GROUP 3 ELECTRICAL SYSTEM (CLUSTER TYPE 1)

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, 8.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace

Check voltage YES

Disconnection in Repair or replace
between CN-56
(3) and (5) wiring harness or (after clean)
Check voltage poor contact
Starting switch : ON between
Voltage : 20~32V between
NO CN- 5 (4) and (5)
CN-5-CN-56
Starting switch : ON
Voltage : 20~32V Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-5 (4)
-GND or fuse
No.7, 8

Check voltage
YES 20~32V
NO 0V

FUSE
CLUSTER NO.7
POWER(24V) 1 6
FUSE
POWER IG(24V) 5 5
NO.8
GND 3 4

CN-56 CN-5

3009SH6ES01

6-24
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2)
·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 cluster Replace

YES Check voltage

between CN-56
(4, 8) and (3) Disconnection in Repair or replace
NO wiring harness or (after clean)
Starting switch : ON
Check voltage Voltage : 2V poor contact
between between CN-56
CN-5 (1) and (2) (4, 8)-CN-5 (1, 2)

Starting switch : ON
Voltage : 2V Defective MCU Replace
NO Disconnection in Repair or replace
wiring harness or (after clean)
poor contact
between CN-5 (1,
2)- CN-51(23, 33)

Check voltage
YES 2V
NO 0V

CLUSTER
GND 3 4 MCU
RS485 RX 8 2 23 RS485 TX
RS485 TX 4 1 33 RS485 RX
CN-51
CN-56 CN-5

3309S6ES02

6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP
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 MCU Replace
YES Check voltage
between CN-52
(27) and chassis Disconnection in Repair or replace
NO
Check voltage wiring harness or (after clean)
YES Voltage : 20~32V
between CN-3 poor contact
(3) and chassis between CN-52
(27)-CN-3 (3)
Voltage : 20~32V
Disconnection in Repair or replace
Check voltage NO wiring harness or (after clean)
between CN-74 poor contact
(2) and chassis between CN-3 (3)-
CN-74 (1)
Engine : Running
Voltage : 20~32V

Defective alternator Replace

NO

Check voltage
YES 20~32V
NO 0V
ALTERNATOR
B+
MCU
G
1 P
27 3 2 L
3 ~
U
3 FI
4 NC
CN-74
CN-52 CN-3

3009S6ES01

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
Coolant overheat Check engine
Resistance (110˚C±2˚C) cooling system
YES between CD-8
(1, 2) is in range
of 120~150Ω?
Defective temp Replace
Disconnect CD-8 NO
sensor
Does display go
off when
disconnect
CD-8?
Starting switch : ON
Engine : Start YES
Short circuit in Repair or replace
Resistance wiring harness (after clean)
between CN-51
NO (13) and CN-52
(25) 0~1Ω?
Defective MCU Replace
Disconnect CN-51 NO
KEY OFF

Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (kΩ) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8

MCU

13

WATER TEMP SENDER

5 1 C
CN-51
6 2

CN-3 CD-8

25

CN-52
3009SH6ES04

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 wiring harness (after clean)
Engine : Start Check resistance
between CD-10-
between CN-51
NO CN-51(29)
(29) and chassis
Starting switch : OFF
Disconnect CN-51
Defective MCU Replace
NO

Check resistance
YES MAX 1Ω
NO MIN 1MΩ

MCU AIR CLEANER SWITCH

Pa
29

CD-10
CN-51

3009SH6ES05

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
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
Does display go
off when
disconnect YES
CD-18? Defective controller Replace
Starting switch : ON
Engine : Start Check resistance
between CN-51
NO
(27) and chassis
Starting switch : OFF
Disconnect CN-51
Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between
CN-51(27)-CD-18

MCU ENGINE OIL PRESSURE SWITCH

27 1 Pa

CN-51 CN-2 CD-18

3009SH6ES06

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 (105˚C±2˚C),
(1, 2) is in range
of 164~151Ω?
Does display go Starting switch : ON Defective temp Replace
Disconnect CD-1 NO
off when sensor
disconnect
CD-1? YES
Short circuit Repair or replace
Starting switch : ON Resistance between temp
Engine : Start between CN-51
sensor and MCU
NO (13) and CN-52
(24) 0~1Ω?
Defective MCU Replace
Starting switch : OFF NO
Disconnect CN-51

