Electronic Control System

8 – 16 Ton Class V Forklift Truck

Electronic control system

• Powered by 24 VDC battery pack (2x12VDC batteries)

• DC/DC converter from 24 VDC to 12 VDC
• Control circuits work on 12 VDC and 24 VDC.
• Some circuits work on both 12 and 24 volts.
• Wire harness is divided into 4 sections.
• 6 control modules
• All controllers share the same can bus signal
• Fuses located in three areas.
• Relays located in two areas.
• Transmission speed selector switch.

2-1
What’s operating voltage !!

12 and 24 volt system. Is there a clear dividing line?

Operating Voltages

24 Volt system 12 Volt system

Engine control components

VCM-3 Fingertip
Control
ECU Gateway

VCM-3 OP Input
Unit
24 Volt
Battery
Output
Dash
Unit

12VDC
Refer to the schematic for
specific power routing.
D/C-D/C
Converter

24 Volt Battery

2-2
24 Volts battery system

Located under the step on left side. (2 x 12VDC)

Batteries located under the step

Left step

2-3
Starter circuit

24v

12v

Dashboard

Components on the dash will have a different supply voltage

h Powershift transmission
oil temperature gauge (24V)

i Hazard switch (24V)

k Other (OPTIONAL) indicator or switch

j Speed selector c Engine warning

switch (12V) Light (Orange, 24V)

g Cab open warning d Engine warning

light (12V) Light (Red, 24V)

f Brake Lining wear e Low air pressure

warning light (24V) warning light (24V)

2-4
Fuse Locations

Fuse Panels (For Chassis)

12VDC and 24 VDC.
Refer to the schematic

Right Lower Dash

Three locations Radiator cooling fan

• Under the dash on the right
side
• Under the hood just above
the radiator
• On top of the transmission a
single fuse
Engine Fuses

Second angle of engine fuses

Engine Control Fuses

Top Radiator Hose

2-5
Engine control fuses

Transmission fuse

Single Transmission Fuse

2-6
Relay locations

On the right side of the hood next to the seat. This panel is 24 VDC
and 12 VDC, refer to the schematic for specific circuits.

Relay Identification

WARNING
Control and supply voltages , will differ from relay to relay
# Part Name Part # Point Coil Relay Outside
IN Point
1 SMALL LAMP 05138-00600 N.O 24V 24V
2 IGN 05138-00600 N.O 24V 24V
3 GLOW LAMP 05138-00600 N.O 24V 12V
4 CHARGE LAMP 05138-00700 N.C 24V 12V
Front Rear
5 HEAD LAMP (Hi-Lo) (O/P) 05138-00800 24V 24V
6 FLASHER RELAY 05138-02300 24V
7 BACK UP 05138-01400 N.O 12V 24V
8 STARTER #2 05138-01400 N.O 12V 24V Inside
9 AUTO LIGHT (O/P) 05138-01400 N.O 12V 24V
10 HEAD LAMP 05138-00600 N.O 24V 24V Item # : 8
11 TURN SIGNAL (L.H) 05318-00600 N.O 24V 24V Starter relay coil voltage 12 V
12 TURN SIGNAL (R.H) 05138-00600 N.O 24V 24V
Relay tips 24V
13 STARTER #1 05138-00600 N.O 24V 24V
Item # : 13
14 WARNING BUZZER 05138-00700 N.C 24V 12V 24V Control, 24V Power
15 AUTO-LIGHT (O/P) 05138-00800 24V 24V

2-7
Second set of relays

Back side of the cross support beam

Relays Identification

The relays control the following:

1. Glow plug relay 24 VDC

Part # : 05138-00600
n o p q
2. Neutral position
Part # : 05138-01400
(Coil in 12vdc control 24 VDC
contacts)

3. Starter safety relay 24vdc

Part # : 05138-00700

4. ECU main relay 24 VDC

Part # : 05138-00600

2-8
DC / DC Converter

Located under the hood secured to the rear cross support beam.
Converts power from 24 volts to 12 volts DC

Power converter

Wire harness

The wire harness is divided into 4 sections.

• Cabin harness (Dash)

• Harness A (Cab Section)

• Harness B (Transition from cab to body)

• Harness C (Back section of forklift)

2-9
Wire Harness Connection

GSE diagnostic port

• Diagnostic port located on the lower right side of the dash.

