GROUP 3 ELECTRICAL SYSTEM

1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.9.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective clucter Replace
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-5 poor contact (After clean)
(3) and chassis between CN-5
(3)-CN-56(1)
Starting switch : ON
Voltage : 20~32V

NO Disconnection in Repair or
wiring harness or replace
poor contact (After clean)
between
CN-5(3) and fuse
No.9

CLUSTER FUSE
POWER IG(24V) 1 3
GND 2 9
NO.9

RX
TX
CN-56 CN-5

Check voltage
YES 20 ~ 32V
NO 0V
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2. COMMUNICATION ERROR "Co : Er" FLASHES ON THE CLUSTER
·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective controller Replace

YES Check voltage

between CN-56
(3,4) and chassis
Disconnection in Repair or replace
NO wiring harness or (After clean)
Check voltage
between CN-5 poor contact
between CN-56
(10,11)and (3,4) CN-5(10,11)
chassis
KEY ON
Disconnection in Repair or replace
NO
wiring harness or (After clean)
poor contact
between CN-5
(10,11)-CN-50
(29,30)

CONTROLLER
Check voltage
YES *4V *12V 29

NO 0V 0V
30

CN-50

CLUSTER
POWER IG(24V)
GND 2 9
RX *12V
3 10
TX *4V 4 11
CN-56 CN-5

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3. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective controller Replace
YES Check voltage
between CN-51
(9) and chassis Disconnection in Repair or replace
Check voltage NO
wiring harness or (After clean)
YES between CN- poor contact
2(13) and between CN-51(9)
chassis -CN-2(13)

Check voltage Disconnection in Repair or replace

NO wiring harness or (After clean)
between alternator
poor contact
terminal "I" and between CN-2(13)-
chassis alternator terminal
Voltage : 20~32V "I"
Engine : Running

Defective alternator Replace

NO

Check voltage
YES 20 ~ 32V
NO 0V

CONTROLLER
B+ G
9 13 3~
I
U
GND
ALTERNATOR
CN-51 CN-2

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4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Disconnection in Repair or replace
wiring harness or (After clean)
Is the CAN poor contact
YES communication between
between CPU ECM-coolant temp
and ECM?
sensor
Starting switch : ON YES
Check resistance Defective controller Replace
Does the gauge
light up and between CN-174 or ECM
down at lamp NO (A-B) & CN-99
check? (A-B).
Defective wiring Replace
NO
Starting switch : ON Spec : 120Ω harness

NO Defective cluster Replace

Green range Red range Check Table

Temperature White range Green range Red range
Item (~29。C ) (30~105。 C) (105。C ~)

White range

RESISTOR RESISTOR
A A A A
ECM
B B
B C B C
CN-174 CN-99

CONTROLLER

25 5 48

26 6 47

27 7 37

CN-50 CN-3

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5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go
off when
disconnect CD-
10? YES
Short circuit in Repair or replace
Starting switch : ON
Engine : Start Check resistance wiring harness (After clean)
between CN-51
NO
(16) and chassis
Starting switch : OFF Defective controller Replace
NO
Disconnect CN-51

Check resistance
YES MAX 1Ω
NO MIN 1MΩ

CONTROLLER AIR CLEANER SWITCH

Pa
16

CD-10
CN-51

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6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Disconnection in Repair or replace
wiring harness or (After clean)
Is the CAN poor contact
YES communication between
between CPU ECM-engine oil
and ECM?
pressare switch.
Starting switch : ON YES
Defective controller Replace
Does the gauge Check resistance
light up and between or ECM
down at lamp NO CN-174 (A-B) &
check? CN-99 (A- B) Defective wiring Replace
NO
Starting switch : ON Spec : 120Ω harness

NO Defective cluster Replace

Check resistance
YES MAX 1Ω
NO MIN 1MΩ

RESISTOR RESISTOR
A A A A
ECM
B B
B C B C
CN-174 CN-99

CONTROLLER

25 5 48

26 6 47

27 7 37

CN-50 CN-3

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7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1 (100。 C±2。 C) ,
(1,2) is in range replace
of 130~150Ω?
Starting switch : ON Defective temp Replace
Does display go Disconnect CD-1 NO
sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Starting switch : ON
Engine : Start
Resistance
between CN-51
NO (31,34) is 0~1Ω?

