Gatekeeper Systems CartManager XD+ Owner's manual

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

CartManager XD+ Owner-Operator Training and Troubleshooting Guide
Corporate Offices
Gatekeeper Systems
8 Studebaker
Irvine, CA 92675
Phone: [phone]
Internet: www.gatekeepersystems.com
For Gatekeeper Systems Regional Customer Support numbers, see page 48.
Copyright
Companies, names, and data used in examples herein are fictitious unless otherwise noted. No part of this document
may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without
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 terms of the license agreement.
© August 2007. Gatekeeper Systems. All rights reserved.
Information in this document is subject to change without notice. Gatekeeper Systems assumes no responsibility or
liability for any errors, omissions, or inaccuracies that may appear in this document.
Trademarks
Gatekeeper Systems is a registered trademark of Gatekeeper Systems. All other brands and products are
trademarks of their respective holder(s).

CartManager XD+ Owner-Operator Training and Troubleshooting Guide
Table of Contents
Overview .......................................................................................................................................................1
Safety Precautions .................................................................................................................................2
CartManager XD+ Views........................................................................................................................3
CartManager XD+ Features and Controls..............................................................................................6
Operator Training..........................................................................................................................................7
Getting Started........................................................................................................................................7
PreOperations Checklist.........................................................................................................................8
Using CartManager XD+ – Manual Mode ..............................................................................................9
Using CartManager XD+ – Remote Operations Mode.........................................................................10
Retrieving Carts....................................................................................................................................11
Safety Guidelines and Operating Tips..................................................................................................13
Care of the CartManager XD+..............................................................................................................15
Charging the CartManager Batteries.............................................................................................15
CartManager XD+ Maintenance ....................................................................................................15
Post Training Quiz................................................................................................................................17
Quiz Answers........................................................................................................................................19
Troubleshooting ..........................................................................................................................................21
Remote Control Issues.........................................................................................................................22
Changing the Remote Control Batteries........................................................................................22
Remote Control Does Not Work ....................................................................................................23
Electrical Issues....................................................................................................................................24
CartManager XD+ Does Not Turn On............................................................................................24
CartManager XD+ Does Not Move................................................................................................25
Battery Issues.......................................................................................................................................26
Battery Chargers............................................................................................................................27
Battery Runs Down Quickly ...........................................................................................................28
Replacing CartManager XD+ Batteries..........................................................................................28
Battery Indicator....................................................................................................................................29
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 1
Overview
A line of thirty shopping carts can easily weigh 1000 pounds or more. When collecting carts from a large parking lot,
that’s a lot of weight to safely get moving, keep moving, steer and stop.
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.
The operator can start the cart line moving with the push of a button, steer the cart line with one hand, and most
importantly, stop the cart line immediately, if necessary.
This guide consists of three main sections; Operator Training, Troubleshooting and Common Mechanical Procedures.
Operator Training presents all the information required to safely operate CartManager XD+ for cart retrieval. This
guide can be given to an operator for self-study or used by a trainer as the basis for a group training plan. Topics
included are:
•Introduction to CartManager XD+
•How to do a pre-operations check
•Driving CartManager XD+ in both Manual and Remote Control Mode
•Safe cart retrieval techniques
•Basic care and maintenance of the CartManager XD+ and remote control unit
At the end of the training section is a quiz that should be given to each prospective CartManager XD+ operator to
evaluate their readiness to safely use CartManager XD+.
The Troubleshooting section contains detailed instructions for on-site resolution of minor problems that may occur
with CartManager XD+, as well as suggestions to help keep your CartManager XD+ running smoothly.
Mechanical Procedures details some of the more common maintenance procedures.
Reference contains technical specifications, wiring diagrams, safety and warning labels, and information on ordering
replacement parts for CartManager XD+ and the remote control unit.
If at any time you need further assistance with training, troubleshooting or maintenance of CartManager XD+, 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 2
Safety Precautions
1. 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.
