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QuicKART 2000 Series

1. less than 2 feet Tires front 12 inches QK 2000 16 inches QK 2500 Tires rear 8 inches diameter ChasSSIS Welded steel with powder coating Body Fiberglass or ABS polymer Safety 40 amp secondary breaker on QK2000 70 amp fuse QK 2500 Automobile type horn Beacon warning light Brake light Emergency stop switch Automatic brake Unique remote security code Brakes Electronic dynamic Mechanical Electrical system Three 12 volt batteries Charger Input 120 VAC 36 VDC 15 amperes max OE Forward 0 3 0 MPH max Heverse 0 1 5 MPH max Hemote slow 0 70 MPH QK2500 Remote slow 1 0 MPH Remote fast 2 80 MPH REMOTE CONTROL Power Requirement 4 Standard 1 5 volt AA radio batteries Range 100 feet Dane Technologies Inc QuicKART 2000 Series Service Manual 43 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART WARRANTY 1 Parts One 1 Year Limited Warranty from
2. 05 810 037 QuicKART EU CHARGER AND OORLD 106 110 066 CART RESTRAINT ASSEMBL Y 107 Dane Technologies Inc QuicKART 2000 Series Service Manual 18 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 150 003 QuicKART 2000 BASIC ASSEMBLY USA L0 80 0 soma Z 1 aans _ 00 091 FEN A TgW3SSvV SIS Va 0006 LY VMOINO FFSS NIA neu AJ uuo uet 9986 gt 15 NFA recrrr sles xed B 2 FFS E z 3NOHd SED SVM SED coe sotur TEE giis TEIDBD DDC g3uuv wc U HHEH 1 LL FEO OLF 1 800 09 1311d4 WVOd ie 910 09 ENS a T33HM TIMMS 88 L 00F 1109 343 010 017 010 066 LayOVHS i 1504 NOOV38 900 00F s z 1109 901 002 82 L 00F Fu Fi 108 000 K AT8W3ssv Hva 3TIINVH x00 A SSV OINOHLO3T3 A ip TANVd TOd1NO9 F a E A Tel E i k divis 280 012 N Yd AT138 _ S0001 F Om d ATHN3SS V LLO 00P s 1109 cz 00P nog m H3HSVM vs i 10 00 E 1109
3. DANE TECHNOLO Gi S ase QuicKART 2000 Series Service Manual QuicKART Electric Utility Machine Manufactured by Dane Technologies Inc Phone 163 544 7779 7105 Northland Terrace Toll Free 1 888 544 7779 Minneapolis MN 55428 Fax 163 544 4234 www danetechnologies com Part No 970 011 Rev Date 3 1 06 Table Contents Topic Section e QuicKART 2000 series Operating Instructions 1 And Diagrams e QuicKART 2000 series Troubleshooting 2 e QuicKART 2000 series Service Bulletins 3 e QuicKART 2000 series Exploded View Diagrams 4 e QuicKART 2000 series Parts Order Information 5 Note on radio equipment used This device complies with part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation Note This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installat
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5. 70 QK 2000 and QK 2500 Drive Wheel Aluminum Hub 72 QK 2000 Drive Motor Brake Assembly Test 73 Gi e E O 74 QK 2000 Battery Pack and Battery Charger 76 Dane Technologies Inc QuicKART 2000 Series Service Manual 59 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QK 2000 System Configuration Service Bulletin 985 001 November 1999 The QK 2000 machine is a powerful battery powered machine that uses remote control to push shopping carts from the parking lot back to the store 1 The QuicKART is driven by an electric motor through three 3 12 volt batteries connected in series 36 volts 2 There is a single 8 inch castered wheel in back of the machine which swivels when the machine turns This wheel is of solid rubber construction and rides on journal roller bearings which should be greased at least once a year 3 The drive axle is one integrated assembly containing three 3 major components the DIFFERENTIAL AND AXLE HOUSING output shafts the MOTOR and the BRAKE ASSEMBLY In general any one of these three components can be replaced separately 4 The axle output shafts are one inch in diameter and are
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7. DID THE QuicKART MOVE IN REVERSE CALL YOUR SERVICE YES PROVIDER CHECK CN5 1 NO GOTO QuicKART DOES NOT OPERATE IN RADIO PG 5 DANE TECHNOLOGIES Inc PHONE 763 544 7779 105 Northland Terrace US FAX 763 544 4234 Minneapolis THLE QUICKART 2000 SERIES TROUBLESHOOTING CHART 70 020 gt To OWGDAt 3 1 06 DWG PART NO Service Manual 9 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART MOVES INTERMITTANTLY OR HAS LOW POWER WITH KEY ON PREESRWARD ON CONTROL PANEL DID THE FORWARD IGHT ON THE PANEL GOTO DOES NOT OPERATE IN REVERSE PG 7 TWIST THE THROTTLE TO MOVE IN FORWARD DID QuicKART MOVE YES NO DOES THE JUNCTION BOX DRIVE COMMAND CONTROL PANEL OR JUNCTION BOX PROBLEM NO CALL YOUR SERVICE PROVIDER BAD MOTOR OR CONTROLLER CALL YOUR SERVICE PROVIDER BAD MOTOR BRUSHES OR CONTROLLER CALL YOUR SERVICE YES AN MORE THAN 20 PROVIDER HORN TO TEST CARTS BE PUSHED ON CHECK BATTERIES OPERATION SEE PLEVEL SURFACE D NO MOTOR AND BRAKE DANE TECHNOLOGIES QuicKART HORN ISN T WORKING TURN KEY OFF AND THEN CHECK TO SEE IF HORN IS PLUGGED INTO JUNCTION BOX PLUG HORN INTO UNCTION BOX Y
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10. 91 007 p L108 X BL SL S 24 Service Manual QuicKART 2000 Series Dane Technologies Inc 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 970 011 Rev 3 1 06 www danetechnoloqies com 3 HITCH REQUIRES ONE 1 4 HOLE THROUGH ONE WALL IN THE BACK SIDE OF EACH CART VERTICAL TUBE THIS HITCH 15 DESIGNED TO USE DROP IN YOKES 850032 HITCH FLEET FARM Dane Technologies Inc QuicKART 2000 Series Service Manual 25 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 031410348 38WMN3HLO SSTNN cre TOT 5581 60007 XXX 0 06007 X0 532NvH3101 3AO8V 021310395 SV vw 4g nua P0 SnV ZL Z 39 aas 9L L sws 70 0S8 9310 Q3siv Ni dOwd TUL vezt rvs E92 E9999 MM NOH eno ONG YIS ONION eim zy z Z WIG SYHIMSPO GOSZ9 dWO2 ONhHdS 8 0 09v 6 t _ NZ AWS 018 AVS BE USHSWM 00027 8 E SOHHS9 LX9L 8 t L1O8 6 10 00 L 1 SX V9 L NidH31100 190096 ou E 351 9 9077 S 1 HY 3XOAG3SIVH H31dnOO 895 022 y EXE GONNFdONG SHOA 912012 Z J SNDOO013831dnOO v60 00Z E 131dnOO 31 1 680 007 ALO NOlLdljos3a ON1NV
11. LOCKING PIN HAIR PIN Dane Technologies Inc QuicKART 2000 Series Service Manual 21 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 ATTACHING COLLECTION CART wm QUICKART E FRONT PLATE GROCERY CART 7 WHEEL LIFTED 1 OFF THE GROUND OPTIONAL METHOD OF CART ATTACHMENT es qmm QUICKART 1 FRONT PLATE GROCERY CART am WHEEL LIFTED 1 OFF THE GROUND Dane Technologies Inc QuicKART 2000 Series Service Manual 22 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 200 089 v 3 8 16 BOLT 400 013 RIGHT YOKE 220 095 v 3 8 16 400 013 200 089 LEFT YOKE 220 094 COUPLERS ARE MOUNTED SO THEY CATCH THE HORIZONTAL BAR ON THE GROCERY CART Dane Technologies Inc QuicKART 2000 Series Service Manual 23 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART HITCHES AND YOKES 0 22TOMNV OOF gag OOF OOF X 8015 SIHL 440 1n2 L108 40 Gy3H SALON r00 00F 2 1108 521 X OZ F L ESL 0 jani GO wh TYLA L108 8LO OLP sp LON SL SL G BOO OLY Z 0Z L HOLIH SL 1d L007
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15. CHARGING IS VOLTS POWER PROBLEM TEST DID THE RED AC THE OUTLET AND OR A CHARGE LIGHT TURN DIFFERENT EXTENSION SRD BEFORE PROCEDING BATTERY LEVEL LIGHTS WITH KEY NOTICE SHOULD SHOW 100 96 CHARGE THE CONTROL PANEL IN CONSTANT VOLTAGE AND BATTERY LEVEL FLOAT STAGE LIGHT START FLASHING FOR A CHECK BATTERIES YES DO THE LIGHTS SHOW THIS INDICATES BATTERY PREQUALIFICATION IS OCCURING IF BATTERY IS LESS THAN 31 VOLTS THIS STAGE MAY LAST FOR A FEW HOURS OPERATE QuicKART FOR 5 10 MINUTES TO CHECK RUNNING TIME A PARTLY CHARGED THIS STEP IS SKIPPED IF BATTERY DID THE YELLOW LIGHT TURN ON ARE LIGHTS STILL GREATER THAN CHECK BATTERIES BATTERY VOLTAGE THIS INDICATES THE SHOULD BE MAXIMUM CHARGE IS INCREASING TO 43 5 OCCURING VOLTS 2 3 HOURS NORMAL TIME OPERATE QuicKART FOR A MUCH LONGER TIME BATTERY IS NOT FULLY CHARGED CALL YOUR SERVICE PROVIDER SHARGER MAY HAVE A Q NO IS QuicKART OPERATING TIME ACCEPTABLE BATTERY VOLTAGE SHOULD BE 40 40 5 VOLTS 2 3 HOURS THIS INDICATES THE CONSTANT VOLTAGE CHARGE IS OCCURING NORMAL TIME DANE TECHNOLOGIES Inc n PHONE 763 544 7779 7105 Northland Terrace Costos 4 Minneapolis MN 55428 ua unl TILE QUICKART 2000 SERIES TROUBLESHOOTING CHART asas 970 020 10 or 12 DWG DATE 3 1 06 Dane Tech
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18. LLI BOLT HOLE AT BOTTOM aA 400 142 7 16 14 x 4 LG BOLT 410 014 7 16 14 5 8 SOCKET REQ D LOCK NUT 11 16 SOCKET REQ D DANE INDUSTRIES Inc DARE PHONE 763 544 7779 5400 Nathan Lane N 150 Plymouth MN 55442 FAX 763 544 4234 TITLE CART RESTRAINT ASSEMBLY WEFAT NO 110 066 peus qu 1 8 SHEET SET em or 2 2502 Dane Technologies Inc QuicKART 2000 Series Service Manual 108 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 DANE TECHNOLOGIES 1 Rl Dear Service Provider Thank you for your interest in joining our team of world class Service Providers By doing so you have demonstrated a commitment to provide excellent service to our joint customers on time every time professionally Attached please find some materials that will help you as you join our team The package includes a training video and a folder that includes an owner s manual a set of Service Bulletins exploded parts drawings and at the back find the following additional materials Y Ordering and invoicing procedures v Recommended parts inventory v QuicKART Warranty Please share the enclosed information with the appropriate people in your organization Thank you again for your interest look forward to a long and mutually rewarding relationship Please feel
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22. CURTIS JUNCTION BOX TEST VOLTAGES CHECK FOR DAMAGED CURTIS CONTROLLER WITH THE KEY ON THE CURTIS MOTOR CONTROL BOX STATUS LIGHT SHOULD BE ON AND NOT FLASHING A FLASHING STATUS LIGHT INDICATES A MOTOR CONTROL BOX PROBLEM REFERTO QK2000 SERIES SERVICE MANUAL SECTION 3 SERVICE BULLETIN 985 006 CURTIS MOTOR CONTROL DIAGNOSTIC LIGHTS THE CONTROL PANEL BATTERY CHARGE LEVEL LIGHTS WILL FLASH THE SAME ERROR CODES AS THE MOTOR CONTROL BOX STATUS LIGHT TO CHECK THE CONTACTOR BY ITSELF MEASURE THE RESISTANCE BETWEEN THE SMALL TERMINALS THE RESISTANCES SHOULD BE 120 125 OHMS ON THE 2000 MODEL AND 193 OHMS ON THE 2500 MODEL DANE TECHNOLOGIES Inc 7105 Northland Terrace m PHONE 763 544 7779 FAX 763 544 4234 TITLE QUICKART 2000 SERIES TROUBLESHOOTING CHART 370 020 ELE DWG DATE 3 1 06 SERVICE PROVIDER APPENDIX DWG PART NO Service Manual 28 Dane Technologies Inc 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 DANE TECHNOLOGIES lt m DANE TECHNOLOGIES Service Bulletins QK 2000 Table of Contents 7000 OME CANNON uuu uu SEES SEES EEE 60 QK 2000 Curtis Junction Box Test Voltages 68 QK 2000 Curtis Motor Control Diagnostic Liehts
23. m i EST 2 H3HSYM OLO OLF Z LNN ABS LIVE 031799078 81 8 8S0 01F LOO O0f t 1108 See 002 SAOMIONI 9 0 018 H39OudVvHo AHdillVv 81 v SINN SNI M AH31LV8 91 8 Z80 0LT x LOC OEF 5 NMOQ JIL 800 008 E AH311V8 FLO OEP 9 1008 01 002 2 31999 890 004 advo pa 80 Service Manual QuicKART 2000 Series Inc les Dane Technolog 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 970 011 Rev 3 1 06 www danetechnologies com 81 QuicKART 2000 Series Service Manual Inc 970 011 Rev 3 1 06 10 22 00 sm ong 77 1 55 5 i ZHWEEt JdOH3 AT18W3SSY 2ISVS 120 012 1 0002 LHVMOICnO 1139 n ic nog 6911 xXV3 95 Nino d m 6 11 INCHA NM i SSHISANI 560 001 AISWASS V m O E gt 8 Semace eorom 8 LAN OM oz z sory 2 67 be 00 zisvwwirbu ci zool asy 0 23137301 1 8000 i gt 8 1108 Is lENEG00z 0399 wete rope 9 Z T33HM 3AIHQ x bz gt SNOISI G3TIId NVO4 Jai cy jp i l i4 A m 10 007 Bt ieu M noowe UP 2 060 002 LLI
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25. 7 QUICK ART 2000 LABEL LOCATIONS 9 QuicK ART 2500 LABEL LOCATIONS 9 QuicKART 2000 CART STRAP ACCESSORY a 10 UNPACKING THE QuIcKART 13 QuicKART 2000 IMPORTANT MAINTENANCE NOTES 14 OVERVIEW 15 eno e quu VIE 16 Z000 RLAR VIE W e 16 Qi SIDE VIEW c 17 SYSTEM WIRING DIAGRAM 15 MIUNCGTION BOR 0S HM 19 SYSTEM JUNCTION BOX DIAGNOSTIC LIGHTS 20 CART COUPLER amp ROLLER GUIDE ASSEMBL Y 21 ATTACHING THE COLLECTION CART 22 QuicKART HITCHES AND YOKES 24 ORIENTATION TO THE K ART 2000 uuu euet 31 REMOTE CONTROL 33 CONTROC 33 OPERATION OF THE QuicKART 2000 sss 34 ueniet RUSO HA
26. CLAMP MOUNTING SCREW 100 055 USA 400 075 RECEIVER MOUNTING SCREW 4 amp STRAIN RELIEF 400 075 CLAMP 430 062 1 BRACKET oro Q 2 0650 025 8 BARCODE LABEL HEX NUT amp LOCK WASHER WITH 720 061 pred au PROGRAMMING SWITCH PART OF 700 105 ANTENNA CONNECTOR COVER MOUNTING SCREW 2 0 720 061 8 32 x 1 2 4 4400 16855 BEACON POST 200 119 REF RUBBER SWITCH COVERD665 007 g CONDLUCTOR CABLE S ANTENNA ASSEMBLY 700 129 418 MHz 430 048 __ MOTHER BOARD WIRE TIE E h DETAIL on m w Em f a E orm Wi ORANGE Jaros ECO 270 DELETED NOT T WHITE BLUE LN i VIOLET BLACK NYLON EY WIRE TIES 3 s fal 104 ng ECO 288 ADDED NOTE APPLY eee pp pu NEN C DANE INDUSTRIES gt TE PHONE FES 544 7773 Inc 5555 13th Ave Morth LJ FAX 7632 644 4234 BEACON POST ASSEMBLY QUICKART 2000 amp 5000 TT 100 095 USA E 0772000 X BLACK BRAKE LAMP APPLY TAPE TO NOT CONNECTED TERMINAL AH AR STROBE LAMP WIRING FOR QUICKART 2000 Dane Technologies Inc QuicKART 2000 Series Service Manual 26 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 01
27. FLASHES MOTOR CONTROL ERROR CODE PRESS TO SWITCH BETWEEN FORWARD AND REVERSE Dane Technologies Inc PRESS TO SOUND HORN FAST SPEED PRESS TO KEEP IN MOTION STOP BUTTON PRESS EITHER BUTTON STOP IN EMERGENCY PRESS AND HOLD UNTIL KEY IS TURNED OFF BATTERY CHARGE LEVEL BATTERY 20 40 60 80 100 CHARGE LEVEL NESSES FORWARD notifies PRESS SWITCH avesse BETWEEN MANUAL AND HORN RADIO CONTROL PRESS TO OPERATE HORN QuicKART 2000 Series Service Manual 33 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 OPERATION OF QuicKART 2000 MANUAL MODE To operate the QuicKART 2000 in the Manual Mode perform the following steps 1 Insert the key into the key switch located on the control panel Turn the key clockwise to turn the QuicKART on 2 Lights on the control panel will show the system status see illustration on page 33 Confirm that all systems are working properly 3 In manual operation while standing behind the machine both hands on the handles slowly twist the throttle control and the QuicKART will start to move forward Slowly release the pressure on the throttle control and the QuicKART will slow to a stop When the throttle control is fully released the electronic brakes will be applied When moving forward or backward
28. LIN FLO 0 t 960 001 z h 8 1008 ZHWNEEP QV3H 4 L01 004 1SOd NOOv38 le 31910 690 001 LA a AT8 3SS V P v pests a 1 HOLON B 3893 G L4 4 ne E W orror RR 00 00 T i IE 108 o 981 007 Aer MHS 922 004 S3UfT19NI T 2 10a 060 018 e f 090 00 WHO AH311VB g lava zeoze OIOOI 2 H3HSVM 2 LINN 87 Service Manual QuicKART 2000 Series Inc les Dane Technolog 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 970 011 Rev 3 1 06 www danetechnologies com 150 017 QuicKART 2500 433 MHZ CE EU CO F siasa 139 LU OS wwe ma JO ZHN 005c LO VMOIF1O rezr rrg ESI Conan PUT 117v v8 USLE N SUE 0075 a BLLIFFS 292 ANOHd mur UE HEN OOF ERE E eoe ci e SM3H2S 661 00r TILON SV Ld32X3 210 051 Sv AWS 210 051 AT8W3SSV ONISNOH 20 087 40 QV31SNI 2 M3H2S 3lV ld uagWwnw 11935 201 005 JO 008 560 001 JO OVALSNI Jer NOO v38 ZHN ter 960 001 E d 7 200 018 30 1HVd g7 B 19 2 004 ALON 7 S8t0 0L8 JO OVALSNI ZH OS 2 0 018 88 Serv
29. a sudden release of the throttle control will cause the automatic brake to bring the QuicKART to a sudden halt 4 To change the direction of travel the QuicKART must be stopped Press the direction switch on the control panel and the light for the selected direction will be displayed 5 To turn the power off press the emergency shut off button or turn the key counter clockwise Note Do not leave the machine ON and do not leave the key in the switch when unattended 6 The collection of grocery carts begins by walking the QuicKART into the parking lot to a location where customers have left carts To attach the first cart open the locking U pin on the left side of the cart coupler assembly Position the rear of the first shopping cart so that its vertical rear frame is aligned with the yoke openings on the coupler assembly Lift the cart slightly off the ground and move It sideways until it engages both coupler yokes Then put the locking U pin back Into place to secure the shopping cart It is recommended that the first cart be left permanently in place or if removed at night identified so the same cart is always attached to the cart The coupler yokes can be adjusted up and down and from side to side to accommodate various types and sizes of grocery carts See illustration on page 22 and 23 7 Additional shopping carts can now be collected to form a train of a maximum of 30 carts Dane Technologies Inc QuicKART 2000 Series Serv
