Schmalz JumboPicker-Flex Operating And Maintenance Instructions Manual Download

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Ergonomic Handling Solutions

Operating and Maintenance Instructions

JumboPicker-Flex Jungheinrich

30.30.01.01183/00 | 11.2016

Summary of Contents for JumboPicker-Flex

Page 1: ...www schmalz com Ergonomic Handling Solutions EN Operating and Maintenance Instructions JumboPicker Flex Jungheinrich 30 30 01 01183 00 11 2016...

Page 2: ...hmalz GmbH retains 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 a...

Page 3: ...mponents of the vacuum tube lifter JumboPicker Flex 15 2 2 Description of Operation 15 2 3 Controls 16 2 3 1 Button Assembly 16 2 3 2 Tube lifter operator handle 16 2 4 Lift tube 16 2 5 Rotary Union 1...

Page 4: ...36 6 6 2 Releasing the Vacuum Tube Lifter from the Parked Position 37 6 7 Handling Loads 38 6 7 1 Lifting Loads 38 6 7 2 Lowering and setting down loads 39 6 7 3 Picking Up Vertically and Depositing...

Page 5: ...rawings and Bill of Material 56 Bill of Material layout drawing 11 05 05 00064 59 Bill of Material mechanical locking system art code 11 05 05 00009 62 Bill of Material storage rack Jumbo art code 11...

Page 6: ...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 inj...

Page 7: ...tage Flying debris Hand injury Crushing injury warning Suspended load Fall hazard Vacuum Hearing damage Falling parts Hot surfaces 1 3 Mandatory symbols Explanation of the mandatory symbols used in th...

Page 8: ...moval only when the device is in an idle depressurized state General safety regulations European standards and VDE guidelines must be observed and complied with Personnel and animals are not permitted...

Page 9: ...e vacuum tube lifter Risk of accidents The designs of the required suction cups must be verified by calculations Relevant safety factors must be taken into account according to standard DIN EN 14238 T...

Page 10: ...site modifications to the tube lifter Use only the original connections mounting holes and attachment materials that have been provided Make electrical connections according to circuit diagram see ap...

Page 11: ...times WARNING Risk of injury due to misuse or non observance of warning and safety notices Persons could be harmed Only for use by authorized and trained personnel Follow local regulations on work br...

Page 12: ...hat the operator can continuously monitor the entire workspace Provide internal instructions and conduct checks to ensure that the area around the workplace is always clean and tidy 1 10 Danger Zone D...

Page 13: ...r zone of the tube lifter 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 Loads should always be...

Page 14: ...time of 60 minutes before working on the vacuum generator CAUTION Risk of eye injury All vacuum generators generate an exhaust air flow Depending on the purity of the ambient air this exhaust air can...

Page 15: ...0 Storage rack for operator handle with sensor 11 Vertical beams part of the industrial truck not included in delivery from Schmalz 2 2 Description of Operation The system is used for fast and frequen...

Page 16: ...of the load which is achieved by changing the vacuum in the lift tube Button e has 2 positions 1 Lower the load 2 Release eject the load 2 4 Lift tube The lift tube transfers the vacuum to the suctio...

Page 17: ...y of environmental conditions To ensure that the tube lifter remains in optimum condition at all times it is important to check and if necessary replace the suction sealing lips at regular intervals s...

Page 18: ...ssor arm is in the parked position Vacuum sensor 3B1 Sensor for jib extension 3B2 The JumboPicker Flex storage rack sensor 3B3 detects when the tube lifter is properly secured in the parked position A...

Page 19: ...tifying the system It must always be specified when ordering replacement parts making warranty claims or other inquiries about the system The type plate contains the following information 2 10 Optiona...

Page 20: ...00 x 200 mm Swivel angle Approx 115 Max load dimensions 2 000 x 800 mm Sound level 74 dB A Max lift speed 0 5 to 1 m s Signal output See circuit diagram Pump for vacuum generation max working vacuum o...

Page 21: ...mm mm mm Hges 2 730 H3 30 Z1 1 270 50 mm HA 272 H4 2 020 T1 341 HP 385 H 2 025 B 810 HS 1 930 H5 388 Lmin Lmax 320 2 100 H 2 140 H6 2 069 HUK 2 600 H1 2 110 H7 1 650 H2 550 Z 1 560 50 mm Tolerances H...

Page 22: ...must be reported immediately to the carrier and J Schmalz GmbH 4 2 Packaging The system is transported in a transportation box The packaging material must be disposed of in accordance with national la...

Page 23: ...ot to damage any of the components when opening the packaging with knives or blades 2 Open the cover so that you can clearly see the locations of the individual assemblies 3 Remove the partition wall...