2. Before operating CartManager XD+, make sure all safety devices are in place and operating properly.
3. When maintaining or servicing CartManager XD+:
•Disconnect battery connection before working on the machine.
•Do not open the sealed, maintenance free batteries.
•Avoid moving parts. Do not wear loose jackets, shirts, ties or sleeves when working on CartManager XD+.
•Use only Manufacturer supplied or equivalent replacement parts.
4. Do not transport CartManager XD+ with hood up.
5. Batteries emit hydrogen gas. When charging, keep away from sparks or open flame and keep hood open.
6. The battery charger supplied with CartManager XD+ shall be grounded while in use to protect the operator from
electric shock. Make sure the charger is connected to an outlet having the same configuration as the plug. No
adapters should be used with this charger.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 3
CartManager XD+ Views
CartManager XD+ Rear View
STROBE LIGHT
BRAKE LIGHT
KEY SWITCH
BATTERY CHARGE
LEVEL & ERROR
CODE INDICATOR
BATTERY CHARGER
ANTI-STATIC CHAIN
DRIVE WHEEL
SOCKET FOR DETACHABLE
CHARGER CORD OPTION
THROTTLE GRIP
SWIVEL WHEEL
EMERGENCY
STOP BUTTON
HORN LIGHT POLE
BRAKE RELEASE LEVER
REMOTE
CONTROL
HOLDER
REMOTE CONTROL
ANTENNA
ATTACHED
CORD OPTION

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 4
CartManager XD+ Side/Front View

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 5
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.
To remove the front access panel:
1. Make sure CartManager XD+ is unplugged.
2. Use a coin or large flat head screwdriver to unlock the hood lock.
3. Grasp one of the inset handles on either side of the hood and lift the hood so that the hydraulic arms lock firmly
in place.
4. Use a #2 Phillips head screwdriver to loosen and remove the two screws indicated in the diagram below.
5. Slide the access panel straight up and off. You may need to move the black plastic hose that protects the
electrical cables.
6. Perform whatever work is required.
7. Replace the front access panel, making sure that the hose protecting the electrical cables is not pinched by the
panel.
8. Grasp one of the handles on either side of the hood and close the hood. DO NOT close the hood by pulling on
the top edge. You will pinch your fingers.
Front access panel screws
Fuse block behind front access panel

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 6
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. DO NOT DETACH THIS CHAIN.
Battery Charger Controls and monitors the battery charging process. LEDs on the charger show charging
status and also serve as warning indicators if the charger is malfunctioning.
Battery Discharge
Indicator and Fault
Indicator
Shows the percentage of charge left in the batteries. You should recharge the batteries
any time the charge falls below 20%. The unit can also be plugged in between runs to
keep the batteries “topped off” at full charge. This indicator also provides error codes that
can be used to diagnose problems with the CartManager XD+.
Brake Light Acts like the brake light on a car. Off when CartManager XD+ is moving, on when
CartManager XD+ is stopped.
Brake Release Engages/disengages the manual brake. When the lever is pulled out, the brake is
disengaged and CartManager XD+ can be manually pushed without using the drive
throttles. When the brake lever is pushed in, the brake is disengaged while the unit being
driven using the drive motor and engaged when the unit is stopped. The brake release
lever must be pushed in to use CartManager XD+ with the drive throttles or the remote
control unit.
Charger Cord/Socket There are two charger cord configurations for CartManager XD+:
•Attached power cord – this cord is permanently attached to CartManager XD+. To
charge, unwrap the cord and plug in to a standard grounded electrical outlet. When
done charging, make sure the cord is securely wrapped around the cord hooks on
the back of the CartManager XD+.
•Detachable power cord – plug the flat end of the cord in to the socket on the back of
the CartManager XD+. Plug the end with the prongs in to a standard grounded
electrical outlet. When not charging, make sure the cord is unplugged from both the
wall receptacle and the charger socket and stored in a safe place. The rubber cap
on the charger socket should be securely fastened when the charger cord is not
attached.
Drive Wheels Foam filled, heavy tread wheels connected to the drive motor.
