Page 1
Original instructions
iGo neo
Supplement to the series operating instructions for the CX-20
CX-20
1063
50108046085 EN - 08/2017
Page 2
Page 3
Preface
Address of manufacturer and contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. +49 (0) 40 7339-0
Fax: +49 (0) 40 7339-1622
Email: info@still.de
Website: http://www.still.de
Rules for the operating company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commissioning and storage of industrial trucks
thesafeoperationof
g
Internet address and QR code
The information c
by pasting the add
in a web browser or
an be accessed at any time
ress https://m.still.de/vdma
by scanning the QR code.
08046085 EN - 08/2017 I
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Page 4
Page 5
Table of contents
1 Foreword
Your iGo neo ........................................................ 2
CElabelling ......................................................... 2
EC declaration of conformity in accordance with the Machinery Directive . ........... 2
Using the iGo neo .................................................... 2
Intended use ........................................................ 2
Improperuse ........................................................ 3
Requirements for the place of use ......................................... 4
Requirements for pallets a
Customer-specificconfigurationbytheauthorisedservicecentre .................. 5
Copyright clause for open-source programs ................................. 7
Roadways .......................................................... 7
Requirements for the ground conditions of roadways ........................... 7
Suitableroadways .................................................... 7
Information about the do
Validity of this supplement to the operating instructions ......................... 8
Issuedateandtopicalityoftheoperatinginstructions ........................... 9
Copyright and trademark
Explanation of information symbols used . . ................................ 10
Informationfortwo-pagePDFdisplay ..................................... 10
Environmental consid
DisposingofcomponentsusedforASSISTANCEmode ....................... 11
nd loads ........................................ 5
cumentation ...................................... 8
rights ........................................... 9
erations .......................................... 11
g
2Safety
Definition of terms used for responsible persons ............................. 14
Duties of the operat
Duties of the operator . . ............................................... 15
Additional requirements applicable to the authorised service centre . . . ............ 15
Specialist .......................................................... 16
Basic principles for safe operation ....................................... 17
Modificationsandretrofitting ............................................ 17
Warning regarding non
Damage, defects and misuse of safety systems .............................. 18
Medicalequipment ................................................... 19
Residual risk ....................................................... 19
Residual dangers, residual risks ......................................... 19
Overviewofhazardsandcountermeasures ................................. 21
Danger to employee
ingcompany ......................................... 14
-genuineparts ..................................... 18
swhenASSISTANCEmodeisused ....................... 22
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Table of contents
g
Safety tests ........................................................ 23
Regularsafetyinspectionofthetruck ..................................... 23
Emissions ......................................................... 24
3 Components of the iGo neo
Overview of components used for ASSISTANCE mode ........................ 26
LED signalling unit ................................................... 27
Signals from the inner lig
Signals from the outer lighting zone on the LED signalling unit ................... 28
Movement tracking sensors ............................................ 29
Function of the movement t
Safety laser scanner ................................................. 31
Functionofthesafetylaserscanner ...................................... 31
Assistance button ................................................... 34
Functionsoftheassistancebutton ....................................... 34
Emergency off switch ................................................. 35
Additional emergency o
Remote control ..................................................... 36
Functionsoftheremotecontrol .......................................... 36
Charging the remote c
Changing the remote control . . .......................................... 40
htingzoneontheLEDsignallingunit ................... 27
rackingsensors ................................. 29
ffswitches ....................................... 35
ontrol ............................................ 38
4 Operating the iGo neo
Checks and tasks to be carried out when commencing ASSISTANCE mode ........ 44
Safety information r
Visual inspection before switching on ASSISTANCE mode ..................... 44
VisualinspectionandbraketestafterswitchingonASSISTANCEmode ............ 45
Safety regulations
Instructionsforsafeoperationofthetruck .................................. 47
PriorityrulesinmixedMANUAL/ASSISTANCEtraffic ......................... 51
Keeping roadways c
Operating the truck in ASSISTANCE mode ................................. 54
OverviewofASSISTANCEmode ........................................54
Switching the truc
SwitchingonASSISTANCEmode .......................................57
Adjustingthetruckalignment ........................................... 58
Positioning the truc
SwitchingbetweenACTIVEandPAUSEDmodesformovementtracking ........... 61
IV 5
elatedtousingthismode ................................ 44
in ASSISTANCE mode .................................. 47
learofobstacles ..................................... 52
konandoff ........................................... 56
kcorrectlyintheaisle .................................. 59
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Table of contents
Identifying the operator . ............................................... 62
Stoppingautomaticallyattheendoftheracking ............................. 64
Behaviour of the truck in respo
Truck behaviour in the event of an emergency stop ........................... 68
Movingthetruckpositiontothenextpallet .................................. 70
Driving automatically withou
SettingthedriveprogrammewhenoperatinginASSISTANCEmode .............. 72
Warning sounds in ASSISTANCE mode . . . ................................ 73
nsetoobstaclesintheroadway ................... 66
tmovementtracking ............................ 71
5 Storage
Storing and shutting down
the iGo neo .................................... 76
6 Cleaning
Cleaning the components used for ASSISTANCE mode ....................... 78
7 Transporting
Transporting the truck ................................................ 82
8 Maintenance
Maintaining the iG
Maintenance - 500 hours/every 6 months .................................. 87
Maintenance - 1000 hours/annually ...................................... 88
o neo ............................................... 86
g
9 Technical data
Dimensions ........................................................ 9
VDI datasheet: iGo neo CX 20 .......................................... 93
Technical data of the remote control components ............................ 95
Technica
l data of the safety laser scanner .................................. 96
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2
Page 8
Page 9
1
Foreword
Page 10
1 Foreword
Your iGo neo
Your iGo neo
CE labelling
The manufacturer uses CE labelling to indicate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of confo
carefully stored and made
responsible authorities
EC declaration of conformity in accordance with the Machinery Directive
The EC declaration of conformity in accordance with the Machinery Directive provided
in the original operating instructions for the
series-production truck is not valid for the iGo
neo.
rmity must be
available to the
.
CE-Symbol
Using the iGo neo
Intended use
The iGo neo is based on a manually operated
STILL series-production truck that has been
equipped with additional navigation and safety
components.
The truck can
of operati
250
switch between different modes
on:
MANUAL and ASSISTANCE.
108046085 EN - 08/2017
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Foreword 1
Using the iGo neo
MANUAL mode corresponds to normal opera-
tion of the series-production truck:
• Ride-on mode
• Pedestrian mode with cockpit (
with drive switch)
• Pedestrian mode with push button (special
equipment)
slow travel
ASSISTANCE mode is the additional opera-
ting mode of the iGo neo.
• When order picking, the truck automatically
detects the aisle and the position of the
operator. As soon as the operator climbs
down from the truck, the truck automatically
follows the operator at the same level along
the racks. The truck maintains a constant
distance to the racking, so that items can be
transferred between the truck and the rack
without interruption.
•
ASSISTANCE modecanalsob
by the operator using a rem
The truck must only be used for its intended
purpose as set out and described in these operating instructions. 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 specified in the operating instructions, the approval of the manufacturer and, if
applicable, the relevant regulatory authorities
must be obtained in advance to prevent hazards.
The truck is only to b
ternal transport in
TANCE
operating mod
is restricted to the
sector.
Regardless of the safety devices present in
the system, the operator remains responsible
for the safe operation of the truck at all times,
even in
ASSISTANCE mode.
e used for company-in-
the
MANUAL and ASSIS-
es. Use of the truck
commercial and industrial
e controlled
ote control.
Improper use
The operating company or operator, and not
the manufacturer, is liable for any hazards
caused by improper use.
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1 Foreword
Using the iGo neo
It is prohibited to use the truck for purposes
other than those described in these operating
instructions.
The truck is not permitted to be used:
• On or along public roads
• In a cold store
• In areas at risk of explosion
• For transporting dangerous goods
• For transporting people or a
nimals as a load
Requirements for the plac
The requirements for the
truck correspond to the r
described in the origina
for the series-producti
In addition, the followi
• The truck must not be operated in cold
stores
•Thetruckisnot suitable for cleanroom
environments
• The truck must only be u
weather-protected lo
Permissible working environment for the truck:
Permitted temperatures
Usage
Operation
Storage
Permitted air humidity
Usage
Operation
Storage
l operating instructions
on truck.
ng restrictions apply:
cations
eofuse
place of use of the
equirements that are
sed indoors in
Min. °C Max. °C
440
5
Min. %
5
5
45
Max. % (without condensation
water)
95
95
During use, ensure that the movement tracking sensors and the safety laser scanner do
not fog up due to changing between hot zones
(approx. 40°C) and cold zones (approx. 4C)
too rapidly. Fogged-up optics covers must be
450
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Foreword 1
Using the iGo neo
cleaned before use in ASSISTANCE mode
(see the chapter entitled "Cleaning").
Requirements for pallets and loads
Pallets that are wider than the truck (max.
80 cm) must not be transported in
TANCE
mode.
The weight and type of load must conform
to the specifications in the original operating
instructions for the series-production truck.
Pallets and loads must not
the lateral dimensions of
The load must not protrud
in a longitudinal or late
The stability of the truck must not be jeopardised by the weight and height of the load,
including when cornering.
The load must be secured so that it cannot fall
from the truck or slip and protrude beyond
the lateral truck contour, including when
cornering. The load must be stacked carefully,
with the centre of gravity as low as possible.
Pallets and loads that
ifications may be moved
mode only if the truck s
justed in advance by th
justments of this typ
by qualified personne
who have been trained to
the truck contour.
ral direction.
do not meet these spec-
in
afety devices are ade manufacturer. Ad-
e must only be performed
l at the manufacturer
ASSIS-
protrude beyond
e beyond the pallet
ASSISTANCE
complete this work.
Customer-specific con
the authorised servi
The authorised servi
ASSISTANCE mode to s
application condi
the following para
• Dynamic and maximum speed of the drive
programs
• Duration of the run-on time (robotics system) after the truck has been switched off
• Minimum distance
SISTANCE
tions. Amongst other things,
meters can be set:
mode
figuration by
ce centre
ce centre can configure
uit the specific
to the racking in
AS-
08046085 EN - 08/2017 5
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1 Foreword
Using the iGo neo
• Minimum width of a crosswise roadway
(crosswise roadway detection)
• Minimum lateral distance to any obstacles
in the roadway
• Minimum distance to trucks ahe
overhang
• Preferred truck alignment
• Adaptation to the fork length of the truck
• Start/stop positions when t
several pallets in successi
• Automatic approach after losing track of
the position of the operator (only the side to
which the truck is aligned/both sides)
ad, with
ransporting
on
650
108046085 EN - 08/2017
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Foreword 1
Roadways
Copyright clause for open-source programs
STILL uses open source software to operate
the iGo neo as licensed by the owners of the
respective rights. The used open source
software can be made available for general
use, however excluding any liability.This
exclusion of liability includes implicit warranty
of marketability or suitability of the software for
a particular use. For more details, please refer
to the individual license documents.
