Mart Cart Commercial 02002 User manual

TM
OWNER'S MANUAL
MODEL #02002, ''Commercial Series''
CONGRATULATIONS!
You have just purchased the best electric shopping cart on the market today, incorporating
the very latest in technological advances. To assure you of the best and safest performance
as well as longest equipment life, please read the enclosed information.
After reading the material in this manual, should you have a service problem or need help
please call our customer service department on our toll free number: 1-800-548-3373.
TO ORDER PARTS CALL: 1-501-636-5776 or 1-800-548-3373
Be sure to give the serial number to the parts department per-
sonnel. This number is located on the rear body near the charging
cord shown at upper middle of exploded view drawing , page 6
in this manual.
TERMS: All parts will be shipped with check in advance or C.O.D.
Commercial accounts are allowed 30 day terms from date on
invoice with approved credit .
FREIGHT: All freight will be paid by the customer. Special consider-
ation will be given to items under warranty coverage.
MART CART,™ 115 E. LINDEN, ROGERS, AR 72756
Form #12889 OM, Rev. 8-91 Pr inted in U. S. A.

TABLE OF CONTENTS
I. WARNINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
II. RESTRICTION TO OPERATION . . . . . . . . . . . . . . . . . . . . . . . 3
III. FREIGHT DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IV. WARRANTY REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . 4
V. PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 4
VI. BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VII. TROUBLE SHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . 5
VIII. EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
IX. PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
X. PICTORIAL WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . 8
XI. BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
XII. THROTTLE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . 9-12
XIII. SAFE-T-STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
XIV. SAFE.:r-STOP, How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . 12
XV. SAFE.:r-STOP, Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 13
XVI. DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
XVII. CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
XVIII. SEAT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
XIX. RELAY, CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
XX. CORD REEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
XXI. RHEOSTAT -Variable Speed Control ..... ...... . .. . .. 15
XXII. MOTOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
XXIII. FOOT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
XXIV. TIRE & WHEEL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
XXV. SEAT ASSEMBLY -Maintenance . . . . . . . . . . . . . . . . . . . . . . 16
XXVI. CONTROL BOX ... .. .... ....... ... .. .. . ... .. ...... 16
XXVII. WARRANTY .. . . . .... . . .. ........ .. ... .... .. . ..... 16
-2 -

I.
PLEASE READ BEFORE OPERATING
WARNINGS: I
A. Neverattempt to charge the battery in this cart without using an electrical outlet that is protected
by a GFCI, (Ground Fault Circuit Interrupter).
B. Replace charging cord or cord reel if either is damaged or if the cord is worn or frayed.
C. Never use the charging cord without proper grounding. Do not use if plug does not have three
terminals.
D. Never allow the Mart Cart to be used out•Of•doors or on any surface that is not level.
E. Always disconnect power before servicing.
WARNING LABELS (RED) ON CART
& WARNING &
TO PRE VENT PERSONAL INJURY FROM
ELECT RI CAL SHOCK DO NOT USE IF:
1) THE ELECTRICAL OUTLET IS N OT PROTECTED
BY A GROU ND FA ULT INTERRUPTER (GFI)
2) THE ELECTRICAL COAD OR PLUG IS
DA M AGED OR WO RN ·· REPLACE BEFORE
USING
"A,B,C" Above
I USE INDOORS ON LEVEL SURFACE ONLY I
"D" Above
D. RESTRICTION TO OPERATION:
HIGH VOLTAGE
Disconnect power before servicing
"E" Above
A. This cart is for use indoors • on level surface only . (See decal "D" above.)
B. Standing on cart is permitted providing the operator stands in the center only. DO NOT STAND
WHILE CART IS MOVING. Be certain all switches are in the "OFF" position before standing. (See
"Operating Instructions" on Cart.)
C. After battery is charged, disconnect power supply cord before operating Cart. (See decal "C"
below.)
D. Do not exceed the load limitations as shown on the Cart. (See decal "D " below.)
E. Do not force power supply cord into the rear housing of cart. Follow posted operating instructions.
(See decal "E " below.)
F. Never leave battery on charger over 10 hours. (See page 4 tor recommended charging time.)
G.Neverfill pneumatictiresabovepressure rating shown on the sidewall of thetires. Foam.filled tires
do not require air, and will exhibit "O" pounds of pressure on tire gauge.
H.DO NOTallowchildren to operatecart. Keep cart secured with key at service counter oroffer "Key
Club" program. (Key Club program • form #111789.)
RESTRICTION LABELS ON CART (BLACK)
ELECTRONIC SHUT-OFF
BATTERY CHARGER
120 VOLTS-INPUT-1.9 AMPS
DISCONNECT
BEFORE OPERATING CART
"C" Above
WARNING : FAILURE TO COMPLY WITH POITEO OPERATINI
INmUCTIONS AND LOAD LIMITATIONS COULD RESULT IN
ACCIDENl OR INJURY .
►-- LOAD LIMITATIONS-- ◄
MAXIMUM PERSON - --- - 1
MAXIMUM WEIGHT IPeraon) .. .............. .. .. . .. 300 LBS.
MAXIMUM LOAD IB11k11,,.__ ___ 75 LBS .
NO CHILDREN ALLOWED IN BASKET
"D" Above
-3-
Automatic Rewind Cord Reel
OPERATING INSTRUCTIONS
TO REWIND : PULL OUT ON CORD UNTIL
LOCK IN G DEV I CE STOPS "C LICK IN G" SO U ND .
ALLOW CORD TO SELF RETRA CT U NDE R
TENSION .
CAUTION: DO NO T PUSH CORD INTO HOLE
OR DA M AGE COU LD RESULT .
"E" Above

