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.3 and No.5.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-56 poor contact (After clean)
(2) and chassis between CN-56
(1) and fuse No.6.
Starting switch : ON
Voltage : 10~12.5V

NO Disconnection in Repair or
wiring harness or replace
poor contact (After clean)
between CN-56
(2) and fuse No.3

Check voltage
YES 10 ~ 12.5V
NO 0V

CLUSTER FUSE
POWER IG(12V) 1
NO.6
NO.5
POWER 12V 2
FUSE

NO.3
CN-56

R5575TS10

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-57
(4) and chassis Disconnection in Repair or replace
NO
wiring harness or (After clean)
YES Check voltage poor contact
between CN-2
(4) and chassis between CN-57(4)
-CN2(4)

Check voltage Disconnection in Repair or replace

NO wiring harness or (After clean)
between alternator
poor contact
terminal "2" and between
chassis CN-2(4)-alternator
Voltage : 10~12.5V terminal "L"
Engine : Running

Defective alternator Replace

NO

Check voltage
YES 10 ~ 12.5V
NO 0V

CLUSTER ALTERNATOR
B+
G
3
4 4
1 S
~
U
2 L
CN-57 CN-2 CN-74

R557A5TS11

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
Resistance
YES between CD-30 (110ÁC Ü2ÁC ) cooling system
(1,2) is in range
of 120~150̫?
NO
Defective temp Replace
Disconnect CD-30 sensor
Does display go
off when
disconnect CD-
30? YES
Starting switch : ON Short circuit in Repair or replace
Engine : Start Resistance wiring harness (After clean)
between CN-56
NO
(4,8) is 0~1̫?
Defective cluster Replace
Disconnect CN-56 NO
KEY OFF

CLUSTER WATER TEMPERATURE

SENSOR

8 8 2 C

4 7 1

CN-56 CN-1 CD-30

R557A5TS12

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
defective switch replace switch
Does display go
off when
disconnect CD-
10? YES
Short circuit in Repair or replace
Starting switch : ON
Engine : Start Check resistance wiring harness (After clean)
between CN-57
NO
(1) and chassis
Starting switch : OFF Defective cluster Replace
NO
Disconnect CN-57

Check resistance
YES MAX 1̫
NO MIN 1M̫

CLUSTER
AIR CLEANER SWITCH

Pa
1 7
CN-57 CN-2 CD-10

R557A5TS13

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-57
NO
(3) and chassis
Starting switch : OFF
Disconnection in Repair or replace
NO
Disconnect CN-57 wiring harness or (After clean)
poor contact
between
CN-57(3)-CD-18

Check resistance
YES MAX 1̫
NO MIN 1M̫

CLUSTER ENGINE OIL PRESSURE SWITCH

3 2 Pa

CN-57 CN-1 CD-18

R557A5TS14

5-28
6. WHEN HYDRAULIC OIL TEMPERATURE 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
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1
(1,2) is in range (100ÁC Ü2ÁC ) ,
of 130~150̫? Replace
Starting switch : ON Defective temp Replace
Does display go NO
Disconnect CD-1 sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Starting switch : ON Resistance
Engine : Start between CN-56
NO (8) and CN-57(2)
is 0~1̫?
Starting switch : OFF NO Defective cluster Replace
Disconnect CN-56,
CN-57

CLUSTER HYDRAULIC OIL

TEMPERATURE SENDER
2 9 2
C

CN-57 CN-1 CD-1

CLUSTER

8 8

CN-56 CN-1
R557A5TS15

5-29
7. 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
(4) and (8) over CN-56-CD-30
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-1
check? (8) and (7)
Defective temp Replace
See Table
NO
Starting switch : ON sensor

Defective cluster Replace

NO

Check Table
Temperature 115Á C
40Á
C 85~110Á
C
Item (Red range)

Unit Resistance(̫) 1170~ 270~130 ~124

Red range Tolerance(%) Ü5 8~0 Ü5

CLUSTER WATER TEMPERATURE

SENSOR

8 8 2 C

4 7 1

CN-56 CN-1 CD-30

R557A5TS12

5-30
8. 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
(3) and (8) over
1k̫? YES
Defective cluster Replace
Starting switch : OFF
Disconnect CN-51
Check resistance
Does the gauge between CD-2(1)
move up and NO and (2)
down at lamp Defective fuel Replace
NO
check? Disconnect CD-2
sensor
See Table
Starting switch : ON

Defective cluster Replace

NO

Check Table
Level Empty 1/2 Full
Item
Unit Resistance(̫) 700 300 ~100
Tolerance(%) Ü5 Ü8 Ü5
Red range

