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Schmalz SK-JU-110-2000-SRS63-3000-VSL-EX Operating And Maintenance Instructions Manual Download Page 9

 

 

SAFETY INSTRUCTIONS 

30.30.01.00226

/03 

www.schmalz.com 

EN   | 9 

  Fundamental safety instructions 

1.5.2

 

 

WARNING 

 

 

 

Ignoring the general safety guidelines 

 

Personal injury/damage to plants or systems 

► 

The operating and maintenance instructions contain important information on 
using the system. All users must have read and understood the operating and 
maintenance instructions and keep them for later reference.

 

 

 

 

►  These operating and maintenance instructions are specific to the items included 

in delivery from J. Schmalz GmbH. They do not take into account any 
modifications to the system made by the customer, which are strictly prohibited. 

 

 

►  The system may only be connected and operations started once the operating 

and maintenance instructions have been read and understood. 

 

►  Use only the connections, mounting holes and attachment materials that have 

been provided. 

 

► 

Only qualified specialist personnel, mechanics and electricians may perform the 
installation. Qualified specialist personnel are persons who have received 
technical training and have the knowledge and experience 

– including 

knowledge of applicable regulations 

– necessary to enable them to recognize 

possible dangers and implement the appropriate safety measures while 
performing tasks. The same applies to maintenance! 

 

 

 

►  General safety regulations, European standards and VDE guidelines must be 

observed and complied with. 

 

►  Personnel and animals are not permitted to sit or stand in the danger zone. 
► 

The system must be used only to lift and transport suitable workpieces. 

 
►  You are responsible for third parties in the working area of the system. In view 

of this, responsibilities for the various tasks to be carried out on the system 
must be clearly specified and adhered to.  

 

 
►  Protect the components from damage of any kind. 

 
 

 

All applicable laws and regulations must be adhered to at all times. 

When using the jib crane, the statutory regulations, safety regulations, standards 
and guidelines applicable at the location of use must be observed. 
Check with the competent authorities for more information.  
The safety instructions in these operating and maintenance instructions do not 
replace these laws and regulations, but are to be regarded as a supplement to 
them. 

 

 

 

Summary of Contents for SK-JU-110-2000-SRS63-3000-VSL-EX

Page 1: ...www schmalz com EN Ergonomic Handling Solutions Operating and Maintenance Instructions Jib Cranes for Potentially Explosive Atmospheres 30 30 01 00226 03 09 2019 ...

Page 2: ...tains the rights established thereby Reproduction of the contents in full or in part is only permitted within the limits of the legal provisions of copyright law Any modifications to or abridgments of the document are prohibited without explicit written agreement from J Schmalz GmbH Contact J Schmalz GmbH Johannes Schmalz Str 1 72293 Glatten Germany Tel 49 0 7443 2403 0 Fax 49 0 7443 2403 259 schm...

Page 3: ...crane 17 1 12 Emissions 17 1 13 Personal protective equipment 17 2 Product description 18 2 1 Description 18 Column mounted jib crane with flat jib 18 2 1 1 Wall mounted jib crane with flat jib 18 2 1 2 Column mounted jib crane with flat jib 18 2 1 3 Wall mounted jib crane with flat jib 18 2 1 4 Column mounted jib crane with articulated arm jib 19 2 1 5 Wall mounted jib crane with articulated arm ...

Page 4: ...45 5 8 3 5 9 Aligning the steel crane jib for column mounted or wall mounted jib crane 46 5 10 Mounting the slewing angle limiter 47 5 11 Mounting the crane buffer for crane rails 48 5 12 Mounting the hoist 48 5 13 Mounting the energy supply 48 Vacuum power supply 48 5 13 1 5 14 Establishing equipotential bonding 49 Grounding points for vacuum tube lifter Jumbo Sprint EX blower 50 5 14 1 Grounding...

Page 5: ...226 03 www schmalz com EN 5 8 Maintenance 59 8 1 General notes 59 8 2 Service table 60 8 3 Cleaning 61 8 4 Spare parts 61 8 5 Circuit diagram 61 8 6 Expert approval 61 9 Dismantling and disposal 62 9 1 Dismantling 62 9 2 Disposal 62 ...