30. and measure DC voltage across pins 1 amp 2 with all plugs connected The two white wires are connected to a small micro switch mounted on the motor s brake assembly It detects the position of the manual brake release lever This lever is a mechanical brake release which allows the machine to be pushed manually The machine will not function electrically if the lever is pulled out Normal operation requires this lever to be pushed in The white wires will show continuity if the switch is closed normal operation and open if the lever is pulled out Dane Technologies Inc QuicKART 2000 Series Service Manual 3 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QK 2000 Throttle Grip Service Bulletin 985 009 July 1999 The right grip on the steering handle serves also as the throttle for the QK 2000 allowing the speed of the machine to be controlled during manual operation The throttle has no function while the machine is in the remote mode The throttle grip controls the speed of the machine by providing a variable voltage to the Curtis motor control box fed through the Junction box at CN 4 connector See Service Bulletin 985 002 The three wires to the throttle grip have the following function Black ground Blue 5 volts Brown 0 5 volts depending on throttle position The throttle grip fits over the handle bar The bar s
31. the frame Save the hardware and use it when replacing the wheel For the QuicKART 2500 use two 9 16 wrenches to remove the four bolts holding the caster assembly to the two caster spacers bolted to the bottom of the frame 3 When replacing the caster assembly reuse the saved hardware Insert bolts apply nuts and tighten 4 Using the jack lift the QuicKART off the supporting blocks Item 1 above remove the blocks then lower the QuicKART to the ground Note Variations in the hardware configuration may occur Save all hardware and use it as it was removed when replacing wheel Dane Technologies Inc QuicKART 2000 Series Service Manual 42 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 TECHNICAL SPECIFICATIONS Weight with batteries 510 pounds 525 pounds QK 2500 20 inches 4 feet 2 inches WO 27 5 inches 2 feet 3 5 inches Height to 8 68 40 5 inches 3 feet 4 5 inches Height to top of beacon 54 inches 4 feet 6 inches Front wheel tread 22 inches Wheel base 19 5 inches forward 14 inches reverse Turning radius
32. 036 QuicK ART 2000 BASIC CHASSIS 89 TOODO 91 100 069 QuicKART 2000 MOTOR CONTROLLER CONTACTOR ASSY 92 100 246 QuicKART 2500 MOTOR CONTROLLER CONTACTOR ASSY 93 100 075 QuicKART 2000 HANDLEBAR ASSEMBL Y 94 100 095 BEACON POST ASSEMBLY QuicK ART 2000 96 100 096 BEACON POST ASSEMBLY QuicKART 2000 97 100 248 QuicKART 2000 BREAKAWAY BEACON 98 100 166 QuicKART 2500 TRANSAXLE ASSEMBLY 99 100 245 QuicKART 2000 TRANSAXLE amp 4 POLE MOTOR 100 100 034 QuicKART 2000 BRAKE ROD ASSEMBL Y 101 100 047 QuicKART 2500 BRAKE ROD ASSEMBL Y 102 680 013 QuicKART WIRING DIAGRAM 103 680 027 QuicKART 2500 OVERALL WIRING DIAGRAM 104 810 036 US CHARGER AND CORLD
33. 1 at 610 01 3A v3 3 fu t LAN 3 4 281 00 t 1108 3 3 620 0 9 Q 000 017 P gt 3ONIH 010 0028 77 22 M I G lt 1340vug T iE 22 1SOd NOOv38 2 j 900 00F i Yk k P L OOF e 2 1108 f 1108 ell __ 901 002 N V aws 343H SE0 0Lc tr p 1N3AQ13M lt 981 00 f WYLS JWYH4 1108 x 760 001 O 3sv313H 3 8 5 510 001 Ca io hy Jj ATaWassy S p 111 002 did uaovas _ w V pras ES 100 006 LO ASSY 313 Yu TANYd TOHINOS les 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com Dane Technolog IEE simmons 230 2 3HOH3 ATIBASSSV 2 5 8 0002 LHVMOInO 691 64 1 PRS east NOH M SNOISI AJY 4 d 31 ld 11 260 007 z 1108 a 611 002 1504 96000 ZHINEEP Qv3H 4 1504 38 URTIS 900 00 p 037 8010 31LIHM mea we C woo 2 HG3HSVM 2 INN iy NIA iON S568 SSMLSOONI ANY TATUN AI8W3SSV NHOH 00 00 1108 07 2 A3H9S Y je d SS 3 h s Aii
34. 3 Unscrew the four 9 16 inch or 5 8 inch front wheel lug nuts and place them in a location where they will not become lost Remove the wheel The new or repaired wheel is placed back on the front hub with the tire stem facing out Replace the 4 lug nuts with the beveled side toward the inside and tighten Using the jack lift the QuicKART off the supporting block see item 2 above Remove the block and use the jack to lower the QuicKART to the ground Tighten the 4 lug nuts again ensuring that they are tightened to a minimum of 50 foot pounds torque Dane Technologies Inc QuicKART 2000 Series Service Manual 41 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 CHANGING REAR TIRE REAR CASTERED TIRE Turn QuicKART off and remove key QuicKART must be on a flat surface Make sure the automatic brake is functional and on Use protective eyewear at all times 1 Lift the back of the QuicKART so the rear caster wheel is approximately 2 inches off the ground This is accomplished by using a jack under the rear frame of the QuicKART in the center Once the QuicKART is lifted place a sturdy and stable block in each corner then lower the jack so the weight of the QuicKART is resting on the blocks Also place blocks on the front wheels to keep the QuicKART from rolling 2 With two 9 16 wrenches remove the four bolts holding the caster assembly to
35. 970 011 Rev 3 1 06 A large red or blue EMERGENCY shut off button is located on the backside the control panel See top and side views of the QuicKART on pages 16 and 17 This is located to provide easy access to stop the machine To restart the machine after the EMERGENCY shut off button has been activated pull out the button turn off the key switch wait 2 seconds then turn it back on STEERING In Manual Mode the QuicKART 2000 is turned by exerting light pressure on the handlebars to the left or right similar to steering a bicycle In Remote Mode steering is controlled by guiding the lead cart in the desired direction ACCELERATION AND BRAKING Acceleration and braking of the QuicKART are controlled by the twist grip throttle located on the right handle bar QuicKART speed is controlled by twisting the throttle similar to a motorcycle throttle Braking action occurs as pressure is released Braking force can be controlled for quick or gradual stops Twisting the grip slowly brings the QuicKART to a gradual stop Releasing it rapidly stops the QuicKART very quickly Maximum braking force is applied when the throttle is fully released Dane Technologies Inc QuicKART 2000 Series Service Manual 32 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 REMOTE CONTROL BATTERY INDICATOR LIGHT SLOW SPEED PRESS TO KEEP IN MOTION 0
36. BOX LIGHTS ON NO HE EMERGENCY STOP BUTTON YES PULL OUT EMERGENCY STOP BUTTON CHECK TO SEE THAT THE REMOTE IS OFF BY REMOVING BATTERIES REMOVE THE STROBE LIGHT COVER AND REPLACE THE LIGHT BULB GOTO PG 5 QuicKART DOES NOT OPERATE IN RADIO IS THE JUNCTION BOX DRIVE SMMAND LIGH NO 2ND CALL YOUR SERVICE PROVIDER CHECK BEACON RED BATTERY CABLE THEN BEACON TOWER CABLE RECONNECT RED BATTERY CALL YOUR SERVICE PROVIDER REPLACE BEACON TOWER IS THE JUNCTION X DRIVE T BOX DRIVE LIGH NO YES GOTO QuicKART DOES NOT OPERATE IN REVERSE PG 7 DANE TECHNOLOGIES Inc mr PHONE 763 544 7779 7105 Northland Terrace FAX DIS SUUM Minneapolis MN THLE QUICKART 2000 SERIES TROUBLESHOOTING CHART NES wm 12 DWG DATE 3 1 06 Dane Technologies Inc QuicKART 2000 Series Service Manual 50 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART DOES NOT IN REVERSE FROMPG4 Dane Technologies Inc WITH KEY ON PRESS MANUAL AND REVERSE ON CONTROL PANEL PRESS THE CONTROL PANEL MANUAL RADIO SWITCH IS THE CONTROL PANEL MANUAL LIGHT ON DID THE REVERSE CALL YOUR SERVICE IS THE JUNCTION PROVIDER CHECK CONTROL PANEL OR CHECK JUNCTION
37. IN A CLEAR AREA AND ALL NEARBY QuicKARTS TURNED OFF RADIO OPERATION LIGHTS FORWARD IGHT AND MANUAL MODS PUSH MODE BUTTON GuicKART SWITCHES REMOTE SLOW DRIV PUSH SLOW BUTTON COMMAND BRAKE RELEASE WILL CLICK TOP PUSH FAST BUTTON LIGHTS FORWARD LIGHT AND MANUAL O STATUS LIGHTS ON THE JUNCTION BOX ARE ON O STATUS LIGHTS ON THE JUNCTION BOX ARE ON STOP QuicKART PUSH REVERSE DIRECTION BUTTON DANE TECHNOLOGIES Inc PHONE 763 544 7779 7105 S FAX 763 544 4234 inne abl I TRE QUICKART 2000 SERIES TROUBLESHOOTING CHART TS 9704020 METRE DWG DATE 3 1 06 Dane Technologies Inc QuicKART 2000 Series Service Manual 47 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART DOES NOT IS PUSHED IN TURN KEY THEN ON DOES THE HORN SOUND DO CONTROL PANEL HTS FLASH ONCE RUSHED IN DO CONTROL AE LIGHTS DOES QuicKART OPERATE IN CIRCUIT BREAKER RED BATTERY CABLE THEN BEACON TOWER CABLE RECONNECT RED BATTERY RBLE AND TURN KEY ON DOES QuicKART OPERATE IN MANUAL YES 5 YES NO Dane Technologies Inc BE SURE BRAKE LEVER CALL YOUR SERVICE PROVIDER CHECK JUN
38. Make sure QuicKART is properly secured when changing tires See instructions on page 41 and 42 Two options are available to tether the carts together a strap or a cart restraint assembly these are available as accessories To view the procedure to strap the carts see the illustration on pages 10 and 11 The cart restraint assembly also has a strap and adds a spring to allow some motion of the carts in turns but still controls them Dane Technologies Inc QuicKART 2000 Series Service Manual 6 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART 2000 SERIES LABELS QuicKART k 1114 The QuicKART 2500 uses label 500 105 instead of 500 021 REMOTE PROGRAMMING Dane Industries Inc INST Receiver Model 100 055 diese i 1 Turn QuicKart on switch to Radio mode on Control Panel 2 Simultaneously push Brake 900 021 Tested to Comply FC With FCC Standards and Horn buttons on Remote and the Rubber button on underside of the Beacon For Home or Office Use This device complies with FCC Rules part 15 Operation is subject to the Tower foliowite two conditions iy Tis dedica 3 Horn will sound when winq two condition Ihi VI programming is may not cause harmful interference and compl ete ere 2 this device must accept any interference that may be received including interference that may
39. O O Output fault Over current fault hardware failsafe 2 4 1 Short in motor or in motor wiring 2 Controller failure O O00 EEPROM fault hardware failsafe 1 1 EEPROM failure or fault Main contactor fault hardware failsafe 3 1 Main contactor welded 2 Main contactor driver fault 3 Main contactor coil fault Precharge fault 1 Internal controller fault 2 Low battery voltage Motor voltage fault HW failsafe 1 Motor voltage does not match throttle request 2 M1 or M2 Output shorted to B or B 3 Internal motor short 4 Controller failure LI LILILI Not Used LI LILILILI Not Used LILI L1 SRO fault Static Return to Off 1 Improper sequencing of KSI Brake Direction inputs 2 Wrong SRO Type selected 3 Direction switch circuit open LILI LILI HPD fault High Pedal Disconnect 1 Improper sequencing of KSI brake throttle inputs 2 Misadjusted throttle pot LILI LILILI HPD fault present 5 seconds PROC Wiring Fault 1 Maladjusted throttle 2 Broken throttle pot 3 Broken throttle mechanism OO O000 speed Limit Pot Fault SPD LIMIT POT FAULT Dane Technologies Inc QuicKART 2000 Series Service Manual 70 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 1 Speed limit pot wire broken 2 Broken speed limit pot LILILI LI Emergency reverse wiring fault BB Wiring Check 1 BB wire open BB Belly Button switch or the Emerg
40. QuicKART US CHARGER AND CORD a a at i di l EE 5 S i 5 cot 5 aj 3 C e cC n i lt DE v C p C 25089 SM ue om he 4 amp 2 A C E 5 C N 9 3 5 y N u a lt L 7 P2272 225 516 5 C 5 ii e E Ta gt 8 ia u X H w i i gt N Og x Ne 2 5 NE w N A Dr F an TE X m in T 5 NN e ZU MNA WT amp 9 GN j Hi 7 Fi j i H N 0 LE NP 222222 V RECEPTACLE FOR AC POWER INCLUDES 1 350347 0 AMP TYCO PANEL d Dane Technologies Inc QuicKART 2000 Series Service Manual 1 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 810 037 QuicKART EU CHARGER AND CORD COL OF da SV ww SZ9 v 0402 ONY J39HVH2 1H VWOInO LP ie OH d 06 0 c JP LNdNI 05 oi Ond 2v i NI rs gt S n14 elt e i Kai MRE samoa un N OVAOEZ HOLOSNNOD v9L 3N E 13883234 S3
41. QuicKART automatically shuts down If the QuicKART does shut down turn the key off for a few minutes then on again This may allow time to reach the charging station Recharge the batteries for at least 8 to 10 hours or until fully recharged The control panel also includes a series of 4 lights and panel button switches with the following functions The light labeled MANUAL is for manual operation and RADIO is for remote operation The push button switch just below these two lights will toggle between manual and remote control The QuicKART will automatically set to manual operation and forward whenever it is turned on It cannot be moved from manual to remote operation when the QuicKART is moving only when it is stopped The light labeled FORWARD is for Forward Direction operation and REVERSE is for Reverse Direction operation The push button switch just below these two lights will toggle between forward and reverse QuicKART direction The QuicKART will always be set to forward operation whenever it is turned on The switch will not change the operational direction until the QuicKART is stopped For safety the remote mode allows operation only in the forward direction Pressing the HORN button will sound the horn loudly as long as it is pressed Dane Technologies Inc QuicKART 2000 Series Service Manual 31 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com
42. T 211 012 910 09 e 10 007 di aiia H3HM AO e gt 610 01 XA i ME E COP d b n i HA ldnoo T3NNS ok gt IAN Y TT 8 6LO OLF r V z BLE P Tn Sa ere 881 007 B gt 39NIH 1708343 i LL t 7 P x a ho LA AI x ENS MN P Wa asc c NAM 900 005 z L108 801 002 H3dOVds 821 00 z e 1308 540 00 L A1gWd3SS v HWA 310NVH 0 001 ASV OINOHLO3 13 TANYA jd3H w i THOSE d3dOVvds L00 006 A3 j k wieg d poo FJ 1108 660 0 L FL O0L Jiva doH 15 3H HYH 859 Service Manual QuicKART 2000 Series Dane Technologies Inc 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 970 011 Rev 3 1 06 www danetechnoloqies com CUPL siasxua gsm amp LO DSL Ohinmaa JHH 91 IS ATgW3SSV 2ISVg EYT 005c IHVMOIO 3ulL 091 8 067 ueuzes 0075 2u S3IH1S nay SN pezr rrslegy Xd z22 PP5 E87 NOH 20 08 030 001 HdHSVM ATSWASS I Y 2 23119905 900 005 a gid 81 91 8 190 015 11048 170 087 v 4 d 6
43. TO MOVE THE QUICKART FORWARD OR REVERSE THE QUICKART SHOULD ROLL TURN THE KEY ON THE QUICKART SHOULD TURN ON BUT THE CONTROL PANEL LIGHTS SHOULD FLASH ONCE WHEN THE THROTTLE IS TWISTED AND THE QUICKART SHOULD NOT MOVE THIS POSITION OF THE BRAKE ROD IS USED FOR MOVING THE QUICKART WHEN IT IS INOPERATIVE PUSH THE BRAKE ROD IN TURN THE KEY ON AND TRY TO MOVE THE QUICKART FORWARD OR REVERSE THE QUICKART AGAIN SHOULD NOT ROLL TURN THE KEY ON THE QUICKART SHOULD TURN ON AND OPERATE NORMALLY WHEN THE THROTTLE IS TWISTED IF THE QUICKART ROLLS WHEN IT SHOULDN T GO TO CHECK FOR DAMAGED AXLE THE QK2000 BRAKE COIL RESISTANCE AS MEASURED BETWEEN PINS 1 AND 2 TWO BLACK WIRES IN THE CONNECTOR SHOULD BE 63 OHMS THE RESISTANCE IS 50 OHMS FOR THE QK2500 DANE TECHNOLOGIES Inc PHONE 763 544 7779 7105 Northland Terrace FAX 763 544 4234 WIE TITLE QUICKART 2000 SERIES TROUBLESHOOTING CHART DWG PART NO wisa 3 1 06 Service Manual 570000 SERVICE PROVIDER APPENDIX 57 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 CAUTION SERVICE PROVIDER INFORMATION ONLY INSTRUCTIONS GIVEN ON THIS PAGE MAY DAMAGE COMPONENTS DO NOT ATTEMPT ANY ACTION ON THIS PAGE UNLESS YOU ARE QUALIFIED CHECK FOR DAMAGED TRANSAXLE CHECK FOR DAMAGED BRAKE BEFORE CHECKING FOR DAMAGED TRANSAXLE IF THE QU
44. box matches an opening in the steering handle and is the means for getting a multi wire cable from the push button controls to the electronic equipment located under the machine s cover This box has mounted to it a key switch and emergency stop switch both of which are closed when in operation The connecting leads to both of these items are plugged into the control panel s printed circuit board The control panel cover contains a bezel plate printed circuit board membrane and associated hardware The printed circuit board contains three push button switches that are activated by pressing through the thin sections of the white membrane These three switches are labeled on the membrane s top surface with the following selections 1 Manual or Remote operation 2 Forward or Reverse operation 3 Stop Dane Technologies Inc QuicKART 2000 Series Service Manual 62 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 There are four corresponding lights on the control panel to let the operator know which selection has been made for manual or remote and forward or reverse In remote operation the machine will only operate in the forward direction The control bezel panel also has a serles of five lights across the tops which sense the battery voltage When all five lights are on the batteries are fully charged or nearly so As the batteries are used over
