manual - KXR 400

 

date last updated : 23rd July 2009

 

This electronic version of the User's Manual for the KXR 400 golf trolley with full remote control operation will be updated as necessary from time to time - as dictated by changes in the trolley design and manufacture, or of its operation. In most cases it will refer to the latest version of the KXR400

PLEASE NOTE THAT IF YOU PREVIOUSLY ACCESSED THIS PAGE THAT YOU SHOULD ALWAYS PRESS THE "REFRESH" BUTTON ON YOUR BROWSER TO ENSURE THAT YOU ARE LOOKING AT A CURRENT VERSION OF THIS MANUAL

         

   

REMOTE CONTROL GOLF TROLLEY

model KXR400

  USER MANUAL

  CONTENTS

 

 

PREFACE

Thank you for purchasing the new KXR400 model electric golf trolley with full remote control operation. Please read this manual carefully before use.

KXM200 owners. If you have a KXM200 single-motor trolley then some of the following will also be applicable to that model. The frame and the majority of the components are shared however please ignore all references to the remote-control functions.

IMPORTANT

After unpacking please keep the carton and all internal sections in safe storage. In the unlikely possibility that you need to return the whole unit due to a defective component, you will need to repack the unit in the original manner to ensure safe and secure transit.

Check all of the following items are included in the package –

  • The main trolley frame.
  • Drive wheels
  • Front wheel assembly
  • Rear wheel assembly
  • Battery complete with battery cover
  • Battery charger
  • Remote Control Transmitter
  • Tool kit

If any of the above contents are missing or damaged, please note the serial number of the unit and contact us at 559 561 1234

After unpacking the trolley place the battery on charge whilst you assemble the unit. The battery will be delivered with a charge but should always be placed on charge overnight before using ( a minimum of 22 hours).

Contents of this manual cover assembly from the delivery carton – operating instructions and conditions – maintenance – and troubleshooting. Please note that our design and manufacturing policy is aimed at continuous improvement – this can result in changes without notice to the specifications contained in our websites and in this manual.

Please read through this manual carefully before use – in particular the section on battery cover connections and battery charging

•  the section on battery maintenance

•  the recommendation to retain the original delivery carton and packing materials

We understand that it can be onerous to store large cartons however in the unlikely event that the trolley has to be returned to the service department this original packing will be essential for safe shipping.

This product has been designed with the use of the golfer in mind – nevertheless the golfer purchasers will be the best judge of the level of success that we have achieved. We welcome any positive suggestions for improvement to design that you as the user might have.

 

   
   
MAIN COMPONENTS
1
front wheel
2
combined front wheel and bottom bag support
3
main lower frame
4
lower frame section - beneath lower hinge
5
lower hinge
6
upper bag support
7
upper hinge
8
upper small frame section - between handle and upper hinge
9
ON/OFF and speed control switch
10
handle
11
locking catch
12
battery tray
13
rear stabilizer wheel
14
rear wheel housing
15
drive wheel
16
motor/gearbox (left and right)
17
center small frame section - between upper and lower hinges
 

 

   

ASSEMBLY

 

  1. Install both of the drive wheels. Push the spring-loaded section of the drive wheel (located on the plastic catch mechanism on the outside of this wheel) inwards and then move the wheel inwards to locate the drive wheel to the drive wheel coupling. In this position it should be positioned onto the innermost of the two slots on the axle. The outer slot is a "free-wheel" position. When releasing this spring-loaded section it is securely located if it cannot be pulled outwards.

 

 

 

2.    Install the complete front wheel assembly. (If not already installed). This is the only other part that is delivered separately in the carton – this to reduce the size of the delivery carton. Push the wheel housing onto the frame tubing as shown. If necessary rotate the housing to align the screw holes. Insert bolts and washers and nuts – tighten.

3. Install the complete rear-wheel assembly by retracting the spring-loaded détente, and then sliding the assembly tube over the square receiving spigot.

