Schmalz Jumbo Sprint 45 Manual

www.schmalz.com
Ergonomic Handling Solutions
EN
Operating and Maintenance Instructions
Vakuum Tube Lifter JumboSprint EX Ejektor
30.30.01.00176/01 | 04.2017

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, 04.2017
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
Vakuum Tube Lifter JumboSprint EX Ejektor
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
1.5.1 Explosion protection..........................................................................................................8
1.5.2 Fundamental safety instructions........................................................................................9
1.6 Intended use......................................................................................................................9
1.7 Non-intended use............................................................................................................10
1.8 Requirements and instructions for installation, maintenance and operating staff...........11
1.9 Installation location/workplace requirements ..................................................................12
1.9.1 Installation location requirements....................................................................................12
1.9.2 Workplace requirements .................................................................................................13
1.10 Danger zone definition ....................................................................................................13
1.11 Emissions........................................................................................................................14
1.12 Personal protective equipment........................................................................................14
1.12.1 Installation/decommissioning and disposal of the tube lifter...........................................14
1.12.2 Operating the tube lifter...................................................................................................15
1.12.3 Troubleshooting/maintenance of the tube lifter...............................................................15
2Product description ...........................................................................................16
2.1 Description of operation ..................................................................................................16
2.2 Components....................................................................................................................16
2.3 Identification ....................................................................................................................17
2.3.1 Type plate........................................................................................................................17
2.4 Compressed air tube.......................................................................................................17
2.5 Turning off compressed air..............................................................................................18
2.6 Ejector .............................................................................................................................18
2.7 Dust filter .........................................................................................................................19
2.8 Vacuum supply hose.......................................................................................................19
2.9 Rotary union....................................................................................................................19
2.10 Lift tube............................................................................................................................19
2.11 Operator handle...............................................................................................................20
2.12 Suction cup......................................................................................................................20
2.13 Safety features ................................................................................................................21
2.13.1 Non-return valve in the rotary union................................................................................21
2.13.2 Vacuum limiting valve......................................................................................................21
2.14 Equipotential bonding......................................................................................................21
2.15 Optional accessories.......................................................................................................21
2.15.1 Quick-change adapter.....................................................................................................21
2.15.2 Rotation unit ....................................................................................................................21
3Technical Data..................................................................................................22
3.1.1 Tube lifter.........................................................................................................................22
3.1.2 Ejector .............................................................................................................................22
4Delivery, packaging and transport.....................................................................23

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4.1 Delivery............................................................................................................................23
4.1.1 Items included in delivery................................................................................................23
4.1.2 Check for completeness..................................................................................................23
4.1.3 Report damage................................................................................................................23
4.2 Packaging........................................................................................................................23
4.3 Transport.........................................................................................................................24
5Installation.........................................................................................................25
5.1 Installing compressed air supply.....................................................................................25
5.2 Installing the tube lifter ....................................................................................................26
5.2.1 Shortening the lift tube ....................................................................................................26
5.2.2 Preparing the earthing for the vacuum supply hose........................................................29
5.3 Establishing equipotential bonding..................................................................................30
5.3.1 Grounding points.............................................................................................................30
5.3.2 Resistance measurement................................................................................................31
5.4 Setting the hovering position...........................................................................................32
5.4.1 Without load.....................................................................................................................32
5.4.2 With load..........................................................................................................................33
5.5 Test..................................................................................................................................33
6Operation ..........................................................................................................34
6.1 General safety instructions..............................................................................................34
6.1.1 Ejector .............................................................................................................................34
6.1.2 Tube lifter.........................................................................................................................35
6.2 Checks Before Starting Work..........................................................................................36
6.3 What to do in an emergency ...........................................................................................36
6.3.1 Production of an ignition source in a potentially explosive atmosphere..........................36
6.3.2 Falling load......................................................................................................................36
6.4 Replacing the suction cups .............................................................................................37
6.4.1 Without quick-change adapter.........................................................................................37
6.4.2 With quick-change adapter (optional) .............................................................................38
6.5 Switching on the vacuum generator................................................................................39
6.6 Lifting the load.................................................................................................................39
6.7 Guiding the load ..............................................................................................................41
6.8 Setting down the load......................................................................................................41
6.9 Parking the tube lifter ......................................................................................................42
7Storage .............................................................................................................43
8Troubleshooting ................................................................................................44
9Maintenance......................................................................................................46
9.1 Inspecting safety features ...............................................................................................46
9.2 Service table....................................................................................................................47
9.3 Dust filter .........................................................................................................................48
9.3.1 Ejector dust filter..............................................................................................................48
9.3.2 Operator handle dust filter...............................................................................................49
9.3.3 Suction cup dust filter......................................................................................................49
9.4 Cleaning ..........................................................................................................................50