Page 6: ...ser of a risk that could result in death or serious injury if it is not avoided WARNING Type and source of danger Consequence Remedial action Caution This warning informs the user of a risk that could result in injury if it is not avoided CAUTION Type and source of danger Consequence Remedial action Attention This warning informs the user of a risk that could result in damage to property if it is ...

Page 7: ...e Electrical voltage Flying debris Hand injury Crushing injury warning Suspended load Fall hazard Vacuum Hearing damage Warning of hot surfaces 1 3 Mandatory symbols Explanation of the mandatory symbols used in the operating and maintenance instructions Icon Description Icon Description Wear ear protectors Wear protective work shoes Wear protective gloves Disconnect mains plug Adhere to the operat...

Page 8: ...by the customer which are strictly prohibited These operating and maintenance instructions do not include the hoist attached to the jib crane e g vacuum tube lifter 1 5 General safety instructions Explosion protection 1 5 1 DANGER Ignition sources Risk of explosion When used in potentially explosive atmospheres Preclude possible ignition sources e g hot surfaces open flames hot gases or liquids me...

Page 9: ...eceived technical training and have the knowledge and experience including knowledge of applicable regulations necessary to enable them to recognize possible dangers and implement the appropriate safety measures while performing tasks The same applies to maintenance General safety regulations European standards and VDE guidelines must be observed and complied with Personnel and animals are not per...

Page 10: ... loads during lifting Where necessary connect them with equipotential bonding not included in the delivery Hoists may only be attached when hanging from the suspension bolt on the transport trolley or with articulated arm jibs to the designated mounting plate The load must be pushed and not pulled Avoid carrying the load diagonally to the transport trolley s direction of travel at an angle of more...

Page 11: ...rane can no longer be guaranteed due to unauthorized modifications or changes to the jib crane There is a risk that the load or hoist may fall crushing body parts or fatally injuring people in the vicinity Do not make any on site modifications to the system Use only the original connections mounting holes and attachment materials that have been provided WARNING Danger of death from falling if used...

Page 12: ...mospheres see chapter 1 6 Usage as a climbing aid Lifting living things Storing a suspended load WARNING Handling a load with more than one jib crane Danger of fatal injuries due to falling objects The load must be handled only with one jib crane The manufacturer must be consulted before handling a load using a combination of more than one jib crane 1 8 Requirements and instructions for installati...

Page 13: ...cialists A qualified employee is defined as an employee who has received technical training and has the knowledge and experience including knowledge of corresponding regulations necessary to enable him or her to recognize possible dangers and implement the appropriate safety measures while performing tasks A technical expert is an employee who based on his or her technical training and experience ...

Page 14: ...t with the manufacturer before starting operations The jib crane is only designed for indoor installation in closed rooms The ambient temperature must be between 0 C and 40 C please consult the manufacturer before operating at temperatures outside of this temperature range Provide internal instructions and conduct checks to ensure that the area of the workplace is always clean and tidy When mounti...

Page 15: ...oms or in an environment with an aggressive atmosphere consult with the manufacturer DANGER Risk of falling objects These can result in death or serious injury If loads are lifted higher than 1 8 m at their center of gravity special additional safeguards must be implemented in the surrounding area Workplace requirements 1 9 2 The operator s workplace is in front of the control handle on the hoist ...

Page 16: ... to break off Components failing due to incorrect loads and overloads or unauthorized modifications There is a risk of death or serious injury from hitting people in the vicinity No person may sit or stand in the danger zone of the load Only work when you have a good view of the entire working area Pay attention to other people in the working area Never transport the load above people The swivelin...

Page 17: ... caused by the jib crane However emissions may be caused by the hoist see the corresponding operating and maintenance instructions 1 13Personal protective equipment DANGER Electrostatic charge on personal protective equipment PPE Risk of explosion Wear conductive PPE that is permitted for use in explosive areas clothing shoes helmets gloves and so on When operating the jib crane always wear suitab...

Page 18: ... Product description 2 1 Description Column mounted jib crane with flat 2 1 1 jib Wall mounted jib crane with flat 2 1 2 jib Column mounted jib crane with flat 2 1 3 jib Wall mounted jib crane with flat jib 2 1 4 1 2 3 3 1 2 3 3 4 4 5 5 7 7 8 34 34 5 5 7 7 8 6 6 ...

