Vetter Smartfork User manual

Operating instructions
U163-934
EN
SmartFork® Scale weighing fork arms
Read the instructions prior to performing any task! Keep for future use!

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The operating instruction (hereinafter also referred to as “manual") contains fundamental
safety instructions for handling the VETTER SmartFork® Scale weighing fork arms
(hereinafter also referred to as "SmartFork® Scale"). Incorrect use of the SmartFork®
Scale can result in serious injuries and even death due to the considerable dead weight
and the mechanical properties. For this reason, this manual and especially the safety
instructions/information contained therein must be read by the competent industrial truck
driver prior to assembly, commissioning and maintenance. The manual must always be
available at the operation site of the SmartFork® Scale (on the industrial truck).
Always observe the information in the industrial truck operating instruction to ensure safe
handling of the SmartFork® Scale.
The SmartFork® Scale can be equipped with other SmartFork® applications (e.g. laser).
If any reference is made to an “assistance system” in the text that follows, such a refer-
ence encompasses all other applications installed in the SmartFork® Scale in addition to
the weighing function.
Illustrations in this manual are for basic understanding and may deviate from the actual
design.
Address VETTER Industrie GmbH
Carl-Benz-Strasse 45
57299 Burbach
GERMANY
Phone [phone]
E-Mail [email protected]
Internet www.smartfork.com
About this
manual
Customer
service
Supplemental directives
EN
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TABLE OF CONTENTS
1OVERVIEW, SMARTFORK® SCALE 6
1.1 Range of application 6
1.2 Variants of the SmartFork® Scale 6
1.3 EC declaration of conformity 8
2 SAFETY 9
2.1 Symbols in this manual 9
2.2 Applicable documents 10
2.3 Intended use 10
2.4 Operator obligations 11
2.5 Dangers when handling the SmartFork® Scale 12
2.6 Safety markings 16
2.7 Personnel requirements 17
2.7.1 Qualifications 17
2.7.2 Unauthorised persons 19
2.7.3 Training 19
2.8 Personal protective equipment 19
2.9 Protection of the environment and disposal 20
2.9.1 Recycling 21
3STRUCTURE OF THE SMARTFORK® SCALE 22
3.1 Structure of basic fork arm and fork shoe 22
3.2 Suspension 23
3.3 Image and signal output devices 24
3.4 Cabling 25
4INITIAL ASSEMBLY OF THE SMARTFORK® SCALE 27
4.1 Installing the SmartFork® Scale on the fork carrier 27
4.2 Installing and connecting the SmartDisplay 28
5OPERATION OF THE SMARTFORK® SCALE 30
5.1 Weight determination with the SmartFork® Scale 30
5.1.1 Prerequisite for correct weight determination 30
5.1.2 Calibrating the SmartFork® Scale 32
5.1.3 Taring/net compensation 33
5.1.4 Load weight display 34
5.1.5 Calculation and addition of individual weights 34
5.1.6 Load centre distance display 34
5.2 Adjusting the distance between the fork arms 34
6MAINTENANCE OF THE SMARTFORK® SCALE 36
6.1 Maintenance intervals 36
6.2 Maintenance activities 36
6.2.1 Daily visual inspection by the driver 36
6.2.2 Checking electronics 37
6.2.3 Checking the fork arms and hooks 38
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6.2.4 Checking the locking device 38
6.2.5 Cleaning the SmartFork® Scale 39
6.2.6 Replacing the SmartFork® Scale 39
6.2.7 Replacing components 41
6.2.8 Spare parts 47
6.3 After completion of maintenance activity 47
7TROUBLESHOOTING ON THE SMARTFORK® SCALE 48
8 TECHNICAL DATA 49
9 INDEX 56
Table of contents
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1 Overview, SmartFork® Scale
1.1 Range of application
The SmartFork® Scale is used to lift, transport and put down loads or goods on pallets
that are intended for transport by fork lift truck or another form of industrial truck.
