Schmalz VACUMASTER HHVM User manual

Operating
Instructions
VACUMASTER HHVM
BA 30.30.01.00218
J. Schmalz GmbH
Aacher Strasse 29
72293 Glatten, Germany
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
e-mail: [e-mail]
30.30.01.00218 / Index 00 Last updated 03/2013 Page 1/22
These operating instructions were originally written in German.
This document must be kept in a safe place for future reference.
E

Operating
Instructions
VACUMASTER HHVM
BA 30.30.01.00218
J. Schmalz GmbH
Aacher Strasse 29
72293 Glatten, Germany
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
e-mail: [e-mail]
30.30.01.00218 / Index 00 Last updated 03/2013 Page 2/22
Contents
1Safety
1.1 Notes for the operating company
1.2 Instructions for installation, maintenance, and operating personnel
1.3 Safety instructions in this manual
1.4 Installation location requirements
1.5 Intended use
1.6 Emissions
1.7 Specific hazards
1.8 Workplaces
1.9 Instructions for users of the lifting device
1.10 Personal protective equipment
1.11 What to do in an emergency
1.12 Check safety equipment
2Technical Data
3Description
3.1 Description of device
3.2 Controls
3.3 Vacuum generation
3.4 Suction plates
3.5 Accessories
4Installation
4.1 Commissioning
4.2 Setting the load holder
4.3 Switching suction plates on and off (optional)
5Operation
5.1 Operational safety information
5.2 Lifting loads
5.3 Depositing loads
5.4 Swiveling the lifting device
5.5 Moving the lifting device with the crane unit
6Troubleshooting
7Maintenance
7.1 General notes
7.2 Maintenance schedule
7.3 Suction plates/sealing lips
7.4 Vacuum filter
7.5 Silencer
7.6 Leak test
7.7 Expert approval
8Notes on the Type Plate
9Warranty, Spare Parts and Wearing Parts

Operating
Instructions
VACUMASTER HHVM
BA 30.30.01.00218
J. Schmalz GmbH
Aacher Strasse 29
72293 Glatten, Germany
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
e-mail: [e-mail]
30.30.01.00218 / Index 00 Last updated 03/2013 Page 3/22
Appendix
Pneumatic circuit plan
Spare and Wearing Parts
Electronic warning device operating instructions; battery operated
Multistage ejector SEM 100 operating instructions
Vacuum switch operating instructions
CE conformity declaration
Chain hoist operating instructions (enclosed with chain hoist)
Special design
The device includes the following special design feature(s):
........................................................................................................................................
........................................................................................................................................
........................................................................................................................................
(See appendix for special operating instructions or spare parts lists.)
If the special design requires a different spare/wearing parts list,
the parts list in the “Spare parts” section does not apply.

Operating
Instructions
VACUMASTER HHVM
Section 1
Safety
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
e-mail: [e-mail]
30.30.01.00218 / Index 00 Last updated 03/2013 Page 4/22
1 Safety
1.1 Notes for the
operating company
The lifting device is state-of-the-art and operationally reliable. However, there
are still risks:
If the device is not used by trained or at least instructed staff
If it is not used for its intended purpose (see 1.5)
In these circumstances, there is a risk of danger to:
Life and limb of the user and third parties
The device and other property belonging to the operator
1.2 Instructions for
installation,
maintenance,
and operating
personnel
This unit should only be installed and maintained by qualified specialist
personnel (mechanics). All persons commissioned with the task of setting up,
starting up, operating, maintaining and repairing the device at the company of
the user must have read and understood the operating instructions, in particular
the “Safety” section.
The company of the user must take internal measures to ensure that:
The users of the device are trained
They have read and understood the operating instructions
The operating instructions are accessible to them at all times
The warning notices on the lifting device are not removed
The responsibilities for the various tasks to be carried out on the device must be
clearly specified and observed. Responsibilities must be clear.
1.3 Safety instructions
in this manual
The safety instructions in this manual are identified as follows:
Danger
Identifies an immediate hazard. Death or serious injury may result if
disregarded.
Caution
Identifies a potentially dangerous situation. Can result in slight or minor injuries
if disregarded.
1.4 Installation location
requirements
The lifting device may not be operated in rooms where there is a risk of
explosion.
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 make checks to ensure that the vicinity of the
workplace is always clean and tidy.

