Mart Cart 3563 Operating instructions

Mart Cart
Model 3563
Technical Overview
This document is a technical overview of the Mart Cart model 3563. Its
purpose is to describe the major components of units that are currently being
produced. Some components may be updated from previous versions of this
model. Some optional components may not be discussed in this document.
For more detailed information, please contact our Service Department at
800-548-3373 or email techservice@assembledproducts.com.
Go to the Table of Contents
Table of Contents
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Major Parts Overview
Potentiometer/PWM Relationship
Calibrate PWM
Parts List
Wiring Diagram
Tools
Safety Check
Warranty
Serial Number Label
Click on one of the subjects above to jump directly to the document page.
Major Parts Overview
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Battery/Circuit Breaker
Charger
Wire Harness
PWM
Control Box
Hub Motor
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Battery/Circuit Breaker
The battery is a 12 volt, AGM (Absorbent Glass Mat), 35 Amp
Hour, Sealed Lead Acid (SLA) battery.
The “quick change” battery cover houses
the 15 amp circuit breaker, 5 amp fuse,
and main wire harness.
280-1214
280-1712
260-1228
280-1799
(Mini Fuse)
280-1627 (Fuse)
Prior to the quick change battery cover, a 15 amp circuit breaker was
attached directly to the negative post of the battery. The copper terminal of
the circuit breaker is attached to the battery terminal with a lock nut. The
black wire lead of the main wire harness is attached to the stainless steel
terminal of the circuit breaker.
280-1610
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Copper
Stainless
Charger
The charger is a 12 volt, 7amp charger with Intelli-Charge™ functionality.
Intelli-Charge monitors the charge capacity of the battery. The charger shuts down when then
battery is completely charged. This feature allows the battery to be plugged into a wall socket
for any length of time without concern about over-charging.
The charger has 3 output wires and is plugged directly into the main wire harness with a 3-pin
connector. The positive and negative wires go to the battery, and an “inhibit” wire goes to the
PWM.
The inhibit wire carries voltage to the PWM on pin 7 when the charger is plugged in and
charging the battery. Voltage on pin 7 “inhibits” the PWM from outputting voltage to the motor
thus not allowing the cart to be operated when the charger is plugged in.
Note: The charger uses power cord 280-1797. The previous
version of the charger uses power cord 280-1647 (“D” Plug).
280-1749
3-pin connector
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Wire Harness
Steering – includes 6-pin, 3-pin,
and 10-pin
Main – part of the quickconnectors, clamps
change battery cover
and 18 inch loom
assembly. Contains
(not shown).
15 amp circuit breaker
and 5 amp mini fuse.
PWM-to-Motor - includes 4-pin
connector.
280-1646
280-1202
280-1712
280-1626
(Wire Guide)
280-1454
Return to Major Parts Overview
The earlier version of the main wire
harness without the quick-change
battery cover contains a 15amp
circuit breaker and 5amp fuse.
PWM
The PWM (Pulse Width Modulator) monitors multiple electronic functions and is the central
processor for the cart’s electronics. The PWM (in conjunction with the potentiometer) controls the
speed and direction of the motor hub.
A 10-pin terminal is designed to monitor the cart’s functions through the control box, charger, and
motor.
Positive
Negative
Motor Terminal
10-pin terminals
1 – Black – Pin 1 on pot (ground)
2 – Yellow – Pin 2 on pot (wiper)
3 – Blue – Pin 3 on pot (terminal)
4 – Green – LED
5 – Orange – LED
6 – White – Common (power)
7 – Yellow – Inhibit from charger
8 – Violet – Horn
9 – Brown – Brake
10 – Not used
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Positive
Battery Terminal
10-pin Terminal
Motor Terminal
Negative
Battery Terminal
280-1569
Control Box
The control box houses the potentiometer and rocker switch (Power Off/On, Horn, LED light).
The potentiometer is connected to the control throttle and regulates the resistance on pins 1,
2, and 3 of the PWM. This, in turn, controls the speed and direction of the motor.
The rocker switch has an imbedded LED that indicates the battery charge process when the
charger is plugged in and indicates the battery charge level while the cart is in service.
When charging
When in service
280-1405
(Rocker Switch)
Amber - Charging
Green - Charged
Green - Good Charge
Amber - Moderate Charge
Red - Low (needs charging)
280-1228
Note: The control box has optional configurations.
Please call the Service Department for detailed
information.
