Alitrak DTRAK 300 User And Maintenance Manual

Ecological vehicle with ground drive control and electric traction

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Ecological vehicle with ground

drive control and electric traction

DTRAK 300

USER AND MAINTENANCE MANUAL

Via Crispi, 10 – 36056 TEZZE SUL BRENTA

Vicenza – ITALY

Tel. +39 0424 898349 – fax +39 0424 536792

e-mail: info@alitrak.com

Rev.01

http://www.alitrak.com

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Page 1 Ecological vehicle with ground drive control and electric traction DTRAK 300 USER AND MAINTENANCE MANUAL Via Crispi, 10 – 36056 TEZZE SUL BRENTA Vicenza – ITALY Tel. +39 0424 898349 – fax +39 0424 536792 e-mail: info@alitrak.com Rev.01 http://www.alitrak.com...
Page 2 October 22, 2008 Rev.01 0 – INDEX This manual is the property of ALITRAK FY310.doc Pages 2 - 57 Any reproduction, even partial, is forbidden.
Page 3: Table Of Contents
5.2.1 Working zones, control zones, danger zones____________________________________________ 28 5.2.3 Informing, educating and training operators to use the machine _____________________________ 30 INTEGRATED SAFETY DEVICES AND OPERATING CYCLE _______________________________ 30 This manual is the property of ALITRAK FY310.doc Pages 3 - 57...
Page 4 7.3.1 Ordinary maintenance program ______________________________________________________ 53 SPECIAL MAINTENANCE ___________________________________________________________ 54 WASTE DISPOSAL ___________________________________________________________ 55 DISPOSAL OF THE MACHINE __________________________________________________ 56 10 ANNEXES ___________________________________________________________________ 57 This manual is the property of ALITRAK FY310.doc Pages 4 - 57 Any reproduction, even partial, is forbidden.
Page 5: Index
Max. capacity xxx Kg Power input 24 volt Motor power 900 W IMPORTANT NOTICE: THIS MANUAL IS THE PROPERTY OF ALITRAK, ANY REPRODUCTION, EVEN PARTIAL, IS FORBIDDEN. DOCUMENT TYPE: INSTRUCTION MANUAL Rev. 01 REFERENCED MACHINE: Mod. DTRAK 300 SERIAL NO.
Page 6 Validation (EN 954-2) EN 1037(1997) Safety of machinery - Prevention of unexpected start-up EN 1050 (1998) Safety of Machinery - Principles for Risk Assessment This manual is the property of ALITRAK FY310.doc Pages 6 - 57 Any reproduction, even partial, is forbidden.
Page 7 Mechanical vibration - Measurement and evaluation of human exposure to hand-transmitted vibration - Part 2 : practical guidance for measurement in the workplace This manual is the property of ALITRAK FY310.doc Pages 7 - 57 Any reproduction, even partial, is forbidden.
Page 8: Introduction
The machine can be used for working with products which have the characteristics described in the data sheet (see chapter 2). Hereafter in the manual, the DTRAK 300 machine will be simply referred to as the “machine”. The manual is written in such a way so as to inform its operator about: - problems regarding the machine and the products being worked with;...
Page 9 CAUTION: Additional notices and/or regulations regarding safety issues during the current operation. NOTE: Provides useful information. IMPORTANT NOTICE: Provides particularly useful or important information. This manual is the property of ALITRAK FY310.doc Pages 9 - 57 Any reproduction, even partial, is forbidden.
Page 10: Operators For Whom The Manual Is Intended And Terminology Used
Moreover, they must possess the necessary, specific and specialized technical knowledge (mechanical or electrical) for the responsibilities foreseen in the manual. This manual is the property of ALITRAK FY310.doc Pages 10 - 57 Any reproduction, even partial, is forbidden.
Page 11: Search Criteria And Consulting Information
Upon receiving the new manual, the user must take care to substitute all existing copies of the previous one in order to ensure congruity between the manual and the system being utilized. This manual is the property of ALITRAK FY310.doc Pages 11 - 57 Any reproduction, even partial, is forbidden.
Page 12: Manufacturer Information
