GROUP 3 ELECTRICAL SYSTEM

1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT
APPEAR
ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No. 2.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
Defective cluster Replace
YES
Check voltage
between CN-56 Disconnection in Repair or
(2) and chassis wiring harness or replace
NO poor contact (After clean)
Starting switch : ON
Voltage : 10~12.5V between CN-56
(1) and fuse No.2.

Check voltage
YES 10 ~ 12.5V
NO 0V

CLUSTER FUSE
POWER IG(12V) 1
2 NO.2
3

17
CN-56

R35Z75TS10

5-24
 2. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace
YES Check voltage
between CN-56
(3) and chassis Disconnection in Repair or replace
NO
wiring harness or (After clean)
YES Check voltage poor contact
between CN-2
(13) and chassis between CN-56(3)
-CN2(13)

Check voltage Disconnection in Repair or replace

NO wiring harness or (After clean)
between alternator
poor contact
terminal "1" and between
chassis CN-2(13)-alternator
Voltage : 10~12.5V terminal "1"
Engine : Running

Defective alternator Replace

NO

Check voltage
YES 10 ~ 12.5V
NO 0V

CLUSTER ALTERNATOR

B+
G
3 13 1 L
2 I
3 ~
U
CN-56 CN-2 3 P
CN-74
R35Z75TS11

5-25
3. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Coolant overheat Check engine
Check resistance
YES between water (110ÁC Ü2ÁC ) cooling system
or defective temp or replace temp
temp switch and
switch switch
chassis?
Disconnect CD-9
Does display go Yesà0~1.1̫
off when No = â̫ NO Defective temp Repair or replace
disconnect CD-9 detector the detector
and CN-167?
Starting switch : ON YES
Engine : Start Short circuit in Repair or replace
Check resistance wiring harness (After clean)
between CN-56
NO
(4) and chassis?
Defective cluster Replace
NO
Disconnect CN-56
Yesà0~1.1̫
No = â̫

CLUSTER WATER TEMP SWITCH

C
4 3
CD-9

CN-56 CN-2
DETECTOR

13 7

CN-8 CN-167 R35Z75TS12

5-26
4. WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Clogged air filter or Check filter or
Check resistance
YES between air defective switch replace switch
cleaner switch
and chassis?
Disconnect CD-10
Does display go Yesà0~1.1̫
off when No = â̫ NO Defective the Repair or replace
disconnect CD-10 detector the detector
and CN-167?
Starting switch : ON YES
Engine : Start Short circuit in Repair or replace
Check resistance wiring harness (After clean)
between CN-56
NO
(5) and chassis?
Defective cluster Replace
NO
Disconnect CN-56
Yesà0~1.1̫
No = â̫

Check resistance
YES MAX 1̫
NO MIN 1M̫

CLUSTER AIR CLEANER SWITCH

Pa
5 4
CD-10

CN-56 CN-2
DETECTOR

9 2

CN-8 CN-167
R35Z75TS13

5-27
5. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter 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 cluster Replace
Starting switch : ON Check resistance
Engine : Start between CN-56
NO
(2) and chassis
Starting switch : OFF
Disconnection in Repair or replace
NO
Disconnect CN-56 wiring harness or (After clean)
poor contact
between
CN-56(2)-CD-18

Check resistance
YES MAX 1̫
NO MIN 1M̫

CLUSTER ENGINE OIL PRESSURE SWITCH

2 1 Pa

CN-56 CN-2 CD-18

R35Z75TS14

5-28
6. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter 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-56 between
(10) and chassis CN-56-CD-30
over 2k̫?
Starting switch : OFF YES
Disconnect CN-50 Defective cluster Replace
Does the gauge
move up and Check resistance
down at lamp NO
between CN-2
check? (9) and chassis
Defective temp Replace
See Table
NO
Starting switch : ON sensor

Defective cluster Replace

NO

Check Table
Temperature 120Á C
50Á
C 80Á
C 100Á
C
Item (Red range)
Unit Resistance(̫) 350 118 63.5 36.2
Red range

CLUSTER WATER TEMP SENSOR

C
10 9
CD-8

CN-56 CN-2

R35Z75TS15

5-29
7. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter 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-56
(11) and chassis
over 1k̫? YES
Defective cluster Replace
Starting switch : OFF
Disconnect CN-51
Check resistance
Does the gauge between CD-2(2)
move up and NO and (3)
down at lamp Defective fuel Replace
NO
check? Disconnect CD-2
sensor
See Table
Starting switch : ON

