Go kart

control systems

Kartrol, traffic lights, track electronics

Fun Parts Xpress

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Suite 150 Phone: 1-503-304-8899
Salem, OR 97305-1126
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Also from Fun Parts Xpress

For Honda engine parts & pricing information, see:
FPX GX 140-160-200 Parts & Price Guide - Vol. 1, #1-60-0060
FPX GX 240-270 Parts & Price Guide - Vol. 1, #1-60-0061

Visit our website for updated manuals (PDF Format)

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Part # x-xx-xxx
© Fun Parts Xpress 2017

2017
About this guide
This aim of this guide is to help you understand the basics of go kart control systems.

This guide contains drawings, illustrations and photographs of parts and accessories for Kartrol systems, traffic lights,
command console, speakers, timing systems and all electronic track control items.

Contents
About this guide .............................................................. 2
Safety first....................................................................... 3
Before servicing .............................................................. 4
General order and shipment policy................................. 7
Ordering Information....................................................... 9
Hull, tubes ................................11
Boat bottom .................................................................. 12
Boat top ........................................................................ 14
Pivot receiver ................................................................ 16
Tube ............................................................................. 17
Color Selection Guide................................................... 18
Tube Color Selection Guide ......................................... 18
Gelcoat Selection Guide ............................................... 19
Cover, motor ................................................................. 20
Electric motor ..........................21
Motor/handle bar assembly .......................................... 22
Power terminals - brass ................................................ 24
Electric motor................................................................ 25
Lower unit assembly ..................................................... 26
Propellor guard/gearbox - electric ................................ 28
Wires, connector, batteries .....29
Flex wire - motor to battery cable ................................ 30
Motor plug to power terminals (flexwire)....................... 31
Wires & connectors ...................................................... 32
Battery to motor plug .................................................... 33
Battery to battery charger ............................................. 34
SB-120 plug .................................................................. 35
Voltmeter to battery ...................................................... 36
Batteries & cables......................................................... 37
Gas boat ...................................39
Pivot - gas motor .......................................................... 40
Handle Bars - BF2D/BF2.3D ........................................ 41
Hull, boat top ................................................................ 42
Decals ......................................43
Decals - warning & safety ............................................. 44
Decals - miscellaneous................................................. 45
The usage of remote shut-off systems has increased to the point that very few fleets of karts are shipped without them.

We utilize the Kartrol system. This system uses a main control console that can control karts with a simple radio signal to
a receiver on the kart. The receiver is integrated into the ignition system and “dithers” with it to allow the track operator to
control the ride. Some states are now requiring concession go karts to be equipped with remote shut-off systems, so check
with your state regulatory bodies.

Gone are the days of a stopwatch and flags: today’s timing systems can provide much more than they did before! We offer
several versions, and the most popular not only times the ride, it can also provide an audio and video brief before the ride
even begins. It has a microphone to allow for extra announcements, and can digitally time the ride while automatically
operating the traffic lights as well. It can even provide a secure place to store and operate the remote shut down
transmitter! Trust us: there’s no button on your stopwatch for that…
Various photos of track electronics
Kartrol components & diagrams

Kartrol EXE table top console

The Kartrol EXE table top Console should be located in the pit
area in such a place where as the attendant has a clear view of
the track and the track operators.
Consists of parts #1-60-9005 (console) and #1-60-9013
(transformer).

Kartrol EXE hand held

console
The Kartrol EXE hand held console is a portable version of the
table top console. Same functions.

Kartrol EXE enclosure

Optional weather proof protective enclosure for table top
console. (part #CC-KARTROL-EXE)
Kartrol EXE pit loop generator
Location determined by layout of track. Position should be
determined by placing pit loop in such a place as to ensure go-
karts are completely slowed to pit speed before entering the pit
area. (See Kartrol EXE Manual for installation instructions).
Consists of parts #1-60-9003 (controller) and #1-60-9014
(transformer).

Kartrol EXE SENSOR/

RECEIVER
Located on each go-kart, Consists of part #1-60-9007 (sensor)
and optional #1-60-9000 (receiver)

Kartrol EXE yellow is used with non-CDI engines. (#1-60-9000)

Kartrol EXE red is used with CDI equipped engines (#1-60-9800)
Kartrol EXE remote switch
The table top console allows for optional, hard wired, remote
switches in key locations around the track, enabling attendants
to access global functions as well as pit control on and off.
(#1-60-9009)

Kartrol EXE pocket

transmitter
The pocket transmitter is a low range device capable of sending
the four global commands. It is best suited for emergency
backup or as a shop tester.
(#x-xx-xxxx)

Kartrol EXE micro transmitter

The mini switch and micro transmitter are best suited for kiddie
karts like the Falcon and for use on bumper boats. This unit is a
low range, two channel control system that can perform a stop/
start function on drive motors as well as squirter control on
bumper boats. Due to its microprocessor control and isolated
contacts, it can also be easily adapted to many other remote
uses around the track.
Kartrol EXE programmer/
shop tester
The programmer/shop tester makes it easy to diagnose
issues or change control unit numbers on site. This allows for
maximum flexibility while reducing the need for spare controls
and unnecessary trips to the repair shop. It can also be used as
to test pit control.
KARTROL EXE - CONSOLE INSTALLATION
The Main Console is intended to be used at a track attendant station. It requires a 110V outlet to power the AC adaptor to
the console. It should be positioned where the attendant has good track visibility of all areas.

