1009 4th St. NW, Little Falls, MN 56345 • PH: 800-686-2651 • FAX: 320-632-3553 www.djproducts.com
Reference Manual
Read manual carefully before operating machine
Rev. 8/12/2013Model Number:CartCaddyHD Chain DriveSerial Number:
2
For Safety:
1. Do not operate, maintain, or service machine: • Unless trained and authorized. • Unless operation manual is read and understood. • In flammable or explosive areas. • Make sure all safety devices are in place and operate properly. 2. When maintaining or servicing machine: • Disconnect battery connections before working on machine. • Avoid contact with battery acid. • Avoid moving parts. Do not wear loose jackets, shirts, ties, or sleeves when working on machine. • Use DJ Products, Inc. supplied or equivalent replacement parts. 3. Do not transport machine with covers off.
Warning:
Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and open flame away.
Attention:
The battery charger supplied with the machine shall be grounded while in use to protect the
operator form electric shock. This charger is designer for use on a nominal 120 volt circuit and has a grounding plug that resembles the plug illustrated. Make sure the charger is con nected to an outlet having the same configuration as the plug. No adapter should be used with this charger. The green conductor in the cord is the ground wire. Never connect this
wire to other than the grounding pin of the attachment plug. Store this machine indoors, do
not expose to rain. This product is intended for commercial use.
General Specifications: Electric 36 V DC — (3) 12V batteries Charger, 110 VAC, 60 HZPower Train / Propelling System 36 V DC Electric motor 36 V DC controllerSuspension System Steer Wheel —(1) rear, 12 in. (305 mm) dia. Drive — (2) front, 12 in. (305 mm) dia.General Machine Dimensions Length — 79.88 (2028.95 mm) Width — 34.40 in. (873.76 mm) Height — 56.02 in. (1422.908 mm)Machine
Total Weight, with batteries— 1250 lbs. (567 kg)Speed of Machine
High speed forward and reverse— 2.86 mph (4.6 Km/hour) Low sped forward and reverse— 1.5 mph (2.41 Km/hour)
Safety Precautions
3
Additional Specifications
Nominal Power 3 hp continous,6 hp peakMass of most useful configuration 1250 lbs. (567 kg)Maximum draw bar pull 2000 lbs (907.2 kg)
Use of Machinery
Controls:The handle assembly can easily be adjusted if the machine comes out of neutral and
begins to creep. By removing the (4) 5/16” self-threaded screws in the yellow control box, you will gain access to the control potentiometer. Adjust the potentiometer with a 1/2 SAE wrench. Turning the potentiometer towards the front of the machine will stop the machine from creeping backwards. Turning the potentiometer towards the rear of the machine will stop the machine from creeping forward. Never adjust the potenti-ometer with the machine on. If you turn the machine on and try to adjust, the machine coule take off and cause bodyily harm.
Additional Specifications
Adjustments
4
1. Make sure the power switch is in the off (0) position.2. Using the lift handles provided on the battery, place batteries in the machine with the terminal posts shown.
For Safety:
When maintaining or servicing the machine: • Battery acid can cause burns. Avoid contact with battery acid. • When working on or around batteries, wear protective clothing, gloves, and safety glasses.
• Do not lay metal tools or metal objects on top of the batteries. • Only install deep cycle marine style lead acid batteries in your CartCaddy. The charger is built specifically for lead acid batteries. Any other battery may become overcharged and cause serious damage to the machine or operator.
• When replacing old batteries, you should replace all three batteries. This will assure the batteries will be kept in sync.3. Remove the nuts from the terminal posts. Connect the
wires as shown.
4. Make sure to attach the positive leads to the positive terminals. Place the nuts on the terminal and tighten securely.
Black
RedBlack
Black
A. Speed Button Used for high and low speed control. Push button in for low speed, pull out for high speed.
B. Spyglass Diagnostics The eight character spyglass displays a continuous sequence of hour meter, battery state of charge, and fault messages. See
the diagnostics and trouble shooting section (page 7).C. Power Key Switch The power switch controls the machine power.
