Electric system & Cluster of

2.2~3.3D-9(E) Diesel FL

HCE Training Center

20FZG12
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Contents
Ⅰ. Electric components
Ⅱ. Useful functions
Ⅲ. Cluster
Ⅳ. Monitoring system
Ⅰ. Electric components

1. Components location 1
1 Head lamp
2 Turn signal lamp
4 Beacon lamp(Opt.)
5 Combination lamp
7 Forward/Reverse lever
8 1 8 Cluster
9 Start switch
5 10 Head lamp switch
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Clearance lamp switch
2 11
4 Turn signal switch
10 11 Horn button
13 15
12 Rear work lamp switch(Opt.)
Deta 25
il 9 13 Flasher unit
7 14 MCU
16 Hazard lamp switch(Opt.)
12 20 21
17 Fuse box
18 Battery
19 Parking switch
20 Beacon switch(Opt.)
17 21 Front Wiper/Washer switch(Opt.)
25 Rear camera(Opt.)
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19

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Ⅰ. Electric components

2. Electric Components on Dash board

Steering Column Switch

Cluster
Warning buzzer

Brake Oil Tank

Flasher unit

MCU(Main Control Unit)

Horn

Block - Brake Pressure Sensor

FWD/REV Solenoid

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Ⅰ. Electric components

3. Sensors and Switchs

- All Sensor and Switch signals are monitored on the Cluster.

T/M Temp., Pressure sensor

FWD Solenoid
Park’g solenoid
(Parking/Release)
REV Solenoid

Hyd. temp./pressure sensor(Opt.)

Brake pressure sensor

Parking Switch(Located on the Drive Axle)

1) Parking-’OFF’ : OPEN
2) Parking-’ON’ : Close
Speed sensor

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Ⅰ. Electric components

4. Symbols of Electric components

 Connectors
Parts Symbol CS : Switch connector
CR : Relay Connector
CD : Sender (Sensor, Press S/W) connector
CL : Light connector
Start switch
DO : Diode connector
CN : Intermediate connector

 Thickness of Wire
Relay - AWG(American Wire Gauge) wiring standard.

Sensor

(on the OHG

support)
~
▶

Head lamp ~
Ⅰ. Electric components

1) Fuse Box

Fuse(B+)

Fuse(IG)

1. Mini Fuse : Total 37ea

1) B(+) Fuse : 10ea
2) IG Fuse : 20ea
3) Spare Fuse : 7ea
2. Slow Blow Fuse : Total 3ea(substituted for Fusible Link)
Fr. Battery(+)
Fr. Key SW ‘ON’
Fr. Key SW ‘ST’

Fr. Key SW ‘ON’

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Ⅰ. Electric components

2) Relay

1. Relay type : Micro-Relay (Plug-in)

2. Relay-12V : 21HN-55510
1) 5P Relay
2) Capacity : 12V 35A/20A (N.O/N.C)
3) Coil protection by Diode
12V

* Symbol-Relay

(N.O type) (N.C type)

(Dis-connection with tool)

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Ⅰ. Electric components

3) Steering column switch

Gear Selector
Connector, color : Gray
CS-11 Combination S/W
Connector, color : Black
CS-12

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Ⅰ. Electric components

4) MCU : Machine Control Unit

No Lamps Description
1 Green Normal
2 Yellow CAN communication error
MCU
3 Red MCU-hardware error

N-Connector
M-Connector

* Disconnection-MCU Connector pins

Lock → Push white Lock and pull appointed port wire.

Face of Connector
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Ⅰ. Electric components

4-1) CAN communication(Controller Area Network)

- Data communication between control devices in longer distance.
- Easier adding of control devices on one network.

Cluster Finger-Tip
ECU Controller RMCU

MCU
* Inputs/Outputs * CAN1 - 250KHz
Sensor signals
Switch inputs
CAN2 - 500KHz
Relay controls
Etc.,

Angle sensor Optional devices

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Ⅱ. Useful functions

1. Electric Parking & Auto Parking

Parking Switch(Rocker) Parking Solenoid

1) Park’g-’Off’: Elec. Power ON.
2) Park’g-’On’: Elec. Power OFF.