m. FREIGHT DAMAGE:
CHECK: 1. The shipping carton for any visible damage. Report the damage to the freight carrier
immediately. File a claim with the carrier if actual damage to your cart has occurred.
2. Contents of the carton. The contents should agree with the information listed on the
packing list. Report any shortage to the carrier and the factory immediately.
IV . WARRANTY REGISTRATION: I
1. Complete & return the WARRANTY REGISTRATION CARD. Noting the serial numberlocated near
the charging cord.
BEFORE OPERATING, READ ALL INSTRUCTIONS THOROUGHLY.
v. IPREVENTATIVE MAINTENANCE: I
VI .
1. Ifrequired, checktire pressure every6 months.Airtiresto30PSI or as printedon thetire sidewalls.
Most carts after November, 1990 are equipped with foam-filled tires, in which case only an occa -
sional inspection of tread wear is necessary.
2. Check cord reel daily for proper operation. Cord should retract fully into rear housing with only
the plug showing. Replace if faulty.
3. Check dailythe condition of the power supply cord. Replace with new cord reel if worn or frayed.
4. Check dailythe operation of the cart -all functions: key switch, forward-reverse switch, battery
condition meter, seat switch, safe-t-stop, chairlock &swivel, throttle, foot brake, etc. Repair if faulty.
5. Check daily the anti-tip castors (dwg. #23, fig. 1) to be sure they are adjusted properly and are
in good condition.
6. Clean cart daily. Use "Appliance Magic" fiberglass & plastic cleaner for high luster.
NOTE: For the best preventative maintenance plan, and best CUSTOMER SERVICE, assign one
employee the daily task of cleaning and inspecting the cart(s). This way you will know who
is responsible for the cart(s) and there should be no excuse for customer dissatisfaction.
BATTERY CHARGING: I
1. Install a Ground-Fault Circuit Interrupter (GFCI) in store's electrical outlet wherever Mart Cart is
to be charged. This is to protect against any possible shock hazard. Installation of the GFCI must
be done by a licensed electrician.
2. AC voltageof the powersource required is 120 VAC currentdraw is 1.6 amps A.C. (output of charger
is 14.5 volts D. C. , 6 amps.)
3. Charge battery nightly after dailyusage. When battery is fully-charged, the charger will ma intain
a "trickle" charge to keep battery at its peak or shut off automatically depending on charger type.
We recommend chargingtime not to exceed 10 hoursto achieve the maximum battery and charger
life. To accomplish thi s, a 110 volt 10 hour timer is recommended.
WARNING- 4. Do notcharge continuously, such as dur ing theday & night, as it's not necessaryand will reduce
the battery life. Daily excessive charging more than the 10 hours recommended could result in
severe damagetothe batteryand possiblythe charger. Always keepbatterycovered whilecharging.
5. One complete charge (14 hours if battery is completely without charge) will allow up to 3 days of
normal grocery store operation.
6. To determine if chargerisworking or battery istaking a charge; 1) Plugcord in to live wall socket, 2)
Turn key switch to " ON" position, 3) Place direction switch (FWD/REV switch) in "OFF" posi-
tion, 4) Rotate throttle grip to full "on" position. Needle should move from left to far-right side of
battery condition meter. If the needle doesn't move, see "Trouble Shooting" Chart on page 5.
7. Maintenance of battery: none required as battery is a gel-eel design and requires no water.
Under normal circumstances, the Mart Cart battery should last 1½ to 3 years, or longe r, if the above
recommendations are followed. Replace with an original gel-eel battery. Mart Cart™is not respon-
sible for any adverse effects caused by a replacement lead-acid battery.
-4 -

TO TEST BATTERY CONDITION: Read The Meter Under Load
To test the battery, turn on the key switch, place rocker switch in forward, twist throttle grip fully-on.
To get a true indication of battery level the cart must be running putting the battery under a load.
VII. I TROUBLE SHOOTING: I
CAUTION: WALL SOCKET SHOULD HAVE GROUND FAULT INTERRUPTER
INSTALLED BY QUALIFIED ELECTRICIAN
TOOLS REQUIRED: screwdrivers-blade & phillips; socket set-7/,s,½,9/,s; box or open-end
wrenches-71,
6
,½,
9
/,
6; alien wrenches-%2
,1/a,%
2
,3/,
6; small crescentwrench; vice-grips; soldering gun,
flux & solder; electric drill & bits; wirecutters, strippers & crimpers (good quality); voltage-Ohm meter
with continuity checker; spray cleaner (Appliance Magic for countertops and plastics); clean rags;
LPS #1 Lubricant, heavy duty grease.
PROBLEM
1. Cart moves with switch in "FWD"
or" REV" without actuating throttle
2. Cart stops when making right or
left turns
3. Cart won't go at all , throttle
sys tem O.K.
4. Cart won't go, throttle system O.K. ,
wiring harness O.K. , battery weak
5. Cart goes but only at higher speed
when t hrottle is at or near full "on"
6. Battery won't take a charge. Cart
quits part way through shopping,
after charging all night
7. Cart goes, but only at low speed ,
or for short duration with above
conditions ruled out
B. Cart won't go , or moves intermit-
tently , or a grinding noise
orig i nates from motor
9. Cart won 't go or operates in only
" FWD" or only "REV". Above
condi tions ruled out
10. Battery test meter won 't operate
11. Seat won't swivel, rocks back &
forth or swivels too freely
PROBABLE CAUSE
1. Broken or weak throttle spring or broken cable
2. Loose set screw on throttle plate
3. Improper adjustment of throttle cable
1. Broken wire in harnes s where it exits
steering column
1. Broken wire in harness
2. Weak battery
3. Defective or old battery
4. Open c ircuit breaker
5. Safe-T-Stop faulty
6. Seat switch not depressed
1. Loose wire(s) in cord reel or defective contacts
2. L oose wire in contro l box
3. Loose wire at key switch
4. Battery terminal loose
5. No power at wall socket
6. Faulty battery charger
1. Broken or cracked wi nd i ng on rheostat
2. Throttle spring broken
1. Defective or old battery
2. Defective cha rger
3. See 4 (1) above
4. Defective line cord, plug
5. No power at wall socket
1. Weak battery
2. Tire rubbing on body
3. Rheostat wiper arm not reaching full "ON"
position
4. Drive belt loose
5. Power cord wrapped around tire
6. Defective wheel bearing
7. Low tire pressure (some models)
1. Mot or gear broken
2. Motor brushes worn out
3. Motor bearing worn out
4. Pulley set screws loose
5. Drive belt loose
1. Defective "F WD/REV " sw it ch
2. Safe+Stop faulty
1. Loose wiring
2. Low battery
3. Defective switch
4. Defective meter
5. Throttle not fully actuated
6. Key switch not turned on
1. Worn swivel
2. Seat-lock engaged
- 5-
SOWTION
1. Replace
2. Tighten , adjust cable
3. Adjust per instructions
1. Replace wi th harness ki t
1. Rep l ace w/ harness kit
2. Charge
3. Replace w/ new battery
4. Reset circu it breaker
5. Examine & repair
6. Operator must be fully seated
1. Replace r eel if necessary
2. Tighten / reconne ct
3. Tigh ten I reconnect
4. Tighten / recon n ect
5. Chec k for 110 vo lts
6. Replace battery c ha r ger
1. Replace rheostat
2. Repla ce
1. Replace battery
2. Needle on charger shou ld move
when plugg ed in. Test volt me te r.
3. See 4 (1) above
4. Repla ce
5. Test , try different socke t
1. Charge or r eplace
2. Check wheel bearing or axle
alignment
3. Ad j ust throttle plate
4. Tigh t en
5. Release & test cord
6. Replace bearing
7. Inflate to pressure shown on side
wall . (NOTE : foam - filled ti res will
read "O " pounds pressure)
1. Rep l ace gear or motor assembly
2. Replace brushes
3. Rep l ace motor asse m bly
4. Tighten set screw
5. Tighten to ½" to ¾" deflection
1. Rep l ace
2. Examine & Repair
1. Tighten I reconnect
2. Charge
3. Check w / cont inuity test er
4. Check wi th volt meter
5. Twist throttle grip to full position speed
6. Turn key switch on
1. Replace swivel or entire sea t
assembly
2. Move & hold lo ck ing l eve r forward ,
rotate seat

