Related Manuals for Schmalz JumboPicker-Flex
Summary of Contents for Schmalz JumboPicker-Flex
- Page 1 Ergonomic Handling Solutions Operating and Maintenance Instructions JumboPicker-Flex Jungheinrich 30.30.01.01183/00 | 11.2016 www.schmalz.com...
- Page 2 Published by © J. Schmalz GmbH, 11.2016 This document is protected by copyright. J. Schmalz 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.
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Page 3: Table Of Contents
1.10 Danger Zone Definition ....................12 1.11 Emissions ........................14 1.12 Personal protective equipment ..................14 Product Description ................... 15 Components of the vacuum tube lifter JumboPicker-Flex ..........15 Description of Operation ....................15 Controls ...........................16 2.3.1 Button Assembly......................16 2.3.2 Tube lifter operator handle ....................16 Lift tube ..........................16... - Page 4 Faults in the Industrial truck ....................46 Faults in the Scissor Arm or Tube Lifter ................46 Maintenance...................... 48 General notes ........................48 Spare parts ........................48 Checking Safety Features ....................49 Service Table........................51 Cleaning ..........................52 Removing the Covers ......................52 Vacuum Pump .........................53 4 | EN www.schmalz.com 30.30.01.01183/00...
- Page 5 Bill of Material push button unit art. code 11.05.05.00036 ............63 Bill of Material Mounting set art. code 11.05.05.00037 ..............64 Brake 11.05.05.00054 ........................65 Drawing basic frame 11.05.05.0057 ....................66 Drawing JumboFlex 11.05.05.0025 .....................67 Approved Grippers and Their Areas of Application ..............68 EC declaration of incorporation ....................69 30.30.01.01183/00 www.schmalz.com EN | 5...
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Page 6: Safety Instructions
This warning informs the user of a risk that could result in damage to property if it is not avoided. ATTENTION Type and source of danger Consequence ► Remedial action Note Important information for efficient and trouble-free use. 6 | EN www.schmalz.com 30.30.01.01183/00... -
Page 7: Warnings
Explanation of the mandatory symbols used in the operating and maintenance instructions. Mandatory Description Mandatory Description symbols symbols Wear ear protectors Wear protective work shoes Wear protective gloves Disconnect mains plug Adhere to the operating instructions Wear eye protection 30.30.01.01183/00 www.schmalz.com EN | 7... -
Page 8: Regulations In These Instructions
► These operating and maintenance instructions are specific to the items included in delivery from Schmalz. They do not take into account any modifications to the system made by the customer, which are strictly prohibited. -
Page 9: Intended Use
Intended use The JumboPicker-Flex system (hereinafter referred to as the “system”) is designed for installation on a industrial truck. It consists of a base frame with a scissor arm, to which a vacuum generator and a tube lifter JumboFlex are attached. -
Page 10: Obligations Of The Manufacturer Of The Finished Unit
Risk of injury if the load or gripper falls Unauthorized modifications or changes to the JumboPicker-Flex will compromise the integrity and function of the system. Any changes to the system not approved by J. Schmalz GmbH releases J. Schmalz GmbH from the warranty and product liability agreements. ►... -
Page 11: Requirements For The Location Of Use
Are at least 18 years of age and are mentally and physically fit for the task Have been trained in operating and maintaining the JumboPicker-Flex Have read and understood the operating instructions Have proven their ability in this regard ... -
Page 12: Danger Zone Definition
In the event that the load falls, the danger zone greatly depends on the type of load and the transport height. 12 | EN www.schmalz.com 30.30.01.01183/00... - Page 13 Do not release the tube lifter's operator handle as long as the vacuum generator is switched 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. 30.30.01.01183/00 www.schmalz.com EN | 13...
