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GROUP 6 TROUBLESHOOTING

1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.26 is not blown out and ON/OFF of bulb.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace
Check voltage
YES
between CN-51
(1, 2) and chassis

NO Disconnection in Repair or replace


wiring harness or (After clean)
Check voltage
poor contact
between CN-12
(1) and chassis between
CN-51(1, 2) and
CN-12(1)

NO
Disconnection in Repair or replace
wiring harness or (After clean)
poor contact
between CN-12(1)
and fuse No.26

CLUSTER
1
FUSE
2 1
No.26
CN-51
CN-12

Check voltage
YES 20 ~ 30V
NO 0V 7607EL14

7-61
2. WHEN BATTERY LAMP LIGHTS UP(Engine is started)
・Before carrying out below procedure, check all the related connectors are properly inserted.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective controller Replace
Check voltage
YES
between CN-58
(25) and chassis
NO Disconnection in Repair or replace
Voltage : 27.5~30V wiring harness or (After clean)
poor contact
Check voltage between CN-58
YES between CN-3(4)
(25) and CN-3(4)
and chassis
YES
Voltage : 26~30V Disconnection in Repair or replace
wiring harness or (After clean)
Check voltage poor contact
between CN-4(8) between CN-4(8)
NO
Check voltage and chassis and CN-3(4)
between
alternator terminal Disconnection in Repair or replace
"I" and chassis NO
wiring harness or (After clean)
Voltage : 26~30V poor contact
Starting switch : ON
between CN-4(8)
and alternator
terminal " I "

Defective alternator Replace


NO

CONTROLLER

ALTERNATOR
25 4 8 " I " TERMINAL
CN-3 CN-4
CN-58

Check valtage
YES 20 ~ 30V
NO 0V 7707EL23

7-62
3. WHEN PARKING SOLENOID DOES NOT WORK
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.8 is not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective parking Replace
Check voltage brake solenoid
between CN-71
(2) and chassis YES
Defective parking
Check voltage
Starting switch : ON switch
Parking switch : ON-OFF NO
between CS-17
Voltage : 20~30V (6) and chassis
Disconnection in
Voltage : 20~30V NO
wiring harness or
poor contact
between CS-17(6)
and Fuse No.8

PARKING SWITCH
8 2
1
5
CN-71
6
CS-17 FUSE

No.8

7707EL24

7-63
4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.17(T/M controller) and No.8 are not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective T/M Replace
controller

Check voltage YES


Disconnection in Repair or replace
between CN-52
wiring harness or (After clean)
(21) and chassis
poor contact
Starting switch : ON Check voltage between CN-52
Parking switch : ON between CS-17
Voltage : 20~30V NO (21) and CS-17(7)
(7) and chassis
YES
Voltage : 20~30V Defective switch Replace
Parking switch : ON Check voltage
between CS-17
NO
(5) and chassis
Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (After clean)
poor contact
between CS-17(5)
and fuse No.8

PARKING SWITCH
FUSE
6
5 No.8
7
CS-17 21

CN-52

Check resistance
YES MAX 1Ω
7707EL25
NO MIN 1MΩ

7-64
5. MACHINE DOES NOT TRAVEL
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.17(Transmission controller) is not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.
・Wiring diagram : See page 7-16.
Cause Remedy
YES
Defective clutch Replace
cut-off switch
Check resistance
YES
between CD-5
and chassis

NO Is there continuity Defective T/M Replace


between CN-52 NO
(66) and chassis? controller

NO
Defective T/M Replace
Is voltage between
controller
CN-52(21) and
chassis 20-28V? YES
Defective parking Replace
Starting switch : ON
Parking switch : OFF
switch
Clutch cut-off Is there continuity
switch : ON between CS-17(7)
YES
and chassis?

Disconnection Repair or replace


NO
wiring harness or (After clean)
poor contact
between CN-52
(21) and CS-17(7)

Check resistance
YES MAX 1Ω
NO MIN 1MΩ

7-65
6. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.9 is not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.
CONTROLLER

HYD TEMP SENDER


CLUTCH CUT-OFF PS
SERIAL-L

SPEEDMETER SIG.