Check Table
Temperature (˚C ) ~ -30 ~ -10 ~0 ~ 40 ~ 70 ~ 80 ~ 90 ~ 100 105~
22.22 8.16 5.18 1.06 0.39 0.322 0.243 0.185 0.164
Resistance (kΩ)
~31.78 ~10.74 ~ 6.6 ~1.28 ~0.476 ~0.298 ~0.219 ~0.167 0.151

MCU

13

CN-51
HYDRAULIC OIL
TEMPERATURE SENDER

1 C

24 2

CD-1

CN-52 3009SH6ES07

6-30
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE (HCESPN 304,
FMI 3 or 4)

·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)
poor contact
Is resistance between
YES between CN-51 CN-52-CD-8
(13) and CN-52
(25) over 2kΩ?
Starting switch : OFF YES
Does the gauge Disconnect CN-50 Defective MCU Replace
light up and Check resistance
down at lamp between CN-3
NO
check? (5) and (6)
Starting switch : ON Defective temp Replace
See Table NO
sensor
NO
Disconnection Replace
cluster

Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (kΩ) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8

MCU

13

WATER TEMP SENDER

5 1 C
CN-51
6 2

CN-3 CD-8

25

CN-52
3009SH6ES04

6-31
9. WHEN FUEL GAUGE DOES NOT OPERATE
OPERATE(HCESPN 301, FMI 3 or 4)

·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 MCU or Replace
Check resistance cluster
YES between CN-51
(13) and CN-52
(26)
Starting switch : OFF Disconnection in Repair or replace
Check resistance Disconnect CN-51 NO
between fuel Spec : 50~600Ω wiring harness or
sender (1) and poor contact
(2) between fuel
Starting switch : OFF sender-MCU
Spec : 50~600Ω
See table
Defective fuel Replace
NO
sender

Check Table
Range Resistance (Ω) Range Resistance (Ω)
Full 50 5/12 400
11/12 100 4/12 450
10/12 150 3/12 500
9/12 200 2/12 550
8/12 250 1/12 600
7/12 300 Empty warning 700
6/12 350 - -

MCU

13

FUEL LEVEL SENDER

1
CN-51
2
CD-2

26

CN-52
3009SH6ES08

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.23.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Hydraulic system Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF

YES
Disconnect in Repair or replace
Check voltage wiring harness or (after clean)
between CN-68 poor contact
Check resistance
(1) - (2) YES between CN-4 between
(16) and chassis CN-4-CN-68
Starting switch : ON
Voltage : 20~30V YES
Safety state Starting switch : OFF Disconnect in Repair or replace
Safety state
Spec : 0Ω
wiring harness or (after clean)
Disconnect CN-4 Check resistance poor contact
Check voltage
between CS-4 between
between CN-68 NO
NO (A)-(C) CN-4-CS-4
(2) and chassis
Starting switch : OFF
Safety lever : OFF Defective safety Replace
Safety switch : ON-0Ω
Starting switch : ON NO
Voltage : 20~30V
OFF-∞ switch

Disconnection in Repair or replace

NO
wiring harness
between
CN-68 (2)-fuse

FUSE

NO.23
SAFETY SWITCH
B C A 14 SAFETY SOLENOID
B 15 2

A C 16 1
CS-4 CN-68
CN-4

21096ES10

6-33
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 5 or 6)

·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.25.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Disconnection in Repair or replace
wiring harness or
Check resistance poor contact
YES
between CN-70 between CN-70-
(1) and (2) CN-52
Starting switch : OFF Defective solenoid Replace
Spec : 30Ω NO
YES Check fault code Disconnect CN-70
167 active?
YES
Defective hydraulic Check hydraulic
Starting switch : ON
system system
Check voltage
Check if travel between CN-70
speed lamps( , NO (1) and (2)
) change when
pressing the travel Starting switch : ON Disconnection in Repair or replace
Spec : 20~30 V NO
speed switch on wiring harness or
Disconnect CN-70
the cluster poor contact
Starting switch : ON
between CN-70-
fuse No. 25
YES
Defective cluster Replace
Check MCU
Y R G
NO
Defective MCU Replace
Starting switch : ON
NO

FUSE

NO.25

MCU TRAVEL SOLENOID

3 1

CN-70

CN-52
3009SH6ES09

6-34
12. WHEN ENGINE DOES NOT START ( lights up condition)

·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. 1, 4, 20.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES START KEY SW
Delective battery Replace CN-5
CS-2