45. cause undesired operation E RG E N CY SHUT OFF Dane Industries Minneapolis MN I eran URAL MES Phone 888 544 7779 OFF AND ON TO RESTART 500 049 The QuicKAR REMOVE SCREWS TOREPLACE4 AA BATTERIES 500 181 DANE INDUSTRIES Inc Minneapolis MN USA DANE INDUSTRIES iln Model No QuicKART 2000 115 60hz 4 7A _ Serial No Gross weight 250Kc IPX4 Suitable for use on surfaces with a gradiant DANE INDUSTRIES INC Manufactured under one or more of the following patents ett d U S 5 934 694 not exceeding 18 U S 6 220 379 All other patents pending us MINNEAPOLIS 1 888 544 7779 within USA MINNESOTA USA 163 544 7779 outside the USA www daneindustries com 500 053 Dane Technologies Inc QuicKART 2000 Series Service Manual 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 WARNING WHO CAN OPERATE THE QUICKART a FEDERAL REGULATIONS REQUIRE THAT YOU BE AT LEAST 18 YEARS OLD AND PASS A VISION TEST TO OPERATE THE SOME STATES MAY REQUIRE OPERATORS TO BE OLDER s DO NOT OPERATE THE QUICKART UNLESS YOU MEET THE MINIMUM OPERATOR REQUIREMENTS SET DWH FEDERAL REGULATIONS AND YOUR STATE DO NOT OPERATE THE QUICKART UNLESS YOU HAVE VIEWED THE CUICKART TRAINING VIDEO AND PASSED THE OUICKART CERTIRED OPERATOR S TEST INCLUDED IN G
46. conditions but the machine does not operate review the mechanical and electrical functions of the motor control box or the motor If this light does not come on review the junction box functions g Low battery diagnostic light Whenever the battery pack three 12 volt batteries in series drains down to 27 volts this light comes on It is time for a recharge or to find a reason the charger is not working h Hour meter records the length of time the machine drive command is on Dane Technologies Inc QuicKART 2000 Series Service Manual 64 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 CLIPLIGHT BATTERY CHARGER OPERATION Battery Charger 810 037 supplied with the QK 2000E machine and the 810 036 supplied with the QK 2000 uses a sophisticated charging algorithm that continually tests the charging process from start to finish Once the charger s output leads are properly connected to the batteries terminals and the charger is plugged into an AC receptacle the charger waits 3 seconds before starting its 5 stage charging process These 5 stages are described in the order in which they take place as follows PRE QUALIFICATION TEST STAGE ONE The Yellow Light Emitting Diode L E D flashes on and oft The duration of this stage is dependent on the condition of the batteries If the batteries have been left in a state of discharge for
47. driven by a differential gear box located near the center of the axle housing The system is sealed with lifetime lubrication 5 The drive motor is rated at 36 volts D C and is capable of a peak of approximately 2 horsepower The motor is rated for continuous duty at 0 972 horsepower The motor drives the axle shafts with ratio of 30 87 1 6 A brake is located on the end of the motor held in place with two 8 82 x 2 1 inch long cap screws The brake assembly contains three major components a A micro switch is mounted on the outside of the circular brake housing which detects the position of the manual release arm When the machine is in normal operation the switch is closed When manual release lever lower right side of back plate is pulled out this switch will open and electronics will shut down preventing the machine from operating without the braking feature Note Pulling this manual release lever will keep the brake assembly from locking the motor allowing the operator to be able to push the machine manually while the QuicKART is turned off While pushing the QuicKART with the brake released the motor burns off generated voltage through occasional braking This can be avoided by pushing the QuicKART slowly b The brake is an electro mechanical design It consists of an electro magnet 63 ohms a moving metal disk plus a fiber brake disk The fiber disk has a hexagon center which mates with a hexagon shaft on the end of the motor
48. free to call or e mail me at any time with questions or comments oincerely Paul Halvorson Vice President Service 888 544 7779 Ext 4436 paulh daneindustries com Dane Technologies Inc QuicKART 2000 Series Service Manual 109 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 DANE NM TECHNOLOGIES ucc m ORDERING AND INVOICING PROCEDURES ORDERING PARTS Call Dane Technologies at 888 544 7779 then choose the parts or service option 1 Please provide a purchase order and if applicable the location of the customer store and the serial number of the QuicKART TECHNICAL SUPPORT Call the same phone number then choose the service option SHIPPING INVOICING WARRANTY 1 If you have the part in stock use it to repair the customer s QuicKART and take the defective part back to your shop 2 Order a replacement part from Dane Please provide the location of the customer store where your part was used so that we can verify warranty coverage 3 Dane will ship a replacement part and invoice you for it Along with the part you will receive a RMA number authorizing the return of the item under warranty 4 Return the part to Dane along with the RMA number 5 Upon verifying that the part is defective Dane will issue a credit canceling the invoice NON WARRANT Y 1 Again use a part from your stock if possible
49. of signals bouncing off buildings and cars The receiver will work with only one antenna but the dependability will be degraded The signal from the radio s circuit board is fed directly to the mother board through a connector The mother board decodes the signal and energizes one of four output wires which corresponds to the command being issued by the remote The radio receiver should be able to operate with the remote at a distance of 100 feet 15 The steering handle is made of heavy gage tubing that is formed welded and nickel plated It contains not only the means for manually operating the machine but is also fitted with the system s control panel and throttle grip a The throttle grip is located on the right side of the handle and a Stationary hand grip is on the left A protective bar is welded to the handle to protect the grips from damage should the machine come in contact with a wall or the edge of a doorframe The throttle grip turns about 90 degrees in one direction only Turning the throttle causes a potentiometer to change the voltage on its output wire from zero volts machine not moving to about 5 volts full speed operation When the control panel has selected remote operation the throttle grip is electrically disconnected b The control panel is the central operating point for the machine The control panel box is mounted at the top of the steering handle with 4 screws An opening in the bottom of the control panel
50. remote This assumes that remote is working and programmed properly The machine can be either in manual or remote mode for this test Failure of this light to come on during this test could be a symptom of either a bad remote or damaged receiver d Fast speed diagnostic light will come on whenever the fast button is pressed on the remote This assumes that remote is working and programmed properly The machine can be either in manual or remote mode for this test Failure of this light to come on during this test could be a symptom of either a bad remote or damaged receiver e Note Possible remote problems Battery dead Does the remote indicator light come on when any button is pushed Water intrusion Bad PCB Broken wire to battery Damaged switch Possible receiver problems Antenna missing one or both Receiver not programmed to match transmitter Damaged receiver or motherboard Wire disconnected f Drive command diagnostic light will tell you that the Curtis motor control box is getting a signal to cause the machine to move There are four signals that cause this to be lighted Note it takes at least a 0 4 volt signal level to activate the Curtis motor control box That is the threshold level for these lights 1 Throttle grip twisted in forward 2 Throttle grip twisted in reverse 3 Low speed remote button pushed in remote mode 4 High speed remote button pushed in remote mode If this light comes on in any of the above four
51. the output cable connector is less than 24 volts Therefore if the three batteries are drained to a total series voltage of 24 or less volts the charger will not become active Generally the batteries used on the QK 2000 should yield at least 30 volts in a discharged condition If only 24 volts is shown on the meter it is likely they are damaged maybe permanently or will have a much shortened life Dane Technologies Inc QuicKART 2000 Series Service Manual 16 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 It is possible to fool the battery charger by jumping the machine s 36 volt battery pack with another 36 volt source such as used in a floor scrubber Once the charger sees more than 24 volts it will turn on and should remain so after the jumper cable has been remove If it does not remain on after the jumper source is removed likely the batteries are beyond their useful life Use extreme caution if using this method to recharge batteries 5 The battery charger is defective Check fuses and replace if necessary If fuses fail again the fault lies within the system Special notes on the Charger before sn 656 When the charger cord is first plugged into an electrical outlet there will be a delay of about one or two seconds before the charger turns on and the meter shows a current reading Once the charger is on it will remain chargi
52. when the battery voltage slowly decays to about 40 to 40 5 volts The charger will now deliver about 300MA which will maintain the charge If an excessive load Is at any time applied and the Terminal Voltage has been forced below a preset level the charger will reinitiate a charge cycle starting with the Constant Current Stage In this standby Float state the charger can be left connected indefinitely limited only by the practical service life of the battery until disconnected Dane Technologies Inc QuicKART 2000 Series Service Manual 65 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 RECYCLE CHARGE STAGE FIVE After completion of the first four stages the charger will sit in Float Mode If the charger is left connected to a battery for many weeks months to maintain the batteries at full charge the charger will automatically reinitiate a charge cycle routine that starts at the Pre Qualification Stage once every 28 days This charger cannot repair the damage done to batteries by someone else s charger Detection Fault The Red L E D illuminates continuously if the charger has not detected the connection of a battery of proper polarity and voltage on it s output leads Once connected a waiting period of about 3 seconds elapses before the charger recognizes the battery Dane Technologies Inc QuicKART 2000 Series Service Manual 66 7105
53. 000 S qayno 0 012 S X QO 529 0 45 80 002 AMY 000240 NOOV38 SENL 66 0020 Z Z AME dO1 NOOV38 38ni 86 00 A0 NOWIHOSSG ON LV 40 T1118 98 Service Manual QuicKART 2000 Series Dane Technologies Inc 970 011 Rev 3 1 06 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnoloqies com 100 166 QuicKART 2500 TRANSAXLE ASSEMBLY 031312345 SMH 3HIO LEZ JE 319 OSOOF XXO 023 S00 0 XXX 0 001 SLIHM HOLIMS SES SU nc Li UI a c MOVIE 1109 3 vua 39V 18 HOO 3 Vvua HO 102 TWNOIS ON Id LINDYIO F MAIA dO L 21722 2 20 022 SONLS M ANH Z LP 2 SZO OL 170 00 LAN ONIdIAN 1o z 9c0 055 A3 WwW 100 072 2012 90 20 1VNIWS3 D 080 022 90 0 91d X31ONW 50 600 969 NA WOO SHIM OILS v 1d 1108 SNIdWv 19 rs 0 L0 S69 3iL 38IM 2 110 072 TVNIW3L ONIY 91 5 99 Service Manual QuicKART 2000 Series Dane Technologies Inc 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 970 011 Rev 3 1 06 www danetechnologies com 100 245 QuicKART 2000 TRANSAXLE amp 4 POLE MOTOR 3142345 3SIW43H10 SSF INN 6zc o13 72319NV oso XXO0
54. 1 Rev 3 1 06 100 096 POST ASSEMBLY QuicKART 2000 STROBE LAMP ASSEMBLY 470 003 LIGHT BULB ONLY 470 017 LENSE 470 030 TERMINAL 2 BRAKE LAMP CABLE 740 019 T BOLT 2 AN 700 111 muc s 500 129 LABEL P 400 070 BRAKE LAMP GASKET 510 014 NUT 2 PLACE PROGRAMMING 410 028 INSTRUCTIONS LABEL BRAKE LAMP A 500 148 ON OPPOSITE 470 031 SIDE OF BEACON TOWER SCREWS 3 RECEIVER BOX 400 166 220 110 RADIO MOTHER BOARD E ASSEMELYI1 00 103 EUROPE 500 180 WARRANTY LABEL CLAMP MOUNTING SCREW 400 075 RECEIVER MOUNTING SCREW 4 AD STRAIN RELIEF 400 075 430 062 Tv L BRACKET 5 gp 2 650 025 210 055 MEL 75 HEX NUT amp LOCK WASHER WITH 720 061 aA SET SCREW E PROGRAMMING SWITCH 400 259 2 PART OF 700 105 ANTENNA CONNECTOR COVER MOUNTING SCREW 2 0 20 061 8 32 x 1 2 4 400 168 SS BEACON POST 200 119 RUBBER SWITCH COVER 665 007 O CONDUCTOR 3 CABLE ANTENNA ASSEMBLY 0700 129 ME PDT FONTE RECEN ER MOTHER BOARD WIRE TIE DETAIL ELACE E Es rme OE 5 tm LJ arenes 275 DELETED NOT CORNECTED HOTE SGFIZSLABEL J WES Wo FS LABEL REGUIRED Do Wn K ss sss ADDED NOTE APPLY TAFE Tu f TO HO
55. 10 06 Sc 220 007 HOLON LNNOW 719 022 H3HSVM BYE 800 0cT X Be 1109 10 00P dO LV 1OSI 1 1 0 HOLVIOSI 3LV 1d c9 00c 19130 LNNOW Yen EA 85 Service Manual QuicKART 2000 Series Dane Technologies Inc 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 970 011 Rev 3 1 06 www danetechnologies com 150 016 QuicKART 2000 BASIC ASSEMBLY UK 433 MHz 20 12 20 30 L 11 90 06 on wvaoma ZHWEEFT MN AT8W3SSv 21579 Z 0 012 023 ISWI 00028 AT138 vCZP ePS xy ZFFSS NIN Ta 9 1708 j OSL N eug OOPS 1 7 5 INVA SF2 001 lt l menassy C ST 70 01 PW 8 1 72 7 Y eooo SY 592 001702 093 95 T did 133 5335 090022 A Al T p L108 8 1108 031390 ecoeswMzoos 58007035 227 OTR s ss BOLEZ 292 soeur k t i 133HM3AHQ XT NO 980 02 AGGONY 031143 WVO3 d ANZ r FJ H3HSVM SNosM3H Z WN 10 00 q hut 050 096 en 133HM k A a 2 7 s L109 v p g ad ad 610 01 a AIMS 154 881 00
56. 2 Invoice the customer for your labor and parts REMEMBER Labor warranty is 90 days from purchase date Parts pricing must agree with the retail price shown on the Dane price list 3 Order replacement parts for your inventory as described above IF YOU DON T HAVE THE PAHT IN STOCK 1 Order the part from Dane as described above Please provide a purchase order number ship to address if different from your business address customer store location and information on the part coming back if applicable 2 Communicate with customer store management about delivery time and any other details about when you estimate the QuicKART will be repaired Dane Technologies Inc QuicKART 2000 Series Service Manual 110 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART 2000 and 2500 TOOLS Size or Qty Tool 1 9 16 Deep socket and regular socket 3 8 drive 2 1 2 Regular socket 3 8 drive 3 5 8 Deep socket and regular socket 3 8 drive 4 3 4 Deep socket 3 8 drive 5 6 Extension 3 8 drive 6 12 Extension 3 8 drive 7 1 12 3 8 drive ratchet 8 1 4 Combination wrench 9 5 16 Combination wrench 10 7 16 Combination wrench 11 1 2 Combination wrench le p 6 Combination wrench n Allen wrench 14 9 64 Allen wrench 15 T25 Torque screw driver 16 Standard Allen wrench set Allen wrench set 18 2 8 Phi
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61. BOTTOM TOWER BOLT BRAKE RELEASE KNOB 120V BATTERY CHARGER RECEPTACLE 10 1 GAUGE EXTENSION CORD REQUIRED Dane Technologies Inc QuicKART 2000 Series Service Manual 16 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART 2000 SIDE VIEW BEACON LIGHT STOP BRAKE LIGHT 4 REMOTE CONTROL Ja PROGRAMMING BUTTON 4 _ RECEIVER ANTENNAS STOP a BUTTON KEY SWITCH BODY HINGE ROLLER BRAKE RELEASE KNOB T 9 PUSH IN FOR NORMAL OPERATION PULL OUT TO i MOVE MACHINE MANUALLY SWIVEL WHEEL DRIVE WHEEL Dane Technologies Inc QuicKART 2000 Series Service Manual 7 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 SYSTEM WIRING DIAGRAM EFA lt FO S F 10 089 oniyvaona rEZr rbS 94 a C 0514 N eue 0075 6 61 5 594 3NOHd SHHLSAONI INYA Z6Scus gt 210 018 L6ScuUS lt 520 018 H3OHVHO poe M D 690 001 31d HOLOVLNOO HOLOW Q318W3SSV 40 001 43H 850 001 N 211 002 H3llIOHLINOO _ 8Nid N VIN 3114 SNLINNOVWL S 110 599 4 JUHM MOIOVINOO
