Vetter DuoLoc, Operation Manual

Page 1: ...Operation manual U163 905 US Folding fork arms Types KGA KGI and DuoLoc Read this manual prior to performing any task Keep for future use ...

Page 2: ...V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 2 ...

Page 3: ...applicable documents to ensure safe handling of the folding fork arms Furthermore the local accident prevention regulations and general safety instructions for the area in which the folding 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 ma...

Page 4: ...r hinge 20 3 2 Type KGA Folding fork arms with outer hinge 21 3 3 Type KGI Folding fork arms with inner hinge 22 3 4 Locking device 23 4 ASSEMBLY 24 5 OPERATION 28 5 1 Operating and transport position 29 5 1 1 DuoLoc KGA SBO operating position 29 5 1 2 DuoLoc KGA SBO transport position 31 5 1 3 KGA and KGI operating position 33 5 1 4 KGA and KGI transport position 35 5 2 Adjusting the fork arm spa...

Page 5: ...ork arm 45 6 2 8 Replacing the fork arm 45 6 3 Repairs and spare parts 47 6 4 After completion of maintenance work 51 7 TECHNICAL DATA 52 8 INDEX 53 Table of contents V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 5 ...

Page 6: ...lding fork arms are available in three variants Type 1 KGA Folding fork arms with outer hinge Ä Chapter 3 2 Type KGA Folding fork arms with outer hinge on page 21 Type 2 KGI Folding fork arms with inner hinge Ä Chapter 3 3 Type KGI Folding fork arms with inner hinge on page 22 Type 3 DuoLoc Folding fork arms with pin retention and outer hinge Ä Chapter 3 1 Type DuoLoc KGA SBO Folding fork arms wit...

Page 7: ...eans of a locking bolt Fig 1 KGA KGI Fork blade securing mechanism by means of a locking bracket Fig 2 Fig 1 DuoLoc with locking bolt Fig 2 KGA and KGI with locking bracket Fork blade securing mechanism Overview of VETTER folding fork arms Folding fork arm variants V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 7 ...

Page 8: ... instructions may relate to certain individual instructions for action Such safety instructions are embedded in the instruction for action so that the user can continue reading the text when performing the action The signal words listed above are used Example 1 Open the locking device of the folding fork arms 2 L WARNING Risk of hands and other body parts being crushed when moving Grip the folding...

Page 9: ...ction machinery with compatible fork carriers which meet the technical requirements of the folding fork arms Ä Incompatibility on page 24 Intended use includes observation of all the information in this manual Any use that goes beyond the scope of intended use is considered incorrect use Incorrect use Safety Intended use V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 9 ...

Page 10: ...iving beings especially people Transport in conjunction with the folding fork arms in so called workman baskets is also not permitted Never use the folding fork arms as reversible fork arms blade on top Never use folding fork arms for demolition work Never use the folding fork arms on a rotary device or on a pallet handler Never use the folding fork arms individually or load them unevenly Never ex...

Page 11: ...ating 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 operation troubleshooting maintenance and cleaning n The operator must ensure that all persons that come into contact with the folding fork arms have read and under...

Page 12: ...olding fork arms Adhere to the prescribed maintenance intervals The load capacity of the folding fork arms ultimately depends on its integrity Unauthorized modification such as boreholes for add ons welding work etc could reduce the load capacity and result in serious accidents from falling loads Risk of injury from tipping or slipping load Space the folding fork arms equally from the middle of th...

Page 13: ...a of the fork blade After folding the fork blade up secure it to prevent it from folding down in an uncontrolled manner use a locking bolt with a locking pin for the DuoLoc fork blade securing mechanism use a locking bracket for the KGA ad KGI fork blade securing mechanism The locking bracket for the KGA and KGI is not secured additionally e g by means of a locking pin Always insert the locking br...

Page 14: ... 4 Center of gravity 5 Blade length 6 Load capacity x load center 7 Note Observe load torque of fork lift truck and fork arm each fork arm The hard stamping specifically the article number specified there identifies the ver sion of the folding fork arms upon delivery The hard stamping is position on the side of the fork back in all three types Ä Further information on page 20 7 Fig 4 Hard stamping...