Defective cluster Replace

NO

Check Table
Temperature
Empty 1/2 Full
Item
Unit Resistance(̫) 90 38 10

Red range

CLUSTER
FUEL SENDER
1 2 3

2
11 10 3 1

CD-2
CN-56 CN-2

R35Z75TS16

5-30
8. WHEN SAFETY SOLENOID DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.10.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Hydraulic Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
Defective switch Repair or replace
YES Check voltage (CS-4)
between CS-4
Check voltage (2) and chassis
between CN-68 Disconnect in Repair or replace
Check voltage Starting switch : ON NO
(1) - CN-68(2) YES between CN-3 Voltage : 10~12.5V wiring harness or (After clean)
Disconnect CN-5 poor contact
Starting switch : ON (12) and chassis
Voltage : 10~12.5V between
Safety state Starting switch : ON CN-3(12)-CS-4(2)
Voltage : 10~12.5V
Check voltage Disconnect CN-5
Disconnect in Repair or replace
between CN-68 NO
wiring harness or (After clean)
NO (2) with chassis
poor contact
Safety lever : OFF between
Starting switch : ON CN-3(12)-CN-
Voltage : 10~12.5V
68(2)

Disconnection in Replace
NO

FUSE
13
NO.10
CN-6

SAFETY SWITCH
SAFETY SOLENOID
2 11 1
1 12 2
CN-68
CS-4 CN-3

R35Z75TS17

5-31
9. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.10 .
ÂAfter 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 CS-8 (1) YES
of solenoid Defective cluster Replace
and chassis
Check if travel Check resistance
speed lamps( , Starting switch : ON Starting switch : ON between CN-70
) change when Voltage : 10~12.5V : OFF NO
(1) and (2)
: ON
pressing the travel Defective solenoid Replace
Starting switch : OFF NO
speed switch
SPEC : 15~25̫
Disconnect CN-70
Starting switch : ON
Defective switch Replace
NO

FUSE
13
NO.10
TRAVEL SPEED CN-6
9 10 10
9
8
8
6 7
2
7
6 TRAVEL SOLENOID
1
5 5 10 1
4
3 9 2
2
1 CN-70
CN-1
CS-8

R35Z75TS18

5-32
10. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the fuse
No.8 is not blown out.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Recheck fuse Replace

Check voltage NO
between CS-3(1) Defective wiper Replace
and chassis switch

Voltage : 10~12.5V Check voltage

between CS-3
YES
(6) and chassis YES
Defective wiper Replace
Wiper switch : ON Check voltage motor
Voltage : 10~12.5V
between CN-21
YES
(3) and chassis
Recheck fuse Replace
Starting switch : ON NO
Voltage : 10~12.5V

WASHER P/P
M 2 3
1
CN-20
CN-3

FUSE CN-8 CN-4 WIPER&WASHER

1 1 1
I 0

2
NO.8
3 3
0, I

WIPER MOTOR 4
5
1
2 E 1 6 6
1 Pf 8
2 7
3 B 3 3
8
4 9
10 9
10
4 Lo
M
CS-3
CN-21 R35Z75TS19

5-33
11. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.6.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Defective lamp Replace switch
switch

YES Check voltage

between CS-21 YES
(1) and (5) Defective bulb Replace
Check voltage
YES between CL-9(2)/
Starting switch : ON CL-10(2) and
Head lamp switch : ON
Voltage : 10~12.5V
chassis Disconnection in Repair or replace
Starting switch : ON NO
Check voltage Head lamp switch : ON wiring harness or (After clean)
between CN-3(2) Voltage : 10~12.5V poor contact
YES and chassis between CN-3(2)-
Check voltage CL-9(2)/CL-10(2)
Starting switch : ON
between CS-21 Head lamp switch : ON
(1) and chassis Voltage : 10~12.5V
Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (After clean)
Head lamp switch :
ON-OFF poor contact
between
CS-21(5)-CN-3(2)

Disconnection in Repair or replace

NO
wiring harness or (After clean)
poor contact
between CS-21(5)
and fuse

HEAD LAMP
1
2
CL-9
LIGHT SW
10
9 10 1
9
4 8
8 3 2
2
7 CL-10
CN-2 CN-11
7 1 6
5 5 2
4 FUSE
3 8 8
I 0

2 NO.6
1 CN-3 CN-6
CS-21
R35Z75TS20

5-34
12. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.5.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Defective lamp Replace switch
switch

YES
Check voltage Defective bulb Replace
YES
between CS-21 YES Check voltage
(4) and (2) between CL-5(2)
and chassis
Starting switch : ON Disconnection in Repair or replace
Work lamp switch : ON Starting switch : ON NO
Work lamp switch : ON
wiring harness or (After clean)
Voltage : 10~12.5V
Check voltage Voltage : 10~12.5V poor contact
between CN-3
YES (14) and chassis between CN3(14)
and CL-5(2)
Starting switch : ON
Check voltage Work lamp switch : ON
between CS-21 Voltage : 10~12.5V
(4) and chassis Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (After clean)
Work lamp switch :
ON-OFF poor contact
Voltage : 10~12.5V between
CS-21(2)-CN-
3(14)

