Alitrak DTRAK 300 Operating instructions

Ecological vehiclewithground
drivecontrol and electrictraction
DTRAK 300
USERAND MAINTENANCEMANUAL
ViaCrispi,10–36056TEZZESULBRENTA
Vicenza–ITALY
Tel. [phone]–fax[phone]
e-mail: [e-mail]
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
0–INDEX
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

October 22, 2008 Rev.01
0–INDEX
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages4-57
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

October 22, 2008 Rev.01
0–INDEX
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages5-57
MACHINEDATALABEL
ViaCrispi,10 –36056 TEZZESUL BRENTA(VI)–ITALIA
Tel.[phone]–fax[phone]
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.

October 22, 2008 Rev.01
0–INDEX
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages6-57
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-
2
(2003) Safetyofmachinery -Safety-related partsofcontrolsystems-Part2: Validation (EN954-2)
EN1037(1997) Safetyofmachinery -Prevention of unexpected start-up
EN1050 (1998) Safetyof Machinery -PrinciplesforRiskAssessment

October 22, 2008 Rev.01
0–INDEX
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages7-57
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
1–INTRODUZIONE
FY310.doc ThismanualisthepropertyofALITRAK
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.

22 ottobre 2008 Rev.01
1–INTRODUZIONE
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages9-57
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.

22 ottobre 2008 Rev.01
1–INTRODUZIONE
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages10 -57
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.

22 ottobre 2008 Rev.01
1–INTRODUZIONE
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages11 -57
ATTENTION:Some importantregulationsprescribedbytheEuropeanDirectiveson
safetyin theworkplace are listed below.
THEPERSONINCHARGEOF WORKPLACESAFETYmust:
-verifythattheemployeesactuallypossesstheknowledgenecessaryforreading and
fullyunderstandingthemanual;
-provideadequatepracticaltrainingandmake sure,eventhroughtesting,thatthe
operatorsare capableofoperatingthemachineinasafeand proper manner,bothin
normaloperating situationsaswell asin emergencysituations.
1.1.5Search criteriaand consultinginformation
The information and the instructionswithinthe manual areorganized bychaptersandbyparagraphs
and can be easilyfound byconsulting the systematicindexat the beginning of the manual.
Page and figurenumbering.
The chaptertowhicheachpage belongsisprovided at the top of the page.
Paragraphsarenumbered using twoormorenumbersseparated byperiods.The firstnumber
indicatesthe chapterandthe numberswhichfollowindicatethe paragraphandsub-paragraph
numbersinlogical order(example: 1.1.5indicateschapter1, paragraph 1,sub-paragraph 5).
Figuresarenumbered using twonumbersseparated byadash. The first numberindicatesthe chapter
whilethe second numberindicatesthe figure(example: fig. 2-23 indicatesfigure23 inchapter2).
ATTENTION:PAYPARTICULAR ATTENTIONWHENREADINGCHAPTER5“SAFETY”
ASIT CONTAINSIMPORTANTAND DETAILEDSAFETYINFORMATIONAND WARNINGS.
1.1.6Preservation ofthemanual
THEPRESENTMANUALand all ofitsannexesMUSTBE PRESERVEDINAPLACEWHICH IS
EASILYACCESSIBLE,NEARTHEMACHINEAND KNOWNTOALL OF THEMACHINE’SUSERS
(OPERATORSASWELL ASPERSONNELINCHARGEOFITSMAINTENANCE).
The operatorsand maintenancepersonnelmust be able toquicklyconsult the manualinanysituation.
FORSAFETYPURPOSES,THEMANUALISTOBECONSIDEREDANINTEGRALPARTOFTHE
MACHINE.
Therefore:
-It must bekept entire(inallofitsparts);
-It mustbe keptwiththe machine untilthe machine isdisposed of(aswell asincasesoftransfer,
sale, rent, etc.ofthe machine itself);
-IT MUSTBEKEPTUPTODATEAND NOTEANYEVENTUALMODIFICATIONSWHICH HAVE
BEENMADETOTHEMACHINE.
1.2HOW TO UPDATETHEMANUAL
Ifthe machine shouldbe subjected tosubstantial modifications,the manufacturershallarrange forthe
Customertobe provided withacorrect and updated version of the presentmanual.
Upon receiving the newmanual,the usermusttakecaretosubstituteall existing copiesofthe
previousone inordertoensurecongruitybetween the manual and the systembeing utilized.

