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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 fuse
No.7 and 8 burnt out.
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
(5) and (3) 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

1409S6ES01

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

1409S6ES02

6-25
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 MCU Replace
YES Check voltage
between CN-52
(27) and chassis Disconnection in Repair or replace
NO wiring harness or (after clean)
YES Check voltage Voltage : 20~32V
between CN-3 poor contact
(3) and chassis between CN-52
(27)-CN-3 (3)
Voltage : 20~32V
Check voltage Disconnection in Repair or replace
NO wiring harness or (after clean)
between alternator poor contact
terminal "L" and between CN-3 (3)
chassis alternator terminal
Engine : Running "L"
Voltage : 20~32V

Defective alternator Replace


NO

Check voltage
YES 20~32V
NO 0V

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

1409S6ES03

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

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

CN-51

13

MCU
WATER TEMP SENDER

5 1 C
25 6 2

CN-3 CD-8

CN-52 1409S6ES04

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 1
NO MIN 1M

MCU AIR CLEANER SWITCH

Pa
29

CD-10
CN-51

1409S6ES05

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

Check resistance
YES MAX 1
NO MIN 1M

MCU ENGINE OIL PRESSURE SWITCH

27 1 Pa

CN-51 CN-2 CD-18

1409S6ES06

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 (105C2C),
(1, 2) is in range
of 164~151?
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) & CN-52
(24) is 0~1?
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 (k)
~31.78 ~10.74 ~ 6.6 ~1.28 ~0.476 ~0.298 ~0.219 ~0.167 0.151

CN-52

24

MCU
HYDRAULIC OIL
TEMPERATURE SENDER

2 C
13 1

CD-1

CN-51

1409S6ES07

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

Defective cluster Replace


NO

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

CN-51

13

MCU
WATER TEMP SENDER

5 1 C
25 6 2

CN-3 CD-8

CN-52
1409S6ES04

6-31
9. WHEN FUEL GAUGE DOES NOT 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 : 50~600 wiring harness or
See table
sender (1) and poor contact
(2) between fuel
Starting switch : OFF sender-MCU
Spec : 50~600
See table
Defective fuel Replace
NO
sender

Check Table
Range Resistance () Range Resistance ()
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 - -

CN-52

26

MCU
FUEL LEVEL SENDER

13 1

CD-2

CN-51
1409S6ES09

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
fuse No.23 burnt out.
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 : 0
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-0
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 fuse
No. 25 burnt out.
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 : 30 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

MCU NO.28
NO.25

TRAVEL SOLENOID

3 1

CN-70
CN-52

1409S6ES11

6-34
12. WHEN ENGINE DOES NOT START ( lights up condition)
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 and fuse
No. 1, 4, 13 and 20 burnt out.
START KEY SW
After checking, insert the disconnected connectors again immediately unless otherwise specified. CN-5
CS-2

H0 I
35 1

0, I
36 2
Cause Remedy 59 3 4

H
YES 60

BR ACC
4 1

B
2
Defective battery Replace 5 3

ST C
5
6

NO.1 CR-35
Check operation YES
Check voltage Defective magnet Replace
of start motor YES between starter of start motor
NO.13

magnet coil and


Starting switch : START chassis Defective start relay Replace
NO NO.4
Starting switch : START POWER RY
YES
Check operation SPEC : 20~30V Check voltage ,
of start relay YES
between CR-5 CS-74A
NO CR-23
(30) and chassis

