GRANITE INDUSTRIES 1400 Series 36V Mega Herc Powered Inflatable Hand Truck Owner’s Manual

: June 8, 2024
: GRANITE INDUSTRIES

Table of Contents

GRANITE INDUSTRIES 1400 Series 36V Mega Herc Powered Inflatable Hand
Product Information
Product Usage Instructions
CART FEATURES
FREQUENTLY ASKED QUESTIONS
CHARGING INFORMATION
OPERATING INSTRUCTIONS
TROUBLESHOOTING
BATTERY INFORMATION
FREEWHEEL MODE
BATTERY REPLACEMENT
2 or #3 Phillips screwdriver
PARTS DIAGRAM
WIRING DIAGRAM – CONTROLLER
REPLACEMENT PARTS LISTING
CONTACT
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

GRANITE INDUSTRIES 1400 Series 36V Mega Herc Powered Inflatable Hand

Truck

Product Information

Specifications

Model: Mega Herc (AGM Batteries)
Manufacturer: Overland Carts, a part of Granite Industries
Warranty: 1 year from delivery date
Battery Type: 22/24 amp-hr AGM rechargeable battery packs
Charging Time: Recommended to charge overnight after use
Customer Service: 877-447-2648, Mon-Fri 8 am – 5 pm EST

Product Usage Instructions

Cart Features

All Overland Carts come fully assembled, charged, and ready to use. To start using the cart:

Power on the cart.
Drive away.

Note: It is recommended to charge the cart overnight after receiving it.

Crate Disassembly

If you need to disassemble the crate, follow these steps:

Use a hammer or crowbar to remove nailed-down portions of the crate.
If any issues arise during disassembly, immediately stop to prevent damage to the cart.

Battery Charging

To ensure optimal battery performance:

Charge the cart immediately after use.
If the battery indicator light turns red during operation, it’s time to recharge.
For battery longevity, leave the cart on the charger overnight.

Battery Replacement

The batteries are expected to last for approximately 300-500 charge/discharge cycles (1-2 years). To replace the batteries:

Purchase replacement batteries from Granite Industries, a local battery supplier, or online retailers like Amazon.

OVERLAND CARTS GUARANTEE
All Overland Carts are designed and assembled in the USA using parts made in- house along with quality global components.

Expect more, get more.
FROM GRANITE INDUSTRIES

Exceptional quality and service on every single product.
Professional grade deisgns by our in-house engineers.
Industry-leading warranties.
Owned and operated in the USA.

1 YEAR WARRANTY

Electronics: Includes controller, s-drive, and wiring
Powertrain: Includes transaxle containing the motor and differential
Wheels, Casters & Tires
Batteries & Charger
Chassis: Includes steel frame and powder coating

TERMS

The warranty starts from the delivery date of the cart.
We will repair, without charge, any defect due to faulty material or workmanship. These warranties do not cover failures due to abuse, misuse, improper installation, accidental damage or when repairs or modifications have been made or attempted to be made by anyone other than Granite Industries. Any defective products that meet warranty specifications and Granite Industries approval, may be returned to the factory to be repaired or replaced free of charge. (Granite Industries will pay to ship replacement item(s) to the customer; however, the customer is responsible for the shipment of products to the factory.)
This remedy is the sole remedy in contract, tort or otherwise, and Granite Industries is not liable for incidental, consequential or special damages.
These warranties give you specific legal rights, and you may have other rights which vary from state to state.
Should you have any questions, contact Granite Industries at 877-447-2648. (Proof of purchase may be required).

CART FEATURES

Built with you in mind.
Our carts come fully assembled
All Overland Carts come fully assembled, charged and ready to use. All you have to do is power the cart on and drive away. (We do recommend charging overnight after receiving.)

Crate Disassembly Instructions
We recommend using a hammer or crowbar to remove the portions that are nailed down.

We designed our carts to be simple to operate:

To turn on, pull the red On/Off switch out towards you.
Toggle the black switch for forward and reverse.
Grasp and twist the throttle.
To turn the cart off, simply push the red button in.

