Still OPX 20 Supplement To The Standard Operating Instructions Download

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4 Operating the iGo neo

Checks and tasks to be carried out when commencing "Assistance" mode . . . . . . . .

Safety information for carrying out the tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Visual inspections before switching on "Assistance" mode. . . . . . . . . . . . . . . . . . . . . . .

Checks after switching on "Assistance" mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety regulations in "Assistance" mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions for the safe operation of the iGo neo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priority rules in mixed "Manual/Assistance" traffic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keeping roadways clear of obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the truck in "Assistance" mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of "Assistance" mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching the truck on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching on "Assistance" mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the truck alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning the truck correctly in the aisle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switching between ACTIVE and PAUSED states for "Assistance" mode . . . . . . . . . . . .

Identifying the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping automatically at the end of the racking or in a crosswise roadway . . . . . . . . .

Behaviour of the truck in response to obstacles in the roadway . . . . . . . . . . . . . . . . . . .

Truck behaviour in the event of an emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moving the stop position next to the operator to the next pallet . . . . . . . . . . . . . . . . . . .

Driving automatically without movement tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting and lowering the fork carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

"Z picking" mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the drive programme when operating in "Assistance" mode. . . . . . . . . . . . . . . .

Warning sounds in "Assistance" mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Storage

Storing and shutting down the iGo neo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Cleaning

Cleaning the components used for "Assistance" mode . . . . . . . . . . . . . . . . . . . . . . . .

7 Transport

Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Table of contents

50108046112 EN - 07/2020 (03)

Summary of Contents for OPX 20

Page 1: ...iGo neo Supplement to the standard operating instructions for the OPX OPX 20 OPX 25 OPX L 12 OPX L 20 OPX L 20 S Original instructions 1089 1090 1091 1092 1093 50108046112 EN 07 2020 03 ...

Page 2: ......

Page 3: ...al informa tion for the operating companies of industrial trucks is also available This guide provides information for handling industrial trucks Support for the creation of the statutory hazard assessment Information on how to select suitable indus trial trucks for a particular area of applica tion Prerequisites for the safe operation of in dustrial trucks Information on the use of industrial tru...

Page 4: ...Internet address and QR code The information can be accessed at any time by pasting the address https m still de vdma in a web browser or by scanning the QR code Preface II 50108046112 EN 07 2020 03 ...

Page 5: ...13 Suitable roadways 13 Information about the documentation 15 Validity of this supplement to the operating instructions 15 Issue date and topicality of the operating instructions 15 Copyright and trademark rights 16 Explanation of information symbols used 16 The term rack in these operating instructions 16 Environmental considerations 18 Disposing of components used for Assistance mode 18 2 Safet...

Page 6: ...D signalling units 38 Operator detection 39 Operator detection system 39 Movement tracking sensors 40 Position tracking of the remote control 41 Laser scanner 42 Function of the safety laser scanner 42 Foot protection sensors 45 Function of the foot protection sensors OPX L 20 S 45 Keypad on the side of the truck 46 Functions of the keypad on the side of the truck 46 iGo neo buttons 47 Functions o...

Page 7: ...oning the truck correctly in the aisle 77 Switching between ACTIVE and PAUSED states for Assistance mode 79 Identifying the operator 80 Stopping automatically at the end of the racking or in a crosswise roadway 81 Behaviour of the truck in response to obstacles in the roadway 83 Truck behaviour in the event of an emergency stop 85 Moving the stop position next to the operator to the next pallet 87...

Page 8: ...nce 1000 hours yearly 108 9 Technical data DimensionsiGo neo OPX 20 25 112 DimensionsiGo neo OPX L 12 113 DimensionsiGo neo OPX L 20 114 DimensionsiGo neo OPX L 20 S 115 VDI datasheetiGo neo OPX 20 25 116 VDI datasheetiGo neo OPX L 12 20 20 S 122 Table of contents VI 50108046112 EN 07 2020 03 ...

Page 9: ...1 Foreword ...

Page 10: ...on at the starting point the highly adaptive iGo neo is ready for operation right away The truck uses sensors to navigate at a selected distance from the racks It intelligently adapts to the traffic situation taking the local conditions into account and slotting seamlessly into the cur rent material flow The iGo neo observes junc tions obstacles and the traffic rules with re spect to other trucks ...

Page 11: ... braking is effectively avoided Less is more The iGo neo also breaks new ground when it comes to communicating with the operator The innovative concept of the iGo eliminates the need for complex cluttered operating sta tus displays Simple light codes and symbols convey everything that the operator needs to know during operation The light codes are displayed via an innovative LED signal strip The n...

Page 12: ...e or addition to the truck can compromise safety thus inva lidating the EC declaration of conformity The EC declaration of conformity must be carefully stored and made available to the rel evant authorities EC declaration of conformity in ac cordance with the Machinery Direc tive The EC declaration of conformity in accord ance with the Machinery Directive provided in the original operating instruc...

Page 13: ...t positions and obstacles The operator can also control truck func tions Assistance mode using a remote control The truck must only be used for its intended purpose as described in these operating in structions In addition the provisions in the original operating instructions for the series production truck apply If the truck is to be used for purposes other than those described in the operating i...

Page 14: ...ruck correspond to the requirements that are described in the original operating instructions for the series production truck In addition the following restrictions apply The truck is not suitable for cleanroom envi ronments The truck must only be used indoors in weather protected locations Special controls apply for use in cold stores and in cold climates below 5 C see the chapter entitled Cold s...

