Dane Technologies SmartKART 120-052, SmartKART 120-053, SmartKART 120-055, SmartKART 120-067, SmartKART 120-081 Service Manual

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SmartKART Series

Service Manual

SmartKART

Electric Utility Machine

Manufactured by:

Dane Technologies, Inc. Phone: [phone]
7105 Northland Terrace Toll Free: 1-888-544-7779
Minneapolis, MN 55428 Fax: [phone]

www.danetechnologies.com

Part No. 970-032 Rev A Rev. Date: 1/20/09

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Table of Contents

Topic Section

• SmartKART Operating Instructions 1

And Diagrams

• SmartKART Troubleshooting 2

• SmartKART Service Bulletins 3

• SmartKART Exploded View Diagrams 4

• SmartKART Parts Order Information 5

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Dane SmartKART

OWNER’S MANUAL

OPERATING INSTRUCTIONS

SmartKART

Electric Utility Machine

Manufactured by:

Dane Technologies, Inc. Phone: [phone]
7105 Northland Terrace Toll Free: 1-888-544-7779
Minneapolis, MN 55428 Fax: [phone]

www.danetechnologies.com

Part No. 970-031 Rev A Rev. Date: 1/20/09

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

Dane SmartKART

INTRODUCTION
Thank you for purchasing the Dane Technologies SmartKART. With proper operation

and maintenance, the 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 it regularly.

If you have questions regarding the safe operation or maintenance of the SmartKART,
which are not covered in this manual, please contact us at our toll-free service line: 888­544-7779.

Dane Technologies, Inc. SmartKART Series Service Manual

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SmartKART

Owner’s Manual

Operating Instructions

Table of Contents

SmartKART WARNINGS AND SAFETY 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 VIEW............................................................................................................ 17

ORIENTATION TO THE SmartKART....................................................................................... 18

OPERATION OF THE SmartKART ........................................................................................... 19

BATTERY CHARGING.............................................................................................................. 20

SmartKART MAINTENANCE....................................................................................................22

TECHNICAL SPECIFICATIONS............................................................................................... 24

SmartKART WARRANTY.......................................................................................................... 25

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SmartKART WARNINGS AND SAFETY NOTES

IMPORTANT SAFETY NOTE:

THE NEGATIVE BATTERY CABLE MUST BE DISCONNECTED FROM
THE BATTERY ANY TIME MAINTENANCE IS BEING PERFORMED
UNDER THE COVER!

1) The SmartKART comes equipped with several warning labels; make sure to read
them before operating the machine.

2) The SmartKART is equipped with a brake that automatically engages when the
machine is turned off or not in motion. To avoid an accident, do not leave the
machine parked or unattended on slopes. When the SmartKART is to be left
unattended or in storage, turn it off using the “On/Off” switch.

3) Always turn the SmartKART off before getting on or off.

4) Operate the vehicle only as fast as safety considerations will allow, taking into
consideration the traffic, 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.

7) Only one individual is allowed on the vehicle at any time. NO PASSENGERS!

8) Always look at the path in front and behind the SmartKART before and while
operating the machine.

9) The SmartKART is intended to move a person with selected items in the basket
on a level surface indoors. Any other use of the vehicle is prohibited unless
specifically endorsed by the manufacturer. The occupant must remain seated
while the SmartKART is in operation.

10) Hydrogen gas is formed when charging the batteries. Use adequate ventilation
when charging batteries. Never smoke near batteries. Do not charge batteries in
an area with open flame or around electrical equipment that could cause an
electrical arc.

11) The batteries do not require regular maintenance.

12) Improper use and operation of the SmartKART may void the warranty.

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13) Do not lay metal objects (wrenches, screwdrivers, etc.) on any of the batteries to
prevent electrical short circuits.

14) Batteries are heavy. Always use care and proper lifting technique to avoid injury
when removing or replacing batteries.

15) Be cautious around other customers, store displays and shelving.

16) Keep legs on the platform while driving the SmartKART.

17) Maximum load capacity for the SmartKART is 200 lbs. basket load not to exceed
a total of 800 lbs. combined weight of rider and basket load.

18) Do not operate the SmartKART under low-light conditions.

19) Drive slowly while turning and on inclines.

20) When driving over bumps, dips or inclines, approach them at a 90-degree angle
and drive straight up and down them. Also do not park on inclines.

21) Do not back down inclines 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 foot
(30.5 cm) (federal standard for wheelchair ramps).

24) Avoid sudden starts while the handle is turned sharply.

25) Do not operate in parking lots or other areas with vehicular traffic.

26) Do not travel over grass, gravel, or soft dirt.