The optional remote switch boxes connect to the main console. Any number of remote switch boxers can be connected.
They can be mounted at additional track attendant stations or at critical areas of the track, making it easy to safely operate
the track from many positions. The remote switch boxes allow the operator to address the STOP, SLOW, MEDIUM and GO
functions as well as turn on and off the Pit Loop Transmitter. These boxes should be mounted securely in a dry, safe
location such as on a light pole. It is low voltage in the wires so while it must be protected from damage, it is not a voltage
hazard.

The Main Console is weather-resistant but NOT waterproof.. It should be protected from rain. Direct sunlight may reduce
the life of the Mylar covering.
Optional enclosure (#CC-KARTROL-EXE) helps protect expensive electronic equipment.

Optional Enclosure
(#CC-KARTROL-EXE)

Table Top Console

(requires 110 vac)

Pit Area
 Audio Speaker(s)
(Typical 4 places around
pit area)

Video Display(s)
Mounted under roof, facing
que area in waterproof enclosures.
(Typical 2 places,)
Traffic Light
(#A01342)
Orient light towards CC-100-1504-FLAS
track so it can be
viewed from go-karts.
& Kartrol Enclosure

12
0V
AC
120
VA
C
Loop
Pit

120
VA
C
Pit Loop

AC
0V
12
Pit Transmitter
General layout of electronic components

(#1-60-9003)

DIR
E
mounted in waterproof
CT
enclosure. (Above ground, on post) IO
Taps into “RED” light for power. N
OF
TRA
VEL

Traffic Light
(#A01342)
Orient light towards Pit Transmitter
track so it can be
viewed from go-karts. (#1-60-9003)
mounted in waterproof
enclosure. (Above ground, on post)
Taps into “GREEN” light for power.
 Kartrol EXE manual
(Manual per Proleg Technologies)

The Kartrol EXE was developed in response to the ever-changing needs of track operators. It incorporates all the features of
the Kartrol EX system and goes way beyond in its flexibility and capability.

THE MOST SIGNIFICANT FEATURES OF THE EXE SYSTEM ARE:

 The ability to control either gas or electric karts. The receivers are different for gas or electric karts; however the
transmitters and other controls are the same.
 The ability of the operator to program the kart receiver number and the track number, meaning a single spare can be
programmed in the field to any track and any kart number.
 The ability to control individual karts in all modes, most notably the reset mode, allowing a single kart to be reset
without resetting any others - the provision for wired remote switches for the main functions, including turning on
and off of the pit loop.
 Three speeds for gas karts: stop, slow and medium plus full throttle.
 The actual rpm of all three modes, stop, slow and medium, can be varied from the factory presets by the operator to
allow for different track variables.
 The ability to remotely control other devices such as traffic lights, message systems or even the pit loop.
 New, more accurate pit loop system, allowing for control of karts without affecting karts on adjacent lanes or elsewhere
on the track.

All of these features combine to make the Kartrol EXE the most flexible and user friendly go-kart control system.

CAUTION: The Kartrol EXE system is designed to be an aid to existing safe track operating procedures, and the
possibility of a failure in the system should always be considered and allowed for in the track operating procedures.
Testing of the system should be done daily and regular inspection of all mounting and wiring should be done every time the
kart is being serviced.

It must be understood that the Kartrol EXE system does not directly slow the karts, but rather reduces engine RPM to where
the kart will coast to a stop. The system does not apply the brakes in any way, and depending on the RPM speed selected
and the condition of clutches, bearings, etc. on the kart, the rate of deceleration can vary somewhat.

All employees operating the track should be familiar with the system, and know what to do in case of a system malfunction.
If safe track operating and pit procedures are used in conjunction with the system, the track should be very safe and easy
to operate.
Testing and Installation
If you are testing an EXE system for evaluation purposes, or have just received karts from the manufacturer with the EXE
system, it is VERY IMPORTANT that you test the system in the following manner.

1. Install an EXE receiver on the kart. If this is a test, you can connect the wires, and duct tape or tie strap the unit and
sensor on the kart in a reasonable location.
2. Start the go kart and test the receiver using a table top or hand held transmitter. Test all functions, and if they work
proceed to #3, or refer to the trouble shooting guide.
3. Have someone drive the kart around the track and try to control the kart at various locations, verifying there are no
dead spots. Attention should be paid to the locations farthest from the transmitter, and behind any obstructions such
as bridges. If there are dead spots, the antennae wire probably needs to be stretched out, or refer to trouble shooting
guide.
4. As the kart is being driven around the track, press the SLOW button at various locations to find the spot on the track
where the pit control loop should be located. The EXE Loop will need to be saw cut in to the track for final installation,
but for testing purposes it can be taped down to the track surface. Determining the correct location for the pit loop is
very important to safely and effectively controlling the karts entering the pit area.
5. Once the location for the loop has been determined, tape the loop to the track surface and connect the pit loop
transmitter. Temporarily run an extension cord and power up the pit transmitter. Powering it up will activate the loop
and the kart should now be driven across the wire at full speed. If the kart does not respond to the loop, the sensor is
probably not mounted in a good location. If this is a test, try moving the sensor to locations where it would be ideal to
be permanently mounted. In that way, once you verify that it works in that location at full speed, you will know were to
begin mounting these sensors for permanent installation. If this kart has the sensor mounted at the factory it should
be in a good location, but there are some variables that may cause the sensor not to work in that location and it may
need to be moved from the factory mounting location. It is very important to get the correct sensor location before
spending time installing all the units. Note that different styles of karts may need the sensor mounted in different
locations, even though the frame looks similar.
6. If this is a demo test you can now read through the manual and try other features such as changing the RPM speeds.
If you have any questions or concerns you can contact your kart manufacturer or our Tech line at 204-254-7176
7. For a track setup, you should now test all karts on all functions including the pit control before you begin final
installation of the pit wire etc.
 TRANSPONDER INSTALLATION
Wiring Diagrams-Gas
Step 1- disconnect the Honda On/Off switch

Step 2- connect the red wire from the transponder to both Honda connectors, and mount the black wire hoop to a good
engine ground such as a carburetor bolt or gas tank bolt.