LO
DED VIEW
EXP
-6-
REV. ' 91
MODEL SHOWN
DELUXE

~ ~ -
.,.. ~ ~ ~ -- -- =-
i Li1n
~.~
-- - -----
- 7 -
ca~
IX. PARTS LIST
DRAWING PART
# #
1
2
3A
38
4A
48
6
7
BA
88
9
10
11
12
14
15
16
17
18
19
20A
2 08
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47A
478
48
200-1316
200-8008
200-8005
200-8000
200 -1035
200-1354
200-1033
200 -1042R
200 -1117
200-1399
200 - 1119
200-1122
200-1120
000-1107
200 -1255
200 -1091
000-0030
000-1095
000-1341
200-1356
200-1334
200 - 1365
200 - 1006
200 -1108
200 - 1052
200-1330
200-1017
200-8015
200 - 1162
200-1154
200-1100
000-1256
200-9000
200-8030
200-8040
200-1016
200-1142
200-1346
200-1331
200-1129
200-1027
200-1298
200-1008
200-8025
200-9010
200-8050
200-8060
200-1265
200-1105
200-1401
200-12
77
200-4000
200-4001
200-8035
COMPONENT NAME
HAND GRIP FOR THROTTLE EXTENSION; ~,o~c~~~ ~ •:r'.°
EXTENSION GRIP COMPLETE ', GR IP USED
MAIN THROTTLE GRIP ASSEMBLY
DUAL THROTTLE SUB-ASSY- 1991
BATTERY CONDITION METER
BATTERY CONDITION METER (FLAT FACE)
FORWARD - OFF -REVERSE SWITCH
STANDARD HAND GRIP
PAD FOR ARM REST
PAD FOR
ARM REST
SEAT (ONLY)
SWIVEL PLATE, LOCKING
SEAT PAD
KEY FOR MOTOR / PULLEY SHAFT
RELAY,
12 voe ,CHASSIS MOUNT
MOTOR
THROTTLE CABLE
THROTTLE SPRING
THROTTLE BRACKET
RHEOSTAT SPEED CONTROLLER
BATTERY CHARGER WITH 18
INCH POWER CORD
BATTER CHARGER WITH 6 FOOT POWER CORD
BATTERY
BRAKE
PAD
ANTHIP CASTOR
FRONT & LEFT REAR
WHEEL & TIRE
CIRCUIT BREAKER
FRONT CART TRIM, COMPLETE
LEFT BASKET TUBE
RIGHT BASKET TUBE
LARGE GROMMET
METAL DRESS WASHER
BASKET WITH TRAY & TRIM
BASKET TRIM, COMPLETE
PRODUCE BASKET, COMPLETE
ELECTRICAL HARNESS, MAIN
KEY SWITCH
FLOOR MAT
DRIVE
WHEEL W / 6" PULLEY
INSTRUCTION PLATE
BATTERY STRAP
V-BELT (USED W / #37 DRIVE WHEEL)
POWER
CORD ASSEMBLY (NOT ALL MODELS)
REAR CART TRIM,
COMPLETE
SEAT ASSEMBLY, COMPLETE
FRONT FIBERGLASS COVER, COMPLETE
REAR FIBERGLASS COVER, COMPLE TE
BOO T, CORD REEL
2" PULLEY
2½ " PULLEY
SEAT SWITCH
SET, MAINTENANCE-FREE TIRES
SET, PNEUMATIC TIRES & WHEELS , INCL.
(2) 200-1015 &
(1) 200 ,1309
ARM REST WITH P ADS

