6-3-3 eled

6-24

GROUP 3 ELECTRICAL SYSTEM

1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR

·Before disconnecting the connector, always turn the starting switch OFF.·Before carrying out below procedure, check all the related connectors are properly inserted and

short of fuse No.7.·After checking, insert the disconnected connectors again immediately unless otherwise specified.

YESYES

NO

NO

Check voltagebetween CN-5(3)and chassis

Check voltagebetween CN-56(1) and chassis

CLUSTER

POWER IG(24V)

GND

RX

TX

2

CN-56

9

CN-5

1FUSE

NO.7

20 ~ 32VYES

Check voltage

NO 0V

3

Starting switch : ONVoltage : 20~32V

Cause Remedy

Defective clucter

Disconnection inwiring harness orpoor contactbetween CN-5(3)-CN-56(1)

Disconnection inwiring harness orpoor contactbetween CN-5(3)-and fuse No.7

Replace

Repair orreplace(After clean)

Repair orreplace(After clean)

210N76ES01

6-25

30

CLUSTER

POWER IG(24V)

GND

RX

TX

2

3

4

CN-56

9

10

11

CN-5

CN-50

*4V

*12V

CONTROLLER

29YES

NO

*4V

0V

*12V

0V

Check voltage

2. COMMUNICATION ERROR "Co : Er" FLASHES ON THE CLUSTER

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

Cause Remedy

Defective controller

Disconnection inwiring harness orpoor contactbetween CN-56(3,4) CN-5(10,11)

Disconnection inwiring harness orpoor contactbetween CN-5(10,11)-CN-50(29,30)

Replace

Repair or replace(After clean)


KEY ON

Check voltagebetween CN-5(10,11)andchassis

YES

YES

NO

NO

Check voltagebetween CN-56(3,4) and chassis

29076ES02

6-26

3. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)


Cause Remedy


Disconnection inwiring harness orpoor contactbetween CN-51(9)-CN3(3)

Disconnection inwiring harness orpoor contactbetween CN-3(3)-altern-atorterminal "I"

Defective alternator

Replace



Replace

YES

YES

YES

NO

NO

NO

CN-3

CONTROLLER

CN-51

ALTERNATOR

CN-74

GND

I

B+G

U

3 ~

20 ~ 32VYES

Check voltage

NO 0V

9 3

Voltage : 20~32VEngine : Running

Check voltagebetween alternatorterminal "I" andchassis



210N76ES02

6-27

4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)


Cause Remedy

Coolant overheat(110。C±2。C )

Defective tempsensor

Short circuit inwiring harness

Defective Controller

Check enginecooling system

Replace


Replace

33

CONTROLLER

CN-51

WATER TEMPERATURE SENDER

31 2

1 o

CD-8

C

CN-3

6

5

Starting switch : ONEngine : Start

Does display gooff whendisconnect CD-8?

Resistancebetween CN-51(31,33) is 0~1Ω?

YES

YES

YES

NO

NO

NO

Disconnect CN-51KEY OFF

Disconnect CD-8

Resistancebetween CD-8(1,2) is in rangeof 120~150Ω?

210N76ES03

6-28

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


Cause Remedy

Clogged air filter ordefective switch

Short circuit inwiring harness


Check filter orreplace switch


Replace

20

CN-50

AIR CLEANER SWITCH

CD-10

Pa

CONTROLLER



Check resistancebetween CN-51(16) and chassis

NO

YES

NO

YES

Starting switch : OFFDisconnect CN-51

YES

NO

MAX 1Ω

MIN 1MΩ

Check resistance

16

51

25036EL05

6-29

6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)


Cause Remedy

Engine oil leakage,or defective switch


Disconnection inwiring harness orpoor contactbetween CN-51(4)-CD-18

Check engine oillevel or replaceswitch

Replace


ENGINE OIL PRESSURE SWITCH

CD-18CN-2

1

CN-51

4 Pa

CONTROLLER

NO

YES

YES

NO


Does display go offwhen disconnectCD-18?

