Bosch rexroth ActiveShuttle User manual

Operating manual
3 842 560 864/2021-10
Replaces: –
ENGLISH
ActiveShuttle
Lithium-ion battery
3842560101
ENGLISH

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The information in this manual is for product description purposes only. Any information in this manual on how to use the product only
constitute examples and recommendations. Catalog information is not binding. The information given does not exempt the user from
the obligation of own judgment and verification. Our products are subject to natural wear and aging.
© All rights reserved by BoschRexrothAG, also for the registration of industrial property rights. This document may not be reproduced
or distributed to third parties without our consent.
An example configuration is shown on the title page. The delivered product may thus vary from the illustration.
The original operating instructions are in German.
DE Die vorliegende Betriebsanleitung ist in den hier angebenen Sprachen verfügbar. Weitere Sprachen auf Anfrage. Als gedruckte
Version oder als PDF-Datei zum Download aus dem Medienverzeichnis: www.boschrexroth.com/medienverzeichnis
Geben Sie in die Suchmaske (oben rechts, unter „Suche“) 3 842 560 863 ein, dann klicken Sie auf „Suche“.
EN This operating manual is available in the languages indicated here. Other languages available on request.
As aprinted version or as aPDF file for download from the Media Directory: www.boschrexroth.com/mediadirectory
In the search mask (at the top right, under "Search"), enter 3 842 560 864, then click on "Search".
FR Les présentes instructions d'utilisation sont disponibles dans les langues spécifiées ici. Autres langues sur demande. Disponible
au téléchargement en version imprimée ou en fichier PDF à partir du répertoire médias:
www.boschrexroth.com/mediadirectory
Saisissez 3 842 560 865 dans le champ de recherche (en haut à droite, sous "Search") puis cliquez sur "Search".
IT Le presenti istruzioni per l’uso sono disponibili nelle lingue qui indicate. Altre lingue su richiesta. Possono essere scaricate
come versione stampata o file PDF dalla Media Directory: www.boschrexroth.com/mediadirectory
Inserire nella maschera di ricerca (in alto a destra, sotto "Search") 3 842 560 866, poi cliccare su "Search".
ES El presente manual de instrucciones está disponible en los idiomas indicados. Hay más idiomas bajo petición.
Las instrucciones están disponibles como versión impresa o como archivo PDF para descargar del directorio de medios:
www.boschrexroth.com/mediadirectory
En el buscador (en la parte superior derecha, en "Search") introduzca 3 842 560 867 y, a continuación, haga clic en "Search".
PT O presente manual de instruções está disponível nos idiomas aqui indicados. Outros idiomas sob consulta.
Como versão impressa ou como arquivo PDF para download no diretório de mídias: www.boschrexroth.com/mediadirectory
Insira a máscara de pesquisa (parte superior direita, em "Search") 3 842 560 868, depois clique em "Search".
ZH 本使用说明书 提供此处给出的语言版本。更多语言版本请咨询。
作为印刷版本或 PDF 文件可从媒体目录下载：www.boschrexroth.com/mediadirectory
在搜索窗口（右上角，"Search"）输入 3 842 560 869，然后点击 "Search" 按钮。
CS Tento návod k obsluze je kdispozici vuvedených jazycích. Další jazykové verze navyžádání.
Jako tištěná verze nebo jako soubor ve formátu PDF ke stažení zadresáře médií: www.boschrexroth.com/mediadirectory
Zadejte do vyhledávacího políčka (vpravo nahoře pod "Search") MTCS 560 863, poté klikněte na tlačítko "Search" (Hledat).
PL Niniejsza instrukcja obsługi dostępna jest w podanych tutaj wersjach językowych. Inne wersje językowe na zapytanie.
W wersji drukowanej lub jako plik PDF do pobrania w wykazie mediów: www.boschrexroth.com/mediadirectory
W polu wyszukiwania (na górze z prawej strony, w polu "Search") wpisać MTPL 560 863, a następnie kliknąć "Search".
HU Ajelen használati utasítás az itt megadott nyelveken áll rendelkezésre. További nyelvek rendelésre.
Nyomtatott változatként vagy amédiakönyvtárból letölthető PDF-fájlként: www.boschrexroth.com/mediadirectory
Írja be a keresőmezőbe (jobbra fent, a "Search" alatt) MTHU 560 863, majd kattintson a "Search" gombra.
RO Aceste instrucțiuni de utilizare sunt disponibile în limbile indicate aici. Alte limbi la cerere. Sub formă de versiune tipărită sau ca
fișier PDF pentru afi descărcat din directorul de conținuturi: www.boschrexroth.com/mediadirectory
Introduceți în masca de căutare (sus, în partea dreaptă, la "Search") MTRO 560 863, apoi faceți clic pe "Search".
TR Bu kullanım kılavuzu burada belirtilmiş dillerde mevcuttur. Diğer diller talep üzerine sunulur.
Basılı versiyon veya medya dizininden indirilebilir PDF dosyası olarak: www.boschrexroth.com/mediadirectory
Arama maskesine (sağ üstte, "Search" altında) MTTR 560 863 girin ve ardından "Search" alanına tıklayın.
DE 3 842 560 863 ActiveShuttle Lithium-Ionen-Akku Deutsch
EN 3 842 560 864 ActiveShuttle Lithium-ion battery English
FR 3 842 560 865 ActiveShuttle Batterie lithium-ion Français
IT 3 842 560 866 ActiveShuttle Batteria agli ioni di litio Italiano
ES 3 842 560 867 ActiveShuttle Batería de ion de litio Español
PT 3 842 560 868 ActiveShuttle Bateria de íons de lítio Português
ZH 3 842 560 869 ActiveShuttle 锂离子蓄电池 中文
CS MTCS 560 863 1) ActiveShuttle Lithio-iontový akumulátor Česky
PL MTPL 560 863 1) ActiveShuttle Akumulator litowo-jonowy Polski
HU MTHU 560 863 1) ActiveShuttle Lítiumion-akkumulátor Magyar
RO MTRO 560 863 1) ActiveShuttle Acumulator litiu-ion Română
TR MTTR 560 863 1) ActiveShuttle Lityum iyon akü Türkçe
1) Only as PDF / Not available in print.