CS-74
Disconnection in Repair or replace 1
NO 2
Starting switch : START Starting switch : START wiring harness or (after clean) CN-95
Check operation poor contact
SPEC : 20~30V NO.20 2
of anti-restart between CR-5 MASTER SW
1
NO relay CR-5
(86) and CN-5(35) FUSIBLE LINK
YES 2
Starting switch : ON
Check voltage Defective relay Replace 1

between CR-5 CN-60


NO
(87) and chassis NO CR-1
BATTERY
Starting switch : ON
YES
Check voltage Defective fuel cut Replace BATT RY
between CN-79 off solenoid DO-3
(F) and chassis 2
Disconnection in Repair or replace 1
NO
Voltage : 20~30V wiring harness or (after clean) DIODE
Starting switch : START poor contact
between CN-2(8)- CN-79
CN-2 G
CN-79(F) F
YES CN-51
5 H
Defective start Replace ANTI-RESTART RY 20
Check voltage 8 FUEL CUT OFF SOL
relay MCU 14
between CR-23
and chassis START MOTOR
CR-5 CN-3 CR-23
NO Disconnection in Repair or replace
Starting switch : ON wiring harness or (after clean) 1 1
poor contact 2 2
between CR-5(87)- CN-45
START RY
CR-23(2)
ANTI-RESTART RY
YES
Check voltage Defective fuel cut- Replace
between CN-79 off solenoid
(H) and chassis
Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (after clean)
poor contact
between CN-2(5) 2209S6ES12
and Fuse No.13

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). START KEY SW
CN-5
After checking, insert the disconnected connectors again immediately unless otherwise specified. CS-2

H0 I
35 1

0, I
36 2
59 3 4

H
60

BR ACC
4 1

B
2
5 3
Cause Remedy 6
YES

ST C
5
Disconnection in Repair or replace 6

wiring harness or (after clean)


poor contact CR-35
YES Check voltage
NO.1
between DO-3 (2)-
between DO-3 CR-1 or defective NO.13
(2) and chassis battery relay
Voltage : 20~30V
Disconnection in Repair or replace NO.4
YES Check voltage NO wiring harness or (after clean)
POWER RY
between CS-2
poor contact
(2) and chassis
between CS-2 (2)- CS-74A
CN-5(60)- DO-3 (2)

CS-74
Voltage : 20~30V 1
Starting switch : ON 2
Defective start key Replace CN-95
NO
YES Check voltage
NO.20
switch 2
between CS-2 1 MASTER SW
(1) and chassis YES FUSIBLE LINK
Disconnection in Replace
2
wiring harness or
Voltage : 20~30V 1
poor contact
CN-60
between CS-2 (1)-
Check voltage
CN-5 (36) CR-1
between CN-5 BATTERY
NO
Check voltage (36) and chassis YES
Disconnection in Charge or replace
of battery Voltage : 20~30V wiring harness or (after clean)
Check voltage poor contact BATT RY
Voltage : MIN 24V between CS-74 between CS-74 (1) DO-3
NO -CN-5 (36) 2
(1) and chassis
1

Voltage : 20~30V DIODE



NO
CN-79
CN-2 G
Battery Replace CN-51
F
NO discharged 5 H
ANTI-RESTART RY 20
8 FUEL CUT OFF SOL
MCU 14
YES START MOTOR
Defective master Replace CR-5 CN-3
Check voltage CR-23
switch
between CS-74 1 1
(2)- chassis 2 2
NO
Disconnection in Charge or replace
Voltage : 20~30V wiring harness or (after clean) START RY CN-45
poor contact ANTI-RESTART RY
between CS-74 (2)
-CR-1

2209S6ES13

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 fuse No. 6,
11 and 17 burnt out.
After checking, insert the disconnected connectors again immediately unless otherwise specified. CN-21
3 1
Cause Remedy 2
NO 5 3 CN-5
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 FUSE
poor contact WIPER MOTOR
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
Starting switch : ON NO VCC 6 4 24
YES of switch panel No.11 NO.17
Vottage : 20~30V 2)Disconnection in Repair or replace CONTINUE 24V 7 5
LED ON. CN-22
wiring harness or (after clean) WASHER P/P 8 6
Starting switch : ON poor contact WASHER SIG. 9 7
2 M
Push wiper switch button YES
between INT. SIG 10 8 1
CN-116(10)-Fuse WIPER CUT SW 11 WASHER PUMP
N.C 12