RIDE CONT. AUTO


COOLANT SIG
SAFETY RY

BUZZER STOP
WIPER RY
STEERING RY

ALT LEVEL
FUEL SENSOR
PREHEATER

WASH SIG
NEUTRAL SIG

CAN-H
AUTO SEL.TCU
REMOTE FAN(+)

CAN-L
REMOTE FAN(-)

STEERING PS

CLUTCH CUT-OFF SW

STEERING P/P PS
ENG OIL PS

TACHO +

RIDE CONT. ON
WIPER INT SIG

PARKING SIG
SERIAL-H

GND
BUZZER

AUTO SEL.SW

BRAKE PS
TAHCO -

AIR FILTER
IG 24V
Cause Remedy FUSE BOX
BEACON LAMP 20A
YES ILL.LAMP 10A
1

Check voltage Defective front Replace 2


HEAD LAMP 20A

23
35
34

24
36

31

26
32

25
33

27

21
20
30
29
28

22

17
19

11
18

16

12

10
13
15
14

1
2
3
6
8

4
5
7
9
YES between front wiper motor BACK/STOP LAMP 10A
3

M30 0.85 Y

M27 0.85 R
CN-58

M22 0.85 Gr
wiper motor and HORN/CONVERTER 30A
5
AIR-CON/HEATER 20A
chassis Poor connection of Replace 6

Check voltage Voltage : 20~30V


NO CIGAR 20A

YES chassis SWITCH 10A


7

between CN-21(5) Starting switch : ON F/R WIPER


8
M14 1.25 L 20A
Wiper switch : 1st 9
and chassis WORK LAMP 30A
10

CN-36
Voltage : 20~30V
Starting switch : ON Disconnection in Repair or replace WIPER RY LO
Check voltage Wiper switch : 1st NO M46 0.85 R
30
YES between CS-12 wiring harness or (After clean) M45A 0.85 W
86
87a 87 85
M45 0.85 W
(4), CN-7(10) and poor contact M22 0.85 Gr
87
85
chassis between CN-7(10) M39 0.85 G
87a 30 86
CR-26
Voltage : 20~30V and CN-21(5),
Starting switch : ON
Wiper switch : OFF CN-13(5)
WIPER RY HI
M14A 1.25 L
30
Defective wiper Repair or replace M38 0.85 Br 87a 87 85
NO M49 0.85 G
86
switch or (After clean) G25 1.25 B
87
85
Check voltage disconnection in M45B 0.85 W
87a 30 86

CS-12(6) wiring harness or CR-4

poor contact
Voltage : 20~30V between CS-12(4)

M27A 0.85 R
Starting switch : ON

M14D 1.25 L

M38 0.85 Br
and CN-7(10).

M39 0.85 G

M30 0.85 Y
Wiper switch : 1st
YES
Disconnection in Repair or replace
wiring harness or (After clean)
Check voltage poor contact

CN-7
between CN-7(8) between CN-7(8)

10
11
12
13
14
6
7

9
8

M45C 0.85 W
NO

M49 0.85 G
M46 0.85 R
G51 1.25 B
and chassis. and fuse No.9

Discomection in

CS-11
Repair or replace

CS-12

CS-5
NO

6
5
4
3
2
1
8
7
6
5
4
3
2
1

CN-13
wiring harness or (After clean)

10
11
12
13
14
1
2
3
4
5
6
7
8
9
BWG 4
poor contact

RW 6
W6

BVi 3
L 4
G 5

BY 1

Gr 2

Y
M40 0.85 VOr
between CS-12(6)

HO
W
II
I
Hi

C
J 0

J
and CN-7(8).

CN-21
1
2
3

5
4

6
0
II
I
Lo
Hi

5 Lo
4 Hi
3E
B+

2Pf
1B
F

R
L
O

R
L

M
7 Y Lo
8 WB

2 BW

3 BG
MULTI FUNCTION SWITCH 5B FRONT WIPER

7607EL12

7-66
7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE
・Before carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.16 is not blown out.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
FUSE BOX
YES
Defective cable Repair or replace RADIO/ROOM LAMP 5A
14

Check voltage (After clean)


15
YES assembly M04 1.25 Or START KEY 30A
16
between CN-60(2) TCU 10A
17
and chassis ECM 10A
18
Short circuit or Replace CLUSTER 10A
19
Voltage : 20~30V NO AC & HEATER 10A
20
Check voltage defect of fusible SPARE 10A
YES 21
between CR-1 link or defective ECM 5A
22
RCV 10A
(R1) and chassis 23
battery relay CONTROLLER 10A
24
Voltage : 20~30V TCU 10A
25
CLUSTER 10A
26
Disconnection in Replace ILL,F/L,R/R 5A
27
NO ILL.F/R,R/L 5A
Check voltage wiring harness or 28

