Professional Documents
Culture Documents
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.26 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-51
(1, 2) and chassis
NO
Disconnection in Repair or replace
wiring harness or (After clean)
poor contact
between CN-12(1)
and fuse No.26
CLUSTER
1
FUSE
2 1
No.26
CN-51
CN-12
Check voltage
YES 20 ~ 30V
NO 0V 7607EL14
7-61
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(4)
(25) and CN-3(4)
and chassis
YES
Voltage : 26~30V Disconnection in Repair or replace
wiring harness or (After clean)
Check voltage poor contact
between CN-4(8) between CN-4(8)
NO
Check voltage and chassis and CN-3(4)
between
alternator terminal Disconnection in Repair or replace
"I" and chassis NO
wiring harness or (After clean)
Voltage : 26~30V poor contact
Starting switch : ON
between CN-4(8)
and alternator
terminal " I "
CONTROLLER
ALTERNATOR
25 4 8 " I " TERMINAL
CN-3 CN-4
CN-58
Check valtage
YES 20 ~ 30V
NO 0V 7707EL23
7-62
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 CS-17(6)
and Fuse No.8
PARKING SWITCH
8 2
1
5
CN-71
6
CS-17 FUSE
No.8
7707EL24
7-63
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 controller) 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
controller
PARKING SWITCH
FUSE
6
5 No.8
7
CS-17 21
CN-52
Check resistance
YES MAX 1Ω
7707EL25
NO MIN 1MΩ
7-64
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
controller
CN-52(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
7-65
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.
CONTROLLER
SPEEDMETER SIG.
BUZZER STOP
WIPER RY
STEERING RY
ALT LEVEL
FUEL SENSOR
PREHEATER
WASH SIG
NEUTRAL SIG
CAN-H
AUTO SEL.TCU
REMOTE FAN(+)
CAN-L
REMOTE FAN(-)
STEERING PS
CLUTCH CUT-OFF SW
STEERING P/P PS
ENG OIL PS
TACHO +
RIDE CONT. ON
WIPER INT SIG
PARKING SIG
SERIAL-H
GND
BUZZER
AUTO SEL.SW
BRAKE PS
TAHCO -
AIR FILTER
IG 24V
Cause Remedy FUSE BOX
BEACON LAMP 20A
YES ILL.LAMP 10A
1
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
2
3
6
8
4
5
7
9
YES between front wiper motor BACK/STOP LAMP 10A
3
M30 0.85 Y
M27 0.85 R
CN-58
M22 0.85 Gr
wiper motor and HORN/CONVERTER 30A
5
AIR-CON/HEATER 20A
chassis Poor connection of Replace 6
CN-36
Voltage : 20~30V
Starting switch : ON Disconnection in Repair or replace WIPER RY LO
Check voltage Wiper switch : 1st NO M46 0.85 R
30
YES between CS-12 wiring harness or (After clean) M45A 0.85 W
86
87a 87 85
M45 0.85 W
(4), CN-7(10) and poor contact M22 0.85 Gr
87
85
chassis between CN-7(10) M39 0.85 G
87a 30 86
CR-26
Voltage : 20~30V and CN-21(5),
Starting switch : ON
Wiper switch : OFF CN-13(5)
WIPER RY HI
M14A 1.25 L
30
Defective wiper Repair or replace M38 0.85 Br 87a 87 85
NO M49 0.85 G
86
switch or (After clean) G25 1.25 B
87
85
Check voltage disconnection in M45B 0.85 W
87a 30 86
poor contact
Voltage : 20~30V between CS-12(4)
M27A 0.85 R
Starting switch : ON
M14D 1.25 L
M38 0.85 Br
and CN-7(10).
