Summary of Contents for Schmalz SK-JU-110-2000-SRS63-3000-VSL-EX
- Page 1 Ergonomic Handling Solutions Operating and Maintenance Instructions Jib Cranes for Potentially Explosive Atmospheres 30.30.01.00226/03 | 09.2019 www.schmalz.com...
- Page 2 Published by © J. Schmalz GmbH, 09.2019 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
Transport trolley.......................24 2.6.6 Bracings ...........................24 2.6.7 End stops .........................25 2.6.8 Cable trolley ........................25 2.6.9 Terminal clamps ......................25 2.6.10 Slewing angle limiter .......................25 2.6.11 Attachments ........................26 2.6.12 Electrical switches ......................26 Technical Data ....................27 Delivery, packaging and transport ..............28 www.schmalz.com... - Page 4 Erecting the crane column on a mobile base plate in another location......56 What to do in an emergency ...................57 6.5.1 Production of an ignition source in a potentially explosive atmosphere......57 6.5.2 Falling load ........................57 Troubleshooting ....................58 4 | EN www.schmalz.com 30.30.01.00226/03...
- Page 5 SAFETY INSTRUCTIONS Maintenance...................... 59 General notes ........................59 Service table ........................60 Cleaning ..........................61 Spare parts ........................61 Circuit diagram ........................61 Expert approval .......................61 Dismantling and disposal .................. 62 Dismantling ........................62 Disposal ...........................62 30.30.01.00226/03 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 Important information for efficient and trouble-free use. 6 | EN www.schmalz.com 30.30.01.00226/03... -
Page 7: Warnings
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 operating instructions Wear eye protection 30.30.01.00226/03 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 J. Schmalz GmbH. They do not take into account any modifications to the jib crane made by the customer, which are strictly prohibited. -
Page 9: Fundamental Safety Instructions
► 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. ►... -
Page 10: Intended Use
SAFETY INSTRUCTIONS 1.6 Intended use Schmalz jib cranes are intended exclusively for the transporting of loads. The loads are raised using special hoists (e.g. vacuum tube lifter Jumbo). The jib crane is intended only for commercial use. The order confirmation defines the specific use of the jib crane. - Page 11 This can result in broken bones, serious injury or even death. ► Use of the jib crane as a climbing aid or to transport humans or animals is prohibited! 30.30.01.00226/03 www.schmalz.com EN | 11...
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Page 12: Non-Intended Use
Errors during operation, maintenance or repair work Risk of explosion ► The operator must ensure that the personnel employed receive special training for performing work in potentially explosive atmospheres. Comply with the applicable national regulations. 12 | EN www.schmalz.com 30.30.01.00226/03... - Page 13 The competency of those responsible must be assured. WARNING Risk of injury due to misuse or non-observance of warning and safety notices Persons could be harmed ► The equipment must be used by trained personnel only. 30.30.01.00226/03 www.schmalz.com EN | 13...
