GROUP 6 TROUBLESHOOTING

1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER AND MONITOR LAMP DOES NOT
LIGHT UP
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.12 is not blown out and ON/OFF of bulb.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise
specified.

Cause Remedy
YES
Defective cluster Replace
Check voltage
Defective monitor Replace
between CN-56
(1), CN-57(1) and
chassis
NO Disconnection in Repair or
wiring harness or replace
poor contact (after clean)
between CN-56
(1), CN-57 (1)
and fuse No.12

MONITOR

CN-57

CLUSTER
FUSE
1
No.12
CN-56

Check voltage

YES 20 ~ 30 V
NO 0V
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2. WHEN BATTERY LAMP LIGHTS UP (engine is started)
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise
specified.
Cause Remedy
YES
Check voltage Defective Replace
YES controller
between CN-58A
(B36) and chassis
NO Disconnection in Repair or replace
Voltage : 27.5~30V wiring harness or (after clean)
poor contact
Check voltage between CN-58A
YES between CN-6
(B36) and CN-6 (49)
(49) and chassis
YES
Voltage : 26~30V Disconnection in Repair or replace
wiring harness or (after clean)
Check voltage poor contact
Check voltage between CN-13 between CN-13
NO
between (8) and chassis (8) and CN-6 (49)
alternator
terminal "2" and Disconnection in Repair or replace
chassis NO
wiring harness or (after clean)
Voltage : 26~30V poor contact
Starting switch : ON
between CN-13
(8) and alternator
terminal " 2 "

Defective alternator Replace

NO

CONTROLLER(MCU)

49
ALTERNATOR
B36 8 " 2 " TERMINAL
CN-6 CN-13
CN-58A
Check valtage
YES 20 ~ 30 V
NO 0V 75797EL30

7-79
3. WHEN PARKING SOLENOID DOES NOT WORK
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.29 is not blown out.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES Defective parking Replace
Check voltage brake solenoid
YES between CS-17
Check voltage (4) and chassis
YES between CN-5 Disconnection in Repair or replace
Voltage : 20~30V NO wiring harness or (after clean)
(30) and chassis
Check voltage
poor contact
between CN-71 Voltage : 20~30V
between CS-17
(2) and chassis
(4) and CN-5 (30)
Starting switch : ON
Parking switch : ON-OFF YES
Voltage : 20~30V Disconnection in Repair or replace
wiring harness or (after clean)
poor contact
Check voltage between CN-12
between CN-12 (13) and CN-5
NO
(13) and chassis
(30)
Voltage : 20~30V
Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-12
(13) and CN-71
(2)

YES
Difective parking Replace
Check voltage
switch
between CS-17
NO
(7) and chassis
Disconnection in Repair or replace
Voltage : 20~30V NO
wiring harness or (after clean)
poor contact
between CS-17
(7) and Fuse
No.29

PARKING SWITCH
8 FUSE[CN-36]
7
4 No.29
CN-5 CN-12
CS-17
30 13 2
1
CN-71

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4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.11 (T/M control unit) and No.29 are not blown out.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise
specified.
Cause Remedy
YES
Defective T/M Replace
control unit

Check voltage YES

Disconnection in Repair or replace
between CN-157
wiring harness or (after clean)
(21) and chassis
poor contact
Starting switch : ON Check voltage between CN-157
Parking switch : ON between CS-17
Voltage : 20~30V NO (3) and chassis (21) and CS-17(3)

YES
Voltage : 20~30V Defective switch Replace
Parking switch : ON Check voltage
between CS-17
NO
(7) and chassis
Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (after clean)
poor contact
between CS-17 (7)
and fuse No.29

PARKING SWITCH
8 FUSE[CN-36]
7
3 No.29
T/M CONTROL UNIT
CS-17
21

CN-157

Check resistance
YES MAX 1̫
7609S7EL32
NO MIN 1M̫

7-81
5. MACHINE DOES NOT TRAVEL
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.11 (transmission controller) is not blown out.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise
specified.
ÂWiring diagram : See page 7-17.
Cause Remedy
YES
Defective clutch Replace
cut-off mode
Check resistance
YES switch
between CD-4
and chassis
Is there continuity
NO
between CN-157
(38) and chassis? Defective T/M Replace
NO
control unit

Is voltage between
Defective T/M Replace
CN-157(21) and NO
chassis 20-28V? control unit

Starting switch : ON YES

Parking switch : OFF Defective Replace
Clutch cut-off parking switch
switch : ON Is there continuity
between CS-17(3)
YES
and chassis?