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ENGLISH

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4/32Contents
1 About this documentation 5
1.1 Validity of the documentation 5
1.2 Required and supplementary documentation 5
1.3 Presentation of information 5
1.3.1 Safety instructions 5
1.3.2 Symbols 6
1.3.3 Designations 6
2 Safety instructions 7
2.1 About this section 7
2.2 Intended use 7
2.3 Improper use 7
2.4 Personnel qualifications 8
2.5 General safety instructions 8
2.6 Product-specific safety instructions 9
2.7 Personal protective equipment 11
2.8 Owner responsibilities 11
2.8.1 Product labeling 11
3 General notes on property and product damage 12
4 Scope of delivery 12
4.1 Condition on delivery 12
5 About this product 13
5.1 Specifications 13
5.2 Product description 13
5.3 Identification of the product 13
6 Transport and storage 14
6.1 Transporting the product 14
6.2 Storing the product 14
7 Installation 15
7.1 Ambient conditions 15
7.2 Symbols used 15
7.3 Unpacking the lithium-ion battery 15
8 Commissioning 16
8.1 Inserting the lithium-ion battery in ActiveShuttle 16
8.2 Initial commissioning in ActiveShuttle 19
8.2.1 Switching on the ActiveShuttle 22
8.2.2 Manually insert the ActiveShuttle into the charging station 23
8.2.3 Fully charge the ActiveShuttle 24
9 Maintenance and repair 25
9.1 Cleaning and care 25
9.2 Maintenance 25
10 Decommissioning 25
11 Disassembly and replacement 25
11.1 Preparing the product for storage/later use 25
12 Disposal 26
13 Upgrading and modification 27
14 Troubleshooting 27
15 Technical data 27
15.1 Lithium-ion battery 27
15.2 Ambient conditions 27
16 Appendix 28
16.1 International contact information 28
Contents