Page 15: ...ue when in Man ual mode Cold store application variant The truck must be fitted with special cold store equipment for operation at temperatures be low 5 C If cold store equipment is fitted the truck may also be operated within the temperature range between 0 C and 5 C CAUTION The truck must not be switched off or parked in the cold store area Always drive out of the cold store area before parking ...

Page 16: ...r load carriers with a width of up to 100 cm The weight and type of load must conform to the specifications in the original operating in structions for the series production truck Load carriers and loads must not protrude be yond the lateral dimensions of the truck con tour The load must not protrude beyond the load carrier in a longitudinal or lateral direc tion The stability of the truck must no...

Page 17: ...anufacturer Adjustments of this type must be performed only by qualified personnel at the manufacturer who have been trained to complete this work Foreword 1 Using the iGo neo 9 50108046112 EN 07 2020 03 ...

Page 18: ...k alignment RIGHT Distance from the rack contour and obstacles on the right X1 50 cm minimum distance X2 Adjustable Distance from obstacles front Y1 100 cm minimum distance Y2 Adjustable Distance from the rack contour and obstacles on the left Z 5 cm minimum distance The truck always maintains a distance X1 of at least 50 cm from the rack contour on the side of the roadway to which the truck is al...

Page 19: ...es Start stop positions when transporting sev eral pallets in succession Duration of the run on time robotics sys tem after the truck has been switched off Minimum distance to the rack in Assis tance mode Minimum width of a crosswise roadway crosswise roadway detection Minimum lateral distance to any obstacles in the roadway Minimum distance to trucks ahead with overhang Preferred truck alignment ...

Page 20: ... refer to the individual license documents On request the license text can be made available in print For further information please contact us www still de igo licence Declaration of conformity in accord ance with the Radio Equipment Di rective 2014 53 EU The manufacturers of the radio equipment in stalled in the industrial truck declare that the radio equipment corresponds to the Radio Equipment...

Page 21: ...r authorised service centre if you are unsure about the correct conditions for the ground Suitable roadways In Assistance mode the truck must only be used on suitable roadways The requirements for roadways described in the original operating instructions of the ser ies production truck also apply to trucks with the additional Assistance mode of opera tion In addition the following provisions apply...

Page 22: ...fer ences on or in the roadway when the truck is in Assistance mode Always use Manual mode to drive along difficult roadways The roadways must meet the requirements as per EN 1525 A 9 Roadways must be free of impairments such as holes troughs or damage to the surface of the roadway The truck must not drive up and down longer gradients when in Assistance mode The truck must always be in Manual mode...

Page 23: ...erating instructions This supplement to the operating instructions must be kept with the operating instructions for the series production truck so that opera tors and the operating company can access these instructions at any time If the operating instructions are lost the operating company must obtain a replacement from the manufac turer immediately The operating instructions are included in the ...

Page 24: ...revent the risk of fatalities WARNING Indicates procedures that must be strictly adhered to in order to prevent the risk of injuries CAUTION Indicates procedures that must be strictly adhered to in order to prevent material damage and or destruc tion NOTE For technical requirements that require special attention ENVIRONMENT NOTE To prevent environmental damage The term rack in these operating inst...

Page 25: ...s also apply to storage area situations in which the truck drives along a contour formed by other load carriers e g pallets in block storage areas Foreword 1 Information about the documentation 17 50108046112 EN 07 2020 03 ...

Page 26: ...e The instructions for environmentally friendly disposal of truck components that are speci fied in the operating instructions for the series production truck also apply to components used for Assistance mode Foreword 1 Environmental considerations 18 50108046112 EN 07 2020 03 ...

Page 27: ...2 Safety ...

Page 28: ...sed for Assis tance mode The requirements for the operating company as well as the rights duties and rules of be haviour of the operating company as descri bed in the operating instructions of the series production truck also apply to trucks with the additional Assistance mode of operation In addition the following provisions apply As part of safety training the operating company must instruct the...

Page 29: ...ator as well as the rights duties and rules of behaviour of the operator as described in the operating in structions of the series production truck also apply to the operators of trucks with the addi tional Assistance mode of operation As a minimum the operator must comply with the following requirements Minimum age 18 years A valid driving license for the truck class Written authorisation from th...

Page 30: ...e authorised by the manufacturer The service engineer must have received spe cial training from the manufacturer regarding the handling processes technology and repair work involved with the iGo neo It is not per mitted for other persons to perform work on the components used for Assistance mode This instruction does not apply to cleaning procedures on components that are not located inside the tr...

Page 31: ...is person has become familiar with a wide range of symptoms that require checks to be carried out such as based on the results of a hazard assessment or a daily inspec tion Recent professional involvement in the field of the industrial truck test in question and an appropriate further qualification are es sential The qualified person must have ex perience of carrying out the test in question or of...

Page 32: ...ponents used for As sistance mode safety laser scanner movement tracking sensors control compo nents control electronics and control soft ware emergency off switches LED signal ling unit switches collision camera var iant foot protection sensors variant re mote control reception components Use of attachment parts e g headlights on the truck Attachment parts may be fitted only with the approval of ...

Page 33: ...ode The manufacturer accepts no liability for any damage caused by the use of non genuine parts and acces sories without approval Damage defects and misuse of safety systems The operator must report any damage or other defects in components used for Assis tance mode to the supervisory personnel im mediately The truck must only be operated in Manual mode until the problem is completely resolved Com...