22 ottobre 2008 Rev.01
1–INTRODUZIONE
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages12 -57
1.3MANUFACTURERINFORMATION
Manufacturer:ALITRAKs.r.l.
Via, Crispin°10
CAP 36056 TEZZESUL BRENTA(VI)Italy
Tel.: [phone]
Fax:[phone]
e-mail: [e-mail]
website: www.alitrak.com
1.4TECHNICAL ASSISTANCE
Ourcustomerassistanceisat the Customer’sdisposalfor:
-clarificationsand information;
-requesting specialized technicalpersonnelforinterventionson site, atthe customer’sfacilities;
-requesting spareparts.
Requestsforspecialmaintenancecan be faxed eitherdirectlytothe Manufacturerortoaqualified
assistancecentre.
ATTENTIONremember that:
-TheCustomer isobligedtopurchase exclusivelyoriginalspare partsorelse those
whichhave been expresslyauthorized inwritingbytheManufacturer;
-Theinstallationandremovalofspare partsmustbeperformedbyqualified
techniciansandcarriedoutin accordance with theManufacturer’sinstructions;
-Theuse ofnon-originalspare partsand/orincorrectinstallationofspare partsshall
exoneratetheManufacturer fromanyresponsibility.
Authorized assistancecentre:ALITRAKs.r.l.
Via, Crispin°10
CAP 36056 TEZZESUL BRENTA(VI)Italy
Tel.: [phone]
Fax:[phone]
e-mail: [e-mail]
website: www.alitrak.com
1.5WARRANTY
ALITRAKguaranteesthatthe machine referred tointhe presentmanualhasbeen designed and
manufactured inaccordancewiththe currentstandards,particularlywiththoseregarding operator
healthand safety;the machine hasbeen inspected and approved (see attached certificate).
The productisguaranteed for12 months; electricalpartsareexcluded fromtheguarantee.
Consumption materialsarealsoexcluded fromthe guarantee.
The purchaserisexclusivelyentitled tothe substitution ofanydefectiveparts.Anytransportcosts
shall be atthe Purchaser’sexpense.
Anydamage deriving fromthe pooroperation ofthe machine,fromfailuretoobservethe maintenance
standardsaswell asfromincorrect manoeuvring on behalf of the operatorshall be excluded fromthe
guarantee.
Anytampering withthe machine, especiallywiththe safetydevices, shall nullifythe GUARANTEEand
exoneratethe Manufacturerfromanyresponsibility.
No refundsshall be granted forreasonsoflackofmachine use.

October 22, 2008 Rev.01
2-DESCRIPTION
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages13 -57
2DESCRIPTION
2.1GENERAL MACHINEDESCRIPTION
Foreword
The DTRAK300 machine (no.1infig.2-1)hasametallicframewhosebaserestsupon three
wheels,twofortraction and one forturning.Anelectricmotor,powered bya24 voltbattery,is
located withinthe basicframe.The manualdumpertray(no.2),inwhichthe materialtobe
transported shall be placed,ispositioned abovethe frame.The battery lodging (no.3)islocated at
the front, abovewhichcan be found the controlpanel (no.4)whichisconnected tothe plough-stilt
drivesystem(no.5)withitsrelativemanualcontrols.The position fromwhichthe operatorshall
conduct the machine isshownwithpoint(A)infig. 2-1.
ATTENTION:some ofthemanual’sillustrationsshow themachine,orpartsofit, without
itsguardsorwithitsprotective devicesremoved.Thishas beendoneexclusivelyfor
explanatory purposes.USE OF THEMACHINEWITHOUTITSGUARDSORWITHTHE
PROTECTIVE DEVICES DEACTIVATEDISALWAYSFORBIDDEN.
FAILURETOOBSERVE THISOBLIGATIONCAN LEAD TOSERIOUSACCIDENTS.
The description ofthe machine hasbeenperformed in aconcisemannersothatthe OPERATORS
and the MAINTENANCEPERSONNELmayacquire:
-an initial knowledge ofthe machine and the partsof whichit iscomposed;
-aknowledge ofthe termsand the nameswhichshall beused withinthe manual.
Theseelementsareessentialtounderstanding the instructionsand the warningswhicharecontained
inthefollowing paragraphs.
Fig. 2-1Machinelay-out
A
1
4
5
3
2