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Page 14: Emissions
Sturdy work gloves (in accordance with EN 388 safety category 2133 or better) Industrial helmet (in accordance with EN 397) Eye protection (class F) Other protective equipment as required by the situation or prescribed by national regulations. 14 | EN www.schmalz.com 30.30.01.01183/00... -
Page 15: Product Description
Product Description Components of the vacuum tube lifter JumboPicker-Flex This figure is only an example. The actual design may differ. Components Vacuum gripper JumboPicker-Flex main switch Operator handle Storage rack for operator handle Lift tube with sensor Rotary union Vertical beams (part of the... -
Page 16: Controls
The rotary union connects the jib (from the vacuum generator) with the lift tube of the vacuum tube lifter. The connection between the lift tube and rotary union has a rotating joint so that the tube lifter can be continuously rotated. 16 | EN www.schmalz.com 30.30.01.01183/00... -
Page 17: Load Suspension Devices / Suction Cups
J. Schmalz GmbH. The suction sealing lips or sealing foams are made from a robust material and, like all seals, are subject to wear. To prolong the life of the sealing elements, make sure the seals are attached properly and not subjected to lateral loads. -
Page 18: Non-Return Valve
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. 2.8.3 Non-return valve A non-return valve in the tube lifter's rotary union causes the tube lifter to be lowered slowly when the vacuum supply fails. -
Page 19: Type Plate
The type plate contains the following information: 2.10 Optional Accessories 2.10.1 Warning Light The warning light signals that the JumboPicker-Flex is in operation. 2.10.2 Scissor arm brake The brake limits the scissor arm's rotary movement. 30.30.01.01183/00 www.schmalz.com... -
Page 20: Technical Data
Technical Data JumboPicker-Flex Max. lift capacity 40 kg * Rated power 2,000 W Power consumption Temperature range 0 - 40 °C (when gripping) At pump speed Lift tube diameter 100 mm n = 800 min 92 A At pump speed... -
Page 21: Dimensions
1.270 (±50 mm) 2.020 2.025 1.930 Lmin/Lmax 320 / 2.100 2.140 2.069 2.600 2.110 1.650 1.560 (±50 mm) Tolerances H1 [mm]: -50; H2 [mm]: +50; H [mm]: +20; B [mm]: +/-5; Z [mm]: +/-50; L [mm]: -50 30.30.01.01183/00 www.schmalz.com EN | 21... -
Page 22: Delivery, Packaging And Transport
Compare the entire delivery with the supplied delivery notes to make sure nothing is missing. 4.1.3 Report damage Following delivery of the shipment, damage caused by defective packaging or in transit must be reported immediately to the carrier and J. Schmalz GmbH. Packaging The system is transported in a transportation box. - Page 23 3. Remove the partition wall. 4. Carefully remove the individual components. 5. Before detaching the base pallet from the JumboPicker-Flex, use a suitable lifting device to suspend the unit with the included sling (see section. 4.3). When unpacking the lift tube, observe the affixed warning notice.
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Page 24: Handling The System
Apply cushioning and straps to the scissor arm whenever you transport the finished unit (see figure). Note: When secured for transportation in this way, the industrial truck can be controlled only from the pedestrian control panel if positioning corrections need to be made. 24 | EN www.schmalz.com 30.30.01.01183/00... - Page 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 measures for transportation. 30.30.01.01183/00 www.schmalz.com EN | 25...
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Page 26: Installation
The industrial truck's control unit must fulfill the signal release functions defined on the specification sheet. The JumboPicker-Flex's operating voltage must be equal to the industrial truck's supply voltage. 26 | EN www.schmalz.com... -
Page 27: Work Steps
2. Attach button assembly to the industrial truck's pedestrian control panel and connect it according to the circuit diagram. 3. Attach the master fuse and connect it according to the circuit diagram. 4. Connect the tube lifter to the scissor arm. 30.30.01.01183/00 www.schmalz.com EN | 27... -
Page 28: Installation Instructions
3. Align the system over the flange plates. 4. Attach 4 screws to each flange using the corresponding nuts. Use a tightening torque of 86 Nm. Then tighten the counter nut. 28 | EN www.schmalz.com 30.30.01.01183/00... - Page 29 Attach the mounting kit (high-load fuse). High-load fuse 7. Connect the voltage supply and the plug connection for signal processing. Attach the protective glass to the beams using screws and locknuts. 30.30.01.01183/00 www.schmalz.com EN | 29...