Using the SmartFork® Scale allows the weight of the load that was lifted to be recorded
during transport and, if necessary, added up. The load centre distance of the load (in lon-
gitudinal direction of the vehicle) that was lifted can also be displayed.
Always observe the information in the industrial truck operating instruction to ensure safe
handling of the SmartFork® Scale.
1.2 Variants of the SmartFork® Scale
Fig. 1: SmartFork® Scale and SmartSupply
1 SmartSupply
2Position of the load cells in the SmartFork® Scale
The SmartFork® Scale is used to weigh a load that was lifted. The signal is transferred
from the load cells (Fig. 1/2) in the fork blade to the output device (SmartDisplay) in the
cab via a radio system, the SmartSupply (Fig. 1/1).
Overview, SmartFork® Scale
Variants of the SmartFork® Scale
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The SmartFork® Scale is delivered together with the SmartSupply and is available in two
variants.
Variant BAT - The power supply for the SmartSupply is realised by means of a
replaceable battery.
Variant CAB - The power supply for the SmartSupply is done via the power source of
the industrial truck by cable.
Additional SmartFork® applications
The SmartFork® Scale can optionally be equipped with other SmartFork®
applications. Information about other installed applications of the
SmartFork® (e.g. laser), the operating manual for the SmartDisplay and
the operating instruction for the SmartSupply can be found in the other
applicable documents.
Variants
Overview, SmartFork® Scale
Variants of the SmartFork® Scale
EN
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1.3 EC declaration of conformity
AS PER EC MACHINERY DIRECTIVE 2006/42/EC
VETTER Industrie GmbH, as the manufacturer, hereby declares that the products listed
below comply with the EC Machinery Directive.
Name: - SmartFork® Scale weighing fork arm
Model: - SCALE25/LLLL/XX/YYY; LLLL = blade length; XX = suspension, YYY = BAT or
CAB
- SCALE50/LLLL/XX/YYY; LLLL = blade length; XX = suspension, YYY = BAT or
CAB
This declaration is void if a change is made to the aforementioned equipment.
The authorised agent for compiling the technical documentation is the signatory.
This declaration applies to all product variations of the product series, and to accessories
(if applicable).
APPLIED NATIONAL STANDARDS AND GUIDELINES:
EN ISO 12100:2011-03 - Safety of machinery
ISO 2328 - Forklift trucks - Hook-on type fork arms and fork arm carriages
- Mounting dimensions
ISO 2330 - Forklift trucks - Fork arms - Technical characteristics and
testing
2014/30/EU - EMC Directive
VETTER Industrie GmbH
Carl-Benz-Strasse 45
57299 Burbach/Germany
Tel.: [phone]
E-Mail: [email protected]
www.forks.com
31/03/2020 Gunther Grindel (Technical Director)
Overview, SmartFork® Scale
EC declaration of conformity
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2 Safety
2.1 Symbols in this manual
Safety instructions in this manual are marked by symbols. The safety instructions are
introduced by signal words which express the extent of the danger.
DANGER!
This combination of symbol and signal word indicates an imminently dan-
gerous situation which, if not avoided, will result in death or serious injury.
WARNING!
This combination of symbol and signal word indicates a potentially dan-
gerous situation which, if not avoided, could result in death or serious
injury.
CAUTION!
This combination of symbol and signal word indicates a potentially dan-
gerous situation which, if not avoided, could result in minor or slight injury.
NOTICE!
This combination of symbol and signal word indicates a potentially dan-
gerous situation which, if not avoided, could result in material damage.
ENVIRONMENT!
This combination of symbol and signal word indicates potential dangers
to the environment.
This symbol highlights useful tips and recommendations as well as infor-
mation designed to ensure efficient and smooth operation.
Safety instructions may refer to specific, individual instructions. Such safety instructions
are integrated into the instruction so that they do not interrupt the flow of reading when
carrying out the task. The signal words described above are used.