YES between CS-2 CN-36


(1)[and CS-2(2)] poor contact F21 3.0 W

and chassis between CS-2(2) - BATTERY MASTER SW


BATT RY
Voltage : 20~30V R4 B G

CN-3(6)-CR-1 F23C 1.25 L R1

G79 1.25 B R3 TO STARTER


(R1) R2 CS-0
CR-1
F22 5.0 R
2 2
F21 3.0 W
Disconnection in Replace 1 1
Check voltage NO CN-1 CN-60
wiring harness or
and specific
gravity of battery poor contact
between fuse No.
Specific gravity : MIN 1.28
Voltage : MIN 24V 16 and CS-2(1) or
1
F23 1.25 L
defect of start 2 2
3 F12 1.25 V
1
switch 4 DO-1
5
6

M04B 1.25 Or
F12 0.85 V
Battery capacity Repair or replace 7
NO 8
too low (After clean) 9
10
11

CS-2
12

5
4

1
6

2
3
13
B 14
0, I

1
15
CN-3
H 0 I II

4
6
5

3
2
H
C ST ACC BR
START SWITCH

7707EL27

7-67
8. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
・Before carrying out below procedure, check all the related connectors are properly inserted, and the
fuse No.10 is not blown out. FUSE BOX
・After checking, connect the disconnected connectors again immediately unless otherwise specified. BEACON LAMP 20A
1
M17 1.25 OrW ILL.LAMP 10A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 20A
6
Cause Remedy CIGAR 20A
7
YES SWITCH 10A
8
Defective lamp Replace F/R WIPER
Check voltage 20A
9
YES between each M10 1.25 Gr WORK LAMP 30A
10
OPTION 10A
lamp and chassis 11
Disconnection in Repair or replace CN-36
NO OPT
Voltage : 20~30V wiring harness or (After clean)
Check voltage Starting switch : ON poor contact C03D 1.25 Or
FRONT WORK LAMP
2
YES between CN-5(4), between CL-6(2),
G15 1.25 B
1
CN-3(10) and CL-5(2), CL-22(1),
CL-36
FRONT WORK LAMP
chassis CL-23(1) and CN-
C03C 1.25 Or
2
G14 1.25 B
1
Voltage : 20~30V 5(4), CN-3(10). CL-35
Starting switch : ON 1
2 FRONT WORK
Check voltage Disconnection in Repair or replace FR WORK LAMP RY 3 LAMP,LH
C03 1.25 Or C03 1.25 Or C03A 1.25 Or
YES between CR-3(4), NO 3 4 4 4 2
wiring harness or (After clean) 3
M51 0.85 W
5 G01 1.25 B
G11 1.25 B
1
CR-6(4) and poor contact 2
M10A 1.25 Gr 6 CL-6
G21 1.25 B 7
chassis between CN-5(4) - 1 2 1
8 FRONT WORK
CR-3 LAMP,RH
Voltage : 20~30V 9 C03B 1.25 Or
Starting switch : ON
CR-3(4) and CN- 10 G12 1.25 B
2
11 1
3(10) - CR-6(4) 12
C14 1.25 Br
CL-5
OPT
Check voltage 13 REAR WORK LAMP
14
between CR- Defective work Replace relay 15
C14A 1.25 Br
2
NO G16 1.25 B
1
3(2), CR-6(2) and lamp relay CN-5
CL-32
chassis REAR WORK LAMP
YES RR WORK LAMP RY C14B 1.25 Br 2
Voltage : 20~30V Disconnection in Repair or replace 3 4 4
CF14A 1.25 Br 1 G17 1.25 B
2 1
Starting switch : ON M52 0.85 L
wiring harness or (After clean) 3
M10B 1.25 Gr 3 CL-33
2 4
Check voltage poor contact 1 2 1
G22 1.25 B
5 REAR WORK
LAMP,LH
6
between CR-3(2), CR-6 F14A 1.25 Br
1
between fuse No. 7 G19 1.25 B
NO CR-6(2) and fuse 8 2
10 and chassis WORK LAMP SW 9 F14 1.25 Br CL-22
No.10 G13 0.85 B 10
9 10 10 C05F 0.85 R
9 11
Voltage : 20~30V 12 REAR WORK
4 8
Starting switch : ON Short circuit of fuse Replace 2 M59 0.85 Y 13 F14B 1.25 Br
LAMP,RH
7
NO 7 1 6
14
G17 1.25 B
1
M51 0.85 W 15 2
5 5
C05G 0.85 R CN-3 CL-23
4
3
M52 0.85 L

