Gatekeeper Systems CartManager XD+ Owner's/Operator's Manual
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Gatekeeper Systems CartManager XD+ Owner's/Operator's Manual

Gatekeeper Systems CartManager XD+ Owner's/Operator's Manual

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CartManager XD+
Owner/Operator Training and
Troubleshooting Guide
Version 1.0
August, 2007

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Summary of Contents for Gatekeeper Systems CartManager XD+

  • Page 1 CartManager XD+ Owner/Operator Training and Troubleshooting Guide Version 1.0 August, 2007...
  • 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.

  • Page 3: Table Of Contents

    Error Codes ............................30 Mechanical Procedures..........................33 Reference..............................36 Technical Specifications ........................36 Wiring Diagrams ........................... 38 Safety and Warning Labels ........................39 Ordering Parts ............................44 Warranty Information ..........................46 Contacting Gatekeeper Systems......................48 CartManager XD+ Owner-Operator Training and Troubleshooting Guide...

  • Page 4: Overview

    The Gatekeeper Systems CartManager XD+ is a battery powered drive unit that easily pushes a line of up to 30 carts. The operator controls the speed and direction of the CartManager XD+ using either a set of throttle grips (much like motorcycle handlebar grips) mounted on the back of the unit, or via a handheld remote control unit.

  • Page 5: Safety Precautions

    Safety Precautions Do not operate, maintain or service CartManager XD+: • Unless trained and authorized, • Unless operation manual is read and understood, • In areas where flammable or explosive gases may be present. Before operating CartManager XD+, make sure all safety devices are in place and operating properly. When maintaining or servicing CartManager XD+: •...

  • Page 6: Cartmanager Xd+ Views

    CartManager XD+ Views CartManager XD+ Rear View REMOTE CONTROL STROBE LIGHT ANTENNA EMERGENCY BRAKE LIGHT STOP BUTTON LIGHT POLE HORN THROTTLE GRIP ATTACHED CORD OPTION REMOTE CONTROL HOLDER BATTERY CHARGE LEVEL & ERROR CODE INDICATOR KEY SWITCH BATTERY CHARGER SOCKET FOR DETACHABLE CHARGER CORD OPTION DRIVE WHEEL BRAKE RELEASE LEVER...
  • Page 7 CartManager XD+ Side/Front View CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 4...
  • Page 8 CartManager XD+ Front Access Panel The Front Access Panel protects the fuse block and controller electronics. The access panel can be easily removed to check for burnt out fuses in the event that CartManager XD+ will not power up or move. This procedure should only be performed by persons who have been trained in basic CartManager XD+ maintenance.

  • Page 9: 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 Antenna Receives signals from the remote control. Anti-Static Chain The anti-static chain prevents damage to the CartManager XD+ electrical components by dissipating static electricity buildup.

  • Page 10: Operator Training

    CartManager XD+ for cart retrieval. This training guide provides instruction on using the Gatekeeper Systems CartManager XD+ for retrieval of shopping carts. While working through this guide, you will complete the following tasks: •...

  • Page 11: Preoperations Checklist

    PreOperations Checklist Run through the tasks listed below. This preop check should be performed each day before CartManager XD+ is taken out for the first retrieval run. The charger cord should be plugged in and the key switch turned off. If you discover any abnormal or potentially unsafe conditions during this check, DO NOT use the CartManager XD+.

  • Page 12: Using Cartmanager Xd+ - Manual Mode

    Using CartManager XD+ – Manual Mode Now that you are familiar with the parts of the CartManager XD+ and have performed the PreOperations check, its time to learn how to use the machine. The first task is to drive the CartManager XD+ using the throttle grips. This is referred to as Manual Mode, since you are not using the remote control.

  • Page 13: Using Cartmanager Xd+ - Remote Operations Mode

    Using CartManager XD+ – Remote Operations Mode In remote operations mode, a handheld remote control unit is used to control the CartManager XD+, instead of the throttle grips. The operator steers from the front of the line of carts. Make sure that the Emergency Stop button on the CartManager XD+ is pushed in.

  • Page 14: Retrieving Carts

    Retrieving Carts This section shows you how to load carts onto the CartManager XD+ and secure them for transport. Use manual mode to drive CartManager XD+ to the area where you are going to start retrieving carts. Leave CartManager XD+ on when loading carts, but make sure that you press the red OFF button on the remote during the loading process.
  • Page 15 Carry the strap up over the top of the row of carts and pass it under the handle of the lead cart. Do not wrap the strap around the handle. Carry the strap back over the top of the carts and pass it under the handle of the cart in the cart cradles. Keep tension on the strap so that the carts are pulled closely together.

