GROUP 6 TROUBLESHOOTING

1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.2 is not blown out and ON/OFF of bulb.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace
YES Check voltage
between CN-58
(1) and chassis
Disconnection in Repair or replace
NO
wiring harness or (After clean)
Check voltage poor contact
between CN-7(4) between
and chassis
CN-58(1) and
fuse No.2

Disconnection in Repair or replace

NO
wiring harness or (After clean)
poor contact
between CN-7(4)
and fuse No.2

CLUSTER
FUSE
4
No.2
CN-7

CHECK UNIT

CN-58

Check voltage
YES 20 ~ 28V
NO 0V

7-61
2. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Coolant overheat Check engine
(105Ş
CŹ2Ş C) system

YES
Defective Replace
Check resistance
YES overheat switch
between CN-13
Does display go (10) and chassis
off when Disconnection in Repair or replace
Starting switch : OFF NO
disconnect CD-9 wiring harness or (After clean)
Check resistance
and connector? YES poor contact
between CN-3(9)
Starting switch : ON between CD-9
Engine : start
and chassis
and CN-3(9)
Starting switch : OFF

Check resistance Disconnection in Repair or replace

NO
between CN-6(4) wiring harness or (After clean)
NO
and chassis poor contact
Starting switch : OFF
between CN-6(4)
Before checking, and CN-3(9)
disconnect CD-9

Defective cluster Replace

NO

CLUSTER OVERHEAT SWITCH

T
4 9 10

CN-6 CN-3 CN-13 CD-9

CHECK UNIT

24

CN-58

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

7-62
3. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch

YES
Disconnection in Repair or replace
Does display go
off when wiring harness or (After clean)
disconnect CD-18 Check resistance poor contact
YES
and connector? between CN-13 between CN-13(7)
Starting switch : ON (7) and chassis -CD-18
Engine : start
Starting switch : OFF
Disconnection in Replace
Check resistance NO
wiring harness or
between CN-6(5)
NO
and chassis poor contact
between CN-6(5) -
Starting switch : OFF CN-3(5)- CN-13(7)
Before checking,
disconnect CD-18
Defective cluster Replace
NO

CLUSTER ENGINE OIL PRESSURE SWITCH

5 5 7 1
Pa
CN-6 2
CN-3 CN-13
CD-18
CHECK UNIT

23

CN-58

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

7-63
4. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
High temperature Check hydraulic
of hydraulic oil or oil temperature
defective switch (105Ş CŹ2Ş C),
hydraulic cooling
or replace switch

Does display go YES

off when Disconnection in
disconnect CD-1 wiring harness or
and connector? Check resistance poor contact
YES
Starting switch : ON between CN-2(10) between CN-6(8)
Engine : start and chassis and CN-2(10)
Starting switch : OFF
Before checking, Disconnection in Repair or replace
Check resistance disconnect CD-1 NO
wiring harness or (After clean)
between CN-6(8)
NO
and chassis poor contact
between CN-
Starting switch : OFF
Before checking,
2(10) and CD-1
disconnect CD-1
Defective cluster Replace
NO

HYDRAULIC OIL
CLUSTER TEMPERATURE SWITCH
T
8 10

CN-6 CN-2 CD-1

CHECK UNIT

12

CN-58

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

7-64
5. WHEN TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT OPERATE
(Check torque converter oil temperature lamp ON/OFF)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace
YES
Check resistance Disconnection in Repair or replace
between CN-7 wiring harness or (After clean)
(10) and chassis poor contact
between CN-
Starting switch : ON Check resistance
7(10) and CN-9(4)
Engine : start between CN-9(4)
See : TABLE NO
and chassis YES
Disconnection in Repair or replace
Starting switch : OFF wiring harness or (After clean)
See : TABLE
Check resistance poor contact
between CD-29 between CN-9(4)
NO
and chassis and CD-29
Starting switch : OFF
See : TABLE Defective sender Replace
NO

TRANS

TRANSMISSION OIL
CLUSTER TEMPERATURE SENDER
Ş
C
10 4

CN-7 CN-9 CD-29

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

Check table
Temperature
50Ş
C 92Ş
C 120Ş
C 130Ş
C
Item
Unit resistance(‫)װ‬ 168.7 (34) 19.5 12.4
Tolerance 0Ş~ -10Ş (-) Ź3Ş +10Ş~ 0Ş
Angle -30Ş -8Ş +27Ş +30Ş