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Page 30: Attaching The Tube Lifter
The working height is adjusted by turning the knurled nuts (2)—this adjusts the idle position of the valve. Lower tube lifter Rotate anti-clockwise: Raise tube lifter Rotate clockwise: 30 | EN www.schmalz.com 30.30.01.01183/00... -
Page 31: Before Initial Start Of Operations
EN 14238 are covered by a type test. The system must be inspected by a qualified specialist before operations are first started (after installation, maintenance or servicing). See section 1.8 (Requirements and instructions for installation, maintenance and operating staff). 30.30.01.01183/00 www.schmalz.com EN | 31... -
Page 32: Operation
People could be hit and injured. ► Never use physical force to assist the lifting process ► Do not exceed the suction cup's maximum lift capacity (see type plate). 32 | EN www.schmalz.com 30.30.01.01183/00... - Page 33 Overloading and premature wear of the lift tube ► Only lower the lift tube from the end position using the button. ► Never pull down the lift tube using physical force. ► Ensure that loads are lifted at their center of gravity. 30.30.01.01183/00 www.schmalz.com EN | 33...
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Page 34: Misuse
What to Do in an Emergency The following cases constitute an emergency: Vacuum supply failure (e.g. power failure vacuum generation switches off) Leakage (e.g.: detached hose) Force resulting from a collision 34 | EN www.schmalz.com 30.30.01.01183/00... -
Page 35: Integrated Quick-Change Adapter - Replacing The Suction Cups
If the suction cup is not properly attached to the operator handle, it can become detached during operation and fall. Risk of injury from falling parts. ► Rotate the suction cup counterclockwise until it stops. The lever (3) must lock into place. 30.30.01.01183/00 www.schmalz.com EN | 35... -
Page 36: Special Case: Mechanical Grippers
Green button (k)* generator Locking mechanisms on the jib are deactivated Switch off vacuum Red button (l) generator Locking mechanisms on the jib are activated *) Flashing green button: error message in the controller. 36 | EN www.schmalz.com 30.30.01.01183/00... -
Page 37: Releasing The Vacuum Tube Lifter From The Parked Position
This can cause injuries 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. 30.30.01.01183/00 www.schmalz.com EN | 37... -
Page 38: Handling Loads
Suction is applied to the load. The load begins to hover above the ground. Always maintain contact with the operator handle and button. The load reaches its highest point when the button has been released completely. 38 | EN www.schmalz.com 30.30.01.01183/00... -
Page 39: Lowering And Setting Down Loads
► 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). 30.30.01.01183/00 www.schmalz.com EN | 39... -
Page 40: Guiding Loads
The tube lifter can be rotated continuously at the rotary union (suspension point). Loads gripped below the operator handle can also be rotated continuously and locked in steps of 90° using the latching bolt (n). Rotary union Operator handle 40 | EN www.schmalz.com 30.30.01.01183/00... -
Page 41: Parking The Vacuum Tube Lifter
3. Pull the spherical head down and move the operator handle’s retaining knob into the locked position. 4. Switch off vacuum generator. 5. The safety switches on the scissor arm are activated. 6. Engage the jib in both locking mechanisms. 30.30.01.01183/00 www.schmalz.com EN | 41... -
Page 42: Release Signals For The Industrial Truck
Safety switch on the scissor arm (2) locked in place Safety switch on the pivot bearing (4) locked in place Operator handle (3) locked in parked position (safety switch), retaining net attached No load on tube lifter (vacuum switch) 42 | EN www.schmalz.com 30.30.01.01183/00... -
Page 43: Conditions For Controlling The Industrial Truck While Walking Alongside
6.9.2 Conditions for Controlling the Industrial truck While Walking Alongside Scissor arm extended to max. of 700 mm No load on tube lifter <= 700mm Sensor Signal Scissor arm (2) extended <= 700 mm No load on tube lifter (vacuum switch) 30.30.01.01183/00 www.schmalz.com EN | 43... -
Page 44: Raising And Lowering The Fork Arms
Fork arms lowering until safety distance With load When the vacuum generator is on and a load attached: Driver control panel Pedestrian control panel No function Fork arms raising locked Fork arms lowering until safety distance 44 | EN www.schmalz.com 30.30.01.01183/00... -
Page 45: Storing The Tube Lifter
(0 °C to + 15 °C, max. 25 °C) that is dark, dry, low in dust and offers protection from the weather, ozone and drafts. They should also be free of tension (e.g. stacked appropriately to avoid deformation). 30.30.01.01183/00 www.schmalz.com EN | 45... -
Page 46: Troubleshooting
The load cannot be lifted; use a rigid. different suction cup for non-rigid parts. The load is too heavy Decrease the load; use a different Ensure that the load to be lifted hoist. does not exceed the maximum lift capacity 46 | EN www.schmalz.com 30.30.01.01183/00... - Page 47 Loose line/plug connections. Safety switch will not release Push scissor arm / lift tube from locked position toward the safety switch Error message on control panel Restart system. Error occurs again. Consult with the manufacturer 30.30.01.01183/00 www.schmalz.com EN | 47...