Page 34: ...st be documented Medical equipment WARNING Electromagnetic interference may occur on medical devices Only use equipment that is sufficiently protected against electromagnetic interference Medical equipment such as pacemakers or hearing aids may not work properly when the truck is in operation Ask your doctor or the manufacturer of the medical equipment to confirm that the medi cal equipment is suf...

Page 35: ...ARNING All persons that are in the vicinity of the truck must be instructed regarding the dangers that arise from a truck operating in Assistance mode In addition your attention is drawn to the safety regu lations given in these operating instructions Additional risks that may arise when operating the truck in Assistance mode include Risk of accident due to obstructed or blind roadways Risk of acc...

Page 36: ...objects are not de tected by the foot protection sensors in im permissible or poor ambient conditions The manufacturer accepts no responsibility for accidents involving the truck caused by the failure of the operating company or the opera tor to note these risks either intentionally or due to lack of care Overview of hazards and countermeasures NOTE This table is designed to help operators evalu a...

Page 37: ...ode Employee training O BetrSichVO Workplace Safety Ordi nance Obstacles such as ladders and working platforms within the movement area of the truck e g for performing repair or mainte nance work in the aisle Close off roadways to the af fected movement or working areas using cones There must be no driverless trucks in the closed off area O BetrSichVO Workplace Safety Ordi nance Risk of accident w...

Page 38: ...etermine and assess hazards dur ing operation and establish the labour protec tion measures required for employees Betr SichVO This investigation must also include any hazards that arise as a result of using Assistance mode The operating company must therefore draw up appropriate operating instructions 6 ArbSchG and make them available to the operator A responsible per son must be appointed NOTE P...

Page 39: ...ary hazards that in the event of non compliance are the most frequent causes of accidents If other major hazards are present as a result of the specific operating conditions these hazards must also be taken into consid eration The conditions of use for the truck are broadly similar in many plants so the hazards can be summarised in one overview Observe the in formation provided by the relevant emp...

Page 40: ... the truck and the effec tiveness of the devices according to technical conventions and the principles for testing in dustrial trucks The basis for the additional testing is provided by the separate Assis tance test log book In addition to the test log for the entire truck the authorised service centre prepares a sep arate Assistance test log The Assistance test log contains the test results for t...

Page 41: ...s 1 1 2 2 2 45904391300 Warning sign Lifting of persons with the forks is prohibited 1 Warning sign Risk of feet being crushed by the pantograph lift OPX L 20 S 2 Safety 2 Labelling points 33 50108046112 EN 07 2020 03 ...

Page 42: ...Safety 2 Labelling points 34 50108046112 EN 07 2020 03 ...

Page 43: ...3 Components of the iGo neo ...

Page 44: ...otection sensors variant Driver platform Additional emergency off switches left and right hand side of the truck 1 2 3 4 5 6 7 Keypad on the left hand side and right hand side of the truck Lift lower the fork carriage Move the stop position next to the opera tor IGO neo button left and right hand side of the truck 8 9 Components of the iGo neo 3 Overview of components used for Assistance mode 36 5...

Page 45: ...h the displayed side of the aisle 2 Lighting zone pulsates slowly approx 1 x per second Truck in Manual mode Operator is on the driver s platform and is operat ing the truck manually 3 Lighting zone remains permanently lit Remote control is not connected to the truck Remote control switched off or battery empty Connection was not active for a long time and needs to be re established 4 Light signal...

Page 46: ...ignal Truck function signalled 1 Light spot moves to the left along the lighting zone Truck alignment LEFT Truck maintains a constant distance to the rack contour on the left 2 Light spot moves to the right along the light ing zone Truck alignment RIGHT Truck maintains a constant distance to the rack contour on the right 3 Light spot moves towards the middle along the lighting zone Truck alignment...

Page 47: ... track the operator s current posi tion Two truck systems work together to achieve this 1 The movement tracking sensors 2 The position tracking of the remote con trol To protect the remote control it must be car ried in the supplied holder when the truck is operated in Assistance mode Components of the iGo neo 3 Operator detection 39 50108046112 EN 07 2020 03 ...

Page 48: ...eye The LED signals from the movement tracking sensors show the status of Assistance mode The symbols shown always point in the direction of the operator LED signals from the movement tracking sensors 1 4 3 2 Operator currently detected Symbols filled in in white Operator not currently detected Symbols with white outline Symbol meaning Information 1 Assistance mode ACTIVE Eye symbol The truck foll...

Page 49: ... Position tracking of the remote con trol The truck uses the position tracking of the re mote control to identify and track the position of the operator In combination with the move ment tracking sensors reliable detection of the operator is guaranteed at all times A transmitter operates inside the remote con trol The position of this transmitter is perma nently determined by four receivers 1 in t...

Page 50: ... truck is aligned the truck automatically drives around the obstacle The truck then contin ues on its path If an obstacle is too large to avoid the truck will stop The truck continues on its path as soon as the obstacle is removed If an obstacle enters the protective field of the safety laser scanner the truck performs an emergency stop The safety laser scanner poses no risk of damaging the human ...

Page 51: ...Cannot be detected by the safety laser scanner DANGER Danger of collisions with obstacles that the safety laser scanner cannot detect This chapter outlines the limits of the iGo neo in de tecting obstacles Check the roadway above all for obstacles that the safety laser scanner cannot detect and re move these obstacles If there is a risk of danger press one of the emer gency off switches on the tru...

