Alitrak DTRAK 300 Instrucciones de funcionamiento

Ecological vehiclewithground

drivecontrol and electrictraction

DTRAK 300

USERAND MAINTENANCEMANUAL

ViaCrispi,10–36056TEZZESULBRENTA

Vicenza–ITALY

Tel. +390424 898349–fax+390424536792

e-mail: info@alitrak.com

http://www.alitrak.com

Rev.01

October 22, 2008 Rev.01

0–INDEX

FY310.doc ThismanualisthepropertyofALITRAK

Anyreproduction,evenpartial, isforbidden. Pages2-57

October 22, 2008 Rev.01

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FY310.doc ThismanualisthepropertyofALITRAK

Anyreproduction,evenpartial, isforbidden. Pages3-57

0INDEX

0INDEX_______________________________________________________________________3

0.1 REFERENCEDSTANDARDS_________________________________________________________5

1INTRODUCTION_______________________________________________________________8

1.1 HOWTO READTHEMANUAL: STRUCTUREAND CONSULTATION__________________________8

1.1.1 Purposeandcontentsofthemanual___________________________________________________8

1.1.2 Generalwarnings__________________________________________________________________8

1.1.3 Safetytermsandsymbolswhichwillbeusedinthemanual_________________________________8

1.1.4 Operatorsforwhomthemanualisintendedandterminologyused___________________________10

1.1.5 Searchcriteriaandconsultinginformation______________________________________________11

1.1.6 Preservationofthemanual_________________________________________________________11

1.2 HOWTO UPDATETHEMANUAL_____________________________________________________11

1.3 MANUFACTURERINFORMATION____________________________________________________12

1.4 TECHNICALASISTANCE___________________________________________________________12

1.5 Warranty_________________________________________________________________________12

2DESCRIPTION_______________________________________________________________13

2.1 GENERALMACHINEDESCRIPTION__________________________________________________13

2.1.1 Machineunits____________________________________________________________________14

2.1.1.1Frameunit______________________________________________________________________14

2.1.1.2Batteryunit______________________________________________________________________14

2.1.1.3Motorunit_______________________________________________________________________14

2.1.1.4Trayunit________________________________________________________________________14

2.1.1.5Driveunit_______________________________________________________________________14

2.1.1.6Commandconsoleunit_____________________________________________________________14

2.2 DATASHEET:CHARACTERISTICS___________________________________________________15

2.2.1 Technicalcharacteristics___________________________________________________________15

2.2.2 Characteristicsof thetransportedproduct__________________ Errore.Ilsegnalibronon èdefinito.

2.3 INTENDEDUSE___________________________________________________________________16

2.3.1 Intededuseandforeseenusageenvironments__________________________________________16

2.3.1.2Unintendeduse__________________________________________________________________16

2.3.1.3Usageenvironment_______________________________________________________________17

2.3.2 Environmentaloperatingconditions___________________________________________________17

2.3.3 Lighting_________________________________________________________________________17

2.3.4 Usageillustration_________________________________________________________________18

2.3.6 Vibrations_______________________________________________________________________19

2.3.7 Noise__________________________________________________________________________19

3TRANPORT_________________________________________________________________20

3.1 WARNINGS______________________________________________________________________20

3.2 TRANSPORINGAND LIFTINGTHEMACHINE___________________________________________20

4WORKAREAUSE____________________________________________________________22

4.1 WARNINGSANDINSTRUCTIONSFORWORKAREA USE________________________________22

4.2 REGULATIONSREGARDING THEENVIRONMENTALCONDITIONS________________________22

4.3 SPACENECESSARYDURINGFUNCTION_____________________________________________23

4.4 RECHARGINGTHEBATTERY_______________________________________________________24

4.4.1 Connectingthebatterycharger______________________________________________________25

5SAFETY____________________________________________________________________26

5.1 GENERALINFORMATION-USES -ZONES____________________________________________26

5.1.1 Generalsafetyinformationandwarnings_______________________________________________26

5.2 WORKAREA _____________________________________________________________________27

5.2.1 Workingzones, controlzones, dangerzones____________________________________________28

5.2.3 Informing,educatingandtraining operatorstousethemachine_____________________________30

5.3 INTEGRATEDSAFETYDEVICESAND OPERATINGCYCLE_______________________________30

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5.4 SAFETYAND CONTROLSYSTEMS___________________________________________________33