Emergency Stop Button The Emergency Stop Button is a safety feature that stops CartManager XD+ immediately
when the button is pushed in. To resume operation, twist and release the Emergency
Stop button.
Hood The hood covers and protects the batteries and the components in the battery
compartment. When opening and closing, use the inset handles on either side of the
hood. Do not grip the hood by the edge; you could pinch your fingers.
Horn Press to sound the horn.
Key Switch Insert the key here to turn CartManager XD+ on and off.
Light Pole Holds the strobe light and brake light. Swings up for operation and down for getting
under low overhangs or doors.
Remote Control Holder Convenient storage for the remote control unit when it is not being used.
Strobe Light Flashes as long as the key switch is turned on.
Swivel Wheel Allows the unit to swivel and turn completely around in its own length. This wheel is not
connected to the drive motor.
Throttle Twist forward to move the CartManager XD+ forward, back to go in reverse. The farther
you twist the throttle, the faster the unit will move. You also use these handles to steer
the unit when in manual drive mode.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 7
Operator Training
All CartManager XD+ operators must be at least 16 years of age and in compliance with any applicable
licensing laws for your city, county or state in which CartManager XD+ is being operated.
Any person operating CartManager XD+ must read the material in this training guide, practice the manual
exercises, and satisfactorily complete the post-training quiz before using 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:
•Familiarize yourself with the Features and Controls of the CartManager XD+.
•Perform a PreOperations Check on CartManager XD+.
•Practice driving CartManager XD+ using the manual controls.
•Practice driving CartManager XD+ using the remote control unit.
•Practice retrieving carts.
•Review the Safety Guidelines and Operating Tips.
•Take the post training quiz.
•Go over the quiz with your manager.
For purposes of this training guide, the terms “supervisor” or “manager” shall mean the direct supervisor or manager
(or their designated representative) of the prospective operator.
Getting Started
The first thing to do is get acquainted with the various parts and controls of the CartManager XD+. Take a walk
around the unit and identify each of the items shown in the diagrams on pages 3 and 4. Also review the table on page
6, which describes the function of each part.
When you are finished, proceed to the PreOperations Checklist on page 8.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 8
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+.
Turn the unit off, make sure the Emergency Stop button is pushed in, remove the key and notify your supervisor.
1. Check the Battery Charger on the back of the CartManager XD+. If the charger is a Minn-Kota charger and you
see any red lights, unplug the charger cord from the electrical receptacle immediately and notify your supervisor.
2. If the CartManager XD+ has a permanently attached power cord, unplug the power cord from the outlet and wrap
it securely around the cord hooks on the back of the CartManager XD+. If the cord is a detachable cord, remove
from both the wall outlet and the CartManager XD+ socket and store in a safe place. Make sure the rubber cap is
secure over the charger socket.
3. Take a walk around the unit and look for any loose or broken parts, leaking fluids, or other indications that there
may be mechanical or electrical problems. If any such conditions are found, leave the CartManager XD+ off and
notify your supervisor.
4. Make sure that the Light Pole is securely latched in a fully upright position. Check the tires for excessive or
uneven tread wear.
5. Unlatch the hood and visually inspect the battery compartment for loose, disconnected or frayed wires, leaking
fluids, corroded battery terminals, etc. DO NOT attempt to correct any abnormal findings unless specifically
trained and instructed to do so. Close and relatch the hood.
6. Turn the red Emergency Stop Button clockwise, then release. The Emergency Stop Button must be disengaged
(pulled out) for to allow CartManager XD+ go move backwards and forwards at normal speeds.
7. Make sure that the Brake Release lever is pushed all the way in.
8. Insert the key in the key switch and turn clockwise one quarter turn. The strobe light should start flashing and the
brake light should come on.
9. Check the Battery Level Indicator. If the level is less than 20%, you should turn off the CartManager XD+, plug
the power cord into a standard electrical outlet and recharge for at least four hours. If you see an error code and
CartManager XD+ will not power up or move and you have been trained to troubleshoot CartManager XD+
problems, work through the CartManager XD+ Troubleshooting procedures starting on page 21. If you have not
been trained to troubleshoot CartManager XD+, turn the unit off and notify your manager.
