Bosch REXROTH ActiveShuttle 1.0 User manual

Operating manual
3 842 560 593/2020-07
Replaces: 2020/02
ENGLISH
ActiveShuttle 1.0
Transport vehicle
3 842 560 431
3 842 560 106
3 842 560 422
3 842 560 101
ENGLISH

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Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07
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 assembly instructions are in German.
DE Die vorliegende Montageanleitung 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“) 3 842 560 592 ein, dann klicken Sie auf „Suche“.
EN These assembly instructions are available in the languages indicated here. Other languages on request.
They come in a hard copy or a PDF file that can be downloaded from the media directory:
www.boschrexroth.com/mediadirectory
In the search mask (at the top right under “Search”) enter 3 842 560 593, then click on “Search”.
FR Les présentes instructions de montage sont disponibles dans les langues suivantes. Autres langues sur demande.
Disponible au téléchargement en version imprimée ou en fichier PDF à partir du répertoire médias :
www.boschrexroth.com/mediadirectory
Saisissez dans le champ de recherche (en haut à droite, sous « Search ») 3 842 560 594 puis cliquez sur « Search ».
IT Le presenti istruzioni di montaggio sono disponibili nelle lingue indicate qui. 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”) 3 842 560 595 e poi fare clic su “Search”.
ES Las presentes instrucciones de montaje están disponibles en los idiomas indicados. Otros idiomas a petición.
Las instrucciones están disponibles como versión impresa o como archivo PDF para descargar del archivo de medios:
www.boschrexroth.com/mediadirectory
En el buscador (en la parte superior derecha, en “Search”) introduzca 3 842 560 596, a continuación haga clic en “Search”.
PT O presente manual de montagem está disponível nos idiomas aqui indicados. Demais idiomas, sob consulta.
Como versão impressa ou o arquivo PDF para download no diretório de mídias: www.boschrexroth.com/mediadirectory
Insira a máscara de pesquisa (parte superior direita, em “Search”) 3 842 560 597, e clique em “Search”.
ZH 本安装说明书有这里给出的语言版本。还可按照需求提供其他语言版本。
有印刷版本或电子版本 PDF 文件供使用，电子版文件可在下列的公司网站媒体网页上下载： www.boschrexroth.com/mediadirectory
在搜索窗口（右上角，“Search”之下）中输入 3 842 560 598，然后点击“Search”。
CS Tento montážní návod 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 560 592, poté klikněte na „Search“.
PL Niniejsza instrukcja montażu 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”) MTPL 560 592, a następnie kliknąć „Search”.
HU A jelen szerelési 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 560 592, majd kattintson a „Search” gombra.
RO Aceste instrucţiuni de montaj sunt disponibile în limbile enumerate aici. Alte limbi la cerere.
Sub formă de versiune tipărită sau ca fişier PDF pentru a fi descărcat din directorul de conţinuturi (mediadirectory):
www.boschrexroth.com/mediadirectory
Introduceţi în masca de căutare (sus, în partea dreaptă, la „Search“) MTRO 560 592, apoi faceţi clic pe „Search“.
DE 3 842 560 592 ActiveShuttle 1.0 Transportfahrzeug Deutsch
EN 3 842 560 593 ActiveShuttle 1.0 Transport vehicle English
FR 3 842 560 594 ActiveShuttle 1.0 Véhicule de transport Français
IT 3 842 560 595 ActiveShuttle 1.0 Veicolo di trasporto Italiano
ES 3 842 560 596 ActiveShuttle 1.0 Vehículo de transporte Español
PT 3 842 560 597 ActiveShuttle 1.0 Veículo de transporte Português
ZH 3 842 560 598 ActiveShuttle 1.0 导引车 中文
CS MTCS 560 592 1) ActiveShuttle 1.0 Transportní vozidlo Česky
PL MTPL 560 592 1)ActiveShuttle 1.0 Pojazd transportowy Polski
HU MTHU 560 592 1)ActiveShuttle 1.0 Szállítójármű Magyar
RO MTRO 560 592 1)ActiveShuttle 1.0 Vehicul de transport Română
1) Only as PDF / Not available in print.

