Radioshuttle Series Users Manual

Table of Contents

Part Contents Page

2.1 Safety Regulations 2
2.2 Safety System 5
2.3 Signal Lamps 6
2.4 Fault Indication 8
2.5 Radio Transmitter 10
2.6 Battery 11
2.7 Start up & switch off 12
2.8 AUTO Mode - Load 14
2.9 AUTO Mode - Unload 15
2.10 MANUAL Mode 15
2.11 SHOW PALLET 16
2.12 REORGANIZATION 17
2.13 COMBI - two pallet sizes 18
2.14 HANDLING OF DOUBLE PALLETS 19
2.15 LIFO/FIFO RACKING 19

This manual is valid for standard versions of the RS 92 and RS 96 models of Radio Shuttle /
Maxipacker. Parts valid for certain models are marked with model number.
The difference between ”Mode” and ”Operation” can be described as:
Mode: What the shuttle do, controlled by the operator.
Operation: How the shuttle works, determined by the racking or pallets.
Position numbers from the assembly drawings are shown within square brackets, e.g. [100].
Only AUTO and MANUAL mode is activated on standard design shuttles. Additional modes and
operations are present on specially ordered or optionally equipped shuttles. Please contact the
supplier for information.
(For the US market only: As the Radio Shuttle System is designed to comply with the demands
of ASME B56.5, Safety Standard for Guided Industrial Vehicles, the user must be familiar with,
and follow, part II of this standard.)

Original instructions Revised 2010-01-01 Page 1 of 19

Radioshuttle Series
2.1 Safety Regulations
Personnel
a) Every one of the personnel, who is using the
Radio Shuttle System, must be well ac-
quainted with the use and function of the sys-
tem.
All authorised personnel must have been
taken part in the training program.
b) Unauthorised use of the Radio Shuttle System
must be avoided by restricting the access to
the radio transmitter. The Radio Shuttle is not
equipped with any lockable switch.
c) It is prohibited to enter or stay in the rack
while shuttles are in operation. Should it be-
come necessary to enter the racking, the in-
structions "Working in the racking" below
must be followed together with local routines
for work in the racking.
Radio Shuttle
a) The Radio Shuttle is designed for a maximum
pallet weight as stated on the machine plate
and at the front end. For COMBI operation
(two pallet sizes), a lower pallet weight is
valid for the smaller pallet. The rack, how-
ever, might be built for lighter pallet weights.
Please refer to the documentation plate for
the rack system.
b) Never lift the Radio Shuttle and the pallet
simultaneously.
c) The Radio Shuttle System may not be modi-
fied in any way without written approval from
the manufacturer.
d) Unless marked EX, the Radio Shuttle may not
be used in explosive locations. Please contact
supplier if uncertainty arises.
e) The Radio Shuttle may not be used in any
other way than in the associated rack system.
f) Riding the Radio Shuttle is prohibited as well
as towing or pulling.
Original instructions Revised 2010-01-01
Users Manual
Location and Rack
a) The entire rack is a RESTRICTED AREA to
which access is prohibited. Some exceptions
exist, see section "Working in the racking" be-
low.
b) The user is responsible for maintaining all
signs, markings and instructions supplied by
the manufacturer.
c) The rack must not be modified or rebuilt with-
out written approval from the manufacturer.
d) The environmental conditions as described in
Appendix A & B, Technical specification, must
not be exceeded.
e) Protective netting must not be removed or
modified in any way. If the rack or location is
rebuilt in a way that enables someone to
reach moving shuttles or pallets, the safety
wire netting must be completed.
If any part of the safety wire netting is dam-
aged, it must immediately be repaired or re-
placed.
f) It is prohibited to climb or step above floor
level near a safety wire net if a Radio Shuttle
operates in an adjacent channel or level.
g) Goods may not be stored in a way that let it
protrude into the operation space required by
the Radio Shuttle.
Page 2 of 19
Radioshuttle Series
Pallets & load
a) Only use first-class quality pallets of the types
the installation is designed for. Damaged pal-
lets could result in great safety risks and must
not be used.
b) Make certain that the goods are stable and
secured to the pallet so that it cannot fall off.
c) No plastic wrapping or any other loose mate-
rial may suspend at the sides or under the
pallet.
d) Maximum allowed load overhang (outside of
pallet) = 50mm per side in the transport di-
rection. If this measure is violated, parts of
the safety design is put out of function and is
therefore prohibited.
e) It is not allowed to let the Radio Shuttle han-
dle two loaded pallets on top of each other or
to place empty pallets in the racking.
If other pallets than specified are to be used,
please contact the supplier for investigation and
possible modification of installation
For pallet handling with FIFO, REORGANIZA-
TION and DOUBLE PALLET the load has a lower
weight limited of 250kg. This weight is valid only
for wooden pallets. If any other types of pallets
are to be used please contact supplier for inves-
tigation and possible modification
Under certain circumstances above minimum
weight limits can be lowered. However it requires
mechanical rebuilt and function must be acti-
vated in the control program. Please contact
supplier for further information
Original instructions Revised 2010-01-01
Users Manual
Other
a) The user is not allowed to use the Radio Shut-
tle System together with self-developed
equipment without written approval from the
manufacturer.
b) Only original spare parts may be used in ser-
vice and maintenance.
c) The Radio Shuttle is tested and approved
according to European standards (EN 61000-
6-2 and EN 61000-6-4) regarding electromag-
netic compatibility. Please contact the supplier
if the shuttle interferes with other equipment.
d) The shuttle must do all placements of pallets in
order to keep the automated functions working
as intended. It is not allowed to place pallets
elsewhere than at the Pick/Drop Station*. If,
for instance, a pallet is pushed into the racking
it is possible for the shuttle to lift it without be-
ing correctly positioned under the pallet. When
unloading, this can lead to the pallet being
placed so that it can not be reached by the
forks or falls down into the aisle.
*) Pick/Drop Station=The end of the rack chan-
nel where the goods and shuttle is placed.
Will further on be referred to as P/D station.
CAUTION
Violations of Safety Regulations can cau-
se serious incidents and lead to both
material and personnel damages
Page 3 of 19
Radioshuttle Series Users Manual

Working in the racking

WARNING
The risk of falling or being hit by a moving shuttle exists while
staying in the racking.