: www.alitrak.com WARRANTY ALITRAK guarantees that the machine referred to in the present manual has been designed and manufactured in accordance with the current standards, particularly with those regarding operator health and safety; the machine has been inspected and approved (see attached certificate).
Page 13: Description
GENERAL MACHINE DESCRIPTION Foreword The DTRAK 300 machine (no.1 in fig. 2-1) has a metallic frame whose base rests upon three wheels, two for traction and one for turning. An electric motor, powered by a 24 volt battery, is located within the basic frame. The manual dumper tray (no.2), in which the material to be transported shall be placed, is positioned above the frame.
Page 14: Machine Units
The battery release, for maintenance operations, can be found next to the console. Fig. 2-2 Machine units This manual is the property of ALITRAK FY310.doc Pages 14 - 57...
Page 15: Data Sheet: Characteristics
2-1. Refer to fig. 2-3 for maximum load height. 900 mm Fig. 2-3 Characteristics of the transported product This manual is the property of ALITRAK FY310.doc Pages 15 - 57 Any reproduction, even partial, is forbidden.
Page 16: Intended Use
The DTRAK 300, with the characteristics shown in table 2-1 of this manual, is suitable for indoor and outdoor use. The machine may not be used in acidic or explosive environments nor in any other environment which has not been expressly approved by the manufacturer.
Page 17: Usage Environment
Use adequate lighting sources for maintenance operations in specific zones (such as in the internal parts of the machine). The workplace lighting devices must not constitute risks of danger. This manual is the property of ALITRAK FY310.doc Pages 17 - 57...
Page 18: Usage Illustration
A. Fig. 2-5 Usage illustration This manual is the property of ALITRAK FY310.doc Pages 18 - 57 Any reproduction, even partial, is forbidden.
Page 19: Vibrations
Perform any necessary maintenance operations as described in the instructions (see chapter 7 “Maintenance”). If such phenomena persist, consult the Manufacturer or your local reseller’s assistance centre, indicated in the first pages of the manual. This manual is the property of ALITRAK FY310.doc Pages 19 - 57...
Page 20: Tranport
(slingers, crane operators, forklift operators, etc). Arrange for a person to be in charge of signalling as the encumbrance of the machine and its packaging can impede sufficient visibility for the operators performing the manoeuvres. This manual is the property of ALITRAK FY310.doc Pages 20 - 57...
Page 21 = Kg.. Use a forklift suitable for the machine’s weight in order to lift the machine and proceed as follows: Use a forklift or pallet jack suitable for the machine’s weight to lift the DTRAK 300 and proceed as follows: ATTENTION: It is a good idea to use lifting equipment with a sufficient capacity to lift and manoeuvre the machine’s weight plus an additional 20%.
Page 22: Work Area Use
ATTENTION: As the machine has not been constructed in an anti-explosion configuration, the workplace must not contain dust concentrations which may pose a risk of explosion. This manual is the property of ALITRAK FY310.doc Pages 22 - 57 Any reproduction, even partial, is forbidden.
Page 23: Space Necessary During Function
-any other means prescribed by the current laws in the country of use. 1000 1000 1000 1000 Fig. 4-1 space necessary around the machine in (mm) This manual is the property of ALITRAK FY310.doc Pages 23 - 57 Any reproduction, even partial, is forbidden.
Page 24: Recharging The Battery
4 – WORK AREA USE RECHARGING THE BATTERY The connection of the DTRAK 300 to the electrical system for recharging the batteries must done using the machine’s appropriate, supplied battery charger and in accordance with the current regulations in the country of use.
Page 25: Connecting The Battery Charger
(no.7); 5) Check the battery’s charge with the led indicators (no.9). Fig. 4-2 Connecting the battery charger This manual is the property of ALITRAK FY310.doc Pages 25 - 57 Any reproduction, even partial, is forbidden.
Page 26: Safety