62. CONTROLLER BLACK is N HORN CONNECTOR Dane Technologies Inc QuicKART 2000 Series Service Manual 19 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 SYSTEM JUNCTION BOX DIAGNOSTIC LIGHTS Supply Fault There are two conditions that cause this diagnostic light to come on 1 When this light remains on but not flashing it indicates the machine was turned off by pushing on the Red emergency button on the control panel The machine will not function while the light is on To reset pull out the button turn the key switch off then on again This condition does not require service The key switch is the correct way to turn off the machine when it is stored or set aside for periods of time 2 When this light is flashing it indicates that there is a problem in either the beacon post or the control panel In a fault condition the supply fault light starts flashing as soon as the machine is turned on with the key switch The machine will not function while the light is flashing The control panel lights may remain lighted for 3 seconds then shut down but the fault light will remain flashing as long as the fault condition exists To determine if the problem is in the beacon post turn off the machine with the key switch unplug the cable leading to the beacon post then turn the key switch on again If the problem is in the beacon post the machine w
63. CTION PULL EMERGENCY IS EMERGENCY SHUTOFF BUTTON SHUTOFF BUTTON OUT RED BUTTON ONLY CALL YOUR SERVICE PROVIDER CURTIS MOTOR CONTROLLER PROBLEM GO TO QuicKART DOES NOT OPERATE IN RADIO TURN KEY OFF AND RECONNECT CABLES TURN PUSH IN CIRCUIT BREAKER TO RESET PLUG IN AC CORD TO RECHARGE BATTERIES GO TO QuicKART DOES NOT OPERATE IN RADIO CALL YOUR SERVICE PROVIDER REPLACE THE HANDLEBAR CAUTION TROUBLE SHOOT WITH THE QuicKART IN A CLEAR AREA AND ALL NEARBY QuicKARTS TURNED OFF Willi ied 29 MIS DWG PART NO ST THETHROTTLE AND LISTEN ALSO SOUND AND THE DID A CLICK BRAKE PUSHED IN PUSH THE QuicKART QuicKART ROLL SOME YOUR SERVICE PROVIDER UNABLE TO RMINE PROBLE DANE TECHNOLOGIES Inc 7105 Northland Terrace TECNOLOGIES FAX CALL YOUR SERVICE PROVIDER CHECK FOR DAMAGED KEY ALL YOUR SERVICE PROVIDER CHECK FOR DAMAGED CALL YOUR SERVICE PROVIDER HECK FOR DAMAGED HECK FOR LOOSE CONNECTIONS ON CURTIS CONTROLLER ARGE BLACK CAB CALL YOUR SERVICE PROVIDER CHECK MICRO SWITCH ON YES BEACON TOWER CABLE CALL YOUR SERVICE NO PROVIDER CHECK BRAKE YES PROVIDER CHECK YES CONTACTOR Con NOTE TRY WITH THROTTLE AND NO THROTTLE CALL YOUR SERVICE P
64. Dane Technologies Inc QuicKART 2000 Series Service Manual fe 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QK 2000 Drive Motor Brake Assembly Test Service Bulletin 985 008 May 1999 There are a pair of white and black wires that connect to the electrical brake assemble which is mounted to the back side of the drive motor These four wires are terminated with a four pin plug and are inserted into a matching receptacle on the junction box The two black wires attach to the magnetic brake release coil and the two white wires are connected to a micro switch which tells the electronics if the brake release lever is pulled Testing either the magnetic brake coil or the micro switch is as follows Pull out the four pin plug from the junction box The resistance between pins 1 and 2 should measure about 63 ohms If the resistance is well above this value basically no continuity or very low a few ohms the coil has been damaged The brake is released when 36 volts are applied across this coil Once the brake has been released the 36 volts is dropped to about 20 volts which is more than enough voltage to keep the brake coil functional yet not draw as much current This brake release or engagement can be heard as a clicking sound when the throttle is turned on or off To measure the voltage across the coil lift the QK 2000 off of the drive wheels
65. EOD MUI NEHME NEM NE 36 REMOTE CONTROL BATTERY CHANGING 37 REMOTE CONTROL BATTERY CHANGING DIAGRAM 38 PROGRAMMING THE REMOTE CONTROL 38 QuicK ART 2000 2500 MAINTENANCE NOTES 30 CHANGING FRONT TIRES amarem mb Ue res PEU E 4 CHANGING REAR TIRE 42 TECHNICAL SC I ursa aident 43 44 Dane Technologies Inc QuicKART 2000 Series Service Manual 4 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART 2000 WARNINGS SAFETY NOTES Please read all the information included in this manual and the service instructions prior to operating or servicing the QuicKART In addition make certain all operators have been given and passed the certified operators course before using the QuicKART IMPORTANT SAFETY NOTE THE RED BATTERY PLUG MUST BE DISCONNECTED FROM THE JUNCTION BOX ANY TIME MAINTENANCE IS BEING PERFORMED UNDER THE COVER See diagram on page 18 1 The QuicKART is designed to push shopping carts Any other use of the QuicKART is prohibited unless specifically endorsed by the manufactur
66. ES PRESSING TH ROL PANEL HORN ON TURN ON THE HORN WITH A WORKING RADIO SYSTEM PRESS THE CONTROL RANEL RADIO BUTTON REMOTE HORN ON TURN ON THE 1 PROVIDER JUMPER BE CAREFUL DANE TECHNOLOGIES Inc 7105 Northland Terrace PHONE 763 544 7779 Minneapolis MN 55428 FAX 763 544 4234 TILE QUICKART 2000 SERIES TROUBLESHOOTING CHART 970 020 su 8 12 DWG DATE 3 1 06 DWG PART NO QuicKART 2000 Series Dane Technologies Inc Service Manual 32 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART OPERATES BUT HAS LIMITED RUNNING TIME CHECK AND FILL WATER IN BATTERIES BEFORE PROCEDING WITH KEY ON PRESS FORWARD ON THE CONTROL PANEL NOTICE THE BATTERY LEVEL INDICATOR LIGHTS ON THE CONTROL PANEL DO THE LIGHTS INDICATE A LOW CHECK THE LOW BATTERY LIGHT ON THE JUNCTION BOX LOW VOLTAGE IS 28 OK CONTROL PANEL LEVEL INDICATOR LIGHTS MAY BE WRONG WAS THE LIGHT ON TO INDICATE A LOW PLUG IN BATTERY CHARGER TO RECHARGE FOR 15 MINUTES HARGER DID NOT GO TO MAXIMUM CHARGE GO TO BATTERY AND CHARGER PROBLEMS PG 10 DID A BATTERY CHARGER YELLOW OPERATE THE QuicKART TO PUSH CARTS FOR A FEW MINUTES DO THE LIGHTS INDICATE A LOWER CHARGE THAN GO TO BA
67. ICE AT 1 888 056 7778 500 042 REV CHARGER PLUG 500 040B A ATTENTIONA The QuicKart has a smart regulator that will stop the QuicKart when it is overloaded To resume operation reduce the number of shopping carts being pushed by the QuicKart 500 101 WARRANTY VOID SEAL BROKEN PULL TO RELEASE AUTOMATIC BRAKE FCC ID N2N 600 023 MODEL No 100 150 Canada IC 4707A 600023 Dane Industrles Inc Minneapolls MN USA 55442 Dane Technologies Inc QuicKART 2000 Series 500 039B 500 135 PUSH TO RUN Service Manual 8 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART 2000 LABEL LOCATIONS 500 041 ge INSIDE 500 042 CUSTOM LABEL HERE IF REQUIRED 500 053 STAMP SERIAL M NUMBER HERE 500 021 2 500 040 RED COVER CUSTOM LABEL HERE IF REQUIRED 500 102 500 108 STAMP SERIAL de NUMBER HERE 2 Wh 500 039 500 105 2 500 040 RED COVER Dane Technologies Inc QuicKART 2000 Series Service Manual 9 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART 2000 CART STRAP ACCESSORY 24 U r TTT mnn k NI 39V1d ONY dvHlS 350071 dN HONNA ON
68. ICKART ROLLS WHEN IT SHOULDN T REMOVE THE BELLY PAN AND REPEAT THE BRAKE ROD IN TEST TURN THE KEY OFF PUSH THE BRAKE ROD IN AND TRY TO ROTATE ONE WHEEL WHILE HOLDING THE OTHER FIXED THE WHEEL SHOULD NOT TURN IF THE WHEEL TURNS REMOVE THE BRAKE ROD AND THE PLASTIC COVER OVER THE BRAKE REMOVE THE 9 64 SCREWS HOLDING THE BRAKE ON THE MOTOR TEST THE DISCONNECTED BRAKE BY SLIDING THE INTERNAL FIBER DISC SIDE TO SIDE THE BRAKE ROD IN POSITION OF THE LEVER SHOULD HOLD THE DISC FIXED THE BRAKE ROD OUT POSITION SHOULD ALLOW DISC MOVEMENT THE EXPOSED SHAFT OF THE MOTOR SHOULD TURN WHEN ROTATING ONE WHEEL WHILE HOLDING THE OTHER FIXED OR TURNING THEM BOTH IN THE SAME DIRECTION IF THE MOTOR SHAFT DOES NOT TURN REMOVE THE THREE 1 2 MOTOR MOUNTING BOLTS ON THE TRANSAXLE SIDE AND REMOVE THE MOTOR TWIST THE MOTOR OUTPUT SHAFT TO VERIFY MOTOR ROTATION THE EXPOSED GEAR OF THE TRANSAXLE SHOULD TURN WHEN ROTATING ONE WHEEL WHILE HOLDING THE OTHER FIXED OR TURNING THEM BOTH IN THE SAME DIRECTION IF THE TRANSAXLE GEAR DOESNT TURN THE TRANSAXLE MUST BE REPLACED IF THE MOTOR OUTPUT SHAFT GEAR OR THE TRANSAXLE GEAR IS NOT DAMAGED AND THE TRANSAXLE TURNS CORRECTLY CHECK THE MOTOR ELECTRICALLY CHECK FOR DAMAGED MOTOR TO CHECK FOR NO MOTION OF THE QUICKART WHEN OTHER TESTS HAVE FAILED DISCONNECT BOTH MOTOR WIRES TO THE CURTIS CONTROLLER PUSH IN THE BRAKE ROD AND LIFT AT LEAST ONE DRIVE WHEEL OFF THE GROUND THIS TEST CAN BE DONE
69. ING PROPERLY Dane Technologies Inc Minneapolis MN Call Toll Free 1 888 544 7779 www danetechnologies com Remote and QuicKART must be re programmed DANE TECHNOLOGIES r after changing batteries Warranty will be VOID if this cover is removed There are no operator serviceable parts inside DANE TECHNOLOGIES Minneapolis MN Part Serial No Date 500 121 QUICKART OPERATING INSTRUCTIONS BEFORE OPERATING THE MAKE SURE YOU MEET THE MINIMUM OPERATOR REQUIREMENTS LISTED ON WARNING LABEL COMPLETE THE PRE OP CHECKLIST ON THE WARNING LABEL WHILE OPERATING THE e NEVER PUGH MORE THAN 33 SHOPPING CARTS OF LESS IF CONDITIONS REQUIRE PUSH ONLY AS MANY CARTS 5 YOU CAN SAFELY CONTROL BUT NEVER MORE THAN 3 USE A SAFETY STRAP TO KEEP THE CARTS UNDER CONTROL ON DOWNHILL SLOPES e NEVER SIT OR CARRY PASSENGERS ON THE OLUICKART s ALWAYS OPERATE THE QUICKART SAFELY AND RESPONSIBLY BE AWARE OF TRAFFIC AND PEOPLE AROUND YOU USE THE SLOW SPEED WHEN NEAR STORE ENTRANCES OR GUESTS BEFORE LEAVING OLICKART PARK QUICKART ON A LEVEL SURFACE AWAY FROM AREAS TRAFFIC TURN KEY TO VERTICAL OFF POSITION AND REMOVE THE KEY _ INFORM YOUR MANAGER IMMEDIATELY IF THE OLICKART IS NOT WORKING PROPERLY IMPROPER USE OF THE CUICKART MAY CAUSE DAMAGE TO PEOPLE OR PROPERTY AND WILL VOID THE MANUFACTURER S WARRANTY CALL DANE TECHNOLOGIES FOR SERV
70. ING SLOW OR FAST AKES CONTROL PANEL JUMP INTO MANUAL H BRAKE LEVER IN ID SOME FUNCTION IST FROM PG 6 LIGHTS COME ON REMOTE MAY NOT BE WORKING CAN YOU TRY OTHER REMOTE ON BOX LIGHTS TURN JUNCTION BOX 2ND BEACON TROUBLESHOOT ONFORALL TRANSAXLE BRAKE OR NO CALL YOUR SERVICE PROVIDER CHECK MOTOR BRUSHES CALL YOUR SERVICE PROVIDER BEACOt TOWER QR JUNCTION BOX HAS A PROBLEM CHECK KOR BEACON TOWER DAMAGE OR MISSING ANTENNAS DANE TECHNOLOGIES Inc SR PHONE 763 544 7779 7105 Northland Terrace FAX 763 544 4234 Minneapolis MN 428 THLE QUICKART 2000 SERIES TROUBLESHOOTING CHART 97002 sor D DWG DATE 3 1 06 Dane Technologies Inc QuicKART 2000 Series Service Manual 49 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART DOES NOT SWITCH RADIO DANE TECHNQLOGIES WITH KEY ON PRESS RADIO ON THE CONTROL PANEL QuicKART STROBE LIGHT ISN T WORKING DID THE RADIO LIGHT ON THE GO TO QuicKART WILL NOT GO INTO RADIO YES PG 5 TURN KEY OFF AND THEN ON CALL YOUR SERVICE PROVIDER CHECK JUNCTION BOX OR CHECK CONTROL IS THE STROBE LIGHT FLASHING HECK TO SEE THAT MANUA THROTTLE IS OFF OR CALL YOUR SERVICE PROVIDER FOR OR ARE OTHER JUNCTION
71. Inc 5400 Nathan Lane N 150 FAX 783 5644 4254 Plymouth MN 55442 I TITLE CART RESTRAINT ASSEMBLY RTT 11006 ORE 72502 Dane Technologies Inc QuicKART 2000 Series Service Manual 11 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 REMOVE AND DISCARD HOOK 430 034 HANDLE OVER CART BUCKLE STRAP 154 ap STEEL GABLE RESTRAINT MAST AS SHOWN SPRING HOOK Cea o V THIS HOOK ATTACHES TO ICS LEAD SHOPPING CART O SHOPPING CART YOKES DANE INDUSTRIES Inc i PHONE 763 544 7779 5400 Nathan Lane N 150 Plymouth MN 55442 HANE TITLE RELEASE ECO CART RESTRAINT ASSEMBLY 216 110 066 DWG DATE 1 25 02 MATL DWCOG PART Dane Technologies Inc QuicKART 2000 Series Service Manual 12 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 UNPACKING QuicKART 2000 1 The QuicKART 2000 is typically shipped on a wooden pallet It comes with addition individual components that are packaged inside the QuicKART Care must be taken not to damage them during the unpacking The components are a QuicKART the basic electric machine with two keys b A box including a Remote Control Transmitter to remotely control the QuicKART and Cart Cou
72. K WIRE IF THE HORN DOES NOT SOUND REPLACE THE HORN IF THE HORN SOUNDS THE PROBLEM IS IN THE CABLE OR JUNCTION BOX USING A VOLT OHM METER CHECK THE CABLE CONTINUITY FROM THE CONNECTOR PINS TO THE HORN EYELETS Dane Technologies Inc QuicKART 2000 Series TECHNOLOGIES CHECK FOR DAMAGED BRAKE SERVICE MANUAL SECTION 3 IF THE CONTROL PANEL LIGHTS FLASH ONCE WHEN THE MACHINE TRIES TO MOVE PUSH THE BRAKE ROD IN IF THE CONTROL PANEL LIGHTS STILL FLASH ONCE VERIFY BRAKE ROD IS CONNECTED TO THE BRAKE LEVER AND TEST AGAIN IF THE CONTROL PANEL LIGHTS STILL FLASH ONCE TURN OFF THE KEY DISCONNECT THE FOUR WIRE CONNECTOR ON THE JUCTION BOX AND CHECK THE TWO WHITE BRAKE SWITCH WIRES PINS 3 AND 4 AT THE CONNECTOR FOR RESISTANCE TO EACH OTHER RESISTANCE SHOULD BE lt 1 OHMS WITH BRAKE ROD IN AND INFINITE WITH BRAKE ROD OUT IF THE SWITCH DOES NOT OPERATE CORRECTLY VERIFY BY RECONNECTING THE FOUR PIN CONNECTOR TO THE JUNCTION BOX AND INSERTING A SMALL BARE WIRE INTO THE BACK SIDE OF THE CONNECTOR JUMPERING THE TWO WHITE WIRES TOGETHER TURN THE KEY ON AND TWIST THE THROTTLE IF THE QUICKART MOVED AND THE CONTROL PANEL LIGHTS DIDN T FLASH ONCE REPLACE THE BRAKE IFTHE BRAKE SWITCH TESTS OK CHECK THE JUNCTION BOX TO CHECK THE BRAKE FOR MECHANICAL OPERATION TURN THE KEY OFF PUSH THE BRAKE ROD IN AND TRY TO MOVE THE QUICKART FORWARD OR REVERSE THE QUICKART SHOULD NOT ROLL PULL THE BRAKE ROD OUT AND TRY
73. N N330 1nHS AON3983NW3 600 026 diH5 FILO GES amp 00 04 3l L38IM div 950 004 610 599 TAY HLIM H2 LI MS A3M SHOLO3NNOO f J1LLOHHL LZ I 00P 5 SINILN ION I3NVd IOHLNOD g 94 Service Manual QuicKART 2000 Series Dane Technologies Inc 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 970 011 Rev 3 1 06 www danetechnologies com NOLLVOIJILLN3GOI 3HIA d3la3WOLlLN3lOd AI w 5 1 ama wv fir JOHLNO2 if AW NdvYH3 d1 I ki 340 QN3 LV 3ONVHY312 S0 0 1537 LV dHfisHN3 OL TIv AXoSg TANYd ONY WHY H3A 31 NHM33 AL38 Alaa 83 30115 LSnW H39wdS ANNI Tv TAINAN 8070 Peer GZ4LI C84 SINCHd Yuen WEL 5596 53131 SON 600 046 z 60 001 LH Vdl 0507016 FLIYHS 3 0 0 ifs WHY H3A3I 1JdvHS 31L10HH1 Mun Nes d P50 001 QR 3 IUE NMOHS ATIVLLY Vd ore d 108 310NYH SSNHL a ral 5 wa z MEN 1 lt 7 T Qoo y HHM Ch s r P We C us 2 F zi BL0O 09F 7 SS v C4 lt E zh hd T 21 006 a OS S DX 861 00 191 001 lt 6 j 0 A LPRLOOL d 5 E
74. Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 Glossary Terms Drive axle Front axle including the motor and brake assembly Junction box Electrical box mounted on the top inside of machine s back panel Motor control box Electronic speed control mounted on the lower inside of the machine s back panel Beacon tower A metal post at the back of the machine which contains a strobe light brake light and radio receiver system Handle The nickel plated handle at the back of the machine used to steer when operating the machine manually Control panel The black metal box mounted on the handle Contains mode switches and battery voltage indicator lights as well as the key switch and emergency switch Swivel wheel The 8 inch tire at the rear of the machine which will swivel when the machine is turned off a straight path Strobe light The light on top of the beacon post Flashes about once each second when the machine is turned on and the E Shut off not pushed in Brake light The brake light goes on whenever the back EMF of the motor is used to slow down the machine Cart coupler The forks that grip the shopping cart fiberglass body that protects the components inside the machine It hinges from the front of the machine Throttle qrip Located on the right side of the steering handle In manual control it is twiste