Safety Features

Emergency Stop – The red E-Stop button allows the user to immediately stop the progress of the cart.
AutoLock – Automatically locks the wheels when the throttle is not being applied. This feature prevents the cart from rolling away from the user and also provides easy loading and unloading on inclines.
HillSense – Allows the cart to be used safely on inclines and declines. The cart will travel at the speed set by the user, not by the incline or decline.
SmoothStart – On acceleration, power is applied to the drive tyres in a controlled manner ensuring a smooth start each time.
Four-Wheel Design – All Overland Carts have at least four wheels to provide maximum stability.

They’ve been tested (again and again)
The standard 22/24 amp-hr AGM rechargeable battery packs have been extensively tested. We are confident to rate the batteries with a 4-6 hour real-world capacity.

Satisfaction Guaranteed
Granite Industries is committed to making sure each Overland Cart meets your expectations. To ensure customer satisfaction, we offer a 15-day money-back guarantee. Use the cart and see how much easier the cart makes your projects. If you’re not satisfied, simply contact Granite Industries at 877-447-2648 for a return authorization and details.
Orders and quote requests can be emailed to support@graniteind.com or faxed to 419-445-3304

FREQUENTLY ASKED QUESTIONS

How long do the batteries last on a single charge?
It is completely dependent upon how much weight is being carried, the type of terrain, and the softness or hardness of the surface. We estimate a range of 4-6 hours of “real world” use. PLEASE NOTE: Most use is not as intense as our “real world” estimates, so actual use time is typically much longer. Visit YouTube.com/OverlandCarts to view videos of our product testing.

When and how long should I charge my cart?

Charge your cart immediately after using. If, during operation, the battery indicator light goes to red, it is time to recharge. It is recommended to leave the cart on the charger overnight to extend the life of the batteries.

How long will the batteries last before needing to be replaced?

The batteries are designed to last for 300-500 charge/discharge cycles, which translate into approximately 1-2 years. The batteries are common and can be purchased from Granite, your local battery supplier, or on Amazon.

Will tipping the unit hurt the batteries, electronics, or drive system?

No. Batteries, electronics, and drives can operate in any orientation.

What is the maximum speed?

All 1400 series carts operate from 0 to 3.5 miles per hour in both forward and reverse.

While pushing my cart in manual/freewheel mode, it suddenly decelerates aggressively. What causes this?

There is a safety feature on your Overland Cart that is designed to prevent the cart from running away when the brake is manually disengaged.

How much weight can my cart handle?

1200 lbs is the maximum load for level ground.

Why does my cart lose traction when one wheel is off the ground?

The drive system is an open differential that allows the machine to efficiently make turns without skidding the tires. The drawback is that if one of the drive tires leaves the ground, it will simply spin until all tires are back on the ground.

Is a balanced load important to the performance?

Yes. Balancing the load so that it is not top-heavy or side-loaded, will allow much safer operation. Furthermore, most of the load should be located over top of the drive wheels for better traction.

How do I clean my Overland Cart?

Simply remove all debris, hose it down with soapy water, and towel dry. We do not recommend using a pressure washer.

Can I use my Overland Cart in cold temperatures?

You certainly can, but we recommend that you charge and store the batteries at room temperature.

Where is the serial number?

Every Overland Cart comes with its own serial number. On the Mega Herc, this is located on the front side of the upper control box.

CHARGING INFORMATION

CHARGE YOUR CART
When your cart arrives, please plug it in and make sure the battery is fully charged. There is a battery charge display on the side of the battery pack.

The smart charger uses a three-stage charging system to optimize battery longevity. Once the charger maximizes the charge to the batteries, it will go into standby/float mode. The charger can be left connected to the batteries after a full charge (green light) without harming the batteries.
The voltage for the battery pack will read 100% after a full charge. If not used immediately, the battery pack will slowly drop to about 90% after 24-48 hours. This is normal. If the battery pack is plugged back in, the percentage will quickly go up to 100%.
For the best battery life, charge the cart after each use or at the end of the work day. It is preferable to let the batteries charge overnight by plugging the cart into a 110V outlet.

State of Charge
The battery capacity can roughly be estimated by its voltage. As there are subtle differences in the voltage of each battery, the following parameters are for reference only. The voltage needs to be tested at rest (with zero current) after 15 minutes of being disconnected from the charger and loads.