Safety instruc-
tions
Tips and rec-
ommenda-
tions
Safety instruc-
tions in spe-
cific instruc-
tions
Safety
Symbols in this manual
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Example:
1. Loosen the screw.
2.
CAUTION!
Risk of pinching by cover!
Close the cover carefully.
3. Tighten the screw.
2.2 Applicable documents
In addition to this manual, also observe the documentation of the other components and
machines used, as well as operator-specific requirements:
nOperating instruction for the industrial truck
nOperating instruction for the mounted fork carrier
nOperating instructions for the operator
nOperating instruction for the SmartSupply
nOperating manual for the SmartDisplay
nEquipment-specific operating instructions for the individual SmartFork® applications
and components
2.3 Intended use
The SmartFork® Scale is used exclusively to record the weight and transport loads
without other SmartFork® applications. Its use does not in any way replace the general
requirements for safety and due diligence. The SmartFork® Scale must only be used on
fork lift trucks or industrial trucks with compatible fork carriers.
Safety
Intended use
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WARNING!
Risk of injury from incorrect use!
Incorrect use of the SmartFork® Scale could lead to dangerous situations
and serious injuries.
– Never neglect the general requirements for safety and due diligence. If
in doubt, personally ensure that there are no people or obstacles in the
danger zone of the industrial truck.
– Do not exceed the maximum load capacity of both SmartFork® Scales
used.
– Never install the SmartFork® Scale on a fork carrier that is incompat-
ible with the SmartFork® Scale supplied. Observe the relevant oper-
ating instruction for the fork carrier installed on the industrial truck.
– Never use the SmartFork® Scale to lift or transport people.
– Never use the SmartFork® Scale for demolition work.
– Never use the SmartFork® Scale as reversible fork arms.
– Never use the SmartFork® Scale separately or load it unevenly.
– Never use the SmartFork® Scale at temperatures outside the tem-
perature range of -10 °C and +40 °C.
– Never expose the SmartFork® Scale to lateral forces. It is not per-
mitted to insert or pull out of the pallet/load at an angle, or to push the
pallet/load from the side.
– Never use the SmartFork® Scale on a rotary device or on a pallet han-
dler.
– Only use (when unloaded) the SmartFork® Scale for road transport
with an approved warning system (e.g. warning bars) as per the road
traffic regulations.
– Never use industrial trucks equipped with the SmartFork® Scale in
areas subject to explosion hazards.
– Never allow unauthorised persons access to the industrial truck.
– Never allow insufficiently qualified persons to carry out maintenance or
troubleshooting work.
– Never skip a maintenance interval.
– Never modify the SmartFork® Scale independently.
Intended use includes observation of all the information in this manual.
Any use that goes beyond the scope of intended use is considered incorrect use.
The use of the SmartFork® Scale without the prescribed safety markings (hard stamping
on the back of the fork, Fig. 2) is considered incorrect use.
2.4 Operator obligations
The operator is the person who operates the SmartFork® Scale on an industrial truck for
industrial or commercial purposes, or who delegates use to a third party and bears the
legal product responsibility during operation for the protection of personnel or third par-
ties.
Operator
Safety
Operator obligations
EN
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The SmartFork® Scale is used in the commercial sector. The operator of the SmartFork®
Scale is therefore subject to the legal requirements for occupational safety.
In particular, the following applies:
nThe operator must be aware of the applicable health and safety regulations and in a
risk assessment must determine any additional dangers that could arise from the par-
ticular working conditions at the operation site of the SmartFork® Scale. These must
be outlined in the form of operating instructions for operation of the SmartFork® Scale.
nThe operator must ensure over the entire operating time that the operating instructions
created by him/her correspond to the current state of the rules and regulations, and
adjust them if necessary.
nThe operator must clearly regulate and specify the responsibilities for assembly, opera-
tion, troubleshooting, maintenance and cleaning.
nThe operator must ensure that all persons that come into contact with the SmartFork®
Scale have read and understood this manual. In addition, he/she must regularly train
personnel and inform them of any dangers.
nThe operator must provide personnel with the required protective equipment and
instruct them that wearing the required protective equipment is mandatory.
