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Electric Club Car Electric DS, and Precedent golf cars



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Unread 01-31-2016, 08:13 PM   #1
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Default 2004 Club Car DS trouble

I am having trouble with my 2004 clubcar ds. I'll tell the whole story so i dont leave anything out. The cart was given to me. Was sitting in guys yard for long time. Said it worked before. When i got it it had 4 12v marine batteries in it. I charged them indiviually just to see if it was working at all. After having to jump the solenoid (which i later replaced) it did work. So off i went to buy new batteries and a charger. Installed new batteries and new solenoid. cart ran but it was only like half speed. ( I did all this at a local small "dealer"/repair shop.) while talking about why it could be running slow we noticed the resistor started over heating and smoking, eventually melting the plastic on it, the key switch was off. We disconnected the batterys. I left the cart there so they could work on it. They couldnt figure out why the resistor was overheating so they sent the cart to an electronic repair shop that also works on carts. They said that the MCOR was bad and also that there was no need to have a resistor on this cart. they replaced the mcor for me and i went pick it up yesterday morning. I first drove it and it was great. lots of power and good speed. I stayed there about an hour after test driving it while they cleaned the cart for me. When i went to load it up on trailer i noticed it started to lose power and run slow. I figured the batteries probly havent been charged yet so i loaded it up, brought it home and charged batteries. later that day when charge was complete i unhooked it and took off. went well for about 40' then started to die down. almost to the point wehre i barely made it back to the charger. I let it charge up again. today i tried and it was the same thing. I checked the controller as per the repair manual. Only thing i found different was the controller capacitor voltage was 0. instead of about 45v like the manual states. pedal down to the floor shows full voltage. ~50-51v. I dont know what else to check. I ran a few other various test. Im stumped. Really dont want to bring it back to shop if all i need to do is change a part. Has anyone else had this problem? Even when it is having this problem i show full voltage. all battery connections are tight. I cleaned all terminals on controller. Please help!!
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Unread 01-31-2016, 08:27 PM   #2
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Default Re: 2004 Club Car DS trouble

To start with it needs the resistor to pre charge the caps in the controller.
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Unread 01-31-2016, 08:46 PM   #3
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Default Re: 2004 Club Car DS trouble

thats what i thought so i put it back on. Still don't understand why it burnt the first one up
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Unread 01-31-2016, 10:04 PM   #4
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Default Re: 2004 Club Car DS trouble

A bad solenoid can cause the resistor to burn up when the large contacts don't close and make good contact the load will try to go through the resistor. Replacing the solenoid should cure that.

Did you use a 48 volt solenoid made for your cart??
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Unread 01-31-2016, 10:08 PM   #5
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Default Re: 2004 Club Car DS trouble

I have a new solenoid on it now. new solenoid with new resistor. Resistor melting as soon as batteries hooked up. Cart will run without resistor but controller caps have no charge. So I don't think it's the new solenoid causing the issue
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Unread 01-31-2016, 11:03 PM   #6
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Default Re: 2004 Club Car DS trouble

99 percent out of the time it's a bad controller that causes the resistor to burn. A shorted motor can cause it as well.
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Unread 02-01-2016, 12:16 PM   #7
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Default Re: 2004 Club Car DS trouble

It may have given to you but you are going to have some money in it to get it going. Good thing is, once all of this is replaced, it should last you a good while.
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Unread 02-01-2016, 02:21 PM   #8
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Default Re: 2004 Club Car DS trouble

First of all, do not take Your cart to either of those 2 shops as they already demonstrated they are incompetent.

With the Key Switch OFF there is no way for the MCOR to cause issues, and removing the resistor OFF the solenoid was a dumb idea that will burn Your new Solenoid contacts.

I agree with TahoeDawg that most likely the issue is the Controller itself, leaving those large filter capacitors inside the Controller on a discharged state for a long period of time will damage them.

That is likely what is discharging Your batteries as well.

If this is a series cart, You can charge the cart with the FNR lever on Neutral, that will disconnect the motor from the controller.

If the Pre-Charge resistor still gets warm and the batteries discharge, the issue is definitely the capacitors inside the controller.
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Unread 02-01-2016, 10:10 PM   #9
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Default Re: 2004 Club Car DS trouble

Thanks a lot for the help. I will test a little further and see if I can pinpoint
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Unread 02-01-2016, 10:16 PM   #10
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Default Re: 2004 Club Car DS trouble

So it burnt the first resistor up and not the second one?
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