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1 About this documentation
1.1 Validity of the documentation
This documentation applies to the following products:
• 3842560101, Lithium-ion battery
This documentation is intended for fitters, operators, service engineers and
system owners.
This documentation contains important information relating to the safe and
proper assembly, transportation, commissioning, operation, use, maintenance and
disassembly of the product, and on how to rectify simple faults yourself.
Read this documentation in full prior to working with the product,
particularly section2 "Safety instructions" and section3 "General notes on
property and product damage".
1.2 Required and supplementary documentation
Only commission the product if he documentation marked with the
book symbol is available and you have understood and followed the
instructions in it.
Table 1: Required and supplementary documentation
Title Document number Document type
General safety instructions
for the electrical installation of
MPS components1)
3842358820
Employee safety training1) 3842527147
ActiveShuttle Transport vehicle1) 3842560852 Operating manual
Battery safety instructions2) Manufacturer documentation
1) If not included in the scope of delivery, download from the media directory:
www.boschrexroth.com/mediadirectory
2) If not included in the scope of delivery, download from the manufacturer's website:
www.bmz-group.com
1.3 Presentation of information
Standardized safety instructions, symbols, terms and abbreviations are used so
that you can use this documentation to work quickly and safely with your product.
These are explained in the following sections to help you understand them better.
1.1.1 Safety instructions
This document contains safety instructions in section2.6 "Product-specific
safety instructions" and section3 "General notes on property and product damage",
as well as before any sequence of actions or any required action which involves arisk
of personal injury or property damage. Be sure to observe all safety precautions.
ENGLISH

6/32 About this documentation
BoschRexrothAG, ActiveShuttle: Lithium-ion battery, 3 842 560 864/2021-10
Safety instructions are set out as follows:
SIGNAL WORD
Type and source of danger!
Consequences of non-compliance
Measures to prevent danger
…
•Safety sign: Points out the danger
•Signal word: Indicates the severity of the danger
•Type and source of danger: Indicates the type and source of the danger
•Consequences: describes the consequences of non-compliance
•Prevention: States how the danger can be avoided
Table 2: Risk classes according to ANSI Z535.6-2006
Warning sign, signal word Meaning
DANGER Indicates ahazardous situation that will result in serious
injury or death if not avoided.
WARNING Indicates a hazardous situation that may result in serious
injury or death if not avoided.
CAUTION Indicates ahazardous situation that may result in minor
to moderate injury if not avoided.
NOTICE Property damage: The product or the surrounding area
could get damaged.
1.1.2 Symbols
The following symbols indicate important information that is not safety-relevant but
increases the comprehensibility of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
If this information is not observed, the product cannot be used and/or
operated as designed.
Single, independent action
1.
2.
3.
Numbered steps:
The numbers indicate that the action steps are subsequent.
1.1.3 Designations
This document uses the following designations:
Table 4: Designations
Designation Meaning
AMS ActiveShuttle Management System

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2 Safety instructions
2.1 About this section
The product has been manufactured in accordance with the generally accepted rules
of current technology. Nevertheless, there is arisk of personal injury and property
damage if you do not read this sectionand follow the safety instructions in this
document.
Read this documentation carefully and completely before you start working with
the product.
Keep the documentation accessible to all users at all times.
Always include them when giving the product to athird party.
2.2 Intended use
The product is an accessory/spare part for the transport vehicle ActiveShuttle.
You may use the product as follows:
• Exclusively to operate the transport vehicle ActiveShuttle. Any other use is not
permitted.
• Technical data seepage 27.
• For ambient conditions, seepage27.
The product is strictly intended for professional use and not for private use.
The intended use also includes having read and understood these instructions,
especially section2 "Safety instructions".
2.3 Improper use
Any use other than that described in the section"Intended use" is considered
improper and is not permitted.
BoschRexrothAG is not liable for any damage resulting from improper use.
The user alone bears any risks associated with improper use.
The following foreseeable misuses also constitute improper use:
• Use in potentially explosive atmospheres.
• Shipping, transport and storage not in original transport packaging.
ENGLISH

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2.4 Personnel qualifications
The activities described in this documentation require basic knowledge of
mechanical, electrical systems, as well as knowledge of the appropriate
technical terms.
To ensure safe use, these activities should therefore only be performed by qualified
personnel or by an instructed person acting under the direction of such aperson.
"Qualified personnel" refers to those who can recognize potential hazards and
take appropriate safety measures based on their technical training, knowledge,
experience, and understanding of the relevant regulations pertaining to the work
being performed. Qualified personnel must comply with the relevant technical
regulations and have the necessary expertise.
BoschRexroth offers training support for specialized fields. You can find an
overview of the training content online at:
https://www.boschrexroth.com/de/de/academy
2.5 General safety instructions
• As owner, please note the following: before the initial commissioning of the
product, carry out arisk assessment in accordance with the national regulations in
your country (in Germany: according to the Occupational Health and Safety Act).
• Observe the applicable accident prevention and environmental protection
regulations.
• Observe the safety rules and regulations of the country in which the product is
being used.
• Only use Rexroth products that are in proper working order.
• Heed all the notices on the product.
• Persons who assemble, operate, disassemble or maintain Rexroth products should
not be under the influence of alcohol, drugs or medication that may affect their
ability to respond.
• Use only original accessories and spare parts from Rexroth in order to prevent
hazards to people due to unsuitable spare parts.
• Observe the technical data and ambient conditions specified in the product
documentation.
• Only start up the product if it has been determined that the end product
(for example, amachine or system) into which the Rexroth products have been
installed complies with national provisions, safety regulations and application
standards.

