Gatekeeper Systems CartManager HD, Field Technician Manual

Page 1: ...THE LEADING PROVIDER OF INTELLIGENT CART SOLUTIONS WWW GATEKEEPERSYSTEMS COM FIELD TECHNICIAN GUIDE V1 2 Moving Cart Retrieval Forward i w CMDOC 010...

Page 2: ...thout the express written permission of 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 ter...

Page 3: ...Issues 11 CartManager XDW Does Not Turn On 11 CartManager XDWi Does Not Turn On 12 CartManager XDW Does Not Move 13 CartManager XDWi Does Not Move 15 Batteries and Chargers 17 Battery Charger 18 Batte...

Page 4: ...so that the field tech can stress the importance of regular maintenance in keeping the CartManager XD in top running order Daily Maintenance All checks listed on the CartManager XD Pre Operations Chec...

Page 5: ...not sticking when pressed Check Tightness of Neck Bolts Tighten two bolts on lower backside of the neck Also remove the front neck cover and tighten two retaining bolts on inside of the neck Replace c...

Page 6: ...CartManager XD Field Technician Guide Page 3 CartManager XD Views CartManager XD Rear View XDW XDWi...

Page 7: ...CartManager XD Field Technician Guide Page 4 CartManager XD Side Front View...

Page 8: ...es or the remote control unit Drive Wheels Foam filled heavy tread tires and wheels connected to the transaxles hubs Hood The hood covers and protects the batteries and components in the battery compa...

Page 9: ...l RELAY B XDWi Puts the CartManager in slow speed mode when the battery is low to avoid damage to the batteries Receiver First talks to the remote to be connected and then receives signal from the rem...

Page 10: ...ockwise to remove cover 3 Gently remove old battery and discard in compliance with your company guidelines 4 Insert a new CR 123A battery with the end facing the top of the remote control unit 5 Set t...

Page 11: ...connect the M lead from the controller to prevent unexpected movement of the unit 3 Check all terminals and tighten any that are loose 4 Make sure that the remote control unit and CartManager XD are b...

Page 12: ...tive connection of junction block on electronic board Does meter read 12v Contact Gatekeeper Customer Service No Replace Receiver No 1 Turn key switch off 2 Perform continuity test on Association butt...

Page 13: ...positive lead on Volt meter to the rabbits terminal post on receiver green wire Continue Does meter read 12v 1 Press and hold the horn button and move your meter to the horn terminal block Brown Wire...

Page 14: ...ctions Clean any dirty or corroded contacts or connections 3 Visually inspect the fuse block and 80 Amp Fuse Replace any that have failed 4 Turn the key switch on Do the lights and horn work No Do the...

Page 15: ...to the batteries Repair any loose connections Clean any dirty or corroded contacts or connections 3 Visually inspect the fuse block and 80 Amp Fuse Replace any that have failed 4 Turn the key switch...

Page 16: ...re Emergency Stop button is out Twist clockwise to release 2 Make sure Manual Brake lever is pushed all the way in 3 Turn Key Switch on No Does CartManager move 1 Turn key switch off 2 Open hood and c...

Page 17: ...move 1 With key switch on and throttle turned to full forward position check voltage across M and M terminals on controller 2 If voltage is less than 0 5 replace controler 3 Turn key switch on Does C...

Page 18: ...sary 3 Remove front access panel Check internal wiring and connectors Repair or replace if necessary 4 Turn key switch on No Done 1 Turn CartManager off and fully charge batteries 2 Check total voltag...

Page 19: ...turned to full forward position check voltage across M and M terminals on controller 2 If voltage is less than 0 5 replace controler 3 Turn key switch on Does CartManager move 1 Turn key switch off 2...

Page 20: ...CartManager XD Field Technician Guide Page 17 Batteries and Chargers...

Page 21: ...LED will be on until the battery is over 75 charged Flashing Yellow indicates the battery charger is in bulk charging mode This LED will continue to flash while the battery charges from 75 to 95 Gree...

Page 22: ...orrect 1 Open hood and check battery terminals and connections between batteries and charger 2 Check inline fuses on charger cables 3 Replace clean or repair as needed Yes 1 Check battery charger per...

Page 23: ...echeck 2 Load test individual voltage of each battery and total voltage of all three batteries If any are low check connections for main battery cables and charging cables Replace any damaged or leaki...

Page 24: ...ition 3 Measure the resistance between pins 1 and 8 You should get the values listed below when the throttle is in the indicated position Check wiring diagram for pin numbers on controller neutral 2 5...

Page 25: ...ding to it Correction 1 Check the Manual Brake Release Make sure it is pushed all the way in 2 Turn the throttle grips You should hear a distinct click as the motor brake disengages If you do not hear...

Page 26: ...urther action is necessary 2 Remove throttle grip housing cover and check throttle grip neutral position adjust if necessary 3 Check throttle grip centering spring Replace if not returning throttle gr...

Page 27: ...CartManager XD Field Technician Guide Page 24 Error Code Label Sheet on XDW...

Page 28: ...el assembly foam filled part A500128 03 A car jack ball jack pallet jack or similar type of device capable of lifting at least 750 pounds Four wheel chocks Several sturdy wood blocks A 9 16 inch 15 mm...

Page 29: ...2 Turn the unit off and push the manual brake level all the way in 3 Wedge a wheel chock in front and in back of the wheel you are NOT working on 4 Wedge two chocks to immobilize the back swivel wheel...

Page 30: ...ur store changes to carts with a different width between the back wheels Adjust height to clear obstacles example Speed Bumps etc You will need A 1 2 inch 13 mm socket a driver and a long extension 1...