27) Front stability wheel attachments on the Dane SmartKART provide additional
stability and are required for rough or uneven surfaces. Do not remove the
stability attachments mounted below the platform next to the front wheel.

28) Don’t expose the SmartKART to spray-on cleaning solutions and excessive
moisture, such as spraying it with a hose or leaving it uncovered in heavy rain.

29) Do not drive at full speed into any fixed obstacles or objects as this may result in
personal injury or structural damage.

CAUTION:

Turning the SmartKART off using the “On/Off while in motion will bring the
SmartKART to an abrupt stop.

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SmartKART LABELS

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SmartKART

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Model

120-052
120-053
120-055

120-067

120-068

120-081

500-040, 500-144, 500-145, 500-147, 500-151, 500-152, 500-170, 500-171, 500-252, 500­335(3)
500-040, 500-144, 500-145, 500-147, 500-151, 500-152, 500-170, 500-171, 500-252, 500­335(3)
500-040, 500-143, 500-144, 500-145, 500-147, 500-150, 500-151, 500-170, 500-252, 500­335(2)

500-040, 500-144, 500-145, 500-147, 500-151, 500-152, 500-170, 500-171, 500-252, 500­334(2), 500-335

500-040, 500-144, 500-145, 500-147, 500-151, 500-152, 500-170, 500-171, 500-252, 500­334(2), 500-335

500-040, 500-143, 500-144, 500-145, 500-147, 500-150, 500-151, 500-170, 500-252, 500­335(2)

Dane Technologies, Inc. SmartKART Series Service Manual

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax [phone]

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Labels

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SmartKART LABEL LOCATIONS

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Dane Technologies, Inc. SmartKART Series Service Manual

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax [phone]

www.danetechnologies.com 970-032 Rev. A 1/20/09

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Dane Technologies, Inc. SmartKART Series Service Manual

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax [phone]

www.danetechnologies.com 970-032 Rev. A 1/20/09

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Dane Technologies, Inc. SmartKART Series Service Manual

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SmartKART – TOP VIEW

SmartKART – SIDE VIEW

(Arms Optional)

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SmartKART – ISO VIEW

TILLER HANDLE AND THROTTLE CONTROL

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SmartKART – REAR VIEW

(Arms Optional)

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SmartKART – ISO VIEW

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ORIENTATION TO THE SmartKART

Pressing the "HORN" button will sound the horn as long as it is pressed.
Handle Controls

The handle includes forward/reverse throttle control levers, “On/Off” switch, horn switch,
and a battery indicator meter. The Dane SmartKART should be parked and turned off
using the “On/Off” while not in use.

Occupant Seat Switch

The occupant seat switch is located under the seat. The occupant’s weight on the seat
activates the switch allowing the SmartKART to operate.

WARNING!

A seat switch that is not properly maintained or is disconnected may cause
personal injury 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 and braking of the SmartKART are

controlled by the throttle control located on both sides of the handle bar. SmartKART
speed is controlled by pushing the throttle control. Braking action occurs as pressure is
released. Braking force can be controlled for quick or gradual stops. Releasing the
control slowly brings the SmartKART to a gradual stop. Releasing it rapidly stops the
SmartKART very quickly. Maximum braking force is applied when the throttle is fully
released.

Manually Moving the SmartKART

To move by hand, empty all materials from the basket. Lift front of machine by pulling
up on the basket. Pull entire machine to desired location.

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OPERATION OF THE SmartKART

To operate the SmartKART, perform the following steps:

1) Sit on the seat.

2) Press the “On/Off” switch located on the tiller handle to the “On” position.

3) The light on the tiller handle will show the battery status. The light will be on
steady for a charged battery.

4) To move forward, push the right side of the hand control lever toward the
handlebar. You can also move forward by pulling the left side of the control lever
toward you. By releasing the control lever, you will come to a stop approximately
one second after release.

5) To operate in reverse, push the left side of the hand control lever toward the
handlebar or pull the 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 brake automatically engages. This
prevents the SmartKART from rolling on slopes or being pushed manually.

8) The electromagnetic brake will stop your SmartKART approximately one second
after releasing the hand control lever.

9) In Emergency Only – Quick stopping with your SmartKART can be accomplished
by turning the SmartKART off or by reversing the handle control in order to
reverse the direction the SmartKART is traveling.

10) You will get years of dependable operation if you follow the suggested
maintenance schedule. For operations questions, 8AM-6PM EST Monday­Friday, call the Dane SmartKART Service Line at 888-544-7779 or contact your
local service representative. Please reference your serial number when calling.