'
X.
PICTORIAL WIRING DIAGRAM: AFTER 1990 :
u.
I
SR#24616 '
. --~
• k ~c•
■ A1 0t \ -- GM-ll
• Rf!l ll- · O'll
• WIIT( tl~ • uw: l
• WlT ( t l\ ·,• ">
PRIOR TO 1990 SR#24615
~I
= :::. i---------1 .... . - .. .... .. . - .. ..... - . .... .
,---
--1-- ,
I
I
I
<fl
~J I CN
L- --- ------------ -- ------------1
,----- f7--- l a--l
~
. p
·~ 11=11 1
k~ I
l
I
I
'"=- -- ~- =- -=-=- =- - =- - =- -=-- ~ ~,--------- -- -------------J -- --
FIGURE 2
/
/ , ~ ;
/ ;; -:-.LAY
DETAIL / - TT !
A /:
i
REL A Y. BA T TERY ,
& C HA RGER WIRI NG
AF TEA SERI AL
NO. 27 27 0-0691
EF F" . D ATE 6 · 2 4-9 1\
'-
'-..
--------- --✓
XI. BATTERY REPLACEMENT:
I
I
I
To replace the battery: (Read precautions on battery -avoid any sparks)
1. Shut off key switch and remove key.
2. Place forward-reverse switch in center "off" position.
FIGURE 3
3. Remove three screws thathold down rear cover. The one in front requires a screwdriver.The two
in the rear require a 7 /,
6"
box wrench.
4. Lift the rear cover straight up and offthe cart. Set on ground beside the cart being sure to pull
out sufficient power supply cord to allow enough slack for cover movement. DO NOT remove
power supply cord from cover unless cart is not equipped with a cord reel. If cart has no cord
reel (cord will not extract), push cord plug through grommet hole, then lift rear cover.
5. Disconnect the negative &positive wire bundles from the two battery posts &remove the battery.
6. Install new battery w/ the negative post(-) towards the right rear ofthe cart -next to the drivewheel.
7. Connect the white and black leads to the negative post. Connect the blue & red leads to the
positive post.
8. Secure battery with rubber strap or clamps. Check to be certain that the bundle of wires on
the right side of the battery (next to drive wheel) are not rubbing the drive wheel pulley.
9. Before re-installing cover -check tire pressure (if applicable -tires may be foam-filled in
which case pressure will read "0"), wheel condition, belt tension and general condition of
other components.
10. Re-install rear cover. Be certain cord reel power supply cord is free to work properly. Make
sure all three cover hold down screws are installed and tightened. (If without cord reel, place
cover in position & push the cord plug back through the grommet hole.)
11. Test cart for proper operation. Charge battery for 10 hours maximum.
IMPORTANT
Your "Mart Cart" has been equipped with a gel-eel battery during the manufac-
turing process as original equipment. The manufacturer recommends that you
replace the original battery only with the same type and rating to prevent pos-
sible damage to your cart's internal components, charging system, or personal
injury to you and your customer. (Mart Cart part number 1006 , item 21 , pg. 6.)
-8 -

XII. THROTTLE CABLE REPLACEMENT:
A. STEPS TO REPLACING THROTTLE CABLE:
1. Shut off key switch and forward-reverse switch
2. Turn to section VIII "Exploded View" pages 6 & 7, figure 1. The following parts will be considered:
DRAWING#
3
16
19
PART#
200-8005
000-0030
200-1356
COMPONENT NAME
MAIN THROTTLE GRIP ASSEMBLY
THROTTLE CABLE
RHEOSTAT SPEED CONTROLLER
3. Begin by dis-assembling the clamps (part #6072, drawing #2 , fig. #4 below) that hold the main
throttle grip assembly onto the steering handle bar. Notice that these clamps are closest to the
black control box mounted on top center of the steeringcolumn. DO NOT remove the extension
arm clamps (part #1042, drawing #2 exploded view page 6) unless this item needs replacement.
4. NOTICE that the main throttle grip clamp (drawing #2, fig. #4) mounted on the top of the steer-
ing column fits down over two screw heads. These heads prevent the clamp assembly from
rotating around the crossbaron the steeringcolumn. Notice also that the lower half of the clamp
has the throttle cable attached to it (drawing #3, figure 4 below)
FIGURE 4
Assembly
Co mplete
AS VIEWED
FROM FRONT
OF BASKET
EXTENSION ARM and THROTTLE GRIP ASSEMBLY
DRAWING#
2
3
4
5
6
7
9
PART NO.
200-8005
200-1042A
200-1042C
200-1042D
200-1042E
200-1042F
000-0030
200-8008
DESCRIPTION
Throttle grip assembly with clamps (items 2 & 3).
Grip (aluminum w/extension arm, nylon w/o extension arm),
casting & vinyl grip less clamps .
Clamp, throttle grip, upper. (set).
Clamp , throttle grip , lower. (set).
Washer, lock. Throttle grip assembly.
Screw, throttle grip & ext. arm assembly.
Adjustment screw (part of cable assembly)
Cable, throttle assembly.
Arm, throttle extension w I grip .
-9-

