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<strong>SmartKART</strong> <strong>Series</strong><br />

Service Manual<br />

<strong>SmartKART</strong><br />

Electric Utility Machine<br />

Manufactured by:<br />

Dane Technologies, Inc. Phone: 763-544-7779<br />

7105 Northland Terrace Toll Free: 1-888-544-7779<br />

Minneapolis, MN 55428 Fax: 763-544-4234<br />

www.danetechnologies.com<br />

Part No. 970-032 Rev D Rev. Date: 10/12/10


Table of Contents<br />

Topic Part<br />

• <strong>SmartKART</strong> Troubleshooting Guide 1<br />

• <strong>SmartKART</strong> Service Bulletins 2<br />

• <strong>SmartKART</strong> Exploded View Diagrams 3<br />

• <strong>SmartKART</strong> Parts Order Information 4


Dane Technologies, Inc.<br />

7105 Northland Terrace<br />

Minneapolis, MN 55428<br />

Part No. 970-104<br />

Rev. - Date: 3-31-10<br />

Dane <strong>SmartKART</strong><br />

Troubleshooting Guide<br />

<strong>SmartKART</strong><br />

Electric Utility Machine<br />

MANUFACTURED BY:<br />

Phone: 763-544-7779<br />

Toll free: 1-888-544-7779<br />

Fax: 763-544-4234<br />

www.danetechnologies.com<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual 3<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10


Troubleshooting Guide<br />

Table of Contents<br />

<strong>SmartKART</strong> Does Not Operate– Section 1 .................................................................................... 5<br />

<strong>SmartKART</strong> Does Not Operate (using tools)– Section 2 ............................................................... 8<br />

<strong>SmartKART</strong> working normally but one item doesn't work – Section 3....................................... 12<br />

Throttle...................................................................................................................................... 12<br />

Control panel LED’s................................................................................................................. 13<br />

Control panel alarm................................................................................................................... 13<br />

Cover under seat won’t open .................................................................................................... 14<br />

<strong>SmartKART</strong> moves when OFF/ON switch turned on – Section 4 ............................................... 15<br />

Green LED on <strong>SmartKART</strong> is flashing. – Section 5.................................................................... 16<br />

<strong>SmartKART</strong> Battery and Charger Problems – Section 6............................................................. 17<br />

<strong>SmartKART</strong> Operates But Has Limited Running Time – Section 7........................................... 20<br />

<strong>SmartKART</strong> needs Service – Section 8....................................................................................... 22<br />

User Assistance Information<br />

An Owners Manual and a Service Manual is available for this machine. If you are unfamiliar<br />

with the operation of this machine, please read and understand all the information in the Owners<br />

Manual before proceeding.<br />

If you have questions regarding the safe operation or maintenance of the this machine, or items<br />

which are not covered in this manual, please contact Dane Technologies at our toll-free service<br />

line: 888-544-7779. Outside the US call 763-746-7779.<br />

IMPORTANT MAINTENANCE NOTES<br />

Check the <strong>SmartKART</strong> daily, for safe operation.<br />

Routine maintenance should only be performed by those permitted by federal and state age<br />

regulations. Repairs should only be completed by Dane Technologies or an authorized service<br />

technician. Federal law requires that you must be at least 18 years old to service the batteries of<br />

the <strong>SmartKART</strong>.<br />

If the <strong>SmartKART</strong> malfunctions in any way, turn it off and tag the unit “DO NOT USE”.<br />

Immediately report the malfunction to the appropriate store manager as well as Dane<br />

Technologies. Do not use the <strong>SmartKART</strong> until it has been repaired by an authorized service<br />

technician.<br />

WARNING<br />

Do not permit open flame, sparks or smoking during maintenance. Adequate<br />

ventilation is essential for safety. Do not lay metal objects on the batteries.<br />

Always test in an unobstructed level area.<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

4


1.0<br />

Status Light<br />

1.4<br />

1.6<br />

<strong>SmartKART</strong> Does Not Operate– Section 1<br />

Turn the OFF/ON switch off, then on<br />

Did the Status Light turn on?<br />

Yes<br />

Is the Status Light flashing?<br />

Yes<br />

Go to next page.<br />

Note: Some<br />

<strong>SmartKART</strong>’s do not<br />

have this label..<br />

Unplug the charger AC cord.<br />

Repeat 1.1 Did the Status Light turn on?<br />

Picture<br />

shows<br />

good fuse.<br />

Bad fuse<br />

has gap<br />

here,<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

No<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

1.1<br />

If you cannot test<br />

the fuse, call for<br />

Service.<br />

No<br />

1.2<br />

Remove the 3 amp blade fuse from under seat<br />

and visually check it. If it is bad and you have a<br />

spare fuse replace it.<br />

Did the Status Light turn on?<br />

No<br />

1.3<br />

Fuse<br />

There is a problem with power or components<br />

requiring repair.<br />

Check the battery before calling for Service.<br />

No<br />

Go to Section 6<br />

1.5<br />

Go to section 5 to review the causes of the light<br />

flashing.<br />

If the flashing light doesn’t stop, Call for<br />

Service<br />

Go to Section 8<br />

5


1.6<br />

Sit on the seat normally, push on the right hand<br />

side of the Hand Control Lever slowly.<br />

Did the <strong>SmartKART</strong> click or move?<br />

1.11<br />

1.13<br />

Sit on the seat normally, turn the OFF/ON<br />

switch ON, push on the right hand side of the<br />

Hand Control Lever slowly.<br />

Did the <strong>SmartKART</strong> move?<br />

1.15<br />

1.17<br />

When pushing on the right hand side of the<br />

Hand Control Lever slowly.<br />

Did the <strong>SmartKART</strong> move forward?<br />

When pushing on the left hand side of the Hand<br />

Control Lever slowly.<br />

Did the <strong>SmartKART</strong> move backward?<br />

1.19<br />

Yes<br />

Turn the OFF/ON switch off.<br />

Push the <strong>SmartKART</strong> forward and reverse. Is<br />

it held in place?<br />

Yes<br />

Yes<br />

Yes<br />

Yes<br />

Go to next page<br />

Yes<br />

1.10<br />

If pressing on the seat switch by hand allowed the<br />

<strong>SmartKART</strong> to operate but sitting on the seat<br />

does not.<br />

There is a problem with the seat switch.<br />

Call for Service.<br />

Go to Section 8<br />

No<br />

The throttle or motor wiring is reversed.<br />

Call for Service.<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

No<br />

No<br />

No<br />

1.7<br />

Get off the seat and looking under the seat, you<br />

can see the seat switch.<br />

Are two wires connected to terminals of the<br />

switch?<br />

1.9<br />

Get off the seat and looking under the seat, press<br />

down in the center of the seat. You should see the<br />

seat switch guides move down. Push the seat<br />

switch down Push the throttle again slightly.<br />

Did the <strong>SmartKART</strong> click or move forward?<br />

No<br />

1.16<br />

Go to Section 8<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

No<br />

1.12<br />

No<br />

1.8<br />

If you can see the two wires, connect them to the<br />

switch.<br />

Could you connect the wires? If not<br />

Call for Service<br />

Go to Section 8<br />

The brake should hold the <strong>SmartKART</strong> in<br />

position.<br />

The brake or the gearbox has a problem,<br />

call for Service. Go to Section 8<br />

1.14<br />

If a click or motor noise is heard but the<br />

<strong>SmartKART</strong> did not move even at full throttle,<br />

power is electrically releasing the brake and<br />

maybe turning the electric motor.<br />

There may problem with the controller, motor,<br />

or gearbox. Check batteries before Calling for<br />

Service.<br />

Go to Section 6<br />

1.18<br />

The throttle or motor wiring is reversed.<br />

Call for Service.<br />

Go to Section 8<br />

6


1.19<br />

The brake is working. Try to drive the machine<br />

at maximum speed forward.<br />

Does <strong>SmartKART</strong> operate at the same speed<br />

it used to? (compare to another <strong>SmartKART</strong>)<br />

1.21<br />

1.23<br />

Forward is good. Try to drive the machine at<br />

maximum speed in reverse.<br />

Does <strong>SmartKART</strong> operate at the same speed<br />

it used to?<br />

1.25<br />

Yes<br />

Forward is good.<br />

Was the <strong>SmartKART</strong> quiet in the area of the<br />

front wheel when driving?<br />

Yes<br />

Yes<br />

The test is complete. Turn OFF the OFF/ON<br />

switch.<br />

The battery charge level may be limiting the<br />

<strong>SmartKART</strong> speed.<br />

Check batteries before Calling for Service.<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

