Schmalz SK-JU-110-2000-SRS63-3000-VSL-EX Manual

www.schmalz.com
EN
Ergonomic Handling Solutions
Operating and Maintenance Instructions
Jib Cranes for Potentially Explosive Atmospheres
30.30.01.00226/03 | 09.2019

www.schmalz.com
Note
These operating and maintenance instructions were originally written in German.
Store in a safe place for future reference.
Subject to technical changes without notice. No responsibility is taken for printing or other types of
errors.
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. 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. [phone]
Fax [phone]
[e-mail]
www.schmalz.com
Contact information for Schmalz companies and trade partners worldwide can be found at
www.schmalz.com/salesnetwork

Contents
Operating and Maintenance Instructions Jib Cranes for Potentially
Explosive Atmospheres
www.schmalz.com
1Safety instructions...............................................................................................6
1.1 Classification of safety instructions ...................................................................................6
1.2 Warnings ...........................................................................................................................7
1.3 Mandatory symbols ...........................................................................................................7
1.4 Regulations in these instructions.......................................................................................8
1.5 General safety instructions................................................................................................8
Explosion protection..........................................................................................................81.5.1 Fundamental safety instructions........................................................................................91.5.2
1.6 Intended use....................................................................................................................10
1.7 Non-intended use............................................................................................................12
1.8 Requirements and instructions for installation, maintenance and operating staff...........12
1.9 Installation location/workplace requirements ..................................................................14
Installation location requirements....................................................................................141.9.1 Workplace requirements .................................................................................................151.9.2
1.10 Danger zone definition ....................................................................................................16
1.11 Operating range of the jib crane......................................................................................17
1.12 Emissions........................................................................................................................17
1.13 Personal protective equipment........................................................................................17
2Product description ...........................................................................................18
2.1 Description.......................................................................................................................18
Column-mounted jib crane with flat jib ............................................................................182.1.1 Wall-mounted jib crane with flat jib..................................................................................182.1.2 Column-mounted jib crane with flat jib ............................................................................182.1.3 Wall-mounted jib crane with flat jib..................................................................................182.1.4 Column-mounted jib crane with articulated-arm jib.........................................................192.1.5 Wall-mounted jib crane with articulated-arm jib ..............................................................192.1.6
2.2 Flat jib..............................................................................................................................20
2.3 Flat jib..............................................................................................................................20
2.4 Articulated-arm jib ...........................................................................................................21
2.5 Type plate........................................................................................................................21
2.6 Description of component parts.......................................................................................22
Pivot bearing....................................................................................................................222.6.1 Crane column..................................................................................................................232.6.2 Wall bracket / clasp bracket ............................................................................................232.6.3 Steel profile......................................................................................................................242.6.4 Transport trolley...............................................................................................................242.6.5 Bracings...........................................................................................................................242.6.6 End stops.........................................................................................................................252.6.7 Cable trolley.....................................................................................................................252.6.8 Terminal clamps..............................................................................................................252.6.9 Slewing angle limiter .......................................................................................................252.6.10 Attachments.....................................................................................................................262.6.11 Electrical switches...........................................................................................................262.6.12
3Technical Data..................................................................................................27
4Delivery, packaging and transport.....................................................................28