If a shuttle does not return to the P/D station as expected, it has stopped in the racking. The reason
can be that the shuttle has got stuck under a defective pallet, that the loaded pallet has got stuck or
that the control program has been unable to deal with an unexpected situation.
The following work flow is recommended:
1) Locate the shuttle and try to decide what has caused the stop:
a) If the red OFF indicator blinks, see chapter 2.4 Fault Indication.
b) In other cases, please refer to the following instructions.
2) Put the shuttle into MANUAL MODE, see chapter 2.10.
3) For shuttles equipped with remotely controlled power off, the radio transmitter STOP button is
once again pushed for at least 5 seconds until all lamps go out.
4) Inform all concerned personnel and remove shuttles in channels over, under and at the sides of
the channel to be entered.
5) Block the section that will be entered and adjacent sections. The easiest way to block a section is
using obstacles on the floor to prevent truck access.
6) Use a ladder or a fork lift cage to enter the racking. To move safely into the racking, EAB can
supply a work platform. If used, all its instructions shall be followed. When working in the racking,
local work at height regulations must always be followed.
7) If shuttle is missing remotely controlled Power off, it should be switched off with the front or rear
OFF button. Pay attention to the lift movement if the shuttle is turned on again.
8) The shuttle can be towed out of the channel
using a rope placed in the slot as shown to
the right.

Original instructions Revised 2010-01-01 Page 4 of 19

Radioshuttle Series
2.2 Safety system
The safety system of the Radio Shuttle System
consists of sensing edges in the directions of
travel, a stop button on the radio transmitter and
power off buttons on the Radio Shuttle.
Due to the mode of operation, the edges of a
carried pallet and its load are not protected by
any mechanical sensing edge.
CAUTION
Maximum allowed load overhang (outside
of pallet) = 50mm per side in the trans-
port direction. If this measure is violated,
parts of the safety design is put out of
function and is therefore prohibited.
Sensing edges
The Radio Shuttle reacts to the sensing edges
only when the driving motor is running. It is not
allowably to obstruct the sensing edges or its
movement in any way.
If a sensing edge is activated in AUTO mode, the
following will happen.
1) The shuttle is halted and reverses approxi-
mately 0,1 m (4”) at low speed.
2) Fault code “Sensing edge(s) circuit activated”
is shown (see section 2.4).
To reset and restart the shuttle, proceed as
follows:
1) Attend to the reason why the sensing edge(s)
is being activated.
2) Verify on the radio transmitter that the correct
shuttle will be controlled.
3) Reset the shuttle by pressing STOP
4) Restart the shuttle by repeat the previous
given command
(IN) or  (OUT).
The shuttle will now complete the already be-
gun working cycle. It will react only to a repe-
tition of the previous command.
In MANUAL or REORGANISATION mode, the
shuttle does not reverse but stops immediately
according to Fault code “Sensing edge(s) circuit
activated”
To resume reorganisation, remove the obstacle
and then press .
Original instructions Revised 2010-01-01
Users Manual
STOP button on the
Radio Transmitter
When the STOP-button is pushed, both the driv-
ing and lifting movements are interrupted and
the green signal lamp STANDBY will light, indicat-
ing that the shuttle is ready for a new command.
Verify on the radio transmitter that the correct
shuttle will be controlled. Use one of two alterna-
tives:
1) Repeat the previous command
(IN) or 
(OUT). The shuttle now completes the already
begun working cycle.
2) Give the reverse command of the previous
one. Shuttle will acknowledge and perform
the new command and then return to P/D sta-
tion
OFF buttons on the
Radio Shuttle
When any of the red POWER OFF buttons on the
Radio Shuttle panels is pushed, the operating
power is switched off. To restart shuttle, the
procedure according to part 2.7 of the Operators
Manual must be followed.
Remotely controlled power off
If the shuttle is equipped with remotely con-
trolled POWER OFF, the STOP button on trans-
mitter can be used by following routine:
1) Locate the shuttle and verify that the yellow
ON lamp is lit.
2) Activate MANUAL MODE by pushing the STOP
button for at least 5 seconds. Verify that the
red and green lamp blinks simultaneously.
3) Shut the shuttle down by once again pushing
the STOP button for at least 5 seconds. Verify
that all lamps have gone out.
4) To restart shuttle, the procedure according to
part 2.7 of the Operators Manual must be fol-
lowed.
Page 5 of 19
Radioshuttle Series Users Manual

Signal lamps and push buttons RS92

RS92 Front view RS92 Rear view

10 10

CHARGE STAND
L1 L2 ON OFF OFF
LEVEL BY

BUTTON All shuttle types

ON (yellow) Power on Front side
OFF (red) Power off Front and rear side

LAMP AUTO MODE MANUAL MODE (see sec. 2.10)

ON (yellow) Continuous Operating power on Operating power on
STANDBY (green) Continuous Ready to receive commands —
OFF (red) Continuous Batteries discharged or sensing edge Sensing edge activated
activated
STANDBY (green) BLINK In continuous operation Lifting device in lowest position
OFF (red) BLINK Fault indication, refer to part 2.4 —
STANDBY / OFF BLINK/BLINK Level empty (alternating blink) Manual mode (simultaneous blink)
CHARGE LEVEL Battery capacity indicator, see section 2.6
RAPID FLASH: The Radio Shuttle is starting to move
Position [10] white lamp SLOW FLASH: The Radio Shuttle is moving towards the flashing side
SHORT Continuous: Confirmation of command from the radio transmitter

Optional functions – Not available on all models

LAMP L1 and L2 Indicates See section
L1 (yellow) BLINK SHOW PALLET 2.11
L1 (yellow) CONTINUOUS LIFO racking (last in – first out) 2.8, 2.9, 2.15
L1 CONTINUOUS and L2 BLINK Handling of DOUBLE PALLET in LIFO racking 2.14
L2 (yellow) BLINK REORGANISATION 2.12
L2 (yellow) CONTINUOUS FIFO racking (first in – first out) 2.8, 2.9, 2.15
L1 BLINK and L2 CONTINUOUS Handling of DOUBLE PALLET in FIFO racking 2.14
L1 and L2 simultaneous BLINK FORCED UNLOAD (COMBI shuttle) 2.13
L1 and L2 alternate BLINK The shuttle cannot determine the pallet size (COMBI) 2.13

The lamps (L1 & L2) are included in an optional kit together with a second radio receiver.
Blue position lights are mounted at the front and rear underneath the shuttle. The lights are in-
tended as an aid in positioning the forks when the shuttle is used in high and poorly lit racks.
The position lights also complement the indications for low battery level and fault indications,
see section 2.4.

