Help with TAPS headache

[wakesurfid]

I have a 2003 Tige 24V and the Lenco Taps2. The Tige dealership is having trouble figuring why the the actuator will not move. The actuator works if connected to direct power, but won't work otherwise. The dealership replaced the control module, the relay, the switch in the throttle, but still no go. Any ideas to help figure things out?

[talltigeguy]

Someone smarter than me will chime in...But I think that there is a propensity to wear the wires out farther in the throttle. And that is about the only thing you haven't checked out. But IIRC the wire bends every time the throttle is moved, so after a few thousand times, and years of weather and water, it finally breaks.

[Stingreye]

Someone smarter than me will chime in...But I think that there is a propensity to wear the wires out farther in the throttle. And that is about the only thing you haven't checked out. But IIRC the wire bends every time the throttle is moved, so after a few thousand times, and years of weather and water, it finally breaks.

X2, I was warned specifically about this by Topaz Surfer.

[JLG]

I agree with above. Have they checked for power at the switch on the throttle as that would be the first area to look as the are notorious for rubbing and grounding out against the inside of the handle. Wires are very tiny and a little strand off one of them will cause this. I'd pull the throttle handle apart to make sure it's not the problem. My 01 20i did it and It took me forever to find issue as I though it was relay also until I tore into the handle and saw the frayed wires.

[wakesurfid]

The dealer already replaced the wiring in the throttle handle, they also replaced the control box and harness. Power checks out at each of those locations too, Lenco is now saying try replacing the actuator, but that meets no sense since the actuator works when powering it directly. What next????

[dom w. forte]

Does the actuator make any noise of running at all when switch is moved in either direction , if no it is a simple system to check , first would check for power at switch , then power from switch to box in both directions, next power and ground to box , then power from box to actuator , they can manually simulate the switch at the box to bypass switch , and they can power and ground the wires at the box and to operate the actuator , this would isolate wiring and the process would lead to the sourse of the problem.

[loudelectronics]

The taps brain is likely failed. I had some thing happen on mine and the early models and to small gauge wire and they would burn out. The updated taps brain has heavier gauge wire and fixes the problem. I fabled up my own switch to get me through. It was a three way switch connected directly to power. To move plate up and down.

[rbsileighty]

Check what power you have (Voltage and Amps) with the system wired correctly... then use these values and check with Lenco what the min input voltage/Amps required to actuate the system. If you're below this level start tracing it back to where the major drop originates.

Just an idea...

[wakesurfid]

If I hook up power directly to the actuator it works fine. The TAPS brain was just replaced but TAPS still does not work. How do I do this?:

... first would check for power at switch , then power from switch to box in both directions, next power and ground to box , then power from box to actuator , they can manually simulate the switch at the box to bypass switch , and they can power and ground the wires at the box and to operate the actuator , this would isolate wiring and the process would lead to the source of the problem.

I have a multimeter. Don or others can you give me a quick description of how to check power and ground at each location?

[wakesurfid]

So I took the switch and wiring out of the handle, got new wire, but still won't work. While trying to troubleshoot I hooked the taps brain up to a constant power source that's always on, w/ key in off position, if I check power at the switch and gauge I get full 12.6v, but still won't work; when I turn the key to on, the voltage at the switch and the gauge drops to around 5v. Is this normal?