Turn the key clockwise and to the horizontal position to turn the machine power on.
Turn the key counterclockwise and to the vertical position to turn off the machine power.
The machines batteries must be charged for the
machine to have power.
D. Resettable Circuit Breaker The main circuit breaker protects the motor from overload. If the load is too high, the main circuit breaker will trip and the unit will stop. To reset the circuit breaker, press the circuit breaker reset button on the accessory panel. It may be necessary to allow the circuit breaker to cool down before resetting, or it may trip again. Reduce the load before resuming. Please review the load limit sections for recommended load limits.
Installing Batteries
Accessory Panel
A B C D
5
Before operating the machine: 1. Make sure the charge is OFF by unplugging the AC power cord from the wall outlet. 2. Make sure all controls are free and clear of any obstructions. 3. Turn the power switch ON. 4. Make sure the emergency stop switch is working correctly. (Optional) 5. Make sure the safety light is operating correctly. (Optional) 6. Make sure the speed control switch is either in fast or slow speed. 7. Now you are ready to operate. If any of the safety features were not operating correctly please contact: • Your Manager • Maintenance Personnel • Your Service Representative • DJ Products, Inc.
The daily and monthly maintenance requirements listed here may be performed without tools by the machine operators. Instructions for these maintenance requirements are provided in this section of the manual.
Daily: Perform all duties listed under Pre-Operation Checklist.
Every Month: Add distilled water if needed. Water should be just over the top of the cells in the batteries.
Every Three Months: Lubricate the castor bearings with grease.
Check and tighten all fasteners and hardware. Clean, tighten, and lubricate all battery posts and cables.
Pre-Operation Checklist
Maintenance
6
The batteries have approximately an eight hour run time when fully charged. The batteries take about eight hours to charge after they have been fully discharged. The battery charger has an
automatic timer that will turn off the charger when the batteries reach full charge. The batteries
should be charged anytime the machine is not in use.
To charge the batteries: 1. Move the machine to a flat, dry surface in a well ventilated room. 2. Open the machine cover. 3. Check the water level in the battery cells. If the level is low, add just enough distilled water to cover plates. DO NOT OVERFILL. (If applicable) 4. Wipe off tops of batteries with a cloth.
5. Plug the charger into a wall outlet.
Whenever ordering parts or requesting any type of service, specify: 1. The model of the machine
2. Serial number 3. The part number
4. The part description
The CartCaddy is specifically designed to push carts and any like device resembling a cart. You should never operate the CartCaddy:
• With an operator under the age of 16. • With an operator sitting or riding on the CartCaddy or any carts it may be pushing. • With added weight not specifically added by DJ Products, Inc. or a certified service rep. • With the hood off the unit. • Without being properly trained by a supervisor. • In severe weather. • With a known feature not working correctly. • While on specific medicine that may impair your vision or reflexes.
By disregarding any of these limits, it may cause damage to the operator, your customer, and
customer’s vehicles, the CartCaddy, and your building.
Disregarding any of these limits will void your warranty in case the CartCaddy is damaged.
Charging Batteries
Service Policy
Load Limits
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Diagnostics and Troubleshooting
13
Troubleshooting
14
Troubleshooting Guide (Questions and Answers)
Q. When I turn the key on, nothing happens at all.A. If the voltmeter doesn’t come on or you don’t hear the contactor click one of three things could be bad. Check the battery voltage across all three batteries; you should have at least 36 volts. If that is ok either the contactor is not working or the key switch is not working. To bypass the key switch take the two wires going to the key switch and touch them together, if the key switch is bad the machine should turn on. To bypass the contactor please call DJ Products, Inc. service dept for further tests.
Q. When I plug the onboard Minn Kota® charger into the wall one or more of the banks say check connection.A. Check the fuse on that bank(s) to see if it is blown. Check the connection to the battery termi-nal. If both of these things are OK the battery voltage on the bank(s) is probably below 9 volts. The charger has a safety feature on it, when the battery voltage drops below 9 volts the charger
says check connection and shuts down that bank. Either charge that battery with an external charger to bring the voltage up or cycle the power on the charger by plugging in the charger and
unplugging it every 5 to 10 minutes until that bank shows it in charging mode.