Original instructions Revised 2010-01-01 Page 6 of 19

Radioshuttle Series Users Manual

2.3b Signal lamps and push buttons RS96

RS96 Front view RS96 Rear view

BUTTON All shuttle types

ON (yellow) Power on Front side
OFF (red) Power off Front- and rear side
Position [11-13] Circuit breakers See spare part list for information

LAMP AUTO MODE MANUAL MODE (see sec. 2.10)

ON (yellow) Continuous Operating power on Operating power on
STANDBY (green) Continuous Ready to receive commands —
OFF (red) Continuous Batteries discharged or sensing edge Sensing edge activated
activated
STANDBY (green) BLINK In continuous operation Lifting device in lowest position
OFF (red) BLINK Fault indication, see section 2.4 —
STANDBY / OFF BLINK/BLINK Level empty (alternating blink) Manual mode (simultaneous blink)
CHARGE LEVEL Battery capacity indicator, see section 2.6
RAPID FLASH: The Radio Shuttle is starting to move
Position [10] white lamp SLOW FLASH: The Radio Shuttle is moving towards the flashing side
SHORT Continuous: Confirmation of command from the radio transmitter
Position [52] Hour counter – Running time accumulates during shuttle movements

Optional functions – Not available on all models

LAMP L1 and L2 Indicates Se section
L1 (yellow) BLINK SHOW PALLET 2.11
L1 (yellow) CONTINUOUS LIFO racking (last in – first out) 2.8, 2.9, 2.15
L1 CONTINUOUS and L2 BLINK Handling of DOUBLE PALLET in LIFO racking 2.14
L2 (yellow) BLINK REORGANISATION 2.12
L2 (yellow) CONTINUOUS FIFO racking (first in – first out) 2.8, 2.9, 2.15
L1 BLINK and L2 CONTINUOUS Handling of DOUBLE PALLET in FIFO racking 2.14
L1 and L2 BLINK FORCED UNLOAD (COMBI shuttle) 2.13
L1 and L2 alternate BLINK The shuttle cannot determine the pallet size (COMBI) 2.13

The lamps (L1 & L2) are included in an optional kit together with a second radio receiver.
Blue position lights are mounted at the front and rear underneath the shuttle. The lights are in-
tended as an aid in positioning the forks when the shuttle is used in high and poorly lit racks.
The position lights also complement the indications for low battery level and fault indications,
see section 2.4.

Original instructions Revised 2010-01-01 Page 7 of 19

Radioshuttle Series
2.4 Fault indication
Red signal lamp
OFF continuous lit
Indicates that the battery voltage is too low. The
Radio Shuttle will complete the already begun
working cycle, but then it will stop at P/D station.
No further commands from the radio transmitter
will be accepted.
To restart the shuttle:
1) Switch off the shuttle by pushing any of the
red buttons.
2) Replace the battery cassettes by fully charged
ones and restart the shuttle.
Red signal lamp
OFF blinking
The safety components are constantly supervised
by the safety system. The red signal lamp OFF
will blink to show what component is malfunc-
tioning.
The fault indication differs between the models
RS 92 and RS 96.
Fault indication RS 92
The following components are internally super-
vised by the shuttle:
• Lifting devices
• Photocells (rail holes and pallet edges)
• Drive motor
Lifting device
If the red lamp POWER OFF starts to blink during
a lifting or lowering operation, one of the follow-
ing faults exists in the lifting device:
1) When a lifting or lowering operation starts, a
15-second time-out period is set. A fault ex-
ists if any of the two lifting devices has not
reached their respective limit switches within
this period.
2) The lifting motors are equipped with tem-
perature sensors. If the temperature gets
too high, the movement will be stopped.
Original instructions Revised 2010-01-01
Users Manual
To make the Radio Shuttle return to P/D station,
proceed as follows:
1) Push the STOP button on the radio transmit-
ter. The red lamp POWER OFF will stop
blinking and the green lamp STANDBY will
light up.
2) Give the reverse command of the previous
one,
(IN) or  (OUT). The shuttle now
starts and returns to P/D station.
3) Lift the shuttle out of the rack and switch it
off.
4) Check the lifting devices and repair the fault
according to the Service Manual.
Photocells (rail holes or pallet edge)
If the red POWER OFF lamp starts to blink when
the shuttle has returned to P/D station and
stopped, any of the rail holes or pallet edge indi-
cating photocells is faulty.
Clean, adjust or replace the photocell, then re-
start the shuttle.
Drive motor
The red lamp POWER OFF starts to blink to pre-
vent over load if the shuttle is stuck while it tries
to move. This error code can be shown anywhere
in the channel where the shuttle has been stuck.
Push the STOP button for 5 seconds to select
manual mode. The shuttle might now be con-
trolled by the manual commands.
If the red lamp POWER OFF starts to blink while
the shuttle is moving this indicates an error in
the pulse transducer.
Complementing indication
During low battery level or shuttle fault indica-
tion, the blue position lights under the shuttle are
blinking.
In this way, indications will be easier to discover
when the shuttle is used in a high racking where
the front end indicators can be difficult to see.
Page 8 of 19
Radioshuttle Series Users Manual

