Vetter ManuTel User manual

Operation manual
U163-530-US
Fork carrier with fork arms
Read this manual prior to performing any task! Keep for future use!

Fork carrier with fork arms
2

This operating manual (hereinafter also referred to as “manual”) contains fundamental
safety instructions for handling fork carriers with hook or shaft suspension as well as
information about the fork arms of VETTER Forks, Inc.
Incorrect use of the fork carrier and 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 fork carrier and fork arms and must be kept at the
work site of the fork carrier and fork arms (on the carrier vehicle) to ensure it is acces-
sible for personnel at all times.
Always observe the information in the carrier vehicle operating manual as well as all
applicable documents to ensure safe handling of the fork carrier and fork arms.
Furthermore, the local accident prevention regulations and general safety instructions
for the area in which the fork carrier and 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:
nTechnical data sheet for fork carrier as a supplement to the operating manual
nOperating manual and load chart for the carrier vehicle
nOperating manual for the tool change device used
nOperating manual for the mounted fork arms
nOperating manual for the operator
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
Fork carrier with fork arms 3

TABLE OF CONTENTS
1 OVERVIEW OF THE FORK CARRIER 6
1.1 Range of application 6
1.2 Designs 6
2 SAFETY 7
2.1 Symbols in this manual 7
2.2 Intended use 7
2.3 Operator obligations 9
2.4 Dangers associated with handling the fork carrier and the fork arms 10
2.5 Safety markings 11
2.6 Personnel requirements 14
2.6.1 Qualifications 14
2.6.2 Unauthorized persons 15
2.6.3 Training 15
2.7 Personal protective equipment 15
2.8 Protection of the environment and disposal 16
3 STRUCTURE 18
3.1 Structure of hook-type suspension 18
3.2 Structure of shaft-type suspension 20
3.3 Fork arm 21
4 ASSEMBLY 22
4.1 Fork carrier 22
4.2 Fork arms with hook suspension 22
4.3 Fork arms with shaft suspension 25
5 OPERATION 27
5.1 Adjusting the distance between the fork arms 27
6 MAINTENANCE 30
6.1 Maintenance intervals 30
6.2 Maintenance activities 30
6.2.1 Daily visual inspection performed by the driver 30
6.3 Checking the fork carrier 31
6.4 Checking the fork arms 32
6.4.1 Checking the locking device and safeguarding device 32
6.4.2 Checking the suspension 33
6.4.3 Crack test for fork arms 36
6.4.4 Deformation of the fork arms 36
6.4.5 Wear on the fork arms 41
6.5 Cleaning the fork carrier and fork arms 42
Table of contents
Fork carrier with fork arms
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6.6 Replacing the fork arms 43
6.7 Repairs and spare parts 46
6.8 After completion of maintenance work 46
7 TROUBLESHOOTING 47
8 TECHNICAL DATA 48
9 INDEX 50
Table of contents
Fork carrier with fork arms 5

1 Overview of the fork carrier
1.1 Range of application
The fork carrier is used to transmit power between the carrier vehicle and the fork arms
used to pick up and transport the load. It lifts or lowers the mounted fork arms, and the
load picked up by them, within the permissible load range.
The fork carrier must only be attached to carrier vehicles and machinery that are
equipped with a suitable tool change device.
The fork arms are used within the designated load range to lift, transport, and put
down, e.g., loads and goods on pallets that are intended for transport by an approved
fork lift truck or another type of carrier vehicle.
Scope
This manual relates to both fork carrier types described (hook-on and shaft suspen-
sion) in conjunction with VETTER fork arms. With regard to specific VETTER fork arms
(e.g., VETTER SmartFork®, VETTER folding fork arms or VETTER ManuTel fork
arms), always observe the operating manual provided.
1.2 Designs
Depending on the manufacturer, fork carriers differ not only in terms of their dimen-
sions, weight, and permissible load capacity, but also in the design of the mounting
equipment for the tool change device and the suspension type. This manual contains
examples of both hook-on and shaft suspensions in conjunction with fork arms. Prior to
use, always ensure the compatibility of all assemblies involved in the system using the
operating manual provided.
Properly mounted fork carriers are used as the mounting point for compatible fork
arms. In this context, compatible means that the respective combination of fork carrier
and fork arm used must be designed for the transport task by the manufacturer and
that the function of the safeguarding mechanisms is ensured through the selection of
the exactly appropriate model.
Fork carrier
Fork arm
Overview of the fork carrier
Designs
Fork carrier with fork arms
6

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 information considered important but not hazard-related such
as property damages.
2.2 Intended use
The fork carrier must only be connected to a suitable tool change device. In conjunc-
tion with the approved fork arms, it must only be used to lift, transport, and set down
loads within the designated load range.
See technical data sheet for fork carrier as a supplement to the operating manual
Safety instructions
L DANGER
L WARNING
L CAUTION
NOTICE
Incorrect use
Safety
Intended use
Fork carrier with fork arms 7

