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Vetter Smartfork, Operating Instructions Manual

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Summary of Contents for Smartfork

Page 1: ...Operating instructions SmartFork The intelligent SensorFork U163 907 Replaced U163 356 Read the instructions prior to performing any task Keep for future use ...

Page 2: ...V1 08 2019 SmartFork The intelligent SensorFork 2 ...

Page 3: ...nce 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 49 2736 4961 964 Email support smartfork com Internet www smartfork com About this manual Custom...

Page 4: ...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 3 STRUCTURE 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 ...

Page 5: ...6 MAINTENANCE 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 c...

Page 6: ...ce 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 V...

Page 7: ...lash warning function 8 VETTER SmartFork EasySecure insertion depth function 9 VETTER 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 ...

Page 8: ...dditional 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 ...

Page 9: ...cally 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 V1 08 20...

Page 10: ...tFork 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 ...

Page 11: ...s 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 overvie...

Page 12: ...r 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...

Page 13: ...asonic 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 V1 08 2019 SmartFork The intelligen...

Page 14: ...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...

Page 15: ...tion of the other components and machines used as well as operator specific requirements n Operating manual for the industrial truck n Operating manual for the mounted fork carriage n Operating instructions for the operator n Equipment specific operating manuals for the individual applications and components Safety Applicable documents V1 08 2019 SmartFork The intelligent SensorFork 15 ...

Page 16: ...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 war...

Page 17: ...g 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 n The operator must clearly regulate and specify the responsibilities for assembly ope ration troubleshooting maintenance and cleaning n The operator must ensure that all persons that come into contact with the assistance system have read and understo...

Page 18: ...ing 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 in...

Page 19: ...ngerous 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 o...

Page 20: ...ed 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...

Page 21: ... hazards may arise which can cause serious injury and substantial damage to property Therefore all work must only be carried out by appropriately qualified personnel Unqualified personnel must be kept away from the danger zones This manual specifies the personnel qualifications required for the different areas of work listed below Driver of industrial trucks The driver of industrial trucks is capa...

Page 22: ...n Carrying out of safety tests on electrical systems components and devices n Analysing and resolving malfunctions with electrical systems The electrician is trained for the particular location in which they are active and is aware of the relevant norms and regulations Service specialist The service specialist has a qualification in mechatronics or similar or has verifiably taken part in training ...

Page 23: ...of the training must be logged for better traceability n Date of training n Name of the trained person n Content of the training n Name of the instructor n Signatures of the trained person and of the instructor 2 8 Personal protective gear Personal protective equipment serves to protect people against hazards to their safety and health while working The personnel must wear the personal protective ...

Page 24: ...ese dangers there is a risk of serious injuries Observe the operating instructions on wearing personal protective equipment 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 ...

Page 25: ...rrect disposal of packaging materials can give rise to dangers to the environment n Reuse packaging materials if possible n If packaging materials cannot be reused have such materials remanufactured or dis posed of in an environmentally sound manner n Observe the locally applicable disposal regulations If necessary arrange for a spe cialist company to take care of the disposal Insofar as there is ...

Page 26: ...ickness GD 5 x 6 Cross section width x thickness 7 Fork blade 8 Taper 9 Fork tip 10 Mounting slot for flash application 11 Blade length L measurement from inner side of back to the tip 12 Inner heel 13 Wear zone 14 Lower hook 15 Upper hook 14 15 Suspension 16 Back height Structure of the VETTER SmartFork Structure of the basic fork V1 08 2019 SmartFork The intelligent SensorFork 26 ...

Page 27: ...ck Observe the operating manual for the industrial truck Assembly of the VETTER SmartFork may only be carried out on a fork carriage that is compatible with the supplied VETTER SmartFork Observe the relevant operating manual for the fork carriage installed on the industrial truck The attachment dimensions for the VETTER SmartFork can be requested from cus tomer service upon stating the order numbe...

Page 28: ...ays use original components 3 3 1 Camera monitor Fig 15 Camera monitor The camera monitor is the joint signal output device for the VETTER SmartFork Camera and die VETTER SmartFork SideCam The projected laser line of the VETTER SmartFork Laser application can also be seen on the monitor All settings can be found in the supplied operating manual for the camera monitor Structure of the VETTER SmartF...

Page 29: ...ntrol device The VETTER SmartFork Flash control device is used to set all LED configurations For installation and all settings e g selection of the LED lighting pattern see the supplied operating manual and applicable documents for the VETTER SmartFork Flash control device 3 5 VETTER SmartFork PremiumCam control device For installation and all settings see the supplied operating manual and applica...

Page 30: ...connection Power source SmartFork Camera SmartFork SideCam Application for the camera monitor Ignition SmartFork Distance SmartFork Level SmartFork Scale Application for the display medium Ignition SmartFork PremiumCam SmartFork Flash Separate control device Ignition SmartFork Secure SmartFork EasySecure Application for the SmartFork EasySecure LED display Ignition SmartFork Laser Application for ...

