Mart Cart Model 3563 Technical Overview This document is a technical overview of the Mart Cart model 3563. Its purpose is to describe the major components of units that are currently being produced. Some components may be updated from previous versions of this model. Some optional components may not be discussed in this document. For more detailed information, please contact our Service Department at 800-548-3373 or email techservice@assembledproducts.com.
Table of Contents • • • • • • • • • Major Parts Overview Potentiometer/PWM Relationship Calibrate PWM Parts List Wiring Diagram Tools Safety Check Warranty Serial Number Label Click on one of the subjects above to jump directly to the document page.
Major Parts Overview • • • • • • Battery/Circuit Breaker Charger Wire Harness PWM Control Box Hub Motor Return to Table of Contents
Battery/Circuit Breaker The battery is a 12 volt, AGM (Absorbent Glass Mat), 35 Amp Hour, Sealed Lead Acid (SLA) battery. The “quick change” battery cover houses the 15 amp circuit breaker, 5 amp fuse, and main wire harness. 280-1214 280-1712 260-1228 280-1799 (Mini Fuse) 280-1627 (Fuse) Prior to the quick change battery cover, a 15 amp circuit breaker was attached directly to the negative post of the battery. The copper terminal of the circuit breaker is attached to the battery terminal with a lock nut.
Charger The charger is a 12 volt, 7amp charger with Intelli-Charge™ functionality. Intelli-Charge monitors the charge capacity of the battery. The charger shuts down when then battery is completely charged. This feature allows the battery to be plugged into a wall socket for any length of time without concern about over-charging. The charger has 3 output wires and is plugged directly into the main wire harness with a 3-pin connector.
Wire Harness Steering – includes 6-pin, 3-pin, and 10-pin Main – part of the quickconnectors, clamps change battery cover and 18 inch loom assembly. Contains (not shown). 15 amp circuit breaker and 5 amp mini fuse. PWM-to-Motor - includes 4-pin connector. 280-1646 280-1202 280-1712 280-1626 (Wire Guide) 280-1454 Return to Major Parts Overview The earlier version of the main wire harness without the quick-change battery cover contains a 15amp circuit breaker and 5amp fuse.
PWM The PWM (Pulse Width Modulator) monitors multiple electronic functions and is the central processor for the cart’s electronics. The PWM (in conjunction with the potentiometer) controls the speed and direction of the motor hub. A 10-pin terminal is designed to monitor the cart’s functions through the control box, charger, and motor.
Control Box The control box houses the potentiometer and rocker switch (Power Off/On, Horn, LED light). The potentiometer is connected to the control throttle and regulates the resistance on pins 1, 2, and 3 of the PWM. This, in turn, controls the speed and direction of the motor. The rocker switch has an imbedded LED that indicates the battery charge process when the charger is plugged in and indicates the battery charge level while the cart is in service.
Hub Motor The hub motor is a direct current, brushed disc, 12 (or 24) volt brake, geared motor. The motor is powered through a positive (red) and a negative (black) wire lead protruding from the axle. 280-1600 The brakes are powered by two black wire leads protruding from the opposite axle. The wire leads are pinned and inserted into a 4-pin connector. The brake leads are inserted into slots 1 and 2. The negative power lead is inserted into slot 3 and the positive lead (red) is inserted into slot 4.
Potentiometer/PWM Relationship The potentiometer (pot) along with the PWM regulates the speed and direction of the motor. The PWM monitors the change in resistance on pins 1, 2, and 3 of the 10-pin connector which are connected to the pot (pins 1, 2, and 3 respectively) through the steering wire harness. The pot is located in the control box and is physically connected to the throttle control on the cart’s handlebars.
Potentiometer/PWM Relationship Over the life of the cart, several things may happen to disrupt the normal resistance between the pot and the PWM…subsequently sending false readings to the PWM. They are: • • • • • The resistance material in the pot becomes damaged (extremely rare). The shaft sticks/freezes (human error during assembly). The spring or fork of the pot assembly become damaged. The connectors of the steering wire harness loose contact. The wires of the steering wire harness break.
