IMPORTANT DOCUMENT - DELIVER TO MANAGER OWNER’S MANUAL and TECHNICAL DOCUMENTATION Model 280-3563 Mart Cart® is a quality product line of Assembled Products® Corporation E 115 E. Linden • Rogers, Arkansas 72756 USA (479) 636-5776 • (479) 636-3245 fax 1-800-548-3373 www.martcart.com — IMPORTANT INFORMATION — • Please read before operating. CONGRATULATIONS! You have just purchased the best electric shopping cart on the market today. This Mart Cart incorporates the very latest in technological advances. To assure you of the best and safest performance as well as longest life, please read the enclosed information. After reading this manual, should you have a service problem or need help, please call our Customer Service Department with the serial number of your cart, at our toll free number: 1-800-548-3373 or (479) 636-5776. DAMAGE: Check 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. Check the contents of the carton. The contents should agree with the information listed on the packing list. Report any discrepancy to the carrier and the factory immediately. TO ORDER PARTS: Call 1-800-548-3373 or (479) 636-5776. Be sure to give the serial number to the Service Department personnel. The Mart Cart serial number is located on the seat support tube under the seat as shown in parts list portion of this manual. TERMS: All parts will be shipped with approved credit card, check in advance or C.O.D. Commercial accounts are allowed 15 day terms from date on invoice with approved credit. FREIGHT: All freight will be paid by the customer. Special consideration will be given to items under warranty coverage. ATTENTION: It is the responsibility of the owner of this cart to maintain the cart in a safe and reliable operating condition at all times. NOTE: Specifications found in this manual subject to change without notice. — IMPORTANT SAFETY INSTRUCTIONS — WARNINGS • • • • • • Please read before operating. Never attempt to charge the battery in this cart without using an electrical outlet that is protected by a GFCI. Replace charging cord if plug is damaged or if the cord is worn or frayed.Never use the charging cord without proper grounding. Do not use if plug does not have three prongs. Never allow the cart to be used out-of-doors or on any surface that is not level. Always disconnect power before servicing. See “Daily Maintenance Checklist,” and follow instructions. Cart can roll. Enter and exit cart with care. OPERATING PROCEDURES • • • • • • • New carts will need charging! Charge batteries for 24 hours prior to first use. THIS CART IS FOR USE INDOORS ON A FLAT, LEVEL SURFACE ONLY. DO NOT STAND ON CAR0T. (See “Operating & Warning Instructions” on cart). After battery is charged, disconnect power supply cord BEFORE operating cart. DO NOT exceed the load limitations as shown on the cart. Return power cord to circular cavity when not charging DO NOT allow children to operate or play on cart. Keep cart secured with key (if applicable), at service counter. DAILY MAINTENANCE CHECK LIST For optimum cart availability and performance, the following items should be checked daily: 2 martcart.com • 1-800-548-3373 • • • • • • ELECTRIC CORD—Replace cord if cord is worn or frayed, 3-pronged plug is broken or reel (optional) will not retract. Be sure power outlet provides protection through an operating “Ground Fault Circuit Interrupter” (GFCI). SEAT AND MOUNTING—Tighten if necessary. If cracks or rust occur, or if seat rocks loosely, replace at once. SEAT SWITCH—Test and replace if not working properly. Cart must stop when weight is removed from seat. THROTTLE—Test for smooth “start, acceleration, deceleration, and stop.” Repair if necessary. Charge or replace battery if needed. ANTI-TIP CASTERS—Replace if broken. Maintain height adjustment of 1/8” to 1/2” above floor level. GENERAL—Repair or replace any component that may cause a potential safety APPEARANCE—Wipe off and