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Unread 09-16-2019, 12:35 PM   #1
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Default 2000 PDS Forward / Reverse Conversion (Bell Type to Rocker Switch on the Dash)

I have the odd ball year 2000 36V EZGO PDS that has the bell housing type Forward Reserve Lever style under the seat switch and I want to convert to the Rocker F/R Switch that goes on the dash.

I've already cut the 3 wires that run to the two microswitches on the original F/R and ran them to the dash. They are "Green, Orange, and Orange/Red". I did a lot of research before posting this and the majority of threads were DCS to PDS conversions as most of the DCS carts have the same type of "bell housing" F/R under the seat.

I was told that I would need to run a diode on the new 3 Prong Rocker Switch. Would this be correct:

Green ---> Forward Prong
Orange ---> Reverse Prong
Orange/Red ---> Middle Prong
***Diode ---> Green to Orange with the banded/cylinder thing closest to the green prong?

Also- As far as the diode, would one similar to what comes with a HD Solenoid work? I received two when I ordered it...

OR am I totally missing this and need to get a 6-Prong rocker switch and utilize all the wires on the original F/R Switch? I cut them above the plugs before they split into two blue/yellow. I've also already re-rerouted the Reverse Beeper to next to the controller.


Thanks for any help!
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Unread 09-16-2019, 10:49 PM   #2
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Default Re: 2000 PDS Forward / Reverse Conversion (Bell Type to Rocker Switch on the Dash)

Man u pulling up the way back. If I remember correctly for the cart to run in forward both micros r pressed when in reverse only one is pressed so the rocker switch idea is a a ruff one. If it was me I would leave reverse micro pressed constantly and use a he on and off style switch for forward. On=f off=r. Hope that made sense. Happy carting.

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Unread 09-17-2019, 07:38 AM   #3
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Default Re: 2000 PDS Forward / Reverse Conversion (Bell Type to Rocker Switch on the Dash)

GACarts, Your proposed wiring is correct.

The diode should be at least 3 amps for reliable operation since it will carry the Solenoid coil current.

The diode shipped with an HD Solenoid should meet the specification.
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Unread 09-17-2019, 12:11 PM   #4
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Default Re: 2000 PDS Forward / Reverse Conversion (Bell Type to Rocker Switch on the Dash)

Please people, be aware he has an early 2000 PDS cart with a hockey puck type F/R.

The dash mounted F/R switch in the later version of the PDS is a SPDT/Center-Off switch (ON-off-ON) without any diodes or anything else.

In a nutshell, pack voltage is placed on J1 Pin-3 for Forward or on J1 Pin-2 for Reverse. (There is a diode between Pins 2 & 3, but it is inside the the PDS controller.)

Here are a couple drawings that may help.
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File Type: jpg PDS Keyswitch without lights.jpg (33.4 KB, 0 views)
File Type: jpg Voltage paths through PDS controller.jpg (138.9 KB, 0 views)
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Unread 09-17-2019, 02:51 PM   #5
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Default Re: 2000 PDS Forward / Reverse Conversion (Bell Type to Rocker Switch on the Dash)

Quote:
Originally Posted by JohnnieB View Post
Please people, be aware he has an early 2000 PDS cart with a hockey puck type F/R.

The dash mounted F/R switch in the later version of the PDS is a SPDT/Center-Off switch (ON-off-ON) without any diodes or anything else.

In a nutshell, pack voltage is placed on J1 Pin-3 for Forward or on J1 Pin-2 for Reverse. (There is a diode between Pins 2 & 3, but it is inside the the PDS controller.)

Here are a couple drawings that may help.
JB - Thanks for your diagrams. Those are very helpful. I still have a couple of questions.

I've upgraded the controller to the AllTrax 500 XCT and also added the HD Solenoid. Does the Alltrax controller have the diode running from Pin3/Pin4 for the Rocker switch, or do I still need to add the Diode between the Orange/Green (F/R) prongs on the dash mounted switch?

Also- The diagram states "Gray" for the middle prong, but I'm assuming that is the Orange/Red wire for the older 2000 PDS carts?
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Unread 09-17-2019, 07:57 PM   #6
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Default Re: 2000 PDS Forward / Reverse Conversion (Bell Type to Rocker Switch on the Dash)

The stock PDS wiring harness plugs plug into the matching jacks provided on the XCT48500-PDS without any additions. deletions or modifications. In other words, the XCT48xxx-PDS has the internal diode, like the stock PDS (Curtis 1206MX) controller does.

However, the solenoid wiring is different for an XCT than it is for a stock PDS controller.

1. No pre-charge resistor is used.
2. A 3A diode is installed between the two small (coil) terminals. The banded end faces the Yellow (+) wire.
3. A 6A 660V diode (Regen Diode) is installed between the two large (High current contacts) terminals. The banded end faces the battery side (+) large terminal.

Attached is a schematic showing an XCT installed in a PDS cart.

The Gray, or the Orange/Red, goes on the common contact (center - usually) terminal. Depends on when the cart was built for the wire color.
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File Type: jpg XCT-PDS with regen diode.jpg (213.2 KB, 0 views)
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Unread 09-18-2019, 05:57 PM   #7
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Default Re: 2000 PDS Forward / Reverse Conversion (Bell Type to Rocker Switch on the Dash)

After using your diagrams, my cart is running! I appreciate your help. The Alltrax was blinking "Green-Red-Red" (Low Battery Voltage) because it was set for 48V from the factory and my cart is only 36V. I was able to plug it in to my computer and "Low Voltage" setting down to 26 per Alltrax customer service and now the wheels are turning.

The Reverse/Forward switch works perfect on the dash.
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Unread 09-18-2019, 06:27 PM   #8
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Default Re: 2000 PDS Forward / Reverse Conversion (Bell Type to Rocker Switch on the Dash)



Thanks for the feedback.
Glad you got it going.
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Unread 09-25-2019, 10:42 PM   #9
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Default Re: 2000 PDS Forward / Reverse Conversion (Bell Type to Rocker Switch on the Dash)

Glad u got it working

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