7-65
6. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace

YES
Disconnection in Repair or replace
Check resistance wiring harness or (After clean)
between CN-7 poor contact
(11) and chassis
between CN-7
Starting switch : ON (11) and CN-3(7)
Engine : start Check resistance
See : TABLE between CN-3(7) YES
NO Disconnection in Repair or replace
and chassis
wiring harness or (After clean)
Starting switch : OFF
Before checking, poor contact
disconnect connector between CN-3(7)
See : TABLE
Check resistance and CN-13(8)
between CN-13
NO
(8) and chassis YES
Disconnection in Repair or replace
Starting switch : OFF wiring harness or (After clean)
See : TABLE
Check resistance poor contact
between CD-8 between CN-13
NO
and chassis (8) and CD-8
Starting switch : OFF
See : TABLE Coolant overheat Check coolant
NO
TRANS
or defective temperature or
sender replace

CLUSTER WATER TEMPERATURE SENDER

Ş
C
11 7 8

CN-7 CN-3 CN-13 CD-8

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

Check table
Temperature
(40Ş
C) 91Ş
C 105Ş
C 120Ş
C
Item
Unit resistance(‫)װ‬ 222 (41.3) 28 19.2
Tolerance Ź5Ş (-) Ź4.5 (-)
Angle -30Ş 0Ş +13Ş +30Ş

7-66
7. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace

YES
Check resistance Disconnection in Repair or replace
between CN-7 wiring harness or (After clean)
(12) and chassis poor contact
Starting switch : OFF between CN-7
See : TABLE (12) and CN-2(11)
Check resistance
between CN-2(11)
NO YES
and chassis Disconnection in Repair or replace
See : TABLE wiring harness or (After clean)
poor contact
Check resistance between CD-2(1)
between CD-2(2) and CN-2(11)
NO
and chassis
YES
See : TABLE Check circuit Repair or replace
Check resistance
between CD-2(2) (After clean)
between CD-2(2)
and chassis
NO and CD-2(1) with
chassis
See : TABLE Defective sensor Replace
NO
E F

FUEL

FUEL SENDER
CLUSTER
1
12 11 2
CD-2
CN-7 CN-2

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

Check table
Temperature
Empty (1/2) Full
Item
Unit resistance(‫)װ‬ 95 (32.5) 7
Tolerance Ź2.5Ş Ź5Ş Ź2.5Ş
Angle -30Ş 0Ş +30Ş

7-67
8. WHEN GAUGES OF FUEL, HYDRAULIC OIL AND COOLANT INDICATE HIGH OR FULL
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES Defective cluster Replace

Check resistance
between CN-7
(13) and chassis
Disconnection in Repair or replace
Starting switch : ON NO
Voltage : 20~28V
wiring harness or (After clean)
poor contact
between CN-7
(13) and chassis

CLUSTER

13

CN-7

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

7-68
9. WHEN PARKING SOLENOID DOES NOT WORK
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.7 is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective parking Replace
brake solenoid

YES
Check voltage Disconnection in Repair or replace
between CN-71 wiring harness or (After clean)
(2) and chassis poor contact
Starting switch : ON between CN-71(2)
Parking switch : ON-OFF Check voltage and CN-8(10)
Voltage : 20~28V
NO between CN-8(10)
and chassis YES
Disconnection in Repair or replace
Parking switch : OFF wiring harness or (After clean)
Voltage : 20~28V poor contact
Check voltage between CS-17(8)
NO between CS-17 and CN-71(2)
(8) and chassis
YES
Parking switch : OFF Defective parking Replace
Voltage : 20~28V Check voltage switch
between CS-17
NO
(6) and chassis
Disconnection in Repair or replace
NO
Voltage : 20~28V wiring harness or (After clean)
poor contact
between CS-17(6)
and CN-36(6)

PARKING SWITCH
8 10

CN-8 FUSE
6
No.7
CS-17
CN-71

D-1
2
2
1

PARKING SOLENOID

7-69
10. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.14(Transmission controller) and No.7 are not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES Defective T/M Replace
controller
Check voltage
between CN-15 YES
Disconnection in Repair or replace
(F) and chassis
wiring harness or (After clean)
Starting switch : ON poor contact
Parking switch : ON Check voltage
Prolix switch : OFF between CN-15
between CS-17
Voltage : 20~28V NO (F) and CS-17(1)
(1) and chassis
Voltage : 20~28V YES
Parking switch : ON Check voltage Defective switch Replace
between CS-17
NO
(5) and chassis Disconnection in Repair or replace
NO
Voltage : 20~28V wiring harness or (After clean)
poor contact
between CS-17(5)
and fuse No.7

