Bosch Rexroth 3 842 560 099 User manual

Operating manual
3 842 560 081/2023-07
Replaces: –
ENGLISH
ACTIVE Shuttle
Transport vehicle
3842560099
3842560570
3842560107
3842560108
3842560206
3842560151
ENGLISH

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The information in these instructions is for product description purposes only. Any information in these instructions on how to
usethe product only constitutes examples and recommendations. Catalog information is not binding. The information given does
not exempt the user from the obligation of own judgment and verication. 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 conguration is shown on the title page. The delivered product may thus vary from the illustration.
The original operating manual is 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") 3 842 560 080 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 le for download from the Media Directory:
www.boschrexroth.com/mediadirectory
In the search mask (at the top right under "Search") enter 3 842 560 081, then click on "Search".
FR Les présentes instructions d‘utilisation sont disponibles dans les langues spéciées ici. Autres langues sur demande.
Téléchargeable en version imprimée ou en chier PDF à partir de la médiathèque:
www.boschrexroth.com/mediadirectory
Saisissez dans le champ de recherche (en haut à droite, sous "Search") 3 842 560 082 puis cliquez sur "Search".
IT Il presente manuale d’uso è disponibile nelle lingue qui indicate. Altre lingue su richiesta.
Possono essere scaricate come versione stampata o le PDF dalla Media Directory:
Inserire www.boschrexroth.com/mediadirectory
nella maschera di ricerca (in alto a destra, sotto "Search") 3 842 560 083 e poi fare clic su "Search".
ES El presente manual de instrucciones está disponible en los idiomas indicados. Otros idiomas a 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 3 842 560 084, a continuación haga clic en "Search".
PT O presente manual de operação 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") 3 842 560 086, e 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" 之下）中输入 3 842 560 087，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 560 080, poté klikněte na "Search".
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") MTPL 560 080, 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 560 080, majd kattintson a "Search" gombra.
RO Aceste instrucțiuni de utilizare sunt disponibile în limbile indicate aici. Versiuni în alte limbi la cerere.
Sub formă de versiune tipărită sau ca șier PDF pentru a  descărcat din directorul de conținuturi:
www.boschrexroth.com/mediadirectory
Introduceţi în masca de căutare (sus, în partea dreaptă, la "Search") MTRO 560 080, apoi faceţi clic pe "Search".
TR Bu kullanım kılavuzu burada belirtilmiş dillerde mevcuttur. Diğer diller talep üzerine sunulur.
Basılı versiyon veya PDF dosyası olarak medya dizininden indirilebilir:
www.boschrexroth.com/mediadirectory
Arama maskesine (sağ üstte, "Search" altında) MTTR 560 080 girin ve ardından "Search" alanına tıklayın.
FI Tämä käyttöohje on saatavilla tässä ilmoitetuilla kielillä. Muita kieliä pyynnöstä.
Painettuna versiona tai PDF-tiedostona ladattavaksi verkosta aineistohakemistosta:
www.boschrexroth.com/mediadirectory
Syötä hakuikkunaan (ylhäällä oikealla, kohtaan "Search") MTFI 560 080 ja valitse sitten "Search".
SV Föreliggande bruksanvisning är tillgänglig på de språk som anges här. Fler språk på förfrågan.
Som tryckt version eller som PDF-l för nedladdning ur mediakatalogen:
www.boschrexroth.com/mediadirectory
I sökrutan (längst upp till höger, under "Search") anger du MTSV 560 080 och klickar sidan på "Search".