10. Twist the throttle grips gently forward. CartManager XD+ will move forward. Twist the throttle grips backwards.
CartManager XD+ will move backwards. There should be no motion when the throttle grips are in the neutral
(released) position.
11. Turn on the remote control unit by pressing and immediately releasing the green ON button. The red Power
Indicator LED should light up while you are holding the button down, and flash while the unit is on. If the remote
control fails to respond, see the Remote Control Issues section on page 22.
12. Press the Slow (turtle) button. The machine should move slowly forward. Release the button to stop the unit. (If
CartManager XD+ does not respond to the remote control, see the instructions on the bottom of page 10 for
linking the remote control to CartManager XD+.)
13. Press the red OFF button to shut off the remote control.
Once you have completed the checklist, proceed to Using CartManager XD+ – Manual Mode.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 9
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.
Use manual mode when moving the CartManager XD+ with no carts attached. DO NOT use manual mode if you
have more than 1 cart attached unless you have two persons; one to run CartManager XD+ and a second to steer
the carts from the front of the cart line. NEVER attempt to steer a line of carts using just the throttle grips.
This part of the training should be done in a open, flat area, free of debris, obstacles, cars and customers. Remove
any carts from the cart cradles for now.
1. Stand behind the CartManager XD+, but do not turn the unit on. Make sure the brake release lever is pushed all
the way in. Try moving the unit forward or backward. You should not be able to move the unit.
2. Now pull the brake release lever all the way out. This unlocks the brake and lets you move the unit without using
the motor. Try moving the unit forward and backward. CartManager XD+ is heavy, so you will need to exert a fair
amount of force.
3. Swing the CartManager XD+ in a full circle without twisting the throttle grips or moving the unit backwards or
forwards. This technique is good for turning sharp corners and maneuvering in tight spaces.
4. Push the brake release lever all the way in. The brake release lever must be pushed all the way in before you
can use the throttle grips or the remote control to drive the CartManager XD+.
5. Make sure the Light Pole is secured in the full upright position. Some stores layouts may require that you swing
the Light Pole into the down position to pass through low doorways.
6. Insert the key in the key switch and turn clockwise one quarter turn. The strobe light will begin to flash and the red
brake light will come on.
7. Press the horn button to alert people in the area that you are going to be moving.
8. Grasp the throttle grips and twist them gently away from you. CartManager XD+ will move forward. The farther
you twist the grips, the faster the unit will move. Top speed is a good, fast walk.
9. Release the throttle grips to stop the CartManager XD+.
10. Now twist the throttle grips back towards you. The unit will move slowly in reverse. Make sure that the path behind
you is clear!
11. Stop CartManager XD+ and press the red Emergency Stop button in until you feel it click into place. Twist the
throttle grips. Note that CartManager XD+ does not move either forward or reverse. This is a safety precaution to
stop CartManager XD+ immediately in the event of an emergency.
12. Disengage the Emergency Stop button by twisting in the direction of the white arrows, then letting go.
13. Practice driving CartManager XD+. Also practice turning sharp corners and swinging the unit completely around in
its own length with the unit on, but without twisting the throttle grips.
Once you are comfortable moving both forwards and backwards, at slow or fast speed, move on to
the next section, Using CartManager XD+ – Remote Operations Mode.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 10
SLOW
ON
OFF
FAST
HORN
POWER LED
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.
1. Make sure that the Emergency Stop button on the CartManager
XD+ is pushed in. This prevents the unit from unexpectedly
moving while you are loading carts.
2. Load one cart onto the cart cradles, as shown in the figure at
right.
3. Stand at the back of the CartManager XD+. Disengage the
Emergency Stop button.
4. Turn the key switch to the ON position.
5. Take the remote control unit and move to the side of the front of
the cart, facing away from the CartManager XD+.