In addition, the operator is responsible for ensuring that the SmartFork® Scale is always
in a technically perfect condition. The following therefore applies:
nThe operator must ensure that the maintenance intervals described in this manual are
adhered to.
nThe operator must regularly have all safety equipment checked for functionality and
integrity.
2.5 Dangers when handling the SmartFork® Scale
WARNING!
Risk of injury due to disregard for the safety and due diligence obli-
gation!
The SmartFork® Scale application is only an assistance system for deter-
mining the weight of loads. As is the case with some other SmartFork®
applications, its use does not assist with forward guidance of the vehicle.
The SmartFork® Scale does not in any way replace the general safety
and due diligence obligation during loading, unloading and the transport
of goods.
– Never neglect the general requirements for safety and due diligence. If
in doubt, actively ensure that people and obstacles in the danger zone
of the industrial truck give due consideration to the presence of the
industrial truck.
– Always ensure that there are no persons or objects in the weighing
range of the SmartFork® Scale when determining the weight.
– Always ensure that all SmartFork® applications have been configured
for the tasks to be carried out.
Safety and
due diligence
obligation
Safety
Dangers when handling the SmartFork® Scale
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WARNING!
Risk of injury from incorrectly executed work on the SmartFork®
Scale!
The faultless function of the SmartFork® Scale application ultimately
depends on the unchanged state of the individual components. Inde-
pendent repairs or the use of third-party components could lead to
damage and a loss of functionality as well as serious injuries during use
(e.g. in the event of overloading). Improper repairs invalidate the guar-
antee and the manufacturer’s responsibility for any consequential
damage.
– Only have the SmartFork® Scale repaired by a service specialist.
– Always use original components.
WARNING!
Risk of injury from incorrectly executed work on the SmartFork®
Scale!
The load capacity of the SmartFork® Scale ultimately depends on a com-
pletely intact structure. Unauthorised modifications such as boreholes for
add-ons, welding work etc. could compromise the load capacity of the
SmartFork® Scale and result in serious accidents from falling loads.
– Never carry out modifications (e.g. boreholes, welding work) on the
SmartFork® Scale.
WARNING!
Risk of injury from tipping or slipping load!
Incorrect lifting of loads could cause the load to tip or slip and cause
serious injuries.
– Space the fork arms equally from the middle of the vehicle and lock
them in position.
– Grip the load with the SmartFork® Scale as far from its centre as pos-
sible.
– Raise the load using its entire length and distribute it evenly on both
SmartFork® Scales.
Improper
repairs
Unauthorised
modification
Incorrect fork
arm spacing
Safety
Dangers when handling the SmartFork® Scale
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WARNING!
Risk of injury from slipping load!
If there is moisture, dirt or ice on the lifting surfaces of the SmartFork®
Scale, there is an increased risk of the load slipping. A slipping load could
cause serious injuries.
– Remove any dirt from the SmartFork® Scale before lifting the load.
– In wet, snowy or icy conditions etc., secure the load with e.g. tension
belts.
WARNING!
Risk of injury from malfunctions on the SmartFork®!
If there is dirt or ice on the individual additional applications of the
SmartFork®, there is a risk of malfunction or loss of function in the
SmartFork® applications. This could result in dangerous situations and
serious injuries.
– Ensure that the sensors and protective screens of the additional appli-
cations are always free from dirt and ice.
– Check the functionality of the respective SmartFork® application
before beginning the activity.
WARNING!
Risk of injury and material damage from incorrect installation!
Incorrectly laid cable connections between the power source (for variant
CAB) and the SmartSupply could be damaged by mechanical influences
such as tension, friction or becoming jammed. Defective cables could
cause short circuits and electronic malfunctions, system failures or cable
fires. Cable fires could result in serious injuries due to fires.
