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Related Manuals for Gatekeeper Systems CartManager HD
Summary of Contents for Gatekeeper Systems CartManager HD
- Page 1 Moving Cart Retrieval Forward FIELD TECHNICIAN GUIDE V1.2 THE LEADING PROVIDER OF INTELLIGENT CART SOLUTIONS WWW.GATEKEEPERSYSTEMS.COM...
- Page 2 Gatekeeper Systems. This document and the products it describes are furnished under a license agreement, and may be used or copied only in accordance with the terms of the license agreement.
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Page 3: Table Of Contents
Adjusting the Cart Cradles ........................27 Wiring Diagram............................28 XDWi ..............................28 XDW ..............................29 Ordering Parts ............................. 30 CartManager XD Safety Guidelines ……………………………………………………………………………………….. CartManager XD Safety Guidelines Continued ..................33 Warranty Information ........................... 34 Contacting Gatekeeper Systems ........................ 36... -
Page 4: What's In This Guide
If you are still experiencing difficulties after completing the troubleshooting tasks, please go to the last page of this guide and contact the Gatekeeper Systems Inc. Customer Support Center closest to your location. CartManager XD Maintenance Daily and quarterly maintenance is generally performed by store personnel. The guidelines below are included so that the field tech can stress the importance of regular maintenance in keeping the CartManager XD in top running order. -
Page 5: Cartmanager Xd Ppm Checklist
CartManager XD PPM Checklist This checklist is intended to be used as a guide while performing a scheduled Periodic Preventative Maintenance (PPM) or whenever a service call is made on a unit. Serial # : Date: Throttle Body Control Working Properly Check resistance readings between red and black wires from potentiometer, in neutral it should be 2.400-2.600 K OHMS, when throttle is turned forward it should read close to 5.00 K OHMS, and backwards it should read close to 0.00 K OHMS. -
Page 6: Cartmanager Xd Views
CartManager XD Views CartManager XD Rear View (XDW & XDWi) CartManager XD Field Technician Guide Page... -
Page 7: Cartmanager Xd Side/Front View
CartManager XD Side/Front View CartManager XD Field Technician Guide Page... -
Page 8: Cartmanager Xd Features And Controls
CartManager XD Features and Controls This table provides a description of each of the parts shown in the preceding diagrams. PART DESCRIPTION OF THE FUNCTION Receives signals from the remote control. Also outputs the (unlock) Antenna signal for the shopping cart wheels. The anti-static chain prevents damage to the CartManager electrical components by dissipating static electricity buildup. - Page 9 Turns the unlock signal on and off when the machine is moving and stopped respectively. This is for use with shopping carts that have a Relay U ( XDWi) Gatekeeper Systems’ wheel. Puts the CartManager in slow speed mode when the battery is low to RELAY B (XDWi) avoid damage to the batteries.
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Page 10: Remote Control Issues
Remote Control Issues CartManager XD Does Not Respond to Remote Use this process to diagnose and correct problems when the remote control unit does not turn on or turns on but does not communicate with CartManager XD. If you are using a new remote for the first time, or using a remote other than the one usually issued to XD units, follow the steps in the Link the remote to the CartManager XD box below to establish a communications link between the remote and the receiver. -
Page 11: Checking The Speed Board Relays
Checking the Speed Board Relays If both the remote control unit and receiver are functioning properly, but the CartManager XD does still not respond, there may be a problem with the relays that actuate the motor in response to signals from the remote. Use the following procedure to troubleshoot these relays. -
Page 12: Cartmanager Xd Receiver Issues
CartManager XD Receiver Issues Follow the steps below if the CartManager XD is turned on but does not move when remote is initiated. 1. Turn key switch on 2. Push red button on remote and release Start Sync Process 3. Push green button on remote and release 4. -
Page 13: Cartmanager Xd Receiver Issues Continued
CartManager XD Receiver Issues - Continued Continue 1. Using appropriate support jacks, lift drive tires off the ground. 2. Remove top cover plate and front lower cover 3. Connect black ground wire of Volt meter to ground post Next on receiver (black wire) 4. -
Page 14: Electrical Issues
Electrical Issues CartManager XDW Does Not Turn On Use this troubleshooting flow chart when there is no power to lights, horn, or travel controls after key switch is on. Start Do the lights 1.Turn key switch to off and horn work? 2. -
Page 15: Cartmanager Xdwi Does Not Turn On
CartManager XDWi Does Not Turn On Use this troubleshooting flow chart when there is no power to lights, horn, or travel controls after key switch is on. Start Do the lights 1.Turn key switch to off and horn work? 2. Turn the key switch on 1. -
Page 16: Cartmanager Xdw Does Not Move
CartManager XDW Does Not Move Follow the steps below if the lights work when key switch is turned on but does not move when throttle grips are initiated. If CartManager XD moves when throttle grips are turned but does not respond to the remote control, see Remote Control Issues. - Page 17 3. Turn key switch on 1. Turn key switch off 2. Check motor connections. Repair or replace if necessary 3. Turn Key switch on. Twist throttle grips Does CartManager Done move? Contact Gatekeeper Systems Regional Customer Support Center CartManager XD Field Technician Guide Page...