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2.6 Product-specific safety instructions
• Do not attempt to modify the product (software or hardware).
• Do not expose the product to any mechanical loads under any circumstances.
Never use the product as ahandhold or step. Do not place any objects
on the product.
• Always secure the product against tipping over.
• Observe the transport instructions on the packaging.
• Inspect the product for obvious transport damage.
• Make sure the system component you are working on is depressurized and
de-energized before assembling the product or inserting or removing plugs.
• Allow the product to acclimatize for afew hours prior to commissioning in order to
prevent water condensation from forming in the housing.
• Only start up aproduct that has been completely installed.
• Make sure that all the safety equipment which forms part of the product is present,
has been properly installed, and is fully functional. Do not move, bypass or disable
any safety equipment.
• Check the product for malfunctions.
• Make sure that only authorized personnel perform the following tasks within the
scope of the product’s intended use:
–Starting or operating the system or interfering with its normal operation.
–Operating component or part adjusters.
• Only allow people to be in the immediate vicinity of the product when it is
operating if they are authorized by the owner to be there. This also applies when
the product is idle.
• Do not reach into moving parts.
• An idle system is not necessarily asafe system, as stored energy can be released
unintentionally or through improper maintenance procedures.
• After amalfunction, only switch the system back on once you have established and
rectified the cause of the fault.
• Make sure that access to maintenance and inspection points is kept unobstructed.
• Make sure that no line connectors, connections or components are disconnected
as long as the system is supplied with pressure and voltage. Secure the system
against being switched back on.
• Dispose of the product in accordance with the regulations in your country.
General
During transport
During assembly
During commissioning
During operation
EMERGENCY STOP,
malfunction
During servicing
and repair
During disposal
ENGLISH

10/32 Safety instructions
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CAUTION
Possible hazard due to incorrect handling of lithium-ion batteries!
The ActiveShuttle is powered by areplaceable lithium-ion battery.
Lithium-ion batteries can be damaged by mechanical, thermal or electrical
stress (e.g.shock, heat, cold, incorrect charging, short circuit). This may
result in the following hazards:
•
Leakage of toxic substances and toxic combustion products in
case of fire.
•
Leakage of corrosive liquid and thus possible skin irritations, burns and
chemical burns.
•
Increased fire hazard due to electrolyte leakage (flammable solvent).
Never use dropped or damaged batteries.
Do not use defective or damaged lithium-ion batteries.
Do not use lithium-ion batteries with adefective connection cable or
defective contacts.
To charge the lithium-ion battery in the ActiveShuttle, use only the charging
station supplied by BoschRexroth or the charger supplied by BoschRexroth.
Only operate lithium-ion batteries and accessories in perfect condition.
Protect the battery terminals from short circuiting.
Protect the lithium-ion batteries from mechanical stress (shocks, falls, vibrations).
Do not expose the lithium-ion batteries to high temperatures and/or large
temperature variations.
Store the lithium-ion batteries in acool, dry and well ventilated place.
Protect the lithium-ion batteries from direct sunlight.
Do not immerse the lithium-ion batteries in liquids.
Please observe the country-specific regulations regarding storage of the
lithium-ion battery.
Check the lithium-ion batteries regularly for damage.
Lithium-ion batteries must not be opened, repaired or serviced.
NOTICE
Handling damaged lithium-ion batteries
• Only touch and transport damaged lithium-ion batteries with personal
protective equipment that is resistant to alkalis and solvents.
•
If there are any signs of heat, smoke, odor, noise, or deformation of the
batteries, disconnect the lithium-ion battery from the vehicle.
•
Store the lithium-ion battery in afire-resistant container or at asafe
distance from combustible materials.
•
Do not inhale any vapors that may be generated.