Page 24: ...materials must be secured in accordance with country specific regulations BAG guidelines in Germany Wear personal protective clothing CAUTION Load suspension outside the center of gravity Danger from...

Page 25: ...z com EN 25 CAUTION Storing the finished unit Risk of corrosion Apply protective or anti corrosion film to the system see figure The manufacturer of the finished unit defines any additional protective...

Page 26: ...x wire cutter 1x bolt cutter 1x spirit level 1x soft head hammer 1x cable stripper 1x crimping pliers 5 2 Tightening Torques Unless otherwise specified the following tightening torques apply for assem...

Page 27: ...ock until the system is assembled 5 3 2 Work Steps 1 Mount the base frame attach to industrial truck according to drawings 11 05 05 00004 11 05 05 00057 see appendix 2 Attach button assembly to the in...

Page 28: ...11 onto the industrial truck s chassis until the drill holes line up 2 Guide two flat bars into the top of each beam 3 Insert screws and tighten them until contact is made 4 Do not tighten the screws...

Page 29: ...r to the beams using welding studs 3 Use the plugs to connect the 2 button assemblies on the left and right of the industrial truck according to the circuit diagram 4 Run the wires inside the industri...

Page 30: ...touch rub against or get caught up in other parts or it can prematurely wear or tear When attaching the hose lines make sure they remain in a coil 5 5 Setting the Hovering Position 1 Screw the counte...

Page 31: ...5 6 Before Initial Start of Operations Installation of the system is complete after 3 to 4 successful test runs with a load The checks required in Europe before the start of operations in accordance w...

Page 32: ...ify the faults 6 2 Safety Instructions for Operation WARNING Risk of injury due to high vacuum and flow rate Hair skin body parts and items of clothing can be sucked in Closely fitting clothing and a...

Page 33: ...on The working area must be secured by the operator The persons equipment necessary to secure this area must be present during the lifting transportation process WARNING Uncontrolled gripper movements...

Page 34: ...parts of the industrial truck Dragging or carrying loads at an angle Never grip immovable equipment parts of the building the supporting surface Never grip parts of the industrial truck Avoid carryin...

Page 35: ...event of danger All persons must leave the danger zone immediately 6 5 Integrated Quick Change Adapter Replacing the Suction Cups CAUTION If the suction cup is not properly attached to the operator h...

Page 36: ...osition and in the retaining net Ensure that it cannot suck onto or grip anything else A minimum distance of approx 10 cm must be maintained between the suction cup and the supporting surface The suct...

Page 37: ...ignal that the scissor arm is in the parked position The switch is inactive when the unit is operational This means the LED will be light up red When you have finished the lifting task perform the pre...

Page 38: ...hat the path is clear and there are no trip hazards Loads should always be transported as close to the floor as possible Adapt the transport speed according to conditions 6 7 1 Lifting Loads Positioni...

Page 39: ...f fingers becoming pinched in the shaft of the joint Always keep one hand on the operator handle Use the other hand to support the swiveling process position your hand on the side of the load Lowering...

Page 40: ...load The shock can dislodge the load and cause injuries The operator must ensure that the work area shown is observed 6 7 5 Continuous rotatability The tube lifter can be rotated continuously at the...

Page 41: ...ies to the driver or to others Properly suspend the operator handle in the retaining net and then secure it in the parked position The scissor arm s locking mechanisms must be secured 1 Move the tube...

Page 42: ...nging the preset parameters is prohibited 6 9 1 Conditions for Fast Travel with Industrial truck at Vmax Controlling from the Driver s Cab Vacuum pump 1 switched off Scissor arm 2 in the parked positi...

Page 43: ...9 2 Conditions for Controlling the Industrial truck While Walking Alongside Scissor arm extended to max of 700 mm No load on tube lifter Sensor Signal Scissor arm 2 extended 700 mm 3B2 0 No load on tu...

Page 44: ...ety switches are activated 4 Jib is locked into both safety switches Driver control panel Fork arms raising Fork arms lowering to the lowest position Pedestrian control panel Fork arms raising Fork ar...

Page 45: ...suction cup must be detached and stored separately ACHTUNG Damage of the suction cup Suction cup will be deformed will age prematurely and fail Store suction cups according to the storing recommandati...

Page 46: ...uck inspected by a qualified specialist 8 2 Faults in the Scissor Arm or Tube Lifter If you cannot lift the load check the following items and fix problems as needed Problem Solution Preventive measur...

Page 47: ...ed but the tube lifter cannot lift porous loads Consult with the manufacturer Consult with the manufacturer While the tube lifter is in use the operator handle of the tube lifter remains in the upper...