 

 

 

BATTERY INSTALLATION

The battery can be installed from either left or right hand side of the trolley. Using the carrying strap, carefully place a fully charged battery into the battery tray with the connector facing the left side of the trolley.

CHECKS BEFORE OPERATION

•  IMPORTANT Put the battery on charge for at least 24-hours before using on the golf course. The battery will probably be delivered to you with some residual charge already, hower it is most important that you completely charge the battery before use

•  IMPORTANT Check the connection underneath the battery cover before use. See section below on BATTERY COVER CONNECTIONS. Ensure that the soldered connections are intact (no transit damage) and that the leads are not in danger of being fouled by the mounting of the battery cover to the battery, and most importantly that the screws on the terminals are fully tightened down.

•  Check that the plug into the battery is firmly connected.

•  Check that the battery securing straps are securely fastened.

           

BATTEY COVER CONNECTIONS

For shipment the connections inside of the battery cover are only loosly connected. Before using the first time you should check all of the connections inside of this cover.

Check

1     The soldered connections for any transit breaks.

2     That the wires connected to the two battery terminals are not in danger being crimped by the closing down of the cover onto the battery - see images below.

Then firmly tighten down the connections to the terminals

Now charge the battery for at least 24 hours before use

 

           

 

 

 

OPERATION

 

MANUAL CONTROL

Switching the ON/OFF switch at the handle to the ON position puts the cart into the REMOTE mode. Turning this switch OFF and then ON again within 2-seconds will put the cart into manual mode.

Roll the knurled knob of the combined ON/OFF switch and Speed control forwards to turn on the power to the cart. Turning this knob further will progressively apply more power to the drive wheels and start the forward motion of the cart. Reversing this knob will reduce the speed of the cart.

When this switch is turned ON for the first time the small LED on the handle should briefly illuminate to indicate that all electrical systems are operating properly.

When operating in manual control please note that there will be a 2-sceond delay after turning the ON/OFF switch to the ON position and response from the same switch to control the forward speed.

 

 
REMOTE CONTROL
 
 

 

There is a cluster of 5 buttons in the middle of the remote control transmitter.

 

The left direction arrow turns the cart to the left

The right direction arrow turns the cart to the right

The “Up” direction button makes the cart go in a forward direction. It also provides acceleration in proportion to the incremental pressing of this button up to a total of 5-clicks..

The “Down” direction button makes the cart go in the reverse direction. It is necessary to bring the trolley to a complete standstill before changing directions – forward to reverse – or reverse to forward. This button is also used for braking.

The STOP button is used to stop the cart. One click will cut power and slow the cart. A second click immediately following the first click will STOP the cart.

 

 

TRANSMITTER USE

•  Your KXR400 transmitter has been designed for ease of use whether you are left or right handed.

•  Take time to practice the difference between a single touch of a key and a prolonged push especially with left and right functions.

•  Never store the transmitter in a pocket with metal or sharp objects, or loose change. Never allow the transmitter to get immersed in water.

•  Because of the need for a removable battery cover, the transmitter is not waterproof, so when playing in the rain it is important to store it in a dry place like a pocket, and to protect it during use.

•  The transmitter takes a replaceable battery, you will need to carefully remove the battery compartment cover to replace it.

•  Do not use a rechargeable battery in the handset as these batteries do not give sufficient voltage for this transmitter

BATTERY

The small battery powering this transmitter is a special high Ampere/hr battery - similar to those used in garage door openers. Replacements can be readily purchased for a little over $2 at most good quality hardware stores. The Duracell equivalent battery is the 21/23 - 12 volt - 23 Ampere/hr - MN21/A23

REPLACEMENT

Replacement of transmitter. If the original transmitter is lost or broken it is a simple process to match the code of the controller to that of the new transmitter.

1.     First turn OFF the ON/OFF switch at the handle

2.     Then holding the new transmitter near to the cart depress the STOP button and hold it depressed

3.     The turn ON the ON/OFF switch on the cart handle

4.     Continue to hold the STOP button depressed for about 3 to 5 second.

The controller on the cart should now be synchronized to the new transmitter. It is not practical to have and operate two separate transmitters because you would have to re-synchronize the cart controller to the battery each time of use.