Release
Auto-Parking
Relay
Parking

MCU

GEAR SELECTOR
(F/N/R)

Parking
switch(Pressure)
Seat Switch (to Indicate Parking)

1. Parking(Negative type)-’ON’
1) Park’g solenoid (2P-Connector) : 0V
2) Park’g switch(pressure) : Close (GND)
2. Parking-’Release’
1) Park’g Solenoid : 12V
2) Park’g switch : OPEN
3. Auto Parking : On condition of Parking-’Release’.
* Gear selector-Neutral/Seat Switch Off(2 sec.) → Auto Parking-’ON’
(Buzzer sounds 1 time)

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Ⅱ. Useful functions

2. Clutch Protection

- To protect the T/M clutches from abusive use of Inching pedal.

- Warning : When the Inching pedal is stepped on half of the full stroke with staying more than
2 seconds, warning happens.
Warning Buzzer

CLUSTER

Inching pedal

T/M OIL Temp./Pressure sensor

MCU

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Ⅱ. Useful functions

3. Hill Start Assistant Control

: When the FL re-start at the upslope, it prevents the rollback phenomenon.

Condition] - Stopping on a slope(3˚↑)
- Stepping on the Brake pedal and stop
- Trying re-start

GEAR SELEC-
TOR TRANSMISSION
MCU
Parking
Brake pressure Solenoid v/v
(Built-in)
Angle sensor

More than 3°
Accelerator
Cluster

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Ⅱ. Useful functions

4. OPSS(Operator Presence Sensing System)

Travel cut
(Travel FWD/REV Sol.)

CAN
Travel-cut
Relay

MCU

Attach-cut
Relay
Hydraulic operation cut
(Lift/Tilt-Cut Sol.)

1. Condition: Operator is out of seat during operation

2. Action: 1) Seat s/w : ON → OFF
Seat switch 2) Travel function : Stop(Travel-cut RY ‘On’).
3) Hydraulic operation : Stop(Attach-cut RY ‘On’).
4) Cluster : OPSS Warning lamp-‘ON’.

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Ⅲ. CLUSTER

Cluster–1. Description of Main screen

- 5.6 inch wide screen
- High brightness LCD
- Day/Night, Automatic brightness control

Buttons

Camera Gauges

Up/Left

Down/Right

Menu/Select Information display

(/Error statements)

ESC

Warning/Indication

Gear - Neutral/FWD/REV

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Ⅲ. CLUSTER

Cluster–2. Gauges, Information display, Indication/Warning

Gauges : ① Fuel(Warning-Red)
④ ④ ② Speed meter
③ Coolant temperature(Warning-Red)
④ Turn signal

⑤ ⑤ Mast tilting(Option, Warning-Red)

① ② ③ ⑥ Time clock

⑥
① ② ④ ⑤
③ Information display(/Error statement)
①,⑤ Vehicle tilt(Warning-Red)
② Load weight(Option)
③ Operation time
④ Trip distance
Warning-Brake oil level
Gear selection - Neutral/FWD/REV

Warning/Indication

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Ⅲ. CLUSTER

Cluster-3. Warning / Indication Lamps

Maximum speed warning indicator lamp

- FL speed is exceeded maximum set speed.

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Ⅲ. CLUSTER

Cluster-4. Reference for Warnings

1) Warning happens → Click the ‘Down’ button.
2) Refer to the warning statements on the screen.

Fuel contains excessive water.

Check fuel filter.

(Engine stop → Check ‘Error code’) (Expendables management → Check ‘replacement’ item)

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Ⅲ. CLUSTER

Cluster-5. Main Menus and Sub Menus

1) Equipment : Model selection, Weight sensor setting, ESL setting …

2) Maintenance : Failure history, Maintenance management, Signal status …
3) Display setting : LCD brightness, Units, Language …

Initial screen Main menus Sub menus

Equipment

Maintenance

Display setting

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Ⅳ. Menu system

1. Main menus

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2. Main Menu
: Equipment / Maintenance / Display Setting

Equipment
Operation screen

Maintenance Display Setting

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2-1. Equipment - Model selection

* How to select the model

1) Fuel type selection
2) Model range selection
3) Exact model selection

※ Selection will be cancelled if press

the Cancel click or ESC button.

※ To use full function of FL, exact

model must be selected.

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2-2. Equipment – Tilt Setting
: Tilt initialization
- The tilt sensor already been initialized before delivery.
- If the Tilt indication(or Warning) is not normal → Re-set tilt setting.
1) Set the vehicle on flat ground.
2) Locate the Mast vertically(Option).

