13-62
GO
-KARTS
B
U
MPERBOAT
S
Specifications subject to change without notice - Check our website for valuable information including videos, workshop and operations manuals. www.jjamusements.com
503-304-8899
ENDURANCE CL
UTCH PLA
TES
TM
SYMPTOM: 2 FLASHES = ILLEGAL START CONDITION.
This code relates to a problem with peripheral inputs during start-up. The controller is very much like any other personal
computer. During start-up, it does a check of all the outside equipment (i.e. the throttle, brake pressure switch, remote shut
down (if used) etc.. to make sure they are connected and functioning properly. If the controller does not see the equipment
connected, or if they are connected but not in the correct setting, it will cause this fault. Most commonly, this fault is
caused by two items in the electric system: the linear throttle potentiometer and the forward/ reverse switch. When the
controller is turned on, it checks the linear throttle controller to be sure it is not showing any pull on the throttle system
(if it did not do this check, the kart would drive away once it was turned on if there was any pull on the throttle cable).
If a guest is sitting in the seat and this happens, they most likely have the pedal slightly pressed. Have them remove their
foot from the pedal and it should clear the flash code. If no one is in the kart, it is possible that the throttle cable might
be slightly stuck. This happens most often at new locations where concrete dust may be present. Clean and lubricate the
throttle cable, and the problem should be cleared. In some cases, the throttle cable may need to be adjusted slightly (see
pg. 13-29). The other potential cause for this fault can be that if the kart is turned on while in the reverse mode; simply put
the kart in a forward gear, and the problem will clear.
SYMPTOM: 3 FLASHES= MOSFET SHORT CIRCUIT.
This code relates to a fatal internal controller issue, but don’t panic; there can be possible solutions other than having to
replace the controller. Sometimes electronics can show this problem when there is a loose wire or connection. Before
you replace the controller, check for loose or corroded connections, and closely inspect the interconnect board cable for
damage to the contacts. This will not fix the problem every time, but operators have seen this flash code at least once in
the past when it turned out to be a loose connection.
SYMPTOM: 4 FLASHES= CONTACTOR FAULT
This code refers to a motor open circuit or field open circuit. The separately-excited motor has independent voltage
supplies to the field and rotor windings, allowing more control over the motor performance. If either of those circuits are
damaged or broken, this code will come up. It can refer to a major problem inside the motor, or just a damaged or broken
cable going to the motor from the controller.
SYMPTOM: 5 FLASHES= NOT USED
SYMPTOM: 6 FLASHES= ACCELERATOR WIRE FAULT.
This code is generated when there is a problem in the linear throttle potentiometer; basically, the controller does not see
it at all. The cause can occur anywhere along the path from the linear throttle potentiometer to the controller, so begin by
looking for loose or damaged connections. The positive power for the linear throttle potentiometer comes from the relay/
contactor (C3) on the interconnect board. The negative comes from the (J2) lug on the edge of the board. The path of the
signal goes from the linear throttle potentiometer to the plug on the board (C7), then to the interconnect board plug (C1).
The signal goes to the controller through the interconnect board cable. If all of the connections and wires look good, try
replacing a single piece of the system, one at a time.
It is best to begin with the interconnect board cable for two reasons; first, it is the easiest to check, and second, it is more
likely to be the problem than any of the other components. The cable is flexible with very small contacts that are crimped
to the wires, so they could have an issue that cannot be seen with a visual inspection. If the problem still exists, the second
part of the system to check would be the linear throttle potentiometer. You can unplug the existing unit and plug a new
one in without removing the old unit; just be sure the kart is off when you unplug and plug in the new unit (be very careful
when you are unplugging and plugging in any linear throttle potentiometer; this plug is directional and some parks have
pushed too hard, causing the board to flex and break traces in the board or worse). If that fixes the problem, the flash code
will be gone when the kart is turned back on with the new unit plugged in. The last piece of the system to replace would
be the interconnect board (see pg. 13-36).
SYMPTOM: 7 FLASHES= LOW OR HIGH VOLTAGE FAULT.
This code is generated when the controller senses that the battery voltage is higher or lower than the predetermined
parameters within the controller. Check the battery voltage as shown on pg. 13-11. If the battery voltage is low, charge the
batteries individually, and look into how the batteries got to this condition. Was the kart run for multiple sessions without
being charged properly? Is the charger working properly? Are the charger wires and plug in good condition?
If the batteries are over standard voltage (64 volts or higher), that may be a sign of a larger problem.
