(1995) Old Style DCS F&R to F&R Rocker upgrade

[hawaiianstyln]

I got this F&R rocker 3 prong today and can't seem to get the wiring correct. I must be missing something simple. My first wiring attempt didn't even turn my Alltrax controller on. However, when I connected the red wire to the red/orange wire (center prong) with a diode over 1 & 3 (yellow and orange) and placed the switch on either forward or reverse it turned the controller on but had the infamous 2 greens/3 red blinks (high throttle over range).

it worked before I cut the wires off this old style F&R switch so it has to be the way I'm wiring this. I've seen diagrams to wire a 6 prong rocker, but not a 3 prong. I thought I saw another thread where 6 prong is just two 3 prong in parallel.

Thank you for any help,
Keith

[JohnnieB]

Here's a DCS schematic with a PDS F/R switch wired in. The original switch is still shown.

Orange/Red and Red to center.
Yellow to Bottom (RUN)
Orange to Top (Reverse)
Banded end of diode connects to Bottom (Yellow)

That isn't how it looks on the schematic, but remember a schematic only shows electrical connections, not physical layout. Also rocker and toggle switches are confusing since the closed contacts are opposite the lever. (When FWD is pressed center and bottom are connected)

Not sure why you get that error code. Hopefully you flipped Run/Tow switch to Tow before messing with the wires!!!

The 6 pin switch is two 3 pin electrically isolated switches sharing a common lever.


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The F/R switch contacts ought be labeled Run and Reverse.
The DCS controller defaults to Forward and has to be told to do reverse, but has to be told to run in either direction. So you need a diode when you use a SPDT switch.

[hawaiianstyln]

sweet thanks for sharing this. Uhhhh I did not switch to tow. hope I didn't hose anything up! :( :(

I will go wire this and test now

[hawaiianstyln]

Originally Posted by JohnnieB

Orange/Red and Red to center.
Yellow to Bottom (RUN)
Orange to Top (Reverse)
Banded end of diode connects to Bottom (Yellow)

JB, big thanks on this, I followed your wiring and cart is back up and running with the new rocker switch upgrade

now I just need to clean up the connections and add some heat shrink after this quick test

[JohnnieB]

Remember to always flip Run/Tow to Tow before doing any electrical work on cart. The XCT is pretty rugged, but if that had been the stock DCS controller, it might have taken it out.

The error code went away?

[hawaiianstyln]

Originally Posted by JohnnieB

The error code went away?

tracked the error code down to a 6 connector that has four wires: Red Black Green White. If I pull on the wires slightly on both sides of the connector, it gives me the error code. If I push the wires in on both sides, controller goes solid green no codes. That connector is bad and temperamental.

[hawaiianstyln]

which makes sense on the error code because those wires are the accelerator micro switch and ITS

[JohnnieB]

That connector is a source of all sorts of weird problems and many people replace it with individual butty-splices or solder joints covered with marine grade (adhesive filled) shrink tubing for waterproofing.

The wire to the pedal switch has B+ on it and if it crosstalks with the ITS wires (Black and white), you get throttle over ranger errors.