6. NEVER WALK DIRECTLY IN FRONT OF A LINE OF MOVING
CARTS!
7. Turn on the Remote Control unit by pressing and immediately
releasing the green ON button. The Power Indicator will light
while the button is held down, and flash while the unit is on.
8. Press and release the HORN button once or twice to alert
persons that you are in the area. If the horn does not sound:
9. Turn off CartManager XD+.
10. Turn on CartManager XD+ and immediately press and hold
the green ON button for 15-20 seconds. This establishes a
new radio link between CartManager XD+ and the remote.
You will only need to use this procedure if CartManager
XD+ fails to respond to the remote control unit, or if you are
using a different remote than the one usually used with the
CartManager XD+.
11. With one hand on the front corner of the cart, press and
hold the SLOW (turtle) button. The CartManager XD+ will
begin to move slowly forward.
12. While holding the slow button down, push the front of the
cart away from you. The cart and CartManager XD+ will
turn in that direction. Pull the cart towards you to move
back the other way.
13. Release the slow button and CartManager XD+ will stop.
14. Now press and hold the FAST (rabbit) button. CartManager XD+ will move forward, but much faster than when in
SLOW mode.
15. Practice using the remote control to move a single cart.
When you are comfortable in both slow and fast modes, press the red OFF button to shut down the
remote control unit and go on to the next section, Retrieving Carts.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 11
Retrieving Carts
This section shows you how to load carts onto the CartManager XD+ and secure them for transport.
1. Use manual mode to drive CartManager XD+ to the area where you are going to start retrieving carts.
2. Leave CartManager XD+ on when loading carts, but make sure that you press the red OFF button on the remote
during the loading process. This prevents the remote from accidentally moving CartManager XD+ while you are
loading carts.
3. Attach the small, spring loaded latch on the
Cart Restraint Strap to the Cart Restraint
Strap Hook on the lower front section of the
CartManager XD+, as shown in the figure at
right.
4. Set one cart into the cart cradles. It is helpful to put a small empty box in the cart to hold the cart strap when it’s
not in use. This prevents the strap from falling on the ground and getting tangled in the drive wheels.
5. Add 8-9 more carts onto the front of the first cart. Make sure the carts are nested snugly without a lot of play
between them.
6. Bring the Cart Restraint Strap up and wrap it
once around the handle of the cart sitting in
the cart cradles.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 12
7. 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.
8. 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.
9. Continue this looping process until you can hook the strap securely around one of the cart handles without any
slack. With more carts you will use fewer loops. When moving a full line of carts, you will probably only be able to
do one loop under the handle of the lead cart.
10. Move to the side of the lead cart. Press and immediately release the green ON button on the remote control unit.
11. Place one hand on the corner of the lead cart and press the SLOW button. The line of carts will move slowly
forward.
12. Practice driving carts at both slow and fast speed. Remember that you cannot move CartManager XD+ In reverse
when using the remote control.
ALWAYS use the restraint strap if you have ANY carts nested in front of the cart in the cradles.
When you are confident with stopping, starting, moving and steering all 10 carts, continue on to the next
section, CartManager XD+ Safety.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 13
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.
•Close and latch the hood before moving CartManager XD+.
•If using a detachable cord, make sure the cord is unplugged from both the wall outlet and the CartManager XD+
charging socket and stored in a safe place. If the CartManager XD+ has an attached cord, unplug the cord from
the wall outlet and wrap securely around the cord hooks on the back of the unit.
•CartManager XD+ should go over the speed bumps and ramps normally found in a parking lot, but it is a good
idea to plan your route so that speed bumps are avoided if possible. This is especially true if CartManager XD+ is
being used to drive a line of carts. If the cart cradles consistently scrape or bottom out, notify your manager to
have the cart cradles adjusted.
•Drive CartManager XD+ only on a solid surface such as asphalt or concrete, not grass or mud.
•CartManager XD+ will work in moderate rain or snow, but should be stored in a protected area between retrieval
runs. Note that run time on a single battery charge may be decreased in extremely cold weather.
