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.25 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-56
(1, 2) and chassis

NO Disconnection in Repair or replace

wiring harness or (After clean)
Check voltage
poor contact
between CN-15
(1) and chassis between
CN-56(1, 2) and
CN-15(1)

NO
Disconnection in Repair or replace
wiring harness or (After clean)
poor contact
between CN-15(1)
and fuse No.25

CLUSTER
1
FUSE
2 1
No.25
CN-56
CN-15

Check voltage
YES 20 ~ 30V
NO 0V
7807AEL15

7-65
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(5)
(25) and CN-3(5)
and chassis
YES
Voltage : 26~30V Disconnection in Repair or replace
wiring harness or (After clean)
Check voltage poor contact
between CN- between CN-13(8)
NO
Check voltage 13(8) and chassis and CN-3(5)
between
alternator terminal Disconnection in Repair or replace
"2" and 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)

ALTERNATOR
25 5 8 " 2 " TERMINAL
CN-3 CN-13
CN-58

Check valtage
YES 20 ~ 30V
NO 0V 7707AEL16

7-66
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 Replace
Check voltage
Starting switch : ON switch
Parking switch : ON-OFF NO
between CS-17
Voltage : 20~30V (6) and chassis
NO
Disconnection in Repair or replace
Voltage : 20~30V
wiring harness or (After clean)
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

7-67
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 control unit) 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
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 (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 T/M CONTROL UNIT
CS-17 21

CN-157

Check resistance
YES MAX 1Ω
7807AEL17
NO MIN 1MΩ

7-68
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 7-17.
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-157 NO
(66) and chassis? control unit

NO
Defective T/M Replace
Is voltage between
control unit
CN-157(21) and
chassis 20-28V? YES
Defective Replace
Starting switch : ON
Parking switch : OFF
parking 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-157
(21) and CS-17(7)

Check resistance
YES MAX 1Ω
NO MIN 1MΩ

7-69
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.
MCU

HYD TEMP SENDER

FAN CLUTCH +
CLUTCH CUT-OFF PS

SPEEDMETER SIG.

RIDE CONT. AUTO

SAFETY RY

COOLANT TEMP

BUZZER STOP
WIPER RY
STEERING RY

ALT LEVEL
FUEL SENSOR

TACHO SENSOR+
PREHEATER

SERIAL-H

WASH SIG
NEUTRAL SIG

FAN CLUTCH -

CAN-H
AUTO SEL.TCU

ELEC STEERING
CAN-L

MAIN PUMP PS

CLUTCH CUT-OFF SW

STEERING P/P PS
RIDE CONT. ON
WIPER INT SIG

PARKING SIG
SERIAL-L

GND
BUZZER

AUTO SEL.SW

BRAKE PS
TAHCO SENSOR -

AIR FILTER
IG 24V
FUSE BOX
BEACON/RR WORK LAMP 20A
1
ILL.LAMP 20A
Cause Remedy 2
HEAD LAMP 20A
YES 3
BACK/STOP LAMP 10A
Check voltage Defective front Replace

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
4

2
3
6
8

4
5
7
9
HORN/CONVERTER 30A
YES between front wiper motor 5

105 GOr

120 LW
CN-58

69A G
AIR-CON/HEATER 30A
6
wiper motor and CIGAR/MIRROR 30A
7
chassis Poor connection of Replace SWITCH 30A
8
Check voltage Voltage : 20~30V
NO 14 L WIPER 20A
YES chassis 9
between CN-21(5) Starting switch : ON FR WORK LAMP 30A
10
Wiper switch : 1st
and chassis CN-36

Voltage : 20~30V WIPER RY LO

173 R
30
Starting switch : ON Disconnection in Repair or replace 8A W 87a 87 85
Check voltage Wiper switch : 1st NO 8 W
86

YES between CS-12 wiring harness or (After clean) 105 GOr

87
85
(4), CN-16(10) poor contact 162 G
87a 30 86
and chassis between CN-16(10) CR-26

Voltage : 20~30V and CN-21(5),

Starting switch : ON
Wiper switch : OFF CN-17(13)
WIPER RY HI
14A L
30
163 Br 87a 87 85
86
NO Defective wiper Repair or replace 172 G
87
G13 B
switch or (After clean) BE W
85
87a 30 86
Check voltage disconnection in CR-4
CS-12(6) wiring harness or
poor contact
Voltage : 20~30V between CS-12(4)
Starting switch : ON
and CN-16(10).

120 LW
163 Br
162 G
14F L

69 Gr
Wiper switch : 1st
YES

CN-16
Disconnection in Repair or replace

10
11
12
13
14
6
7

9
8
wiring harness or (After clean)
Check voltage poor contact
between CN-16(8) between CN-16(8)
NO

G61 B
172 G
173 R
and chassis. and fuse No.9

8 W
VOr 38

LW 17
Gr 18
Br 19
G 20
L 21

CN-17
10
11
12
13
14
1
2
3
4
5
6
7
8
9
Discomection in Repair or replace

CS-11

CS-12

CS-5
NO

6
5
4
3
2
1
8
7
6
5
4
3
2
1
wiring harness or (After clean) 38 VOr
poor contact

BWG 4

RW 6
W6

BVi 3
L 4
G 5

BY 1

Gr 2

VOr
W
Y

B
G
R
between CS-12(6)

G1
28
38

27
26
HO
and CN-16(8).

