6-3-3 Eled

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.
Cause
YES Check voltage
YES
Defective clucter
between CN-56
(1) and chassis
Remedy
Replace
Disconnection in Repair or
wiring harness or replace
poor contact
(After clean)
between CN-5(3)CN-56(1)
NO
Check voltage
between CN-5(3)
and chassis
Starting switch : ON
Voltage : 20~32V
Disconnection in Repair or
wiring harness or replace
poor contact
(After clean)
between CN-5(3)and fuse No.7
NO
Check voltage
YES
20 ~ 32V
NO
0V
CLUSTER
FUSE
POWER IG(24V)
GND
NO.7
RX
TX
CN-56
CN-5
210N76ES01
6-24
2. COMMUNICATION ERROR "Co : Er" FLASHES ON THE CLUSTER

Before carrying out below procedure, check all the related connectors are properly inserted.
Cause
Remedy
YES
Defective controller Replace
YES Check voltage
between CN-56
(3,4) and chassis
Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CN-56
(3,4) CN-5(10,11)
NO
Check voltage
between CN-5
(10,11)and
chassis
KEY ON

poor contact
between CN-5
(10,11)-CN-50
(29,30)
NO
CONTROLLER
Check voltage
YES
*4V
*12V
NO
0V
0V
29
30
CN-50
CLUSTER
POWER IG(24V)
GND
RX
*12V
TX
*4V
10
11
CN-56
CN-5
29076ES02
6-25
3.
BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)
Cause
YES
YES Check voltage
between CN-51
(9) and chassis
NO
Check voltage
YES between CN-3
(3) and chassis
Check voltage
between alternator
terminal "I" and
chassis
Remedy

Disconnection in
Repair or replace
poor contact
between CN-51(9)
-CN3(3)
Disconnection in
Repair or replace
poor contact
between
CN-3(3)-altern-ator
terminal "I"
NO
Voltage : 20~32V
Engine : Running
Defective alternator Replace
NO
Check voltage
YES
20 ~ 32V
NO
0V
CONTROLLER
ALTERNATOR
B+
3~
I
GND
CN-51
CN-74
CN-3
210N76ES02
6-26
4.
WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)
Cause
YES
Resistance
YES between CD-8
(1,2) is in range
of 120~150?
Does display go
off when
disconnect CD-8?
Disconnect CD-8
NO
YES
Engine : Start
Resistance
between CN-51
NO
(31,33) is 0~1?
Disconnect CN-51
KEY OFF
Remedy
Coolant overheat
(110C 2C )
Check engine
cooling system
Defective temp
sensor
Replace
Short circuit in
wiring harness
Repair or replace
(After clean)
Defective Controller Replace
NO
CONTROLLER
WATER TEMPERATURE SENDER
33
31
CD-8
CN-51
CN-3
210N76ES03
6-27
5.
WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)
Cause
YES
Clogged air filter or Check filter or

defective switch
replace switch
Does display go
off when
disconnect CD10?
Engine : Start
Remedy
YES
Short circuit in
wiring harness
Check resistance
between CN-51
NO
(16) and chassis
Starting switch : OFF
Disconnect CN-51
Repair or replace
(After clean)
NO
Check resistance
YES
MAX 1
NO
MIN 1M
AIR CLEANER SWITCH
CONTROLLER
Pa
16
20
CD-10
CN-50
51
25036EL05
6-28
6.
WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)
Cause
YES
Engine oil leakage, Check engine oil

or defective switch level or replace
switch
Does display go off

when disconnect
CD-18?
Engine : Start
Remedy
YES
Check resistance
between CN-51
NO
(4) and chassis
Disconnect CN-51
Disconnection in
wiring harness or
poor contact
between
CN-51(4)-CD-18
NO
Repair or replace
(After clean)
Check resistance
YES
MAX 1
NO
MIN 1M
CONTROLLER
ENGINE OIL PRESSURE SWITCH
CN-51
Pa
CD-18
CN-2
29076ES03
6-29
7.
WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)
Cause
YES
High temperature
Resistance
YES between CD-1
(1,2) is in range
of 130~150?
Does display go
off when
disconnect CD-1?
Engine : Start
Disconnect CD-1
Defective torque
sensor
NO
YES
Short circuit
Remedy
Check hydraulic
oil temperature
(100C 2C ) ,
Replace
Replace
Check and repair
Resistance
between CN-51
NO (31,34) is 0~1?
Disconnect CN-51
NO
HYDRAULIC OIL
TEMPERATURE SENDER
CONTROLLER
34
C
31
CD-1
CN-51
29076ES04
6-30
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE

Cause
YES
Disconnection in
wiring harness or
poor contact
between
CN-51-CD-8
Is resistance
YES between CN-51
(31) and (33)

over 2k?
YES

Disconnect CN-50
Does the gauge

light up and
down at lamp
check?
NO
See Table
Repair or replace
(After clean)
Check resistance
between CN-3(5)
NO
and (6)
Remedy
NO
Defective temp
sensor
Replace
Defective cluster
Replace
Check Table
Temperature
Green range Red range
White range
(~29
C)
Green range
(30~105
C)
Red range
(105
C ~)
Unit Resistance()
1646~
1645~158
~139
Tolerance(%)
20
20
20
Item
White range
CONTROLLER
WATER TEMPERATURE SENDER
33
31
CD-8
CN-51
CN-3
210N76ES03
6-31
9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)

Cause
YES
Remedy
Disconnection in
wiring harness
Check and repair
Is resistance
YES between CN-51
(24) and (31)

over 1k?
Does the gauge
light up and
down at lamp
check?
YES

Disconnect CN-51
Check resistance
between CD-2(1)
NO and (2)
NO
Disconnect CD-2
See Table
NO
Defective fuel
sensor
Replace
Defective cluster
Replace
Check Table
Green range Red range
Level
White range
Green range
Red range
Unit Resistance()
700~601
600~101
~100
Tolerance(%)
Item
White range
CONTROLLER
FUEL SENDER
1
24
CD-2
31
CN-51
29076ES06
6-32
10. WHEN SAFETY SOLENOID DOES NOT OPERATE

short of fuse No.24.
Cause
Remedy
YES
Hydraulic
malfunction
YES Check operation
Check hydraulic
system
of solenoid
Defective solenoid Replace
Safety lever : ON-OFF
NO
YES
YES Check voltage

between CS-4
(C) and chassis
Check voltage
between CN-68
(1) - CN-68(2)
Check voltage
YES between CN-4(8)
and chassis
Voltage : 20~30V
Safety state
Check voltage
between CN-68
NO (2) with chassis
Voltage : 20~30V
Disconnect CN-4
NO
Voltage : 20~30V
Disconnect CN-4
Disconnect in
wiring harness or
poor contact
between
CN-4(8)-CS-4(C)
Repair or replace
(After clean)
Repair or replace
Disconnect in
poor contact
between
CN-4(8)-CN-68(1)
NO
Safety lever : OFF

Voltage : 20~30V
NO
Disconnection in
fuse
Replace
Defective switch
(CS-20)
Repair or replace
Defective switch
(CS-4)
Repair or replace
YES
Check voltage
between CS-20
and chassis
Voltage : 20~30V
NO
21076ES54
6-33
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE

short of fuse No.22 .
Cause
YES
YES Check voltage
between CN-50
(13) and chassis
Check if travel
speed lamps(
,
) change when
pressing the travel
speed switch on
the cluster
Volage : 20~30V
Disconnect CN-50
Defective hydraulic Check hydraulic

system
system
YES Check operation

YES
of solenoid
: OFF
: ON
YES
NO
Defective solenoid Replace
Defective cluster
Check controller
NO
Check resistance
between CN-70
NO
(1) and (2)
SPEC : 15~25
Disconnect CN-70
Remedy
Replace
NO
FUSE
NO.22
TRAVEL SOLENOID
CONTROLLER
13
CN-70
CN-50
21076ES04
6-34
12. WHEN ENGINE DOES NOT START

Check supply of the power at engine stop solenoid while starting switch is ON.
Cause
YES
Check operation
of start motor
Defective battery
YES
Check voltage
YES between starter
magnet coil and
chassis
Starting switch : START