•If the driving surface is icy, wet or slippery, reduce speed when moving and leave extra distance for stopping.
•When driving a line of carts downhill, leave extra room to stop and stop slowly to avoid placing excessive strain
on the Cart Restraint Strap.
•When approaching an area where cars or people are present, sound the horn to let them know you are coming.
•If cars or people are in your line of travel, stop until they have passed. If you must proceed, politely ask them to
move aside until you have gone by.
•NEVER walk directly in front of a line of moving carts. Always steer from the side of the lead cart.
•When steering from the lead cart in narrow areas, allow sufficient room so you don’t get stuck between the cart
line and a wall.
•When moving more than 2 carts in manual mode, you will need two people; one to run CartManager XD+ with
the throttle grips and the other to steer from the lead cart. NEVER attempt to move a line of carts in manual
mode by yourself.
•NEVER allow anyone to ride on CartManager XD+ or attached carts.
•When you leave CartManager XD+ unattended, ALWAYS remove the keys, press the red Emergency Stop
button and make sure the Brake Release lever is pushed in.
•Check that your path is clear before you move CartManager XD+, both in front and behind. ALWAYS pay
attention to where you are going.
•Unless specifically directed by your store policy, do not use CartManager XD+ to drive carts directly into a cart
holding area. Stop CartManager XD+, off load the carts and move them in by hand.
•If you do drive carts directly into a cart storage area with a low opening, unclamp the Light Pole and swing it into
the down position before moving through the opening.
•CartManager XD+ is designed for pushing shopping carts. Using the unit for any other purpose may cause injury
or damage and will void the warranty.
•Never operate the CartManager XD+ in a negligent, unsafe or inappropriate manner, in other than full
compliance with applicable laws, regulations, and the guideline set out in this training guide.
•DO NOT operate the CartManager XD+ if you are taking any medication known to cause impairment of vision,
reflexes or judgment, are overly fatigued, or have any other circumstances that would prevent safe use of the
unit.
Disregarding any of these warnings may cause injury, severe damage, or even death to you, other
employees, customers, the building, other property (including merchandise), equipment, vehicles, or the
CartManager XD+ itself.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 14
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.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 15
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.
The batteries are charged by plugging the charger cord on the back of the CartManager XD+ into a standard
grounded (three prong) electrical outlet.
CartManager XD+ will operate for approximately 8-10 hours on a full charge. Recommended procedure is to plug
CartManager XD+ in at the end of each work day and leave it to charge overnight (8 hours). It is also a good idea to
plug CartManager XD+ in between runs. This type of intermittent charging will not harm the batteries.
To charge the CartManager XD+ Batteries:
1. Drive CartManager XD+ to a clean, dry, well ventilated area, close to a standard grounded (three prong) electrical
outlet. This charging area should be sheltered from the weather and out of the way of customer traffic.
2. Turn CartManager XD+ off and remove the key.
3. Make sure that the Emergency Stop Button and Manual Brake Lever are both pushed in.
4. If using a detachable cord, plug the flat end into the charging socket on the back of the CartManager XD+. Plug
the end with the prongs into a standard grounded electrical outlet. If the charging cord is permanently attached to
CartManager XD+, unwrap the charging cord and plug directly into the electrical outlet. DO NOT use adapters
that bypass the grounding prong and allow the cord to be plugged in to a two-prong outlet. If an extension cord is
used it must be at least 10 gauge and not more than 10 feet in length.
5. When charging is complete, or CartManager XD+ is needed for cart retrieval, unplug the cord from the wall outlet.
If the cord is detachable, unplug it from the charging socket on the back of the CartManager XD+ and store in a
safe place. If the cord is permanently attached to the CartManager XD+, wrap it securely on the cord hooks on the
back of the unit.
6. If an extension cord was used, make sure it is stored so that it does not present a tripping hazard.
CartManager XD+ Maintenance
This section details maintenance procedures that should be performed on a daily and quarterly (every 3 months)
basis.