For optimal battery life and long-term performance recharge when the battery pack reaches 40%.
The chart below shows how each individual 12V battery should perform and then also shows how two 12V batteries should perform when put into series. This is the configuration for your cart.

Balancing Batteries
As a part of routine battery maintenance, you may want to rebalance the batteries once or twice a year. We recommend a charger like the Noco Genius GEN5X1. It charges and balances one 12V battery at a time. Each battery can be rebalanced and then put back into the battery pack. This can also be helpful if the battery pack is dropping to 90% quickly after being recharged.

BATTERY CAUTIONS AND WARNINGS

Before using the battery charger, read all instructions and cautionary markings on the battery charger, batteries and the product using the batteries.
Only use the type of batteries that the charger is specified for. Other types of batteries may burst, causing personal injury or damage.
Do not expose the charger to rain or snow.
Do not cover the charger or charge the battery in an airtight enclosure. Ventilation is important to prevent overheating.
Make sure the extension cord is not used unless necessary. The use of improper extension cords could result in the risk of fire and electric shock. If an extension cord must be used, make sure:
- The pins on the plug of the extension cord are the same number, size and shape as those on the charger. (3 prong with ground)
- The extension cord is properly wired and in good electrical condition. A 16 ga cord or heavier-duty extension cord is recommended.
Do not operate a charger that has been dropped, damaged or has a damaged cord or plug – replace immediately if there are signs of damage!
Do not disassemble the charger.

OPERATING INSTRUCTIONS

SAFETY INFORMATION

Only use chargers and batteries issued by Overland Carts. Use of third-party batteries or chargers may cause harm to the user and the cart.
Always make sure the load is distributed evenly in the hopper and the cart is stable before operating.
Push in the red E-Stop whenever the cart is sitting still or whenever the batteries are charging.
Do not exceed the rated capacity of 1200 pounds for the cart on flat surfaces.
Exercise caution when operating on inclines or declines.
Do not drive the cart over sudden drops such as curbs, steps, or ledges. We recommend using ramps to navigate uneven surfaces.
The metal battery pack can be opened to reveal the batteries; however, the physical batteries should never be opened. They are sealed AGM batteries and cannot be resealed. Do not attempt to add more battery acid or water. If the batteries need replaced, please purchase new batteries.

BEST PRACTICES

Hand wash your Overland Cart with soapy water. Never use a pressure washer.
Do not drive your cart through deep puddles of water and do not submerge the drive system or battery box.
The drive system is lubricated for life, so no maintenance is required.
When the battery indicator light goes to red, it is time to recharge.
Recharge cart immediately after use.

POWER YOUR CART ON
To power your cart on, pull the red E-stop button out. You will notice the battery indicator lights light up and your cart is now ready for operation.
If the Overland Cart sits inactive for 20 minutes while on, it will go to sleep to conserve power. To wake the cart up, push the E-Stop button in, and pull it back out to power your cart on again.

TROUBLESHOOTING

Issue	Possible Problem	Solution

The cart will not run

| Batteries are dead| Charge the Overland Cart
E-Stop is in the OFF position| Pull the e-stop out, to the ON position
The unit is in sleep mode| Cycle the unit OFF for a couple of seconds, then back ON
The cart is in freewheel mode (the brake is disengaged)| Re-engage motor brake (see free wheel mode section)
Electrical malfunction| Disconnect and connect all electrical connections, and make sure they are all secure
Moisture issue| Let dry, avoid getting the s-drive and battery

box wet

Cart shuts off during use

| The circuit breaker has tripped| Push the reset button on the battery pack (see diagram below).
Thermal overload (weight, climb angle, or terrain may have exceeded transaxle capacity)| Release the throttle, and allow the transaxle to cool down for at least 30 seconds. Unload some weight, cycle the power switch and operate the machine again. The reset button will likely need to be pushed.

