Schmalz JumboPicker-Flex Manual

www.schmalz.com
Ergonomic Handling Solutions
EN
Operating and Maintenance Instructions
JumboPicker-Flex Jungheinrich
30.30.01.01183/00 | 11.2016

www.schmalz.com
Note
These operating instructions were originally written in German and have been translated into English.
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, 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. Any modifications to or abridgments of the document are prohibited without explicit
written agreement from J. Schmalz GmbH.
Contact
J. Schmalz GmbH
Aacher Strasse 29
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
JumboPicker-Flex Jungheinrich
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 Fundamental safety instructions........................................................................................8
1.6 Intended use......................................................................................................................9
1.7 Obligations of the Manufacturer of the Finished Unit......................................................10
1.8 Requirements and Instructions for Installation, Maintenance and Operating Staff.........10
1.9 Requirements for the Location of Use.............................................................................11
1.10 Danger Zone Definition ...................................................................................................12
1.11 Emissions........................................................................................................................14
1.12 Personal protective equipment........................................................................................14
2Product Description...........................................................................................15
2.1 Components of the vacuum tube lifter JumboPicker-Flex ..............................................15
2.2 Description of Operation..................................................................................................15
2.3 Controls...........................................................................................................................16
2.3.1 Button Assembly..............................................................................................................16
2.3.2 Tube lifter operator handle..............................................................................................16
2.4 Lift tube............................................................................................................................16
2.5 Rotary Union....................................................................................................................16
2.6 Load suspension devices / suction cups.........................................................................17
2.7 Vacuum Generation ........................................................................................................17
2.7.1 Vacuum Generator..........................................................................................................17
2.7.2 Dust Filter (STF)..............................................................................................................17
2.8 Safety Features...............................................................................................................17
2.8.1 Vacuum Limiting Valve....................................................................................................17
2.8.2 Sensors ...........................................................................................................................17
2.8.3 Non-return valve..............................................................................................................18
2.9 Type Plate .......................................................................................................................19
2.10 Optional Accessories.......................................................................................................19
2.10.1 Warning Light ..................................................................................................................19
2.10.2 Scissor arm brake ...........................................................................................................19
3Technical Data..................................................................................................20
3.1 JumboPicker-Flex............................................................................................................20
3.2 Dimensions......................................................................................................................21
4Delivery, Packaging and Transport...................................................................22
4.1 Delivery............................................................................................................................22
4.1.1 Items Included in Delivery ...............................................................................................22
4.1.2 Check for Completeness.................................................................................................22
4.1.3 Report damage................................................................................................................22
4.2 Packaging........................................................................................................................22
4.3 Handling the System .......................................................................................................24
4.4 Transporting the Finished Unit ........................................................................................24

SAFETY INSTRUCTIONS
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5Installation.........................................................................................................26
5.1 Tool List...........................................................................................................................26
5.2 Tightening Torques .........................................................................................................26
5.3 Mounting on the Industrial truck......................................................................................26
5.3.1 Basic Notes .....................................................................................................................26
5.3.2 Work Steps......................................................................................................................27
5.3.3 Installation Instructions....................................................................................................28
5.4 Attaching the Tube Lifter .................................................................................................30
5.5 Setting the Hovering Position..........................................................................................30
5.6 Before Initial Start of Operations.....................................................................................31
6Operation ..........................................................................................................32
6.1 Checks Before Starting Work..........................................................................................32
6.2 Safety Instructions for Operation.....................................................................................32
6.3 Misuse.............................................................................................................................34
6.4 What to Do in an Emergency ..........................................................................................34
6.5 Integrated Quick-Change Adapter –Replacing the Suction Cups..................................35
6.5.1 Special Case: Mechanical Grippers................................................................................36
6.6 Switching On and Off ......................................................................................................36
6.6.1 Starting Up the Industrial truck with the Tube Lifter Attached.........................................36
6.6.2 Releasing the Vacuum Tube Lifter from the Parked Position .........................................37
6.7 Handling Loads................................................................................................................38
6.7.1 Lifting Loads....................................................................................................................38
6.7.2 Lowering and setting down loads....................................................................................39
6.7.3 Picking Up Vertically and Depositing Horizontally...........................................................39
6.7.4 Guiding Loads .................................................................................................................40
6.7.5 Continuous rotatability.....................................................................................................40
6.8 Parking the Vacuum Tube Lifter......................................................................................41
6.9 Release Signals for the Industrial truck...........................................................................42
6.9.1 Conditions for Fast Travel with Industrial truck at Vmax –Controlling from the Driver's
Cab 42
6.9.2 Conditions for Controlling the Industrial truck While Walking Alongside.........................43
6.9.3 Raising and Lowering the Fork Arms..............................................................................44
7Storing the Tube Lifter.......................................................................................45
8Troubleshooting ................................................................................................46
8.1 Faults in the Industrial truck ............................................................................................46
8.2 Faults in the Scissor Arm or Tube Lifter..........................................................................46
9Maintenance......................................................................................................48
9.1 General notes..................................................................................................................48
9.2 Spare parts......................................................................................................................48
9.3 Checking Safety Features...............................................................................................49
9.4 Service Table...................................................................................................................51
9.5 Cleaning ..........................................................................................................................52
9.6 Removing the Covers......................................................................................................52
9.7 Vacuum Pump.................................................................................................................53