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BATTERY CHARGING

The battery charger is designed to charge 2-12 volt gel, sealed or wet lead acid deep
cycle batteries hooked up in series to full charge. The charger may be left connected to
the batteries after full charge (steady green light). The charger uses minimum power in
this standby-mode, maintains the batteries at full charge and extends battery life. This is
accomplished with an electronics circuitry that controls and regulates the amount of
charging current that is sent from the charger to the batteries being charged.

To recharge the batteries, park the SmartKART in a well-ventilated location near an
electrical outlet. The SmartKART must be turned off.

• Plug the coiled cord at the rear of the SmartKART into a wall receptacle. The
battery charger will automatically shut off when the batteries are fully charged.
This takes between two and ten hours, depending upon initial state of charge and
battery condition. Make sure the power to the wall receptacle is not turned
off during the nightly recharging time.

• The LED light 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 SmartKART back into service after the batteries are fully charged,

disconnect the charger's power extension cord from the wall receptacle and
place it in the cavity in the back of the seat console of the SmartKART.

The lights on the battery charger under the seat will show the charging state while the
charging cord is connected. Fully discharged batteries will result in a charging rate of 4
amperes (6 amperes for XD model). As the batteries become fully charged this rate will
drop to less than 1 amp.

The explanation of the charging cycle is as follows.

Stages

Stage 1 Charging Pulse Mode Pulse Mode 4 A (6 A) Pulsing 0.5 V to 5.0 V Flash
Stage 2 Constant Current Mode
Stage 3 Constant Voltage Mode
Stage 4 Standby Voltage Mode Standby CV Mode

Recharging Mode CC Mode 4 A (6A) 27.6 V Orange
** XD Model amperage shown in ()
*CC Mode - Constant Current Charge
*CV Mode - Constant Voltage Charge

NOTE: Charge batteries whenever SmartKART is not in use.

Condition Mode* Current** Voltage LED Indication

CC Mode 4 A (6A) 5.0 V to 28.8 V Orange
CV Mode Reduces from 4 A (6A) Holds at 28.8 V

Reduces to Zero Maintains 27.6 V

Orange

Green

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WARNING

Do not use long extension cords. Use the cord supplied with the machine. Find a
location for re-charging, which is close to an electrical outlet receptacle. If
another cord must be used, it must be 16 gauge or larger and no more than 10
feet in length.

1. Before using the battery charger, read all instructions and cautionary marking
related to the:

a. Battery charger
b. Battery

2. CAUTION:

wet lead type rechargeable batteries hooked up in series. Other types of
batteries may burst causing personal injury or damage.

3. Do not expose charger to rain or snow.

4. CAUTION: To prevent the risk of fire, use the charger only in dry and

ventilated rooms without flammable fluids and explosive gases.

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 improper
extension cord could result in risk of fire and electric shock. If an extension cord
must be used, make sure:

a. The pins on the plug of extension cord are the same number, size and

shape as those on the charger

b. The extension cord is properly wired and in good electrical condition and

the wire size is 16 gauge or larger and no more than 10 feet in length

7. Make sure cord is located so that it will not be stepped on, tripped over or
otherwise subject to damage or stress.

8. Do not operate charger with damaged cord or plug – replace immediately!

9. Do not operate a charger if it received a sharp blow, has been dropped or
otherwise damaged in any way.

10. Do not disassemble charger!

11. To reduce risk of electric shock, unplug charger from AC mains and battery outlet
before attempting any maintenance or cleaning.

To reduce risk of injury, charge only 2-12 volt gel, sealed, or

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SmartKART MAINTENANCE

Check the SmartKART daily for safe operation: Routine maintenance should only be

performed by those permitted by federal and state regulations. Repairs should only be
completed by Dane Technologies or an authorized service technician.

Batteries: Recharge to a full charge after each day's usage or when not in use.
Throttle Control: (Acceleration and braking) Check for proper operation every time the

Smart KART is operated. See "OPERATION OF THE SmartKART" on page 17.

MAINTENANCE SCHEDULE
Keep you SmartKART Shining

Minimum maintenance is required to increase your service ease and dependability.
Wipe clean with mild household cleaner and a damp cloth.

Daily

• Maintain battery charge. When not in use, turn the SmartKART "OFF" to prevent
battery drainage.

• Charge overnight, every night.

• We recommend 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 tighten any exposed fasteners.

• Check wheel bearings for roughness during rotation. Replace if necessary.

• Check charge cord receptacle.

Three Months

• Check all bolts and connections for tightness and wear.

• Check basket welds and wire.

Six Months

• Check all electrical connections for clean contact.