Page 15: ...e folding fork arms or remain in the danger zone of the folding fork arms dangers arise that could cause serious injuries and significant 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 ...

Page 16: ...f 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 transport 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 ...

Page 17: ...rk arms 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 Protective clothing Protective clothing is close fitting with low...

Page 18: ...disposing of environmentally hazardous substances If environmentally hazardous substances are handled incorrectly particularly if such substances are disposed of incorrectly this could cause significant damage to the environment Always observe the following points Packaging materials are valuable raw materials and as such they can continue to be used or be reprocessed for practical purposes in man...

Page 19: ...o material and send it for recycling n Scrap metals n Send plastic elements to be recycled n Sort and dispose of the other components according to their material characteris tics Recycling Safety Protection of the environment and disposal V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 19 ...

Page 20: ... together due to the external hinges Fig 7 Type DuoLoc KGA SBO 1 Pin retainer for securing the fork version DuoLoc KGA SBO 2 Fork back 3 Locking pin with ring 4 Fork blade 5 Locking bolt 6 Hinge pin pivot point including cotter pin and locking screw with washer 7 Safety label 8 Type plate Structure Type DuoLoc KGA SBO Folding fork arms with pin retention and outer hinge V1 07 2021 Folding fork arm...

Page 21: ...the KGI It is not possible to push the KGA pair flush together due to the external hinges Fig 8 Type KGA 1 Locking bracket for securing the fork 2 Fork back 3 Fork blade 4 Hinge pin pivot point including lock with pin and locking screw 5 Safety label 6 Type plate 7 Locking screw for locking bracket Structure Type KGA Folding fork arms with outer hinge V1 07 2021 Folding fork armsTypes KGA KGI and ...

Page 22: ...the KGI pair flush together Fig 9 Type KGI 1 Locking bracket for securing the fork 2 Fork back 3 Fork blade 4 Hinge pin pivot point including lock with pin and locking screw 5 Safety label 6 Type plate 7 Locking screw for locking bracket Structure Type KGI Folding fork arms with inner hinge V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 22 ...

Page 23: ...3 4 Locking device Fig 10 Structure of the locking device 1 Roll pin 2 Lever 3 Spring 4 Locking pin 5 Locking groove Structure Locking device V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 23 ...

Page 24: ...ion 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 The type of fork arm suspension may deviate from the image depending on the carrier vehicle Observe the operating manual for the carrier vehicle DuoLoc KGA SBO KGA and KGI are installed on the fork carrier using the same locking device ...

Page 25: ...e folding fork arm 3 Remove the locking screw on the assembly side of the fork carrier Fig 11 Opening the locking device 4 Open the locking device of the folding fork arm To do so pull the lever of the locking device vertically upwards using appropriate force Fig 11 5 Secure the folding fork arm with the lifting device e g using an indoor crane and lifting straps Raise it to a height that allows f...

Page 26: ...carrier from the outside using appropriate force Fig 12 Ensure that the upper and lower hook of the folding fork arm enc loses the profile of the fork carrier 7 Repeat the procedure for the second folding fork arm Carry out assembly from the other side of the fork carrier 8 Align both folding fork arms evenly to the center of the fork carrier at the required width Assembly V1 07 2021 Folding fork ...

Page 27: ...he lever Fig 13 Ensure that they are locked inside the locking grooves Ä Chapter 3 4 Locking device on page 23 5 10 Fit the locking screws on the fork carrier again 11 Lower the fork carrier to the base position Assembly V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 27 ...

Page 28: ... the middle of the vehicle and lock them in position Take hold of the load with the folding fork arms as far from its center as pos sible Raise the load using its entire length and distribute it evenly on both folding fork arms 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 the folding fork arms to break This could ...

Page 29: ...he ring out of the locking bolt Fig 14 2 2 Pull out and remove the locking bolt Fig 14 1 3 High weight The fork blade could be very heavy For this reason use suitable lifting gear if necessary L WARNING Risk of injury from a fork blade falling down Ensure that there are no people or objects in the folding area Slowly move the fork blade downward in a controlled manner until the operating position ...

Page 30: ...ocking bolt on the fork bend into the hole Fig 15 1 5 Secure the locking bolt using the locking pin with the ring Fig 15 2 Operation Operating and transport position DuoLoc KGA SBO operating position V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 30 ...