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NOTICE
Disposal of lithium-ion batteries
Dispose of lithium-ion batteries properly.
Tape off the connection contacts for disposal.
Store damaged lithium-ion batteries in fire-resistant containers.
During transport, observe the relevant hazardous goods requirements for
lithium-ion batteries.
Observe the operating manual of the manufacturer:
BMZ Batterien-Montage-Zentrum GmbH
Am Sportplatz 28
63791 Karlstein
Germany
www.bmz-group.com
Recommendations for best possible battery life
Store lithium-ion batteries with acharge level of about 50%.
After three months, check the charge level and recharge to approx. 50%
if necessary.
2.7 Personal protective equipment
Appropriate protective clothing should be worn when handling/using the product
(e.g.safety shoes, close-fitting clothing, ahair net for long, loose hair).
As the system user or operator, you are personally responsible for ensuring the use
of appropriate protective equipment when the product is being used.
All component parts of the personal protective equipment must be free of damage.
2.8 Owner responsibilities
Provide safety-related instructions/training to the operating personnel before the
first commissioning or recommissioning and afterwards regularly.
1.1.4 Product labeling
CAUTION
Risk of injury due to incorrect behavior due to missing safety signs!
The lithium-ion battery is marked with the following safety signs/technical
information:
Make sure that these safety signs/technical information are present and legible.
ENGLISH

12/32 General notes on property and product damage
BoschRexrothAG, ActiveShuttle: Lithium-ion battery, 3 842 560 864/2021-10
3 General notes on property and
product damage
The warranty only applies to the delivered configuration.
• The warranty is void in the event of incorrect assembly, commissioning and
operation, as well as improper use and/or improper handling.
• The cleaning personnel must be informed of the possible hazards to the system
before starting the cleaning work.
• Prevent cleaning agents from getting into the product.
• Never use solvents or corrosive cleaning agents.
• Do not use apressure washer for cleaning.
4 Scope of delivery
• 3842560101, Lithium-ion battery incl. operating manual "ActiveShuttle
Lithium-ion battery"
4.1 Condition on delivery
• Lithium-ion battery ActiveShuttle ready for connection
During cleaning

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5 About this product
5.1 Specifications
The lithium-ion battery is used exclusively to operate the transport vehicle
ActiveShuttle.
5.2 Product description
Fig. 1:
560 863-03
C
0% 100%50%
D
A
B
Lithium-ion battery
5.3 Identification of the product
For the name plate, see section 2.8.1 Product labeling.
A: Lithium-ion battery
48V/17Ah
B: Connection socket
C: Lithium-ion battery
charge indicator with
ON/OFF button
D: Unlocking button
Battery charge indicator (C)
(display by pressing the
ON/OFF key)
Display State of charge [%]
 0…9 1)
 10…19
 20 … 39
 40 … 59
 60 … 79
 80…100
 Battery defective 2)
Explanation of symbols

LED
off

LED
on

LED
flashing
1) To avoid permanent damage,
recharge after 2 days at
the latest.
2) Contact the manufacturer.
ENGLISH

14/32 Transport and storage
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6 Transport and storage
• Observe the transport instructions on the packaging.
• Transport weight: seedelivery documents.
• Always maintain ambient conditions during loading and transport, seepage27.
• Shipping, transport and storage only in original transport packaging.
6.1 Transporting the product
• For transport and shipping of lithium-ion batteries, applicable hazardous goods
requirements for lithium-ion batteries must be observed.
• Lithium-ion batteries may only be packaged and shipped by trained personnel.
• In case of any questions regarding packaging, shipping and transport,
please contact BoschRexroth.
6.2 Storing the product
• Only set the product down on aflat surface.
• Protect the product from mechanical stress.
• Protect the product from environmental influences, such as dirt and moisture.
• Observe the ambient conditions, seepage27.
• When storing lithium-ion batteries, observe the safety instructions on page 9 and
the recommendations of the VdS data sheet 3103 (Association of Property Insurers).