Operating
Instructions
VACUMASTER HHVM
Section 1
Safety
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
e-mail: [e-mail]
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1.5 Intended use
The lifting device with pneumatic vacuum generation is used for lifting flat items,
workpieces, or plates from a range of materials at low heights, as well as porous
workpieces such as particle boards or MDF sheets. This means that the center
of gravity of the workpiece must not be lifted above 1.80 m. In addition to
purely horizontal or vertical handling, workpieces can also either be picked
up horizontally and swiveled vertically or picked up vertically and swiveled
horizontally. Workpiece swiveling is limited to +90° or -90°.
Danger
The lifting device may only be used while hung from a suspension
bar/bolt.
No people or animals may be transported with the load or the lifting
device.
For safety reasons, the lifting device may not be modified or changed
without approval.
The operating, maintenance and servicing conditions prescribed in
these operating instructions must be observed.
The maximum permissible load must not be exceeded.
1.6 Emissions
The continuous sound pressure output by the device is less than 70 db(A).
1.7 Specific hazards
As the load is held to the suction plates of the device by means of a vacuum,
it is dropped as soon as the vacuum collapses.
This can occur during a vacuum generator failure. In such cases, a built-in
reservoir maintains the vacuum for a short safety period (depends on the
density of the workpiece surface).
In the event of a failure, set down the load immediately if possible.
If this is not possible, leave the danger zone immediately.
Danger
The device generates very high suction, which can suck in hair and items
of clothing. Do not look into the suction connection when the device is
switched on. Eyes can be sucked in.
1.8 Workplaces
The user’s workplace is at the handle. Users must stand in a way that ensures
that they can see the vacuum gauge at all times.
1.9 Instructions for
users of the lifting
device
If you use the lifting device, ensure that you have been appropriately trained
before you start operations for the first time. You must have read and
understood the operating instructions, in particular the “Safety” section.
Ensure that only authorized personnel work with the device.
You are responsible for third parties in the working area of the device.
Local safety regulations apply. In Germany, this includes, but is not limited to
BGR 500.
Other safety instructions in this manual do not replace these –they are to be
considered as additions.

Operating
Instructions
VACUMASTER HHVM
Section 1
Safety
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
e-mail: [e-mail]
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1.10 Personal protective
equipment
When operating the device, always wear:
Protective work shoes (with steel toe caps)
Sturdy work gloves
1.11 What to do in an
emergency
Danger
There is an emergency
Sudden loss of power (power failure)
Device switches off
Vacuum pressure falls below -0.2 bar in the red zone of the manometer.
Set down the load immediately if possible. If this is no longer possible,
leave the danger zone immediately. The load will fall.
1.12 Check safety
equipment
The lifting device has the following safety equipment:
Manometer with red danger zone indicator
Electronic audible warning device, battery operated
Check this safety equipment at the start of every shift (if the device is not
operated continuously) or once a week (if operated continuously).
Testing the warning
device
The warning device monitors the operating vacuum and power failures.
Switch on the vacuum generator.
Place the lifting device on a smooth metal plate or on another dense, smooth
surface and apply suction.
Danger
Important: Only apply suction to the workpiece, do not lift it.
The workpiece could come loose and fall off during the inspection.
When the partial vacuum has been generated, loosen the sealing lip of the
suction plate to break the seal.
The partial vacuum on the manometer is reduced. When the partial vacuum
falls below the alarm threshold of 0.2 bar for pneumatic lifting devices, the
warning device must trigger the alarm.
Danger
The alarm threshold of the warning device is set for the lifting device and
may not be changed for safety reasons.
See the separate operating instructions for further information on the warning
device.
Checking the suction
hoses and clamps
Check that all suction hoses and hose clamps are tightly secured, tighten if
necessary.
Checking the vacuum
storage unit
See the “Leak test” section in the “Maintenance” section.
Rectify any faults before starting up the device. Should faults occur during
operation, switch off the device and rectify the faults.

