Vetter ManuTel G2 Series User manual

Operating instructions
ManuTel® telescopic fork arm
Type G2
U163-904/Replaces:U163-10
Read the instructions prior to performing any task! Keep for future use!

V1.09/2019ManuTel® telescopic fork arm Type G22

This operating manual (hereinafter also referred to as “manual”) contains basic informa-
tion that is to be observed during the assembly, operation and maintenance of the
VETTER ManuTel® G2 telescopicfork arms (hereinafter referred to as ManuTel® G2). It
is therefore imperative that this manual be read prior to all work on and with the ManuTel®
G2. Ensure that the manual is always available at the operation site (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.forks.com
About this
operating
manual
Customer
service
Supplemental directives
V1.09/2019 ManuTel® telescopic fork arm Type G2 3

TABLE OF CONTENTS
1OVERVIEW OF MANUTEL® G2 5
1.1 Range of application 5
1.2 Variants of the ManuTel® G2 5
1.3 Declaration of conformity 6
2 SAFETY 7
2.1 Symbols in this manual 7
2.2 Applicable documents 8
2.3 Intended use 9
2.4 Operator obligations 9
2.5 Dangers associated with handling the ManuTel® G2 10
2.6 Safety markings 12
2.7 Personnel requirements 14
2.7.1 Qualification 14
2.7.2 Unauthorised persons 15
2.7.3 Training 15
2.8 Personal protective equipment 16
2.9 Protection of the environment and disposal 17
3 STRUCTURE 18
4 ASSEMBLY AND DISASSEMBLY 19
4.1 Assembly 19
4.2 Disassembly 21
5 OPERATION 24
5.1 Telescoping the ManuTel® G2 24
5.2 Adjusting the fork arm spacing 26
6 MAINTENANCE 29
6.1 Daily visual inspection by the user 29
6.2 Routine check 30
6.3 Wear check for the slip-on coupling 30
6.4 Repairs and spare parts 32
6.5 After completion of maintenance work 34
7 TECHNICAL DATA 35
8 INDEX 41
Table of contents
V1.09/2019ManuTel® telescopic fork arm Type G24

1 Overview of ManuTel® G2
1.1 Range of application
ManuTel® G2s are used to lift, transport and put down goods on pallets, for example, or
loads that are intended for transport with a forklift or another form of industrial truck.
Always observe the information in the industrial truck operating manual to ensure safe
handling of the ManuTel® G2.
1.2 Variants of the ManuTel® G2
ManuTel® G2s are available in several weight classes. These also differ in terms of their
suspension class, carrying capacity, centre of gravity and dimensions Ä Chapter 7 “Tech-
nical data” on page 35.
View the current type lists at www.forks.com. With regard to any special
designs, please also note the other applicable documents Ä Chapter 2.2
“Applicable documents” on page 8.
Overview of ManuTel® G2
Variants of the ManuTel® G2
V1.09/2019 ManuTel® telescopic fork arm Type G2 5

1.3 Declaration of conformity
EC declaration of conformity as per EC Machinery Directive 2006/42/EC
VETTER Industrie GmbH, as the manufacturer, hereby declares that the models of the
ManuTel® G2 telescopicfork arm listed below comply with the EC Machinery Directive:
Name - Manual telescopicfork arms ManuTel® G2
Type -MTGZ 16/XX/XX/X; MTGZ 25/XX/XX/X; MTGZ 35/XX/XX/X;
MTGZ 50/XX/XX/X; MTGZ 50-6/XX/XX/X; MTGZ XX/XX/XX/X
Please refer to the name on the type plate for details of the exact type.
This declaration is void if a change is made to the aforementioned equipment. The
authorised agent for compiling the technical documentation is the signatory.
Applied national standards and guidelines:
DIN EN ISO
12100
- Safety of machinery
ISO 13284 - Forklift trucks – Fork-arm extensions and telescopic fork arms –
Technical characteristics and strength requirements
ISO 2328 - Forklift trucks - Hook-on type fork arms and fork arm carriages -
Mounting dimensions
VETTER Industrie GmbH
Carl-Benz-Strasse 45
57299 Burbach/Germany
Tel.: [phone]
Email: [email protected]
14/09/2016 Gunther Grindel (Technical Director)
Overview of ManuTel® G2
Declaration of conformity
V1.09/2019ManuTel® telescopic fork arm Type G26