No<br />

No<br />

No<br />

1.20<br />

1.22<br />

1.24<br />

Go to Section 6<br />

The front wheel is loose, or the motor or<br />

gearbox has a problem.<br />

Call for Service.<br />

Go to Section 8<br />

Start this troubleshooting section again<br />

or call for Service.<br />

Go to Section 8<br />

7


<strong>SmartKART</strong> Does Not Operate (using tools)– Section 2<br />

Tools required: volt/ohm<br />

meter, allen wrench set,<br />

phillips screwdriver.<br />

2.0<br />

Status Light<br />

2.7<br />

Batt Neg.<br />

Circuit Breaker<br />

3 amp Fuse<br />

Turn the OFF/ON switch off, then on<br />

Did the Status Light turn on?<br />

Yes<br />

Go to 2.11 on next page.<br />

Unplug the charger AC cord. Turn the OFF/ON<br />

switch off, then on<br />

Did the Status Light turn on?<br />

Picture<br />

shows<br />

good fuse.<br />

Bad fuse<br />

has gap<br />

here,<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

No<br />

Note: Some<br />

<strong>SmartKART</strong>’s do not<br />

have this label..<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

2.1<br />

2.2<br />

No<br />

Check the voltage on the batteries. If the voltage<br />

is over 16 volts the controller should turn on.<br />

Did the batteries have 16 to 28 volts?<br />

Yes<br />

2.4<br />

Check the voltage between the battery negative<br />

terminal and the two sides of the circuit breaker.<br />

Did the circuit breaker have 16 to 28 volts on<br />

both sides?<br />

Yes<br />

2.6<br />

Remove the 3 amp blade fuse and check the fuse<br />

with the volt/ohm meter. If it is bad and you have<br />

a spare fuse replace it.<br />

Did the Status Light turn on?<br />

2.8<br />

2.3<br />

Check the battery wiring for problems. If the<br />

voltage is still low.<br />

Check the batteries before calling for Service<br />

Go to next page<br />

No<br />

No<br />

If you cannot test<br />

the fuse,<br />

call for Service.<br />

Go to Section 6<br />

2.5<br />

Check the circuit breaker wiring for problems. If<br />

the voltage is still low on one side, the circuit<br />

breaker is bad..<br />

Call for Service<br />

Go to Section 8<br />

No<br />

8


2.8<br />

Remove the back half of the motor cover in front<br />

of operators feet and check every connector for<br />

proper fit.<br />

Did the Status Light turn on?<br />

2.11<br />

Sit on the seat normally, push on the right hand<br />

side of the Hand Control Lever slowly.<br />

Did the <strong>SmartKART</strong> click or move?<br />

2.16<br />

Yes<br />

Yes<br />

Go to next page<br />

2.9 Check for voltage at the ON/OFF switch.<br />

Use the black horn switch wire as ground. The<br />

red wire should have battery voltage. The blue<br />

wire should have battery voltage with the key<br />

on.<br />

Is there power on the blue wire?<br />

2.10<br />

No<br />

No<br />

If no power is getting to the keyswitch,<br />

Call for Service<br />

Yes<br />

Go to Section 8<br />

2.12<br />

No Get off the seat and looking under the seat, you<br />

can see the seat switch.<br />

Are two wires connected to terminals of the<br />

switch?<br />

2.14<br />

Get off the seat and looking under the seat, press<br />

down in the center of the seat. You should see the<br />

seat switch guides move down. Push the seat<br />

switch down Push the throttle again slightly.<br />

Did the <strong>SmartKART</strong> move forward?<br />

2.15<br />

Both wires should have battery voltage. If<br />

pressing on the seat switch by hand does not<br />

allow the voltage to drop on one wire.<br />

There is a problem with the seat switch.<br />

Call for Service.<br />

Go to Section 8<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

No<br />

2.13<br />

No<br />

If you can see the two wires, connect them to the<br />

switch.<br />

Could you connect the wires?<br />

Go to Section 8<br />

9


2.16<br />

Turn the OFF/ON switch OFF.<br />

Push the <strong>SmartKART</strong> forward and reverse. Is<br />

it held in place?<br />

2.18<br />

Sit on the seat normally, turn the OFF/ON<br />

switch ON, push on the right hand side of the<br />

Hand Control Lever slowly.<br />

Did the <strong>SmartKART</strong> move?<br />

2.20<br />

2.23<br />

When pushing on the right hand side of the<br />

Hand Control Lever slowly.<br />

Did the <strong>SmartKART</strong> move forward?<br />

When pushing on the left hand side of the Hand<br />

Control Lever slowly.<br />

Did the <strong>SmartKART</strong> move backward?<br />

Yes<br />

2.25<br />

The brake is working. Try to drive the machine<br />

at maximum speed forward.<br />

Does <strong>SmartKART</strong> operate at the same speed<br />

it used to? (compare to another <strong>SmartKART</strong>)<br />

2.27<br />

Yes<br />

Yes<br />

Yes<br />

Yes<br />

Yes<br />

Connector P1<br />

Connector P4<br />

Red<br />

Black<br />

Black<br />

Red<br />

Go to next page<br />

Blue<br />

Brown<br />

Black<br />

No<br />

No<br />

No<br />

No<br />

No<br />

2.19<br />

If a click or motor noise is heard but the<br />

<strong>SmartKART</strong> did not move even at full throttle,<br />

power is electrically releasing the brake and<br />

maybe turning the electric motor.<br />

There may problem with the controller, motor,<br />

or gearbox. Check batteries before Calling for<br />

Service. Go to Section 6<br />

2.21 The throttle or motor wiring is reversed.<br />

Check the large red and black wires under the<br />

motor cover; red to red, black to black. Check<br />

the pot wires in the control box; Wire colors on<br />

the pot are in the order shown. Voltage to brown<br />

wire varies 0-.5 V reverse, 2.25V neutral, 4.0-<br />

4.5V forward. Check the wires on the controller<br />

under the rear cover.<br />

Does the <strong>SmartKART</strong> move in the correct<br />

direction?<br />

The battery charge level may be limiting the<br />

<strong>SmartKART</strong> speed.<br />

Check batteries before Calling for Service.<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