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.
– Only use fork carriers in carrier vehicles that have been designed to accom-
modate fork carriers and only use them in a technically perfect condition.
– Never mount fork carriers on a tool change device if the device is incompat-
ible with the fork carrier. Observe the relevant operating manual for the
respective tool change device installed on the carrier vehicle.
– Never exceed the maximum load capacity of the carrier vehicle, the fork car-
rier and fork arms used.
– Never use fork carriers in conjunction with incompatible fork arms or with
fork arms that have not been approved by the manufacturer.
– Never use the fork carrier and fork arms at temperatures outside the tempera-
ture range of -4 °F (-20 °C) to +122 °F (+50 °C).
– Never use the fork carrier and fork arms if they are excessively dirty, greasy,
or covered in ice.
– Never use the fork carrier and fork arms in areas subject to explosion haz-
ards.
– Never use the fork carrier and fork arms to lift or transport living beings, espe-
cially people. Transport in conjunction with the fork carrier in so-called
workman baskets is also not permitted.
– Never use the fork carrier and mounted fork arms for demolition work.
– Never mount the fork arms on the fork carrier as reversible fork arms (blade
on top).
– Never use the fork arms individually or load them unevenly.
– Never use the fork arms on a rotary device or on a pallet handler.
– Never expose the fork arms to lateral forces. It is not permitted to drive into or
out of the pallet/load at an angle, or to push the pallet/load from the side.
– Never use fork carriers with auxiliary equipment on fork carriers or fork arms
(e.g., snow clearing equipment, slings).
– Only use the fork carrier with mounted fork arms for road transport with an
approved warning system (e.g., warning bars) in accordance with traffic laws,
and without a load.
– Never allow insufficiently qualified persons to carry out maintenance or repair
work.
– Never skip a maintenance interval.
– Never modify the fork carrier and fork arms independently.
– Never use fork carriers with fork arms without an engaged locking device or
shaft safeguard.
– Never operate the fork carrier and fork arms without safety markings.
– Never allow unauthorized persons access to the carrier vehicle.
Incorrect use of the fork carrier and fork arms could lead to life-threatening sit-
uations and serious injuries.
L WARNING
Safety
Intended use
Fork carrier with fork arms
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2.3 Operator obligations
The operator is the person who operates the fork carrier (with or without 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 parties.
The fork carrier and the fork arms are used in the commercial sector. The operator 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 fork carrier and fork arms.
These must be outlined in the form of an operating manual for operation of the fork
carrier and fork arms.
nThe operator must ensure over the entire operating time that the operating manual
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 fork car-
rier and 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 fork carrier and the fork
arms are 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.
Operator
Operator obligations
Safety
Operator obligations
Fork carrier with fork arms 9

2.4 Dangers associated with handling the fork carrier and the fork
arms
Danger to life from the use of incorrect components!
– Only mount fork carriers on designated, exactly suitable carrier vehicle sus-
pension.
– Ensure that the fork arms used have the exact attachment dimensions of the
fork carrier.
– Ensure that the fork arms used have at least the load capacity of the fork car-
rier.
– Ensure that all safeguarding devices (fork arm locking device as well as safe-
guarding device for the shaft suspension) are fully in place and are func-
tioning flawlessly.
– Always use genuine components for safeguarding devices.
If the system is not aligned (suspension type, fork carrier and fork arm), the safe
transmission of power is not ensured and there is a danger of serious accidents,
e.g., due to breakage or the load falling.
Danger to life due to restricted view!
– 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 are not detected
depending on the position and size of the load. If people or objects in the danger
zone are not detected, there is a risk of serious accidents.
Risk of injury from incorrectly performed work!
– Never carry out modifications (e.g., boreholes, welding work) on the fork car-
rier and fork arms.
The load capacity of the fork carrier and the fork arms depends significantly on a
completely intact structure. Unauthorized modifications such as boreholes for
add-ons, welding work, etc., could compromise the load capacity and result in
serious accidents due to breakage and falling loads, for example.
Incompatibility
L WARNING
General requirement
for safety
L WARNING
Unauthorized modi-
fication
L WARNING
Safety
Dangers associated with handling the fork carrier and the fork arms
Fork carrier with fork arms
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Danger to life due to incorrectly lifted load!
– Always observe the load and load center distance of the load and use the load
charts for the carrier vehicle and the fork arms to compare them.
– Do not exceed the maximum load capacity of both fork arms used.
– Align the fork arms on the fork carrier at the same distance from the middle of
the vehicle and lock them in position.
– Take hold of the load with the fork arms as far from its center as possible.
– Raise the load using its entire length and distribute it evenly on both fork
arms. It is imperative that you avoid insertion and lifting at an angle and off-
center.
Incorrect lifting of loads or loads that are too heavy could cause the load to tip
or slip or, in the event of extreme overloading, to breakage of the fork arms. This
could cause accidents involving serious injuries.
Risk of injury from slipping load!
– Remove any dirt from the fork carrier and fork arms before lifting the load.
– In wet, snowy, or icy conditions, etc.,, secure the load with, e.g., tension belts.
If there is moisture, dirt, or ice on the lifting surfaces of the fork arms, there is an
increased risk of the load slipping. A slipping load could cause serious injuries.
Risk of injury from crushing!
– Always wear the specified protective clothing.
– Always exercise caution and act with reason when performing assembly and
disassembly of the fork carrier and the fork arms.
– Store the detached fork arms so that they cannot fall over.
The heavy weight of the fork carrier and the fork arms could lead to crushing
and serious injuries. Observe the safety instructions in instructions for action in
relation to all of the following assembly, disassembly, and adjustment tasks:
2.5 Safety markings
The type plate identifies (via the article number it contains) the version of the fork car-
rier upon delivery. Fork carriers without a marking must not be put into operation. For
details on the type plate position for the respective fork carrier, see Ä Chapter 3.1
“Structure of hook-type suspension” on page 18.
Incorrect loading
L WARNING
Moisture and dirt
L WARNING
Crushing
L WARNING
Type plate
Safety
Safety markings
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Fig. 1: Fork carrier type plate
1 Article/serial number
2 Dead weight
3 Maximum permissible load
4 Center of gravity
5 Year of manufacture
6 Load center - distance from fork back
The use of the fork carrier without the prescribed type plate is considered incor-
rect use.
NOTICE
Safety
Safety markings
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The hard stamping identifies (via the article number it contains) the version of the fork
arm upon delivery. Fork arms without a marking must not be put into operation. The
hard stamping of the fork arm is located on the fork back at the side (Fig. 2).
The use of the fork arms without the prescribed markings is considered incor-
rect use.
Fig. 2: Hard stamping of the fork arm
A: Article number
t: Load capacity
l: Load center
C: Material code
M: Material
V: Manufacturer marking
W: Week of manufacture
J: Year of manufacture
F: Production order number
Hard stamping
NOTICE
Safety
Safety markings
Fork carrier with fork arms 13