75. OVE THE CONTROL PANEL COVER USING THE TOP FOUR SCREWS CHECK RESISTANCE WITH A METER BETWEEN TWO POSTS WITH SOLDERED WIRES ON THE BACK OF THE KEY RESISTANCE SHOULD BE INFINITE WITH KEY OFF AND 1 OHMS WITH KEY ON CHECK FOR DAMAGED EMERGENCY SHUT OFF SWITCH THE BLUE EMERGENCY SHUT OFF SWITCH WAS USED ON EARLY QUICKARTS AND SPRINGS OUT AFTER BEING PRESSED IN THE RED EMERGENCY SHUT OFF SWITCH IS USED ON LATER QUICKARTS AND STAYS IN AFTER BEING PRESSED IN THIS SWITCH MUST BE MANUALLY PULLED OUT TO ALLOW THE QUICKART TO TURN ON TO TEST THE EMERGENCY SHUT OFF SWITCH REMOVE THE CONTROL PANEL COVER USING THE TOP FOUR SCREWS CHECK RESISTANCE WITH A METER BETWEEN TWO POSTS WITH CONNECTED WIRES ON THE BACK OF THE SWITCH RESISTANCE SHOULD lt 1 OHMS WITH EMERGENCY SHUT OFF SWITCH OUT AND INFINITE WITH SWITCH IN CHECK FOR DAMAGED CONTROL PANEL WITH KEY OFF NO LIGHTS SHOULD BE ON WITH EMERGENCY SHUT OFF BUTTON PUSHED IN REMOVE THE CONTROL PANEL COVER USING THE TOP FOUR SCREWS AND DISCONNECT INTERNAL HARNESS CONNECTORS CHECK FOR DAMAGED HORN WITH KEY ON THE HORN SHOULD OPERATE FROM THE CONTROL PANEL OR THE REMOTE IF THE HORN DOES NOT OPERATE JUMPER THE HORN TO TEST OPERATION UNPLUG THE HORN CABLE CONNECTOR FROM THE JUNCTION BOX USING TWO SHORT WIRES CONNECT THE RED POSITIVE BATTERY CABLE TO THE EYELET OF THE HORN RED WIRE THEN CONNECT THE BLACK NEGATIVE BATTERY CABLE TO THE EYELET OF THE HORN BLAC
76. P button Sudden stops will require the operator to hold back the lead cart at the front of the train to prevent cart separation In an emergency press and hold the stop button until you walk over and shut off the key When the QuicKART 2000 is stopped the parking brake automatically engages This prevents the QuicKART from rolling on slopes or being pushed manually If it is necessary to push the QuicKART i e dead battery or machine not working the parking brake can be released by pulling the release lever marked Brake Release on the lower right corner at the back of the machine Once the parking brake is released the QuicKART will not operate until the parking brake is pushed back in It is recommended that the brake be released only if batteries are dead and manual pushing is required The QuicKART 2000 follows the train of shopping carts as guided by the cart attendant The actual turning radius of the cart chain is a function of the design of the shopping carts being used The tighter the carts nest together the longer the turning radius will be After some experience the QuicKART operator will become familiar with this and be able to judge what turns will be practical In practice the operator places one hand on the cart at the front of the train walking along side and guiding the cart in the desired direction The other hand is used to operate the hand held remote control transmitter When turning the cart chain it is easier to ma
77. QuicKART 2000 Series Service Manual 39 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 Inspect throttle turn keyswitch to On The cart should not move Check that the RH throttle grip moves freely in a CW direction The cart should move forward Push the reverse button the cart should move backward Test the brake system With the keyswitch Off try to move the X machine The brake should keep the drive wheels from rotating Test the Emergency shut off button With the cart in Manual or Remote pressing the Emergency shut off will disable all controls and X stop the machine otrobe Light Check for damage and proper operation X Remote Check for damage With the cart in Remote check operation with all buttons The remote should operate up to 100 from X the machine _ Charge batteries overnight every night Check couplers and yokes for unsafe wear loose or missing fasteners X and safe connection Batteries Inspect loose connections frayed insulation and corrosion Clean away corrosion Check charger operation Wiring Inspect all wiring and electrical connections for loose connections frayed or deteriorated insulation exposed wire and broken or missing hardware Maintenance Type Batteries Check water levels add distilled water as necessary Check the machine for damaged or missing labels Che
78. ROVIDER CHECK TRANSAXLE YES NO PHONE 763 544 7779 763 544 4234 4 QUICKART 2000 SERIES TROUBLESHOOTING CHART 570020 gt ori DWG DATE 3 1 06 QuicKART 2000 Series Service Manual 48 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART DOES NOT IN RADIO DANE TECHNQLOGIES WITH KEY ON PRESS RADIO ON THE CONTROL PANEL PUT QuicKART IN MANUAL MODE GO TO QuicKART DOES NOT OPERATE IN REVERSE PG 7 DID THE MANUAL IGHT ON THE PANEL CHECK ALL REMOTE BUTTONS ON JUNCTION BOX FOR STATUS REPEAT FOR EACH BUTTON PRESS THE STOP BUTTON ON THE REMOTE REMOTE MAY NOT BE WORKING PROPERLY CAN YOU TRY ANOTHER REMOTE REPROGRAM YES PID THE JUNCTION BOX BRAKE LIGHT TURN NO lt H EALL BUTTONS ECKED AND WORKING PROPERLY NO REPLACE BATTERY IN REMOTE SEE SECTION 1 OF THE OWNERS MANUAL YES HAS BATTERY IN REMOTE BEEN CHANGED PUT QuicKART IN RADIO MODE TURN QuicKART OFF THEN ON REPROGRAM THE REMOTE TO THE QuicKART SEE SECTION 1 OF THE OWNERS MANUAL CALL YOUR SERVICE PROVIDER BAD CONTROL PANEL OR BAD GREEN WIRE IN CABLE DID THE QuicK ART HORN SOUND PUSH
79. Rev 3 1 06 ORIENTATION QuicKART 2000 MANUAL MODE Manual Mode is defined as operating the QuicKART while walking behind the QuicKART 2000 Direction is controlled by the handle bar Speed is controlled by turning the twist grip throttle Direction is controlled by touching the touch pad switch located on the control panel When the switch is pressed the direction changes between forward and reverse as indicated by the direction light REMOTE MODE See diagram on page 33 Remote Mode is defined as operating the QuicKART with the remote control while standing or walking alongside the lead cart of the cart chain coupled to the QuicKART 2000 Steering is controlled by guiding the lead cart in the desired direction Forward speed brakes and horn are operated with the hand held radio remote control While in remote mode the QuicKART will only move forward CONTROL PANEL See diagram on page 33 At the top of the Control Panel are five lights that show the percent of remaining battery capacity Battery Charge Level When the batteries are fully charged the light at the 100 mark will be lighted As the QuicKART is used throughout the day the lights will slowly change from 100 to 80 60 and 40 until the light for 20 is lighted The charging level is most accurately shown when the QuicKART is pushing carts When the 20 capacity light starts to flash on and off it means there are approximately 4 minutes of remaining power before the
80. S JHL DNILYVILS 3 LSVTdO 1015 OL A THIN3SSV ONY HOLY HOOH Od 8 ONDITVM 3 TIHA dVH LS N31HOHS OL A 1qQ31v3d3tu dVYLS JO 35001 Nd MOOH SNIQTOH 11115 FWHM HO1V 1 30 09 131 59 HV83 10NVH MOOH 3AONW3H ONVH H3HLO HLIM 3015 OL dVHlS MOTIV OL QNVH HLIM HOLY dVH lS 353138 V SLEVO ONIAOIN3H N31H9IL OL dVH 1S 30 35001 T1Nd MOOH SNIQTOH 1115 3 TIHM HOLY 40 OD 131 2 s 1Hvo aaaav OL SAOWSY H3HLO HLIM 8 3dris OL 5 MOTIV OL dVHl1S 35943413 V SLEVO SNIGGV 3110 dVHlS ONIAOIN dvdls 3SOO 1 d 10H OL LHV9 NI H3NIV LNOO 32V Id 2 j es U HAN FETA HU QU art 00 a HV83 IONVH Lgv2 lSV1OL dVHlS 311 10 Service Manual QuicKART 2000 Series Dane Technologies Inc 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 970 011 Rev 3 1 06 www danetechnologies com STEEL CABLE 100 140 Cart Restraint with cable QUICKART __ a 400 006 5 16 18 BOLT 4 5 1 2 SOCKET REQ D 220 045 SUPPORT gt P IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIll BOLT HOLE AT BOTTOM w 400 142 7 16 14 x 4 LG BOLT 410 014 7 16 14 5 8 SOCKET REQ D LOCK NUT 11 16 SOCKET REQ D DANE INDUSTRIES
81. T CONNECTED TERMIRHAL B AGK NYLON WIRE TIES 3 BLACK BRAKE LAMP APPLY TAPE TO TERMINALS DANE INDUSTRIES Inc 400 Nathan Lane N 160 PHONE 763 544 7779 EE 63544 4234 BEACON POST ASSEMBLY WIRING FOR QUICKART 2000 QUICKART 2000 EUROPE gt 072400 Dane Technologies Inc QuicKART 2000 Series Service Manual 97 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 100 248 QuicKART 2000 BREAKAWAY BEACON G82 ZOF ONY 01007 X 0 S00 0 XXX 0 0 007 2X0 IH3SNL LAD 600 029 093 SJONVETIOL rors 190 0 90 8 3AO8V 031310345 SV uyw Hd a na 90 498 8 oma on anv 98 023 som v pet sso Pf SPC 001 ONN 584 xv r lt gt 6222 75 92 3NOHd vo SIIHLSNANI INYO ONITIVLSNI 3MO4d38 MWESIONVH H1 N LH3SNI 39318 HOWa OL 3AIS3HQQV AlddV STVH NI 4 V A18W3SSV NIYNA Qquvno 3 vaa TINYH 38 LN3SNI 8 w k s ANTIONIANS 311007 3AIS3HGV 600 079 6 w GZ L X Z L dIHLS WVO4 10 005 8 WYO4 M TANIA dY ANNOY 1193 S NZ 91 8 1 610 017 9 NZ SZ X 91 8 1108 060
82. TTERY AND CHARGER PROBLEMS PG 10 YES Dane Technologies Inc DANE TECHNOLOGIES QuicKA M D OPERAT STILL UNACCEPTABLE GOTO BATTERY AND DANE TECHNOLOGIES Inc 7105 Northland Terrace Minneapoli TITLE QUICKART 2000 SERIES TROUBLESHOOTING CHART DWG PART NO QuicKART 2000 Series OPERATE THE CARTS FOR AN ADDITIONAL 30 DO THE LIGHTS INDICATE A LOW CHARGE DID THE QuicKART GO SLOW OR STOP RT TO PUSH INUTES GOTO BATTERY AND CHARGER PROBLEMS PG 10 YES NO ALL YOUR SERVICE PROVIDER BATTERY CHARGE LEVEL DISPLAY PROBLEMS YES t IF QuicKAR ING TIME IS Qromooars gt PHONE 763 544 7779 S FAX 763 544 4234 MN 55428 970 020 GELEE DWG DATE 3 1 06 Service Manual 23 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART BATTERY AND CHARGER PROBLEMS CHECK AND FILL WATER IN BATTERIES AND CHECK CABLE CONNECTIONS BEFORE PROCEDING DANE TECHNOLOGIES GOTO PG 11 BATTERY VOLTAGE SHOULD BE 43 5 VOLTS CHECK BATTERY VOLTAGE BATTERY IS NOT FULL CHARGED CALL YOUR SERVICE PROVIDER BATTERY OR CHARGER MAY HAVE A PROBLEM NO WITH KEY OFF PLUG IN BATTERY CHARGER THIS INDICATES THE FLOAT STAGE
83. Technologies Inc QuicKART 2000 Series Service Manual 55 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART WILL NOT TURN OFF QuicKART JUMPS INTO MANUAL MODE QuicKAR JUMPS INTO MANUAL DOES THE QuicKART TURN OFF GOTO QuickKART DOES NOT OPERATE IN RADIO PG 5 NO YES DOES THE CONTROL BOX TATUS TURN OFF CALL YOUR SERVICE PROVIDER CHECK KEY SWITCH AND CONTROL PANEL DOES THE QuicKART RUN SLOW YES NO CALL YOUR SERVICE PROVIDER CHECK JUNCTION BOX DISENGAGE OLD BRAKE AND PLUG IN NEW BRAKE TO JUNCTION BOX ALL YOUR SERVICE PROVIDER QuicKART OPERATES SLOWER AN NORMAL REPLACE DOES THE QuicKART YES NO CALLYOUR SERVICE PROVIDER REPLACE BRAKE DANE TECHNOLOGIES Inc mm T 7105 Northland Terrace ae TITLE QUICKART 2000 SERIES TROUBLESHOOTING CHART TTS 970020 miro DWG DATE 3 1 06 Dane Technologies Inc QuicKART 2000 Series Service Manual 96 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 CAUTION SERVICE PROVIDER INFORMATION ONLY INSTRUCTIONS GIVEN ON THIS PAGE MAY DAMAGE COMPONENTS DO NOT ATTEMPT ANY ACTION ON THIS PAGE UNLESS YOU ARE QUALIFIED CHECK FOR DAMAGED KEY SWITCH REM
84. Two screws hold the brake assembly to the back bell housing of the motor This arrangement means the braking action is through the differential gear box With the lever in a counter clockwise rotation viewed from the end the brake pad is pressed between a fixed and movable plate in the brake housing When 36 volts are applied to the brake coil the movable plate releases the brake pad and allows it to turn with the motor In the QK 2000 36 volts is used to release the brake but after a few seconds it drops to approximately 18 volts to reduce battery consumption and heat generation Dane Technologies Inc QuicKART 2000 Series Service Manual 60 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 The frame is of a one piece welded construction using 3 16 is steel The welded assembly is black powder coated Most of the bolt holes in the frame are tapped so nuts are not required 8 Attached to the underside of the frame is a belly pan held in place with two bolts near the center and three bolts at the bottom of the back This belly pan protects the motor axle assembly from contamination driving over curbs or running over objects The belly pan must be removed if any of the motor axle parts are to be serviced or replaced 9 The front drive wheels are 12 inches in diameter with four 5 16 18 bolts holding it to an aluminum hub The hub is clamped and key
85. UICKART OPERATOR S MANUAL PRE OP CHECKLIST URPLUG THE BATTERY CHARGING CORD s PERFORM A COMPLETE SAFETY CHECK T ENSURE THAT ALL EQUIPMENT 15 WORKING PROPERLY INCLUDING 1 EMERGENCY SHUT OFF 2 THROTTLE 3 HORN SAFETY LIGHTS 5 CONTROL 6 AUTOMATIC BRAKE DO HOT OPERATE THE CICKART IF ANY PART IS HOT WORKING CORRE TELL YOUR MANAGER EMMEDIATEL AND CALL DANE TECHNOLOGIES AT 1 888 544 7778 STOP before performing any service or maintenance procedures refer to the QuicKart owner s manual for full instructions and CAUTION THE BATTERY CABLE MARKED WITH A YELLOW BAND MUST BE DISCONNECTED ANY TIME MAINTENANCE 15 BEING DONE UNDER THE COVER BEFORE PERFOMING ANY MAINTENANCE ON THE QUICKART TURM OFF AND REMOVE THE KEY MAKE SURE THE QUICKART IS ON A LEVEL SURFACE SECURE COVER OPEN SUPPORT MUST BE PROVIDED AND WHEEL BLOCKED BEFORE CHANGING TIRES SEE INSTRUCTION MANUAL SAF TET PRECAUTIONS USE PROTECTIVE EYEWARE AT ALL TIMES DURING MAINTENANCE CHEMICAL SPLASH GOGGLES FACE SHIELD DO NOT PERMIT OPEN FLAME SPARKS OR SMOKING IN THE AREA WHERE THE BATTERIES ARE BEING CHARGED OR DURING MAINTENANCE ADEQUATE VENTILATION IS ESSENTIAL FOR SAFTEY DONOTLAY METAL OBJECTS ON THE BATTERIES BATTERIES ARE HEAVY LIFT CAREFULLY TO AVOID INJURY IMPROPER MAINTENANCE PROCEDURES MAY VOID THE MANUFACTURER S WARRANTY INFORM YOUR MANAGER AND DANE INDUSTRIES IMMEDIATELY IF THE QUICKART IS NOT WORK
86. WITH THE MOTOR INSTALLED IN THE TRANSAXLE OR WHEN THE MOTOR HAS BEEN REMOVED IF DONE CAREFULLY TOUCH A MOTOR WIRE TO EACH OF THE POS AND NEG TERMINALS OF ONE BATTERY MOTOR SHOULD TURN AT A SPEED NOT TOO FAST OR TOO SLOW IF THE MOTOR SHAFT IS NOT VISIBLE THE WHEELS SHOULD TURN IF THE MOTOR DOES NOT TURN SMOOTHLY REPLACE THE MOTOR QuicKART 2000 Series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
87. YES THROTTLE IS OFF OR CALL YOUR SERVICE PROVIDER BROKEN OR CALL YOUR SERVICE PROVIDER CHECK CONTROL PANEL OR CHECK JUNCTION IS THE JUNCTION BOX DRIVE COMMAND YES CALL YOUR SERVICE PROVIDER CHECK CONTROL PANEL OR HECK JUNCTION DID PRESSING REVERSE TURN HE LIGHT ON NO WHEN THE THROTTLE IS TWISTED DID THE QuicKART MOVE IN EVERSE YES NO THE QuicKART HAS RECENTLY HAD REPAIRS CALL YOUR SERVICE PROVIDER CHECK AND REVERS DID THE QuicKART MOVE FORWARD YES NO DOES THE JUNCTION BOX DRIVE COMMAND HT TURN O GOTO QuicKART MOVES INTERMITTANTLY PG 8 YES NO CALL YOUR SERVICE PROVIDER CHECK FOR BROKEN THROTTLE QuicKART 2000 Series DANE TECHNOLOGIES QuicKART MOVES THE WRONG WAY OR MOVES IN REVERSE ONLY WITH KEY ON PRESS MANUAL ON THE CONTROL PANEL REPEAT FOR REVERSE PRESS FORWARD REVERSE ON THE CONTROL PANEL TWIST THE THROTTLE TO MOVE IN FORWARD REVERSE DID THE QuicKART MOVE FOWARD YES 2ND D THE QuickKART MOVE IN REVERSE QR FORWARD CALL YOUR SERVICE PROVIDER CHECK CN5 1 YES POT QuicKART IN RADIO MODE AND PRESS THE RABBIT FAST TURTLE SLOW REMOTE BUTT REPEAT FOR TURTLE SLOW DID THE QuicKART OVE FOWARD FAST YES 2ND NO
88. a long period of time days to months The terminal voltage of the batteries has decayed to less than 1 75V per cell then the charger may require up to 3 hours of pre qualification controlled charging This is to determine if the batteries will even accept a charge The charger will not function if the total voltage of the three batteries is less than 18 volts Between 18 and 24 volts the charger will slowly charge the batteries During this extended testing stage the Yellow L E D will flash at a slow rate CONSTANT CURRENT CHARGE STAGE TWO Once the Pre Qualification Test completes successfully the Yellow L E D illuminates continuously indicating that the charger is charging the batteries at the full rated output of 16 amperes This stage ends when the batteries state of charge is at approximately 50 70 The voltage during this period will be about 41 volts CONSTANT VOLTAGE CHARGE STAGE THREE The Green L E D flashes on and off and the Yellow L E D flashes fast This stage is also referred to as the Absorption Charge or Equalization Charge since the individual cells inside the batteries are forced to become equalized in charge This stage is exited when the state of charge of the battery has approached near or is at 100 charge The voltage will peak at about 43 5 volts when the charger disconnects FLOAT CHARGE STAGE FOUR This final stage is signaled with the Green Charged L E D on The Trickle Charge will begin