H0 I
35 1

0, I
36 2
59 3 4

H
60

BR ACC
4 1

B
2
5 3

6
Check operation YES

ST C
5
Check voltage Defective magnet Replace 6
start motor
YES between starter of start motor
magnet coil and CR-35
Starting switch : START NO.1
chassis Defective start relay Replace
NO
Starting switch : START
Check operation Spec : 20~30V YES
YES Check voltage ⓐ
of start relay between CN-3
NO
CR-23 (2) and chassis
NO.4
POWER RY
Disconnection in Repair or replace
NO
Starting switch : START wiring harness or
Starting switch : START poor contact
Check operation Spec : 20~30V between CN-3 (2) CS-74
of anti-restart -CR-5 (87) 1
NO relay CR-5 2
CN-95
NO.20
Starting switch : ON
YES 2

Check voltage Defective anti- Replace 1 MASTER SW

between CR-5 restart relay FUSIBLE LINK

NO 2
(85, 86)
NO
ⓑ 1
CN-60
Starting switch : START
Spec : 20~30V
CR-1 BATTERY

YES
Check voltage Defective start relay Replace
ⓐ between CR-23 BATT RY
and chassis Disconnection in Repair or replace DO-3
NO
wiring harness or 2
Starting switch : START CN-51
poor contact ANTI-RESTART RY 20
1
Spec : 20~30V DIODE
between CN-3- MCU
CR-5
CR-5 CN-3 CR-23 START MOTOR
YES
Disconnection in Repair or replace 1 1

wiring harness or 2 2
Check voltage poor contact START RY
ⓑ between CR-5 between CN-51 CN-45
(86) and chassis ANTI-RESTART RY
(20)-CR-5 (85)
Starting switch : START NO Disconnection in Repair or replace
Spec : 20~30V wiring harness or
poor contact
between CS-2 (6)-
CR-5 (86)

3009SH6ES10

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, master
switch ON and check open circuit of fusible link (CN-60).
·After checking, insert the disconnected connectors again immediately unless otherwise specified.
START KEY SW
CN-5
CS-2

H0 I
35 1

Cause Remedy

0, I
36 2
59 3 4

H
YES 60

BR ACC
4 1

B
Disconnection in Repair or replace 5
2
3
wiring harness or (after clean) 6
poor contact

ST C
5

YES Check voltage

6
between DO-3 (1)-
between DO-3 CR-1 or defective
(1) and chassis battery relay CR-35
NO.1
Voltage : 20~30V
Disconnection in Repair or replace
YES Check voltage NO wiring harness or (after clean)
between CS-2
poor contact
(2) and chassis NO.4
between CS-2 (2)- POWER RY
Voltage : 20~30V CN-5(60)- DO-3 (1)
Starting switch : ON
Defective start Replace CS-74
NO
YES Check voltage switch 1
between CS-2 2
(1) and chassis YES CN-95
Disconnection in Replace NO.20 2
wiring harness or 1 MASTER SW
Voltage : 20~30V
poor contact FUSIBLE LINK
between CS-2 (1)-
Check voltage 2
CN-5 (36) 1
between CN-5
NO CN-60
Check voltage (36) and chassis YES
Disconnection in Charge or replace
and specific wiring harness or (after clean) CR-1 BATTERY
gravity of battery Voltage : 20~30V
Check voltage poor contact
Specific gravity : MIN 1.28 between CS-74 between CS-74 (1)
Voltage : MIN 24V NO -CN-5 (36)
(1) and chassis BATT RY
Voltage : 20~30V ⓐ DO-3
NO CN-51
2
1
ANTI-RESTART RY 20
DIODE
MCU
Battery capacity Charge or replace
NO too low (after clean) CR-5 CN-3 CR-23 START MOTOR

YES 1 1
Defective master Replace 2 2
Check voltage
ⓐ switch START RY
between CS-74
CN-45
(2)- chassis ANTI-RESTART RY
NO
Disconnection in Charge or replace
Voltage : 20~30V wiring harness or (after clean)
poor contact
between CS-74 (2)
-CR-1

