Vetter Smartfork User manual

Operating instructions
SmartFork®-
The intelligent SensorFork
U163-907/Replaced:U163-356
Read the instructions prior to performing any task! Keep for future use!

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This operating manual (hereafter ‘manual’) contains basic information that is to be
observed during the assembly, operation and maintenance of the SmartFork® fork arms
(hereafter ‘SmartFork®’ or ‘assistance system’). For this reason, this manual must be
read before any work on or with the assistance system, and ensure that the manual is
always available at the operation site of the assistance system (on the industrial truck).
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]
Email [email protected]
Internet www.smartfork.com
About this
manual
Customer
service
Supplemental directives
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TABLE OF CONTENTS
1VETTER SMARTFORK® OVERVIEW 6
1.1 Range of application 6
1.2 Overview of applications 7
1.2.1 VETTER SmartFork® Camera, camera function 8
1.2.2 VETTER SmartFork® SideCam, camera function 8
1.2.3 VETTER SmartFork® PremiumCam, camera function 9
1.2.4 VETTER SmartFork® Laser, line laser target function 9
1.2.5 VETTER SmartFork® Secure, loading function 10
1.2.6 VETTER SmartFork® EasySecure, insertion depth function 11
1.2.7 VETTER SmartFork® Flash, warning function/insertion depth function 11
1.2.8 VETTER SmartFork® Level, tilt function 12
1.2.9 VETTER SmartFork® Distance, distance function 13
2 SAFETY 14
2.1 Symbols in this manual 14
2.2 Applicable documents 15
2.3 Intended use 16
2.4 Operator obligations 17
2.5 Dangers when handling the VETTER SmartFork®18
2.6 Safety markings 20
2.7 Personnel requirements 21
2.7.1 Qualifications 21
2.7.2 Unauthorised persons 23
2.7.3 Training 23
2.8 Personal protective gear 23
2.9 Protection of the environment and disposal 24
3STRUCTURE OF THE VETTER SMARTFORK®26
3.1 Structure of the basic fork 26
3.2 Suspension 27
3.3 Image and signal output devices 28
3.3.1 Camera monitor 28
3.3.2 VETTER EasySecure LED display 29
3.4 VETTER SmartFork® Flash control device 29
3.5 VETTER SmartFork® PremiumCam control device 29
3.6 Cabling 30
3.7 Radio connection 31
4INITIAL ASSEMBLY OF THE VETTER SMARTFORK®32
4.1 Installing the VETTER SmartFork® on the fork carriage 32
4.2 Installing and connecting the monitor 33
4.3 Installing and connecting the EasySecure LED display 34
4.4 Establishing cable connections 35
4.5 Installing the radio transmitter 35
Table of contents
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5OPERATION OF THE VETTER SMARTFORK®37
5.1 VETTER SmartFork® Camera 37
5.2 VETTER SmartFork® SideCam 38
5.3 VETTER SmartFork® PremiumCam 39
5.4 VETTER SmartFork® Laser 40
5.5 VETTER SmartFork® Secure 42
5.6 VETTER SmartFork® EasySecure 43
5.7 VETTER SmartFork® Flash 44
5.8 VETTER SmartFork® Level 45
5.9 VETTER SmartFork® Distance 46
5.10 Adjusting the distance between the fork arms 48
6MAINTENANCE OF THE VETTER SMARTFORK®49
6.1 Maintenance table 49
6.2 Maintenance activities 50
6.2.1 Daily visual inspection by the driver 50
6.2.2 Checking electronics 51
6.2.3 Regularly check the fork arms and hooks 51
6.2.4 Checking the locking device 52
6.2.5 Cleaning the VETTER SmartFork®52
6.2.6 Replacing the VETTER SmartFork®53
6.2.7 Replacing components 55
6.2.8 Spare parts 55
6.3 After completion of maintenance activity 56
7TROUBLESHOOTING ON THE VETTER SMARTFORK®57
8 TECHNICAL DATA 58
9 INDEX 59
Table of contents
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1 VETTER SmartFork® overview
1.1 Range of application
The VETTER SmartFork® is used to lift, transport and put down loads or goods on pallets
that are intended for transport with a forklift or another form of industrial truck.