89. ck body for damage Check all bolts fasteners and connections for tightness and wear X Check tires and caster wheel for wear bent rims and missing or loose lug nuts Check the antennas for damage EN Check tires and caster wheel for wear bent rims and missing or loose lug nuts Check the AC charger cord for frayed or deteriorated insulation and exposed wire X Apply grease to rear swivel wheel using a standard grease gun two places Have your authorized service center check your QuicKART completely _ _ xxx xxx lt Dane Technologies Inc QuicKART 2000 Series Service Manual 40 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 CHANGING FRONT TIRES FRONT DRIVE TIRES Turn QuicKART off and remove key QuicKART must be on a flat surface Make sure the automatic brake is functional and on Use protective eye wear at all times 1 Slightly loosen the four 4 lug nuts about 1 2 turn from the wheel needing service Use a 9 16 inch socket on the QK 2000 12 inch tires Use a 5 8 inch socket on the 16 inch tires for the QK 2500 IMPORTANT Do not remove any of the nuts only slightly loosen them while the wheel is still on the ground 2 Use a jack to lift the front of the QuicKART off the ground approximately 2 to 3 inches Insert a sturdy and stable block under the frame to hold it securely in this elevated position
90. d X3QNI TWIMSLYW dO 7118 A8 SHLGIM LHVO Q3MOTIV S3SV3MHONI S33 ldn1OO 925 027 ONY 895 022 JHL ONISH3A3MH S 96 H3AO OL S 8 SHLGIM 380 L 3415 LYYO ONY Ol STOL NOUS SLHOI3H QOH LNOMNHJ LHVO SAMOA Z ST H3AO OL SHLAM 3015 L4Vv2 HOJ ONY 5 OL WOYS SLHOI3H HV3H LHVD HOJ 5310 QON SLYVD OL LdvVOV OL S3304A OOY 929 022 ONY 899 022 E NOILVTIVLSNI GOH 40 109 TWNOILdO 6 92 S S S LL 005210 QNHVONVIS 6 c m 00 vi SC OL 00020 i S 6Z S LZ LdO 1 61 4 5 9z S 9 S pZ S 9L 62 E 1 140 096 006 140 phar Por 0 SZ O L1 26 Service Manual QuicKART 2000 Series Dane Technologies Inc 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 970 011 Rev 3 1 06 www danetechnologies com AIS 3543H10 SS3TN Z0 319NV 01001 3AO8V SV 11 Ag po inr 6z arva cog 133H8 0 IWS rF0 0S8 LHvd oMO S330A Q3SIv4 GOY Ni dOwd TUL 27795 NW wnouAd Vni gt eg le io U S3IHLISnONI INYO LYV9 OILSV d 25 1 TVLIW TIVWS 8 Lavo Z 30S SSNOA WO GSAOWSY 38 OL NOILISOd NI 133 LYVD SNIMOHS 27 Service Manual QuicKART 2000 Series Dane Technologies Inc
91. d to give the required speed when walking behind the machine in forward or reverse Hand grip The rubber grip on the left side of the steering handle Brake release A lever that releases the brake on the end of the motor by hand This lever has a black knob which is on the lower right of the back panel When it is pushed in it is in normal operating position Pulled out will turn off all the electronic controls and release the brake so it can be moved by hand Hinge Allows the body to be opened for viewing the insides of the machine This hinge is made of stainless steel so it will not rust Dane Technologies Inc QuicKART 2000 Series Service Manual 67 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QK 2000 Curtis Junction Box Test Voltages Service Bulletin 985 002 November 1999 The junction box part number 100 060 used in conjunction with the Curtis motor control is used as standard equipment on all QK 2000 machines with serial numbers from 119 and higher Plugs are left in their sockets and the machine is turned on for these tests Use a thin probe on the voltmeter to make connections to the pins from the outside of the connector The voltage readings are from the Neg side of the battery to points listed below on side of junction box 3 cir Plug CN 4 to hand grip throttle control 1 blue About 5volts 2 br
92. date shipment 2 Labor Ninety 90 Day Limited Warranty from date of shipment 3 Batteries Covered by the manufacturer s warranty 1 PARTS Limited Warranty All parts except batteries covered by battery manufacturers warranty tires and circuit breakers needing resetting are warranted by Dane Technologies to be free of defects in material and workmanship for a period of one 1 year from date of shipment This warranty does not include tire wear or wear and tear caused by abuse negligence freight damage or damage caused by improper use or care or by external sources such as fires floods or other acts of God Should any component fail during the first year of ownership except those mentioned as not under warranty the component in question is to be returned to Dane Technologies or to an authorized Dane Technologies representative for inspection lf the component has failed due to a defect in material or workmanship it will be exchanged or repaired at the discretion of Dane Technologies at no charge to the QuicKART owner Dane Technologies Inc will cover the costs of shipping parts covered under warranty to the customer based on UPS standard ground rates 2 LABOR Limited Warranty Dane Technologies will cover labor charges for work performed in the field for ninety 90 days from the date of shipment as a result of defects in materials or workmanship Charges incurred for failure to charge and maintain the batteries in
93. dn 19NI dauoo szz 004 _ m NINOLOANNODOL g a S HOLOSNNOD dl 05 AHD ES c gt rh LOIN Wad 0Z t L oe Ss j I 1 1 el Vra J3MOd 2v 304 3101430381 E TANYA OO A L diAv 0 LFEOSE L SACMIONI 106 Service Manual 970 011 Rev 3 1 06 QuicKART 2000 Series 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com Dane Technologies Inc 110 066 CART RESTRAINT ASSEMBLY REMOVE AND DISCARD HOOK PASS SHOPPING CART 430 034 STEEL CABLE HANDLE BAR OVER CART BUCKLE STRAP 15ft 460 030 RESTRAINT MAST AS SHOWN SPRING HOOK THIS HOOK ATTACHES TO Go LEAD SHOPPING CART TUTTI i 4 o om CART TO YOKES DANE INDUSTRIES Inc PHONE 763 544 7779 5400 Nathan Lane N 150 Plymouth MN 55442 7 FAX 763 544 4234 TITLE RELEASE ECO CART RESTRAINT ASSEMBLY 216 TO T0006 DWG DATE 1 25 02 Dane Technologies Inc QuicKART 2000 Series Service Manual 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 STEEL CABLE 100 140 Cart Restraint with cable za QUICKART Ta 400 006 5 16 18 BOLT 4 h 1 2 SOCKET REQ D T umma
94. e Technologies Inc QuicKART 2000 Series Service Manual 45 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART OPERATES CORRECTLY TURN KEY TO ON POSITION LEVEL LIGHTS ORWARD LIGHT AND RNLIAL MODE LI GO TO QuicKART DOES NOT OPERATE PG 4 ARE ANY STATUS LIGHTS ON THE NCTION BOX ON GO TO QuicKART DOES NOT OPERATE PG 4 YES NO PUSH HORN BUTTON HORN SOUNDS TuicKART MOVES FORWARD AND PUSH DIRECTION BUTTON FROM FORWARD TO REVERSE AND REVERSE O FORWARD QuicKART WORKS IN ONLY MANUAL AND ONLY RADIO RESPECTIVELY PUSH MODE BUTTON FROM MANUAL TO RADIO AND FROM RADIO TO MANUAL PUSH MODE TO RADIO PUSH MODE TO MANUAL Dane Technologies Inc QuicKART 2000 Series CAUTION TROUBLE SHOOT WITH THE QuicKART IN A CLEAR AREA AND ALL NEARBY QuicKARTS TURNED DANE OFF TECHNQLOGIES DANE TECHNOLOGIES Inc 763 544 7779 7105 Northland Terrace r iY DER SOAM WOODSI po VD TILE QUICKART 2000 SERIES TROUBLESHOOTING CHART ame _ Is DWG DATE 3 1 06 Service Manual 46 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 CAUTION MANUAL OPERATION TROUBLE SHOOT WITH THE DANE TECHNQLOGIES QuicKART
95. ed 11 Replace the back with the two Phillips screws 12 Reprogram the remote control as described on page 38 Dane Technologies Inc QuicKART 2000 Series Service Manual 37 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 BACK COVER RE PROGRAMMING THE REMOTE CONTROL Each hand held remote control transmitter operates on a unique pre programmed code For the QuicKART to operate in the Remote Mode the receiver which is in the beacon tower must be programmed to match the hand held remote control Every time the batteries in the remote control are replaced the remote control needs to be reprogrammed to match the receiver code in the beacon tower If the QuicKART stops responding to the remote control check the status of the remote battery by depressing one of the remote buttons If the red LED light does not illuminate change the battery and reprogram the remote control as follows Turn on the QuicKART Switch to RADIO on the control panel Hold remote about arms length from the beacon post Simultaneously push these three buttons e Rubber button located on the underside of the square box on the beacon post see pages 16 and 17 e Stop button on the hand held remote page 33 e Horn button on the hand held remote page 33 The horn should sound indicating the reprogram is complete and the QuicKART is ready for ope
96. ed to the axle These drive wheels are available as either pneumatic or foam filled Available tread types include saw tooth knobby or snow lugs Tire chains for traction in snow are also offered 10 The standard batteries are deep cycle maintenance free group 27 rated at 180 minutes of reserve capacity 11 The beacon post contains three major components strobe light brake light and radio system It is mounted in a channel on the back of the machine with two bolts The beacon tower can be folded down for shipping or storage by removing the bottom bolt loosening the top bolt which also acts as a hinge point In doing this the cable at the bottom of the beacon post must first be disconnected from the junction box and its end pulled through the hole in the back of the frame on older models Newer models have long cables that do not have to be disconnected 12 The strobe light remains flashing whenever the machine s key switch is turned on unless the emergency stop switch has been pressed Re cycling the key will restart the machine The strobe light will operate when the manual brake release lever is pulled out The strobe light bulb can be reached by unscrewing the colored lens 13 The brake light comes on whenever the drive motor acts to slow the machine down by releasing the hand throttle grip or letting up on one of the two remote speed control buttons The brake light uses a 36 volt bulb or LED light 14 The radio system is o
97. ency Shut OFF switch on all models except the PP3000 PP3100 PP3150 The switch is called the Emergency Reverse switch on the PP3000 PP3100 PP3150 2 BB check wire open LILILI LILI EM Brake driver fault 1 Electromagnetic brake coil open 2 Electromagnetic brake wiring open LILILI LILILI Throttle fault Throttle fault 1 1 Throttle input wire open 2 Throttle input wire shorted to ground or B 3 Throttle pot defective 4 Wrong throttle type selected OOO O000 Not Used LILILILI LI Low battery voltage 1 Battery voltage below 21 volt cutoff level 2 Corroded or loose battery terminal 3 Loose controller terminal LILILILI LILI Overvoltage 1 Battery voltage above 48 volt cutoff 2 Vehicle operating with charger attached LILILILI LILIL Over under temperature cutback Thermal cutback 1 Temperature more than 95 C or less than 25 C 2 Excessive load on vehicle 3 Improper mounting of controller 4 Operation in extreme environment OOOO 0O000 Not Used Dane Technologies Inc QuicKART 2000 Series Service Manual 71 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QK 2000 and QK 2500 Drive Wheel Aluminum Hub Service Bulletin 985 007 May 1999 There are two aluminum hubs that clamp on the ends of the two axle shafts which drive the wheels that propel the QK 2000 and the QK 2500 machine These hubs are the same for both sides
98. er Improper usage and operation of the QuicKART may void the warranty 2 You must be at least 16 years old with a valid driver s license or vision test to operate the QuicKART In certain states regulations may require operators to be older Please check your states regulations regarding operation of motorized equipment before using the QuicKART 3 Never carry passengers on the QuicKART 2000 4 The QuicKART is equipped with a brake which automatically engages when the machine is turned off or not in motion To avoid an accident do not leave the machine parked or unattended on slopes When the QuicKART is to be left unattended or in storage turn it OFF and remove the key 5 Do not leave the QuicKART unattended while it is turned ON 6 Operate the QuicKART at a safe speed go only as fast as safety considerations allow Take into consideration the location of store entrances sidewalks pedestrian and vehicle traffic driveways and parking lot layout 7 Always operate in slow speed when near store guests Operating conditions such as wet or slippery pavement or slopes can affect the stopping distance of the QuicKART Do not push more carts than the individual operator can safely control when those conditions are present Do not exceed 30 carts at a time under any circumstance Refer to your store policy for the maximum cart number 8 Verify all warning and emergency labels are legible and mounted in correct areas sho
99. he remote is powered by internal batteries which should be changed every two months for dependable operation The small light on the remote will cease to operate when the battery needs replacing After battery replacement the remote must be reprogrammed see page 38 for details The QuicKART is a productivity enhancing tool which will be most effective when it is well maintained and used responsibly Training of employees is very important Please read and review this manual We strongly recommend that a training and operator certification program be developed and implemented to assure adequate training and safe operation The use of the Dane Technologies Cart Depot creates an integrated system for cart collection which enhances productivity even further Additional optional accessories are also available These include an optional snowplow snow tires and chains Dane Technologies Inc QuicKART 2000 Series Service Manual 15 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART 2000 TOP VIEW FIBERGLASS BODY CART COUPLER YOKE LEFT STOP BUTTON CART COUPLER YOKE RIGHT THROTTLE GRIP SYSTEM JUNCTION BOX LATCH PIN QuicKART 2000 REAR VIEW BEACON TOWER REMOTE CONTROL PROGRAMMING BUTTON j THROTTLE GRIP STOP BUTTON TOWER BOLT _ STEERING HANDLE TOWER SUPPORT BRACKET c
100. hould be wiped clean before inserting a replacement throttle grip The wire cable from the throttle grip is fed through the small hole on the control panel box and the grip is butted up against this box and the two clamping screws are tightened After installing a throttle grip turn it to the full on position several times to assure it is not sticking Inside the box are three wires which match the colors of the throttle grip Attach each of these wires as shown in the attached drawing To test a throttle grip when it is not connected to the machine in its off position use an ohmmeter between the wires as shown below Brown to Black 0 ohms to 5 000 ohms Brown to Blue 5 000 ohms to 0 ohms Blue to Black 5 000 ohms By twisting the throttle grip when disconnected from the machine the following change in resistance will be noted Blue to black will remain at 5 000 ohms Brown to black will go from zero ohms to about 5 000 ohms Blue to brown will go from 5 000 ohms to zero ohms Dane Technologies Inc QuicKART 2000 Series Service Manual 14 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 By twisting the throttle grip when the machine is tuned on manual mode the following voltages will be measured Black to blue 5 volts will not change with throttle position Brown to blue 5 volts will decrease to zero volts as the throttle is twisted ful
101. hts up the battery does not need replacing 2 Before opening the remote turn off the QuicKART that had been using this remote If another remote is being used by this QuicKART it is OK to proceed 3 To open remote control place the control panel face down on a table top and use a medium size Phillips screw driver to remove the two 2 screws from the corners of the remote s back cover 4 After the screws are removed leave the remote face down and remove the back cover 5 replace the batteries take out the old batteries and replace them with new ensuring that the new batteries are inserted as diagramed inside the battery compartment Properly dispose of the old batteries in an environmentally correct depository Examine the inside of the remote for any signs of condensation or water If signs of moisture are present allow the compartment to dry fully before replacing the back 8 Before replacing the back ensure that the gray rectangular gasket around the edge of the battery compartment is in good condition If the gasket is damaged return the remote to Dane Technologies for repair 9 Also ensure that the red and black wires leading away from the battery terminals and the black wire at the opposite end of the remote are intact If they are broken return the remote to Dane for repair 10 The QuicKART should be off Before replacing the back ensure the panel light comes on when any one of the function buttons is press