Fault indication RS96 Sensing edge(s) circuit activated

The red signal lamp OFF will blink a number of
times followed by a pause and then repeat to
show what component is malfunctioning.
Time out Drive motor
Indicated by two blinks:







Shown to prevent over load if the shuttle is stuck
while it tries to move. This error code can be
shown any place where the shuttle is stuck.
Push the STOP button for 5 seconds to enter
manual mode (see section 2.10). Using manual
commands, the shuttle might now be possible to
drive out of the racking.
If this error code is shown while the shuttle is not
blocked this indicates an error in the pulse trans-
ducer.
Rail hole detection photocell S11
Indicated by three blinks:










Shown if the photocell for rail hole detection is
malfunctioning. This error code is shown at the
P/D station after a complete working cycle.
Clean, adjust or replace the photocell, then re-
start the shuttle.
Pallet edge detection photocell
S13 (for COMBI also S19)
Indicated by four blinks:













Shown if any of the photocells for pallet edge
detection is malfunctioning. This error code is
shown at the P/D station after a complete work-
ing cycle.
Clean, adjust or replace the photocell, then re-
start the shuttle.
S5 and/or S6
Indicated by five blinks:
















Shown if one or both sensing edges are acti-
vated, defected or not correctly connected.
Result is that shuttles stops according to proce-
dure in section 2.2.
Reconnect the sensing edges correctly or attend
to the reason why the sending edges are being
activated.
Subsequently reset and restart the shuttle
according to instruction in section 2.2
Pallet detection photocell S14-17
Indicated by six blinks:



















Shown if any of the photocells for front- or rear
pallet detection is malfunctioning. This error code
is shown at the P/D station after a complete
working cycle.
Clean, adjust or replace the photocell, then re-
start the shuttle.
Time out Lift motor
Indicated by seven blinks:






















Shown if the lift device did not reach its end posi-
tion in a certain amount of time.
Push the STOP button for 5 seconds to enter
manual mode (see section 2.10). Using manual
commands, the shuttle might now be possible to
operate.
If the lift device is moving, in manual mode, this
indicates that the sensor for lift positioning needs
to be adjusted or replaced.
Complementing indication
During low battery level or shuttle fault indica-
tion, the blue position lights under the shuttle are
blinking.
In this way, indications will be easier to discover
when the shuttle is used in a high racking where
the front end indicators can be difficult to see.

Original instructions Revised 2010-01-01 Page 9 of 19

Radioshuttle Series Users Manual

2.5 Radio transmitter

CAUTION
The Radio Transmitter has no ON/OFF switch and will send a signal as soon as one of the buttons
is being pushed. The transmitter must be kept under surveillance of the operator at all times to
prevent unintended actions.
The transmitter may be handled by authorised operators only.

The Radio Transmitter is powered by a built in 9V battery. Whenever the transmitter is

placed in the forklift cassette, this battery is disconnected and power is supplied from the
cassette. No recharging is done from the cassette.
If the Radio Transmitter battery has ran down, an automated Radio Shuttle operation
might not be possible to interrupt. Therefore, at the first sign of battery discharge, usu-
ally noticed as a shorter range, have the battery replaced according to part 3.2 Mainte-
nance.
Control buttons
The buttons
(IN), STOP and  (OUT) control shuttle
movement.

STOP
Buttons F1 and F2 control mode selection if the shuttle is
equipped with a second radio receiver. Operations are de-
1 2 3 scribed in the respective part 2.11 - 2.15 of this manual.

4 5 6 Whenever F1 and F2 are used to select modes and opera-

tions, the shuttle will not move until
(IN) or  (OUT) is
7 8 9 pushed.
F1 0 F2 The STOP button interrupts all movements, see chapter 2.2.

Numerical section
Each Radio Transmitter can control one of 242 shuttles using a communication number
called "address". On each shuttle, the address is shown on the machine plate and by a label
at the front of the shuttle.
To select Radio Shuttle no. Push
1 0-1
15 0-1-5
134 0-1-3-4
If no command is given between selection of Radio Shuttle, additional pushes on the button
0 may be required. The selected number is shown in the radio transmitter display and will
remain fixed until a new address has been selected.
The address setting of the Radio Shuttle receivers are fixed and may be changed only by the
system manager according to instructions in the service manual.

CAUTION:
During the time a control button is being pushed on a radio transmitter a radio wave is
sent, resulting in disturbed or inhibited commands from other transmitters within the oper-
ating range. Especially when a button is being pushed for an extended time, for instance
during manual mode, other users should be informed about control command disturbances.

