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Unread 11-05-2019, 11:20 PM   #1
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Default Diode on solenoid melts

Hello I have a club car ds 2001 48v Iíve replaced all the batteries the controller and solenoid. For some reason when cart is in forward or reverse and the petal is pressed the diode going across both large terminals on the solenoid gets so hot it starts to smoke and melt. Iíve also replaced all battery cable to 2 gauge wire and help will be appreciated thanks
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Unread 11-05-2019, 11:28 PM   #2
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Default Diode on solenoid melts

The thing on the large terminals should be the pre charge resistor. Does the cart still drive? Iíve seen a lot of different things cause this issue, from water on the controller connectors to a bad solenoidÖ
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Unread 11-05-2019, 11:46 PM   #3
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Default Re: Diode on solenoid melts

I think Luke has pretty much covered what it could be.

Does the solenoid click when you hit the go pedal?
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Unread 11-05-2019, 11:52 PM   #4
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Default Re: Diode on solenoid melts

Yes the solenoid clicks the old one did to. It how ever did move sluggish with old solenoid. With new solenoid it moves properly. Just the resistor will be to hot to touch just from pressing pedal down for 2seconds.
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Unread 11-06-2019, 03:13 AM   #5
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Default Re: Diode on solenoid melts

Is this a regen cart with 2 solenoids?

Can you post a photo of the solenoid?
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Unread 11-06-2019, 10:00 AM   #6
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Default Re: Diode on solenoid melts

Here is the picture of the solenoid
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Unread 11-06-2019, 10:06 AM   #7
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Default Re: Diode on solenoid melts

Here is the old solenoid and resistor. Is it normal to melt like that
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Unread 11-06-2019, 10:55 AM   #8
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Default Re: Diode on solenoid melts

No it is not normal for the resistor to burn.

Unless You have a bad controller, That can only happen if the Controller is trying to power the motor and the Solenoid is not closing.

If the current runs through the resistor instead of the Solenoid contacts, it would heat up pretty quick until it burns, but the cart would not drive.
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Unread 11-06-2019, 02:35 PM   #9
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Default Re: Diode on solenoid melts

Is that some sort of diode going to one of the small posts?
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Unread 11-06-2019, 03:22 PM   #10
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Default Re: Diode on solenoid melts

Take it from me....A cold Resistor looks just like a hot resistor...Fingers found out the hard way. Is it true that the solenoid is the number 1 replacement item on an electric cart?
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