W
II
I
Hi

C
J 0

J
C

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
5B
FRONT WIPER
MULTI FUNCTION SWITCH

7707AEL18

7-70
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.

FUSE BOX
Cause Remedy EMER STEER/RIDE CON 20A
10

11
YES NEUTRAL RY/JOYSTICK F/R 10A
Defective cable Repair or replace 12
PREHEATER 30A
Check voltage 13
YES assembly (After clean) TURN LAMP
14
between CN-60(2) CASSETTE/ROOM LAMP 5A 3R 34
15
and chassis 21 3Or START KEY 30A
16
TCU
Short circuit or Replace 10A
17
Voltage : 20~30V NO ECM 10A
18
Check voltage defect of fusible CLUSTER/MCU 10A
YES 19
between CR-1 link or defective AC & HEATER 20A
20
ECM 10A
and chassis 21
battery relay RCV 10A
22
Voltage : 20~30V MCU 10A
23
TCU 10A
24
Disconnection in Replace CLUSTER 10A
25
NO CASSETTE 10A
Check voltage wiring harness or 26
ILLUMINATION LAMP 5A
YES between CS-2 ILLUMINATION LAMP 5A
27

(1)[and CS-2(2)] poor contact 28

and chassis between CS-2(2) CN-36

Voltage : 20~30V MASTER SW
- CN-3(9)-CR-1.
34 3R 1 5R
1 2
2 1
CS-74 FUSIBLE LINK
CN-1 2 5W CN-60
2
69 5W
Disconnection in Replace 1
Check voltage NO CN-95
BATTERY
BATT RY
wiring harness or
and specific 66 G

gravity of battery poor contact G12 B

between fuse CR-1

Specific gravity : MIN 1.28
Voltage : MIN 24V No. 16 and CS- 1
2
2(1) or defect of 3
4
start switch 5
6
7
G 66
Battery capacity Repair or replace 8 2
NO 9
L 22
1
too low (After clean)

21E Or
153 L
10 DO-1
11
12
CN-3

CS-2

5
4

1
6

2
3
B
0, I

1
H 0 I II

4
6
5

3
2
H
C ST ACC BR
START SWITCH

7807AEL19

7-71
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.1, 10 is not blown out.
·After checking, connect the disconnected connectors again immediately unless otherwise specified. FUSE BOX
5 G BEACON/RR WORK LAMP 20A
1
10 OrW ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
Cause Remedy AIR-CON/HEATER 30A
5

6
YES CIGAR LIGHTER/MIRROR 30A

Check voltage Defective lamp Replace SWITCH 30A

7

8
YES
between each WIPER 20A
9
15 Gr FR WORK LAMP 30A
lamp and chassis 10
Disconnection in Repair or replace EMER STEER/RIDE CON 20A
11
NO
Voltage : 20~30V wiring harness or (After clean) CN-36
Check voltage Starting switch : ON poor contact OPT
YES between CN-7(2), between CL-6(2), RW 2F
FRONT WORK LAMP
2
CN-4(14) and CL-5(2), CL-22(2),
B G24
1
chassis CL-23(2) and CN-
CL-36
FRONT WORK LAMP
Voltage : 20~30V RW 2E
7(2), CN-4(14). B G23
2
Starting switch : ON 1
CL-35
Check voltage
Disconnection in Repair or replace FR WORK LAMP RY 1 FRONT WORK
YES between CR- NO 2
RW 2
LAMP,LH
wiring harness or (After clean) 86 30 87a
B G16 RW 2A
3(87), CR-55(87) 85 3 2
poor contact 87
RW 171 4 B G22
1
and chassis G 170 5
between CN-7(2) - 85 87 87a
86
Gr 15 6
CL-6
Voltage : 20~30V 30 7 FRONT WORK
Starting switch : ON
CR-3(87) and CN- CR-3 8
B G21
LAMP,RH
RW 2
4(14) - CR-55(87) 9
B G21
2
Check voltage 10
11
1
CL-5
between CR- Defective work Replace relay 12 OPT
REAR WORK LAMP
3(30), CR-55(30) NO 13 R 10 R 10
lamp relay 14
B G25
2
and chassis 15 1
CN-7 CL-32
Voltage : 20~30V YES RR WORK LAMP RY
Disconnection in Repair or replace R 10A
REAR WORK LAMP
Starting switch : ON 86 30 87a
B G17 1 2
wiring harness or (After clean) 85 2
B G26
1
R 63
Check voltage poor contact 87
L 180 3 CL-33
86 4
between fuse No. between CR- 85 87 87a
30
Gr 5
5 REAR WORK
LAMP,LH
NO 3(30), CR-55(30) CR-55 6 40A R
2
1, 10 and chassis 7 G3 B
and fuse No.1, 10 8 1
WORK LAMP SW 9 CL-22
Voltage : 20~30V B G36 10
9 10 10
Starting switch : ON Short circuit of fuse Replace 9 R 1G 11
NO 4 8 12 REAR WORK
LAMP,RH
2 G 170 13
7 R 40 40 R
14 2
7 1 6 G2 B
15 1
5 5
R 1F CN-4 CL-23
4

