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.7.
·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(3) poor contact (After clean)
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.7

CLUSTER FUSE
POWER IG(24V) 1 3
NO.7
GND 2 9
RX
TX
CN-56 CN-5

Check voltage
YES 20 ~ 32V
NO 0V
3607A6ES01

6-24
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
29
YES *4V *12V
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

29076ES02

6-25
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
NO
wiring harness or (After clean)
YES Check voltage poor contact
between CN-2
(13) and chassis between CN-51(9)
-CN-2(13)

Check voltage Disconnection in Repair or replace

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

Defective alternator Replace

NO

Check voltage
YES 20 ~ 32V
NO 0V

CONTROLLER ALTERNATOR
B+ G
9 13 3~
I
U
GND
CN-74
CN-51 CN-2

36076MS05

6-26
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 OK?
sensor
Starting switch : ON YES
Defective controller Replace
Does the gauge Check resistance
light up and between CN-98 or ECM
down at lamp NO (A-B) & CN-99
check? (A-B). Defective wiring Replace
NO
Starting switch : ON Spec : 120Ω harness

Defective cluster Replace

NO

RESISTOR RESISTOR
A A A A
ECM
B B
B C B C
CN-98 CN-99

CONTROLLER

25 5 48

26 6 47

27 7 37

CN-50 CN-3 CN-93

3607A6ES02

6-27
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 YES
CD-10? Short circuit in Repair or replace
Starting switch : ON Check resistance wiring harness (After clean)
Engine : Start 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

3607A6ES03

6-28
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 OK?
pressure switch.
Starting switch : ON YES
Defective controller Replace
Does the gauge Check resistance
light up and between CN-98 or ECM
down at lamp NO (A-B) & CN-99
check? (A- B) Defective wiring Replace
NO
Starting switch : ON Spec : 120Ω
harness

Defective cluster Replace

NO

RESISTOR RESISTOR
A A A A
ECM
B B
B C B C
CN-98 CN-99

CONTROLLER

25 5 48

26 6 47

27 7 37

CN-50 CN-3 CN-93

3607A6ES02

6-29
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

29076ES04

6-30
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 OK?
sensor
Starting switch : ON YES
Defective controller Replace
Does the gauge Check resistance
light up and between CN-98 or ECM
down at lamp NO (A-B) & CN-99
check? (A-B). Defective wiring Replace
NO
Starting switch : ON Spec : 120Ω
harness

Defective cluster Replace

NO

RESISTOR RESISTOR
A A A A
ECM
B B
B C B C
CN-98 CN-99

CONTROLLER

25 5 48

26 6 47

27 7 37

CN-50 CN-3 CN-93

3607A6ES02

6-31
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

29076ES06

6-32
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

SAFETY SWITCH

CS-20 FUSE

NO.26
SAFETY SWITCH
B C A 6 SAFETY SOLENOID
B 7 2

A C 8 1
CS-4 CN-4 CN-68

3607A6ES04

6-33
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
Voltage : 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

CONTROLLER
TRAVEL SOLENOID

13 1

CN-50 CN-70

FUSE

NO.24

36076ES04

6-34
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. CN-8
·After checking, insert the disconnected connectors again immediately unless otherwise specified. CS-2

II I O H
1

I,O
9
2
4

H
10 3

ACC BR
4 1

B
11 2
5 3

Cause Remedy 12
6

C ST
YES 5
Defective battery Check engine 6

system charge or ECM POWER RY START SWITCH

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

BATTERY RY
1
NO 23 85 2 2
(30) and chassis
Defective start Repair or replace 87a 87 85 1 CN-60
NO 87a

CR-1
Starting switch : START safety relay (After clean)
Starting switch :START
Check operation SPEC : 20~30V
CR-35
of start safety FUSE
NO relay CR-5
NO.1
YES DO-2 DO-1
Starting switch : ON
Check voltage Defective relay Replace
between CR-5
NO (86) and chassis Disconnection in Repair or replace

1
2

2
NO
wiring harness or (After clean)
Starting switch : ON poor contact
Voltage : 20~30V
between CR-5(86)
and CS-2(5) CN-51

YES 9
Defective start relay Replace
Check voltage
ⓐ between CR-23 CPU CONTROLLER
(2) and chassis Disconnection in Repair or replace CN-92
NO wiring harness or (After clean) 11
Starting switch : ON
Voltage : 20~30V poor contact CN-50
between CR-5(87)-
CR-23(2)
START RY STARTER
ANTI-RESTART RY
M M
30 7 2
86 30
86 1
87 B+
85 CN-2 CR-23
85 87 87a CN-45
87a
CR-5

3607A6ES05

6-35
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. CN-8
CS-2
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

II I O H
1

I,O
9
2
4

H
10 3

ACC BR
4 1

B
11 2
Cause Remedy 5 3

YES 12
6
Disconnection in Repair or replace

C ST
5
6
wiring harness or (After clean)
poor contact ECM POWER RY START SWITCH
YES Check voltage 1 2 1
between DO-2 between DO-2(1)-
2
(1) and chassis CR-1 or defective
3
Voltage : 20~30V
battery relay
4 4 3
CR-45
YES Check voltage Disconnection in Replace
between CS-2 NO POWER RY
wiring harness or
(2) and chassis 30
30 86
poor contact
86
Voltage : 20~30V between CS-2(2)-
Check voltage Starting switch : ON 87 CS-74

