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Model LCD 501---502. KEYTROLLER LCD Vehicle Monitoring Devices. KEYTROLLER available in 2 model series. Keypad Model 105 Code input RFID card input LCD Model 500 series Full featured start from keypad Model 501 –impacts/speeding etc Keyless ignition Model 502

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Model LCD 501---502

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Model lcd 501 502

Model LCD 501---502




Monitoring Devices

Keytroller available in 2 model series

KEYTROLLERavailable in 2 model series

  • Keypad Model 105

    • Code input

    • RFID card input

  • LCD Model 500 series

    • Full featured start from keypad Model 501 –impacts/speeding etc

    • Keyless ignition Model 502

      This presentation covers these LCD models

Model lcd 501 502

KEYTROLLERVehicle Monitoring Systems

Can be installed on ANY make/model electric, gas, LPG or Diesel powered vehicle

Model lcd 501 502

KEYTROLLERVehicle Monitoring Systems


Start—stop engine/motor right from keypad!

How much time is lost at your company with lost and broken keys?

Keytroller lcd vehicle monitoring systems

KEYTROLLERLCD Vehicle Monitoring Systems

2 LCD models to choose from

  • Use code or company ID (RFID) card to enable

    • Standard RFID, HID-Prox or HID i-class

  • Feature packed devices---value pricing, dealer support

  • Operator abuse and speeding accountability

  • Significantly improves operator productivity

  • Significantly reduces damage to rack and product

  • Monitors and protects engine

  • Data on equipment utilization and movements

  • Automates several OSHA requirements

    • Trained and authorized operators only

    • Recurrent training

    • Operator checklist

    • Maintenance scheduling

Model lcd 501 502

  • 2 LCD models

    • LCD-502

      • Keyless ignition, code/card expiration, checklist, Maintenance scheduling, wireless communication,

      • NOT available with impact or speed sensing

      • Less expensive


      • Full featured vehicle monitoring

Vehicle monitoring basic device model lcd 502

Vehicle Monitoring Basic Device Model LCD-502

  • Enable device by RFID card or PIN code

  • Operator enables at start of shift to electronically complete his checklist

  • Connects into ignition switch and enables it ---allowing key to start vehicle. Can not start until key is enabled by device

  • Start--stop times are recorded as events

  • Maintenance due by date or hour meter is shown on LCD screen

  • Events can be reviewed by supervisor

  • Event log shows when operator logged in/out, checklist items, maintenance due scheduling---events reviewed by logged or graphs

  • Includes: LCD keypad and RFID reader

    • Connects to input power

    • Connects to ignition switch

    • Output to alarm

Advanced vehicle monitoring system model lcd 501

Advanced Vehicle Monitoring SystemModel LCD-501

  • Includes relay module that allows starting from keypad –eliminating ignition key

  • Includes speed and impact capabilities

  • Text messaging with wireless modem

  • Includes 5 auxiliary inputs for:

    • Seat switch

    • Seat belt switch

    • Monitoring movement and productivity

Operator s checklist getting done

Operator’s checklist getting done?

Automate operator’s checklist---all events recorded ---immediate supervisor or mechanic interface if checklist “flagged event” FAILS

OSHA regulation 1910.178(q)(7)Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily. Where industrial trucks are used on a round-the-clock basis, they shall be examined after each shift. Defects shall be immediately reported and corrected.

Customized checklist

Customized checklist

  • LCD version allows fully customized items

  • Set up by first start of each shift, or by operator

  • Event log show each item: PASS—FAIL + time to complete

  • Critical items can be “flagged” If “flagged item is failed, vehicle shuts down requiring supervisor or mechanic to clear

  • Event log shows how long item took for Pass/Fail—adding accountability

  • Event log downloading allows filtering of checklist items for records

  • In development: emailing of failed events to mechanic’s shop

Osha recurrent training requirements

OSHA recurrent training requirements

  • Refresher training in relevant topics shall be provided to operator when:

    (A) The operator has been observed to operate the vehicle in an unsafe manner;

    (B) The operator has been involved in an accident or near-miss incident;

    (C) The operator has received an evaluation that reveals that the operator is not operating the truck safely;

    (D) The operator is assigned to drive a different type of truck;

    (E) A condition in the workplace changes in a manner that could affect safe operation of the truck.

  • An evaluation of each powered industrial truck operator's performance shall be conducted at least once every three years.

  • KEYTROLLER can alert you when each operators training is due as well as give you a logged records of impacts and speeding events to evaluate if additional training is required.