Page 19: ...ne with 2 1 6 articulated arm jib Item Description Section 1 Crane column 2 6 2 2 Wall bracket 2 6 3 3 Pivot bearing 2 6 1 4 Flat jib 2 2 5 Transport trolley 2 6 5 6 Bracing 2 6 6 7 Energy supply vacuum hose 8 Power supply switch motor protection switch 9 Mounting plate 34 Flat jib 2 3 40 Articulated arm jib 2 4 40 40 7 9 2 3 7 9 1 3 8 ...

Page 20: ...y 2 6 5 6 Bracing 10 Flat jib 12 Cable trolley 2 6 8 14 End stop 2 6 7 15 Variable end stop 2 6 7 17 Bolt for bracing 18 Locking plate 2 3 Flat jib Item Name Section 14 End stop 2 6 7 34 Pre assembled flat jib 35 Transport trolley 2 6 5 36 Cable trolley not shown 2 6 8 38 End caps not shown 3 10 6 5 12 14 34 35 88 36 14 38 15 17 18 ...

Page 21: ...Name Section 40 Pre assembled articulated arm jib 41 Pipe elbow 42 Connection piece 2 5 Type plate When ordering spare parts submitting warranty claims or placing other inquiries regarding the hoist always provide the device type the part number the order number and the year of manufacture The type plate is firmly attached to the exterior of the jib crane The type plate contains the following info...

Page 22: ...ring 2 6 1 Item Name 3 1 Steel profile 3 2 Upper bearing plate 3 3 Bearing 3 4 Lower bearing bolt 3 6 Lower bearing plate welded 23 Safety washer 24 Bolt for upper pivot bearing 25 Machine screw M8x16 27 Disc with slot 32 Machine screw M8x16 33 Safety washer 24 15 25 23 3 3 3 4 32 3 3 27 33 15 3 1 3 6 3 2 ...

Page 23: ... clasp bracket 2 6 3 Fig 1 Fig 2 Wall bracket push through installation Wall bracket shear connector installation Fig 3 Clasp bracket Item Name 2 1 Crane bracket 2 2 Lower bearing plate 2 3 Upper bearing plate 2 4 Clamp plate 2 5 Hexagonal nut 2 6 Threaded rod 2 7 Shear connector 2 8 Mounting plate 1 2 1 3 1 4 1 1 2 1 2 1 2 1 2 3 2 2 2 3 2 2 2 3 2 2 2 6 2 5 2 4 2 5 2 7 2 8 2 6 2 5 2 4 ...

Page 24: ... 5 Transport trolley Connecting component between jib and hoist for direct connection of tube lifter without shackles Maximum load bearing capacity is 250 kg Bracings 2 6 6 Bracing for different jib lengths Item Name 6 1 Fork head 6 2 Pre assembled lower brace attachment 6 3 Tie bar 6 4 Flat bar 6 5 Bolt for fork head 17 Bolt for bracing 18 Locking plate 21 Bracket with inner bracing 6 3 6 3 6 2 6...

Page 25: ...t the end serves as a secured end stop for transport trolleys Cable trolley 2 6 8 Cable trolley enabling supply hoses for energy supply e g for tube lifter Jumbo to be taken out safely and smoothly Terminal clamps 2 6 9 Terminal clamp limits the travel area of the supply hose on the pivot bearing Slewing angle limiter 2 6 10 Slewing angle limiter SWBG ...

Page 26: ...for disconnecting the power supply of electrical components hoist etc The crane mains supply switch does not contain any protective elements A motor protection switch is used when a vacuum blower or a vacuum pump is used The motor protection switch serves to switch off the vacuum generator and simultaneously protects it The motor protection switch is designed for the connected vacuum generator No ...

Page 27: ...RS63 3000 VSL EX 110 2 000 185 14 02 01 11267 SK JU 110 3000 SRS63 3000 VSL EX 110 3 000 192 14 02 01 11261 SK JU 110 4000 SRS63 3000 VSL EX 110 4 000 199 14 02 01 11268 SK JU 140 5000 SRS63 3200 VSL EX 140 5 000 237 14 02 01 11269 WK JU 110 2000 SR63 505 VSL EX 110 2 000 54 14 03 01 10275 WK JU 110 3000 SR63 505 VSL EX 110 3 000 61 14 03 01 10274 WK JU 110 4000 SR63 505 VSL EX 110 4 000 68 14 03 ...

