Vetter KGA User manual

Operation manual
U163-905-US
Folding fork arms
Types KGA, KGI, and DuoLoc
Read this manual prior to performing any
task! Keep for future use!

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Folding fork armsTypes KGA, KGI, and DuoLoc
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This operating manual (hereinafter also referred to as “manual”) contains fundamental
safety instructions for handling folding fork arms of VETTER Forks, Inc.
Incorrect use of the folding fork arms can result in serious injuries and even death. For
this reason, this manual and, in particular, the safety information it contains must be
read by the carrier vehicle driver responsible for the carrier vehicle prior to assembly,
commissioning, and maintenance.
The manual is a component of the folding fork arms and must always be kept at the
work site of the folding fork arms (on the carrier vehicle) to ensure it is accessible for
personnel at all times.
Always observe the information in the carrier vehicle operating manual as well as the
applicable documents to ensure safe handling of the folding fork arms.
Furthermore, the local accident prevention regulations and general safety instructions
for the area in which the folding fork arms are used apply.
Illustrations in this manual are for basic understanding and may deviate from the actual
design.
In addition to this manual, also observe the documentation for the other components
and machines used, as well as operator-specific requirements:
nOperating manual and load chart for the carrier vehicle
nOperating manual for the mounted fork carrier
nOperating instructions for the operator
nPossible documentation of the special version
Address VETTER Forks, Inc.
1711 Opportunity Avenue
Chambersburg, PA 17201
USA
Phone [phone]
Email [email protected]
Internet www.forks.com
About this manual
Applicable docu-
ments
Customer service
Supplemental directives
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TABLE OF CONTENTS
1 OVERVIEW OF VETTER FOLDING FORK ARMS 6
1.1 Range of application 6
1.2 Folding fork arm variants 6
2 SAFETY 8
2.1 Symbols in this manual 8
2.2 Intended use 9
2.3 Operator obligations 11
2.4 Dangers associated with handling the folding fork arms 12
2.5 Safety markings 14
2.6 Personnel requirements 15
2.6.1 Qualifications 15
2.6.2 Unauthorized persons 16
2.6.3 Training 17
2.7 Personal protective equipment 17
2.8 Protection of the environment and disposal 18
3 STRUCTURE 20
3.1 Type DuoLoc (KGA-SBO) – Folding fork arms with pin retention and outer
hinge 20
3.2 Type KGA – Folding fork arms with outer hinge 21
3.3 Type KGI – Folding fork arms with inner hinge 22
3.4 Locking device 23
4 ASSEMBLY 24
5 OPERATION 28
5.1 Operating and transport position 29
5.1.1 DuoLoc (KGA-SBO) operating position 29
5.1.2 DuoLoc (KGA-SBO) transport position 31
5.1.3 KGA and KGI operating position 33
5.1.4 KGA and KGI transport position 35
5.2 Adjusting the fork arm spacing 36
6 MAINTENANCE 39
6.1 Maintenance intervals 39
6.2 Maintenance activities 39
6.2.1 Daily visual inspection by the driver 39
6.2.2 Fork arm inspection 41
6.2.3 Check for wear 41
6.2.4 Checking the locking device 42
6.2.5 Checking the locking bracket 43
6.2.6 Checking the suspension 44
Table of contents
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6.2.7 Cleaning the fork arm 45
6.2.8 Replacing the fork arm 45
6.3 Repairs and spare parts 47
6.4 After completion of maintenance work 51
7 TECHNICAL DATA 52
8 INDEX 53
Table of contents
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1 Overview of VETTER folding fork arms
1.1 Range of application
Folding fork arms are used to lift, transport, and put down, e.g., loads and goods on
pallets that are intended for transport by an fork lift truck or another type of carrier
vehicle. Folding fork arms can be folded when unloaded. The fork blade can be folded
upward and secured in this position. Always observe the information in the carrier
vehicle operating manual to ensure safe handling of the folding fork arms.
1.2 Folding fork arm variants
The folding fork arms are available in three variants:
Type 1 - KGA – Folding fork arms with outer hinge ( Ä Chapter 3.2 “Type KGA –
Folding fork arms with outer hinge” on page 21).
Type 2 - KGI – Folding fork arms with inner hinge ( Ä Chapter 3.3 “Type KGI –
Folding fork arms with inner hinge” on page 22).
Type 3 - DuoLoc – Folding fork arms with pin retention and outer hinge ( Ä Chapter
3.1 “Type DuoLoc (KGA-SBO) – Folding fork arms with pin retention and
outer hinge” on page 20).
View the current type lists at www.forks.com. In possible special versions, observe the
additional applicable documents Ä “Applicable documents” on page 3.
Overview of VETTER folding fork arms
Folding fork arm variants
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There are two different mechanisms for securing the fork blade for transport:
DuoLoc - Fork blade securing mechanism by means of a locking bolt (Fig. 1).