XII . THROTTLE CABLE REPLACEMENT Continued
5. Slide the ball end of the throttle cable out of the take up spool on the end of the throttle grip.
(see "arrow" in figure 4, page 9).
6. Remove the cable from the lower clamp by turning the adjustment screw (dwg. #6, figure 4)
counter-clockwise.
7. Remove the rear cover of the Cart. See section XI "Battery Replacement" for instructions on
removing the rear cover, page 8.
8. You are now ready to pull the throttle cable through the front housing (dwg. #44, figure 1) of the
cart. Notice the routing of the throttle cable as shown on the exploded view drawing, pages 6
& 7. Start by feeding the cable down through the grommet in the front cover while pulling from
the bottom side. Notice that the cable passes through a restraining clamp on the left upperchasis
support near the base of the key switch. Pull the cable from front to back.
ITEM
PART NO.
DESCRIPTION
1
200·1356
RHEOSTAT
2
NA
WIPER ARM, RHEOSTAT
3
000·1198
WASHER, SPLIT LOCK If 10
4 000 · 1077
SCREW, SOCKET HEAD, TEK # 10• \12
5 200 · 1340
PLATE. RHEOSTAT MOUNT ''-'G
6 000 - 1185
NUT II 8 - 32
7 000 - 1198
WASHER, S PLIT LOCK ti 10
8 000·1082 NUT, ',, 4 -20
9
000·1083
LOCK WASHER, 1 '4
10 000 - 1234
WA SHER, ,,. ec: s
11
000·1217
SET SCREW, SOCKET ti
10
132 • 5 1s
12 NA
WASHER, RHEOSTAT ASSEMBLY
13 000-1185
NUT, # 8 - 32
14
200 · 1095 THROTTLE SPRING
15 000 - 1391 SCREW , 118- 32 • 3 14
16
NA
NUT , RHEOSTAT A SSE MBLY
ITEM
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
MART CART
THROTTLE SYSTEM
- parallel
I
PART NO.
DESCRIPTION
000·1366
THROTTLE PLATE
000·6109
SET SCREW, THROTTLE PLATE COLLAR
000 · 1201 WASHER, PLASTIC
000 - 0030
CABLE, THROTTLE ASSEMBLY
NA
NUT , THROTTLE CABLE
NA
WASHER, THROTTLE CABLE
000·1234
WASHER,' '• USS
000 · 1144
SCREW, SOCKET HEAD , 114 - 20 • 3 14
NA
WASHER.THROTTLE CABLE
NA NUT , THROTTLE CABLE
NA
WIRE , THROTTLE CABLE
NA
EYELET.THROTTLE CABLE
000 · 1201 WASHER, PLASTIC
000 · 1097 PIN, CABLE RETAINER, %2 • 3 1/u
NA
DARK BLUE LEAD TO BATTERY
NA
DARK BLUE LEAD TO CONTROL BOX
200 - 1341
BRACKE~THROTTLE CA BLE
Wiper arm adjustment (2). The wiper arm should rest on the " OFF" band when the throttle is released. It is permissible for the
wiper arm to go bey ond the " OFF " band and rest on the ceramic portion of the rheostat. When the throttle grip is twisted to
the full "O N" position, the wiper arm should not cover more than ½ of the full "ON" band. The throttle plate (17) should be
parallelto the rheostat mountingplate (5) when properlyadjusted. Alwayssecureset screw (18) and other fasteners. Checkcondi-
tion of sp ring (14) and other components when se rvi c-; ng.
-10 -

XII. THROTTLE CABLE REPLACEMENT: Continued
9. Notice the large gentle loop in the cable as it comes off of the rheostat (drawing #19, figure 1,
exploded view). When installing the new cable, you will want to maintain this loop. There should
not be any tight bends in the new cable when it is installed.
10. Disconnect the cable from the throttle plate (drawing #17, figure 5) by pulling outthe hair pin re-
taining the cable (dwg. #30, figure 5). Save the washer and pin.
11. Disconnect the cable from the cable mounting bracket (drawing #33, figure 5) by loosening the
nut closest to the throttle cable eyelet (drawing #26, figure 5) and drawing #28, figure 5). Notice
the position of the second nut (dwg. #21, figure 5) furthest away from the eyelet. This nut has
been turned up onto the adjusting screw (dwg. #20, fig. 5) to allow for proper cable adjustment
in relation to the wiper arm movement on the rheostat. When installing the new cable, set this
nut (dwg. #21) up onto the adjusting screw on the new cable in the same relative position as on
the old cable. Thiswill giveyou a good starting point from whichto make adjustments if necessary.
1 2. Install the new cable. Begin at the back of the cart by feeding the cable eyelet (dwg. #28, fig.
5) through the hole in the throttle cable bracket (dwg. #33, fig. 5) . Be certain that one nut and
one washer are on each side of the bracket as shown in figure 5.
13 . Tighten nut(#26) closestto the eyelet (#28) up against the bracket (# 33) . Secure both nuts tight
against bracket. (Ref. figure 5 ).
14. Place eyelet (#28) over spindle on throttle plate (# 17 , fig. 5). Be sure a washer (# 19 & 29) is posi-
tioned on top and bottom of eyelet. Insert pin (#30) to retain cable.
15. Route the new cable through the retaining clamps from which you pulled the old cable through.
IMPORTANT: DO NOT kink cable atany time. DO NOT USE if cable has been kinked. All bends
should be gradual. The cable should move freely through the cable's housing when installed.
16. IMPORTANT: Be sure the newthrottlecable is secured out ofthe way ofthe front wheel assembly
when turning, clear of brake movement, and rear tire rotation.
17. Push the ball end of thecable upthrough thegrommetinthefront cover. You maywant to lubricate
the grommet or cable before pushing through. DO NOT remove the grommet to install the cable.
18 . You are now ready to connect the cable to the clamp that holds the throttle grip to the steering
column (drawing #3, figure 1) . Feed the ball end of the cable through the clamp and screw in
the nylon adjusting screw until it is tight.
19 . Place the ball end ofthecable into the receptacle on the end ofthe throttle grip. Slide this assembly
onto the steering column. Place bearing grease onto the ball end and the bare cable. ( HINT: To
get the ball into the throttle, it may be necessary to disconnect the throttle return spring (#14,
fig. 5). Be sure to re -connect later).
IMPORTANT: Always check the condition of the throttle grip (dwg. #1 , fig. 4) for wear or cracks.
Replace if necessary.
20. Install top half ofthrottle gripclamp (dwg. #2, fig. 4) . This clamp must be positioned directlyover
the 2 screw heads on the steering column crossbar. The throttle grip must be positioned inside
the two clamps so as to twist freely.
IMPORTANT: The throttle grip must stop rotating when it strikes a pin which has been inserted
into the upper clamp. The grip must not bind againstthis pin when twisted to the full "ON" posi-
tion. Also the extension arm assembly (dwg. #9, fig. 4) must rest parallel to the floor, facing the
basket, when in the "OFF" position. The exploded view drawing ofthe cart shows the extension
arm in the "OFF" position.(dwg. #1 , fig. 1) .
21 . Once you have the throttle grip assembly back together test for proper action. First, pull back
on the extension arm or twist the grip to the full " ON " position. The grip must stop against the
pin in the upperclampbefore the wiper arm on the rheostat reaches the stop built into therheostat.
If the throttle grip does not stop first tw o symptoms will appear: 1) The cable will "strangle the
grip" causing the metal-ball-retaining-position of the grip to crack and break apart, OR 2) The
force of the cable pulling on the rheostat wiper arm will crack and break the porcelain holding
the wiper arm.
22. Turn to figure 5 and be certain the wiper arm on the rheostat does two things: 1) The wiper arm
must not touch the wires that create the "ON" position when the throttle grip is resting in the
"OFF" or forward position. AND 2) The wiper arm must not go beyond half way onto the last
band of wire on the rheostat when in the fullest "ON" position.
- 11 -

