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

Check voltage
YES 20 ~ 32V
NO 0V

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

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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
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

29076ES02

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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-3 poor contact
(3) and chassis between CN-51(9)
-CN3(3)

Check voltage Disconnection in Repair or replace

NO wiring harness or (After clean)
between alternator
poor contact
terminal "I" and between
chassis CN-3(3)-altern-ator
Voltage : 20~32V terminal "I"
Engine : Running

Defective alternator Replace

NO

Check voltage
YES 20 ~ 32V
NO 0V

CONTROLLER ALTERNATOR

B+
G

3~
9 3 I
U
GND

CN-51 CN-3 CN-74

210N76ES02

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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
Coolant overheat Check engine
Resistance
YES between CD-8 (110°C ±2°C ) cooling system
(1,2) is in range
of 120~150Ω?
NO
Defective temp Replace
Disconnect CD-8 sensor
Does display go
off when
disconnect CD-8?
YES
Starting switch : ON Short circuit in Repair or replace
Engine : Start Resistance wiring harness (After clean)
between CN-51
NO
(31,33) is 0~1Ω?
Defective Controller Replace
Disconnect CN-51 NO
KEY OFF

CONTROLLER
WATER TEMPERATURE SENDER

33 6 1 o
C

31 5 2

CD-8

CN-51 CN-3

210N76ES03

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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
20

CD-10
CN-50
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
Engine oil leakage, Check engine oil
or defective switch level or replace
Does display go off switch
when disconnect
YES
CD-18? Defective controller Replace
Starting switch : ON Check resistance
Engine : Start between CN-51
NO
(4) and chassis
Starting switch : OFF
Disconnection in Repair or replace
NO
Disconnect CN-51 wiring harness or (After clean)
poor contact
between
CN-51(4)-CD-18

Check resistance
YES MAX 1Ω
NO MIN 1MΩ

CONTROLLER ENGINE OIL PRESSURE SWITCH

4 1 Pa

CN-51 CN-2 CD-18

29076ES03

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

Starting switch : OFF NO Defective controller Replace

Disconnect CN-51

CONTROLLER HYDRAULIC OIL

TEMPERATURE SENDER

34 2
C
31 1

CN-51 CD-1

29076ES04

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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 resistance poor contact
YES between CN-51 between
(31) and (33) CN-51-CD-8
over 2kΩ?
Starting switch : OFF YES
Disconnect CN-50 Defective controller Replace
Does the gauge
light up and Check resistance
down at lamp NO
between CN-3(5)
check? and (6)
Defective temp Replace
See Table
NO
Starting switch : ON sensor

Defective cluster Replace

NO

Check Table
Green range Red range Temperature White range Green range Red range
Item (~29° C) (30~105° C) (105°C ~)
Unit Resistance(Ω) 1646~ 1645~158 ~139
White range Tolerance(%) ±20 ±20 ±20

CONTROLLER
WATER TEMPERATURE SENDER

33 6 1 o
C

31 5 2

CD-8

CN-51 CN-3

210N76ES03

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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.24.
・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
NO
Safety lever : ON-OFF
YES
ⓐ
YES Check voltage
between CS-4
Check voltage (C) and chassis
between CN-68 Disconnect in Repair or replace
(1) - CN-68(2) Check voltage Starting switch : ON NO
YES between CN-4(8) Voltage : 20~30V wiring harness or (After clean)
Starting switch : ON and chassis Disconnect CN-4 poor contact
Voltage : 20~30V between
Safety state Starting switch : ON CN-4(8)-CS-4(C)
Voltage : 20~30V
Disconnect CN-4
Check voltage Disconnect in Repair or replace
between CN-68 NO
wiring harness or (After clean)
NO (2) with chassis
poor contact
Safety lever : OFF between
Starting switch : ON CN-4(8)-CN-68(1)
Voltage : 20~30V

NO Disconnection in Replace
fuse
YES
Defective switch Repair or replace
Check voltage
ⓐ between CS-20 (CS-20)
and chassis
NO
Defective switch Repair or replace
Starting switch : ON (CS-4)
Voltage : 20~30V

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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.22 .
・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

FUSE

NO.22

TRAVEL SOLENOID
CONTROLLER
2

13 1

CN-70

CN-50

21076ES04

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12. WHEN ENGINE DOES NOT START

・Check supply of the power at engine stop solenoid while starting switch is 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 battery Check engine
system charge or
replace(After
checking specific
gravity of battery)
Check operation YES
Check voltage Defective magnet Replace
of start motor YES between starter of start motor
magnet coil and
Starting switch : START chassis Defective start relay Replace
NO
Starting switch : START YES
SPEC : 20~30V ⓐ, ⓑ
Check operation YES
Check voltage
NO of start relay
between CR-5
(30) and chassis
Disconnection in Repair or replace
Starting switch : START
NO
Starting switch :START wiring harness or (After clean)
Check operation poor contact
of start safety between CR-5
NO relay
(86) and CN-8(9)
YES
Starting switch : ON
Check voltage Defective relay Replace
between CR-
NO 5(87) and chassis ⓒ
NO
Starting switch : ON