Page 28: ...wing delivery of the shipment damage caused by defective packaging or in transit must be reported immediately to the carrier and J Schmalz GmbH 4 2 Packaging Column mounted jib crane 2 bundles 1x crane column 1x crane jib with bracing if needed 1 pallet 80 cm x 60 cm 120 cm x 80 cm or 150 cm x 80 cm Wall mounted jib crane 1 bundle 1x crane jib with bracing if needed 1 pallet 80 cm x 60 cm 120 cm x...

Page 29: ...y cannot be damaged Avoid undertaking any other mechanical tasks in the area of the sections otherwise there is a danger that chips and dirt could get into the section grooves CAUTION Heavy components in the transportation box When opening the transportation box parts can splinter or fall This can cause crushing wounds and lacerations Wear protective work shoes S1 and work gloves safety category 2...

Page 30: ...stallation in accordance with ATEX 1999 92 EC and the national regulations before the start of operations WARNING Danger due to parts with sharp edges and heavy components There is a risk that you may cut yourself when installing the parts these may also fall or topple over thereby hitting and injuring people Wear an industrial safety helmet in accordance with EN 397 Wear work gloves in accordance...

Page 31: ...re should be no parts left over Please contact the manufacturer in the event of any problems telephone no 49 7443 2403 0 5 2 Tool list 1x combination wrench SW10 SW13 2x SW19 SW24 SW36 SW46 1x hexagon pin spanner 1x spirit level 1x torque wrench 23 1 400 Nm 1x hexagon socket wrench bit SW10 SW13 SW19 SW24 SW36 SW46 1x Phillips head PH2x100 1x flat screwdriver 1x carpet cutter 1x wire cutter 1x 10 ...

Page 32: ... mm must be used 1 Ground supply through the base plate Before erecting the crane column the line must be fed through the base plate to the hole for the switch When erecting the crane column the line must not be pinched or cut at any point 2 Ground supply from the side Before erecting the crane column the line must be pulled through the cable screw connection and bore hole into the crane column an...

Page 33: ... to insufficient bearing capacity of the floor or the wall element fastening points may shear or become loose This can result in personal injury or material damage The following applies when installing using anchors Concrete floors or walls without an insulating plate bitumen coating screed or similar must comply with the minimum requirements specified in section 1 9 1 The customer must verify the...

Page 34: ... the nuts washers and template are removed Part no of mounting kit No of anchor bolts Depth T mm L x W mm 14 04 02 10274 8 x M12 800 1 300 x 1 300 Template T Concrete groundwork Mortar belonging to mortar group III in accordance with DIN 1053 Anchoring Anchor bolts in strength grade 8 8 Reinforcement B500 Crane column Corner compression max 200 kN mm Foundation C25 30 concrete Processing and inspe...

Page 35: ...e leveled out using the included bearing plates before the anchors are positioned The best alignment when several bearing plates are stacked should always be with them turned at 90 to one another To ensure optimal performance for the jib crane the crane column must be aligned correctly Column leaning to right Raise the base plate on the right Column leaning to left Raise the base plate on the left...

Page 36: ...ane column using the machine feet Mounting the wall bracket 5 4 3 5 4 3 1 Attach push through installation with securing screws In order to attach the jib crane by means of push through installation attach a drilling template to a wall segment statical verification must be provided by the customer Pre assemble wall bracket with threaded rods 2 6 nuts 2 5 and counter plates 2 4 Do not tighten nuts ...

Page 37: ...a suitable structure for securing the crane against vertical slipping and install it accordingly Clamp the two plates 2 4 and 45 with both threaded rods 2 6 and nuts 2 5 Screw the wall bracket 2 1 onto the plate 45 Next screw the lower clamp plate 50 to the wall bracket Mount the rear clamp plate 2 4 with the two threaded rods 2 6 and nuts 2 5 After aligning the wall bracket 2 1 move the side plat...

Page 38: ... be aligned carefully Sliding direction at wall level Sliding direction at wall level Push the bracket upwards toward the front i e apply pressure from below using the adjustment screws and then fill the gap created with the bearing plates Push the bracket downwards toward the front i e apply pressure from above using the adjustment screws and then fill the gap created with the bearing plates 2 2 ...