3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG
3/68Contents
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 7
2 Safety instructions 7
2.1 About this section 7
2.2 Intended use 7
2.3 Improper use 8
2.4 Personnel qualifications 8
2.5 General safety instructions 8
2.6 Product-specific safety instructions 9
2.6.1 ActiveShuttle 10
2.6.2 Lithium-ion batteries 12
2.6.3 Handheld controller 1.0 13
2.6.4 Charging station 1.0 14
2.7 Personal protective equipment 15
2.8 Owner responsibilities/obligations 15
2.8.1 Minimum marking 16
2.9 Training of the operating personnel 17
2.9.1 Manual operation 17
2.9.2 Logistics employees 17
2.9.3 Logistics planner 17
3 General notes on property and product damage 18
4 Scope of delivery 19
4.1 Condition on delivery 19
5 About this product 19
5.1 Specifications 19
5.1.1 Use 19
5.2 Product description 20
5.3 Safety and warning devices 25
5.3.1 Signaling 26
5.3.2 Protective fields 27
5.3.3 Reference to limits of the personal protection system 27
5.4 Identification of the product 28
6 Transport and storage 28
6.1 Transporting the product 28
6.1.1 Mounting/removing lift aid 29
6.2 Storing the product 29
7 Assembly 30
7.1 Ambient conditions 30
7.2 Required tools 30
7.3 Symbols used 30
7.4 Unpacking the charging station 30
7.5 Positioning/preassembling the charging station 31
7.5.1 Connecting the charging station electrically 33
7.6 Unpacking the ActiveShuttle 34
8 Commissioning 35
8.1 Emergency measure Pressing emergency stop device 35
8.2 Emergency measure Removing lithium-ion battery 36
Contents
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8.3 Initial commissioning 39
8.3.1 Switching on the ActiveShuttle 41
8.3.2 Switching to "Manual" operating mode 42
8.3.3 Move ActiveShuttle to the charging station using the handheld controller 43
8.3.4 Manually insert the ActiveShuttle into the charging station 43
8.3.5 Fully charge the ActiveShuttle 44
8.3.6 Raising/lowering the loading area without handheld controller 44
8.3.7 Switching off the ActiveShuttle 44
8.4 Re-commissioning after a standstill 44
8.5 Preparing the supermarket 45
8.5.1 Permissible dollies 46
9 Operation 47
9.1 Notes regarding operation 47
9.1.1 ActiveShuttle 47
9.1.2 Lithium-ion batteries 49
9.1.3 Handheld controller 1.0 50
9.1.4 Charging station 1.0 51
9.1.5 Wear 51
9.1.6 Measures to reduce wear 51
9.1.7 Environmental factors 51
10 Maintenance and repair 52
10.1 Cleaning and care 52
10.2 Regular safety inspections 52
10.2.1 Periodic inspection - minimum requirements 53
10.3 Procedure for testing the personal protection systems (laser scanner) 54
10.3.1 Checking the basic function of the personal protection systems
(laser scanner) 54
10.3.2 Checking the areas to be protected 54
10.4 Maintenance 54
10.5 Replacement of wear parts 55
11 Decommissioning 55
12 Disassembly and replacement 55
12.1 Preparing the product for storage/later use 55
13 Disposal 56
14 Upgrading and modification 57
15 Troubleshooting 57
16 Technical data 58
16.1 ActiveShuttle 1.0 58
16.2 Lithium-ion battery 58
16.3 Charging station 1.0 58
16.4 Ambient conditions 59
16.5 Floor requirements 59
16.6 Load distribution on the loading area 60
16.7 Scanning levels of the personal protection systems (laser scanner) 60
16.8 Protective fields 61
16.8.1 Front protective fields 61
16.8.2 Rear protective fields 63

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1 About this documentation
1.1 Validity of the documentation
This documentation applies to the following products:
• 3 842 560 431, Transport vehicle ActiveShuttle 1.0
• 3 842 560 106, Handheld Controller 1.0
• 3 842 560 422, Charging station ActiveShuttle 1.0
• 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
Handheld Controller 1.0 2) Manufacturer documentation Manual
Battery Safety Instructions 3) 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.keba.com
3) 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.
1.3.1 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.
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Safety instructions are set out as follows:
SIGNAL WORD
Type and source of danger!
Consequences of non-compliance
Measures to prevent danger
…
•Warning 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 severe
injury or death if not avoided.
WARNING Indicates a hazardous situation that may result in severe
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.
1.3.2 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.