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DE 3 842 560 080 print media ACTIVE Shuttle Transportfahrzeug Deutsch
EN 3 842 560 081 print media ACTIVE Shuttle Transport vehicle English
FR 3 842 560 082 print media ACTIVE Shuttle Véhicule de transport Français
IT 3 842 560 083 print media ACTIVE Shuttle Veicolo di trasporto Italiano
ES 3 842 560 084 print media ACTIVE Shuttle Vehículo de transporte Español
PT 3 842 560 086 print media ACTIVE Shuttle Veículo de transporte Português
ZH 3 842 560 087 print media ACTIVE Shuttle 导引车 中文
CS MTCS 560 080 media ACTIVE Shuttle Transportní vozidlo Česky
PL MTPL 560 080 media ACTIVE Shuttle Pojazd transportowy Polski
HU MTHU 560 080 media ACTIVE Shuttle Szállítójármű Magyar
RO MTRO 560 080 media ACTIVE Shuttle Vehicul de transport Română
TR MTTR 560 080 media ACTIVE Shuttle Taşıma arabası Türkçe
FI MTFI 560 080 media ACTIVE Shuttle Kuljetusajoneuvo Suomi
SV MTSV 560 080 media ACTIVE Shuttle Transportfordon Svenska
BG MTBG 560 080 media ACTIVE Shuttle Транспортен автомобил Български
HR MTHR 560 080 media ACTIVE Shuttle Transportno vozilo Hrvatski
NO MTNO 560 080 media ACTIVE Shuttle Transportkjøretøy Norsk
SL MTSL 560 080 media ACTIVE Shuttle Transportno vozilo Slovenščina
SK MTSK 560 080 media ACTIVE Shuttle Prepravné vozidlo Slovenčina
BG Настоящата инструкция за експлоатация е на разположение на следните езици. Други езици при запитване.
Като печатна версия или като PDF файл за изтегляне от медийната директория:
www.boschrexroth.com/mediadirectory
Въведете в прозореца за търсене (горе вдясно, на "Search") MTBG 560 080, след това щракнете върху "Search".
HR Ove upute za uporabu dostupne su na ovdje navedenim jezicima. Ostali jezici dostupni su na upit.
U ispisanom obliku (print) ili u obliku PDF datoteke (medij) za download iz popisa na stranici:
www.boschrexroth.com/mediadirectory
Upišite u praznu kućicu za pretraživanje (gore desno pod "Search") MTHR 560 080, zatim kliknite na "Search".
NO Den aktuelle bruksanvisningen er tilgjengelig på språkene angitt her. Flere språk på forespørsel.
Som trykt versjon eller som PDF-l som kan lastes ned fra mediemappen:
www.boschrexroth.com/mediadirectory
Gå til søkeboksen (øverst til høyre under "Search") og oppgi MTNO 560 080, og klikk deretter på "Search".
SL Ta navodila za uporabo so na voljo v tukaj navedenih jezikih. Ostali jeziki so na voljo na zahtevo.
Navodila so na voljo v tiskani različici ali kot datoteka PDF za prenos s seznama medijev:
www.boschrexroth.com/mediadirectory
V polje za iskanje (zgoraj desno pod "Search") vpišite MTSL 560 080, nato kliknite na "Search".
SK Predložený návod na obsluhu je k dispozícii v tu uvedených jazykoch. Ďalšie jazyky sú k dispozícii na vyžiadanie.
Ako tlačená verzia alebo ako PDF súbor na stiahnutie z adresára médií:
www.boschrexroth.com/mediadirectory
Do vyhľadávacieho okna (hore vpravo, pod "Search") zadajte MTSK 560 080 potom kliknite na "Search".
ENGLISH