2.17<br />

2.24<br />

2.26<br />

The brake should hold the <strong>SmartKART</strong> in<br />

position.<br />

The brake or the gearbox has a problem,<br />

call for Service. Go to Section 8<br />

Black<br />

Brown<br />

Blue<br />

The throttle or motor wiring or controller is a<br />

problem.<br />

Call for Service.<br />

Go to Section 8<br />

Go to Section 8<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

2.22<br />

No<br />

The throttle or motor wiring or controller<br />

is a problem.<br />

Call for Service.<br />

Go to Section 8<br />

Connector P2<br />

10


2.27 2.28 The front wheel is loose, or the motor or<br />

Forward is good.<br />

Was the <strong>SmartKART</strong> quiet in the area of the<br />

front wheel when driving?<br />

Yes<br />

Yes<br />

2.29<br />

Forward is good. Try to drive the machine at<br />

maximum speed in reverse.<br />

Does <strong>SmartKART</strong> operate at the same speed<br />

it used to?<br />

Yes<br />

2.31<br />

The test is complete. Turn off the OFF/ON<br />

switch. Reassemble any items or covers<br />

removed.<br />

The test is complete.<br />

gearbox has a problem. Lift up the front of the<br />

<strong>SmartKART</strong> and wiggle the front wheel. If the<br />

wheel moves but not the gearbox shaft, the<br />

wheel is a problem. If the gearbox shaft moves<br />

the gearbox has a problem.<br />

Call for Service. Go to Section 8<br />

Check the wheel, motor, and gearbox like in the<br />

above step.<br />

or call for Service.<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

No<br />

No<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

2.30<br />

Go to Section 8<br />

11


<strong>SmartKART</strong> working normally but one item doesn't work –<br />

Section 3<br />

3.0<br />

The throttle lever is loose, makes a grinding<br />

noise, or doesn't smoothly snap back when<br />

released.<br />

Is the throttle lever tight on the shaft?<br />

3.2<br />

Pushing/pulling both sides of the throttle lever at<br />

the same time.<br />

Does the throttle lever move?<br />

3.4<br />

3.8<br />

Yes<br />

Yes<br />

tools: allen wrench set,<br />

phillips screwdriver<br />

Does the throttle lever rotate smoothly?<br />

Throttle<br />

3.6 Loosen the throttle lever, slide it<br />

lower on the shaft, and tighten.<br />

Does the throttle lever rotate<br />

smoothly?<br />

Push on the RH side of the throttle lever till it<br />

touches the hand grip and then release.<br />

Did the throttle lever spring back to center?<br />

3.9<br />

Push on the LH side of the throttle lever till it<br />

touches the hand grip and then release.<br />

Did the throttle lever spring back to center?<br />

3.11<br />

Yes<br />

Yes<br />

Yes<br />

Troubleshooting complete<br />

3.1<br />

Using a screwdriver tighten the throttle pot screws<br />

next to the lever under the control panel. Tighten<br />

the set screw holding the lever to the throttle pot.<br />

.<br />

3.5<br />

Is the throttle lever touching the bottom of the<br />

control box?<br />

3.7<br />

The shaft of the potentiometer is<br />

binding in the housing of the pot. The<br />

pot is bad.<br />

Call for Service<br />

Go to Section 8<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

No<br />

No<br />

No<br />

Yes No<br />

No<br />

3.3<br />

The shaft of the potentiometer is moving in the<br />

housing of the pot. The pot is bad.<br />

Call for Service?<br />

Go to Section 8<br />

3.10<br />

No<br />

No<br />

Problems with throttle pot.<br />

Call for Service<br />

Go to Section 8<br />

12


3.12<br />

The status light on the control panel doesn’t<br />

work.<br />

Turning the key to “on”, does the Status<br />

Light turn on?<br />

3.16<br />

Yes<br />

Troubleshooting complete<br />

Control panel LED’s<br />

Yes<br />

3.17<br />

The alarm on the control panel doesn’t work.<br />

Turn the key to “on”, push the horn button<br />

and then move the throttle lever to go in<br />

reverse, did the alarm sound both times?<br />

3.22<br />

Yes<br />

Troubleshooting complete<br />

Is the machine operating normally but the light<br />

is not on?<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

No<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

3.13<br />

3.14 Remove the cover and check the wire<br />

connections to the LED. Using a voltmeter check<br />

the blue and white wires. Is a steady or fluctuating<br />

voltage greater than 18 volts shown?<br />

If voltage is present and no light, replace the<br />

light or Call for Service. Go to Section 8<br />

3.19<br />

3.15<br />

Control panel alarm<br />

Yes<br />

No<br />

3.18<br />

If the machine does not go in reverse with the<br />

throttle lever go to section 1 or 2 to find cause<br />

or Call for Service<br />

Go to Section 1 or 2 Go to Section 8<br />

tools: voltmeter, phillips screwdriver<br />

No<br />

Go to section 1 or 2 to find cause?<br />

Go to Section 8<br />

tools: volt/ohm meter, phillips screwdriver<br />

Did the horn work with the horn button?<br />

No<br />

3.20 Remove the cover and using a volt/ohm<br />

meter, disconnect one wire on the horn switch<br />

and check the horn switch pins for continuity with<br />

the switch pushed in.<br />

If no continuity, replace the switch or Call for<br />

Service. Go to Section 8<br />

Yes<br />

3.21 Reconnect the wire and check the horn<br />

switch wires with the blue keyswitch wire for<br />

voltage with the switch pushed in.<br />

If no voltage, check black wire continuity to<br />

battery negative on battery pack or Call for<br />

Service. Go to Section 8<br />

13


3.23<br />

The cover under the operators seat won't open.<br />

Using the figures below, follow the label<br />

instructions. Are you able to lift the cover?<br />

3.26<br />

Yes<br />

3.24<br />

Troubleshooting complete<br />

Cover under seat won’t open<br />

Note: Some <strong>SmartKART</strong>’s<br />

do not have this label..<br />

No<br />

Wiggle the seat frame while pushing the rod to the<br />

front.<br />

Are you able to lift the cover?<br />

There is a problem with the cover release<br />

latch, Call for Service<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

3.25<br />

No<br />

Go to Section 8<br />

14


<strong>SmartKART</strong> moves when OFF/ON switch turned on – Section<br />

4<br />

4.0<br />

4.9<br />

Do not sit on seat for first step.<br />

When ON/OFF switch turned to ON the<br />

<strong>SmartKART</strong> moves right away?<br />

Yes<br />

4.5<br />

Sit down on the seat.<br />

(reconnect seat switch if necessary)<br />

When ON/OFF switch turned to ON the<br />

<strong>SmartKART</strong> stays in place?<br />

Yes<br />

Press the RH side of the Manual Throttle<br />

Lever..<br />

Did the <strong>SmartKART</strong> move forward?<br />

Yes<br />

4.13<br />

Press the LH side of the Manual Throttle Lever..<br />

Did the <strong>SmartKART</strong> move backward?<br />

4.15<br />

Yes<br />

Yes<br />

Disconnect one wire from the seat switch.<br />

When ON/OFF switch is turned to ON, does<br />

the <strong>SmartKART</strong> stay in place?<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

Yes<br />

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No<br />

No<br />

No<br />

No<br />

4.1<br />

4.2<br />

4.3<br />

Problem with the controller, The controller<br />

should not allow movement and should have<br />

shown a throttle fault (1 flash).<br />

Call for Service.<br />

Go to Section 8<br />

4.7<br />

4.11<br />

After moving,<br />

does the <strong>SmartKART</strong> stop when the lever is<br />

released?<br />

Test complete<br />

Yes<br />

4.6<br />

Problem with the controller, Call for Service.<br />

Go to Section 8<br />

No<br />

No<br />

Is the throttle lever centered and does it<br />

snap back to center?<br />

No<br />

4.4<br />

Go to section 3.1 and try to repair the throttle<br />

lever or pot.<br />

Repair or Call for Service.<br />

Go to Section 8<br />

Block up front wheel and test. Is the throttle<br />

lever centered and does it snap back to center?<br />

Problem with the controller, Call for Service.<br />

No<br />

Go to Section 8<br />

4.8<br />

Go to section 3.1 and try to repair the throttle<br />

lever or pot.<br />

Repair or Call for Service.<br />

Go to Section 8<br />

4.10<br />

4.12<br />

4.14<br />

Problem with the <strong>SmartKART</strong>.<br />

Go to Section 1<br />

Go to Section 1<br />

Turn ON/OFF switch to off. Problem with the<br />

throttle pot or controller..<br />

Call for Service<br />

Go to Section 8<br />

Problem with the <strong>SmartKART</strong>.<br />

Go to Section 1<br />

Go to Section 1<br />

15


5.0<br />

Green LED on <strong>SmartKART</strong> is flashing. – Section 5<br />

When the OFF/ON switch is turned to On is<br />

the Status Light on steady?<br />

5.2<br />

5.4<br />

Yes<br />

Did the code information help you solve your<br />

problems?<br />

Is the machine operating correctly?<br />

Yes<br />

Test complete.<br />

The Status Light blinks out a code. <strong>SmartKART</strong><br />

still has problems.<br />

Try to fix the problem or Call for Service<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

