Vetter ManuTel Operation Manual Download Page 43

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6.6

Replacing the fork arms

Personnel:

Driver of carrier vehicles

Protective equipment:

Protective clothing

Industrial hard hat

Protective gloves

Safety shoes

Danger when replacing only one fork arm!
– If one fork arm is damaged, always replace the fork arms in pairs.

If one fork arm is damaged, it is to be expected that the other arm has, or will

have, the same damage.

Have a lifting device available for large loads, e.g., indoor crane. The work must

be carried out by 2 people.

Align the fork arm so that it is parallel with the ground.

Raise the fork arm up from the ground by raising the fork carrier until it is no

longer in contact with the ground. Secure the fork carrier against unintended low-

ering.

Remove the locking screw from the fork carrier.

Open the fork arm locking device. To do so, put the lever vertically upwards.

NOTICE

Fork arms with hook

suspension

Maintenance

Replacing the fork arms

Fork carrier with fork arms

Summary of Contents for ManuTel

Page 1: ...Operation manual U163 530 US Fork carrier with fork arms Read this manual prior to performing any task Keep for future use ...

Page 2: ...Fork carrier with fork arms 2 ...

Page 3: ...ell 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 fo...

Page 4: ...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 3...

Page 5: ...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 ...

Page 6: ...artFork 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...

Page 7: ... 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 ...

Page 8: ...le 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 ...

Page 9: ...erating time that the operating manual created by him her correspond to the current state of the rules and regulations and adjust them if necessary n The operator must clearly regulate and specify the responsibilities for assembly operation troubleshooting maintenance and cleaning n The operator must ensure that all persons that come into contact with the fork car rier and fork arms have read and ...

Page 10: ...o 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 o...

Page 11: ...tc 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 for...

Page 12: ...eight 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 Fork carrier with fork arms 12 ...

Page 13: ...ocated 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 ar...

Page 14: ...ers 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 ve...

Page 15: ...tocol must be created with the following minimum information n Date of instruction n Name of the instructed person n Content of instruction n Name of the instructor n Signatures 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 t...

Page 16: ...to 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 t...

Page 17: ...ace separate compo nents by material and send them for recycling n Sort 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 ...

Page 18: ...e 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 ...

Page 19: ...urface 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 ...

Page 20: ...ension 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 20 ...

Page 21: ...ckness GD 5 Fork blade 4 x 6 Cross section 6 Fork width GB 7 Taper 8 Fork tip 9 Blade length L 10 Lower hook 11 Upper hook 10 11 Suspension 12 Back height 13 Locking pin 14 Spring 15 Lever 16 Roll pin 13 16 Locking device 17 Shaft 18 Eye tube Structure Fork arm Fork carrier with fork arms 21 ...

Page 22: ... observe the safety instructions and operating manual for the carrier vehicle and tool change device The fork carrier must only be connected to and used with vehicles approved by the manufacturer with a suitable tool change device Non compliance can result in serious accidents and injuries due to the high dead weight of the fork carrier 4 2 Fork arms with hook suspension Personnel n Driver of carr...

Page 23: ...sembly of the fork arms 3 Remove the locking screw on the assembly side of the fork carrier Fig 7 Locking device fork arm with hook suspension 4 Open the locking device of the fork arms To do so put the lever Fig 7 1 of the locking device vertically upwards Fig 7 3 5 Secure the fork arm with the lifting device e g using a crane and belts Raise it to a height that allows for the fork carrier to be ...

Page 24: ... other side of the fork carrier 8 Align both fork arms evenly to the center of the fork carrier at the required width 9 L WARNING Risk of crush injuries to hands when closing the locking device Lock both fork arms by closing the lever inside the locking grooves Fig 7 2 When doing so ensure your fingers are not in the danger zone and flip the lever again using appropriate force 10 Check that the fo...

Page 25: ...the shaft Assemble the fork arms on the fork carrier in the following order 1 Prepare the lifting device for large loads e g indoor crane and lifting straps The work must be carried out by 2 people 2 Move the fork carrier to the vertical position and move it to a height that allows for safe and comfortable assembly of the fork arm 3 Remove the safeguarding device from one side of the shaft 4 Pull ...

Page 26: ... being crushed when aligning and pushing on Position the second fork arm and adjusting rings if present not shown here and push the shaft through the socket of the second fork arm and the outer elongated hole 8 Re install the safeguarding device from the outside 9 Align both fork arms evenly to the center of the fork carrier at the required width 10 If the position is to be fixed fix both fork arm...