M39 0.85 G
M30 0.85 Y
Wiper switch : 1st
YES
Disconnection in Repair or replace
wiring harness or (After clean)
Check voltage poor contact
CN-7
between CN-7(8) between CN-7(8)
10
11
12
13
14
6
7
9
8
M45C 0.85 W
NO
M49 0.85 G
M46 0.85 R
G51 1.25 B
and chassis. and fuse No.9
Discomection in
CS-11
Repair or replace
CS-12
CS-5
NO
6
5
4
3
2
1
8
7
6
5
4
3
2
1
CN-13
wiring harness or (After clean)
10
11
12
13
14
1
2
3
4
5
6
7
8
9
BWG 4
poor contact
RW 6
W6
BVi 3
L 4
G 5
BY 1
Gr 2
Y
M40 0.85 VOr
between CS-12(6)
HO
W
II
I
Hi
C
J 0
J
and CN-7(8).
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
MULTI FUNCTION SWITCH 5B FRONT WIPER
7607EL12
7-66
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.
Cause Remedy
FUSE BOX
YES
Defective cable Repair or replace RADIO/ROOM LAMP 5A
14
M04B 1.25 Or
F12 0.85 V
Battery capacity Repair or replace 7
NO 8
too low (After clean) 9
10
11
CS-2
12
5
4
1
6
2
3
13
B 14
0, I
1
15
CN-3
H 0 I II
4
6
5
3
2
H
C ST ACC BR
START SWITCH
7707EL27
7-67
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.10 is not blown out. FUSE BOX
・After checking, connect the disconnected connectors again immediately unless otherwise specified. BEACON LAMP 20A
1
M17 1.25 OrW ILL.LAMP 10A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 20A
6
Cause Remedy CIGAR 20A
7
YES SWITCH 10A
8
Defective lamp Replace F/R WIPER
Check voltage 20A
9
YES between each M10 1.25 Gr WORK LAMP 30A
10
OPTION 10A
lamp and chassis 11
Disconnection in Repair or replace CN-36
NO OPT
Voltage : 20~30V wiring harness or (After clean)