The use of the assistance system allows the distance to the load, the position of the load
before and after lifting and the area directly in front of the VETTER SmartFork® to be
more quickly and efficiently evaluated. This facilitates quicker and safer work.
Always observe the information in the industrial truck operating manual to ensure safe
handling of the VETTER SmartFork®.
VETTER SmartFork® overview
Range of application
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1.2 Overview of applications
Fig. 1: Overview of all applications
1VETTER SmartFork® Flash, loading help
2VETTER SmartFork® Level, tilt function
3VETTER SmartFork® Laser, line laser target function
4VETTER SmartFork® Secure, loading function
5VETTER SmartFork® Distance, distance function
6VETTER SmartFork® Camera, camera function
7VETTER SmartFork® Flash, warning function
8VETTER SmartFork® EasySecure, insertion depth function
9VETTER SmartFork® SideCam, camera function
The VETTER SmartFork® can optionally be equipped with a total of 9 applications and a
combination application (VETTER SmartFork® PremiumCam).
The telescopic VETTER SmartFork® ManuTel is equipped with the VETTER SmartFork®
Camera and/or the VETTER SmartFork® SideCam and can optionally be upgraded with
the target line laser function.
VETTER SmartFork® overview
Overview of applications
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1.2.1 VETTER SmartFork® Camera, camera function
Fig. 2: VETTER SmartFork® Camera
When a raised load obstructs the view, the area in front of the fork tips is visible on the
monitor. Raising the load on the VETTER SmartFork® is monitored thanks to the direct
transmission to the monitor. The fork tip can be equipped with additional LED lighting to
improve illumination of the image area.
1.2.2 VETTER SmartFork® SideCam, camera function
Fig. 3: VETTER SmartFork® SideCam
The positioning of the VETTER SmartFork® SideCam application on the inside of the fork
arms near the heel allows the position of both fork arms to be monitored on the monitor.
This facilitates simple and safe insertion into the load.
VETTER SmartFork® overview
Overview of applications > VETTER SmartFork® SideCam, camera function
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1.2.3 VETTER SmartFork® PremiumCam, camera function
Fig. 4: VETTER SmartFork® PremiumCam
The VETTER SmartFork® PremiumCam is a combination of the SmartFork® SideCam
(fig. 4/1) and the SmartFork® Camera (fig. 4/2). The camera perspective changes auto-
matically depending on the load status of the VETTER SmartFork®. While picking up the
load, the VETTER SmartFork® SideCam transmits. When the load has been completely
picked up, the VETTER SmartFork® Camera transmits.
1.2.4 VETTER SmartFork® Laser, line laser target function
Fig. 5: VETTER SmartFork® Laser
VETTER SmartFork® overview
Overview of applications > VETTER SmartFork® Laser, line laser target function
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The line laser of the VETTER SmartFork® laser application is integrated into the tip of the
SmartFork®. The line laser projects a horizontal line onto the load directly in front of the
SmartFork® and facilitates precise targeting of the load to be lifted.
1.2.5 VETTER SmartFork® Secure, loading function
Fig. 6: VETTER SmartFork® Secure
The VETTER SmartFork® Secure application in the surface of the fork tip displays
whether the fork tips have completely picked up the load upon lifting or whether the fork
tips are still free/unoccupied. As an option, both SmartForks® can be equipped with the
sensor. The occupation of the fork tips is then also displayed when insertion into the load
is at an angle.
VETTER SmartFork® overview
Overview of applications > VETTER SmartFork® Secure, loading function
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1.2.6 VETTER SmartFork® EasySecure, insertion depth function
Fig. 7: VETTER SmartFork® EasySecure
The VETTER SmartFork® EasySecure application in the surface of the fork blade dis-
plays whether the load has been completely picked up or not. It allows for an additional
signal detection via a light scanner mounted in the fork blade. This position is useful to
detect safe crosswise lifting of Euro pallets. As an option, up to 3 positions per fork blade
can be equipped with sensors. When both fork arms are equipped with the sensor, the
occupation of the fork tips is also displayed when insertion into the load is at an angle.