  • Page 16: Safety Guidelines And Operating Tips

    Safety Guidelines and Operating Tips This section lists some tips to make your cart retrieval with CartManager XD+ safe and efficient. • Familiarize yourself with the location and content of the Safety and Warning Labels on pages 39 - 43. •...
  • Page 17 Gatekeeper Systems Inc. assumes no liability for any consequences arising from use of the CartManager XD+ in any manner other than full compliance with the instructions set forth in this training manual, or in disregard of any of the warnings contained herein.

  • Page 18: Care Of The Cartmanager Xd

    Care of the CartManager XD+ Charging the CartManager Batteries CartManager uses 3 heavy-duty 12 volt batteries for a full output of 36 volts. The batteries are fully charged when the 3 green LEDs on the back of the battery charger show a steady green. Note that the battery charge indicator may initially show 100%, even though the batteries are not fully charged.
  • Page 19 Quarterly Maintenance: Clean the battery cables and connectors: • Put on rubber gloves and safety goggles. • Disconnect the battery cables from one of the main batteries and remove the battery from the CartManager XD+. • Clean the terminals with a solution of 1 tbsp of baking soda to one cup of warm water. •...

  • Page 20: Post Training Quiz

    Successful completion of this quiz indicates that you have read and understand the material contained in this training manual. Gatekeeper Systems does not guarantee the skill or ability of cart operators. True/False CartManager XD+ is used to pull a line of shopping carts.
  • Page 21 True/False CartManager XD+ should be turned off and the keys removed from the keyswitch whenever the machine is left unattended. The battery charging area should be clean, dry and well ventilated. The batteries are fully charged when all three green LEDs on the battery charger show a steady green.

  • Page 22: Quiz Answers

    Quiz Answers The following section provides the correct answers for the post training quiz, as well as the rationale for the correct answer and a page reference indicating where the information is given. The operator and supervisor should go over the answers together.
  • Page 23 Driving carts through a narrow area increases the potential for injury if the operator gets caught between the line of moving carts and a wall. (page 13) Always use two persons when using the throttle grips (instead of the remote) to move more than 1-2 carts.

  • Page 24: Troubleshooting

    If you are still experiencing difficulties after completing the troubleshooting tasks, please refer to the last page in this guide for information on contacting your nearest Gatekeeper Systems regional Customer Support center. CartManager XD+ Owner-Operator Training and Troubleshooting Guide...

  • Page 25: Remote Control Issues

    Remote Control Issues Changing the Remote Control Batteries Follow these steps to change the batteries in the remote control unit: Peel back one edge of the rubber sleeve surrounding the remote control unit and remove the unit from the sleeve. Turn the unit over to expose the battery compartment cover.

  • Page 26: Remote Control Does Not Work

    Remote Control Does Not Work Use this process to diagnose and correct problems when the remote control unit either 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 used with a particular CartManager XD+ unit, follow the steps in the Link the remote to CartManager XD+ flow below to set up a communications link between the remote and the CartManager XD+ unit.

  • Page 27: Electrical Issues

    Electrical Issues CartManager XD+ Does Not Turn On Use this troubleshooting flow if nothing happens (no lights, no horn, no movement) when the keyswitch is turned on. START Charge the battery: Turn the key switch off and charge the unit for 6-8 hours. Done When charging is complete, unplug the power cord and turn the key switch on.

  • Page 28: Cartmanager Xd+ Does Not Move

    CartManager XD+ Does Not Move Follow the steps below if the lights go on when you turn the keyswitch, but CartManager XD+ does not respond when you turn the throttle grips. If CartManager XD+ moves when you turn the throttle grips, but does not respond to the remote control, see Remote Control Issues on page 23.

  • Page 29: Battery Issues

    Battery Issues CartManager XD+ is powered by three heavy duty, rechargeable, 12 volt batteries. The batteries are located under the hood in the front section of the CartManager XD+ and are sealed so there is no need to add fluid to the cells. Regular maintenance consists of checking for leaks and loose connections on a daily basis, and cleaning the terminals and battery connectors every three months.

  • Page 30: Battery Chargers

    Battery Chargers The symptoms of battery charge malfunction will differ depending the type of charger in your particular CartManager XD+: For 110 volt chargers: LEDs - the charger has three LEDS; red, yellow and green, for each of the batteries in CartManager XD+. Only one of these LEDs should be illuminated at a time.

