99 36v Series TXT Reverse buzzer

[ridepate]

For some strange reason our TXT reverse indicator is sounding off in forward? Not as loud as reverse, but still, making noise in forward it also seems to be down a little on power up-hill. Pack-voltage is fine ,all cells check great. The boys did ride it in the rain last night,smh, now the problem. Nothing got really wet but I blew everything dry with air but no change.

[scottyb]

Check the micro switch on the passenger side of the F&R

[ridepate]

I think maybe the throttle-micro got wet. It sounds faintly when pushing the pedal in forward. Not at rest in forward.

[ridepate]

Checked the reverse-micro. Cycles and functions correctly.

[ridepate]

Throttle Micro dry as a bone...Not sure where to go from here.

[JohnnieB]

Check for voltage on the red wire going to beeper when there shouldn't be any voltage.

It's a piezoelectric beeper, so it doesn't take much voltage for it to make sound and it doesn't draw much current, so just a bit of conductive dirt could cause it to beep softly.

Since it doesn't beep at rest in forward, but beeps when pedal is pushed, check for cross-talk between pins 3 & 4 on top of controller.

[ridepate]

Originally Posted by JohnnieB

Check for voltage on the red wire going to beeper when there shouldn't be any voltage.

It's a piezoelectric beeper, so it doesn't take much voltage for it to make sound and it doesn't draw much current, so just a bit of conductive dirt could cause it to beep softly.

Since it doesn't beep at rest in forward, but beeps when pedal is pushed, check for cross-talk between pins 3 & 4 on top of controller.

Johnny,
I am getting about 7v on pin #3 when the pedal is pushed. Checked the plug and the obvious. What next? Tried another beeper just to be sure,same result. Zero voltage at rest.

[JohnnieB]

Sounds like a ghost circuit is feeding voltage to the beeper, or a bad controller is back-feeding voltage via Pin-3.

Disconnect the 6-pin connector on top of the controller and see if the beeper still sounds softly in Forward when pedal is pushed.

If it does, the problem is in the wiring someplace.
If it doesn't, the problem may be the controller.

If it is the controller, start looking for a replacement. It might last a long time , or it might fail completely the next time you use the cart.

Disconnecting the orange wire at MS-4 (Reverse microswitch) will probably keep the beeper from sounding when it shouldn't be, but the controller won't go into half-speed when in Reverse.

[ridepate]

O.K. Have sorta affirmed my suspicions. Nothing but moisture-related. (I Hope) Told the kid to go out and flog it today and put some heat in the system. It must have dried-out whatever was damp. Buzzer in forward gone, no more voltage at #3, performance came back. After adding 2Ga. cables I left the controller cover off. Guess I need to hack it up some and make it work for some wetness protection vs. none.....Thanks guys for the responses!!!

[JohnnieB]

Great news. If the voltage at Pin-3 went away, it's source was most likely external to the controller.

Disconnect and spray clean the 6-pin connector on top of the controller and the 4-pin in-line connector between controller and pedal box and reconnect using dielectric grease.