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9.5 Spare parts......................................................................................................................50
9.6 Circuit Diagram................................................................................................................50
9.7 Expert approval ...............................................................................................................50
10 Decommissioning and Disposal........................................................................51
10.1 Decommissioning............................................................................................................51
10.2 Disposal...........................................................................................................................51

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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 tube lifter until you have read and understood the
operating and maintenance instructions.
These operating and maintenance instructions are an integral part of the tube lifter. They must
accompany it wherever it is transported.
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 tube lifter made by the customer,
which are strictly prohibited.
These operating instructions do not include the suspension of the tube lifter (crane systems, column-
mounted jib cranes, etc.).
1.5 General safety instructions
1.5.1 Explosion protection
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).
Ensure that no explosive media can be picked up.
Never allow the lifting device to be hit with force (spark discharge).
Never strike the lifting device with objects or tools (spark discharge).
DANGER
Creation of an explosive atmosphere
Risk of explosion
►
Use only bags with an inner liner made from plastic to prevent the bags from
ripping. If any bag rips, switch off and clean the vacuum generator
immediately.

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1.5.2 Fundamental safety instructions
WARNING
Ignoring the general safety guidelines
Personal injury / damage to plants/systems
►
►
►
►
►
Carry out mounting or removal only when the device is disconnected from the
power supply and depressurized.
Before working on the tube lifter, ensure that the crane cannot move.
Personnel and animals are not permitted to sit or stand in the danger zone.
Only use the tube lifter for its intended use (chapter 1.6).
Do not pick up liquids or bulk materials.
You are also responsible for third parties in the working area of the tube lifter. For this reason, the
responsibilities for the various tasks to be carried out on the tube lifter must be clearly defined and
observed. The competency of those responsible must be assured.
WARNING
Ignoring the general safety guidelines
Personal injury / damage to plants/systems
►
►
►
►
All safety features must be in proper working order.
Safety features must not be altered or disabled.
The tube lifter must be in perfect working order and must have the necessary
specifications for the particular load.
The tube lifter must be operated only in the original condition as delivered. The
manufacturer assumes no liability for consequences of modifications over
which it has no control, in particular, replacement of original parts with parts
from other sources.
You must adhere to the legal regulations and safety regulations applicable at the
location of use when using the tube lifter.
1.6 Intended use
The Vakuum Tube Lifter JumboSprint EX Ejektor (referred to below as the “tube lifter”) is used to lift
and transport loads in combination with a crane system or jib crane.
The tube lifter is intended only for commercial use. The order confirmation defines the specific use of
the tube lifter.
The tube lifter is classified as follows according to ATEX directive 2014/34 EU:
II 2G c IIB T6
II 2D c T85°C

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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)
Before handling unfamiliar loads, ensure that the loads to be lifted are rigid enough that they are not
destroyed during lifting. Perform tests to do so where necessary.
For the permitted load capacities, see chapter 3.
The tube lifter must be used only when hung from the rotary union suspension eye.
Observe the type plate and load capacity sticker.
DANGER
Unsuitable crane system
Risk of fatal injuries
►
Ensure that:
The crane system and hoist used have the appropriate dimensions.
The overall system (tube lifters in combination with the crane system)
is designed for use in potentially explosive atmospheres in
accordance with ATEX 1999/92 EC.
Avoid carrying loads at an angle!
Always pick up loads above the center of gravity
1.7 Non-intended use
The manufacturer accepts no liability for damages caused by the use of the tube lifter for other
purposes. The use of the tube lifter for loads that are not specified in the order confirmation or have
different physical properties than those specified in the order confirmation shall be considered non-
intended use.