3009SH6ES11

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. 6, 11 and 17 is not blown out.
·After checking, insert the disconnected connectors again immediately unless otherwise specified. CN-21
3 1
Cause Remedy 2
5 3 CN-5
NO
Defective wiper Replace 4 4
cut switch 5
NO 6 M 2 6
Short circuit in Repair or replace
Check operation wiring harness or (after clean)
wiper cut switch WIPER MOTOR FUSE
poor contact 18
between CN-141 NO.6
Front sliding door (11)- CS-53 CN-141 19
open-close
Check valtage
FEED BACK 1
between CN-141 YES
YES (11) and chassis Defective switch Replace MOTOR DRIVE SIG 2 CN-17
panel
NO Check voltage
MOTOR DRIVE- 3 1
Front sliding door-close between CN-116 MOTOR DRIVE+ 4 2
Voltage : 4~5V (10) and chassis GND 5 3
Check operation 1)Recheck fuse Replace FUSE
NO VCC 6 4 24
Starting switch : ON No.11
YES of switch panel Vottage : 20~30V CONTINUE 24V 7 5 NO.17
LED ON. 2)Disconnection in Repair or replace CN-22
wiring harness or (after clean) WASHER P/P 8 6
Starting switch : ON ⓐ 2 M
Push wiper switch button YES
poor contact WASHER SIG. 9 7
between INT. SIG 10 8 1
CN-116(6)-Fuse WIPER CUT SW 11 WASHER PUMP
between N.C 12
CN-116 (13)-Chassis FEED BACK 13
Check voltage between NO
Defective switch Replace WIPER MOTOR CONTROLLER
CN-116 (4) and chassis panel
Intermittent
NO CS-53
1) Recheck fuse Replace
Check voltage CN-116 No.6
ⓐ
(5) 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 WIPER CUT SW
(3) and chassis check voltage CN-141(7)-Fuse,
YES CN-141 (7) and
Sarting switch : ON CN-21(4)-Fuse CN-116
Voltage : 0~1V
chassis, CN-21 HEAD LIGHT OUT 1
(4) and chassis NO
1) Recheck fuse Replace WORK LIGHT OUT 2
Starting switch : OFF No.17 INT. SIG 3
Voltage : 20~30V Check voltage WIPER MOTOR DRIVE 4
2) Disconnection Repair or replace
CN-141 (6) and WASHER SIG 5
YES chassis CN-141(6)-Fuse (after clean)
PRE-HEAT 6
CABIN LIGHT OUT 7
Starting switch : ON ⓑ
Check continuity YES TRAVEL ALARM 8
Voltage : 20~30V
NO NC 9 FUSE
between Disconnection in Repair or replace POWER 24V 10 57
CN-141 (2)-CN-116 (4), wiring harness or (after clean) GND 11 NO.11
CN-141 (9)-CN-116 (5), poor contact NC 12
CN-141 (10)-CN-116 (3),
ⓑ NO SWITCH PANEL
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
CN-141 (13)-CN-21 (3) YES motor controller
Resistance : 3~4Ω
21096ES14

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.18.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

CN-5
Cause Remedy FUSE
YES NO.18
Check voltage Defective bulb Replace
YES between CL-4 CN-116
(1) and chassis, HEAD LIGHT OUT 1
CL-3(1) and WORK LIGHT OUT 2
chassis Disconnection in Repair or replace INT. SIG 3
NO CR-13
Voltage : 20~30V wiring harness or (after clean) WIPER MOTOR DRIVE 4
30 30 86
poor contact WASHER SIG 5
Check voltage between CR-13 PRE-HEAT 6 86
YES
between CR-13 (87)-CL-4 (1) or CABIN LIGHT OUT 7 87
(87) and chassis CR-13 (87)-CL-3 TRAVEL ALARM 8 49 85
87a 87 85
(1) NC 9 87a
Starting switch : ON POWER 24V 10 HEAD LAMP RY
Head lamp switch : ON GND 11
Voltage : 20~30V YES NC 12
Defective switch Replace CL-4
panel SWITCH PANEL
Check voltage Check voltage 2
between CR-13 between CN-116 1
(30) and chassis, NO
(1) and chassis
CR-13 (86) and Repair or replace HEAD LAMP
Disconnection in
chassis Starting switch : ON NO (after clean)
Head lamp switch : ON wiring harness or
Starting switch : ON
Voltage : 20~30V Voltage : 20~30V poor contact CL-3
between CN-116
(1)-CR-13 (87) 2
1

Disconnection in Repair or replace HEAD LAMP

NO wiring harness or (after clean)
poor contact
between CR-13
(30) and chassis
or CR-13 (86) -
chassis

Recheck fuse Replace

No. 18
3009SH6ES12

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.15.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective bulb Replace