• Inspect seat structure for wear.

• Inspect seat switch operation to insure wire assembly is properly connected.

• Check tires for wear.

Yearly

• Have your authorized service center check your SmartKART completely.

• Inspect seat bracket and bolts for wear.

Circuit Breaker Replacement Instructions
An automatic resetting circuit breaker protects the wiring and battery in the event of a
short circuit.

Seat Switch Troubleshooting Instructions

If the SmartKART operates while the occupant is not seated, disconnect the wires from
the switch. If the SmartKART no longer moves, replace the switch.

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If the SmartKART malfunctions in any way, turn it off and tag the machine "DO
NOT USE". Remove the optional key (if present). Immediately report the malfunction to
the appropriate supervisor 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
moisture such as spraying it with a hose, or leaving it uncovered in heavy rain.
Excessive moisture around the controller or electrical connections may cause
contamination of electrical circuitry, damage and malfunction, as well as personal
injury.

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TECHNICAL SPECIFICATIONS

Length with basket.......................................................58 inches with 6400 cu. in.

and 9380 cu. in. baskets and nerf
bar

57.125 inches with 6400 cu. in.
and 9380 cu. in. baskets and
bumpers

63.6 inches with 9450 cu. in.
basket

Width............................................................................26.38 inches

(Basket width 23.75 inches)

Height ..........................................................................35.5 inches with 6400 cu. in.

9450 cu. in. 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

Wheel, Front................................................................8.3 inches diameter

Wheel, Rear.................................................................8 inches diameter

Maximum Load Capacity, Single Passenger ...............600 lbs.

Maximum Load Capacity, Basket ................................200 lbs.

Chassis........................................................................Welded

Safety...........................................................................12 Amp breaker

Brakes..........................................................................Electronic dynamic

Mechanical

Electrical system..........................................................2-12 volt batteries

Charger........................................................................Input 120 VAC

24 VDC, 4 amperes max.
(6 A max for XD model)

Speed ..........................................................................Forward 0 – 3.0 MPH max.

Reverse 0 – 2.0 MPH max.

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SmartKART WARRANTY

1) Parts: Two (2) Years Limited Warranty from date of shipment.

2) Labor: One (1) Year Limited Warranty from date of shipment.

3) Batteries: Covered by the manufacturer’s warranty.

4) Frame: Ten (10) Year Limited Warranty from date of shipment.

1) Parts – Limited Warranty

All parts except batteries (covered by the battery manufacturer’s warranty), tires,
upholstery, armrests, and circuit breakers needing resetting are warranted by Dane
Technologies to be free of defects in material and workmanship for a period of two (2)
years from date of shipment. This warranty does not include tire wear or wear and tear
caused by abuse, negligence, freight damage or damage caused by improper use of
care, or by external sources such as fires, floods or other 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 authorized Dane Technologies representative for inspection. If the
component has failed due to a defect in material or workmanship, it will be exchanged
or repaired at the discretion of Dane Technologies at no charge to the SmartKART
owner.

Dane Technologies, Inc. will cover the costs of shipping parts covered under warranty to
the customer based on UPS standard ground rates.

2) LABOR – Limited Warranty

Dane Technologies will cover labor charges for work performed in the field for one (1)
year from date of shipment as a result of defects in materials or workmanship. Charges
incurred for resetting circuit breakers, replacing seat, armrests, or failure to change and
maintain batteries in the SmartKART are exempt. Non-warranty service performed
during the same visit as for warranty service is not covered by the warranty.

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DANE TECHNOLOGIES

Troubleshooting Guide — SmartKART

Table of Contents

SmartKART TROUBLESHOOTING GUIDE.............................................................................27

TILLER HEAD ASSEMBLY AND WIRING.............................................................................28

SmartKART TEST POINTS......................................................................................................... 29

SmartKART CONTROLLER STATUS INDICATOR................................................................ 30

BATTERY CHARGER................................................................................................................ 32

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SmartKART TROUBLESHOOTING GUIDE

1) SYSTEM WILL NOT SWITCH ON *
a) Check P2-5/6 BLUE/ RED or P1-5 BLUE should be equal to battery positive +/-

.5v

2) VEHICLE DRIVES SLOWLY *
a) Check that solenoid brake is not jammed (P3-1&2 BROWN) or bad pot.
b) New motor 300-065 or 300-075 replacing 300-061, controller needs

programming.