Check voltage between NO FEED BACK 13


Defective switch Replace
CN-116 (4) and chassis panel WIPER MOTOR CONTROLLER
Intermittent CS-53
NO 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
and controller WIPER CUT SW
Check voltage CN-116 between
(3) and chassis check voltage CN-141(7)-Fuse,
YES CN-141 (7) and
Sarting switch : ON
CN-21(4)-Fuse
Voltage : 0~1V
chassis, CN-21 CN-116
(4) and chassis NO
1) Recheck fuse Replace HEAD LIGHT OUT 1
Starting switch : OFF No.17 WORK LIGHT OUT 2
Voltage : 20~30V Check voltage 2) Disconnection Repair or replace INT. SIG 3
CN-141 (6) and CN-141(6)-Fuse (after clean) WIPER MOTOR DRIVE 4
YES chassis WASHER SIG 5
PRE-HEAT 6
Starting switch : ON
YES CABIN LIGHT OUT 7
Check continuity Voltage : 20~30V TRAVEL ALARM 8
NO
between Disconnection in Repair or replace NC 9 FUSE
CN-141 (2)-CN-116 (4), wiring harness or (after clean) POWER 24V 10 57
CN-141 (9)-CN-116 (5), poor contact GND 11 NO.11
CN-141 (10)-CN-116 (3), NC 12
NO
CN-141 (5)-Chassis , Check wiper Defective wiper Replace SWITCH PANEL
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 : 3~4

2209S6ES14

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 fuse
No.18 burnt out.
After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy CN-5


YES FUSE
Defective bulb Replace
Check voltage NO.18
YES between CL-4
(1) and chassis, CN-116
CL-3 (1) and Disconnection in Repair or replace HEAD LIGHT OUT 1
chassis NO
wiring harness or (after clean) WORK LIGHT OUT 2
Voltage : 20~30V INT. SIG 3 CR-13
poor contact WIPER MOTOR DRIVE 4
Check voltage between CR-13 30 30 86
YES WASHER SIG 5
between CR-13 (87)-CL-4 (1) or PRE-HEAT 6 86
(87) and chassis CR-13(87)-CL-3(1) CABIN LIGHT OUT 7 87

YES TRAVEL ALARM 8 49 85


Replace 87a 87 85
Starting switch : ON Defective switch NC 9 87a
Head lamp switch : ON panel POWER 24V 10
Voltage : 20~30V HEAD LAMP RY
Check voltage GND 11
Check voltage between CN-116 NC 12
between CR-13 NO CL-4
(1) and chassis SWITCH PANEL
(30) and chassis,
CR-13 (86) and Disconnection in Repair or replace 2
Starting switch : ON NO
chassis Head lamp switch : ON wiring harness or (after clean) 1
Starting switch : ON Voltage : 20~30V poor contact
Voltage : 20~30V between CN-116 HEAD LAMP
(1)-CR-13 (87) CL-3
2
1
Disconnection in Repair or replace
NO wiring harness or (after clean)
poor contact
between CR-13
(30) and chassis
or CR-13 (86) -
chassis

Recheck fuse Replace


No. 18

14096ES15

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 fuse
No.15 burnt out.
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
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
fuse No. 8 burnt out.
After checking, insert the disconnected connectors again immediately unless otherwise specified.