YES
Check voltage
between CL-5 (1)
and chassis CN-5
FUSE
Disconnection in Repair or replace
NO wiring harness or (after clean) NO.15
poor contact
CN-116
between CR-4
YES Check voltage HEAD LIGHT OUT 1
between CR-4 (87)-CL-5 (2) WORK LIGHT OUT 2
(87) and chassis INT. SIG 3 CR-4
WIPER MOTOR DRIVE 4
Starting switch : ON 30 30 86
WASHER SIG 5
Work lamp switch : ON PRE-HEAT 6 86
Voltage : 20~30V YES
Defective switch Replace CABIN LIGHT OUT 7 87

panel TRAVEL ALARM 8 50 85

87a 87 85
Check voltage Check voltage NC 9 87a
between CR-4 between CN-116 POWER 24V 10 WORK LAMP RY
(30) and chassis, NO GND 11
(2) and chassis
CR-4(86) chassis NC 12 CL-5
CN-12
Starting switch : ON Starting switch : ON Disconnection in Repair or replace SWITCH PANEL
Work lamp switch : ON NO 2 1
Voltage : 20~30V wiring harness or (after clean)
Voltage : 20~30V poor contact 1 2
between CR-4
(87)-CN-116 (2) WORK LAMP

1
Disconnection in Repair or replace 2
NO
wiring harness or (after clean)
poor contact CL-6
between CR-4
(30) and chassis
or CR-4 (86) and
chassis

Recheck fuse Replace

No.15

21096ES16

6-39
 GROUP 3 ELECTRICAL SYSTEM (CLUSTER TYPE 2)

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.8.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

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

NO Disconnection in Repair or
wiring harness or replace
poor contact (after clean)
between CN-5(5)-
and fuse No.8

CLUSTER
FUSE
POWER IG(24V) 1 5
NO.8
GND 2 4

RX
TX
CN-56 CN-5

Check voltage
YES 20 ~ 32V
NO 0V
3009SH6ES20

6-40
2. COMMUNICATION ERROR 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 poor contact
between CN-5 between CN-56
(1,2)and chassis (3,4) CN-5(1,2)
KEY ON
Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-5
(1,2)-CN-50
(29,30)

Check voltage
YES *4V *12V
NO 0V 0V

CLUSTER MCU
POWER IG(24V)
GND 2 4
*12V
RX 3 2 29
*4V
TX 4 1 30
CN-56 CN-5 CN-50

3009SH6ES21

6-41
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
Check voltage wiring harness or (after clean)
YES poor contact
between CN-3(3)
and chassis between CN-51(9)
-CN-3(3)

Disconnection in Repair or replace

Check voltage NO wiring harness or (after clean)
between CN-74(2) poor contact
and chassis between CN-3(3)-
CN-74(1)
Voltage : 20~32V
Engine : Running

NO
Defective alternator Replace

Check voltage
YES 20 ~ 32V
NO 0V

ALTERNATOR
B+
MCU
G
1 P
27 3 2 L
3 ~
U
3 FI
4 NC
CN-74
CN-52 CN-3

3009S6ES01

6-42
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
(110。C±2。C) cooling system
YES Resistance
between CD-8
(1,2) is in range
of 120~150Ω?
Disconnect : CD-8 Replace
NO Defective temp
Does display go
sensor
off when
disconnect
CD-8?
Starting switch : ON YES
Engine : Start Shot circuit in Repair or replace
Resistance
between CN-51 wiring harness (after clean)
NO (31,33) is
0~1Ω? Defective MCU Replace
NO
Disconnect : CD-51
KEY OFF

12th step
Check Table
Range 1st step 2nd~10th step 11th~12th step
Temperature ~29。C 30~105。C 105。C ~

1 st step

MCU
WATER TEMP SENDER

31 5 1 C
33 6 2

CN-3 CD-8

CN-51

3009SH6ES23

6-43
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 MCU Replace
NO
Disconnect CN-51

Check resistance
YES MAX 1Ω
NO MIN 1MΩ

MCU AIR CLEANER SWITCH

Pa
16

CD-10
CN-51
3009SH6ES24

6-44
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
Does display go
off when Engine oil leakage Check engine oil
disconnect
CD-18? of defective switch level or replace
Starting switch : ON switch
Does the gauge
light up and
down at lamp
check? YES Defective controller
Starting switch : ON Check resistance Replace
Engine : Start between
NO CN-51(4) and
chassis Disconnection in Repair or replace
Starting switch : OFF
NO
wiring harness or (after clean)
Disconnect : CN-51
poor contact
between CN-51(4)
-CD-18

Check resistance
YES MAX 1Ω
NO MIN 1MΩ

MCU ENGINE OIL PRESSURE SWITCH

4 1 Pa

CN-51 CN-2 CD-18

3009SH6ES25

6-45
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
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 MCU Replace