– Have the electrical connection and cable connections carried out by an
electrician without exception.
– Protect the cable connections from damage.
– Adhere to the prescribed maintenance intervals.
Moisture and
dirt
Loss of func-
tionality due
to dirt and ice
Incorrect
cable connec-
tions
Safety
Dangers when handling the SmartFork® Scale
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WARNING!
Risk of explosion and fire as a result of damage to the lithium-con-
taining battery!
The faultless function of the SmartSupply in variant BAT ultimately
depends on the intact state of the SmartSupply battery. Independent
modifications and repairs as well as damage or opening the battery
casing could cause the battery to ignite suddenly and result in serious
injuries.
– Never use defective, damaged, deformed or swollen batteries.
– Always replace the SmartSupply battery with caution and pay atten-
tion to the integrity of the battery.
– Do not use pointed tools to deal with the battery if it is jamming and do
not use force to beat out the battery.
– Always use the original charger and ensure faultless function prior to
use.
– Mask the terminals of the lithium-ion battery during transport and do
not transport it with other metallic objects in order to prevent short cir-
cuits.
– Do not charge lithium-ion batteries outdoors, or in humid rooms or in
places where very high temperatures are to be expected.
Risk of fire
Safety
Dangers when handling the SmartFork® Scale
EN
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2.6 Safety markings
The hard stamping identifies (via the article number it contains) the version of the
SmartFork® upon delivery. SmartFork® fork arms without a marking must not be put into
operation. The SmartFork® hard stamping is on the side of the back of the fork (Fig. 2).
NOTICE!
The use of the SmartFork® without the prescribed markings is considered
incorrect use.
Fig. 2: Hard stamping, SmartFork® Scale
A: Article number (optional)
t: Load capacity
l: Load centre
C: Material code
M: Material
V: Manufacturer marking
W: Week of manufacture
J: Year of manufacture
F: Production order number
Hard stamping
Safety
Safety markings
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The type plate identifies (via the article number it contains) the version of the SmartFork®
Scale upon delivery. Do not put the SmartFork® Scale into operation without a type plate.
The type plate is located on the outside of the fork head.
Fig. 3: Type plate, SmartFork® Scale
1 Article number
2 Dead weight (unit)
3 Blade length
4 Centre of gravity
5 Note “Pay attention to load torque of forklift and fork arm”
6 Display increments of the weighing system
7 Load capacity x load centre
Attachment of the type plate
A type plate with an “L” at the end of the article number is always
attached on the left side in the direction of travel. A type plate with an “R”
at the end of the article number is always attached on the right side in the
direction of travel.
2.7 Personnel requirements
2.7.1 Qualifications
WARNING!
Danger of injury if personnel are insufficiently qualified!
If unqualified personnel perform work on the appliance or are in the appli-
ance's danger zone, hazards may arise which can cause serious injury
and substantial damage to property.
– Therefore, all work must only be carried out by appropriately qualified
personnel.
– Unqualified personnel must be kept away from the danger zones.
Type plate
Safety
Personnel requirements > Qualifications
EN
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This manual specifies the personnel qualifications required for the different areas of work,
listed below:
Driver of industrial trucks
The driver of industrial trucks is capable of operating industrial trucks with a driver’s seat
or a driver’s platform thanks to their education, knowledge and experience. The driver of
industrial trucks is aware of the dangers involved with lifting and transportation tasks.
The driver of industrial trucks has proven their ability to drive industrial trucks with a driv-
er’s seat or a driver’s platform to the operator and has consequently been assigned con-
trol by the operator.
The driver of industrial trucks is familiar with the use of the VETTER SmartFork® Scale
and the associated dangers.
Electrician
Due to their specialist training, knowledge and experience, as well as knowledge of the
relevant norms and regulations, the electrician is capable of carrying out work on elec-
trical systems and independently recognising and avoiding possible dangers.