Q. When I plug in my onboard Minn Kota® charger no lights come on at all.A. Try plugging it into a different outlet, if that doesn’t work call DJ Products, Inc., you may need a new charger.
Q. When I push the up/down switch it does not raise or lower the electric actuator.A. Check the fuse on the lift harness; it’s a yellow in-line fuse holder with a 15 amp glass fuse in it. Check to make sure the wires on the lift are all plugged in tightly. Check for damaged or burned wires from the electric actuator. If all those are good, call DJ Products, Inc. for further testing suggestions.
Q. When I press the optional horn button the horn does not sound.
A. Check the connections to the horn and the horn switch. If OK you can hook the horn directly to 36 volts, if the horn sounds then your switch is bad.
Q. When I rotate the handle bar it does not snap back into the center position. A. The torsion spring has either slipped off the centering bolt or the spring has broke. Take the screws out of the control box to and pull the box apart, the bottom part will pull completely off and the top part can rotate up. Inspect the torsion spring to make sure it is in the proper posi-tion.
Q. The CartCaddy shows full power until I start using it, then the needle on the voltmeter drops down into the red.A. You probably have one or more bad batteries. You can check the batteries with a multi-meter but a load cell tester is preferred. You should have 12 volts on each of the batteries; you may have a bad cell in one or more of the batteries causing the machine to loose power.
15
Warranty
IMPORTANT: Read this entire Limited Warranty before using the CartCaddy™ product. The CartCaddy™ product (or other DJ Products Inc. product-collectively referred to herein as the “Product”) manufactured by DJ Products Inc., a Minnesota corporation (“Manufacturer”) is believed to be reliable if the directions for its use, maintenance, and operating procedures are
followed carefully. However, it is impossible to eliminate all risks inherently associated with the use of this Product. Risk of failure, including personal injury, dismemberment, injury to property or even death, may result form misuse, abuse, neglect, negligent use, accidental or intensional
damage, ordinary wear and tear, violation or omission of standard operating procedures, im-proper maintenance, failure to perform routine and preventive maintenance, alterations, addi-tions and/or modifications to the Product, use by any individual not fully trained and fully autho-rized operator, and improper training of the operator, all of which are beyond the control of the Manufacturer. All such risks are fully assumed by the purchaser/customer of the Product (“Cus-tomer”).Manufacturer offers a limited warranty (the “Limited Warranty”) to each Customer who is the original purchaser of this Product that, effective for a period of one year (“Limited Warranty Period”) from the date of delivery of the Product to the Customer, that the Product is free from defects in material or workmanship in normal use and service. Should any Product prove not to conform to foregoing Limited Warranty, the remedies of Customer for any breach of the forego-ing Limited Warranty shall be limited to the repair or replacement of the Product. IN NO EVENT SHALL MANUFACTURER’S OBLIGATIONS PURSUANT TO THIS LIMITED WARRANTY EXCEED THE PURCHASE PAID TO THE MANUFACTURER BY THE CUSTOMER FOR THE PARTICULAR PRODUCT INVOLVED, TO THE EXCLUSION OF ALL OTHER REMEDIES OR LIMITATIONS, INCIDENTAL OR CONSEQUENTIAL DAMAGES. The Limited warranty, which is Customer’s EXCLUSIVE REMEDY, shall be FURTHER LIMITED as follows:1. If the defect in material or workmanship is disclosed to the Manufacturer by the Customer within the first ninety (90) days following delivery of the Product to the Customer, the Limited Warranty shall be the full cost of the labor and parts to repair or replace the defective Product or component parts thereof.