Defective controller Replace

Starting switch : OFF NO
Disconnect CN-51

CONTROLLER HYDRAULIC OIL

TEMPERATURE SENDER

34 2
C
31 1

CN-51 CD-1

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8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Disconnection in Repair or replace
wiring harness or (After clean)
Is the CAN poor contact
YES communication between
between CPU
ECM-coolant temp
and ECM?
Starting switch : ON
sensor
YES
Check resistance Defective controller Replace
Does the gauge
light up and between CN-174 or ECM
down at lamp NO (A-B) & CN-99
check? (A-B).
NO
Defective wiring Replace
Starting switch : ON Spec : 120Ω
harness

NO
Defective cluster Replace

Green range Red range Check Table

Temperature White range Green range Red range
Item (~29。 C) (30~105。 C) (105。C ~)
White range

RESISTOR RESISTOR
A A A A
ECM
B B
B C B C
CN-174 CN-99

CONTROLLER

25 5 48

26 6 47

27 7 37

CN-50 CN-3

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9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-51
(24) and (31)
over 1kΩ? YES
Defective controller Replace
Starting switch : OFF
Disconnect CN-51
Check resistance
Does the gauge between CD-2(1)
light up and NO and (2)
down at lamp Defective fuel Replace
NO
check? Disconnect CD-2
sensor
See Table
Starting switch : ON

Defective cluster Replace

NO

Green range Red range

Check Table
Level White range Green range Red range
Item
Unit Resistance(Ω) 700~601 600~101 ~100
White range Tolerance(%) ±5 ±5 ±5

CONTROLLER
FUEL SENDER

24 1

CD-2

31

CN-51

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10. WHEN SAFETY SOLENOID DOES NOT OPERATE

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.26.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Hydraulic Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
Safety lever : ON-OFF NO
YES
Defective switch Replace
YES Check voltage
between CS-4(C)
Check voltage and chassis
between CN- Disconnection in Repair or replace
68(1) - CN-68(2) Start switch : ON NO
wiring harness or (After clean)
YES Check voltage Voltage : 20~30V
Starting switch : ON between CN-4(8) Disconnect CN-4 poor contact
Voltage : 20~30V and chassis between
Safety state
Starting switch : ON
CS-4(C)-CN-68(2)
Voltage : 20~30V
Disconnect CN-4 Disconnect in Repair or replace
Check voltage NO
between CN-68(2) wiring harness or (After clean)
NO
with chassis poor contact
between
Safety lever : OFF
Starting switch : ON CN-4(8)-CN-68(2)
Voltage : 20~30V
Disconnection in Replace
NO
fuse No. 26

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11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.24 .
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective hydraulic Check hydraulic
system system
YES Check voltage YES Check operation
between CN-50 YES
of solenoid Defective controller Replace
(13) and chassis
Check resistance
Check if travel Starting switch : ON Starting switch : ON between CN-70
Volage : 20~30V : OFF NO
speed lamps( , (1) and (2)
Disconnect CN-50 : ON
) change when Defective solenoid Replace
Starting switch : OFF NO
pressing the travel
speed switch on SPEC : 15~25Ω
Disconnect CN-70
the cluster YES
Starting switch : ON
Defective cluster Replace
Check controller
Y R G
NO
Defective controller Replace
Starting switch : ON
NO

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12. WHEN ENGINE DOES NOT START

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted.
START SWITCH
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

II I O H
1

I,O
9
2
Cause Remedy 10 3 4

H
YES 4 1

ACC BR
B
Defective battery Check engine 11 2
5 3
system charge or 12
6
replace(After

C ST
5
checking specific CN-8 6
gravity of battery) CS-2
ECM POWER RY
Check operation YES 1 2 1
Check voltage Defective magnet Replace
of start motor YES between starter of start motor 2
magnet coil and 3
Starting switch : START chassis Defective start relay Replace 4 4 3
NO
Starting switch : START YES CR-45
Check operation SPEC : 20~30V ⓐ
YES
Check voltage POWER RY
of start relay CR- between CR-5
NO 30
30 86
23 (30) and chassis
Defective start Repair or replace 86
Starting switch : START anti-restart relay (After clean)
Check operation Starting switch :START 87 CS-74

BATTERY RY
1
of start anti- SPEC : 20~30V 85 2 2
87a 87 85
NO restart relay 87a 1 CN-60

CR-1
CR-5 CR-35
YES
Starting switch : ON FUSE
Check voltage Defective relay Replace
between CR-5 NO.1
NO (86) and chassis Disconnection in Repair or replace
NO DO-2 DO-1
wiring harness or (After clean)
Starting switch : ON poor contact
Voltage : 20~30V between CR-5(86)