Check resistancebetween CN-51(4) and chassis


YES

NO

MAX 1Ω

MIN 1MΩ

Check resistance

29076ES03

6-30

7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)


Cause Remedy

High temperature

Defective torquesensor

Short circuit


Check hydraulicoil temperature(100。C±2。C ) ,ReplaceReplace

Check and repair

Replace

HYDRAULIC OIL TEMPERATURE SENDER

CD-1

C2

1

CN-51

34

CONTROLLER

31



Resistancebetween CN-51(31,34) is 0~1Ω?


Resistancebetween CD-1(1,2) is in rangeof 130~150Ω?

Starting switch : ONDisconnect CD-1

YES

YES

YES

NO

NO

NO

29076ES04

6-31

8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE


Cause Remedy

Disconnection inwiring harness orpoor contactbetween CN-51-CD-8


Defective tempsensor

Defective cluster


Replace

Replace

Replace

33

CONTROLLER

CN-51

WATER TEMPERATURE SENDER

31 2

1 o

CD-8

C

CN-3

6

5

YES

YES

YES

NO

NO

NO

Temperature White range(~29。C)

Green range(30~105。C)

Red range(105。C ~)

Check Table

Item

Unit Resistance(Ω)

Tolerance(%)

1646~

±20

1645~158

±20

~139

±20

Starting switch : ON

Does the gaugelight up anddown at lampcheck?

Is resistancebetween CN-51(31) and (33)over 2kΩ?


See Table

Check resistancebetween CN-3(5)and (6)

Green range Red range

White range

210N76ES03

6-32

9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)


FUEL SENDER

CD-2

24

CN-51

31

2

1

CONTROLLER

Level White range Green range Red range

Check Table

Item

Unit Resistance(Ω)

Tolerance(%)

700~601

±5

600~101

±5

~100

±5

Cause Remedy

Disconnection inwiring harness


Defective fuelsensor

Defective cluster

Check and repair

Replace

Replace

Replace

YES

YES


Does the gaugelight up anddown at lampcheck?

Is resistancebetween CN-51(24) and (31)over 1kΩ?


Disconnect CD-2See Table

Check resistancebetween CD-2(1)and (2)

YES

NO

NO

NO

Green range Red range

White range

29076ES06

6-33

10. WHEN SAFETY SOLENOID DOES NOT OPERATE



Cause Remedy

Hydraulicmalfunction

Defective solenoid

Disconnect inwiring harness orpoor contactbetween CN-4(8)-CS-4(C)

Disconnect inwiring harness orpoor contactbetween CN-4(8)-CN-68(1)

Disconnection infuse

Defective switch(CS-20)

Defective switch(CS-4)

Check hydraulicsystem

Replace



Replace

Repair or replace

Repair or replace

Check voltagebetween CN-68(1) - CN-68(2)

YES

YES

YES

YES

NO

NO

NO

NO

NO

Safety lever : OFFStarting switch : ONVoltage : 20~30V

NO

Check operationof solenoid

Safety lever : ON-OFF

Starting switch : ONVoltage : 20~30VDisconnect CN-4

Starting switch : ONVoltage : 20~30VDisconnect CN-4


Starting switch : ONVoltage : 20~30VSafety state

Check voltagebetween CN-68(2) with chassis

Check voltagebetween CS-4(C) and chassis

Check voltagebetween CS-20and chassis


YES

YES

21076ES54

6-34

11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE


short of fuse No.22 .·After checking, insert the disconnected connectors again immediately unless otherwise specified.