On request, the license text can be made
available in print.
For further information p
lease contact us:
www.still.de/igo-licence
.
Roadways
Requirements for the ground conditions of roadways
The truck is equipped with running wheels
and drive wheels made from Vulkollan. The
ground conditions of roadways affect the
length of the braking distance (e.g. when
performing an emergency stop) and therefore
also have implications for the safety of persons
and equipment.
The roadways on which the iGo neo will
be used must be sufficiently flat, provide
sufficient grip (good roughness properties)
and offer sufficient load-bearing capacity.
The requirements for the ground conditions
correspond to the requirements for the seriesproduction truck.
– Contact your aut
you are unsure ab
for the ground.
horised service centre if
out the correct conditions
Suitable road
In ASSISTANCE
be used on suita
ways
mode, the truck must only
ble roadways:
501
08046085 EN - 08/2017 7
Page 16
1 Foreword
Information about the documentati
The requirements for roadways described
in the original operating instructions of the
series-production truck also apply to trucks
with the additional
ASSISTANCE mode of
operation.
In addition, the following provisions apply:
Additional requirements for roadways
suitable for the ASSISTANCE mode of
operation
DANGER
Risk of accident due to dirty roadways
Roadways must always be kept clean. Contami-
nation resulting from moisture, oils, greases, dust,
chips etc. can cause faults and reduce safety.
– Always keep roadways clean.
– For roadways, do not use any cleaning materials
or care products that smooth the surface.
DANGER
Risk of accident f
on or in the roadwa
ASSISTANCE mo
In
the roadway for h
edges, steps, p
truck will tip o
– Maintain a sa
differences o
ASSISTAN
is in
– Always cover d
mode.
rom sloping edges and gradients
y
de, the truck does not check
eight differences, e.g. on sloping
latforms, ramps and gradients. The
rfallover.
fe distance away from height
n or in the roadway when the truck
CE
mode.
ifficult roadways in
on
MANUAL
Roadways must
as holes, trou
be free of impairments, such
ghs or damage to the surface of
the roadway.
The roadways must be free of sloped sections.
Information about the documentation
Validity of this supplement to the operating instructions
This supplement to the operating instructions
applies in addition to the existing operating
instructions for the series-production truck
and both are to be considered as the original
850
108046085 EN - 08/2017
Page 17
Foreword 1
on
operating instructions. The operational and
safety information in the standard operating
instructions continues to be valid in its entirety
unless it is specifically countermanded in this
supplement to the operating instructions.
DANGER
Risk of accident!
It is essential that information in this supplement
to the operating instructions that differs to the
information in the operating instructions for the
series-production truck is observed!
Information about the documentati
Storing the operating instructions
This supplement to the operating instructions
must be kept with the operating instructions
for the series-production truck so that operators 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 manufacturer immediately. The operating instructions
are included in the spare parts list and can be
reordered as a spare part.
Sufficient quantities of the documentation
must also be made available for staff training
purposes.
Issue date and topicality of the operating instructions
The issue date of these operating instructions
can be found on the title page.
STILL is continuously working to enhance and
improve the trucks. These instructions are
subject to change, and any claims based on
the information and/or illustrations contained
in these operating instructions cannot be
asserted.
If you require technical support for the truck,
please contact the authorised service centre.
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third par-
08046085 EN - 08/2017 9
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Page 18
1 Foreword
Information about the documentati
ties—including as excerpts—except with the
express written approval of the manufacturer.
Explanation of information symbols used
DANGER
Indicates procedures that must be strictly adhered
to in order to prevent the risk of fatalities.
WARNING
Indicates procedures
to in order to prevent
CAUTION
Indicates procedures that must be strictly adhered
to in order to prevent material damage and/or
destruction.
NOTE
For technical r
special attent
that must be strictly adhered
the risk of injuries.
equirements that require
ion.
on
ENVIRONMENT NOTE
To prevent environmental damage.
Information for two-page PDF display
These operating instructions are optimised for
both printing and for on-screen display.
The document contains double pages, with
the illustrations on one side and the instructions shown in a table on the other side. To
ensure that this arrangement is shown correctly on your screen, please set the following
options in your PDF program:
View/Page Display
• Two Page View
• Show Cover Page in Two Page View
ACTIVE(2)
10 5
ACTIVE(1)
0108046085 EN - 08/2017
1
2
Page 19
Foreword 1
Environmental considerations
Environmental considerations
Disposing of components used for ASSISTANCE mode
The instructions for environmentally friendly
disposal of truck components that are specified in the operating instructions for the series-production truck also apply to components used for
Disposing of the remote control and
battery charger
Once they are deemed obsolete, the radio
remote control and the battery charger must
be scrapped in a collection point for hazardous
waste.
NOTE
Batteries that are no longer in use must be
collected in appropriate containers.
ASSISTANCE mode.
08046085 EN - 08/2017 11
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1 Foreword
Environmental considerations
12 5
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2
Safety
Page 22
2 Safety
Definition of terms used for respons
ible persons
Definition of terms used for responsible persons
Duties of the operating company
The operating company is the natural or legal
person or group who uses the truck or on
whose authority the truck is used.
The operating company must ensure that the
truck is only used for its intended purpose and
in compliance with the safety regulations in
these operating instructions and the operating
instructions for the series-production truck.
The operating company must
all users read and understa
information in these oper
and in the operating instr
series-productiontruck
instructions must be acce
operator at all times.
The operating company is responsible for
scheduling and correctly performing regular
safety inspections, including safety inspections on the components used for
TANCE
mode.
The requirements for the operating company—as well as the rights, duties and rules
of behaviour of the operating company—as
described in the operating instructions of the
series-production truck also apply to trucks
with the additional
operation.
In addition, the following provisions apply:
• As part of safety train
company must instruct t
to handle the truck in
This information applies
different methods of handl
MANUAL and ASSISTANCE m
the
operation.
• The operating company must instruct all
affected personnel in the safe handling of a
truck in
• The operating company is responsible for
ensuring the safe condition of roadways
(refer to the chapter entitled "Suitable
roadways").
• The operating company m
the truck is only operate
ASSISTANCE mode of
ASSISTANCE mode.
ensure that
nd the safety
ating instructions
uctions for the
. Both sets of operating
ssible to the truck
ASSIS-
ing, the operating
he operator on how
STANCE
ASSI
in particular for the
ing the truck in
ust ensure that
d by persons
mode.
odes of
14 5
0108046085 EN - 08/2017
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Safety 2
Definition of terms used for respons
who have been trained in the handling of
ible persons
ASSISTANCE mode.
The operating company must observe the
national regulations, laws and accident
prevention regulations.
Duties of the operator
The operator is the person who drives the truck
in
MANUAL mode or ASSISTANCE mode.
The requirements for the d
the rights, duties and rul
the driver—as described i
instructions of the seri
also apply to the operato
additional
As part of safety training, the operator must receive instruction from the operating company
on how to handle the truck in
mode.
In addition, the following provisions apply:
ASSISTANCE m
Special responsibility of the operator for
theremotecontrol
The operator must nev
control unattended w
work and must never gi
to anyone else. The rem
be operated by the operat
Once work has been completed, the operator
must ensure that the remote control cannot be
accessed by unauthorised persons.
river—as well as
es of behaviour of
n the operating
es-production truck
roftruckswiththe
ode of operation.
ASSISTANCE
er leave the remote
hen performing their
ve the remote control
ote control may only
or.
Additional requirements applicable to the authorised service centre
Work on components used for ASSISTANCE
mode must only be performed only by the service centre authorised by the manufacturer.
The service engineer must have received special training from the manufacturer regarding
the handling processes, technology and repair
work involved with the iGo neo. It is not permitted for other persons to perform work on the
components used for
ASSISTANCE mode.
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2 Safety
Definition of terms used for respons
This instruction does not apply to cleaning procedures on components that are not located
inside the truck; refer to the chapter entitled
"Cleaning".
The following components are used for
ASSISTANCE mode:
• Safety laser scanner
• Movement tracking sensors
• Control components
• Control electronics and control software
• Emergency off switches
• LED signalling unit
• Switches
• Remote control
Specialist
A qualified person is defin
engineer or a person who f
requirements:
• A completed vocational qualification that
demonstrably proves their professional
expertise. This proof should consist of
a vocational qualification or a similar
document.
• Professional experience indicating that
the qualified person has gained practical
experience of industrial trucks over a
proven period during their career During
this time, this 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 inspection
• Recent professional in
field of the industrial tr
and an appropriate furthe
are essential. The qualified
have experience of carrying ou
in question or of carrying out s
Moreover, this person must be a
the latest technological deve
regarding the industrial truck t
and the risk being assessed
ed as a service
ulfils the following
volvement in the
uck test in question
r qualification
person must
lopments
ible persons
tthetest
imilar tests.
ware of
obetested
16 5
0108046085 EN - 08/2017
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Safety 2
Basic principles for safe operatio
Basic principles for safe operation
Modifications and retrofitting
If the truck needs to be converted or retrofitted
for work that is not listed in these operating
instructions or in the operating instructions for
the series-production truck, approval from the
manufacturer must be obtained in advance.
Any modifications to the construction can
impair the safety of the truck in
mode and cause accidents.
Modifications to components used for
SISTANCE
with the specific approval of the manufacturer.
Approval from the relevant authority must be
obtained where applicable. If modifications
are carried out without the required approval,
the CE declaration of conformity provided by
the manufacturer is invalidated.
In particular, the following are not permitted:
• Modifications to compone
SISTANCE
movement tracking sens
ponents, control elect
software, emergency of
nalling unit, switches
• Use of attachment parts (e.g. headlights)
on the truck. Attachment parts may be fitted
only with the approval of the manufacturer
as attachment parts can impair the safety
functions of the truck. Approved attachment
parts must not project beyond the contour
of the truck
• Use of fork extensions on the truck
• Modifications to t
mode may be carried out only
mode (safety l
he fork spacing
ASSISTANCE
AS-
nts used for
aser scanner,
ors, control com-
ronics and control
f switches, LED sig-
and remote control)
AS-
n
Modifying the tru
DANGER
Risk of accident as a result of all safety functions
being lost
Modifications by unauthorised persons to the
parameters used by safety devices are forbidden.