SAFETY INSTRUCTIONS
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9.8 Filter.................................................................................................................................53
9.8.1 Filter in the Vacuum Pump..............................................................................................53
9.8.2 Filter in the Vacuum Pump..............................................................................................53
9.8.3 Filter in Suction Cup........................................................................................................53
9.9 Scissor arm brake ...........................................................................................................53
9.10 Expert approval ...............................................................................................................54
10 Decommissioning and Disposal........................................................................55
10.1 Dismantling......................................................................................................................55
10.2 Disposal...........................................................................................................................55
Appendix....................................................................................................................56
Design Drawings and Bill of Material ...........................................................................................56
Bill of Material layout drawing 11.05.05.00064 ............................................................................59
Bill of Material mechanical locking system art. code 11.05.05.00009 .........................................62
Bill of Material storage rack Jumbo art. code 11.05.05.00050.....................................................62
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

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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
Note
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.
Warning
symbol
Description
Warning
symbol
Description
General warning symbol
Explosive atmosphere
Electrical voltage
Flying debris
Hand injury
Crushing injury warning
Suspended load
Fall hazard
Vacuum
Hearing damage
Falling parts
Hot surfaces
1.3 Mandatory symbols
Explanation of the mandatory symbols used in the operating and maintenance instructions.
Mandatory
symbols
Description
Mandatory
symbols
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
Risk of accidents if this information is not observed
►
These operating and maintenance instructions are considered a permanent
part of the system and contain important information on its use. They must
accompany the system 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 system made by the customer, which are strictly
prohibited.
►
The system may only be connected and started after reading and
understanding the operating and maintenance instructions.
1.5 Fundamental safety instructions
WARNING
Risk of injury if the general safety instructions are not observed
►
Carry out mounting or removal only when the device is in an idle, depressurized
state.
►
General safety regulations, European standards and VDE guidelines must be
observed and complied with.
►
Personnel and animals are not permitted to sit or stand in the danger zone
area.
►
Only grip and lift suitable loads.
Run tests to check the rigidity and porosity.
Do not grip any loads that are in danger of imploding.
►
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. The competency of those responsible
must be assured.
►
Never use the tube lifter to apply suction to fluids or bulk materials.
►
Protect the components from damage of any kind.
WARNING
Risk of injury from exposed vacuum suction points
►
Never look into the openings of suction points or place your ear or other body
orifices in the vicinity of these openings.
►
The device generates very high suction that can suck in hair and items of
clothing.

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All applicable laws and regulations must be adhered to at all times.
When using the JumboPicker-Flex, observe the statutory regulations, safety
regulations, standards and guidelines applicable at the location of use.
Check with the relevant authorities for more information.
The safety instructions in these operating instructions do not replace these laws and
regulations, but are to be regarded as a supplement to them.
1.6 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. The system is used for lifting and moving loads depending on the travel
situation of the industrial truck. The loads to be lifted must be rigid enough to ensure they are not
destroyed during lifting.
CAUTION
Load not suitable for the vacuum tube lifter
Risk of accidents
►
►
►
The designs of the required suction cups must be verified by calculations.
Relevant safety factors must be taken into account (according to standard DIN
EN 14238).
The loads must be tested in advance to ensure they are suitable for
handling; this must be documented with appropriate suction tests (see
section 5.6).
The gripper must be able to grip and lift the load safely and without assistance.
Using additional forces to assist in the lifting process is not permitted.
The industrial truck must be designed for use with the JumboPicker-Flex and have the necessary
interfaces for connecting and incorporating the system. The manufacturer of the finished unit is
responsible for ensuring that the unit is stable.
Use of the JumboPicker-Flex for products that have not been sufficiently tested and analyzed is
considered unintended and improper use.
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.
►
Using the system as a climbing aid or to transport humans or animals is
prohibited.

