CartManager XD Field Technician Guide Page 22
The motor controller has detected a self-fault.
Correction
1. Check that the wire harness at the bottom of the controller is securely in place.
2. Run the tests listed in the “7 Bars Flashing” section above.
3. Go through the “CartManager XD Does Not Turn On” algorithm on page 11.
4. Remove the front access panel.
5. Disconnect the M- lead from the controller to prevent unexpected movement of the unit.
6. Check all connections at the connector blocks and fix any loose connections.
7. Make sure that the remote control unit is on. Press the “SLOW” button on the remote. You should
hear a distinct click as the relay on the back of the speed control as the relay responds to the
remote. If you do not hear the click, replace the relay.
8. Repeat the previous step with the “FAST” button on the remote control unit.
9. If still flashing 8 bars, replace the controller.
Cause Failure of the motor brake solenoid or the wires leading to it.
Correction
1. Check the Manual Brake Release. Make sure it is pushed all the way in.
2. Turn the throttle grips. You should hear a distinct click as the motor brake disengages. If you do
not hear the click:
• Check the brake switch. Replace if needed.
• Check that the wires to the motor brake are not loose or disconnected. Repair or replace
wires as needed.
3. If fault is not cleared, measure the total voltage across all three batteries.
4. Check the voltage between two pins on the white 2-pin connector on controller. When the throttle
is turned away from the neutral position, voltage across these pins should equal the total battery
voltage measured in the previous step ± 1V. When throttles are in neutral position, voltage across
these pins should be 0V ± 0.5V. If you do not get these values, the controller is faulty and should
be replaced.
5. If fault is not cleared, replace the motor brake.
Total battery voltage is greater than 45 volts.
Correction
1. Unplug the charging cord before starting the CartManager XD.
2. Turn the CartManager XD off. Wait 5 seconds and turn back on.
3. Check for faulty connections between battery and charger.
10 Bars Rippling Up and Down
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