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1.3.3 Designations
This document uses the following designations:
Table 4: Designations
Designation Meaning
AMS ActiveShuttle Management System
AGV Automated Guided Vehicle system
KLT Small load carrier according to VDA 4500
Source Loading point
Dip Unloading point
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
ActiveShuttle 1.0
The product is a complete machine.
You may use the product as follows:
• For automated material transport in production with operator-defined
–driving ranges
– Loading (sources) and unloading points (dips)
– Speeds
in areas used jointly with passenger traffic.
• For the transport of KLTs stacked on approved dollies (see chapter 8.5.1
Permissible dollies) with a
– total weight incl. dolly of up to 260 kg and a
– max. stacking height of 1,200 mm.
• Technical data see page 58.
• For ambient conditions, see page 59.
Handheld controller 1.0
The handheld controller 1.0 is used in the "Manual" operating mode exclusively for
controlling the ActiveShuttle 1.0.
Charging station ActiveShuttle 1.0
The charging station is used exclusively for charging the ActiveShuttle 1.0.
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".
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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:
• Transporting goods other than those specified.
• Transporting people on the product or transported material.
• Private use.
• The charging station 1.0 must not be used as a stepladder or climbing aid.
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. Additional knowledge regarding the use of lifting gear and corresponding
slings is required for transporting and handling the product. 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: http://www.boschrexroth.de/didactic
2.5 General safety instructions
• As owner, please note the following: before the initial start-up 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 commission 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.
• 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.
• Route the cables and lines adequately protected to prevent mechanical damage
and ensure that no one can trip over them.
• Make sure the system component you are working on is depressurized and
de-energized before assembling the product or inserting or removing plugs.
• Ensure that the system component cannot be switched back on.
• Allow the product to acclimatize for a few hours prior to start-up in order to
prevent water condensation from forming in the housing.
• Check the safety requirements according to DIN EN 60204-1.
• Only commission 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 use EMERGENCY STOP controls for routine stopping.
• Regularly check the EMERGENCY STOP controls to ensure that they are functioning
properly.
• Following an EMERGENCY STOP or in the event of a fault or other irregularity, turn
the product off and secure it against being switched back on.
• 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 an EMERGENCY STOP or 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.
• Perform the prescribed maintenance work at the intervals specified in section 10.3
"Maintenance".
• 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 start-up
During operation
EMERGENCY STOP,
malfunction
During servicing and repair
During disposal
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2.6.1 ActiveShuttle
WARNING
Hazards based on the nature of the load!
Hazardous load (e.g. hazardous substances, hot materials, etc.) can lead to serious
injury or even death.
The operator is solely responsible for any hazards arising from the nature of
the load.
The load must not pose any risk to persons (e.g. catching items of clothing,
scalding, burning, etching, cutting, stabbing).
CAUTION
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 on a daily basis.
Carry out a test of the safety devices at least every 6 months (see chapter 10.2
Regular safety inspections).
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.

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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 chapter 16.6).
Only use the ActiveShuttle in accordance with its intended use.
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.
After manual loading, no change to the "Automatic" operating mode is permitted.
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.
Danger of collision with obstacles outside the protective area!
The ActiveShuttle can be damaged by obstacles outside the protective area.
Keep the driving range free of obstacles, especially flat objects or objects
protruding into the driving range.
Risk of overheating of the ActiveShuttle!
If the ventilation slots of the ActiveShuttle are covered, there is a risk of overheating
and thus damage to the ActiveShuttle.
The ventilation slots of the ActiveShuttle must always be free and uncovered to
ensure sufficient cooling.
ENGLISH

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NOTICE
Risk of damage through unauthorized use!
Unauthorized opening of the ActiveShuttle housing can damage the vehicle.
Always keep the square key secured against unauthorized use.
2.6.2 Lithium-ion batteries
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.