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WARNING
Non-intended use
Risk of fatal injuries
►
►
►
►
►
►
►
Usage in impermissible potentially explosive atmospheres (see chapter 1.6).
Usage as a climbing aid
Lifting people or animals
Storing loads while picked up
Supporting the lifting process by applying external forces
Picking up building components, equipment or supporting surfaces
Evacuation of objects that are in danger of imploding
WARNING
Handling a load with more than on tube lifter
Danger of fatal injuries due to falling objects
►
►
The load must be handled only with one tube lifter.
The manufacturer must be consulted before handling a load using a
combination of more than one tube lifter.
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 tube lifter:
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 tube lifter
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 tube lifter must be installed, maintained and repaired only by qualified specialist electricians and
mechanics.
Qualified specialist = 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.
1.9 Installation location/workplace requirements
1.9.1 Installation location requirements
DANGER
Usage in impermissible potentially explosive zones
Risk of explosion
►
►
►
►
►
The tube lifter is classified as follows according to ATEX directive 2014/34 EU:
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
tube lifter is suitable for its task. The manufacturer accepts no liability for
damages caused by the use of the tube lifter in areas with a high risk of
explosion.
Integrate the tube lifter 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 tube lifter must not be operated under the following conditions:
Areas with acidic or alkaline media or in contaminated atmospheres
In moist, wet, oily, icy, dirty or dusty environments, or in any other environments that might
reduce the level of friction
Outside the temperature range of +0° C to +40° C
Protect the tube lifter from direct UV exposure (due to the service life of the plastic parts).
If you have doubts, consult with the manufacturer before starting operations.

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1.9.2 Workplace requirements
The operator workstation is located by the operator handle.
Ensure that:
The operator has a good view of the entire working area
The operator’s work station is sufficiently lit and free of glare
The work station environment is neat and clean
ATTENTION
Picking up small parts
Damage to the vacuum generator
►
Keep the location of use and the area around the tube lifter free of small parts
that could be picked up.
1.10 Danger zone definition
Danger areas (in red shading):
The areas directly above and below the tube lifter and load
The area around the tube lifter and load
The crane system danger area
DANGER
Danger of falling objects when:
The vacuum fails
The load breaks off due to a collision
Component failure resulting from incorrect loads, overloading or
unauthorized modifications
Risk of injury when:
The tube lifter jolts upward
The load falls
►
►
Secure the work area before handling.
During handling:
Hold the operator handle firmly.
Do not bend over the operator handle.
Stay outside the danger area.
Loads should always be transported as close to the floor as possible.
Never transport the load above people.

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1.11 Emissions
The tube lifter emits noise and exhaust air.
The equivalent continuous sound pressure produced by the tube lifter during operation depends on
the surface properties of the load. For information on the noise emissions of the ejector, see chapter 3.
The surface temperature of the JUMBO SPRINT EX depends on the operating conditions and the
temperature of the compressed air supply. The JUMBO SPRINT EX itself does not contain any heat
source.
CAUTION
Noise pollution from vacuum generator
Danger of hearing damage
►
Wear ear protectors (in accordance with EN 352 class L or higher).
CAUTION
Particles in the vacuum generator exhaust air flow
The vacuum generator will atomize and disperse any media that is sucked in.
It is therefore important that no polluted or contaminated ambient air (particle
size < 5 µm) is sucked in.
Risk of eye injury
►
►
►
Manufacturer’s recommendation: Operate the tube lifter with dust filters at all
times (see chapter 2.4).
Do not look into the exhaust air flow.
Wear eye protection (class F).
1.12 Personal protective equipment
DANGER
Electrostatic charge on personal protective equipment (PPE)
Risk of explosion
►
Wear conductive PPE that is permitted fur use in explosive areas (clothing,
shoes, helmets, gloves, and so on).
Always wear suitable personal protective equipment that has been adapted to the conditions (for
example, for handling hazardous materials, loads with sharp edges, and so on). Observe the
applicable national regulations.
1.12.1 Installation/decommissioning and disposal of the tube lifter
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)

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1.12.2 Operating the tube lifter
Protective work shoes (in accordance with EN 20345 safety class S1 or better)
Depending on the load, sturdy work gloves (in accordance with EN 388 safety category 2133 or
better)
1.12.3 Troubleshooting/maintenance of the tube lifter
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)
Eye protection (class F)
Ear protectors (in accordance with EN 352 class L or higher)