Page 39: ...0 of the pivot bearing 3 5 Push the bolt 7 through the holes in the fork head 8 and the bracket 10 and secure it with the split pin 11 6 Be sure that the lock washers are correctly installed For a bolt diameter of 12 use size 12mbo08 Schmalz no 20 06 04 00036 For a bolt diameter of 20 use size 16mbo08 Schmalz no 20 06 04 00037 7 Move the cable trolley 12 into the rail of the crane jib 1 8 Also mov...

Page 40: ...re is no pre assembly 5 7 Pre assembly of flat jib 1 Insert the cable trolley 36 with snap hooks and strap 22 for the hose into the pre assembled flat jib 34 Quantity according to scope of delivery 2 Insert the transport trolley 35 into the flat jib 34 3 Place the fixed end stops 14 on the inside and outside of the designated holes on the flat jib 34 34 36 14 35 22 ...

Page 41: ...ews 33 Safety washer Tool list 5 8 1 1x Allan key Lower bearing mounting 5 8 2 1 Lift the crane jib with appropriate hoist to the height of the lower bearing plate of the wall bracket crane column 1 2 2 Push the bolt 3 4 in the bearing plate 3 6 until the lower edge of the bolts is flush with the lower edge of the bearing plate The plastic film 3 7 holds the bolt and the bolt cannot slip into the ...

Page 42: ...umn 1 2 until the bolt 3 4 is flush with the hole in the lower bearing plate 1 2 4 Screw one of the two machine screws 32 approx 10 mm into the bolt 3 4 from below through the lower bearing plate of the wall bracket crane column 1 2 5 Pull the bolt 3 4 down through the hole of the lower bearing plate 1 2 using the machine screw 32 3 4 32 1 2 32 ...

Page 43: ...STALLATION 30 30 01 00226 03 www schmalz com EN 43 6 Remove machine screw 32 CAUTION Falling crane components from improper mounting can result in injury Bolt 3 4 must be completely in the hole 3 4 32 3 4 ...

Page 44: ... with washers 27 and 33 and tighten with a torque wrench see section 5 4 WARNING Mounting in a way other than defined and falling parts can result in injury Special case for wall brackets with bearing heights of 500 or 750 mm Insert washer 27 1 to maintain separation 27 1 27 27 33 32 ...

Page 45: ... 1 Insert the upper bolt 24 through the hole in the upper bearing plate of the wall bracket crane column 1 3 and in the upper bearing 3 8 of the pivot bearing 2 Screw on the two M8 machine screws 25 with safety washer 23 and tighten with the torque wrench The pivot bearing of the crane jib is completely mounted 25 23 3 8 24 1 3 ...

Page 46: ...ly Align the steel profile horizontally with the hexagonal mid section of the bracing 6 using the open ended wrench For 2 bracings repeat the process on the second bracing Place the union nut on the fork head 6 1 Tighten with a drift punch or hook wrench and check to see if the thread is no longer visible Design with spanner nut Loosen both nuts 10 and 11 on the spanner nut 12 and turn them back S...

Page 47: ...wall bracket so that the surfaces 55 fit Mount the new stop nut 33 included with the washer 29 Washer 27 is not necessary for bearing heights 500 and 750 see section 5 8 Washer 27 1 is not necessary for bearing height 1 000 see section 5 8 Tighten the stop nut 53 and the screw 52 on the clamping bracket 50 using the torque wrench 80 Nm For a single sided swivel limit the clamping bracket 50 can be...

Page 48: ...oved for the relevant load bearing capacity should be used In this case the U shaped metal clamp must likewise be in the transport trolley Screw the tube lifter onto the articulated arm jib 40 with the screws Make sure that the sealing is inserted 5 13Mounting the energy supply Vacuum power supply 5 13 1 Please note the number of cable trolleys in the parts list these are specifically designated f...

Page 49: ...n vacuum supply hose vacuum generator and crane system to the customer supplied connection point for equipotential bonding Additional grounding wires should be installed on all moving parts WARNING Insufficient grounding Risk of explosion Grounding connections must be checked regularly to ensure explosion protection All grounding wires for equipotential bonding must be provided with a green and ye...