• Laptop software, UP-TIME Version 3.00

VCM-3OP
Diagnostic Port

GSE Cable VCM-3

Part # :16A68-11320 Diagnostic Port

2-10
Sealed connections

Locking sealed
connectors

Meter Panel

Engine Oil Pressure Seat Belt Indicator

Warning Lamp
Multi-purpose Indicator
T/M Oil Temp.
Warning Lamp Battery Charge Lamp

Park Brake Glow Pilot Lamp

Indicator
Mast Interlock Indicator

Water Temp Indicator

LCD H/M & Error Indicator

Fuel Filter Drain Warning Lamp

Fuel Meter
Neutral Indicator

Dash Display
• No logics in the dash it is a display only.
• The dash operates on 12 VDC.

2-11
VCM-3

The VCM-3 is responsible for chassis functions.

The following functions are included:

• Seat switch
• Speedometer output
• Travel speed sensor input
• Emergency stop circuit
• Park brake switch
• Speed sensor input from the differential

Also the location for diagnostic interface

VCM-3 location

VCM-3 located on the hood to the left of the seat.

Seat

VCM-3

2-12
Transmission control VCM-3 OP

• The VCM-3 OP (option) was initially designed as optional

equipment for transmission control during development. During
the test phase of the design the decision was made to keep this
option as standard equipment. Due to the production schedule
and other factors, the name will remain the same as VCM-3 OP
(or VCM-3 option)

• The VCM-3 OP serves two operational functions. The first is the

input location for the hood safety switches. The second and
primary function is transmission speed control.

• All weight class models have a three speed transmission. The

speed selector switch is located on the dash next to the
headlight switch.

• The input voltage for the controller is 12 VDC.

VCM-3 OP Location

VCM-3 OP

# Part Name Part Number

1 Controller, VCM-3 OP 16A36-00050
2 Controller, ECU (Engine Part list)
3 Controller,Gateway 92E04-00100
View of the rear panel removed

2-13
CAN-BUS Connection

Alternate Engine Code retrieval

There are two possible methods to retrieve the engine

fault code from the control system
• First method:
Uses GSE diagnostic plug and UP-TIME Laptop
software.

• Second method:
Uses two plugs and the dash warning lights to
display the error.

This presentations primary discussion will focus on the

alternate dash method.

2-14
Fault History

This method will be the only way to access the engines fault history.

The UP-Time software will only display the current fault code. You will also
have the current fault display in the hour meter screen located on the dash.

Current GSE fault will

be displayed here

Fault code system

In the service manual, you have a code listed with a secondary fault code. The
coding system that is referred to for this method

Diagnostic Code List

UP-TIME
GSE Flashes Message Code
Code
E-01 24 Accel Pedal Sensor 1 P0122
E-01 24 Accel Pedal Sensor 1 P0123
Warning
Lamp E-02 16 Accel Pedal Sensor 2 P0222
Flashing E-02 16 Accel Pedal Sensor 2 P0223
Code
E-03 65 Accel SW P0510
E-04 12 Camshaft Position SNSR P0340
E-05 23 Common Rail Pressure Defect P0254
E-05 23 Common Rail Pressure M/V 1 P0255

2-15
Dash light used for code retrieval

Red dash light used

for manual code retrieval

Diagnostic plug location

Two plugs located

Behind this plate

2-16
Diagnostic plug location

Gateway

2 diagnostic plugs
will be located below
the Gateway in the
wire harness.

Harness
Harness will
be located here
indicated in red

Panel removed showing the location of the wire harness.

The two diagnostic plugs will be located directly below the gateway

Diagnostic plugs

These plugs will be connected in a loop during normal operation.

The red and grey wires were used as a jumper during the demonstration

Round plug for

Current fault code

Square plug for

code history

CONTROLLER, GATEWAY

2-17
Procedure for retrieving fault codes

Current Fault Code History Fault Code

• Set the key switch to ON. • Disconnect the memory
• Disconnect the diagnostic clear switch connector
switch connector (Square plug)
(Round plug). • This time, the warning lamp
• This will display the current will restart flashing history
fault by flashes of the red code.
dash check engine light.

Clear History Code!!

Keeping the code history

Turn the key switch off before plugging the connectors
back together.

Clearing the code history

Plug both connectors back together while the key switch
is on.

2-18
Error Code in OMM

Questions ?

Electronic Control System

2-19