5.5 CHARACTERISTICSOFGUARDS,PROTECTIONSAND SAFETYDEVICES WHICH HAVE BEEN

EMPLOYEDTOREDUCEMECHANICALRISKS_________________________________________34

5.5.1 Fixedguards____________________________________________________________________34

5.5.2 Riskofbreakageduringfunction_____________________________________________________34

5.5.3 Riskspresentedbyedges, obstaclesandcorners________________________________________34

5.5.4 Burnrisks_______________________________________________________________________34

5.5.5 Risksanddangersofinstability______________________________________________________35

5.5.6 Residualriskspresentedbymobile(driveorworking)elements_____________________________36

5.5.7 Safetydevices___________________________________________________________________37

5.6 PROTECTIONMEASURES AGAINSTOTHERRISKS_____________________________________39

5.6.1 Protectionagainsttherisks presentedbyelectricalenergy_________________________________39

5.6.2 Protectionagainsttherisks ofexplosion_______________________________________________39

5.6.3 Protectionagainsttherisks presentedbynoiselevels_____________________________________39

5.7 SAFETYDURING MAINTENANCE,REGULATION, USAGEAND ADJUSTMENTPHASES________40

5.7.1 Prohibitionsandregulations_________________________________________________________40

5.8 SAFETYDURING CLEANING________________________________________________________40

6FIRST USE__________________________________________________________________41

6.1.1 Controls________________________________________________________________________41

6.2 STARTINGUPTHEMACHINE_______________________________________________________43

6.2.1 Uphill/downhillmaneuvering________________________________________________________44

6.2.2 Parking themachine_______________________________________________________________44

6.2.3 Intensiveandprolongeduse________________________________________________________44

6.3 DISCONNECTINGTHEENERGYSOURCES____________________________________________45

7ORDINARYMAINTENANCE____________________________________________________46

7.1 SAFETYPRECAUTIONS:PREPARINGTHEMACHINEFORMAINTENANCEAND RELATIVE

PRECAUTIONS___________________________________________________________________46

7.1.1 Preparingthemachineformaintenance________________________________________________46

7.1.2 Generalsafetyprecautions_________________________________________________________47

7.1.3 Safetydevicechecks and functionalitytesting___________________________________________47

7.1.4 Electricalsystemmaintenance_______________________________________________________48

7.2 ORDINARYMAINTENANCEACTIVITIES(GENERALINFORMATION)________________________49

7.2.1 Technicalprecautionsforpropermaintenance__________________________________________49

7.2.2 Maintenanceplan_________________________________________________________________51

7.3 ORDINARYMAINTENANCE_________________________________________________________52

7.3.1 Ordinarymaintenanceprogram______________________________________________________53

7.4 SPECIALMAINTENANCE___________________________________________________________54

8WASTEDISPOSAL___________________________________________________________55

9DISPOSALOFTHEMACHINE__________________________________________________56

10 ANNEXES___________________________________________________________________57

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MACHINEDATALABEL

ViaCrispi,10 –36056 TEZZESUL BRENTA(VI)–ITALIA

Tel.+390424898349–fax+390424536792

Model DTRAK300

Year ofmanufacture

xxxx

Serial number xxxxxxxxxxx

Max. capacity xxx Kg

Power input 24 volt

Motorpower 900 W

IMPORTANTNOTICE:THISMANUALISTHEPROPERTYOFALITRAK,ANYREPRODUCTION,

EVENPARTIAL, ISFORBIDDEN.

DOCUMENTTYPE: INSTRUCTIONMANUAL Rev. 01

REFERENCEDMACHINE:Mod. DTRAK300

SERIALNO.

0.1REFERENCEDSTANDARDS

The manualhasbeen drafted inconsideration ofthe indicationsprovided by:

UNI 10893 July2000;

UNI 10653 November1997;

IECEN62079 January 2002.