3) STATUS INDICATOR DOES NOT LIGHT (No power is reaching the controller) *
a) Check the wiring and connectors from the controller’s status indicator output to

the status indicator itself P2-7 WHITE (OPEN)

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

(with fully charged batteries)

4) REVERSE ALARM DOES NOT SOUND
a) Check wiring and connectors from the controller’s reverse alarm output and the

sounder itself

i) P2-4 GREEN (OPEN)

5) VEHICLE WILL NOT DRIVE IN REVERSE *
a) Check voltage at reverse input (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 jamming (P3-1&2 BROWN) 52 OHMS brake coil

7) BATTERIES DISCHARGE VERY QUICKLY
a) Worn or damaged batteries (check battery condition)
b) Charger is defective (check charger operation)
c) Incorrect batteries being used (check correct battery type 800-016 standard

model, 800-022 XD model)

d) Solenoid brake jamming P3-1&2 BROWN 52 Ohms brake coil.

8) DETECTING A TRIP HAS OCCURRED (flashing status light)
a) Flashing rapidly (connecting programmer will give you a trip code)

i) Reference: chart to determine the problem and repair procedure (nine

different codes)
b) Flashing slowly (no trip is currently detected) batteries require charging
c) Display is steady (the controller is not currently tripped

9) INHIBIT 2 OR 3 SEAT/CHARGER OCCURRED (Continuous blink 1/second) After
drives FWD. Or REV.

a) P1-6 RED or P1-14 WHITE (OPEN)

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

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Horn

Horn

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TILLER HEAD ASSEMBLY AND WIRING

Throttle
Control

Horn
Switch

On/Off

Status
Indicator

Switch

Original Style Potentiometer

Throttle
Control

Status
Indicator

On/Off
Switch

Horn
Switch

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New Style Potentiometer

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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+ 0V
Inhibit 2 Red 6 To Seat Switch B+ 0V
B+ RED/BLK 7 To 3A Fuse to Seat On/Off Switch B+ 0V
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 0V
KSI BLU 5 On/Off Switch B+ 0V
B+ RED 6 To 3A Fuse to Seat On/Off Switch B+ 0V
LED WHT 7 .8V 0V
B- BLK 8 Horn (Ground) 0V 0V

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 P1 GRN/WHT 14 No inhibit 3 (drives plugged in)
Alarm P2
KSI P3
B+ P4
LED P5
Horn P6
Inhibit 2 and 3 Seat/Charger Continuous flash 1/sec., Drive forward and reverse
Motor RED/BLK 2 flashes, close to 0ohms is normal

GRN 4 No horn in Reverse, all else normal

BLU 5 No power on (no light)

RED 6 No power on (no light)

WHT 7 No status light (runs OK)

BLK 8 No horn (runs OK)

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SmartKART CONTROLLER STATUS INDICATOR

The SmartKART contains a green LED on the tiller handle assembly. The LED is a
controller status indicator light. If the light is on steady, the SmartKART is ready to
drive. If the light is flashing a repeating code there is a problem. Consult the list below
to determine the possible problem and solution.

1 Flash
The battery needs charging or there is a bad connection to the battery. The battery is
below 16V Check the connections to the battery. If the connections are good, try
charging the battery. Also the potentiometer or controller may be bad.

2 Flashes
There is a bad connection to the motor. Check all connections between the motor and
the controller. The motor wires are red/black and will have a resistance of 8 ohms or
less.

3 Flashes
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 inhibited from driving, this may be because the battery charger is
connected or the seat is not in the driving position.

7 Flashes
A throttle fault is indicated. Make sure that the throttle is in the rest position before
switching on the SmartKART. The resistance of the throttle (pins 1 and 2) is 2.6K-ohms
+/- .3K-ohms. Potentiometer setting instructions are on pg. 52.

8 Flashes
A controller fault is indicated. Make sure that all the connections are secure.

9 Flashes
The parking brakes have a bad connection. Check the parking brake and motor
connections. Make sure the controller connections are secure. P3 pins 1and 2 are 52
ohms. Should be able to move forward and backward 2” is normal.

10 Flashes
An excessive voltage has been applied to the controller. This is usually caused by a
poor battery connection. Check the battery connections should be over 38VDC.

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Note: 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/Black are more than 8 ohms.
a. Bad motor crimp.

2) Bad charger or low batteries.

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BATTERY CHARGER

The battery charger for the SmartKART is a five-stage charger. The following explains
each stage of the charger. To view the status of the charger check the LED on the front
face of the charger.

Charging Stages

Stage 1: Deep Discharge Charging Pulse Mode: LED Flash
The charger starts charging at 0.5V and give pulse current up to 5V. This has effect of
removing loose sulphation formed during deep discharge state of the battery.