XII. THROTTLE
CABLE REPLACEMENT:
Continued
23. You can adjust wiper arm movement by adjusting the nuts(dwg. #26 & 21, figure 5)on the adjust-
ment screw (dwg. #20, figure 5) on the end of the throttle cable OR you can make adjustments
by following the procedure shown at the bottom of figure 5.
24. Once you are certain of proper adjustments, you are ready to test the cart with power applied.
Turn on key switch, select "forward" or "reverse", and twistthe throttle grip slowly.The cart should
slowly move with an increase in speed with further advancement of the throttle.
XIII. I SAFE-T-STOP I (Optional)
Another exclusive featurethat keeps the MART CART years ahead of the competition. SAFE-T-STOP
works in conjunction with MART CART's exclusive "Resilient Mounted Basket". When an object or
person bumps the leading edge of the basketthe cart instantly stops. Powerto the motor is instantly
cut off, stopping the continuous forward driving motion.
SAFE-T-STOP works so well it is now offered as optional equipment on all models.
XIV. I SAFE - T-STOP How It Works :
When the Sate.:r-Stop bumpertouches the basket, a circuit is closed causing thecartto stop. In order
for the cart to continue again, the operator of the cart must release the throttle grip allowing it to
go to the full " OFF" position. The cart will resume operating when the throttle grip is re-activated.
In order for the Safe-T-Stop to work, 4 components are required: 1) Safe.:r-Stop Lever (Bumper), (2)
Microswitch or Mercuryswitch, (3) SCR (Silicone rectifier), and (4) a relay. Thesework in conjunction
with each other to make up the Safe.:r-Stop system.
This system is energized by a lead wire from the "positive" battery post to the microswitch or mer-
cury switch. The mercury switch rests in a "normally open" position. When the throttle on the cart
is advanced, the microswitch rotates(or mercury switch tilts),closingthecircuittothe SCR. The SCR
now waits in a stand-by mode for another signal (i.e., the closing of the external circuit: the bumper
lever hitting thebasket) before itclosesan internal circuitgoing to the relay.When the bumper strikes
the basket momentarily,the SCR passes power onto the relay. The relayiswired in a "normally clos-
ed" position. When energized by the SCR, the coil of the relay holds the contacts of the relay in
an "open" position until the SCR is de-energized. The relay interrupts power to one of the motor
leads. Thus, when the relay is energized by the SCR, the motor will not run. When the SCR is no
longerenergized, the motor relay contacts will once again close completing the motor circuit. In order
for the SCR to be de-energized, the microswitch or mercuryswitch must return to its "normally open"
or resting position. This is accomplished when the operator of the cartreleases the throttle.The mer-
cury switch is mounted on the spring loaded throttle plate which rotates when the throttle is twisted
at the hand grip or released.
Trouble shooting the Safe-T-Stop system can be quite simple. If the cart won't run, bypass the SCR
activated relay. To dothis, simplyjoin the positive motorlead wiretogetherwith a jumperwire across
the two relay terminals where the two lead wires are attached. In so doing, you have by-passed the
system entirely. Now, if the cart won't run your problem is not with the Safe-T-Stop system. You will
have to trouble shoot the problem like any other cart that won't run.
Should the cart begin to function, however; then the problem rests with the Safe.:r-Stop system. Even
though the system can be easily by-passed as mentioned above or by disconnecting the positive
lead wire to the microswitch (or mercuryswitch), it is recommended that you trouble shootthe cause
of failure and repair.
If the cart won't run with the Safe-T-Stop system connected, there are three places to look:
1. Short in external circuit
2. Defective relay
3. Defective SCR
Ifthe Bumperlever is touching any part of the basket or thewire lead goingtothe Bumper is touching
the basket or shorting against the frame, a false signal will be sent to the SCR causing it to energize
the relay.
If the relay does not reset itself to a " normally closed" position, then it must be replaced. To test
the relay, simplydisconnect the leadwire from the SCR. Use a continuitytester acrossthe "normally
closed" terminals (the onesto which the motor leads should be attached). There should be continui-
ty across these terminals when the relay is non-energized.
- 12 -