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 system or remain in the danger
zone of the system, dangers arise that could cause serious injuries and signifi-
cant 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 transportation
tasks.
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 fork carrier
and compatible 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 fork carrier and 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 fork carrier and com-
patible 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 transportation 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.
L WARNING
Safety
Personnel requirements > Qualifications
Fork carrier with fork arms
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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.
2.6.3 Training
The operator must instruct the personnel regularly. To improve tracking measures, an
instruction protocol must be created with the following minimum information:
nDate of instruction
nName of the instructed person
nContent of instruction
nName of the instructor
nSignatures of the instructed person and the instructor
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 system, 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.
L WARNING
Description of per-
sonal protective
equipment
Safety
Personal protective equipment
Fork carrier with fork arms 15

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.
Safety shoes
Safety shoes protect the feet against crushing, falling components and slipping on slip-
pery floor surfaces.
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 inadvertently released into the
environment, take suitable actions immediately. If in doubt, notify the authori-
ties responsible about the damage and ask about suitable actions to be taken.
If environmentally hazardous substances are handled incorrectly, particularly if
such substances are disposed of incorrectly, this could cause significant
damage to the environment.
Packaging materials are valuable raw materials and, as such, they can continue to be
used or be recycled for practical purposes in many cases. Incorrect disposal of pack-
aging materials can pose dangers to the environment.
nReuse packaging materials if possible.
nIf packaging materials cannot be reused, have the materials recycled or disposed 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.
NOTICE
Packaging materials
Safety
Protection of the environment and disposal
Fork carrier with fork arms
16

If there is no take-back agreement or disposal agreement in place, separate compo-
nents by material and send them for recycling:
nSort and dispose of the other components according to their material characteris-
tics.
General disposal
instructions
Safety
Protection of the environment and disposal
Fork carrier with fork arms 17

3 Structure
3.1 Structure of hook-type suspension
Fig. 3: Fork carrier, example of design A
1 Upper suspension for tool change device
2 Contact surface
3 Lock borehole for tool change device
4 Locking screw
5 Type plate
6 Hook profile for ITA/square-hook forks
Example of design A
Structure
Structure of hook-type suspension
Fork carrier with fork arms
18

Fig. 4: Fork carrier, example of design B
1 Contact surface
2 Lock borehole for tool change device
3 Upper suspension for tool change device
4 Locking screw
5 Type plate
6 Hook profile for ITA/square-hook forks
Example of design B
Structure
Structure of hook-type suspension
Fork carrier with fork arms 19

3.2 Structure of shaft-type suspension
Fig. 5: Fork carrier, shaft suspension
1 Upper suspension for tool change device
2 Shaft suspension for shaft forks
3 Lock borehole for tool change device
4 Contact surface
5 Safeguarding device (plate and 2 screws)
6 Type plate
Structure
Structure of shaft-type suspension
Fork carrier with fork arms
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