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5.1<br />

5.3<br />

Go to Section 8<br />

Continuous flash: charger plugged in. Unplug AC cord, turn switch off then on.<br />

Slow continuous flash: recharge soon<br />

Flash every 5 seconds: controller in sleep mode<br />

Fast continuous flash: controller problem<br />

Flash sequence:<br />

Flash Extended Description .<br />

1 The battery needs charging or there is a bad connection to the battery.<br />

2 There is a bad connection to the motor. (may flash continuous after first code.)<br />

2- Then continuous slow flash, throttle fault out of position at startup.<br />

3 The motor has a short circuit to a battery connection.<br />

6 The controller is being inhibited from driving. Is the battery charger connected or<br />

the seat switch is not pressed.<br />

7 A throttle fault is indicated. Make sure that the throttle is in the center at rest<br />

position before switching on the <strong>SmartKART</strong>.<br />

8 A controller fault is indicated. Make sure that all the connections are secure.<br />

9 The parking brakes have a bad connection. Check the parking brake and<br />

motor connections.<br />

10 An excessive voltage has been applied to the controller. Check the battery<br />

connections.<br />

No<br />

No<br />

<strong>SmartKART</strong> still has problems.<br />

Use another section of this troubleshooting<br />

aid or Call for Service<br />

Go to Section 8<br />

16


<strong>SmartKART</strong> Battery and Charger Problems – Section 6<br />

6.0<br />

The <strong>SmartKART</strong> charger is accessible under<br />

the seat. See section 1 for instructions to lift the<br />

seat.<br />

Go to next step.<br />

6.1<br />

With the OFF/ON switch off, plug in the AC cord<br />

to the charger.<br />

Did the red Charger or AC Power LED on the<br />

charger come on steady?<br />

Standard Model Charger (4A Max output)<br />

Charger LED<br />

(red/orange/green)<br />

6.4<br />

6.8<br />

Yes<br />

XD Model Charger (6A Max output)<br />

AC power<br />

(red)<br />

Charger LED<br />

(yellow/green)<br />

After a few seconds did the orange/yellow<br />

Charger LED turn on steady?<br />

Yes<br />

The charger is starting.<br />

Go to next page<br />

6.2<br />

Double check AC cord connections.<br />

Did the red charger AC Power LED on the<br />

charger come on?<br />

6.3<br />

Try a different AC cord and/or a different AC<br />

outlet.<br />

If the red Charger or AC Power LED on the<br />

charger still does not come on, call for<br />

Service to check the AC cord and charger.<br />

Go to Section 8<br />

On the 4 amp standard charger only a flashing<br />

orange light indicates the batteries are being<br />

charged from a very low voltage.<br />

Did the orange/yellow Charging LED turn on<br />

steady?<br />

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No<br />

6.5<br />

A voltmeter and DC ammeter<br />

would be helpful for this<br />

testing to measure the voltage<br />

in the batteries and charging<br />

current.<br />

No<br />

No<br />

Were the batteries changed recently? Check that<br />

the battery cable connections against the picture<br />

below.<br />

Did the orange/yellow Charging LED flash or<br />

turn on steady?<br />

No<br />

No<br />

Wire connecting<br />

Battery + to<br />

Battery – of<br />

other battery<br />

Battery +<br />

to charger<br />

and<br />

controller<br />

red wire<br />

6.7<br />

Open the battery fuse holder on top of the<br />

batteries and remove and inspect the battery<br />

fuse. If the fuse is bad and you have a<br />

replacement installed, replace and start<br />

troubleshooting again.<br />

Otherwise the charger has a problem or the<br />

batteries have too low a voltage, call for<br />

Go to Section 2.2<br />

Service.<br />

Go to Section 8<br />

Battery - to charger and<br />

controller Black wire<br />

17


6.8<br />

Is the orange/yellow Charging LED still on<br />

steady?<br />

1. With a DC ammeter<br />

measure the current<br />

through the large<br />

center battery cable.<br />

The current should<br />

start at a zero and<br />

increase to and hold at<br />

4 amps, 6 amps on<br />

the XD charger.<br />

2. With a voltmeter<br />

measure the voltage<br />

across both batteries.<br />

The voltage should be<br />

increasing to a<br />

maximum of 28.8<br />

volts.<br />

3. When the voltmeter<br />

voltage 28.8 volts the<br />

cycle is half over. The<br />

voltage will hold<br />

steady to the end of<br />

the cycle.<br />

4. After the voltmeter<br />

reaches 28.8 volts, the<br />

DC ammeter will show<br />

the current dropping<br />

slowly to zero.<br />

Yes<br />

6.12<br />

6.10<br />

The yellow Charging LED is on steady to show<br />

the charger is performing its charge cycle. This<br />

step may last many hours.<br />

Is the green Charger LED on steady?<br />

6.14<br />

Yes<br />

Go to next page<br />

Yes<br />

The orange/yellow Charging LED may be off to<br />

indicate the main part of the charging cycle is<br />

over.<br />

Is the green Maintaining LED on steady?<br />

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No<br />

6.9<br />

The green Charging LED is on steady to indicate<br />

the charger may have jumped past the main<br />

charging cycle because the batteries are fully<br />

charged.<br />

Go to Section 6.10<br />

6.11<br />

Having the yellow Charging LED and green<br />

Maintaining LED stay off indicate the batteries are<br />

not connected properly or the charger has a<br />

problem. Go to Section 8<br />

Call for Service.<br />

Is there a sulfur or rotten egg smell noticed?<br />

Stop testing; the charger or batteries have a<br />

problem.<br />

No<br />

6.13<br />

No<br />

If the green Charger LED never comes on unplug<br />

the charger.<br />

The charger or the batteries have a problem.<br />

Call for service. Go to Section 8<br />

18


6.14<br />

Having the green LED on shows the charge is<br />

complete. The charger is starting the float or<br />

maintaining cycle. This step will last until the AC<br />

cord is unplugged.<br />

With a DC ammeter<br />

measure the current<br />

through the large<br />

center battery cable.<br />

The current should<br />

stay near zero or<br />

slowly reduce to near<br />

zero amps.<br />

6.15<br />

Completion of these steps indicate that the<br />

charger is working OK and the batteries are being<br />

charged to their fullest potential.<br />

Is the battery run time too short?<br />

Yes<br />

6.17<br />

Even if the charger is OK the batteries may not be<br />

accepting a full charge like they did when they<br />

were new.<br />

Are the batteries more than 9 months old?<br />

Yes<br />

With a voltmeter<br />

measure the voltage<br />

across both batteries.<br />

The voltage should be<br />

constant at 27.7 volts.<br />

6.20<br />

Batteries more than 9 months old at a high<br />

volume store may have reached their end of life.<br />

Go to section 9 for additional troubleshooting or<br />

Call for Service.<br />

Go to Section 8<br />

Note: the charger LED may turn back to orange or<br />

yellow if a battery voltage change shows the<br />

battery needs to be recharged.<br />

Troubleshooting complete.<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

Yes<br />

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No<br />

No<br />

6.16<br />

6.18<br />

6.19<br />

This may indicate a problem with one or two<br />

batteries.<br />

Battery warranty is handled by the battery<br />

manufacturer. Call the battery supplier or<br />

battery store for service.<br />

Is there a sulfur or rotten egg smell noticed?<br />

Stop testing; the charger or batteries have a<br />

problem.<br />

6.21<br />

Were the batteries used installed or<br />

recommend by Dane?<br />

No<br />

The batteries were not recommended by Dane.<br />

Call for Service to get recommendations for<br />

batteries.<br />

Go to Section 8<br />

19


<strong>SmartKART</strong> Operates But Has Limited Running Time –<br />

Section 7<br />

7.0<br />

Measure the battery voltage.<br />

Is the voltage greater than 24 volts?<br />

7.4<br />

Yes<br />

Drive the <strong>SmartKART</strong> for 5 minutes and<br />

measure the lowest voltage during use.<br />

Review the table to estimate the batteries<br />

current state of charge.<br />

If the voltage cannot be<br />