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4/100Contents
1 About this documentation 6
1.1 Validity of the documentation 6
1.2 Required and supplementary documentation 6
1.3 Presentation of information 7
1.3.1 Warnings and safety instructions 7
1.3.2 Symbols 8
1.3.3 Designations 8
2 Safety instructions 9
2.1 About this chapter 9
2.2 Intended use 9
2.3 Improper use 10
2.4 Personnel qualications 10
2.5 General safety instructions 10
2.6 Product-specic safety instructions 11
2.6.1 ACTIVEShuttle 12
2.6.2 Lithium-ion batteries 15
2.6.3 Handheld controller 17
2.6.4 Charging station 18
2.7 Personal protective equipment 19
2.8 Owner responsibilities/obligations 19
2.8.1 Minimum marking 21
2.9 Training of the operating personnel 22
2.9.1 Manual operation 22
2.9.2 Logistics employees 22
2.9.3 Logistics planner 22
3 General notes on property and product damage 23
4 Scope of delivery 24
4.1 Condition on delivery 24
5 About this product 24
5.1 Specications 24
5.1.1 Use 24
5.2 Product description 25
5.3 Safety and warning devices 30
5.3.1 Signaling 31
5.3.2 Protective elds 32
5.3.3 Reference to limits of the personal protection system 32
5.4 Touchscreen display 33
5.5 Identication of the product 35
6 Transport and storage 35
6.1 Transporting the product 35
6.1.1 Mounting/removing the lift aid 36
6.2 Storing the product 36
7 Installation 37
7.1 Ambient conditions 37
7.2 Required tools 37
7.3 Symbols used 37
7.4 Unpacking the charging station 37
7.5 Positioning/preassembling the charging station 38
7.5.1 Connecting the charging station electrically 43
7.6 Unpacking the ACTIVEShuttle 45
8 Commissioning 46
8.1 Emergency measure pressing emergency stop device 46
8.2 Emergency measure removing lithium-ion battery 47
8.3 Initial commissioning 50
Contents

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8.3.1 Switching on the ACTIVEShuttle 53
8.3.2 Switching to "Manual" operating mode 54
8.3.3 Checking the lower and upper loading area height
and adjusting it, if necessary 55
8.3.4 Moving the ACTIVEShuttle to the charging station
with the handheld controller 56
8.3.5 Fully charge the ACTIVEShuttle 56
8.3.6 Moving the ACTIVEShuttle manually 57
8.3.7 Raising/lowering the loading area without handheld controller 58
8.3.8 Switching off the ACTIVEShuttle 58
8.3.9
Mounting safety ags (accessories, not included in the scope of delivery) 59
8.3.10 IT setup 59
8.4 Re-commissioning after astandstill 59
8.5 Preparing the supermarket 60
8.5.1 Permissible dollies 62
9 Operation 63
9.1 Information on operation 63
9.1.1 ACTIVEShuttle 63
9.1.2 Lithium-ion batteries 66
9.1.3 Handheld controller 68
9.1.4 Charging station 68
9.1.5 Wear 69
9.1.6 Measures to reduce wear 69
9.1.7 Environmental factors 69
10 Maintenance and repair 70
10.1 Cleaning and care 71
10.2 Regular safety inspections 72
10.2.1 Periodic inspection - minimum requirements 73
10.3 Procedure for testing the personal protection systems (laser scanner) 74
10.3.1 Checking the basic function of the personal protection systems
(laser scanner) 74
10.3.2 Checking the areas to be protected 74
10.4 Checking the optical and acoustic safety equipment 74
10.5 Maintenance 75
10.6 Replacement of wear parts 77
10.6.1 Replacing lter mats of the fan 77
10.6.2 Replacing the cam rollers 79
10.6.3 Replacing the anti-slip mat of the loading area 80
10.6.4 Replacing the lithium-ion battery 81
11 Decommissioning 82
11.1 Preparing the product for storage/later use 82
12 Disposal 82
13 Upgrading and modication 83
14 Troubleshooting 83
15 Service 84
16 Technical data 85
16.1 ACTIVE Shuttle 85
16.2 Lithium-ion battery 86
16.3 Charging station 86
16.4 Ambient conditions 87
16.5 IT infrastructure 87
16.6 Floor requirements 88
16.7 Load distribution on the loading area 89
16.8 Scanning levels of the personal protection systems (laser scanner) 91
16.9 Protective elds 92
16.9.1 Front protective elds 92
16.9.2 Rear protective elds 94
16.10 Stereo camera elds for 3D obstacle detection 96
ENGLISH