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ECStandards

Reference Title

ECDirectiveno. 98/37 Knownas"The MachinerySafetyDirective"

ECDirectiveno. 2004/108

Regarding ElectromagneticCompatibility(EMC)

ECDirectiveno. 2006/95 Regarding the LowVoltage Directive,regarding theCEmarking

ECDirectiveno. 2000/14 Environmentalacousticemissionsofmachinery and equipmentintended

forexternaluse

ECDirectiveno. 2002/44 Minimumsafetyand healthrequirementsregarding the exposureof

workerstorisksderivingfrommechanicalvibrations

Harmonizedstandards, exposuredraftsandnational technical standards

Reference Title

ISOEN12100

(2003) Safetyofmachinery --Basicconcepts, generalprinciplesfordesign

Part 1–Basicterminology, methodology(exEN292-1)

Part 2–Technical principles(exEN292-2)

EN294 (1993) SafetyofMachinery -SafetyDistancestoPreventDangerZonesBeing

Reached bythe UpperLimbs

EN349 (1994) Safetyofmachinery -Minimumgapstoavoidcrushing ofpartsofthe human

body

EN418 (1994) SafetyofMachinery.Emergency Stop Equipment,Functional Aspects-

PrinciplesforDesign

EN457 (1993) SafetyofMachinery -Auditory DangerSignals-GeneralRequirements,

Design and Testing

EN563 (2000) SafetyofMachinery -TemperaturesofTouchableSurfaces-Ergonomics

DatatoEstablishTemperatureLimitValuesforHotSurfaces

EN953 (2000) Safetyofmachinery.Guards.Generalrequirementsforthe design and

construction offixed and movableguards.

EN954-1 (1998) Safetyofmachinery.Safetyrelated partsofcontrolsystems.Part1:general

principlesfordesign.

ENISO13849-

(2003) Safetyofmachinery -Safety-related partsofcontrolsystems-Part2:

Validation (EN954-2)

EN1037(1997) Safetyofmachinery -Prevention of unexpected start-up

EN1050 (1998) Safetyof Machinery -PrinciplesforRiskAssessment

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Reference Title

EN1070 (2000) Safetyofmachinery.Terminology

EN60204-1 (1998) Safetyofmachinery -Electricalequipmentofmachines-Part1:general

requirements

EN60445 (1992) Basicand safetyprinciplesforman-machine interface,marking and

identification -Identification ofequipmentterminalsand ofterminationsof

certaindesignated conductors,including general rulesforan alphanumeric

system

EN60447 (1997) Man-machine interface(MMI)-Actuating principles

EN60529 (1977) Degreesofprotection provided byenclosures(IPCode)

EN61082-1 (1993) Preparation of documentsused inelectrotechnology-Part 1: rules

EN61310-1 (1996) Safetyofmachinery -Indication,marking and actuation-Part 1: requirements

forvisual, acousticand tactilesignals

EN61310-2 (1996) Safetyofmachinery -Indication,marking and actuation-Part 2: requirements

formarking

EN61310-3 (2000) Safetyofmachinery -Indication,marking and actuation-Part 3: requirements

forthe location and operation ofactuators

UNI 10653 (1997) Technicaldocumentation -Qualityofproducttechnical documentation

UNI 10893 (2000) Technicaldocumentation ofproduct-Instructionsforuse-Articulation and

exposition of the content

CEI 64-8 (2003) Electricalsystemswithnominaltension valuesnotsuperiorto1000 Vin

alternatecurrent and 1500 Vindirectcurrent–Parts1through 7

EN1175-1 (1999) Safetyofindustrialtrucks.Electricalrequirements.Part1:general

requirementsforbattery powered trucks.

EN474-1 (1997) Earth-movingmachinery.Safety. Part 1: general requirements

EN474-6 (1997) Earth-movingmachinery -Safety-Part 6: requirementsfordumpers

ENISO 3450 (1997)

Earth-movingmachinery.Brakingsystemsofrubber-tired machines.Systems

and performancerequirementsand test procedures.