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Page 14: Installation Location/Workplace Requirements
Concrete floor without screed, bitumen floor covering or similar. Concrete grade B25-B55, C20/25 or C50/60 Min. concrete thickness 130 mm with min. 200 mm edge spacing. Min. concrete thickness 200 mm with min. 100 mm edge spacing. 14 | EN www.schmalz.com 30.30.01.00226/03... -
Page 15: Workplace Requirements
The operator’s workplace is in front of the control handle on the hoist. It must be ensured that 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. 30.30.01.00226/03 www.schmalz.com EN | 15... -
Page 16: Danger Zone Definition
Never release the control handle of the hoist while lifting a load. ► 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. 16 | EN www.schmalz.com 30.30.01.00226/03... -
Page 17: Operating Range Of The Jib Crane
Sturdy work gloves (in accordance with EN 388 safety category 2133 or better) Industrial helmet (in accordance with EN 397) Other protective equipment as required by the situation or prescribed by national regulations. 30.30.01.00226/03 www.schmalz.com EN | 17... -
Page 18: Product Description
PRODUCT DESCRIPTION Product description 2.1 Description 2.1.1 Column-mounted jib crane with flat 2.1.2 Wall-mounted jib crane with flat 2.1.3 Column-mounted jib crane with flat 2.1.4 Wall-mounted jib crane with flat jib 18 | EN www.schmalz.com 30.30.01.00226/03... -
Page 19: Column-Mounted Jib Crane With Articulated-Arm Jib
Crane column 2.6.2 Wall bracket 2.6.3 Pivot bearing 2.6.1 Flat jib Transport trolley 2.6.5 Bracing 2.6.6 — Energy supply, vacuum hose — Power supply switch / motor-protection switch — Mounting plate Flat jib Articulated-arm jib 30.30.01.00226/03 www.schmalz.com EN | 19... -
Page 20: Flat Jib
Variable end stop 2.6.7 — Bolt for bracing — Locking plate 2.3 Flat jib Item Name Section. End stop 2.6.7 — Pre-assembled flat jib Transport trolley 2.6.5 Cable trolley (not shown) 2.6.8 — End caps (not shown) 20 | EN www.schmalz.com 30.30.01.00226/03... -
Page 21: Articulated-Arm Jib
The type plate is firmly attached to the exterior of the jib crane. The type plate contains the following information: Type Part no. P/N: www.schmalz.com Order number: Year of manufacture: Capacity: Weight: Made in Germany J. Schmalz GmbH Johannes-Schmalz-Str. 1 72293 Glatten Germany 30.30.01.00226/03 www.schmalz.com EN | 21... -
Page 22: Description Of Component Parts
Pivot bearing Item Name Steel profile Upper bearing plate Bearing Lower bearing bolt Lower bearing plate, welded Safety washer Bolt for upper pivot bearing Machine screw M8x16 Disc with slot Machine screw M8x16 Safety washer 22 | EN www.schmalz.com 30.30.01.00226/03... -
Page 23: Crane Column
Fig.2 Wall bracket - push-through installation Wall bracket - shear connector installation Fig.3 Clasp bracket Item Name Crane bracket Lower bearing plate Upper bearing plate Clamp plate Hexagonal nut Threaded rod Shear connector Mounting plate 30.30.01.00226/03 www.schmalz.com EN | 23... -
Page 24: Steel Profile
(without shackles). Maximum load-bearing capacity is: 250 kg. 2.6.6 Bracings Bracing for different jib lengths Item Name Fork head Pre-assembled lower brace attachment Tie bar Flat bar Bolt for fork head Bolt for bracing Locking plate Bracket with inner bracing 24 | EN www.schmalz.com 30.30.01.00226/03... -
Page 25: End Stops
Cable trolley, enabling supply hoses for energy supply, e.g. for tube lifter Jumbo, to be taken out safely and smoothly. 2.6.9 Terminal clamps Terminal clamp, limits the travel area of the supply hose on the pivot bearing. 2.6.10 Slewing angle limiter Slewing angle limiter SWBG 30.30.01.00226/03 www.schmalz.com EN | 25... -
Page 26: Attachments
The crane mains supply switch does not contain generator and simultaneously protects it. The any protective elements. motor protection switch is designed for the connected vacuum generator. No further consuming devices may be connected to the outlet of the motor protection switch. 26 | EN www.schmalz.com 30.30.01.00226/03... -
Page 27: Technical Data