102. ice Manual QuicKART 2000 Series Dane Technologies Inc 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 970 011 Rev 3 1 06 www danetechnologies com 150 036 QuicKART 2000 BASIC CHASSIS WALMART 03912345 33 MH3H 10 553 WN aif JENY XXO XXXO oor xo 0321519345 SV uwi S3OHvH3 VOL JEL ZD t aae VN swos HOchawso 90 091 on merona 2345 S002 1H V WTVM SISSVHO 2IS VB 0002MO suu iwyd BEF NA WE 3 pz GL PFS ESL 5319 LISTON NYA NWd A1138 ZE0 0 te peoo 272 8 1nN S 01 195335 Cer 0313130 sie cca 7 4 3 HINNAN Taas devis gt 3ACW3H ziHS 335 ze000rS vM ran 900 09 d co cor sior SAI EICOP On cer I33HM3AHG ig SMD Z0 cer sez sorzei g BHONDI Q3 T TI NVO SRO es 910 092 V t 1 108 133 E TA AIMS V 610 01 881 00 11O8 3A3 010 017 1 ozo ozz X lt 13x0vH8 EF aa 1SOd NOOV38 jou 7 900 00F 2 1708 P A E 901 00 d3oVds J 8c 1 00 ip 1108 d fg 520001 J 1 v RN Fy i 00 006 920001 SN ana A35 ASSY 1 9313 nd E TANYd TOHLNOD FLO 0S dl 19 110 00 8 1108 00 Al8 i3ssv 3AIHQ 21 00t 1108 900 005
103. ice Manual 34 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 REMOTE The QuicKART can be operated in the remote mode by pressing the Radio Manual switch located on the control panel 1 While in remote mode only one person is needed to collect shopping carts This person gathers the carts and adds them to the train while using the remote control to control forward speed braking and the warning horn It is recommended that carts be formed into a line and then the machine brought up to the line in the SLOW speed to nest the carts Continue to use the SLOW speed while operating near entrances and near store guests Never use the fast remote speed near guests the entrance or within the store NEVER press on the remote buttons unless you are at the front of the cart chain and controlling the lead cart NEVER advance additional carts into the store unless you are at the front of the cart chain The SLOW speed is 7Omph The FAST speed allows movement at a safe walking pace of 2 8mph as carts are returned to the store Only one button of the remote control is usable at a time Press the SLOW or FAST button for the speed desired for the existing conditions The QuicKART will briefly coast when the control buttons are released helping to prevent a separation of carts If a sudden stop is required press the STO
104. ill operate normally but only in the manual mode If the problem is somewhere in the control panel circuitry the fault light will continue to flash and the panel lights will go off in about 3 seconds Remote Brake LED lights to indicate presence of Brake command from receiver It has no effect in manual mode Remote Slow LED lights to indicate presence of Slow drive command from receiver Must light in conjunction with Drive Command LED in Remote mode in order to operate machine It has no effect in manual mode Remote Fast LED lights to indicate presence of Fast drive command from receiver Must light in conjunction with Drive command LED in Remote mode in order to operate machine It has no effect in manual mode Drive Command LED lights to indicate drive signal is being sent to motor control Low Battery LED lights when battery voltage is too low to operate machine properly below approximately 27 volts Hour Meter Hourglass symbol blinks every ten seconds when drive command is present to indicate that meter is timing machine operation Dane Technologies Inc QuicKART 2000 Series Service Manual 20 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 CART COUPLER amp ROLLER GUIDE ASSEMBLY COVERBUMPER 480 029 ROLLER GUIDE 480 018 COUPLER YOKE COUPLER FRAME SUPPORT
105. ing the nightly recharging time To put the QuicKART back into service after the batteries are fully charged disconnect the charger s power extension cord from the wall receptacle and from the lower receptacle at the lower left rear of the QuicKART Store the extension cord in an appropriate location Lights on the battery charger show the charging rate Fully discharged batteries will result in a charging rate of up to 15 amperes As the batteries become fully charged this rate will drop to less than 10 amperes A solid yellow light indicates maximum charge a yellow and flashing green indicate partial charge completion A green light indicates completion of charge The red light indicates AC power is connected and on WARNING Do not use long extension cords Use the 10 foot cord supplied with the machine Find a location for re charging that is close to an electrical outlet receptacle If another cord must be used it must be 16 gauge or larger and no longer than 10 feet in length Dane Technologies Inc QuicKART 2000 Series Service Manual 36 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 REMOTE CONTROL BATTERY CHANGING Refer to Diagrams on page 38 1 The remote control is to be taken apart only when the batteries need replacing There are no adjustments or switches inside the module As long as the small light on the remote panel lig
106. intain safe footing by leaning against the lead cart rather than pulling Dane Technologies Inc QuicKART 2000 Series Service Manual 35 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 BATTERY CHARGING The QuicKART 2000 is powered by three 12 volt Deep Cycle batteries Under normal usage they will power the QuicKART for 10 or more hours when the ambient temperatures are above approximately 40 degrees F Colder temperatures will reduce the operating time of the batteries and increase the charging time To optimize battery power store the QuicKART in a room with a temperature of at least 50 degrees F To recharge the batteries park the QuicKART in a well ventilated location near an electrical outlet The QuicKART must be turned off and the key removed FIRST plug the 10 foot extension cord into the connector located at the lower left rear of the QuicKART Use special care to ensure the extension cord is properly seated inside the connector Failure to do so can cause improper charging or damage to the battery charger SECOND connect the charger s 10 foot power extension cord into a wall receptacle The battery charger will automatically shut off when the batteries are fully charged This takes between eight to ten hours depending upon initial state of charge and battery condition Make sure the power to the wall receptacle is not turned off dur
107. ion If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that which the receiver is connected Consult the dealer or an experienced radio TV technician for help The abbreviation IC before the Canadian Registration Number signifies that registration was performed based on a Declaration of Conformity indicating that Industry Canada technical specifications were met It does not imply that Industry Canada approved the equipment The CE mark if present declares that this equipment meets relevant EU Directives and Standards TECHNOLOGIES 3 Operating Instructions QuicKART Electric Utility Machine Manufactured by Dane Technologies Inc Phone 163 544 7779 7105 Northland Terrace Toll Free 1 888 544 7779 Minneapolis MN 55428 Fax 163 544 4234 www danetechnologies com Part No 970 011 Rev Date 3 1 06 QuicKART 2000 SERIES Owner s Manual Operating Instructions Table of Contents QuicKART 2000 WARNINGS amp SAFETY NOTES 5 SL bil u Em Haie
108. k connected to CN 2 pin 14 same readings brake coil white volts ground 4 white volts with brake lever in normal 12 volts with lever pulled out QK 2500 1 brown connected to CN 2 pin 1 same readings brake coil 2 blue connected to CN 2 pin 14 same readings brake coil white volts ground 4 black volts with brake lever in normal 12 volts with lever pulled out Dane Technologies Inc QuicKART 2000 Series Service Manual 69 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QK 2000 Curtis Motor Control Diagnostic Lights Service Bulletin 985 006 May 1999 rev 7 16 03 The QK2000 series machines with a 1237 3402 Curtis motor control box have a fault light as standard equipment At the left side of the Curtis motor controller s label is a 3 16 inch window with the word STATUS written over it This window contains a light which can be used to help diagnose a problem if a machine fails to operate The flashing will be in the form of a code with dots and spaces to identify the fault The LI shown below is a short flash of the fault light the is a space The fault code will be repeated until the fault is corrected or the machine is shut down These fault codes are common for the 1227 controller on the QK1000 PP1000 1237 controller on the PP3000 and 1235 controller on the PP3100 and PP3150
109. llips screw driver 19 2 14 Straight screw driver 20 Medium Needle nose pliers 21 Medium Wire Cutters 22 Medium Pliers or channel lock 23 1 Programmable Programmer 100 106 24 1 16 Molex pin extractor WM 9929 ND Dane Technologies Inc QuicKART 2000 Series Service Manual 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 A DANE EC HINO 21 ae Service Provider Recommended Parts Inventory Suggested Quantities are for every 10 QuicKARTs in your service area Part Description TOTAL 10 QK 360 008 12 tire knobby foam filled 6 Dane Technologies Inc QuicKART 2000 Series Service Manual 112 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 300 033 Brake assy 300 041 Motor axle brake w o hubs 300 042 Gear box w o hubs 300 029 Motor 300 030 Motor brush kit 4 Only needed if 2500 s are being serviced Dane Technologies Inc QuicKART 2000 Series Service Manual 113 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 WARRANTY PARTS REQUIRED BE RETURNED The following parts must be returned to Dane Technologies on all warranty claims Returning the Warranty Claim Form with the par
110. ly Black to brown zero volts will increase to 5 volts as the throttle is twisted fully In addition to these tests it will be noted that there are six diagnostic lights on the topside of the Junction Box inside the machine mounted against the back frame plate The fifth light from the left side is called the Drive Command As the throttle grip is twisted the voltage between the black and brown wire will start to increase When the brown wire is about 0 40 volts this light will turn on inducting the throttle is sending its proper command It does not however indicate if the throttle is working properly over its entire range of travel Dane Technologies Inc QuicKART 2000 Series Service Manual 5 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QK 2000 Battery Pack and Battery Charger Service Bulletin 985 010 July 1999 When the batteries fail to charge check the following items 1 The water acid level has fallen to a level which may have permanently damaged the batteries Note As of January 1 1999 all units are shipped with Delco Maintenance Free M27A batteries Before January 1999 units were shipped with Trojan deep cycle model 30 XHS batteries that require water level maintenance At the end of the useful life of the Trojan batteries the unit can be fitted with the Delco maintenance free batteries if the customer prefer
111. ne of the more sophisticated aspects of the machine It deals with 4 separate commands control functions of which only one at a time is allowed Brake Slow Fast or Horn a The hand held remote has a separate button for each of the four functions When a button is pressed an encoded 418 or 433 MHz radio signal is sent by the remote and picked up by the receiver The remote operates on four AA batteries which should have a life of 2 to 3 months under normal conditions Each hand held remote has a unique built in identification code To program a receiver the stop and horn button are pressed simultaneously while a small button switch is pressed on the bottom of the beacon post box Once the receiver is matched to a specific remote no other remote will cause it to operate If the remote is changed the receiver must be re programmed Dane Technologies Inc QuicKART 2000 Series Service Manual 61 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 b The receiver is located inside the beacon post box It consists of two small printed circuit boards with the receiver being the smallest mounted to the larger mother board The receiver is a superhetrodyne using two separate antennas The electronics of the receiver will lock on whichever antenna has the most signal strength This design is a means of avoiding interference problems and reducing the effects
112. ng until there is no voltage increase across the battery terminals The change increase in voltage must be at least 15 mv in a 40 minute time period in order for the charger to remain on If the charger does not read at least a 15 mv increase battery is then fully charged it will turn off automatically in about 40 minutes If the charger has turned itself off automatically unplugging it and then re plugging it back into the receptacle will restart the charging cycle It will therefore remain on for at least another 40 minutes A fully charged battery pack could read as high as 44 volts for a period of time after charging Dane Technologies Inc QuicKART 2000 Series Service Manual 11 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 DANE TECHNOLOGIES lt m DANE TECHNOLOGIES QuicKART 2000 and QuicKART 2500 EXPLODED VIEW DIAGRAM Table of Contents 150 003 QuicKART 2000 BASIC ASSEMBLY USA 79 150 005 QuicKART 2000 BASIC ASSEMBLY EUROPE 433 MHz 81 150 012 QuicKART 2500 BASIC ASSEMBLY 16 TIRE 83 150 016 QuicKART 2000 BASIC ASSEMBLY UK 433 MHzZz 86 150 017 QuicKART 2500 433 MHZ 88 150
113. nologies Inc QuicKART 2000 Series Service Manual 34 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART AND CHARGER PROBLEMS CONTINUED DAN TECHNO FoGIES VOLTAGE AT EACH BATTERY SHOULD BE BETWEEN 10 5 AND CALL YOUR SERVICE PROVIDER CHECK FROM PG 10 BATTERY VOLTAGE 14 5 VOLTS THE DIFFERENCE VITH A VOLTMETER BETWEEN BATTERIES SHOULD BE LESS THAN ONE VOLT CALL YOUR SERVICE PROVIDER CHANGE ALL THREE BATTERIES IS ONE OR MORE BATTERIES VOLTAGE YES BATTERY LIFE IS RELATED TO THE THE NUMBER OF FULL CHARGE AND CHECK THE AGE OF DISCHARGE CYCLES PROPER THE BATTERIES WATERFILLING AND CHARGER OPERATION GIVE MAXIMUM LIFE MAINTENANCE FREE BATTERIES HAVE SHORT LIFE SOME BATTERIES HAVE LONGER THAN AVERAGE LIFE CALL YOUR SERVICE PROVIDER CHANGE ALL THREE BATTERIES ARE THE BATTERIES OLD YES NO ALL YOUR SERVICE PROVIDER CHANGE ALL THREE BATTERIES CHARGER ALSO MAY HAVE PROBLEMS THE BATTERIES VERY YES CALL YOUR SERVICE PROVIDER BATTERY CHARGER PROBLEM DANE TECHNOLOGIES Inc A PHONE 763 544 7779 7105 Northland Terrace I Minneapolis MN 55428 ED HAT TILE QUICKART 2000 SERIES TROUBLESHOOTING CHART 976020 12 DWG DATE 3 1 06 Dane
114. of the machine The drive axle shafts are one inch in diameter 1 and the hub is held on with a 1 4 square key plus the clamping action of a side bolt nut which closes a slot in the depth of the hub If the axle shafts spin in the hub s center hole without moving the machine the 1 4 square key needs to be replaced This key is a standard hardware store item and has a length of one inch When replacing the Key use the following procedure 1 Lift machine off the ground using the same procedure as you would when changing a rear tire 2 Remove the four lug nuts and pull the wheel off the four studs in the offending hub 3 Loosen the clamping bolt so the hub will be loose on the shaft 4 Align both 1 4 inch key slots Half is in the in hub and the other is in the axle shaft 5 assure the key will not become loose again give it an almost imperceptible bend by holding it between two crescent wrenches and apply a small bending force 6 With a small hammer tap the key into the 1 4 square keyway opening 7 Clamp the hub onto the shaft with the bolt If center hole in the aluminum hub is damaged it must be replaced If one or more of the 3 8 24 studs are broken or the threads damaged it is easiest to replace the entire hub However a stud can be replaced if necessary by first removing the bad stud and pressing in a new one A hammer can be used for this operation but must have solid support to drive in the new stud
