Still KANVAN-05 User manual

Original instructions
Forklift towing tractor
KANVAN-05
KANVAN-10
1067 1068
50108043033 EN - 00-10/2013

Table of contents
g
1 Foreword
Your industrial truck ................................................... 2
General ............................................................ 2
EC declaration of conformity in accordance with Machinery Directive ............... 3
Information about documentation ......................................... 4
Documentationscope ................................................. 4
Date of edition and latest update of this manual ............................... 6
Copyrightandtrademarkrights ........................................... 6
Explanation of symbols used ............................................ 7
Explanation of the cross-references ....................................... 7
Sample graphics ..................................................... 8
Environmental considerations ........................................... 9
Packaging .......................................................... 9
Disposal of components and batteries ...................................... 9
2 Introduction
Technical description ................................................. 12
Operating the truck .................................................. 14
Intended use of the trucks .............................................. 14
Approved applications ................................................ 14
Unintended use ..................................................... 14
Placeofuse ........................................................ 15
Residual risks ...................................................... 17
Residual dangers, residual risks ......................................... 17
Specialrisksarisingfromuseofthetruckanditsaccessories .................... 18
Overview of hazards andcountermeasures ................................. 20
Hazardstoemployees ................................................ 22
3Safety
Definition of responsible persons ........................................ 26
Operating company .................................................. 26
Specialist .......................................................... 26
Expert ............................................................ 27
Driver ............................................................ 27
Basic principles for safe operation ....................................... 29
Insurance cover on company premises .................................... 29
Warning regardingnon-originalparts ..................................... 29
Modificationsandrefitting .............................................. 29
Medicalequipment .................................................. 30
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Safety tests ........................................................ 31
Regularsafetyinspectionofthetruck ..................................... 31
Electricalinsulationtest ............................................... 31
Safety regulations for handling consumables ............................... 33
Permissibleconsumables ............................................. 33
Oils .............................................................. 33
Hydraulicfluid ...................................................... 34
Batteryacid ........................................................ 35
Disposalofconsumables .............................................. 36
Emissions ......................................................... 37
Safety devices ...................................................... 39
Location of safety devices ............................................. 39
Damage, defects and misuse of safety devices . . . ........................... 40
Battery connection cables ............................................. 40
4Overview
Total overview ...................................................... 42
Control and display elements ........................................... 43
Controldevices ..................................................... 43
Cockpit ........................................................... 45
Markings .......................................................... 46
Markingpositions .................................................... 46
Labels ............................................................ 49
Chassisframelabelling ............................................... 51
Dataplate ......................................................... 51
Options and variants................................................. 52
Standard equipment and options ........................................ 52
BatteryelectrolytelevelindicatorLED(optional) ............................. 56
5 Operation
Intended use of the trucks .............................................. 58
Checks and actions prior to use ......................................... 58
Listofcheckspriortostart-up ........................................... 58
Check the operation and security of the trailer coupling ........................ 60
Connecting the battery plug (charging station) ............................... 60
Commissioning ..................................................... 61
Turningonthet
ruck .................................................. 61
Enteringtheusercode ................................................ 62
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Starting with FleetManager (optional) ..................................... 63
Hourmeter ........................................................ 64
Batterycharge ...................................................... 64
Maintenance interval management ....................................... 65
Operatingthehorn ................................................... 65
Check of brake and presence area ....................................... 66
Checking the emergency brake ......................................... 66
Driving ............................................................ 67
Driving safety instructions .............................................. 67
Visibilitywhendriving ................................................. 67
Beforedriving ...................................................... 68
Behaviour in emergency situations ....................................... 69
Differentdrivingmodes ............................................... 69
Driving,ride-onstandingmode .......................................... 70
Selecting the driving mode ............................................. 71
Driving in accompanied mode with cockpit, slow forward travel using the throttles ..... 72
Drivinginpedestrianmodewithbackrestpushbuttons ........................ 75
Steering ........................................................... 75
Braking ........................................................... 76
Emergency stop brake . ............................................... 77
Parkingbrake ...................................................... 78
Automaticshutdown .................................................. 78
Lifting ............................................................ 79
Liftcontrols ........................................................ 79
Handling trailers ..................................................... 81
Proper use during towing .............................................. 81
Coupling trailers ..................................................... 83
Single-positionormulti-positiontrailercoupling .............................. 84
Automaticallyclosingtrailercoupling ..................................... 86
ROCKINGER trailer coupling ........................................... 88
Towingatrailer ..................................................... 89
Working with loads ................................................... 90
Safety regulations when handing loads .................................... 90
Beforepickingupaload ............................................... 90
Pickingupaload .................................................... 91
Danger area ....................................................... 91
Transportingpalletsorothercontainers ................................... 92
Handling a load ..................................................... 92
Drivingonramps .................................................... 95
Transportinlifts ..................................................... 95
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Digicode .......................................................... 96
Digicodecontrol ..................................................... 96
Addingthemastercode ............................................... 97
Deletingamastercode ................................................ 99
Addingadriver’scode ................................................100
Deletingadriver’scode ...............................................102
Error codes ........................................................103
Errordisplay .......................................................103
Handling the truck in specific situations ....................................104
Transport ..........................................................104
Towing procedure ...................................................104
Loadingwithahoist ..................................................104
Handling the battery ..................................................105
Preparation ........................................................105
Battery weight and dimensions ..........................................105
Opening/closing the battery compartment ..................................106
Batteryreplacement ..................................................108
Battery replacement withcrane ..........................................109
Battery change with a roller battery holder ..................................109
Servicingthebattery .................................................110
Decommissioning ...................................................111
Leaving the truck unattended . ..........................................111
Storage ...........................................................111
Measures when taking thetruckoutofserviceforalongperiod ..................111
Recommissioningafterstorage .........................................111
6 Maintenance
General maintenance information ........................................114
General . . .........................................................114
Staff training and qualifications for maintenance and repairs ....................115
Maintenance personnel for batteries ......................................115
Services not requiringspecialqualifications ................................115
Servicingandinspectionintervals ........................................116
Orderingsparepartsandconsumables ....................................118
Table of maintenancecharacteristics .....................................119
Safety instructions for maintenance ......................................119
Safety measures for maintenance and repair ...............................119
Work on the electricalequipment ........................................120
Safetydevices ......................................................120
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Settings ...........................................................120
Preparatory procedures for maintenance ..................................120
Slingingorjackingthetruck ............................................1
20
Cleaning ..........................................................122
Cleaningthetruck ...................................................122
Maintenance as required ..............................................125
Service the wheels and rollers ..........................................125
Servicingthebattery .................................................125
Chargingtheleadbattery ..............................................1
27
Chargingthegelbattery ...............................................127
Checking operation of the brake, checking the emergency brake .................129
Liftingdevice .......................................................129
Fuses ........................................................... . 131
Maintenance every 500 hours ...........................................133
Othertasks ...................................................... . . 133
Checking the gearbox oil level ..........................................133
Checking the gearbox for leaks ..........................................133
Servicing the pump motor ..............................................133
Servicetheelectricalsystem ...........................................134
Servicingthebrake ..................................................135
Checking the condition oftheforks .......................................135
Servicingthemast ...................................................136
Maintenance every 1000 hours ..........................................137
Work that must also be carriedout .......................................137
Insulationresistancecheck(earthing) .....................................137
Performingtheaccidentpreventioncheck ..................................138
Maintenance every 2000 hours ..........................................139
Othertasks ...................................................... . . 139
Maintainingthehydraulicsystem ........................................140
Servicingthemast ...................................................14
0
Checkingandcleaningthebattery .......................................141
Servicingthebatteryaccordingtothemanufacturer’sinstructions ................141
Insulation resistancecheck(earthing) .....................................141
Performingtheaccidentpreventioncheck ..................................142
Maintenance every 5000 hours ..........................................142
Otheractivities ......................................................1
42
Servicingthegearbox ................................................143
50108043033 [EN] V