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7 Installation
7.1 Ambient conditions
Always comply with the environmental conditions specified in the technical data
(seepage 27) are specified.
7.2 Symbols used
Table 5: Symbols used
213
Graphical depiction of the installation steps.
The numbers correspond to the sequence of installation steps, in accordance with
the instructions in the accompanying text.
AB CX
Graphical depiction of the designation of components.
The letters denote the components mentioned in the accompanying text.
Detail view from adifferent direction,
for example, the back or the bottom side of the product.
7.3 Unpacking the lithium-ion battery
Keep the transport packaging for further use (e.g.return shipment to the
manufacturer).
Dispose of the packaging material (film, cardboard boxes, etc.) in accordance
with the applicable regulations in your country.
ENGLISH

16/32 Commissioning
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8 Commissioning
8.1 Inserting the lithium-ion battery in ActiveShuttle
CAUTION
Possible hazard due to incorrect handling of lithium-ion batteries!
The ActiveShuttle is powered by areplaceable lithium-ion battery.
Lithium-ion batteries can be damaged by mechanical, thermal or electrical
stress (e.g.shock, heat, cold, incorrect charging, short circuit). This may
result in the following hazards:
•
Leakage of toxic substances and toxic combustion products in case of
fire.
•
Leakage of corrosive liquid and thus possible skin irritations, burns and
chemical burns.
•
Increased fire hazard due to electrolyte leakage (flammable solvent).
Never use dropped or damaged batteries.
Do not use defective or damaged lithium-ion batteries.
Do not use lithium-ion batteries with adefective connection cable or
defective contacts.
To charge the lithium-ion battery in the ActiveShuttle, use only the charging
station supplied by BoschRexroth or the charger supplied by BoschRexroth.
Only operate lithium-ion batteries and accessories in perfect condition.
Protect the battery terminals from short circuiting.
Protect the lithium-ion batteries from mechanical stress (shocks, falls, vibrations).
Do not expose the lithium-ion batteries to high temperatures and/or large
temperature variations.
Store the lithium-ion batteries in acool, dry and well ventilated place.
Protect the lithium-ion batteries from direct sunlight.
Do not immerse the lithium-ion batteries in liquids.
Please observe the country-specific regulations regarding storage of the
lithium-ion battery.
Check the lithium-ion batteries regularly for damage.
Lithium-ion batteries must not be opened, repaired or serviced.
NOTICE
Handling damaged lithium-ion batteries
• Only touch and transport damaged lithium-ion batteries with personal
protective equipment that is resistant to alkalis and solvents.
•
If there are any signs of heat, smoke, odor, noise, or deformation of the
batteries, disconnect the lithium-ion battery from the vehicle.
•
Store the lithium-ion battery in afire-resistant container or at asafe
distance from combustible materials.
•
Do not inhale any vapors that may be generated.

Commissioning 17/32
3 842 560 864/2021-10, ActiveShuttle: Lithium-ion battery, BoschRexrothAG
NOTICE
Disposal of lithium-ion batteries
Dispose of lithium-ion batteries properly.
Tape off the connection contacts for disposal.
Store damaged lithium-ion batteries in fire-resistant containers.
During transport, observe the relevant hazardous goods requirements for
lithium-ion batteries.
Observe the operating manual of the manufacturer:
BMZ Batterien-Montage-Zentrum GmbH
Am Sportplatz 28
63791 Karlstein
Germany
www.bmz-group.com
Damage to the lithium-ion battery due to alow state of charge!
The state of charge of the lithium-ion battery should not fall below 15%.
Below a charge of 15%, move the ActiveShuttle by hand
- to acharging station (see section 8.2.2) or
- switch the ActiveShuttle to the "Manual" operating mode and move
the ActiveShuttle to acharging station using the handheld controller
(see "ActiveShuttle transport vehicle operating manual") or
- switch the ActiveShuttle to "Automatic" operating mode
(see "ActiveShuttle transport vehicle operating manual").
ENGLISH

18/32 Commissioning
BoschRexrothAG, ActiveShuttle: Lithium-ion battery, 3 842 560 864/2021-10
Fig. 2:
560 863-04
1
PUSH
2.2
D
C
2.1
Removal of the lithium-ion battery in case of emergency
Please note:
Remove or insert the
lithium-ion battery only
when it is switched off.
1. Open the cover of the
battery compartment.
2. Press the release button
(D) at the battery and
remove the battery.
To insert the new
battery, proceed in
reverse order.
After inserting the
battery, check that
the release button
is engaged and that
the battery is firmly
seated in the battery
compartment.
Battery charge indicator (C)
(display by pressing the
ON/OFF key)
Display State of charge [%]
 0…9 1)
 10…19
 20 … 39
 40 … 59
 60 … 79
 80…100
 Battery defective 2)
Explanation of symbols

LED
off

LED
on

LED
flashing
1) To avoid permanent damage,
recharge after 2 days at
the latest.
2) Contact the manufacturer.