Location of the transponder may be critical to reliable operation and longevity of the unit. The transponder should be
mounted in a relatively dry and safe location on the kart, away from the motor or batteries and motor controller on
electric karts. Some possible locations for mounting transponders are:

 On the roll bar or headrest

 On the steering support column
 Under the body along the side by the seat
 Near the front of the kart frame under the body
The transponder must be mounted with the harness plug towards the ground to prevent any water from wicking along
the harness.

The black wire is the antenna and should be stretched out as much as possible. Preferably away from motor, motor
controllers, and batteries. It is wise to mount one transponder and then test on the track for proper range and function. If
it is not satisfactory, change the antennae routing and retest. Once you are satisfied the unit operates correctly, mount the
remaining units the same way.

If the kart transponder has the optional pit loop sensor, it must be mounted on the frame away from motor, motor
controller, and batteries. A good location is in the front half of the kart as close to the outside of kart as is safely possible.
It is also a good idea to stay out from a corner between two frame members. The wire coming out of the sensor must be
to the top and the sensor bottom should be as close to the bottom of the frame rail without hanging below the frame.
Again, a single unit should be mounted and tested on the track to ensure correct operation with the pit loop before
installing the remainder of the units.

If there is no suitable location down on the frame, or if the sensor does not pick up the loop signal on that style of kart
when mounted down on the frame, you can mount the sensor on an upright or body support near the side or rear of the
kart.

Some kart models work best with the pit sensor mounted approximately 8 to 10 inches off the ground on a wing support.
The pit loop signal can be received as much as 2 feet above the ground when properly installed.

Loop sensor (Factory location)

Engine

Possible location
Some trial may be needed on location for each model of kart (top view of go kart)
Secure to frame rail using self tapping screw.

Optional mounting on upright.

 During kart maintenance, do not pressure wash the transponder boxes.

 If you need to weld a kart frame, disconnect the transponder from its harness to avoid back feeding power through the
ground.
 The wiring harness should be routed and secured such that it will not get damaged.
 The transponder must be securely mounted and protected from damage when removing kart body.
 A little care in good solid installation will go a long way
Wiring Diagrams- Electric

KARTROL EXE
GO-KART
REMOTE ENGINE CONTROL

MODEL: EXEG-0207 MADE IN CANADA

Antenna wire - stretch out as much as possible

Black - ground, battery 12v

Orange - Turbo

White - cut back speed

Blue- cut back speed

Yellow - Center/FWD/REV switch

Red - 12v+ on Sevcon

The actual wiring will be slightly different depending on engine, motor controller, and kart model. You must follow the kart
manufacturer’s exact wiring diagram.

Pit Loops are not often required on electric kart tracks as the medium or slow speeds are very accurate and the tracks are
generally short enough, such that a lap on the slow speed does not present a large problem. However if Pit Control is desired
on electric karts we require the specifics on motor, motor controller and type of chassis to determine if the pit loop sensor
will work in that application. The electrical fields given off by the motor can cause the pit sensor to false trigger or may
prevent it from operating at all. The sensor location becomes very critical on electric karts.

The pit loop sensor is different on electric karts and must be specified at time of ordering.

In addition, the Pit Loop transmitter is different from the gas EXE Pit Loop Transmitter.
 Pit loop installation

Track railing

2”

10’
Place wire in 1/4” to 1/2”
deep saw cut.

2”
Track railing

110 vac

Pit loop signal generator

(Mount to post in water tight enclosure)

The Pit Loop is intended to slow karts to a safe speed before entering the pit area. It requires
the Optional pit loop sensor installed on each kart, connected to the kart transponder.

The Pit Loop Transmitter generates a coded signal that is picked up by the kart sensor when
it drives across the Pit Loop wire embedded in the track. The actual location of the Pit Loop
wire is the point on the track where you want the karts to begin slowing. By using duct tape
to hold the Pit Loop wire on the track, you can experiment to find the correct location for
the pit wire, such that the kart will be at the desired speed as it enters the pit area. Generally the Pit Loop transmitter is set
to the SLOW speed, so as to allow karts to propel themselves all the way to the front of the Pit area. Once all karts are in the
Pit area, the attendant can push the STOP button to make loading safer.

Once the ideal location of the Pit Loop wire is determined, it should be installed in a saw cut in the track surface and sealed
with a sealer or caulking. The Pit Loop wire runs from the Pit Loop transmitter, across the track, along the other side of the
track for 10 feet, and then back across the track to reconnect to the pit transmitter.
It is recommended that the wire be put into a saw cut of approximately ¼ to ½-inch deep. It is best if the wire is run
approximately 6 inches out from the guardrail on the far side of the track (see diagram). We have found that the pit signal
is optimized when the wire actually makes two loops. This means the wire is run across the track, along the far side, back
across, down the close side to the starting point, then across, along the far side, across, and along the track to the starting
point, then back to the pit transmitter. The wire can be set on top of one another in the saw cut.