1) Vehicle tilt Indication/Warning : MCU “G-sensor”

Mast tilt(Option)
- Setting the Vehicle to ground level(0°).

2) Auto-Leveling function : Mast tilt sensor Vehicle tilt – Left/Right

- Setting the Mast to be vertical(90°) against Vehicle
level.

Vehicle tilt – Front/Rear

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2-2-1. Vehicle Tilt

Front/Rear tilt Left/Right tilt

Warning Warning

G 센서 -MCU 내장

Warning Warning

(1) MCU senses Vehicle tilt using its inside angle sensor in real time.
(2) Two graphic tilt indication : ①Front/Rear ②Left/Right
(3) Warning when the vehicle is tilted excessively more than the stability reference.

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2-3. Equipment – (Option)Auto Leveling -1

Tilt Switch
(Mast Tilt Lever) Two way

Mast angle sensor(G-sensor)

Mast angle indication

1. Using the Tilt switch(on Mast tilt lever) to locate the Mast vertically against Vehicle.
2. MCU controls Hydraulic action considering the Tilt switch and Mast angle state.

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2-3. Equipment – (Option)Auto Leveling -2

Tilt Switch
(Mast Tilt Lever)

MCU
Attach Cut
Relay

Mast tilt sensor(G-sensor)

CAN2 CAN1

Cluster

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2-3. Equipment - (Option)Weight Sensor setting : Cylinder Cross-section( ㎠ )

Load weight
indication

* Cylinder Cross-Section setting

: The Weight sensor is already been initialized.
If the Cylinder is newly changed with different
Cross-section, re-set the Cylinder Cross-section.

Menu move

Enter

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2-3. Equipment – (Option)Weight Sensor setting : Unload Status Adjustment(Kg)

* How to set the Unloaded State adjustment

1. Equipment → Weight Sensor Setting
2. Remove the load.
3. Locate the Fork approximately 300mm from
the ground level.
4. Wait for 3 seconds and click ‘OK’ button.

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2-3. Equipment – (Option)Weight Sensor setting : Load Status Adjustment(Kg)

* How to set the Load Weight

1. Equipment → Weight Sensor Setting
2. Select Load Weight Adjust
3. Enter user password
4. Put a real weight on the Fork.
5. Locate the loaded fork approximately 300mm
from the ground level.
6. Enter Load weight as same as real weight
→ Click ‘Enter’
7. Wait about 30 seconds and click ‘OK’ button.

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2-3. Equipment – (Option)Weight Sensor setting : Initialization
: Initialize the all values of “No-Load adjustment” and “Load adjustment” that were entered previously.

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2-4. Equipment – (Option)Weight Display Setting

* Selection - the number of decimal places.

- Weight will be displayed as 1.5 tons if set as 100kg unit.
- Weight will be displayed as 1.5x tons if set as 10kg unit.

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2-4-1. Circuit of Load weight indication
: The function is usable with just to install a Load-Sensor(Option) in the Hydraulic passage.

Load-Sensor (Pressure Sensor) MCU CLUSTER

CAN

Max.

1) Load weight evaluation on condition of Lift operation stop for a while.

2) Overload warning : Buzzer sounds and Load weight indication blinks(Red)

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2-5. Equipment – Engine Start Limit

(Delay time set)

* Engine Start Limit setting
1) Inactive : Engine starting is possible without Password.
2) Active : Password is used every time to start Engine.
3) Delay time : Password is used to start Engine after the Delay time passed from Key ‘On’.

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2-5-1. Circuit of Engine Start Limit

MCU Mechanical Engine

Anti-Restart
Relay
Confirm-
ation
Start
Motor

CAN

ECU

Electronic Engine

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2-6. Equipment – Camera setting

* Reverse gear interworking

1) ON : Rear video will be displayed automatically when the
gear is selected reverse.
2) OFF : Rear video will be displayed on the screen when the
camera button is touched.

Gear-REV

( Reverse gear interworking – ‘OFF’)

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2-6-1. Concept of Rear view camera setting

1) The function is usable with just to install a camera(Option).

2) Default setting of Reverse gear interworking : ON.