Commissioning 19/32
3 842 560 864/2021-10, ActiveShuttle: Lithium-ion battery, BoschRexrothAG
8.2 Initial commissioning in ActiveShuttle
CAUTION
Risk of injury and damage to the ActiveShuttle
On new commissioning of additional ActiveShuttles, they are not yet entered in the
AMS and therefore not known to the already autonomous ActiveShuttles (e.g.if the
additional ActiveShuttles have been pushed manually into acharging station).
The operator must take appropriate measures to prevent dangerous states and
damage to the ActiveShuttle.
Danger of injury due to safety checks not carried out!
Risk of serious injury from non-functioning safety and warning devices.
Carry out atest of the visual and audible warning devices every quarter
(see "ActiveShuttle transport vehicle operating manual").
Carry out atest of the safety devices in accordance with the test cycles
specified in the "ActiveShuttle transport vehicle operating manual".
Take vehicles with non-functional safety and warning devices out of service and
contact the BoschRexroth Service.
Risk of burns from hot components inside the ActiveShuttle!
During operation, individual components inside the housing may heat up.
•
Wait areasonable time before opening the housing.
Personal injury when staying in the driving range, especially in curve areas!
Risk of serious injury from collision with the ActiveShuttle.
• If possible, do not stay within the driving range of the ActiveShuttle.
•
Restrict passenger traffic within the ActiveShuttle's driving range as
much as possible.
•
Always wear safety shoes.
Insufficient stopping distance, e.g.by entering the protective area from the side!
Risk of serious injury from collision with the ActiveShuttle.
• Do not step into the protective area of the vehicle from the side.
•
Do not move against the direction of travel towards the ActiveShuttle.
•
Always wear safety shoes.
Risk of crushing at the rear wheels of the load!
When aloaded vehicle starts up/restarts, there is adanger of crushing the rear
wheels of the load.
• Do not put your feet between the wheels.
•
Observe start-up warning.
•
Always wear safety shoes.
Danger due to unadapted speed!
Risk of serious injury due to aspeed not adapted to the situation.
The speed of the ActiveShuttle must be reduced in narrow corridors, curves,
intersections and areas with passenger traffic.
ENGLISH

20/32 Commissioning
BoschRexrothAG, ActiveShuttle: Lithium-ion battery, 3 842 560 864/2021-10
CAUTION
Danger of the ActiveShuttle tipping over if loaded incorrectly!
Risk of serious injury due to the ActiveShuttle tipping over.
Observe the permissible load and the maximum stacking height.
Ensure that the load is evenly distributed (see"ActiveShuttle transport vehicle
operating manual").
Only use the ActiveShuttle in accordance with its intended use.
CAUTION
Danger due to falling load in case of incorrect loading!
Risk of serious injury from falling load.
Ensure that the load is evenly distributed.
Only use the ActiveShuttle in accordance with its intended use. Danger from
unpredictable movements of the ActiveShuttle due to insufficient ground
conditions!
Risk of serious injuries due to unpredictable movements of the ActiveShuttle,
e.g.slipping, especially during emergency braking.
The driving range of the ActiveShuttle must have sufficient traction.
The driving range of the ActiveShuttle must be level, dry, clean and free of objects
lying around. Danger from dirty driveways!
Risk of serious injury from unpredictable movements of the ActiveShuttle due to
dirty driveways.
The driving range of the ActiveShuttle must be free from contamination.
Danger due to incorrect loading condition!
Risk of serious injury due to incorrect loading condition when changing to the
"Automatic" operating mode.
The change to the "Automatic" operating mode may only take place in an
unloaded condition.
Danger due to limited safety functions in the "Manual" operating mode!
Risk of serious injury from incorrect operation.
In the "Manual" operating mode, the ActiveShuttle may only be operated by
specially trained staff using the handheld controller 1.0.
The responsibility for vehicle control in "Manual" mode lies entirely with
the operator.
Risk of personal injury when intervening into automated processes!
Risk of serious injury due to unauthorized intervention in automated processes by
operating personnel.
Under no circumstances may operating personnel intervene in the automated
processes such as loading and unloading positions and when moving in and out
at the charging stations.