CN-15

PARKING SWITCH
FUSE
6
No.7
5
1
CS-17

7-70
11. MACHINE DOES NOT TRAVEL
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
CONTROL UNIT
fuse No.1(Transmission controller) is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

CANB-H
CANF-H

CANF-T

CANB-L
VMGA2
CANF-L
VMGA1

ADM8
ADM7

VPE2
VPE1
ED10

ED11
ED12
ED13

AIP7
AIP6
VGS

AIP3

ED5
ED2
ED9
ED6
ED3

ED7

SD3
SD4
AU1
EU1
ER1

ED4
ED8

ER2
EF1

EF6
EF2
EF3

VPI

63
64
65
66
67
68
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51

816
820
X1

Cause Remedy
YES
Defective clutch Replace
cut-off switch

CN-15
YES Check resistance FUSE BOX
between CD-5

044 BY
205 BY
and chassis
Is there continuity
NO between CN-
Defective T/M Replace
15(E) and NO
chassis? controller

Defective T/M Replace

NO
Is voltage between controller
CN-15(F) and
chassis 20-28V? YES
Defective parking Replace
Starting switch : ON switch
Parking switch : OFF
Clutch cut-off Is voltage between
switch : ON
YES CS-17(1) and
chassis 20-28V?
CN-36

Disconnection in Repair or replace

NO
wiring harness or (After clean) PARKING SW

poor contact
between CN-15(F)
and CS-17(1)

Check resistance CS-17

YES MAX 1‫װ‬ CLUTCH CUT-OFF SW

CN-71
NO MIN 1M‫װ‬
PARK SOL

CD-5
D-1

CLUTCH CUT OFF

CS-42

CN-8

7-71
12. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
şBefore carrying out below procedure, check all the related connectors are properly inserted and the FUSE BOX
fuse No.19 is not blown out and ON/OFF of bulb.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective bulb Replace
Check voltage
YES
between CL-3(1) -
(3) and CL-4(1) -(3)
Voltage : 20~28V Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (After clean)
Check voltage Head lamp switch : ON
poor contact
YES between CN-
10(4) and CN- between CN-10(4)-
8(11), (12) CL-3(1), 4(1) and
CN-36
Voltage : 20~28V CL-3(3) - CN-8(11),
Starting switch : ON CL-4(3) - CN-8(12). LH HEAD LIGHT
Head lamp switch : ON ILL & HEAD LAMP SW

Disconnection in Repair or replace

NO CL-3
wiring harness or (After clean)
Check voltage
poor contact
between CS-11 RH HEAD LIGHT
between CN-10(4)
(7) and chassis
and CS-11(7)
Starting switch : ON CS-39
Head lamp switch : CL-4
YES
ON-OFF Defective Replace CN-8
multifunction switch

Check voltage
YES HI BEAM PILOT LAMP
between CS-11 Disconnection in Repair or replace
NO
(8) and chassis wiring harness or (After clean) CL-41

Voltage : 20~28V poor contact CN-4

Starting switch : ON Check voltage between CS-11(8)

between CS-39 and CS-39(2)
NO
(2) and chassis
YES Defective head Replace switch
Check voltage lamp switch
between CS-39
NO
(4) and chassis

CS-11
Disconnection in Repair or replace
NO
wiring harness or (After clean)
poor contact
between CS-39(4)
and fuse No.19

MULTI FUNCTION SW CN-7

7-72
13. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.7 is not blown out. CHECK UNIT CN-36
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy

CN-58
YES
Check voltage Defective front Replace
YES between front wiper motor
wiper motor and
chassis Poor connection of Replace
Check voltage Voltage : 20~28V
NO
YES chassis
between CN-21(5) Starting switch : ON
Wiper switch : 1st
and chassis
Voltage : 20~28V
Starting switch : ON Disconnection in Repair or replace
Check voltage Wiper switch : 1st NO
YES wiring harness or (After clean) FUSE BOX
between CS-12
(4) and chassis poor contact
between CS-12(4)
Voltage : 20~28V
Check voltage Starting switch : ON
and CN-21(5)
Wiper switch : OFF CR-26
between CS-12

WIPER RY Lo
(6) and chassis Defective wiper Replace
NO
switch
Voltage : 20~28V
Starting switch : ON
Wiper switch : 1st Disconnection in Repair or replace
NO
wiring harness or (After clean)
poor contact
between CS-12(6)
CR-4
and fuse No.7

