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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)
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(9)
NO
Check voltage 13(9) 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(9)
and alternator
terminal " 2 "
CONTROLLER(MCU)
ALTERNATOR
25 5 9 " 2 " TERMINAL
CN-3 CN-13
CN-58
Check valtage
YES 20 ~ 30V
NO 0V 7807AEL16
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
Check voltage
Starting switch : ON switch
Parking switch : ON-OFF NO
between CS-17
Voltage : 20~30V (6) and chassis
Disconnection in
Voltage : 20~30V NO
wiring harness or
poor contact
between CS17(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
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 7-16.
Cause Remedy
YES
Defective clutch Replace
cut-off switch
Check resistance
YES
between CD-5
and chassis
NO
Defective T/M Replace
Is voltage between
control unit
CN-157(21) and
chassis 20-28V? YES
Defective parking Replace
Starting switch : ON
Parking switch : OFF
switch
Clutch cut-off
Is there continuity
switch : ON between CS-17(7)
YES
and chassis?
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
7-69
6. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.9 is not blown out.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
MCU
FAN CLUTCH +
CLUTCH CUT-OFF PS
SPEEDMETER SIG.
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
CAN-L
MAIN PUMP PS
ELEC STEERING
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
Defective front Replace BACK/STOP LAMP 10A
Check voltage
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
120 LW
163 Br
wiring harness or (After clean)
162 G
14F L
59 Gr
Check voltage poor contact
CN-15
between CN-15(8) between CN-15(8)
10
11
12
13
14
6
7
9
8
NO
and chassis. and fuse No.9
G61 B
172 G
173 R
8 W
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
CN-17
wiring harness or (After clean)
10
11
12
13
14
1
2
3
4
5
6
7
8
9
poor contact
BWG 4
RW 6
W6
BVi 3
L 4
G 5
BY 1
Gr 2
Y
between CS-12(6) 38 VOr
HO
and CN-15(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
7807AEL18
7-70
7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.16 is not blown out.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
FUSE BOX
Cause Remedy EMER STEER/RIDE CON 20A
10
11
NEUTRAL RY/JOYSTICK F/R 10A
Defective cable Repair or replace 12
PREHEATER 30A
Check voltage (After clean)
13
YES assembly TURN LAMP
14
between CN-60(2) CASSETTE/ROOM LAMP 5A 3R 34
15
and chassis 21 3Or START KEY 30A
16
Short circuit or Replace TCU 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
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
ÂBefore carrying out below procedure, check all the related connectors are properly inserted, and the
fuse No.1, 10 is not blown out.
ÂAfter 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
Defective lamp Replace 7
Check voltage SWITCH 30A
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 RW 2
wiring harness or (After clean) 86 30 87a
B G16
2
RW 2A
LAMP,LH
3(87), CR-55(87) poor contact
85
RW 171
3
B G22
2
87 4 1
and chassis between CN-7(2) - 86
G 170 5 CL-6
85 87 87a Gr 15 6
Voltage : 20~30V 30 FRONT WORK
Starting switch : ON
CR-3(87) and CN- CR-3
7
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
YES CN-7 CL-32
Voltage : 20~30V Disconnection in Repair or replace RR WORK LAMP RY REAR WORK LAMP
Starting switch : ON 86 30 87a R 10A 2
wiring harness or (After clean) 85
B G17 1
2
B G26
1
R 63
Check voltage poor contact 87
L 180 3 CL-33
86 4
between CR-3(30), 85 87 87a Gr 5
5 REAR WORK
between fuse No. 30
LAMP,LH
NO CR-55(30) and CR-55 6 40A R
2
1, 10 and chassis 7 G3 B
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
2 G 170 13 LAMP,RH
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
ÂCheck supply of the power at engine stop solenoid while starting switch is ON.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, connect the disconnected connectors again immediately unless other wise specified.
T/M CONTROL UNIT MCU
ÂCheck forward reverse switch at neutral position.
SAFETY RY
ADM5-JOYSTICK SELLECTER(+)
WIPER RY
STEERING RY
PREHEATER
NEUTRAL SIG
ADM1-START INTERLOCK RY(-)
ED9-CLUTCH CUT-OFF SW(+)
VPE2-CONTINUANCE 24V
ED14-NEU-JOYSTICK
ED13-REV-JOYSTICK
FUSE BOX
ED8-FWD-JOYSTICK
10
Cause Remedy EMER STEER/RIDE CON 20A
11
YES 17 G NEUTRAL RY/JOYSTICK F/R 10A
12
Defective batteryCheck engine PREHEATER 30A
35
34
36
32
33
SAFETY RY 13
system charge or G 17 TURN LAMP
30
65
66
67
68
44
31
35
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
30 ECM 10A
20
21E Or
157 GrW
65 G
10
and chassis 11
Disconnection in Repair or replace 12
Voltage : 20~30V NO CN-3
Starting switch : ON wiring harness or
21 3Or
G14 B
31 3Br
65A G
G15 B
32 3Y
65 G
21A Or
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(8)-CR-23
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-
(4) and chassis 17(4) and CN-157
Starting switch : OFF
Defective DW-3 Replace 7807AEL21
NO
7-73