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
YES
YES

Remedy

Defective cluster Replace

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

NO

Check voltage
between CN-15
(1) and chassis

Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CN-15(1)
and fuse No.25

NO

CLUSTER
1
FUSE

1
No.25

CN-56

CN-15

Check voltage
YES

20 ~ 30V

NO

0V

7807AEL15

7-67

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
YES

Defective controller Replace

Check voltage
YES
between CN-58
(25) and chassis
Voltage : 27.5~30V

Disconnection in
wiring harness or
poor contact
between CN-58
(25) and CN-3(5)

NO

Check voltage

YES between CN-3(5)

and chassis
YES

Voltage : 26~30V

Repair or replace
(After clean)

Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CN-13(8)
and CN-3(5)

Check voltage
between CNNO
13(8) and chassis

Check voltage
between
alternator terminal
"2" and chassis

Remedy

Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CN-13(8)
and alternator
terminal " 2 "

NO

Voltage : 26~30V
Starting switch : ON

Defective alternator Replace

NO

CONTROLLER(MCU)

25

ALTERNATOR
" 2 " TERMINAL

CN-13

CN-3
CN-58
Check valtage
YES

20 ~ 30V

NO

0V

7707AEL16

7-68

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
YES

Remedy

Defective parking Replace

brake solenoid

Check voltage
between CN-71
(2) and chassis

YES

Check voltage
between CS-17
(6) and chassis

Starting switch : ON
Parking switch : ON-OFF NO
Voltage : 20~30V

NO

Voltage : 20~30V

Defective parking Replace

switch
Disconnection in Repair or replace
wiring harness or (After clean)
poor contact
between CS-17
(6) and Fuse
No.8

PARKING SWITCH
8

CN-71

FUSE

CS-17

No.8

7707EL24

7-69

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
YES

Defective T/M
control unit
YES

Check voltage
between CN-157
(21) and chassis
Starting switch : ON
Parking switch : ON
Voltage : 20~30V

Replace

Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CN-157
(21) and CS-17(7)

Check voltage
between CS-17
NO
(7) and chassis
Voltage : 20~30V
Parking switch : ON

Remedy

YES

Check voltage
between CS-17
NO
(5) and chassis
Voltage : 20~30V

PARKING SWITCH

NO

Defective switch

Replace

Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CS-17(5)
and fuse No.8

FUSE

6
No.8

5
7

T/M CONTROL UNIT

CS-17

21
CN-157

Check resistance
YES

MAX 1

NO

MIN 1M

7807AEL17

7-70

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
YES

YES

Check resistance
between CD-5
and chassis

NO Is there continuity

between CN-157
(66) and chassis?
NO

Is voltage between
CN-157(21) and
chassis 20-28V?
Starting switch : ON
Parking switch : OFF
Clutch cut-off
switch : ON

NO

YES

Is there continuity
between CS-17(7)
YES
and chassis?

Check resistance
MAX 1

NO

MIN 1M

Defective clutch
cut-off switch

Replace

Defective T/M
control unit

Replace

Defective T/M
control unit

Replace

Defective
parking switch

Replace

Repair or replace
Disconnection
wiring harness or (After clean)
poor contact
between CN-157
(21) and CS-17(7)

NO

YES

Remedy

7-71

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.

69A G

5
4

TACHO SENSOR+
WIPER INT SIG
RIDE CONT. ON
RIDE CONT. AUTO
WASH SIG
BUZZER STOP
STEERING P/P PS
PARKING SIG
BRAKE PS
8

CLUTCH CUT-OFF SW

120 LW

11

10

12

13

15
14

17

16

18

20

19

23

21

22

24

26

25

FUEL SENSOR
HYD TEMP SENDER
COOLANT TEMP
ALT LEVEL
FAN CLUTCH FAN CLUTCH +
GND
BUZZER
SPEEDMETER SIG.
CAN-L
CAN-H
AUTO SEL.TCU
TAHCO SENSOR MAIN PUMP PS
ELEC STEERING
AIR FILTER
IG 24V
AUTO SEL.SW
27