Check voltage Starting switch : ON poor contact C03D 1.25 Or
FRONT WORK LAMP
2
YES between CN-5(4), between CL-6(2),
G15 1.25 B
1
CN-3(10) and CL-5(2), CL-22(1),
CL-36
FRONT WORK LAMP
chassis CL-23(1) and CN-
C03C 1.25 Or
2
G14 1.25 B
1
Voltage : 20~30V 5(4), CN-3(10). CL-35
Starting switch : ON 1
2 FRONT WORK
Check voltage Disconnection in Repair or replace FR WORK LAMP RY 3 LAMP,LH
C03 1.25 Or C03 1.25 Or C03A 1.25 Or
YES between CR-3(4), NO 3 4 4 4 2
wiring harness or (After clean) 3
M51 0.85 W
5 G01 1.25 B
G11 1.25 B
1
CR-6(4) and poor contact 2
M10A 1.25 Gr 6 CL-6
G21 1.25 B 7
chassis between CN-5(4) - 1 2 1
8 FRONT WORK
CR-3 LAMP,RH
Voltage : 20~30V 9 C03B 1.25 Or
Starting switch : ON
CR-3(4) and CN- 10 G12 1.25 B
2
11 1
3(10) - CR-6(4) 12
C14 1.25 Br
CL-5
OPT
Check voltage 13 REAR WORK LAMP
14
between CR- Defective work Replace relay 15
C14A 1.25 Br
2
NO G16 1.25 B
1
3(2), CR-6(2) and lamp relay CN-5
CL-32
chassis REAR WORK LAMP
YES RR WORK LAMP RY C14B 1.25 Br 2
Voltage : 20~30V Disconnection in Repair or replace 3 4 4
CF14A 1.25 Br 1 G17 1.25 B
2 1
Starting switch : ON M52 0.85 L
wiring harness or (After clean) 3
M10B 1.25 Gr 3 CL-33
2 4
Check voltage poor contact 1 2 1
G22 1.25 B
5 REAR WORK
LAMP,LH
6
between CR-3(2), CR-6 F14A 1.25 Br
1
between fuse No. 7 G19 1.25 B
NO CR-6(2) and fuse 8 2
10 and chassis WORK LAMP SW 9 F14 1.25 Br CL-22
No.10 G13 0.85 B 10
9 10 10 C05F 0.85 R
9 11
Voltage : 20~30V 12 REAR WORK
4 8
Starting switch : ON Short circuit of fuse Replace 2 M59 0.85 Y 13 F14B 1.25 Br
LAMP,RH
7
NO 7 1 6
14
G17 1.25 B
1
M51 0.85 W 15 2
5 5
C05G 0.85 R CN-3 CL-23
4
3
M52 0.85 L
II I 0
2 CLUSTER
1 C05H 0.85 R 20 TX-PC
CS-20 19 GND
17 ILL.
CS-39
16 T/M ERROR
15 SERIAL-L
9 10 10 14 SERIAL-H
9 12 12 GND
4 8 11 GND
2 C05C 0.85 R 11
7 10 RX-PC
10 9 FWE
7 1 6 9
5 M59 0.5 Y 8 N.C
5 WORK LAMP
8 7
4 7 6 HIGH BEAM
II I 0 3 6 5 RH TURN
2 4 LH.TURN
M17 1.25 OrW 5 3 24V PER.
1
4 2 24V IG
ILL & HEAD LAMP SW : ON(1st step) 3 1 24V IG
2 CN-51
1
CN-12
7707EL28
7-68
9. WHEN ENGINE DOES NOT START
・Check supply of the power at engine stop solenoid while starting switch is ON. CONTROL UNIT
・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.
VMGA2
ADM5
・Check forward reverse switch at neutral position.
VPE2
AIP6
AIP4
AIP1
ED1
ED5
ED2
ED9
ED6
EF4
VPI
45
46
51
55
56
57
62
63
64
65
66
67
68
FUSE BOX
Cause Remedy CN-52
T37 0.85 W
A 14
VM OUTPUT SIGNAL K RADIO/ROOM LAMP 5A
YES VP F B N D B
START KEY
15
Defective battery Check engine ED 1 2 3 4 1 2 3 4 1 2 3 4 C 30A
16
AD1 B1 D TCU 10A
system charge or AD2 B2 CN-121 ECM 10A
17
AD3 B3 18
replace (after AD4 V CLUSTER 10A
7 24
of start motor magnet coil and X1
D AD7(KD)
8
87a 30 86 TCU 10A
25
CR-5 CLUSTER
chassis Defective start Replace
A ED1(VP) 9 10A
26
Starting switch : start NO D AD6 10 ILL,F/L,R/R 5A
Starting switch : start relay B AD4 11 27
ILL.F/R,R/L 5A
C AD5 12 28
X2
13
YES CN-36
ⓐ 14
CN-13
Check operation Check voltage
NO of starter relay YES
between CR-5
(87) and chassis
Starting switch : start
Disconnection in Replace
Starting switch : OFF NO
wiring harness or
Check operation poor contact
of start safety between CN-2(11)
NO
relay and CR-5(87)
Check switch : neutral YES
Defective relay Replace
Check voltage
between CR-5 STARTER
NO TO BATT
(86) and chassis B+
M04B 1.25 Or
M43 1.25 R
F12 0.85 V
Check voltage relay START RY
G15 1.25 B
ⓐ between CR-23 1
E05 1.25 R
1
2 2
(2) and chassis
CS-2
3 CR-23
5
4
1
6
2
3
Disconnection in Repair or replace 4
Voltage : 20~30V NO B
Starting switch : ON wiring harness or 0, I 5 1
1
6 2
poor contact
7 3
between CN-2(11) H 0 I II
8 4
4
6
5
3
2
-CN-4(7)-CR-23(2)
H
C ST ACC BR 9 5
START SWITCH 10 6
E05 0.85 R
YES 11 7
Disconnection in Repair or replace 12 8
wiring harness or CN-2 9
10
Check voltage poor contact 11
ⓑ between CN-13 between CN-13(4) 12
(4) and chassis and CR-5(86) CN-4
7-69