The load classes correspond to the nominal loads of the tube lifters, the weight of the tube lifters is already taken into account. Type Max. lift capacity [kg] L [mm] Weight [kg] Part no. SK-JU-110-2000-SRS63-3000-VSL-EX 2,000 14.02.01.11267 SK-JU-110-3000-SRS63-3000-VSL-EX 3,000 14.02.01.11261 SK-JU-110-4000-SRS63-3000-VSL-EX 4,000 14.02.01.11268... -
Page 28: Delivery, Packaging And Transport
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. 4.2 Packaging Column-mounted jib crane: 2 bundles (1x crane column, 1x crane jib with bracing if needed) -
Page 29: Removal Of Crane Components
► Observe the instructions for removing the system from the transportation box The packaging material must be disposed of in accordance with national laws and guidelines. Labeled transport aids and safety mechanisms must be removed. 30.30.01.00226/03 www.schmalz.com EN | 29... -
Page 30: Installation
An explosion protection representative commissioned by the operator must check and approve the entire plant (the items included in the delivery from J. Schmalz GmbH and the customer-side installation) in accordance with ATEX 1999/92 EC and the national regulations before the start of operations. -
Page 31: Preparation Of Parts
1x plumb with centering discs (included in scope of delivery) 1x plastic hammer 1x hammer drill 1x percussion drill ø14 mm, minimum 200 mm long 1x blow gun (unoiled compressed air) 1x cartridge gun 30.30.01.00226/03 www.schmalz.com EN | 31... -
Page 32: Electrical Installation
INSTALLATION 5.3 Electrical installation You can mount only the on/off switch (8.1) on the Schmalz crane column (which is permitted for potentially explosive atmospheres; see section 2.6.12). DANGER Source of ignition with the motor-protection switch (8.2) Risk of explosion ►... -
Page 33: Mechanical Installation
M12x100) with mortar cartridges (any other shear connectors must have the same properties as the aforementioned model or improved properties). Instructions regarding installation of the shear connectors can be found on their packaging. 30.30.01.00226/03 www.schmalz.com EN | 33... - Page 34 DIN EN 206 Position of the pivot Corner compression: max 200 kN/mm² Part no. of mounting kit No. of anchor bolts Depth T [mm] L x W [mm] 14.04.02.10274 8 x M12 1,300 x 1,300 34 | EN www.schmalz.com 30.30.01.00226/03...
- Page 35 Column leaning to right: Raise the base plate on Column leaning to left: Raise the base plate on the right the left Pillar leaning backwards: Column leaning forwards: Raise the base plate Raise base plate from the back from the front 30.30.01.00226/03 www.schmalz.com EN | 35...
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Page 36: Erecting The Crane Column With Mobile Base Plate
(2.5) and counter plates (2.4). Do not tighten nuts. Align wall bracket (21) as described in section 5.4.3.4. Tighten and lock nuts (2.5) to the torque specified. Mounting height Drill diameter 505 mm 160 mm 645 mm 18 mm 36 | EN www.schmalz.com 30.30.01.00226/03... - Page 37 (31) onto the beam and tighten them until they are without play. The screws must be tightened with the appropriate torque (see section 5.4). The customer must provide a suitable structure for securing the crane against vertical slipping and install it accordingly. 30.30.01.00226/03 www.schmalz.com EN | 37...
- Page 38 38 | EN www.schmalz.com 30.30.01.00226/03...
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Page 39: Mounting The Flat Jib
(11). 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) Move the cable trolley (12) into the rail of the crane jib (1). -
Page 40: Pre-Assembly Of Articulated-Arm Jib
(34). Quantity according to scope of delivery. Insert the transport trolley (35) into the flat jib (34). Place the fixed end stops (14) on the inside and outside of the designated holes on the flat jib (34). 40 | EN www.schmalz.com 30.30.01.00226/03... -
Page 41: Mounting The Crane Jib On The Crane Column Or Wall Bracket
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 pivot bearing. 30.30.01.00226/03 www.schmalz.com EN | 41... - Page 42 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). 42 | EN www.schmalz.com 30.30.01.00226/03...
- Page 43 INSTALLATION 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. 30.30.01.00226/03 www.schmalz.com EN | 43...
- Page 44 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. 44 | EN www.schmalz.com 30.30.01.00226/03...
