Control Es

This document describes the controllers that control the lift truck and engine. The main controllers are the Vehicle Control Module (VCM), Engine Control Module (ECM), and Diesel Control Module (DCM). The VCM controls the overall vehicle system and is located on the right side of the truck. The ECM controls the gasoline engine and is located on the left side. The DCM controls diesel engines. Other controllers include the instrument panel, remote input/output units, and connectors for service tools.

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Control Es

Uploaded by

Pepe Al

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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 DCM (Diesel Engine Control Module) ..................................................................... 4-2
2.5 Remote Input/Output Units ...................................................................................... 4-2
2.6 GSE Connector ....................................................................................................... 4-3
3. Service Tool Functions........................................................................... 4-4
3.1 Service Tool Menus................................................................................................. 4-4
3.2 Service Tool Box ..................................................................................................... 4-5
4. Mast Interlock System .......................................................................... 4-18 4
4.1 Function................................................................................................................. 4-18
4.2 VCM1-M Controller, Mast Interlock System Checking Procedure......................... 4-18
4.3 Active Test Inspection Procedure.......................................................................... 4-21
5. Driving Interlock System ...................................................................... 4-24
5.1 Function................................................................................................................. 4-24
5.2 Driving Interlock System Checking Procedure for Powershift T/M Trucks ............ 4-25
5.3 Active Test Inspection Procedure.......................................................................... 4-28
6. Seat Belt Warning Lamp....................................................................... 4-30
6.1 Function................................................................................................................. 4-30
6.2 Seat Belt Warning Lamp Checking Procedure ...................................................... 4-30
7. Parking Brake Warning Buzzer and Lamp.......................................... 4-31
7.1 Function................................................................................................................. 4-31
7.2 Parking Brake Warning Buzzer/Lamp Checking Procedure.................................. 4-31
7.3 Parking Brake Warning Buzzer/Lamp Checking Procedure
with Key in OFF Position ...................................................................................... 4-34
8. Harness Codes ...................................................................................... 4-35
9. Controller Details .................................................................................. 4-36
9.1 VCM1-M Controller................................................................................................ 4-36
9.2 Seat Switch/Seat Belt Switch ................................................................................ 4-37
9.3 Parking Brake Switch ............................................................................................ 4-37
9.4 Direction Lever ...................................................................................................... 4-37
9.5 Speed Sensor........................................................................................................ 4-38
9.6 T/M Solenoid ......................................................................................................... 4-39
9.7 Unload Solenoid .................................................................................................... 4-39
9.8 Lift Lock Solenoid .................................................................................................. 4-39
9.9 Warning Buzzer ..................................................................................................... 4-41
9.10 Warning Buzzer Relay........................................................................................... 4-41
9.11 Warning Buzzer Circuit.......................................................................................... 4-42
9.12 Instrument Panel ................................................................................................... 4-42
10. Error Codes and Troubleshootings..................................................... 4-44
10.1 Error Code Display ................................................................................................ 4-44
10.2 Diagnosis Table (F Code)...................................................................................... 4-45
10.3 Error Codes and Troubleshooting ......................................................................... 4-58
11. Locations of Sensors and Switches.................................................... 4-69
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

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
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

panel Armrest FC valve
unit unit

Direction
lever
Operating
ECM / DCM
Steering
wheel VCM-1M

Driving

Lamps
Parking
switch
Instrument
Engine
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 DCM (Diesel Engine Control Module)

The DCM controller is located on the left side of the lift
truck and controls the diesel engine.

2.5 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

2.6 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.

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 [%]

4-5
CONTROLLERS

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
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]

4-6
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]

4-7
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 -8
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

4-9
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

4-10
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

4-11
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

4-12
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

4-13
CONTROLLERS

214900

4-14
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

4-15
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

4-16
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

4-17
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.

217332

Instrument panel Operating control lever

Operator Seat
Key switch position Engine Mast interlock indi-
occupancy Lift Tilt
cator lamp
Seated OFF Not active Not active
٤ (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.

4.2 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.

4-18
CONTROLLERS

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
(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

4-19
CONTROLLERS

214158
Fig. 1-4 Input monitor screen
(7) Make sure that the mast interlock indicator lamp
on the instrument panel blinks. (Fig. 1-5)

214159
Fig. 1-5 Instrument panel screen

(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.

4-20
CONTROLLERS

If Lift Lock 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
inspection, refer to "Error Codes and Troubleshooting
of Section 10" and check for the possible causes of the
error code F-77 and F-79.

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

4-21
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
Fig. 1-10 Active test check screen
4-22
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
Fig. 1-11 Output monitor screen
(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.

4-23
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.

4-24
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
(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) 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
Fig. 2-1 Input monitor screen

4-25
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
Fig. 2-3 Input monitor screen

214179
Fig. 2-4 Input monitor screen

4-26
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
Fig. 2-5 Instrument panel screen
(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
If Seat SW does not indicate ON
Check the seat switch operation and wiring connec-
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

Check the solenoid output by referring to "Active test
inspection procedure of section 5.3." If the solenoid
output does not turn ON even after the active test
inspection, refer to "Error Codes and Troubleshooting
of Section 10" and check for the possible causes of the
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.

4-27
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
Fig. 2-7 Active test screen
(3) Check the box of the active test flag, and press
the write button. (Fig. 2-8) Write button
Check

214169
Fig. 2-8 Active test check screen
(4) When the write confirmation dialogue box is dis-
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

4-28
CONTROLLERS

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

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

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

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
Fig. 2-10 Active test check screen
(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
Fig. 2-11 Output monitor screen
(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.