XIV.
xv.
K>TOR
SAFE-T-STOP How It Works: Continued
To test the SCR, there should be no continuity across the center leg of the SCR and the leg with
the lead going to the relay coil when power to the SCR from the microswitch (or mercury switch)
has been disconnected. It is important that the mercury in the switch does not make contact with
its internal terminals when the switch is in a resting position (throttle closed).
Due to the high rate of reliability of SCR' s, microswitches(or mercuryswitches), and relays, it is likely
that mostproblemsencountered will be associated with dailyabuse of the bumper or possiblejarring
andmis-alignment of the mercuryswitch. Replacementmicroswitches(ormercuryswitches) and SCR's
will be provided with pre-soldered leads and insulators for easy replacement.
CAUTION: The SCA is a "positive D.C. operative" circuit. NEVER APPLY ANY NEGATIVE
CURRENT TO THE SCA OR COMPONENT WILL BE DESTROYED!
Do not by-pass resistor to SCA or component failure may result!
SAFE-T-STOP Wiring Diagram :
0 SCR
(rn-220>
LEVER
DPST RELAY (N/C)
h~
RESISTOR
FIGURE 6
JI
BASKET
rFTI
FRAME(+)
CIRCUIT <l-- --'
XVI.
(-) BATTERY
DRIVE BELT I
SPOT MICROSWITCH
........ ~NO
NC
(+) BATTERY
ELECTRICAL CIRCUIT SAFE-T-STOP
NOTE: SCA
PIN 1 = CATHODE
PIN 2 = ANODE
PIN 3 = GATE
1. The drive belt is shown in the exploded view drawing on page 6. See drawing #40. On account
of the slow speed at which the motor turns and due to the heft of the belt used, your belt should
never require replacement. For this reason Mart Cart offers a lifetime limited parts warranty on
the drive belt.
2. Proper belt tension will extend the life of the drive system components. The dr i ve belt is installed
by the factory using 20 ft. lbs. of torque. This results in a belt that when pressed in the center
will deflect approximately ½" to ¾". ·
3. Proper belt tensionwill reduce belt wear, increase drivewheel bearing life, reduce drive train shock
when the cart isswitched from "forward" to "reverse" or viseversa, and increase motor gear and
bearing life.
-13-

XVI.
XVII.
DRIVE BELT
Continued
4. To adjust belt tension:
- Shut off power, remove key.
-Remove rear cover (see section XI). Keep fingers clear of belt & pulleys!
-Locate and loosen the two motor mounting plate bolts which pass through the frame.
-Pry upwards on the motor plate until belt is tight (½" deflection).
-Test cartbydriving in forward and reverse. A small amount of slippage is desirablewhen making
rapid changes in direction. The belt should not be so tight as to cause the cart to jerk when
switching rapidly from forward to reverse or vice-versa. On the otherhand, the belt should not
be so loose as to not allow the cart to move when fully loaded.
CIRCUIT BREAKER I
1. The circuit breaker is designed to protect yourelectrical system from transient overloads or elec-
trical shorts. Either could cause serious damage without a circuit breaker to open the circuit.
2. MartCarts manufacturedafterJanuary 1, 1990 have the circuit breakermounted under the control
boxcover on top of the steering column. It isa " manual" type breakerrated at 15amps. It requires
resetting once it has been activated. Itwill not reset itselfautomatically for safety reasons. To reset
the breaker insert a pen or pencil point into the circuit breaker access hole on the front left of the
control box cover. Press inward on the circuit breaker button until a "clicking" sound is heard.
The cart should now be ready to operate providing the cause for the circuit breaker tripping was
not serious enough to trip the breaker a second time .
3. Mart Carts manufactured before 1990 have their circuit breaker mounted under the front cover
as shown in the exploded view drawing on page 6.
4. Some of the most common causes for the circuit breaker to open are:
1) Low tire pressure
2) Worn wheel bearings which cause...
3) Tires rubbing body of cart
4) Short in "forward-off-reverse" switch
5) Shortin wiring harness-usually located at base of steering column on carts manufactured prior
to 1986.
6) Activating throttle while pressing brake pedal.
X VIII. SEAT SWITCH I(Standard on deluxe model)
XIX.
1. The seat switch is a standard feature on all deluxe mart carts and optional on other models.
2. The seatswitch consists of a plate and rod assembly mounted underthe chairs seat pad. Pressure
downwards on the seat pad causes the rod to depress a spring-steel plate which rests on top of
a 60 amp rated push button switch. This switch closes the circuit to the motor. The cart will not
operate if this switch is not depressed.
3. Seat switch adjustments can be made by putting pressure upwards or downwards on the switch
support bracket located under the rear cover. NOTE: Foreign objects between seat pad and chair
may prevent the plunger rod from operating properly.
RELAY, CHARGING I(Standard on any models with cord reel)
1. Thisrelayis located underthe rear cover. It is mountedto the frame of the cartclosest totherheostat
or furthest from the drive wheel, (see exploded view, drawing #14, page 7) .
2. The relay is wired in the "normally closed" position. When the coil of the relay is energized the
relay contacts "open" the motor circuit. This is to preventthe motor from operati ng while the bat-
tery is being charged. This will also prevent potential damage to your charging system -cord,
cord reel, charger, and electrical outlet.
3. HOWIT WORKS: When the powersupplycord is plugged into the store's electrical outlet the bat-
tery charger is energized. The charger sends approximately 14.5 volts to the battery for charging.
Along the way the coil of the charging relay is also energized. It will remain energized until the
power to the charger is disconnected. The motor circuit is interrupted until charging is complete.
When the charger is unplugged the motor circuit through the relay will be " closed" again.
- 14 -

