Dane Technologies SmartKART 120-052 Service Manual Download

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Dane Technologies, Inc.

SmartKART Series

Service Manual

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

www.danetechnologies.com

970-032 Rev. A 1/20/09

SmartKART TEST POINTS

SmartKART Test Points

B+ = Voltage across the two batteries.

Resistance

Test Plug (700-053), P1-Tiller 14 Pins

Forward/Reverse

Signal Color

Pin Description

Power On Power Off 2.5K Ref.

Wiper BRN

1 Pot Wiper (1-8)

2.25V

.75V

4.75K-ohm

Pot. Hi BLU

2 Pot High (Forward, 1-2)

4.22V

1.4V

11ohm/4.75K-ohm

Alarm GRN

3 Horn and Back Up Horn (2-8)

.22V

.075V 4.75K-ohm/11ohm

KSI

BLU

5 On/Off Switch

B+

Inhibit 2 Red

6 To Seat Switch

B+

RED/BLK 7 To 3A Fuse to Seat On/Off Switch

B+

Ground RED/BLK 8 Pot Ground (Reverse)

LED

WHT

10 Status

B-

BLK

13 Ground

Inhibit 3 WHT

14 To Charger (No Inhibit)

2.45V

.135V

Inhibit

.135V

Pins 4, 9,11, and 12 not used.

Test Plug (700-049), P2-Tiller 9 Pins

Signal Color

Pin Destination

Power On Power Off 2.5K Ref.

Pot Hi BLU

1 Pot High (Forward, 7 Flashes, 1-2)

4.22V

1.4V

11ohms/4.75K-ohms

Wiper BRN

2 Pot Wiper (7 Flashes, 2-3)

2.25V

.75V

4.75K-ohms/11ohms

Ground BLK

3 Pot Ground (Reverse, 7 Flashes, 2-3)

.22V

.075V 4.75K-ohms

Alarm GRN

4 Horn and Back Up Horn

19.6V

KSI

BLU

5 On/Off Switch

B+

RED

6 To 3A Fuse to Seat On/Off Switch

B+

LED

WHT

.8V

B-

BLK

8 Horn (Ground)

P3-Brake 2 Pins

Signal Color

Pin Destination

Power On

Brake 1 WHT/BRN 1 Brake Coil (9 Flashes)

21.8V

52ohms

Brake 2 WHT/BRN 2 Brake Coil (9 Flashes)

21.8V

52ohms

All conditions are open wire.

Test Points Quick Reference

Charger

GRN/WHT

14 No inhibit 3 (drives plugged in)

Alarm

GRN

4 No horn in Reverse, all else normal

KSI

BLU

5 No power on (no light)

B+

RED

6 No power on (no light)

LED

WHT

7 No status light (runs OK)

Horn

BLK

8 No horn (runs OK)

Inhibit 2 and 3

Seat/Charger

Continuous flash 1/sec., Drive forward and reverse

Motor

RED/BLK

2 flashes, close to 0ohms is normal

To Order Parts Call 1-888-702-5326 - https://monsterfloorequipmentparts.com

Summary of Contents for SmartKART 120-052

Page 1: ...es Inc Phone 763 544 7779 7105 Northland Terrace Toll Free 1 888 544 7779 Minneapolis MN 55428 Fax 763 544 4234 www danetechnologies com Part No 970 032 Rev A Rev Date 1 20 09 T o O r d e r P a r t s...

Page 2: ...1 And Diagrams SmartKART Troubleshooting 2 SmartKART Service Bulletins 3 SmartKART Exploded View Diagrams 4 SmartKART Parts Order Information 5 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h...

Page 3: ...Technologies Inc Phone 763 544 7779 7105 Northland Terrace Toll Free 1 888 544 7779 Minneapolis MN 55428 Fax 763 544 4234 www danetechnologies com Part No 970 031 Rev A Rev Date 1 20 09 T o O r d e r...

Page 4: ...e SmartKART will provide years of dependable service This manual contains information which will assist in the training operation and maintenance of the SmartKART Please read it thoroughly and review...

Page 5: ...NOTES 6 SmartKART LABELS 8 SmartKART LABEL LOCATIONS 10 SmartKART TOP VIEW 14 SmartKART SIDE VIEW 14 SmartKART ISO VIEW 15 TILLER HANDLE AND THROTTLE CONTROL 15 SmartKART REAR VIEW 16 SmartKART ISO V...

Page 6: ...ic doors and size of the load in the basket 5 Always take operating conditions such as wet or slippery floors into consideration 6 Do not drive over objects or irregular surfaces more than 1 inch high...

Page 7: ...es or onto any changes in surfaces or grade 22 Do not make sharp abrupt turns at high speeds or while going down an incline 23 Avoid inclines or ramps having a rise of more than 1 inch 2 5 cm per one...

Page 8: ...land Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 8 SmartKART LABELS T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t...

