Granite OVERLAND MEGA HERC User manual

- OVERLANDCARTS.COM -
97026-1
MEGA HERC
OWNER’S MANUAL
Revised: March 2023
- 1400 SERIES WITH LITHIUM BATTERY -

2
CONTENTS
CART FEATURES..............................................................3
FREQUENTLY ASKED QUESTIONS ................................4
CHARGING INFORMATION............................................5
OPERATING INSTRUCTIONS ..........................................6
TROUBLESHOOTING ......................................................7
BATTERY INFORMATION................................................8
FREE WHEEL MODE .......................................................9
HANDLE ADJUSTMENT................................................10
OPERATING THE KICK STAND .....................................12
BATTERY REPLACEMENT .............................................13
REPLACEMENT PARTS..................................................16
1 YEAR WARRANTY
• Electronics: Includes controller, s-drive, and wiring
• Powertrain: Includes transaxle containing the motor
and differential
• Wheels, Casters & Tires
• Batteries & Charger
• Chassis: Includes steel frame and powder coating
TERMS
Warranty starts from the delivery date of the cart.
We will repair, without charge, any defect due to faulty
material or workmanship. These warranties do not cover
failures due to abuse, misuse, improper installation,
accidental damage or when repairs or modifications
have been made or attempted to be made by anyone
other than Granite Industries. Any defective products
that meet warranty specifications and Granite Industries
approval, may be returned to the factory to be repaired
or replaced free of charge. (Granite Industries will pay to
ship replacement item(s) to the customer; however the
customer is responsible for shipment of products to the
factory.)
This remedy is the sole remedy in contact, tort or
otherwise, and Granite Industries is not liable for
incidental, consequential or special damages.
These warranties give you specific legal rights, and you
may have other rights which vary from state to state.
Should you have any questions, contact Granite Industries
at 877-447-2648. (Proof of purchase may be required).
Customer Service
877-447-2648
M-F, 8am - 5pm EST
US D752,834 S
US D752,835 S
US D752,836 S
US D752,837 S
US D752,838 S
US D752,307 S
US D752,308 S
US D779,762 S
US D779,765 S
US D781,020 S
Overland Carts are covered by one or more of the following patents:
Overland carts are a part of the Granite Industries family. All
carts are manufactured by Granite Industries in Archbold, Ohio.
To view more products from
Overland Carts scan the QR code
with your phone
or visit OverlandCarts.com

3
CART FEATURES
Built with you in mind.
Our carts come fully assembled
All Overland Carts come fully assembled, charged and ready to
use. All you have to do is power the cart on and drive away. (We do
recommend charging overnight after receiving.)
Crate Disassembly Instructions:
We recommend using a drill or an electric screwdriver with a #2
Phillips bit or a #2 square bit to remove the screws.
We recommend using a hammer or crowbar to remove the
portions that are nailed down.
We designed our carts to be simple to operate:
• To turn on, pull the red On/Off switch out towards you.
• Toggle the black switch for forward and reverse.
• Grasp and twist the throttle.
• To turn the cart off, simply push the red button in.
Safety Features
• Emergency Stop – The red E-Stop button allows the user to
immediately stop the progress of the cart.
• AutoLock – Automatically locks the wheels when the throttle
is not being applied. This feature prevents the cart from
rolling away from the user and also provides easy loading and
unloading on inclines.
• HillSense – Allows the cart to be used safely on inclines and
declines. The cart will travel at the speed set by the user, not
by the incline or decline.
• SmoothStart – On acceleration, power is applied to the drive
tires in a controlled manner ensuring a smooth start each time.
• Four Wheel Design – All Overland Carts have at least four
wheels to provide maximum stability.
They’ve been tested (again and again)
The standard 20 amp-hr lithium rechargeable battery packs have
been extensively tested. We are confident to rate the batteries
with a 4-6 hour real world capacity.
Satisfaction Guaranteed
Granite Industries is committed to making sure each Overland Cart meets your expectations. To ensure
customer satisfaction, we offer a 15 day money back guarantee. Use the cart and see how much easier the
cart makes your projects. If you’re not satisfied, simply contact Granite Industries at 877-447-2648 for a return
authorization and details.
Orders and quote requests can be emailed to [email protected] or faxed to 419-445-3304