Page 48: ...r arm against uncontrolled movement This does not apply if the maintenance and inspection work can only be carried while the unit is switched on e g function tests of the electrical system or safety f...

Page 49: ...wer slowly The load may only be released when it is near the floor it must not be dropped abruptly X X X Safety switch 4S1 see table below Switch functioning properly Secure attachment of the componen...

Page 50: ...t secured Open Off Off Off 1 x O Normal operation jib open Error display X Off Off Off 2 x Input error e g missing test impulse illogical switching state from previous element in switch chain X Off Of...

Page 51: ...untwisted X X Tube lifter Is the lift tube in good condition not porous no worn sections no holes i e not leaking X X Is the lift tube attached properly correct position correctly sealed X Can the ro...

Page 52: ...d and lowered when not carrying a vacuum gripped load X X Does the non return valve work when there is a power failure X X X Is the UVV German Accident Prevention Regulations test label current X Gene...

Page 53: ...s Ensure that the filter is installed correctly WARNING Risk of injury from falling loads If the filter screen in the suction cup is not cleaned regularly the vacuum at the suction cup is reduced and...

Page 54: ...egulations Make sure that inspections and tests are arranged for the required times and never operate equipment if it does not have the relevant official approval documents In order to comply with acc...

Page 55: ...the lines and hoses Use suitable lifting equipment to support the base frame and scissor arm see section 4 3 Disconnect from the industrial truck Set the system down on the floor 10 2 Disposal Only qu...

Page 56: ...56 EN www schmalz com 30 30 01 01183 00 Appendix Design Drawings and Bill of Material...

Page 57: ...30 30 01 01183 00 www schmalz com EN 57...

Page 58: ...58 EN www schmalz com 30 30 01 01183 00...

Page 59: ...ck washer M5 7 150 11 05 05 00009 mechanical locking system 1 160 14 02 10 00151 mounting bracket 1 170 20 01 02 01013 machine screw M6x55 4 180 20 06 01 00004 washer standard M6 16 190 20 03 08 00004...

Page 60: ...08 02 00201 screw plug connection straight 1 510 20 03 09 00012 hexagon nut pipe thread 1 520 10 07 09 00002 vacuum hos 1 530 14 02 10 00052 cover complex 1 540 14 02 10 00153 cover complex 1 550 10...

Page 61: ...05 05 00062 pipe 1 810 20 05 07 00010 setscrew M6x10 2 820 21 05 02 00079 cable channel 1 830 27 03 01 00717 adhesive label 2 840 27 03 01 00471 adhesive label 1 850 21 04 06 00341 connection cable 1...

Page 62: ...1 Bill of Material storage rack Jumbo art code 11 05 05 00050 Pos Art Code Discription Qty 1 11 05 05 00044 square tube maschined ROHR 6 1 2 11 05 05 00047 slide FUEH SCHL 55x2 1 3 11 05 05 00051 thr...

Page 63: ...M5x55 2 13 20 08 02 00140 pressure spring DRUCK FED 0 7x7 3 41 2 14 20 06 01 00018 washer standard SCHE 134 M5 ST VZ 4 15 11 05 05 00045 u shaped metal sheet BLEC UFOR 68 5x84 5 1 16 21 01 09 00015 pr...

Page 64: ...label AUFK 38 4x40 3 9010 TR 1 7 20 10 03 00041 counter sink screw f Kunst 8 8 21 01 03 00072 contact block KONT BLO 3 9 21 01 03 00102 contact block KONT BLOC 1 2 Bill of Material Mounting set art co...

Page 65: ...30 30 01 01183 00 www schmalz com EN 65 Brake 11 05 05 00054 Pos Artikel Nummer Bezeichnung DE Qty 14 02 10 00101 Brake element 2...

Page 66: ...66 EN www schmalz com 30 30 01 01183 00 Drawing basic frame 11 05 05 0057 Vertical beams part of the industrial truck not included in delivery from Schmalz...

Page 67: ...30 30 01 01183 00 www schmalz com EN 67 Drawing JumboFlex 11 05 05 0025...

Page 68: ...plastic sacks raw rubber bales shrink wrapped packages etc Double suction cup 11 01 42 01243 Clamped glued strapped or open cardboard boxes also for crates sheets etc Double suction cup with adjustab...

Page 69: ...30 30 01 01183 00 www schmalz com EN 69 EC declaration of incorporation...

Page 70: ...70 EN www schmalz com 30 30 01 01183 00...

Page 71: ...ing instructions and CAD data and get comprehensive information about our products and services www schmalz com dokumentationen How to videos In short easy to understand videos we explain the comprehe...

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