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Old 05-08-2018, 12:01 PM   #1
S281
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Default 2010 48v club car quit running. Need help to diagnose

I have a 2010 Club car villager which I think is based on the club car DS. Haven't ran it in about a year since the batteries were dead. Replaced the batteries with brand new Trojans. Drove it up the block and it was limping at half speed. Then I smelled something burning and the cart quit moving.

All the electronics still work and turn on, but it won't move. Took off the rear cover to find this jumper wire smoldering and smoking.... This is to the left side of the cart next to controller.

What is this part and what could be the cause? How do I diagnose what else could be wrong to cause this..

Thanks!

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Old 05-08-2018, 12:10 PM   #2
gtistiffler
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Default Re: 2010 48v club car quit running. Need help to diagnose

That is a precharge resistor on the solenoid. Any golf cart dealer or one of the site sponsors should have one. Make sure that yellow cable goes on the post first then the eyelet for the resistor goes on top then the nut. Seems like a lot of current must have been pulled through it.

Same with the red wire. The thicker cables go on first.

Last edited by gtistiffler; 05-08-2018 at 12:11 PM.. Reason: A
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Old 05-08-2018, 12:29 PM   #3
NoleFan4Ever
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Default Re: 2010 48v club car quit running. Need help to diagnose

Something caused it to burn up. You need to check all the leads going to the controller and motor to be tight and undamaged (corrosion, frayed, etc.) If nothing is found wrong, this is usually a sign of a controller issue.
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Old 05-08-2018, 12:30 PM   #4
S281
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Default Re: 2010 48v club car quit running. Need help to diagnose

Thanks for the quick response. I'll get another one. But why would it burn up like that. Anything that could have been caused by the new batteries? Just don't want the new one to burn up too if something else is wrong
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Old 05-08-2018, 12:33 PM   #5
S281
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Default Re: 2010 48v club car quit running. Need help to diagnose

Nolefan - everything else looks perfect....
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Old 05-08-2018, 12:40 PM   #6
NoleFan4Ever
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Default Re: 2010 48v club car quit running. Need help to diagnose

Double check the A2 able (nuts, cable, tightness, etc.).... If it is not that, you may have a controller failing.
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Old 05-08-2018, 04:51 PM   #7
mrgolf
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Default Re: 2010 48v club car quit running. Need help to diagnose

If the solenoid is not closing the big post then the current is trying to go through the resistor. It is not made for heavy loads. The solenoid is failing.
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Old 05-08-2018, 09:26 PM   #8
S281
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Default Re: 2010 48v club car quit running. Need help to diagnose

Got a new solenoid and resistor. I'll install them this week and see if it fixes the issue. Hopefully it's not the controller.
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Old 05-16-2018, 11:24 PM   #9
S281
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Default Re: 2010 48v club car quit running. Need help to diagnose

Installed the new solenoid and resistor. Still nothing. Solenoid won't even click.

Does the resistor have to be a certain direction? +/-?

Should I be ordering a new controller yet?
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Old 05-17-2018, 08:14 AM   #10
twilliams81
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Default Re: 2010 48v club car quit running. Need help to diagnose

Following..


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