Page 52: ...e could include The load on a pallet that protrudes into the roadway above the scanning height of the safety laser scanner A bar in a rack that protrudes into the road way above the scanning height of the safety laser scanner Hand pallet trucks and their tillers or the forks of trucks A cable that hangs crosswise to the road way Ladders and mobile workshop hoists that protrude into the roadway An ...

Page 53: ...s protects the feet of the oper ator from being driven over by the load castors of the forks However the operator can still lower the forks The warning signs 2 tell the operator to keep their feet away from the area around the pan tograph lift at all times WARNING Risk of injury in areas not covered by the foot protec tion sensors The area between the forks and the area above a lift height of 50 c...

Page 54: ...e the chapter entitled Lifting and lowering the fork carriage Move the stop position next to the operator standard assignment Button 3 Move the stop position next to the operator in the direction of the drive side Button 4 Move the stop position next to the operator in the direction of the load side See the chapter entitled Moving the stop position next to the operator The authorised service centr...

Page 55: ...ssed the operator is identi fied iGo neo buttons 1 2 Assistance mode Push 1 x briefly When the truck is stationary PAUSED ACTIVE When the truck is in motion ACTIVE PAUSED 1 x long press min sec When the truck is stationary ACTIVE PAUSED Additional functions of the two iGo neo buttons are described in the chapters about operating the iGo neo see the chapter entitled Operat ing the truck in Assistan...

Page 56: ...nger to people the load or the truck press one of the emer gency off switches immediately This is the fastest way to bring the truck to a standstill When the emergency off switch is pressed the truck performs an emergency stop refer to the chapter entitled Truck behaviour in the event of an emergency stop 1 Components of the iGo neo 3 Emergency off switch 48 50108046112 EN 07 2020 03 ...

Page 57: ...n by flashing the display LEDs for 5 seconds and by means of a vibration signal If the connection fails the truck will not set off or stops in Assistance mode The LED signalling units on the truck illu minate with a steady light The truck only ever executes the inputs of the remote control currently connected Display LEDs on the remote control The display LEDs 6 switch on when the re mote control ...

Page 58: ...ower the fork carriage Operation Information Hold the button down Release the button to stop the lowering procedure Button 3 Lift the fork carriage Operation Information Hold the button down Release the button to stop the lifting operation Button 4 Switch truck alignment LEFT RIGHT MIDDLE Operation Information LEFT RIGHT Briefly push the button Can only be executed when the truck is stationary MID...

Page 59: ...n the remote control will now show the battery charge level Battery charge display 100 90 90 60 60 30 30 0 LED 1 Flashing On On Flashing LED 2 Flashing On Flashing LED 3 Flashing Flashing When the battery charge drops below 30 LED 1 flashing the remote control must be charged If the battery charge level drops to 0 the re mote control switches off In Assistance mode the truck either will not set of...

Page 60: ...formation Green Charging active Red flashing Charging paused overtemperature Off No remote control on the charger Remote control is not currently charging No power supply to the charger Changing the remote control Each remote control has a unique pairing code that is defined by the manufacturer Re mote controls are only able to control the truck if the relevant pairing code has been recog nised by...

Page 61: ...e remote controls that are registered to a truck attempt to access the truck simulta neously the remote control that first made contact with the truck retains control Other re mote controls do not receive access until the first remote control has stopped transmitting Registering a new or additional remote control on the truck Contact the authorised service centre to register a remote control on th...

Page 62: ...Components of the iGo neo 3 Remote control 54 50108046112 EN 07 2020 03 ...

Page 63: ...4 Operating the iGo neo ...

Page 64: ... truck that protects the safety laser scanner against mechanical damage must be undamaged The alignment and the scanner s field of vision must not be impaired The mountings for the movement tracking sensors must not be damaged The alignment of the sensors must not be impaired The mountings for the foot protection sensors must not be damaged The alignment of the scanners must not be impaired The LE...

Page 65: ...of the obstacle Once the truck stops the LED signalling unit and the warning buzzer emit the Emergency stop signal Report defects to the supervisory personnel and do not use the truck until it has been properly repaired Function checking of the side emergen cy off switches after switching on As sistance mode After switching on Assistance mode the operator must check that the two side emer gency of...

Page 66: ...the area below or next to the forks Lift the forks approximately 20 cm Walk in the area to the right of the raised forks and observe the display LEDs on the foot protection sensor Place one foot parallel to the fork in the area next to the fork Do not lower the fork When the foot protection sensor detects your foot correctly the yellow display LED lights up Repeat the test on the left side of the ...

Page 67: ...s and warning signals are part of the safety concept These signals pro vide important information for people in the working area as they indicate that there is a driverless truck close by The signals will help to avoid accidents See the chapter entitled Information signals and warning signals in Assistance mode Report defects to the supervisory person nel Do not use the truck until it has been pro...

Page 68: ... crushed when lowering the forks DANGER Risk of feet being crushed by the forks of the truck When the truck moves off in Assistance mode or when lowering the load feet can be crushed if they project beneath the forks Keep your feet a safe distance away from the forks Pay attention to the warning sound from the truck when the truck moves off in Assistance mode Wear suitable work safety shoes in the...

Page 69: ...keep feet away from the area under the forks Observe the warning signs 1 on the truck Always wear suitable work safety shoes in the correct size Averting the risk of collision using the emergency off switches CAUTION Averting the risk of collision using the emergency off switches If there is a risk of collision with persons or objects push one of the emergency off switches on the truck The truck s...

