Generic Golf (1268-5403) Install Sheet-370 Rev 01 05/25/18
Sheet 3 of 6
Generic Golf (1268-5403) Troubleshooting Sequence
FOR SAFETY, ALWAYS LIFT THE DRIVE WHEELS OFF THE GROUND WHEN TROUBLESHOOTING!
THE FOLLOWING TESTS ARE CONDUCTED WITH RUN-TOW/MAINTENANCE SWITCH IN THE RUN POSITION AND
WITH A GOOD BATTERY PACK VOLTAGE MEASUREMENT. ALSO, THE CONNECTOR MUST BE ATTACHED TO THE
CONTROLLER WHEN MAKING THESE CHECKS. YOU WILL NEED TO ‘BACK PROBE’ THE PINS FROM THE WIRE SIDE
OF THE CONNECTOR. USE A PAPERCLIP IF NECESSARY.
Attach voltmeter negative (-) lead to main Battery Negative (-) for the following tests.
Use the following sequence when checking individual pins (don’t skip steps). If you find a fault, do not move on
to the next step until the fault is corrected:
Measure the voltage at the main battery positive post (let’s call it Pack Voltage)
Pin J1-4 Must be Pack Voltage
-
If not Pack Voltage, check wiring, Run/Tow switch and fuse for an open condition
Pin J1-2 With Charger Disconnected, must be Pack Voltage
-
If not Pack Voltage, check wiring and charger interlock switch for an open condition
Pin J1-1 With Key Switch Off, must be equal to 0 volts
-
If not 0 volts, check wiring, and Key Switch for a shorted condition
Pin J1-1 With Key Switch On, must be Pack Voltage
-
If not Pack Voltage, check wiring and Key Switch for an open condition
Pin J1-17 Must be Pack Voltage
-
If not Pack Voltage, check wiring and solenoid coil (small terminals) for an open condition
Pin J1-10 With F/R Switch in Reverse, must equal 0 volts
-
If not 0 volts, check wiring and F/R Switch for a shorted condition
Pin J1-10 With F/R Switch in Forward, must equal Pack Voltage
-
If not Pack Voltage, check wiring and F/R Switch for an open condition
Pin J1-11 With F/R Switch in Forward, must equal 0 volts
-
If not 0 volts, check wiring and F/R Switch for a shorted condition
Pin J1-11 With F/R Switch in Reverse must equal Pack Voltage
-
If not Pack Voltage, check wiring and F/R Switch for an open condition
Pin J1-8 With Pedal Up, must equal 0 volts
-
If not 0 volts, check wiring and Pedal Switch for a shorted condition
Pin J1-8 With Pedal Down, must equal Pack Voltage
-
If not Pack Voltage, check wiring and Pedal Switch for an open condition
Pin J1-19 With F/R Switch in Neutral, must equal approximately Pack Voltage
-
If not approximately Pack Voltage, check wiring and Reverse Alarm for an open condition
Pin J1-19 With F/R Switch in Reverse, must equal less than approximately 1 volt (and backup alarm beeps)
-
If correct voltage, but no sound from reverse alarm, replace beeper
Pin J1-13 (If no wire in this position then skip step, otherwise) must equal approximately 5 volts
-
If not approximately 5 volts, check connector and wire terminal for being burnt/corroded. If
terminal is clean, controller may be defective
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