4
FREQUENTLY ASKED QUESTIONS
How long do the batteries last on a single charge?
It is completely dependent upon how much weight is being carried, the type of terrain, and the softness or hardness of the
surface. We estimate a range of 4-6 hours of “real world” use. PLEASE NOTE: Most use is not as intense as our “real world”
estimates, so actual use time is typically much longer. Visit YouTube.com/OverlandCarts to view videos of our product testing.
When and how long should I charge my cart?
Charge your cart immediately after using. If, during operation, the battery indicator light goes to red, it is time to recharge. It is
recommended to leave the cart on the charger overnight to extend the life of the batteries.
How long will the batteries last before needing to be replaced?
The batteries are designed to last for 1,000-2,000 charge/discharge cycles, which translate into approximately 2-4 years. The
batteries are common and can be purchased from Granite, your local battery supplier, or on Amazon.
Will tipping the unit hurt the batteries, electronics, or drive system?
No. Batteries, electronics, and drives can operate in any orientation.
What is the maximum speed?
All 1400 series carts operate from 0 to 3.5 miles per hour in both forward and reverse.
While pushing my cart in manual/freewheel mode, it suddenly decelerates aggressively. What causes this?
There is a safety feature on your Overland Cart that is designed to prevent the cart from running away when the brake is
manually disengaged.
How much weight can my cart handle?
1200 lbs is the maximum load for level ground.
Why does my cart lose traction when one wheel is off the ground?
The drive system is an open differential that allows the machine to efficiently make turns without skidding the tires. The drawback
is that if one of the drive tires leaves the ground, it will simply spin until all tires are back on the ground.
Is a balanced load important to the performance?
Yes. Balancing the load so that it is not top-heavy or side-loaded, will allow much safer operation. Furthermore, most of the load
should be located over top of the drive wheels for better traction.
How do I clean my Overland Cart?
Simply remove all debris, hose it down with soapy water, and towel dry. We do not recommend using a pressure washer.
Can I use my Overland Cart in cold temperatures?
You certainly can, but we recommend that you charge and store the batteries at room temperature.
What maintenance is required?
Not much, really! Simply remember to always recharge when not in use - it’s okay to leave the cart on the charger. The drive
system is sealed for life, thus no lubrication is required. Also, keep the unit dry to enhance its life and appearance.
How should I store my cart?
We recommend keeping your cart indoors, out of the rain and other
elements. For long-term or “off season” storage, give the battery an
overnight charge, then disconnect the battery pack from the cart and store
it indoors at room temperature. Every 3-4 months, fully charge the battery
even though it’s not in use. This helps to prolong the life of the batteries.
Where is the serial number?
Every Overland Cart comes with its own serial number. On the Mega Herc,
this is located on the front side of the upper control box.
SERIAL NUMBERCART INFO

