Bosch REXROTH ActiveShuttle 1.0 Bedienungsanleitung

Operating manual

3 842 560 593/2020-07

Replaces: 2020/02

ENGLISH

ActiveShuttle 1.0

Transport vehicle

3 842 560 431

3 842 560 106

3 842 560 422

3 842 560 101

ENGLISH

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Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07

The information in this manual is for product description purposes only. Any information in this manual on how to use the product only

constitute examples and recommendations. Catalog information is not binding. The information given does not exempt the user from

the obligation of own judgment and veriﬁcation. Our products are subject to natural wear and aging.

or distributed to third parties without our consent.

An example conﬁguration is shown on the title page. The delivered product may thus vary from the illustration.

The original assembly instructions are in German.

DE Die vorliegende Montageanleitung ist in den hier angebenen Sprachen verfügbar. Weitere Sprachen auf Anfrage.

Als gedruckte Version oder als PDF-Datei zum Download aus dem Medienverzeichnis:

www.boschrexroth.com/medienverzeichnis

Geben Sie in die Suchmaske (oben rechts, unter „Suche“) 3 842 560 592 ein, dann klicken Sie auf „Suche“.

EN These assembly instructions are available in the languages indicated here. Other languages on request.

They come in a hard copy or a PDF ﬁle that can be downloaded from the media directory:

www.boschrexroth.com/mediadirectory

In the search mask (at the top right under “Search”) enter 3 842 560 593, then click on “Search”.

FR Les présentes instructions de montage sont disponibles dans les langues suivantes. Autres langues sur demande.

Disponible au téléchargement en version imprimée ou en ﬁchier PDF à partir du répertoire médias :

www.boschrexroth.com/mediadirectory

Saisissez dans le champ de recherche (en haut à droite, sous « Search ») 3 842 560 594 puis cliquez sur « Search ».

IT Le presenti istruzioni di montaggio sono disponibili nelle lingue indicate qui. Altre lingue su richiesta.

Possono essere scaricate come versione stampata o ﬁle PDF dalla Media Directory:

www.boschrexroth.com/mediadirectory

Inserire nella maschera di ricerca (in alto a destra, sotto “Search”) 3 842 560 595 e poi fare clic su “Search”.

ES Las presentes instrucciones de montaje están disponibles en los idiomas indicados. Otros idiomas a petición.

Las instrucciones están disponibles como versión impresa o como archivo PDF para descargar del archivo de medios:

www.boschrexroth.com/mediadirectory

En el buscador (en la parte superior derecha, en “Search”) introduzca 3 842 560 596, a continuación haga clic en “Search”.

PT O presente manual de montagem está disponível nos idiomas aqui indicados. Demais idiomas, sob consulta.

Como versão impressa ou o arquivo PDF para download no diretório de mídias: www.boschrexroth.com/mediadirectory

Insira a máscara de pesquisa (parte superior direita, em “Search”) 3 842 560 597, e clique em “Search”.

ZH 本安装说明书有这里给出的语言版本。还可按照需求提供其他语言版本。

有印刷版本或电子版本 PDF 文件供使用，电子版文件可在下列的公司网站媒体网页上下载： www.boschrexroth.com/mediadirectory

在搜索窗口（右上角，“Search”之下）中输入 3 842 560 598，然后点击“Search”。

CS Tento montážní návod je k dispozici v uvedených jazycích. Další jazykové verze na vyžádání.

Jako tištěná verze nebo jako soubor ve formátu PDF ke stažení z adresáře médií: www.boschrexroth.com/mediadirectory

Zadejte do vyhledávacího políčka (vpravo nahoře, pod „Search“) MTCS 560 592, poté klikněte na „Search“.

PL Niniejsza instrukcja montażu dostępna jest w podanych tutaj wersjach językowych. Inne wersje językowe na zapytanie.

W wersji drukowanej lub jako plik PDF do pobrania w wykazie mediów: www.boschrexroth.com/mediadirectory

W polu wyszukiwania (na górze z prawej strony, w polu „Search”) MTPL 560 592, a następnie kliknąć „Search”.

HU A jelen szerelési utasítás az itt megadott nyelveken áll rendelkezésre. További nyelvek rendelésre.