ISO6393 (1985) Acoustics-Measurementofairborne noiseemitted byearth-moving

machinery -Method fordetermining compliancewithlimitsforexteriornoise-

Stationary test conditions

ISO5349-2 (2004) Mechanicalvibration -Measurementand evaluation ofhuman exposureto

hand-transmitted vibration -Part 2: practicalguidanceformeasurementinthe

workplace

22 ottobre 2008 Rev.01

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Anyreproduction,evenpartial, isforbidden. Pages8-57

1INTRODUCTION

1.1HOW TO READTHEMANUAL:STRUCTUREAND CONSULTATION

1.1.1Purpose and contentsofthemanual

Thismanual describesthe DTRAK 300 machine.

The machine can be used forworking withproductswhichhavethe characteristicsdescribed inthe

datasheet (see chapter2).

Hereafterinthe manual,the DTRAK 300 machine willbesimplyreferred toasthe “machine”.

The manualiswritten insuchawaysoastoinformitsoperatorabout:

-problemsregarding themachineand the productsbeing worked with;

-safeoperation.

Therefore,withinthe manualthe operatorwillfinduserinstructionsand propermaintenance

procedures, togetherwithsafetyand accidentprevention regulations.

1.1.2Generalwarnings

WARNING:BEFOREPERFORMINGANYOPERATIONupon themachine,ITS

OPERATORSAND QUALIFIEDTECHNICIANSMUSTCAREFULLYREAD THE

INSTRUCTIONSCONTAINEDINTHEPRESENTDOCUMENT(and relative annexes)AND

FOLLOWTHEMWHENPERFORMINGANYOPERATIONS.

The generalwarningscontainimportantinformation regarding:

-the safetyofthe personnelassigned tothe machine’suse, operation and maintenance;

-the safetyand the efficiency of the machine;

-work quality.

WARNING:USEOFTHEMACHINEISNOTTOBEPERMITTEDIF THEREAREANY

DOUBTSREGARDINGTHECORRECTINTERPRETATIONOFTHEINSTRUCTIONS.

REQUESTANYNECESSARYCLARIFICATIONSFROMTHEMANUFACTURERORFROM

AN AUTHORIZEDASSITANCECENTRE.

The manufactureriswilling toprovide training coursesatitsfacilitiesorelseatthe facilitiesofthe

machine’sdistributor.

Availability, times,costsand methodsmust be agreed upon beforehand.

1.1.3Safetyterms andsymbolswhichwillbeusedin themanual

-DANGERZONE:zone withinornearthe machine whichconstitutesahealthand safetyriskforany

person exposed tothe zone.

-EXPOSEDPERSON:aperson located entirelyorpartiallywithinadangerzone.

-OPERATORS:peopleincharge ofinstalling,operating,adjusting,maintaining orcleaning the

machine, eachwithinthe limitsofthe responsibilitiesassigned tothem.

Risk:The combinationofprobabilityand severityofpossiblepersonalinjuryorhealth

risksindangeroussituations.

Residualrisk:Anyriskremaining afterhaving adopted the appropriatesafetymeasures;

Danger:Sourcesofpossiblepersonalinjury.

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NOTE:Theresponsibilities ofthevariousoperators willbedefinedwithinthemanual.

-QUALIFIEDOPERATOR:

The useofthe machine mustbe permitted exclusivelytoadequatelytrained,qualified personnel.

Thispersonnelmustbe capableofoperating the machine through the useofthe appropriate

controls,of managing alloperationalproceduresand ofperforming the start-up orwork recovery

phasesfollowing anyinterruptions.

-SPECIALIZEDMAINTENANCEMECHANIC:

Aqualified technician capableofoperating the machine innormalconditions,ofoperating the

machine withthe safetydevicesdisabled and ofperforming allofthe necessary adjustments,

maintenanceoperationsand repairwork upon the mechanic, pneumaticand hydraulicparts.

WARNING:SPECIALIZEDMAINTENANCEMECHANICSARENOT AUTHORIZEDTO

WORKONLIVE ELECTRICSYSTEMS.