 

LED LIGHT INDICATIONS

1

When the combined ON/OFF and speed control switch in the handle is turned ON the BLUE LED light at the handle should illuminate once for a very short period to indicate that all parts of the cart are connected and functioning correctly. It will then turn off.

If this does not happen then there are three possibilities

•  Blown controller fuse. Fuse is located in a connector inside of the battery cover. A blown fuse will normally indicate a recent condition of excessive load onto the battery – for example too steep a gradient or too heavy a load.

•  A break in one of the soldered connections inside of the battery cover. A break in wiring to the switch connection in the handle or a break in the wiring from the handle down to the main controller

•  A problem with the main controller (the small sealed box underneath the battery tray). Either a faulty IC board, or a short-circuit within the controller.

2

   The handle LED emits short flashes of 1 second duration. This indicates that the trolley is being controlled in MANUAL mode (not by the remote transmitter).

3

The handle LED emits longer flashes of 2 second duration. This indicates that the remaining voltage in the main battery has dropped below 10.5 volts.

4

If when pressing any button on the transmitter its LED light does not appear as a solid strong RED but is dimmed, then this indicates a low transmitter battery condition, and it needs to be replaced as soon as possible.

 

ALIGNMENT ADJUSTMENT

Loosen the axle nuts using two 14mm wrenches. This will allow front wheel movement – left or right – up to 5 degrees. Re-tighten securely.

More than one such adjustment might be necessary to achieve alignment.

Before making any adjustments it should be understood that a golf trolley with a very narrow wheelbase and with an uneven – and sometimes shifting – load will probably never be able to maintain a forward direction and a straight line – mainly because even a small directional bias at the start quickly magnifies to a much larger directional deviation. Indeed the whole point of having a remote operation cart is to be able to ignore the exact position of the cart – as long as it is within the fairway and clear of other golfers and water hazards. The user has the ability to bring his cart and clubs over to him when he gets up to his ball.

 

FREE-WHEEL MODE

In the event of a complete power failure of the gof trolley on the golf-course it is a simple matter to put the cart into a free-wheel mode. Simply disengage the drive wheel from the drive-axle by depressing the button on the outside of the wheel. Then slide the wheel outwards a short way to the second slot on the axle.

USE & MAINTENANCE

TROLLEY

•  Your trolley has been made as robust as is possible, whilst at the same time making it as light-weight as possible, with the use of aluminum and plastic and nylon components. It is nevertheless subject to damage if roughly treated. Always avoid any unnecessary jarring to the frame and the controller - for example do not drive it over curbs, or into trees. Clean the whole cart as convenient. Remove any caked mud and grass cuttings.

•  Do NOT lift up the trolley by the handle when loaded with battery and clubs - similarly do not press downwards on the handle with undue force. No electric golf trolleys are designed to be lifted upwards by the handle. With the battery installed, and a full set of clubs in the bag, all of this weight plus the trolley frame and motors - probably about 100 lb - is placed onto the top hinge mechanism if lifted by the handle.

•  Store it indoors in dry conditions

•  Always remove the battery from the cart as soon as possible.

BATTERIES

•  Regularly check to see if the battery is damaged

•  Keep the battery surface clean, and check underneath the battery cover to make sure that no dirt or water has accumulated inside of it.

•  Check the battery connections – underneath the plastic battery-cover– for any signs of corrosion or bad connection.

•  Check that the wires from the battery cover are firmly fixed to the terminal posts.

•  After use always place the battery on charge – in warm dry conditions.

•  Leave the battery on charge until it is to be used again. Always allow sufficient charging time to completely charge the battery – overnight or 6 to 8-hours should be sufficient.

•  If the battery is to be stored – for instance over winter – and not used it can either be left connected to the charger, or disconnected. If disconnected for storage always recharge the battery completely at intervals – at least once every two months. Allowing the charge of the battery to drop to a completely exhausted state can shorten the life of the battery.