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2 Product description
2.1 Description of operation
The tube lifter is used for fast and frequent lifting and moving of loads (for the maximum load capacity,
see the type plate). The vacuum generator generates the vacuum, which is then directed to the
suction cups via the supply hose and lift tube. The vacuum keeps the load attached to the suction cup.
Controlled leakage of the vacuum in the lift tube is used for lifting and lowering.
2.2 Components
6.1
7
6
6.2
6.3
2
1
4
8
5
6
10
4.1
1
3
2
11
1 Ejector
2 Compressed air hose
3 Vacuum supply hose
4 Rotary union
4.1 Suspension eye
5 Lift tube
6 Operator handle
6.1 Operator handle
6.2 Valve unit
6.3 Grip
7 Suction cup
8 Compressed air off
9 Vacuum limiter valve
10 Supply hose carrier unit
11 Tube lifter carrier unit

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The components of the system may not be opened or modified for the entire warranty
period. Opening the components, or making modifications or mechanical changes to
the components, voids the warranty.
2.3 Identification
2.3.1 Type plate
When ordering spare parts, submitting warranty claims or placing other inquiries
regarding the lifting device, always provide the device type, the part number, the order
number and the year of manufacture.
2.4 Compressed air tube
The compressed air required for vacuum generation is supplied to the ejector (1) via the compressed
air hose (2). Length of compressed air hose can be specified by customer.
Type
Part no.
P/N:
www.schmalz.com
Order number:
Year of manufacture:
Capacity:
Weight:II 2G c IIB T6
II 2D c T85°C
J. Schmalz GmbH Johannes-Schmalz-Str. 1 D-72293 Glatten
Made in Germany

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2.5 Turning off compressed air
The vacuum can be switched on and off via a ball
valve on the ejector, the compressed air off switch
(8).
Compressed
air ON
Open valve
Pull the black ball
knob (8.1)
Compressed
air OFF
Close valve
Pull the red ball knob
(8.2)
WARNING
Vacuum failure
Falling load
►
Pull the red ball knob only if no load is suspended from the tube lifter.
2.6 Ejector
Ejector (1) produces vacuum for lifting unit. Compressed air is supplied to ejector via pressurised air
connection (1.1). Lifting hose is attached to vacuum connection (1.2) by means of a rotary connection
socket. Outlet air is discharged via sound absorbing duct on outlet side (1.3).
8.2
8.1
8.3
8

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2.7 Dust filter
It is recommended that you operate the tube lifter only with a dust filter (2).
For maintenance information, see chapter 9.3
For installation information, see chapter 5.1
2.8 Vacuum supply hose
The supply hose (3) transfers the vacuum to the rotary union of the tube lifter. The metal support
spindle on the vacuum supply hose acts as an earthing lead (for installation instructions, see chapter
5.2.2).
2.9 Rotary union
The rotary union (4) connects the vacuum supply hose (3) to
the lift tube (5). The suspension eye (4.1) on the rotary union is
used as the connection to the crane system. The tube lifter can
be turned continuously.
2.10 Lift tube
The lift tube (5) transfers the vacuum to the suction cup, creating the lifting force for the tube lifter.
4.1
5
3
4
1.3
1
1.1
1.2

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2.11 Operator handle
The operator handle (6) consists of:
6.1 Operator handle
6.2 Valve unit
6.3 Grip
You pull up or press down the operator handle (6.1) to
lift, release, and lower the load.
On the operator handle, there are 2 adjustment screws for setting the hovering position of the tube
lifter (see chapter 5.3).
2.12 Suction cup
Various suction cups can be used depending on the load. Tests must be performed in accordance
with EN 14238 to verify that the suction cup is suitable for the load to be lifted (see chapter 5.5).
suction cups and their applications
Single suction cups
Glued cardboard boxes, sheets, furniture
bodies etc.
Single suction cups, long
Pallets, narrow cardboard boxes, beams,
square tubes etc.
Round vacuum gripper
Barrels, buckets, stone slabs with rough
surfaces.
Option: Round vacuum gripper with
conductive foam.
Sack gripper
Paper sacks (with plastic liner), plastic
sacks, raw rubber bales, shrink-wrapped
packages, etc.
Double suction cup
Clamped, glued, strapped or open
cardboard boxes, crates and sheets etc.
The two suction cups are continuously
adjustable on the main beam.
6.1
6
6.2
6.3