5
The chart below shows how each individual 12V battery should
perform and then also shows how three batteries should
perform when put into series. This is the configuration for
your cart.
Balancing Batteries
As a part of routine battery maintenance, you may want to
rebalance the batteries once or twice a year. We recommend
a charger like the Noco Genius GEN5X1. It charges and
balances one 12V battery at a time. Each battery can be
rebalanced and then put back into the battery pack. This can
also be helpful if the battery pack is dropping to 90% quickly
after being recharged.
CHARGING INFORMATION
CHARGE YOUR CART
When your cart arrives, please plug it in and make sure the
battery is fully charged. There is a battery charge display on
the side of the battery pack.
The smart charger uses a three-stage charging system to
optimize battery longevity. Once the charger maximizes the
charge to the batteries, it will go into standby/float mode.
The charger can be left connected to the batteries after a full
charge (green light) without harming the batteries.
The voltage for the battery pack will read 100% after a full
charge. If not used immediately, the battery pack will slowly
drop to about 90% after 24-48 hours. This is normal. If the
battery pack is plugged back in, the percent will quickly go up
to 100%.
For the best battery life, charge the cart after each use or at
the end of the work day. It is preferable to let the batteries
charge overnight by plugging the cart into a 110V outlet.
State of Charge
The battery capacity can roughly be estimated by its voltage.
As there are subtle differences in the voltage of each battery,
the below parameters are for reference only. The voltage
needs to be tested at rest (with zero current) after 15 minutes
of being disconnected from the charger and loads. For
optimal battery life and long-term performance recharge
when the battery pack reaches 40%.
80 39.8
%
V
Battery Capacity Voltage
Capacity Single 12V
Lithium Battery
36V Lithium Bat-
tery Pack
(Three 12V Bat-
teries
in series)
100% Floating Charge
(when plugged in)
13.80V 41.40V
100% 13.50V 40.50V
99% 13.40V 40.20V
90% 13.30V 39.90V
80% 13.25V 39.75V
70% 13.20V 39.60V
60% 13.17V 39.51V
50% 13.14V 39.42V
40%
*Recharge Batteries*
13.10V 39.30V
30% 13.00V 39.00V
20% 12.90V 38.70V
10% 12.80V 38.40V
1% 10.80V 32.40V
0% 9.50V 28.50V
BATTERY CAUTIONS AND WARNINGS
1. Before using the battery charger, read all instructions and
cautionary markings on the battery charger, batteries and
the product using the batteries.
2. Only use the type of batteries that the charger is specified
for. Other types of batteries may burst, causing personal
injury or damage.
3. Do not expose charger to rain or snow.
4. Do not cover the charger or charge battery in an airtight
enclosure. Ventilation is important to prevent overheating.
5. Make sure extension cord is not used unless absolutely
necessary. Use of improper extension cord could result in
risk of fire and electric shock. If extension cord must be
used, make sure:
• The pins on the plug of the extension cord are the
same number, size and shape as those on the charger.
(3 prong with ground)
• The extension cord is properly wired and in good
electrical condition. A 16 ga cord or heavier duty
extension cord is recommended.
6. Do not operate a charger that has been dropped,
damaged or has a damaged cord or plug - replace
immediately if there are signs of damage!
7. Do not disassemble the charger.

6
POWER YOUR CART ON
To power your cart on, pull the red E-stop button out. You will notice the battery indicator lights light up and your cart is now
ready for operation.
If the Overland Cart sits inactive for 20 minutes while on, it will go to sleep in order to conserve power. To wake the cart up,
push the E-Stop button in, and pull it back out to power your cart on again.
FORWARD/REVERSE
BUTTON E-STOP BUTTON
OPERATING INSTRUCTIONS
SAFETY INFORMATION
• Only use chargers and batteries issued by Overland Carts. Use of third party batteries or chargers may cause harm to
the user and the cart.
• Always make sure the load is distributed evenly in the hopper and the cart is stable before operating.
• Push in the red E-Stop whenever the cart is sitting still or whenever the batteries are charging.
• Do not exceed the rated capacity of 1200 pounds for the cart on flat surfaces.
• Exercise caution when operating on inclines or declines.
• Do not drive the cart over sudden drops such as curbs, steps, or ledges. We recommend using ramps to navigate
uneven surfaces.
• The metal battery pack can be opened to reveal the batteries; however, the physical batteries should never be opened.
They are sealed lithium batteries and cannot be resealed. Do not attempt to add more battery acid or water. If the
batteries need replaced, please purchase new batteries.
BEST PRACTICES
• Hand wash your Overland Cart with soapy water. Never use a pressure washer.
• Do not drive your cart through deep puddles of water and do not submerge the drive system or battery box.
• The drive system is lubricated for life, so no maintenance is required.
• When the battery indicator light goes to red, it is time to recharge.
• Recharge cart immediately after using.