Disconnection in Repair or replace

NO
wiring harness or (After clean)
poor contact
between CS-21
(4) and fuse

LIGHT SW
9 10 10
9
4 8 WORK LAMP
2
7
1
7 1 6
5 5
8 2 2
4 CL-5
CN-2 CN-12
3
I 0

2 14
1 FUSE
CS-21 13 3
NO.5
CN-3 CN-7

R35Z75TS21

5-35
13. WHEN ENGINE DOES NOT START

ÂCheck supply of the power at engine stop solenoid while starting switch is ON.
ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified. FUSIBLE LINK

CN-60
2
1
Cause Remedy START SWITCH
CS-2
YES Defective fuel Check fuel line
Check operation

H0 I
line 1

A
YES of fuel feed pump 2

0, I

(H) (BR) (ACC)

A2

(B)
YES
1

MASTER SWITCH
YES Defective fuel Repair or replace
Check operation Check voltage 2
A1 B2
Starting switch : ON feel pump feel pump FUSE B3

B
of fuel cut-off between CN-145 1 3
Motor : RUN
solenoid valve (2) and chassis NO.3 4

(ST) (C)
Disconnection in Repair or replace B1
NO B4
Starting switch : START Starting switch :START wiring harness (After clean)
With in 1 sec Voltage : 10 ~ 12.5 V or poor contact CN-7
Check operation between CN-
of start motor 145(2) and fuse
No. 11
Starting switch : START
Check voltage
between CN-79 Defective fuel cut Repair or replace
NO (B) and chassis off valve fuel cut off valve FUEL CUT-OFF RY
87 30 86
Starting switch : ON YES START MOTOR
Check voltage Defective timer Repair or replace 30
With in 1 sec M B+
Voltage : 10~12.5V between CR-50 Timer 86
NO (4) and chassis 85 87 85
NO Defective fuel cut Repair or replace M CR-51
Starting switch : ON off relay or fuel cut off relay or
disconnection in repair or replace CN-45
wiring harness or (After clean) TIMER
OUT 4 IG
1
poor contact 2
1

between CR-50 3 2

(4) and fuse NO.3 SAFETY RELAY 4 OUT 3 GND

START SIG. 1 CR-50

Check voltage
YES between starter YES NC 2
Defective magnet Repair or replace 3
magnet coil and IG FUEL CUT-OFF SOL
of start motor start motor
chassis ALT PULSE 4 7 A H
Voltage : 10~12.5V
Defective safety Repair or replace GROUND 5 2 B F

Check operation NO safety relay NC 6 12 C E

relay 3 CN-79
NO of safety relay CN-166
CN-6
Check voltage BATTERY 1 2
YES CN-8
Starting switch : START between safety MAGNET 2 1
Defective safety Repair or replace
NO relay(IG) and relay safety relay CN-165
chassis
CN-5
Voltage : 10~12.5V
NO
Disconnection in Repair or replace
wiring harness or (After clean) FUEL FEED P/P
poor contact FUSE 1 M
between CN-166 2

(1)and CS-2(1) NO.11 CN-145

R35Z75TS22

5-36
14. WHEN STARTING SWITCH ON DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and
master switch ON.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified. FUSIBLE LINK

CN-60
2
1
Cause Remedy START SWITCH
Check voltage YES
YES CS-2
between CS-2A Disconnection in Replace

H0 I
(2) and chassis 1

A
wiring harness or 2

0, I
poor contact

(H) (BR) (ACC)

Voltage : 10~12.5V A2

(B)
1

MASTER SWITCH
between CS-2A
YES Check voltage
A1 B2
FUSE 2
between CS-2A (2)-CN-2(1) B3

B
1 3
(1) and chassis NO.3 4

(ST) (C)
B1
Defective start Replace B4
Voltage : 10~12.5V NO
switch CN-7
Check voltage
and specific Disconnection in Replace
NO
gravity of battery wiring harness or
Specific gravity : MIN 1.28 poor contact
Voltage : MIN 12V between CS-2A FUEL CUT-OFF RY
(1)-Master switch 87 30 86
START MOTOR
30
M B+
Battery capacity Charge or 86
NO
too low replace 85 87 85
(After clean) M CR-51

CN-45
TIMER
OUT 4 IG
1
1
2
3 2
SAFETY RELAY 4 OUT 3 GND

START SIG. 1 CR-50

NC 2
IG 3
FUEL CUT-OFF SOL
ALT PULSE 4 7 A H
GROUND 5 2 B F
6 C E
NC 12
3 CN-79
CN-166
CN-6
BATTERY 1 2
CN-8
MAGNET 2 1
CN-165
CN-5

FUEL FEED P/P

FUSE 1 M
2
NO.11 CN-145

R35Z75TS22

5-37