Stage 2: Constant Current Mode (CC): LED Orange
The charger changes to constant current 4A (6A for XD model). When the battery
voltage reaches up to 28.8V, the charging stage changes 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, it can adjust the current automatically according to battery
capacity. This is called the Switching Point. Other chargers are not capable to adjust
the current automatically.

Stage 4: Standby Voltage Mode: LED Green
The charger maintains the battery voltage at 27.6V and current slowly reduces to zero.
The charger can be left connected indefinitely without harming the battery.

Stage 5: LED Orange
If the battery voltage drops below 27.6V, the charger changes from any mode to
Constant Current mode and restart charging. The charging cycle will go through Stage
2 to Stage 4.

SmartKART Standard
Model Charger

Standard Model Charger (4A Max output) XD Model Charger (6A Max output)

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LED Status Lights

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DANE TECHNOLOGIES

Service Bulletins — SmartKART

No Service Bulletins as of January 20, 2009

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DANE TECHNOLOGIES

SmartKART

Exploded Views and Diagrams

Table of Contents

120-036 SmartKART 24V, DANE............................................................................................... 35

120-042 SmartKART 24V, TARGET .......................................................................................... 36

120-052 SmartKART 24V, DANE............................................................................................... 37

120-053 SmartKART 24V, DANE............................................................................................... 38

120-055 SmartKART 24V, TARGET .......................................................................................... 39

120-067 SmartKART XD - RED COVER, STD BASKET......................................................... 40

120-068 SmartKART XD - RED COVER, LARGE 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

100-197 ASM, YOKE AND MOTOR ......................................................................................... 55

100-203 ASSEMBLY, TILLER................................................................................................... 56

110-078 KIT, SmartKART HORN/HARNESS ........................................................................... 57

110-092 KIT, SmartKART POT AND SPRING REPLACEMENT............................................ 58

430-081 STEERING BEARING HEADSET............................................................................... 60

680-039 WIRING DIAGRAM..................................................................................................... 61

680-042 WIRING DIAGRAM..................................................................................................... 62

700-204 CONTROLLER/MOTOR HARNESS........................................................................... 63

700-205 TILLER HEAD HARNESS........................................................................................... 64

700-206 POWER HARNESS....................................................................................................... 65

910-008 SmartKART POTENTIOMETER SETTING INSTRUCTIONS.................................. 66

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120-036 SmartKART 24V, DANE

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120-042 SmartKART 24V, TARGET

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120-052 SmartKART 24V, DANE

Dane Technologies, Inc. SmartKART Series Service Manual

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120-053 SmartKART 24V, DANE

Dane Technologies, Inc. SmartKART Series Service Manual

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120-055 SmartKART 24V, TARGET

Dane Technologies, Inc. SmartKART Series Service Manual

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120-067 SmartKART XD - RED COVER, STD BASKET

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120-068 SmartKART XD - RED COVER, LARGE BASKET

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120-081 SmartKART, TARGET SKE

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150-027 SmartKART, 24V W/BASKET

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Dane Technologies, Inc. SmartKART Series Service Manual

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Dane Technologies, Inc. SmartKART Series Service Manual

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150-031 SmartKART DANE RED REAR COVER

Dane Technologies, Inc. SmartKART Series Service Manual

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Dane Technologies, Inc. SmartKART Series Service Manual

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Dane Technologies, Inc. SmartKART Series Service Manual

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150-038 SmartKART 24V W/BASKET

Dane Technologies, Inc. SmartKART Series Service Manual

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Dane Technologies, Inc. SmartKART Series Service Manual

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Dane Technologies, Inc. SmartKART Series Service Manual

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150-041 SmartKART DANE RED REAR COVER

Dane Technologies, Inc. SmartKART Series Service Manual

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Dane Technologies, Inc. SmartKART Series Service Manual

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Dane Technologies, Inc. SmartKART Series Service Manual

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100-197 ASM, YOKE AND MOTOR

Dane Technologies, Inc. SmartKART Series Service Manual

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100-203 ASSEMBLY, TILLER

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110-078 KIT, SmartKART HORN/HARNESS

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110-092 KIT, SmartKART POT AND SPRING REPLACEMENT

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Dane Technologies, Inc. SmartKART Series Service Manual

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430-081 STEERING BEARING HEADSET

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680-039 WIRING DIAGRAM

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680-042 WIRING DIAGRAM

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700-204 CONTROLLER/MOTOR HARNESS

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700-205 TILLER HEAD HARNESS

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700-206 POWER HARNESS

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POTENTIOMETER/SPRING ASSY

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910-008 SmartKART POTENTIOMETER SETTING