Original instructions Revised 2010-01-01 Page 10 of 19

Radioshuttle Series
2.6 Battery
Only the supplied battery cassettes and batteries
of the same type and rating as the original may
be used, please refer to the spare parts list.
Inside the battery cassettes there are two 12 V
batteries connected in series using a fuse holder
with a 30 A fuse. If no voltage is present at the
connector, this fuse is probably blown. Check all
leads and connectors and then replace the fuse
with the same type and size.
Battery voltage
surveillance
The Radio Shuttle is equipped with two different
kinds of battery voltage surveillance. One of them
interrupts operation when the battery voltage
drops below the required level, the other gives
information about remaining battery capacity.
Battery guard
If the battery voltage becomes too low to secure
operation, this is indicated by a continuous red
light OFF after a completed working cycle.
To continue the procedure, the batteries of the
shuttle must be replaced by fully charged ones.
Capacity indicator
The indicator is made up of the three-coloured
LED-lamp CHARGE LEVEL. The battery voltage is
measured during the most current demanding
operations and the indicator is controlled with
this information.
Green High remaining capacity.
Yellow On some occasions, the voltage has
dropped below the threshold voltage.
Red The voltage has dropped below the
threshold voltage many times. The bat-
tery guard will soon interrupt operation.
The indication depends on pallet weights and
shuttle workload. Fixed limits for number of re-
maining work cycles can not be given.
Battery charging
Fully charged Radio Shuttle batteries have ap-
proximately 8-hour operating capacity. Charging
to full capacity takes 7 to 8 hours. Two or three
shifts working hours therefore require at least
one extra set of batteries.
After a period of short charging times, the capac-
ity of the respective cells of the battery can vary.
To prevent this, once in a while the battery
Original instructions Revised 2010-01-01
Users Manual
should be connected to the charger for one or
more days of maintenance charging.
When the shuttle is used in a cold-storage room
the charging time is prolonged. The batteries
must reach room temperature in order to be fully
charged. Therefore, two extra sets of batteries
and one additional charger are required for cold-
storage three shifts working hours.
Low shuttle utilization in cold-storage rooms de-
teriorates battery capacity.
Make it a habit to charge the batteries after a
working shift, even if they are not completely
discharged. This will ensure that the batteries will
be fully charged for the next working shift. Al-
ways keeping the batteries fully charged will
prolong their service life.
The charging location must keep a temperature
of +15 to +25 °C (59 to 77 °F) in order for the
batteries to be fully charged.
Please observe that gas, explosive in high con-
centrations, may accumulate when charging bat-
teries. The ventilation should be at least 0,3 li-
tres/second in locations where two battery cas-
settes are charged. (Referring to Swedish work
environment standard AFS 1988:4)
Charging
1) Turn the shuttle off using one of the OFF
buttons.
a) Charging in EAB charger cabinet or
other separate charger location
RS92: Lift the battery cassettes out of the
shuttle.
RS 96: Open the hood and lift the battery
cassettes out of the shuttle.
b) Charging in the shuttle
Connect the charger to the rear end con-
nector. On RS96 the hood must be open
during charging.
2) Follow the supplied charging instructions for
the appropriate charger.
3) Put the battery cassettes back in place.
WARNING: Always lift the battery cas-
sette using both handles. A crushing haz-
ard exists between the shuttle cover and
the edge of the battery cassette.
Page 11 of 19
Radioshuttle Series Users Manual

2.7 Radio Shuttle start up & switch off

Preparations to start The shuttle must be placed with all four wheels
on the lower part of the rail with the front end
• Replace the Radio Shuttle batteries by fully facing the aisle of the rack from where com-
charged ones. mands will be sent.
• Make sure that the daily maintenance routine It is preferable, especially when lifting out of the
has been carried out, see chapter 3.2 racking, to use a forklift with pre-selective fork
heights, in order to prevent the shuttle from be-
Start up ing accidentally struck by the forks.

1) Push the yellow ON button on the Radio Shut-
tle. The yellow signal lamp in the button will
light up indicating that the shuttle is turned
on. After a short moment, when the PLC car-
ries out internal checks, all indicator lamps are
lit for three seconds.
During this lamp check, the CHARGE LEVEL
lamp changes from red to yellow to green.
Should any indication lamp not light up, a se-
curity risk exists. Correct the fault before tak-
ing the shuttle into operation.
CAUTION
RS 92:
The lifts will be lowered if they are in upper
position when the power is turned on.
RS 96:
Every time the power turns on, the driving
axles will operate a complete lifting cycle.
This ensures the shuttle to start in the right
height position.
Exercise great caution when lifting shuttle out of
the rack. If any part of the shuttle gets stuck on
racking there is a possibility that it could slide off
the forks and fall down.
Switch off
Push the red OFF button on the front or rear
panel to turn the shuttle off. All signal lamps will
go out.
When the shuttle is equipped with remotely con-
trolled power off, see chapter 2.2.
Automatic switch off
The Radio Shuttle is equipped with an automatic
switch off device. It shuts down when the shuttle
has not received any command from the radio
transmitter for 8 hours (standard setting).
To restart the shuttle, proceed according to the
start up instructions above.

2) The green signal lamp STANDBY will light up,

indicating that the shuttle is ready to receive a
command.
3) The shuttle is now ready to be lifted into the
rack and operated. Make sure no one stays in,
or nearby, the channel where the shuttle will
operate.
Lifting in and out of racking
The underside of the shuttle is equipped with
pockets intended for truck forks. Distance be-
tween forks should be adjusted according to
figure 1. Intention is to minimize risk for shuttle
to slide of forks. During positioning, aiming lights
are located on shuttle underside, see chapter
2.3.
When placing the shuttle into the racking, the
operator must always have a clear view of how Fig1
the shuttle is placed. It is the responsibility of the
user to ensure the necessary view regardless of
lifting height.

Original instructions Revised 2010-01-01 Page 12 of 19

Radioshuttle Series Users Manual

2.8 AUTO mode - LOADING

AUTO mode is used to load and unload pallets Continuous loading

and is the basic mode of the shuttle.
No indication is shown for AUTO mode and it is
always active if no other mode is selected.
Loading
1) Place the Radio Shuttle on the P/D Station, in
which channel loading will take place. The
shuttle must be placed so that the front end,
marked with the address number label, faces
the aisle of the rack from where commands
will be sent.
If needed, choose the correct shuttle by se-
lecting the appropriate address number on
the radio transmitter.
2) Lift the pallet into the rack. The pallet must
not protrude outside the support rails.
3) Push the
(IN) button of the radio transmit-
ter. The shuttle acknowledges the received
command by turning the green STANDBY
lamp off.
If the green lamp light up again, as soon as
the
(IN) button of the transmitter is re-
leased, the pallet has been placed too close to
the front of the channel. Lift the pallet further
in and give a new
(IN) command.
4) The shuttle now locates the pallet, lifts and
transports it as far as possible into the rack.
Then it returns to the P/D Station and is ready
to receive a new command.
If a channel is to be filled, continuous loading
can be used. This operation assumes that pallets
can be placed on the rails before the shuttle has
returned to the P/D Station.
1) Start continues loading by pushing the
(IN)
button twice within 2 seconds. The Radio
Shuttle will acknowledge the command with
the green STANDBY lamp blinking.
2) The shuttle will now continuously transport
pallets into the channel, unless another com-
mand is given.
If the P/D Station is empty when the shuttle re-
turns, continuous loading is interrupted and the
shuttle stops, ready to receive a new command.
Continuous loading puts a certain demand on the
pallets used, see chapter "Pallet design…" below.
Pallet design for repeated
and continuous loading
In order for the control system to be able to
bring the shuttle to the right position below a
pallet that has been placed at the P/D Station,
the underside of the pallet must have three
boards with intervening gaps. Pallets with flat
bottom or transverse boards cannot be used.
Gaps

Repeated loading
If a new pallet is placed into the channel before
the Radio Shuttle returns, a new
(IN) com-
mand may be entered as soon as the shuttle has
started the return to the P/D Station.
The shuttle will acknowledge the new
(IN)
command with the green STANDBY lamp blink-
ing.
Repeated loading puts a certain demand on the
pallets used, see chapter "Pallet design…" below.