Cart suddenly stops

| Broken or loose motor wire or connector| Check motor wires and brake wires to make sure none are broken, and also check the connector to make sure wires are secure
Cart abruptly slows down while in freewheel mode| A safety feature has been triggered preventing the cart from rolling away| Push the cart slower while in freewheel mode

Batteries do not last as long as desired

| Cold batteries| Keep batteries warm
Batteries not fully charged| Make sure your cart is fully charged before using
Batteries are damaged or too old| Replace your batteries
Loose wire connections| Check all connections to make sure everything

is secure

The charger light goes directly to green when charging, but the battery is not charged| The battery and/or charger may have gone bad| Test the charger on another battery if possible. Replace battery and/or charger
The connections may have come loose, or disconnected| Check the charger and battery connections

BATTERY INFORMATION

IMPORTANT RECOMMENDATIONS

It is recommended to wear insulated gloves when handling batteries.
If equipment is to be stored for a long period, the batteries should be disconnected to avoid undue drain.
When replacing your batteries, fasten them tightly, but do not apply undue force to the terminals or bend them.
Do not place batteries close to objects which can produce sparks or flames.
Avoid exposing batteries to heat.
Do not mix batteries with different capacities, different ages or different makes.
For best results and generally acceptable performance and longevity, keep the operating temperature range between 5º F (-15º C) and 113º F (45º C)
It is good practice to ensure that the connections are re-torqued and the batteries are cleaned periodically.
Do not attempt to disassemble batteries. Contact with sulfuric acid may cause harm. If it should occur, wash skin and clothing with liberal amounts of water.
Batteries should not be stored in a discharged state or at elevated temperatures.
Please recycle old batteries. Do not throw them away, or attempt to burn them. Attempting to burn batteries (new or old) may cause them to rupture or explode.

BATTERY FEATURES

Absorbent Glass Mat (AGM) technology for superior performance.
- AGM design ensures the acid inside the battery is spill-proof
- Vibration resistant
- Better performance in cold temperatures
- Faster charging
- Longer expected life
Valve-regulated, spill-proof construction allows safe operation in any position. However, upside down is not recommended.
Maintenance-free design. There is no need to add electrolytes as gases generated during the charge phase are recombined in a unique oxygen cycle.
Power/volume ratio yielding unrivalled energy density.
Special separators, advanced plate composition and a carefully balanced electrolyte system ensure the battery can recover from an excessively deep discharge.
All batteries feature a series of low-pressure, one-way relief valves. These valves safely release any excessive accumulation of gas inside the battery and then reseal themselves.
Batteries may be discharged over a temperature range of -5º F (-15º C) and 113º F (45º C), and charged at temperatures ranging from -32º F (0º C) and 104º F (40º C). For best results, we recommend charging the batteries at room temperature.

FREEWHEEL MODE

FREEWHEEL MODE
The drive system is equipped with a lever that overrides the electromechanical brake for manually operating your Overland Cart. The brake lever allows you to override the electric brake when you need to push the cart manually when a loss of power has occurred. With the brake in the disengaged position, the E-Stop button must be pushed in, and the power turned off or the drive system will not move freely. The controller will NOT operate the motor when the brake is disengaged.
When the lever is in the down position the brake is engaged. When the lever is in the up position, the brake is disengaged. When you reset the brake system the unit will not operate until you toggle the power button off and back on. This process will need to be repeated every time the brake in manually disengaged.

OPERATING THE KICKSTAND

The kickstand is located on the back of the cart.
Stand the cart up in the upright position. Pull the kickstand off of the magnetic holding plate.
Lower the kickstand to the floor.
To lock it into place, lean the cart forward slightly, and slide the bar up into the notches to secure into place.
To return the kickstand to the upright position, rock the cart forward slightly again to disengage the kickstand from the notches. Repeat the remaining steps in reverse order.

BATTERY REPLACEMENT

TOOLS

2 or #3 Phillips screwdriver

8mm wrench & socket (for bolt-style connectors)

Disconnect the wires going to the battery box. Remove the battery from the cart by taking out the hairpin and removing the rod. Slide the battery box out from its housing.
Remove the four (4) #10 screws holding the lid in place. Remove the lid and set aside.
Remove the rubber insulator sheet and set it aside.
Carefully remove the batteries, and disconnect the screw or bolt-style connectors, depending on your battery type.
PLEASE RECYCLE YOUR OLD BATTERIES

BATTERY REPLACEMENT

Place the batteries back into the box one at a time. Tuck the wires into the box and out of the way.
Replace the rubber insulator sheet and then the box lid. Secure the lid with four (4) #10 screws.
Place the battery box back onto the cart, insert the rod and secure it with the hairpin. Finally, reconnect the wires to the power terminal.