13-60
EL
EC
TR
IC
G
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AR
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Speci
fi
cations and prices subject to change without notice. Download latest update to this manual on-line.
Controller Flash Faults
SYMPTOM: NO LIGHT = NO POWER TO CONTROLLER
Check the kart on/o
ff
switch to make sure it is in the “on” position.
Check the batteries (see pg 13-11). If the batteries test ok, check the power and ground leads.
The main ground (negative lead) from the battery pack is attached to the (B-) lug on the Sevcon controller. From the (B-)
lug, there is an 18-gauge wire going to the negative terminal on the top of the interconnect board. Check all connections
for proper installation and condition.
The main power (positive lead) goes from the battery to the fuse block on the heat sink board. Check continuity of the fuse
and replace as necessary (see page 13-13). From the fuse, the positive lead goes to the input side of the relay/contactor
and splits o
ff
in two directions.
A 10-gauge red wire goes from the output side of the relay/contactor to the (B+) lug on the controller. The positive power
also goes from the relay/contactor to the interconnect circuit board through four much smaller wires. Two of the smaller
wires connect to the large lugs on the relay/contactor. Two wires attach to the smaller posts on the bottom of the relay/
contactor. The wires are part of a multi-conductor cable with a Deutsch connector on the end. Check to see that the
connector is securely fastened to the interconnect board. While at the interconnect board, check all of the other plugs
to ensure they are securely attached to the board. The cable with the white Molex-style plugs on both ends, going from
the interconnect board to the controller, is called the interconnect board cable. Unplug the interconnect board cable
and visually inspect the terminals to be sure they are all in place. Re-connect the interconnect board cable. Be sure it
is attached correctly, as there is a speci
fi
c side that plugs into the interconnect and a speci
fi
c side that plugs into the
controller (there is a red tag on the side that attaches to the controller; see pg 13-35).
SYMPTOM: SOLID LIGHT = NORMAL CONDITION (NO FAULT)
What if there is a solid light, but the Kart does not move when the pedal is depressed? The kart is in neutral: the problem
relates to the brake safety switch. Locate the brake switch and place a jumper from terminal to terminal. If problem goes
away, replace brake pressure switch.
SYMPTOM: SOLID LIGHT WHEN KART IS TURNED ON, GOING TO A 2 FLASH WHEN PEDAL IS DEPRESSED.
This
fl
ash refers to the seat switch being open (the “seat switch” circuit is used for remote shut-down systems on J&J
go-karts), and the problem typically relates to the remote shut- down receiver. Replace the remote shut down receiver
with a known-working unit. If the problem persists, the issue may be in the cable going to the interconnect board from
the remote shut-down receiver. This condition can also happen if the kart is put into the “stop” mode from the main
transmitter, and the “go” pedal is being held down. To clear these faults, make sure the “go” pedal is fully released. Once
the “go”pedal is released, the fault will clear on its own.
SYMPTOM: 1 FLASH = PERSONALITY OUT OF RANGE.
The controller pro
fi
le is not programmed or corrupted. J&J has yet to see a pro
fi
le become spontaneously corrupted. This
is why we suggest that only quali
fi
ed personnel make changes to the parameters in the controller. This
fl
ash can also
happen when a new controller does not have a pro
fi
le on it. In either case, the
fi
x is the same.