KGA, KGI - Fork blade securing mechanism by means of a locking bracket (Fig. 2).
Fig. 1: DuoLoc with locking bolt
Fig. 2: KGA and KGI with locking bracket
Fork blade securing
mechanism
Overview of VETTER folding fork arms
Folding fork arm variants
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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 indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE indicates a situation which, if not avoided, could result in material
damage.
This symbol highlights useful tips and recommendations as well as information for effi-
cient and fault-free operation.
Safety instructions may relate to certain, individual instructions for action. Such safety
instructions are embedded in the instruction for action so that the user can continue
reading the text when performing the action. The signal words listed above are used.
Example:
1. Open the locking device of the folding fork arms.
2. L WARNING! Risk of hands and other body parts being crushed when
moving!
Grip the folding fork arms at the head and fork blade and carefully move it to the
side on the fork carrier with appropriate force.
3. Close the locking device of the folding fork arms.
Scope of application!
All of the following safety information applies to all variants of the folding fork
arms.
Safety instructions
L DANGER
L WARNING
L CAUTION
NOTICE
Tips and recommen-
dations
Safety instructions
in instructions for
action.
NOTICE
Safety
Symbols in this manual
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2.2 Intended use
Folding fork arms are used solely for lifting and transporting loads. Only install and
used the folding fork arms on carrier vehicles (industrial trucks, construction
machinery) with compatible fork carriers which meet the technical requirements of the
folding fork arms ( Ä “Incompatibility ” on page 24).
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.
Incorrect use
Safety
Intended use
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Risk of injury from incorrect use!
– 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 carrier vehicle.
– Never install the folding fork arms on a fork carrier that is incompatible with
the delivered folding fork arms or not approved by the manufacturer. Observe
the relevant operating manual for the fork carrier installed on the carrier
vehicle.
– Never use the folding fork arms at temperatures outside the temperature
range of -4 °F (-20 °C) to +122 °F (+50 °C).
– Never exceed the maximum load capacity of the carrier vehicle, the fork car-
rier, and the two folding fork arms used. Always observe the load and load
center distance of the load and use the load charts for the carrier vehicle and
the folding fork arms to compare them.
– Never use the folding fork arms in maritime applications (on ships, oil rigs,
etc.) or under the surface of the water.
– Never use the folding fork arms below ground, in radioactive areas, or military
security areas.
– Never use the folding fork arms if they are dirty, greasy, or covered in ice.
– Never use the folding fork arms to lift or transport living beings, especially
people. Transport in conjunction with the folding fork arms in so-called
workman baskets is also not permitted.
– Never use the folding fork arms as reversible fork arms (blade on top).
– Never use folding fork arms for demolition work.
– Never use the folding fork arms on a rotary device or on a pallet handler.
– Never use the folding fork arms individually or load them unevenly.
– Never expose the folding fork arms to lateral forces. It is not permitted to
insert or pull out of the pallet/load at an angle, or to push the pallet/load from
the side.
– Fold up the folding fork arms for road transport or fit them with a warning
system approved as per the road traffic regulations (e.g., warning bars) (when
unloaded).
– Never use carrier vehicles equipped with folding fork arms in areas subject to
explosion hazards.
– Never allow unauthorized persons access to the carrier vehicle.
– Never allow insufficiently qualified persons to carry out maintenance or trou-
bleshooting work.
– Never skip a maintenance interval.
– Never use the folding fork arms without the locking device engaged.
– Never operate the folding fork arms without safety markings.
– Never independently modify folding fork arms.
Incorrect use of the folding fork arms could lead to dangerous situations and
serious injuries.
L WARNING
Safety
Intended use
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2.3 Operator obligations
The operator is the person who operates the folding fork arms on an carrier vehicle 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.
The folding fork arms are used in the commercial sector. The operator of the carrier
vehicle 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
particular working conditions at the operation site of the folding fork arms. These
must be outlined in the form of operating instructions for operation of the folding
fork arms.
nThe operator must ensure over the entire operating time that the operating instruc-
tions 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,
operation, troubleshooting, maintenance and cleaning.
nThe operator must ensure that all persons that come into contact with the folding
fork arms 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 folding fork arms 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 have all safety devices checked regularly for functionality and
integrity.
Safety
Operator obligations
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2.4 Dangers associated with handling the folding fork arms
Danger to life due to restricted view!
– Always adhere to the general requirements for safety and due diligence.
– Ensure that there are no people or objects in the danger zone of the carrier
vehicle.
– If the situation in the transport area is not visible, get out and carry out a
visual inspection or consult someone who can guide and assist you.
People and objects under or in front of the raised load may not be visible due to
an obstructed view. If people or objects in the danger zone are not detected,
there is a risk of serious accidents.
