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Unread 04-17-2014, 07:23 PM   #1
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Default 48 volt club car - hot resistor

Greetings Gents,

I have owned this cart for a while and put in new batteries last year. Lots of kids over this weekend and someone "broke" the car. It does appear that it got ran into something.

The batteries read good - they were loose, and the hold downs got broken, but I got them all back in place. The only thing I can find is the resistor wire on the solenoid is "melt the skin off your fingers" hot and is cooking the insulation around it.

Any ideas? I dont see it could be a bad resistor (although im sure it is now) but I'm wondering what could have blown it

The reverse beep works and I here the click under the go pedal when pressed.
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Unread 04-17-2014, 07:56 PM   #2
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Default Re: 48 volt club car - hot resistor

BY the way the serial is AQ0302 if that helps, and running great before accident.
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Unread 04-18-2014, 10:32 AM   #3
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Default Re: 48 volt club car - hot resistor

This is almost always the sign of a bad motor controller.
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Unread 04-18-2014, 10:40 AM   #4
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Default Re: 48 volt club car - hot resistor

I'm not disagreeing

Cart will run without resistor in place. Resistor usually heats up when solenoid does not close and control tries to feed the motor by pulling amperage through the resistor... Could you try moving one large solenoid cable to the other side so both big cables are landing on the same post?
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Unread 04-18-2014, 11:04 AM   #5
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Default Re: 48 volt club car - hot resistor

Quote:
Originally Posted by scottyb View Post
I'm not disagreeing

Cart will run without resistor in place. Resistor usually heats up when solenoid does not close and control tries to feed the motor by pulling amperage through the resistor... Could you try moving one large solenoid cable to the other side so both big cables are landing on the same post?
That's kinda of scary in this case, a hot resistor usually means a shorted controller if you jump the large battery cables you will be giving full power to the motor with no control this could lead to multiple disastrous outcomes..
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Unread 04-18-2014, 11:10 AM   #6
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Default Re: 48 volt club car - hot resistor

Quote:
Originally Posted by greg-g View Post
That's kinda of scary in this case, a hot resistor usually means a shorted controller if you jump the large battery cables you will be giving full power to the motor with no control this could lead to multiple disastrous outcomes..
Please answer this for me.... What in the controller is shorted if the precharge resistor is hot?

What I'm saying is if the solenoid is not operating, operate it manually or bypass it.
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Unread 04-18-2014, 12:02 PM   #7
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Default Re: 48 volt club car - hot resistor

I'll put in my 2 cents and y'all can take it for what it worth.

If the resistor is hot all the time, I would say its a bad controller.

If it only gets hot when you try to drive the cart, I would say its a bad contactor. Or contactor not getting coil voltage.
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Unread 04-18-2014, 12:05 PM   #8
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Default Re: 48 volt club car - hot resistor

One more thing. In a situation like this do your testing with the rear wheels off the ground! You don't want a runaway cart!
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Unread 04-18-2014, 01:25 PM   #9
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Default Re: 48 volt club car - hot resistor

Quote:
Originally Posted by scottyb View Post
Please answer this for me.... What in the controller is shorted if the precharge resistor is hot?

What I'm saying is if the solenoid is not operating, operate it manually or bypass it.
The controller output transistors are shorted, power is going to the motor through the resistor thus the hot resistor. To test this Disconnect the motor and the resistor cools. Now jumping the solenoid in this case could weld the last connection made and now there is no disconnect. Its just not safe even if off the ground the motor will spin up at full power or burn up having no control of speed.
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Unread 04-18-2014, 01:53 PM   #10
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Default Re: 48 volt club car - hot resistor

Curious to see what he finds now.
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