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4.1 Delivery............................................................................................................................28
Items included in delivery................................................................................................284.1.1 Check for completeness..................................................................................................284.1.2 Report damage................................................................................................................284.1.3
4.2 Packaging........................................................................................................................28
4.3 Transport.........................................................................................................................28
4.4 Removal of crane components........................................................................................29
5Installation.........................................................................................................30
5.1 Preparation of parts.........................................................................................................31
5.2 Tool list............................................................................................................................31
5.3 Electrical installation........................................................................................................32
Installation of electrical supply lines................................................................................325.3.1
5.4 Mechanical installation ....................................................................................................33
Positioning the crane column..........................................................................................335.4.1 Erecting the crane column with mobile base plate..........................................................365.4.2 Mounting the wall bracket................................................................................................365.4.3
5.5 Mounting the flat jib .........................................................................................................39
5.6 Pre-assembly of articulated-arm jib.................................................................................40
5.7 Pre-assembly of flat jib....................................................................................................40
5.8 Mounting the crane jib on the crane column or wall bracket...........................................41
Tool list............................................................................................................................415.8.1 Lower bearing mounting..................................................................................................41
5.8.2 Upper bearing mounting..................................................................................................455.8.3
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.....................................................................................................485.13.1
5.14 Establishing equipotential bonding..................................................................................49
Grounding points for vacuum tube lifter Jumbo Sprint EX blower ..................................505.14.1 Grounding points for vacuum tube lifter Jumbo Sprint EX ejector ..................................515.14.2 Connecting grounding wires............................................................................................525.14.3 Resistance measurement................................................................................................525.14.4
5.15 Preparing for operation....................................................................................................53
Other energy supply........................................................................................................535.15.1 Attaching the type plate...................................................................................................535.15.2
6Operation ..........................................................................................................54
6.1 General safety instructions regarding operation .............................................................54
6.2 Operation.........................................................................................................................55
6.3 Checks before starting work............................................................................................56
6.4 Erecting the crane column on a mobile base plate in another location...........................56
6.5 What to do in an emergency ...........................................................................................57
Production of an ignition source in a potentially explosive atmosphere..........................576.5.1 Falling load......................................................................................................................576.5.2
7Troubleshooting ................................................................................................58

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8Maintenance......................................................................................................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
9Dismantling and disposal ..................................................................................62
9.1 Dismantling......................................................................................................................62
9.2 Disposal...........................................................................................................................62

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1 Safety instructions
1.1 Classification of safety instructions
Danger
This warning informs the user of a risk that will result in death or serious injury if it is not avoided.
DANGER
Type and source of danger
Consequence
►
Remedial action
Warning
This warning informs the user 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 not avoided.
ATTENTION
Type and source of danger
Consequence
►
Remedial action
Important information for efficient and trouble-free use.

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1.2 Warnings
Explanation of the warning symbols used in the operating and maintenance instructions.
Icon
Description
Icon
Description
General warning symbol
Explosive atmosphere
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 operating instructions
Wear eye protection

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1.4 Regulations in these instructions
WARNING
Failure to observe the instructions
Risk of fatal injuries
►
Do not start or use the jib crane until you have read and understood the
operating and maintenance instructions.
These operating and maintenance instructions are an integral part of the jib crane. They must
accompany it wherever it is transported.
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.
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 protection1.5.1
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, 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 components of the jib crane to be hit with force (spark
discharge).
Never strike the components of the jib crane with objects or tools (spark
discharge).

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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.

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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.
The jib crane is classified as follows in accordance with ATEX directive 2014/34 EU:
Jumbo with 50-Hz blower Jumbo with 60-Hz blower Jumbo with ejector
II 3G IIB T4 II 3G IIB T3 II 2G c IIB T6
II 3D T135° C II 3D T200° C II 2D c T85° C
DANGER
Electrostatic charge on the load
Risk of explosion
►
During operation in potentially explosive atmospheres as defined by ATEX
1999/92 EC, ensure that the load does not pose a danger:
The load must be conductive. A measurement of potential is required.
Ensure that electrostatic charges cannot develop on 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
than 5° from vertical.
Avoid a build up of rocking in loads.
Storing loads on the jib crane is prohibited.
Only the designated mounting holes and attachment materials must be used.
The operating, maintenance and servicing conditions specified in these operating and
maintenance instructions must be observed.
The maximum permissible load must not be exceeded.
The working area must be observed.
The jib crane is designed for the hoisting class HC3 and hoist HD1 in accordance with DIN EN
13001.
The jib crane is state of the art and operationally reliable, provided full
compliance with these instructions is assured. Incorrect handling of the crane
system could cause dangers to arise.

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DANGER
Unsuitable crane system
Risk of fatal injuries
►
Ensure that:
The crane system and hoist used have the appropriate dimensions.
The overall system (jib crane with tube lifter or other hoist) is
designed for use in potentially explosive atmospheres in accordance
with ATEX 1999/92 EC.
WARNING
Risk of falling objects
The integrity and function of the jib crane 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 as a means of transport for humans
or animals, or as a climbing aid
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!

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1.7 Non-intended use
The manufacturer accepts no liability for damages caused by the use of the jib crane for other
purposes. The use of the jib crane for loads that are not specified in the order confirmation or that
have different physical properties than those specified in the order confirmation shall be considered
non-intended use.
WARNING
Non-intended use
Risk of fatal injuries
►
►
►
►
Usage in impermissible potentially explosive atmospheres (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 installation, maintenance and
operating staff
DANGER
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.