CLUTCH CUT-OFF PS
29

31
30

32

33

105 GOr

10A

HORN/CONVERTER

30A

AIR-CON/HEATER

30A

3
4
5
6

CIGAR/MIRROR

30A

SWITCH

30A

WIPER

20A

FR WORK LAMP

30A

7
8
9
10

WIPER RY LO
30
87a 87 85
86
87
85
30 86
87a

WIPER RY HI
30
87a 87 85
86
87
85
30 86
87a
CR-4

162 G
10
163 Br
11
69 Gr
12
120 LW
13
14
15
CN-16

14F L

8 W

G61 B
172 G
173 R

W
VOr
B
G
R
28
38
G1
27
26
3E
2Pf
1B

4 Hi
5 Lo

Y
HO

1
2
3
4
5
6

BY 1
RW 6
Gr 2
C
W

CN-21

G 5
BVi 3
L 4

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
CN-17

CS-5

CS-12
6
5
4
3
2
1

Br 19
Gr 18
LW 17

L 21
VOr 38
G 20

6
7
8
9
R

L
3 BG

MULTI FUNCTION SWITCH

38 VOr

II
I
0
J 0
II
I

BWG 4

W6
Hi

Discomection in
Repair or replace
wiring harness or (After clean)
poor contact
between CS-12(6)
and CN-16(8).

2 BW

NO

Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CN-16(8)
and fuse No.9

7 Y Lo

Check voltage
between CN-16(8)
NO
and chassis.

Defective wiper
Repair or replace
switch or
(After clean)
disconnection in
wiring harness or
poor contact
between CS-12(4)
and CN-16(10).

CS-11

YES

20A

BACK/STOP LAMP

14A L
163 Br
172 G
G13 B
BE W

8 WB

Voltage : 20~30V
Starting switch : ON
Wiper switch : 1st

HEAD LAMP

CR-26

B+

Check voltage
CS-12(6)

Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CN-16(10)
and CN-21(5),
CN-17(13)

5B

NO

20A

173 R
8A W
8 W
105 GOr
162 G

L
O
R

Voltage : 20~30V
Starting switch : ON
Wiper switch : OFF

ILL.LAMP

CN-36

Lo

(4), CN-16(10)
and chassis

NO

BEACON/RR WORK LAMP 20A

14 L

Check voltage
YES between CS-12

FUSE BOX

CN-58

Poor connection of Replace

NO
chassis

8
7
6
5
4
3
2
1

Voltage : 20~30V
Starting switch : ON
Wiper switch : 1st

Voltage : 20~30V
Starting switch : ON
Wiper switch : 1st

Replace

Hi

Check voltage
YES
between CN-21(5)
and chassis

Defective front
wiper motor

35
34

Check voltage
YES between front
wiper motor and
chassis

Remedy
36

Cause
YES

28

NEUTRAL SIG
SAFETY RY
PREHEATER
WIPER RY
STEERING RY
SERIAL-H
SERIAL-L

MCU

FRONT WIPER

7577AEL12

7-72

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
YES

Check voltage
between CN-60(2)
and chassis

YES

Voltage : 20~30V

Check voltage
YES
between CR-1
and chassis

Remedy

10

EMER STEER/RIDE CON 20A

Defective cable

Repair or replace

NEUTRAL RY/JOYSTICK F/R 10A

assembly

(After clean)

TURN LAMP

PREHEATER
CASSETTE/ROOM LAMP

NO

10A

CLUSTER/MCU

10A

link or defective

AC & HEATER

20A

ECM

10A

battery relay

RCV

10A

MCU

10A

TCU

10A

CLUSTER

10A

CASSETTE

10A

ILLUMINATION LAMP

5A

poor contact

ILLUMINATION LAMP

5A

between CS-2(2)

CN-36

Repair or replace

1
2

1 3R

19
20
21

23
24
25
26
27
28

2
1
CS-74

CN-1

NO

18

MASTER SW

- CN-3(9)-CR-1.