Calibrate PWM On occasion, the cart may function erratically. As the last step in troubleshooting a problem, the PWM can be “calibrated” to the neutral position of the potentiometer. Be certain that the battery is charged above 10.5 volts and the horn and the seat switch are connected and working properly before attempting to calibrate the PWM. Without them working properly, the PWM will not calibrate. 1. 2. 3. 4. 5. Stand next to the cart. Do not sit on the seat during the calibration steps.
Calibrate PWM – Check Brake Leads When attempting to calibrate the PWM one might hear 3 short chirps. This indicates that the PWM did not recognized a brake circuit. The PWM will still function but the brakes will not release causing undesired performance from the motor. To resolve the brake issues, check the brake circuit from the PWM to the motor by disconnecting the brake leads from the wire harness at the PWM and placing an ohm meter on each lead. The meter should read approximately 20 ohms.
Parts List Item 1 1a 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17A 18 18A 19 20 20A 21 22 23 24 25 26 27 28 29 30 31 32 33 Notes: 7 8 10 11 22 24 26 Part# Description 280-1818 Main Frame (contains Bumper/hardware) 280-1840 Bumper Only (with hardware) 280-1268 Rear Wheels – Poly-U, 8” 000-1224 Bushing – 5/8” (1 on each wheel) 280-1335 Grommet – 5/8” (1 on each wheel) 000-1075 Retaining Ring “E” Type (1 on each wheel) 280-1214 Battery – 35AH 280-1797 Charger Cord – 6’ Coiled (See Notes) 260-1228 Circuit Break
Parts List – Steering Column Steering Column and Control Box Parts List Item Parts# Description 1 2 3 4 5 6 7 8 9 10 11 12 280-1178 280-1177 280-1184 280-1187 200-1640 280-1405 280-1863 280-1185 280-1862 280-1602 280-1179 280-1199 Control Box Bottom Cover Control Box Top Cover Control Box Divider Potentiometer Assembly Key Switch (Optional) Rocker Switch Overlay – Control Box Top Overlay – Control Box Front Intelli-Charge Indicator Decal Grip Throttle Grip – Thumb Control Steering Column (w/Rod and Gr
Wiring Diagram 6-pin connector 3-pin connector Return to Table of Contents 1 – Black – Pin 1 on pot (Neg) 2 – Yellow – Pin 2 on pot (wiper) 3 – Blue – Pin 3 on pot (terminal) 4 – Green – LED 5 – Orange – LED 6 – White – Power (Pos) 7 – Yellow – Inhibit from charger 8 – Violet – Horn 9 – Brown – Brake 10 – Not used
Tools The suggested tool kit should contain: Screwdrivers: #2 Phillips T15 Star #2 Flat Head Wrenches: 3/4” Open End 1/2” Open End 1/2” Box End 10mm Open End Torque Punch or Nail: Sockets: 5/16” 1/4” 7/16” 1/2” Deep Well 1/2” 10mm Pliers: Needle Nose Regular Wire Snips 1/8” Electronics: Multi-meter - Ohms, AC and DC voltage Load Tester - Should be able to load test battery without having to charger the battery first Jumper cable- Alligator clips on both ends Return to Table of Contents
Safety Check This checklist is designed for service technicians to use as a guideline when servicing electrical Mart Cart shopping carts. The list covers common system safety features that should be checked for proper installation and functionality. While they may not be presented on this list, all parts and components of the cart should be checked for proper functionality and either fixed or reported to authorized facility personnel. All parts must be OEM to ensure proper safety and warranty compliance.
Warranty The warranty period is calculated from the month and year of manufacture. The month and year of manufacture is determined by the punch-out positions on the serial number label. In a standard, 2-year warranty period, a cart would be out of warranty in 2 years on the month following the month punched out. Example: Cart built October, 2008 would be in warranty through October, 2010. Warranty periods can differ from customer to customer.
Serial Number Label The serial number label is located underneath the rear cover. The manufacture date is represented by the year and month “punch-out” as shown below (review the previous page for warranty period information. Lift the spring loaded seat latch (hidden below the cover) and push forward on the seat to reveal the label.
Mart Cart End Technical Overview
