2010 CC DS throwing main drop out fault

[NoleFan4Ever]

Originally Posted by Sergio

-snip-
Adding a diode or the Club Car "dropout harness" should fix the issue.

Sergio/tw81, just an FYI but Club Car discontinued the Main Dropout Harness last month. No reason given, but none can be purchased from them and what is out in the market place is all there is unless someone starts making their own version of them.....

[twilliams81]

Update...I’ve replaced the main harness because after butchering the last one trying to remedy the situation to no avail. I’m still getting the same main coil fault/main dropout from before. I’ve changed the solenoid and MCOR and STILL am getting the same results. I’m also getting voltage drops on the handheld that I’m not getting on my meter...drops so low; (30v and under) that’s it’s triggering low voltage faults. Any ideas? Controller is what I’m guessing but what would cause this to just start happening all of a sudden??


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[NoleFan4Ever]

I know you have replaced it already, but everything you state says "Main Contactor" to me....

[twilliams81]

Yessir I’ve replaced with a brand new and even tried the old one for shids and giggles. I’m thinking something’s going with the controller due to the voltage not only dropping severely but also shooting up past 50v (on the handheld not my meter) and FYI these voltage fluctuations happen every time I get the cart to engage with the pedal.


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[NoleFan4Ever]

That is just strange occurrences from within the controller. But if you have one to swap out to test I guess that will confirm the theory..... I want to know now....

[twilliams81]

I have one but it’s not the same model number and I tried it today and couldn’t get any activation. Gonna send this one off and I’ll keep you posted


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[Sergio]

If You have already provided plenty of voltage drop in the Gray aux power using the diodes, the issue has to be inside the Controller at this point.

[twilliams81]

Hey guys...back on this demon cart. I’ve replaced the controller, solenoid and main harness and yet I STILL have the main drop out issue [emoji2361]. Could this be a motor issue I’m having??


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[NoleFan4Ever]

You bring up a good point and based on the gremlins you are seeing, maybe a winding or something intermittently opening under heat.... I am really lost too and would try that next. You can test it, but it will not reveal anything (Continuity and Ohms) unless it is occurring at that time....

[twilliams81]

I’ve actually got 2 of these carts doing the exact same thing; one is an ‘01 that I’m converting over to an IQ and this one (2010). Both have new main harnesses, new solenoids, and controllers. Both are now throwing a combination of the “main dropout/open armature” faults. They both run the same 10-20 feet before stopping. And they both are showing dramatic voltage drops & spikes ON THE HANDHELD but NOT ON THE METER. I pulled the motor off the 2001 today and didn’t see anything obvious but I didn’t do any resistance tests yet. Weird crazy stuff


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