Otto motors Lifter mkiv User manual

OTTO Lifter MkIV - OMM-000108

Operation and maintenance manual

OMM-000108

Publication date Jan-23

English

product and company names listed are trademarks or trade names of their respective companies. The

information provided herein is for general guidance only and is subject to change. For support, please

contact your sales or customer success representative.

TABLE OF CONTENTS

1. IMPORTANT SAFETY INFORMATION ..................................................................................... 6

1.1. Hazards ....................................................................................................................... 6

General hazards ......................................................................................................... 7

Robot hazards ............................................................................................................ 8

Charger hazards ......................................................................................................... 9

1.2. Hazard labels .............................................................................................................. 10

1.3. Safety awareness ........................................................................................................ 12

Facility conditions ...................................................................................................... 13

Payload maximums and stability ................................................................................. 14

Battery handling ........................................................................................................ 15

Overhang and underhang detection ............................................................................ 15

Safety system functionality ......................................................................................... 16

Perception sensor layout ............................................................................................ 16

Emergency stop system ............................................................................................. 17

Safety stop system .................................................................................................... 17

Zone-specific behavior ............................................................................................... 17

Robot modes ............................................................................................................. 17

Footprint safety .......................................................................................................... 18

1.4. Disclaimer ................................................................................................................... 19

2. Intended use .......................................................................................................................... 19

3. Introduction ........................................................................................................................... 19

3.1. Included items ............................................................................................................. 20

4. Applicable documents ............................................................................................................ 22

5. In case of a collision ............................................................................................................... 22

6. OTTO Lifter specifications ...................................................................................................... 23

6.1. Size and weight ........................................................................................................... 23

6.2. Speed and performance .............................................................................................. 24

6.3. Battery and power system ............................................................................................ 25

6.4. Control system ............................................................................................................ 25

6.5. Interfacing and communication ..................................................................................... 25

6.6. Operating environment ................................................................................................ 26

6.7. Safety system ............................................................................................................. 27

7. Components overview ............................................................................................................ 27

7.1. Components ............................................................................................................... 28

7.2. Power button .............................................................................................................. 30

7.3. Emergency Stop buttons .............................................................................................. 30

7.4. Safety Reset button ..................................................................................................... 30

7.5. Auto button ................................................................................................................. 31

7.6. Digital interface ........................................................................................................... 31

7.7. Tiller ........................................................................................................................... 31

7.8. Robot battery state indicator ........................................................................................ 32

7.9. Light pipe and visual indications ................................................................................... 33

7.10. Safety Reset button states ......................................................................................... 35

7.11. Speakers .................................................................................................................. 36

7.12. Dome light ................................................................................................................ 36

7.13. Direction lights .......................................................................................................... 37

7.14. Lift points .................................................................................................................. 37

OTTO Lifter MkIV - OMM-000108

All other product and company names listed are trademarks or trade names of their respective companies. 3

7.15. Top door ................................................................................................................... 37

7.16. Left side door ............................................................................................................ 38

7.17. Safety LiDAR ............................................................................................................ 38

7.18. 3D perception cameras .............................................................................................. 38

7.19. Fork impact sensors .................................................................................................. 39

7.20. Dock assist sensors ................................................................................................... 39

7.21. Incremental encoders ................................................................................................ 39

8. Basic usage ........................................................................................................................... 39

8.1. Locking-out/tagging-out the OTTO Lifter ....................................................................... 40

8.2. Starting up the OTTO Lifter .......................................................................................... 41

8.3. Shutting down the OTTO Lifter ..................................................................................... 42

8.4. Replacing the OTTO Lifter battery ................................................................................ 42

8.5. Manually charging the OTTO Lifter ............................................................................... 46

8.6. Storing the OTTO Lifter ................................................................................................ 47

8.7. Connecting to a robot using an Ethernet cable .............................................................. 47

8.8. Connecting a robot to a network ................................................................................... 48

8.9. Adding a robot to a fleet ............................................................................................... 48

8.10. Autonomous operation ............................................................................................... 49

Enabling autonomous mode ....................................................................................... 49

Dispatching jobs ........................................................................................................ 50

Troubleshooting autonomous mode ............................................................................ 50

8.11. Manual mode operation ............................................................................................. 51

Enabling manual mode .............................................................................................. 51

Raising and lowering forks ......................................................................................... 52

Moving forward and backward .................................................................................... 53

Using the horn ........................................................................................................... 54

8.12. Exceptions ................................................................................................................ 54

Accessing exceptions in OTTO Fleet Manager ............................................................ 54

Accessing exceptions in OTTO App ............................................................................ 54

Navigating exceptions ................................................................................................ 55

Filtering exceptions .................................................................................................... 55

9. Preventative maintenance ...................................................................................................... 55

9.1. Maintenance schedule ................................................................................................. 56

9.2. Circle check ................................................................................................................ 56

Robot off checks ........................................................................................................ 57

Robot on checks ........................................................................................................ 57

Checking the battery water level ................................................................................. 58