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1.7 Obligations of the Manufacturer of the Finished Unit
The system is delivered as an incomplete machine as defined by Machinery
Directive 2006/42. The manufacturer delivers a declaration of incorporation
according to Annex I Part 1 Section B of the Machinery Directive.
The manufacturer of the finished unit integrates the system into a finished unit
according to the assembly instructions in section 5.
The manufacturer of the finished unit is obligated to perform a conformity
assessment on the finished unit according to Article 12 of the Machinery Directive.
The system is state of the art and operationally reliable, provided full compliance
with these instructions is ensured. Incorrect use of the system can result in serious
hazards.
WARNING
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.
►
Do not make any on-site modifications to the tube lifter.
►
Use only the original connections, mounting holes and attachment materials
that have been provided.
Make electrical connections according to circuit diagram (see appendix).
The manufacturer of the finished unit must define the requirements regarding the load-bearing
capacity and surface properties of the floor.
1.8 Requirements and Instructions for Installation, Maintenance and
Operating Staff
Only qualified specialists, mechanics and electricians may perform the installation, maintenance and
repair work. Qualified specialists 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. Work on electronic equipment must be carried out by qualified electrical specialists only.
A qualified specialist 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. Qualified specialists must observe the relevant industry-specific rules and
regulations.

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The user’s company must ensure by means of internal measures that all
persons commissioned with the task of setting up, starting, operating,
maintaining and repairing the system employ only insured persons who:
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
Can be expected to reliably perform the tasks assigned to them
The operating instructions must be accessible at all times.
WARNING
Risk of injury due to misuse or non-observance of warning and safety
notices
Persons could be harmed.
►
►
Only for use by authorized and trained personnel.
Follow local regulations on work breaks to prevent accidents due to
negligence.
1.9 Requirements for the Location of Use
DANGER
Switching components that are not explosion-proof
Risk of fire and explosion
►
Product must not be used in potentially explosive atmospheres.
The system must not be used in areas with acidic, alkaline or ozone-containing materials or in
contaminated atmospheres.
Dusts and vapors, e.g. wood, CFRP materials, oils or cleaning agents, must not be sucked
into or through the unit.
The system can be used indoors in locations without exposure to UV light and with an ambient
temperature of 0° C to +40° C and humidity up to 90%.

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CAUTION
Use outside the permitted temperature range
Damage to the tube lifter.
►
Only use the tube lifter 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.
CAUTION
Tube lifter failure due to small parts being sucked in
Damage to or destruction of the vacuum generator
►
Keep the location of use and vicinity of the tube lifter free of small parts.
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.
1.10 Danger Zone Definition
The danger zone is the area in the vicinity of working equipment in which the equipment poses a
hazard to the safety of persons.
The danger zone is beneath the gripper and load and also directly above the gripper and operator
handle.
When lifting or transporting the load, it is possible that the load and parts of the vacuum tube lifter will
fall or drop quickly or that the gripper will become detached from the load and spring upward.
In the event that the load falls, the danger zone greatly depends on the type of load and the transport
height.

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Ranges of movement that result when the unit is used within the larger machine must be defined and
secured by the manufacturer of the finished unit.
WARNING
Risk of injury from falling objects in case of:
–Vacuum failure
–The load breaking off due to a collision
- Components failing due to incorrect loads and overloads or unauthorized
modifications
There is a risk of death or seriously injury from hitting people in the
vicinity.
►
No person may sit or stand in the danger zone of the tube lifter.
►
Only work when you have a good view of the entire working area.
►
Pay attention to other people in the working area.
►
Never transport the load above people.
►
Loads should always be transported as close to the floor as possible.
►
The swiveling point of the load must always be located within the working area
of the jib.
►
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.
Danger zone
Work area (range of
movement) of the tube
lifter axis
Fork arms
Industrial truck
Scissor arm
Tube lifter

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1.11 Emissions
The vacuum tube lifter emits noise and hot exhaust air.
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 max. 5 µm) is sucked in.
CAUTION
Noise pollution from vacuum generator
Noise pollution can cause hearing damage.
►
Wear ear protectors
CAUTION
Hot air flows from the outlet side of the vacuum generator, heating up the
vacuum generator and surrounding components
Burn hazard
►
Keep your distance from the vacuum generator.
►
Observe a cooling time of 60 minutes before working on the vacuum generator.
CAUTION
Risk of eye injury
All vacuum generators generate an exhaust air flow. Depending on the purity of
the ambient air, this exhaust air can contain particles, which escape from the
exhaust air outlet at high speed, potentially injuring people in the face and eye
area.
►
Do not look into the exhaust air flow.
►
Wear eye protection.
1.12 Personal protective equipment
When operating the system, 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)
Eye protection (class F)
Other protective equipment as required by the situation or prescribed by national regulations.