Disconnection Repair or replace

NO
wiring harness (after clean)
or poor contact
between CN-157
(21) and CS-17 (3)

Check resistance
YES MAX 1̫
NO MIN 1M̫

7-82
6. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.28 is not blown out.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise
specified.
FUSE BOX
SERVICE SOCKET 1 20A
25
SEAT HEAT/AIR-RIDE 20A
26
Cause Remedy WORK LAMP_REAR 20A
27
YES Br WIPER 20A
28
Check voltage Defective front Replace PARK, PILOT CUT 20A
29
YES between front wiper motor JOYSTICK-DETENT 10A
30
PRE-HEAT, FUEL WARMER 30A
wiper motor and FAN REVERSE, ATT. 20A
31
32
chassis Poor connection of Replace RIDE CONTROL 10A

Check voltage Voltage : 20~30V

NO 10A
33

YES chassis JOYSTIC_SWITCH

34
between CN-21(5) Starting switch : ON
Wiper switch : 1st CN-36
and chassis
Voltage : 20~30V
Starting switch : ON Disconnection in Repair or replace WIPER RY HI
NO Y
Check voltage Wiper switch : 1st 4 3 2
YES between CS-12 wiring harness or (after clean) B
1
R
5
(4) and chassis poor contact Br
2
Br
between CN-21(5) 3 4 5 1

Voltage : 20~30V CR-4

and CR-26(3)
Starting switch : ON
WIPER RY LO
Wiper switch : OFF G
4 3 2
W
1
Y
FRONT WIPER 5
Y Y Y
3E 1 2
G LW W
Defective wiper Repair or replace 2Pf
B
2
B 3 4 5 1
NO 1B
L
3
R CR-26
Check voltage switch or (after clean) R
4
W
4 Hi 5
CS-12 (6) disconnection in M
5 Lo 6
CN-21
wiring harness or CN-102
Voltage : 20~30V poor contact
Starting switch : ON
Wiper switch : 1st
between CS-12(4)
and CR-26(4).

LOr
Disconnection in Repair or replace

LW
Gr
Br

Br
G
NO
wiring harness or (After clean)
poor contact

CS-11
CS-12
CS-5

CN-58A
between CS-12(6)

WIPER INT SIG A23

A31

B02
1
2
3
4
5
6

8
7
6
5
4
3
2
1
and fuse No.28.

HO

RW

BVi
BY

4BWG
Gr

W
G
L

WIPER RLY
Y

6
2
6
1

3
5

WASH SIG
C

Hi
J

C
W

II

II
J

Hi Lo
I
O

B+
C
MCU

F
L
R
O
L
R

Y 7 Lo

B 5
WB 8
BG 3

BW 2
MULTI FUNCTION SWITCH

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7-83
7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.3 is not blown out.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise MASTER SW CN-60
3R 104 105
specified. 3R 102 106

Cause Remedy CN-95

2RW 532
YES 2RW 541 FUSIBLE LINK
Check voltage Defective cable Repair or replace CS-74 BATTERY RY
RW 80R
assembly (after clean)
YES between
CN-60(1) and B 80R BATTERY
chassis Short circuit or Replace CR-1
Voltage : 20~30V NO DO-2
defect of fusible RW
Check voltage B
2
YES link or defective 1
between CR-1 FUSE BOX
battery relay 10A BEACON
and chassis 15
20A
1 To starter
WORK LAMP_FRONT
16 2
Voltage : 20~30V 17
20A MIRROR,SER.SOCKET2
20A
3
ILL.LAMP
18
4
Disconnection in Repair or replace 19
20A HEAD LAMP
NO 10A BACK.STOP LAMP 23
Check voltage wiring harness (after clean) 20
20A HORN/CONVERTER 24
YES between CS-2 or poor contact 21
30A AIR-CON/HEATER 1 25
(1)[and CS-2(2)] 22
between CS-2 20A FUEL WARMER
and chassis 23 26
(2) - CN-5(37)- 24
30A CIGARLIGHTER
27
Voltage : 20~30V W
CS-74-CR-1. 28
20A TURN LAMP 36
1
5A RADIO/ROOM LAMP 37
2
30A START KEY SWITCH R
3 38
Disconnection in Repair or replace 4
10A TCU 24V BATTERY
47
Check voltage NO 20A ECM 24V BATTERY
wiring harness (after clean) 5
20A
48
MCU 24V BATTERY
and specific or poor contact 6
20A CN-5
AIR-CON/HEATER 2
gravity of battery between fuse
7
10A CLUSTER 24V BATTERY
8
Specific gravity : MIN 1.28 No. 3 and CS-2 3R
Voltage : MIN 24V (1) or defect of
CN-36
start switch

