Dane Technologies SmartKART 120-052 User manual

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
ToOrderPartsCall1-888-702-5326-https://monsterfloorequipmentparts.com

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
ToOrderPartsCall1-888-702-5326-https://monsterfloorequipmentparts.com

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
4
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: 888-
544-7779.
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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
5
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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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
6
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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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
7
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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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
8
SmartKART LABELS
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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
9
SmartKART
Model Labels
120-052 500-040, 500-144, 500-145, 500-147, 500-151, 500-152, 500-170, 500-171, 500-252, 500-
335(3)
120-053 500-040, 500-144, 500-145, 500-147, 500-151, 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, 500-170, 500-171, 500-252, 500-
334(2), 500-335
120-068 500-040, 500-144, 500-145, 500-147, 500-151, 500-152, 500-170, 500-171, 500-252, 500-
334(2), 500-335
120-081 500-040, 500-143, 500-144, 500-145, 500-147, 500-150, 500-151, 500-170, 500-252, 500-
335(2)
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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
10
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
11
ToOrderPartsCall1-888-702-5326-https://monsterfloorequipmentparts.com

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
12
ToOrderPartsCall1-888-702-5326-https://monsterfloorequipmentparts.com

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
13
ToOrderPartsCall1-888-702-5326-https://monsterfloorequipmentparts.com

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
14
SmartKART – TOP VIEW
SmartKART – SIDE VIEW
(Arms Optional)
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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
15
SmartKART – ISO VIEW
TILLER HANDLE AND THROTTLE CONTROL
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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
16
SmartKART – REAR VIEW
(Arms Optional)
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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
17
SmartKART – ISO VIEW
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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
18
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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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
19
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 Monday-
Friday, 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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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
20
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.
NOTE: Charge batteries whenever SmartKART is not in use.
The explanation of the charging cycle is as follows.
Stages
Condition Mode* Current** Voltage LED Indication
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 CC Mode 4 A (6A) 5.0 V to 28.8 V Orange
Stage 3 Constant Voltage Mode CV Mode Reduces from 4 A (6A) Holds at 28.8 V Orange
Stage 4 Standby Voltage Mode Standby CV Mode Reduces to Zero Maintains 27.6 V Green
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
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