Page 9: ...0 151 500 152 500 170 500 171 500 252 500 335 3 120 055 500 040 500 143 500 144 500 145 500 147 500 150 500 151 500 170 500 252 500 335 2 120 067 500 040 500 144 500 145 500 147 500 151 500 152 500 17...

Page 10: ...Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 10 SmartKART LABEL LOCATIONS T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2...

Page 11: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 11 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 12: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 12 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 13: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 13 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 14: ...polis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 14 SmartKART TOP VIEW SmartKART SIDE VIEW Arms Optional T o O r d e r P a r t s C a l l 1 8 8 8...

Page 15: ...polis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 15 SmartKART ISO VIEW TILLER HANDLE AND THROTTLE CONTROL T o O r d e r P a r t s C a l l 1 8 8...

Page 16: ...ace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 16 SmartKART REAR VIEW Arms Optional T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5...

Page 17: ...nd Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 17 SmartKART ISO VIEW T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h...

Page 18: ...njury and property damage STEERING The SmartKART is turned by exerting light pressure to move the tiller handle to the left or right similar to steering a bicycle ACCELERATION AND BRAKING Acceleration...

Page 19: ...he right side control lever toward you 6 To turn the power off press the On Off switch to the Off position Note Do not leave the machine ON when unattended 7 When the SmartKART is stopped the parking...

Page 20: ...indicator is visible by lifting the rear cover The cover release will have to be raised out of the way to open the rear cover Leave the charger connected until ready to use vehicle To put the SmartKA...

Page 21: ...es 5 To reduce the risk of damage to the electric plugs and cord pull by plug rather than the cord when disconnecting the charger 6 Do not use an extension cord unless absolutely necessary Use of an i...

Page 22: ...ommend keeping the SmartKART plugged into a wall outlet when not in use Extended charging will not damage the batteries Monthly Clean upholstery plastic and metal with a mild surface cleaner Check and...

Page 23: ...pervisor as well as Dane Technologies Do not use the SmartKART until an authorized service technician has repaired it WARNING Do not expose your SmartKART to spray on cleaning solutions and excessive...

Page 24: ...basket 39 inches with 9380 cu in basket All around rear frame Height front 5 0 inches Rear 2 0 inches Rear wheel tread 19 75 inches Wheel base 33 0 inches Inside turning radius less than 3 inches Whee...

Page 25: ...acts of God Should any component fail during the first two years of ownership except those mentioned as not under warranty the component in question is to be returned to Dane Technologies or an autho...

Page 26: ...0 032 Rev A 1 20 09 26 DANE TECHNOLOGIES Troubleshooting Guide SmartKART Table of Contents SmartKART TROUBLESHOOTING GUIDE 27 TILLER HEAD ASSEMBLY AND WIRING 28 SmartKART TEST POINTS 29 SmartKART CONT...

Page 27: ...reverse switch is in correct position i Reverse to battery 0v 5v to drive in reverse 5v 5v to drive forward ii P1 1 BROWN and P1 8 BLACK 6 MOTOR BRAKE BECOMES VERY WARM a Check solenoid brake may be j...

Page 28: ...A 1 20 09 28 TILLER HEAD ASSEMBLY AND WIRING Original Style Potentiometer New Style Potentiometer Throttle Control On Off Switch Horn Switch Horn Potentiometer Status Indicator Throttle Control On Off...

Page 29: ...tion Power On Power Off 2 5K Ref Pot Hi BLU 1 Pot High Forward 7 Flashes 1 2 4 22V 1 4V 11ohms 4 75K ohms Wiper BRN 2 Pot Wiper 7 Flashes 2 3 2 25V 75V 4 75K ohms 11ohms Ground BLK 3 Pot Ground Revers...

Page 30: ...es The motor has a short circuit to a battery connection Contact your service provider to check motor connectors and wiring 4 Flashes Not Used 5 Flashes Not used 6 Flashes The controller is being inhi...

Page 31: ...e If controller has a repeating sequence that is not listed above controller is malfunctioning and needs to be replaced Note 2 quick flashes then a pause then continuous flashes 1 Motor leads Red Blac...

Page 32: ...from CC Constant Current to CV Constant Voltage mode Stage 3 Constant Voltage Mode CV LED Orange The charger holds the battery at 28 8V and the current slowly reduces When the current reaches 0 50CC i...

Page 33: ...544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 33 DANE TECHNOLOGIES Service Bulletins SmartKART No Service Bulletins as of January 20 2009 T o O r d e r P a r t...

Page 34: ...E BASKET 41 120 081 SmartKART TARGET SKE 42 150 027 SmartKART 24V W BASKET 43 150 031 SmartKART DANE RED REAR COVER 46 150 038 SmartKART 24V W BASKET 49 150 041 SmartKART DANE RED REAR COVER 52 100 19...

Page 35: ...errace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 35 120 036 SmartKART 24V DANE T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2...