Rear view
Reverse gear camera
interworking
- ON Video signal

Reverse gear
interworking
- OFF
MCU

CAN

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 ※ Model : 35/40/45D-9S
2-7. Equipment – Auto Shift setting 50D-9SA

* 2-Setting values of Speed setting

1. Up-shift : Reference speed set to up shift(1st → 2nd gear).
2. Down-shift : Reference speed set to down shift(2nd → 1st gear).

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 ※ Model : 35/40/45D-9S
50D-9SA
2-7-1. Circuit of Auto Shift function

GEAR SELECTOR Transmission

-Solenoid v/v(1st/2nd)

MCU
Auto-Shift
T/M SPEED SENSOR Relay

CAN

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2-8. Equipment – DCSR(Direction Change Shock Relief)

Mode ‘ON’

* 2-Setting values of Speed setting

1. Block Drive Speed : Reference speed set to make the gear neutral when drive
direction is reversed.
2. Restore Drive Speed : Reference speed set to make the gear clutching.

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2-8-1. Circuit of DCSR

* DCSR (Direction Change Shock Relief)

1) On condition of high speed, if direction lever is reversed, make the T/M in neutral state.
2) Shock relief of T/M and Drive Axle.

Gear status Travel speed T/M Control

>= 4km/h (Block Drive Speed) T/M - Neutral
FWD→N→REV
DCSR <= 3km/h (Restore Drive
(REV→N→FWD) T/M - Clutching
Speed)

Transmission
-Solenoid v/v
GEAR SELECTOR MCU Travel-Cut (FWD/REV)
Relay

T/M SPEED SENSOR

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2-9. Equipment – Speed Limit Set

* Overspeed Warning
: If alarm is set to Active and the drive speed is over the limit speed,
setting speed will be displayed on the screen, and the buzzer rings
every 2 seconds.

Warning - Speed limit

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2-10. Equipment – MCU / Cluster information

* Information of MCU / Cluster

: P/No., Manufacturing Date, Software version No. and Serial No.

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3. Maintenance

Initial screen

1. Engine Failure History : Current fault / Logged fault

2. Maintenance Management : Expendables management
3. Signal Status : MCU – Input / Output information
4. User Password Change

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 ※ Model : 35/40/45D-9F
3-1. Maintenance – Engine Failure History 50DA-9F

Engine Failure History

Current Engine Fault

Failure informa-
tion

Ex) Error Code : P0642

J1939
Engine Failure History P-Code Description
SPN FMI
P0642 3509 4
Sensor supply voltage 1 abnormality.
P0643 3509 3

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3-2. Maintenance – Maintenance Management

- If the expendables replacement cycle

has been reached, warning will
be happen on the Cluster.
① Click the “Replacement” button, if the item is replaced.
② If you want to change the replacement cycle time, click the
“Change” button.
②
①

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※ Planned Maintenance

※ Oil symbols

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3-3. Maintenance – Signal Status

- Switches, Relay control output

- Sensor signal(MCU input)

- Input/Output ports of MCU can be classified as Two data types.
1) Analog : Numeric signal
2) Digital : On/Off information

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3-4. Maintenance – User Password Change

② ①

* How to set the User password

1. Maintenance → User Password
Change.
① Enter current password.
② Enter new password
③ Retype it.
2. Password length must be longer
③

than
5 digits and less than 10 digits.
Password change has been completed.

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 4. Display Setting

LCD Adjustment Time Setting Unit Setting Language Setting - A/S Phone No.
- ESL Password Change

▶ Manual ▶ Year / Month / Day ▶ Speed / Weight ▶ Korean Maintenance Management

▶ Automatic ▶ Hour / Minute ▶ Temperature ▶ English

▶ Pressure / Date type ▶ Other languages

(Maintenance Items, Viewing only)

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4-1. Display Setting – A/S Phone No.

- User can revise the A/S contact point(Phone number) when the vehicle is delivered.

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 4-2. Display Setting – ESL Password Change

② ①

* How to set the ESL Password Change

1. Display Setting → ESL Password Change.
① Enter current password.
② Enter new password
③ Retype it.
2. Password length must be longer than 5 dig-
its ③
and less than 10 digits.

Password change has been completed.

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4-3. Display Setting - Maintenance Management

• Maintenance items viewing only.

• Other management options.
1) Elapsed time reset
2) Replacement Interval adjustment
☞ ‘Maintenance’ – ‘Maintenance Management’ menu.

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