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BoschRexrothAG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07
1 About this documentation
1.1 Validity of the documentation
This documentation applies to the following products:
• 3842560099, ACTIVE Shuttle 2.1 transport vehicle
•3842560151, ACTIVE Shuttle AMR transport vehicle
• 3842560570, lithium ion battery
• 3842560206, handheld controller
• 3842560107, charging station ACTIVE Shuttle 2.1
• 3 842 560 108, assembly frame for charging station ACTIVE Shuttle 2.1
This documentation is intended for tters, 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
Declaration of conformity
ACTIVEShuttle 2.11)
3842560085
Wall box2) Manufacturer documentation
Handheld controller3) Manufacturer documentation Manual
Battery safety instructions4) Manufacturer documentation
Assembly instructions adapter
cable wall box ‒ battery 1)
3 842 560 088 Assembly
instructions
Manual AMR RB02831888 Manual
Manual AMS RB02831885 Manual
Manual VDA 5050 RB02831992 Manual
1) If not included in the scope of delivery, download from the website:
www.boschrexroth.com
2) If not included in the scope of delivery, download from the manufacturer's website:
www.axima-power.com
3) If not included in the scope of delivery, download from the manufacturer's website:
www.keba.com
4) If not included in the scope of delivery, download from the manufacturer's website:
[email protected]
AMR RB02831888 manual
This manual explains the AMR (Autonomous Mobile Robot) and its functionalities.
This manual provides information on conguration and operation of the
ACTIVE Shuttle.

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AMS RB02831885 manual
In this manual you will nd the hardware and software requirements of the
Rexroth ACTIVE Shuttle Management System AMS, how to install the software
and which features are included. It explains how to integrate the ACTIVE Shuttle
and set up a complete use case.
VDA 5050 RB02831992 manual
This manual is intended for the integration and control of the AMR via the
VDA 5050 interface. It is aimed at people who want to connect ACTIVE Shuttle
to an external eet management system, for example.
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 Warnings and safety instructions
This document contains safety instructions in chapter2.6 "Product-specic
safety instructions" and chapter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.
Warnings are structured 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 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.
ENGLISH

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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.
1.3.3 Designations
This document uses the following designations:
Table 4: Designations
Designation Meaning
AMR Autonomous Mobile Robots
AMS Rexroth ACTIVEShuttle Management System
FTS Automated Guided Vehicle system
KLT Small load carrier according to VDA 4500
Source Loading point
Dip Unloading point
VDA German Association of the Automotive Industry

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2 Safety instructions
2.1 About this chapter
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 chapter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
ACTIVE Shuttle
The product is acomplete machine.
You may use the product as follows:
• For automated material transport in production with operator-dened
– driving ranges
– loading (sources) and unloading points (dips)
– speeds
in areas used jointly with passenger trafc.
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.
• For permissible load dimensions, load positioning and load distribution,
see page 89.
• Technical data seepage 85.
• For ambient conditions, seepage87.
Handheld controller
The handheld controller is used in the "Manual" operating mode exclusively for
controlling the ACTIVE Shuttle.
ENGLISH

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Charging station ACTIVE Shuttle
The charging station is used exclusively for charging the ACTIVE Shuttle.
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 chapter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:
• Installation and operation in potentially explosive atmospheres/Ex zones.
• Transporting goods other than those specied.
• Transporting people on the product or transported material.
• Private use.
• The charging station must not be used as astepladder or climbing aid.
2.4 Personnel qualications
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 qualied personnel or by
an instructed person acting under the direction of such aperson.
"Qualied 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. Qualied personnel must comply with the relevant technical
regulations and have the necessary expertise.
BoschRexroth offers training support for specialized elds. You can nd 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, re protection 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.
• Observe all the notices on the product.
• Persons who assemble, operate, disassemble or maintain Rexroth products
should not be under the inuence 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.