-SPECIALIZEDMAINTENANCEELECTRICIANS:

Qualified technicianscapableofoperating the machineinnormalconditionsand ofoperating the

machine withthe safetydevicesdisabled;areincharge ofthe performing adjustments,

maintenanceoperationsand repairwork upon the machine’selectrical components.

Thesetechniciansshall be capableofworking on the liveelectricalsystemswithinthe appropriate

cabinetsand boxes.

-MANUFACTURERSPECIALIZEDTECHNICIANS:

Specialized personnel,employed bythe Manufacturerorbyan authorized assistancecentre,

appropriatelytrained and authorized toperformspecialmaintenanceorrepairwork whichrequire

specialized knowledge ofthe machine, of howthe machine works, ofthe safetydevicesand of the

mannerinwhichsafetydevicesinterveneduring the machine’sfunction.

Symbolsused forsafetywarningsinordertofacilitatethe reading and comprehension of the text:

ATTENTION:Indicatesdangeroussituationsforpersonnelandinjury prevention

standardsfortheoperators.

NOTICE: Indicatesdangeroussituationsforthemachineand/oritscomponentsand/or

theproductbeingworkedwith.

CAUTION:Additionalnoticesand/orregulationsregardingsafetyissuesduring the

currentoperation.

NOTE:Provides usefulinformation.

IMPORTANT NOTICE: Provides particularlyusefulorimportantinformation.

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1.1.4Operators forwhomthemanualisintended andterminologyused

The manualisintended for:

-personnelincharge ofoperating the machine (hereafterreferredtointhe manual simplyas

“operators”);

-technicalpersonnelincharge of ordinary maintenance(hereafterreferred tointhe manualsimplyas

“maintenancepersonnel“), eachwithregardstotheirownspecialty(mechanicalorelectrical);

-maintenancemechanics:personnelwhichhasbeentrained and authorized formaintaining the

mechanical parts, the pneumaticsystems, and the hydraulicsystems;

-maintenanceelectricians:personnelwhichhasbeen trained and authorized formaintaining electric

and/orelectronicpartsand systems;

-qualified technicians(employed bythe manufacturerorbyan authorized assistancecentre),in

charge of specialmaintenanceaswell ascomplexand/orspecialized operations.

NOTE:Thismanual shall definetheduties, theresponsibilities and theoperationallimitsofthe

variousoperators.

ATTENTION:Itisforbidden forthemachine’soperatorsto perform operationswhich are

reservedforthequalifiedmaintenance ortechnicalpersonnel. TheManufacturer bears

noresponsibilityfordamagesderived fromfailure toobserve thisprohibition.

NOTICE: Some activities(suchasopening thepackaging, assemblyand setup, initial

calibration and adjustments, repairwork, servicing and movementand/ordismantling of

themachine)require thepresence ofqualifiedtechniciansemployedbythe

Manufacturer orbyanauthorizedassistance centre.

Inordertofullyunderstand the instructions(textand illustrations),the machine’soperatorsmusthave

(ormust acquirebymeansofadequateeducation and training)atleast the following characteristics:

-generaleducation and technical knowledge atalevelwhichissufficienttobe abletoread and

understand the partsofthe manual’scontentswhichapplytothemand tobe abletoproperly

interpretthe drawingsand figures;

-the capabilityofunderstanding and interpreting thesymbols,the pictogramsand the visual

messages;

-knowledge ofthe mainhygiene,injury prevention and technological standards;

-knowledge ofthe location of the machine withinthe workplace;

-knowledge ofwhattodo incaseofemergency,wheretofind the personalprotection devicesand

howtousethemproperly.

The maintenancepersonnel,inaddition tothe abovecharacteristics,mustalsopossessthe

appropriatetechnicaleducation,acquired bymeansofadiploma,aprofessionalqualification and/or

adequate,relevantwork experience.Moreover,theymustpossessthe necessary,specificand

specialized technicalknowledge (mechanical orelectrical)forthe responsibilitiesforeseen inthe

manual.

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