WARNING: When necessary, gather and cover long hair appropriately so as to avoid getting them caught in the machine's moving parts. This manual is the property of ALITRAK FY310.doc Pages 26 - 57 Any reproduction, even partial, is forbidden.
Page 27: Work Area
ATTENTION: It is absolutely forbidden to tamper with and/or substitute any part of the machine, without authorization, or to use accessories, utensils and consumption materials different than those prescribed by ALITRAK. Failure to observe this prohibition shall relieve ALITRAK from any civil or criminal responsibility. WORK AREA...
Page 28: Working Zones, Control Zones, Danger Zones
The manufacturer has equipped the machine with active and passive safety devices in order to guarantee safe operation. The machine can be prepared for maintenance by following the subsequent, detailed instructions at the beginning of chapter 7 (“Maintenance”) of this manual. This manual is the property of ALITRAK FY310.doc Pages 28 - 57...
Page 29 (P) = Danger zones; (L1, L2, L3) = Working zones; (C) = Command zones. Fig. 5-1 Working zones, command zone, danger zones This manual is the property of ALITRAK FY310.doc Pages 29 - 57 Any reproduction, even partial, is forbidden.
Page 30: Informing, Educating And Training Operators To Use The Machine
CAUTION: the machine always requires its operator to be present This manual is the property of ALITRAK FY310.doc Pages 30 - 57 Any reproduction, even partial, is forbidden.
Page 31 The operators, for their part, must always use the personal protection measures adapted to the risks at hand. This manual is the property of ALITRAK FY310.doc Pages 31 - 57...
Page 32 ATTENTION: It is absolutely forbidden to use free burning flames as sources of illumination for the internal parts of the machine. This manual is the property of ALITRAK FY310.doc Pages 32 - 57...
Page 33 4; C emergency arrest by releasing lever no. 2; D if the machine has suffered a malfunction, the electric brake will keep it from functioning. This manual is the property of ALITRAK FY310.doc Pages 33 - 57...
Page 34 Safety signal positioned on the machine to reduce the risk of being burned: danger symbol on yellow background BURN DANGER; This manual is the property of ALITRAK FY310.doc Pages 34 - 57...
Page 35 10) use loading and unloading ramps with capacities which are double those declared in the technical data table; 11) avoid ascending onto sidewalks which are higher than 10cm; This manual is the property of ALITRAK FY310.doc Pages 35 - 57...
Page 36 ♦ extended stopping distance on slippery terrain. Fig. 5-3A Residual risks of crushing 1000 1000 1000 1000 Fig. 5-3B Minimum safety distances This manual is the property of ALITRAK FY310.doc Pages 36 - 57 Any reproduction, even partial, is forbidden.
Page 37 It is forbidden to transport people Danger: Possible burns 14 use of the following personal safety gear is obligatory 15 OBBLIGATORY MOVEMENT This manual is the property of ALITRAK FY310.doc Pages 37 - 57 Any reproduction, even partial, is forbidden.
Page 38 October 22, 2008 Rev.01 5 - SAFETY Fig. 5-4 Safety device locations This manual is the property of ALITRAK FY310.doc Pages 38 - 57 Any reproduction, even partial, is forbidden.
Page 39 Perform any necessary maintenance operations as described in the instructions (see chapter 7 “Maintenance”). If such phenomena persist, consult the Manufacturer or your local reseller’s assistance centre, indicated in the first pages of the manual. This manual is the property of ALITRAK FY310.doc Pages 39 - 57...
Page 40 ATTENTION: IT IS FORBIDDEN TO WASH THE MACHINE WITH LIQUIDS, PRESSURE- WASHERS, etc. This manual is the property of ALITRAK FY310.doc Pages 40 - 57 Any reproduction, even partial, is forbidden.
Page 41 3. A forward/reverse movement lever; 4. A handle for speed adjustment, 5. A display which shows the battery’s charge level; This manual is the property of ALITRAK FY310.doc Pages 41 - 57 Any reproduction, even partial, is forbidden.
Page 42 October 22, 2008 Rev.01 6 – FIRST USE Fig. 6-1 Command devices This manual is the property of ALITRAK FY310.doc Pages 42 - 57 Any reproduction, even partial, is forbidden.