Page 36: ...rrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 36 120 042 SmartKART 24V TARGET T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2...

Page 37: ...errace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 37 120 052 SmartKART 24V DANE T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2...

Page 38: ...errace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 38 120 053 SmartKART 24V DANE T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2...

Page 39: ...rrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 39 120 055 SmartKART 24V TARGET T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2...

Page 40: ...Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 40 120 067 SmartKART XD RED COVER STD BASKET T o O r d e r P a r t s C a l l 1 8 8 8 7 0...

Page 41: ...inneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 41 120 068 SmartKART XD RED COVER LARGE BASKET T o O r d e r P a r t s C a l l 1 8 8 8 7 0...

Page 42: ...rrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 42 120 081 SmartKART TARGET SKE T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2...

Page 43: ...race Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 43 150 027 SmartKART 24V W BASKET T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3...

Page 44: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 44 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 45: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 45 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 46: ...e Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 46 150 031 SmartKART DANE RED REAR COVER T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2...

Page 47: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 47 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 48: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 48 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 49: ...race Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 49 150 038 SmartKART 24V W BASKET T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3...

Page 50: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 50 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 51: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 51 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 52: ...e Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 52 150 041 SmartKART DANE RED REAR COVER T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2...

Page 53: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 53 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 54: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 54 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 55: ...errace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 55 100 197 ASM YOKE AND MOTOR T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2...

Page 56: ...Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 56 100 203 ASSEMBLY TILLER T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6...

Page 57: ...ce Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 57 110 078 KIT SmartKART HORN HARNESS T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5...

Page 58: ...eapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 58 110 092 KIT SmartKART POT AND SPRING REPLACEMENT T o O r d e r P a r t s C a l l 1 8 8 8 7...

Page 59: ...05 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 59 T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m...

Page 60: ...ace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 60 430 081 STEERING BEARING HEADSET T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3...

Page 61: ...Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 61 680 039 WIRING DIAGRAM T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6...

Page 62: ...Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 62 680 042 WIRING DIAGRAM T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6...

Page 63: ...ace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 63 700 204 CONTROLLER MOTOR HARNESS T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3...

Page 64: ...errace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 64 700 205 TILLER HEAD HARNESS T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2...

Page 65: ...d Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 65 700 206 POWER HARNESS T o O r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6...

Page 66: ...3 544 7779 Fax 763 544 4234 www danetechnologies com 970 032 Rev A 1 20 09 66 910 008 SmartKART POTENTIOMETER SETTING INSTRUCTIONS FOR USE WITH UNITS HAVING ORIGINAL POTENTIOMETER SPRING ASSY T o O r...

Page 67: ...technologies com 970 032 Rev A 1 20 09 67 DANE TECHNOLOGIES Parts and Recommended Parts Inventory SmartKART Table of Contents PARTS NEEDED TO SERVICE THE SmartKART 68 COMPLETE PARTS LIST FOR THE Smart...

Page 68: ...METER AND SPRING REPLACEMENT 110 108 POTENTIOMETER W HARNESS 210 199 WELDMENT YOKE 220 517 PLATE ANTI TIP CASTER MOUNT 300 075 MOTOR 360 061 8 WHEEL W SEALED BEARING 2 360 062 2 WHEEL CASTER SWIVEL 2...

Page 69: ...20 548 CORD COVER PLATE 220 867 PLATE ANTI TIP CASTER MOUNT 220 869 BASKET HOLDING CLIP 300 075 DRIVE MOTOR ASI 140 RMP 24V 360 061 8 WHEEL W SEALED BEARING 360 062 SWIVEL CASTER W 2 WHEEL 360 067 WHE...

Page 70: ...040 SEAT SWITCH 665 048 ROCKER SWITCH 665 049 PUSH BUTTON SWITCH 670 015 LED GREEN 700 142 BATTERY JUMPER HARNESS 700 204 TILLER MOTOR S DRIVE HARNESS 700 205 HARNESS TILLER HEAD 700 206 HARNESS BATTE...

Page 71: ...OUNT WRENCH SOCKET SEAT AND SEAT SUPPORT 11 16 DP SOCKET TORQUE ADAPTER SHAFT FRONT WHEEL 2 OPEN END WRENCH BACK WHEELS 5mm BALL HEX TILLER ARM TO MOTOR MOTOR 2 PHILIPS SCREW DRIVER TILLER AND CONTROL...

Page 72: ...a training video and a folder that includes an owner s manual a set of Service Bulletins exploded parts drawings and at the back find the following additional materials Ordering and invoicing procedu...

Page 73: ...eceive a RMA Number authorizing the return of the item under warranty 4 Return the part to Dane Technologies along with the RMA Number 5 Upon verifying that the part is defective Dane Technologies wil...

Page 74: ...k battery charger operation Check for blinking status light fault condition Inspect tires Inspect body parts Inspect throttle pot for 2 6K 3K at rest Inspect and tighten loose screws bolts Inspect sea...

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