Safety Precautions:
•Never perform maintenance or troubleshooting procedures for which you have not been trained.
•It is always a good idea to have a partner when doing any procedures (replacing a wheel, changing a battery,
etc.) on the CartManager XD+. If this is not possible, at least have someone within calling distance so you can
get assistance if you run into trouble.
•Always wear appropriate safety gear such as safety glasses and rubber gloves when cleaning or replacing the
main batteries.
Daily/Weekly Maintenance:
•Perform the checks shown on the CartManager XD+ PreOperations Checklist located inside the hood of the
CartManager XD+ before the first run of the day.
•The outside of the CartManager XD+ can be washed just like a car; use a mild solution of dish detergent and a
soft rag. Rinse with clear water. It is important to wash or at least thoroughly rinse CartManager XD+ on a weekly
basis during seasons where de-icing chemicals or solvents are being used in the cart collection area.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 16
Quarterly Maintenance:
1. 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.
•Use a wire brush or medium sandpaper to remove any corrosion or buildup.
•While the battery is out, buff the cable connectors down to bare metal with sandpaper, a wire brush or a wire
wheel.
•Use a clean dry cloth to wipe the connectors and terminals.
•Replace the battery, reconnect cables and tighten all connections.
•Spread a thin layer of waterproof grease over the terminals and connectors.
•Replace the plastic terminal covers.
•Repeat this process for the next battery.
2. Check each battery for leaks or cracks in the casing. If there is any fluid leaking from a battery, it should be
replaced immediately. See Replacing the CartManager XD+ Batteries on page 28.
3. Check all fasteners and hardware. Tighten any loose items.
4. Apply axle grease to the rear swivel wheel bearings.

CartManager XD+ Owner-Operator Training and Troubleshooting Guide Page 17
Post Training Quiz
Take the following short quiz to make sure that you know how to safely operate the CartManager XD+. When you are
done, review the quiz with your manager. Go over any questions you missed or answers that you are unsure of. You
should also ask your manager or a designated representative to observe you while you are performing cart retrieval
using both manual and remote modes.
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
1. CartManager XD+ is used to pull a line of shopping carts.
2. It is not necessary for a person to complete the CartManager XD+ training before they use
CartManager XD+ for cart retrieval, as long as they will only be moving the unit a short distance.
3. Before turning the key to start the CartManager XD+, you should make sure that the power cord has
been unplugged and securely wrapped around the cord hooks on the back of the unit.
4. If you discover any unsafe conditions when doing the PreOperations check or while using the
CartManager XD+, you should continue using CartManager XD+ and tell your manager at the end
of the day.
5. The red Emergency Stop Button must be pulled out for normal operation of the CartManager XD+.
6. The Brake Release lever must be pushed in when using CartManager XD+ with the drive throttle or
the remote control unit.
7. If the battery level indicator is 20% or less, CartManager XD+ should be charged before using.
8. The operator should steer a line of carts by walking directly in front of the lead cart.
9. To turn on the remote control unit, press and then immediately release the green ON button.
10. The Cart Restraint Strap is only necessary if you are moving more than 5 carts.
11. CartManager XD+ can be driven with the hood open, as long as it is only a short distance.
12. The large tread on the CartManager XD+ drive wheels makes it OK to drive through the mud or on
grass.
13. CartManager XD+ can be used in rain or snow, so long as the conditions are not so severe as to be
unsafe.
14. When driving a line of carts downhill, or in wet or slippery conditions, you should reduce speed and
allow extra distance for stopping.
15. When approaching an area where customers or vehicles are in your line of travel, you don’t need to
stop, as long as you sound the horn to let them know you are coming.
16. If you are using the remote control to drive carts into a narrow area such as a hall or aisle, where
you cannot steer from the side of the lead cart, you should stop CartManager XD+ and move the
carts manually to the cart storage area.
17. It is OK for a single operator to move a line of carts using just the throttle grips on the back of the
CartManager XD+.
18. You can let someone ride on the CartManager XD+, as long as there are no carts attached.