Page 31: ...CartManager XD Field Technician Guide Page 28 Wiring Diagram XDWi...

Page 32: ...CartManager XD Field Technician Guide Page 29 XDW...

Page 33: ...26 13 Controller XDWi XDWi E500126 215 Controller XDW XDW E500127 02 Relay charger interlock 120 V XDW XDWi E500145 01 Key switch all carts XDW XDWi E500145 02 Extra spare keys XDW XDWi E500149 250 SW...

Page 34: ...DWi 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 M500...

Page 35: ...e batteries 7 If exchange of batteries is required follow the manufacturer s safety guidelines for the safe handling storage transportation and disposal of batteries 8 Before removing electrical parts...

Page 36: ...front of the unit Be sure to use caution being careful to not pinch fingers Note The bottle jack used should have lifting height greater than 16 1 2 The photo to the left demonstrates blocks securely...

Page 37: ...anty shall be limited to the repair or replacement of the Product IN NO EVENT SHALL MANUFACTURER S OBLIGATIONS PURSUANT TO THIS LIMITED WARRANTY EXCEED THE PURCHASE PRICE PAID TO THE MANFACTURER BY TH...

Page 38: ...PARTICULAR PURPOSE AND ANY IMPLIED WARRANTY ARISING FROM PERFORMANCE COURSE OF DEALING OR USAGE OF TRADE AND ALL OTHER OBLIGATIONS LIABILITIES RIGHTS CLAIMS OR REMEDIES INCLUDING ANY RIGHT IN CONTRAC...

Page 39: ...Great Southwest Parkway Suite 110 Grand Prairie TX 75050 USA Toll free 1 888 808 9433 Tel 1 949 453 1940 Canada Gatekeeper Systems Canada Ltd 272 Galaxy Boulevard Etobicoke Ontario Canada M9W 5R8 Toll...

Page 40: ...Addendum...

Page 41: ...is rectangle in shape and has three red four yellow and three green LED s from left to right CartManager SD models will have a 2 inch round digital BDI gauge with an LED under each symbol CartManager...

Page 42: ...0216 13 Note This electronic board does not have a contactor XD Note XD units were built with two different model controllers 1 The XD had Controller P N E500126 03 which is DISCONTINUED It is Replace...

Page 43: ...llers XD 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 XD Shown in the photo on left the XD with the C...

Page 44: ...located below the red E stop button 2 Disconnect the wires going to the horn switch and the connector block Remove the E stop switch 3 Remount the top cover back onto the neck 4 Take a rubber mallet a...

Page 45: ...ther the contact block with the red tab and the shell or the contact block with the green tab and the shell It is VERY important to leave the correct contact block attached to the connector block 9 Re...

Page 46: ...utside is flush with the black plastic adapter There are two grooves cut outs on the cylindrical part of the red E stop button These grooves should be horizontal when the top cover lays flat on the ta...

Page 47: ...or 17 Test the E stop switch to make sure it is functioning properly Because of the modification to the E stop guard make sure that the switch engages and disengages properly There should not be any b...

Page 48: ...o the CartManager before working on the machine Assembly steps 1 Using a 2 Phillips screwdriver remove the top cover F14753 39 by removing the four black counter sunk screws from the front and back of...

Page 49: ...wire at 90 On the top right corner of the PC board there is a two slot connection block Install the U shape wire to that connection block and carefully screw back the PC board to its original positio...

Page 50: ...about 8 of both coaxial cables coming out of the hole on the top of the arm weldment At about 4 from the hole bend both cables and tie them together to relieve pressure on the connections to the flat...

Page 51: ...nd 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 Make sure there are no wires touch...

Page 52: ...wires and inline fuse block is through caddy corner the temperature switch block in order for it to pass through You may have to apply force or you can trim off the corners of the block If you do dec...

Page 53: ...male connector 4 0145385 10 24 x 38 screws 1 H500409 01 Light pole plug 20 Expandable sleeve You will need Wire cutter Wire stripper Crimper 2 Phillips screwdriver 1 1 8 wrench Caution please disconne...

Page 54: ...etely by disconnecting the horn switch and E stop 3 Using 1 1 8 wrench remove the 3 4 16 nut and pull out the light pole Note by removing the plug at the bottom of the light pole you have access to th...

Page 55: ...4 of wire only pull it out of the corrugated loom Note This way you are extending the length of the wires to go up the light pole Because the new light pole is longer than the old light pole you need...

Page 56: ...stall the light pole bushings 9 Install the upper arm weldment Make sure the Belleville washers make a convex shape when they come together 10 Use a 16 fishing wire to pull the wires with the expandab...

Page 57: ...e turns counter clockwise to twist the wires backwards and then screw the strobe light to the light pole 13 Make a mark on the lens and base of the strobe light This mark should be in front of the ope...

Page 58: ...K LIGHT POLE 3 INSIDE ELECTRIC PANEL COVER 2 UNDER THE TOP NECK COVER 4 ATTACHED TO HOOD 7 REAR 5 FRONT 9 INSIDE BOTTOM COVER 6 UNDER THE HOOD BATTERY COMPARTMENT PART S LOCATIONS IDENTIFIED FOR PARTS...

Page 59: ...5 05 E500345 05 E500345 06 E500345 07 E500345 07 E500345 07 E500345 03 E500124 041 E506023 H5059 E500124 041 E500345 05 E500345 06 E500345 03 E500345 04 E506023 E500345 07 E500345 07 E500345 07 E50034...

Page 60: ...EPERSYSTEMS COM CUSTOMERSERVICE GATEKEEPERSYSTEMS COM For immediate assistance Please contact Customer Service at 888 808 9433 within the U S or by email at customerservice gatekeepersystems com Outsi...