DCS F & R Rocker switch conversion

[ForseeBob]

I was told I need to address my questions to JOHNNIE B but this is my first post and I don't know what I am doing.

I have a DCS cart that is from about 1996 or so. The controller is an FSIP brand that was rebuilt by the factory just last month. The "hockey puck" cam action F & R switch started rotating 360 degrees (i.e., the internal stop broke?) so I bought a F & R rocker switch from Carts Unlimited (who directed me to contact JOHNNIE B).

Although forward & reverse were both working up until yesterday (before I began the changeover) I now only have reverse (even when bypassing the switch) and (strangely) it is running off what is supposed to be the forward (YELLOW WIRE) circuit. I have a diode installed across the F & R switch as I was instructed to do.

How do I begin to figure this out?

[ForseeBob]

PS When I checked the wires it was over 37 volts from each of the common wires (one orange and one red/orange) to either directional line (yellow for forward and the second orange for reverse),

[JohnnieB]

The controller defaults to forward and has to be told to do reverse.
Technically, the two switches are RUN and REVERSE.
For Forward, only the RUN switch contacts are closed.
For Reverse, contacts of both switches are closed.

When using a SPDT switch, a diode is used to connect battery voltage to the RUN wire when the REVERSE switch is closed.

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Is the rocker switch you got like the one shown in the picture below?

Here is a schematic showing how to connect it.

[scottyb]

Thank you for helping JB. He has the CC F&R with 2 independent rows of 3 terminals.

[JohnnieB]

Originally Posted by scottyb

Thank you for helping JB. He has the CC F&R with 2 independent rows of 3 terminals.

Okay, that makes a big difference.

That's a DPDT switch rather than a SPDT like the PDS F/R is.

Attached is a drawing showing the jumper that needs to be added as well as the wire colors from the puck style DCS F/R assembly.

Also attached are a couple pictures of a conventional DPDT toggle switch wired to replace the puck style DCS F/R.

Note: When the F end of the rocker is depressed, it is the terminals under the R end that are connected to the center terminals.

[ForseeBob]

Johnnie B:
The seller sent me the same schematic that you posted.

I am not sure how to get the photo from my computer to load in my reply. The rocker switch I got from Carts unlimited is a DPDT switch that mounts over the hole previously occupied by the cam switch handle. I bought the diode and mounted it across the side of the switch I am using with the band towards the yellow (forward) wire side. When switch to that position the cart goes in reverse but doesn't run when thrown the other way. As a check I reversed the diode and in the opposite position I think it ran in reverse regardless of the way the switch was thrown.

I see that you sent me another response and did not yet read it so maybe all will soon be clear.

[ForseeBob]

Johnnie B:
Thanks a lot for your help as well as ScottyB chiming in.

Since I have a DPDT switch your pictures make it a whole lot simpler to follow than the SPST schematic (could have saved me a few hours of head scratching).

There isn't enough detail when I zoom in on the photo for me to see if that is a diode (or just a blur) between the right hand two terminals. However, your schematic for the DPDT switch appears to show that there isn't a diode. Isn't a diode necessary in this layout?

You are giving me hope.......

[Sir Nuke]

Originally Posted by ForseeBob

Johnnie B:
Thanks a lot for your help as well as ScottyB chiming in.

Since I have a DPDT switch your pictures make it a whole lot simpler to follow than the SPST schematic (could have saved me a few hours of head scratching).

There isn't enough detail when I zoom in on the photo for me to see if that is a diode (or just a blur) between the right hand two terminals. However, your schematic for the DPDT switch appears to show that there isn't a diode. Isn't a diode necessary in this layout?

You are giving me hope.......

Bob....Its just a simple wire jumper, I did this very mod with scotty and johnnies help a few years ago. no diode

[JohnnieB]

Originally Posted by ForseeBob

Johnnie B:
Thanks a lot for your help as well as ScottyB chiming in.

Since I have a DPDT switch your pictures make it a whole lot simpler to follow than the SPST schematic (could have saved me a few hours of head scratching).

There isn't enough detail when I zoom in on the photo for me to see if that is a diode (or just a blur) between the right hand two terminals. However, your schematic for the DPDT switch appears to show that there isn't a diode. Isn't a diode necessary in this layout?

You are giving me hope.......

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.

[ForseeBob]

Thanks JohnnieB!