The Pit Loop transmitter should be mounted on a short post in a waterproof enclosure. Failure to do so may destroy unit.

The Pit Loop transmitter has an AC adaptor that is plugged into a 110V outlet. Plugging the unit in directly to 110 volt will
fatally damage the unit.

The Pit Loop Transmitter can be programmed to output any of the main functions: STOP, SLOW, MEDIUM, or GO.
The SLOW speed is the most common for pit speed, but other codes may be used for additional track operations.
Programming is done using dip switches inside the Pit Loop transmitter box.

To turn the Pit Loop ON and OFF there are a number of options:

1. Switch the 110V power ON and OFF to turn on and off the pit transmitter. This also could be done by connecting
the 110V outlet into the traffic light system if equipped. In this way the Pit Loop would turn on when the red light is
activated.

2. A switch could be put in the low voltage line from the AC adaptor to the Pit Transmitter

3. Using the optional remote switch box on the Main Console.

4. By radio signal from the Hand Held Transmitter or Main Console. In order to use this feature the radio receiver inside
the Pit Loop Transmitter must be activated. This is done by selecting Switch #4 on the dip switch bank inside the Pit
Loop Transmitter.

Then to activate the Pit Loop, push #91 and then GO to activate the Pit Loop. To deactivate the Pit Loop, push #91 then
STOP.

Programming the Pit Loop

The Pit Loop is generally shipped programmed to Track#1 and to address the Crawl function. To program the Loop to
operate on a different Track # you need to program as follows: with the cover off.

 Unplug the AC adapter from the 110 volt supply and wait 20 seconds
 Make sure dip switch # 4 is ON, and turn ON dip switch #8
 Plug the power back in and using a Table Top or Hand Held Control programmed to the Track# you want the Pit Loop
to respond to, press 91, then GO and then 91 and STOP. The LED light on the Pit should be ON after this.
 Unplug the power once more and wait 20 seconds, then turn dip switch # 8 OFF
 Plug back in the power and the lights should be ON. Press 91, GO, and then 91, STOP. The light should be off now and
the unit is ready to operate.

To change or reprogram the function that the Pit Loop addresses, you need to open the cover then using the yellow guide
label, only adjust the first 3 switches as follows:

For STOP- #1, 2, 3 all OFF

For Crawl- #1, 2 OFF, 3 ON
For Medium - #1,3 OFF, 2 ON
For Go or Reset - #1 OFF, 2, 3 ON
 OPERATIONS
The KARTROL EXE is very easy to use right out of the box. However, certain steps must be followed to enjoy all the
features.

CAUTION: Never power up a console or Hand held transmitter without having the correct antennae installed. This
can damage the transmitter.
Most EXE systems have the transponders already mounted on the karts by the kart manufacturer. The transponders may
be programmed to the correct kart number and track, if this information was conveyed to the manufacturer before or
during installation. If this was not done, all KARTROL EXE receivers will come pre programmed to respond to Kart #1, Track
#1. If they are mounted on an electric kart they should also have been set to electric operation.

The following procedures will guide you through the programming and operations of the EXE system.

Programming the Hand Held or Table Top Console

 Programming must be done when more than one track at one location will be using the Kartrol EXE, and also if
batteries are removed or discharged completely in the Hand Held or Table Top Console. The Hand Held transmitters
are generally shipped with batteries removed and therefore will need to be programmed upon arrival. The factory
default is Track 1 with Gas function.
 Power ON – push and hold PWR button for 2 seconds on older models, or instant on new models.
 If there is a letter “P” on the back of your table top console, you can activate programming mode by pushing a
straightened paper clip gently into the hole in the center of the letter P. If it does not have the P etched into the
console, follow the instructions below.
 Hand Held transmitters may have a programming hole in the back, but it is not etched with the letter “P” as the Table
Top console is. If there is a small hole on the back of your hand held, in the top half in the middle, then gently push a
paper clip in to enter programming mode. If there is no hole, or you choose to do so, follow the directions below.
 With power on, enter programming mode by simultaneously pressing the bottom left three buttons (PWR, O and CLR).
This may take a few attempts as it was designed to be such that accidental access would not occur. When successful,
the LCD screen will read:

Software version 1.1.1

Note: If you have a console with the letter “P” etched on the back the software version will read 2.1.1
(Stop continues) Individual kart,
press #, then function. Function

1 2 3 GO
4 5 6 MED
All karts
respond
7 8 9 SLOW
Press on/off
Press & hold.
PWR 0 CLR STOP

Push all three buttons at same time

to enter program mode.
 Pressing the STOP button will change the screen to the next screen where a different track number can be set. The
screen will appear as:

Enter Track #
( stop sets )
01
 If only one track is one the site and no other tracks are within the effective radio area, it can be left at Track #1. If so,
simply push Stop to set this number and advance to next screen. To change the track number, press CLR and then
the track number desired, e.g. “2” It is not necessary to enter the zero before numbers 1 thru 9. Then press the STOP
button to set this track # into memory. It will also change to the next screen.

Note: The letter P console has one additional screen before the gas / electric screen. It will have - Pit: shared or
standard. In almost all cases you would select standard by pushing the STOP button. The shared pit is only used when
you have two different coded fleets of cars using the same track. The shared pit feature allows the cars of both fleets to
respond to the same pit control. For this feature please contact our tech line first.

Select Mode
Go= Gas
Stop= Electric

 This screen allows you to select for Gas or Electric kart. Press GO to program for Gas Karts and STOP to program
Electric Karts. Pressing either one will enter that setting into memory and advance to the next screen.
 · If Electric operation was selected then programming is complete and the transmitter is ready for operation. The Track
# is displayed and a letter “E” for Electric is also displayed in the upper right of the screen.