Modifications to the truck parameters or
component parameters may be performed
exclusively by qualified personnel at the
manufacturer who have been trained to
ck parameters
08046085 EN - 08/2017 17
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Page 26
2 Safety
Basic principles for safe operatio
complete this work! All modifications must
be documented.
Warning regarding non-genuine parts
Genuine parts, components and accessories,
including for
cially designed for this truck. We specifically
draw your attention to the fact that parts, components and attachments and accessories
supplied by other companies have not been
tested and approved by STILL.
Installation and/or use of such products may therefore have a negative impact on the design features
of the truck and thereby impair active and/or passive driving safety in certain circumstances.
Only the authorised service centre may perform
work on the components used for
mode. The manufacturer accepts no liability for any
damage caused by the use of non-genuine parts
and accessories without approval.
ASSISTANCE mode, are spe-
CAUTION
n
ASSISTANCE
Damage, defects and misuse of safety systems
The operator must report any damage or other
defects in components used for
TANCE
mode to the supervisory personnel
immediately. The truck must only be operated in
MANUAL mode until the problem is
completely resolved. Components used for
ASSISTANCE mode include the safety laser
scanner, movement tracking sensors, control
components, control electronics and control
software, emergency off switches, LED signalling unit, switches and remote control.
Trucks that are not safe for operation or for use
on the road must not be used until they have
been properly repaired.
Do not remove or deactivate safety systems
and switches.
The contractually agreed set values for
ASSISTANCE mode may be changed only
18 5
ASSIS-
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Page 27
Safety 2
Residual risk
by qualified personnel at the manufacturer
who have been trained to complete this work.
Work on the electrical system (e.g. additional
headlights) is only permitted with the manu-
facturer's written approval. All work carried out
on the electrical system must be documented.
Medical equipment
WARNING
Electromagnetic interferencemayoccur 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
truckisinoperation.
– Ask your doctor or the manufacturer of
the medical equipment to confirm that the
medical equipment is sufficiently protected
against electromagnetic interference.
Residual risk
Residual dangers, residual risks
Despite working carefully and complying with
directives and standards, the possibility of
other dangers occurring when operating
the truck in
entirely excluded.
The system components used for
TANCE
quirements. Nevertheless, there remains a
degree of residual risk, even when the truck is
used for its intended purpose and all instruc-
tions are followed.
Even beyond the narrow danger area of the
truck itself, a residual risk cannot be excluded
when operating the truck in
mode. Persons and drivers of other trucks
must exercise a heightened degree of aware-
ness regarding the truck, so that they can react
ASSISTANCE mode cannot be
ASSIS-
mode comply with current safety re-
ASSISTANCE
08046085 EN - 08/2017 19
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Page 28
2 Safety
Residual risk
immediately in the event of any malfunction,
incident or breakdown etc.
WARNING
All persons that are in the vicinity of the truck must
be instructed regarding the dangers that arise from
a truck operating in
In addition, we draw attention to the safety regulations given in these operating instructions.
Additional risks that may arise when operating
the truck in
• Risk of accident due to obstructed or blind
roadways
• Risk of accident due to an unsuitable
working environment that the scanner
cannot detect, e.g. operation in unsuitable
warehouse aisles
• Risk of accident as a result of objects
protruding into the driving area that the
safety laser scanner cannot detect (e.g.
obstacles above or below the scanner
range)
• Risk of accident due to poor operator
visibility over the working area
• Unintentional operation of the remote
control by the operator
• Human error resulting from failure to
observe the safety regulations
• Unrepaired damage caused by force, or
faulty and worn components
• Work performed on components in the
system by unauthorised persons
• Insufficient maintenance and testing of
safety components
• Exceeding the test intervals of safety
components
• Risk of accident if the truck automatically
restarts movement following an emergency
stop when operating in
mode
The manufacturer accepts no responsibility
for accidents involving the truck caused by the
failure of the operating company or operator to
note these risks either intentionally or due to
lack of care.
ASSISTANCE mode.
ASSISTANCE mode include:
ASSISTANCE
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Safety 2
Residual risk
Overview of hazards and counter-
measures
NOTE
This table is designed to help operators eva-
luate the hazards present in
mode. It does not claim to be complete.
NOTE
Observe the national regulations for your
country!
Hazard
For transport systems with an assistance system for driverless operation
Roadway quality
inadequate
Load-carrying
equipment incorrect;
load could slip
Unpredictable driving
behaviour
Roadways blocked or
(temporarily) closed
Roadways intersect
in a mix of ASSISTANCE/MANUAL
mode
No person detection in
ASSISTANCE mode
ASSISTANCE
Course of action Check note
Clean/clear roadways O BetrSichVO
Reposition load on
pallet
Employee training
Mark roadways
Keep roadways clear
Announce right-of-way
rule
Employee training
√ Complete
- Not applicable
OBetrSichVO
OBetrSichVO
OBetrSichVO
OBetrSichVO
OBetrSichVO
Notes
(Workplace Safety
Ordinance)
(Workplace Safety
Ordinance)
(Workplace Safety
Ordinance)
(Workplace Safety
Ordinance)
(Workplace Safety
Ordinance)
(Workplace Safety
Ordinance)
08046085 EN - 08/2017 21
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2 Safety
Residual risk
Hazard
Obstacles such as
ladders and working
platforms within the
movement area of
the truck, e.g. for
performing repair or
maintenance work in
the aisle
Obstacles at right
angles to the roadway
or that protrude into the
roadway that cannot be
detected by the safety
systems on the truck
.
Course of action Check note
Close off roadways to
the affected movement
or working areas using
cones. Driverless
trucks may not be
operated in the
closed-off area
Employee training
Danger to employees when ASSISTANCE mode is used
According to the German Ordinance on Industrial Safety and Health (BetrSichV) and
labour protection law (ArbSchG), the operating company must determine and assess
hazards during operation, and establish the
labour protection measures required for employees (BetrSichVO). 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 person must be appointed.
√ Complete
Notes
- Not applicable
O
O
NOTE
Please note the definition of the following
responsible persons: "operating company"
and "operator".
The construction and equipment of the
truck correspond to the Machinery Directive
2006/42/EC and are therefore marked with
CE labelling. These elements are therefore
not included in the hazard assessment. Attachments possess their own CE labelling and
likewise are not included for that reason. However, the operating company must select the
22 5
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Safety 2
Safety tests
type and equipment of the truck so as to comply with the local provisions for deployment.
The result must be documented (§ 6 ArbSchG). In the case of applications involving
similar hazard situations, it is permitted to
summarise the results. The overview in the
chapter entitled "Overview of hazards and
countermeasures" provides advice on complying with this regulation. The overview specifies the primary 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 consideration.
The conditions of use for th
similar in many plants, so t
be summarised in one overvi
the information provided b
employers' liability insu
this subject.
e truck are broadly
he hazards can
ew. Observe
y the relevant
rance association on
Safety tests
Regular safety inspec
Safety inspection b
extraordinary inc
The operating company must ensure that the
entire truck is inspected by a qualified person
at least once a year or after unusual incidents.
As part of this inspection of the entire truck,
the condition and function of the components
used for
checked.
These components (saf
movement tracking sen
nents, emergency off s
unit, switches and rem
be inspected by the autho
tre. The person performi
the authorised service c
ficient knowledge and exp
to assess the condition
effectiveness of the de
ASSISTANCE mode must also be
tion of the truck
ased on time and
idents
ety laser scanner,
sors, control compo-
witch, LED signalling
ote control) must only
rised service cen-
ng the inspection in
entre must have suf-
erience to be able
of the truck and the
vices according to tech-
501
08046085 EN - 08/2017 23
Page 32
2 Safety
Emissions
nical conventions and the principles for testing
industrial trucks.
A test log must be created, with the date
specified. The results of the inspection
must be retained at least until a further two
inspections have been carried out.
The operating company is res
ensuring that any faults on t
are rectified without delay b
service centre.
ponsible for
hese components
y the authorised
Emissions
NOTE
The emissions values correspond to the values listed in the standard operating instructions.
24 5
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3
Components of the iGo neo
Page 34
3 Components of the iGo neo
Overview of components used for ASS
ISTANCE mode
Overview of components used for ASSISTANCE mode
1
2
3
4
5
1 LED signalling unit
2 Movement tracking sensors (left and right-
hand side of the truck)
3 Additional emergency off switches (left and
right-hand side of the truck)
4 Assistance button (on switch/two-way
switch for
right-hand side of the truck)
ASSISTANCE mode; left and
6
7
5 Driver's platform (for switching be-
tween movement tracking modes ACTIVE/PAUSED)
6 Two-way switch for drive programmes in
ASSISTANCE mode (hare/tortoise buttons)
7 Safety laser scanner
26 5
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Components of the iGo neo 3
LED signalling unit
LED signalling unit
Signals from the inner lighting zone on the LED signalling unit
The inner zone (1) provides information on:
• Whether
on/switched off
• Emergency stops
ASSISTANCE mode is switched
1
2
3
Signal Truck function signalled
(1) - Lighting zone remains
permanently lit
(2) - Lighting zone pulsates
slowly (approx. once per
second)
(3) - Light signal flashes quickly
(approx. 10 x per second)
.
ASSISTANCE mode
Truck in
Truck in
MANUAL mode
Emergency stop
Description
Movement tracking set to
ACTIVE or PAUSED
The operator has exited the
driver's compartment
Movement tracking is not
active
Operator is in the driver's
compartment and is operating
the truck manually
Truck is stationary, triggered
by the safety laser scanner or
by pressing the emergency off
switch
08046085 EN - 08/2017 27
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Page 36
3 Components of the iGo neo
LED signalling unit
Signals from the outer lighting zone on the LED signalling unit
A
A light spot (A) in
the selected truc
The remote contro
to be set to RIGHT,
Signal Truck function signalled
(1) - Light spot
along the lighti
(2) - Light spot moves to the
right along the lighting zone
(3) - Light spot moves towards
the centre along the lighting
zone
Truck alignment (1, 2, 3)plus
"PAUSED" LED signal for the
movement-tracking sensors
.
the outer rotating zone shows
k alignment to the racking.
l allows the truck alignment
LEFT or CENTRE.
moves to the left
ng zone
Truck alignment LEFT
Truck alignment RIGHT
Truck alignment CENTRE
Waiting in front of an intersection or rack end
1
2
3
Description
Truck maintains a constant
distance to the rack contour on
the left
Truck maintains a constant
distance to the rack contour on
the right
Truck moves in the centre
between the two rack contours
e truck manually to the
Drive th
next rack c
can detect
ontour that the truck
28 5
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Page 37
Components of the iGo neo 3
Movement tracking sensors
Movement tracking sensors
Function of the movement tracking sensors
Using the sensors, the truck identifies and
tracks the position of the operator.