SPEC : 20~30V
Check operation
NO of start relay
Defective start relay Replace

YES
Check voltage
between CR-5
(30) and chassis
NO
Starting switch :START
Check operation
of start safety
NO relay
Check voltage
between CRNO 5(87) and chassis
Check engine
system charge or
replace(After
checking specific
gravity of battery)
Defective magnet Replace

of start motor
NO
YES
Remedy
,
Disconnection in
wiring harness or
poor contact
between CR-5
(86) and CN-8(9)
Repair or replace
(After clean)
Defective relay
Replace
YES
NO
YES
Check voltage
between CN-79
(2) and chassis
NO
Voltage : 20~30V
YES
Check voltage
between CR-23
and chassis
Disconnection in
wiring harness or
poor contact
between CN-2(4)CN-79(2)
Repair or replace
(After clean)
Defective relay
Replace
Repair or replace
poor contact
between CR-5(30)CR-23
YES
Check voltage
between CN-79
(1) and chassis
NO
Voltage : 20~30V
Replace
NO Disconnection in
Voltage : 20~30V
Defective fuel cut

off solenoid
Defective fuel cutoff solenoid
Replace
Disconnection in
wiring harness or
poor contact
between CN-2(5)
and Fuse No.12
Repair or replace
(After clean)
21076ES14A
6 - 35
13. WHEN STARTING SWITCH ON ELECTRIC PART DOES NOT OPERATE

master switch ON
Cause
YES
YES Check voltage
between DO-2
(1) and chassis
Voltage : 20~30V
YES Check voltage
NO
between CS-2
(2) and chassis
YES
Check voltage
between CS-2(1)
and chassis
Voltage : 20~30V
Voltage : 20~30V
Check voltage
and specific
gravity of battery
NO
NO
Specific gravity : MIN 1.28

Voltage : MIN 24V
NO
Remedy
Repair or replace
Disconnection in
poor contact
between DO-2(1)CR-1 or defective
battery relay
Replace
Disconnection in
wiring harness or
poor contact
between CS-2(2)CN-8(11)- DO-2(1)
Defective start key Replace
switch
Replace
Disconnection in
wiring harness or
poor contact
between CS-2(1)CN-8(12)-CS-61,
CN-60-CR-1
Battery
Battery capacity too Charge or replace
low
(After clean)
21076ES14A
6-36
14. 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.4,11 and 13 is not blown out.
Cause
NO
Defective wiper
cut switch
YES
Check valtage
between CN-141
YES (11) and chassis
YES
NO Check voltage
between CN-116
(6) and chassis
Front sliding door-close

Voltage : 0~1V
Check operation
of switch panel
NO
LED ON.
Vottage : 20~30V
Push wiper switch button YES
Check voltage between

CN-116(4) and chassis
Check voltage CN-116

(15) and chassis
Sarting switch : ON
Voltage : 0~1V
NO
Check operation
of wiper motor
and controller
check voltage
YES CN-141(7) and
chassis, CN-21(4)
and chassis
Voltage : 20~30V
Check continuity
NO
between
CN-141(2)-CN-116(4),
CN-141(9)-CN-116(12),
CN-141(10)-CN-116(15),
CN-141(5)-Chassis ,
Check wiper
CN-141(1)-CN-21(5),
motor resistance
CN-141(3)-CN-21(6),
YES between CN-21
CN-141(4)-CN-21(2),
(2)-CN-21(6)
CN-141(13)-CN-21(3)
Resistance : 3~4
Defective switch
panel
Replace
1) Recheck fuse Replace

NO.4
2) Disconnection Repair or replace
in wiring harness (After clean)
or poor contact
between CN141(7)-Fuse,
CN-21(4)-Fuse
NO
Check voltage
CN-141(6)-and
YES chassis
Voltage : 20~30V
Replace
1)Recheck fuse Replace

NO.11
2)Disconnection in Repair or replace
poor contact
between CN116(6)-Fuse
between CN116(13)-Chassis
Defective switch
panel
Check voltage CN-116

(12) and chassis
Washing
NO
NO
Intermittent
Replace

poor contact
between CN-141
(11)- CS-53
Check operation
wiper cut switch
Front sliding door
open-close
Remedy
YES
1) Recheck fuse Replace