clean as needed for customer satisfaction and for store’s public image. — BATTERY CHARGING INSTRUCTIONS — Please read before charging. Your cart is equipped with the Intelli-Charge™ system. While operating the cart, the LED will be solid green until the battery falls below 12.4 volts and then turns solid amber. When the battery charge falls below 10.5 volts, the LED will begin flashing red. The person riding the cart should have ample time to return the cart for charging. When the rider exits the cart, the horn will start beeping in unison with the red flashing LED. This will alert those responsible for maintaining the cart to plug in the charger. When plugged into a 120v AC wall socket, the LED will flash amber and the horn will silence. When charging is complete the LED will start flashing green. The charger may be left plugged in even longer as it will NOT harm the battery. LED Color Status LED Off Description while opertating Off/On rocker switch is set to “Off” position Green (solid)Off/On rocker switch is set to “On” position - seat switch is engaged - battery is fully charged Amber (solid)Off/On rocker switch is set to “On” position - seat switch is engaged - battery is below 12.4 volts Red - FlashingBattery needs to be charged - below 10.5 volts LED Color Status Amber - Flashing Description while charging Charger is plugged in and battery is being charged Green - Flashing Charger is plugged in and battery is charged •Install a Ground Fault Circuit Interrupter (GFCI) in the electrical circuit wherever the cart is to be charged. This is to protect against any possible shock hazard. •AC voltage required is 100-240 VAC (50/60 Hz). The current draw is 3.5 amps maximum. •Charge battery every night, all night, and at every opportunity. When the battery is fully charged, the charger will maintain a “float voltage” which will not damage the battery. •Do not allow the battery to fully discharge by skipping the nightly charging cycle. A fully discharged battery will take 7 hours to fully charge, so it is best not to let the battery become completely discharged. •Do not store the cart with a discharged battery. This can cause premature battery failure. Fully charge the battery at least every 30 days if in a low usage location. •No maintenance of battery is required. The AGM battery is maintenance free and water cannot be added. NOTE: Under normal conditions, the battery will last more than 2 years or longer if the above recommendations are followed. Replace with original Mart Cart battery only. Mart Cart is not responsible for any adverse effects caused by replacement with any other type of battery. IMPORTANT: Your cart has been equipped with an AGM (Suspended Electrolyte) Battery during the manufacturing process as original equipment. The manufacturer recommends that you replace the original battery only with the same type and rating to prevent damage to your cart’s internal components, charging system, or personal injury to you and your customer. — BATTERY REPLACEMENT INSTRUCTIONS — Please read before replacing battery. Be Responsible! Recycle old battery or dispose of according to local or national codes. See next column, under DISPOSAL. To Replace Battery: (Read precautions on batteries, under Charging Instructions and Safety Precautions, to avoid any sparks) 1. Turn off key switch (if equipped, or flip On/Off switch to “Off” position). Disconnect charger cord from wall outlet, if plugged in. 2.Reach under right rear of back cover and pull latch, then tilt chair forward. 3.Remove rear cover. 