SmartKART Series - Berkel Midwest
SmartKART Series - Berkel Midwest
SmartKART Series - Berkel Midwest
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
<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 />
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 />
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 />
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 />
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 />
Dane Technologies, Inc. <strong>SmartKART</strong> <strong>Series</strong> Service Manual<br />
6.6<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 />
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 />
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 />
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 />
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 />
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 />
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 />
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 />
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 />
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 />
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 />
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 />
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 />
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 />
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 />
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