Battery capacity Repair or replace

NO
too low (after clean)

RW
R
CS-2

2
6
5
4

1
B
0, I

1
H 0 I II

4
6
5

3
2
H
C ST ACC BR
START SWITCH

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8. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP FUSE BOX
1
BEACON 10A

ÂBefore carrying out below procedure, check all the related connectors are properly inserted, and 2 GW WORK LAMP_FRONT 20A
15
16
3
the fuse No.16, 27 is not blown out. MIRROR,SER.SOCKET2 20A
17
4 ILL.LAMP 20A

ÂAfter checking, connect the disconnected connectors again immediately unless otherwise 5 HEAD LAMP 20A
18
19

specified. 6 BACK.STOP LAMP 10A

20A
20
HORN/CONVERTER
7 21
AIR-CON/HEATER 1 30A

8 22
FUEL WARMER 20A
23
9 CIGARLIGHTER 30A
24
Cause Remedy 10
YES 11
Defective lamp Replace
YES Check voltage
SERVICE SOCKET 1 20A
12 25
SEAT HEAT/AIR-RIDE 20A
between each 13
Y WORK LAMP_REAR 20A
26
W
lamp and chassis FR WORK 1
B
14 WIPER 20A
27

Disconnection in Repair or replace LAMP,LH 2

15
28
NO CL-5 PARK, PILOT CUT 20A

Check voltage Voltage : 20~30V wiring harness or (after clean) CN-7 JOYSTICK-DETENT 10A
29

Starting switch : ON W 30
between poor contact FR WORK
LAMP,RH
1
B PRE-HEAT, FUEL WARMER 30A
31
YES 2
CN-7(14), between CL-6 (2), CL-6 FAN REVERSE, ATT. 20A
32
RIDE CONTROL 10A
CN-6(33) and CL-5 (2), CL-22 33
OPTION JOYSTIC_SWITCH 10A

chassis (2), CL-23 (2) and CL-35

1 34
W
Check voltage Voltage : 20~30V CN-7 (14), CN-6 1
B
2 CN-36
2
between Starting switch : ON (33). 3
FR WORK LAMP
4
W
YES CR-3(5), 1
B 5 LOr
FUSE BOX

CR-55(5) and Disconnection in Repair or replace 2

NO CL-36 6 ILLUMINATION 1 5A

chassis wiring harness or (after clean) 35

7
poor contact CL-32
RW ILLUMINATION 2 5A
Voltage : 20~30V 1 8 36

Starting switch : ON between CN-7 2

B
CN-36
Check voltage (14) -CR-3 (5) and
9
RR WORK LAMP
between 10
RW
CN-6 (33) - CR-55 1 11
CR-3(3), (5) 2
B FR WORK LAMP RY
CL-33 12 4
CR-55(3) and B
1
3 2
13 W
chassis Defective work Replace relay Y
5
NO 14 2
Voltage : 20~30V GW
lamp relay 15
3 4 5 1
Starting switch : ON RR WORK 8 CR-3
LAMP,LH CN-9
YES 1
RW 9
Disconnection in Repair or replace 2
B
10 31 RR WORK LAMP RY
wiring harness or (after clean) RR WORK CL-22
11 32 B
4 3 2
LAMP,RH 1
Check voltage poor contact 1
RW
12 33 RW
5
B VW
between fuse No. between CR-3 (3), 2
CN-14 34 Y
2
4 5 1
CL-23 3
NO 16, 27 and CR-55 (3) and fuse 35 CR-55

chassis No.16, 27 59
60
Voltage : 20~30V WORK LAMP SW
Starting switch : ON Short circuit of Replace CN-6
NO 12 11
1
fuse 3
Y
4
VW

6
LOr
6 7
LOr
4

9 9
3
7
R
11
12 1
12
B
CS-36

ILL & HEAD LAMP SW

12 11
1
3
4 CLUSTER
R 17 ILLUMINATION
6
6 LOr CN-56
7
4
MONITOR
R R
9 9 18 ILLUMINATION
3
7 CN-57
R
11
12 1
12
B
CS-21
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