Granite Overland mega herc User manual

- OVERLANDCARTS.COM -

97026-2

MEGA HERC

OWNER’S MANUAL

Revised: DECEMBER 2022

- 1400 SERIES WITH AGM 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

OPERATING THE KICK STAND .....................................10

BATTERY REPLACEMENT .............................................11

REPLACEMENT PARTS..................................................14

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 22 amp-hr AGM 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 300-500 charge/discharge cycles, which translate into approximately 1-2 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

CHARGING INFORMATION

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. To reduce risk of injury, charge only lead-acid type of

rechargeable batteries. Other types of batteries may

burst, causing personal injury or damage.

3. Do not expose charger to rain or snow.

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

and ventilated rooms without ﬂammable ﬂuids and

explosive gases.

5. Do not cover the charger with clothing, fabric or

similar items during the charging process. Ventilation is

important to prevent overheating.

6. To reduce the risk of damage to the electric plugs

and cords, pull by the plug rather than the cord when

disconnecting the charger.

7. 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.

8. Make sure charging cord is located so that it will not

be stepped on, tripped over or otherwise subject to

damage or stress.

9. Do not operate charger with damaged cord or plug -

replace immediately if there are signs of damage!

10. Do not operate charger if it has received a sharp blow,

has been dropped or otherwise damaged in any way.

11. Do not disassemble the charger.

12. Never charge a battery in an airtight enclosure.

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 charger can be left connected to the batteries after a full

charge (green light) without harming the batteries. It uses

a four stage charging system to optimize battery longevity.

The charger uses minimum power in standby mode and

maintains the batteries at full charge.

For the best battery life, charge the cart after each use or at

the end of the work day. It’s preferable to let the batteries

charge overnight by plugging the cart into a 110V outlet.

80 37.5

%

V

Battery Capacity Voltage

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.

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.

FORWARD/REVERSE

BUTTON E-STOP BUTTON

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 5º F

(-15º C) and 113º F (45º 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.

BATTERY FEATURES

• Absorbent Glass Mat (AGM) technology for superior performance.

• AGM design ensures the acid inside the battery is spill-proof

• Vibration resistant

• Better performance in cold temperatures

• Faster charging

• Longer expected life

• Valve regulated, spill proof construction allows safe operation in any position. However upside down is not

recommended.

• Maintenance free design. There is no need to add electrolyte as gases generated during the charge phase are

recombined in a unique oxygen cycle.

• Power/volume ratio yielding unrivaled energy density.

• Special separators, advanced plate composition and a carefully balanced electrolyte system ensure the battery has the

ability to recover from an excessively deep discharge.

• All batteries feature a series of low pressure, one-way relief valves. These valves safely release any excessive

accumulation of gas inside the battery and then reseal themselves.

• Batteries may be discharged over a temperature range of -5º F (-15º C) and 113º F (45º C), and charged at temperatures

ranging from -32º F (0º C) and 104º F (40º C). For best results we recommend charging the batteries at room

temperature.

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.

FREE WHEEL MODE

BRAKE

OVERRIDE LEVER

FREE WHEEL MODE

(LEVER DISENGAGED)

POWER MODE

(LEVER ENGAGED)

10

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

11

2

TOOLS

#2 or #3 Phillips screwdriver

8mm wrench & socket (for bot style connectors)

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 or bolt style

connectors, depending on your

battery type.

PLEASE RECYCLE YOUR OLD BATTERIES

12

70381 - 36V 22/24AH AGM Battery pack with 80A breaker

+ -

80A Breaker/

Reset Button

Charging

Port

+

-

Power

Port

100 39.0

%

V

Battery Capacity Voltage

BATTERY REPLACEMENT

13

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.

14

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 22AH AGM

BATTERY PACK

70381

PARTS

15

WIRING DIAGRAM

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

16

E-Stop Switch

PI-08-0075

Throttle Kit

PI-08-0053

S Drive 200

PI-11-0253

Fwd / Rev Switch

PI-08-0061

SWITCHES AND OTHER COMPONENTS

Part No Description Weight Dimensions

PI-08-0098 Transaxle 1400

PI-08-0250 Transaxle Hub 1400

PI-11-0253 S Drive 200

PI-08-0053 Throttle Kit

PI-08-0061 Forward/Reverse Switch

PI-08-0075 E-Stop Switch

PI-08-0147 80 Amp Circuit Breaker

80AH Circuit Breaker

PI-08-0147

BATTERY PACKS & CHARGERS

Part No Description Weight Dimensions

70381 36V, 22AH Lithium Battery Pack

PI-11-0191 5AH AGM Charger

PI-11-0215 12V 22AH / 24AH Lithium Battery

PI-08-0108 Battery Indicator

PI-06-0188 16” Pneumatic Tire

PI-06-0055 Rear Caster with 10” Flat Free Tire

36V, 22AH AGM

Battery Pack

70381

5AH AGM

Charger

PI-11-0191

KICK STAND AND WINCH COMPONENTS

Part No Description Weight Dimensions

MI-12-7069 Kick Stand

PI-11-0267 Magnet for Kick Stand

70389 Winch Kit

PI-11-0264 Winch

70379 12V 20AH Lithium Battery Pack for Winch

PI-11-0274 12V 3AH Battery Charger for Winch

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

PI-11-0275

12V 3AH Lithium

Battery Charger for

Winch

PI-11-0274

Rear Caster with

10” Flat Free Tire

PI-06-0055

12V 22/24AH AGM

Battery (3 required)

PI-11-0215

17

NOTES

_______________________________________________________________

18

NOTES

_______________________________________________________________

19

NOTES

_______________________________________________________________

20

All Overland Carts are manufactured by:

Granite Industries

595 East Lugbill Rd.

Archbold, Ohio 43502

877-447-2648

OverlandCarts.com | GraniteInd.com

Granite OVERLAND MEGA HERC User manual

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