Risk of injury from incorrectly executed work on the folding fork arms!
– Never make any independent modifications (e.g., boreholes, welding) to the
folding fork arms.
– Adhere to the prescribed maintenance intervals.
The load capacity of the folding fork arms ultimately depends on its integrity.
Unauthorized modification such as boreholes for add-ons, welding work, etc.,
could reduce the load capacity and result in serious accidents from falling loads.
Risk of injury from tipping or slipping load!
– Space the folding fork arms equally from the middle of the vehicle and lock
them in position.
– Take hold of the load with the folding fork arms as far from its center as pos-
sible.
– Raise the load using its entire length and distribute it evenly on both folding
fork arms.
Incorrect lifting of the load could cause the load to tip or slip and cause serious
injuries.
General requirement
for safety
L WARNING
Unauthorized modi-
fication
L WARNING
Incorrect fork arm
spacing
L WARNING
Safety
Dangers associated with handling the folding fork arms
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Risk of injury from slipping load!
– Remove any dirt from the folding fork arms before lifting the load.
– In wet, snowy, or icy conditions, etc., secure the load to be lifted with, e.g.,
tension belts.
If there is moisture, dirt, or ice on the lifting surfaces of the folding fork arms,
there is an increased risk of the load slipping. A slipping load could cause
serious injuries.
Risk of injury from missing locking device!
– Ensure the function of the locking device.
– Replace damaged locking devices immediately.
– If the locking device is missing, it must be replaced before commissioning.
The locking device prevents undesired lateral movement of the folding fork arms
on the profile of the fork carrier. Uncontrolled movement of the folding fork arms
during transportation could cause the load to slip and cause serious injuries!
Risk of injury from folding mechanism!
– Wear the personal protective equipment.
– Exercise caution and act with reason when folding the fork blade up and
down.
– Instruct persons to leave the folding area of the fork blade.
– After folding the fork blade up, secure it to prevent it from folding down in an
uncontrolled manner (use a locking bolt with a locking pin for the DuoLoc fork
blade securing mechanism, use a locking bracket for the KGA ad KGI fork
blade securing mechanism).
– The locking bracket for the KGA and KGI is not secured additionally (e.g., by
means of a locking pin). Always insert the locking bracket up to the stop into
the designated receptacle hole.
Due to the high weight of the fork blade and the folding mechanism of the
folding fork arms, there is a risk of serious injuries due to limbs getting caught
or from a fork blade falling down.
Risk of injury from unsecured fork blade!
– Always exercise caution when approaching the load to be lifted.
In types KGA and KGI, the fork blade is not secured in the operating position. In
case of collision, e.g., with a loading edge, the fork blade can fold up inadver-
tently and therefore cause severe damage and serious injuries.
Moisture and dirt
L WARNING
Checking the
locking device
L WARNING
Crushing
L WARNING
Unsecured fork
blade
L WARNING
Safety
Dangers associated with handling the folding fork arms
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2.5 Safety markings
The use of the folding fork arms without the prescribed markings is considered incor-
rect use.
The type plate (specifically the article number specified there) identifies the version of
the folding fork arms upon delivery. Do not operate folding fork arms without a type
plate. The type plate is located on the side of the fork back (Fig. 7/8).
Fig. 3: Type plate
1 Article number
2 Dead weight (unit)
3 Year of manufacture
4 Center of gravity
5 Blade length
6 Load capacity x load center
7 Note “Observe load torque of fork lift truck and fork arm!” (each fork arm)
The hard stamping (specifically the article number specified there) identifies the ver-
sion of the folding fork arms upon delivery. The hard stamping is position on the side
of the fork back in all three types (
Ä Further information on page 20/7).
Fig. 4: Hard stamping of folding fork arms
A: Article number (optional)
t: Load capacity
l: Load center
C: Material code
M: Material
V: Manufacturer marking
Type plate
Hard stamping
Safety
Safety markings
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W: Week of manufacture
J: Year of manufacture
F: Production order number
The safety labels are located on the front and side of the fork back.
Fig. 5: Note: Risk of injury from crushing
Fig. 6: Note: Read the manual
2.6 Personnel requirements
2.6.1 Qualifications
Risk of injury if personnel are not sufficiently qualified!
– Have all tasks carried out by personnel qualified to do so without exception.
– Keep unqualified personnel away from the danger zones.
If unqualified personnel perform work on the folding fork arms or remain in the
danger zone of the folding fork arms, dangers arise that could cause serious
injuries and significant material damage.
The following section of this manual stipulates qualifications for personnel in relation to
the various fields of activity:
Driver of carrier vehicles
The driver of carrier vehicles is capable of operating carrier vehicles with a driver’s
seat or a driver’s platform due to his/her education, knowledge, and experience. The
driver of carrier vehicles is aware of the dangers involved in lifting and transport tasks.