Original instructions Revised 2010-01-01 Page 13 of 19

Radioshuttle Series Users Manual

2.9 AUTO mode - UNLOADING

Unloading Continuous unloading

1) Place the Radio Shuttle on the P/D Station, in If all the pallets in a channel are to be taken out,
which channel unloading will take place. The continuous unloading mode can be used.
shuttle must be placed so that the front end,
1) Start continuous unloading by pushing the 
marked with the address number label, faces
(OUT) button twice within 2 seconds. The Ra-
the aisle of the rack from where commands
dio Shuttle will acknowledge the command
will be sent.
with the green STANDBY lamp blinking.
If needed, choose the correct shuttle by se-
2) The shuttle will now continuously transport all
lecting the appropriate address number on
pallets out of the channel until it is emptied,
the radio transmitter.
unless another command is given.
2) Push the  (OUT) button of the radio trans-
If there is a remaining pallet at the P/D Station
mitter. The shuttle now locates the first pallet
when the shuttle returns, it will stop at a 0,5 m
in the channel, lifts and transports it to the
(20") distance. As soon as this front pallet has
P/D Station and is ready to receive a new
been removed from of the rack, the shuttle will
command.
automatically restart and complete its work with-
3) Lift the pallet out of the rack. out having to receive a new command from the
radio transmitter.
As soon as the green STANDBY lamp lights up,
the shuttle is ready to receive a new OUT com- If pallet at the P/D Station remains for one hour,
mand, even if there is still a pallet placed at the shuttle will relocate its load back into the channel
P/D Station. and then return to the P/D station.
A combi shuttle will place the pallet directly and
Should the shuttle stop at the front position with
then return to the P/D station.
green STANDBY and red OFF lamps alternate
blinking, it means that the channel is empty (ex- Should the shuttle stop at the P/D Station with
cept for the pallet at the P/D station). Reset the green STANDBY and red OFF lamps alternate
shuttle by pushing the STOP button of the radio blinking, it means that the channel is empty (ex-
transmitter. As soon as the green STAND BY cept for the pallet at the P/D station).
lamp shows continuous light, the shuttle is ready
Reset the shuttle by pushing the STOP button of
to receive a new command.
the radio transmitter. As soon as the green
STAND BY lamp shows continuous light, the
COMBI operation shuttle is ready to receive a new command.
If a shuttle in COMBI operation cannot decide the
pallet size, it will return to the P/D Station with
function lamps L1 and L2 alternately blinking.
Forced unloading (see chapter 2.13) can be used
as an attempt to get the pallet out of the racking.

Original instructions Revised 2010-01-01 Page 14 of 19

Radioshuttle Series
2.10 MANUAL mode
The Manual Mode may only be used as an emer-
gency operation of the shuttle. The purpose is to
be able to bring the shuttle out of the racking if
something unforeseeable has happened.
Choose the correct shuttle by selecting the appro-
priate address number on the radio transmitter.
The Manual mode is entered by pushing the
STOP button of the radio transmitter for at least
5 seconds and is indicated by the green
STANDBY and red OFF lamps simultaneously
blinking.
Switching the shuttle off will interrupt the Manual
mode operation.
Please observe that pushing a control button dur-
ing extended time will disturb other transmitters,
see chapter 2.5 Radio Transmitter.

