2004 TXT PDS w/ 1206MX Controller Issue

[JohnnieB]

Originally Posted by nosugrefnaes

Question on troubleshooting pins 4 and 5. Without J1 harness attached, both should have battery pack voltage, right? If so, how might the 6.5V on pin 5 be explained?

Yes. Pins 4 & 5 ought to have full battery pack voltage on then whether or not J1 is plugged in. The are voltage sources for the controller.

I explained why pin-5 can be low in my post#4. here is a cut and paste:

6.5V at J1 Pin-5 is a problem. Pin-5 is connected to the solenoid's battery side large terminal and should have pack voltage on it 100% of the time the batteries are connected.

That same wire also feed the beeper and it splits inside the wiring harness. The split (wire tap) is called a "Sonic Weld" and the continuous wire runs to the beeper while the tap wire goes to Pin-5.

Trace the wire from Pin-5 into the wiring harness and find the wire tap and replace it with a solder joint or some other type quality connection.