The two movement tracking sensors (1) detect
the area around the truck at a height of 135 cm.
The sensors follow the position of the operator
in a line-of-sight radius of max. 15 m. The light
from the sensors (infrared laser scanner) is
not dangerous for the human eye.
LED signals from the movement tracking sensors
1
ERR
PWR
1 2 3 4
ERR
PWR
The indicator LEDs on the movement tracking sensors inform the operator about the status of the
movement tracking system.
(1) "Operator detected/ACTIVE" signal
Information
Operator detected.
Movement tracking system ACTIVE.
The "Eye" icon (1) is displayed.
The truck follows the operator automatically.
Theiconal
and follow
indicates
tracking s
ways points toward the operator
s the position of the operator. This
to the operator that the movement
ystem is focused on him.
08046085 EN - 08/2017 29
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Page 38
3 Components of the iGo neo
Movement tracking sensors
(2) "Operator detected/PAUSED" signal
The "paused icon" (2) is displayed within the
current "eye" icon.
(3) "Operator not detected" signal
The "lines" icon (3) is displayed.
(4) "Operator not detected/PAUSED" signal
The "paused icon" (4) is displayed within the
current "lines" icon.
.
Information
Operator detected.
Movement tracking system PAUSED.
The truck remains stationary
or stops.
The icon always points toward the operator
and follows the position of the operator. This
indicates to the operator that the movement
tracking system is focused on him.
Information
Operator currently not detected or position lost.
The truck remains stationary or stops.
As soon as the system detects the operator
again, movement tracking is ACTIVE again.
The truck follows the operator again without
further intervention.
If the operator is not detected for more than 30
seconds, the truck switches to "Operator not
detected/PAUSED"
If necessary, refocus the movement tracking
system back onto the operator using the assistance button.
Information
Operator currently not detected or position lost.
The truck remains
stationary.
As soon as the system detects the operator
again, the display changes to "Operator detected/PAUSED".
If necessary, refocus the movement tracking
system back onto the operator using the assistance button.
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Page 39
Components of the iGo neo 3
Safety laser scanner
Safety laser scanner
Function of the safety laser scanner
The safety laser scanner (1) is part of the
safety concept for driverless navigation.
The safety laser scanner checks the roadway
for obstacles while the truck is in motion.
• If the scanner detects an obstacle on the
side of the roadway to which the truck
is aligned, the truck automatically drives
around the obstacle. The truck then continues on its path.
• Ifanobstacleistoolarget
the truck will stop. The tr
continue on its path as soo
is removed.
• If an obstacle enters the p
the safety laser scanner,
an emergency stop.
The safety laser scanner d
contour and the surroundi
• Using the spatial data, the truck can automatically follow the operator along the rack
contour.
The safety laser scanner poses no risk of
damaging the human eye.
o drive around,
uck will then
n as the obstacle
rotectivefieldof
the truck performs
etects the rack
ng environment.
1
Size and location of the monitored area
2
1
3
08046085 EN - 08/2017 31
501
4
Page 40
3 Components of the iGo neo
Safety laser scanner
The safety laser scanner (1) monitors the area
(2) in front of the truck.
• In the drive direction, the size of the monitored range depends on the current speed.
At higher speeds, the monitored area (3) in
front of the truck also increases.
• The monitored area at the sid
beyond the truck contour.
e (4) extends
Limits to the detection of o
Detection of obstacles
Can be detected by the safety laser
scanner
Cannot be detected by the safety laser
scanner
DANGER
of collisions with obstacles that the safety
Danger
anner cannot detect.
laser sc
pter outlines the limits of the iGo neo in
This cha
ng obstacles.
detecti
–Checkth
– If there
e roadway above all for obstacles that
ety laser scanner cannot detect and
the saf
hese obstacles.
remove t
is a risk of danger, press one of the
ncy off switches on the truck. The truck
emerge
mediately come to a standstill.
will im
bstacles
15 cm
1
2
(1) Safety laser scanner
(2) 15 cm scanning height of the safety laser
scanner
he truck is in motion, the safety laser
While t
r horizontally scans the area in front
scanne
32 5
0108046085 EN - 08/2017
Page 41
Components of the iGo neo 3
Safety laser scanner
of the truck. The scanning height is approx.
15 cm (position (2) on the illustration).
The safety laser scanner detects stationary
objects on the ground that have the following
minimum dimensions (
• Diameter: at least 70 mm in scanning height
(on the side facing the safety laser scanner)
• Height: at least 200 mm
If the safety laser scanner does not detect an
obstacle because these required dimensions
do not apply, the truck could ram the obstacle.
For this reason, it is necessary to pay special
attention to the following obstacles (
illustration):
• Obstacles that are too flat to be detected by
the safety laser scanner
• Obstacles that do not reac
floor
Obstacles of this nature c
• 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
roadway above the scanning height of the
safety laser scanner
• Hand pallet trucks and t
forks of trucks
• A cable that hangs crosswise to the roadway
• Ladders and mobile workshop hoists that
protrude into the roadway
• An object that is too sm
to be detected by the sa
(e.g. a narrow rack sup
chair)
on the illustration):
on the
hdowntothe
ould include:
heir tillers, or the
all or too narrow
fety laser scanner
port or the leg of a
08046085 EN - 08/2017 33
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Page 42
3 Components of the iGo neo
Assistance button
Assistance button
Functions of the assistance button
1
1 Assistance button o
Function in ASSISTA
Truck is stationary
Identify and track the operator
(Movement tracking PAUSED
Pause movement tracking
(Movement tracking ACTIVE
NCE mode
ACTIVE)
PAUSED)
Assistance button
Press 1 x briefly
Press 1 x long (2 sec.)
Truck is in motion Assistance button
Stop the truck
(Movement tracking ACTIVE
.
PAUSED)
Press 1 x briefly
Function in MANUAL mode
Switch on ASSISTANCE mode initially Press 1 x briefly
.
nthetruck
34 5
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Page 43
Components of the iGo neo 3
Emergency off switch
Emergency off switch
Additional emergency off switches
The truck is equipped with additional emergency off switches (1) (left and right-hand side
of the truck).
– In the event of imminent danger to people,
the load or the truck, press one of the
emergency off switches immediately. This
is the fastest way to bring the truck to a
standstill.
When the emergency off swit
the truck performs an emerg
to the chapter entitled "
event of an emergency sto
ch is pressed,
ency stop (refer
Truck behaviour in the
p").
1 Additional emergen
right-hand side of t
cy off switches (left and
he truck)
1
08046085 EN - 08/2017 35
501
Page 44
3 Components of the iGo neo
Remote control
Remote control
Functions of the remote control
NOTE
The"Check" (A)indicator light shows that the
remote control is connected to the truck by
flashing continually.
The remote control can be operated intuitively
after a short time.
Operating movement tracking
123
A
54
Truck is stationary
Identify and track
(Movement trackin
1
Pause movement
(Movement trac
Truck is in motion
Stop the truck
1
(Movement t
.
the operator
g PAUSED
tracking
king ACTIVE
racking ACTIVE PAUSED)
ACTIVE)
PAUSED)
iGo button
Press 1 x briefly
Press 1 x briefly
iGo button
Press 1 x brie
Driving automatically without movement tracking
Function iGo button Information
The truck is travelling along the rack
1
contour automatically
.
Press and hold
(>2 sec.)
Canonlybeexecuted
with "movement tracking
PAUSED"
Setting the truck position
Function
Move the truck position to the next
pallet (in the direction of the load
2
side)
Move the truck position to the next
pallet (in the direction of the drive
3
side)
utton
iGo b
Press 1 x long (2 sec.)
Press 1 x long (2 sec.)
Info
Canonlybeexecuted
with "movement tracking
PAUSED"
Canonlybeexecuted
with "movement tracking
PAUSED"
fly
rmation
36 5
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Page 45
Components of the iGo neo 3
Remote control
Function iGo button Information
Switch the truck alignment in sequence
4
(LEFT► MIDDLE► RIGHT► LEFT
etc.)
Switch the truck alignment in sequence
5
(RIGHT► MIDDLE ► LEFT ► RIGHT
etc.)
.
Push once briefly
Push once briefly
Can only be executed when
the truck is stationary.
Can only be executed when
the truck is stationary.
08046085 EN - 08/2017 37
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Page 46
3 Components of the iGo neo
Remote control
Charging the remote control
Discharge indicator on the remote control
The charging state of the battery is displayed
by the "Check" indicator light (1).
If the battery is charged, the
light flashes quickly (ligh
ond).
If the battery capacity is close to the lower
limit, the "Check" indicator light flashes slowly
(lights up once every two seconds). This
happens for approx. 10 minutes before the
remote control automatically switches off.
If the battery charge is no longer sufficient to
ensure that commands are reliably transmitted, the remote control remains switched off.
Keeping the remote control charged prolongs
the life cycle of the rechargeable batteries.
"Check" indicator
ts up once per sec-
1
38 5
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Page 47
Components of the iGo neo 3
Remote control
Charging process
NOTE
The rechargeable batteries are permanently
1
installed in the remote control. In the event of
a malfunction, do not force the remote control
open. Notify the authorised service centre.
Rechargeable batteries are installed in the
remote control (1) that can be recharged using
the appropriate battery charger (2). When
using the battery charger, the charging state
of the rechargeable batteries is displayed by
the "Power"(3) and "Status"(4)indicator lights.
As far as possible, the remote control must
2
3
POWER STATUS
4
be charged without interruption and at a room
temperature of between +0°C and +45°C.
– Connect the supplied power supply unit to
the battery charger.
– Connect the power supply unit to the socket.
The "Power" indicator light is switched on.
– Insert the remote control into the battery
charger and press down until the remote
control snaps firmly into place in the battery
charger. Charging of the rechargeable
batteries then starts. Inserting the remote
control into the battery charger ends any
radio communication with the truck that
may still be active.
The rechargeable batteries are charged in two
phases.