Disconnection in

17

22

34 3R

Check voltage
and specific
gravity of battery

16
10A

Disconnection in

3R 34

30A

ECM

Replace

wiring harness or (After clean)

Voltage : 20~30V

13
14
5A

TCU

Short circuit or
defect of fusible

NO

30A

15

21 3Or START KEY

Voltage : 20~30V

Check voltage
YES between CS-2
(1)[and CS-2(2)]
and chassis

11
12

FUSIBLE LINK
2 5W
69 5W

Repair or replace
BATT RY

wiring harness or (After clean)

CN-60

CN-95

BATTERY

66 G

poor contact

G12 B

between fuse

Specific gravity : MIN 1.28

Voltage : MIN 24V

CR-1

No. 16 and CS-

1
2
3

2(1) or defect of
start switch

(After clean)

G 66
L 22

2
1

DO-1

CN-3

1
2
3
4
5
6
CS-2
B
1

2
3

5
6

C ST ACC BR

0, I

too low

21E Or

Repair or replace
153 L

Battery capacity

H 0 I II

NO

4
5
6
7
8
9
10
11
12

START SWITCH

7607AEL19

7-73

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.

Cause
YES

Check voltage
YES
between each
lamp and chassis

Voltage : 20~30V
Starting switch : ON

Check voltage
NO

YES between CR-

3(87), CR-55(87)
and chassis
Voltage : 20~30V
Starting switch : ON

Check voltage
between CR3(30), CR-55(30)
and chassis

NO
YES

Voltage : 20~30V
Starting switch : ON

Check voltage
between fuse No.
NO
1, 10 and chassis
Voltage : 20~30V
Starting switch : ON

NO

20A

HEAD LAMP

20A

BACK/STOP LAMP

10A

HORN/CONVERTER

30A

AIR-CON/HEATER

30A

Repair or replace
Disconnection in
wiring harness or (After clean)
poor contact
between CL-6(2),
CL-5(2), CL-22(2),
CL-23(2) and CN7(2), CN-4(14).

3
4

SWITCH

30A

WIPER

20A

FR WORK LAMP

30A

EMER STEER/RIDE CON

20A

7
8
9
10
11

CN-36

OPT
RW 2F
B G24

RW 2E
B G23

Repair or replace
Disconnection in
wiring harness or (After clean)
poor contact
between CN-7(2) CR-3(87) and CN4(14) - CR-55(87)
Defective work
lamp relay

CIGAR LIGHTER/MIRROR 30A

Replace
15 Gr

NO

FR WORK LAMP RY
87a
86 30
B G16
85
RW 171
87
G 170
86
85 87 87a
Gr 15
30
CR-3

Replace relay

RR WORK LAMP RY
87a
86 30
85
87
86
85 87 87a
30
CR-55

Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CR3(30), CR-55(30)
and fuse No.1, 10

WORK LAMP SW
10 10
9
9
4 8
2
7
1 6
7
5
5
4
3
2
1
CS-36

Short circuit of fuse Replace

9
2
7
5

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

FRONT WORK LAMP

2
1
CL-36
FRONT WORK LAMP
2
1
CL-35

RW 2
RW 2A
B G22

B G21

B G36
R 1G
G 170

R 1F
L 180
R 1E

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

FRONT WORK
LAMP,RH
2
1
CL-5
OPT
REAR WORK LAMP
2
1
CL-32
REAR WORK LAMP
2
1
CL-33

RW 2
B G21

R 10

R 10
B G25

CN-7
B G17
R 63
L 180
Gr 5

FRONT WORK
LAMP,LH
2
1
CL-6

R 10A
B G26

R 40

CN-4

40A R
G3 B

REAR WORK
LAMP,LH
2
1
CL-22

40 R
G2 B

REAR WORK
LAMP,RH
2
1
CL-23

G1

CN-4(14) and
chassis

ILL.LAMP

II I 0

YES between CN-7(2),

BEACON/RR WORK LAMP 20A

10 OrW

Remedy

II I 0

Check voltage

Voltage : 20~30V
Starting switch : ON

Defective lamp

FUSE BOX
5 G

EARTH 1

CS-21
10 10
9
4 8
R 1
7
1 6
5
4
3
2
OrW 10
1

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

7807AEL20

7-74

9. WHEN ENGINE DOES NOT START

Check voltage
YES between starter
magnet coil and
chassis

NEUTRAL SIG
SAFETY RY
PREHEATER
WIPER RY
STEERING RY
32

36

73 BOr

CN-58

NO

Starting switch : start

YES

Check operation
NO of starter relay

Replace

BOr 73
BOr 88

GrW 157

VM
VP
ED
AD1
AD2
AD3
AD4
AD5
AD6
AD7

Check voltage
YES
between CR-5
(87) and chassis

Starting switch : start

Starting switch : OFF

Check operation
of start safety
NO
relay

B1
B2
B3
V
R
AS
A AD3

Disconnection in Replace
NO
wiring harness or
poor contact
between CN-3(4)
and CR-5(87)