The electrician is qualified for the following activities in particular:
nPlanning and connecting electrical systems based on circuit diagrams and the specific
configuration for the overall installation
nHandling the network protocols used
nPreparing cables and connecting electrical components
nAnalysing, measuring and checking electrical systems and functions
nCarrying out of safety tests on electrical systems, components and devices
nAnalysing and resolving malfunctions with electrical systems
The electrician is trained for the particular location in which they are active and is aware
of the relevant norms and regulations.
Service specialist
The service specialist has a qualification in mechatronics or similar or has verifiably taken
part in training in which the necessary knowledge and procedures for safe performance of
assembly, installation, commissioning and service on the VETTER SmartFork® Scale fork
arms has been taught.
The service specialist is familiar with the use of the VETTER SmartFork® Scale and the
associated dangers.
The service specialist is capable of operating industrial trucks with a driver’s seat or a
driver’s platform thanks to their education, knowledge and experience. The service spe-
cialist is aware of the dangers involved with lifting and transportation tasks.
The workforce must only consist of persons who can be expected to carry out their work
reliably. Persons with impaired reactions due to, for example, the consumption of drugs,
alcohol, or medication are prohibited.
When selecting personnel, the age-related and occupation-related regulations governing
the usage location must be observed.
Safety
Personnel requirements > Qualifications
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2.7.2 Unauthorised persons
WARNING!
Danger to life for unauthorised persons due to dangers in the
danger and work area!
Unauthorised persons, who do not meet the requirements described in
this manual, are not aware of the dangers in the work area. For this
reason, there is the danger of serious injuries and even death for unau-
thorised persons.
– Keep unauthorised persons away from the danger and work area.
– If in doubt, address such persons and direct them away from the
danger and work area.
– Suspend work while there are unauthorised persons loitering in the
danger and work area.
2.7.3 Training
The operator must train personnel on a regular basis. For purposes of improved tracking,
a training report containing the following information as a minimum requirement needs to
be created:
nTraining date
nName of person receiving the training
nTraining content
nName of person providing the training
nSignatures of person receiving the training and person giving the training
2.8 Personal protective equipment
Personal protective equipment serves to protect people against hazards to their safety
and health while working.
The personnel must wear the personal protective equipment while working on and with
the device which is referred specially to in the individual sections of these instructions.
The personal protective equipment is explained below:
Industrial safety helmet
Industrial safety helmets protect the head from falling objects, swinging loads and from
bumping against fixed objects.
Description of
the personal
protective
equipment
Safety
Personal protective equipment
EN
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Protective clothing
Protective clothing is tight fitting workwear with low tensile strength, short sleeves and
without any protruding parts.
Protective gloves
Protective gloves are used to protect hands from friction, abrasions, punctures and
deeper injuries. They also offer protection in the event of contact with hot surfaces.
Safety shoes
Safety shoes protect the feet from being crushed, falling parts and from slipping on slip-
pery surfaces.
WARNING!
Risk of injury from the work environment!
Regardless of the personal protective equipment required for the tasks
described, it is possible that additional dangers that are not described in
this manual could arise due to the operation site of the SmartFork®
Scale. If suitable personal protective equipment is not worn for these dan-
gers, there is a risk of serious injuries.
– Observe the operating instructions on wearing personal protective
equipment.
2.9 Protection of the environment and disposal
ENVIRONMENT!
Danger to the environment from incorrect handling of environmen-
tally hazardous substances!
If environmentally hazardous substances are handled incorrectly, particu-
larly if such substances are disposed of incorrectly, this could cause sig-
nificant damage to the environment.
Always observe the instructions given below when handling and dis-
posing of environmentally hazardous substances.
– If environmentally hazardous substances are inadvertently released
into the environment, take suitable measures immediately. If in doubt,
notify the competent municipal authorities of the damage and inquire
about suitable measures to be taken.
The following environmentally hazardous substances are used:
Further opera-
tional require-
ments
Safety
Protection of the environment and disposal
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