October 22, 2008 Rev.01
2-DESCRIPTION
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages14 -57
2.1.1Machineunits
The machine isconstituted bythe following unitsasindicated infig. 2-2;
1)frameunit;
2)battery unit;
3)motorunit;
4)trayunit;
5)driveunit;
6)commandconsoleunit.
2.1.1.6 Commandconsoleunit
2.1.1.1Frame unit
The frameunitisconstituted byiron barswhichhavebeen welded togetherinsuchawaysoasto
formthe load-bearing partofthe machine.The motorhousing,withitsrelativeconnectionstothe
traction wheels,islocated upon the frame.Onthe frontalportion ofthe framearelocated:the turning
wheels, the batterylodging,the command consolelodging and the plough-stilt drivesystem.
2.1.1.2Battery unit
The battery unit, located underneaththe command console,iscomposed of a60ah battery whichhas
acharge-lifeof approximately4hours. The machine comesequipped withan externalbattery charger.
2.1.1.3Motorunit
The motorunit,located initsappropriatelodging underneaththe tray,ispowered bythe battery
through acontrol unit positioned withinthe command console.
2.1.1.4Tray unit
The steeltrayunitisattached tothe framewithhingeswhichallowthe operatortoeasilyemptythe
trayof product being transported.
2.1.1.5Drive unit
The driveunitiscomposed ofaplough-stiltdrivesystemwhichisattached tothe frame.The
movement and stopping commandscan be found upon the driveunit.
2.1.1.6Commandconsoleunit
The command consoleunit, located infrontofthe operator'sdriving position,allowstheoperatorto
check the battery’scharge and toturnthe machine on oroff withthe ignition key.The battery release,
formaintenanceoperations, can be found nexttothe console.
Fig. 2-2Machineunits
1 2
3 4 5
6

October 22, 2008 Rev.01
2-DESCRIPTION
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages15 -57
2.2DATASHEET:CHARACTERISTICS
2.2.1Technical characteristics
DESRIPTION DTRAK300
Machinedimensions (mm)
Length=1325
Width=775
Height =1060
Weightempty (Kg) 152
Weighttransportableonalevelsurface (Kg) 300
Maximumweight at20%incline (Kg) 300
Motorpower (W) 900
Batteries (Ah) 80
Powersupply (V) 24
Autonomy (h) 8
Rechargetime (h) 8
Forwardspeed (Km/h) 5
Reversespeed (Km/h) 2,5
Maxinclineforwardandreverse (%) 20
Pivotingtirepressure Bar 2,0
Tractiontirepressure Bar 1,9
Table2-1machinetechnicaldata
2.2.2Characteristics ofthetransportedproduct
The machine hasbeen designed totransportinertmaterialssuchasgravel,soiland sand inthe
quantitiesindicated intable2-1. Refertofig.2-3formaximumload height.
Fig. 2-3Characteristics ofthetransportedproduct
900mm

October 22, 2008 Rev.01
2-DESCRIPTION
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages16 -57
2.3INTENDEDUSE
2.3.1Intendeduse andforeseen usageenvironments
2.3.1.1Foreseen use
The DTRAK 300 isan ecologicalvehiclewithground drivecontroland electrictraction whichcanbe
used fortransporting inert materialsinaccordancewiththe product datacontained withinthismanual’s
datasheet. The DTRAK 300,withthe characteristicsshown intable2-1of thismanual, issuitablefor
indoorand outdooruse.The machine maynotbe used inacidicorexplosiveenvironmentsnorinany
otherenvironmentwhichhasnot been expresslyapproved bythe manufacturer.
Allofthe operating proceduressuchasloading and unloading can be performed byasingleoperator.
The machine and itsaccessoriesaredesigned andmanufactured forsafeoperation underthe
following conditions:
-usage withinthe prescribed limits;
-the operatorsmustfollowthe proceduresdescribed inthe instruction manual;
-the operatorsmust respect the foreseen working conditions, paying special attention to:
-the totaloperationallimits;
-the servicecoefficient(working hourspershift);
-environmental conditions(dust, temperatureand humidityinthe workplace).
2.3.1.2Unintendeduse
It if FORBIDDENtousethe machine fortransporting:
a)liquidsofanykind,explosives,flammablematerials, corrosivematerials, etc.;
b)explosivematerials, dynamite,fireworksetc. ;
c) people, animals;
It isFORBIDDENtousethe machine inenvironmental conditionssuchas:
a)inthepresenceofsnoworice;
b)lowvisibility;
c) slippery surfaces;
d)surfaceswithinclinessuperiortothosewhichareprescribed on the datalabellocated on every
side of the machine;
e)constant wind;
f)rainand stormswithrisksoflightning.
ATTENTION:UNFORSEENAND/ORIMPROPERAND/ORINCORRECT USE.
Using themachinewithdifferentmaterialsorforthepurposeofobtaining production
valuessuperiortothosewhich are indicatedisconsidered “IMPROPERUSE”.
Anyulterioremploymentofthe machine mustbe authorized beforehand inwriting bythe
manufacturer.Withoutauthorization,suchemploymentistobe considered “improperuse”and
therefore,insuchcases,the Manufacturershallbearno responsibilityforanyeventualdamagesto
peopleorobjectsand shall considerevery type ofwarrantyforthe machine and forthe devices
furnished asnullified.