1. First phase (quick charge)
• "Power" indicator light off, "Status" indicator
light on
• Duration: 2–3 hours
• Charge capacity once finished: 90%
1 Remote control
2 Battery charger
3 "Power" indicator light for the charger
4 "Status" indicator light for the charger
%
100
90
80
70
60
50
40
30
20
10
123
Charging phases of the remote control
1 1. Phase (2–3 hours)
2 2. Phase (1–2 hours)
3 Charging complete
2. Second phase (slow charge)
• "Power" indicator light on, "Status" indicator
light on
• Duration: 1–2 hours
• Charge capacity once finished: 100%
At very high (above 45°C) or very low (below
0°C) temperatures, charging is interrupted
in order to protect the batteries. To indicate
such instances, the "Power" indicator light is
08046085 EN - 08/2017 39
501
Page 48
3 Components of the iGo neo
Remote control
switched on and the "Status" indicator light is
switched off. Charging resumes as soon as
the temperature returns to within the safety
limits.
– Only store the remote control for a pro-
longed period when the rechargeable batteries are fully charged. If the remote control
is not used for an extended period of time
and the rechargeable batteries are nearly
empty, the service life of the remote control
can be significantly reduced.
Maximum operating time of remote
control when the battery is fully charged
The maximum operating tim
control when the battery i
approx. 50 hours (at 20°C)
e of the remote
s fully charged is
.
Changing the remote con
Each remote control ha
code that is defined by t
Remote controls are on
the truck if the releva
been recognised by the
prevents non-registe
accessing the truck.
If a truck is to be controlled using a new or
additional remote control, the pairing code for
the remote control must first be saved in the
receiving unit on the truck.
Each receiving unit can save a maximum of 20
pairing codes. If there are already 20 pairing
codes present and more codes need to be
saved, all existing pairing codes must first be
deleted. Individual pairing codes cannot be
deleted from the memory of the receiving unit.
If multiple remote co
to a truck attempt to acc
taneously, the remote c
contact with the truck r
remote controls do not rec
first remote control has st
nt pairing code has
red remote controls from
ntrols that are registered
etains control. Other
trol
s a unique pairing
he manufacturer.
ly able to control
receiving unit. This
ess the truck simul-
ontrol that first made
eive access until the
opped transmitting.
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Components of the iGo neo 3
Remote control
Registering a new or additional remote
control on the truck
Registration must be performedin accordance
with the supplied operating instructions from
the manufacturer of the remote control.
– Contact the authorised serv
register a remote control on
ice centre to
the truck.
08046085 EN - 08/2017 41
501
Page 50
3 Components of the iGo neo
Remote control
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Page 51
4
Operating the iGo neo
Page 52
4 Operating the iGo neo
Checks and tasks to be carried out wh
en commencing ASSISTANCE mode
Checks and tasks to be carried out when commencing ASSISTANCE mode
Safety information related to using this mode
WARNING
Damage or other defects to the components used
for
ASSISTANCE mode can result in accidents.
If damage or other defects are identified on the
components during the following inspections, the
truck must not be used until it has been properly
repaired. Do not open, remove or deactivate
components for
change any predefined set values.
– Report defects to the supervisory personnel.
Visual inspection before switching on ASSISTANCE mode
Before commencing ASSISTANCE mode,
the operator must ensure that the components
used for
operation:
• The hoop guard on the front of the 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 LED signalling unit and its mountings
must not be damaged
• The optics covers (windows) in front of
safety laser scanner and the movement
tracking sensors must be free of dirt,
scratches and damage. This is important to
ensure that the sensor system can function
correctly
• All covers must be present and sealed
• The remote control for
must not be damaged and must be fully
charged. The remote control must be worn
on the arm in the supplied holder to protect
the remote control and prevent operating
errors
ASSISTANCE mode. Do not
ASSISTANCE mode are safe for
ASSISTANCE mode
44 5
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Operating the iGo neo 4
Checks and tasks to be carried out wh
– Report defects to the supervisory person-
nel. Do not use the truck until it has been
properly repaired
en commencing ASSISTANCE mode
Visual inspection and brake test after switching on ASSISTANCE mode
Safety brake test after switching on
ASSISTANCE mode
After switching on ASSISTANCE mode, a
check must be performed to ascertain whether
the truck automatically stops in front of an
obstacle.
– Stop the truck in front o
straight section of roa
– Place a suitable test object (with an edge
length and height of at least 20 cm) one
metreinfrontofthetruck.
– Move off the driver's platform and move
the truck using the remote control so that it
approaches the test object.
The truck must automa
standstill just in fr
the truck stops, the L
the warning buzzer em
signal.
– Report defects to the supervisory personnel
and do not use the truck until it has been
properly repaired.
f an unobstructed,
dway.
tically come to a
ont of the obstacle. Once
ED signalling unit and
it the "Emergency stop"
Visual inspections after switching on
ASSISTANCE mode
After switching on ASSISTANCE mode,
the operator must check the following truck
functions during operation:
• During operation, check that the truck
responds correctly to entries made with
the remote control.
• During operation, check that
signals and information sign
the warning
als function in
ASSISTANCE mode.
The signals are part of the safety concept of
the truck. These signals provide important
information for people in the working area
08046085 EN - 08/2017 45
501
Page 54
4 Operating the iGo neo
Checks and tasks to be carried out wh
as they indicate that there is a driverless
truck close by. The signals will help to avoid
accidents.
– For details on the information and warning
signals in
chapter entitled "Information and warning
signals in
– Report defects to the superv
and do not use the truck until
properly repaired.
ASSISTANCE mode, refer to the
ASSISTANCE mode".
isory personnel
it has been
en commencing ASSISTANCE mode
46 5
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Page 55
Operating the iGo neo 4
Safety regulations in ASSISTANCE m
ode
Safety regulations in ASSISTANCE mode
Instructions for safe operation of the truck
Wear safety shoes
In the interest of safety, the operator and
people in close proximity to the truck must
wear work safety shoes while the truck is being
operated.
Risk of crushing feet
DANGER
Risk of feet being crushed by the fork of the truck
When the truck moves off in
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 work safety shoes.
Risk of accident from crossing the
roadway immediately in front of the truck
DANGER
Danger for p
roadway i
The safe
roadw
quic
in f
the
llision.
co
–Do
alm
–Don
ma
a
m
– The truck operating in
always has priority. Observe lighting signals
from the iGo neo.
eople or objects that quickly cross the
mmediately in front of the truck.
ty laser scanner detects obstacles in the
ay in front of the truck. If a person or object
kly crosses the detection area (1) immediately
ront of the truck, under certain circumstances
immediate emergency stop may not prevent a
not jump or step in the roadway if the truck is
ost at the same level.
ot cross the roadway of the iGo neo with a
nually operated truck if the iGo neo is almost
t the same level. Note the fork length of the
anually operated truck.
ASSISTANCE mode
1
ASSISTANCE mode
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4 Operating the iGo neo
Safety regulations in ASSISTANCE m
Maintain a safe distance from sloping
edges and gradients
DANGER
Risk of accident from slopin
on or in the roadway
ASSISTANCE mode, the t
In
the roadway for height di
edges, steps, platform
truck will tip or fall o
– Maintain a safe distan
differences on or in t
ASSISTANCE mode
is in
– Always cover difficu
mode.
g edges and gradients
ruck does not check
fferences, e.g. on sloping
s, ramps and gradients. The
ver.
ce away from height
he roadway when the truck
.
lt roadways in
MANUAL
ode
Observe the maxim
dimensions of pal
um permissible
lets and loads
DANGER
Risk of accident from pallets and loads that protrude
beyond the truck contour
The load must not protrude beyond the truck contour in a longitudinal or lateral direction, as otherwise the load may collide with persons or the load
may fall off.
– Only use suitable pallets (refer to the chapter
entitled "Suitable pallets and loads").
Risk of accident due to excessive speed
DANGER
Risk of collision due to excessive speed when
operating in
When operating in ASSISTANCE mode, the operator controls the driving speed of the truck via
movement tracking or by using the remote control.
Accidents may occur if the speed is not adapted to
the current operating situation.
– When operating in
ASSISTANCE mode
allow the truck to drive at such a speed so that no
persons or objects are endangered.
ASSISTANCE mode, only
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Safety regulations in ASSISTANCE m
ode
Risk of collision when driving on slopes
DANGER
Risk of collision when driving on slopes when
operating in
When driving on slopes, the alignment of the safety
laser scanner is no longer horizontal. Under certain
circumstances, obstacles may not be detected.
– Always cover slopes in
ASSISTANCE mode
MANUAL mode.
Information and warning signals in
ASSISTANCE mode
DANGER
Risk of accident due to failure to observe warning
signals
When operating in
truck emits audible and optical information signals
and warning signals. The LED signalling unit
provides information about
the warning buzzer uses a rhythmic sound to warn
when the truck is moving off.
– Observe warning signals. Act with due care and
attention
DANGER
Risk of accident due to faulty warning units
When operating in
emits audible and optical information signals and
warning signals.
– Faulty components (LED signalling unit, warning
buzzer) must be changed immediately, before
operation in
ced or resumed.
ASSISTANCE mode, the
ASSISTANCE mode,
ASSISTANCE mode, the truck
ASSISTANCE mode is commen-
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4 Operating the iGo neo
Safety regulations in ASSISTANCE m
Transport of people and jumping onto
the truck prohibited when operating in
ASSISTANCE mode
DANGER
Risk of injury for persons when travelling as a passenger or when jumping onto the truck in ASSISTANCE mode
While the truck is being controlled via movement
tracking or by using the remote control, only the
operator is permitted to stand in the working area of
the truck. If people ride the truck as passengers or
jump onto the truck, they are at risk of falling down
or interrupting operation of the truck.
–In
ASSISTANCE mode, do not travel on the
truck as a passenger or jump onto the truck.
Risk of accident due to smoke in the
event of fire
DANGER
Risk of accident due to optical safety systems being
rendered inactive by smoke in the event of fire
The optical assistance systems (safety laser scanner, movement tracking sensors) can be affected
by smoke in the event of fire.
– Do not operate the truck in
if there is smoke in the area surrounding the
truck.
ASSISTANCE mode
ode
Safe storage of the remote control
DANGER
Risk of accident if the remote control is actuated by
anyone other than the operator
If anyone else actuates the remote control, the truck
may move unexpectedly and injure people.
– Never give the remote control to anyone else
while you are working. The remote control may
only be operated by the operator.
– Never leave the remote control unattended while
you are working. Always wear the remote control
on your arm in the supplied holder.
– Once work has been completed, ensure that
the remote control cannot be accessed by
unauthorised persons.
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Safety regulations in ASSISTANCE m
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Risk of accident due to incorrect detection of the operator
DANGER
Risk of accident due to incorrect detection of the
operator
In some circumstances, the truck can identify
another person moving in the working environment
of the truck as the operator. As a result, the truck
can unexpectedly follow this other person along the
aisle.
– Ensure that there are no persons moving or
standing between the truck and the operator.
