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Unread 09-13-2019, 03:08 PM   #1
Not Yet Wild
Join Date: Sep 2019
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Default No Start Resistor on Solenoid Getting Hot

I have a 2001 Club Cart 48v and the problem is will not move, batteries good, the solenoid resister connecting the two top connector is getting hot. Replace solenoid and resister still nothing and yes getting hot again. What do I need to check on this system. Does anyone have a wiring diagram or suggestions. Thanks
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Unread 09-13-2019, 06:45 PM   #2
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scottyb's Avatar
Join Date: Dec 2007
Location: Southern California
Posts: 68,428
Cool Re: No Start Resistor on Solenoid Getting Hot

The resistor gets smoking hot when the controller calls for power and the solenoid is not closing. The result is the motor is trying to pull a bunch of amperage through the resistor which make it burn your fingers hot.

Start by figuring out if the problem is a bad solenoid or a problem in the solenoid activation circuit. The solenoid activation circuit consists of putting 36 or 48 volts to the 2 small posts on the solenoid.
Test this with the voltmeter by a test lead on each of the small post and key on, in gear, wheels off the deck, try to go.
No power on the small posts? repeat the test with the red test lead on the big
solenoid post with the battery lead connected and test each post. One should give you power reading. If yes you have a negative present on that post.
Put the black test lead on the Controller B- terminal or battery main Negative. Now test the not negative small post with the red lead. Power? If yes you have a bad solenoid. Verify by putting a test lead on each small post and trying to go. If power and no click here replace the solenoid.
If no Positive power present trace the activation circuit back to the pedal and F&R switches to see where it stopped
GL and have a nice weekend.
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