CLUSTER
FUEL SENDER

3 6 2

8 8 1

CN-56 CN-1 CD-2

R557A5TS16

5-31
9. 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.14.
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 (3) and chassis
between CN-68 Disconnect in Repair or replace
Check voltage Starting switch : ON NO
(1) - CN-68(2) YES between CN5(15) Voltage : 10~12.5V wiring harness or (After clean)
Starting switch : ON and chassis Disconnect CN-5 poor contact
Voltage : 10~12.5V between
Safety state Starting switch : ON CN-5(15)-CS-4(3)
Voltage : 10~12.5V
Disconnect CN-5
Check voltage 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-5(15)-CN-68(2)
Voltage : 10~12.5V

NO Disconnection in Replace
fuse

FUSE

NO.14

SAFETY SWITCH
2 3 1 SAFETY SOLENOID
2 1
1 3 15 2
CS-4 CN-68
CN-5

R557A5TS17

5-32
10. 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.22 .
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 CN-56 YES
of solenoid Defective cluster Replace
(9) 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)
Disconnect CN-56 : ON
pressing the travel Defective solenoid Replace
Starting switch : OFF NO
speed switch on
the cluster SPEC : 15~25̫
Disconnect CN-70
Starting switch : ON
Defective cluster Replace
NO

CLUSTER

TRAVEL SOLENOID
CN-56 1
9 2
CR-12 CN-70
87a CN-4
86 30
85
87 FUSE
86
85 87 87a
30 NO.17
TRAVEL HI-LO SOL

R557A5TS18

5-33
11. 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.7 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- Defective wiper Replace
3(10) and switch
chassis
Voltage : 10~12.5V Check voltage
between CS-3
YES
(6) and chassis YES
Defective Int wiper Replace
Wiper switch : ON
Check voltage relay, wiper relay,
Voltage : 10~12.5V between CR-6
wiper motor
YES (4),CR-4(86),CN-
21(3) and chassis
Recheck fuse Replace
Starting switch : ON NO
Voltage : 10~12.5V

WIPER SW WIPER RY WIPER MOTOR WASHER SW

10
4

INT WIPER RY
2
1
87a 87 85

30 86

I 0 DO-10
9
5
7

8
1

2
6

CR-6

CR-4

CS-30
CN-21
CS-3

6
4 Lo

1 Pf
2 E
3 B
87a

CS-82
30
86

85
87
1
4
6

3
10
7

9
2

8
5
6
1

3
4

10
2
3
4
5
6
1

9
8
2
1
1
2
3
4

CN-20
M 2
1
WASHER P/P
FUSE 3
4
NO.7
CN-5
R557A5TS21

5-34
12. 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.9.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Defective light Replace switch
switch

YES Check voltage

between CS-21 YES
(1) and CR-13(86) Defective bulb Replace
Check voltage
YES between CL-3(2)/
Starting switch : ON CL-4(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-4(2) Voltage : 10~12.5V poor contact
YES and chassis between CN-4(2)-
Check voltage CL-3(2)/CL-4(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
CR-13(8)-CN-4(2)

Disconnection in Repair or replace

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

CN-4 HEAD LAMP

1
2 2

CL-3
LIGHT SW
9 10 10 1
9
CR-13 2
4 8
2 87a 30 86
7 85 CL-4
7 1 6 87
5 5 86
87a 87 85
4 30
3
I 0

2 FUSE
1
CS-21 NO.10
R557A5TS22

5-35
13. 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.10.
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
NO
Defective light Replace switch
switch

YES
Defective bulb Replace
YES Check voltage
between CS-21 YES Check voltage
(4) and CR-3(86) 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-4
YES (8) and chassis between CN-4(8)
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
CR-3(86)-CN-4(8)

Disconnection in Repair or replace

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

WORK LAMP
CN-4 CN-12 1
LIGHT SW 2
8 2
9 10 10
9 CL-5
4 8
2
7
7 1 6
5
CR-3
5 87a 30 86
4 85
3 87
I 0

2 86
1 30
87a 87 85 FUSE
CS-21
NO.11

R557A5TS23

5-36
14. WHEN ENGINE DOES NOT START

ÂCheck supply of the power at engine stop solenoid while starting switch is ON. FUSIBLE LINK MASTER SW

ÂBefore disconnecting the connector, always turn the starting switch OFF.