9.3. Monthly preventative maintenance ............................................................................... 59

Inspecting and replacing OTTO Lifter guarding ............................................................ 59

Inspecting string pots ................................................................................................. 60

9.4. 3-month preventative maintenance ............................................................................... 60

Lubricating the OTTO Lifter periodically ....................................................................... 60

9.5. 6-month preventative maintenance ............................................................................... 60

Brake inspection ........................................................................................................ 60

9.6. Annual preventative maintenance ................................................................................. 60

Inspecting and refilling hydraulic fluid .......................................................................... 60

10. Disposal .............................................................................................................................. 61

11. Troubleshooting ................................................................................................................... 61

12. Declarations ........................................................................................................................ 63

12.1. SUPPLIER'S DECLARATION OF CONFORMITY ........................................................ 63

OTTO Lifter MkIV - OMM-000108

All other product and company names listed are trademarks or trade names of their respective companies. 4

12.2. CAN ICES-003(A) / NMB-003(A) ................................................................................ 64

13. Robot forklift pre-op checklist - OMM-000105 ......................................................................... 64

13.1. Robot forklift safety and operational checks ................................................................ 64

Robot off checks ........................................................................................................ 64

Robot on checks ........................................................................................................ 65

OTTO Lifter MkIV - OMM-000108

All other product and company names listed are trademarks or trade names of their respective companies. 5

1. IMPORTANT SAFETY INFORMATION

The top priority of OTTO Motors is the safety of its users. OTTO Motors produces high power and

fast-moving pieces of machinery that could cause serious injury, including death, if improperly used or

maintained. Additional hazards may be identified and need to be addressed during the site-specific risk

assessment.

Review the safety messages and all instructions before using the product. Save this document for

reference.

WARNING

Failure to follow operating instructions may result in death or serious injury.

• Read and understand the operation and maintenance manual before using the robot,

charger, or attachment.

• For the physical location of elements on the product, refer to the Component Overview

section of the operation and maintenance manual.

1.1. Hazards

The following are examples of hazard notices:

DANGER

Failure to follow these instructions will result in SERIOUS INJURY, INCLUDING DEATH.

WARNING

Failure to follow these instructions may result in SERIOUS INJURY, INCLUDING DEATH.

CAUTION

Failure to follow these instructions may result in MINOR or MODERATE INJURY or

DAMAGE to the system and/or property.

OTTO Lifter MkIV - OMM-000108

All other product and company names listed are trademarks or trade names of their respective companies. 6

General hazards

WARNING

• BURN or SHOCK HAZARD! Never use this product if the enclosure or any of the

connectors are broken, cracked, open, or show any other indication of damage.

• SHOCK HAZARD! Always perform the lock-out/tag-out procedure at the facility or on

the product before inspecting, servicing, cleaning, removing components, or opening

any enclosure.

• FIRE HAZARD! Observe all safety precautions when using flammable fluids.

• CRUSH HAZARD! Keep a safe distance from suspended loads.

• Always be aware of operation limitations such as floor grades, negative and

overhanging obstacles, and the LiDAR obstacle detection plane.

• FIRE OR SHOCK HAZARD! Never use a power cord or cable that appears damaged.

CAUTION

• Never operate the product after faulty parts are identified.

• Never expose OTTO Motors products to rain, condensation, or standing water. Store

products in a clean and dry location.

• Use appropriately rated lift equipment and follow safe lifting procedures as defined by

the facility when lifting the product.

• Wear appropriate safety equipment when operating or working around the product.

• TRIP HAZARD! Take care when walking around the product.

• Only qualified personnel should perform installations, maintenance, and inspections.

• Only use the attachments, accessories, tools, replacement parts, and cleaning

products approved by OTTO Motors.

• Installation must be performed by an electrically qualified person to ensure compliance

with local electrical codes.

• PINCH HAZARD! Keep objects and body parts away from pinch points.

• FIRE HAZARD! Observe all safety precautions when using flammable fluids.

OTTO Lifter MkIV - OMM-000108

All other product and company names listed are trademarks or trade names of their respective companies. 7

Robot hazards

WARNING

• Always use level rigging when lifting or lowering the product.

• IMPACT HAZARD! Never bypass the drive wheels of the robot while on a sloped

surface.

• Never use OTTO Motors products to transport people or live animals.

• CRUSH or IMPACT HAZARD! Robots must be prevented from traveling in areas that

do not follow Facility Conditions specifications, such as ramps and stairwells.

• FIRE HAZARD! If the battery is damaged or a battery fire occurs, contact local

emergency services and vacate the area. Do not use water to douse the fire.

• FIRE OR SHOCK HAZARD! Never use a power cord or cable that appears damaged.

• SHOCK HAZARD! Never attempt operation if the power supply is not within the

specified voltage and current, as identified in the product documentation.

• FIRE HAZARD! Observe all safety precautions when using flammable fluids.