October 22, 2008 Rev.01
2-DESCRIPTION
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages17 -57
Fig. 2-4Tableoftoxicandharmfulproductsforwhich transportisFORBIDDEN
2.3.1.3Usageenvironment
ATTENTION:EXPLOSIVE ATMOSPHERE.
ThismachineISNOT AVAILABLEINAN ANTI-EXPLOSIONCONFIGURATION, butisonly
availableinastandardconfiguration.
ITSUSE ISTHEREFOREFORBIDDENINWORKPLACES WHERETHECONCENTRATION
OF EXPLOSIVESUBSTANCESMAYEXCEDETHEMAXIMUMLIMITSAND CREATEAN
ATMOSPHEREAT RISKOFEXPLOSION.
2.3.2Environmentaloperatingconditions
The properfunction,the reliabilityand the workinglifeofthe machine and itscomponentsare
guaranteed ifthe environmentalconditionsarewithinthelimitslisted below.
Temperature Environmentalairtemperaturebetween+5°Cand +40°C–Average
environmental airtemperaturenotinexcess of +35°Cforperiodsof 24 hours.
Relativehumidity% Max. 95% withoutcondensation
Altitude Max. 1000mabovesea levelif not otherwisespecified
Transport Transporttemperaturebetween -25°Cand +55°Cwithvariationsup to70°Cfor
amaximumtimeof 24 hours.
Storage Storage temperaturebetween -25°Cand +55°Cwithvariationsup to70°Cfora
maximumtimeof24 hours.
2.3.3Lighting
The working environmentmustbe sufficientlyilluminated withnaturallighting and be equipped with
adequateartificialillumination devicesforthe safeguarding ofhealthand safetyinaccordancewiththe
European Directive89/654/EEC(workplaces).
The illumination of the workplacemust conformtothe current lawsofthe countryinwhichthe machine
isinstalled and must, inall cases,beuniformand guarantee good visibilityforevery partofthe
machine,mustnotcausedangerousreflectionsand mustallowforthe command panelstobe read
clearlyand forthe emergencybuttonstobe identified.
The illumination mustallowforthe safeexecution ofanymaintenanceoperationsforeseen bythe
manual.Useadequatelighting sourcesformaintenanceoperationsinspecificzones(suchasinthe
internal partsofthe machine).
The workplacelighting devicesmust notconstituterisksofdanger.

October 22, 2008 Rev.01
2-DESCRIPTION
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages18 -57
2.3.4Usageillustration
ATTENTION:UNFORSEENAND/ORIMPROPERAND/ORINCORRECT USE.
Using themachineanditsunitswithdifferentmaterialsorforthepurposeofobtaining
productionvaluessuperiortothosewhichare indicatedisconsidered“IMPROPER
USE”.
The usage illustration showninfig. 2-5isdescribed below.
The producttobe transported isloaded intothe tray(no.1)and unloaded manuallybythe operatorby
meansofthe twohandles(no.2)located on the sidesofthe tray. The plough-stilt driving position,from
whichthe operatorconductsthe machine withagoodvisibilityofthe necessary commands,isgiven
bythe letterA.
Fig. 2-5Usageillustration
1
A
2