Page 31: ...locking bolt Fig 16 2 2 Pull out and remove the locking bolt Fig 16 1 3 High weight The fork blade could be very heavy For this reason use suitable lifting gear if necessary L WARNING Risk of hands and other body parts being crushed Remove hands and other body parts from the folding area and move the fork blade up in a controlled manner until the transport position is reached Operation Operating a...

Page 32: ...nsert the locking bolt through both locating holes Fig 17 1 ð The fork blade can no longer be folded out 5 Secure the locking bolt using the locking pin with the ring Fig 17 2 Operation Operating and transport position DuoLoc KGA SBO transport position V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 32 ...

Page 33: ... fork blade is flexible in the operating position Switch to the operating position Fig 18 Pulling out the locking bracket 1 Pull the locking bracket out of the folding fork arms up to the stop Fig 18 Fig 19 Setting the operating position Operation Operating and transport position KGA and KGI operating position V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 33 ...

Page 34: ...g area Slowly move the fork blade downward in a controlled manner Fig 19 until the end position is reached Do not allow the fork blade to fall while folding out Fig 20 Operating position and inserting the locking bracket 3 Insert the locking bracket into the hole on the fork back Fig 20 Operation Operating and transport position KGA and KGI operating position V1 07 2021 Folding fork armsTypes KGA ...

Page 35: ...thout a transport task Switch to the transport position Fig 21 Pulling out the locking bracket 1 Pull the locking bracket out of the folding fork arms up to the stop Fig 21 Fig 22 Setting the transport position Operation Operating and transport position KGA and KGI transport position V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 35 ...

Page 36: ...Prevent the fork blade from folding down in an uncontrolled manner Fig 23 Transport position and inserting the locking bracket 3 Insert the locking bracket into the designated hole of the fork blade Fig 23 ð The fork blade can no longer be folded out 5 2 Adjusting the fork arm spacing Personnel n Driver of carrier vehicles Protective equipment n Protective clothing n Industrial hard hat n Protecti...

Page 37: ...priate force Fig 24 3 L WARNING Risk of hands and other body parts being crushed when moving Grip the folding fork arms at the head and fork blade and carefully move it to the side on the fork carrier with appropriate force 4 Align both folding fork arms evenly to the center of the fork carrier and at the required width Operation Adjusting the fork arm spacing V1 07 2021 Folding fork armsTypes KGA...

Page 38: ...When doing so ensure your fingers are not in the danger zone and flip the lever again using appropriate force Fig 25 6 Check whether the folding fork arms are locked into the locking groove If this is not the case move the folding fork arms horizontally until the lock engages Operation Adjusting the fork arm spacing V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 38 ...

Page 39: ...hecking the locking bracket Ä Chapter 6 2 5 Checking the locking bracket on page 43 Service specialist Checking the suspension Ä Chapter 6 2 6 Checking the sus pension on page 44 Service specialist If necessary Replacing the fork arm Ä Chapter 6 2 8 Replacing the fork arm on page 45 Driver of carrier vehi cles Cleaning Ä Chapter 6 2 7 Cleaning the fork arm on page 45 Driver of carrier vehi cles De...

Page 40: ...s is fully engaged n Function check of the locking bracket Check the cylinder head screw Fig 27 1 for tight seating If necessary secure it with screw adhesive and tighten it n Function check for the locking screw Ensure that the folding fork arms cannot be pushed off of the fork carrier from the side when the fork arm locking device is open or loosened n Ensure that the hinge pins are not bent and...

Page 41: ... fork arms are damaged Use thereof can e g in the event of material breakage due to micro cracks can cause serious accidents 6 2 3 Check for wear Personnel n Service specialist Protective equipment n Protective clothing n Industrial hard hat n Protective gloves n Safety shoes Danger of accidents due to worn fork arms Perform a check for wear at least once a year The load capacity of the fork arms ...

Page 42: ... blade 6 2 4 Checking the locking device Personnel n Driver of carrier vehicles Protective equipment n Protective clothing n Industrial hard hat n Protective gloves n Safety shoes Risk of injury from a defective locking device Replace damaged locking devices immediately If the locking device is missing it must be replaced before commissioning It is not permissible to use the folding fork arms with...

