Knight Smart Cart User manual

Smart Cart
Operation Manual
THIS MANUAL CONTAINS IMPORTANT INFORMATION REGARDING INSTALLATION, SAFETY, MAINTENANCE,
AND OPERATION OF THE KNIGHT GLOBAL SERVO CART AND SHOULD BE AVAILABLE TO ALL PERSONNEL.
RESPONSIBLE FOR USING THE CART.
REV: 020-202201

KNIGHT SMART CART LIFT ASSIST OPERATION MANUAL
This manual provides important information for all personnel involved in the installation, operation
and maintenance of the Knight Global Smart Cart. All personnel must read this document before
operating the equipment.
Every effort has been made to provide complete and accurate product information in this manual.
However, due to product improvements and changes, discrepancies and omissions may be
present. Visit our website at www.knight-ind.com for the updated information on all our products.
It is the responsibility of the end user to exercise common sense and judgment when performing
the tasks described in this manual. If any procedure seems inaccurate, incomplete or unsafe
please put the equipment in a safe condition and contact Knight Global service department for
assistance. Knight service department’s phone number is: [phone].
Throughout this manual there are steps and procedures that if not performed correctly can result
in personal injury or equipment damage. The following signal words are used to identify the level
of potential hazard.
WARNING
Indicates a hazard which will cause severe injury, death or substantial
equipment damage.
CAUTION
Indicates a hazard which can or will cause injury or equipment damage.
NOTE
Notifies personnel of installation, operation or maintenance information
which is important but not hazard related.

KNIGHT SMART CART OPERATION MANUAL
i
TABLE OF CONTENTS
1. SAFETY........................................................................................................................................................1
A. General Safety Precautions ...................................................................................................................2
Basic Safety Procedures.....................................................................................................................2
Lithium-Ion Battery and Charging Safety Precautions:.......................................................................2
B. Safety Devices .......................................................................................................................................3
Motor Holding Brake ...........................................................................................................................3
Overload Capacity Protection .............................................................................................................3
Safety Drop Stop (SDS) Chain ...........................................................................................................3
2. INSTALLATION ...........................................................................................................................................5
A. Introduction.............................................................................................................................................6
B. General Operation..................................................................................................................................7
Step 1: Control Handle Set-up...........................................................................................................8
Step 1a) Analog Lever Handle Setup: .......................................................................................8
Step 1b) Discrete Up / Down Handle setup:..............................................................................8
Step 2: Test Cart Movement..............................................................................................................9
Step 3: Sequence of Operation..........................................................................................................9
3. OPERATION...............................................................................................................................................10
A. Principle of Operation...........................................................................................................................10
Smart Cart Control Configurations....................................................................................................10
B. Smart Cart Functionality Modes...........................................................................................................11
Shut Down.........................................................................................................................................11
Start Up.............................................................................................................................................11
Work Mode........................................................................................................................................11
Travel Limits......................................................................................................................................11
Fault Mode........................................................................................................................................11
4. MAINTENANCE .........................................................................................................................................12
A. CHAIN INSPECTION...........................................................................................................................12
4.1 Inspection Overview....................................................................................................................12
4.2 Use of LIFT Safely in Any Application ........................................................................................13
4.3 Determining the Frequency of Chain Inspections.......................................................................14
4.3.1 Service Rating Load Criteria............................................................................................14
4.3.2 Service Class (Duty Cycle)..............................................................................................14
4.4 Type of Inspections.....................................................................................................................15
4.4.1 Frequent Inspection (Visual)............................................................................................15
4.4.1.1 What to Look for During a Frequent Inspection...............................................15
4.4.2 Periodic Inspection (Documented)...................................................................................16
4.4.2.1 Recommendations for Periodic Inspections ....................................................16
4.4.2.2 Recommended Record Keeping for Periodic Inspections...............................20
4.4.3 Chain Lubrication:............................................................................................................21
4.4.4 Load Chain Replacement: ...............................................................................................21
B. PREVENTATIVE MAINTENANCE FOR KNIGHT SMART CART.......................................................22
4.5 Smart Carts Inspections..............................................................................................................22
4.5.1 Recommendations for Frequent Inspections for Smart Carts (Visual)............................22
4.5.2 Periodic Inspection (Documented)...................................................................................23
4.6 Load and Safety Drop Stop Chain Replacement (Normal Maintenance)...................................26
4.7 Broken Chain Replacement........................................................................................................30
5. ELECTRICAL INFORMATION...................................................................................................................34
A. CHARGING THE BATTERY:...............................................................................................................34
B. LITHIUM-ION BATTERY:.....................................................................................................................35
C. DC-MOTOR CONTROLLER INFORMATION .....................................................................................36
6. TROUBLESHOOTING CHART..................................................................................................................38
7. SPARE PARTS LIST .................................................................................................................................40
8. DECOMMISSIONING OF A SMART CART ..............................................................................................40