Code expiration

Code Expiration

Code expiration “red flags” management that recurrent training is due for that operator

OSHA regulation 1910.178(l)(4)(i)Refresher training, including an evaluation of the effectiveness of that training, shall be conducted as required by paragraph (l)(4)(ii) to ensure that the operator has the knowledge and skills needed to operate the powered industrial trucksafely.

Maintenance scheduling

Maintenance scheduling

Insures that maintenance is completed! By a date or an hour meter reading----refuses start at due date/time.

LCD device warns operator of upcoming maintenance due on the screen

OSHA regulation 1910.178(q)(10)Industrial trucks shall be kept in a clean condition, free of lint, excess oil, and grease.

See when maintenance is due right from lcd screen

See when maintenance is due right from LCD screen

  • Shows date maintenance is due

  • Show # of hours until maintenance is due

  • If maintenance is NOT done and cleared by mechanic or supervisor, then vehicle will NOT start unless by mechanic or supervisor—or through a computer, Cyberkey or Cyberwire connection

Reduce damage to rack equipment product

Reduce damage to rack, equipment + product

Click on the picture to start video

Device can be programmed to record impact event (intensity + direction), sound external alarm (120dB strobe/siren), and shut down ignition in programmable # of seconds (to be re-enabled by supervisor).

Unsafe speeds in your plant

Unsafe speeds in your plant?

OSHA regulation 1910.178(n)(1)All traffic regulations shall be observed, including authorized plant speed limits. A safe distance shall be maintained approximately three truck lengths from the truck ahead, and the truck shall be kept under control at all times.

Two types of speed sensing

Two types of speed sensing

  • Magnetic or gear tooth sensors provide speed output.

  • Speed limit and “Grace period” is set by programmer from keypad or through PC software

Speeding options

Speeding options

  • Basic: Speed limit set by programmer

    • “Grace” period set by programmer (4-5 seconds)

    • When operator begins to speed – beeps + warns him

    • If operator speeds through “grace” period—alarm sounds and event is recorded making operator accountable

  • Automatic: Speed limit set by programmer

    • NO “Grace” period set

    • When operators begins to speed automatically actuates electric actuator that restricts accelerator cable or rod stroke to restrict engine RPMs and therefore top speed automatically

      Neither option restricts engine RPMs at low speed---so operator can maintain high engine RPM necessary for hydraulic speed and performance

  • Setting speed limit

    Setting Speed Limit

    • Set speed limit in MPH or KPH

    • Set up grace period (time that device beeps/flashes until external alarm sounds and event is recorded)

    • Set wheel diameter in in/cm

    • Speed is shown on main screen to operator

    Mechanic s lock out code

    Mechanic’s lock out code

    Supervisor or mechanic can lock out all “RED FLAG” driver/operators to prevent usage until repairs are completed.

    OSHA regulation 1910.178(q)(1)Any power-operated industrial truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel.

    1910.178(p)(1)If at any time a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck shall be taken out of service until it has been restored to safe operating condition.

    Lcd unit installation advanced model

    LCD Unit Installation—Advanced Model

    Usually installed with 2-3 hours. Keypad mounted to dash—connected to power, relay wired into ignition switch, alarm wired to relay, impact/GPS sensor mounted to frame. Add 1 hour for speed sensor.

    Design schematic advanced 501 lcd model

    Design SchematicAdvanced 501 LCD Model

    Programming operator codes and settings

    Programming operator codes and settings

    Can be done from the keypad, with a laptop, long connection to PC, CYBERKEY or CYBERWIRE wireless connection.

    Easy to learn with desktop plug in transformer connection

    Programming from keypad

    Programming From Keypad

    • EVERY programming feature can be programmed by the programmer----right from the keypad—LCD screen interface!

    • “Text” is written in like a cell phone message

    • Easy change of codes or settings on the vehicle by the programmer

    Rfid card enabling

    RFID card enabling

    RFID card, FOB or “DIME” sized wafer can be used to activate KEYTROLLER. Wafers can be fixed to existing card, turning it into an RFID card.

    Codes/cards are inputted from individual keypads or KEYSOFT PC software.

    OSHA regulation 1910.178(l)(6)Certification.The employer shall certify that each operator has been trained and evaluated as required by this paragraph (l). The certification shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation.

    Rfid card reader options

    RFID card reader options

    • Standard 125mhz card reader

    • HID-Prox card reader

    • HID i-Class card reader

      **It is recommended you send an RFID card to Keytroller to evaluate to insure it works properly with the model you choose

    Engine event

    Engine event

    • Low oil pressure or high engine temperature will trigger alarm on LCD screen and can be set to shut down engine, protecting it from expensive damage

    • If shut down, requires supervisor or mechanic to re-enable

    Reviewing events from lcd screen

    Reviewing events from LCD screen

    Allows supervisor access to all events (not downloaded) from the device to immediately evaluate the event and discuss it with the operator.