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

Check voltage
YES 20 ~ 32V
NO 0V

CLUSTER FUSE
POWER IG(24V) 1 5
NO.8
GND 2 4
RX
TX
CN-56A CN-5

2209S6ES51

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 MCU Replace

YES Check voltage


between CN-56A
(3,4) and chassis

Check voltage Disconnection in Repair or replace


NO wiring harness or (after clean)
between CN-5
(1,2) and chassis poor contact
between CN-56A
KEY ON
(3,4) CN-5(1,2)

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-56A CN-5 CN-50

1409S6ES52

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 MCU Replace
YES Check voltage
between CN-51
(9) and chassis Disconnection in Repair or replace
NO wiring harness or (after clean)
YES Check voltage Voltage : 20~32V
between CN-3 poor contact
(3) and chassis between CN-51
(9)-CN-3 (3)
Voltage : 20~32V
Check voltage Disconnection in Repair or replace
NO wiring harness or (after clean)
between alternator poor contact
terminal "L" and between CN-3 (3)
chassis alternator terminal
Engine : Running "L"
Voltage : 20~32V

Defective alternator Replace


NO

Check voltage
YES 20~32V
NO 0V

ALTERNATOR
MCU B+
G
1 P
9 3 2 L 3~
3 FI U
4 NC
CN-74
CN-51 CN-3

1409S6ES53

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
Resistance
YES between CD-8 (110C2C) cooling system
(1,2) is in range
of 120~150?
Defective temp Replace
Disconnect CD-8 NO
sensor
Does display go
off when
disconnect CD-8?
YES
Starting switch : ON Short circuit in Repair or replace
Resistance wiring harness (after clean)
Engine : Start
between CN-51
NO (31,33) is
0~1? Defective MCU Replace
Disconnect CN-51 NO
KEY OFF

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

1 st step

MCU
WATER TEMP SENDER

31 5 1 C
33 6 2

CN-3 CD-8

CN-51

1409S6ES54

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
wiring harness (after clean)
Engine : Start Check resistance between
between CN-51 CD-10-CN-51(16)
NO
(16) and chassis
Starting switch : OFF
Defective MCU Replace
NO
Disconnect CN-51

Check resistance
YES MAX 1
NO MIN 1M

MCU AIR CLEANER SWITCH

Pa
16

CD-10
CN-51

1409S6ES55

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

Check resistance
YES MAX 1
NO MIN 1M

MCU ENGINE OIL PRESSURE SWITCH

4 1 Pa

CN-51 CN-2 CD-18

1409S6ES56

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 and replace
(1,2) is in range (100C2C)
of 130~150?
Does display go Starting switch : ON Defective temp Replace
Disconnect CD-1 NO
off when sensor
disconnect
YES
CD-1? Short circuit Check and repair
Starting switch : ON between temp
Engine : Start
Resistance
between CN-51 sensor and MCU
NO (31,34) is 0~1?

Starting switch : OFF


Defective MCU Replace
NO
Disconnect CN-51

MCU HYDRAULIC OIL


TEMPERATURE SENDER

34 2 C
31 1

CD-1

CN-51

1409S6ES57

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

Defective cluster Replace


NO

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

MCU
WATER TEMP SENDER

31 5 1 C
33 6 2

CN-3 CD-8

CN-51

1409S6ES54

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 1k? YES
Defective Replace
Starting switch : OFF
Disconnect CN-51
Check resistance controller
Does the gauge between CD-2(1)
light up and NO and (2)
down at lamp Replace
Disconnect CD-2 NO
check? Defective fuel
See Table
Starting switch : ON sensor

Defective cluster Replace


NO

2nd~10th step
Check Table
1 st step 11th~12th
step
Range 1st step 2nd~10th step 11th~12th step
Item
Unit Resistance() 700~601 600~101 ~100
Tolerance(%) 5 5 5

MCU
FUEL LEVEL SENDER

24 2

31 1

CD-2

CN-51

1409S6ES59

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
fuse No.23 burnt out.
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 : 0
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-0
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

6-49
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
speed lamps( , Voltage : 20~30V : OFF NO
(1) and (2)
Disconnect CN-50 : ON
) change when
Starting switch : OFF NO Defective solenoid Replace
pressing the travel
SPEC : 15~25
speed switch on Disconnect CN-70
the cluster YES
Starting switch : ON Defective cluster 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