measured during use,<br />

measure 30 seconds or<br />

more after the<br />

<strong>SmartKART</strong> has<br />

stopped and reduce the<br />

SOC by 10 to 15%.<br />

7.5<br />

Drive the <strong>SmartKART</strong> for about 20 minutes<br />

and measure the lowest voltage during use.<br />

Review the table to estimate the batteries<br />

current state of charge. Did the SOC move<br />

down more than 10%?<br />

With a voltmeter<br />

measure the voltage<br />

of each battery<br />

separately. Any<br />

battery that measures<br />

1 volt or more different<br />

from the other has a<br />

problem and the set of<br />

batteries needs to be<br />

replaced.<br />

7.2<br />

This indicates the batteries need to be<br />

charged more but continue with this quick test.<br />

Yes<br />

Yes<br />

7.7 This test should normally take 3 to 4 % of<br />

battery capacity. Lowering the SOC by 10%<br />

indicates that the batteries may be weak<br />

. Try the overnight charging and then retest to<br />

more fully evaluate the batteries or Test<br />

complete Go to 7.8<br />

7.1<br />

Plug in the charger AC cord to recharge for 5<br />

minutes,<br />

Did the orange/yellow Charging LED stay on<br />

for most of the 5 minutes?<br />

7.3<br />

This probably means the batteries are fully<br />

charged.<br />

7.6<br />

This indicates the batteries are fairly strong.<br />

Evaluate the <strong>SmartKART</strong> for a full day and see<br />

what the battery voltage reads at the end of the<br />

day. The value from the table estimates the<br />

amount of charge left in the batteries.<br />

Test complete, Call for Service if the batteries<br />

do not provide sufficient energy for the days<br />

use.<br />

Go to Section 8<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

No<br />

SOC Volts<br />

100% 25.6<br />

90% 25.4<br />

80% 25.2<br />

70% 25.0<br />

60% 24.8<br />

50% 24.6<br />

40% 24.4<br />

30% 24.2<br />

20% 24.0<br />

10% 23.8<br />

Note: Battery voltage<br />

should be measured during<br />

testing and is the lowest<br />

value seen.<br />

The Battery Current State of Charge<br />

(SOC) Test is a way to evaluate the<br />

batteries current charge.<br />

This test requires a voltmeter.<br />

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No<br />

No<br />

Measure battery voltage<br />

Note: Battery SOC % vs Volts table is for AGM<br />

batteries only. Other battery types have other values.<br />

Note: Testing the batteries late in the day gives a better evaluation of the batteries capability for this application .<br />

Estimate % use so far by hours vs total hours. 6 hrs use vs 8 total hrs = 75% use or 25% use remaining. If battery SOC<br />

is


The Overnight Charger/Battery Test is a way to evaluate whether the charger is<br />

working and the batteries capacity at full charge. As a battery ages it is less capable of<br />

holding a full charge and will run out of charge during the day.<br />

This test requires that the <strong>SmartKART</strong> be used on the day the test starts and that a<br />

voltmeter is available for measuring battery voltage..<br />

7.8<br />

Start the overnight charger/battery test at night.<br />

Park the machine inside in a warm cart room.<br />

Plug in the charger AC cord.<br />

Did the charger orange/yellow charging LED<br />

come on steady?<br />

7.10<br />

After 30 minutes of charging is the charger<br />

orange/yellow LED still on steady ?<br />

7.12<br />

Yes<br />

Yes<br />

Let the <strong>SmartKART</strong> charge overnight.<br />

In the morning is the charger green LED on<br />

steady?<br />

7.14<br />

Unplug the AC cord and drive the<br />

<strong>SmartKART</strong> for 15 to 20 minutes around the store<br />

while measuring the lowest voltage seen. Review<br />

the table to estimate the batteries state of charge.<br />

Did the battery SOC stay at or above<br />

90% SOC?<br />

If the voltage cannot be<br />

measured during use,<br />

measure 30 seconds or<br />

more after the<br />

<strong>SmartKART</strong> has<br />

stopped and reduce the<br />

SOC by 10 to 15%.<br />

7.15 This test should normally take 3 to 4 % of<br />

battery capacity. Lowering the SOC more than<br />

10% indicates that the batteries may be weak.<br />

Continue use and at the end of the day<br />

estimate % use vs battery SOC or<br />

Test complete.<br />

7.16<br />

Go to the charger test section 6 to verify that<br />

the charger is working.<br />

or, continue.<br />

Go to Section 6<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

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7.9<br />

7.11 If the <strong>SmartKART</strong> use that day was less<br />

than 30 minutes this may indicate the charger is<br />

not charging or that the batteries have a low<br />

capacity for charge and are already fully charged.<br />

Keep going.<br />

Yes Is there a sulfur or rotten egg smell<br />

Yes<br />

Note: Testing the batteries late in the<br />

day gives a better evaluation of the<br />

batteries capability for this application.<br />

Estimate % use so far by hours vs<br />

total hours. 6 hrs use vs 8 total hrs =<br />

75% use or 25% use remaining. If<br />

battery SOC is


8.0<br />

<strong>SmartKART</strong> needs Service – Section 8<br />

Are you sure of which part you need?<br />

Did you use the Troubleshooting Guide?<br />

Yes<br />

8.2 Before you call please have the following<br />

information ready:<br />

> Your Store Name and number<br />

> Contact person<br />

> Contact phone number<br />

> Model number and Serial number of<br />

machine<br />

> (listed on label on the back cover)<br />

> Part number or Step number of<br />

troubleshooting guide indicating your<br />

problem.<br />

> Call Dane Service at 888-544-7779 or<br />

outside the US at 763-746-4422<br />

8.1<br />

Using the Troubleshooting Guide may solve<br />

your problem today without calling for Parts or<br />

Service..<br />

Go to section 0<br />

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No<br />

22


DANE TECHNOLOGIES<br />

Additional Troubleshooting Information<br />

Table of Contents<br />

ADDITIONAL TROUBLESHOOTING TESTS......................................................................... 24<br />

<strong>SmartKART</strong> TEST POINTS......................................................................................................... 25<br />

BATTERY CHARGER................................................................................................................ 26<br />

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23


ADDITIONAL TROUBLESHOOTING TESTS<br />

1) SYSTEM WILL NOT SWITCH ON *<br />

a) Check P2-5/6 BLUE/ RED or P1-5 BLUE should be equal to battery positive +/-<br />

.5v<br />

2) VEHICLE DRIVES SLOWLY *<br />

a) Check that solenoid brake is not jammed (P3-1&2 BROWN) or bad pot.<br />

b) New motor 300-065 or 300-075 replacing 300-061, controller needs<br />

programming.<br />

3) STATUS INDICATOR DOES NOT LIGHT (No power is reaching the controller) *<br />

a) Check the wiring and connectors from the controller’s status indicator output to<br />

the status indicator itself P2-7 WHITE (OPEN)<br />

i) The voltage should be 25v +/- 1v P1-5 BLUE P1-10 WHITE PWR.ON<br />

(with fully charged batteries)<br />

4) REVERSE ALARM DOES NOT SOUND<br />

a) Check wiring and connectors from the controller’s reverse alarm output and the<br />

sounder itself<br />

i) P2-4 GREEN (OPEN)<br />

5) VEHICLE WILL NOT DRIVE IN REVERSE *<br />

a) Check voltage at reverse input (reverse switch is in correct position)<br />

i) Reverse to battery-: 0v +/- .5v to drive in reverse; 5v +/- .5v to drive<br />

forward<br />

ii) P1-1 BROWN and P1-8 BLACK<br />

6) MOTOR BRAKE BECOMES VERY WARM<br />

a) Check solenoid brake may be jamming (P3-1&2 BROWN) 52 OHMS brake coil<br />

7) BATTERIES DISCHARGE VERY QUICKLY<br />

a) Worn or damaged batteries (check battery condition)<br />

b) Charger is defective (check charger operation)<br />

c) Incorrect batteries being used (check correct battery type 800-016 standard<br />

model, 800-022 XD model)<br />

d) Solenoid brake jamming P3-1&2 BROWN 52 Ohms brake coil.<br />

8) INHIBIT 2 OR 3 SEAT/CHARGER OCCURRED (Continuous blink 1/second) After<br />

drives FWD. Or REV.<br />

a) P1-6 RED or P1-14 WHITE (OPEN)<br />

NOTE: * Controller may be defective (there are no serviceable parts in the controller)<br />