X1

YES

Defective relay

B AD2
C AD1
D AD7(KD)

CR-5

CLUSTER/MCU

10A

SAFETY RY

AC & HEATER

20A

ECM

10A

RCV

10A

MCU

10A

TCU

10A

CLUSTER

10A

CASSETTE

10A

ILLUMINATION LAMP

5A

ILLUMINATION LAMP

5A

30
85
86 87a 87
87
85
87a 30 86

18
19
20
21
22
23
24
25
26
27
28

1
W 33

CN-159

A ED1(VP)
D AD6
B AD4
C AD5

Replace

CN-36

2
3
4
5
6
7
8
9
10
11
12
13
14
CN-17

STARTER

B+

TO BATT

YES

1
2
3

Defective start
relay

Replace
21E Or

ECM POWER RY

BW 18

START RY
G1 B
17 BW

1
2

CR-23

CN-13

CN-3

0, I

2
3

C ST ACC BR

POWER RY

4
5
6
7
8
9
10
11
12

5
6
7
8
9
10
11
12

B
1

87a
87
85

5
6

30
86

1
2
3
4
5
6
CS-2

87a 85 87 86 30

CR-25

Disconnection in Repair or replace

wiring harness or
poor contact
between CN-17(4)
and CN-157

21A Or
65 G
32 3Y

30
86

87a
87
85

G15 B

87a 85 87 86 30

CR-35

Check voltage
between CN-17
(4) and chassis

21 3Or
65A G
31 3Br
G14 B

Disconnection in Repair or replace

NO
wiring harness or
poor contact
between CN-3(4) CN-13(7)-CR-23(2)

65 G

157 GrW

Check voltage
between CR-23
(2) and chassis

YES

17

CN-45

Starting switch : OFF NO

Voltage : 20~30V
Starting switch : ON

16
10A

CR-5

Check voltage
between CR-5
NO
(86) and chassis

30A

ECM

X-2
A
B
C
D

13
14
5A
15

21 3Or START KEY

CN-158

X2

Check switch : neutral

A
B
C
D

CASSETTE/ROOM LAMP

TCU

X-1

OUTPUT SIGNAL
K
N
F
B
D
1 2 3 4 1 2 3 4 1 2 3 4

30A

TURN LAMP

10A

BW 151
GEAR SELECTOR LEVER

PREHEATER

30
85
86 87a 87
87
85
87a 30 86

BOr 73A

Defective start
relay

12

SAFETY RY
G 17
G 17A

11

NEUTRAL RY/JOYSTICK F/R 10A

17 G
33

ADM2-JOYSTICK SELECT LAMP(-)

ADM5-JOYSTICK SELLECTER(+)

ADM1-START INTERLOCK RY(-)

ADM4-REVERSE DRIVE RY(-)

ED14-NEU-JOYSTICK

ED13-REV-JOYSTICK

ED8-FWD-JOYSTICK

VPE2-CONTINUANCE 24V

ED6-SHIFT LEVER X2D-NEU

65
66
67
68
44
31
30
52
5
7
59

85 W

CN-157

10

EMER STEER/RIDE CON 20A

Starting switch : start

Check engine
system charge or
replace (after
checking specific
gravity of battery)
Defective magnet Replace
of start motor

FUSE BOX

H 0 I II

Check operation
of start motor

Remedy

Defective battery

YES

ED9-CLUTCH CUT-OFF SW(+)

YES

ED2-SHIFT LEVER X1B-B2

Cause

MCU

T/M CONTROL UNIT

35
34

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.
Check forward reverse switch at neutral position.

START SWITCH

Starting switch : OFF

NO

Defective DW-3

Replace

7707AEL21

7-75