(IN) button
RS92: Lift devices are lowered as long as the
button is pushed.
RS96: Lift device is lifted or lowered depending
on the position when the button was pushed.
When fault indication “Time out lift motor” is
shown, the lift device is moving as long as the
button is pushed
2.11 SHOW PALLET
The SHOW PALLET mode is used to bring a pallet
out towards the unloading side of the rack so
that the content of the pallet can be viewed. This
mode is useful in deep racks where it can be
difficult to see the content of a channel.
This mode requires additional equipment and
must be activated in the control program.
1) Place the Radio Shuttle on the P/D Station, in
which channel pallet should be brought to
show position. In a FIFO rack, the shuttle
should be placed at the unloading side.
2) If needed, choose the correct shuttle by se-
lecting the appropriate address number on
the radio transmitter.
3) Push the F1 button of the radio transmitter for
less then 2 seconds.
The function lamp L1 starts to blink, indicat-
ing that the shuttle is in SHOW PALLET mode.
The STOP button interrupts and brings the
shuttle back into AUTO mode.
Original instructions Revised 2010-01-01
Users Manual
Due to safety reasons, lowering of pallets is not
possible at the P/D station.
 (OUT) button
The shuttle returns, with reduced speed, towards
P/D Station as long as the button is being
pushed.
F1 button (RS 92)
Valid for shuttles with two radio receivers. The
lift devices are raised as long as the button is
pushed.
F2 button
Valid for shuttles with two radio receivers. The
shuttle moves, with reduced speed, into the rack-
ing from the P/D Station as long as the button is
being pushed. In this way, an attempt can be
done to unload a pallet when forced unloading
(see chapter 2.14) has failed.
STOP button
A repeated 5 second push turns the shuttle off if
it is equipped with remotely controlled power off.
4) Push the  (OUT) button of the radio trans-
mitter. The shuttle now locates the first pallet
and transports it as close as possible to the
front of the rack. Space is left to make it pos-
sible to lift the shuttle out of the rack.
5) The shuttle returns to the P/D Station and
enters AUTO mode.
Combination with other
modes and operations
Pushing the F1 button for more than two seconds
activates another command.
In this case, the L1 lamp will not blink and acti-
vation of SHOW PALLET mode has failed.
Reset the shuttle by pushing the STOP button
and then repeat the SHOW PALLET command.
Page 15 of 19
Radioshuttle Series
2.12 REORGANISATION
REORGANISATION mode means that all pallets
are automatically moved towards the unloading
side in order to create space for pallets to be
loaded. Reorganization is always started and
controlled from the unloading side.
This mode requires additional equipment and
must be activated in the control program.
Reorganization can be started if there are at least
three free pallet locations at the unloading side.
CAUTION
The minimum pallet weight during reorgani-
sation is 250 kg. This pallet weight must not
under any circumstances be lower as this
cause major safety hazards.
This applies to wooden pallets only. Pallets
in other materials have other minimum
weights, see chapter 2.1.
Loading or unloading using another shuttle in a
channel where reorganisation takes place is pro-
hibited.
1) If the remaining battery capacity is unknown,
always change to fully charged batteries be-
fore reorganisation.
2) Place the Radio Shuttle on the P/D Station, in
which channel reorganisation will take place.
The shuttle must be placed so that the front
end, marked with the address number label,
faces the aisle of the rack from where com-
mands will be sent.
3) If needed, choose the correct shuttle by se-
lecting the appropriate address number on
the radio transmitter.
4) Push the radio transmitter button F2 for less
than 2 seconds.
The function lamp L2 starts to blink to indi-
cate that the shuttle is ready for reorganisa-
tion.
The STOP button interrupts and brings the
shuttle back into AUTO mode.
5) Push radio transmitter button  (OUT). The
reorganisation starts and continues automati-
cally until all pallets in the channel have been
replaced.
6) The shuttle returns to the P/D Station and
enters AUTO mode.
Original instructions Revised 2010-01-01
Users Manual
Temporary interruption
of reorganisation
The reorganisation can during operation tempo-
rarily be stopped using the STOP button. After a
new  (OUT) command, reorganisation contin-
ues from its previous position.
Permanent interruption
of reorganisation
MANUAL mode interrupts reorganisation perma-
nently. Lower the pallet and bring the shuttle out
to the P/D station.
The reorganisation is also permanently inter-
rupted if the battery guard indicates low battery
capacity when only a certain number of pallets
has been moved.
The shuttle will then return to the P/D Station
with the red POWER OFF lamp lit.
Address the reason for permanent interruption
and restart the Reorganisation using normal pro-
cedure. The shuttle will locate last reorganised
pallet and continue its cycle.
Combination with other
modes and operations
Pushing the F2 button for more than two seconds
activates another command.
In this case, the L2 lamp will not blink and acti-
vation of REORGANIZATION mode has failed.
Reset the shuttle by pushing the STOP button
and repeat the REORGANIZATION command.
Reorganization using a
COMBI shuttle
A COMBI shuttle can automatically identify and
handle two different pallet sizes. REORGANIZA-
TION mode can be used in channels where two
different pallet sizes occur.
If the shuttle cannot identify the size of a pallet
due for reorganisation, operation will be inter-
rupted and the shuttle will return to the P/D Sta-
tion with function lamps L1 and L2 alternately
blinking.
Already reorganized pallets must be unloaded
from the unloading side and FORCED UNLOAD
mode can be used as an attempt to unload the
pallet.
For some types of pallet damages it is possible
for the shuttle to identify the pallet size when
loading from the loading side but not when un-
loading from the unloading side. In this case, the
channel, including the damaged pallet, must be
unloaded from the loading side.
Page 16 of 19
Radioshuttle Series
2.13 COMBI
COMBI operation is used if the shuttle needs to
handle two different pallet sizes.
The operation requires additional equipment and
must be activated in the control program.
COMBI operation cannot be combined with han-
dling of double pallets (part 2.14).
In COMBI operation, the rear end of the pallet
correspond with the rear end of the shuttle, en-
suring that the pallets are closely packed and
that two pallets are not lifted at the same time.
Pallet size selection at loading
The shuttle does selection of pallet size auto-
matically. When the shuttle receives an
(IN)
command, it will locate the front pallet edge and,
using the upward facing photocells, evaluate if
the larger or smaller pallet is to be loaded.
If the smaller pallet is placed close to the edge of
the racking, shuttle will rearrange/relocate the
pallet to ensure that rear end correspond with
the rear pallet edge and then continue the load-
ing.
If the smaller pallet is placed at a distance from
the edge of the racking the pallet will be loaded
without reloading.
If the pallet size cannot be decided, the shuttle
will return to the P/D Station with function lamps
L1 and L2 alternately blinking.
Reset by pushing the STOP button at the radio
transmitter.
Check the condition and position of the pallet and
give a new
(IN) command.
Pallet size selection
at unloading
At unloading, the shuttle identifies the pallet and
the correct size is selected.
If it returns empty with lamps L1 and L2 alter-
nately blinking after a given  (OUT) command,