280-1187
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Hub Motor
The hub motor is a direct current, brushed disc, 12 (or 24)
volt brake, geared motor.
The motor is powered through a positive (red) and a
negative (black) wire lead protruding from the axle.
280-1600
The brakes are powered by two black wire leads
protruding from the opposite axle.
The wire leads are pinned and inserted into a 4-pin
connector. The brake leads are inserted into slots 1 and 2.
The negative power lead is inserted into slot 3 and the
positive lead (red) is inserted into slot 4.
Return to Major Parts Overview
Potentiometer/PWM
Relationship
The potentiometer (pot) along with the PWM regulates the speed and direction of the motor. The
PWM monitors the change in resistance on pins 1, 2, and 3 of the 10-pin connector which are
connected to the pot (pins 1, 2, and 3 respectively) through the steering wire harness. The pot is
located in the control box and is physically connected to the throttle control on the cart’s
handlebars. The resistance is varied by the movement of the thumb-control throttle in a forward
and backward direction.
In turn, the PWM emits variable voltage to the positive and negative motor leads (connected to the
PWM), allowing the motor to move at varied speeds forward and backward.
The pot is rated at 5K ohms +/- 10%. This is the resistance between pin 1 and pin 3 on the pot’s
terminals. When the pot assembly is set at the factory, the wiper (pin 2) is calculated and preset to
24% of the total resistance (approx 1.08K to 1.32K ohms). The wiper position of the pot is where
the PWM looks for the “neutral” position. In the neutral position, the PWM cuts power to the motor
leads and brake leads (engaging the brake).
Pot
PWM
3
2
1
Continued on next page
Hub Motor
Potentiometer/PWM
Relationship
Over the life of the cart, several things may happen to disrupt the normal resistance between the
pot and the PWM…subsequently sending false readings to the PWM. They are:
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The resistance material in the pot becomes damaged (extremely rare).
The shaft sticks/freezes (human error during assembly).
The spring or fork of the pot assembly become damaged.
The connectors of the steering wire harness loose contact.
The wires of the steering wire harness break.
When any of these situations occur, the PWM (movement of the cart) may act erratically. Often, the
PWM is diagnosed as having a problem when, in fact, a problem exists with the pot, connectors, or
wire harness.
The PWM is “calibrated” (see next page “Calibrate PWM”) at the factory to the neutral range of the
pot. If the pot assembly or wires become damaged, the resistance (and neutral range) of the pot
can change. Re-calibrating the PWM may resolve the immediate problem but the fix may not be
permanent. The best practice is to validate the condition of the pot, connectors, and wire harness
before attempting to re-calibrate the PWM.
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Calibrate PWM
On occasion, the cart may function erratically. As the last step in troubleshooting a problem, the
PWM can be “calibrated” to the neutral position of the potentiometer. Be certain that the battery is
charged above 10.5 volts and the horn and the seat switch are connected and working properly
before attempting to calibrate the PWM. Without them working properly, the PWM will not calibrate.
1.
2.
3.
4.
5.
Stand next to the cart. Do not sit on the seat during the calibration steps.
Turn the rocker switch to the “ON” position (and the key switch if so equipped).
Be sure that the throttle is in neutral position (hands off).
Hold down the horn button for a minimum of 10 seconds. Do not let off of the horn.
While continuing to hold down the horn, push down and then release in the center of the seat
(activating seat switch) 3 times.
6. Wait a second or two and then release the horn.
If you hear 2 short chirps, the PWM calibrated successfully.
Retest the cart.
If you hear 3 short chirps, the PWM did not recognize a brake
circuit (see the next page “Check Brake Lead”).
If you hear a long chirp in any combination, the PWM did not
calibrate successfully. Calibrate again or replace the PWM.
Turn on sound and click video
Continue on next page
Calibrate PWM –
Check Brake Leads
When attempting to calibrate the PWM one might hear 3 short chirps. This indicates that the PWM
did not recognized a brake circuit. The PWM will still function but the brakes will not release causing
undesired performance from the motor. To resolve the brake issues, check the brake circuit from the
PWM to the motor by disconnecting the brake leads from the wire harness at the PWM and placing
an ohm meter on each lead. The meter should read approximately 20 ohms.
If you do not get a good reading, run the same test on brake leads from the motor to the 4-pin
connector.
If you do not get a good reading there, either the male
pins in the connector are bad or the brake circuit inside
the hub motor is bad…repair the pins or replace the
motor.