    Automatic disable time

    Automatic disable time

    Allows for automatic shut off of the KEYTROLLER after operator leaves his seat (requires seat switch circuit). Engine driven forklifts can enjoy up to 25% increase in fuel economy!

    OSHA regulation 1910.178(m)(5)(i)When a powered industrial truck is left unattended, load engaging means shall be fully lowered, controls shall be neutralized, power shall be shut off, and brakes set.

    Wireless text messaging

    Wireless Text Messaging

    • Individual LCD units can receive wireless test message from host PC

    • Operator must respond alerting host he has received message

    • Messages can be sent to individual operators or broadcast to all vehicles

    • Example of broadcast message: “Fire in building #2---EVACUATE IMMEDIATELY!”

    Advantages disadvantages keypad vs lcd


    Advantages of keypad 105 model (vs LCD)

    • Inexpensive, but very effective system

    • Multiple configurations---box keypad, flush keypad, double keypad models

    • “Bullet proof” design for real tough applications

      Disadvantages of keypad 105 model (vs LCD)

    • No LCD screen for many operator and supervisor interfaces (like checklists, recent events, wireless text messages, etc)

    • Keypad only automates checklist with only PASS or FAIL for entire checklist not individual items. Entire list recorded as one event---not individual checklist logged items

    • Less memory of 2,040 events vs up to 10,000

    Downloading uploading data

    Downloading/uploading data

    CYBERWIRE Wireless 2.4ghz radio


    CYBERWIRE Wireless 802.11 radio


    CYBERKEY 1028k memory key

    By direct connection to computer

    Cyberkey memory key device

    CYBERKEYmemory key device

    CYBERKEY povides a low-cost way of making memory portable and durable. 1028 K bit EEPROM Memory 50,000+ cycle life. Up to 16,000 events can be stored in each key from multiple KEYTROLLER devices---no computer literacy required. Used for uploading codes and settings or downloading event data without computer connection!

    Clone file

    Clone File

    • Clone files are produced with codes and settings you want to keep for other vehicles

    • Clone files can be easily modified using Keysoft PC software

    • Clone files can be loaded into other Keytrollers by:

      • Direct connection

      • Cyberkey memory key

      • Cyberwire wireless connection

    Evaluating event log data

    Evaluating Event Log Data

    Event logs can be filtered by time, date, operator, vehicle, event and deleted or exported to Access or Excel for further manipulation

    Graphing event logs

    Graphing Event Logs

    Monthly graphing can be done by operator, by vehicle for impacts, speeding, daily usage—per operator---per vehicle

    Impact event in log

    Impact Event in Log

    • Impact event shows:

      • Time

      • Date

      • Operator

      • Vehicle

      • Intensity of event

      • Direction of event

      • Speed of operator

        • (if unit has speed option)

    Engine monitoring

    Engine monitoring

    Connections for engine “idiot” lights on dash for low oil pressure and high engine temp. Programmable ignition shut down after “idiot” light stays lit for programmable time---requires supervisor or mechanic’s code to restart.

    OSHA regulation 1910.178(q)(9)When the temperature of any part of any truck is found to be in excess of its normal operating temperature, thus creating a hazardous condition, the vehicle shall be removed from service and not returned to service until the cause for such overheating has been eliminated.

    Seat belt

    Seat Belt

    • Auxiliary input can be connected to a seat belt with an internal switch (available as option from Keytroller)

    • Insures that operator engages seat belt clip or Keytroller device will shut down vehicle

    Keytroller vs oem lift mfg monitoring systems

    KEYTROLLER VS OEM Lift Mfg Monitoring Systems

    • Keytroller systems can work on ANY make or model Gas, LPG, Diesel or Electric vehicle and they will be compatible with ANY future forklifts that you may purchase

    • Most lift truck users have a variety of makes and models in use in their facility. Therefore, buying an OEM lift manufacturer’s monitoring system—MAY NOT fit onto competitive lift trucks in use in the same plant.

    • If you purchase an OEM vehicle monitoring system from a lift truck OEM and then purchase additional lifts later from a different lift truck manufacturer---your original OEM system will NOT be compatible with the new lift trucks.

    • Some lift truck OEM systems to not offer advanced features like wireless connectivity or model variations available from Keytroller.

    • When dealing with Keytroller, you are dealing with a company who’s expertise lies in design and manufacturing of electronic vehicle monitoring systems. Lift truck manufacturers are good at manufacturing lift trucks.

    Demonstrating a keytroller

    Demonstrating a KEYTROLLER

    • Free 30 day trial

    • Full functionality of the device right from your desktop!