Page 43 Furthermore, the machine’s operator must remove, and hold on to, the ignition key (no.1) every time the machine is stopped. It is absolutely forbidden to leave the ignition key in the machine while the machine is stationary. This manual is the property of ALITRAK FY310.doc Pages 43 - 57...
Page 44 In such cases it is recommended to stop for a few minutes in order to avoid compromising the proper functioning of the motor. This manual is the property of ALITRAK FY310.doc Pages 44 - 57...
Page 45 ♦ The manufacturer bears no responsibility for failure to observe the warnings above. NOTICE: See paragraph 4.4.1 for information on recharging the batteries. This manual is the property of ALITRAK FY310.doc Pages 45 - 57 Any reproduction, even partial, is forbidden.
Page 46 - Remove the electrical plug (no.2) to disconnect the batteries. Fig. 7-1 Preparing for maintenance This manual is the property of ALITRAK FY310.doc Pages 46 - 57 Any reproduction, even partial, is forbidden.
Page 47 - the emergency stop lever which permits the machine’s functions; - the moveable tray’s mechanical stopper. The fixed guards must be checked manually to ensure that they are properly fastened to the machine; This manual is the property of ALITRAK FY310.doc Pages 47 - 57...
Page 48 Complex repairs and maintenance operations which require the modification of such systems must be performed by technical personnel employed either by the manufacturer or by an authorized assistance centre. This manual is the property of ALITRAK FY310.doc Pages 48 - 57...
Page 49 Immediately identify the cause of any eventual anomaly, such as excessive noise, overheating, fluid leakage, etc., and take the appropriate measures to resolve it. If in doubt, contact the manufacturer or an authorized assistance centre. This manual is the property of ALITRAK FY310.doc Pages 49 - 57...
Page 50 7 – ORDINARY MAINTENANCE Always refer to the annexed documentation, such as system and equipment functional schemes (electrical, hydraulic, etc.) in chapter 10 of this manual, when performing maintenance operations; This manual is the property of ALITRAK FY310.doc Pages 50 - 57...
Page 51 These components must be kept under observation and replaced when their wear status renders them unsuitable for use. This manual is the property of ALITRAK FY310.doc Pages 51 - 57 Any reproduction, even partial, is forbidden.
Page 52 ATTENTION: Waste materials such as oil, grease, inert materials and others must be collected, recycled or disposed of according to the current laws in the country where the machine has been installed This manual is the property of ALITRAK FY310.doc Pages 52 - 57...
Page 53 Cleaning the machine allows for the removal of any encrustations or deposits which could compromise the proper functioning of the machine. Use a damp cloth to remove any dust from the adhesive labels located externally upon the DTRAK 300. Check the proper function of the machine’s safety devices daily.
Page 54 Special maintenance, as such, must be performed by Authorized Technical Personnel. Any tampering by unqualified or unauthorized personnel can compromise the functionality of the machine and exonerates the manufacturer from any responsibility. This manual is the property of ALITRAK FY310.doc Pages 54 - 57...
Page 55 The following items must be properly disposed of: • batteries; • oils and grease for lubrication; This manual is the property of ALITRAK FY310.doc Pages 55 - 57 Any reproduction, even partial, is forbidden.
Page 56 Attention: The drained fluids should not be mixed together and should be preserved in closed containers in order to avoid being contaminated with foreign substances. Their disposal must absolutely be entrusted to an appropriate waste disposal facility. This manual is the property of ALITRAK FY310.doc Pages 56 - 57...
Page 57 10 - ANNEXES ANNEXES The following documents are included as annexes to the present manual: ¨ Declaration of conformity; ¨ Electrical schemes. ¨ ¨ This manual is the property of ALITRAK FY310.doc Pages 57 - 57 Any reproduction, even partial, is forbidden.