CN-95

CN-60
ÂBefore carrying out below procedure, check all the related connectors are properly inserted. CR-1

1
2

1
2
NO.14
FUSE
1
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

NO.2

CS-74
2

CR-1 BATT RY

1
2
CN-3
Cause Remedy BATTERY
1
YES
Defective battery Check engine 2
system charge
or replace(After 9
checking specific
DO-1 RS-2
gravity of battery) 1 2
CN-5 2 1
Check operation YES
Check voltage Defective magnet Replace RESISTER
of start motor YES between starter of start motor FUSE CN-74
magnet coil and NO.16
CLUSTER CN-2 B+
G
3
Starting switch : START chassis Defective start relay Replace ~
CN-4 1
NO ALT LEVEL 4 4 2
U
Starting switch : START YES CR-5 ALTERNATOR
SPEC : 10~12.5V ͽ 87a 10 CN-57
Check operation YES
Check voltage 86 30
85 STARTER MOTOR
between CR-5(30) 87 11
NO of start relay 86 M
M
and chassis 85 87 87a
30
Disconnection in Repair or replace ANTI-RESTART RY
Starting switch : START wiring harness or (After clean) START SWITCH B+
Starting switch :START
Check operation poor contact CN-45
of start safety between CR-5 FUSE START RY
NO relay

II I O H
C2 1 C1
1

I,O
(86) and CN-4(11) NO.1 C1
2 1
Starting switch : ON 3 4

H
2 2 C2

4 CR-23

ACC BR
1

B
Defective relay Replace 2
NO 5 3

6 CN-194

FUSE

NO.4

C ST
5 1 1 ry
6
CS-2 2
2 sol
YES 3
5 avb
Defective relay Replace CR-45
4
Check voltage 87a
5
4 rps
6 gnd
ͽ between CR-23 85
30 86 6

87 RACK ACTUATOR
and chassis
Disconnection in Repair or replace 86
CN-193
NO 30 87a 87 85

Starting switch : ON wiring harness or (After clean) ECU IG POWER 1

stpm d

poor contact 2 com

stpm b
between CR-5(87) CR-67 3
stpm c
1 4
6 3 1
-CR-23(2) 2
3
5 com
stpm a
6
4
EGR VALVE
6 24
RACK ACTUATOR
CR-68
1 ECM
6 3 1
2
3
4
6 2 4

ECU MAIN POWER

2
3 48 Main power 12V
6
8 7 IG power
10 8 Start signal
11 33 Rack AC relay(-)
14 34 Main power relay(-)
CN-2 CN-93

R557A5TS20

5-37
15. WHEN STARTING SWITCH ON DOES NOT OPERATE

ÂBefore disconnecting the connector, always turn the starting switch OFF. FUSIBLE LINK MASTER SW

ÂBefore carrying out below procedure, check all the related connectors are properly inserted and

CN-95

CN-60
master switch ON. CR-1

1
2

1
2
NO.14
FUSE
1
ÂAfter checking, insert the disconnected connectors again immediately unless otherwise specified.

NO.2

CS-74
2

CR-1 BATT RY

1
2
CN-3
Cause Remedy
1 BATTERY
YES
Disconnection in Repair or 2
wiring harness or replace
poor contact (After clean) 9

Check voltage between CN-5(9)- DO-1 RS-2

YES 1 2
between CR-1 CR-1(2) or CN-5 2 1

(2) and chassis defective battery

RESISTER
FUSE CN-74
Voltage : 10~12.5V relay CLUSTER CN-2 B+
G
NO.16 3
~
CN-4 1
U
ALT LEVEL 4 4 2
Check voltage NO
Disconnection in Replace CR-5 ALTERNATOR
YES
between CS-2 wiring harness or 86 30
87a
85
10 CN-57 STARTER MOTOR
(2) and chassis poor contact 87 11 M
85 87 87a
86
M
Voltage : 10~12.5V between CS-2(2)- 30

ANTI-RESTART RY
CN-5(9) START SWITCH B+
YES Check voltage CN-45
between CS-2(1)
START RY
and chassis FUSE

II I O H
Defective start Replace 1 C2 1 C1

I,O
NO NO.1 C1
Voltage : 10~12.5V switch 2 1
3 4

H
2 2 C2

4 CR-23

ACC BR
1

B
2
Check voltage Disconnection in Replace 3
NO 5
and specific wiring harness or 6 CN-194

FUSE

NO.4
gravity of battery

C ST
poor contact 5 1 1 ry
6
CS-2 2
2 sol
Specific gravity : MIN 1.28 between CS-2(1)- 3
5 avb
4
Voltage : MIN 12V CR-45
fuse No.1 87a 30 86
5
4 rps
6 gnd
6
85
87 RACK ACTUATOR
Battery capacity Charge or 86
30 87a 87 85
CN-193
NO ECU IG POWER stpm d
too low replace 1
com
2
stpm b
(After clean) CR-67
1
3
stpm c
6 3 1
4
2 5 com
3 stpm a
6
4
EGR VALVE
6 24
RACK ACTUATOR
CR-68
1 ECM
6 3 1
2
3
4
6 2 4

ECU MAIN POWER

2
3 48 Main power 12V
6
8 7 IG power
10 8 Start signal
11 33 Rack AC relay(-)
14 34 Main power relay(-)
CN-2 CN-93

R557A5TS20

5-38