7
TROUBLESHOOTING
Issue Possible Problem Solution
Cart will not run
Batteries are dead Charge the Overland Cart
E-Stop is in the OFF position Pull e-stop out, to the ON position
Unit is in sleep mode Cycle the unit OFF for a couple seconds, then back ON
Cart is in freewheel mode (brake is
disengaged)
Re-engage motor brake (see free wheel mode section)
Electrical malfunction Disconnect and connect all electrical connections, and
make sure they are all secure
Moisture issue Let dry, avoid getting the s-drive and battery
box wet
Cart shuts off during use
Circuit breaker has tripped Push the reset button on the battery pack (see diagram
below).
Thermal overload (weight, climb angle,
or terrain may have exceeded transaxle
capacity)
Release throttle, allow transaxle to cool down at least
30 seconds. Unload some weight, cycle power switch
and operate machine again. Reset button will likely
need to be pushed.
Cart suddenly stops
Broken or loose motor wire or connector Check motor wires and brake wires to make sure none
are broken, and also check connector to make sure
wires are secure
Cart abruptly slows
down while in
freewheel mode
Safety feature has triggered preventing
the cart from rolling away
Push the cart slower while in freewheel mode
Batteries are not lasting
as long as desired
Cold batteries Keep batteries warm
Batteries not fully charged Make sure your cart is fully charged before using
Batteries are damaged or too old Replace your batteries
Loose wire connections Check all connections to make sure everything
is secure
Charger light goes
directly to green when
charging, but battery is
not charged
The battery and/or charger may have
gone bad
Test the charger on another battery if possible.
Replace battery and/or charger
The connections may have come loose,
or disconnected
Check charger and battery connections
RESET BUTTON

8
BATTERY INFORMATION
IMPORTANT RECOMMENDATIONS
• It is recommended to wear insulated gloves when handling batteries.
• If equipment is to be stored for a long period of time, the batteries should be disconnected to avoid undue drain.
• When replacing your batteries, fasten them tightly, but do not apply undue force to the terminals or bend them.
• Do not place batteries in close proximity to objects which can produce sparks or flames.
• Avoid exposing batteries to heat.
• Do not mix batteries with different capacities, different ages or different makes.
• For best results and generally acceptable performance and longevity, keep operating temperature range between -4º F
(-20º C) and 140º F (60º C)
• It is good practice to ensure that the connections are re-torqued and the batteries are cleaned periodically.
• Do not attempt to disassemble batteries. Contact with sulfuric acid may cause harm. If it should occur, wash skin and
clothing with liberal amounts of water.
• Batteries should not be stored in a discharged state or at elevated temperatures.
• Please recycle old batteries. Do not throw them away, or attempt to burn them. Attempting to burn batteries (new or
old) may cause them to rupture or explode.
LiFePO4 BATTERY FEATURES
• Longer Cycle Life: Offers up to 20 times longer cycle life and five times longer float/calendar life than lead acid
batteries, helping to minimize replacement cost and reduce total cost of owner.
• Lighter Weight: about 40% of the weight of a comparable lead acid battery.
• Higher Power: Delivers twice the power of lead acid batteries, even higher discharge rates, wile maintaining high energy
capacity.
• Wider Temperature Range: Batteries may be discharged over a temperature range of -4º F (-20º C) and 140º F (60º C)
and charged at a temperature range of 32º F (0º C) and 113º F (45º C)
• Superior Safety: Automatic protection with internal battery management system. Lithium Iron Phosphate chemistry
eliminates the risk of explosion or combustion due to high impact, overcharging or short circuit situation.
• Increased Flexibility: Modular design enables deployment of up to four batteries in a series and up to ten batteries in
parallel.