1409S6ES61

6-50
12. WHEN ENGINE DOES NOT START ( lights up condition)
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 and fuse
No. 1, 4, 10 and 20 burnt out.
START KEY SW
After checking, insert the disconnected connectors again immediately unless otherwise specified. CN-5
CS-2

H0 I
35 1

0, I
36 2
Cause Remedy 59 3 4

H
YES 60

BR ACC
4 1

B
2
Defective battery Replace 5 3

ST C
5
6

NO.1 CR-35
Check operation YES
Check voltage Defective magnet Replace
of start motor YES between starter of start motor
NO.10

magnet coil and


Starting switch : START chassis Defective start relay Replace
NO NO.4
Starting switch : START POWER RY
YES
Check operation SPEC : 20~30V Check voltage ,
of start relay YES
between CR-5 CS-74A
NO CR-23
(30) and chassis

CS-74
Disconnection in Repair or replace 1
NO 2
Starting switch : START Starting switch : START wiring harness or (after clean) CN-95
Check operation poor contact
SPEC : 20~30V NO.20 2
of anti-restart between CR-5 MASTER SW
1
NO relay CR-5
(86) and CN-5(35) FUSIBLE LINK
YES 2
Starting switch : ON
Check voltage Defective relay Replace 1

between CR-5 CN-60


NO (87) and chassis
NO CR-1
BATTERY
Starting switch : ON
YES
Check voltage Defective fuel cut Replace BATT RY
between CN-79 off solenoid DO-3
(F) and chassis 2
Disconnection in Repair or replace 1
NO
Voltage : 20~30V wiring harness or (after clean) DIODE
Starting switch : START poor contact
between CN-2(8)- CN-79
CN-2 G
CN-79(F) F
YES CN-50
5 H
Defective start Replace ANTI-RESTART RY 11
Check voltage 8 FUEL CUT OFF SOL
relay MCU 14
between CR-23
and chassis START MOTOR
CR-5 CN-3 CR-23
NO Disconnection in Repair or replace
Starting switch : ON wiring harness or (after clean) 1 1
poor contact 2 2
between CR-5(87)- CN-45
START RY
CR-23(2)
ANTI-RESTART RY
YES
Check voltage Defective fuel cut- Replace
between CN-79 off solenoid
(H) and chassis
Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (after clean)
poor contact
between CN-2(5) 2209S6ES15
and Fuse No.10

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). START KEY SW
CN-5
After checking, insert the disconnected connectors again immediately unless otherwise specified. CS-2

H0 I
35 1

0, I
36 2
59 3 4

H
60

BR ACC
4 1

B
2
5 3
Cause Remedy 6
YES

ST C
5
Disconnection in Repair or replace 6

wiring harness or (after clean)


poor contact CR-35
YES Check voltage
NO.1
between DO-3 (2)-
between DO-3 CR-1 or defective NO.10
(2) and chassis battery relay
Voltage : 20~30V
Disconnection in Repair or replace NO.4
YES Check voltage NO wiring harness or (after clean)
POWER RY
between CS-2
poor contact
(2) and chassis
between CS-2 (2)- CS-74A
CN-5(60)- DO-3 (2)

CS-74
Voltage : 20~30V 1
Starting switch : ON 2
Defective start key Replace CN-95
NO
YES Check voltage
NO.20
switch 2
between CS-2 1 MASTER SW
(1) and chassis YES FUSIBLE LINK
Disconnection in Replace
2
wiring harness or
Voltage : 20~30V 1
poor contact
CN-60
between CS-2 (1)-
Check voltage
CN-5 (36) CR-1
between CN-5 BATTERY
NO
Check voltage (36) and chassis YES
Disconnection in Charge or replace
of battery Voltage : 20~30V wiring harness or (after clean)
Check voltage poor contact BATT RY
Voltage : MIN 24V between CS-74 between CS-74 (1) DO-3
NO -CN-5 (36) 2
(1) and chassis
1