Nyomtatott változatként vagy a médiakönyvtárból letölthető PDF-fájlként: www.boschrexroth.com/mediadirectory

Írja be a keresőmezőbe (jobbra fent, a „Search” alatt): MTHU 560 592, majd kattintson a „Search” gombra.

RO Aceste instrucţiuni de montaj sunt disponibile în limbile enumerate aici. Alte limbi la cerere.

Sub formă de versiune tipărită sau ca ﬁşier PDF pentru a ﬁ descărcat din directorul de conţinuturi (mediadirectory):

www.boschrexroth.com/mediadirectory

Introduceţi în masca de căutare (sus, în partea dreaptă, la „Search“) MTRO 560 592, apoi faceţi clic pe „Search“.

DE 3 842 560 592 ActiveShuttle 1.0 Transportfahrzeug Deutsch

EN 3 842 560 593 ActiveShuttle 1.0 Transport vehicle English

FR 3 842 560 594 ActiveShuttle 1.0 Véhicule de transport Français

IT 3 842 560 595 ActiveShuttle 1.0 Veicolo di trasporto Italiano

ES 3 842 560 596 ActiveShuttle 1.0 Vehículo de transporte Español

PT 3 842 560 597 ActiveShuttle 1.0 Veículo de transporte Português

ZH 3 842 560 598 ActiveShuttle 1.0 导引车中文

CS MTCS 560 592 1) ActiveShuttle 1.0 Transportní vozidlo Česky

PL MTPL 560 592 1)ActiveShuttle 1.0 Pojazd transportowy Polski

HU MTHU 560 592 1)ActiveShuttle 1.0 Szállítójármű Magyar

RO MTRO 560 592 1)ActiveShuttle 1.0 Vehicul de transport Română

1) Only as PDF / Not available in print.

3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG

3/68Contents

1 About this documentation 5

1.1 Validity of the documentation 5

1.2 Required and supplementary documentation 5

1.3 Presentation of information 5

1.3.1 Safety instructions 5

1.3.2 Symbols 6

1.3.3 Designations 7

2 Safety instructions 7

2.1 About this section 7

2.2 Intended use 7

2.3 Improper use 8

2.4 Personnel qualiﬁcations 8

2.5 General safety instructions 8

2.6 Product-speciﬁc safety instructions 9

2.6.1 ActiveShuttle 10

2.6.2 Lithium-ion batteries 12

2.6.3 Handheld controller 1.0 13

2.6.4 Charging station 1.0 14

2.7 Personal protective equipment 15

2.8 Owner responsibilities/obligations 15

2.8.1 Minimum marking 16

2.9 Training of the operating personnel 17

2.9.1 Manual operation 17

2.9.2 Logistics employees 17

2.9.3 Logistics planner 17

3 General notes on property and product damage 18

4 Scope of delivery 19

4.1 Condition on delivery 19

5 About this product 19

5.1 Speciﬁcations 19

5.1.1 Use 19

5.2 Product description 20

5.3 Safety and warning devices 25

5.3.1 Signaling 26

5.3.2 Protective ﬁelds 27

5.3.3 Reference to limits of the personal protection system 27

5.4 Identiﬁcation of the product 28

6 Transport and storage 28

6.1 Transporting the product 28

6.1.1 Mounting/removing lift aid 29

6.2 Storing the product 29

7 Assembly 30

7.1 Ambient conditions 30

7.2 Required tools 30

7.3 Symbols used 30

7.4 Unpacking the charging station 30

7.5 Positioning/preassembling the charging station 31

7.5.1 Connecting the charging station electrically 33

7.6 Unpacking the ActiveShuttle 34

8 Commissioning 35

8.1 Emergency measure Pressing emergency stop device 35

8.2 Emergency measure Removing lithium-ion battery 36

Contents

ENGLISH

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8.3 Initial commissioning 39