Page 31: ... applications via a radio system is possible as an option Contact customer service if you have questions about the radio system Ä Cus tomer service on page 3 Structure of the VETTER SmartFork Radio connection V1 08 2019 SmartFork The intelligent SensorFork 31 ...

Page 32: ...iage 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 VETTER SmartFork 3 Remove the locking screw on the assembly side of the fork carriage Fig 17 Opening the locking devic...

Page 33: ...TTER SmartFork Carry out assembly from the other side of the fork carriage 8 Align both VETTER SmartFork fork arms equally to the centre of the fork carriage 9 Lock the VETTER SmartFork by closing the lever inside the locking groove 10 Fit the locking screw on the fork carriage again 11 Establish cable connections Ä Chapter 4 4 Establishing cable connections on page 35 12 Lower the fork carriage t...

Page 34: ...rotective equipment n Industrial helmet n Protective work clothing n Protective gloves n Safety shoes NOTICE Install the EasySecure LED display in the driver s cab so that the EasySecure LED display does not obstruct or impede any functions or elements of the industrial truck Install and connect the EasySecure LED display as per the supplied operating manual Initial assembly of the VETTER SmartFor...

Page 35: ...he lift mast connector observe the supplied cable diagram Remove any dirt from the plug before establishing a connection Matching connectors should be securely connected and if necessary secured to prevent unintended unplugging Ensure that all plugged connec tions are secure 4 5 Installing the radio transmitter Personnel n Electrician Protective equipment n Industrial helmet n Protective work clot...

Page 36: ...e radio system Ä Customer service on page 3 For all information on correct installation and connection see the appli cable documents Initial assembly of the VETTER SmartFork Installing the radio transmitter V1 08 2019 SmartFork The intelligent SensorFork 36 ...

Page 37: ...ral 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 Personnel n Driver of industrial trucks Protective equipment n Protective work clothing n Industrial helmet n Protective gl...

Page 38: ...amera monitor 3 Move the fork arms in front of the load to be lifted 4 Additionally monitor and control the lifting of the load on the camera monitor 5 During transport use the VETTER SmartFork Camera for additional securing monitoring of the area in front of the lifted load All settings such as e g selecting between the SmartFork Camera and SmartFork SideCam are in the supplied operating manual f...

Page 39: ...3 Move the fork arms in front of the load to be lifted 4 Additionally monitor and control the lifting of the load on the camera monitor All settings such as e g selecting between the SmartFork Camera and SmartFork SideCam are in the supplied operating manual for the mon itor 5 3 VETTER SmartFork PremiumCam Fig 22 VETTER SmartFork PremiumCam Particularly helpful for all lifting transport and puttin...

Page 40: ...e in the sup plied operating manual for the monitor and the applicable documents 5 4 VETTER SmartFork Laser 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 obser...

Page 41: ... is projected horizontally onto the load at the current height of the fork arm tips 3 Adjust the height of the VETTER SmartFork until the projected laser line marks the insertion position for the load 4 Pick up the load As an option the power supply for the line laser can be provided by a battery Start up is carried out via the switching facility of the circuit Ä Further information on page 30 Ope...

Page 42: ... pallet pockets do not disrupt the system and do not pre vent safe functioning Fig 24 VETTER SmartFork Secure Particularly helpful when lifting loads in block storage or for a load that must be supported across its entire length 1 Switch on the industrial truck The power to the VETTER SmartFork Secure appli cation is supplied by the ignition of the industrial truck ð The VETTER EasySecure LED disp...

Page 43: ...ping load Incorrect lifting of loads could cause the load to tip or slip and cause serious injuries Observe the following to ensure reliable functioning of the SmartFork EasySecure application Ensure that the sensors on the upper side of the SmartFork EasySecure application are never covered and are always kept clean Ensure that non reflective materials e g black plastic pallets do not prevent saf...

Page 44: ... monitored using the VETTER EasySecure LED display When both fork tips are equipped with the VETTER SmartFork EasySecure application the first VETTER SmartFork to enter the load is displayed when approaching at an angle All settings for the VETTER SmartFork EasySecure application are in the supplied documents for the VETTER EasySecure LED display 5 7 VETTER SmartFork Flash Fig 26 VETTER SmartFork ...

Page 45: ...of the fork arms Programming of the LED lighting pattern e g for determining the inser tion depth is carried out with the supplied software via the USB interface on the inside of the driver or via the position of the internal switch Detailed information on settings can be found in the supplied VETTER SmartFork Flash operating manual and the corresponding documenta tion 5 8 VETTER SmartFork Level F...

Page 46: ... of injury from tipping or slipping load Incorrect lifting of loads could cause the load to tip or slip and cause serious injuries For round objects such as pipes the reflection of the VETTER SmartFork Distance application is disrupted The VETTER SmartFork Distance application cannot be used safely in this circumstance Always observe the following When using only one sensor do not approach the loa...