Track 01 E
Enter Kart /Func:

This is the general operation screen and you have left the programming mode. If you made an error, simply repeat the
process.
 If Gas was selected, the next three screens allow the operator to vary the actual rpm that the karts will be slowed to
at each of the speed settings, beginning with the Medium Speed. The factory presets are in the middle of the range,
and should be correct for most locations.. If no change to the preset speed is desired, simply press STOP and the next
screen will be the rpm for the SLOW speed. Again pressing Stop will advance to the next screen which is the Stop rpm
speed. It is recommended that you try the karts at the factory set speeds first and only if you see a need, modify these
settings.
 To change the rpm of the speed, you press the MEDIUM button to increase the speed or the Slow button to decrease
the speed. Each press changes the rpm by about 25 rpms, and one bar will be added or subtracted from the bar
graph. When you have adjusted speed to where you want to try it on the karts, press STOP to set into memory.

Note: When you make a change to the RPM settings this change is sent to the receiver from the transmitter. In order
for it to be locked into the memory in the receiver, you must cycle through all the functions once. Then the next time the
receiver gets the signal it will respond to the new RPM. If you are changing the RPM on one unit to try, all transponders
that are turned on will receive this information. Those that are not on will not hear that change until they are cycled
through the functions one time.
 The screen will advance to the SLOW speed. If desired, adjust the settings for the SLOW speed and press STOP. The
screen will now move to the STOP speed rpm settings. Adjust as desired and press STOP to set it into memory. This
will complete programming and will enter normal operation mode. The track number is displayed and the letter “G”
for GAS is displayed in the upper right corner.

Track 01 G
Enter Kart #/Function:
_
If any mistake has been made, simply re-enter the programming mode and reprogram.

 Now that the transmitter, either Hand Held or Main Console version, is programmed, it is necessary to program the
receiver units to match that transmitter. If no changes were made on the programming this may not be necessary.
The information such as Track # and Gas or Electric is transferred to the receivers from the transmitter when
programming the receivers, therefore it is necessary to program the transmitter first and then the receivers.
 If two transmitters are to be used on the same track, it is necessary for them to be programmed exactly the same.

PROGRAMMING KART TRANSPONDER/RECEIVER

To program the kart receiver/transponder it is necessary to use the transmitter that you will be using on that track. This
transmitter should be programmed to the Track #, and mode of Gas or Electric, that you require. The information from the
transmitter is transferred to the transponder which will lock this into memory. On Gas karts the RPM speed settings are
changed on the transmitter and then sent to the receiver.

 Connect the transponder to the Programmer/Shop Tester. Be sure connection is secure. It is a good idea to gently
twist the connector back and forth as you push the connectors together. There is a raised mark on both halves of the
connector that must be aligned. Failure to properly connect the two halves will make it impossible to program the
unit.
 Press the Power button and turn on the Programmer. The green LED will flash. Wait until flashing stops. The LED light
should be on in the SLOW mode. If not, check the connection between the connector halves.
 Turn on the Program mode button. This causes the red LED to light up, and again, wait for the green LED to stop
flashing. The STOP LED light should be lit.
 - Turn on the transmitter, either Hand held or Table Top model. It is very IMPORTANT that the transmitter is at least 3
feet away from the programmer so as not to distort the signal. If you are using a Hand Held transmitter, it must be
held in the vertical position, Not laying down on a table.
 - If you do not want, or desire, to have the ability to address karts individually by kart number, simply push #1 button
then GO button. This will program the unit to Kart 1. If programming was received by the transponder the tester will
change to GO.
 To program a kart number, enter the number you wish to program into the transmitter, check on the LCD screen that
the correct number is showing, then push GO on the transmitter. The LED on the tester should change to GO mode.
 Turn off the program mode button and wait for the green LED to stop flashing. This is very important to wait during
this time period. Do not unplug the transponder from the tester before the flashing stops.
 Using the transmitter, test the transponder by pushing the GO, MEDIUM, SLOW and STOP buttons and watch that the
LED’s on the tester change accordingly. This confirms the transponder works on the global settings.
 Select a kart number different than the one you programmed, enter that number, and then push a function that is
different from the current mode.

Example: Kart #1 was programmed, push #2 and then GO if the tester showed STOP. The tester should not respond.

 Select the kart # you programmed, enter it, and then push a function that is different from what is showing on the
tester. The tester should respond to the function you selected.

Example: Tester shows STOP. Enter #1, then push GO. Tester should change to GO, confirming that the signal was
understood.

 Turn off Programmer/Tester and disconnect the transponder. It is now ready for installation on the kart. This can also
be done while the transponder is mounted on the kart simply by disconnecting the kart harness and connecting the
Programmer.
 Repeat this programming to all receivers to be used on that track. If individual control of karts is not desired, program
all of them to Kart #1.
*CAUTION: The Programmer/Tester has a fairly significant draw on the batteries, and if they become low, the
programming or testing may not work. The power LED should go to yellow when the batteries are low, but it may be
possible for the tester to begin malfunctioning just before this happens. If you detect any problem in either testing or
programming, put a fresh set of batteries into the tester and retry. Note: you can use either a 9 volt battery or 2 AA
batteries. We recommend the use of the 9 volt as it lasts much longer.