– Immediately switch the movement tracking to
PAUSEDusingtheiGobuttonontheremote
control. If necessary, press the emergency off
switch on the truck.
Priority rules in mixed MANUAL/ASSISTANCE traffic
DANGER
Risk of collision in areas with mixed MANUAL/AS-
SISTANCE
Atruckin
second truck or may detect it too late, for example if
the forks of the second truck are above or below the
15-cm scanning height of the safety laser scanner.
Atruckin
stop moving unexpectedly.
– Observe the flashing and warning signals from
the truck that indicate that the truck is driving or
setting off in
– Always give trucks operating in
mode priority over trucks being driven manually.
–Inareaswithmixed
traffic, always drive with special care.
traffic
ASSISTANCE mode may not detect a
ASSISTANCE mode may start moving or
ASSISTANCE mode.
ASSISTANCE
MANUAL/ASSISTANCE
"Mixed traffic" means that trucks in ASSIS-
TANCE
mode and trucks driven manually are
operated in the same area.
In these areas, the following rule applies:
•Driverl
esstrucksalwayshavepriorityover
manually
driven trucks.
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4 Operating the iGo neo
Safety regulations in ASSISTANCE m
ode
Keeping roadways clear of obs
tacles
DANGER
Risk of accident in the event of additional work
being performed in the roadway that could impede
ASSISTANCE mode, e.g. in the form of people on
ladders and workshop hoists.
– If additional work is being performed in the
working area, close off the roadways using
cones at a maximum distance of 1.0 m.
– The cones must have a minimum height of
200 mm so that they can be reliably detected
by the safety laser scanner.
CAUTION
Increased dange
safety laser sca
The safety lase
close to the gro
extend more th
the ground pos
The truck doe
instances.
– Before mov
obstacles
detect. P
extend la
roadway
– Pay atte
hoists
acles
obst
– Pay at
ety laser scanner cannot detect half-open
saf
l-up doors.
rol
r of collisions with objects that the
nner cannot detect.
r scanner covers only the area
und. Objects in the roadway that
an approx. 15 cm in height above
e an increased risk of accidents.
s not brake automatically in such
ing the truck, check the roadway for
that the safety laser scanner cannot
ay particular attention to objects that
terally into the roadway. Clear the
ntion to cables, ladders and workshop
that cross the roadway. Remove these
tention to half-open roll-up doors as the
e roadways for driving in
Th
de must be level and free of obstacles in
mo
ASSISTANCE
order for the safety laser scanner to reliably
detect the working environment.
– Before moving the truck, check the roadway
for any obstacles. Clear the roadway
– Pay particular attention to objects in the
roadway that extend more than approx. 15
cm in height above the ground, e.g. long
objects that protrude out of the rack. The
safety laser scanner detects only the area
close to the ground.
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Safety regulations in ASSISTANCE m
ode
Minimum distance to obstacles in the
roadway
Pallets, containers and similar items must
always be set down in such a way that a
safety distance of 50 cm is always maintained
between the truck contour (including the load)
and the obstacles.
If this safety distance is no
operating company must ensu
guaranteed for persons and o
way.
t maintained, the
re that safety is
bjects in another
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4 Operating the iGo neo
Operating the truck in ASSISTANCE m
ode
Operating the truck in ASSISTANCE mode
Overview of ASSISTANCE mode
CAUTION
Risk of accident as a result of differences between
the
MANUAL and ASSISTANCE modes of opera-
tion.
In
MANUAL mode, the safety devices available
in
ASSISTANCE mode do not assist the driver.
The truck does not brake automatically or steer
automatically.
When manoeuvring in
that the safety laser scanner extends out over the
truck contour at the front of the truck.
– Pay full attention when operating the truck,
taking safety into account at all times.
The operator can switch between the different
modes of operation:
TANCE
.
MANUAL mode corresponds to the operation
of the series-production truck:
• Ride-on mode
• Pedestrian mode with cockpit, slow travel
with drive switch
• Pedestrian mode with push button (special
equipment)
• Controlling the truck using the remote
control or via automatic movement tracking
is not possible in
ASSISTANCE mode is the additional operat-
ing mode of the iGo neo.
MANUAL mode, be aware
MANUAL and ASSIS-
MANUAL mode.
ASSISTANCE mode
ASSISTANCE mode supports the operator
when picking items from the rack or placing
them into the rack.
While the operator is standing on the driver's
platform, the truck behaves exactly as it does
MANUAL mode.
ASSISTANCE mode, the movement
In
tracking sensors on the truck automatically
detect the position of the operator. As soon as
the operator moves off the bottom plate of the
driver's compartment, the truck automatically
follows him at the same level along the racks.
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Operating the iGo neo 4
ode
The operator can transfer between the truck
and the rack without interruption.
During this process, the truck maintains a
safety distance (1) to the rack in which the
operator can move safely. The safety distance
is always set to at least 50 cm.
ASSISTANCE mode, the tru
In
in the drive direction, not
The operator can also control
mode using a remote control.
A safety laser scanner monitors the roadway.
The safety laser scanner stops the truck in the
event of danger represented by obstacles or
persons.
ck moves only
in the load direction.
ASSISTANCE
Operating the truck in ASSISTANCE m
1
min. 50 cm
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4 Operating the iGo neo
mode are
ode
+
30 sec.
1x
ERR
= ON
PWR
Operating the truck in ASSISTANCE m
Switching the truck on and off
Switchingonthetruck
– Plug in the battery male connector.
The components for
initialised when the battery
on the truck is plugged in. T
are ready to operate after a
seconds.
– Switch on the truck following the instruc-
tions given in the original operating instructions for the series-production truck.
The truck can now be operated in
mode.
NOTE
ASSISTANC
The truck can be switched on during the
initialisation of ASSISTANCE mode and
operated in
MANUAL
mode.
Switching off the truck
– Switch off the truck following the instruc-
tions given in the original operating instructions for the series-production truck. The
truck is switched off.
E
male connector
he components
pproximately 30
MANUAL
NOTE
The robotics syste
automatically until
has elapsed. The author
can configure the run-on
between 30 seconds and 6
56 5
m does not switch off
the selected run-on time
ised service centre
time to a period
0 minutes.
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Operating the iGo neo 4
Operating the truck in ASSISTANCE m
ode
Switching on ASSISTANCE mode
Before ASSISTANCE mode is available,
the remote control must be activated and
ASSISTANCE mode must be switched on.
Activating the remote control
The connection between the truck and remote
control must first be established.
– Press the button (1) on the r
for two seconds.
If the CHECK indicator light flashes continuously, there is a connection between the
remote control and truck.
The LED signalling unit shows the truck
alignment in the aisle (LEFT - MIDDLE RIGHT). The authorised service centre can
configure the preferred initial truck alignment.
emote control
Switching on ASSISTANCE mode
– If necessary, the des
can be adjusted using
(see the following ch
truck alignment").
– Press the assistance buttons on the side
to which the truck is aligned to switch on
ired truck alignment
the remote control
apter "Adjusting the
ASSISTANCE mode.
ASSISTANCE mode has been
Once
switched on, movement tracking is ACTIVE
immediately and is focused on the operator.
The truck follows the operator along the rack
contour.
1x 2 Sec.
1
=
1x
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4 Operating the iGo neo
Operating the truck in ASSISTANCE m
Adjusting the truck alignment
Before order picking starts, the operator
specifies whether the truck must align to
the right (1), left (3) or to the centre (2) of
the aisle. In
then automatically follows the selected rack
contour.
The truck can only be set to an alignment for
which the truck has detected a corresponding
rack contour. If the selected alignment cannot
be set, the truck emits the "Truck alignment
not possible" warning sound (a warning sound
for one second).
– Adjust the truck alignment
control:
Button (A)
• Push once briefly: Switch the truck alignment in sequence (LEFT ► MIDDLE ►
RIGHT ► LEFT)
Button (B)
• Push once briefly: Switch the truck alignment in sequence (RIGHT ► MIDDLE ►
LEFT ► RIGHT)
The LED signalling unit signals the set truck
alignment:
• Truck alignment RIGHT (1)
• Truck alignment MIDDLE (2)
• Truck alignment LEFT (3)
If the desired truck ali
thetruckpositionmustbe
ASSISTANCE mode, the truck
using the remote
gnment cannot be set,
corrected.
ode
AB
1
2
3
1
2
3
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Operating the iGo neo 4
Operating the truck in ASSISTANCE m
ode
Positioning the truck correctly in the aisle
Positioning the truck in the aisle
It must be possible for the truck to detect a
straight rack contour.
The rack contour must not have any gaps
larger than 2.7 m (can be parameterised).
It must be possible for the truck to detect the
rack contour (1) over a distance of 2–3 m in
front of the truck.
The truck must be positioned parallel to the
rack.
1
min. 2 - 3 m
Specifying the dis
contour in combina
tance to the rack
tion with movement
tracking
The distance to the rack contour when movement tracking is activated specifies the distance that the truck maintains when it drives
automatically. If movement tracking is already
switched on, the distance is determined when
the operator leaves the driver's platform.
– Drive the truck manually to the starting point
for movement tracking.
– Position the truck a
parallel to the ra
distance (2) mus
and 250 cm. If an i
specified, the tr
off until a distanc
– Move off the driver's platform and, if neces-
sary, switch on movement tracking.
The truck follows the rack contour at the
specified distance.
NOTE
t the required distance
ck contour. The selected
t be between 50 cm
nsufficient distance is
uck will steer when it moves
e of 50 cm is reached.
The authorised service centre can configure
a permanent minimum distance to the rack
contour.
min. 50 cm
max. 250 cm
2
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4 Operating the iGo neo
Operating the truck in ASSISTANCE m
Correctly positioning the truck in line
with the rack when the truck is aligned
sideways
CAUTION
Risk of collision if the truc
anangleinrelationtoth
If the truck is positione
relation to the rack con
correctly detect the ra
ces and will therefore
– Before starting movem
position the truck pa
–Slowlysetthetruck
an immediate stands
50 cm to the rack is
– Move the truck in M
starting point fo
k is positioned at too sharp
e rack contour
d at too sharp an angle in
tour, the system may not
ck under certain circumstancollide with the rack.
ent tracking, always
rallel to the rack.
in motion. Bring the truck to
till if the safety distance of
not reached.
ANUAL
r
ASSISTANCE mode.
mode to the
– Position the truck parallel to the rack at the
desired distance (min. 50 cm).