2 Safety
NOTICE!
Scope
All of the following safety information applies to all variants of the
ManuTel® G2.
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 property 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
information for ensuring efficient and faultless operation.”
Safety instruc-
tions
Tips and rec-
ommenda-
tions
Safety
Symbols in this manual
V1.09/2019 ManuTel® telescopic fork arm Type G2 7

Safety information may relate to certain, individual instructions for action. Such safety
information is embedded in the instruction for action so that readability is not disturbed
when performing the action. The aforementioned signal words are used.
Example:
1. Loosen the screw.
2.
CAUTION!
Danger of pinching on the 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
nAny documentation available for the special design
Safety infor-
mation in
instructions
for action
Safety
Applicable documents
V1.09/2019ManuTel® telescopic fork arm Type G28

2.3 Intended use
The ManuTel® G2s are used solely for lifting and transporting loads and may/can only
be used on industrial trucks.
WARNING!
Risk of injury from improper use!
Improper use of the ManuTel® G2 could lead to dangerous situations and
serious injuries.
– Never disregard the general obligations vis-à-vis safety and due dili-
gence. 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 the two ManuTel®
G2s used.
– Never use the ManuTel® G2 to transport or lift people.
– Never use the ManuTel® G2 for demolition work.
– Never use the ManuTel® G2 as a reversible fork arm.
– Never use the ManuTel® G2 individually or load unevenly.
– Never use the ManuTel® G2 at temperatures outside the temperature
range of -20 °C to +50 °C.
– Never expose the ManuTel® G2 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.
– Never use the ManuTel® G2 on a rotary device or on a pallet handler.
– Only use the ManuTel® G2 with a warning system (e.g. warning bars)
for road transport (when unloaded) as per the road traffic regulations.
– Never use industrial trucks equipped with ManuTel® G2 in areas sub-
ject 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 maintenance cycles.
– Never modify the ManuTel® G2 independently.
Intended use includes observation of all the information in this manual.
Any use that goes beyond the scope of intended use is considered misuse.
Using the ManuTel® G2 without the specified markings
(
Ä Chapter 2.6 “Safety markings” on page 12) is considered improper use.
2.4 Operator obligations
The operator is the person who operates the ManuTel® G2 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.
Safety
Operator obligations
V1.09/2019 ManuTel® telescopic fork arm Type G2 9

The ManuTel® G2 is used in the commercial sector. The operator of the industrial truck 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 ManuTel® G2. These must be
outlined in the form of operating instructions for operation of the ManuTel® G2.
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 ManuTel®
G2 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 ManuTel® G2 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 associated with handling the ManuTel® G2
WARNING!
Danger to life from obstructed view!
Persons and objects under or in front of the raised load may not be seen
under certain circumstances due to the field of vision being obstructed. If
people or objects in the danger zone are not detected, there is a risk of
serious accidents.
– Always adhere to the general requirements for safety and due dili-
gence.
– 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.
General
requirement
for safety
Safety
Dangers associated with handling the ManuTel® G2
V1.09/2019ManuTel® telescopic fork arm Type G210

WARNING!
Risk of injury from incorrectly executed work on the ManuTel® G2!
The carrying capacity of the ManuTel® G2 ultimately depends on its
material characteristics. Unauthorised modification such as boreholes for
add-ons, welding work etc. could compromise the carrying capacity and
result in serious accidents from falling loads.
– Never make any independent modifications (e.g. boreholes, welding)
to the ManuTel® G2.
– 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 ManuTel® G2 as far from its centre as
possible.
– Raise the load using its entire length and distribute it evenly on both
ManuTel® G2s.
WARNING!
Danger due to slipping load!
If there is moisture, dirt or ice on the lifting surfaces of the ManuTel® G2,
there is an increased risk of the load slipping. A slipping load could cause
serious injuries.
– Remove any dirt from the ManuTel® G2 before lifting the load.
– In wet, snowy or icy conditions etc., secure the load with e.g. tension
belts.
WARNING!
Risk of injury from missing locking device!
The locking device prevents undesired lateral movement of the ManuTel®
G2 on the profile of the fork carriage. Uncontrolled movement of the
ManuTel® G2 during transportation could cause the load to slip and
cause serious injuries!
– Safeguard the function of the locking device.
– Replace damaged locking devices immediately.
– If the locking device is missing, it must be replaced before start-up.
Unauthorised
modification
Incorrect fork
arm spacing
Moisture and
dirt
Checking the
locking device
Safety
Dangers associated with handling the ManuTel® G2
V1.09/2019 ManuTel® telescopic fork arm Type G2 11