If you get a good reading, then the PWM-to-Motor wire
harness is bad or the pins in the 4-pin connector are not
making good contact…repair the pins or replace the
harness.
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Brake Leads
Parts List
Item
1
1a
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17A
18
18A
19
20
20A
21
22
23
24
25
26
27
28
29
30
31
32
33
Notes:
7
8
10
11
22
24
26
Part#
Description
280-1818
Main Frame (contains Bumper/hardware)
280-1840
Bumper Only (with hardware)
280-1268
Rear Wheels – Poly-U, 8”
000-1224
Bushing – 5/8” (1 on each wheel)
280-1335
Grommet – 5/8” (1 on each wheel)
000-1075
Retaining Ring “E” Type (1 on each wheel)
280-1214
Battery – 35AH
280-1797
Charger Cord – 6’ Coiled (See Notes)
260-1228
Circuit Breaker – 15amp (See Notes)
280-1743
Charger – 7AMP, 3-Prong Pigtail
280-1799
Fuse, Mini – 5AMP (See Notes)
280-1712
Battery Cover Assembly – (See Notes)
280-1280
Rear Cover (Select Color Options)
280-1637
Charger Cord Cover
280-1711
Spring Latch Assembly
280-1262
Seat Mount Tube – LH
280-1261
Seat Mount Tube – RH
280-1797
Seat, PVC-Free (includes Seat Switch)
200-1558
Seat, Padded (Optional – includes Seat Switch)
280-1553
Seat Switch (for PVC-Free Seat 280-1797)
280-1484
Seat Switch (for Padded Seat 200-1558)
280-1264
Basket Tube (2 each)
200-1802
Basket, Lil Max
280-1614
Basket Bumpers – 15” (2 each)
200-1236
Basket Mounting Clips (4 each)
280-1626
Wire Guide (See Notes)
280-1202
Wire Harness – Steering
280-1646
Wire Harness – Hub Motor to PWM (See Notes)
280-1569
PWM (Pulse Width Modulator)
280-1454
Wire Harness – Main (part of Battery Cover Assembly)
280-1346
Tire for Hub Motor
280-1279
Front Cover (Select Color Option)
280-1441
Bridge Cover
280-1600
Hub Motor
200-1052
Caster – 2” (2 each)
280-1273
Fork Assembly
280-1281
Floor Cover
Steering Column/Controls (See Detail on next page)
Use Charger Cord 280-1647 (“D” plug) if cart has 280-1630 charger (older version).
Use Circuit Breaker 280-1610 if cart does not have the Battery Cover 280-1712.
Use Fuse 280-1627 if cart does not have a Battery Cover 280-1712.
Battery Cover Assembly 280-1712 contains Main Wire Harness, Fuse, and Circuit Breaker.
Wire Guide Assembly (280-1656) contains Wire Guide (280-1626), Wire Harness (280-1646), and Hardware.
Wire Guide Assembly (280-1656) contains Wire Guide (280-1626), Wire Harness (280-1646), and Hardware.
Order this part only if cart does not have Battery Cover 280-1712.