Starting switch : OFF NO
Disconnect CN-51

MCU HYDRAULIC OIL

TEMPERATURE SENDER

31 1 C
34 2

CD-1
CN-51

3009SH6ES26

6-46
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
between
CN-51(31) and
(33) over 2kΩ? CN-51-CD-8
Starting switch : ON YES
Defective MCU Replace
Does the gauge Check resistance
light up and down between CN-2(5)
NO
at lamp check? and (6)
NO Defective temp Replace
Starting switch : ON Spec : 120Ω
See table sensor

NO
Defective cluster Replace

12th step Check Table

Range 1st step 2nd~10th step 11th~12th step
Temperature ~29。C 30~105。C 105。C ~

1 st step

MCU
WATER TEMP SENDER

31 5 1 C
33 6 2

CN-3 CD-8

CN-51

3009SH6ES23

6-47
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 MCU 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
Disconnect CD-2 NO
check? sensor
See Table
Starting switch : ON

Defective cluster Replace

NO

2nd~10th step
Check Table
1 st step 11th~12th
step Range
Item 1st step 2nd~10th step 11th~12th step

Unit Resistance(Ω) 700~601 600~101 ~100

Tolerance(%) ±5 ±5 ±5

MCU
FUEL LEVEL SENDER

24 2

31 1

CD-2

CN-51

3009SH6ES27

6-48
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.23.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Hydraulic system 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 Disconnection in Repair or replace
CN-68(1) - (2) Start switch : ON NO
wiring harness or (after clean)
YES Check voltage Voltage : 20~30V
Starting switch : ON between CN-4(16) Disconnect CN-4 poor contact
Voltage : 20~30V and chassis between
Safety state
Starting switch : ON CS-4(C)-CN-68(1)
Voltage : 20~30V
Disconnect CN-4
Check voltage Disconnect in Repair or replace
NO
between CN-68(2) wiring harness or (after clean)
NO
with chassis poor contact
between
Safety lever : OFF
Starting switch : ON CN-4(16)-CN-68(1)
Voltage : 20~30V
Disconnection in Replace
NO
fuse No. 23

FUSE

NO.23
SAFETY SWITCH
B C A 14 SAFETY SOLENOID
B 15 2

A C 16 1
CS-4 CN-68
CN-4

21096ES10

6-49
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.28 .
·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 MCU Replace
(13) and chassis
Check resistance
Check if travel Starting switch : ON Starting switch : ON between CN-70
Voltage : 20~30V : OFF NO Defective solenoid
speed lamps( , (1) and (2)
Disconnect CN-50 : ON
) change when Replace
Starting switch : OFF NO
pressing the travel
SPEC : 15~25Ω
speed switch on Disconnect CN-70
the cluster Defective cluster
YES
Starting switch : ON Replace
Check controller
Y R G
NO Defective MCU
Replace
Starting switch : ON
NO

FUSE

MCU NO.28

TRAVEL SOLENOID

13 1

CN-70
CN-50

3009SH6ES28

6-50
12. WHEN ENGINE DOES NOT START ( lights up condition)

·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. 1, 4, 20.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES START KEY SW
Delective battery Replace CN-5
CS-2

H0 I
35 1

0, I
36 2
59 3 4

H
60

BR ACC
4 1

B
2
5 3

6
Check operation YES

ST C
5
Check voltage Defective magnet Replace 6
start motor
YES between starter of start motor
magnet coil and CR-35
Starting switch : START NO.1
chassis Defective start relay Replace
NO
Starting switch : START
Check operation Spec : 20~30V YES
YES Check voltage ⓐ
of start relay between CN-3
NO
CR-23 (2) and chassis
NO.4
POWER RY
Disconnection in Repair or replace
NO
Starting switch : START wiring harness or
Starting switch : START poor contact
Check operation Spec : 20~30V between CN-3 (2) CS-74
of anti-restart -CR-5 (87) 1
NO relay CR-5 2
CN-95
NO.20
Starting switch : ON
YES 2

Check voltage Defective anti- Replace 1 MASTER SW

between CR-5 restart relay FUSIBLE LINK

NO 2
(85, 86)
NO
ⓑ 1
CN-60
Starting switch : START
Spec : 20~30V
CR-1 BATTERY

YES
Check voltage Defective start relay Replace
ⓐ between CR-23 BATT RY
and chassis Disconnection in Repair or replace DO-3
NO
wiring harness or 2
Starting switch : START CN-50
poor contact ANTI-RESTART RY 11
1
Spec : 20~30V DIODE
between CN-3- MCU
CR-5
CR-5 CN-3 CR-23 START MOTOR
YES
Disconnection in Repair or replace 1 1

wiring harness or 2 2
Check voltage poor contact START RY
ⓑ between CR-5 between CN-50 CN-45
(86) and chassis ANTI-RESTART RY
(11)-CR-5 (85)
Starting switch : START NO Disconnection in Repair or replace
Spec : 20~30V wiring harness or
poor contact
between CS-2 (6)-
CR-5 (86)