KNIGHT SMART CART OPERATION MANUAL
ii
TABLE OF CONTENTS
9. KNIGHT’S PERFORMANCE WARRANTY...............................................................................................41
10. APPENDIX A: USB LOCATION IN SMART CART MANUAL.................................................................42
11. APPENDIX B: EMENTOOL LITE V1.0: PROGRAMMING SOFTWARE ...............................................43
12. APPENDIX C: EM-243C-JS1 DC-MOTOR CONTROLLER.....................................................................45

KNIGHT SMART CART OPERATION MANUAL
SECTION 1
SAFETY
1
1. SAFETY
Knight Global cannot be aware of or provide for all the procedures by which the Smart Cart operations or
repairs may be conducted and the hazards which may result from each method. If operation or maintenance
not specifically recommended by Knight Global is conducted, it must be ensured that product or personnel
safety is not endangered by these actions. If not sure of an operation or maintenance procedure or step,
personnel should place the Smart Cart in a safe condition and contact a supervisor and/or Knight Global’s
service department for technical support. Modifications to upgrade, re-rate or otherwise alter this equipment
shall be authorized only by the original equipment manufacturer.
If a below-the-hook lifting device or sling is used with the Smart Cart, refer to ANSI/ASME B30.9 “Safety
Standard for Slings”, or ANSI/ASME B30.20 “Safety Standard for Below-the-Hook Lifting Devices”.
Electrical equipment described in this manual are designed and built-in compliance with ANSI/NFPA 70,
“National Electrical Code”. It is the responsibility of the system designer, system manufacturer, crane or rail
manufacturer, installer, and user to ensure that the installation and associated wiring of the Smart Cart and
components are in compliance with ANSI/NFPA 70, and all applicable Federal, State and Local Codes.
Hazardous voltages are present in the Smart Cart and components. Only properly trained and competent
personnel should perform inspections or repairs on the Smart Cart or accessories. Prior to performing any
maintenance (mechanical or electrical) on the Smart Cart, de-energize (disconnect) the main switch supplying
power to the Smart Cart. Lock out the power supply following standard plant procedures.
Ensure that the installation, inspection, testing, maintenance and operation are in compliance with
ANSI/ASME B30.16 “Safety Standard for Overhead Carts”, OSHA Regulations, ANSI/NFPA 70, National
Electric Code, and applicable ANSI/ASME standards.This is the responsibility of the owner/operator.
All personnel that will install, operate, inspect, test or maintain the cart should read this manual and be
familiar with all applicable portions of the referenced standards.
If clarification of any information in this manual or additional information is required, contact Knight Global.
Do not install, operate, inspect, test or maintain the cart unless all information is understood.