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Page 18: Cartmanager Xdwi Does Not Move
CartManager XDWi Does Not Move Follow the steps below if the lights work when key switch is turned on but does not move when throttle grips are initiated. If CartManager XD moves when throttle grips are turned but does not respond to remote control, see Remote Control Issues. - Page 19 3. Turn key switch on 1. Turn key switch off 2. Check motor connections. Repair or replace if necessary 3. Turn Key switch on. Twist throttle grips Does CartManager Done move? Contact Gatekeeper Systems Regional Customer Support Center CartManager XD Field Technician Guide Page...
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Page 20: Batteries And Chargers
Batteries and Chargers CartManager XD Field Technician Guide Page... -
Page 21: Battery Charger
Battery Charger The symptoms of battery charge malfunction will differ depending on the type of charger in your particular CartManager XD: LEDs - the charger has three LEDS; red, yellow and green, for each of the batteries in the CartManager XD. Only one of these LEDs should be illuminated at a time. -
Page 22: Battery Voltage Is Low Or Battery Runs Down Quickly
Battery Voltage is Low or Battery Runs Down Quickly CartManager XD should operate for 8-10 hours on an eight hour charge. If run time is consistently low, despite a full charge, it means that the batteries are either not receiving a full charge or are not holding the charge. Start 1. -
Page 23: Error Codes
Error Codes When the key switch is turned on, the CartManager XD powers up and runs through a brief diagnostic routine. If any electrical or electrical-mechanical faults are detected, the battery charge indicator displays a series of lights that indicate the type of fault and the drive motor remains offline until the fault is corrected. The sections below list the possible error codes and give some diagnostic tips for finding and correcting the problem. - Page 24 6 Bars Flashing Twist and release E-Stop Button. 7 Bars Flashing XDWi 2.2, 2.3 & 3.3 Cause There is a problem with the throttle potentiometer or the wires leading to it. Correction Remove the white 14-pin connector from the bottom of the motor controller. Make sure that the throttle is in the neutral position.
- Page 25 8 Bars Flashing XDWi Cause The motor controller has detected a self-fault. Correction Check that the wire harness at the bottom of the controller is securely in place. Run the tests listed in the “7 Bars Flashing” section above. Go through the “CartManager XD Does Not Turn On” algorithm on page 11. Remove the front access panel.
- Page 26 Cause The throttle is engaged when the CartManager XD is started. This cutout prevents the CartManager XD from lurching forward if the throttle grips are not in neutral position when the key switch is turned Correction Release the throttle grips and do not turn them while starting the CartManager XD. If this clears the error, no further action is necessary.
- Page 27 Error Code Label Sheet on XDW CartManager XD Field Technician Guide Page...
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Page 28: Mechanical Procedures
Mechanical Procedures Replacing the Strobe Light Bulb You will need: • A replacement strobe light bulb, part #E500238-02. • A pair of pliers or vice grips and Phillips P2 screwdriver. Remove four screws from protective cage and remove protective cage. Grasp the orange strobe light cover with your hand and twist counter clockwise to remove it from the strobe housing. -
Page 29: Replacing The Main Drive Tires
Replacing the Main Drive Tires The foam-filled main drive tires are designed to give maximum traction and durability over a wide range of working conditions and surfaces. The only time you should need to replace a tire is in the case of excessive wear or damage. If you need to replace both tires, do them one at a time. -
Page 30: Adjusting The Cart Cradles
Adjusting the Cart Cradles You will need to adjust the height of the cart cradles on the front of the CartManager XD if they consistently scrape when going over speed bumps, up ramps, over door sills, etc. You may also need to adjust the distance between the cradles if your store changes to carts with a different width between the back wheels. -
Page 31: Wiring Diagram
Wiring Diagram XDWi CartManager XD Field Technician Guide Page... -
Page 32: Xdw
CartManager XD Field Technician Guide Page... -
Page 33: Ordering Parts
Ordering Parts When ordering parts, you will need the following information: • Model of the unit • Serial number • Part number • Part description Part Number Part Description Model A3085 Ground chain XDW/XDWi A500128-03 Caster (all carts) XDW/XDWi A500129-000 Tire (all carts) XDW/XDWi A500219... - Page 34 Part Number Part Description Model E506831 Charger cord (WMT) XDW/XDWi E7031 Antenna (all carts) XDW/XDWi E7031 Flat antenna XDW/XDWi F14753-38 Upper arm side bracket XDW/XDWi H500409-01 Light pole plug XDW/XDWi K9400 Remote transmitter XDW/XDWi M3079 Ball knob XDW/XDWi M3088 Motor brake XDW/XDWi M500141 Cord grip...