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24


<strong>SmartKART</strong> TEST POINTS<br />

<strong>SmartKART</strong> Test Points<br />

B+ = Voltage across the two batteries.<br />

Test Plug (700-053), P1-Tiller 14 Pins<br />

Resistance<br />

Forward/Reverse<br />

Signal Color Pin Description Power On Power Off 2.5K Ref.<br />

Wiper BRN 1 Pot Wiper (1-8) 2.25V .75V 4.75K-ohm<br />

Pot. Hi BLU 2 Pot High (Forward, 1-2) 4.22V 1.4V 11ohm/4.75K-ohm<br />

Alarm GRN 3 Horn and Back Up Horn (2-8) .22V .075V 4.75K-ohm/11ohm<br />

KSI BLU 5 On/Off Switch B+ 0V<br />

Inhibit 2 Red 6 To Seat Switch B+ 0V<br />

B+ RED/BLK 7 To 3A Fuse to Seat On/Off Switch B+ 0V<br />

Ground RED/BLK 8 Pot Ground (Reverse)<br />

LED WHT 10 Status<br />

B- BLK 13 Ground<br />

Inhibit 3 WHT 14 To Charger (No Inhibit) 2.45V .135V<br />

Inhibit .135V<br />

Pins 4, 9,11, and 12 not used.<br />

Test Plug (700-049), P2-Tiller 9 Pins<br />

Signal Color Pin Destination Power On Power Off 2.5K Ref.<br />

Pot Hi BLU 1 Pot High (Forward, 7 Flashes, 1-2) 4.22V 1.4V 11ohms/4.75K-ohms<br />

Wiper BRN 2 Pot Wiper (7 Flashes, 2-3) 2.25V .75V 4.75K-ohms/11ohms<br />

Ground BLK 3 Pot Ground (Reverse, 7 Flashes, 2-3) .22V .075V 4.75K-ohms<br />

Alarm GRN 4 Horn and Back Up Horn 19.6V 0V<br />

KSI BLU 5 On/Off Switch B+ 0V<br />

B+ RED 6 To 3A Fuse to Seat On/Off Switch B+ 0V<br />

LED WHT 7 .8V 0V<br />

B- BLK 8 Horn (Ground) 0V 0V<br />

P3-Brake 2 Pins<br />

Signal Color Pin Destination Power On<br />

Brake 1 WHT/BRN 1 Brake Coil (9 Flashes) 21.8V 52ohms<br />

Brake 2 WHT/BRN 2 Brake Coil (9 Flashes) 21.8V 52ohms<br />

All conditions are open wire.<br />

Test Points Quick Reference<br />

Charger P1 GRN/WHT 14 No inhibit 3 (drives plugged in)<br />

Alarm P2 GRN 4 No horn in Reverse, all else normal<br />

KSI P3 BLU 5 No power on (no light)<br />

B+ P4 RED 6 No power on (no light)<br />

LED P5 WHT 7 No status light (runs OK)<br />

Horn P6 BLK 8 No horn (runs OK)<br />

Inhibit 2 and 3 Seat/Charger Continuous flash 1/sec., Drive forward and reverse<br />

Motor RED/BLK 2 flashes, close to 0ohms is normal<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

25


BATTERY CHARGER<br />

The battery charger for the <strong>SmartKART</strong> is a five-stage charger. The following explains<br />

each stage of the charger. To view the status of the charger check the LED on the front<br />

face of the charger.<br />

Charging Stages<br />

Stage 1: Deep Discharge Charging Pulse Mode: LED Flash<br />

The charger starts charging at 0.5V and give pulse current up to 5V. This has effect of<br />

removing loose sulphation formed during deep discharge state of the battery.<br />

Stage 2: Constant Current Mode (CC): LED Orange<br />

The charger changes to constant current 4A (6A for XD model). When the battery<br />

voltage reaches up to 28.8V, the charging stage changes from CC (Constant Current) to<br />

CV (Constant Voltage) mode.<br />

Stage 3: Constant Voltage Mode (CV): LED Orange<br />

The charger holds the battery at 28.8V and the current slowly reduces. When the<br />

current reaches 0.50CC, it can adjust the current automatically according to battery<br />

capacity. This is called the Switching Point. Other chargers are not capable to adjust<br />

the current automatically.<br />

Stage 4: Standby Voltage Mode: LED Green<br />

The charger maintains the battery voltage at 27.6V and current slowly reduces to zero.<br />

The charger can be left connected indefinitely without harming the battery.<br />

Stage 5: LED Orange<br />

If the battery voltage drops below 27.6V, the charger changes from any mode to<br />

Constant Current mode and restart charging. The charging cycle will go through Stage<br />

2 to Stage 4.<br />

LED Status Lights<br />

Standard Model Charger (4A Max output) XD Model Charger (6A Max output)<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

26


DANE TECHNOLOGIES<br />

Service Bulletins — <strong>SmartKART</strong><br />

No Service Bulletins as of June 2, 2010<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

27


DANE TECHNOLOGIES<br />

<strong>SmartKART</strong><br />

Exploded Views and Diagrams<br />

Table of Contents<br />

120-036 <strong>SmartKART</strong> 24V, DANE............................................................................................... 29<br />

120-042 <strong>SmartKART</strong> 24V, TARGET .......................................................................................... 30<br />

120-052 <strong>SmartKART</strong> 24V, DANE............................................................................................... 31<br />

120-053 <strong>SmartKART</strong> 24V, DANE............................................................................................... 32<br />

120-055 <strong>SmartKART</strong> 24V, TARGET .......................................................................................... 33<br />

120-067 <strong>SmartKART</strong> XD - RED COVER, STD BASKET ......................................................... 34<br />

120-068 <strong>SmartKART</strong> XD - RED COVER, LARGE BASKET ................................................... 35<br />

120-081 <strong>SmartKART</strong>, TARGET SKE ......................................................................................... 36<br />

120-082 <strong>SmartKART</strong> E MODEL, SMALL BASKET................................................................. 37<br />

120-088 <strong>SmartKART</strong> XD W/ 12A CHARGER ........................................................................... 38<br />

120-089 <strong>SmartKART</strong>, LARGE BASKET, RED COVER, SEAT W/ NO ARMRESTS ............ 39<br />

120-090 <strong>SmartKART</strong>, TARGET XD ........................................................................................... 40<br />

150-027 <strong>SmartKART</strong>, 24V W/BASKET ..................................................................................... 41<br />

150-031 <strong>SmartKART</strong> DANE RED REAR COVER..................................................................... 44<br />

150-038 <strong>SmartKART</strong> 24V W/BASKET....................................................................................... 47<br />

150-041 <strong>SmartKART</strong> DANE RED REAR COVER..................................................................... 50<br />

150-045 <strong>SmartKART</strong>, TARGET XD ........................................................................................... 53<br />

100-197 ASM, YOKE AND MOTOR ......................................................................................... 56<br />

100-203 ASSEMBLY, TILLER ................................................................................................... 57<br />

110-108 KIT, POT W/HARNESS................................................................................................ 58<br />

110-078 KIT, <strong>SmartKART</strong> HORN/HARNESS ........................................................................... 59<br />

110-092 KIT, <strong>SmartKART</strong> POT AND SPRING REPLACEMENT............................................ 60<br />

110-121 KIT, TABBED THROTTLE.......................................................................................... 62<br />