INSTRUCTIONS

Dane Technologies, Inc. SmartKART Series Service Manual

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FOR USE WITH UNITS HAVING ORIGINAL

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DANE TECHNOLOGIES

Parts and Recommended Parts Inventory

SmartKART

Table of Contents

PARTS NEEDED TO SERVICE THE SmartKART................................................................... 68

COMPLETE PARTS LIST FOR THE SmartKART.................................................................... 69

SmartKART TOOLS.................................................................................................................... 71

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PARTS NEEDED TO SERVICE THE SmartKART

This is a suggested list of parts for a service provider to have on hand.
Part #: Description:

100-194...................................................CONTROLLER 24V

100-197...................................................ASM, YOKE AND MOTOR

100-203...................................................ASSY. TILLER

110-077...................................................SmartKART WHEEL NUT REPLACEMENT

110-078...................................................KIT, SmartKART HORN REPLACEMENT

110-081...................................................KIT, SmartKART SEAT

110-092...................................................KIT, POTENTIOMETER 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)

360-067...................................................WHEEL (FRONT)

370-010...................................................POTENTIOMETER ONLY

460-044...................................................TORSION SPRING

470-045...................................................SEAT AND ARM REST ASSY.

470-043...................................................ARM RESTS (2)

660-035...................................................12-AMP CIRCUIT BREAKER AUTO RESET

665-040...................................................SEAT SWITCH

700-142...................................................HARNESS BATT. JUMPER

700-204...................................................TILLER MOTOR WIRE HARNESS

700-205...................................................TILLER HEAD HARNESS

700-206...................................................HARNESS POWER

700-207...................................................HARNESS STATIC DISCHARGE

700-222...................................................POWER CORD

810-039...................................................CHARGER, 24V 4A

810-038...................................................CHARGER, 24V 6A

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COMPLETE PARTS LIST FOR THE SmartKART

This is a complete parts list of items that can be acquired from Dane Technologies by a
service provider.
PART #: DESCRIPTION:

100-194...................................................CONTROLLER 24V

100-197...................................................ASM YOKE AND MOTOR

100-203...................................................TILLER ASSEMBLY

110-092...................................................KIT, POTENTIOMETER AND SPRING

110-108...................................................KIT, POTENTIOMETER W/ HARNESS

110-118...................................................KIT, FRONT/BACK TILLER COVER

200-291...................................................ROD LATCH

200-417...................................................BASKET SUPPORT

210-199...................................................WELDMENT YOKE

210-217...................................................STEER COLUMN

210-218...................................................THROTTLE CONTROL

210-324...................................................NERF BAR WELDMENT

220-545...................................................TILLER HEAD COVER

220-548...................................................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...................................................WHEEL, 8” STEEL-KEYED, NO BEARING

370-002...................................................HANDGRIPS

370-010...................................................POTENTIOMETER ONLY

410-065...................................................NUT M10 1 25 SHAFT (17mm)

430-081...................................................STEERING BEARING HEADSET

430-171...................................................SMALL BASKET

430-178...................................................LARGE BASKET

460-044...................................................TORSION SPRING

470-049...................................................BUZZER, 5-30 VDC, FLANGE MOUNT

470-050...................................................SEAT AND ARMRESTS ASSEMBLY (3 BOLT)

470-051...................................................SEAT

470-052...................................................ARM RESTS RH & LH (3 BOLT)

470-060...................................................SEAT

480-087...................................................THROTTLE END CAP

480-089, 480-090 ...................................SEE 110-118

480-091...................................................COVER REAR, TARGET RED

480-092...................................................COVER REAR, DANE RED

480-157...................................................COVER REAR, BLACK

501-020...................................................SMARTKART LABEL KIT

501-021...................................................SMARTKART LABEL KIT

501-023...................................................SMARTKART LABEL KIT

501-030...................................................SMARTKART LABEL KIT

Dane Technologies, Inc. SmartKART Series Service Manual

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax [phone]

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REPLACEMENT

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660-035...................................................CIRCUIT BREAKER 24V 12A AUTO RESET

665-040...................................................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 BATTERY SEAT