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Page 45: Upper Bearing Mounting
(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. 30.30.01.00226/03 www.schmalz.com EN | 45... -
Page 46: Aligning The Steel Crane Jib For Column-Mounted Or Wall-Mounted Jib Crane
Loosen both nuts (10 and 11) on the spanner nut (12) and turn them back. Set the length of the bracing (7) using the spanner nut (12). Check whether the threaded rods (14 and 15) are visible in the holes (13) and then tighten using the nuts. 46 | EN www.schmalz.com 30.30.01.00226/03... -
Page 47: Mounting The Slewing Angle Limiter
Swivel the jib into an end position. Slide the limit stop angle (55) onto the jib and clamp tight. Swivel the jib to the other end position and repeat the procedure. 30.30.01.00226/03 www.schmalz.com EN | 47... -
Page 48: Mounting The Crane Buffer For Crane Rails
For jib cranes with crane rails: Insert the cable trolley into the crane rail as specified in the parts list. A variable terminal clamp must be properly installed at the ends of the crane rail. Insert snap hooks on the hose into the clip bolts of the cable trolley and terminal clamp. 48 | EN www.schmalz.com 30.30.01.00226/03... -
Page 49: Establishing Equipotential Bonding
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 yellow cable. Minimum cross section 4 mm². 30.30.01.00226/03 www.schmalz.com EN | 49... -
Page 50: Grounding Points For Vacuum Tube Lifter Jumbo Sprint Ex Blower
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 50 | EN www.schmalz.com 30.30.01.00226/03... -
Page 51: Grounding Points For Vacuum Tube Lifter Jumbo Sprint Ex Ejector
The connection points are marked with the following symbol: Lift tube Vacuum hose (each end) Ejector to compressed air hose Jib to pivot bearing Pivot bearing to column Mobile base plate to column (optional) Connection to customer's equipotential bonding _________ 30.30.01.00226/03 www.schmalz.com EN | 51... -
Page 52: Connecting Grounding Wires
Resistance measurement Measure the total resistance once the installation is complete. 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, 2 1. -
Page 53: Preparing For Operation
In Germany, the operating instructions for cranes (§§ 29 – 43 of Regulation 52 of the German social accident insurance (DGUV)) must be attached in the vicinity of the crane. The label is available from Schmalz (part number 14.04.02.10136). 30.30.01.00226/03 www.schmalz.com... -
Page 54: Operation
► The system must only be operated by trained personnel who have read and understood both the jib crane and hoist operating and maintenance instructions. ► The operator may not leave the control handle of the hoist when a load is attached to the jib crane. 54 | EN www.schmalz.com 30.30.01.00226/03... -
Page 55: Operation
This can result in broken bones, serious injury or even death. ► Use of the jib crane as a climbing aid or to transport humans or animals is prohibited! 30.30.01.00226/03 www.schmalz.com EN | 55... -
Page 56: Checks Before Starting Work
Align the base plate with the M20 screws so that the crane jib and hoist remain still in every angle and position respectively. Reconnect the power supply cables in accordance with the guidelines. An explosion protection representative commissioned by the operator must check and approve the crane system again. 56 | EN www.schmalz.com 30.30.01.00226/03... -
Page 57: What To Do In An Emergency
When operating a defective jib crane or hoist, the load or parts of the unit may fall and persons may be hit, injured or killed. ► Rectify any faults before starting the jib crane. ► Should faults occur during operation, switch the jib crane off and rectify the faults. 30.30.01.00226/03 www.schmalz.com EN | 57... -
Page 58: Troubleshooting
Crane jib not aligned exactly Align rail exactly horizontally Check the pivot bearing No power for tube lifter Vacuum supply line defective Check hose length Replace entire hose Check spacing between cable trolleys, use additional ones if required 58 | EN www.schmalz.com 30.30.01.00226/03... -
Page 59: Maintenance
► When performing work on the jib crane, the entire installation must be cordoned off! ► When performing work on the jib crane an appropriate climbing aid, lifting platform or fall prevention device must be used. 30.30.01.00226/03 www.schmalz.com EN | 59... -
Page 60: Service Table
Are the type plate and maximum load plate still attached to the crane system? Are the operating and maintenance instructions still available and are the operators familiar with them? Has the test label been updated? General condition of the crane system 60 | EN www.schmalz.com 30.30.01.00226/03... -
Page 61: Cleaning
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. Schmalz GmbH offers an inspection contract for an annual test with a certificate from an expert. -
Page 62: Dismantling And Disposal
For proper disposal, please contact a company specializing in the disposal of technical goods and instruct the company to observe the applicable disposal and environmental regulations. The manufacturer of the device will be happy to assist you in finding a suitable company. 62 | EN www.schmalz.com 30.30.01.00226/03... - Page 63 30.30.01.00226/03 | 09.2019 www.schmalz.com...
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