power assist hand truck troubleshooting guide g… · power assist hand truck troubleshooting guide...

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Power Assist Hand TruckTROUBLESHOOTING GUIDE

The Mart Cart® Power Truck is a quality product line of Assembled Products® CorporationThe Challenger hand truck is a quality product of Motor Dolly, LLC

Customer Service: 1-800-548-3373

Models: 610-1300, 610-1301, 610-1304, 610-1305,280-3600, 280-3604, 280-3605

WARNING: Only experienced professionals should attempt to troubleshoot. If you are not an experienced and trainedprofessional in electronics, wiring, and battery-operated machinery, STOP and call an Authorized Service Company.For a list of Authorized Service Companies, call Customer Service at (800) 548-3373.

WARNING: This is a battery-operated device. Failure to observe safe handling procedures when servicing can result in shock.

NOTICE: Attempts to troubleshoot or repair by unauthorized personnel may void your warranty.

2 Customer Service 1-800-548-3373

Figure 1

Figure 2

Battery Level Indicator

Charging Socket

Controller Status Indicator

Main Power Button

Throttle

WHAT’S THE PROBLEM?Reference Page

Setup Status Battery See Charger Power Symptom Indicator Fig.1 Indicator Fig.2 Checks Pages

Unplugged “On” (in)

Unit will not turn “On” “Off” All “Off” A through D 3-7

“Flashing” Red Only D 6-7

Unit will turn “On” “On” All “On” D through E but will not run 6-9

Wiring Diagram and Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .back cover


Figure A1 Figure A2

Battery #1 Battery #1

Yellow (+)Black (-)

Yellow (+)Black (-)

Black (-)Blue (+)

Black (-)Blue (+)

Battery #2 Battery #2

BATTERY AND CHARGING SYSTEMSChecks A-C

A . Battery Voltage Check 1. Detach charger and set the red main power button to “Off” (out). 2. Remove battery cover. 3. Check the voltage of each battery: See Figure A1. Battery #1: Yellow (+) Black (-) Leads Battery #2: Blue (+) Black (-) Leads

Charger Power Unplugged “Off” (out)

Setup: NOTE: “Smart Batteries” are designed to shutdown at approximately 9Vdc.A short charging for only a few minutes will turn the batteries back “On”.If not, replace battery.

Battery #1 Battery #2 Steps See Figure 9 to 12 Vdc 9 to 12 Vdc

Less than 2 Vdc 9 to 12 Vdc Charge both batteries and reconnect. A1

Less than 2 Vdc Less than 2 Vdc

9 to 12 Vdc Less than 2 Vdc Charge both batteries and reconnect after A2 swapping battery locations and leads.

+13 Vdc + 13 Vdc Batteries Operational n/a


Figure B1

(-) BATTERY #2 (+) (+) BATTERY #1 (-)

BATTERY AND CHARGING SYSTEMS (continued)Checks A-C

B . Battery Harness and Fuse Check 1. Open the controller and check the voltage of each battery at the battery terminals. See Figure B1.

Note:Battery #2: Blue (+), Black (-) Leads Battery #1: Yellow (+), Black (-) Leads

Figure B2

FUSESBattery #1Harness

Battery #2Harness

Blue

Black

Black

Yellow

Charger Batteries Power Unplugged +13 Vdc “Off” (out)

Setup:

Voltage Possible Cause Steps See Figure Faulty Harness Check the conductivity of Battery Harness, 0 Vdc Replace Battery Harness as needed. B2

Blown Fuse Check the conductivity of Fuses, Replace Fuse as needed.

+13 Vdc – Battery Harness Operational n/a


Figure C3

Pin 3 (-)GREEN

Pin 2 (-)BLACK

Pin 1 (+)WHITE

5 PinUNPLUGGED

Figure C1

Status Indicator 5 Pin Unplugged

Figure C2

Pin 1 (+)Pin 2 (-)

Pin 3 (-)

C . Battery Charger Check 1. Disconnect the yellow (+) battery lead from Battery #1 2. Open the controller and unplug controller 5 pin connector. See Figure C1. 3. Reconnect the yellow (+) battery lead to battery #1 4. Plug charger into power outlet and controller charging socket, wait 30 seconds. See Figure C1.

