Troubleshooting
MERGE 10-8
Chapter 10
Check Procedure 7B—Pin 4 and 5
Please refer to Chapter 1 “Protection for Electrical Safety”.
Pin 4 and 5 of the 9-wire connector are designed to connect Forward/Reverse switch and the controller.
When Forward/Reverse switch is on FORWARD position, the switch sends a +48V signal to the
controller through Pin 4; when Forward/Reverse switch is on REVERSE position, the switch sends a
+48V signal to the controller through Pin 5.
1. Use a multimeter set at 200V DC, insert the red (+) probe of the multimeter into Pin 4 (black/yellow
wire).Refer to the following Note. Connect the black (-) probe to the negative binding post of the
battery pack.
Δ Note:
• Never insert the complete probe into the 9-wire plug for fear of poor contact.
2. When Tow /Run switch is turned on RUN and Forward/Reverse switch is on NEUTRAL, the
multimeter should display a 0V DC voltage.
3. While observing the multimeter, turn the Forward/Reverse switch to REVERSE. The multimeter
should display a voltage of +48V.
4. Turn Forward/Reverse switch to FORWARD, the multimeter should display a full battery voltage
(about 48V).
5. Insert the red (+) probe of the multimeter into Pin 5 (blue/black wire) of the 9-wire connector. Leave
the black (-) probe connected to the negative binding post of the battery pack. Refer to the above
Note.
6. Turn the Forward/Reverse switch to NEUTRAL. Now, the multimeter should display a 0V DC
voltage.
7. While observing the multimeter, turn Forward/Reverse switch to FORWARD, the multimeter should
display a voltage of +48V.
8. Turn Forward/Reverse switch to REVERSE, the multimeter should display a full battery voltage
(about 48V).
9. If another reading is displayed, the following items must be checked:
• Continuity of wires in harness;
• Whether Forward/Reverse switch operates normally. Refer to “Check Procedure
10—Forward/Reverse gear switch”.
• Check whether Tow/Run switch operates normally. Refer to “Check Procedure 4 - TOW/RUN
switch”.
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