the automatic pallet size selection has failed.
Reset by pushing the STOP button at the radio
transmitter.
Check the condition and position of the pallet and
give a new  (OUT) command.
Original instructions Revised 2010-01-01
Users Manual
Reloading
Reloading implies smaller pallet to be rearranged
before placed at P/D station during an unload.
Sequence puts the pallet down, relocate the
shuttle so the front edge correspond with the
pallet front edge, lifts the pallet and place it at
P/D station.
If reloading is not activated, smaller pallet will be
placed at a distance, from the edge of the rack-
ing, which equals the difference between the
smaller and larger pallet.
Reloading is preset in shuttle setup and can be
altered by reprogramming only, please contact
the supplier.
Forced unload
Forced unload mode is available on COMBI shut-
tles.
If shuttle cannot decide the pallet size, it will
return to the P/D Station with function lamps L1
and L2 alternately blinking.
1) To unload the pallet, whose size cannot be
automatically selected, push the button F2 at
the radio transmitter for at least 2 seconds.
The function lamps L1 and L2 will start to
blink simultaneously to indicate that the shut-
tle is in forced unload mode.
The STOP button interrupts and brings the
shuttle back to AUTO mode.
2) Push the button  (OUT) at the radio trans-
mitter. The shuttle will start and unloads the
pallet according to its routines for unloading
the smaller pallet. Shuttle will relocate pallet
ensuring that it is lifted under all blocks re-
gardless of pallet size. For security reasons, a
lower speed is used during the forced unload
operation.
3) The pallet is placed at the P/D Station and the
shuttle returns to AUTO mode.
CAUTION
Due to the fact that a possibly damaged pallet
is handled, the use of forced unload is poten-
tially hazardous.
Therefore, forced unload must always be su-
pervised. If the pallet seems to be placed in a
wrong position when the shuttle approaches
the P/D Station, the STOP button should be
pushed. The pallet can then be lowered using
manual mode.
Page 17 of 19
Radioshuttle Series
2.14 HANDLING OF DOUBLE PALLETS
DOUBLE PALLET operation is used if pallets are
to be handled two by two in loading and unload-
ing situations.
This operation requires additional equipment and
must be activated in the control program.
CAUTION
The minimum pallet weight for double
pallet handling is 250 kg. This pallet weight
must not under any circumstances be
lower as this cause major safety hazards.
This applies to wooden pallets only. Pallets
in other materials have other minimum
weights, see chapter 2.1.
Selecting single or
double pallet handling
Switching between single and double pallets is
done by pushing the F2 button for more than two
seconds and indicated as follows:
• LIFO single pallet: L1 continuous
• LIFO double pallet: L1 continuous / L2 blink
• FIFO single pallet: L2 continuous
• FIFO double pallet: L2 continuous / L1 blink
Loading
1) Place the Radio Shuttle on the P/D Station, in
which channel loading will take place. The
shuttle must be placed so that the front end,
marked with the address number label, faces
the aisle of the rack from where commands
will be sent.
2) If needed, choose the correct shuttle by se-
lecting the appropriate address number on
the radio transmitter.
3) Lift two pallets into the rack at the same time.
4) Push the
(IN) button of the radio transmit-
ter. The shuttle now searches for the edge of
the pallet nearest the aisle and then moves
one pallet into the channel.
5) If the shuttle finds an inner pallet, this will be
transports it as far as possible into the rack.
Next, shuttle continues by loading outer pallet
with same procedure.
6) When two pallets have been loaded into the
channel the shuttle returns to the P/D Station.
If only one pallet has been lifted into the P/D
station, the search for an inner pallet is termi-
nated and the shuttle transports the single pallet
into the channel.
Original instructions Revised 2010-01-01
Users Manual
Continuous loading
If the radio transmitter button
(IN) is pushed
twice within 2 seconds, continuous loading of
double pallets is started.
If a single pallet is placed at the P/D station, the
continuous loading is terminated. The shuttle will
return to its P/D Station and stop, ready to re-
ceive a new command.
Unloading
1) Place the Radio Shuttle on the P/D Station, in
which channel loading will take place, see sec-
tion “Loading” above.
2) Push the  (OUT) button of the radio trans-
mitter. The shuttle now locates the first pallet
in the channel, lifts and transports it to the
P/D Station.
3) The shuttle now locates the next pallet in the
channel, lifts it and places it directly behind
the first pallet.
4) When two pallets are placed at the P/D sta-
tion, the shuttle stops under the inner pallet.
5) When both pallets are lifted out of the rack,
shuttle returns to the P/D Station, the green
STANDBY lamp is lit and the shuttle is ready
to receive a new command.
Continuous unloading
If the radio transmitter button  (OUT) is
pushed twice within 2 seconds, continuous un-
loading of double pallets is started.
If a single pallet is lifted out from the rack before
the shuttle has brought the second pallet, this
second pallet will be placed at the P/D station
and the shuttle will interrupt continuous unload-
ing, ready to receive a new command.
Combination with other
modes and operations
Pushing the F2 button for less than two seconds
activates another command.
If function lamp L2 blinks and L1 is turned off,
switching between single- and double pallet op-
eration has failed.
Reset the shuttle by pushing the STOP button
and then repeat the DOUBLE PALLET HANDLING
command.
Page 18 of 19
Radioshuttle Series
2.15 LIFO/FIFO
LIFO
Last in – First Out
Operation is chosen when the shuttle is used in a
channel where loading and unloading is per-
formed from the same aisle.
FIFO
First in – First Out
Operation is chosen when the shuttle is used in a
channel where loading and unloading is per-
formed from opposite aisles.
When loading the first pallets into an empty
channel, placements are made with a certain
distance at the unloading side. This operation is
made to create sufficient space during unloading.
The control program can be set up for fixed op-
eration or changeable operation controlled from
the radio transmitter.
CAUTION
The minimum pallet weight for FIFO op-
eration is 250 kg. This pallet weight must
not under any circumstances be lower as
this cause major safety hazards.
This applies to wooden pallets only. Pallets
in other materials have other minimum
weights, see chapter 2.1.
Original instructions Revised 2010-01-01
Users Manual
Fixed operation
If a shuttle is to be used in one kind of racking
only, LIFO or FIFO operation is set in the control
program. No indication is given on the shuttle.
Changeable operation
Ability to choose LIFO or FIFO operation requires
additional equipment and must be activated in
the control program.
The most frequent mode of operation is set in
the control program and used as default during
start up.
The other mode of LIFO/FIFO operation is se-
lected by pushing the F1 button on the radio
transmitter for at least two seconds. Additional
two second pushes switch operation between
LIFO and FIFO.
The function lamp L1 is lit to show that the shut-
tle uses LIFO operation while the function lamp
L2 shows that FIFO operation is used.
Combination with other
modes and operations
Pushing the F1 button for less than two seconds
activates another command.
If the shuttle shows other indications than de-
scribed above, LIFO/FIFO changeover has failed.
Reset the shuttle by pushing the STOP button
and then repeat the LIFO/FIFO changeover com-
mand.
Page 19 of 19