Charger Plug:

Pin 1 (+) White

Pin 2 (-) Black

Pin 3 (-) JumperGreen Pin(unused)

Status Indicator Possible Cause Steps See Figure Unplug Charger from the Controller Charging Socket and check Pin output:

Faulty Charger Plug

Pin1 - Pin2: +13Vdc, If 0Vdc replace Charger Plug, Charger. C2

Pin1 - Pin3: +13Vdc, If 0Vdc replace Charger Plug, Charger.

“OFF” With Charger plugged-in check Pin input:

Faulty Charger Socket Pin1 - Pin2: +13Vdc, If 0Vdc replace Socket. C3

Pin1 - Pin3: +13Vdc, If 0Vdc replace Socket.

Faulty Controller

If both the Plug and Socket pass the above checks, n/a

replace the controller.

“Flashing” – Charging System Operational n/a

BATTERY AND CHARGING SYSTEMS (continued)Checks A-C


CONTROLLER, THROTTLE and DRIVE MOTOR SYSTEMSChecks D-E

D . Throttle Assembly and Throttle connections to Controller Check 1. Open controller, check 5 pin and white throttle lead

connecters for secure connection and conductivity. 2. Disconnectcharger and set the red main power button to

“On” (in).

3. Unplug 5 pin from controller. Check ohms between the white throttle lead connecter and P3 (Red) of the 5 pin connecter. See Figure D2.

Figure D1

Figure D2

Charger Batteries Power Unplugged +13 Vdc “Off” (out)

Setup:

Charger Batteries Power 5 pin Connector Unplugged +13 Vdc “Off” (out) Unplugged

Setup:

Pin 1 - Blue or BlackPin 2 - OpenPin 3 - RedPin 4 - YellowPin 5 - Green

Throttle Status Indicator Battery Level Indicator Steps See Figure

All Lights “Off” Check P4 (Yellow) lead of the 5 pin connector,

“Off”

replace 5 pin or Throttle Handle Assembly

All Lights “On” Check P5 (Green) lead of the 5 pin connector, replace 5 pin or Throttle Handle Assembly

Inoperative “Flashing”

Red Light Only

Check P1 (Black or Blue) lead of the 5 pin connector, D1 replace 5 pin or Throttle Handle Assembly

Check P3 (Red) lead of the 5 pin connector, “On” All Lights “On” replace 5 pin or Throttle Handle Assembly

Check White lead, go to next check

Pin 3 - Red Throttle Connector

Ohms Possible Cause Steps See Figure Faulty Connector Check white controller throttle lead connecter, D2

0 replace connector.

Faulty Throttle Replace the Throttle Handle Assembly Handle Assembly

3M to 20M

– Reconnect 5 pin connector. Throttle Assembly Operational, go to next check


D . Throttle Assembly and Throttle connections to Controller Check (continued) 4. Using a test lead momentarily (about 3 sec.) jump between

the white throttle lead connecter and either the battery #1 yellow (+) controller terminal or battery #1 yellow (+) battery terminal. See Figure D3.

Charger Batteries Power 5 pin Connector Unplugged +13 Vdc “Off” (out) White Lead to Battery 1 (+)

Setup:

Figure D3

Status Indicator JUMPER

Status Indicator Possible Cause Steps See Figure “Off” Faulty Harness Check white controller throttle lead connecter, D3 replace connector.

“Flashing” – Disconnect the battery #1 yellow (+) lead for 3 seconds then reconnect to reset controller. Controller Throttle Lead operational.

CONTROLLER, THROTTLE and DRIVE MOTOR SYSTEMS (continued)Checks D-E


CONTROLLER, THROTTLE and DRIVE MOTOR SYSTEMS (continued)Checks D-E

E . Controller - Motor Output Check 1. Open the controller and check the output voltage of the

controller motor terminals at full throttle. See Figure E1.

Figure E1

Right Motor Left Motor

Setup: Status Battery Charger Batteries Power Indicator Indicator Throttle Unplugged +13 Vdc “On” (in) “On’ All “On” Full Operation

Setup: Status Battery Charger Batteries Power Indicator Indicator Throttle Unplugged +13 Vdc “On” (in) “On’ All “On” Full Operation

Voltage Possible Cause Steps See Figure 0 Vdc Faulty Controller Replace Controller E1

+24 Vdc – Controller - Motor Output Operational, go to next check

Voltage Possible Cause Steps See Figure Less than 24 Vdc Faulty Motor Harness Check conductivity of both motor harness. Replace as needed. E2

+24 Vdc – Controller - Motor Output Operational, go to next check

2. Unplug both motors. Check the voltage between the red leads of each motor lead at full throttle. See Figure E2.

Figure E2

RED MOTOR LEADSRight Left


Setup: Status Battery Charger Batteries Power Indicator Indicator Controller Unplugged +13 Vdc “On” (in) “On’ All “On” Operational

Motor Possible Cause Steps See Figure Inoperative Faulty Motor Confirm controller motor output (see “E” above) Replace motor as needed. E3

Operative – DRIVE MOTORS (Electrical) Operational

E . Controller - Motor Output Check 3. Unplug one motor and add a wiring “short”

terminator jumper to the unplugged motor lead. See Figure E3.