G1
3
L 180

II I 0
2
1 R 1E
CS-36 EARTH 1

CS-21
9 10 10
9
4 8
2 R 1
7
7 1 6
5 5
4
3
II I 0

2
OrW 10
1
ILL & HEAD LAMP SW : ON(1st step)

7807AEL20

7-72
9. WHEN ENGINE DOES NOT START
·Check supply of the power at engine stop solenoid while starting switch is ON.
·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.
T/M CONTROL UNIT MCU
·Check forward reverse switch at neutral position.

ADM2-JOYSTICK SELECT LAMP(-)

SAFETY RY
ADM5-JOYSTICK SELLECTER(+)

WIPER RY
STEERING RY
PREHEATER
NEUTRAL SIG
ADM1-START INTERLOCK RY(-)
ED9-CLUTCH CUT-OFF SW(+)

ADM4-REVERSE DRIVE RY(-)

ED6-SHIFT LEVER X2D-NEU
ED2-SHIFT LEVER X1B-B2

VPE2-CONTINUANCE 24V

ED14-NEU-JOYSTICK
ED13-REV-JOYSTICK
FUSE BOX

ED8-FWD-JOYSTICK
10
Cause Remedy EMER STEER/RIDE CON 20A
11
17 G NEUTRAL RY/JOYSTICK F/R 10A
YES 12
Defective batteryCheck engine PREHEATER 30A

35
34
36

32
33
SAFETY RY 13
TURN LAMP
system charge or G 17
30

65
66
67
68
44
31
30
52

59
CN-58 14

5
7

73 BOr
85
86 87a 87
G 17A CASSETTE/ROOM LAMP 5A
replace (after CN-157

85 W
15
BOr 73 21 3Or START KEY 30A
87 16
checking specific BOr 88
85 TCU 10A
17
gravity of battery) 87a 30 86 ECM 10A
18
YES CLUSTER/MCU 10A
Check voltage Defective magnet Replace CR-5 19
Check operation SAFETY RY AC & HEATER 20A
YES between starter of start motor GrW 157 ECM
20
30 10A
of start motor magnet coil and 85 21
BOr 73A
86 87a 87 RCV 10A
22
BW 151
chassis Defective start Replace X-1 87 MCU 10A
23
Starting switch : start NO VM OUTPUT SIGNAL K A 85 TCU 10A
Starting switch : start relay 24
VP F B N D B 87a 30 86 CLUSTER 10A
ED 1 2 3 4 1 2 3 4 1 2 3 4 C 25
CR-5 CASSETTE 10A
YES AD1 B1 D 26
ⓐ AD2 B2 CN-158 ILLUMINATION LAMP 5A
27
Check operation Check voltage
AD3
AD4
B3
V X-2
ILLUMINATION LAMP 5A
28
NO of starter relay YES AD5 R A 1
between CR-5 AD6 AS B 2 CN-36
AD7 C 3
(87) and chassis A AD3 D
W 33
4
Starting switch : start
NO
Disconnection in Replace B AD2 CN-159 5
Starting switch : OFF 6
wiring harness or C AD1
D AD7(KD) 7
X1
Check operation poor contact 8
A ED1(VP) 9
of start safety between CN-3(4) D AD6 10
NO B AD4 11
relay and CR-5(87) C AD5 12 STARTER
X2 TO BATT
13 B+
Check switch : neutral YES 14
Defective relay Replace CN-17
Check voltage M
between CR-5 CN-45
NO 1
(86) and chassis 2 5
START RY
G1 B
Starting switch : OFF NO
ⓑ 3
BW 18
6 1
4 7 2
17 BW
YES 5 8
CR-23
Defective start Replace 6 9
Check voltage relay 7 10
8 11
ⓐ between CR-23

21E Or
157 GrW

65 G
9 12
(2) and chassis 10 CN-13
Disconnection in Repair or replace 11
Voltage : 20~30V NO 12
Starting switch : ON wiring harness or

21 3Or
G14 B
31 3Br
65A G

G15 B
32 3Y
65 G
21A Or
CN-3

CS-2
poor contact

5
4

1
6

2
3
between CN-3(4) -

CR-35

CR-25
87a 85 87 86 30 87a 85 87 86 30 B
0, I

1
CN-13(7)-CR-23(2) 87a 87a
30 87 30 87
YES 86 85 86 85
H 0 I II
Disconnection in Repair or replace

4
6
5

3
2
H
C ST ACC BR
wiring harness or POWER RY ECM POWER RY START SWITCH
Check voltage poor contact
ⓑ between CN-17 between CN-17(4)
(4) and chassis and CN-157
Starting switch : OFF
NO
Defective DW-3 Replace 7707AEL21

7-73