9
FREE WHEEL MODE
The drive system is equipped with a lever that overrides the electromechanical brake for manually operating your Overland
Cart. The brake lever allows you to override the electric brake when you need to push the cart manually, when loss of power
had occurred. With the brake in the disengaged position, the E-Stop button must be pushed in, and the power turned off or
the drive system will not move freely. The controller will NOT operate the motor when the brake is disengaged.
When the lever is in the down position the brake is engaged. When the lever is in the up position, the brake is disengaged.
When you reset the brake system the unit will not operate until you toggle the power button off and back on. This process
will need to be repeated every time the brake in manually disengaged.
BRAKE
OVERRIDE LEVER
FREE WHEEL MODE
(LEVER DISENGAGED)
POWER MODE
(LEVER ENGAGED)
FREE WHEEL MODE

10
NOTES
HANDLE ADJUSTMENT
You will see four bolt sets that have not
been tightened down.
The handle on the Mega Herc needs to be
adjusted when you receive your cart. For
shipping purposes, it arrives in a lowered
position to reduce the overall height.
You should be able to remove them by
hand. However if needed, you can use a
3/4” wrench and socket.
We recommend that you slide the handle
up to the top two sets of holes. However,
you can put the handle at the level that
best suits your needs (72” or 66” high).
3
21
4
Align the handle over the holes and insert
the bolts and washers to hold it in place.
5
Install a washer and nut onto the bolt and
tighten down using a 3/4” wrench and
socket.
6

11
NOTESHANDLE ADJUSTMENT
Your handle is now correctly installed and your Mega Herc is ready for use.

12
OPERATING THE KICK STAND
Stand the cart up into the upright position.
Pull the kick stand off of the magnetic
holding plate.
The kickstand is located on the back
of the cart.
Lower the kick stand to the floor.
To lock it into place, lean the cart forward
slightly, and slide the bar up into the
notches to secure into place.
3
21
4
To return the kickstand into the upright
position, rock the cart forward slightly
again to disengage the kick stand from
the notches. Repeat the remaining steps in
reverse order.
5

13
2
TOOLS
#2 or #3 Phillips screwdriver
NOTE: If you are using a different brand battery than
the ones that came with your cart, you may need to
change your connectors to accomodate the different
size screws.
Remove the four (4) #10 screws
holding the lid in place.
Remove the lid and set aside.
1
Disconnect the wires going to the battery
box. Remove the battery from the cart by
taking out the hair pin and removing the rod.
Slide the battery box out from its housing.
BATTERY REPLACEMENT
3
Remove the rubber insulator sheet and
set aside.
4
Carefully remove the batteries, and
disconnect the screw style connectors.
PLEASE RECYCLE YOUR OLD BATTERIES

14
+ -
Charging
Port
Power
Connector
+
-
Lithium
Battery
+
-
Lithium
Battery
+
-
Lithium
Battery
12
80 Amp Fuse/
Reset Button
79 25.2
%
V
Battery Capacity Voltage
BATTERY REPLACEMENT
80 39.8
%
V
Battery Capacity Voltage

15
5
Place the batteries back into the box one at a time. Tuck the wires into the box and out of the way.
BATTERY REPLACEMENT
7
Place the battery box back onto the cart,
insert the rod and secure with the hair pin.
Finally, reconnect the wires to the power
terminal.
6
Replace the rubber insulator sheet and
then the box lid. Secure the lid with four
(4) #10 screws.