4. Check motor for operation and repeat E3 for second motor.

Figure E3

Plugged in Jumper


TECHNICAL SHEET - 280-3600Power Assisted Convertible Hand Truck

CONVERTIBLE TECH SHEET

1. Exploded View and Parts List a. Replacement Parts List Item Part# Description 1 610-1175 THUMB THROTTLE ASSEMBLY

2 610-1046 DRIVE TIRE/TUBE, PNEUMATIC, 10”

3 610-1226 FREEWHEEL DRIVE HUB, LEFT

4 610-1043 DRIVE SUPPORT ARM, LEFT

5 610-1044 GEARMOTOR ASSEMBLY, LEFT

6 610-1162 CONTROLLER, PWM / CHARGING

7 610-1091 BATTERY BOX, FRONT COVER

8 610-1089 BATTERY, 10AH

9 610-1093 BATTERY BOX

10 610-1045 AXLE, 5/8”

11 610-1013 GEARMOTOR ASSEMBLY, RIGHT

12 610-1159 DRIVE SUPPORT ARM, RIGHT

13 610-1230 FREEWHEEL DRIVE HUB, RIGHT

14 610-1075 CASTER, 3”

15 610-1260 HALF RIM

16 610-1259 HALF RIM W/ VALUE STEM HOLE

17 610-1281 HARNESS, CHARGING PLUG - OFF BOARD

PARTS NOT SHOWN

Part# Description

610-1092 HARNESS, BATTERY #1


610-1096 HARNESS, GEARMOTOR, RIGHT

610-1170 HARNESS, GEARMOTOR, LEFT

610-1047 DRIVE WHEEL, FLAT-FREE, 10”

610-1262 NOSE PLATE KIT 18 x 7½


TECHNICAL SHEET - 280-3601Power Assisted Standard Hand Truck

STANDARD TECH SHEET

1. Exploded View and Parts List a. Replacement Parts List Item Part# Description 1 610-10015 GRIP THROTTLE ASSEMBLY

2 610-1046 DRIVE TIRE/TUBE, PNEUMATIC, 10”

3 610-1226 FREEWHEEL DRIVE HUB, LEFT

4 610-1043 DRIVE SUPPORT ARM, LEFT

5 610-1044 GEARMOTOR ASSEMBLY, LEFT

6 610-1162 CONTROLLER, PWM / CHARGING

7 610-1091 BATTERY BOX, FRONT COVER

8 610-1089 BATTERY, 10AH

9 610-1093 BATTERY BOX

10 610-0011 AXLE WITH KICK RIM, 5/8”

11 610-1013 GEARMOTOR ASSEMBLY, RIGHT

12 610-1159 DRIVE SUPPORT ARM, RIGHT

13 610-1230 FREEWHEEL DRIVE HUB, RIGHT

14 610-1260 HALF RIM

15 610-1259 HALF RIM W/ VALUE STEM HOLE

16 610-1281 HARNESS, CHARGING PLUG - OFF BOARD

17 610-0003 HANDLE, DOUBLE GRIP, 52”

18 610-0002 GRIP, BLACK, 1-1/8”

PARTS NOT SHOWN

Part# Description



610-1096 HARNESS, GEARMOTOR, RIGHT

610-1170 HARNESS, GEARMOTOR, LEFT

610-1047 DRIVE WHEEL, FLAT-FREE, 10”

610-1262 NOSE PLATE KIT 18 x 7½”

115 E. Linden Street, Rogers, Arkansas 72756Service (800) 548-3373 | e-mail: [email protected]

Sales (262) 754-6990 | e-mail: [email protected]

MC-PT-TRBL GUIDE-120712 Specifications are subject to change without notice . Printed in the USA.

Wiring DiagramWiring Schematic

mailto:[email protected]

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