Page 50: ...stance grounding Ensure that any original accessory installed subsequently is provided with a low resistance grounding The connection points are marked with the following symbol 1 1 2 2 2 2 3 4 5 7 1 Lift tube 2 Vacuum hose each end 3 Blower to column 4 Jib to pivot bearing 5 Pivot bearing to column 6 Mobile base plate to column optional 7 Connection to customer s equipotential bonding 6 ...

Page 51: ...ounding Ensure that any original accessory installed subsequently is provided with a low resistance grounding The connection points are marked with the following symbol _________ 1 1 2 3 4 5 7 1 Lift tube 2 Vacuum hose each end 3 Ejector to compressed air hose 4 Jib to pivot bearing 5 Pivot bearing to column 6 Mobile base plate to column optional 7 Connection to customer s equipotential bonding 6 ...

Page 52: ...omplete The resistance between the measuring points must not be higher than 10 ohm the Schmalz definition of low resistance If the resistance is higher check all the grounding connections 1 From the stainless steel suction cup to the customer s equipotential bonding connection 2 From the tip of the crane jib to the customer s equipotential bonding connection All other attachment parts that are not...

Page 53: ...the media lines are functional and correctly laid Are loops and distances evenly spaced Hoist must travel evenly and easily within the entire travel area Smooth easy swiveling must be possible across the entire area The crane jib must stop in every swivel position Other energy supply 5 15 1 Please observe the specifications of the hoist manufacturer Attaching the type plate 5 15 2 The type plate i...

Page 54: ... for installation maintenance and operating staff must be read 6 1 General safety instructions regarding operation DANGER Electrostatic charge during handling Risk of explosion The operator must prevent any charge generating processes WARNING Non observance of the general safety instructions for normal operation This can result in personal injury or damage to the system The system must only be ope...

Page 55: ...perator The persons equipment necessary to secure this area must be present during the lifting transportation process The maximum load must not be exceeded Never transport the load above people Observe the working area Do not start up limit stops in normal operation Do not set down any parts on the jib crane as they will fall off when working with the jib crane 6 2 Operation The jib crane enables ...

Page 56: ... conductive parts are connected to the earth see chapter 5 14 Ensure that the vacuum generation is operating reliably Inspect safety features 6 4 Erecting the crane column on a mobile base plate in another location To position the crane in another location no workpiece may be attached to any hoist Move the hoist to the crane column and secure it to the column Swivel the crane jib into an end posit...

Page 57: ...n flames hot gases or liquids mechanically produced sparks adiabatic compression shock waves exothermic chemical reactions thermal reactions the spontaneous combustion of dust electric arcs or the discharge of static electricity or propagating brush discharges Never allow the lifting device to be hit with force spark discharge Never strike the hoist with objects or tools spark discharge Falling lo...

Page 58: ...identify and rectify the fault Problem Solution Preventive measures Trolleys only roll with great difficulty or loudly on the rails Overloading Check whether overloading has occurred now or previously and replace the affected trolley if necessary Dirt Check the bearing surfaces of the sections for dirt remove any dirt with a cloth Check the bearing surfaces of the rollers for dirt remove any trapp...

Page 59: ...lt in serious injury The system may be maintained only by trained personnel who have read and understood the operating and maintenance instructions WARNING Risk of injury from worn unmaintained parts Worn and unmaintained parts can cause damage resulting in failure of the crane system and potentially causing severe injury Observe the operating maintenance and servicing requirements specified in th...

Page 60: ...heck all load bearing parts e g suspensions for correct attachment as well as deformation wear or other damage X Check trolleys for wear rollers bolts area of hoist X X Test trolleys for ease of movement and noise level during travel X For vacuum supply line Is the supply hose in good condition not brittle not kinked no worn sections i e not leaking Are all connections secure hose clamps etc X X A...

Page 61: ...xpert approval Please observe the national accident prevention laws and regulations Make sure that inspections and tests are arranged for the required times and never operate the device if it does not have the necessary official approval documents In compliance with German accident prevention regulations the crane system must be tested once a year by an expert As a special service within Germany J...

Page 62: ...s down to a safe level from the floor For reuse store this in a suitable base without damage Loosen the wall bracket and crane column screws and bring down safely to the floor or place the crane column on the floor using a suitable lifting aid All components must be checked for damage and wear prior to reuse In Germany a re assembled jib crane requires renewed approval by a crane expert Observe th...

Page 63: ...www schmalz com 30 30 01 00226 03 09 2019 ...

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