WARNING!
Risk of injury from crushing!
Due to the considerable weight of the fork blade, there is a danger of
serious injuries from limbs getting trapped during all work on the fork
blade.
– Wear protective gloves.
– Push the fork arms on and off with care and prudence.
– Secure the fork arm against falling immediately after disassembly by
putting it down.
2.6 Safety markings
The type plate (and the article number it contains) identifies the version of the ManuTel®
G2 upon delivery. Do not put the ManuTel® G2 into operation without a type plate. The
type plate is located on the side of the fork back (Fig. 5/8).
Fig. 1: ManuTel® G2 type plate
1 Article number
2 Dead weight (unit)
3 Blade length
4 Centre of gravity
5 Carrying capacity x load centre
6 Note “Pay attention to load torque of forklift and fork arm”
Crushing
Type plate
Safety
Safety markings
V1.09/2019ManuTel® telescopic fork arm Type G212

The hard stamping (and the article number it contains) identifies the version of the
ManuTel® G2 upon delivery. The hard stamping is located on the side of the back of the
fork (Fig. 5/9).
Fig. 2: ManuTel® G2 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
Fig. 3: Note: Read the instructions
The “Read the instructions” safety label is located on the side of the fork back.
Hard stamping
Safety label
Safety
Safety markings
V1.09/2019 ManuTel® telescopic fork arm Type G2 13

Fig. 4: Note: Locking pin
The “Locking pin” safety label is located on the front of the fork back.
2.7 Personnel requirements
2.7.1 Qualification
WARNING!
Risk of injury if personnel are not sufficiently qualified!
If unqualified personnel perform work on the ManuTel® G2 or loiter in the
danger area of the ManuTel® G2, dangers arise that could cause serious
injuries and significant property damage.
– Have all tasks carried out by personnel qualified to do so without
exception.
– Keep unqualified personnel away from the danger areas.
The following section of this manual stipulates qualifications for personnel in relation to
the various fields of activity:
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 ManuTel® G2 and the associ-
ated dangers.
Safety
Personnel requirements> Qualification
V1.09/2019ManuTel® telescopic fork arm Type G214

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, start-up and service on the ManuTel® G2 has been taught.
The service specialist is familiar with the use of the ManuTel® G2 and the associated dan-
gers.
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.
Only persons of whom it can be expected that the will carry out their duties reliably are
permitted as personnel. Persons whose ability to react is affected, for example, by drugs,
alcohol or medicine are not permitted.
When selecting personnel, note the age and occupation-specific regulations applicable at
the operation site.
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 owner must train personnel on a regular basis. Execution of the training must be
logged for better traceability.
nDate of training
nName of the trained person
nContent of the training
nName of the instructor
nSignatures of the trained person and of the instructor
Safety
Personnel requirements> Training
V1.09/2019 ManuTel® telescopic fork arm Type G2 15

2.8 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 ManuTel® G2, personnel must wear the per-
sonal protective equipment that is specifically referenced in the individual sections of this
manual.
The personal protective equipment is explained below:
Industrial helmet
Industrial helmets protect the head against falling objects, swinging loads and impacts
with fixed objects.
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.
Protective work clothing
Protective work clothing consists of tight-fitting work clothing with low breaking strength,
tight sleeves and no parts that stick out.
Safety shoes
Safety shoes protect the feet from crushing, from dropping parts, and from slipping on
slippery floors.
WARNING!
Risk of injury from the work environment!
Regardless of the required personal protective equipment for the activity
in question, it is possible that additional dangers that are not described in
this operating manual may arise due to the operation site of the
ManuTel® G2. If suitable personal protective equipment is not used for
these dangers, there is a risk of serious injuries.
– Observe the operating instructions on wearing personal protective
equipment.
Description of
the personal
protective
equipment
Further opera-
tional require-
ments
Safety
Personal protective equipment
V1.09/2019ManuTel® telescopic fork arm Type G216

