DCS F & R Rocker switch conversion

[JohnnieB]

Originally Posted by ForseeBob

Thanks JohnnieB!

Take some high resolution pictures and attach them to a post using the paperclip, I'll add them to my collection.

[ForseeBob]

JohnnieB:
Even after wiring the DPDT switch per your excellent photos and diagram the cart still only runs in reverse and only when the switch is thrown one way (opposite throw is dead). What do I need to check now?
Bob

[JohnnieB]

Originally Posted by ForseeBob

JohnnieB:
Even after wiring the DPDT switch per your excellent photos and diagram the cart still only runs in reverse and only when the switch is thrown one way (opposite throw is dead). What do I need to check now?
Bob

Sounds like the "Run" wire and the "Reverse" wires are swapped or the jumper wire on the wrong set of contacts.

The color of the wires may be different in your carts wiring harness, so trace the wire from Pin-4 on the controller back to the new F/R switch.
It should be connected in the set of terminals that does not have the jumper.

[scottyb]

Johnnie, Just for grins check the switch or switch all terminals to the other row.

[ForseeBob]

JohnnieB:
Still no forward, just reverse.

I now find that the Red & Orange striped wire is dead. Unfortunately I drove off from home (79 mikes away) with out a paper copy of the schematic. I’ll try to read the schematic you posted online.

[JohnnieB]

Originally Posted by ForseeBob

JohnnieB:
Still no forward, just reverse.

I now find that the Red & Orange striped wire is dead. Unfortunately I drove off from home (79 mikes away) with out a paper copy of the schematic. I’ll try to read the schematic you posted online.

That schematic is using a SPDT switch and a diode.

As I understand it, you've got a CC F/R switch with two rows of three terminals (DPDT), so that schematic doesn't apply.

Here is a schematic for your cart, but it only shows how the original microswitches were connected electrically, not how they wired physically.

The stuff to remember is when in Forward, the wire to the keyswitch has voltage on it and in Reverse both the wire to the keyswitch and the wire to Pin-4 on the controller have voltage on them.


Some things to check.
1. Is there voltage on both center terminals?
2. When either end of rocker is pushed, is there voltage on four of the six terminals? (The two terminals under the end pushed will be dead)
3. When other end of rocker is pushed, did the other two end terminals get voltage on them and the previous end terminal are now dead?

[ForseeBob]

Originally Posted by JohnnieB

The problem is the DCS had two different F/R switches and either can be replaced with a SPDT or a DPDT.

The DPDT I now know you're trying to install, doesn't use a diode.

JohnnieB:
I did a clean re-wire of the switch following your simplified schematic and photos. However, although both pairs of the former micro-switch wires are live (37 volts) to the switch and the switch is working the motor still only runs in reverse. What can be wrong?

[scottyb]

See post 14. If the switch checks out good then swap the F1 and F2 wires on the speed controller and see what effect that has.

Curious - did the cart fun forward and reverse before the switch change?

[ForseeBob]

JohnnieB:
I just ran a quick test at each of the double plug sets where the cart wiring transitions to the former micro switch wiring (now connected to the rocker switch). The passenger side pair comes alive when the run/admin switch is thrown irrespective of the key switch. The driver’s side pair comes alive only when both the hey and the run switch are on.

[ForseeBob]

Johnnie B:
Is there a relay somewhere that could be stuck? Like a flakey started in a car could a well placed tap from a hammer break something free?
Bob