October 22, 2008 Rev.01
2-DESCRIPTION
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages19 -57
2.3.6Vibrations
The machineisequipped withthree vibration-absorbing wheelswhichwill nottransmitanyvibrations
whichcouldcompromisestability.The machine,beingpowered byan electricmotor,emitsvibration
levelsinferiorto2.5m/sec2.
Anyanomalousvibrationsmaycausemechanicalproblems(suchasflange and beltloosening, etc.). If
suchphenomena persist, consultthe Manufactureroryourlocalreseller’sassistancecentre,indicated
inthefirst pagesofthe manual.
2.3.7Noise
The machine isdesigned and builtinsuchawaysoastoreducenoiselevelsattheirsource.The
noiselevelsindicated areemission levelsand do notnecessarilyrepresentsafeoperativelevels.
Although thereisarelationshipbetween emission levelsand exposurelevels,thisrelationshipcannot
be utilized inareliablemannerinordertoestablishwhetherulteriorprecautionsarenecessary.The
factorswhichdetermine the exposurelevelstowhichthe operatorisexposedarethe duration of
exposure, the characteristicsofthe workplaceand othernoisesources(numberofmachines, adjacent
processes, etc.). Moreover, the maximumallowed exposurelevelscan vary fromcountry tocountry.In
anycase,the information provided willallowthe machine’suserbetterevaluateanyeventualdanger
orrisks.
ATTENTIONChanging thetypologyoftheproductbeingworkedwithand changingthe
operatingconditionswillalso changethenoiselevels.
Anyeventualanomalousnoisescancausemechanicalproblems(suchasbeltorchainloosening,
etc.).Performanynecessary maintenanceoperationsasdescribed inthe instructions(see chapter7
“Maintenance”).Ifsuchphenomena persist, consultthe Manufactureroryourlocalreseller’s
assistancecentre, indicated inthe first pagesof the manual.

October 22, 2008 Rev.01
3-TRANSPORT
FY310.doc ThismanualisthepropertyofALITRAK
Anyreproduction,evenpartial, isforbidden. Pages20 -57
3TRANSPORT
3.1WARNINGS
ATTENTION:Thelifting, handling, transportingandunpacking ofthemachineandits
componentsmustbeperformedunder thefollowing conditions:
-theseoperationsmustbeentrustedexclusivelytoqualifiedpersonnel(slingers,crane
operators, forkliftoperators, signalmen).
Theoperatorsmustalso be:
-informedasto thenature oftheloadsto belifted, astotheoperationstobecarriedout
and astotheproceduresforeseen bythemanual;
-authorized;
-assisted byemployeesofthemanufacturer (oroftheauthorized assistance centre)who
have agood knowledgeofthemachineanditsmanual;
-operatein accordance withtheproceduresindicated in themanualitself.
ATTENTION:Duringtheseoperationstheoperatorsinvolvedmustwear personal
protection gear suchas:helmets,gloves,safetyshoes,work coverallsand anyother
meansrequiredbythecurrentstandardsbasedon thenature oftheoperationstobe
performed.
ATTENTION:Theoperatorsmustrespecttheregulationsandprohibitionsprescribedby
thecurrentstandardsforliftingandtransportoperations;amongstthese,thefollowing
generaloperative rulesare tobekeptin mind:
-stand back fromtheloadsbefore performing lifting andlowering manoeuvres;
-donotstandunderneath suspendedloads;
-accessto unauthorizedpersonnelistobeprohibited;
-keep asafedistance fromthesuspendedmachineduringanymanoeuvres.
ATTENTION:Failure toobserve theabove warningscanleadtoseriousinjury and/or
accidentswith consequentmachinery damageandpersonal injury.
InthemostseriouscasestheseaccidentsCAN CAUSE THEDEATHOF THE
OPERATORSINVOLVED.
3.2TRANSPORTING AND LIFTING THEMACHINE
The machine isshipped completelyassembled and packaged inacardboardboxattached toapallet.
Upon arrival,verifythatthe machine hasnotbeen damaged during transportand thatall ofthe parts
indicated inthe packing listarepresent, including the instruction manual.
ATTENTION:Anymeansusedforhandlingmustbesuitableforliftingthemachine,
keeping in mind:
-theshapeand size;
-themass (weight)and itsdistribution (centre ofgravity);
-theforeseen liftingconnectionpoints.
NOTICE: Arrangethelifting apparatusin suchaway soastoavoid collisionsand/or
pressure uponprotruding parts(especiallythecommand panel, etc.).
ATTENTION:Appropriatelytrainedpersonnelshouldbeassignedtotheseoperations
(slingers,craneoperators,forklift operators,etc).Arrangeforaperson tobein charge
ofsignalling astheencumbrance ofthemachineanditspackaging canimpede
sufficientvisibilityfortheoperatorsperformingthemanoeuvres.