110-140 BRUSH KIT ................................................................................................................... 63<br />

110-143 KIT, <strong>SmartKART</strong> THROTTLE ..................................................................................... 64<br />

430-081 STEERING BEARING HEADSET............................................................................... 65<br />

680-039 WIRING DIAGRAM ..................................................................................................... 66<br />

680-042 WIRING DIAGRAM ..................................................................................................... 67<br />

700-204 CONTROLLER/MOTOR HARNESS........................................................................... 68<br />

700-205 TILLER HEAD HARNESS ........................................................................................... 69<br />

700-206 POWER HARNESS....................................................................................................... 70<br />

910-008 <strong>SmartKART</strong> POTENTIOMETER SETTING INSTRUCTIONS .................................. 71<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

28


120-036 <strong>SmartKART</strong> 24V, DANE<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

29


120-042 <strong>SmartKART</strong> 24V, TARGET<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

30


120-052 <strong>SmartKART</strong> 24V, DANE<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

31


120-053 <strong>SmartKART</strong> 24V, DANE<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

32


120-055 <strong>SmartKART</strong> 24V, TARGET<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

33


120-067 <strong>SmartKART</strong> XD - RED COVER, STD BASKET<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

34


120-068 <strong>SmartKART</strong> XD - RED COVER, LARGE BASKET<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

35


120-081 <strong>SmartKART</strong>, TARGET SKE<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

36


120-082 <strong>SmartKART</strong> E MODEL, SMALL BASKET<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

37


120-088 <strong>SmartKART</strong> XD W/ 12A CHARGER<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

38


120-089 <strong>SmartKART</strong>, LARGE BASKET, RED COVER, SEAT W/<br />

NO ARMRESTS<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

39


120-090 <strong>SmartKART</strong>, TARGET XD<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

40


150-027 <strong>SmartKART</strong>, 24V W/BASKET<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

41


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

42


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

43


150-031 <strong>SmartKART</strong> DANE RED REAR COVER<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

44


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

45


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

46


150-038 <strong>SmartKART</strong> 24V W/BASKET<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

47


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

48


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

49


150-041 <strong>SmartKART</strong> DANE RED REAR COVER<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

50


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

51


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

52


150-045 <strong>SmartKART</strong>, TARGET XD<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

53


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

54


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

55


100-197 ASM, YOKE AND MOTOR<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

56


100-203 ASSEMBLY, TILLER<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

57


110-108 KIT, POT W/HARNESS<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

58


110-078 KIT, <strong>SmartKART</strong> HORN/HARNESS<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

59


110-092 KIT, <strong>SmartKART</strong> POT AND SPRING REPLACEMENT<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

60


Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

61


110-121 KIT, TABBED THROTTLE<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

62


110-140 BRUSH KIT<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

63


110-143 KIT, <strong>SmartKART</strong> THROTTLE<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

64


430-081 STEERING BEARING HEADSET<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

65


680-039 WIRING DIAGRAM<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

66


680-042 WIRING DIAGRAM<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

67


700-204 CONTROLLER/MOTOR HARNESS<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

68


700-205 TILLER HEAD HARNESS<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

69


700-206 POWER HARNESS<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

70


910-008 <strong>SmartKART</strong> POTENTIOMETER SETTING<br />

INSTRUCTIONS<br />

FOR USE WITH UNITS HAVING ORIGINAL<br />

POTENTIOMETER/SPRING ASSY<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

71


DANE TECHNOLOGIES<br />

Parts and Recommended Parts Inventory<br />

<strong>SmartKART</strong><br />

Table of Contents<br />

PARTS NEEDED TO SERVICE THE <strong>SmartKART</strong>................................................................... 73<br />

COMPLETE PARTS LIST FOR THE <strong>SmartKART</strong>.................................................................... 74<br />

<strong>SmartKART</strong> TOOLS .................................................................................................................... 76<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

72


PARTS NEEDED TO SERVICE THE <strong>SmartKART</strong><br />

This is a suggested list of parts for a service provider to have on hand.<br />

Part #: Description:<br />

100-194...................................................CONTROLLER 24V<br />

100-197...................................................ASM, YOKE AND MOTOR<br />

100-203...................................................ASSY. TILLER<br />

110-108...................................................POTENTIOMETER W/ HARNESS<br />

110-077...................................................<strong>SmartKART</strong> WHEEL NUT REPLACEMENT<br />

110-078...................................................KIT, <strong>SmartKART</strong> HORN REPLACEMENT<br />

110-081...................................................KIT, <strong>SmartKART</strong> SEAT<br />

110-092...................................................KIT, POTENTIOMETER AND SPRING<br />

REPLACEMENT<br />

110-140...................................................BRUSH KIT<br />

210-199...................................................WELDMENT YOKE<br />

220-517...................................................PLATE ANTI-TIP CASTER MOUNT<br />

300-075...................................................DRIVE MOTOR, 140 RPM, 24V<br />

360-061...................................................8” WHEEL W/ SEALED BEARING (2)<br />

360-062...................................................2” WHEEL CASTER SWIVEL (2)<br />

360-067...................................................WHEEL (FRONT)<br />

370-010...................................................POTENTIOMETER ONLY<br />

460-044...................................................TORSION SPRING<br />

470-045...................................................SEAT AND ARM REST ASSY.<br />

470-043...................................................ARM RESTS (2)<br />

660-035...................................................12-AMP CIRCUIT BREAKER AUTO RESET<br />

665-040...................................................SEAT SWITCH<br />

700-142...................................................HARNESS BATT. JUMPER<br />

700-204...................................................TILLER MOTOR WIRE HARNESS<br />

700-205...................................................TILLER HEAD HARNESS<br />

700-206...................................................HARNESS POWER<br />

700-207...................................................HARNESS STATIC DISCHARGE<br />

700-222...................................................POWER CORD<br />

810-039...................................................CHARGER, 24V 4A<br />

810-038...................................................CHARGER, 24V 6A<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

73


COMPLETE PARTS LIST FOR THE <strong>SmartKART</strong><br />

This is a complete parts list of items that can be acquired from Dane Technologies by a<br />

service provider.<br />

PART #: DESCRIPTION:<br />

100-194...................................................CONTROLLER 24V<br />

100-197...................................................ASM YOKE AND MOTOR<br />

100-203...................................................TILLER ASSEMBLY<br />

110-108...................................................KIT, POTENTIOMETER W/ HARNESS<br />

110-092...................................................KIT, POTENTIOMETER AND SPRING<br />

REPLACEMENT<br />

110-121...................................................KIT, TABBED THROTTLE<br />

110-143...................................................KIT, SMARTKART THROTTLE (NO TAB)<br />

110-118...................................................KIT, FRONT/BACK TILLER COVER<br />

110-140...................................................BRUSH KIT<br />

200-291...................................................ROD LATCH<br />

200-417...................................................BASKET SUPPORT<br />

210-199...................................................WELDMENT YOKE<br />

210-217...................................................STEER COLUMN<br />

210-218...................................................THROTTLE CONTROL<br />

210-324...................................................NERF BAR WELDMENT<br />

220-545...................................................TILLER HEAD COVER<br />

220-548...................................................CORD COVER PLATE<br />

220-867...................................................PLATE ANTI-TIP CASTER MOUNT<br />

220-869...................................................BASKET HOLDING CLIP<br />

300-075...................................................DRIVE MOTOR, 140 RPM, 24V<br />

360-061...................................................8" WHEEL W/ SEALED BEARING<br />

360-062...................................................SWIVEL CASTER W/2" WHEEL<br />

360-067...................................................WHEEL, 8” STEEL-KEYED, NO BEARING<br />

370-002...................................................HANDGRIPS<br />

370-010...................................................POTENTIOMETER ONLY<br />

410-065...................................................NUT M10 1 25 SHAFT (17mm)<br />