8.3.1 Switching on the ActiveShuttle 41

8.3.2 Switching to "Manual" operating mode 42

8.3.3 Move ActiveShuttle to the charging station using the handheld controller 43

8.3.4 Manually insert the ActiveShuttle into the charging station 43

8.3.5 Fully charge the ActiveShuttle 44

8.3.6 Raising/lowering the loading area without handheld controller 44

8.3.7 Switching off the ActiveShuttle 44

8.4 Re-commissioning after a standstill 44

8.5 Preparing the supermarket 45

8.5.1 Permissible dollies 46

9 Operation 47

9.1 Notes regarding operation 47

9.1.1 ActiveShuttle 47

9.1.2 Lithium-ion batteries 49

9.1.3 Handheld controller 1.0 50

9.1.4 Charging station 1.0 51

9.1.5 Wear 51

9.1.6 Measures to reduce wear 51

9.1.7 Environmental factors 51

10 Maintenance and repair 52

10.1 Cleaning and care 52

10.2 Regular safety inspections 52

10.2.1 Periodic inspection - minimum requirements 53

10.3 Procedure for testing the personal protection systems (laser scanner) 54

10.3.1 Checking the basic function of the personal protection systems

(laser scanner) 54

10.3.2 Checking the areas to be protected 54

10.4 Maintenance 54

10.5 Replacement of wear parts 55

11 Decommissioning 55

12 Disassembly and replacement 55

12.1 Preparing the product for storage/later use 55

13 Disposal 56

14 Upgrading and modiﬁcation 57

15 Troubleshooting 57

16 Technical data 58

16.1 ActiveShuttle 1.0 58

16.2 Lithium-ion battery 58

16.3 Charging station 1.0 58

16.4 Ambient conditions 59

16.5 Floor requirements 59

16.6 Load distribution on the loading area 60

16.7 Scanning levels of the personal protection systems (laser scanner) 60

16.8 Protective ﬁelds 61

16.8.1 Front protective ﬁelds 61

16.8.2 Rear protective ﬁelds 63

About this documentation 5/68

3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG

1 About this documentation

1.1 Validity of the documentation

This documentation applies to the following products:

• 3 842 560 431, Transport vehicle ActiveShuttle 1.0

• 3 842 560 106, Handheld Controller 1.0

• 3 842 560 422, Charging station ActiveShuttle 1.0

• 3 842 560 101, Lithium-ion battery

This documentation is intended for ﬁtters, operators, service engineers and system

owners.

This documentation contains important information relating to the safe and

proper assembly, transportation, commissioning, operation, use, maintenance and

disassembly of the product, and on how to rectify simple faults yourself.

Read this documentation in full prior to working with the product, particularly

section 2 "Safety instructions" and section 3 "General notes on property and

product damage".

1.2 Required and supplementary documentation

Only commission the product if he documentation marked with the

book symbol is available and you have understood and followed the

instructions in it.

Table 1: Required and supplementary documentation

Title Document number Document type

General safety instructions

for the electrical installation of

MPS components 1)

3 842 358 820

Employee safety training 1) 3 842 527 147

Handheld Controller 1.0 2) Manufacturer documentation Manual

Battery Safety Instructions 3) Manufacturer documentation

1) If not included in the scope of delivery, download from the media directory:

www.boschrexroth.com/mediadirectory

2) If not included in the scope of delivery, download from the manufacturer's website:

www.keba.com

3) If not included in the scope of delivery, download from the manufacturer's website:

www.bmz-group.com

1.3 Presentation of information

Standardized safety instructions, symbols, terms and abbreviations are used so that

you can use this documentation to work quickly and safely with your product. These

are explained in the following sections to help you understand them better.

1.3.1 Safety instructions

This document contains safety instructions in section 2.6 "Product-speciﬁc

safety instructions" and section 3 "General notes on property and product

damage", as well as before any sequence of actions or any required action which

involves a risk of personal injury or property damage. Be sure to observe all safety

precautions.

ENGLISH

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Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07

Safety instructions are set out as follows:

SIGNAL WORD

Type and source of danger!

Consequences of non-compliance

Measures to prevent danger

…

•Warning sign: points out the danger

•Signal word: indicates the severity of the danger

•Type and source of danger: indicates the type and source of the danger

•Consequences: describes the consequences of non-compliance

•Prevention: states how the danger can be avoided

Table 2: Risk classes according to ANSI Z535.6-2006

Warning sign, signal word Meaning

DANGER Indicates a hazardous situation that will result in severe

injury or death if not avoided.

WARNING Indicates a hazardous situation that may result in severe

injury or death if not avoided.

CAUTION Indicates a hazardous situation that may result in minor to

moderate injury if not avoided.