1.2.7 VETTER SmartFork® Flash, warning function/insertion depth function
Fig. 8: VETTER SmartFork® Flash
VETTER SmartFork® overview
Overview of applications > VETTER SmartFork® Flash, warning function/insertion depth function
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The VETTER SmartFork® Flash application on the outside (fig. 8/2) of the fork arms uses
the installed LEDs to increase visibility of the fork arms and therefore improve safety in
day-to-day use. In addition, it is possible to install the VETTER SmartFork® Flash appli-
cation on the inside (fig. 8/1) of the fork arms. The configurable display of the LED lighting
pattern allows for an insertion depth that is adjusted to the load.
1.2.8 VETTER SmartFork® Level, tilt function
Fig. 9: VETTER SmartFork® Level
The VETTER SmartFork® Level application allows for precise control of the current tilt
angle of the VETTER SmartFork®. The tilt sensor measures the actual tilt of the VETTER
SmartFork® fork arms to the vertical. Together with the VETTER SmartFork® Camera,
the load can be safely raised horizontally, e.g. to a high rack.
VETTER SmartFork® overview
Overview of applications > VETTER SmartFork® Level, tilt function
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1.2.9 VETTER SmartFork® Distance, distance function
Fig. 10: VETTER SmartFork® Distance
The VETTER SmartFork® Distance application measures the distance between the fork
tip and objects in the area in front of it. An ultrasonic sensor in the fork tip shows the dis-
tance when approaching an object on the display medium. As an option, both
SmartForks® can be equipped with the sensor. The distance to objects in front of the fork
tip is then also displayed when approaching the load at an angle.
VETTER SmartFork® overview
Overview of applications > VETTER SmartFork® Distance, distance function
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2 Safety
2.1 Symbols in this manual
Safety instructions are indicated by symbols in this manual. The safety instructions are
initiated by signal words that indicate the degree 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 slight or minor inju-
ries.
NOTICE!
This combination of symbol and signal word indicates a potentially dan-
gerous situation which, if not avoided, could result in damage to property.
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 manual for the industrial truck
nOperating manual for the mounted fork carriage
nOperating instructions for the operator
nEquipment-specific operating manuals for the individual applications and components
Safety
Applicable documents
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2.3 Intended use
The VETTER SmartFork® is intended exclusively for the lifting and transporting of
loads. The VETTER SmartFork® is only an assistance system. Its use does not in any
way replace the general requirements for safety and due diligence. The VETTER
SmartFork® is intended exclusively for use with industrial trucks.
WARNING!
Risk of injury from improper use!
Improper use of the VETTER SmartFork® could lead to dangerous situa-
tions 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 carrying capacity of both VETTER
SmartForks® used.
– Never use the VETTER SmartFork® to lift or transport people.
– Never use the VETTER SmartFork® for demolition work.
– Never use the VETTER SmartFork® as upside-down forks.
– Never use the VETTER SmartForks® separately or load them
unequally.
– Never use the VETTER SmartFork® at temperatures outside the tem-
perature range of -20 °C to +50 °C.
– Never subject the VETTER SmartFork® 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 VETTER SmartFork® on a rotary device or pallet han-
dler.
– The VETTER SmartFork® may only be used (when unloaded) for
road transport with a warning system (e.g. warning bars) as per the
road traffic regulations.
– Never use industrial trucks equipped with VETTER SmartFork® 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 independently modify the VETTER SmartFork®.
Intended use includes observation of all the information in this manual.
Any use that goes beyond the scope of intended use is considered misuse.
The use of the VETTER SmartFork® without the prescribed safety markings (hard
stamping on the back of the fork
Ä Chapter 2.6 “Safety markings” on page 20) is con-
sidered misuse.