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Page 35: Cartmanager Xd Safety Guidelines
CartManager XD Safety Guidelines Note: The following guidelines are suggested practices for safely performing repairs on the CartManager XD and are designed to protect both the technician and the public at large. The safety guidelines are not meant to be a replacement for good maintenance practices or common knowledge. -
Page 36: Cartmanager Xd Safety Guidelines Continued
CartManager XD Safety Guidelines - Continued The photo to the left demonstrates a technician having tilted a unit by using a bottle jack placed behind the drive wheel, lifting carefully on one side, and placing a block under the front of the unit. Be sure to use caution, being careful to not pinch fingers. -
Page 37: Warranty Information
(or other Gatekeeper Systems, Inc. product-collectively referred to herein as the “Product”) manufactured by Gatekeeper Systems, Inc (“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. - Page 38 Limited Warranty Program (continued) The Limited Warranty is invalid if the factory-applied 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, alternations, additions and/or modifications to the Product, use by any individual not a fully trained and fully authorized operator, and...
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Page 39: Contacting Gatekeeper Systems
Contacting Gatekeeper Systems For more information about CartManager XD training and troubleshooting, or to order replacement parts or report an issue, contact the Gatekeeper Systems, Inc. regional Customer Support office nearest to your location. Gatekeeper Systems, Inc. 2520 N. Great Southwest Parkway... - Page 40 Addendum...
- Page 41 CartManager XD CartManager XDWi Differentiating CartManager model types from outside. CartManager HD and SD Models - the key switch will be located by your waist area. CartManager HD models will have a Truecharge Battery Discharge Indicator (BDI), which is rectangle in shape and has three red, four yellow and three green LED’s from left to right.
- Page 42 Differentiating CartManager XD model types by electronic board. By opening up the hood and removing the electronic board cover you can determine which model of CartManager you are working with. Model Part Description Uses Controller P/N: E500126-215 Uses Controller P/N: E500126-210 XDWi Uses Controller P/N: E500216-13 Note: This electronic board does not have a contactor! Note: XD units were built with two different model controllers.
- Page 43 The CartManager XD units were built with two different model controllers. Shown on left is the CartManager XD with the Controller P/N: E500126-03 DISCONTINUED! Replacement part is Controller P/N: E500126-23 (this is a KIT). Shown in the photo on left, the XD with the Controller P/N: E500126-13.
- Page 44 E-Stop Replacement Parts needed: Quantity Part # Part Description E500187-07 Emergency stop switch (E-stop switch) E500187-08 Plastic adapter -------------- 6" zip tie You will need: • Channel locks • Small screwdriver • Wire cutters • Rubber mallet • Tape measure Using a #2 Phillips screwdriver, remove the upper arm cover (F14753-39) by removing the four black counter-sunk screws from the front and back of the upper arm cover.
- Page 45 There is a "U" shape, silver colored plastic clip (which has spring- action built into it) on the side of the connector block. By pushing it in firmly and pulling the connector block away from the red switch, separate the connector block from the red switch. There are three contact blocks attached to the connector block: normally closed (terminals 1, 2 - with the red tab between screw terminals), the shell, and normally open (terminal 3, 4 - with the green tab).
- Page 46 13. Turn over the top cover and insert the second black plastic adapter through the back of the E-stop push button. Again, the flat side of the adapter facing outward. Insert the plastic nut and tighten it first by hand and then by channel locks. **Before tightening the plastic nut with the channel locks, make sure that the red E-stop switch (from the outside) is flush with the black plastic adapter.