Page 27: ...rder to grip the load as far from its center as possible with the fork arms Fig 10 Overview of hook suspension locking device 1 Raise the fork arms up from the ground 2 Open the locking device of the fork arms To do so put the lever Fig 10 1 of the locking device vertically upwards Fig 10 3 3 L WARNING Risk of hands and other body parts being crushed when moving Grip the fork arms at the head and ...

Page 28: ...ither freely movable on the shaft using adjusting rings on both sides of the two shaft fork arms or with a locking screw on the shaft 1 Raise the fork arms up from the ground 2 If installed loosen the locking device adjusting rings or locking screw in the shaft of the shaft fork arms Fig 11 Shaft fork arm spacing 3 L WARNING Risk of hands and other body parts being crushed when moving Grip the for...

Page 29: ...shaft horizon tally by tightening the screw connection at the adjusting rings or by using the locking screws available in the scope of delivery depending on the configuration not shown here Operation Adjusting the distance between the fork arms Fork carrier with fork arms 29 ...

Page 30: ...uspension Ä Chapter 6 4 2 Checking the suspen sion on page 33 Service specialist Check for surface cracks Ä Chapter 6 4 3 Crack test for fork arms on page 36 Service specialist Check for deformation Ä Chapter 6 4 4 Deformation of the fork arms on page 36 Service specialist Check for wear Ä Chapter 6 4 5 Wear on the fork arms on page 41 Service specialist If necessary Cleaning Ä Chapter 6 5 Cleanin...

Page 31: ...e hook on fork arm cannot be pushed off of the fork carrier from the side when the fork arm locking device is open or loosened n Check the safeguarding device and adjusting rings of the shaft suspension Ensure that the safeguarding device as well as the adjusting rings or locking screw are in place and securely mounted n The fork arms must be free from dirt including grease and ice n The fork arm ...

Page 32: ...of the fork carrier 6 4 Checking the fork arms Risk of injury due to irregular checks Have the fork arms checked by a service specialist or the manufacturer at least once a year more frequently for heavy usage or multiple shift opera tion Carry out the test based on the currently relevant standard The service spe cialist will specify the scope of the test and the test interval The load capacity of...

Page 33: ...arried out after a successful repair n Remove any dirt from the locking device Shaft fork arm locking device Depending on the operator s requirements and intended use shaft fork arms are sup plied as follows either freely movable on the shaft using adjusting rings on both sides of the two shaft fork arms or with a locking screw on the shaft Always observe the following n Check that all the screws ...

Page 34: ...ipment n Protective clothing n Industrial hard hat n Protective gloves n Safety shoes Special tool n Measuring tool caliper gage feeler gage Danger to life due to deformed fork hooks Always observe the following Ensure that the hooks of the fork arm do not bend upwards by more than 0 079 inches 2 mm Fork hooks are used for both power transmission and as the locking device If the fork hooks are def...

Page 35: ...missioning must only be carried out after a suc cessful repair or replacement Personnel n Service specialist Protective equipment n Protective clothing n Industrial hard hat n Protective gloves n Safety shoes Special tool n Measuring tool caliper gage feeler gage The sockets of the shaft fork arms are used for both power transmission and to guide the fork arms onto the shaft Defective or severely ...

Page 36: ...ft using a caliper gage If the differences are greater than 0 079 mm inches 2 mm Fig 13 the per missible value has been exceeded In those cases replace the fork arms in pairs immediately 6 4 3 Crack test for fork arms Have crack tests performed in the area of the fork bend and fork hook welds by a trained service specialist If there are any signs of cracks immediately ban any further use of the fo...

Page 37: ...issible bend kmax is exceeded the specified nominal load capacity of the fork arm is no longer ensured This could e g due to breakage cause the load to fall and result in serious accidents Fig 14 Bending of the blade 1 Calculate the maximum permissible bend kmax To do so divide blade length L in inches by 66 kmax L inches 66 2 Move the fork arm to a comfortable working height 3 Place the ruler flu...

Page 38: ...r Danger to life due to fork arms bent upwards Check the fork arms for deformation on a regular basis Never use fork arms that exceed the maximum permissible diagonal dimen sion Fork arms that are bent upwards are a sign of overloading and material fatigue The fork arms are delivered with an angle of 90 If the maximum permissible angle is exceeded the specified nominal load capacity of the fork ar...