Safety label
L WARNING
Safety
Personnel requirements > Qualifications
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The driver of carrier vehicles has proven his/her ability to drive carrier vehicles with a
driver’s seat or a driver’s platform to the operator and has consequently been put in
charge by the operator.
The driver of carrier vehicles is familiar with the use of all variants of the folding fork
arms and the associated dangers.
Service specialist
The service specialist has completed technical training (e.g., technician, agricultural
machinery technician) or has a similar qualification 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 folding fork arms have been
taught.
The service specialist can verify that they have taken part in training which qualifies
them to perform the regular inspection of the fork arms in accordance with
ANSI/ITSDF B56.1 as a technical expert.
The service specialist is familiar with the use of all variants of the folding fork arms
and the associated dangers.
The service specialist is capable of operating carrier vehicles with a driver’s seat or a
driver’s platform due to his/her education, knowledge, and experience. The service
specialist is aware of the dangers involved with lifting and transport tasks.
Only persons of whom it can be expected that they will carry out their duties reliably
are permitted as personnel. Persons whose ability to react is affected by drugs,
alcohol, or medication, for example, are not permitted.
When selecting personnel, note the age and occupation-specific regulations applicable
at the operation site.
2.6.2 Unauthorized persons
Danger to life for unauthorized persons due to dangers in the danger and work
area!
– Keep unauthorized persons away from the danger and work area.
– If in doubt, speak to these persons and tell them to leave the danger and work
area.
– Suspend work while there are unauthorized persons remaining in the danger
and work area.
Unauthorized 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 unauthorized persons.
Access to work
areas
L WARNING
Safety
Personnel requirements > Unauthorized persons
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2.6.3 Training
The operator must train personnel regularly. 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
2.7 Personal protective equipment
Personal protective equipment is used to protect persons from safety impairments and
adverse health effects while working.
During the different tasks on and with the folding fork arms, personnel must wear the
personal protective equipment that is specifically referenced in the individual sections
of this manual.
The personal protective equipment is explained in the following section:
Industrial hard hat
Industrial hard hats protect the head from falling objects, oscillating loads and impact
from fixed objects.
Protective clothing
Protective clothing is close-fitting, with low resistance to tearing, with narrow sleeves
and without 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.
Description of per-
sonal protective
equipment
Safety
Personal protective equipment
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Safety shoes
Safety shoes protect the feet against crushing, falling components and slipping on slip-
pery floor surfaces.
Risk of injury from the work environment!
– Observe the operating instructions on wearing personal protective equip-
ment.
Regardless of the required personal protective equipment for the activity in
question, it is possible that additional dangers that are not described in this
manual may arise due to the operation site of the folding fork arms. If suitable
personal protective equipment is not used for these dangers, there is a risk of
serious injuries.
2.8 Protection of the environment and disposal
Danger to the environment from incorrect handling of environmentally haz-
ardous substances!
– Always observe the instructions given below when handling and disposing of
environmentally hazardous substances.
If environmentally hazardous substances are handled incorrectly, particularly if
such substances are disposed of incorrectly, this could cause significant
damage to the environment.
Always observe the following points:
Packaging materials are valuable raw materials and, as such, they can continue to be
used or be reprocessed for practical purposes in many cases. Incorrect disposal of
packaging materials can give rise to dangers to the environment.
nReuse packaging materials if possible.
nIf packaging materials cannot be reused, have the materials remanufactured or dis-
posed of in an environmentally responsible manner.
nObserve the locally applicable disposal regulations. If necessary, arrange for a spe-
cialist company to take care of the disposal.
Further operational
requirements
L WARNING
NOTICE
Packaging materials
Safety
Protection of the environment and disposal
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If there is no take-back agreement or disposal agreement in place, separate waste
according to material and send it for recycling:
nScrap metals.
nSend plastic elements to be recycled.
nSort and dispose of the other components according to their material characteris-
tics.
Recycling
Safety
Protection of the environment and disposal
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3 Structure
3.1 Type DuoLoc (KGA-SBO) – Folding fork arms with pin retention
and outer hinge
The DuoLoc (KGA-SBO) differs from the KGA and KGI in terms of how the fork blade
is secured.
It is not possible to push the DuoLoc pair flush together due to the external hinges.
Fig. 7: Type DuoLoc (KGA-SBO)
1 Pin retainer for securing the fork (version DuoLoc (KGA-SBO))
2 Fork back
3 Locking pin with ring
4 Fork blade
5 Locking bolt
6 Hinge pin (pivot point) including cotter pin and locking screw with washer
7 Safety label
8 Type plate
Structure
Type DuoLoc (KGA-SBO) – Folding fork arms with pin retention and outer hinge
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