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

CN-58

Check voltage
YES 20 ~ 30V
NO 0V

7-59
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-4
Does display go (11) 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-2(4)
Starting switch : ON between CD-9
Engine : start
and chassis
and CN-2(4)
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-2(4)
disconnect CD-9

Defective cluster Replace

NO

CLUSTER OVERHEAT SWITCH

T
4 4 11

CN-6 CN-2 CN-4 CD-9

CHECK UNIT

24

CN-58

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

7-60
3. WHEN AIR CLEANER 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
Defective air Repair air cleaner
cleaner or air or replace air
cleaner switch cleaner switch
Does display go
off when YES
Disconnection in Repair or replace
disconnect CD-10
wiring harness or (After clean)
and connector?
poor contact
Starting switch : ON
Engine : start between CN-2(6)
Check resistance
and CD-10
between CN-2(6)
NO
and chassis YES
Disconnection in Repair or replace
Starting switch : OFF
Before checking, wiring harness or (After clean)
disconnect CD-10 Check resistance poor contact
between CN-6(6) between CN-4(6)-
NO
and chassis CN-2(6) - CN-6(6)
Starting switch : OFF
Defective cluster Replace
NO

CLUSTER
AIR CLEANER SWITCH
6 6 6 Pa
CN-6 CN-2 CN-4
CD-10
CHECK UNIT

36

CN-58

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

7-61
4. 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-4 between CN-4(10)
Starting switch : ON (10) 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-2(5)- CN-4(10)
Before checking,
disconnect CD-18
Defective cluster Replace
NO

ENGINE OIL PRESSURE SWITCH

CLUSTER

5 5 10 Pa

CN-6 CN-2 CN-4 CD-18

CHECK UNIT

23

CN-58

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

7-62
5. 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(9) between CN-6(8)
Engine : start and chassis and CN-2(9)
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-2(9)
Starting switch : OFF
Before checking,
and CD-1
disconnect CD-1
Defective cluster Replace
NO

HYDRAULIC OIL
CLUSTER TEMPERATURE SWITCH
T
8 9

CN-6 CN-2 CD-1

CHECK UNIT

12

CN-58

Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬

7-63
6. 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(6)
Engine : start between CN-9(6)
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(6)
NO
and chassis and CD-29
Starting switch : OFF
See : TABLE Defective sender Replace
NO

TRANS

TRANSMISSION OIL
CLUSTER TEMPERATURE SENDER
Ş
C
10 6

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

7-64
7. 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-2(3)
Engine : start Check resistance
See : TABLE between CN-2(3) 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-2(3)
See : TABLE
Check resistance and CN-4(12)
between CN-4
NO
(12) 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-4
NO
and chassis (12) and CD-8
Starting switch : OFF
See : TABLE Coolant overheat Check coolant
NO
TRANS
or defective temperature or
sender replace

CLUSTER WATER TEMPERATURE SENDER

11 Ş
C
3 12

CN-7 CN-2 CN-4 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

7-65
8. 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(7)
Check resistance
between CN-2(7)
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(7)
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 7 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

7-66
9. 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 : 20~30v
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

7-67
10. WHEN BATTERY 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
Check voltage Defective cluster Replace
YES
between CN-6(1)
and chassis Disconnection in Repair or replace
NO
wiring harness or (After clean)
poor contact
between CN-6(1)
and CN-58(18)
YES
Defective check Replace
Check voltage
YES unit
between CN-58
(2) and chassis
Disconnection in Repair or replace
Voltage : 27.5~30V
NO
wiring harness or (After clean)
poor contact
Check voltage Check voltage between CN-58(2)
YES
between between CN-2(2) and CN-2(2)
alternator terminal and chassis
YES
"I" and chassis Voltage : 26~30V Disconnection in Repair or replace
Voltage : 26~30V wiring harness or (After clean)
Starting switch : ON
Check voltage poor contact
between CN-4(3) between CN-4(3)
NO
and chassis and CN-2(2)

Disconnection in Repair or replace

NO
wiring harness or (After clean)
poor contact
between CN-4(3)
and alternator
terminal " H "

Defective alternator Replace

NO

CLUSTER CHECK UNIT

1 18

CN-6
2

CN-58

ALTERNATOR
2 3 "I" TERMINAL
Check valtage
CN-2 CN-4
YES 20 ~ 30V
NO 0V

7-68
11. WHEN PARKING SOLENOID DOES NOT WORK
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.6 is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective parking Replace
brake solenoid