4.Untie battery cover strap and remove battery cover. — DISPOSAL — Please read before disposing your old battery. The Mart Cart model number 280-3563 is certified 100% by Recycle America, LLC., a subsidiary of Waste Management and those models are PVC free. Spent batteries must be treated as hazardous waste and disposed of in accordance with local, state and federal guidelines. The BATTERY ACT of 1996 applies to battery disposal and recycling. The life expectancy of the Mart Cart is 7-10 years. The life expectancy of the battery can be 2 years or longer with recommended charging procedures. The disposal of the Mart Cart can be administered by any local metal recycling center. The recycling of the battery can be administered by any local battery recycling center. — PARTS LISTS AND SCHEMATICS — CAUTION: Do not cross battery posts with metal object! 5. Remove old battery and place new battery. 6. Reinstall battery cover. It will only fit one way. 7.Secure battery cover strap. 8.Before reinstalling cover, check wheel condition, and general condition of the chair. 9.Reinstall rear cover and tilt chair back. 10.Test cart for proper operation. Charge battery if necessary. — ADDITIONAL INFORMATION — SEAT LOCK For XTi 12 with sliding seat. The seat lock and the chair should be inspected daily for proper function. The release/locking arm should move freely and spring back into locking position. If return spring is broken, DO NOT USE cart until spring is replaced. SEAT SWITCH The seat switch is located under seat. Pressure (weight) on the seat closes the control circuit, and allows the cart to operate. 12 VARIABLE SPEED CONTROL The cart’s speed is regulated by a potentiometer. This provides extremely smooth acceleration from 0 to 2.2 MPH, and is located in the control box on the steering column. CIRCUIT BREAKER The circuit breaker is designed to protect your electrical system from transient overloads or electrical shorts. Either could cause serious damage without a circuit breaker to open the circuit. The circuit breaker is a manual reset type. It requires manual resetting once it has been tripped. It is located on the battery cover. CHARGING HOW IT WORKS: When the power supply cord is plugged into the store’s electrical outlet the battery charger is energized. The charger sends approximately 14.5 volts to the battery for charging. A third wire (yellow) from the charger output inhibits the PWM until the power to the charger is disconnected. The motor circuit is interrupted until charging is complete. NOTE: The cart will not move under power when the battery is being charged. If the cart moves while plugged in, check the power to your outlet before calling for service. CONTROL BOX The master control box is located on top of the steering column. It contains the RUN/STOP/HORN switch, and key switch (optional keyless system available). The cover can be removed by removing the four bottom screws. Our models are equipped with the Intelli-Charge™ system, a bicolor LED can be found in the RUN/STOP/HORN switch. COMPONENTS: Item Part # 1 280-1178 2 280-1177 3 280-1184 4 280-1187 5 200-1640 6 280-1405 7 280-1863 8 280-1185 9 280-1199 10280-1602 11 280-1862 Description *Control Box Bottom Cover *Control Box Top Cover *Control Box Divider Potentiometer Assembly Key Switch Rocker Switch Assembly *Top Control Box Overlay *Front Control Box Overlay Steering Column w/Rod & Grips Grip *Intelli-Charge Indicator decal *NOTE: Parts are ordered in Contol Box Kits below. CONTROL BOX KITS: Part # 280-1228 280-1229 280-1230 280-1231 280-1232 Description 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) Box Top with Decals (2, 7, 8) 1-800-548-3373 • martcart.com 3 — DECALS FOUND ON MART CART® ELECTRIC SHOPPING CART — Please call 1-800-548-3373 if your decals are missing or are needing replacement. Standard decals and signs are English and Spanish (see part numbers below). Call for other languages. 