KNIGHT SMART CART OPERATION MANUAL
SECTION 1
SAFETY
2
A. General Safety Precautions
NOTE
Read all technical manuals/directions provided with the product before
attempting to operate or perform service/maintenance on any part of
the system.
Although the procedures covered in this manual have proven to be safe in use, Knight Global assumes no
responsibility for personal injury or damage to the equipment resulting from their application.
WARNING
It is not possible to cover all safety conditions in this manual. Therefore,
always be alert and work safely.
Basic Safety Procedures
Although the procedures covered in this manual have proven to be safe in use, Knight Global assumes no
responsibility for personal injury or damage to the equipment resulting from their application. It is not possible
to cover all safety conditions in this manual. Therefore, always be alert and work safely.
!Follow all applicable Federal, State, Local or Company policies or regulations
!Do not overload the Smart Cart, this could damage the cart.
!Do not let loads significantly over hang the sides of the platform; this could cause the Smart Cart
to tip over.
!Lock the wheels when leaving the cart unattended.
!Do not move the Smart Cart with the load in the uppermost position.
!Do not use the Smart Cart if any damage is evident.
Lithium-Ion Battery and Charging Safety Precautions:
!Do not short circuit the battery.
!Do not drop, throw or crush the battery.
!Keep battery away from heat sources, high voltage, and other high-temperature sources.
!Never smoke or allow an open flame in the vicinity of the battery.
!Do not leave the battery exposed to sunlight for extended periods of time.
!Do not attempt to dissemble the battery.
!Do not connect to the battery in reverse polarity.
!Do not use charger with a two bladed adapter plug or extension cord. Doing so can result in serious
personal injury.

KNIGHT SMART CART OPERATION MANUAL
SECTION 1
SAFETY
3
B. Safety Devices
Motor Holding Brake
A motor holding braking system engages and holds the vertical axis in place when power is removed from the
cart or in the event of a power outage.The motor holding break is also engaged when there the chain is not
moving.
Overload Capacity Protection
Protects the equipment and prevents the operator from lifting or moving more weight than the system is rated
for. If the load weight causes the cart to draw more amps then the programmed current limit, the cart will not
lift any further until the excess load is removed. Downward motion is permitted when overloaded to allow the
user to safely set the weight back down on a stable surface.
Safety Drop Stop (SDS) Chain
All Standard units have a Safety Drop Stop (SDS) chain included. The SDS Chain moves up and down the
vertical axis with the load chain. It provides load stabilization in the event of a catastrophic load chain failure.
This unique feature has a US Patent NO. 10,099,904 awarded as of 2018.

KNIGHT SMART CART OPERATION MANUAL
SECTION 1
SAFETY
4

KNIGHT SMART CART OPERATION MANUAL
SECTION 2
INSTALLATION
5
2. INSTALLATION
Prior to installation, visually inspect the Smart Cart for signs of damage or missing parts.
CAUTION
Knight Global recommends the use of Demag Chain Grease.
The part number of the Demag Chain grease tube is 665 009 44.
If Demag Chain Grease is not available, SAE 50 to 90 EP oil or equivalent
may be used.
Follow the procedure detailed in section 4.4.3 “Chain Lubrication”
of this manual.
CAUTION
Prior to placing this unit into service, the owners and user are advised
to examine specific local and/or other regulations, including ANSI and
OSHA regulations that may apply to the use of this product.
WARNING
A falling load can cause injury or death. Before installing this cart read
the “Safety” section of this manual.
Follow all procedures in this section for installation and set-up of the Smart Cart.
Retain all product information supplied with the Smart Cart for future reference.
When installation is complete and prior to placing the Smart Cart into operation, inspect the Smart Cart
following the instructions in section 4.4.2.1 “Recommendations for Periodic Inspections” of the “Maintenance”
portion of this manual.

KNIGHT SMART CART OPERATION MANUAL
SECTION 2
INSTALLATION
6
A. Introduction
Prior to installing and operating the Knight Smart Cart, all operators using this device should be familiar with
the main components of the lifting system. (Refer to Figure 2-1)
Smart Cart: The Smart Cart assembly is a powered lifting device. The upper drive assembly contains the
servo motor with holding brake, gearbox and chain bucket. The lower controls box contains the 24 VDC
power supply and AC Plug and charger.
Control Handle: The main interface between the operator and the lifting device.
Foot Brake: Prevents the cart from moving unintentionally.
Figure 2-1
•This ergonomic lift cart is designed to assist the operator when lifting heavy loads up to 400 lbs.
•The lift assist system consists of a stabilizing cart and a fixture attached to a vertical mast.
•The fixture travels along the rail on the cart’s load trolley, enabling the system to move vertically.
•The optional custom fixture holds the part or tool while it is being manipulated.
•Control handles are used to guide the load vertically and move the cart within your facility.
System functionality are activated through the control handles.
Motor, Gear box
and Chain bucket
Vertical
Mast
Foot
Brake
Controls
Enclosure
Control
Handle