WIPER RY Hi
CS-11

CS-12

CS-5

CN-21
MULTIFUNCTION SWITCH FRONT WIPER

7-73
14. WHEN STARTING SWITCH ON DOES NOT OPERATE
şBefore carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.15 is not blown out.
FUSE BOX
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cable Repair or replace
Check voltage (After clean)
YES assembly
between CN-60(2)
and chassis
Short circuit or Replace
Voltage : 20~28V NO
Check voltage defect of fusible
YES
between CR-1 link or defective
(M4) and chassis
battery relay
Voltage : 20~28V

Disconnection in Replace
NO
Check voltage wiring harness or CN-36
YES between CS-2(1)
and CS-2(2) poor contact
MASTER SW
and chassis between CS-2(2) - BATT RY
Voltage : 20~28V 60R 60R 60B 60B
CN-2(1)-CR-1
(M4)
CR-1

Disconnection in Replace
Check voltage NO TO STARTER
wiring harness or
and specific
gravity of battery poor contact
between fuse No. CN-60
Specific gravity : MIN 1.28
Voltage : MIN 24V 13 and CS-2(1) or
defect of start
switch

Battery capacity Repair or replace

NO
too low (After clean)
CN-1

DO-1

CS-2

START SWITCH CN-2

7-74
 15. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
şBefore carrying out below procedure, check all the related connectors are properly inserted, and the
fuse No.16 is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Check voltage Defective lamp Replace FUSE BOX

YES between each

lamp(2) and
chassis Disconnection in Repair or replace
NO
Voltage : 20~28V wiring harness or (After clean)
Starting switch : ON poor contact
Check voltage
YES between CN-5(3) -
between CN-5(4),
(3) and chassis CL-22(2), CL23(2)
and CN-5(4) - CL-
Voltage : 20~28V 5(2), CL-6(2)
Starting switch : ON
Check voltage Disconnection in Repair or replace
YES between CS-21 NO
wiring harness or (After clean)
(2), CS-20(2) and poor contact
chassis between CN-5(3) -
Voltage : 20~28V
Starting switch : ON
CS-20(2) and CN-
5(4) - CS-21(2)
CN-36
Check voltage
between CS-21 Defective work Replace switch
(6), CS-20(6) and NO
lamp switch
chassis
YES FRONT WORK
Voltage : 20~28V Disconnection in Repair or replace LIGHT,LH
Starting switch : ON
wiring harness or (After clean) WORK LAMP FRONT
CN-5
Check voltage poor contact CL-6

between CS-21(6), FRONT WORK

between fuse No. LIGHT,RH
NO CS-20(6) and fuse
16 and chassis
No.16
CL-5
Voltage : 20~28V
Starting switch : ON Short circuit of fuse Replace
NO CS-21
WORK LAMP REAR
REAR WORK
LIGHT,LH

CL-22

REAR WORK
LIGHT,RH

CS-20 CL-23

7-75
16. WHEN ENGINE DOES NOT START
şCheck supply of the power at engine stop solenoid while starting switch is ON.
CONTROL UNIT CHECK UNIT
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless other wise specified.
şCheck forward reverse switch at neutral position.

30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

CN-58
Cause Remedy
YES GEAR SELECTOR
Defective battery Check engine
system charge or SAFETY RY
replace (After
checking specific
gravity of battery)
YES CR-5
Check voltage Defective magnet Replace A
Check operation YES between starter of start motor B
C
of start motor magnet coil and D
E FUSE BOX
chassis Defective start Replace F
Starting switch : Start NO G
Starting switch : Start relay H
J
K
YES
‫ڞ‬ CN-15

Check operation Check voltage

NO of starter relay YES
between CR-5(4)
and chassis
Starting switch : Start
Disconnection in Replace
Starting switch : OFF NO
wiring harness or
Check operation poor contact
of start safety between CN-3(2)
NO
relay and CR-5(4)
Check switch : Neutral YES
Defective relay Replace
Check voltage
between CR-5(3)
NO
and chassis
Starting switch : OFF NO
‫ڟ‬

YES STARTER
Defective start Replace TO BATT

Check voltage relay

‫ڞ‬ between CR-23
CN-45
(1) and chassis
START RY
Disconnection in Repair or replace
Voltage : 20~28V NO

CS-2
Starting switch : ON wiring harness or
poor contact CR-23

between CN-3(2)-
CR-23(1) START SWITCH

YES FUEL SHUT OFF SOL

Disconnection in Repair or replace CN-13
wiring harness or
CN-79
CN-3
Check voltage poor contact
‫ڟ‬ between CN-15 between CN-15(B)
(B) and chassis and CR-5(3)
Starting switch : OFF
Defective DW-3 Replace
NO

7-76