MAIN CONSOLE INSTALLATION

The Main Console is intended to be used at a track attendant station. It requires a 110V outlet to power the AC adaptor to
the console. It should be positioned where the attendant has good track visibility of all areas.

The optional remote switch boxes connect to the main console. Any number of remote switch boxers can be connected.
They can be mounted at additional track attendant stations or at critical areas of the track, making it easy to safely operate
the track from many positions. The remote switch boxes allow the operator to address the STOP, SLOW, MEDIUM and GO
functions as well as turn on and off the Pit Loop Transmitter. These boxes should be mounted securely in a dry safe
location such as on a light pole. It is low voltage in the wires so while it must be protected from damage, it is not a voltage
hazard.

The Main Console is weather-resistant but NOT waterproof. It should be protected from rain. Direct sunlight may reduce
the life of the Mylar covering.

CAUTION: Never use a transmitter without the antennae being connected. If antenna gets damaged, replace it
immediately. An extension cable can be used to locate the antennae in a better location. This may be very important
when the console is located under a pit structure, or if bridges or other obstructions may block the signal from the console
location.

The proper cable and maximum length are very important. Only an extension cable supplied by Proleg Technologies can
be used. Failure to use the correct cable will damage the transmitter immediately.

MAIN CONSOLE/HAND HELD OPERATIONS

Both Hand Held and Main Consoles have the ability to control all karts, individual karts, and may control other devices
such as the Pit Loop, a message system, or traffic lights. The Transmitters are capable of controlling 89 karts individually
and up to 99 different tracks. Unlimited numbers of karts can be controlled at a time if they are numbered the same.

Individual kart,
press #, then function. Function

1 2 3 GO
4 5 6 MED
All karts
respond
7 8 9 SLOW
Press on/off
Press & hold.
PWR 0 CLR STOP

Push all three buttons at same time

to enter program mode.
To control all karts on the track, simply push the function you want to activate. e.g. SLOW. All karts will respond to these
four functions. To address a single kart, push the kart # and then the function. Only that kart will respond.

* CAUTION: It can be dangerous to slow an individual kart down on the track. It should only be done when
attendant has total track visibility and can determine it is safe to do so. Many tracks do not allow attendants to slow
individual karts. It is far safer to slow all karts to deal with a problem driver or accident.

Below is a chart of the additional functions that can be accessed on the Hand Held
or Main Console.

# GO STOP
91 Activates Pit #1 Deactivates Pit #1
92 Activates Pit #2 Deactivates Pit #2
93 Activates Pit #3 Deactivates Pit #3
94 Activates Pit#4 Deactivates Pit#4
95 Activates Rookie Deactivates Rookie
96 Turns on lights Turns OFF lights
97 Starts Timer Stops Timer
98 Aux 1 ON Aux 1 OFF
99 Activates TURBO Deactivates Turbo

Some of these features require an additional receiver or control to activate.

The Main Console has battery backup in case of power failure. The AC adaptor keeps these batteries charged.

The power must be turned off or disconnected once per day to reactivate the battery charging circuit. If left powered on
continually, the charging circuit may turn off and the unit will run on the batteries until they run down.

*** Only use rechargeable nickel metal hydride batteries. Use of alkaline batteries could cause fire or explosion if put on
charge!***

Trouble Shooting and Diagnostics

When troubleshooting a transponder, it is important to carefully revue the symptoms and confirm them. This is especially
important when the information was relayed to the mechanic by an attendant. Not having all the information may make
diagnostics very difficult and time consuming. Methodically testing all functions and noting under what circumstances the
symptoms are occurring, will give valuable information for determining exact cause.

For example: the attendant says the kart won’t slow down. Does this mean it will not slow down when all Slow is pushed,
or when it crosses over the pit loop? Does it function off the hand held transmitter, but not off the pit loop?

One of the advantages of the Kartrol EXE transponders is the ability to use the Kartrol Programmer/Tester. The use of the
tester will immediately confirm if the problem is in the transponder or the harness and installation.

To test a Kartrol transponder, unplug the unit from its harness right at the transponder. It is not necessary to remove the
transponder. Then plug the unit into the Programmer/tester, being careful to get a good secure connection. Turn the
power On and wait for the LED to stop blinking. If the programmer does not light up in the Slow mode, check the
connections. It is possible that pins in the connector are pushed in, preventing a good connection. Inspect both sides of
the connector and if needed, gently push the pins back into position using a fine screwdriver, being careful not to damage
the wire. If the tester still will not boot up in the Slow mode, try plugging a known working transponder in to the tester. If
that also does not boot up in Slow mode, change the batteries in the programmer.

With the transponder plugged in to the tester and the Slow light is on, push each one of the all kart functions and if the
corresponding LED lights come on, then the unit is working. If you have the optional Pit Loop, you can walk over to the
Loop with the tester and wave the sensor over the loop wire. It should make the tester change to whatever mode the pit
loop is set to.

If the transponder does not respond to the testing, you can try to reprogram the transponder and retest. It is possible that
something has caused the programming to be corrupt, and following the procedures in the Programming Transponder
section will correct this.

If you do not have a Programmer/Tester, the easiest way to begin diagnostics is to plug a spare or known working
transponder into the kart harness on the problem kart. If the new transponder works, recheck the suspect transponder,
being sure to inspect the pins in the connector. If it still does not work, send it in for repair.
If the spare transponder also does not work, then the problem is in the harness or installation. Check all wiring and
connectors. It may require a continuity meter to properly verify connectors are working.