1
2

2
CS-2(5)

YES CN-51
Defective start relay Replace
Check voltage
ⓐ between CR-23 9
and chassis
NO
Disconnection in Repair or replace
CPU CONTROLLER
Starting switch : ON wiring harness or (After clean)
CN-92
poor contact
between CR-5(87)- 11
CR-23
CN-50

START RY STARTER
ANTI-RESTART RY
M M
86 30 30 7
86
87 B+
85 CN-2 CR-23
85 87 87a CN-45
87a
CR-5

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13. WHEN STARTING SWITCH ON DOES NOT OPERATE

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
master switch ON
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES ECM POWER RY
Disconnection in Repair or replace
1 2 1
wiring harness or (After clean)
2
poor contact
YES Check voltage 3
between DO-2 between DO-2(1)-
4 4 3
(1) and chassis CR-1 or defective CR-45
Voltage : 20~30V
battery relay

YES Check voltage Disconnection in Replace

between CS-2 NO
wiring harness or
(2) and chassis
poor contact
CS-74
Voltage : 20~30V between CS-2(2)-
Check voltage 2
YES CN-8(11)- DO-2(1) 1
between CS-2(1)
and chassis
Defective start Replace
Voltage : 20~30V NO
switch

Check voltage Disconnection in Replace

and specific NO
gravity of battery wiring harness or
poor contact
Specific gravity : MIN 1.28
Voltage : MIN 24V between CS-2(1)-
CN-8(12)-CN-60-
CR-1-Battery

Battery capacity too Charge or replace

NO
low (After clean)

ANTI-RESTART RY

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14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse
No.5, 8 and 15 is not blown out. CN-21
3 1
·After checking, insert the disconnected connectors again immediately unless otherwise specified.
2
5 3
Cause Remedy 4
4
NO
Defective wiper Replace 5
M CN-5
cut switch 6 2 6
1
NO
Disconnection in Repair or replace WIPER MOTOR FUSE
Check operation wiring harness or (After clean) 4
wiper cut switch poor contact NO.5
CN-141
between CN-141 FEED BACK 1 CN-6 FUSE
Front sliding door Check valtage (11)- CS-53 2 5
open-close MOTOR DRIVE SIG CN-17
between CN-141 YES MOTOR DRIVE- 3 1 6 NO.15
YES (11) and chassis Defective switch Replace CN-22
panel MOTOR DRIVE+ 4 2 9
NO Check voltage GND 5 3 10 2 M
Front sliding door-close between CN-116
Voltage : 4~5V (6) and chassis VCC 6 4 11 1
Check operation 1)Recheck fuse Replace CONTINUE 24V 7 5 WASHER TANK
NO NO.8
YES of switch panel
Starting switch : ON WASHER P/P 8 6
LED ON. Vottage : 20~30V 2)Disconnection in Repair or replace WASHER SIG. 9 7
wiring harness or (After clean)
Starting switch : ON ⓐ INT. SIG 10 8
Push wiper switch button YES
poor contact
WIPER CUT SW 11
between CN-
116(6)-Fuse N.C 12 CN-7
between CN- FEED BACK 13 3 FUSE
116(13)-Chassis WIPER MOTOR CONTROLLER 5
9 NO.8
Check voltage between NO
Defective switch Replace 10
CN-116(4) and chassis panel WIPER CUT SW
Intermittent
NO
1) Recheck fuse Replace CS-53
Check voltage CN-116 NO.5 CN-9
ⓐ (12) and chassis 2) Disconnection Repair or replace
Washing
Check operation in wiring harness (After clean)
of wiper motor or poor contact 4
and controller CN-116
Check voltage CN-116 between CN- HEAD LIGHT OUT 1
(15) and chassis check voltage 141(7)-Fuse,
YES CN-141(7) and WORK LIGHT OUT 2
Sarting switch : ON CN-21(4)-Fuse WORK LIGHT OUT 3
Voltage : 0~1V
chassis, CN-21(4) WIPER MOTOR DRIVE 4
and chassis NO
1) Recheck fuse Replace PRE-HEAT 5
Starting switch : OFF NO.15 POWER 24V 6
Voltage : 20~30V Check voltage CABIN LIGHT OUT 7
2) Disconnection Repair or replace
CN-141(6)-and CABIN LIGHT OUT 8
YES chassis CN-141(6)-Fuse (After clean) HEAD LIHGT 24V 9
WORK LIGHT 24V 10
Starting switch : ON ⓑ WORK LIGHT 24V 11
Check continuity YES
Voltage : 20~30V WASHER SIG 12
NO
between Disconnection in Repair or replace GND 13
CN-141(2)-CN-116(4), wiring harness or (After clean) TRAVEL ALARM 14
CN-141(9)-CN-116(12), poor contact INT. SIG 15
CN-141(10)-CN-116(15), CABIN LIGHT 24V 16
ⓑ CN-141(5)-Chassis , NO CABIN LIGHT 24V 17
Check wiper Defective wiper Replace
CN-141(1)-CN-21(5), SWITCH PANEL
motor resistance motor
CN-141(3)-CN-21(6),
YES between CN-21
CN-141(4)-CN-21(2), (2)-CN-21(6) Defective wiper Replace
CN-141(13)-CN-21(3) YES motor controller
Resistance : 3~4Ω
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15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.16.
·After checking, insert the disconnected connectors again immediately unless otherwise specified. HEAD LAMP