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• Observe the technical data and ambient conditions specied 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.
2.6 Product-specic 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.
• De-energize the vehicle during transport (switch off the battery main switch).
• 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 commissioning 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 rectied the cause of the fault.
• Make sure that access to maintenance and inspection points is kept unobstructed.
• Perform the prescribed maintenance use at the intervals specied in chapter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 commissioning
During operation
EMERGENCY STOP,
malfunction
During servicing and repair
During disposal
ENGLISH

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2.6.1 ACTIVEShuttle
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 every quarter.
Carry out atest of the safety equipment in accordance with the test cycles
specied in chapter 10.2.
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 ACTIVEShuttle!
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 ACTIVEShuttle.
• If possible, do not stay within the driving range of the ACTIVEShuttle.
• Restrict passenger trafc within the ACTIVEShuttle's driving range as
much as possible.
• Always wear safety shoes.
Insufcient stopping distance, e.g.by entering the protective area from
the side!
Risk of serious injury from collision with the ACTIVEShuttle.
• Do not step into the protective area of the vehicle from the side.
• Do not move against the direction of travel towards the ACTIVEShuttle.
• 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 ACTIVEShuttle must be reduced in narrow corridors, curves,
intersections and areas with passenger trafc.

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CAUTION
Danger of the ACTIVEShuttle tipping over if loaded incorrectly!
Risk of serious injury due to the ACTIVEShuttle tipping over.
 Observe the permissible load and the maximum stacking height.
 Ensure that the load is evenly distributed (seechapter16.7).
Only use the ACTIVEShuttle 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 ACTIVEShuttle in accordance with its intended use.
Danger from unpredictable movements of the ACTIVEShuttle due to
insufcient ground conditions!
Risk of serious injuries due to unpredictable movements of the ACTIVEShuttle,
e.g.slipping, especially during emergency braking.
The driving range of the ACTIVEShuttle must have sufcient traction.
The driving range of the ACTIVEShuttle must be level, dry, clean and free of
objects lying around.
Danger from dirty driveways!
Risk of serious injury from unpredictable movements of the ACTIVEShuttle due
to dirty driveways.
The driving range of the ACTIVEShuttle 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 ACTIVEShuttle may only be operated by
specially trained staff using the handheld controller.
The responsibility for vehicle control in "Manual" operating 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 ACTIVEShuttle can be damaged by obstacles outside the protective area.
Keep the driving range free of obstacles, especially at objects or objects
protruding into the driving range.
ENGLISH

14/100 Safety instructions
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CAUTION
Risk of overheating of the ACTIVEShuttle!
If the ventilation slots of the ACTIVEShuttle are covered or if the lter mats of
the fans are not maintained, there is arisk of overheating and thus damage to the
ACTIVEShuttle.
The ventilation slots of the ACTIVEShuttle must always be free and uncovered
to ensure sufcient cooling.
The lter mats of the fans must be maintained regularly depending on the
ambient/operating conditions (see chapter 10.5).
NOTICE
Risk of damage through unauthorized use!
Unauthorized opening of the ACTIVEShuttle housing can damage the vehicle.
Always keep the square key secured against unauthorized use.

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2.6.2 Lithium-ion batteries
CAUTION
Possible hazard due to incorrect handling of lithium-ion batteries!
The ACTIVEShuttle 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 re.
• Leakage of corrosive liquid and thus possible skin irritations,
burns and chemical burns.
• Increased re hazard due to electrolyte leakage
(ammable 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 ACTIVEShuttle, 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-specic 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re-resistant container or at asafe
distance from combustible materials.
• Do not inhale any vapors that may be generated.
ENGLISH

16/100 Safety instructions
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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 re-resistant containers.
During transport, observe the relevant hazardous goods requirements for
lithium-ion batteries.
Observe the operating manual of the manufacturer:
VARTA AG
VARTA-Platz1
73479 Ellwangen/Germany
[email protected]om
Recommendations for best possible battery service 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.