Voltage : 20~30V DIODE



NO
CN-79
CN-2 G
Battery Replace CN-50
F
NO discharged 5 H
ANTI-RESTART RY 11
8 FUEL CUT OFF SOL
MCU 14
YES START MOTOR
Defective master Replace CR-5 CN-3
Check voltage CR-23
switch
between CS-74 1 1
(2)- chassis 2 2
NO
Disconnection in Charge or replace
Voltage : 20~30V wiring harness or (after clean) START RY CN-45
poor contact ANTI-RESTART RY
between CS-74 (2)
-CR-1

2209S6ES16

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 fuse No. 6,
11 and 17 burnt 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(10)-Fuse WIPER CUT SW 11 WASHER PUMP
No.11 N.C 12
Check voltage between NO FEED BACK 13
Defective switch Replace
CN-116 (4) and chassis panel WIPER MOTOR CONTROLLER
Intermittent
NO 1) Recheck fuse Replace
Check voltage CN-116 CS-53
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
(3) and chassis check voltage CN-141(7)-Fuse, WIPER CUT SW
YES CN-141 (7) and
Sarting switch : ON
CN-21(4)-Fuse
Voltage : 0~1V
chassis, CN-21 CN-116
(4) and chassis NO
1) Recheck fuse Replace HEAD LIGHT OUT 1
Starting switch : OFF No.17 WORK LIGHT OUT 2
Voltage : 20~30V Check voltage 2) Disconnection Repair or replace INT. SIG 3
CN-141 (6) and CN-141(6)-Fuse (after clean) WIPER MOTOR DRIVE 4
YES chassis
No.17 WASHER SIG 5
PRE-HEAT 6
Starting switch : ON YES CABIN LIGHT OUT 7
Check continuity Voltage : 20~30V
NO TRAVEL ALARM 8
between Disconnection in Repair or replace NC 9 FUSE
CN-141 (2)-CN-116 (4), wiring harness or (after clean) POWER 24V 10 57
CN-141 (9)-CN-116 (5), poor contact GND 11 NO.11
CN-141 (10)-CN-116 (3), NC 12
NO
CN-141 (5)-Chassis , Check wiper Defective wiper Replace SWITCH PANEL
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 : 3~4

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 fuse
No.18 burnt out.
After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy CN-5


YES FUSE
Defective bulb Replace
Check voltage NO.18
YES between CL-4
(1) and chassis, CN-116
CL-3 (1) and Disconnection in Repair or replace HEAD LIGHT OUT 1
chassis NO
wiring harness or (after clean) WORK LIGHT OUT 2
Voltage : 20~30V INT. SIG 3 CR-13
poor contact WIPER MOTOR DRIVE 4
Check voltage between CR-13 30 30 86
YES WASHER SIG 5
between CR-13 (87)-CL-4 (1) or PRE-HEAT 6 86
(87) and chassis CR-13(87)-CL-3(1) CABIN LIGHT OUT 7 87

YES TRAVEL ALARM 8 49 85


Replace 87a 87 85
Starting switch : ON Defective switch NC 9 87a
Head lamp switch : ON panel POWER 24V 10
Voltage : 20~30V HEAD LAMP RY
Check voltage GND 11
Check voltage between CN-116 NC 12
between CR-13 NO CL-4
(1) and chassis SWITCH PANEL
(30) and chassis,
CR-13 (86) and Disconnection in Repair or replace 2
Starting switch : ON NO
chassis Head lamp switch : ON wiring harness or (after clean) 1
Starting switch : ON Voltage : 20~30V poor contact
Voltage : 20~30V between CN-116 HEAD LAMP
(1)-CR-13 (87) CL-3
2
1
Disconnection in Repair or replace
NO wiring harness or (after clean)
poor contact
between CR-13
(30) and chassis
or CR-13 (86) -
chassis

Recheck fuse Replace


No. 18

14096ES15

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 fuse
No.15 burnt out.
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