Operating
Instructions
VACUMASTER HHVM
Section 2 / 3
Technical Data / Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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2 Technical Data
Vacuum generation with multi-stage ejector
Type of ejector
SEM 100 - SDA
Compressed air connection
G ¼”
Vacuum connection
G 1”
Max. suction rate [m³/h]
58.6
Noise [dB(A)] free
81
Noise [dB(A)] with suction
60
See the ejector operating instructions for the further technical information about the ejector.
The maximum permissible load is 200 kg.
The permissible load refers to a vacuum of -0.2 bar, all suction plates are covered by the workpiece.
3 Description
3.1 Description of device
Item
Description
Item
Description
1
Pivot bearing with suspension eye
8
Control handle
2
Vacuum gauge
9
Suction plate
3
Pressure reducer
10
Manual slide valve
4
Pneumatic unit
11
Suction plate holder
5
Main beam with integrated vacuum‚
storage unit
12
Pneumatic handle; snap bolts for
positions 0°, +90°, and -90°
6
Vacuum distributor
13
Valve for loosening the handle
7
Vacuum filter
The items in bold have safety functions.

Operating
Instructions
VACUMASTER HHVM
Section 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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3.2 Controls
Pressure reducer
For connecting and regulating compressed air (set by default to 5.5 bar to 6 bar
flowing compressed air pressure)
Manual sliding valve on
the control handle
Picks up and releases the load:
Push right = Pick up load, hold
Push left = Release load
(against spring tension)
To move the manual sliding valve into the “Pick up load”
or “release load” position, the locking button must be
pressed!
Locking button
“Pick up load” position
“Release load” position

Operating
Instructions
VACUMASTER HHVM
Section 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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Pivot bearing handle
According to the Intended use (section 1.5), the lifting device is used for
swiveling workpieces. The handle catches via a bolt that is permanently
extended through spring action, which is attached to the piston rod of a
double action pneumatic cylinder.
To loosen the handle or insert the bold, hold down the push-button for the
valve on the operator handle. If the bolt is loosened from the handle position
in the pivot bearing, the push-button can be released.
The handle catches at three positions on the pivot bearing: horizontal, +90°,
and -90°.
The handle can only be unlocked if the lifting device is in operating mode and
the compressed air is supplied with sufficient pressure.
f
Pneumatic cylinder
Latch bolt
Pivot bearing
Valve with push-button

Operating
Instructions
VACUMASTER HHVM
Section 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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3.3 Vacuum
generation
The vacuum generator is compact and mounted on the main beam. The
vacuum is generated by the regulated multistage ejector. The ejector is
optimally set by default. At an operating vacuum of approx. -0.6 bar in the
storage unit, the vacuum switch regulates the supply valve on the ejector so
that its compressed air intake is stopped. The ejector evacuates the vacuum
storage unit (integrated into the main beam), and a non-return valve secures
the storage unit. The pressure reducer sets the compressed air intake to the
optimum setting (factory setting of between 5 and 5.5 bar flowing compressed
air pressure). An added compressed air filter ensures clean, particle-free
compressed air in the ejector. The warning device checks the existing vacuum
in the vacuum distributor (integrated into the main beam).
3.4
3.4 Suction plates
The suction plates are used to pick up workpieces.
Danger
All suction plates must be entirely on the workpiece in order to generate
a vacuum and be able to lift loads.
(Except devices with suction plates which can be switched off).
Individual suction plates can also be switched on/off via the valves on the
suction plates.
Suction plates not used to pick up the load must be switched off; otherwise no
vacuum can be generated to lift the load.
Danger
The suction plates may only be switched on and off when they are not
bearing any load (i.e. no load picked up). If suction plates are switched
on or off when a load is being held, the vacuum collapses suddenly and
the load is dropped.
If not all suction plates are activated, the load that can be borne by the lifting
device is reduced proportionally to the number of deactivated suction plates.
Non-return valve
Multi-stage ejector
Non return valve ejector
Main beam
Pressure reduction valve
Vacuum switch
Warning device
Compressed air filter

Operating
Instructions
VACUMASTER HHVM
Section 3
Description
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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Danger
The permissible load per suction plate must not be exceeded.
3.5 Accessories
Valve for switching
individual suction
plates off
If individual suction plates are not used, they can be
manually blocked with optional valves.
When the red marking ring is visible, the valve is closed
–there is no vacuum on the suction plate!
Note that this reduces the carrying capacity of the lifting
device accordingly! Suction plates can be switched off
individually (image on the left) or in pairs (image on the
right).