Page 39: ...etween 27 36 inches and 28 07 inches 695 mm and 713 mm immediately ban any further use of the fork arm Commissioning must only be carried out after a successful repair or replacement Personnel n Service specialist Protective equipment n Protective clothing n Industrial hard hat n Protective gloves n Safety shoes Special tool n Ruler n Spirit level Height difference fork tip Maintenance Checking th...

Page 40: ...issible height difference hmax Δhmax blade length inches 100 x 1 5 2 Mount the fork arms on the fork carrier and move them to a comfortable working height 3 Place a level or ruler above both fork tips and in doing so put it flush against the higher fork arm 4 Measure the difference h between the level and the lower fork blade at the fork tip Fig 16 5 If the measured height difference h exceeds the...

Page 41: ...ective clothing n Industrial hard hat n Protective gloves n Safety shoes Special tool n Measuring tool caliper gage feeler gage Note zones with increased wear Fork arm wear can occur on all four sides of the fork arm depending on use It is necessary to check for wear in every area Due to the increased ground contact the fork arm must be checked particularly on the underside in the vicinity of the ...

Page 42: ...k arms out of service immediately 6 5 Cleaning the fork carrier and fork arms Personnel n Driver of carrier vehicles Protective equipment n Protective clothing n Industrial hard hat n Protective gloves n Safety shoes Observe the following points when cleaning n Clean the fork carrier and fork arms on a regular basis n Do not use high pressure cleaning devices and do not use any aggressive cleaning...

Page 43: ...ge 1 Have a lifting device available for large loads e g indoor crane The work must be carried out by 2 people 2 Align the fork arm so that it is parallel with the ground 3 Raise the fork arm up from the ground by raising the fork carrier until it is no longer in contact with the ground Secure the fork carrier against unintended low ering 4 Remove the locking screw from the fork carrier 5 Open the...

Page 44: ...rk blade with someone else to assist you and push it down from the fork carrier with appropriate force Fig 19 7 L WARNING Risk of injury from falling fork arms Secure the fork arm against falling immediately after disassembly by setting it down to one side 8 Install the new fork arm Ä Assembly on page 23 Maintenance Replacing the fork arms Fork carrier with fork arms 44 ...

Page 45: ...ings or locking screw present in the scope of delivery depending on the configuration not shown here Fig 20 Disassembling the shaft fork arms 6 L WARNING Risk of hands and other body parts being crushed when pulling out the shaft Pull the shaft out to the side Fig 20 and put it safely aside 7 Remove the fork arms and store them in such a way that prevents them falling over 8 Install the new fork a...

Page 46: ...fy the required spare parts from the order number on the type plate of the fork carrier and from the hard stamping of the fork arm Always install genuine components The use of third party components voids any liability and invalidates the warranty and the manufacturer s responsibility for any consequential damage 6 8 After completion of maintenance work Personnel n Driver of carrier vehicles Prote...

Page 47: ...7 Troubleshooting Should you have any technical difficulties or questions contact customer service Ä Customer service on page 3 Troubleshooting Fork carrier with fork arms 47 ...

Page 48: ...8 Technical data Fig 21 Dimensions A Total width of fork carrier inches B Working width of fork carrier inches Technical data Fork carrier with fork arms 48 ...

Page 49: ...Fig 22 Rated load capacity C Load capacity of fork arms lbs pair D For load center distance LC inches Technical data Fork carrier with fork arms 49 ...

Page 50: ...ns 6 Fork width 27 G General requirement for safety 10 H Hard stamping 13 Height difference fork tip 39 I Incompatibility 10 Incorrect use 7 Intended use 7 M Maintenance Fork arms 32 Fork carrier 31 Locking device 33 Maintenance activities 30 Maintenance intervals 30 Safeguarding device 33 Suspension 33 Malfunction 47 Modifications 10 O Operation 27 Operator 9 Operator obligations 9 P Personnel 14...

Page 51: ...rm 28 Spare parts 46 Structure Example hook suspension 18 19 Example shaft suspension 20 Fork arm 21 Symbols in this manual 7 on the fork arm 11 13 T Technical data 48 Type plate 11 U Upward bending of the hook 34 W Wear 40 41 Wear zones 41 Index Fork carrier with fork arms 51 ...

Page 52: ......

Page 53: ...evelopment Deviations and changes are part of our ongoing review and improvement of the product VETTER Industrie GmbH does not accept any responsibility or liability for errors that arise from the use and application of this document This document including all parts is protected by copyright All rights reserved No part of this document may be copied translated microfilmed or used in any way for p...

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