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7 Technical data
Datasheet (VDI) .....................................................146
Wheels and tyres ....................................................149
VI 50108043033 [EN]

1
Foreword

1Foreword
Your industrial truck
Your industrial truck
General
The truck described in these operating instruc-
tions corresponds to the applicable standards
and safety regulations.
If the truck is to be operated on public roads, it
must conform to the existing national regula-
tions for the country in which it is being used.
The driving permit must be obtained from the
appropriate office.
Thetruckshavebeenfittedw
ith state-of-the-
art technology. All that remains is to handle
the truck safely and maintain its functionality.
These operating instructions provide the
necessary information to do this. Read and
observe the information provided before
commissioning the truck. This will prevent
accidents and ensure that the warranty
remains valid.
25
0108043033 [EN]

Foreword 1
Your industrial truck
EC declaration of conformity in accordance with Machinery Directive
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
Industrial truck according to these operating instructions
Model according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
.
50108043033 [EN] 3

1Foreword
Information about documentation
Information about documentation
Documentation scope
• Operating instructions
• Operating instructions for attachment parts
(special equipment)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks
These operating instructions describe all mea-
sures necessary for the safe operation and
proper maintenance of the truck in all possible
variants at the time of printing. Special de-
signs to meet customer requirements are doc-
umented in separate operating instructions. If
you have any questions, please contact your
service centre.
Enter the production number and the year
of production located on the nameplate
⇒ Chapter "Data plate", P.4-51inthefield
provided:
Production no. ...........................................
Year of production
...................................................
Please quote these numbers for all technical
enquiries.
Operating instructions are provided with each
truck. These instructions must be stored
carefully and must be available to the driver
and operator at all times.
If the operating instructions are lost, the oper-
ator must immediately request a replacement
from the manufacturer.
The operating instructions are included in the
spare parts list and can be reordered there as
a spare part.
Personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company (see ⇒ Chapter "Def-
inition of responsible persons", P. 26) must
ensure that all operators have received, read
and understood these instructions.
45
0108043033 [EN]