Operating
Instructions
VACUMASTER HHVM
Section 4
Installation
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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4 Installation
4.1 Commissioning
This unit should only be installed and maintained by qualified specialist
personnel (mechanics).
Attach the lifting device to the suspension eye of the crane being used.
Attach it securely. Be sure to take the weight of the lifting device and the
load into account.
Operator handle
attachment
The operator handle was already attached to the main beam at the factory.
It is forbidden to remove this, as the operator handle must be installed vacuum-
tight on the main beam.
Danger
Failure to observe the maximum load of the crane will lead to
overloading.
This can cause the crane to topple over or the lifting device to fall.
The minimum load of the crane or chain hoist must be at least high enough
to equal the combined weight and load of the lifting unit.
Pneumatic connection
Ensure that there is a sufficient supply of compressed air. Minimum operating
pressure 5.5 bar (unoiled air –max. 6 bar). Connect compressed air supply to
the lifting device or pressure reducer.
After installation is completed, the system must be tested for leaks (see
“Maintenance” section).
4.2 Setting the load
holder
The load holder is permanently attached to the basic body.
Ensure that the screw connections are secure before startup.
The suction plates are adjustable. Open the clamping levers on the holders
by approx. one turn to adjust them. Adjust the suction plate to the required
distance and close the clamping lever tightly again. Ensure that the load holder
is always symmetrical to the pivot bearing.
Afterwards, check the vacuum connections (hoses).
Item
Description
1
Main beam with vacuum storage unit and distributor
2
Suction plate holder

Operating
Instructions
VACUMASTER HHVM
Section 4
Installation
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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3
Suction plate
4.3 Switching suction
plates on and off
(optional)
Suction plates can be switched on and off on lifting devices with suction plates
that can be deactivated. This is done using the valves attached to the vacuum
distributor of the main beam.
Switching off suction plates reduces the load-bearing capacity of the load
holder by the load-bearing capacity of the deactivated suction plates.
Danger
The suction plates may only be switched on and off when the lifting
device is not bearing any load.
Unused suction plates must be switched off.

Operating
Instructions
VACUMASTER HHVM
Section 5
Operation
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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5 Operation
5.1 Operational
safety
information
Local safety regulations apply. In Germany, this includes, but is not limited to
BGR 500. The following work safety instructions do not replace these –they are
to be considered as additions:
Wear protective work shoes and gloves.
Never exceed the maximum load-bearing capacity of the lifting device. Never
exceed the maximum load-bearing capacity of the hoist (e.g. crane) used.
Include the weight of the lifting device in your calculations.
Observe the specifications on the ultimate load plate.
Do not stand under the load. Always remain outside the danger zone of the
load.
Never transport people or animals with the load or the lifting device.
Do not work unless you have a good view of the entire working area.
Pay attention to other people in the working area.
Never transport the load over people.
Never leave the handle of the lifting device while a load is being lifted.
Never carry loads at an angle and never drag them.
Do not use the lifting device to break stuck loads free.
If the vacuum generator fails, set down the load immediately if possible.
Leave the danger zone immediately.
Only pick up and lift suitable loads (check inherent stability and surface
density).
Always keep an eye on the gauge. Never lift items if the vacuum is less than
–0.2 bar. If the gauge provides a reading in the red zone, set down the load
immediately.
Lower the load immediately if possible when the warning device sounds
(vacuum less than -0.2 bar).
Set down workpieces onto clear, even surfaces only, or place them vertically
on suitable frames or equipment/machines.
Otherwise, they could slide away when released.
Do not release the load until it rests completely and safely on a secure surface.
Keep your fingers clear of the load when releasing it. There is a risk of
crushing!
Always load suction areas evenly.
If not all suction plates are activated, the load-bearing capacity is reduced
proportionally to the number of unused suction plates.
Only switch suction plates on or off when they are not bearing any load
(i.e. no items picked up).
Check all seals, hoses and hose clamps regularly.
Clean and maintain the vacuum filter regularly.
It is forbidden to switch off the vacuum generator at any time during handling.
When the locking bolt is released, hold the workpiece to prevent the part from
swiveling uncontrollably
Caution
The following operating steps must be checked by a mechanic before the device is
started up by operating staff.
Rectify any faults identified during this process before starting up the device.