II I 0
2 CLUSTER
1 C05H 0.85 R 20 TX-PC
CS-20 19 GND
17 ILL.
CS-39
16 T/M ERROR
15 SERIAL-L
9 10 10 14 SERIAL-H
9 12 12 GND
4 8 11 GND
2 C05C 0.85 R 11
7 10 RX-PC
10 9 FWE
7 1 6 9
5 M59 0.5 Y 8 N.C
5 WORK LAMP
8 7
4 7 6 HIGH BEAM
II I 0 3 6 5 RH TURN
2 4 LH.TURN
M17 1.25 OrW 5 3 24V PER.
1
4 2 24V IG
ILL & HEAD LAMP SW : ON(1st step) 3 1 24V IG
2 CN-51
1
CN-12

7707EL28

7-68
9. WHEN ENGINE DOES NOT START
・Check supply of the power at engine stop solenoid while starting switch is ON. CONTROL UNIT
・Before carrying out below procedure, check all the related connectors are properly inserted.
・After checking, connect the disconnected connectors again immediately unless other wise specified.

VMGA2

ADM5
・Check forward reverse switch at neutral position.

VPE2
AIP6
AIP4
AIP1

ED1
ED5
ED2
ED9
ED6
EF4
VPI
45
46
51
55
56
57
62
63
64
65
66
67
68
FUSE BOX
Cause Remedy CN-52

T37 0.85 W
A 14
VM OUTPUT SIGNAL K RADIO/ROOM LAMP 5A
YES VP F B N D B
START KEY
15
Defective battery Check engine ED 1 2 3 4 1 2 3 4 1 2 3 4 C 30A
16
AD1 B1 D TCU 10A
system charge or AD2 B2 CN-121 ECM 10A
17
AD3 B3 18
replace (after AD4 V CLUSTER 10A

M01 1.25 WOr


19
1
checking specific AD5 R A
SAFETY RY AC & HEATER 10A
20
AD6 AS B 2 M43 1.25 R
gravity of battery) AD7 C 3 30 SPARE 10A
21
85
YES A AD3 D 4
T37C 0.85 W
86 87a 87 ECM 5A
Check voltage Defective magnet Replace CN-122 5 E05 0.85 R
87 RCV 10A
22
B AD2
Check operation YES between starter of start motor C AD1 6 M21 0.85 L
85 CONTROLLER 10A
23

7 24
of start motor magnet coil and X1
D AD7(KD)
8
87a 30 86 TCU 10A
25
CR-5 CLUSTER
chassis Defective start Replace
A ED1(VP) 9 10A
26
Starting switch : start NO D AD6 10 ILL,F/L,R/R 5A
Starting switch : start relay B AD4 11 27
ILL.F/R,R/L 5A
C AD5 12 28
X2
13
YES CN-36
ⓐ 14
CN-13
Check operation Check voltage
NO of starter relay YES
between CR-5
(87) and chassis
Starting switch : start
Disconnection in Replace
Starting switch : OFF NO
wiring harness or
Check operation poor contact
of start safety between CN-2(11)
NO
relay and CR-5(87)
Check switch : neutral YES
Defective relay Replace
Check voltage
between CR-5 STARTER
NO TO BATT
(86) and chassis B+

Starting switch : OFF NO



M
YES CN-45
Defective start Replace

M01 1.25 WOr

M04B 1.25 Or
M43 1.25 R

F12 0.85 V
Check voltage relay START RY
G15 1.25 B
ⓐ between CR-23 1
E05 1.25 R
1
2 2
(2) and chassis

CS-2
3 CR-23

5
4

1
6

2
3
Disconnection in Repair or replace 4
Voltage : 20~30V NO B
Starting switch : ON wiring harness or 0, I 5 1

1
6 2
poor contact
7 3
between CN-2(11) H 0 I II
8 4

4
6
5

3
2
-CN-4(7)-CR-23(2)
H
C ST ACC BR 9 5
START SWITCH 10 6
E05 0.85 R
YES 11 7
Disconnection in Repair or replace 12 8
wiring harness or CN-2 9
10
Check voltage poor contact 11
ⓑ between CN-13 between CN-13(4) 12
(4) and chassis and CR-5(86) CN-4

Starting switch : OFF


Defective DW-3 Replace 7707EL29
NO

7-69