NOTICE Property damage: The product or the surrounding area

could get damaged.

1.3.2 Symbols

The following symbols indicate important information that is not safety-relevant but

increases the comprehensibility of the documentation.

Table 3: Meaning of the symbols

Symbol Meaning

If this information is not observed, the product cannot be used and/or

operated as designed.

Single, independent action

Numbered steps:

The numbers indicate that the action steps are subsequent.

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1.3.3 Designations

This document uses the following designations:

Table 4: Designations

Designation Meaning

AMS ActiveShuttle Management System

AGV Automated Guided Vehicle system

KLT Small load carrier according to VDA 4500

Source Loading point

Dip Unloading point

2 Safety instructions

2.1 About this section

The product has been manufactured in accordance with the generally accepted rules

of current technology. Nevertheless, there is a risk of personal injury and property

damage if you do not read this section and follow the safety instructions in this

document.

Read this documentation carefully and completely before you start working with

the product.

Keep the documentation accessible to all users at all times.

Always include them when giving the product to a third party.

2.2 Intended use

ActiveShuttle 1.0

The product is a complete machine.

You may use the product as follows:

• For automated material transport in production with operator-deﬁned

–driving ranges

– Loading (sources) and unloading points (dips)

– Speeds

in areas used jointly with passenger trafﬁc.

• For the transport of KLTs stacked on approved dollies (see chapter 8.5.1

Permissible dollies) with a

– total weight incl. dolly of up to 260 kg and a

– max. stacking height of 1,200 mm.

• Technical data see page 58.

• For ambient conditions, see page 59.

Handheld controller 1.0

The handheld controller 1.0 is used in the "Manual" operating mode exclusively for

controlling the ActiveShuttle 1.0.

Charging station ActiveShuttle 1.0

The charging station is used exclusively for charging the ActiveShuttle 1.0.

The product is strictly intended for professional use and not for private use.

The intended use also includes having read and understood these instructions,

especially section 2 "Safety instructions".

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2.3 Improper use

Any use other than that described in the section "Intended use" is considered

improper and is not permitted.

Bosch Rexroth AG is not liable for any damage resulting from improper use. The user

alone bears any risks associated with improper use.

The following foreseeable misuses also constitute improper use:

• Transporting goods other than those speciﬁed.

• Transporting people on the product or transported material.

• Private use.

• The charging station 1.0 must not be used as a stepladder or climbing aid.

2.4 Personnel qualiﬁcations

The activities described in this documentation require basic knowledge of

mechanical, electrical systems, as well as knowledge of the appropriate technical

terms. Additional knowledge regarding the use of lifting gear and corresponding

slings is required for transporting and handling the product. To ensure safe use,

these activities should therefore only be performed by qualiﬁed personnel or by an

instructed person acting under the direction of such a person.

Qualiﬁed personnel refers to those who can recognize potential hazards and

take appropriate safety measures based on their technical training, knowledge,

experience, and understanding of the relevant regulations pertaining to the work

being performed. Qualiﬁed personnel must comply with the relevant technical

regulations and have the necessary expertise.

Bosch Rexroth offers training support for specialized ﬁelds. You can ﬁnd an

overview of the training content online at: http://www.boschrexroth.de/didactic

2.5 General safety instructions

• As owner, please note the following: before the initial start-up of the product, carry

out a risk assessment in accordance with the national regulations in your country

(in Germany: according to the Occupational Health and Safety Act).

• Observe the applicable accident prevention and environmental protection

regulations.

• Observe the safety rules and regulations of the country in which the product is

being used.

• Only use Rexroth products that are in proper working order.

• Heed all the notices on the product.

• Persons who assemble, operate, disassemble or maintain Rexroth products should

not be under the inﬂuence of alcohol, drugs or medication that may affect their

ability to respond.

• Use only original accessories and spare parts from Rexroth in order to prevent

hazards to people due to unsuitable spare parts.

• Observe the technical data and ambient conditions speciﬁed in the product

documentation.

• Only commission the product if it has been determined that the end product

(for example, a machine or system) into which the Rexroth products have been

installed complies with national provisions, safety regulations and application

standards.

Safety instructions 9/68

3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG

2.6 Product-speciﬁc safety instructions

• Do not attempt to modify the product.

