Generic Golf (1268-5403) Install Sheet-370 Rev 01 05/25/18
Sheet 5 of 6
TROUBLESHOOTING CHART
LED
CODE
PROGRAMMER LCD
DISPLAY
EXPLANATION
POSSIBLE CAUSE
1,1
HW FAILSAFE
Self-test or watchdog fault
1.
Controller Defective
1,2
THROTTLE FAULT 1
Wiper Signal out of range (pot
low fault)
1.
Throttle input wire open
2.
Throttle input wire shorted to B+ or B-
3.
Throttle pot defective
1,3
SPEED SENSOR FAULT
No pulses from speed sensor
1.
Speed sensor not connected
2.
Speed sensor defective
3.
Speed sensor magnet damaged
1,4
HPD
High Pedal Disable fault
1.
Improper sequence of direction and throttle inputs
1,5
MOTOR STALL
Motor stall at current
1.
Slope too steep for vehicle weight
2.
Mechanically locked motor
3.
EM brake wiring fault
4.
Speed sensor defective
2,1
LOW BATTERY VOLTAGE
Low battery voltage
1.
Battery voltage < under voltage cutback threshold
2.
Corroded battery terminal
2,2
OVERVOLTAGE
Overvoltage
1.
Battery voltage > overvoltage shutdown threshold
2.
Vehicle operating with charger attached
3.
Battery disconnected during regen braking
2,3
THERMAL CUTBACK
Over/under temperature
cutback
1.
Temperature > 85 degrees C or < 25 degrees C
2.
Excessive load on vehicle
3.
Improper mounting of controller
4.
Operation in extreme environment
2,4
MAIN DRIVER ON
Main contactor coil held low
1.
Main contactor missing or wire to coil open
2.
Controller defective
2,5
AUX COIL FAULT
Missing aux (brake, walkaway
relay) coil
1.
Aux coil open or not connected
3,1
MAIN DRIVER OFF
Main contactor driver held high
1.
Main contactor coil shorted
2.
Controller defective
3,2
MAIN WELDED
Main contactor welded
1.
Main contactor stuck closed
2.
Main contactor driver shorted
3,3
PRECHARGE FAULT
Internal voltage too low at
startup
1.
External short or leakage path to B- on external B+
connection (lighting, DC-DC converter connected to
controller B+?)
2.
Controller defective
3,4
FIELD MISSING
Field winding fault
1.
Motor field wiring loose
2.
Motor field wiring open
3,5
AUX DRIVER OFF
Aux (brake, walkaway relay)
driver held high
1.
Aux coil shorted
2.
Controller defective
4,1
CURRENT SENSE FAULT
Armature or field current
sensor fault
1.
Controller defective
4,2
DRIVER OVERCURRENT
Contactor driver or aux driver
overcurrent
1.
Contactor or aux coil shorted
4,3
M- SHORTED
Internal M- short to B-
1.
Verify M- and B- cables are not swapped
2.
Controller defective
4,4
AUX RELAY DNC
Aux relay did not close
1.
Aux relay missing or wire to coil open
4,5
WELDED AUX RELAY
Welded aux relay
1.
Aux relay stuck closed
2.
Aux relay shorted
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