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Page 48: Maintenance
Observe the operating, maintenance and servicing requirements specified in these operating instructions. Spare parts Refer to bill of material in the appendix. The replacement of original parts by parts of other origin releases the manufacturer from its liability. 48 | EN www.schmalz.com 30.30.01.01183/00... -
Page 49: Checking Safety Features
Close it multiple times to check that the safety feature works. Check the sensor query signals for the vacuum switch (3B1), jib extension (3B2) and Jumbo storage rack (3B3). 30.30.01.01183/00 www.schmalz.com EN | 49... - Page 50 (e.g. component fault, data error or short circuit at the outputs) Internal error LED not illuminated LED illuminated Explanation of 10 Hz (8 s) LED flashes for 8 seconds at 10 Hz symbols LED flashes three times Any state 50 | EN www.schmalz.com 30.30.01.01183/00...
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Page 51: Service Table
Is the seal of the tube holder/gripper OK? Does the suction cup still fit tightly; and is it working properly? Are the sealing lips even? Replace as needed Is the filter fleece in the suction cup clean? 30.30.01.01183/00 www.schmalz.com EN | 51... -
Page 52: Cleaning
Pull the hood backward out of the holding brackets. Remove two screws on bottom Remove the two hexagonal nuts and washers Remove the cable bushing and cables from the hole in the hood Lift up to remove the hood. 52 | EN www.schmalz.com 30.30.01.01183/00... -
Page 53: Vacuum Pump
Check the functioning and wear of the scissor arm brake once a year. Replace the brake elements if necessary (see appendix). After replacing the brake elements adjust the brake pressure with the help of the threaded rod so that the scissor arm movement is limited. 30.30.01.01183/00 www.schmalz.com EN | 53... -
Page 54: Expert Approval
In order to comply with accident prevention regulations in Germany, the crane system and the system ordered must be tested once a year by an expert. 54 | EN www.schmalz.com 30.30.01.01183/00... -
Page 55: Decommissioning And Disposal
For proper disposal, please contact a company specializing in the disposal of technical goods and instruct it to observe the prevailing disposal and environmental regulations. The manufacturer of the device will be happy to assist you in finding a suitable company. 30.30.01.01183/00 www.schmalz.com EN | 55... -
Page 56: Appendix
Appendix Design Drawings and Bill of Material 56 | EN www.schmalz.com 30.30.01.01183/00... - Page 57 30.30.01.01183/00 www.schmalz.com EN | 57...
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Page 59: Bill Of Material Layout Drawing 11.05.05.00064
270 10.07.08.00025 sealing ring 280 10.07.01.00008 dust filter 290 10.07.08.00026 sealing ring 300 12.02.18.00862 hose sleeve 310 11.05.05.00073 welded metal part 320 10.07.10.00088 hose clamp 330 20.13.03.00057 pipe clamp 340 20.03.02.00004 hexagon nut - low form 30.30.01.01183/00 www.schmalz.com EN | 59... - Page 60 650 20.01.03.00030 counter sink screw 660 21.01.09.00077 proximity switch 670 20.05.02.00004 tension pin 680 21.05.02.00050 cable sleeve 690 20.01.02.00501 machine screw M5x10 700 11.05.05.00056 mechanical locking system 710 21.04.05.00079 connection cable 720 11.05.05.00055 sealing plate 60 | EN www.schmalz.com 30.30.01.01183/00...