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2.6.3 Handheld controller
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 ACTIVEShuttle may only be operated by
specially trained staff using the handheld controller.
The responsibility for vehicle control in "Manual" operating 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
NOTICE
Loss of operational readiness due to non-use
If the handheld controller is not used and charged regularly, this may lead to loss
of the operational readiness (battery discharge).
Use the handheld controller regularly to charge it.
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 ACTIVEShuttle 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 elds.
ENGLISH

18/100 Safety instructions
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2.6.4 Charging station
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 16 Acircuit breaker, triggering
characteristic 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 re.
Do not place any objects, especially electrically conductive or ammable
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!
Observe the operating manual of the manufacturer:
AXIMA, spol. s r.o.
Vídeňská 204/125
CZ - 619 00
Brno
Anchor the charging station in the hall oor to avoid malfunctioning and
associated risks.
Route the connection cable according to the country-specic specications
for avoiding risks.
Protect the connecting cables from mechanical damage.
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 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-tting 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 the ACTIVE Shuttle is obliged to comply with all requirements of
• DIN EN ISO 3691-4 "Industrial trucks ‒ Safety requirements and verication ‒
Part 4: Driverless industrial trucks and their systems"; Annex A "Requirements for
preparation of the operating zones"
• Guideline VDI 2510 Part 1 "Infrastructure and peripheral installations for
Automated Guides Vehicle Systems (AGVS)"
• Guideline VDI 2510 Part 2 "Automated Guided Vehicle Systems (AGVS) ‒ Safety of
AGVS"
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 trafc in hazardous areas.
• Attaching warning notices in hazardous areas.
• Ensuring sufcient distance when driving past junctions, if necessary reduced
speed.
• Further measures after evaluation of the user to prevent stepping into the
protective eld from the side, e.g.
- installing mirrors at narrow junctions,
- providing doors at junctions,
- information on the function of the Bluespot of ACTIVE Shuttle,
- information on the function of the warning tones for narrow 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, dene slow speed zones for slopes/gradients depending on the
actual load.
• Plan escape routes between routes and obstacles in accordance with national
standards and regulations.
• 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 ACTIVE Shuttles must not lead to consequential hazards
(e.g.due to falling load).
• Passageways must be designed in such away that there is sufcient
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 ACTIVE Shuttle must be planned at asufcient 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 16.6 Floor requirements.
ENGLISH

20/100 Safety instructions
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• After cleaning the hall oor, the surface nish 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 eld (seechapter16.8 Scanning levels of the personal protection
systems (laser scanner)).
• Driveways must be free of projecting obstacles.
• In the event of amalfunction, collisions with obstacles next to and on driveways
must not lead to consequential hazards.
• After amalfunction, restarting next to or on driveways must not lead to hazards.
• Faulty or defective ACTIVE Shuttle 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sufcient 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sufcient distance from the
driveway and must be protected against trafc by barriers visible for the
protective eld.
• Automatic doors and gates (e.g.roller shutters) must not be used jointly by the
ACTIVE Shuttle and persons.
• Work in the driving ranges, especially with ladders, must be avoided or secured
sufciently (e.g.by asecond person).
• Escape routes must not be constricted or even blocked by ACTIVE Shuttle.
• 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 use in supermarkets,
the affected areas must be secured. To do this, abarrier must be used that can
be recognized by the ACTIVE Shuttle, in combination with adenition of the work
location as arestricted area in the higher-level control system. Alternatively by
setting the operation of the AMS / external eet management system.
• Setting of the operation of the AMS / external eet management system must
be checked on the affected ACTIVE Shuttle since the transmission of the stop
command to the ACTIVE Shuttle does not take place as asafety function.
• Protect the WIFI network from unauthorized access.
• When operating on your own server, protect the server from unauthorized access,
keep the operating system up to date.
• Upon new commissioning of additional ACTIVEShuttles, they are not yet entered
in the AMS / external eet management system and therefore not known to the
already autonomous ACTIVEShuttles (e.g.if the additional ACTIVEShuttles
have been pushed manually into acharging station). The operator must
take appropriate measures to prevent dangerous states and damage to the
ACTIVEShuttle.
After setting up ACTIVEShuttle, 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 rst
commissioning or recommissioning and afterwards regularly.