280-1095 200-1127 280-3007 280-1663 200-1155 (front & back) 280-1307 280-1831 200-1387 000-1183 280-1730 (front & back) 280-1298 280-1570 280-1783 280-1185 280-1545 280-1863 280-1862 4 martcart.com • 1-800-548-3373 280-2103 280-1509 280-1624 9 Serial # Location 11 35 37 6 34 33 22 24 17 15 12 31 19 26 20 25 32 7 30 8 18 16 29 36 2 4 1 10 27 3 14 21 13 28 23 Item Part No. Description Item Part No. Description 1 280-1818 Main Frame (280-1820 with bumper) 19 280-1712 Main Wire Harness/Battery Cover Assy. 2 000-1224 5/8” Bushing (2 on each wheel) 20 280-1202 Steering Wire Harness w/Connectors 3 280-1268 8” Wheel, Poly-U 21 280-1281 Floor Cover 4 000-1075 5/8” “E” Type Retaining Ring 22 280-1280 Rear Cover (select color option) 6 280-1261 Seat Mount Tube 23 280-1279 Front Cover (select color option) 7 280-1799 Fuse, 5 AMP Mini 24 280-1711 Spring Latch for Seat 8 280-1228 Circuit Breaker, 15 AMP 25 280-1569 PWM Controller 9 280-1798 Mart Cart Seat 26 280-1646 Wire Harness (see note) PWM to Motor 10 280-1264 Basket Tube (see options pg. 6) 27 280-1269 Fork Assembly 11 200-1802 Basket, LIL Max (see options pg. 6) 28 280-1441 Bridge Cover 12 200-1236 Basket Mounting Clip (4) 29 280-1346 Tire/Outer Shell 13 200-1052 2” Caster 30 280-1797 Charging Cord, coiled 14 280-2012 Hub Motor/Wheel/Tire, GREEN 31 280-1626 Wire Guide (see note) 15 see pg. 3 Steering Column 32 280-1840 Rear Bumper 16 280-1214 Battery, 35 Ahr 33 see pg. 3 Control Box 17 200-1553 Seat Switch 34 280-1614 Basket bumpers (gray) 18 280-1936 12 VDC Charger - 10 AMP 35 280-1637 Cord Cover (see note) 36 280-1335 Grommet - 5/8” 37 280-1659 Cord Cover Lid (see note) NOTE: #31 (wire guide) and #26 (wire harness) can be ordered as an assembly part 280-1656 #35 (cord cover) & #37 (cord cover lid) can be ordered as an assembly part 280-0004 1-800-548-3373 • martcart.com 5 Optional Parts Item 1 2 3 4 5 6 7 8 9 10 6 Part # Description 290-1385 Small Basket 280-1374 Jumbo Basket (w/castors & lower shelf) 200-8153 Folding Produce Tray 280-1586Check-Writer 280-1653 Safety Flag 200-1393 Cord Reel - 6’ 280-1956 Hour Meter 280-1609 Crutch Holder Assembly (for basket) 280-1440 Seat Latch Hook Assembly 280-1833 Crutch Holder Assembly (for seat) martcart.com • 1-800-548-3373 1 6 2 7 3 8 4 9 5 10 2 1 4 RED 280-1569 Electrical Schematic DETAIL -A- BROWN RED YELLOW When this cart is equipped with controller 280-1569, use this schematic. WHITE RED Brown For USB Charger 1. BLACK 2. YELLOW 3. BLUE 4. GREEN 5. ORANGE 6. WHITE 7. YELLOW 8. VIOLET 9. BROWN 10. NOT USED RED 12V BATTERY BROWN RED BLUE YELLOW OPTIONAL HOUR METER HOUR METER 00.0 RED BLACK BLACK YELLOW - + RED 12V CHARGER RED 02 B- ON PWM BROWN BLACK 15A CIRCUIT BREAKER 5A FUSE RED RED MART CART WAG-FLAG W/BI COLOR LED PICTORIAL WIRING DIAGRAM REL#: BLUE WHITE CONNECTOR BRAKE LEADS 05 2044 04 1094 03 207 02 01 Motor & brake leads color change Hr Meter connection Option 280-1945 Dock and Shop With USB Charger SSC 9/7/12 MOTOR LEADS Added Option, USB Charger SSC Removed color from charger's leads. Added Mart Cart. Added connector. 158 142 1 REVISED WIRING TO CIRCUIT BREAKERS, ADDED Brown HOUR METER OPTION 2 3 4 SSC 7/02/08 BY CHG ECN# DESCRIPITION OF CHG 3/20/06 TDM DATE: 12/12/05 TM ASSEMBLED PRODUCTS CORPORATION ROGERS, AR 72756 SCALE: NONE TITLE: DRWN BY: USED ON: Mart Cart DATE: 10/30/06 TDM White TDM REVISED WIRING TO CIRCUIT BREAKERS USB Connector 5/16/12 BY: ECN 137 TDM CHKD BY: Mart Cart WAG-FLAG W/BI COLOR LED PART NO.: MATRL: 280-2114 DATE DC to DC Converter 12V to 5V DRIVE WHEEL BROWN RED RED GREEN BLACK VIOLET WHITE RED ORANGE BRN BLACK YEL BLUE BLACK POTENTIOMETER 4 2 1 RED 280-1569 YELLOW Brown For USB Charger RED WHITE RED 12V BATTERY DETAIL -A1. BLACK 2. YELLOW 3. BLUE 4. GREEN 5. ORANGE 6. WHITE 7. YELLOW 8. VIOLET 9. BROWN 10. NOT USED HOUR METER 00.0 RED BLACK BLACK YELLOW - + BROWN RED RED 12V CHARGER RED 02 BROWN BLACK 15A CIRCUIT BREAKER 5A FUSE BROWN RED BLUE YELLOW OPTIONAL HOUR METER B- ON PWM RED RED 1-800-548-3373 • martcart.com 7 115 E. Linden • Rogers, Arkansas 72756 USA (479) 636-5776 • Fax: (479) 636-3245 International (001) 479-636-5776 www.martcart.com 800-548-3373 MC1-MODEL 3563-OM-140423-ENSpecifications are subject to change without notice . Printed in the USA.