    • Plug in transformer and you can:

      • Program the device

      • Create events, starts, impacts, etc

      • Download event data using PC, Cyberkey, or Cyberwire

    • After “learning” the device from the desktop, the fully programmed KEYTROLLERcan then be installed on a forklift for further evaluation for suitability to your application.

    Model lcd 501 502

    • Works like indoor GPS

    • Can track KEYTROLLER devices or any other tagged items

    • Real time and historical tracking

    • Email critical event data

    • Compares moving vs idle time

    Results of implementing keytroller in your forklift fleet

    Results of implementing KEYTROLLER in your forklift fleet

    • 50+% reduction in damage is typical

    • Insures untrained, unauthorized operators

      cannot operate your equipment

    • Eliminates keys totally

    • Automates checklist

    • Use your company RFID card!

    • Helps with recurrent training

    • Insures safe speeds

    • Insures maintenance is scheduled

    • Provides data for fleet management

    • Easy programming and downloading

    • Makes operators accountable!

    • With MOVETROLLER option:

      • Track real time and historical position and movement of EVERY KEYTROLLER enabled vehicle


    : : : : : : :CYBERWIRE: : : : : : :

    Keytroller now has the option of downloading events from several Keytroller units or

    uploading a clone file to several Keytroller units from a remote PC Host or location using one

    of our wireless applications (Cyberwire). The advantage of this system is that now you don’t

    have to take a PC Laptop or Cyberkey physically and connect locally to the Keytroller units,

    you can conduct all necessary tasks from your office desktop PC or any other remote location.

    With the wireless system you can perform two distinct and separate functions:

    1. You can download events from one or more Keytroller units mounted on vehicle

    from your office PC or remote location for analysis.

    2. Program remotely by entering user codes and settings previously saved on a clone file and upload them to the target Keytroller unit. A wireless connection provides an easy way to program the same settings into any number of vehicles without having to visit the unit physically.

    Our Keytroller wireless system supports the Radio RF technology. These wireless

    infrastructures or designed and implemented based on the end users network environment.

    2 4ghz wireless connection option

    2.4ghz Wireless connection option

    • Downloads available event log data automatically when vehicle is within range

    • Uploads new codes or settings from host PC

    • Weatherproof enclosure for harsh environments

    • 2.4ghz transceiver device---plugs directly into RS232 serial port of the KEYTROLLER Radio receives it power from Keytroller

    • Data rate: Up to 115.2 kbps

    • Transmission range: up to 1500’ indoor, up to 20 miles outdoors depending upon interference

    • Operating temperature: -40 to +80C

    • One required per vehicle and 1 for host PC

    • LCD device can text messaging to individual vehicles from host

    • Host PC Ethernet hard wired radio option will extend effective range by mounting of the radio out in the warehouse (top picture)

    Cyberwire advantages

    CYBERWIRE Advantages

    • Improves productivity by eliminating manual downloading/uploading

    • Because data retrieval is easy, management has quick access to vehicle logs

    • Easily upload new codes/cards and settings into individual units

    • Download event logs from individual vehicles or automatic scan of fleet

    • Send text messages to LCD screen

    • Radio connects and powered by RS232 serial port on KEYTROLLER

    • Retro-fittable at future date as budget allows---just plug into serial port

    • Easy “plug and play” set up of serial radios

    Cyberwire base station options

    CYBERWIRE Base Station Options

    Two forms of "BASE STATION" radios.

    The Serial Base radios and the Ethernet Radios.

    1)The Serial version is directly connected to the serial port of the host computer with the Keytroller software. You can only use one serial “base station” radio in this configuration.

    1.1) Additional serial cable can be purchased to increase the length of the radio from the computer with a 30' Serial extension cable. Maximum distance from host PC is approximately 60’

    2) The Ethernet base station version connects by a Cat-5 cable to your Local Area Network (LAN). As long as the host computer that is running the Keytroller software has access to this LAN, then you will have access to this radio. This greatly increases your placement options for the radio as it is no longer limited to the area around the system running the software.

    2.1) Ethernet set up allows placement of multiple “base station” radios throughout the facility, greatly increasing the coverage and range of communication than just using one base station alone.

    Keytroller llc the company

    KEYTROLLER, LLC.The Company

    • Full line of award winning

      equipment safety devices

    • Over 400 equipment dealers for

      local representation and support

    • OEM installation of devices available

    • Over 10,000 devices installed in the field

    • All models designed to install on any gas, diesel

      or electric powered vehicles

    • Keytroller devices designed and supported in house

    • Manufactured and/or distributed from Tampa, Fla 813-877-4500 [email protected]

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