Page 70: ...en there are bottlenecks in the aisle WARNING It is possible to set safety distances that are main tained between the truck and the rack contour or any obstacles A safety distance of less than 50 cm can be set on the opposite side of the roadway to which the truck is aligned if the truck is being used in nar row aisles See the chapter entitled Required safety distances in the aisle If there are bo...

Page 71: ...truck is in Assistance mode When driving up and down longer gradients the alignment of the safety laser scanner is no longer horizontal to the roadway Under certain circumstan ces obstacles may not be detected Always drive up and down longer gradients in Manual mode Observe the maximum permissible di mensions of pallets and loads DANGER Risk of accident from pallets and loads that pro trude beyond...

Page 72: ...ad and unload the pallet from the side This ensures that the operator does not enter the unladen area of the fork which could result in injury Observe the risk of accident due to ex cessive speed DANGER Risk of collision due to excessive speed when op erating in Assistance mode When operating in ASSISTANCE mode the opera tor controls the driving speed of the truck via move ment tracking or by usin...

Page 73: ...rning units When operating in Assistance mode the truck emits audible and optical information signals and warning signals Faulty components LED signalling unit warning buzzer must be replaced immediately before op eration in Assistance mode is commenced or resumed Transport of people and jumping onto the truck is prohibited when operating in Assistance mode DANGER Risk of injury for persons when t...

Page 74: ...f fire or by other view obstructing vapours If there is smoke or other view obstructing va pours in the area surrounding the truck operate the truck in Manual mode only Observe instructions regarding safe storage of the remote control DANGER Risk of accident from unintentional actuation of the remote control When the truck is switched on the remote control must always be kept in a safe place to pr...

Page 75: ...sons Observe the risk of accident due to in correct detection of the operator DANGER Risk of accident due to incorrect detection of the operator In some circumstances the truck can identify anoth er person moving in the working environment of the truck as the operator As a result the truck can unex pectedly follow this other person along the aisle Ensure that there are no persons moving or standin...

Page 76: ...shing and warning signals from the truck that indicate that the truck is driving or set ting off in Assistance mode Always give trucks operating in Assistance mode priority over trucks being driven manually In areas with mixed Manual Assistance traf fic always drive with extra care Mixed traffic refers to situations in which trucks in Assistance mode and trucks driv en manually are operated in the...

Page 77: ... approx 9 cm in height above the ground pose an increased risk of accidents The truck does not brake automatically in such instances Before moving the truck check the roadway for obstacles that the safety laser scanner cannot de tect Pay particular attention to objects that extend laterally into the roadway Clear the roadway Pay attention to cables ladders and workshop hoists that cross the roadwa...

Page 78: ...orded and monitored as well Minimum distance to obstacles in the roadway Pallets containers and similar items must al ways be set down in such a way that a safety distance of 50 cm is always maintained be tween the truck contour including the load and the obstacles If this safety distance is not maintained the operating company must ensure that safety is guaranteed for persons and objects in anoth...

Page 79: ...into the rack The truck detects the posi tion of the operator and the contour of the warehouse aisle During order picking the truck independently follows the operator along this contour This enables the operator to load and unload the truck without interruption Whenever the operator is standing on the driv er s platform of the truck the truck is in Man ual mode As soon as the operator leaves the d...

Page 80: ...set by the authorised service centre The truck automatically drives around obsta cles in the roadway provided that safety dis tances and the size of the obstacle allow for this If it is not possible to avoid an obstacle the truck will stop in front of the obstacle The safety laser scanner monitors the road way The safety laser scanner stops the truck in the event of danger to persons or resulting ...

Page 81: ...rox 20 seconds the truck is ready to be op erated in Manual mode Switching off the truck Switch off the truck following the instruc tions given in the original operating instruc tions for the series production truck The truck is switched off NOTE The robotics system does not switch off auto matically until the selected run on time has elapsed The authorised service centre can configure the run on ...

Page 82: ...firms successful regis tration by flashing the display LEDs for 5 sec onds and by a vibration signal If the connection is successful the LED sig nalling units show the truck alignment in the aisle LEFT MIDDLE RIGHT The author ised service centre can configure the preferred initial truck alignment If the connection fails Assistance mode is disabled While operating the truck keep the remote control ...

Page 83: ...o neo button on the remote control or on the truck Assistance mode is ACTIVE immediately The truck follows the operator along the rack contour In the event of a dangerous situation the op erator can bring the truck to an immediate standstill at any time with the emergency off switches 1x Operating the iGo neo 4 Operating the truck in Assistance mode 75 50108046112 EN 07 2020 03 ...

Page 84: ...efly Switch the truck alignment in sequence LEFT MIDDLE RIGHT LEFT The LED signalling units signal the set truck alignment Truck alignment RIGHT 1 Truck alignment MIDDLE 2 Truck alignment LEFT 3 The truck emits a short signal tone to confirm the selection of the truck alignment If the truck does not detect the rack contour on the side of the roadway to which the truck is aligned the truck position...

Page 85: ...had when switched to Assis tance mode ACTIVE This distance is set when the operator leaves the driver s platform Drive the truck manually to the starting point for Assistance mode Position the truck at the required distance parallel to the rack The selected distance 2 must be between 50 cm and 250 cm If an insufficient distance is specified the truck will steer until a distance of 50 cm or a large...

Page 86: ... position the truck parallel to the rack Slowly set the truck in motion Bring the truck to an immediate standstill if the safety distance of 50 cm to the rack is not reached Drive the truck in Manual mode to the starting point for Assistance mode Position the truck parallel to the rack at the desired distance min 50 cm Correctly positioning the truck in the centre of the aisle Drive the truck in M...