2. If the defect in material or workmanship is disclosed to the Manufacturer by the Customer prior to the expiration of the Limited Warranty Period but more than ninety (90) days following the delivery of the Product, the Limited Warranty shall be the Manufacturer’s cost of the replace-ment parts (excluding repair labor) required to repair the defective Product or component part. Any warranty repair or replacement of Products or defective component parts shall occur at the Manufacturer’s (or authorized service provide’s) place of business. In order to obtain a warranty service, the Customer must return the defective Product to the Manufacturer within the Warranty Period, together with proof of purchase by Customer establishing date of delivery, with freight charges and applicable costs of repair, if any, prepaid, which Product the Manufacturer shall sip, prepaid, any repaired or replaced product covered by the Limited Warranty, to the Customer’s
facility located within the continental United States.
16
The Limited Warranty is invalid if the factory-applied serial number has been altered or removed from the Product.
The Limited Warranty does not cover cosmetic damage or damage due to acts of God, accident, misuse, abuse,
neglect, negligent use, accidental or intentional damage, ordinary wear and tear, violation or omission of
standard operating procedures, improper maintenance, failure to perform routine and preventative maintenance,
alterations, additions and/or modifications to the Product, use by any individual not a fully trained and fully
authorized operator, and improper training of the operator, or repair or attempted repair by anyone other than
Manufacturer or its authorized agents, nor to any Product which is leased or used as rental equipment. The
occurrence of any of the foregoing voids the Limited Warranty.
This Limited Warranty does not cover Customer instruction or training.
THIS LIMITED WARRANTY PROGRAM IS EXCLUSIVE AND IS GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL
OTHER WARRANTIES, WHETHER WRITTEN OR ORAL, EXPRESSED OR IMPLIED OR INFERABLE FROM THE
COURSE OF DEALING OR USAGE OF TRADE, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTY
OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND ANY
IMPLIED WARRANTY ARISING FROM PERFORMANCE, COURSE OF DEALING OR USAGE OF TRADE, AND ALL
OTHER OBLIGATIONS, LIABILITIES, RIGHTS, CLAIMS OR REMEDIES, INCLUDING ANY RIGHT IN CONTRACT,
TORT, STRICT LIABILITY OR ANY RIGHT ARISING FROM MANUFACTURER'S NEGLIGENCE, ACTUAL OR
IMPUTED.FOR CLARIFICATION ONLY (AND NOT IN ANY WAY TO EXPAND THE FOREGOING EXCLUISVE
REMEDIES):
(A) UNDER NO CIRCUMSTANCES WILL MANUFACTURER BE LIABLE FOR LOST PROFITS OR ANY OTHER
INCIDENTAL, CONSEQUENTIAL, SPECIAL OR INDIRECT DAMAGES RESULTING FROM THE PURCHASE OR
USE OF THIS PRODUCT, INCLUDING, WITHOUT LIMITATION, ECONOMIC LOSS, COST OF CAPITAL, CLAIMS
OF CUSTOMERS FOR FAILURE OF SUPPLY OR LOSS OF USE OR DAMAGE TO PERSONS OR TO OTHER
PROPERTY, NOTWITHSTANDING THE FACT THAT THE MANUFACTURER HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH DAMAGES; (B) THE TOTAL LIABILTIY OF THE MANUFACTURER TO CUSTOMER SHALL
NOT EXCEED THE TOTAL PURCHASE PRICE PAID BY THE DISTRIBUTOR TO MANUFACTURER FOR THE
PARTICULAR PRODUCT INVOLVED; AND (C) NO AGREEMENT VARYING OR EXTENDING THE FOREGOING
WARRANTIES, REMEDIES OR LIMITATIONS WILL BE BINDING UPON THE MANUFACTURER UNLESS IN
WRITING AND SIGNED BY A DULY AUTHORIZED CORPORATE OFFICER OF THE MANUFACTURER.
If any term or condition of this Limited Warranty program is in violation of applicable local, state, or federal law, this
Limited Warranty program shall not be voided in its entirety, but rather, the court, or other appropriate authority
having jurisdiction in the matter, shall rewrite and reform the Limited Warranty to the minimum extent required
so as to be permitted under applicable law.
Warranty Continued