Return to Table of Contents
Optional Parts
Part#
Description
290-1123
280-1373
200-8153
280-1562
280-1653
200-1393
280-1178
200-1728
280-1440
Jr Basket
Jumbo Basket (w/castors and lower shelf)
Folding Produce Tray
Chek-Riter
Safety Flag
Cord Reel – 6’
Hour Meter
Crutch Holder Assembly
Seat Latch Hook Assembly
Decals/Signs (English – call for other)
Part#
Description
200-1382
200-1387
200-1231
200-1299
200-1095
280-1307
000-1183
280-2103
280-1545
280-1532
Sign – Operating Instructions
Sign – Personal Injury
Sign – No Children
Decal – Personal Injury
Decal – Load Limits
Decal – Pull Latch
Decal – High Voltage
Decal – Do Not Stand
Decal – Charging Instructions
Decal – Daily Maintenance
Parts List –
Steering Column
Steering Column and Control Box Parts List
Item
Parts#
Description
1
2
3
4
5
6
7
8
9
10
11
12
280-1178
280-1177
280-1184
280-1187
200-1640
280-1405
280-1863
280-1185
280-1862
280-1602
280-1179
280-1199
Control Box Bottom Cover
Control Box Top Cover
Control Box Divider
Potentiometer Assembly
Key Switch (Optional)
Rocker Switch
Overlay – Control Box Top
Overlay – Control Box Front
Intelli-Charge Indicator Decal
Grip
Throttle Grip – Thumb Control
Steering Column (w/Rod and Grips)
280-1228
280-1229
280-1230
280-1231
280-1232
Control Box – Keyless (1-4, 6-8)
Control Box – Keyed (1-8)
Control Box Top – Keyless (2, 4, 6-8)
Control Box Top – Keyed (2, 4-8)
Control Box Top – w/Decals (2, 7, 8)
Control Box Kits
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Wiring Diagram
6-pin connector
3-pin connector
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1 – Black – Pin 1 on pot (Neg)
2 – Yellow – Pin 2 on pot (wiper)
3 – Blue – Pin 3 on pot (terminal)
4 – Green – LED
5 – Orange – LED
6 – White – Power (Pos)
7 – Yellow – Inhibit from charger
8 – Violet – Horn
9 – Brown – Brake
10 – Not used
Tools
The suggested tool kit should contain:
Screwdrivers:
#2 Phillips
T15 Star
#2 Flat Head
Wrenches:
3/4” Open End
1/2” Open End
1/2” Box End
10mm Open End
Torque
Punch or Nail:
Sockets:
5/16”
1/4”
7/16”
1/2” Deep Well
1/2”
10mm
Pliers:
Needle Nose
Regular
Wire Snips
1/8”
Electronics: Multi-meter - Ohms, AC and DC voltage
Load Tester - Should be able to load test battery
without having to charger the battery first
Jumper cable- Alligator clips on both ends
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Safety Check
This checklist is designed for service technicians to use as a guideline when servicing electrical Mart
Cart shopping carts. The list covers common system safety features that should be checked for proper
installation and functionality. While they may not be presented on this list, all parts and components of
the cart should be checked for proper functionality and either fixed or reported to authorized facility
personnel. All parts must be OEM to ensure proper safety and warranty compliance.
• General Condition – Check for broken frame, tubes, bumpers (frame and basket), basket, handlebars, covers, seats, and armrests.
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Any part or piece that may snag a person or store display should be repaired. All mounting screws (e.g. front cover screws) should be
checked and replaced as necessary.
Electrical components – Check all wiring to ensure no evidence of fraying, crimps or cuts. Ensure that the harness is laying inside
the rear pan and not in a bind or contact with metal parts or components that could rub through the insulation (for example – between the
seat tube and frame on an XTi model cart). Ensure proper circuit breakers are installed and functional.
Charger cord – In addition to the other electrical components, check for fraying of charger cord and cord plug for damage. Replace
with OEM cord. It is not recommended to replace plug.
Casters – Check for proper distance from the floor (about ½ inch). Check for bracket welds and position (perpendicular to the floor).
Seat Latch – Ensure that the latch engages properly and that it secures the seat from tilting forward.
Horn – Check for proper functionality and audible level. The horn should activate when pressed and when the cart is moving in reverse.
Grips – Check the grips on the handlebars to ensure that they firmly grasp. The grips should not be easily twisted or removed.
Charger – Check the “inhibit” functionality of the charger. Ensure that the cart does not move under power when plugged into a power
outlet and charging the battery.
Seat Switch – Ensure that the cart only moves under power ONLY when someone is sitting in the seat. Occasionally, the seat switch
may be bypassed (jumpered) during cart maintenance to facilitate problem diagnosis. Never leave the seat switch bypassed for
normal operation.
Wheels and Axle – Ensure that wheels are properly aligned, bearings are functional, and axle is not bent or bowed. Check for flat
spots and wear.
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Warranty
The warranty period is calculated from the
month and year of manufacture. The month
and year of manufacture is determined by the
punch-out positions on the serial number label.
In a standard, 2-year warranty period, a cart
would be out of warranty in 2 years on the
month following the month punched out.
Example: Cart built October, 2008 would be in
warranty through October, 2010.
Warranty periods can differ from customer to customer.
Please call our Service department for verification of
warranty periods.
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Serial Number Label
The serial number label is located underneath the rear cover. The manufacture date is represented by
the year and month “punch-out” as shown below (review the previous page for warranty period
information.
Lift the spring loaded seat latch (hidden
below the cover) and push forward on the
seat to reveal the label.
SN Label
Location
Latch
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Mart Cart
End
Technical Overview