Solenoid powered when shifted to forward

Airboataddict

Hello everyone, new to the site. I’ve searched and searched all over looking for answers but haven’t been able to find anything on my issue. I just had a cart given to me and I’m trying to get the thing working. Previous owner could not fix it and wanted it gone. It is a 1999 DS Club Car 48V. Serial number A9920-763585. It is a series cart with shift lever by right leg. I’ve tested batteries, they are good. Resting voltage is about 52V. I’ve checked the V-glide and it seems to be working properly. Looks like all micro switches were just replaced. The 3 on shifter and the one in V-glide. When the key is switched on, and the cart is shifted to forward, the solenoid engages and the resistor gets really hot. When I press the throttle, the solenoid releases. When put in reverse, the buzzer sounds but the solenoid doesn’t click. I’ve looked over the wiring schematic and everything seems to be wired correctly. I’m just new to these things and don’t want to start throwing parts at it. I’m a mechanic so I have most of the proper tools for testing and repairs, just need help pointing me in the right direction. Sorry for the long thread and thank you for any help! It’s much appreciated

BGW

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scottyb

Recheck the micro switch in the Vglide.... should be open when pedal is up and closed when the pedal is down.

Airboataddict

The V glide was removed when I got it but the new micro switch was already installed. When the pedal is NOT pressed the V-glide arm is pressing the micro switch. When the pedal IS pressed it is no longer touching the micro switch.

Airboataddict

Anyone else have this issue before?

Sergio

All of your issues are related to incorrectly connected micro-switches.

The micro-switch in the VGlide should be using the N.C. contacts, if it is a 3 terminal micro-switch, You want to use the terminals on each end (not the one in the middle).

Also verify the wires and the micro-switches on the FNR are in the proper location (1, 2 and 3), use the diagram below:

Airboataddict

Just got home from work and looked over what you suggested. All wires going to micro switches on FNR switch are correct. The micro switch in the V-glide is only a 2 terminal micro switch. The green/white wire is on top terminal and the blue wire is on the bottom terminal

Sergio

It is probably the wrong micro-switch, N.O. instead of a N.C. switch.

Disconnect those 2 wires from the micro-switch and put your meter on continuity test.

Test the continuity on the micro-switch with the pedal UP and after you move the pedal enough to release the lever on the micro-switch.

Airboataddict

0.6 with the pedal up (switch pressed) and open lead when pedal down (switch not pressed)

Sergio

Yep, that is the wrong switch, the results should have been the opposite, "Open Lead" when the switch is pressed (Pedal UP).

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Airboataddict

Yes sir just pulled the v-glide out and pulled the switch off. Green was on N/O and blue was on common. I’ll get a new one ordered and see what happens. Hopefully I don’t have anymore issues after that but I may still have questions. Thank you very much for the help! I’m lost on these things and a lot of you guys have much knowledge on this forum.