Check voltage YES

between CN-71 Disconnection in Repair or replace
(2) and chassis wiring harness or (After clean)
poor contact
Starting switch : ON
Parking switch : ON-OFF
Check voltage between CS-17(8)
Voltage : 20~30V NO between CS-17 and CN-71(2)
(8) and chassis
YES
Parking switch : OFF Defective parking Replace
Voltage : 20~30V Check voltage switch
between CS-17
NO
(6) and chassis
Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (After clean)
poor contact
between CS-17(6)
and CN-36(6)

PARKING SWITCH
8
FUSE
6
No.6
CS-17
CN-71

2
2
1

PARKING SOLENOID

7-69
12. 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.1(Transmission controller) and No.6 are not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective T/M Replace
Check voltage
YES controller
between EN-111
(14) and chassis
Disconnection in Repair or replace
Voltage : 20~30V NO
wiring harness or (After clean)
poor contact
Check voltage between CS-17(6)
between CN-15 and fuse No.6
(1) and chassis
YES
Starting switch : ON Disconnection in Repair or replace
Parking switch : ON wiring harness or (After clean)
Prolix switch : OFF
Voltage : 20~30V poor contact
Check voltage
between CN-15
between CS-17
NO (4) and CS-17(1)
(1) and chassis
Voltage : 20~30V YES
Parking switch : ON Check voltage Defective switch Replace
between CS-17
NO
(5) and chassis Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (After clean)
poor contact
between CS-17(5)
and fuse No.6

4
PROLIX SWITCH
FUSE
CN-15
5
No.1
6
8
CS-7

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

7-70
13. MACHINE DOES NOT TRAVEL
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.1(Transmission controller) is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
şWiring diagram : See page 7-17.
Cause Remedy
YES
Disconnection in Repair or replace
wiring harness or (After clean)
poor contact
Is there continuity
YES between CS-42(5)
between CN-15
(4) and chassis? - CS-42(1) -CD-5 -
CN-15(4)
Disconnect parking
switch connector
Clutch cut-off switch Defective parking Repair or replace
:OFF NO
Is voltage switch or (After clean)
YES between CN-15 disconnection
(4) and chassis
wiring harness or
20-30V?
poor contact
Starting switch : ON
Parking switch : OFF between CN-15
Is there continuity (4) and CS-17(1)
YES
between CN-15 (2)
and chassis?
‫ڞ‬
NO

Is voltage between Disconnection in Repair or replace

NO
CN-15(1) and wiring harness or (After clean)
chassis 20-30V? poor contact
Starting switch : ON between CN-15
(2) and chassis

Disconnection in Repair or replace

NO
wiring harness or (After clean)
poor contact
between CN-15
(1) and fuse No.1

YES
Defective T/M Replace
Is problem controller(EGS)
‫ڞ‬ removed when
EN-111 is YES
replaced? Is problem Defective T/M Replace
removed when harness
NO T/M harness is
replaced?
Check solenoid Repair or replace
NO
(After clean)

7-71
14. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.19 is not blown out and ON/OFF of bulb. FUSE BOX

After 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 : 20~30V 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
Voltage : 20~30V CL-3(3) - CN-8(11),
Starting switch : ON CN-36
CL-4(3) - CN-8(12).
Head lamp switch : ON
ILL & HEAD LAMP SW LH HEAD LIGHT
Disconnection in Repair or replace
NO
wiring harness or (After clean)
Check voltage
poor contact
between CS-11 CL-3
between CN-10(4)
(7) and chassis RH HEAD LIGHT
and CS-11(7)
Starting switch : ON
Head lamp switch :
YES CS-39
ON-OFF Defective Replace CL-4
CN-8
multifunction switch

Check voltage
YES
between CS-11 Disconnection in Repair or replace
NO HI BEAM PILOT LAMP
(8) and chassis wiring harness or (After clean)
Voltage : 20~30V poor contact CL-41
Starting switch : ON Check voltage between CS-11(8) CN-10
between CS-39 and CS-39(2)
NO
(2) and chassis
YES Defective head Replace switch
Check voltage lamp switch EARTH
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

MULTIFUNCTION SW CN-7 JT-28

7-72
15. 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.7 is not blown out.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

CHECK UNIT FUSE BOX

Cause Remedy
YES
Check voltage Defective front Replace
YES between front wiper motor