- Page 61 880 10.08.03.00308 Hose sleeve 890 20.01.02.00503 Machine screw 900 10.07.09.00036 vacuum hose 910 10.07.09.00036 vacuum hose 920 10.07.09.00036 vacuum hose 930 10.07.09.00036 vacuum hose 940 11.05.05.00063 Unit with pushbutton 950 11.05.05.00037 mounting set *) Not shown 30.30.01.01183/00 www.schmalz.com EN | 61...
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Page 62: Bill Of Material Mechanical Locking System Art. Code 11.05.05.00009
Qty. 11.05.05.00044 square tube (maschined);ROHR 6 11.05.05.00047 slide;FUEH-SCHL 55x2 11.05.05.00051 threaded rod (through);GEW- 20.01.01.01518 hexagon head screw;SCHR 4017 M6x3 11.05.05.00046 flat rod (machined) ;FL-STAB 2 20.03.01.00004 hexagon nut;MUTT 4032 M6x5.2 11.05.05.00052 ball handle;KUG-GRIF 319 M6-IGx9 62 | EN www.schmalz.com 30.30.01.01183/00... -
Page 63: Bill Of Material Push Button Unit Art. Code 11.05.05.00036
134.5x57x141 EP; 20.01.03.00030 counter sink screw (f. steel 20.10.03.00015 counter sink screw (f. steel 20.01.03.00031 counter sink screw (f. steel 20.06.01.00031 washer (standard);SCHE 9021 M4 ST-H Bill of Material push button unit art. code 11.05.05.00036 30.30.01.01183/00 www.schmalz.com EN | 63... -
Page 64: Bill Of Material Mounting Set Art. Code 11.05.05.00037
L-shaped metal seet, BLEC-LFOR 50x55x125 20.01.02.01003 Machine screw, CHR 4762 M6x16 ST-8.8 VZ 20.06.01.00004 Washer (Norm), SCHE 7090 M6 ST-HV 20.01.02.00262 Machine screw, SCHR 4762 M4x8 ST-8.8 VZ 21.05.04.00090 Accessories, ZUB VM fuse holder 21.05.04.00055 Fuse, SICH-150 64 | EN www.schmalz.com 30.30.01.01183/00... -
Page 65: Brake 11.05.05.00054
Brake 11.05.05.00054 Pos Artikel-Nummer Bezeichnung DE Qty. 14.02.10.00101 Brake element 30.30.01.01183/00 www.schmalz.com EN | 65... -
Page 66: Drawing Basic Frame 11.05.05.0057
Drawing basic frame 11.05.05.0057 Vertical beams (part of the industrial truck, not included in delivery from Schmalz) 66 | EN www.schmalz.com 30.30.01.01183/00... -
Page 67: Drawing Jumboflex 11.05.05.0025
Drawing JumboFlex 11.05.05.0025 30.30.01.01183/00 www.schmalz.com EN | 67... -
Page 68: Approved Grippers And Their Areas Of Application
Four head suction 11.01.42.01418 Cardboard boxes, sheets and non-rigid parts. The individual suction plates are continuously adjustable along the main and cross beam. Suspension hooks 11.01.42.01419 Buckets, jugs and other loads with suspension points 68 | EN www.schmalz.com 30.30.01.01183/00... -
Page 69: Ec Declaration Of Incorporation
EC declaration of incorporation 30.30.01.01183/00 www.schmalz.com EN | 69... - Page 70 70 | EN www.schmalz.com 30.30.01.01183/00...
- Page 71 In short, easy-to-understand videos we explain the comprehensive functions offered by our products. Take a look, it’s worth it! www.schmalz.com/gewusst-wie Further services ranging from consultation to training can be found at www.schmalz.com/services J. Schmalz GmbH Aacher Strasse 29 72293 Glatten, Germany Tel. +49 (0)7443 2403-0 Fax +49 (0)7443 2403-259 schmalz@schmalz.de...