• Do not expose the product to any mechanical loads under any circumstances.

Never use the product as a handhold or step. Do not place any objects on the

product.

• Always secure the product against tipping over.

• Observe the transport instructions on the packaging.

• Inspect the product for obvious transport damage.

• Route the cables and lines adequately protected to prevent mechanical damage

and ensure that no one can trip over them.

• Make sure the system component you are working on is depressurized and

de-energized before assembling the product or inserting or removing plugs.

• Ensure that the system component cannot be switched back on.

• Allow the product to acclimatize for a few hours prior to start-up in order to

prevent water condensation from forming in the housing.

• Check the safety requirements according to DIN EN 60204-1.

• Only commission a product that has been completely installed.

• Make sure that all the safety equipment which forms part of the product is present,

has been properly installed, and is fully functional. Do not move, bypass or disable

any safety equipment.

• Check the product for malfunctions.

• Make sure that only authorized personnel perform the following tasks within the

scope of the product’s intended use:

– Starting or operating the system, or interfering with its normal operation.

– Operating component or part adjusters.

• Only allow people to be in the immediate vicinity of the product when it is

operating if they are authorized by the owner to be there. This also applies when

the product is idle.

• Do not use EMERGENCY STOP controls for routine stopping.

• Regularly check the EMERGENCY STOP controls to ensure that they are functioning

properly.

• Following an EMERGENCY STOP or in the event of a fault or other irregularity, turn

the product off and secure it against being switched back on.

• Do not reach into moving parts.

• An idle system is not necessarily a safe system, as stored energy can be released

unintentionally or through improper maintenance procedures.

• After an EMERGENCY STOP or a malfunction, only switch the system back on once

you have established and rectiﬁed the cause of the fault.

• Make sure that access to maintenance and inspection points is kept unobstructed.

• Perform the prescribed maintenance work at the intervals speciﬁed in section 10.3

"Maintenance".

• Make sure that no line connectors, connections or components are disconnected

as long as the system is supplied with pressure and voltage. Secure the system

against being switched back on.

• Dispose of the product in accordance with the regulations in your country.

General

During transport

During assembly

During start-up

During operation

EMERGENCY STOP,

malfunction

During servicing and repair

During disposal

ENGLISH

10/68 Safety instructions

Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07

2.6.1 ActiveShuttle

WARNING

Hazards based on the nature of the load!

Hazardous load (e.g. hazardous substances, hot materials, etc.) can lead to serious

injury or even death.

The operator is solely responsible for any hazards arising from the nature of

the load.

The load must not pose any risk to persons (e.g. catching items of clothing,

scalding, burning, etching, cutting, stabbing).

CAUTION

Danger of injury due to safety checks not carried out!

Risk of serious injury from non-functioning safety and warning devices.

Carry out a test of the visual and audible warning devices on a daily basis.

Carry out a test of the safety devices at least every 6 months (see chapter 10.2

Regular safety inspections).

Take vehicles with non-functional safety and warning devices out of service and

contact the Bosch Rexroth Service.

Risk of burns from hot components inside the ActiveShuttle!

During operation, individual components inside the housing may heat up.

•

Wait a reasonable time before opening the housing.

Personal injury when staying in the driving range, especially in curve areas!

Risk of serious injury from collision with the ActiveShuttle.

• If possible, do not stay within the driving range of the ActiveShuttle.

•

Restrict passenger trafﬁc within the ActiveShuttle's driving range as much

as possible.

•

Always wear safety shoes.

Insufﬁcient stopping distance, e.g. by entering the protective area from the side!

Risk of serious injury from collision with the ActiveShuttle.

• Do not step into the protective area of the vehicle from the side.

•

Do not move against the direction of travel towards the ActiveShuttle.

•

Always wear safety shoes.

Risk of crushing at the rear wheels of the load

When a loaded vehicle starts up/restarts, there is a danger of crushing the rear

wheels of the load.

• Do not put your feet between the wheels.

•

Observe start-up warning.

•

Always wear safety shoes.

Danger due to unadapted speed!

Risk of serious injury due to a speed not adapted to the situation.

The speed of the ActiveShuttle must be reduced in narrow corridors, curves,

intersections and areas with passenger trafﬁc.

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