• CRUSH HAZARD! Pedestrians should be aware of hazard mode or docking mode

audio-visual indications. When robots are in docking mode, the front of the robot is

no longer safeguarded—personnel must be restricted from areas where robots will be

docking. When robots are in hazard mode, the region safeguarded by LiDAR safety

scanners is reduced in size. Under rare circumstances, robots can get mislocalized

and enter docking hazard mode in an unintended location. For audio-visual indicator

identification, refer to the Component Overview section of the robot operation and

maintenance manual.

• CRUSH HAZARD! Payloads, attachments, or a combination thereof, should always

remain within the stability envelope relevant to the specific robot model. For payload

constraints, refer to the System Specifications for the product.

• CRUSH/PINCH HAZARD! Manual or automatic load transfer may introduce a crush or

pinch hazard. Take care when performing a manual load transfer. A risk assessment

should be conducted to mitigate hazard risk when designing load transfer systems.

• CRUSH or IMPACT HAZARD! All stairwells or similarly open holes must be marked

and surrounded by obstacles exceeding 20 cm in height with spacing no greater than

30 cm. These obstacles must be able to withstand 2000 N of force without failing or be

at least 70 mm wide from all directions and visible to the LiDAR.

OTTO Lifter MkIV - OMM-000108

All other product and company names listed are trademarks or trade names of their respective companies. 8

CAUTION

• IMPACT HAZARD! Always maintain a safe distance from a robot in operation. A

robot being operated in manual mode should only be operated by personnel who

have been trained and authorized according to the standards of the facility in which

the robot is in use. Be aware of the Emergency Stop button locations. For button

location information, refer to the Component Overview section of the robot operation

and maintenance manual.

• IMPACT HAZARD! While driving the robot in manual mode, the safety field sets

monitored by the LiDAR scanners can be disabled. To avoid impact, be aware of the

robot's surroundings.

• Avoid making contact with the LiDAR safety sensors as they are fragile and easily

damaged. For sensor locations, refer to the Component Overview section of the robot

operation and maintenance manual.

• Do not expose the product for a prolonged period to temperatures outside the ranges

specified in the product documentation.

• IMPACT HAZARD! Do not place anything on the robot that extends beyond

its footprint. Refer to the robot Safety Configuration document for the footprint

dimensions.

• CRUSH or IMPACT HAZARD! Keep low profile objects that the LiDAR cannot detect,

such as forklift tines and pallets, outside of the robot's path. For sensor layouts, refer

to the Component Overview section of the robot operation and maintenance manual.

• BURN HAZARD! Allow the product to cool before performing maintenance.

• Do not connect the robot to a manual charger and an automatic charger at the same

time as this can result in damage to either charger.

• SHOCK HAZARD! Improper use or maintenance of robot batteries may result in a high

energy discharge.

• Never exceed the maximum total payload constraints of the product. For payload

constraints, refer to the System Specifications for the product.

• CRUSH HAZARD! Objects can fall from the product. Where possible, secure loads to

the product to avoid falling, tipping, shifting, or sliding.

Charger hazards

For instructions on connecting the robot to a charger, refer to the charging information in the Basic Usage

section of the product operation and maintenance manual.

OTTO Lifter MkIV - OMM-000108

All other product and company names listed are trademarks or trade names of their respective companies. 9

WARNING

• FIRE OR SHOCK HAZARD! Never use a power cord or cable that appears damaged.

• SHOCK HAZARD! Automatic chargers are powered by hazardous voltage levels. Do

not touch the charge contacts when the product is in operation.

• Chargers must be installed with a disconnect that electrically isolates the charger and

functions as an emergency switch.

• FIRE HAZARD! If the battery is damaged or a battery fire occurs, contact local

emergency services and vacate the area. Do not use water to douse the fire.

• SHOCK HAZARD! Never attempt operation if the power supply is not within the

specified voltage and current, as identified in the product documentation.

CAUTION

• CRUSH HAZARD! Always maintain a safe distance from a charger in operation.

• SHOCK HAZARD! Improper use or maintenance of robot batteries may result in a high

energy discharge.

• Installation must be performed by an electrically qualified person to ensure compliance

with local electrical codes.

• Do not connect the robot to a manual charger and an automatic charger at the same

time as this can result in damage to either charger.

• BURN HAZARD! Allow the product to cool before performing maintenance.

• TRIP OR FIRE HAZARD! Position all cables where they cannot contact hot surfaces,

be pulled, tripped over, or damaged.

• Never disconnect the system while it is under electrical load.

• GROUNDING ELECTRICAL HAZARD! The power supply for the charger must be

grounded.

• FIRE HAZARD! Chargers and batteries must only be used in a well-ventilated area

and must be easily accessible.

• FIRE HAZARD! Never smoke, use power tools, or perform any activity that can create

sparks around a battery or charger.

1.2. Hazard labels

Review the following to learn more about the labels that may be used on OTTO Motors products. Hazards

can also apply to attachments and accessories used in conjunction with an OTTO Motors product.

OTTO Lifter MkIV - OMM-000108

All other product and company names listed are trademarks or trade names of their respective companies. 10

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