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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.
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 Battery Assembly Centre GmbH
Am Sportplatz 28
63791 Karlstein
Germany
www.bmz-group.com
NOTICE
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.
2.6.3 Handheld controller 1.0
CAUTION
Possible hazard through unauthorized use!
Unauthorized activation of the "Manual" operating mode can cause damage to
property and danger to life and limb.
Always keep the handheld controller secured against unauthorized use.
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.
Also observe the operating manual of the manufacturer:
KEBA AG
Gewerbepark Urfahr
Reindlstraße 51
4041 Linz
Austria
www.keba.com
ENGLISH

14/68 Safety instructions
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NOTICE
Handling the handheld controller
Handheld controllers must not be opened.
Repair and maintenance only by the manufacturer.
When using the handheld controller, make sure that no one can trip over
the cable or the ActiveShuttle can run over the cable, causing the handheld
controller to fall to the ground or be damaged.
Do not expose the handheld controller to high temperatures, large temperature
variations or direct sunlight.
Do not expose the handheld controller to mechanical shocks, excessive dust,
moisture or strong magnetic fields.
2.6.4 Charging station 1.0
WARNING
Risk of injury due to incorrect pre-fuse!
Operation of the charging station with an incorrect pre-fuse can lead to serious
injuries or even death and equipment damage.
Only operate the charging station with a circuit breaker ≤ 16 A with triggering
characteristic B or C.
Risk of injury by bridging the charging contacts of the charging station!
By bridging the charging contacts, there is a risk of damage, sparks, overheating
and fire.
Do not place any objects, especially electrically conductive or flammable
objects, in the area in front of the charging contacts of the charging station.
CAUTION
Risk of injury due to incorrect positioning of the charging station!
If the charging station is positioned in walkways and corridors, there is a risk of
tripping.
Do not position the charging station in walkways and corridors.
Risk of injury due to improper installation of the charging station!
Anchor the charging station in the hall floor to avoid malfunctioning and
associated risks.
Route the connection cable according to the country-specific specifications for
avoiding risks.
Risk of injury and possible damage due to incorrect use!
When climbing or stepping onto the charging station, there is a risk of injury from
falling and of damage to the housing of the charging station.
Do not use the charging station 1.0 as a stepladder or climbing aid.
• The emergency stop function is carried out on the charging station by pulling out
the mains plug.

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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 owner 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/obligations
The user is responsible for hazards arising from the nature of the load.
The load must not pose any risk to persons (e.g. catching items of clothing, scalding,
burning, etching, cutting, stabbing).
The user of an AGV is obliged to comply with all requirements of
• DIN EN 1525 "Safety of industrial trucks - Automated guided vehicles and their
systems"; Annex A "Requirements for the preparation of the environment"
• Guideline VDI 2510 Part 1 "Infrastructure and peripheral equipment for Automated
Guided Vehicles (AGV)"
• Guideline VDI 2510 Part 2 "Infrastructure and peripheral equipment for Automated
Guided Vehicles (AGV)"
and to keep it under constant review.
This also includes, among other things:
• Training of the logistics staff (see chapter 2.9 Training of the operating personnel).
• Reducing the passenger traffic in hazardous areas.
• Attaching warning notices in hazardous areas.
• Ensuring sufficient distance when driving past junctions, if necessary reduced
speed.
• Further measures after evaluation of the user to prevent stepping into the
protective field from the side, e.g.
- Installing mirrors at narrow junctions,
- Using the Bluespot of the AGV,
- Giving warning tones for narrow junctions,
- Providing doors at junctions etc.
• Driving routes must be planned in such a way that gradients are only used in the
direction of travel (forwards or backwards).
• Driveways must not be inclined sideways.
• Do not plan curves/turns on slopes/gradients.
• If necessary, define slow speed zones for slopes/gradients depending on the
actual load.
• Driveways must be planned at a distance of 0.5 m from solid obstacles.
• Driveways must be planned in such a way that vehicle encounters are avoided as
far as possible and collisions and loss of load are avoided to the greatest possible
extent.
• A collision of AGVs must not lead to consequential hazards (e.g. due to falling load).
• Passageways must be designed in such a way that there is sufficient distance to
avoid shearing (risk assessment according to the situation). Between automatically
and manually used supermarket tracks must be a distance of at least 50 mm.
• Turns of the AGV must be planned at a sufficient distance from solid obstacles.
• Driveways must be level, dry, clean and free of objects lying around. For exact
requirements regarding the ground conditions of the driveways, see chapter 16.5
Floor requirements.
• After cleaning the hall floor, the surface finish of the driveways must not be altered
(e.g. due to cleaning agent residues).
• The driveways must be kept clear of objects that cannot be detected by the
protective field (see chapter 16.7 Scanning levels of the personal protection
systems (laser scanner)).
• Driveways must be free of projecting obstacles.
ENGLISH