Some Common symptoms and solutions:

All karts will respond to STOP, MEDIUM, but will not GO
Check the LCD screen, it will probably have an R . This is for a Rookie speed on electric karts to deactivate the Full speed on
the transmitter, o an attendant can’t accidentally hit GO during a ride. It was activated by someone pushing #95 then GO.
To deactivate, push # 95 then STOP.

Transmitter won’t power up-

Check batteries and charging cord, then wait at least 3 minutes with unit on charge and try again. If batteries are too weak,
it will take a few minutes of charging before unit will power up.

Pit control transmitter not working-

Check the power to the pit transmitter and unplug, wait 15 seconds, and plug back in. If the radio feature on the pit
transmitter has been activated (see pit control programming) it may be turned off by pushing 91 STOP. To turn on, push
91 GO. Hook a transponder to the programmer/tester, turn on the tester, hit GO on the transmitter, and then walk across
the pit wire with the tester sensor hanging in a vertical position 1 foot above the wire. It should change the tester to the
SLOW position if the pit transmitter is working. If it is and a kart does not respond, then the pit sensor on the kart needs to
be relocated or is faulty.

Constant Beeping from Table Top transmitter-

Check remote switch connector on side of console to see if pins are shorting, or if remote switches are hooked up, a
button is sticking or a short is in the wiring.

Testing Pit Loop Sensor-

Gas – using a multi-meter set on continuity, you should get a reading of approximately 1.3. Setting the range to the 20k
scale, the reading should be 2.2k.
For electric sensors the reading is .48k approximately on the 20k scale or 4.2 on the continuity scale
 KARTROL COMPONENT WIRING
Hip transmitter (#1-60-9017)

Hip receiver (#1-60-9018)

Remote switch with pit control
(#1-60-9009)

Requires 120Vac circut. Low voltage cable Carried on person, near to

in conduit to control panel (pit area). hip receiver. Transmits
wirelessly. Range is
approximately 50’-100’.

Or

Remote switch (#1-60-9043)

Conduit, Low voltage from hip receiver to console.

Conduit, Low voltage from remote switch to console.

Antenna extension
(#1-60-9019), used
on larger tracks.
Includes 25’ cable, mount

Conduit, Low voltage from remote switch to console.

plate and antenna.

Ground

8 pin cable
(#1-60-9011)
Green
Green to green, etc.
Command console, to green, etc.
located in pit area.
(#1-60-5005)
ORANGE WIRE

WHITE WIRE

GREEN WIRE
GREEN BUTTON
“ALL GO”
BLACK WIRE

Kartrol EXE, BLACK WIRE (GROUND)

not included in BLACK WIRE

BLUE BUTTON PIT ON/PIT OFF SWITCH
“ALL MEDIUM”
command console.
BLUE WIRE
(#1-60-9005)
BLACK WIRE
YELLOW BUTTON
“ALL SLOW”

YELLOW WIRE

BLACK WIRE
RED BUTTON
“ALL STOP”

RED WIRE

Inside of console door.

to buttons
on door.
 TRAFFIC LIGHT WIRE DIAGRAM
, g

CONDUIT WITH 120VAC TO LIGHT

CONDUIT WITH 120VAC TO LIGHT

cc-100

traffic control

OFF ON

Installation Instructions:
MESSAGE

LOCAL
PAGE

1) Mount console to any surface using

Unistrut and spring nuts.
2) Remove bottom panel and knockout
holes for all conduit connections (power,
speakers, track control system).
3) Connect one dedicated 12-
vac/20amp circuit to the terminal
strip(H=hot, N=neutral and ground is the
OUTPUT TO SPEAKERS

yellow/green.
Di
cc-100

4) A terminal strip is provided for

re
traffic control

connection of traffic lights. N = neutral, ct

io
TR = Red light flashing, AF = Yellow n
OFF ON

light, FIC = Green light.

5) Connect 70v P/A speakers to the
positive/negative for speakers out. MESSAGE

Speakers should be tapped at a max of

2 watts to protect amp.
LOCAL
PAGE

6)Caution Power Switch does not turn

off Amp and Message Repeater, outlet
is always on.

POWER IN:
CONDUIT WITH 120VAC, CONDUIT WITH 120VAC TO LIGHT
20 AMP CIRCUIT
CONTROL CONSOLE

TOP CAP (#013446)

TRAFFIC LIGHT
8X8X8 Inside the console
(#013434)

COMMON/WHITE WIRES

GREEN LIGHT/GREEN WIRE

YELLOW LIGHT/YELLOW WIRE
RED LIGHT/BLACK WIRE

ENLARGMENT
WIRE DIAGRAM OF TERMINALS
LOCATED INSIDE OF STOP LIGHT
4’ to 6’
(1.2 to 1.8m)
MOUNT KIT (#013445)

1-1/2” PIPE

Video Audio Speaker Traffic lights, Traffic lights,

AC lights
70 volt, 12 watt 70 volt, 12 watt
industrial speaker industrial speaker

Black -

Black -

Brown +
Brown +
- +
SPEAKER WIRE DIAGRAM

Brown +

Brown +
Black -
Black -
70 volt, 12 watt 70 volt, 12 watt
industrial speaker industrial speaker
How the traffic light console works

Start ride

To start the ride timer, push the green traffic light control button. This will start the timer and begin the ride. After the
time has completed, the night ringer will sound indicating to the attendant this is the last lap and the ride is over.
The yellow traffic lights on the track and console button will flash for 15 seconds. After that time, the red traffic lights
and console button will switch to a solid red light. The audio message will play “ Stay Seated Until All Karts Are
Stopped”. To stop the audio message, push the message button up or down. The audio message will stop and the
ride briefing will begin.