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2 Product Description
2.1 Components of the vacuum tube lifter JumboPicker-Flex
This figure is only an example. The actual design may differ.
Components
1 Vacuum gripper
2 Operator handle
3 Lift tube
4 Rotary union
5 Retaining net
6 Scissor arm
7 Vacuum generator
8 Jib safety switch with guard
locking
9 JumboPicker-Flex main switch
10 Storage rack for operator handle
with sensor
11 Vertical beams (part of the
industrial truck, not included in
delivery from Schmalz)
2.2 Description of Operation
The system is used for fast and frequent lifting and moving of loads weighing up to 40 kg.
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.
1
2
4
3
6
7
8
5
9
10
11
Included in delivery from Schmalz
Customer

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2.3 Controls
2.3.1 Button Assembly
The system includes two button assemblies. They are to be installed
in the industrial truck's pedestrian control panel.
k Switch on the vacuum generator
l Switch off the vacuum generator
m Selector switch for controlling the vacuum generator (only on
one of the two switch assemblies)
2.3.2 Tube lifter operator handle
The operator handle is used to control the lifting and lowering of the tube lifter as well as the gripping
and releasing of the load, which is achieved by changing the vacuum in the lift tube.
Button (e) has 2 positions:
1. Lower the load
2. Release/eject the load
2.4 Lift tube
The lift tube transfers the vacuum to the suction cup, creating the lifting force for the tube lifter.
2.5 Rotary Union
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.
Operator Handle Components
a Suction cup
b Quick-change adapter
c Lock for rotation unit
d Swiveling unit
e Button with 2 positions
f Suspension height adjustment (without
load)
g Lift tube
l
k
m
a
d
e
g
c
b
f

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2.6 Load suspension devices / suction cups
Various standard suction cups are available for the tube lifter (see the list in the appendix). Other
suction cups and mechanical grippers must be carefully tested before use and approved by 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. Check the resistance of foams and sealing lips to
prevailing environmental conditions, such as ozone, acid, oil, grease, solvents etc.
Sealing lips can become aged and brittle due to a variety of environmental conditions. To ensure that
the tube lifter remains in optimum condition at all times, it is important to check and, if necessary,
replace the suction sealing lips at regular intervals (see service table 9.3).
2.7 Vacuum Generation
2.7.1 Vacuum Generator
The electric vacuum pump generates the vacuum for the tube lifter.
2.7.2 Dust Filter (STF)
2.8 Safety Features
2.8.1 Vacuum Limiting Valve
The vacuum limiting valve limits the vacuum level to 620 mbar.
CAUTION
Vacuum value too high
Setting the vacuum too high can cause the lift tube to implode.
►
The vacuum tube lifter must only be operated with a vacuum limiting valve set
to 620 mbar.
2.8.2 Sensors
The signals from the safety features must be evaluated by the industrial truck's central
control unit.
The dust filter in the vacuum line protects the vacuum generator from
all types of contamination (ambient dust, soiled transport materials,
etc.).

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2.8.3 Non-return valve
The two safety switches (4S1 and 4S2) emit a signal once the
scissor arm is in the parked position.
Vacuum sensor (3B1).
Sensor for jib extension (3B2)
The JumboPicker-Flex storage rack sensor (3B3) detects when the
tube lifter is properly secured in the parked position.
A non-return valve in the tube lifter's rotary union causes the tube
lifter to be lowered slowly when the vacuum supply fails.

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2.9 Type Plate
The device type, device number and year of manufacture are specified on the type
plate. This information is important for identifying the system. It must always be
specified when ordering replacement parts, making warranty claims or other
inquiries about the system.
The type plate contains the following information:
2.10 Optional Accessories
2.10.1Warning Light
2.10.2Scissor arm brake
The warning light signals that the JumboPicker-Flex is in operation.
The brake limits the scissor arm's rotary movement.

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3 Technical Data
3.1 JumboPicker-Flex
Max. lift capacity
40 kg *
Rated power
2,000 W
Temperature range
0 - 40 °C
Power consumption
(when gripping)
Lift tube diameter
100 mm
At pump speed
n = 800 min-1
92 A
Jib length
2,100 mm
At pump speed
n = 1,200 min-1
102 A
Min. load dimensions
200 x 200 mm
Swivel angle
Approx. +/- 115°
Max. load dimensions
2,000 x 800 mm
Sound level
74 dB(A)
Max. lift speed
0.5 to 1 m/s **
Signal output
See circuit diagram
Pump for vacuum
generation
(max. working vacuum of
620 mbar)
EVE 80
Unladen weight of main
assembly with tube
lifter
210 kg
Suction flow
55 m³/h
Unladen weight of tube
lifter
5 kg
Speed levels
2
Unladen weight of
suction cup
Depending on the gripper
Voltage
DC 24 V
* The suction cup can have a lower lift capacity.
** Max. lift speed depends on the weight of the load.