Page 47: ...not available ð The distance function is now ready for use 3 Pick up the load 4 Move the load to a small niche or to a wall for example ð The distance between the fork tips and e g the wall is displayed on the display medium 5 Use the information on the display medium to put down the load in a space efficient position All settings for the VETTER SmartFork Distance application are in the supplied o...

Page 48: ...locking device vertically upwards fig 30 3 3 WARNING Risk of crushing the hands when moving Grasp the VETTER SmartFork at the head and fork blade and carefully move it to the side onto the fork carriage 4 Align both VETTER SmartForks equally to the centre of the fork carriage 6 Close the locking device of the VETTER SmartFork move the lever again 7 Check that the VETTER SmartFork is locked into th...

Page 49: ...s at least annually Check the electronics Ä Chapter 6 2 2 Checking elec tronics on page 51 Electrician Fork arms inspection as per ISO 5057 Ä Chapter 6 2 3 Reg ularly check the fork arms and hooks on page 51 Service specialist Check the locking device Ä Chapter 6 2 4 Checking the locking device on page 52 Service specialist Depending on operating time wear and use the operator can independently ch...

Page 50: ...n The VETTER SmartFork must be free from dirt and ice n The VETTER SmartFork hooks must not be damaged n The VETTER SmartFork must have any deformations cracks damage or sharp edges n Function check for strain relief The connection cable must have enough play in every position and may not be under tension or be trapped or kinked n Function check for the connection cable All plug connections must b...

Page 51: ...e carried out after a successful repair Check the following points 1 Check all applications for functionality 2 Check that all exposed components are seated securely 3 Check all plug connections of the electronic components 4 Check the cables for damage cracks or kinks 5 Check the protective screens in the fork blades and fork tips for dirt and scratches 6 2 3 Regularly check the fork arms and hoo...

Page 52: ...mage and completeness Ä Chapter 3 1 Structure of the basic fork on page 26 3 Remove any dirt from the locking device 6 2 5 Cleaning the VETTER SmartFork Personnel n Driver of industrial trucks Protective equipment n Protective work clothing n Industrial helmet n Protective gloves n Safety shoes Check the following points n Regularly clean the VETTER SmartFork n Do not use a high pressure cleaning ...

Page 53: ...d Secure the fork carriage against unin tended lowering 4 Disconnect the plug connections between the VETTER SmartFork applications and the corresponding cables of the lift mast connector 5 Remove moveable cables from the immediate assembly area and protect them against damage 6 Open the VETTER SmartFork locking device To do so move the lever of the locking device vertically upwards Fig 30 Moving ...

Page 54: ...ork carriage 11 Repeat the procedure for the second VETTER SmartFork 12 Align both VETTER SmartForks equally to the centre of the fork carriage 13 Close the locking device of the VETTER SmartFork move the lever again 14 Check that the VETTER SmartFork is locked into the locking groove If this is not the case move the arms horizontally until the lock engages 15 Reconnect the connections between the...

Page 55: ...ious injuries could result Improper repairs invalidate the guarantee and the manufacturer s responsibility for any consequential damage Have VETTER SmartFork applications replaced by an electrician only Always use original components Observe the safety information in the relevant separate instructions 6 2 8 Spare parts Spare parts for the VETTER SmartFork can be ordered from the manufacturer If in...

Page 56: ... 1 Tighten all previously loosened screw connections 2 Reinstall all previously removed protective equipment and covers 3 Check the cable routing To prevent damage cables must be out of the range of movement for moving parts 4 Reset the lift truck fuse 5 Remove all tools materials and other equipment from the work area 6 Clean the work area remove any leaked materials such as e g liquids processin...

Page 57: ... the driver on page 50 2 Check the power supply and ensure that all plugged connections are secure 3 Sensors and camera optics and their protective screens must not be dirty or scratched If these measures do not resolve the malfunction please contact your dealer and state the data on the hard stamping Troubleshooting on the VETTER SmartFork V1 08 2019 SmartFork The intelligent SensorFork 57 ...

Page 58: ...8 Technical data All technical data on the individual applications can be found in the sup plied documentation Technical data V1 08 2019 SmartFork The intelligent SensorFork 58 ...

Page 59: ...Operation of the camera switch function 40 of the distance function 47 of the front camera 38 of the insertion depth function 44 of the line laser target function 41 of the loading function 42 of the side camera 39 of the tilt function 46 of the warning function insertion depth func tion 45 Operator 17 Operator obligations 17 Overview of functions Camera function 8 Distance function 13 Insertion d...

Page 60: ...on the fork arm 21 T Troubleshooting 56 U Use 16 V Visual inspection daily 50 Index V1 08 2019 SmartFork The intelligent SensorFork 60 ...

Page 61: ......

Page 62: ...pment Deviations and changes are part of our ongoing review and improvement of the product VETTER Industrie GmbH does not accept any respon sibility 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 This document or any part thereof may not be copied translated microfilmed or used in any ...

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