Operating
Instructions
VACUMASTER HHVM
Section 5
Operation
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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5.2 Lifting loads
Ensure that the compressed air supply is switched on
Switch on the vacuum generator
Position the lifting device directly above the load. Do not lift the load at an
angle.
Ensure that the load is distributed evenly.
Lower the lifting device onto the load. Ensure that all suction plates are in
contact with the load. If the device has suction plates which can be deactivated,
ensure that the unused suction plates are deactivated and that the suction
plates on the workpiece are activated.
Move the sleeve of the manual sliding valve on the handle to the “Vacuum on”
position. Suction is applied to the load.
Observe the manometer. You can lift the load as
soon as the partial vacuum reaches -0.2 bar (manometer pointer is in the green
zone).
Under no circumstances should you lift the load before this, as it will fall off.
Danger
When lifting, ensure that only one of the items is being lifted. If other items
have become attached, carefully detach them with a screwdriver or other
tool before lifting the item further. Do not use your hands to detach the item
as they may be crushed.
For more information, see the “Description” section and the separate operating
instructions for the chain hoist.
5.3 Depositing
loads
Lower the load and place it on a clear, even surface so that it cannot slip or
tilt, or
Place the load on suitable frames or equipment/machines with a slight
vertical tilt.
Press the locking button and move the sleeve
of the manual sliding valve on the handle to the
“Vacuum off” position.
The load is released.

Operating
Instructions
VACUMASTER HHVM
Section 5
Operation
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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5.4 Swiveling the
lifting device
Danger
Danger
The lifting device can be swiveled manually within a range of -90° to +90° and
locked at -90°, 0°, and +90°. If sheets need to be swiveled, it is important to
ensure that the lifting device is positioned at the center of the workpiece. If the
lifting device is off-center,
greater force is applied to swivel the sheet
and a vertically positioned workpiece is sucked and lifted up, the workpiece
swivels uncontrollably. Risk of accidents.
Swiveling
Hold the workpiece and activate the valve using the push-button on the
control handle
Swivel the workpiece slightly; the push-button can be released again
Swivel the workpiece to the required position (-90°/ 0°/ +90°)
Once you achieve the required position, the snap bolt must be locked onto
the pivot bearing.
Ensure that the snap bolt locks into place.
If a workpiece is particularly heavy, to loosen the handle the operator may
need to push the operator handle to release the snap bolt.
5.5 Moving the
lifting device
with the crane
unit
Avoid jolting movement of the lifting device (especially built up in inching mode),
as otherwise the resulting inertia of mass could cause the lifting device and any
lifted load to begin turning or swinging Risk of accidents.

Operating
Instructions
VACUMASTER HHVM
Section 6
Troubleshooting, solutions
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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6 Troubleshooting
This unit should only be installed and maintained by qualified specialist
personnel (mechanics).
After repair and maintenance work, always check safety equipment as set out
in the “Safety” operating instructions.
Problem
Cause
Solution
Vacuum generation is not
operational
No compressed air supply
Check supply system or pressure reducer
Pressure in compressed air supply
system too low
Set flowing compressed air pressure
(when ejector is running) to 5.5 to 6 bar
Filter (VFI) in compressed air supply is
dirty
Clean or replace cartridge
Vacuum of -0.2 bar not
reached
Sealing lip on suction plate is damaged
Replace suction plate
Workpiece has cracks,
gaps or is too porous
The workpiece cannot be handled with this
lifting device
Manometer defective
Replace manometer
Leaking hose/screw connections
Replace/seal components
Operating pressure too low
Set operating pressure on pressure
reducer to 5.5 to 6 bar
Not all suction plates cover the work-
piece (leaking air is being sucked in)
Position the lifting device on the workpiece
so that all suction plates completely cover
the workpiece
Optional valve on suction plates not
covered by the workpiece is open
Switch off the suction plate in question
using the valve on the suction plate
Vacuum filter is dirty
Clean or replace cartridge
Vacuum filter not closed
Mount the cover and secure it
Leaking hose/screw connections
Replace/seal components
Valve is dirty
Clean the valve (must be cleaned by
manufacturer)
Filter (VFI) in compressed air supply is
dirty
Clean or replace cartridge
Warning device activated
Workpiece has cracks, gaps or is
porous
The workpiece cannot be handled with this
lifting device
Sealing lip is damaged
Replace sealing lip
Defective hose/leaking screw
connections
Replace components
Vacuum switch misaligned/defective
See the operating instructions for vacuum
switches or contact customer services
Operating pressure too low
Set operating pressure on pressure
reducer to 5.5 to 6 bar
Valve is dirty
Clean the valve (must be cleaned by
manufacturer)