16/68 Safety instructions
Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07
• In the event of a malfunction, the approaching of obstacles next to and on
driveways must not lead to consequential hazards.
• Faulty AGVs must be detected by the operator and put out of operation.
• Do not plan stopping, loading and unloading positions in escape routes or
driveways.
• Do not plan stopping, loading and unloading positions on, next to or near
inclinations/slopes/gradients.
• To avoid shearing, stopping, loading and unloading positions must have a sufficient
distance from solid obstacles.
• Operating personnel must not intervene in the automated processes at stopping,
loading and unloading positions.
• Stairwells must be separated from the normal driving range by closed doors.
Keeping doors open, e.g. by blocking with wedges, is regarded as abuse.
• Stairs, doors, loading ramps, etc. must be at a sufficient distance from the
driveway and must be protected against traffic by barriers visible for the protective
field.
• Automatic doors and gates (e.g. roller shutters) must not be used jointly by the
AGV and persons.
• Work in the driving ranges, especially with ladders, must be avoided or secured
sufficiently (e.g. by a second person).
• Escape routes must not be constricted or even blocked by AGVs.
• Due to the danger of tripping, do not plan any waiting positions in walkways.
• When employees are in hazardous areas, or in sources or dips, e.g. between crate
stacks in a supermarket, e.g. in the case of maintenance work in supermarkets,
the affected areas must be secured. To do this, a barrier must be used that can
be recognized by the AGV, in combination with a definition of the work location
as a restricted area in the higher-level control system. Alternatively by setting the
operation of the AMS.
• A setting of the operation of the AMS must be checked on the affected AGV,
since the transmission of the stop command to the AGV does not take place as
a safety function.
• Protect the WLAN network from unauthorized access.
• When operating on your own server, protect the server from unauthorized access,
keep the operating system up to date.
After setting up ActiveShuttle, the operator is obliged to check all driveways again
for possible hazards!
• Provide safety-related instructions/training to the operating personnel
(see chapter 2.9 Training of the operating personnel) before the first
commissioning or recommissioning and afterwards regularly.
2.8.1 Minimum marking
CAUTION
Risk of injury due to incorrect behavior due to missing safety signs!
The ActiveShuttle is marked with the following safety labels:
Complies with 21 CFR 1040.10, 1040.11
& IEC 60825.1
LASER
1
Make sure that these safety labels are present and legible.

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2.9 Training of the operating personnel
2.9.1 Manual operation
• The responsibility for vehicle control in the "Manual" mode lies with the operator.
• The personal protection systems are deactivated in manual operation.
• The vehicle must always be operated in such a way that non-execution of the
driving commands (stopping or halting) is safe.
• The remote control must be protected against unauthorized use.
2.9.2 Logistics employees
• The driver of a manned vehicle must ensure that his vehicle does not drive into
the braking path of the ActiveShuttle. The driver must be given the opportunity to
become familiar with this area.
• The personnel driving the manned vehicles must be trained in the behavior of the
ActiveShuttle. In particular, the braking path and the behavior of the AGV must be
known.
• Keep sufficient distance from the future track of the AGV, slow down or stop if
necessary to avoid collisions with the AGV or crushing persons between your own
vehicle and the AGV.
2.9.3 Logistics planner
Safety zones and intersection areas must be defined during installation.
Tests after set-up
A newly created order must first be tested in the presence of a qualified person.
Route planning
Distance of the route from permanent or expected obstacles
The installer must plan a sufficient distance to permanent or expected obstacles on
the driveway (also bypassing zones with regard to free cornering, also taking into
account vehicle rotation and vehicle parts moving out). Expected obstacles are, for
example, pallets at a designated unloading position.
This serves for the
• Avoidance of shearing points (sufficient distance: 50 cm plus the accuracy of
the navigation in normal operation; less only if the operator can exclude certain
scenarios on a case-by-case basis) and
• Prevention of stepping into the protective field from the side. Sufficient distance:
to be determined by the operator depending on the concrete situation
(clarity, constriction, additional measures of the operator) and
• Avoidance of turning into an obstacle (sufficient distance: the same as "Avoidance
of shearing points")
Distance and speed at intersections/junctions
• The speed when passing junctions and crossings shall be reduced during set-up
where it is necessary to ensure sufficient responsiveness of the intersecting traffic
and to shorten the braking path.
• The distance to the intersecting paths must be large enough that a person will not
enter the track of the ActiveShuttle in the area of the protective field (protective
field length max. 970 mm).
ENGLISH