Page 43: ... device is complete Fig 26 1 4 Replace any missing components immediately If the locking device of the folding fork arms is incomplete immediately prevent any further use Commissioning must only be car ried out after a successful repair n Remove any dirt from the locking device 6 2 5 Checking the locking bracket Personnel n Driver of carrier vehicles Protective equipment n Protective clothing n In...

Page 44: ... 1 is firmly screwed into the hole If necessary secure it with screw adhesive and tighten it firmly An unsecured fork blade can move in an uncontrolled manner and due to its high weight result in serious injuries Fig 27 Screw of the locking bracket 6 2 6 Checking the suspension Personnel n Service specialist Protective equipment n Protective clothing n Industrial hard hat n Protective gloves n Saf...

Page 45: ...ll and result in serious accidents 6 2 7 Cleaning the fork arm 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 folding fork arm on a regular basis n Do not use high pressure cleaning devices and do not use any aggressive cleaning agents n Clean the fork ...

Page 46: ...eople 2 Align the folding fork arms so that they are parallel with the ground 3 Put the fork carrier in a vertical position and lift the folding fork arms up from the ground by raising the fork carriage until it is no longer in contact with the ground Secure the fork carrier against unintended lowering 4 Remove the locking screw Fig 28 Opening the locking device 5 Open the locking device of the fo...

Page 47: ...falling fork arms Secure the folding fork arm against falling immediately after disassembly by set ting it down to one side 8 Install the new folding fork arms Ä Assembly on page 25 9 Fit the locking screw again 6 3 Repairs and spare parts Personnel n Service specialist Protective equipment n Protective clothing n Industrial hard hat n Protective gloves n Safety shoes Maintenance Repairs and spare...

Page 48: ... dangerous situations and serious injuries Improper repair invalidates the guarantee and the manufacturer s responsibility for any consequential damage As manufacturer VETTER Forks Inc reserves the right to make changes at any time as part of continuous product improvement For this reason it is important to state the type and article number with every order for spare parts Ä Chapter 2 5 Safety mar...

Page 49: ...must only be replaced by manufacturer 3 Locking pin with ring 4 Locking bolt 5 Hinge pin pivot point including cotter pin and locking screw with washer 6 Safety label 7 Type plate DuoLoc KGA SBO spare parts Maintenance Repairs and spare parts V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 49 ...

Page 50: ...Maintenance Repairs and spare parts V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 50 ...

Page 51: ...folding fork arms and the carrier vehicle 1 Tighten all previously loosened screw connections 2 Remove all tools materials and other equipment from the work area and clean the work area Remove any leaked materials e g liquids processing materials or similar 3 Ensure that all safeguarding devices are functioning flawlessly 4 If necessary put the lift truck safeguard back in place Maintenance After ...

Page 52: ...bserve the applicable documents Ä Applicable docu ments on page 3 Should you have any technical difficulties or questions contact cus tomer service Ä Customer service on page 3 Technical data V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 52 ...

Page 53: ...22 Intended use 9 K KGA 21 KGI 22 L Locking bolt 7 Locking bracket 7 43 Locking device 23 37 M Maintenance 40 Maintenance activities 40 Check for wear 41 Checking the locking bracket 44 Checking the locking device 42 Checking the suspension 45 Cleaning the fork arm 45 Replacing the fork arm 46 Routine maintenance 41 Maintenance intervals 39 O Obligations of the operator 11 Operating position DuoLo...

Page 54: ...oc 49 KGA 49 KGI 48 Structure DuoLoc 20 KGA 21 KGI 22 Locking device 23 37 Symbols in this manual 8 on the folding fork arms 15 T Technical data 52 Transport position DuoLoc 31 KGA 31 KGI 35 Type plate 14 U Use 9 V Variants 6 Visual inspection 40 W Warning label 15 Wear 41 Wear zones 42 Index V1 07 2021 Folding fork armsTypes KGA KGI and DuoLoc 54 ...

Page 55: ......

Page 56: ... development Deviations and changes are part of our ongoing review and improvement of the product VETTER Forks Inc 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 proc...