NO.13
2) Disconnection Repair or replace
CN-141(6)-Fuse (After clean)

poor contact
NO
YES
Defective wiper
motor
Replace
Defective wiper
motor controller
Replace
21076ES15A
6-37
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
Cause
NO
Defective lamp
switch
Remedy
HEAD LAMP
Replace switch
1
2
CL-4
YES
Check voltage
between CN-116
(1) and chassis
YES
YES
Head lamp switch : ON
Voltage : 20~30V
Check voltage
between CN-7(1)
YES and chassis
Voltage : 20~30V
Voltage : 20~30V
Check voltage
between CN-116
(9) and chassis
NO
Head lamp switch :
ON-OFF
YES
Check voltage
between CNNO 7(7) and chassis
Defective bulb
Replace
Check voltage
between CL-4(2)
and chassis
CN-7
NO
Repair or replace
Disconnection in
poor contact
between CN-7(1)CL-4(2)
Disconnection in
wiring harness or
poor contact
between
CN-116(1)-CN7(1)
Repair or replace
(After clean)
10
CN-116
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
HEAD 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
SWITCH PANEL
Disconnection in
wiring harness or
poor contact
between CN-116
(9)-CN-7(7)
Repair or replace
(After clean)
Recheck fuse
No.14
Replace
FUSE
NO.14
NO
29076ES12
6-38
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Cause
NO
Defective lamp
switch
Remedy
WORK LAMP
Replace switch
1
2
CL-5
CN-12
Check voltage
YES
between CN-116
(10,11) and chassis
YES
Defective bulb
Check voltage
between CL-5(2)
and chassis
YES
Work lamp switch : ON
Voltage : 20~30V
Check voltage
between CN-7(2)
YES and chassis
NO
Voltage : 20~30V
Voltage : 20~30V
Check voltage
between CN-116
(10,11) and
chassis
NO
Work lamp switch :
ON-OFF
Voltage : 20~30V
Replace
CL-6
Repair or replace
Disconnection in
poor contact
between CN-7(2)
-CL-5(2) and
CL-6 (2)
CN-7
2
Repair or replace
Disconnection in
poor contact
between CN-116
(2,3)-CN-7(2)
10
YES
Disconnection in
Repair or replace
poor contact
between CN-116
(10,11)-CN-7(8)
Check voltage
between CN-7(8)
NO and chassis
WORK LAMP
CN-116
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
HEAD 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
SWITCH PANEL
FUSE

Voltage : 20~30V
NO
Recheck fuse
No.15
Replace
NO.15
29076ES13
6-39

6-3-3 Eled

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6-3-3 Eled

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GROUP 3 ELECTRICAL SYSTEM

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

Defective controller Replace

YES Check voltage

Disconnection in Repair or replace

Disconnection in Repair or replace

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

Defective controller Replace

Defective alternator Replace

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

Defective Controller Replace

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

Clogged air filter or Check filter or

Defective controller Replace

AIR CLEANER SWITCH

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

Engine oil leakage, Check engine oil

Does display go off

Defective controller Replace

ENGINE OIL PRESSURE SWITCH

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

Check and repair

Defective controller Replace

8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE

YES between CN-51

(31) and (33)

Starting switch : OFF

Does the gauge

Defective controller Replace

Green range Red range

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

Check and repair

(24) and (31)

Starting switch : OFF

Defective controller Replace

Green range Red range

10. WHEN SAFETY SOLENOID DOES NOT OPERATE

YES Check operation

YES Check voltage

Safety lever : OFF

11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE

Defective hydraulic Check hydraulic

YES Check operation

Defective solenoid Replace

Defective controller Replace

Defective controller Replace

12. WHEN ENGINE DOES NOT START

Starting switch : START

Starting switch : START

Defective start relay Replace

Starting switch : START

Starting switch :START

Defective magnet Replace

Defective fuel cut

Defective fuel cutoff solenoid

13. WHEN STARTING SWITCH ON ELECTRIC PART DOES NOT OPERATE

YES Check voltage

YES Check voltage

Specific gravity : MIN 1.28

Front sliding door-close

Check voltage between

Check voltage CN-116

1) Recheck fuse Replace