BATTERY RY
YES 1
between CS-2(1) CN-8(11)- DO-2(1) 85 2 2
87a 87 85
and chassis 87a
1 CN-60

CR-1
Defective starting Replace CR-35
Voltage : 20~30V NO
switch
FUSE
Check voltage Disconnection in Replace NO.1
and specific NO
wiring harness or DO-2
gravity of battery
poor contact
Specific gravity : MIN 1.28

1
2
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)
CPU CONTROLLER
11

CN-50
ANTI-RESTART RY
86 30 30
START RY STARTER
86
M M
87 7 2
85 1
85 87 87a
87a
B+
CR-5 CN-2 CR-23
CN-45

3607A6ES06

6-36
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 CN-21
No.5,10 and 15 is not blown out. 3 1
2
·After checking, insert the disconnected connectors again immediately unless otherwise specified.
5 3
4 4
Cause Remedy 5
NO CN-5
6 M 2 6
Defective wiper Replace 1
cut switch
WIPER MOTOR FUSE
YES 4
Disconnection in Repair or replace
Check operation wiring harness or (After clean) CN-141 NO.5
wiper cut switch poor contact FEED BACK 1 CN-6
FUSE
between CN-141 MOTOR DRIVE SIG 2 CN-17 5
Front sliding door Check voltage (11)- CS-53 MOTOR DRIVE- 3 1 6 NO.15
open-close CN-22
between CN-141 YES MOTOR DRIVE+ 4 2 9
YES (11) and chassis Defective switch Replace 2 M
GND 5 3 10
panel
NO Check voltage VCC 6 4 11 1
Front sliding door-close between CN-116
Voltage : 4~5V (6) and chassis CONTINUE 24V 7 5 WASHER TANK
Check operation 1)Recheck fuse Replace WASHER P/P 8 6
NO NO.10
of switch panel Starting switch : ON WASHER SIG. 9 7
NO Voltage : 20~30V
LED ON. 2)Disconnection in Repair or replace INT. SIG 10 8
wiring harness or (After clean) WIPER CUT SW 11
Starting switch : ON ⓐ poor contact
Push wiper switch button YES N.C 12 CN-7
between CN-
116(6)-Fuse FEED BACK 13 3 FUSE
between CN- WIPER MOTOR CONTROLLER 5
116(13)-Chassis 9 NO.10
NO 10
Check voltage between Defective switch Replace WIPER CUT SW
CN-116(4) and chassis panel
Intermittent CS-53 CN-9
NO
1) Recheck fuse Replace
Check voltage CN-116 NO.5
ⓐ
(12) and chassis 2) Disconnection Repair or replace
Washing
Check operation in wiring harness (After clean) 4
CN-116
of wiper motor or poor contact HEAD LIGHT OUT 1
Check voltage CN-116 and controller between CN- WORK LIGHT OUT 2
(15) and chassis check voltage 141(7)-Fuse, WORK LIGHT OUT 3
YES CN-141(7) and
CN-21(4)-Fuse WIPER MOTOR DRIVE 4
Starting switch : ON
Voltage : 0~1V
chassis, CN-21(4) PRE-HEAT 5
and chassis NO POWER 24V 6
1) Recheck fuse Replace CABIN LIGHT OUT 7
Starting switch : OFF NO.15
Voltage : 20~30V Check voltage CABIN LIGHT OUT 8
2) Disconnection Repair or replace HEAD LIHGT 24V 9
CN-141(6)-and
YES chassis CN-141(6)-Fuse (After clean) WORK LIGHT 24V 10
WORK LIGHT 24V 11
Starting switch : ON ⓑ WASHER SIG 12
Check continuity YES GND 13
Voltage : 20~30V
NO
between Disconnection in Repair or replace TRAVEL ALARM 14
CN-141(2)-CN-116(4), wiring harness or (After clean)
INT. SIG 15
CN-141(9)-CN-116(12), CABIN LIGHT 24V 16
poor contact CABIN LIGHT 24V 17
CN-141(10)-CN-116(15),
ⓑ CN-141(5)-Chassis , NO SWITCH PANEL
Check wiper Defective wiper Replace
CN-141(1)-CN-21(5), 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 3607A6ES07
Resistance : 3~4Ω

6-37
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
HEAD LAMP
short of fuse No.16.
·After checking, insert the disconnected connectors again immediately unless otherwise specified. 2
1

Cause Remedy CL-4

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

3607A6ES08

6-38
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
CN-12 WORK LAMP
Check voltage
YES
between CN-116 YES 2 1
(2, 3) and chassis Defective bulb Replace
Check voltage 1 2
YES
Starting switch : ON between CL-5(2)
Work lamp switch : ON and chassis CL-6
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
between CN-7(2) CN-7
YES and chassis between CN-7(1) CN-116
1 HEAD LIGHT OUT
-CL-5(2) and 2 2 WORK LIGHT OUT
Starting switch : ON
Work lamp switch : ON
CL-6(2) 3 WORK LIGHT OUT
Check voltage Voltage : 20~30V
4 WIPER MOTOR DRIVE

between CN-116 5 PRE-HEAT

(10,11) and Disconnection in Repair or replace 6 POWER 24V

NO
wiring harness or (After clean) 8 7 CABIN LIGHT OUT
chassis
8 CABIN LIGHT OUT
Starting switch : ON poor contact 9 HEAD LIHGT 24V
Work lamp switch : 10 WORK LIGHT 24V
ON-OFF
between CN-116 10
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)
Check voltage SWITCH PANEL
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

36076ES09

6-39