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The operator must ensure that any people charged with installing, starting
operations on, operating, maintaining or repairing the jib crane:
Have received special training for performing work in potentially explosive
atmospheres
Are at least 18 years of age
Are mentally and physically fit for the task
Have been trained in operating and maintaining the crane
Possess a crane driving license
Have read and understood the operating instructions
Can be expected to reliably perform the tasks assigned to them
The operating instructions must be accessible at all times.
The type plate and warning signs must be legible.
The operator is obligated to perform a risk assessment for the ambient
conditions at the installation location.
The operator has to assign crane operators and maintenance personnel
their tasks. For mobile, power-operated cranes, the employer has to
commission crane operators in writing.
The crane system should only be installed and maintained by qualified specialist personnel,
mechanics and electricians. Work on electrical equipment must be carried out only by qualified
electrical specialists.
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, has
sufficient knowledge in the field of cranes and is sufficiently familiar with the applicable national
occupational safety regulations, accident prevention regulations, directives and generally accepted
technical guidelines, such as BG regulations [German workmen’s compensation], DIN standards, VDE
guidelines, technical guidelines from other European Union Member States or other European
Economic Area member states, to determine whether or not the cranes are in good working condition.
Experts for checking cranes are, in addition to the experts for technical monitoring, those persons
identified as authorized experts by the trade association.
The responsibilities for the various tasks on the crane system must be clearly specified and observed.
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.

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1.9 Installation location/workplace requirements
Installation location requirements1.9.1
DANGER
Usage in impermissible potentially explosive zones
Risk of explosion
►
►
The jib crane is classified as follows in accordance with ATEX directive
2014/34 EU:
Jumbo with 50-Hz blower:
II 3G IIB T4
II 3D T135° C
Jumbo with 60-Hz blower:
II 3G IIB T3
II 3D T200° C
Jumbo with ejector:
II 2G c IIB T6
II 2D c T85°C
As per ATEX directive 1999/92 EC, the operator is obligated to ensure that the
jib crane is suitable for its task. The manufacturer accepts no liability for
damages caused by the use of the jib crane in areas with a high risk of
explosion.
Integrate the jib crane into the lightning protection concept at the location of
use.
Observe the applicable national regulations.
If you have doubts, consult 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 mounting using shear connectors, it is essential that the base plate is placed directly on the
concrete without an intermediary layer. For shear connectors, it is not permitted to hold lateral loads
with the level arm (bending).
Verification of immediate application of force at the site across the concrete has been provided. The
anchor load transfer in the component must be verified by the customer.
The following minimum requirements apply:
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.

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ATTENTION
Damage to the crane system due to using outside of the permitted
temperature range
If the crane system is used outside of the permitted temperature range,
it will become damaged and fail.
►
Only use the crane system at the permitted ambient temperature.
►
Before operating outside of the permitted temperature range, outside of closed
rooms 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 requirements1.9.2
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.

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1.10Danger zone definition
The danger zone is the area inside or in the vicinity of working equipment that poses a hazard or
potential hazard to the health of persons located within this area.
When lifting the load or transporting it, it is possible that the load could fall, which is why the
swivel range of the jib crane and hoist is always considered a danger zone.
WARNING
Risk of injury from falling objects in case of:
- A collision, causing the load 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 swiveling point of the load must always be located within the working area
of the jib crane.
►
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.

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1.11Operating range of the jib crane
The operating range of the jib crane is the area in which the hoist is able to lift the load in accordance
with its intended use and simultaneously transfer the load vertically into the crane jibs. The working
area is restricted by the variable end stops and crane column or wall bracket.
Column-mounted jib crane
Wall-mounted jib crane
Column-mounted jib crane with articulated-arm jib
1.12Emissions
No emissions are 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 suitable protective equipment:
Protective work shoes (in accordance with EN 20345 safety class S1 or better)
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.

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2 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

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Column-mounted jib crane with
2.1.5
articulated-arm jib
Wall-mounted jib crane 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
3
40
40
7
9
2
3
7
9
1
3
8

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2.2 Flat jib
Item
Name
Section.
3
Pivot bearing
2.6.1
5
Transport trolley
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