430-081...................................................STEERING BEARING HEADSET<br />

430-171...................................................SMALL BASKET<br />

430-178...................................................LARGE BASKET<br />

460-044...................................................TORSION SPRING<br />

470-049...................................................BUZZER, 5-30 VDC, FLANGE MOUNT<br />

470-050...................................................SEAT AND ARMRESTS ASSEMBLY (3 BOLT)<br />

470-051...................................................SEAT<br />

470-052...................................................ARM RESTS RH & LH (3 BOLT)<br />

470-060...................................................SEAT<br />

480-087...................................................THROTTLE END CAP<br />

480-089, 480-090 ...................................SEE 110-118<br />

480-091...................................................COVER REAR, TARGET RED<br />

480-092...................................................COVER REAR, DANE RED<br />

480-129...................................................COVER REAR, GREEN<br />

480-157...................................................COVER REAR, BLACK<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual 74<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10


501-020...................................................SMARTKART LABEL KIT<br />

501-021...................................................SMARTKART LABEL KIT<br />

501-023...................................................SMARTKART LABEL KIT<br />

501-030...................................................SMARTKART LABEL KIT<br />

660-035...................................................CIRCUIT BREAKER 24V 12A AUTO RESET<br />

665-040...................................................SEAT SWITCH<br />

665-048...................................................ROCKER SWITCH<br />

665-049...................................................PUSH BUTTON SWITCH<br />

670-015...................................................LED, GREEN<br />

700-142...................................................BATTERY JUMPER HARNESS<br />

700-204...................................................TILLER/ MOTOR S-DRIVE HARNESS<br />

700-205...................................................HARNESS TILLER HEAD<br />

700-206...................................................HARNESS BATTERY SEAT<br />

700-207...................................................HARNESS STATIC DISCHARGE<br />

700-222...................................................<strong>SmartKART</strong> POWER CORD<br />

810-038...................................................CHARGER, 24V 6A<br />

810-039...................................................CHARGER, 24V 4A<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

75


<strong>SmartKART</strong> TOOLS<br />

Size: Tool: Application:<br />

1-1/4” CROWFOOT WRENCH (TORQUE) TILLER ARM NUTS<br />

10 mm WRENCH/SOCKET BATTERIES<br />

11/32” WRENCH/SOCKET FUSE, CONTROLLER, TILLER<br />

COVER<br />

3/32” HEX THROTTLE CONTROL<br />

POTENTIOMETER<br />

7/16” WRENCH/SOCKET TILLER, BASKET, YOKE<br />

9/16” WRENCH/SOCKET NERF BAR, CASTER MOUNT<br />

½” WRENCH/SOCKET SEAT AND SEAT SUPPORT<br />

11/16” DP SOCKET (TORQUE) ADAPTER SHAFT FRONT WHEEL<br />

¾” (2) OPEN END WRENCH BACK WHEELS<br />

5mm BALL HEX TILLER ARM TO MOTOR, MOTOR<br />

#2 PHILIPS SCREW DRIVER TILLER AND CONTROL COVERS<br />

1/16” MOLEX EXTRACTOR PART # 11-03-0002 P2 AND P3<br />

MOLEX MOLEX EXTRACTOR PART # 11-03-0044 P1<br />

Size<br />

Dane Technologies<br />

Fastener Torque Chart<br />

Grade 1<br />

Torque<br />

in/lbs<br />

Grade 5<br />

Torque<br />

ft/lbs<br />

Grade 8 Torque<br />

ft/lbs<br />

#6 5<br />

#8 8<br />

#10 12<br />

1/4 6 9<br />

5/16 13 18<br />

3/8 23 32<br />

7/16 36 51<br />

1/2 55 78<br />

9/16 80 113<br />

5/8 110 156<br />

3/4 195 276<br />

Dane Technologies Inc.<br />

925-001 Rev -<br />

02/2006<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

76


Dear Service Provider:<br />

Thank you for your interest in joining our team of world-class Service Providers. By<br />

doing so, you have demonstrated a commitment to provide excellent service to our joint<br />

customers, on time, every time, professionally. Attached please find some materials<br />

that will help you as you join our team.<br />

The package includes a Troubleshooting Guide, a set of Service Bulletins (if any),<br />

exploded parts drawings and, at the back, find the following additional materials:<br />

Ordering and invoicing procedures<br />

Recommended parts inventory<br />

<strong>SmartKART</strong> Warranty<br />

Please share the enclosed information with the appropriate people in your organization.<br />

Thank you again for your interest. I look forward to a long and mutually rewarding<br />

relationship. Please feel free to call or e-mail me at any time with questions or<br />

comments.<br />

Sincerely,<br />

Scott Carlson<br />

Director Customer Service<br />

888-544-7779, Ext 4436<br />

scottc@danetechnologies.com<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

77


ORDERING AND INVOICING PROCEDURES<br />

ORDERING<br />

PARTS:<br />

Call Dane Technologies at 1-888-544-7779, then choose the parts or service option.<br />

1. Please provide a purchase order # and, if applicable, the location of the<br />

customer store and the serial number of the <strong>SmartKART</strong>.<br />

TECHNICAL SUPPORT:<br />

Call the same phone number then choose the service option.<br />

SHIPPING / INVOICING<br />

WARRANTY:<br />

1. If you have the part in stock, use it to repair the customer’s <strong>SmartKART</strong> and<br />

take the defective part back to your shop.<br />

2. Order a replacement part from Dane Technologies. Please provide the<br />

location of the customer store where your part was used so that we can verify<br />

warranty coverage. Also include the serial number of the <strong>SmartKART</strong>.<br />

3. Dane Technologies will ship a replacement part and invoice you for it. Along<br />

with the part, you will receive a RMA Number, authorizing the return of the item<br />

under warranty.<br />

4. Return the part to Dane Technologies along with the RMA Number.<br />

5. Upon verifying that the part is defective, Dane Technologies will issue a credit,<br />

canceling the invoice.<br />

6. For battery replacement contact Dane Technologies at 1-888-544-7779 and<br />

choose the service option.<br />

NON-WARRANTY:<br />

1. Again, use a part from your stock if possible.<br />

2. Invoice the customer for your labor and parts. REMEMBER: Labor warranty is<br />

90 days from purchase date. Parts pricing must agree with the retail price<br />

shown on the Dane Technologies price list.<br />

3. Order replacement parts for your inventory as described above.<br />

IF YOU DON’T HAVE THE PART IN STOCK:<br />

1. Order the part from Dane Technologies as described above. Please provide a<br />

purchase order number, ship-to address if different from your business<br />

address, customer store location, and information on the part coming back, if<br />

applicable.<br />

2. Communicate with customer store management about delivery time and any<br />

other details about when you estimate the <strong>SmartKART</strong> will be repaired.<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

78


Store: ________________ Date: _________________<br />

Location: ____________________ Serial Number: SK-______<br />

Sticker Condition: ___________<br />

Inspect cord, cord plug<br />

Inspect seat and arms<br />

<strong>SmartKART</strong> Preventive Maintenance<br />

PM Checklist Inspected OK Needs Repair/Replacement<br />

Inspect, clean battery terminals and cables<br />

Inspect throttle spring<br />

Check wiring, wiring plugs for damage<br />

Check battery charger operation<br />

Check for blinking status light (fault condition)<br />

Inspect tires<br />

Inspect body parts (covers and frame)<br />

Inspect throttle pot for 2.6K +/-.3K at rest<br />

Inspect and tighten loose screws/bolts<br />

Inspect seat switch connections<br />

Test horn operation<br />

Check throttle for missing or cracked end caps<br />

Check brake move forward/backwards 2”<br />

(normal)<br />

Operation test forward/ backwards motion<br />

Any other problems:<br />

______________________________________________________________________<br />

______________________________________________________________________<br />

______________________________________________________________________<br />

______________________________________________________________________<br />

Comments:<br />

______________________________________________________________________<br />

______________________________________________________________________<br />

______________________________________________________________________<br />

______________________________________________________________________<br />

Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax 763-544-4234<br />

www.danetechnologies.com 970-032 Rev. D 10/12/10<br />

79

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