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Old 06-13-2019, 08:15 AM   #6
Sergio
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Join Date: Sep 2012
Location: Charlotte, NC
Posts: 9,329
Default Re: 1/2 speed not working on DS 99 with 1205-203 Curtis

In my diagram:
The throttle "High" is the Black wire.

The throttle "Wiper" is the Yellow wire.

The throttle "Low" is the purple wire and not used.

The micro-switch "com", "NC" and "NO" terminals are marked that way in your existing reverse switch.

The #2 and #3 switch outputs go to the Controller Terminals #2 and #3.

In the original wiring, the Yellow wire from the throttle goes to controller #3 so that needs to change.

The best way is to run two new 16ga wires from the controller to the FNR micro-switch.

Disconnect the existing yellow wire from Controller #3 and splice to one of the new wires that will go to the micro switch "com" terminal and one side of the 2.5kΩ resistor.

Connect the other new wire to Controller #3 and micro-switch "NC" terminal as well as the other side of the 2.5kΩ resistor.

The existing Green wire from Controller #2 will go to the micro-switch and connect to the 5.1kΩ resistor that goes to micro-switch "NO" terminal.

The existing Black wire from the throttle will get cut at the old resistor/white wire junction and will get spliced with the Green wire at the 5.1kΩ resistor that goes to micro-switch "NO" terminal.

The diagram you posted does not support "plug brake" so make sure You have the new Controller wired properly as I mentioned in the previous post or the Controller cannot modulate the "plug brake" current and will hard lock.
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