18/68 General notes on property and product damage
Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07
Unloading positions
• Do not plan unloading positions for free unloading outside the supermarket in the
immediate vicinity of gradients or ramps.
• Do not plan supermarkets in the immediate vicinity of gradients or ramps.
(Incorrectly extended dollies should not roll away uncontrolled, and an incorrectly
detected unloading position should not lead to unloading on gradients).
Gradients
• Driving routes must be planned in such a way that gradients are only used in the
direction of travel (forwards or backwards).
• Driveways must not be inclined sideways.
• Do not plan curves/turns on slopes/gradients.
• If necessary, define slow speed zones for slopes/gradients depending on the
actual load.
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 system.
• Never use solvents or corrosive cleaning agents.
• Do not use a pressure washer for cleaning.
During cleaning

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4 Scope of delivery
The scope of delivery includes the following, according to customer order:
• 3 842 560 431 ActiveShuttle 1.0 Transport vehicle incl. square spanner, mounted
lifting aid, operating instructions "ActiveShuttle 1.0 Transport vehicle"
• 3 842 560 106, Handheld Controller 1.0
• 3 842 560 422, Charging station ActiveShuttle 1.0 incl. operating instructions
"ActiveShuttle 1.0 Transport vehicle"
• 3 842 560 101, Lithium-ion battery incl. operating instructions
"ActiveShuttle 1.0 Transport vehicle"
4.1 Condition on delivery
• Transport vehicle ActiveShuttle 1.0 ready for use incl. lithium-ion battery and
installed lift aid
• Handheld controller 1.0 ready for connection
• Charging station ActiveShuttle 1.0 ready for connection
• Lithium-ion battery ready for connection
5 About this product
5.1 Specifications
5.1.1 Use
ActiveShuttle 1.0
• Automated material transport in production with operator-defined
–driving ranges
– loading and unloading points and
– speeds
in areas used jointly with passenger traffic.
• Transport of KLTs stacked on dollies with a
– total weight incl. dolly of up to 260 kg and a
– max. stacking height of 1,200 mm.
Handheld controller 1.0
To control the ActiveShuttle 1.0 in the "Manual" operating mode
Charging station ActiveShuttle 1.0
To charge the lithium-ion battery in the ActiveShuttle 1.0.
ENGLISH

20/68 About this product
Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07
5.2 Product description
Fig. 1:
560 592-01
B
A
F
J
E2
HI
F
E1
D
C
A
F
D
H
I
E1
F
G
L
K
J
T
B2
0% 100%50%
B1
B
ActiveShuttle 1.0
A: Control panel
B: Lithium-ion battery
48 V/17 Ah
(plugged in)
B1: Unlocking button
B2: Battery charge
indicator
Lithium-ion battery
with on/off button
C: Battery compartment
(flap with lock)
D: Loading area
E1: Personal protection
system (laser scanner)
E2: Personal protection
system (laser scanner)
and laser navigation
F: Warning signal lamps
G: Bluespot
H: Drive rollers
I: Cam rollers
J: Ventilation slots
K: Battery charging
contacts
L: Detection of dolly/
charging station
T: Lift aid with Velcro
strap, mounted to
ActiveShuttle in
condition on delivery
Battery charge
indicator (B2)
(display by pressing the
ON/OFF key)
Display State of charge [%]
 0 … 15 1)
 16 … 33
 34 … 50
 51 … 67
 68 … 83
 84 … 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.