TRAVEL SOLENOID

CN-70

1

2

FUSE

NO.22

13

CN-50

CONTROLLER

YES

NOCheck if travelspeed lamps( ,

) change whenpressing the travelspeed switch onthe cluster

Check controller

Cause Remedy

Defective hydraulicsystem


Defective solenoid

Defective cluster


Check hydraulicsystem

Replace

Replace

Replace

Replace

Check operationof solenoid

Check resistancebetween CN-70(1) and (2)


Starting switch : ONVolage : 20~30VDisconnect CN-50

Starting switch : ON: OFF: ON

Starting switch : OFFSPEC : 15~25ΩDisconnect CN-70



YES

RY G

YES

YES

YES

NO

NO

NO

21076ES04

6 -35

12. WHEN ENGINE DOES NOT START

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

Cause Remedy

Defective battery

Defective magnetof start motor

Defective start relay

,

Disconnection inwiring harness orpoor contactbetween CR-5(86) and CN-8(9)

Defective relay

Defective fuel cutoff solenoid

Disconnection in wiring harness orpoor contactbetween CN-2(4)-CN-79(2)

Defective relay

Disconnection in wiring harness orpoor contactbetween CR-5(30)-CR-23

Defective fuel cut-off solenoid

Disconnection in wiring harness orpoor contactbetween CN-2(5)and Fuse No.12

Check enginesystem charge orreplace(Afterchecking specificgravity of battery)

Replace

Replace


Replace

Replace


Replace


Replace


NO

YES

YES

NOStarting switch : START

Starting switch : START

Check operationof start motor

Starting switch : STARTSPEC : 20~30V

Starting switch :START

YES


YES

NO

Voltage : 20~30VStarting switch : ON

Voltage : 20~30VStarting switch : START

NO


NO

Check voltagebetween startermagnet coil andchassis

Check voltagebetween CR-5(30) and chassis

YES

Check voltagebetween CR-5(87) and chassis

YES


YES


Check operationof start safetyrelay

Check operationof start relayNO

NO

YES

Voltage : 20~30VStarting switch : ON

Check voltagebetween CR-23and chassis

NO

YES

NO

21076ES14A

6-36

13. WHEN STARTING SWITCH “ON” ELECTRIC PART DOES NOT OPERATE


master switch ON·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Cause Remedy

Disconnection inwiring harness orpoor contactbetween DO-2(1)-CR-1 or defectivebattery relay

Disconnection inwiring harness orpoor contactbetween CS-2(2)-CN-8(11)- DO-2(1)

Defective start keyswitch

Disconnection inwiring harness orpoor contactbetween CS-2(1)-CN-8(12)-CS-61,CN-60-CR-1BatteryBattery capacity toolow


Replace

Replace

Replace

Charge or replace(After clean)

Specific gravity : MIN 1.28Voltage : MIN 24V

Check voltageand specificgravity of battery

Voltage : 20~30V

Voltage : 20~30V

Voltage : 20~30V

Check voltagebetween DO-2(1) and chassis

Check voltagebetween CS-2(2) and chassis

Check voltagebetween CS-2(1)and chassis

YES

YES

YES

YES

NO

NO

NO

NO

21076ES14A

6-37

14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE

·Before disconnecting the connector, always turn the starting switch OFF.·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse

No.4,11 and 13 is not blown out.·After checking, insert the disconnected connectors again immediately unless otherwise specified.

Defective wipercut switch

Disconnection inwiring harness orpoor contactbetween CN-141(11)- CS-53

Defective switchpanel

1)Recheck fuseNO.11

2)Disconnection inwiring harness orpoor contactbetween CN-116(6)-Fusebetween CN-116(13)-Chassis

Defective switchpanel

1) Recheck fuseNO.4

2) Disconnectionin wiring harnessor poor contactbetween CN-141(7)-Fuse,CN-21(4)-Fuse

1) Recheck fuseNO.13

2) DisconnectionCN-141(6)-Fuse

Disconnection inwiring harness orpoor contact

Defective wipermotor

Defective wipermotor controller

Replace


Replace

Replace


Replace

Replace


Replace



Replace

Replace

Cause Remedy


Check valtagebetween CN-141(11) and chassis

Check operationwiper cut switch

Check operationof switch panelLED ON.