Page 87: ...tch Assistance mode to PAUSED Allow the truck to come to a standstill The LED dis plays of the movement tracking sensors must display the symbol iGo neo button Assistance mode Push 1 x briefly When the truck is stationary PAUSED ACTIVE When the truck is in motion ACTIVE PAUSED 1 x long press min sec When the truck is stationary ACTIVE PAUSED 1 1 2 2 1x Operating the iGo neo 4 Operating the truck i...

Page 88: ...fication as operator in Assistance mode Automatically when the operator steps off the driver s platform Press the assistance button on the remote control or on the truck Always pay attention to the LED signals of the movement tracking sensors to check whether Assistance mode is ACTIVE and focussed on the operator Operating the iGo neo 4 Operating the truck in Assistance mode 80 50108046112 EN 07 2...

Page 89: ...st ensure that the truck does not drive beyond the end of the rack The operator is responsible for stopping the truck safe ly The truck is equipped with automatic end of rack detection If the racking on the side to which the truck is aligned ends or if the rack ing is interrupted by a crosswise roadway the truck will stop automatically Stopping at the end of the racking The truck detects that the ...

Page 90: ...n cross the crosswise roadway safely Briefly press the iGo neo button on the re mote control or on the truck once The LED display of the movement tracking sensors changes to Assistance mode ACTIVE The truck follows the operator over the crosswise roadway If the truck fails to detect a continuation of the rack contour beyond the crosswise roadway the truck will not move off The truck must then be d...

Page 91: ...etect Remove these obstacles If there is a risk of danger immediately bring the truck to a standstill by pressing one of the emer gency off switches If the truck detects an obstacle on the side of the roadway to which the truck is aligned the truck automatically avoids the obstacle and continues on its path A If an obstacle is too large to drive around the truck stops in front of the obstacle B As...

Page 92: ...cle Minimum distance to obstacles The authorised service centre can configure a minimum distance 1 at which the truck may pass an obstacle when in Assistance mode Observe the notes in the chapter entitled Required safety distances in the aisle min 1 Operating the iGo neo 4 Operating the truck in Assistance mode 84 50108046112 EN 07 2020 03 ...

Page 93: ...ntain a safety distance if the truck starts to move again automatically after an emergency stop If an obstacle appears suddenly in front of the truck or approaches the truck the safety laser scanner detects a critical situation The truck will automatically perform an emergency stop to prevent a collision Assistance mode is resumed without inter vention from the operator as soon as the ob stacle is...

Page 94: ...ruck brake is released The LED signalling unit stops showing the Emergency stop signal and changes back to the previous display The truck stops emitting the audible warning sound to indi cate the emergency stop Assistance mode only becomes AC TIVE when the operator presses the iGo neo button on the remote control or on the truck Pay attention to the Assistance mode PAUSED LED signal of the movemen...

Page 95: ...pallets one behind the other The remote con trol can be used to move the truck stop posi tion next to the operator so that the required pallet is always within range The authorised service centre can configure a maximum of four different stop positions The LED display on the remote control 2 shows the position currently selected 1 2 3 If all of the LEDs are lit position 4 is selec ted Moving the s...

Page 96: ...moves along one position in the direction of the drive side When the end position 1 is reached the truck emits two short beeps Push button 2 The selected truck position moves along one position in the directions of the load side When the end position 4 is reached the truck emits two short beeps 1 2 Operating the iGo neo 4 Operating the truck in Assistance mode 88 50108046112 EN 07 2020 03 ...

Page 97: ...ing sen sors changes to operator not identified The truck moves along the rack contour until the button is released The truck safety func tions remain active If necessary perform operator identification again on the truck If the truck fails to detect a rack contour it does not set off or stops The movement tracking sensors will show the PAUSED LED signal NOTE The authorised service centre can deac...

Page 98: ...the button down The fork carriage comes to a stop when the button is re leased Briefly push the button The fork carriage stops after 1 sec Hold the button down The fork carriage comes to a stop when the button is re leased OPX L 12 main lift 1 OPX L 20 main lift 1 Hold the button down The fork carriage comes to a stop when the button is released Briefly push the button The fork carriage stops afte...

Page 99: ...er ing procedure Press the button for lifting or lowering again or press it and hold it The lifting operation or lowering procedure stops immediately Operating the iGo neo 4 Operating the truck in Assistance mode 91 50108046112 EN 07 2020 03 ...

Page 100: ...ation conditions The minimum distance that can be set is 30 cm Z picking mode must be set up and perma nently enabled by an authorised service cen tre The operator cannot switch between standard mode in which the distance can be changed and Z picking mode Operating the truck in Z picking mode Press the iGo neo button 1 on the re quired picked side The truck then follows the operator at a fixed dis...

Page 101: ...amics braking dynamics to suit the application situation All safety related fea tures of the truck remain unchanged Push the tortoise button to toggle between the drive programmes The current drive programme is indicated on the display oper ating unit NOTE The authorised service centre can configure the drive programmes for Assistance mode to suit the specific requirements of the customer Operatin...

Page 102: ...or at least 10 seconds Short rhythmic warning sounds Emergency stop warning sound safety laser scanner Truck has performed an emer gency stop Emergency stop warning sound emergency off switch The operator has pressed the emergency off switch Brief warning sounds increas ing in frequency Lifting or lowering of the forks Increase in the frequency of the sound when lowering into the danger area for f...

Page 103: ...5 Storage ...