700-207...................................................HARNESS STATIC DISCHARGE

700-222...................................................SmartKART POWER CORD

810-039...................................................CHARGER, 24V 4A

810-038...................................................CHARGER, 24V 6A

Dane Technologies, Inc. SmartKART Series Service Manual

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SmartKART TOOLS

Size: Tool: Application:
1-1/4” CROWFOOT WRENCH (TORQUE) TILLER ARM NUTS
10 mm WRENCH/SOCKET BATTERIES
11/32” WRENCH/SOCKET FUSE, CONTROLLER, TILLER
COVER
3/32” HEX THROTTLE CONTROL
POTENTIOMETER
7/16” WRENCH/SOCKET TILLER, BASKET, YOKE
9/16” WRENCH/SOCKET NERF BAR, CASTER MOUNT
½” WRENCH/SOCKET SEAT AND SEAT SUPPORT
11/16” DP SOCKET (TORQUE) ADAPTER SHAFT FRONT WHEEL
¾” (2) OPEN END WRENCH BACK WHEELS
5mm BALL HEX TILLER ARM TO MOTOR, MOTOR
#2 PHILIPS SCREW DRIVER TILLER AND CONTROL COVERS
1/16” MOLEX EXTRACTOR PART # 11-03-0002 P2 AND P3
MOLEX MOLEX EXTRACTOR PART # 11-03-0044 P1

Dane Technologies Fastener
Torque Chart

Grade 1

Torque

Size

#6 5
#8 8

#10 12

1/4 6 9

5/16 13 18

3/8 23 32

7/16 36 51

1/2 55 78

9/16 80 113

5/8 110 156
3/4 195 276

Dane Technologies Inc.

in/lbs

Grade 5

Torque

ft/lbs

Grade 8

Torque

ft/lbs

925-001 -

02/2006

Dane Technologies, Inc. SmartKART Series Service Manual

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax [phone]

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Dear Service Provider:
Thank you for your interest in joining our team of world-class Service Providers. By

doing so, you have demonstrated a commitment to provide excellent service to our joint
customers, on time, every time, professionally. Attached please find some materials
that will help you as you join our team.

The package includes 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 procedures
 Recommended parts inventory
 SmartKART Warranty

Please share the enclosed information with the appropriate people in your organization.
Thank you again for your interest. I look forward to a long and mutually rewarding

relationship. Please feel free to call or e-mail me at any time with questions or
comments.

Sincerely,

Ken Guzel
Vice President-Service
888-544-7779, Ext 4436
[e-mail]

Dane Technologies, Inc. SmartKART Series Service Manual

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax [phone]

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

ORDERING AND INVOICING PROCEDURES

ORDERING
PARTS:

Call Dane Technologies at 1-888-544-7779, then choose the parts or service option.

1. Please provide a purchase order # and, if applicable, the location of the
customer store and the serial number of the SmartKART.

TECHNICAL SUPPORT:

Call the same phone number then choose the service option.

SHIPPING / INVOICING
WARRANTY:

1. If you have the part in stock, use it to repair the customer’s SmartKART and
take the defective part back to your shop.

2. Order a replacement part from Dane Technologies. Please provide the
location of the customer store where your part was used so that we can verify
warranty coverage. Also include the serial number of the SmartKART.

3. Dane Technologies will ship a replacement part and invoice you for it. Along
with the part, you will receive 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 will issue a credit,
canceling the invoice.

6. For battery replacement contact Dane Technologies at 1-888-544-7779 and
choose the service option.

NON-WARRANTY:

1. Again, use a part from your stock if possible.

2. Invoice the customer for your labor and parts. REMEMBER: Labor warranty is
90 days from purchase date. Parts pricing must agree with the retail price
shown on the Dane Technologies price list.

3. Order replacement parts for your inventory as described above.

IF YOU DON’T HAVE THE PART IN STOCK:

1. Order the part from Dane Technologies as described above. Please provide a
purchase order number, ship-to address if different from your business
address, customer store location, and information on the part coming back, if
applicable.

2. Communicate with customer store management about delivery time and any
other details about when you estimate the SmartKART will be repaired.

Dane Technologies, Inc. SmartKART Series Service Manual

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax [phone]

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Store: ________________ Date: _________________
Location: ____________________ Serial Number: SK-______
Sticker Condition: ___________

SmartKART Preventive Maintenance

PM Checklist

Inspect cord, cord plug
Inspect seat and arms
Inspect, clean battery terminals and cables
Inspect throttle spring
Check wiring, wiring plugs for damage
Check 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 seat switch connections
Test horn operation
Check brake move forward/backwards 2”

(normal)

Operation test forward/ backwards motion

Any other problems:
______________________________________________________________________
______________________________________________________________________
Comments:
______________________________________________________________________
______________________________________________________________________

Dane Technologies, Inc. SmartKART Series Service Manual

7105 Northland Terrace Minneapolis, MN 55428 / 888-544-7779 / 763-544-7779 / Fax [phone]

www.danetechnologies.com 970-032 Rev. A 1/20/09

Inspected OK Needs Repair/Replacement

74