Acquisition.com — Facilities Operations

Pony Express™ Cart
Training & Certification

Complete the training modules, then pass the quiz before operating the cart.

1
Introduction & Overview
Overview
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The Pony Express™ Motorized Ergo Handling Cart is an electric-powered transport cart used to move drinks, snacks, and supplies around the office safely and efficiently. It reaches speeds up to 3 MPH and is designed for smooth, flat indoor surfaces.

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Only trained, manual-reviewed personnel may operate the cart.
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If anything in this training is unclear, do NOT operate the cart — call service at 1-800-824-1068.
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Failure to read the owner's manual voids the warranty.
2
Safety Rules — Read Before Every Use
Safety
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These rules must be followed every single time the cart is used. No exceptions.

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Always turn the key switch OFF before loading or unloading the cart.
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Load items evenly to prevent tipping. Never exceed 1,000–1,500 lbs depending on your model.
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Take corners slowly and with caution — loads can shift.
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Use the Turtle (slow) speed mode in hallways, doorways, near stairwells, or in tight spaces.
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Always announce your presence when approaching blind corners.
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Never operate on inclines greater than 6°. Do not travel sideways across inclines.
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Never park, load, or unload on an incline — always use flat, level surfaces.
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Never operate in wet environments or expose the cart to high temperatures.
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Never use the cart to push or pull other objects or carts.
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Never allow unauthorized or untrained personnel to operate the cart.
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Never operate with a broken wheel or bent caster.
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Never go up or down curbs — only operate on smooth surfaces.
⚠️ If an injury or emergency occurs: call 911 immediately. The AED is located on the 1st floor between the stairs and reception desk.
3
Controls Walkthrough — Know Before You Go
Operation
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Familiarize yourself with every control on the EZ-Grip control unit before your first run.

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Key Switch (side of unit): Insert key and turn clockwise to power ON. The status LED on top will illuminate. Always remove key when cart is parked or charging.
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Thumb-Wheels (both sides): Push forward (clockwise) to move forward. Push backward (counterclockwise) to reverse. Release to stop.
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Rabbit/Turtle Switch (top of unit): Front of rocker = Rabbit (fast). Back of rocker = Turtle (slow). Always default to Turtle in the office.
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Emergency Stop Button (large red button, front): Press to stop immediately. To restart, cycle the key switch OFF then ON.
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Battery Gauge (top of unit): Green + Yellow + Red = charged. Red + Yellow = charge soon. Red only = charge immediately.
⚡ Always wait at least 1 minute after powering on before trusting the battery gauge reading — it needs time to stabilize.
4
Step-by-Step: How to Operate the Cart
Operation
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Follow these steps in order every time you use the cart.

1
Inspect the cart before use — check for broken wheels, bent casters, or damage. Do not use if damaged.
2
Check the battery gauge. If showing red only, charge the cart before using.
3
Turn the key switch OFF. Load your items evenly on the platform, distributing weight to prevent tipping.
4
Insert the key and turn clockwise to power ON. Select Turtle (slow) mode using the rocker switch.
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Gently push either thumb-wheel forward. Start slow and stay aware of your surroundings.
6
Reduce speed near doorways, hallways, corners, and stairwells. Announce your presence if needed.
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To stop, release the thumb-wheel. The cart will slow using dynamic regenerative braking and lock via the electromechanical brake.
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Turn the key switch OFF before unloading. Remove the key when done and store the cart in its designated spot.
💡 First-time operators should do a practice run in an open, obstacle-free area before using the cart in the office.
5
Braking Systems — How the Cart Stops
Operation
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The Pony Express has two braking systems that work together. Understanding both is critical for safe operation.

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Dynamic Regenerative Braking: Automatically activates when you release the thumb-wheel. Brings the cart to a smooth stop but does NOT lock the wheels in place.
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Electromechanical (Parking) Brake: Activates after dynamic braking brings the cart to a stop. Locks the drive wheels in place. Can also be applied instantly using the Emergency Stop button.
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Never manually release the electromechanical brake on or near an incline — the cart will roll freely and cannot stop on its own.
⚠️ If you need to push the cart manually: only disable the brake on a completely level surface with the cart fully unloaded. Return the brake lever to the DOWN position before driving again.
6
Charging the Cart — Best Practices
Maintenance
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Proper charging is the single biggest factor in extending battery life. Make it a habit.

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Charge the cart whenever it is not in use — it cannot be overcharged.
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Turn the key switch OFF and remove the key before connecting to power.
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Locate the coil cord below the frame at the control handle end. Plug directly into a standard AC outlet (100–240V).
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Allow 6–8 hours for a full charge. Overnight charging is recommended.
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If using an extension cord, use industrial grade only with a grounded plug.
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Never attempt to turn the cart on while still plugged in — unplug first.
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Never add water to the batteries — they are sealed AGM (maintenance-free).
🔋 If you notice the cart isn't traveling as far on a full charge, or ramps that used to be easy are now difficult, the batteries may need testing or replacement. Contact facilities.
7
Daily & Monthly Maintenance
Maintenance
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Regular upkeep keeps the cart safe and extends its lifespan. Always disconnect the batteries before performing any maintenance.

Daily
Maintain the battery charge. Clear any debris from the wheels and drive unit.
Monthly
Check for loose connectors and signs of unusual wear. Grease caster wheel swivel assemblies with industrial grade grease.
Quarterly
Wipe down the cart with a warm, soapy damp sponge (no pressure washing). Check wires for fraying. Inspect tires and wheel assemblies.
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Never pressure-wash or hose down the cart — water damages the electronics.
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Never use abrasive cleaners — they damage the finish and cause premature tire wear.
💡 If white crusty buildup appears on battery terminals, clean with a baking soda + water solution and a toothbrush. Don't let it sit — it degrades battery performance over time.
8
Troubleshooting Common Issues
Diagnostics
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If the cart isn't behaving normally, check these common causes before contacting service.

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Cart won't turn on: Check that the key switch is turned fully clockwise. Check that the Emergency Stop hasn't been pressed (cycle the key). Check the circuit breaker on the battery — push the tab down to reset.
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Cart runs very slowly: Battery charge is low. Charge the cart fully and try again.
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Hard to steer or turn: Casters may need lubrication. Apply spray silicone or WD-40.
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Status LED flashing: Count the flashes. 1 flash = charge battery. 6 flashes = Emergency Stop was pressed (cycle key). 7 flashes = release the throttle before powering on. Any other code — contact service.
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Never bypass, tape down, or remove the circuit breaker — this is a critical safety component.
📞 For issues you cannot resolve, call the service hotline: 1-800-824-1068. Do not attempt repairs beyond what is listed in the manual.

Operator Knowledge Quiz

15 questions based on the Pony Express™ Owner's Manual. Pass this quiz before operating the cart.