Page 104: ...ss transport vehicles cannot be stored in an operational state They must therefore be taken out of operation To shut down the truck contact the author ised service centre Storage 5 Storing and shutting down the iGo neo 96 50108046112 EN 07 2020 03 ...

Page 105: ...6 Cleaning ...

Page 106: ...UTION Risk of component damage If the battery male connector is disconnected while the truck is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the truck before the battery male con nector is disconnected Do not disconnect the battery male connector while the truck is switched on except ...

Page 107: ...ift A static charge causes dust particles to ac cumulate on the optics cover To clean the optics cover use the cleaning material lis ted in the table Recommended cleaning material for the optics covers Cleaning material SICK item number STILL order number Antistatic plastic cleaning agent 5600006 7302000907 SICK cleaning cloth 4003353 50103612103 Remove any dust from the optics covers us ing a cle...

Page 108: ...windows on the movement tracking sensors on the safety laser scanner and on the foot protection sen sors do not fog up If the optics cover of the safety laser scanner fogs up the truck may respond by initiating an emergency stop Clean any fogged up optics covers before starting operation in Assistance mode see the chap ter entitled Cleaning Cleaning 6 Cleaning the components used for Assistance mo...

Page 109: ...7 Transport ...

Page 110: ...impermissible crane loading The mounting bracket for the LED signalling unit or the safety laser scanner can be damaged when load ing by crane Loading of the truck by crane is not permitted Safety regulations for lashing down the truck DANGER Risk of accident if the lashing straps slip The truck must be lashed securely so that it cannot move during transportation Make sure that the lashing straps ...

Page 111: ... the truck is to be driven has been sufficiently secured to prevent it from moving Maintain a safety distance from other loading bridges ramps working platforms and similar ob jects Drive slowly and carefully onto the transport vehi cle CAUTION Risk of damage to the protective guard 1 and the safety laser scanner on loading bridges and ramps In the transition to gradients or slopes the protective ...

Page 112: ...tual total weight of the truck Components can be permanently deformed or damaged due to over loading Determine the actual total weight from the name plate on the truck Only load the truck if the load capacity of the means of transport ramps and loading bridges is greater than the total actual weight of the truck Transport 7 Transporting the truck 104 50108046112 EN 07 2020 03 ...

Page 113: ...8 Maintenance ...

Page 114: ...sitate shorter maintenance intervals Dirty poor quality roadways Dusty or salty air High levels of air humidity Extremely high or low ambient tempera tures or extreme changes in temperature Multi shift operation with a high duty cycle National regulations for the truck or for indi vidual components Responsibility for maintenance DANGER Work performed by unauthorised persons on com ponents used for...

Page 115: ...ion camera variant Foot protection sensors variant Safety regulations for maintenance Before starting any work on electrical and mechanical equipment disconnect the sys tem from the power supply On the iGo neo this is done by disconnecting the battery male connector Secure and demarcate the working area Use warning signs to indicate the increased level of danger Maintenance documentation The maint...

Page 116: ...gnment and the field of vision of the SICK safety laser scanner using the SICK CDS software Clean the optical cover of the safety laser scanner Movement tracking sensors Check the movement tracking sensors and the mounting for damage visual inspec tion Check the plug contacts power supply and communications supply Check the status LEDs for the movement tracking sensors visual inspection Clean the ...

Page 117: ...ystem Practical function checking of the robotics system when Assistance mode is ac tive Check the function of the safety laser scanner S300 and the movement track ing sensors including the LED signals foot protection sensors LED signalling unit assistance button emergency off switch and remote control Personal protection system MPSE Check the function of the personal protection system Check the f...

Page 118: ...Maintenance 8 Maintenance 1000 hours yearly 110 50108046112 EN 07 2020 03 ...

Page 119: ...9 Technical data ...

Page 120: ...Dimensions iGo neo OPX 20 25 Technical data 9 DimensionsiGo neo OPX 20 25 112 50108046112 EN 07 2020 03 ...

Page 121: ...Dimensions iGo neo OPX L 12 Technical data 9 DimensionsiGo neo OPX L 12 113 50108046112 EN 07 2020 03 ...

Page 122: ...Dimensions iGo neo OPX L 20 Technical data 9 DimensionsiGo neo OPX L 20 114 50108046112 EN 07 2020 03 ...

Page 123: ...Dimensions iGo neo OPX L 20 S Technical data 9 DimensionsiGo neo OPX L 20 S 115 50108046112 EN 07 2020 03 ...

Page 124: ...ravity distance c mm 1200 1200 1 8 Load distance x mm 1615 2 1615 2 1 9 Wheelbase y mm 2717 2 2717 2 Weights Model OPX 20 iGo neo OPX 25 iGo neo 2 1 Net weight including battery kg 1265 2 1290 2 2 2 Axle load with load drive side load side kg 1211 2054 1279 2511 2 3 Axle load without load drive side load side kg 988 277 997 293 Wheels chassis frame Model OPX 20 iGo neo OPX 25 iGo neo 3 1 Tyres Pol...

Page 125: ...4 10 Height of load wheel supports h8 mm 4 14 Standing height extended with driver s platform that can be raised h12 mm 1197 1197 4 15 Fork height lowered h13 mm 85 85 4 19 Overall length l1 mm 3851 3851 4 20 Length including fork back l2 mm 1461 1461 4 21 Overall width b1 mm 830 830 4 22 Fork arm dimensions s e l mm 61 78 max 172 2390 61 78 max 172 2390 4 24 Fork carriage width b3 mm 4 25 Width o...