YES
Defective fuel cut Replace
Check voltage
off solenoid
ⓐ between CN-79
(2) and chassis
Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (After clean)
Starting switch : START poor contact
between CN-2(4)-
CN-79(2)
YES
Check voltage Defective relay Replace
ⓑ between CR-23
and chassis
NO Disconnection in Repair or replace
Voltage : 20~30V wiring harness or (After clean)
Starting switch : ON poor contact
between CR-5(30)-
CR-23
YES
Check voltage Defective fuel cut- Replace
ⓒ between CN-79 off solenoid
(1) and chassis
Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (After clean)
Starting switch : ON poor contact
between CN-2(5)
and Fuse No.12
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6 - 35
13. WHEN STARTING SWITCH “ON” ELECTRIC PART 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
Disconnection in Repair or replace
wiring harness or (After clean)
poor contact
YES Check voltage
between DO-2 between DO-2(1)-
(1) and chassis CR-1 or defective
Voltage : 20~30V
battery relay

YES Check voltage Disconnection in Replace

between CS-2 NO
wiring harness or
(2) and chassis
poor contact
Voltage : 20~30V between CS-2(2)-
Check voltage
YES CN-8(11)- DO-2(1)
between CS-2(1)
and chassis
Defective start key 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)-CS-61,
CN-60-CR-1
Battery
Battery capacity too Charge or replace
NO
low (After clean)

21076ES14A

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
No.4,11 and 13 is not blown out.
・After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Defective wiper Replace
cut switch
YES
Disconnection in Repair or replace
Check operation wiring harness or (After clean)
wiper cut switch poor contact
between CN-141
Front sliding door Check valtage (11)- CS-53
open-close
between CN-141 YES
YES (11) and chassis Defective switch Replace
panel
NO Check voltage
Front sliding door-close between CN-116
Voltage : 0~1V (6) and chassis
Check operation 1)Recheck fuse Replace
Starting switch : ON NO NO.11
of switch panel
NO Vottage : 20~30V
LED ON. 2)Disconnection in Repair or replace
wiring harness or (After clean)
Starting switch : ON ⓐ poor contact
Push wiper switch button YES
between CN-
116(6)-Fuse
between CN-
116(13)-Chassis
Check voltage between NO
Defective switch Replace
CN-116(4) and chassis panel
Intermittent
NO
1) Recheck fuse Replace
Check voltage CN-116 NO.4
ⓐ (12) and chassis 2) Disconnection Repair or replace
Washing
Check operation in wiring harness (After clean)
of wiper motor or poor contact
Check voltage CN-116 and controller between CN-
(15) and chassis check voltage 141(7)-Fuse,
YES CN-141(7) and
Sarting switch : ON CN-21(4)-Fuse
Voltage : 0~1V
chassis, CN-21(4)
and chassis NO
1) Recheck fuse Replace
Starting switch : OFF NO.13
Voltage : 20~30V Check voltage
2) Disconnection Repair or replace
CN-141(6)-and
YES chassis CN-141(6)-Fuse (After clean)

Starting switch : ON ⓑ
Check continuity YES
Voltage : 20~30V
NO
between Disconnection in Repair or replace
CN-141(2)-CN-116(4), wiring harness or (After clean)
CN-141(9)-CN-116(12), poor contact
CN-141(10)-CN-116(15),
ⓑ NO
CN-141(5)-Chassis , 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 21076ES15A
CN-141(13)-CN-21(3) YES motor controller
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
short of fuse No.14.
・After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy HEAD LAMP

NO
Defective lamp Replace switch 1
switch 2

CL-4

Check voltage
YES
between CN-116 YES
(1) and chassis Defective bulb Replace
YES
Check voltage
Starting switch : ON between CL-4(2)
CN-7
Head lamp switch : ON and chassis CN-116
Voltage : 20~30V Disconnection in Repair or replace 1 1 HEAD LIGHT OUT
Starting switch : ON NO
wiring harness or (After clean) 2 WORK LIGHT OUT
Check voltage Head lamp switch : ON 3 WORK LIGHT OUT
between CN-7(1)
Voltage : 20~30V poor contact 4 WIPER MOTOR DRIVE
YES and chassis between CN-7(1)- 5 PRE-HEAT
6 POWER 24V
CL-4(2)
Starting switch : ON 7 7 CABIN LIGHT OUT

Head lamp switch : ON 8 CABIN LIGHT OUT

Voltage : 20~30V 9 HEAD LIHGT 24V
Check voltage Disconnection in Repair or replace
NO 10 10 WORK LIGHT 24V
between CN-116 wiring harness or (After clean) 11 WORK LIGHT 24V
(9) and chassis 12 WASHER SIG
poor contact
13 GND
Starting switch : ON between 14 TRAVEL ALARM
Head lamp switch :
ON-OFF
CN-116(1)-CN- 15 INT. SIG
16 CABIN LIGHT 24V
7(1) 17 CABIN LIGHT 24V

YES SWITCH PANEL

Disconnection in Repair or replace
wiring harness or (After clean)
Check voltage poor contact
FUSE
between CN- between CN-116
NO 7(7) and chassis
(9)-CN-7(7) NO.14
Head lamp switch : ON
Recheck fuse Replace
NO
No.14

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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.15.
・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 1 1
(10,11) and chassis Defective bulb Replace
2 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
between CN-7(2) CN-7
between CN-7(2) CN-116
YES and chassis
1 HEAD LIGHT OUT
-CL-5(2) and 2 2 WORK LIGHT OUT
Starting switch : ON 3
Work lamp switch : ON
CL-6 (2) WORK LIGHT OUT

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 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.15
No.15

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