3009SH6ES29

6-51
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, master
switch ON and check open circuit of fusible link (CN-60).
·After checking, insert the disconnected connectors again immediately unless otherwise specified.
START KEY SW
CN-5
CS-2

H0 I
35 1

Cause Remedy

0, I
36 2
59 3 4

H
YES 60

BR ACC
4 1

B
Disconnection in Repair or replace 5
2
3
wiring harness or (after clean) 6
poor contact

ST C
5

YES Check voltage

6
between DO-3 (1)-
between DO-3 CR-1 or defective
(1) and chassis battery relay CR-35
NO.1
Voltage : 20~30V
Disconnection in Repair or replace
YES Check voltage NO wiring harness or (after clean)
between CS-2
poor contact
(2) and chassis NO.4
between CS-2 (2)- POWER RY
Voltage : 20~30V CN-5(60)- DO-3 (1)
Starting switch : ON
Defective start Replace CS-74
NO
YES Check voltage switch 1
between CS-2 2
(1) and chassis YES CN-95
Disconnection in Replace NO.20 2
wiring harness or 1 MASTER SW
Voltage : 20~30V
poor contact FUSIBLE LINK
between CS-2 (1)-
Check voltage 2
CN-5 (36) 1
between CN-5
NO CN-60
Check voltage (36) and chassis YES
Disconnection in Charge or replace
and specific wiring harness or (after clean) CR-1 BATTERY
gravity of battery Voltage : 20~30V
Check voltage poor contact
Specific gravity : MIN 1.28 between CS-74 between CS-74 (1)
Voltage : MIN 24V NO -CN-5 (36)
(1) and chassis BATT RY
Voltage : 20~30V ⓐ DO-3
NO CN-50
2
1
ANTI-RESTART RY 11
DIODE
MCU
Battery capacity too Charge or replace
NO low (after clean) CR-5 CN-3 CR-23 START MOTOR

YES 1 1
Defective master Replace 2 2
Check voltage
ⓐ switch START RY
between CS-74
CN-45
(2)- chassis ANTI-RESTART RY
NO
Disconnection in Charge or replace
Voltage : 20~30V wiring harness or (after clean)
poor contact
between CS-74 (2)
-CR-1

3009SH6ES30

6-52
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. 6, 11 and 17 is not blown out.
·After checking, insert the disconnected connectors again immediately unless otherwise specified. CN-21
3 1
Cause Remedy 2
5 3 CN-5
NO
Defective wiper Replace 4 4
cut switch 5
NO 6 M 2 6
Short circuit in Repair or replace
Check operation wiring harness or (after clean)
wiper cut switch WIPER MOTOR FUSE
poor contact 18
between CN-141 NO.6
Front sliding door (11)- CS-53 CN-141 19
open-close
Check valtage
FEED BACK 1
between CN-141 YES
YES (11) and chassis Defective switch Replace MOTOR DRIVE SIG 2 CN-17
panel
NO Check voltage
MOTOR DRIVE- 3 1
Front sliding door-close between CN-116 MOTOR DRIVE+ 4 2
Voltage : 4~5V (10) and chassis GND 5 3
Check operation 1)Recheck fuse Replace FUSE
NO VCC 6 4 24
Starting switch : ON No.11
YES of switch panel Vottage : 20~30V CONTINUE 24V 7 5 NO.17
LED ON. 2)Disconnection in Repair or replace CN-22
wiring harness or (after clean) WASHER P/P 8 6
Starting switch : ON ⓐ 2 M
Push wiper switch button YES
poor contact WASHER SIG. 9 7
between INT. SIG 10 8 1
CN-116(6)-Fuse WIPER CUT SW 11 WASHER PUMP
between N.C 12
CN-116 (13)-Chassis FEED BACK 13
Check voltage between NO
Defective switch Replace WIPER MOTOR CONTROLLER
CN-116 (4) and chassis panel
Intermittent
NO CS-53
1) Recheck fuse Replace
Check voltage CN-116 No.6
ⓐ
(5) 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 WIPER CUT SW
(3) and chassis check voltage CN-141(7)-Fuse,
YES CN-141 (7) and
Sarting switch : ON CN-21(4)-Fuse CN-116
Voltage : 0~1V
chassis, CN-21 HEAD LIGHT OUT 1
(4) and chassis NO
1) Recheck fuse Replace WORK LIGHT OUT 2
Starting switch : OFF No.17 INT. SIG 3
Voltage : 20~30V Check voltage WIPER MOTOR DRIVE 4
2) Disconnection Repair or replace
CN-141 (6) and WASHER SIG 5
YES chassis CN-141(6)-Fuse (after clean)
PRE-HEAT 6
CABIN LIGHT OUT 7
Starting switch : ON ⓑ
Check continuity YES TRAVEL ALARM 8
Voltage : 20~30V
NO NC 9 FUSE
between Disconnection in Repair or replace POWER 24V 10 57
CN-141 (2)-CN-116 (4), wiring harness or (after clean) GND 11 NO.11
CN-141 (9)-CN-116 (5), poor contact NC 12
CN-141 (10)-CN-116 (3),
ⓑ NO SWITCH PANEL
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
CN-141 (13)-CN-21 (3) YES motor controller
Resistance : 3~4Ω
21096ES14