XIX.
xx .
XXI.
XXII.
:xxm.
RELAY, CHARGING Continued
4. You can tell if the relay is working properly if you hear a distinct "clicking" sound coming from
the relay when you plug in the powersupply cord. Also, the cart should notoperatewhile charging.
CORD REEL I (Standard on deluxe model, Optional on all others)
1. The cord reel has been provided to save you hundreds of man hours in trying to find an extension
cord tocharge yourcarton a daily basis. Itwill alsokeepthe cord stored in a safe, protected place,
out of sight, where customers can neither see it or trip over it.
2. The cord reel will give you years of trouble-free service providing thesimple operating instructions
posted on the cart are followed. (See "Operating Instructions" on page 3).
3. Most cord reel failures are due to abuse such as tugging on the cord to pull the cart plug, or by
not letting the reel retract the cord and the operator shoves the cord into the cart's rear housing.
The cord gets tangled around the rear wheel which in turn pulls on the cord and damages the
reel. Although a rubber boot has been installed between the cart housing and the cord reel to
prevent the cord from being shoved in, a heavy handed operator may try to push the cord past
the boot.
4. Always inspect the condition of the power supply cord on a daily basis. Replace the reel if the
cord or plug is damaged or if reel does not function properly.
IMPORTANT: Aground fault circuit interrupter (GFCI) should be used in your store's electrical outlet
where you intend to draw current to charge your cart.
VARIABLE SPEED CONTROL I
1. The cart's speed is regulated by a heavy duty rheostat. This device provides extremely smooth
acceleration from Oto 1.3 MPH.
2. The rheostat is located nearesttheleft rearwheel and slightlyabove,(see theexploded view, drawing
#19 , page 7).
3. Although rheostat failures are very uncommon, the majori ty have been due to improper throttle
cable installation. In most instances the wiper arm on the rheostat has not been allowed to retract
off of the last band of energized wire. The rheostat then overheats and, like a fuse, quits working.
In some instances, the throttle cable allowed the operator to pull the wiper arm too far causing
the arm to strain against a built-in stopping mechanism. This mechanism will break if too much
strain is placed on it. See section XII for proper throttle cable replacement.
MOTOR MAINTENANCE I
1. There is no scheduled maintenancerequired. However, whenthe rear cover of the cart is removed
for other reasons (such as to replace the battery) the motor should be examined.
2. Whatto look for -checkthe belttension (see section XVI), check for any motor shaft seal leakage,
check the motor mounts, check the brushes at least once every 5 years.
3. Motor brushes -there are two brushes at the rear end of the motor, one on top and one on the
bottom. They are each located inside a small round plastic housing. A small screwdriver may be
used to back outeach brush. If your motor stops running, worn brushes could be the cause. Due
tothe fact that your motor hasexternal brushes theywill outlast internal brusheswhich are smaller
and they are easier to replace.
FOOT BRAKE I
1. The foot brake does not require any scheduled maintenance.
2. In order for the brake to offer maximum efficiency the left rear tire should be filled with air (if not
foam-filled) to its maximum rating. Also, the rear wheel bearings should be checked and replaced
if excessive play is found.
-15-

XXIV.
XXV.
XXVI.
XXVII.
TIRE AND WHEEL REPAIR (For proper pressures
of pneumatic tires see section V.)
1. The large 10" tires will provide many years of long tread wear before requiring replacement. The
tires should be replaced when the tread is worn off or if there are signs of aging such as peeling
of the tread or cracking of the side walls.
2. Foam-filled tires require no air, therefore the only maintenance is described in (1) above. They are
distinguished from pneumatic tires by a "O" pounds pressure reading when checked with an air
gauge. On models with pneumatic tires, flats usually result from failure to keep the tires inflated,
a puncture of the tire, or a leaky valve stem.
3. Tire and wheel removal has been made easy as the axles are equipped with snap rings.
4. Pneumatic tires are equipped with an inner tube. Most lawn mower dealers have repair facilities
that handle the inner tubes and flat repair work at a nominal fee. "Fix A Flat™" works well to
seal a puncture and inflate the tire without having to remove the wheel.
SEAT ASSEMBLY: I
1. The seatassemblymayconsist of the following items all of which are replaceable:the chair, tubular
arm rest, plastic arm rest pads, seat cushion, and chair swivel plate.
2. The swivel plateshould be lubricated with grease at least once a year. It should also be examined
forexcessive play. Itshould be replaced when the chair rocks back and forth on the plate or when
the chair swivels too freely.
3. Seat-lock should be inspected dailyfor properfunction. The release/locking arm should move for-
ward freely, and spring back into one of four locking positions. If return spring is broken,
DO NOT USE cart until spring is replaced.
CONTROL BOX I
1. The mastercontrol box islocated ontop of the steering column.Itcontainsthe "forward-off-reverse"
switch, the battery condition meter, and when ordered the horn and horn switch. Underthe cover
is the circuit breaker (units manufactured after January 1, 1990).
2. The cover can be removed by removing the two side screws. All components can be replaced if
necessary.
WARRANTY I
A. PARTS: 1 Year Limited Warranty from date of shipment.
B. BATTERY: Full Warranty first 9 Months from date of shipment.
C. LABOR: 1 Year Limited Warranty
A. PARTS -Limited Warranty
All parts, except battery (See B. Battery below) flat tires (when applicable to some models), and
circuit breaker needing resetting, are warranted by the manufacturer to be free from defects in
material and work-manship for a period of 1 year from date of shipment. This warranty does not
include wear and tear caused by above -normal usage, abuse, negligence, freight damage, or
damage caused by improper use or care, or by outside sources such as fire, floods, etc.
Should anycomponentfail (except those mentioned) during the first year of ownership, return com-
ponent in question to the manufacturer or authorized representative for inspection. If component
hasfailed dueto defect in material or workmanship, itwill be exchanged or repaired at the manufac-
turer's discretion at no charge to the owner.
B. BATTERY
The battery is fully warranted up to and including the first 9 months from date of shipment, and
prorated based on the net price of the battery 10 through 12 months from the date of shipment.
C. LABOR
The manufacturer will cover labor charges for work performed in the field for one full year from
thedate of shipmentas a result of defectin materials and workmanship. Charges incurred for reset-
tingthe circuitbreakerare exempted. Double servicecalls due to improperfirst-call service or lack
of repair parts are exempted.
The above warranties exclude shipping, handling, or travel expenses incurred for the repair
of said cart or parts as well as items worn out through normal use whose malfunction is
not attributable to defect.
Mart Cart, Inc.
115 E. Linden, Rogers, AR 72756
800-548-3373
501-636-5776