After 5 minutes of inactivity, the console will switch to a sleep mode. The traffic lights will also switch off. Simply
push one of the green buttons to wake up the console.
note; the console power is still on when in sleep mode.

When the main power switch is first turned on, the console will switch to the same steps as if the ride is over.

See the buttons function & operations for more details.

Button description and operation
Power switch:
Turns the main console power on and off.

Power switch

Traffic light control buttons:

RED TRAFFIC CONTROL BUTTON; ends ride

cycle and activates red traffic lights. Red light
YELLOW TRAFFIC CONTROL BUTTON; activates
the yellow traffic lights signaling a full track
caution. Message
Yellow light
NOTE; ride timer is still active.
GREEN TRAFFIC CONTROL BUTTON; activates
ride time cycle and turns the green traffic lights on. Green light
MESSAGE SWITCH; push the switch down to play
the message once. Push the switch up to have the
message play continuously.

Kartrol remote switch buttons: on/

off
Pit

GREEN ALL GO BUTTON; activates the karts to All go

“All Go” cycle and activates the green traffic light.
Micr
oph
BLUE ALL MEDIUM BUTTON; activates the karts one All med

to “All Medium” speed cycle.

YELLOW ALL SLOW BUTTON; activates the karts All slow

to “All Slow” cycle and activates the yellow traffic

light signaling a full track caution. All stop

NOTE; ride timer is still active.

RED ALL STOP BUTTON; activates the karts to
“All Stop” cycle and activates the yellow traffic light
signaling a full track caution.
NOTE; ride timer is still active.
PIT ON/OFF SWITCH; activates and deactivate
the pit loop in wireless mode only.
NOTE; if the pit loop signal generator is being
powered by the traffic light, the switch will have no
function.
MICROPHONE; this allows the operator to speak
thru the overhead speakers.
Programming the smart relay

Press the arrow down key

Display will flash.

Press the “ESC” key.

Arrow down to “Set Param”.

Press “OK” key.

 “B1”
RIDE TIME.

Adjust the “T” colum only.

00: = minutes & :00 = seconds.

Image shown here is set to 5 minute ride time.

Press the down key for the next setting.

“B27”
YELLOW LIGHT FLASH
Setting the flash time after the end of the ride.
The yellow light will flash equally between off and
on.

“TH”= light on.

“TL”= light off.
“TA” not used.
00: = second & :00 = tenth of a second.
Image shown is set to 4 tenths of a second.
“TH & “TL’ are set the same.
Press the down key for the next setting.

“B26”
RED LIGHT.
Setting the red light to stay on and not flash.

“TH” = light on.

“TL” = light off.
00: = seconds & :00s = tenth of a second.
Image shows “TH” set at 5 tenths of a second.
“TL” set at 0.
“Ta” cannot be adjusted.
Press down key for next setting.

ADJUSTING TIMES IN SETTING MODE.

To adjust times press “OK” key.
The first digit will flash.
Press the up & down arrow key to raise and lower
the time.
Press the right arrow key to adjust the next digit.
Press the “OK” key to save the setting.
“B19”
YELLOW LIGHT.

“T” can be set at minutes & seconds

00: = minutes & :00m = seconds.
“Ta” cannot be changed.
Image shows “T” set at 15 seconds.

Press down key for next setting.

“B15”
SLEEP MODE.
Setting the time before the console switches into
sleep mode. If the console is inactive for set period
of time, the console will go into “Sleep Mode”.

“T” can be set to minutes & seconds.

00: = minutes & :00 = seconds.
Image shown is set to 5 minutes.
“Ta” cannot be changed.
Press the down key for the next setting.

“B12”
ATTENDANT ALERT TIME.
The amount of time alert sound plays.

00: = seconds & :00s = tenth of a second.

Image shows “T” & “Ta” set at 6 seconds.
“T” & “Ta” need to be set to the same time.

Press down key for next setting.

ADJUSTING TIMES IN SETTING MODE.

To adjust times, press “OK” key.
The first digit will flash.
Press the up & down arrow key to raise and lower
the time.
Press the right arrow key to adjust the next digit.
Press the “OK” key to save the setting.
AFTER SETTINGS HAVE BEEN CHANGED.

Press “ESC”

Display will return to settings screen.

Display will be flashing.

Press up key and smart relay will return to

operation mode.
Panel power:
Connect 120 VAC hot wire to terminal “L”.
Connect neutral wire to terminal “N”.
Connect ground wire to terminal “GND” (green & yellow terminal color).
NOTE; the “H” black terminal is not used for connecting panel power.
Traffic signal:
Connect all the traffic lights neutral wires to terminal “N”.
Connect ground wires to terminal “GND” (green and yellow terminal color).
Connect red light hot wire to terminal “204” (red terminal color).
Connect yellow light hot wire to terminal “203” (yellow terminal color).
Connect green light hot wire to terminal “202” (green terminal color).
Speaker:
Speaker output is for 70 Volt speaker only. Most commercial speakers are multi-tap type.
Connect the speaker common wire to the “-” speaker terminal.
Connect the speaker 70Volt wire to the “+” speaker terminal.
Video:
Video style cable must be used for this purpose.
Connect the wire to the “+” video terminal.
Connect the outside shield wire to the “-” video terminal.
Audio:
Audio out is a millivolt-type output and is for feeding into audio equipment.
System requirements:
120v 20 amp dedicated circuit for console and traffic lights.