115. ologies com 970 011 Rev 3 1 06 OVERVIEW OF The QuicKART is an electrically powered shopping cart collection machine It has several unique and patented features which allow it to be used safely and simply in the shopping cart collection process The QuicKART provides the pushing power for a single employee to safely and easily move a maximum of 30 shopping carts from the parking lot into the store Its ability to Operate in remote control mode allows a single employee to steer the chain of carts from the front of the cart line while controlling the QuicKART as it pushes and follows from behind The QuicKART has proven its ability to work in all types of weather ranging from extreme heat or cold to rain and snow The QuicKART has operated dependably in winter weather as cold as 20 degrees It will also push carts through loose snow On packed snow the QuicKART 2000 will push 10 to 20 carts Winter operation can be enhanced with the use of optional snow tires The QuicKART operates on a 36 volt battery system It will operate for up to ten hours on a single charge Cold weather will reduce operating time It will require eight to ten hours to fully recharge the batteries Each hand held remote control transmitter operates on a unique pre programmed code For the QuicKART to operate in the Remote Mode the receiver which is in the beacon post must be programmed to match the hand held transmitter see page 38 for details T
116. own Changes from 0 to 5 volts with the hand throttle grip twisted 3 black Zero voltage ground 12 cir plug CN 5 to control panel on steering handle 1 green 12 volts when forward direction is selected 0 volts in reverse Note pin 1 and pin 3 should never be 0 volts at the same time 2 black volts 3 white 12 volts when manual mode is selected 0 volts in remote mode Note pin 1 and pin 2 should never be 0 volts at the same time 4 yellow 12 volts When horn is pressed it drops to 0 volts 5 brown High impedence line not easily measurable Ignore 6 red 12 volts whenever key switch is on and 0 volts with key switch is off 7 blue 36 volts whenever key switch is on and 0 volts with key switch off 8 blue 36 volts all the time 9 orange Ignore 10 gray 0 volts normal goes to 12 volt when emergency stop is pressed in 11 none No connection 12 violet 9 volts all the time REV 8 21 03 9 cir plug CN 3 to beacon post 1 yellow 12 volts when remote is selected 0 volts when horn button is pressed on remote 2 brown 12 volts when machine is stopped 0 volts when slow speed is activated by remote green 12 volts when machine is stopped 0 volts when fast speed is activated by remote Dane Technologies Inc QuicKART 2000 Series Service Manual 68 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Re
117. pler Hardware yokes for the cart coupler 2 Remove all the plastic film that is wrapped around the system components Take care not to bend beacon post components especially the antennas when removing the plastic Cut banding material which holds the QuicKART to the pallet 3 Raise the hood to find a small box containing the remote control beacon post bolt and nut and cart coupler hardware Remove this box and set it aside 4 To remove the QuicKART from the pallet use a sturdy wooden board s to create a ramp Remove all straps holding the QuicKART to the shipping pallet Insert the key and turn on the QuicKART Turn the twist grip slowly and guide the QuicKART forward down the ramp to the floor 5 Turn OFF the QuicKART 6 Make sure the machine is OFF the Beacon post hinges from a center position on a bolt and nut already installed Swing it to an 11 00 o clock position Remove the bolt at the bottom of the beacon post bracket Replace the bolt in the bottom holes and tighten lightly Use care not to damage the wires Take care not to damage the antenna lights or the cable connectors at the ends of this beacon post 7 To attach the cart coupler yokes refer to the diagrams starting on page 21 of the Owner s Manual 8 Each hand held remote control transmitter operates on a unique pre programmed code For the QuicKART to operate in the Remote Mode the receiver which is in the beacon post must be programmed to match
118. ration If the horn did not sound retry the above steps making sure that the switch on the control panel is on RADIO If the horn still did not sound you can also determine if the reprogram was successful by pressing the slow button on the remote to see if the QuicKART now responds to the remote signal Dane Technologies Inc QuicKART 2000 Series Service Manual 38 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART 2000 2500 NOTES Check the QuicKART daily for safe operation Routine maintenance should only be performed by those permitted by federal and state age regulations Repairs should only be completed by Dane Technologies or an authorized service technician Federal law requires that you must be at least 18 years old to service the batteries of the QuicKART General condition Keep the QuicKART free from the accumulation of grease dirt and other materials If the QuicKART malfunctions in any way turn it off and remove the key Immediately report the malfunction to the appropriate store manager as well as Dane Technologies Do not use the QuicKART until it has been repaired by an authorized service technician WARNING Do not permit open flame sparks or smoking during maintenance Adequate ventilation is essential for safety Do not lay metal objects on the batteries Dane Technologies Inc
119. s this option 2 The machine s retractable cord is plugged into an outlet that is not active Note Test this condition by plugging something into the outlet that can easily determine if the receptacle is alive Generally a dead output receptacle can be traced to a blown fuse or turned off switch 3 There is a problem with one of the connectors or a damaged cord de reeler before sn 1603 Note The cord de reeler can be tested by unplugging the battery charger s cord from the de reelers and plugging the charger directly into an electrical outlet If the battery charger starts to work the de reeler is defective If the charger does not work check the connectors The QK 2000 charging circuit starts with the outout cord from the charger 50 amp with a gray housing This plugs into the same matching gray connector plug on the side of the junction box The red 50 amp connector plug goes to the three batteries and it is tied directly in parallel with the gray connector plug A meter test at both the gray and red connector should show 36 volts nominal if the batteries are charged Use thin meter probes at the back of the connector to make this test Do not disconnect the 50 Amp plugs for this test 4 The battery voltage has fallen to 24 volts or less before sn 656 This charger has a built in safety feature which prevents it from being used with common 12 volt automobile batteries The charger will not turn itself on if the voltage at
120. several hours the voltage will drop and the lights will change accordingly When the light on the extreme left starts flashing it means that the battery capacity is expired and should be put on charge again It will also flash a motor control error code if present 16 The junction box is located under the body cover mounted on the vertical plate at the back All electrical connections from various parts of the machine junction in this box Batteries Charger Motor control Beacon post Throttle Control panel Horn Motor brake assembly The Junction box contains a printed circuit board which takes all the various electrical components and appropriately ties them together for the machine s operation 17 The Curtis compatible junction box contains seven 7 indicators on the top side as it is mounted a Supply fault light There are two conditions which will cause the supply fault light to turn on 1 When this light remains on without flashing it indicates the machine had been turned off by means of pushing on the red emergency button on the control panel The machine will not function while the light is on To reset the key switch is turned off the button pulled out and the key turned on again This condition does not require service The key switch is the correct way to turn off the machine when it is stored or set aside for periods of time 2 When this light is flashing it indicates that there is a problem in either the beacon po
121. st or the control panel In a fault condition the supply fault light starts flashing immediately when the machine is turned on with the key switch The control panel lights may remain lighted for 3 second then also shut down but the fault light will remain flashing as long as the fault condition exists You can determine if the problem is in the Beacon post by turning off the machine with the key switch unplugging the cable leading to the beacon post then turn on the key switch If the problem is in the beacon post the machine will operate normally but only in the manual mode If the problem is somewhere in the control panel circuitry the fault light will continue to flash and the panel lights will go off in about 3 seconds b Remote brake diagnostic light will come on whenever the stop button is pressed on the remote This assumes that remote is working and programmed properly The machine can be either in manual or remote mode for this test Failure of this light to come on during this test could be a symptom of either a bad remote or damaged receiver Test the other two diagnostic lights to determine if it is a total radio system failure or not Dane Technologies Inc QuicKART 2000 Series Service Manual 63 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 Slow speed diagnostic light will come on whenever the slow button is pressed on the
122. the QuicKART or change the battery in the hand held remote are exempted Non warranty service performed during the same visit as for warranty service is not covered by the warranty Rev 3 1 06 Dane Technologies Inc QuicKART 2000 Series Service Manual 44 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART CORRECTLY GO TO PAGE 2 QK2000 SERIES MANUAL MODE GOTO PAGE 3 TROUBLESHOOTING RADIO MODE GOTO PAGE 3 CHART QuicKART DOES NOT OPERATE GO TO PAGE 4 QuicKART DOES NOT OPERATE IN RADIO GO TO PAGE 5 QuicKART DOES NOT SWITCH TO RADIO GOTO PAGE 6 QuicKART STROBE LIGHT ISN T WORKING GO TO PAGE 6 QuicKART DOES NOT OPERATE IN REVERSE GO TO PAGE 7 c A gt gt gt 4 mx rm 22 O z Cc gt o 2 2 22 m lt rm Ww m O z lt GOTO PAGE 7 QuicKART MOVES INTERMITTANTLY OR HAS LOW POWER GO TO PAGE 8 QuicKART HORN ISN T WORKING GO TO PAGE 8 QuicKART OPERATES BUT HAS LIMITED RUNNING TIME GO TO PAGE 9 QuicKART BATTERY AND CHARGER PROBLEMS GO TO PAGE 10 QuicKART WILL NOT TURN OFF GO TO PAGE 12 QuicKART JUMPS INTO MANUAL MODE GOTO PAGE 12 DANE TECHNOLOGIES Inc 763 544 D PHONE 763 544 7779 7105 Northland Terrace FAX 763 544 4234 LM TME QUICKART 2000 SERIES TROUBLESHOOTING CHART mmo 970 4020 DWGDATE 3 1 06 Dan
123. the hand held transmitter See page 38 for directions on how to program the remote control transmitter Dane Technologies Inc QuicKART 2000 Series Service Manual 13 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 QuicKART 2000 IMPORTANT NOTES Check the QuicKART daily for safe operation Improper use or operation of the QuicKART or the lack of proper maintenance may result in decreased performance or damage to the QuicKART The following parts of the QuicKART need regular and routine maintenance 1 Batteries Add distilled water as necessary Water levels should be checked monthly 2 Tires Tires are solid foam filled Check weekly for wear 3 Rear Swivel Wheel Bearing Grease every 6 months grease gun compatible If at any time the QuicKART does not operate correctly immediately turn it off and remove the key to prevent further operation Immediately report any malfunctions to the store manager responsible for the QuicKART and Dane Technologies at 1 888 544 7779 WARNING Do not permit open flame sparks or smoking during maintenance Adequate ventilation is essential for safety Do not lay metal objects on the batteries Dane Technologies Inc QuicKART 2000 Series Service Manual 14 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechn
124. ts will ensure prompt accurate processing If you have questions please call 888 544 7779 QuicKART 2000 2500 Part Description 100 112 Control Panel Assembly 100 060 100 154 Junction Box Assembly 100 069 Curtis Control Assembly 100 072 Beacon Tower Old Style 100 095 1 00 096 Beacon Head New Style 100 030 100 150 Remote Control 100 035 100 145 Motor Brake Gearbox Dane Technologies Inc QuicKART 2000 Series Service Manual 114 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 Store Date Location Serial Number Meter Hours Sticker Condition QuicKART 2000 and 2500 Preventive Maintenance PM Checklist Inspected Needs Repair Replacement Inspeci tires rims and lug nuts Strobe light Battery Ignition switch Any other problems Comments Dane Technologies Inc QuicKART 2000 Series Service Manual 115 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06
125. v 3 1 06 4 white 12 volts stopped When the brake is activated by remote it drops to 0 volts 5 red 12 volts whenever key switch is on 6 black ground volts 7 blue ground O volts 8 violet 36 volts to beacon light whenever key switch is on 9 orange 1 volt goes to 36 volts whenever brake light comes on 15 cir plug CN 2 to curtis motor control and contactor plate assembl 1 red B 36 volts when key switch is on 2 none Not used 3 brown Forward 0 volts reverse 36 volts 4 orange 36 volts when key switch is on 5 yellow Manual operation O volts Remote operation 36 volts voltage drops to zero when in remote mode and stop button is pressed on the remote control 6 none Not used 7 green 36 volts with key switch on 0 volts with key switch off 8 none Not used 9 blue to 5 volts when handle bar throttle control is operated over its range while in manual mode 10 none connection 11 none connection 12 violet 1 volt goes to 36 volts whenever brake light comes on 13 gray 5 volts all the time except when brake release lever is pulled out then it drops to O volts 14 white Brake voltage 28 volts when machine first starts to move drops to 16 volts about 1 second after machine remains in motion 15 none Not used 4 cir pluq CN 1 to Motor brake release coil and switch QK 2000 1 black connected to CN 2 pin 1 same readings brake coil 2 blac
126. wn on drawings shown on pages and 8 9 Do not drive over curbs or the edges of hardened surfaces higher than one inch 10 Always look behind the QuicKART before and while operating in reverse 11 Batteries must be fully charged initially before using the QuicKART Dane Technologies Inc QuicKART 2000 Series Service Manual 5 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011 Rev 3 1 06 19 13 14 15 16 17 18 The electrolyte in a storage battery is an acid which can cause severe burns to the skin and eyes Wear appropriate protective clothing when working with batteries Treat all electrolyte spills with an extended flushing with clear water Contact a physician immediately if contact is made with battery acid Standard batteries do require regular maintenance It may be necessary to add distilled water to the batteries Hydrogen gas is formed when charging the batteries Use a location with adequate ventilation when charging QuicKART batteries Never smoke near batteries Do not charge batteries in an area with open flame or where there is electrical equipment that could cause an electrical arc Do not lay metal objects wrenches screwdrivers etc on any of the batteries to prevent electrical short circuits Batteries are heavy Always use care and proper lifting technique to avoid injury when removing or replacing batteries
127. yo 1MVMOInD FEEFFFG EBL uu 091 SV N VIEN E94 HNOHd u a Ul 341 SnaNir 5 60 851 81 951 80 L 65 5 0 SHIM S 0 GO SO L S3HANOD ONIMdS 90 097 fL Wid HIM FFL GO 001 S3HdNOD ONIHdS eee NZ SEL X SLL X ZIL 1914 H3HSVM NZ Lv 14 015 2 1 H3HSVM a NZ SeOOLr SO 91 9005 1 glolr 6 EN LE E IE z EA JOviHHvo X 8L 9L S 1708 ETE EA ES ES ALO SS X I Z L L108 rai e 2708 910007 s HJHOIvO LHYD 4OOH 229 002 GHYSHOLVOLYVOHOLIH Alwid 149022 HOLY HIHDLYD LAYO HOLIH C HDLIH LYVNOIND a3lvid b ALO NOWeI OSIC dO THE 29 Service Manual 970 011 Rev 3 1 06 QuicKART 2000 Series 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnoloqies com Dane Technologies Inc PHONE 763 544 7778 FAX 783 544 4234 DESCRIPTION YOKE ASSY DROP IN CHANNEL UNLESS SPECIFIED 5 3 BILL OF MATERIAL DXX 0 010 QK2000 GROUND Dane Technologies Inc QuicKART 2000 Series Service Manual 30 7105 Northland Terrace Minneapolis MN 55428 888 544 7779 763 544 7779 Fax 763 544 4234 www danetechnologies com 970 011

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