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Old 05-31-2015, 05:26 PM   #1
smokey tennis shoe
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Default Help- "Main Drop Out" on curtis controller

Can someone direct me on this? I have a cart that has a Curtis 1268-5403 controller in it, 48 volt .

The cart stopped and wont move. My batteries are 2 year old Trojans, eight 6 volt batteries, After charging and letting rest for 12 hours, I have 50.6 volts.

I have installed 2 new Albright solenoids. The solenoid clicks when stepping on the go pedal, it clicks twice, so I guess the second click is when it drops out.

I hooked up a diagnostic tool, and it gives me 2 errors. One error says low battery voltage, 47 volts??/ I have 50 volts at the solenoid, so not sure why programmer says 47 volts. The other error code says " main drop out"??

I have took the microswitch out of the floor box, and checked it, it opens every time, so the micro at the floor is fine. I know you don't want to hear this, but its a 2010 star cart. I heard it is a chinese knock off of an ezgo, but it doesn't look like an ezgo to me??

What could be causing the solenoid to drop out? If I clear the fault history, the low voltage error goes away and I just get the drop out error.

Also, evry once in awhile, while messing with the cart, it will kick in and start to drive when stepping on the pedal.

Any help??

Thanks guys, I am lost and frustrated.
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Old 05-31-2015, 08:55 PM   #2
cgtech
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Default Re: Help- "Main Drop Out" on curtis controller

The element in the fuse bolted on top of the controller is "stress fractured". That fuse is redundant (there is another large fuse on the other side of the contactor). Try bypassing that fuse on top of the controller. I have seen this many, many times.
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Old 05-31-2015, 10:04 PM   #3
smokey tennis shoe
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Default Re: Help- "Main Drop Out" on curtis controller

CG

Are you saying the round tubular fuse is bad? Or the 425amp fuse that is flat and next to the round one?


Just remove the tube fuse, and hook the 2 wires together?
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Old 06-01-2015, 04:07 AM   #4
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Default Re: Help- "Main Drop Out" on curtis controller

Post a pic of the controller area, so we can see more. The round fuse is for the low current side (inputs to the controller). The large 425 fuse is what i am concerned about.
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Old 06-01-2015, 10:48 AM   #5
smokey tennis shoe
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Default Re: Help- "Main Drop Out" on curtis controller

CG, here is a picture of the controller. I only see one large fuse.

So are you saying, to try and bypass this 425A flat fuse, to see if it will run?

I don't see a second large fuse anywhere, just the round tubular fuse next to the 425.
Attached Images
File Type: jpg star.jpg (256.0 KB, 0 views)
File Type: jpg star1.jpg (256.0 KB, 0 views)
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Old 06-01-2015, 05:04 PM   #6
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Default Re: Help- "Main Drop Out" on curtis controller

CG, I bypassed the 425 amp fuse, still nothing has changed.

All along, you hear the solenoid engage and drop out. Every once in while, after about 40 tries, the solenoid will stay engaged and cart will move, . I have it in my garage, and keep stepping on the pedal. So when it does engage, I don't drive the cart, I make sure it moves then I let off and try again, and then it will not work for another 40 or so tries.

Since the cart will go, once in awhile, would that eliminate the controller, as a problem??
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Old 06-01-2015, 05:15 PM   #7
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Default Re: Help- "Main Drop Out" on curtis controller

also, on my diagnostic tool, under " monitor", it says battery voltage is 46 volts. However, when I measure the pack it is 50.9. also 50.9 at one side of solenoid, and 50.8 at the other side for a brief moment, before solenoid drops????


why would tool measure 46 and I measure 50.9 everywhere else?
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Old 06-01-2015, 08:35 PM   #8
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Default Re: Help- "Main Drop Out" on curtis controller

Never worked on a Star Car, but in my experience when the controller is not reading correct battery voltage, it's always a controller problem.
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Old 06-01-2015, 08:58 PM   #9
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Default Re: Help- "Main Drop Out" on curtis controller

David your experience is worth a million. Thanks for that. I guess I will be pulling this bad boy out and having it rebuilt then. Hope it fixes it.
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Old 06-01-2015, 09:00 PM   #10
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Default Re: Help- "Main Drop Out" on curtis controller

Are you also getting 50.8v right on the controller B+ terminal when the solenoid closes?
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