Page 126: ...utonomous driving speed with with out load km h 7 2 7 2 5 2 Lifting speed with without load m s 0 070 0 111 0 064 0 089 5 3 Lowering speed with without load m s 0 084 0 067 0 068 0 066 5 8 Max climbing capability with without load 7 12 8 9 7 12 8 9 5 9 Acceleration time with without load s 6 1 4 8 6 4 4 8 5 10 Service brake Electromagnetic Electromagnetic Traction motor Model OPX 20 iGo neo OPX 25...

Page 127: ... brackets limit values for gradients slopes with hard transitions or with foot protection if different due to manufacturing and assembly tolerances it is recommended to reduce the nominal values by at least 1 11 With a load of 1000 kg on the lift mast and a load of 1000 kg on the initial lift at the maxi mum initial lift height OPX 20 25 iGo neo forks overview l mm c mm x a mm y a b mm Ast b c mm ...

Page 128: ...lly raised 57 mm Wa with forks lowered for thrust rod version 108 mm Wa for tie rod version d Long wheelbase suitable for holding 3 europallets crosswise e Short wheelbase suitable for holding 2 europallets lengthwise Holding pallets crosswise in relation to the forks is only allowed in Manual mode OPX 20 25 iGo neo geometric climbing capability a l mm c mm x mm Tray 53 Tray 54 or lithium ion bat ...

Page 129: ...ion bat tery with foot protection 3100 1600 2125 7 0 5 3 a Due to manufacturing and assembly tolerances it is recommended to reduce the nominal val ues by at least 1 Technical data 9 VDI datasheetiGo neo OPX 20 25 121 50108046112 EN 07 2020 03 ...

Page 130: ...0 1000 for mast lift 2000 1200 1 6 Load centre of gravity distance c mm 1248 600 for mast lift 1 1200 600 1 8 Load distance x mm 1910 1782 3 1474 1310 3 670 1 9 Wheelbase y mm 3225 3097 3 4 2661 2497 3 4 1823 4 Weights Model OPX L 20 iGo neo OPX L 20 S iGo neo OPX L 12 iGo neo 2 1 Net weight including battery kg 1654 1543 1395 2 2 Axle load with load drive side load side kg 1629 2025 1231 2312 101...

Page 131: ...4 Lift h3 mm 800 700 700 4 5 Height lift mast extended h4 mm See table be low 2075 5 2075 5 4 6 Initial lift h5 mm 130 4 8 Standing height h7 mm 130 130 130 4 9 Steering wheel height in driving position min max h14 mm 1250 6 1250 6 1250 6 4 10 Height of load wheel supports h8 mm 85 4 14 Standing height extended with driver s platform that can be raised h12 mm 1197 1197 1197 4 15 Fork height lowere...

Page 132: ...3 4 2181 4 Performance data Model OPX L 20 iGo neo OPX L 20 S iGo neo OPX L 12 iGo neo 5 1 Conventional driving speed with without load km h 9 12 9 12 9 12 5 1 1 Conventional driving speed re verse with without load km h 8 11 8 11 8 11 5 1 2 Autonomous driving speed with without load km h 7 2 7 2 7 2 5 2 Lifting speed with without load m s 0 159 0 253 0 095 0 176 0 135 0 218 5 3 Lowering speed wit...

Page 133: ...le below for other fork dimensions 3 With the crane booms raised or the fork raised 4 114 mm with tray 54 or lithium ion battery 5 With the specified load backrest 1290 mm measured from the fork onwards 6 With tiller adjustment option h14 adjustment range 89 mm 19 mm 7 Minimum ground clearance under the chassis with specified foot protection 8 On gradients slopes with soft transitions crane booms ...

Page 134: ...ncreased lift mast height h1 b With the specified load backrest on the accessory bracket for high loads OPX L 20 iGo neo aisle widths with crane booms raised OPX L 20 iGo neo aisle widths with crane booms raised Fork length Dimensions of pallet vertical mm Crane boom length mm x mm Wa c mm Load at aisle width Ast 1295 1207 1782 3455 2 pallets 800 x 1200 lengthwise 1295 165 1137 1617 3455 2 pallets...

Page 135: ...ccordance with the Machinery Directive 4 Emergency off switch 48 Emergency stop 85 End of the racking 81 F Foot protection sensors Cleaning 99 function 45 H Hazards and countermeasures 28 I Identifying the operator 80 iGo neo buttons functions 47 Improper use 6 Information symbols 16 Intended use 5 K Keypad functions 46 L Labelling points 33 LED signalling units Information and warning signals 37 ...

Page 136: ...e 10 Requirements for load carriers and loads 8 Requirements for the ground conditions of roadways 13 Requirements for the place of use 6 Residual dangers residual risks 27 Retrofitting 24 Roadways Keeping roadways clear of obstacles 69 Minimum distance to obstacles 70 Suitable roadways 13 S Safety distances 10 Safety inspection 32 Safety laser scanner function 42 Limits to the detection of obstac...

Page 137: ...of the racking 81 82 Switching off the truck 73 Switching off truck 73 Switching on the truck 73 Switching on truck 73 T Technical data Dimensions of iGo neo OPX L 12 113 Dimensions of iGo neo OPX L 20 114 Dimensions of iGo neo OPX L 20 S 115 Dimensions of iGo neo OPX 20 25 112 VDI datasheet iGo neo OPX L 12 20 20 S 122 VDI datasheet iGo neo OPX 20 25 116 Transport 102 Driving on loading bridges 1...

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