Troubleshooting Chart - Curtis 1268-5411 Manual

LED PROGRAMMER LCD
CODE DISPLAY
1,1 HW FAILSAFE
1,2 THROTTLE FAULT 1
1,3 SPEED SENSOR FAULT
1,4 HPD
1,5 MOTOR STALL
2,1 LOW BATTERY VOLTAGE
2,2 OVERVOLTAGE
2,3 THERMAL CUTBACK
2,4 MAIN DRIVER ON
2,5 AUX COIL FAULT
3,1 MAIN DRIVER OFF
3,2 MAIN WELDED
3,3 PRECHARGE FAULT
3,4 FIELD MISSING
3,5 AUX DRIVER OFF
4,1 CURRENT SENSE FAULT
4,2 DRIVER OVERCURRENT
4,3 M- SHORTED
4,4 AUX RELAY DNC
4,5 WELDED AUX RELAY

TROUBLESHOOTING CHART

EXPLANATION
Self-test or watchdog fault
Wiper Signal out of range (ITS
fault)
No pulses from speed sensor
High Pedal Disable fault
Motor stall at current
Low battery voltage
Overvoltage
Over/under temperature
cutback
Main contactor coil held low
Missing aux (brake, walkaway
relay) coil
Main contactor driver held high
Main contactor welded
Internal voltage too low at
startup
Field winding fault
Aux (brake, walkaway relay)
driver held high
Armature or field current
sensor fault
Contactor driver or aux driver
overcurrent
Internal M- short to B-
Aux relay did not close
Welded aux relay
Continued on next page ...
Generic Golf (1268-5411) Install Sheet-370 Rev 01 05/24/18
POSSIBLE CAUSE
1. Controller Defective
1. Throttle input wire open
2. Throttle input wire shorted to B+ or B-
3. ITS defective
1. Speed sensor not connected
2. Speed sensor defective
3. Speed sensor magnet damaged
1. Improper sequence of direction and throttle inputs
1. Slope too steep for vehicle weight
2. Mechanically locked motor
3. EM brake wiring fault
4. Speed sensor defective
1. Battery voltage < undervoltage cutback threshold
2. Corroded battery terminal
1. Battery voltage > overvoltage shutdown threshold
2. Vehicle operating with charger attached
3. Battery disconnected during regen braking
1. Temperature > 85 degrees C or < 25 degrees C
2. Excessive load on vehicle
3. Improper mounting of controller
4. Operation in extreme environment
1. Main contactor missing or wire to coil open
2. Controller defective
1. Aux coil open or not connected
1. Main contactor coil shorted
2. Controller defective
1. Main contactor stuck closed
2. Main contactor driver shorted
1. External short or leakage path to B- on external B+
connection (lighting, DC-DC converter connected to
controller B+?)
2. Controller defective
1. Motor field wiring loose
2. Motor field wiring open
1. Aux coil shorted
2. Controller defective
1. Controller defective
1. Contactor or aux coil shorted
1. Verify M- and B- cables are not swapped
2. Controller defective
1. Aux relay missing or wire to coil open
1. Aux relay stuck closed
2. Aux relay shorted
Sheet 5 of 6