- Page 47 15. To further secure the contactor to the connector block, use a 6" zip tie and go around the contactor at the point of the snap-on clips. This helps secure it from coming loose. 16. Connect the proper wires to the contactor. 17.
- Page 48 Flat Antenna Kit Change Out Parts Needed: BOM Part Number E14753-528 Quantity Part Number Part Description E7026 RF cable, SMA plug, LMR195, 3ft E7031 Flat antenna for the CartManager F14753-506 Lower arm cover weldment H6012 6-32 x 5/8 machine screw H9258 Top cover plug You will need:...
- Page 49 Now you are looking at the receiver (E500356-043). Remove the receiver's cover by using a #1 Phillips screwdriver. **Note: If the PC board does not have the two slot connection block located in the top right corner, skip the rest of this step.** Remove the small Phillips screws on the PC board and carefully tilt the PC board outward.
- Page 50 Connect the second coaxial cable to the free coaxial connection on the receiver. The cable goes through the Dip switch 3 needs to be flipped on. grip and grip hole then to the coaxial connection. Start tightening it first by hand, then use the 5/16" wrench. Tighten all the cable grips.
- Page 51 10. Apply a small amount of low strength Loctite on two pan head screws 6-32 x 5/8 Antenna cable (0145353) and secure the flat antenna to the lower arm cover. DO NOT over tighten. Slide back the lower arm cover in its place. Secure the coaxial cable inside the upper arm cover.
- Page 52 The chargers will be prepped for each order (if needed). In a case where you receive a charger and the 3 lead has not been prepped call Gatekeeper Systems’ Tech Support at (888) 808-9433 before deciding to shave the temperature switch yourself.
- Page 53 Strobe Light Kit Upgrade Parts Needed: BOM Part Number: E500131-002 Quantity Part Number Part Description F14753-402 Upper arm weldment F14753-401 Guard strobe light E500238-01 Strobe light F14753-41B Arm I mount bushing 30512 Large male connector 30513 Large female connector 0145385 10-24 x 38 screws H500409-01 Light pole plug...
- Page 54 Using a #2 Phillips screwdriver, remove the upper arm cover (F14753-39) by removing the four black counter-sunk screws from the front and the back of the upper arm cover. On the back of the cover remove only two screws which are located below the red E-stop button.
- Page 55 Remove the two washers and nut from wires (with expandable sleeve) and feed them down through the hole toward the receiver. Remove the expandable sleeve. Now compare the length of the new light pole to the old light pole you just removed, if it is longer pull out about 4 more inches of these wires from the corrugated loom as shown in the picture.
- Page 56 Secure the loom by cable tie. Install 20" of expandable sleeve over wires #43 and #45. Use a cable tie to secure the sleeve at the bottom and electrical tape at the open end. Zip tie Electrical tape Thread back the expandable sleeve with the wires through the top hole back to the upper arm cover.
- Page 57 11. Preparing the strobe light: remove the nut from the strobe light. Cut the wires to 2" in length. Install two large ¼” male push on quick connectors on them. 12. Connect the black wire #45 to the black wire from the strobe light and red #43 to the red wire from the strobe light.
- Page 58 1. VISIBLE FROM OUT SIDE NECK & LIGHT POLE 2. UNDER THE TOP & NECK COVER 3. INSIDE ELECTRIC PANEL COVER 4. ATTACHED TO HOOD 7. REAR 8. IN THE WHEEL WELLS 6. UNDER THE HOOD BATTERY COMPARTMENT 9. INSIDE BOTTOM COVER 5.
- Page 59 PARTS UNDER ELECTRIC PANEL COVER E500345-05 E500345-07 E500345-07 E500345-06 H5059 E500345-07 E500345-07 E506023 E500345-04 E500124-041 E506023 E500345-03 E500124-041 D5061 E500216-13 MODEL XDW-i E500345-07 E500345-06 E500345-07 H5059 E500149-250 E500345-05 E500345-07 E500345-04 E500345-05 E506023 E500345-03 E500124-041 D5061 E500126-215 MODEL XDW...
- Page 60 For immediate assistance: Please contact Customer Service at (888) 808.9433 (within the U.S.) or by email at customerservice@gatekeepersystems.com. Outside of the U.S.: Tel: +1 (949) 453.1940 Fax: +1 (949) 453.8148 GATEKEEPER SYSTEMS TOLL FREE: (888) 808-9433 WWW.GATEKEEPERSYSTEMS.COM CUSTOMERSERVICE@GATEKEEPERSYSTEMS.COM...
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