2.9 Protection of the environment and disposal
ENVIRONMENT!
Danger to the environment from improper handling of substances
that are harmful to the environment!
Incorrect handling of environmentally hazardous substances, especially
incorrect waste disposal, can cause considerable damage to the environ-
ment.
– Always observe the instructions below on how to handle and dispose
of environmentally hazardous substances.
– If environmentally hazardous substances are accidentally released
into the environment, you must immediately apply appropriate coun-
termeasures. If in doubt, notify the responsible municipal authority
and inquire about the appropriate measures that need to be taken.
The following environmentally hazardous substances are used:
Packaging materials are valuable raw materials and, as such, they can be further used or
meaningfully processed 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 such materials remanufactured or dis-
posed of in an environmentally sound manner.
nObserve the locally applicable disposal regulations. If necessary, arrange for a spe-
cialist company to take care of the disposal.
Insofar as 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 characteristics.
Packaging
materials
Recycling
Safety
Protection of the environment and disposal
V1.09/2019 ManuTel® telescopic fork arm Type G2 17

3 Structure
Fig. 5: Structure of the ManuTel® G2
AManuTel® G2 retracted
BManuTel® G2 extended
1 Fork arm locking device
2 Locking pin
3 Basic fork arm
4 Retainer
5 Locking sleeve
6 Slip-on coupling for basic fork arm
7 Pull-out protection
8 Type plate
9 Hard stamping position
10 Hooks
Structure
V1.09/2019ManuTel® telescopic fork arm Type G218

4 Assembly and disassembly
4.1 Assembly
NOTICE!
Carry out a compatibility check prior to assembly.
1. Compare the suspension dimensions of the fork carriage with those of the
ManuTel® G2.
2. Compare the load chart of the industrial truck with the ManuTel® G2:
nDetermine the weight and load centre for the transport task.
nCheck the load chart of the industrial truck with regard to the transport task.
nCheck the load chart of the ManuTel® G2 with regard to the transport task.
3. In the event of compatibility, carry out assembly.
The type of fork arm suspension may deviate from the image depending
on the industrial truck. Observe the operating manual for the industrial
truck.
WARNING!
Risk of injury from crushing!
Due to the considerable weight of the fork arms, crushing can result in
serious injuries. Note the following points in relation to all of the following
assembly, disassembly and adjustment tasks:
– Wear protective gloves.
– Carry out lifting and lowering of fork arms with care and prudence.
– Do not use force to open and close locking latches.
Personnel: nDriver of industrial trucks
Protective equipment: nIndustrial helmet
nProtective work clothing
nProtective gloves
nSafety shoes
Special tool: nLifting device
Carry out assembly of the ManuTel® G2 on the fork carriage in the following order:
1. Prepare the lifting device for large loads, e.g. indoor crane and lifting straps. The
work is to be carried out by 2 people.
2. Move the fork carriage to the vertical position and move it to a height that allows for
safe and comfortable installation of the ManuTel® G2.
3. Remove the locking screw on the assembly side of the fork carriage.
Checking
compatibility
Assembly
Assembly and disassembly
Assembly
V1.09/2019 ManuTel® telescopic fork arm Type G2 19

4. Open the locking device of the ManuTel® G2 by raising the lever (Fig. 6).
Fig. 6: Opening the locking device
5. Secure the ManuTel® G2 (e.g. by means of straps). Lift the ManuTel® G2 until it is
at the same level as the fork carriage.
Fig. 7: Putting on the ManuTel® G2
6.
CAUTION!
Risk of crushing the hands when aligning and putting on!
Take hold of the ManuTel® G2 at the head and fork blade and put it onto the side of
the fork carriage (Fig. 7). Ensure that the upper and lower hooks of the ManuTel®
G2 enclose the profile of the fork carriage.
Assembly and disassembly
Assembly
V1.09/2019ManuTel® telescopic fork arm Type G220