Correctly positioning the truck in the
centre of the aisle
– Move the truck in MANUAL mode to the
starting point for
– Position the truck
it is in the centr
ASSISTANCE mode.
parallel to the rack so that
ebetweenthetworacks.
ode
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Operating the iGo neo 4
Operating the truck in ASSISTANCE m
ode
Switching between ACTIVE and PAUSED modes for movement tracking
Movement tracking can be int
restartedusingtheremotec
or the assistance button.
– Monitor the signals displayed by the indi-
cator LEDs for the movement tracking sensors. The indicator LEDs show the current
status of the movement tracking function.
Truck is stationary
Identify and track the operator
1
(Movement tracking PAUSED
Truck is in moti
Stop the truck
2
(Movement tracking ACTIVE
on
errupted or
ontrol (iGo button)
ACTIVE)
PAUSED)
1
1
2
2
iGo button or assistance button
Press 1 x briefly
iGo button or assistance button
Press 1 x briefly
1x
Pause movement tracking (truck is stationary)
Truck is stationary
Pause movement tracking
(Movement tracking ACTIVE
Truck is stationary
Pause mo
(Move
.
vement tracking
ment tracking ACTIVE
PAUSED)
PAUSED)
08046085 EN - 08/2017 61
501
Assistance butt
Press 1 x
iGo button
Press 1 x briefly
long (2 sec.)
on
Page 70
4 Operating the iGo neo
Operating the truck in ASSISTANCE m
Identifying the operator
For the movement tracking to work, the truck
must identify the operator. This is necessary
when you start ASSISTANCE mode or if the
truck has lost the position of the operator.
Identification as operator in ASSISTANCE mode
Automatically when the oper
By pressing the assistance button on the truck
By pressing the iGo button on the remote control (identifies the person who is closest to the driver's
platform)
Automatically in the zones close to the truck (depending on the settings configured by the authorised service centre)
ator steps off the driver's platform
ode
– Carefully monitor t
movement-tracking
whether the movemen
on the operator and i
NOTE
he LED signals for the
sensors which indicate
t tracking is focussed
s ACTIVE.
The truck loses the position of the operator if
the operator changes to the other side of the
truck beyond the fork.
•
Change sides in front of/behind the truck or
via the driver's compartment
Automatic approach of the truck
1x
A
62 5
B
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Operating the iGo neo 4
ode
If there is heavy pedestrian traffic, the movement tracking can focus on a third party, having lost track of the position of the operator.
It may therefore be prudent to have the automatic approach of the truck dependent on
confirmation by the operator.
The authorised service centre can configure
how the truck responds when the operator is
re-identified:
• (A) Automatic approach only on the side to
which the truck is aligned
• (B) Automatic approach on bo
th sides
Configuration (A)
Identification
Side to which the truck is
aligned
The opposite side to which the
truck is aligned
LED signals
Movement tracking ACTIVE
Motion tracking PAUSE
Configuration (B)
Identification
On both sides
.
LED signals
Movement tracking ACTIVE
Operating the truck in ASSISTANCE m
Information
The truck follows the operator
immediately.
The truck follows the operator
only after confirmation with the
D
iGo button or the assistance
button.
Information
The truck follows the operator
immediately.
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4 Operating the iGo neo
Operating the truck in ASSISTANCE m
Stopping automatically at the end of the racking
CAUTION
Risk of collision by entering the crosswise roadway
at the end of a rack
If an object, e.g. another truck, is stationary in
an unfavourable position at the end of a rack or
in a crosswise roadway, the truck may not detect
the end of the rack under certain circumstances.
Crossing trucks could then collide with the truck
that is operating in
– The operator must be particularly alert at the
end of a rack. When using movement tracking,
the operator must ensure that the truck does not
drive beyond the end of the rack. When using
remote control, the operator must stop the truck
in good time. The operator is responsible for
stopping the truck safely.
The truck is equipped with automatic end-ofrack detection. If the racking on the side to
which the truck is aligned ends or if the racking
is interrupted by a crosswise roadway, the
truck will stop automatically. The movementtracking sensors will show the "PAUSED" LED
signal.
ASSISTANCE mode.
ode
Stopping at the end of the aisle
The truck detects that the rack contour does
not continue, and will stop automatically at the
end of the aisle.
– To continue operating in
mode, first drive to a rack contour that the
truck can detect in
64 5
ASSISTANCE
MANUAL mode.
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Page 73
Operating the iGo neo 4
Operating the truck in ASSISTANCE m
ode
Stopping before a crosswise roadway
When the truck is in ASSISTANCE mode,
the truck can proceed across a crosswise
roadway after confirmation using the remote
control.
The truck detects that the rack contour continues beyond the crosswise roadway, and
will stop automatically before the crosswise
roadway.
– Press the iGo button on the remote control
1 x long (> 2 sec.). The LED signals for
the movement tracking scanner switch to
"movement tracking PAUSED" (1).
– Makesurethatthetruckcancrossthe
crosswise roadway safely.
– Press and hold the iGo button (2). The
truck will drive over the crosswise roadway.
Once the truck has passed the crosswise
roadway, release the iGo button. The truck
will stop.
– Press the iGO button 1 x briefly. The
LED signals for the movement tracking
scanner switch to "movement tracking
ACTIVE". The truck again follows the
operator automatically.
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 driven in
contour.
MANUAL mode to the next rack
> 2 Sec.
2
1
NOTE
The authorised service centre can configure
the value for the minimum width of crosswise
roadways, thereby improving the detection of
crosswise roadways.
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4 Operating the iGo neo
Operating the truck in ASSISTANCE m
Behaviour of the truck in response to obstacles in the roadway
ode
A
DRIVE
DANGER
Danger of coll
laser scanne
Observe the n
obstacles gi
the safety l
–Checkthe
the safe
remove t
–Ifthere
the tru
emerg
isions with obstacles that the safety
r cannot detect.
otes about the limits to detecting
ven in the chapter entitled "Function of
aser scanner".
roadway above all for obstacles that
ty laser scanner cannot detect and
hese obstacles.
is a risk of danger, immediately bring
ck to a standstill by pressing one of the
ency off switches.
B
STOP
DRIVE
truck detects an obstacle on the side of
If the
way to which the truck is aligned, the
the road
omatically drives around the obstacle
truck aut
and conti
nues on its path (A).
If an obstacle is too large to drive around,
the truck will stop in front of the obstacle (B).
ASSISTANCE mode is resumed without
intervention from the operator as soon as
the obstacle is removed.
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Operating the iGo neo 4
Operating the truck in ASSISTANCE m
ode
Minimum distance to obstacles
min.
The authorised service centre can configure
a minimum distance (1) at which the truck
thetruckmaypassanobstaclewhenin
1
ASSISTANCE mode.
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4 Operating the iGo neo
Operating the truck in ASSISTANCE m
ode
Truck behaviour in the event o
fan
emergency stop
CAUTION
Risk of accident if the truck starts moving again after
an emergency stop.
After an emergency stop, movement tracking is
ACTIVE again as soon as the reason for the stop
has been eliminated or the emergency off switch
has been reset.
– Maintain 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.
Truck response in the event of an emergency
stop
• The electromagnetic truck brake is applied.
The truck stops at the maximum deceleration rate
• The LED signalling unit shows the "Emergency stop" signal. The lighting zones flash
in rapid alternation (approx. ten times per
second)
• The truck emits the audible warning sound
to indicate the "emergency stop" (short,
rhythmic warning sounds for two seconds)
Setting off after an emergency stop
• The electromagnetic truck 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 indicate the "emergency stop"
• The truck emits the warning tone to indicate
that it is "setting off" (two short warning
sounds in succession)
ASSISTANCE mode is resumed without
intervention from the operator as soon as
the obstacle is removed.
=
STOP
!
=
STOP
LED
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Operating the iGo neo 4
Operating the truck in ASSISTANCE m
– If the emergency stop was triggered via one
of the emergency off switches (1) on the
side of the truck, pull out the emergency off
switch before resuming operation.
ode
1
– If the emergency stop w
the emergency brake pu
the cockpit, switch o
n the truck again by
pressing the ON push b
as triggered via
sh button (2) in
utton (3).
3
789
456
123
PRG
PRG
2
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4 Operating the iGo neo
Operating the truck in ASSISTANCE m
Moving the truck position to the next pallet
Trucks with long forks can transport several
pallets one behind another. The position of the
truck relative to the operator can be changed
using the remote control so that the desired
pallet is at the same level as the driver.
– Press and hold button (1): Move the truck
position by one position in the drive side
direction.
– Press and hold button (2): M
position by one position in
direction.
NOTE
The authorised service centre can configure a
maximum of four different truck positions.
ove the truck
the load side
ode
2 Sec.
1 2
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Operating the iGo neo 4
Operating the truck in ASSISTANCE m
ode
Driving automatically without movement tracking
The operator can allow the truck to drive
a short distance along the rack contour
independently of the movement tracking.
– The LED signals for the movement tracking
scanner must display "movement tracking
PAUSED" (1).
– Press and hold the iGo butto
control for at least two sec
The truck moves along the rack contour until
the button is released. Movement tracking
and the safety functions of the truck remain
active.
NOTE
If the truck fails to detects a rack contour it will
not proceed. The movement tracking-sensors
will show the "PAUSED" LED signal.
nontheremote
onds.
> 2 Sec.
1
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4 Operating the iGo neo
Operating the truck in ASSISTANCE m
ode
Setting the drive programme w
operating in ASSISTANCE mod
In ASSISTANCE mode, the oper
select between two drive pro
setting the drive program, t
istics (driving, steering a
can be adapted to the releva
uation. All safety-relate
grammes. By
he truck character-
nd braking dynamics)
nt operating sit-
d features of the truck
hen
e
ator can
remain unchanged.
– Press button (1) or (2) to set the drive
programme.
NOTE
The authorised service centre can configure
the drive programs for
ASSISTANCE
mode to
suit the specific requirements of the customer.
21
789
456
123
PRG
PRG
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Operating the iGo neo 4
Operating the truck in ASSISTANCE m
ode
Warning sounds in ASSISTANCE mode
The truck produces different warning sounds
to alert the driver and bystanders that the truck
is being operated in
Audible signals
ASSISTANCE mode.
Type of signal Signal
1 short warning sound
Short, rhythmic warning sounds
(for two seconds)
Short, rhythmic warning sounds
A warning sound for one
second
.
"Setting off" warning sound
"Safety stop" warning sound
(safety laser scanner)
"Safety stop" warning sound
(emergency off switch)
"Truck alignment not possible"
warning sound
Information
Truck begins moving automati-
cally (with "movement tracking
switched on")
Truck has performed an
emergency stop
The operator has pressed the
emergency off switch
The truck does not detect a rack
contour on the selected side
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4 Operating the iGo neo
Operating the truck in ASSISTANCE m
ode
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5
Storage
Page 84
5 Storage
Storing and shutting down the iGo ne
o
Storing and shutting down the iGo neo
Driverless transport vehicles cannot be stored
in an operational state. They must therefore
be taken out of operation.
