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
II 50108043033 [EN]

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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
50108043033 [EN] III

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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
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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]