16
MEGA HERC
CHASSIS
MI-12-7059
REAR 10” CASTER
PI-06-0055
REAR WHEEL
MOUNT
MI-12-6774
16” PNEUMATIC
TIRE
PI-06-0188
KICK STAND
MI-12-0769
1400 TRANSAXLE
PI-08-0098
S DRIVE BOX
CONTAINS 200A
S DRIVE PI-11-0253
THROTTLE
PI-08-0053
HANDLE
MI-12-6976
36V 20AH LITHIUM
BATTERY PACK
70375
PARTS

17
FUSE
CHARGING
PORT
THROTTLE
CLOSE UP OF S DRIVE CONNECTIONS
21
22
12
11
E-STOP
FORWARD
REVERSE
SWITCH
1
2
3
4
5
6
+ -
+ -
BATTERY PACK
M- M+ B- B+
TRANSAXLE
MOTOR
WIRING DIAGRAM

18
E-Stop Switch
PI-08-0075
Throttle Kit
PI-08-0053
S Drive 200
PI-11-0253
Fwd / Rev Switch
PI-08-0145
SWITCHES AND OTHER COMPONENTS
Part No Description Weight Dimensions
PI-08-0098 36V 1400W Transaxle 47 lb 10"H x 6"W x 27"D
PI-11-0250 36V 1400W Transaxle Hub (Need QTY: 2) 3 lb 5" Diameter - 2" Depth
PI-11-0253 S Drive 200 2 lb 2"H x 7"W x 5"D
PI-08-0053 Throttle Kit 8 oz 4' cord
PI-08-0145 Forward/Reverse Switch - NEW 1 oz 1.75"H x 2"W x 1"W
PI-08-0075 E-Stop Switch 2 oz 1.5"H x 3"W x 1.5"D
PI-08-0147 80A Replacement Circuit Breaker 3 oz 3"H x 1.5"W x 2"D
80AH Circuit Breaker
PI-08-0147
BATTERY PACKS & CHARGERS
Part No Description Weight Dimensions
70375 36V 20/23A Lithium Battery Pack with 80A Breaker 32 lb 7"H x 10"W x 10"D
PI-11-0273 36V 5A Lithium Charger 2 lb 10' Cord
PI-11-0273 12V 20/23AH Lithium Battery 12 lb 3.5"H x 11.5"W x 8.5"D
PI-08-0108 Battery Indicator 1 oz 1.25"H x 2.25"W x .5"D
PI-06-0188 Kenda 16" All Terrain Tire for Mega Herc 12 lb 16" Diameter - 6.5"W
PI-06-0055 Rear Swivel Caster with 10" Flat Free Tire 10 lb 10” Diameter - 3“W
36V, 20AH LITHIUM
Battery Pack
70375
5AH LITHIUM
Charger
PI-11-0273
KICK STAND AND WINCH COMPONENTS
Part No Description Weight Dimensions
MI-12-7069 Mega Herc Kick Stand 14 lb 26"H x 15"W x 12"D
PI-11-0267 Magnet Kit for Kick Stand 0.5 lb 1.5" Diameter
70389 Winch Kit 34 lb
PI-11-0264 3500 lb Champion Winch - 50 ft 20 lb 4"H x 13"W x 4"D
70379 12V 20/23AH Lithium Battery Pack for Winch 12 lb 3.5"H x 11.5"W x 8.5"D
PI-11-0274 12V 3AH Lithium Battery Charger for Winch 2 lb 10' cord
Battery Indicator
PI-08-0108
REPLACEMENT PARTS LISTING
TransAxle 1400
PI-08-0098
Kick Stand
MI-12-7069
Winch Kit
70389
16” Pneumatic Tire
PI-06-0188
Magnet
PI-11-0267
TransAxle Hub 1400
PI-08-0250
Winch
PI-11-0264
12V 20AH Lithium
Battery Pack for
Winch
70379
12V 3AH Lithium
Battery Charger for
Winch
PI-11-0274
Rear Caster with
10” Flat Free Tire
PI-06-0055
12V 20/23AH Lithium
Battery (3 required)
PI-11-0271

19
NOTES
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20
All Overland Carts are manufactured by:
Granite Industries
595 East Lugbill Rd.
Archbold, Ohio 43502
877-447-2648
OverlandCarts.com | GraniteInd.com