– To shut down the truck, contact the autho-
rised service centre.
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6
Cleaning
Page 86
6 Cleaning
Cleaning the components used for AS
SISTANCE mode
Cleaning the components used for ASSISTANCE mode
Preparing the components used for
ASSISTANCE mode for cleaning
CAUTION
If water penetrates the electrical system, there is a
risk of a short circuit occurring!
– Never clean the components used for
– While cleaning the rest of the truck, avoid clea-
mode using devices such as high-pres-
STANCE
sure cleaners or rotating brushes.
ning the components used for
mode and only clean these components in accordance with the instructions specified below.
CAUTION
Risk from damage to electrical components when
cleaning!
Only the authorised service centre is permitted
to clean the components used for
mode inside the truck.
– Contact the authorised service centre.
– Park the truck securely.
CAUTION
Risk of component damage!
If you remove the battery male connector when the
key switch is switched on (under load), an arc will be
produced. This can lead to erosion at the contacts,
which considerably shortens their service life.
– Switch off the key switch before the battery male
connector is disconnected.
– Do not disconnect the battery male connector
while the key switch is switched on, except in an
emergency.
ASSI-
ASSISTANCE
ASSISTANCE
– Disconnect the battery male connector.
– Contact the authorised service centre
to arrange for the components used for
ASSISTANCE mode inside the truck to be
cleaned.
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Cleaning 6
Cleaning the components used for AS
SISTANCE mode
Cleaning the optics covers of the safety
laser scanner and the movement
tracking sensors
CAUTION
Abrasive cleaning materials can damage the surfaces of components!
Using abrasive cleaning materials that are unsuitable for plastics may dissolve plastic parts or make
them brittle. The covers of optical sensors can become cloudy.
– Do not use aggressive cleaning materials.
– Do not use any abrasive cleaning materials.
– Clean the optics covers (windows) on the
safety laser scanner and on the movement
tracking sensors regularly and in the event
of contamination.
– A static charge causes dust particles to
accumulate on the optics cover. To clean
the optics cover, use the antistatic plastic
cleaning agent listed in the table.
Recommended cleaning material for the
optics covers
Cleaning material
Antistatic pla
cleaning agent
SICK optics cloth
stic
SICK item number
5600006
4003353
– Remove any dust from the optics covers
using a clean, soft brush.
– Moisten the SICK optics cloth with the
antistatic plastic cleaning agent. Use the
damp cloth to wipe the light output window
on the optics covers.
Cleaning other components used for
ASSISTANCE mode
– Regularly clean the LED signalling unit
using a soft, damp cloth without cleaning
agents.
– Clean the remote control using a brush and
a damp cloth. Do not use alcohol, solvents
or cleaning materials.
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6 Cleaning
Cleaning the components used for AS
Alternating operation between hot zones
(approx. 40°C) and cold zones (approx.
4°C)
The operator must ensure that the optics
covers of the movement tracking sensors
and of the safety laser scanner do not fog up
due to changing between hot zones and cold
zones too rapidly.
– If necessary, clean fogged
before use in
ASSISTANCE mo
-up optics covers
SISTANCE mode
de.
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7
Transporting
Page 90
7 Transporting
Transporting the truck
Transporting the truck
The instructions in the operating instructions
for the series-production truck apply for transporting the truck. In addition, the following
provisions listed in this chapter also apply.
CAUTION
Risk of accident when using ASSISTANCE mode
for loading purposes
When operating in
truck can respond with involuntary steering and
driving movements when used in an unsuitable
environment.
– Routes to a loading point, on a loading bridge or
on the transport vehicle must always be driven in
MANUAL mode.
Crane loading of the truck not permitted
CAUTION
Risk of damage to the truck by impermissible crane
loading
The mounting bracket for the LED signalling unit
or the safety laser scanner can be damaged when
loading by crane. Loading of the truck by crane is
not permitted.
ASSISTANCE mode, the
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 are tightened
securely and that the pads cannot slip off.
CAUTION
k of damage to the truck due to improper lashing
Ris
e mounting bracket for the LED signalling unit
Th
or the safety laser scanner can be damaged by
ashing straps.
l
– Do not attach lashing straps to the LED signalling
unit or the safety laser scanner or guide lashing
straps over these components.
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Transporting 7
Transporting the truck
CAUTION
Abrasive lashing straps can rub against the surface
of the truck and cause damage.
– Position slip-resistant pads underneath the lifting
points (e.g. rubber mats or foam).
Safety regulations for driving on loading
bridges
DANGER
Risk of accident from the truck falling off the loading
bridge
Steering movements can cause the truck to fall from
the loading bridge.
– Before driving across a loading bridge, ensure
that the loading bridge is properly attached and
secured.
– Ensure that the transport vehicle onto which the
truck is to be driven has been sufficiently secured
against moving.
– Maintain a safe distance from loading bridges,
ramps, working platforms and similar objects.
– Drive slowly and carefully onto the transport
vehicle.
CAUTION
Danger due t
loading bri
The load capa
ramps and the
the actual to
canbeperma
overloadin
– Determine th
nameplate on
– Only load th
means of tra
is greater
o excessive transport weight on the
dge
city of the means of transport, the
loading bridges must be greater than
tal weight of the truck. Components
nently deformed or damaged due to
g.
e actual total weight from the
the truck.
e truck if the load capacity of the
nsport, ramps and loading bridges
than the total actual weight of the truck.
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7 Transporting
Transporting the truck
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8
Maintenance
Page 94
8 Maintenance
Maintaining the iGo neo
Maintaining the iGo neo
This section contains all of the information
required for maintaining the iGo neo. Maintenance must be performed in accordance with
the points in the maintenance checklist. This is
the only way guarantee that the truck remains
ready for operation; it is also a pre-condition
for any warranty claims.
Maintenance schedule
Maintenance tasks on the components for
the
ASSISTANCE mode of the iGo neo must
be performed in addition to the scheduled
maintenance of the series-production truck.
The intervals are defined f
Shorter maintenance inte
in consultation with the o
depending on the applicat
truck.
The following factors ma
maintenance intervals
• Dirty, poor-quality roadways
• Dusty or salty air
• High levels of air humid
• Extremely high or low ambient temperatures, or extreme changes in temperature
• Multi-shift operation with a high duty cycle
• National regulations fo
individual components
or standard use.
rvals can be defined
perating company,
ion conditions of the
y necessitate shorter
:
ity
r the truck or for
Responsibility for main
DANGER
Work performed by unauthorised persons on components used for
the safety functions of the truck.
To maintain components used for
mode, contact the authorised service centre.
Maintenance work on components used for
ASSISTANCE mode jeopardises
tenance
ASSISTANCE
ASSISTANCE mode must only be performed
by the service centre authorised by the
manufacturer.
The service engineer must have received special training from the manufacturer regarding
the handling processes, technology and repair
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Maintenance 8
ths
work involved with the iGo neo. It is not permitted for other persons to perform work on the
components used for
This instruction does not apply to cleaning procedures on components that are not located
inside the truck; refer to the chapter entitled
"Cleaning".
The following components are used for
ASSISTANCE mode.
Maintenance - 500 hours/every 6 mon
ASSISTANCE mode:
• Safety laser scanner
• Movement tracking sensors
• Control components
• Control electronics and control software
• Emergency off switches
• LED signalling unit
• Switches
• Remote control
Safety regulations for m
– Before starting any work on electrical and
mechanical equipment, disconnect the
system 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.
aintenance
Maintenance documentation
The maintenance steps a
documented in writin
operating company.
Maintenance - 500 hour
At operating hours
500 1000 1500 2000 2500 Carried out
3000 3500 4000 4 500 5000
Brake
Check the clearance of the electromagnetic brake (in accordance with the maintenance manual for the series-production truck)
General
nd results must be
g and archived by the
s/every 6 months
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8 Maintenance
Maintenance - 1000 hours/annually
At operating hours
500 1000 1500 2000 2500 Carried out
3000 3500 4000 4500 5000
Read out and check the error numbers and clear the list
Reset the maintenance interval
Maintenance - 1000 hours/annually
At operating hours
1000 2000 4000 5000 7000
8000 10000 11000 13000 14000
Note
Perform all 500-hour maintenance work.
Safety laser scanner S300
Check the safety laser scanner and the support mounting for damage (visual inspection).
Check the alignment and the field of vision of the SICK safety laser scanner using the
SICK CDS software.
Clean the opti
Movement tracking sensors
Check the movement tracking sensors and the mounting for damage (visual inspection).
Check the plug contacts (power supply and communications supply).
Check the status LEDs for the movement tracking sensors (visual inspection).
Clean the movement tracking sensors.
LED signalling unit
Check the LED signalling unit and the support mounting for damage (visual inspection).
Components compartment (load side)
Perform a visual inspection of the wiring and of the components (robotics computer,
safety controller [MCU2], receiving unit for the remote control, switchbox, DC/DC
converter and Digisound beeper)
Check the mechanical attachment of all components.
ck all screwed contacts on the robotics computer are securely attached.
Che
Check that the earth cable between the chassis and the carrier plate is securely
attached.
cal cover of the safety laser scanner.
Carried out
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Maintenance 8
Maintenance - 1000 hours/annually
At operating hours
1000 2000 4000 5000 7000
8000 10000 11000 13000 14000
Components compartment (drive side)
Perform a visual inspection of the mountings, wiring and components (odometry
signal transmitter, signal converter [analogue/CAN] IN/OUT, LES steering controller,
incremental transducer for speed)
Robotics system
Practical function check of the robotics system in ASSISTANCE mode. Check
the function of the safety laser scanner S300 and the movement tracking sensors,
including the LED signals, LED signalling unit, assistance button, emergency off
switch, remote control.
Personal protectio
Check the function of the personal protection system. Check the function ofthe
emergency off switch and the safety laser scanner S300 in
Check the emergency off switching signal in DIAMON.
General
Read out and check the error numbers and clear the list.
Reset the maintenance interval.
n system (PPS)
ASSISTANCE mode.
Carried out
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8 Maintenance
Maintenance - 1000 hours/annually
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9
Technical data
Page 100
9 Technical data
Dimensions
Dimensions
W
a
e
5
11
b
b
832
1
b
c
l
2
1
h
14
h
1900
150
60
1025
7
h
452185 420
l
1080
m
x
1
l
s
2
y
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