•  Do not charge the battery with a different charger that that supplied with the trolley.

•  If stored place the battery on a wooden shelf – not on a concrete floor. Keep away from fire – flames – heaters – and do not allow it to be in a temperature of over 45 deg C (113 deg F)

CHARGER

•  Do not attempt to open the case of the charger

•  Only use the charger to charge the battery of this golf trolley

•  Operate only indoors – in clean dry conditions

•  Immediately remove from the mains electrical supply in the event of the charger overheating (over 70 deg C)

TRANSMITTER

•  Avoid using excessive force when pressing the function keys on the transmitter

•  Replace the battery immediately a low battery condition is evidenced – either by the LED or by reduced control distance.

•  Because of the battery cover this transmitter is not waterproof – so keep dry when operating in rainy conditions – either in a pocket or under a jacket.

 

TROUBLESHOOTING

The following is general information for the customer. A lot of problems can be quickly fixed, however if you have a persistent problem always call the service department. It will always help if you can tell them the sequence and condition of the LED lights.

   

 

INDICATION POSSIBLE CAUSE - REMEDY
The blue LED light on the handle illuminates when the combined ON/OFF and speed control switch in the handle is turned ON – but does not then turn off.

1    Blown controller fuse. Fuse is located in a connector inside of the battery cover. A blown fuse will normally indicate a recent condition of excessive load onto the battery – for example too steep a gradient or too heavy a load.

2    A break in wiring to the switch connection in the handle or a break in the wiring from the handle down to the main controller

3    A problem with the main controller (the small sealed box underneath the battery tray). Either a faulty IC board, or a short-circuit within the controller.

With the ON/OFF switch turned ON – the speed control knob is turned for speed. The LED on the handle does not illuminate. There is no forward movement of the trolley1   

1   Bad wire connection. Either to the switch in the handle – or at the connection jacks to the controller

2   No battery power getting from the battery to the controller.

Carefully check the connection ends of all of the wires inside of the battery cover. These are soldered connections. If any one of these is faulty then it would need to be reattached properly, or the battery cover be replaced.

3   Then please check the battery to ensure that it is fully charged. It is highly unlikely that anything is wrong with it, but its condition can easily and quickly be checked at any auto-repair center.

Same conditions as above – but the LED is illuminated
Bad wire connection to the motor. Either at the connection plug at the controller – or even internal to the controller
The battery is not accepting a charge

1. First carefully check the connection ends of all of the wires inside of the battery cover. These are soldered connections. If any one of these is faulty then it would need to be reattached properly, or the battery cover be replaced.

2. Then please check the battery. It is highly unlikely that anything is wrong with it, but it easily and quickly be checked at any auto-repair center.

Always check for correct connection of the plugs into and out of the charger.

3. Lastly a faulty charger. Easiest check here would be to charge the battery overnight with any 12 volt auto trickle-charger. If this works then the charger is faulty and needs to be replaced

Transmitter not operational

The main ON/OFF switch has not been turned ON

Battery in transmitter - check - replace

Faulty transmitter

Reduced operational distance of the transmitter
Low battery condition in the transmitter - replace
LED on transmitter does not light Low battery condition in the transmitter - replace
One motor turns - the other does not

Possible break or bad connection of a wire into, or at, one of the plug connections between the motor and the controller. Wiggling these connections might make a temporary connection and expose such a disconnect. Checking and cleaning the plug connectors might provide a permanent solution

Possible burnt-out motor - check motor connection wires for signs of burnt or melted wires

One wheel turns and the other does not

Could be caused by the catch mechanism on the wheel being too far away from the drive-slot in the axle - either by incorrect manufacturing tolerances or by wear. Often the simplest solution is the addition of a washer (a little over 1/16th inch thick) to each of the mechanism fixing bolts.

Click here to see separate page for details of this addition

Possible motor problem - see above

Possible problem with the controller