  • Page 31: Battery Runs Down Quickly

    Check for any leaks around the bases of the batteries. If you find leaks, replace the faulty battery as per the directions in the Replacing CartManager XD+ Batteries section below. If the problem persists, contact Gatekeeper Systems Customer Support. Replacing CartManager XD+ Batteries If you find a leaking battery or you suspect that the battery is faulty, the battery should be replaced.

  • Page 32: Battery Indicator

    Battery Indicator When the CartManager XD+ is turned on, the battery indicator displays various information, including the percentage of charge left in the battery, the total amount of time the unit has been used since leaving the factory, and diagnostic fault codes.

  • Page 33: Error Codes

    Open the hood and check for any loose or disconnected wiring. Close the hood and turn the unit back on. If the problem has not been resolved, contact Gatekeeper Systems Customer Service. Error Code 14 The throttle turned forward or backwards when CartManager XD+ is turned on: Turn the key switch off.
  • Page 34 Wait 5 seconds and turn the unit back on. Listen carefully for a loud click down towards the lower left rear section of the CartManager XD+ as soon as you turn the keyswitch. Contact Gatekeeper Systems Customer Service. Inform them of the error code and whether or not you heard the click.
  • Page 35 If you do a retrieval run and any of the carts are loaded, reduce the number of carts that you drive with the CartManager XD+. If the error continues, turn CartManager XD+ off and contact Gatekeeper Systems. CartManager XD+ Owner-Operator Training and Troubleshooting Guide...

  • Page 36: Mechanical Procedures

    Mechanical Procedures Replacing the Strobe Light Bulb You will need: • A replacement strobe light bulb, part #E500238-02 (Do not remove the new bulb from its protective wrapping.) • A pair of pliers or vise grips Park CartManager XD+ and turn the key off. Grasp the orange strobe light cover with your hand and twist counter clockwise to remove it from the strobe housing.
  • Page 37 Attach the new swivel wheel assembly. Tighten the bolts securely. Place the jack, remove the wood blocks and lower CartManager XD+ back down. Remove all tools and materials from the area. 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.
  • Page 38 Adjusting the Cart Cradles You will need to adjust the height of the cart cradles on the front of 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 39: Reference

    Reference Technical Specifications Electrical • Batteries — 36-Volts D.C.; three, marine-grade, maintenance free, group 30, 12-volts batteries, with a 180 minute reserve capacity • Battery Charger — Marine-grade, 30 Amp charger with automatic peak charge shut off, and trickle charge mode.
  • Page 40 Mechanical • Weight: 696 pounds (316 Kg). • 12.5" (318 mm) foam filled tire • Ergonomically correct hand grip throttle control • 6' (1.83 Meter) charger cord • Integral motor drive and axle assembly • Pressure sealed transaxle and differential to prevent water or debris intrusion •...

  • Page 41: Wiring Diagrams

    Wiring Diagrams CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 38...

  • Page 42: Safety And Warning Labels

    Safety and Warning Labels This diagram shows the placement of the various safety and warning labels on CartManager XD+. The actual labels are shown on the following pages. CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 39...
  • Page 43 Safety and Warning Labels #1 – Emergency Stop #2 – Remote Control Must Read #3 – Serial Number CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 40...
  • Page 44 Safety and Warning Labels – continued #4 – Manual Brake Lever Release Warning #5 – Finger Pinch Warning # 6 – Maximum Cart Number CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 41...
  • Page 45 Safety and Warning Labels – continued #7 – Remote Control Diagnostic #8 – Pre Operations Checklist CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 42...
  • Page 46 Safety and Warning Labels – continued # 9 – Battery Indicator Error Codes CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 43...

  • Page 47: Ordering Parts

    Ordering Parts When ordering parts, you will need the following information: • Model of the unit • Serial number • Part number • Part description List of most commonly replaced parts: Item No. Part Number Part Description Swivel wheel caster 8" A500128-03 Strobe light assembly E500238-01...
  • Page 48 Item No. Part Number Part Description Wheel assembly, foam filled A500129 Aggressive tread tire A500273 Shag Strap A500150-03 CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 45...

  • Page 49: Warranty Information

    (or other Gatekeeper Systems, Inc. product-collectively referred to herein as the “Product”) manufactured by Gatekeeper Systems, Inc, a Delaware 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.
  • Page 50 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...

  • Page 51: Contacting Gatekeeper Systems

    Contacting Gatekeeper Systems For more information about CartManager 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...

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