4-29
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

(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) 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
Fig. 3-1 Input monitor screen
(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
Fig. 3-2 Input monitor screen

215107
Fig. 3-3 Instrument panel screen
4-30
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.

7.2 Parking Brake Warning Buzzer/Lamp Checking 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. (Leave the parking brake engaged.)
(3) Display the input monitor screen of the service
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
Fig. 4-1 Input monitor screen

4-31
CONTROLLERS

(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
Fig. 4-2 Input monitor screen

Glow

215108
Fig. 4-3 Instrument panel screen
(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
Fig. 4-4 Input monitor screen

4-32
CONTROLLERS

214194
Fig. 4-5 Input monitor screen

Turn off

215109
Fig. 4-6 Instrument panel screen

4-33
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 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 Parking Brake Switch 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 9.3."
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
Fig. 4-8 Active test screen

4-34
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

4-35
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

9 611 677 676 1 9 374 343 346 345 642 623 612 609 610 1

17 664 663 662 613 10 17 672 671 670 711 710 709 703 702 10

25 975 618 617 616 970 615 600 18 25 701 678 700 18

34 976 625 631 628 630 706 705 704 601 26 34 716 715 865 242 241 866 26

VCM CN1 VCM CN2

213503
Fig. 7-2 Controller code allocation (VCM1-M)

4-36
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 GW
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(GW)

126 Diesel engine truck(GY/L)
213507
Fig. 7-5 Direction lever switch

4-37
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

213509
Fig. 7-7 Speed sensor

4-38
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

4-39
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

4-40
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

4-41
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 button

Fuel gauge Water temperature gauge
214202
Fig. 7-16 Instrument panel
4-42
HARNESS M/P HARNESS M/P
0.5L/W 0.5L/W A040
A040 0.5L/G
0.5L/G A039 A039
0.5G/B 0.5G/B A038
A038 0.5W/L 0.5R/W BAT
0.5W/L 360 0.5R/W 360 BAT 360 360
0.5G 0.5OR BFS 0.5G 348 0.5OR 348 BFS
348 348 0.5Y/B 0.5BR FUEL
0.5Y/B 302 0.5BR 302 FUEL 302 302
0.5L 0.5L PKB 0.5L 349 0.5L 349 PKB
349 349 0.5Y 0.5W/Y OPS
0.5Y 342 0.5W/Y 342 OPS 342 342
0.5Y/R 0.5Y/R TEMP 0.5Y/R 301 0.5Y/R 301 TEMP
301 301
0.5W 344 GLOW
0.5W 0.5W/B CAN H 0.5W/B 717 CAN H
344 717 0.5R/B CAN L
0.5R/B 230 0.5L/R 718 CAN L 230 0.5L/R 718
0.5W/B 0.5Y ING 0.5W/B 717 0.5Y 300 IGN
717 300 0.5L/R
0.5L/R 0.5R ALT R 718

DIESEL ENGINE TRUCK

718 102 1.25Y 0.5G ALT L
1.25Y 0.5G ALT L 300 341
GASOLINE ENGINE TRUCK

300 341 0.85G 0.5B GND

0.85R 102 0.5B 920 GND 341 920
0.85G 0.5Y/G SP 1.25B 920 0.5Y/G 303 SP
341 303 0.5Y/G 0.5B GND
1.25B 920 0.5B G045 GND 303 G045
0.5GY 0.5GY 308 RL1
0.5Y/G 303 308 RL1 0.5Y/L RL2
0.5Y/L RL2 309
309 0.5GY 308
0.5GY 308 0.5Y/L
0.5Y/L 309
309
300

300 102
920 718 717
920 718 717

360 301 302

Fig. 7-18 Instrument panel circuit (diesel-engine model only)

Fig. 7-17 Instrument panel circuit (gasoline-engine model only)

308 309
308 309

(WHITE)

(BLACK)
(BLACK)
(WHITE)

(BLACK)
(BLACK)
349 348 342 A040 A039
A038

349 348 342 A040 A039

A038
303 230
341

303 230
344 341

215206
214875
CONTROLLERS

4-43
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

4-44
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 < 2.3 V F10

Error logic
Logic conditions Input signal < 2.7 V (with the
conditions
key in ON position)

A
A F٤٤ F٤٤
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 7 V or less
Power supply voltage is 21 V or more F02
(1-second continuity)

Recovery Recovers automatically

Action Turn OFF the all solenoid outputs.
LED blink pattern B

4-45
CONTROLLERS

Diagnosis VCM communication error (F03)

Logic conditions
CAN transmission from VCM1-M is impractical.
F03
(2-second continuity)

Recovery Recovers automatically

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
(2-second continuity)

Recovery Recovers automatically

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
(2-second continuity)

Recovery Recovers automatically

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
(2-second continuity)

Recovery Recovers automatically

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
(2-second continuity)

Recovery Recovers automatically

Action Activates with default values of instrument panel incoming data.
LED blink pattern B

4-46
CONTROLLERS

Diagnosis TMS communication error (F08)

Logic conditions
CAN receiving from TMS is impractical.
F08
(2-second continuity)

Recovery Recovers automatically

Action Activates with default values of TMS incoming data.
LED blink pattern B