Safety
Intended use
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2.4 Operator obligations
The operator is the person who operates the VETTER SmartFork® 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.
The assistance system is used in the commercial sector. The operator of the assistance
system 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 assistance system. These must
be outlined in the form of operating instructions for operation of the assistance
system.
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, ope-
ration, troubleshooting, maintenance and cleaning.
nThe operator must ensure that all persons that come into contact with the assistance
system 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 assistance system 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
completeness.
Operator
Safety
Operator obligations
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2.5 Dangers when handling the VETTER SmartFork®
WARNING!
Danger to life from obstructed view!
People and objects under or in front of the raised load are not detected
depending on the features of the VETTER SmartFork® or depending on
the position of the sensors. If people or objects in the danger zone are
not detected, there is a risk of serious accidents.
– The VETTER SmartFork® is only an assistance system. 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
industrial truck.
– If the situation in the transport area is not visible, get out and carry
out a visual inspection or refer to someone who can guide and assist
you.
WARNING!
Risk of injury from incorrectly executed work on the VETTER Smart-
Fork®!
The carrying capacity of the VETTER SmartFork® depends significantly
on a completely intact structure. Unauthorised modification such as bore-
holes for add-ons, welding work etc. could compromise the carrying
capacity of the VETTER SmartFork® and result in serious accidents from
falling loads.
– Never carry out modifications (e.g. boreholes, welding work) on the
VETTER SmartFork®.
– Adhere to the prescribed maintenance intervals.
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.
– Take hold of the load with the VETTER SmartFork® as far from its
centre as possible.
– Raise the load using its entire length and distribute it evenly on both
VETTER SmartForks®.
General
requirement
for safety
Unauthorised
modification
Incorrect fork
arm spacing
Safety
Dangers when handling the VETTER SmartFork®
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WARNING!
Risk of injury from slipping load!
If there is moisture, dirt or ice on the lifting surfaces of the VETTER
SmartFork®, there is an increased risk of the load slipping. A slipping
load could cause serious injuries.
– Remove any dirt from the VETTER SmartFork® before lifting any
loads.
– In wet, snowy or icy conditions etc., secure the load with e.g. tension
belts.
WARNING!
Risk of injury from malfunctions in the assistance system!
If there is dirt or ice on the individual additional applications of the
VETTER SmartFork®, there is a risk of malfunction or loss of function in
the assistance system. Dangerous situations and serious injuries could
result.
– Ensure that the sensors and protective screens of the additional
applications are always free from dirt and ice.
– Check the functionality of the assistance system before beginning the
activity.
CAUTION!
Risk of blinding from laser beams!
The line laser target function uses class 2M laser beams. There is a risk
of blinding.
In addition, there is a risk of damage to eyes when deliberately looking
into the beam path for a prolonged period.
– Do not look into the beam and do not directly observe the beam with
optical instruments (e.g. magnifying glass or binoculars).
Moisture and
dirt
Loss of func-
tionality due
to dirt and ice
Risks from
laser beams
Safety
Dangers when handling the VETTER SmartFork®
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WARNING!
Material damage from incorrect installation!
Incorrectly laid cables 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 or the failure of the assistance system could cause injuries
from fires or transport accidents.
– Electrical connections and cable connections may only be carried out
by an electrician.
– Protect the cable connections from damage.
– Adhere to the prescribed maintenance intervals.
2.6 Safety markings
The hard stamping (and the article number it contains) identifies the version of the
VETTER SmartFork® upon delivery. VETTER SmartFork® fork arms without a marking
must not be put into operation. The VETTER SmartFork® hard stamping is on the side of
the back of the fork (Fig. 11).
NOTICE!
The use of the VETTER SmartFork® without the prescribed markings is
considered misuse.
Fig. 11: Hard stamping
A: Article number (optional)
t: Carrying capacity
l: Load centre
C: Material code
M: Material
V: Manufacturer marking
W: Week of manufacture
J: Year of manufacture
F: Production order number
Incorrect
cable connec-
tions
Hard stamping
Safety
Safety markings
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