Foreword 1
Information about documentation
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any faults, please contact
your service centre.
50108043033 [EN] 5

1Foreword
Information about documentation
Date of edition and latest update of
this manual
The publication date of these operating
instructions is printed on the cover sheet.
The manufacturer makes continuous efforts
to improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
To receive technical assistance, please
contact the service centre authorised by your
closest manufacturer.
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.
65
0108043033 [EN]

Foreword 1
Information about documentation
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid danger to life or physical harm.
WARNING
Compulsory procedure that must followed to avoid
injury.
CAUTION
Compulsory procedure that must be followed to
avoid material damage and/or destruction.
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
Explanation of the cross-references
Cross references are used to direct the reader
to the appropriate section or chapter.
Examples:
• Cross reference to a section: ⇒ Chap-
ter "Explanation of the cross-refer-
ences",P.1-7
• Cross reference to a chapter: ⇒ Chap-
ter "Definition of responsible persons", P. 26
50108043033 [EN] 7

1Foreword
Information about documentation
Sample graphics
This documentation explains the cycle (usu-
ally sequential) of certain functions or opera-
tions. Schematic diagrams of a truck are used
to illustrate these cycles.
NOTE
These schematic diagrams are not represen-
tative of the constructed state of the docu-
mented truck.
85
0108043033 [EN]

Foreword 1
Environmental considerations
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
Disposal of components and
batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, they must be:
• disposed of,
• treated or
• recycled in accordance with regional and
national regulations.
NOTE
The documentation provided by the battery
manufacturer must be observed when dispo-
sing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company for disposal purposes.
50108043033 [EN] 9

1Foreword
Environmental considerations
10 50108043033 [EN]

2
Introduction

2Introduction
Technical description
Technical description
The KANVAN forklift tractor combines the
driveability and compactness of a platform
tractor with the option of handling loads of
up to 500 kg (KANVAN 05) and 1000 kg
(KANVAN 10) at a height of 1250 or even
1800 mm. Its 3 kW AC motor ensures a
traction capacity of 4000 kg and a speed of
7.5 km/h with load and 13 km/h without load.
Its compact construction with a length of 1595
mm guarantees maximum manoeuvrability
even in the narrowest aisles.
Steering
• Electric steering with automatic return to
neutral.
• On straight runs, an electrical compen-
sation system for involuntary steering ac-
tions made by the driver ensures a perfectly
straight trajectory without the trailer sway-
ing.
• The drive wheel’s central position guar-
antees optimal traction and stability when
moving in a straight line and when slowing.
• Automatic speed reduction when cornering
ensures a very high level of lateral stability
by reducing the effects of centrifugal force.
Chassis
• The front part is reinforced by a large fender.
A removable front hood ensures quick and
easy access to all of the vehicle’s subplates.
Multi-function control panel
The new-generation multi-function cockpit
brings together all of the KANVAN’s driving,
manoeuvring and control functions. The
ergonomic position of the different buttons
allows all the functions to be used without
having to move your hand. The cockpit brings
together the following functions:
•Driving
• Steering
• Lifting and lowering
• Hour meter
• Battery charge indicator
• Adjustable driving programs
• PIN code access control included as
standard
• Diagnostics by service codes
Furthermore, the multi-function joystick on the
STILL cockpit control panel allows steady and
tension-free steering during driving.
Handling functions
• The lifting device is very simply operated
from the driver’s platform via the cockpit.
An additional control is also included as
standard at the front of the vehicle for
greater comfort and visibility of the fork
ends when handling loads.
• A patented system allows the fork arms
to be raised and lowered at the touch of
a button. The driver is therefore able to
control and check all handling functions on
the vehicle without leaving the platform.
Driver’s platform
• The suspended driver’s platform offers
optimal comfort when driving as well as
when mounting and dismounting from the
platform thanks to its low access height and
its thick, anti-slip mat.
• This mat includes a detector switch safety
mechanism: The driver must be on-board
the vehicle while carrying out fork lifting and
lowering operations.
• The support area at the front of the platform
is covered by a high-strength moulded
(RIM) plastic coating that is ergonomically
designed to support a standing driver.
• Rear backrest with ergonomic side handles
offers a high standard of comfort and safety
when moving.
• Platform with several storage options, as
well as fastenings for rolls of plastic film or
document holders.
12 50108043033 [EN]