96 Club Car DS - Beeps in forward?

tntsmallenginerepair

Hi, new to the forums here. I've done some searching on this and can't seem to find anyone with the same problem (lots that are pretty close, but not exact).

Our company recently purchased a 1996 electric Club Car DS. We've done some major overhauling to it, and in the process, the F/R Switch was broken (dry rotted). We left the wires intact and ordered a replacement. When an employee went to install it, he removed the wires one by one and put them on the new one in the same spots. Now..here comes the problem:

When shifted into Reverse, the golf cart acts normally. It has a continuous 'beep' for the reverse warning and it moves when the accelerator is depressed.
When shifted into Forward, however, the golf cart acts very strange. When the accelerator is depressed, the reverse 'beep' warning sounds and the cart doesn't move.

I've found the wiring diagram for a '96 on here and have double checked the wiring. Everything seems to be in order. I did notice the diagram does NOT have the A1, A2, S1, S2 clearly marked on the motor, so these connections could be incorrect.

Any info or help on this matter would be greatly appreciated. Thanks in advance!

BGW

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shadowman

did cart work ok before guys started working on it? if so its something somewhere that someone did.....you need to go over everything that was touched very slowley and carefully.....and most important give the job of preforming maintence and repairs to one person and one person only........you start having 2 or 3 different people messing with the cart and your asking for trouble, but for now double check and triple check what was done ...........it sounds like a cable or wire was put in the wrong spot..............................

tntsmallenginerepair

All of the work, except for the F/R switch install, has been done by one person so far (and I definitely agree on that one). We had to disconnect the motor cables to install the rear lift kit, but the wires were clearly marked and put back accordingly. The cart was tested afterwards and still ran properly. This problem didn't pop up (including the beeping) until the new F/R switch was installed. I've tried to locate the old switch to make sure it was the same as the new one, but apparently it was discarded. Does anyone have an up-close picture of an original '96 (or similar) F/R switch?

shadowman

can you post a pic of it in the cart as is............................

tntsmallenginerepair

I kept the images at their original size so that no detail was lost. I can also post them resized if needed.

http://www.tntlaporte.com/images/ccds/DSC00156.JPG
http://www.tntlaporte.com/images/ccds/DSC00157.JPG
http://www.tntlaporte.com/images/ccds/DSC00158.JPG
http://www.tntlaporte.com/images/ccds/DSC00159.JPG
http://www.tntlaporte.com/images/ccds/DSC00160.JPG

tntsmallenginerepair

Was wondering if anyone had anymore information on this?

shadowman

i wish i did, i looked at pics but nothing jumped out.....it sounds as if somehow it got miswired or something is going on with the controller..........sorta like its not coming out of reverse all the way........................

tntsmallenginerepair

How about this question, then? If I were to completely remove the motor from the golf cart and hook it up just to some batteries, how would the A1, A2, S1 & S2 posts need to be hooked up for the motor to spin forward and reverse properly?

gaminde

like this

gaminde

sorry that last one was 2 speed

Reverse f1 and f2 for direction