2
1
Cause Remedy
NO CL-4
Defective lamp Replace switch
switch
HEAD LAMP RY
1 2 1
2
Check voltage 3
YES
between CN-116 YES 4 4 3
(1) and chasis Defective bulb Replace CR-13
YES
Check voltage
Starting switch : ON between CL-4(1)
Head lamp switch : ON and chassis
Voltage : 20~30V Disconnection in Repair or replace
Starting switch : ON NO
Head lamp switch : ON wiring harness or (After clean)
Check voltage CN-7
between CN-7(1)
Voltage : 20~30V poor contact CN-116
YES and chassis 1 1 HEAD LIGHT OUT
between CN-7(1)-
2 WORK LIGHT OUT
CL-4(1) 3 WORK LIGHT OUT
Starting switch : ON 4 WIPER MOTOR DRIVE
Head lamp switch : ON
5 PRE-HEAT
Check voltage Voltage : 20~30V Disconnection in Repair or replace
NO 6 POWER 24V
between CN-116 wiring harness or (After clean) 7 7 CABIN LIGHT OUT
(9) and chassis 8 CABIN LIGHT OUT
poor contact 9 HEAD LIHGT 24V
Starting switch : ON between 10 10 WORK LIGHT 24V
Head lamp switch : 11 WORK LIGHT 24V
ON-OFF
CN-116(1)-CN- 12 WASHER SIG
7(1) 13 GND
14 TRAVEL ALARM
YES 15 INT. SIG
Disconnection in Repair or replace 16 CABIN LIGHT 24V

wiring harness or (After clean) 17 CABIN LIGHT 24V

SWITCH PANEL
Check voltage poor contact
between CN- between CN-116
NO 7(7) and chassis
(9)-CN-7(7)
Head lamp switch : ON FUSE
Recheck fuse Replace
NO NO.16

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16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP

·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.17.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy WORK LAMP

NO
Defective lamp Replace switch 1
switch 2

CL-5

Check voltage CN-12 WORK LAMP

YES between CN-116
YES 2 1
and (2, 3) and Defective bulb Replace
chasis 1 2
Check voltage
YES
Starting switch : ON between CL-5(2) CL-6
Work lamp switch : ON and chassis
Voltage : 20~30V Disconnection in Repair or replace
Starting switch : ON NO
Work lamp switch : ON wiring harness or (After clean)
Check voltage Voltage : 20~30V poor contact CN-7
between CN-7(2) CN-116
YES and chassis between CN-7(2)
1 HEAD LIGHT OUT
-CL-5(2) and 2 2 WORK LIGHT OUT
Starting switch : ON 3 WORK LIGHT OUT
Work lamp switch : ON
CL-6 (2)
Check voltage 4 WIPER MOTOR DRIVE
Voltage : 20~30V 5 PRE-HEAT
between CN-116
(10,11) and Disconnection in Repair or replace 6 POWER 24V
NO 8 7 CABIN LIGHT OUT
chassis wiring harness or (After clean) 8 CABIN LIGHT OUT
Starting switch : ON poor contact 9 HEAD LIHGT 24V
Work lamp switch : 10 10 WORK LIGHT 24V
ON-OFF
between CN-116
11 WORK LIGHT 24V
Voltage : 20~30V (2,3)-CN-7(2) 12 WASHER SIG
13 GND
14 TRAVEL ALARM
YES 15 INT. SIG
Disconnection in Repair or replace 16 CABIN LIGHT 24V
17 CABIN LIGHT 24V
wiring harness or (After clean)
SWITCH PANEL
Check voltage poor contact
between CN-7(8) between CN-116
NO and chassis
(10,11)-CN-7(8)
Head lamp switch : ON FUSE
Voltage : 20~30V
NO Recheck fuse Replace NO.17
NO.17

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