Check voltageCN-141(6)-andchassis

Check operationof wiper motorand controllercheck voltageCN-141(7) andchassis, CN-21(4)and chassis

Check voltage betweenCN-116(4) and chassis

Check voltage CN-116(12) and chassis

Check voltage CN-116(15) and chassis

Check wipermotor resistancebetween CN-21(2)-CN-21(6)

Check continuitybetween CN-141(2)-CN-116(4),CN-141(9)-CN-116(12),CN-141(10)-CN-116(15),CN-141(5)-Chassis , CN-141(1)-CN-21(5),CN-141(3)-CN-21(6),CN-141(4)-CN-21(2),CN-141(13)-CN-21(3)

Intermittent

Starting switch : OFFVoltage : 20~30V

Resistance : 3~4Ω


Washing

Sarting switch : ONVoltage : 0~1V

YES

YES

NO

NO

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

Front sliding dooropen-close

Front sliding door-closeVoltage : 0~1V

Starting switch : ONPush wiper switch button

Starting switch : ONVottage : 20~30V

NO

21076ES15A

6-38

15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP



HEAD LAMP

1

7

CL-4

1

2

CN-7

10

321

4567891011121314151617

SWITCH PANEL

CN-116HEAD LIGHT OUT

WORK LIGHT OUT

WORK LIGHT OUT

WIPER MOTOR DRIVE

PRE-HEAT

POWER 24V

CABIN LIGHT OUT

CABIN LIGHT OUT

HEAD LIHGT 24V

WORK LIGHT 24V

WORK LIGHT 24V

WASHER SIG

GND

TRAVEL ALARM

INT. SIG

CABIN LIGHT 24V

CABIN LIGHT 24V

FUSE

NO.14

Cause Remedy

Defective lampswitch

Defective bulb

Disconnection inwiring harness orpoor contactbetween CN-7(1)-CL-4(2)



Recheck fuseNo.14

Replace switch

Replace




Replace


Head lamp switch : ON

YES

YES

Starting switch : ONHead lamp switch :ON-OFF

Starting switch : ONHead lamp switch : ONVoltage : 20~30V



Check voltagebetween CL-4(2)and chassis




NO

YES

NO

YES

YES

NO

NO

NO

29076ES12

6-39

WORK LAMP

2

8

CL-6

1

2

CN-7

10

321

4567891011121314151617

SWITCH PANEL

CN-116HEAD LIGHT OUT

WORK LIGHT OUT

WORK LIGHT OUT

WIPER MOTOR DRIVE

PRE-HEAT

POWER 24V

CABIN LIGHT OUT

CABIN LIGHT OUT

HEAD LIHGT 24V

WORK LIGHT 24V

WORK LIGHT 24V

WASHER SIG

GND

TRAVEL ALARM

INT. SIG

CABIN LIGHT 24V

CABIN LIGHT 24V

FUSE

NO.15

WORK LAMP

CL-5

1

2

1

CN-12

2

16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP



Cause Remedy

Defective lampswitch

Defective bulb

Disconnection inwiring harness orpoor contactbetween CN-7(2)-CL-5(2) andCL-6 (2)

Disconnection inwiring harness orpoor contactbetween CN-116(2,3)-CN-7(2)

Disconnection inwiring harness orpoor contactbetween CN-116(10,11)-CN-7(8)

Recheck fuseNo.15

Replace switch

Replace




Replace

Check voltagebetween CN-116(10,11) andchassis

Head lamp switch : ONVoltage : 20~30V

YES

NO

Starting switch : ONWork lamp switch :

ON-OFFVoltage : 20~30V

Starting switch : ONWork lamp switch : ONVoltage : 20~30V



Check voltagebetween CL-5(2)and chassis



Check voltagebetween CN-116(10,11) and chassis

NO

YES

YES

YES

YES

NO

NO

NO

29076ES13

Documents

6-3-3 eled