OTTO MOTORS Lifter V1 User manual

OTTO Lifter V1 - OMM-000111
Operation and maintenance manual
OMM-000111
Publication date Jan-23
English

Copyright © 2023 CLEARPATH and OTTO Motors are trademarks of Clearpath Robotics Inc. All other
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 ............................................................................................................ 21
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 ............................................................................................................... 27
7.2. Emergency Stop buttons .............................................................................................. 28
7.3. Safety Reset button ..................................................................................................... 29
7.4. Auto button ................................................................................................................. 29
7.5. Digital interface ........................................................................................................... 30
7.6. Robot off checks ......................................................................................................... 30
7.7. Tiller ........................................................................................................................... 31
7.8. Forks .......................................................................................................................... 32
7.9. Robot battery state indicator ........................................................................................ 33
7.10. Light pipe and visual indications ................................................................................. 33
7.11. Safety Reset button states ......................................................................................... 36
7.12. Speakers .................................................................................................................. 36
7.13. Dome light ................................................................................................................ 36
7.14. Direction lights .......................................................................................................... 37
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 3

7.15. Lift points .................................................................................................................. 38
7.16. Top door ................................................................................................................... 38
7.17. Top rear door ............................................................................................................ 38
7.18. Left side door ............................................................................................................ 39
7.19. Right side door .......................................................................................................... 39
7.20. Rear door ................................................................................................................. 39
7.21. Safety LiDAR ............................................................................................................ 40
7.22. 3D perception cameras .............................................................................................. 41
7.23. Fork impact sensors .................................................................................................. 41
7.24. Dock assist sensors ................................................................................................... 41
7.25. Incremental encoders ................................................................................................ 41
7.26. Thermal detectors ..................................................................................................... 42
8. Basic usage ........................................................................................................................... 42
8.1. Locking-out/tagging-out the OTTO Lifter ....................................................................... 42
8.2. First time OTTO Lifter digital interface setup ................................................................. 43
8.3. Starting up the OTTO Lifter .......................................................................................... 44
8.4. Shutting down the OTTO Lifter ..................................................................................... 45
8.5. Replacing the OTTO Lifter battery ................................................................................ 45
8.6. Manually charging the OTTO Lifter ............................................................................... 49
8.7. Moving the OTTO Lifter V1 .......................................................................................... 50
8.8. Storing the OTTO Lifter ................................................................................................ 53
8.9. Connecting to a robot using an Ethernet cable .............................................................. 53
8.10. Connecting a robot to a network ................................................................................. 54
8.11. Adding a robot to a fleet ............................................................................................. 54
8.12. Autonomous operation ............................................................................................... 55
Enabling autonomous mode ....................................................................................... 55
Dispatching jobs ........................................................................................................ 56
Troubleshooting autonomous mode ............................................................................ 56
8.13. Manual mode operation ............................................................................................. 57
Enabling manual mode .............................................................................................. 57
Raising and lowering forks ......................................................................................... 58
Moving forward and backward .................................................................................... 58
Using the horn ........................................................................................................... 59
8.14. Robot dashboards ..................................................................................................... 59
Accessing robot dashboards ....................................................................................... 60
Interacting with jobs in a robot dashboard .................................................................... 60
Monitoring robot sensors in robot dashboard ............................................................... 61
8.15. Exceptions ................................................................................................................ 62
Accessing exceptions in OTTO Fleet Manager ............................................................ 62
Accessing exceptions in OTTO App ............................................................................ 63
Accessing exceptions in robot dashboard .................................................................... 63
Navigating exceptions ................................................................................................ 63
Filtering exceptions .................................................................................................... 64
9. Preventative maintenance ...................................................................................................... 64
9.1. Maintenance schedule ................................................................................................. 64
9.2. Circle check ................................................................................................................ 65
Robot off checks ........................................................................................................ 65
Robot on checks ........................................................................................................ 66
Checking the battery water level ................................................................................. 67
9.3. Monthly preventative maintenance ............................................................................... 67
Inspecting and replacing OTTO Lifter guarding ............................................................ 68
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 4

Inspecting string pots ................................................................................................. 68
9.4. 3-month preventative maintenance ............................................................................... 68
Lubricating the OTTO Lifter periodically ....................................................................... 68
9.5. 6-month preventative maintenance ............................................................................... 68
Brake inspection ........................................................................................................ 69
9.6. Annual preventative maintenance ................................................................................. 69
Inspecting and refilling hydraulic fluid .......................................................................... 69
10. Disposal .............................................................................................................................. 69
11. Troubleshooting ................................................................................................................... 69
12. Robot forklift pre-op checklist - OMM-000105 ......................................................................... 72
12.1. Robot forklift safety and operational checks ................................................................ 72
Robot off checks ........................................................................................................ 72
Robot on checks ........................................................................................................ 73
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
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 V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
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 V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
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 V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
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 V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
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 V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 10