CN-58
wiper motor and
chassis Poor connection of Replace
Check voltage Voltage : 20~30V
NO
YES chassis
between CN-21(5) Starting switch : ON
Wiper switch : 1st
and chassis
Voltage : 20~30V
Starting switch : ON Disconnection in Repair or replace
Check voltage Wiper switch : 1st NO
YES wiring harness or (After clean)
between CS-12
(4) and chassis poor contact
between CS-12(4)
Voltage : 20~30V
Check voltage Starting switch : ON
and CN-21(5) CN-36
between CS-12 Wiper switch : OFF
(6) and chassis Defective wiper Replace
NO
switch WIPER RY2
Voltage : 20~30V
Starting switch : ON
Wiper switch : 1st Disconnection in Repair or replace
NO CR-26
wiring harness or (After clean)
poor contact
WIPER RY
between CS-12(6)
and fuse No.7

CR-4

DO-10
CS-11

CS-12

CS-5
CN-21
FRONT WIPER

MULTIFUNCTION SWITCH

7-73
16. WHEN STARTING SWITCH ON DOES NOT OPERATE
FUSE BOX
Before carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.15 is not blown out.
After 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 : 20~30V NO
Check voltage defect of fusible
YES
between CR-1 link or defective
(M4) and chassis
battery relay
Voltage : 20~30V

Disconnection in Replace
NO
Check voltage wiring harness or
YES between CS-2
(1)[and CS-2(2)] poor contact
and chassis between CS-2(2) -
CN-36
Voltage : 20~30V
CN-2(1)-CR-1
(M4)

Disconnection in Replace
Check voltage NO MASTER SW
wiring harness or BATT RY
and specific 60R 60R 60B 60B
gravity of battery poor contact
between fuse No.
Specific gravity : MIN 1.28 CR-1
Voltage : MIN 24V 13 and CS-2(1) or
defect of start
TO STARTER
switch
CN-1
CN-60
Battery capacity Repair or replace
NO
too low (After clean) DO-2

CN-2
CS-2

START SWITCH

7-74
 17. 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.16 is not blown out.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

FUSE BOX

Cause Remedy
YES
Check voltage Defective lamp Replace
YES between each
lamp(2) and
chassis Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (After clean)
Starting switch : ON poor contact
Check voltage
YES between CN-5(3) -
between CN-5(3),
(4) and chassis CL-22(2), CL23(2)
and CN-5(4) - CL-
Voltage : 20~30V 5(2), CL-6(2)
Starting switch : ON

Check voltage Disconnection in Repair or replace

YES NO
between CS-21 wiring harness or (After clean)
(2) and chassis poor contact
between CN-5(3) - CN-36
Voltage : 20~30V
Starting switch : ON
CS-21(2) and CN-
5(4) - CS-21(1)
Check voltage
between CS-21 Defective work Replace switch
NO
(6) and chassis lamp switch WORK LAMP SW

Voltage : 20~30V YES

Disconnection in Repair or replace FRONT WORK
Starting switch : ON CN-5 LIGHT,LH
wiring harness or (After clean)
Check voltage poor contact
CL-6
between CS--21(6)
between fuse No.
NO and fuse No.16 CS-21
16 and chassis FRONT WORK
LIGHT,RH
Voltage : 20~30V
Starting switch : ON Short circuit of fuse Replace CL-5
NO

REAR WORK
LIGHT,LH

CL-22

REAR WORK
LIGHT,RH

CL-23

7-75
18. WHEN ENGINE DOES NOT START
EGS
Check supply of the power at engine stop solenoid while starting switch is ON. FUSE BOX

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.
Check forward reverse switch at neutral position.

CN-111
Cause Remedy
YES
Defective battery Check engine
system charge or
replace (After
checking specific
gravity of battery)
YES
Check voltage Defective magnet Replace
Check operation YES between starter of start motor
of start motor magnet coil and

CN-15
chassis Defective start Replace
Starting switch : Start NO
Starting switch : Start relay

YES CN-36

Check operation Check voltage

SAFETY RY

NO of starter relay YES STARTER

between CR-5(4) TO BATT
and chassis
Starting switch : Start
Disconnection in Replace
Starting switch : OFF NO CR-5
wiring harness or
CN-45
Check operation poor contact
START RY
of start safety between CN-3(3)
NO
relay and CR-5(4)
CR-23
Check switch : Neutral YES
Defective relay Replace
Check voltage ENG STOP SOL
between CR-5(3)
NO
and chassis
CN-79
Starting switch : OFF NO

YES
Defective start Replace
Check voltage relay
between CR-23
(2) and chassis
Disconnection in Repair or replace
Voltage : 20~30V NO
Starting switch : ON wiring harness or
poor contact
between CN-3(3)-
CR-23(2)
CN-2
CS-2

YES
Disconnection in Repair or replace
wiring harness or CN-4
Check voltage poor contact
between CN-15 between CN-15(3) START SWITCH

(2) and chassis and CR-5(3)

Starting switch : OFF CN-3
Defective EGS Replace
NO

7-76