6-53
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.18.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.

CN-5
Cause Remedy FUSE
YES NO.18
Check voltage Defective bulb Replace
YES between CL-4 CN-116
(1) and chassis, HEAD LIGHT OUT 1
CL-3(1) and WORK LIGHT OUT 2
chassis Disconnection in Repair or replace INT. SIG 3
NO CR-13
Voltage : 20~30V wiring harness or (after clean) WIPER MOTOR DRIVE 4
30 30 86
poor contact WASHER SIG 5
Check voltage between CR-13 PRE-HEAT 6 86
YES
between CR-13 (87)-CL-4 (1) or CABIN LIGHT OUT 7 87
(87) and chassis CR-13 (87)-CL-3 TRAVEL ALARM 8 49 85
87a 87 85
(1) NC 9 87a
Starting switch : ON POWER 24V 10 HEAD LAMP RY
Head lamp switch : ON GND 11
Voltage : 20~30V YES NC 12
Defective switch Replace CL-4
panel SWITCH PANEL
Check voltage Check voltage 2
between CR-13 between CN-116 1
(30) and chassis, NO
(1) and chassis
CR-13 (86) and Repair or replace HEAD LAMP
Disconnection in
chassis Starting switch : ON NO (after clean)
Head lamp switch : ON wiring harness or
Starting switch : ON
Voltage : 20~30V Voltage : 20~30V poor contact CL-3
between CN-116
(1)-CR-13 (87) 2
1

Disconnection in Repair or replace HEAD LAMP

NO wiring harness or (after clean)
poor contact
between CR-13
(30) and chassis
or CR-13 (86) -
chassis

Recheck fuse Replace

No. 18
3009SH6ES12

6-54
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
YES
Defective bulb Replace

YES
Check voltage
between CL-5 (1)
and chassis CN-5
FUSE
Disconnection in Repair or replace
NO wiring harness or (after clean) NO.15
poor contact
CN-116
between CR-4
YES Check voltage HEAD LIGHT OUT 1
between CR-4 (87)-CL-5 (2) WORK LIGHT OUT 2
(87) and chassis INT. SIG 3 CR-4
WIPER MOTOR DRIVE 4
Starting switch : ON 30 30 86
WASHER SIG 5
Work lamp switch : ON PRE-HEAT 6 86
Voltage : 20~30V YES
Defective switch Replace CABIN LIGHT OUT 7 87

panel TRAVEL ALARM 8 50 85

87a 87 85
Check voltage Check voltage NC 9 87a
between CR-4 between CN-116 POWER 24V 10 WORK LAMP RY
(30) and chassis, NO GND 11
(2) and chassis
CR-4(86) chassis NC 12 CL-5
CN-12
Starting switch : ON Starting switch : ON Disconnection in Repair or replace SWITCH PANEL
Work lamp switch : ON NO 2 1
Voltage : 20~30V wiring harness or (after clean)
Voltage : 20~30V poor contact 1 2
between CR-4
(87)-CN-116 (2) WORK LAMP

1
Disconnection in Repair or replace 2
NO
wiring harness or (after clean)
poor contact CL-6
between CR-4
(30) and chassis
or CR-4 (86) and
chassis

Recheck fuse Replace

No.15

21096ES16

6-55