Operating
Instructions
VACUMASTER HHVM
Section 7
Maintenance
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
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7 Maintenance
7.1 General notes
This unit should only be installed and maintained by qualified specialist personnel
(mechanics).
Use cleaning solvents to clean the device (not petroleum ether or corrosive liquids,
as this will destroy or cause leaks in the vacuum hoses).
After repair and maintenance work, always check safety equipment as set out in
the “Safety” section.
7.2 Maintenance schedule
Interval
Daily
Weekly
Monthly
Every 6
months
Annual
check
Check safety equipment:
- Manometer OK?
- Does warning device emit signal at correct low/excess
pressure value?
X
X
Vacuum filter cleaned?
X
X
Compressed air filter cleaned?
X
Are the vacuum hoses in good condition (not brittle,
not kinked, no worn sections and no leaks)?
X
X
Are all connections secure, hose clamps, etc.?
X
Are the type plate and ultimate load plate still attached to
the device?
X
Is the operating manual still available and
are workers familiar with it?
X
Check all load-bearing parts (e.g. suspension eye) for
deformation, wear, or other damage.
X
Clean suction plates. Check for cracks,
evenness of suction lip, etc. and replace if necessary.
X
X
Has the test label been updated?
X
General condition of the device
X
Leak test
X
X
7.3 Suction plates/
sealing lips
Clean stuck objects and dirt such as adhesive, glue, chips, dust, etc. from sealing
lips at least once a week. Use soapy water for cleaning.
Replace damaged or worn suction plates/sealing lips immediately (cracks, holes,
corrugation).
Always replace suction plates completely.
Tip: Heating the screw connection of the suction plate makes it easier to open.
Seal the suction plate connection again when screwing on.

Operating
Instructions
VACUMASTER HHVM
Section 7
Maintenance
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
30.30.01.00218 / Index 00 Last updated 03/2013 Page 19/22
7.4 Vacuum filter
Check the filter at least once a week and blow the filter cartridge clear (from the
inside to the outside). Replace the filter cartridge if there is heavy soiling.
Danger
Important: When the vacuum filter is dirty, the vacuum at the suction grips
differs from that at the warning device.
Therefore, the vacuum filter must be cleaned and maintained regularly to
guarantee the safety of the device.
Do not beat the vacuum filter.
When removing the filter cartridge, ensure that no dust enters the lines.
7.5 Silencer
The ejector silencer can become dirty over time. For cleaning and maintenance,
see the operating instructions for the ejector (appendix).
7.6 Leak test
Carry out a leak test once a month.
To do this, position the suction plates on a dense and smooth surface,
for instance a metal sheet.
Supply the ejector with compressed air, and pick up the workpiece.
Danger
Important: Only apply suction to the sheet, do not lift it. The sheet could
work loose and fall off during the inspection.
Wait until a vacuum of approx. -0.6 bar is reached (regulated by the vacuum
switch)
Separate the compressed air supply. The vacuum should not drop by more
than 0.1 bar in 5 minutes.
If the vacuum drops at a faster rate:
Check suction plate/sealing lip, hose, hose connections and screw connections
for damage and leaks, replace if necessary.
Check whether the vacuum filter is blocked or dirty.
If necessary, clean or replace the filter cartridge.
7.7 Expert approval
In compliance with accident prevention regulations, the lifting device and the crane
unit must be tested once a year by an expert.
As a special service within Germany, J. Schmalz GmbH offers an inspection
contract for an annual test with a certificate from an expert.

Operating
Instructions
VACUMASTER HHVM
Section 8
Notes on the Type Plate
J. Schmalz GmbH
Aacher Straße 29
D - 72293 Glatten
Tel [phone] - 0
Fax [phone] / 2403 - 259
http://www.schmalz.com
[e-mail]
30.30.01.00218 / Index 00 Last updated 03/2013 Page 20/22
8 Notes on the
Type Plate
The type plate contains important information regarding the device.
The type plate is attached to the exterior of the device.
The type plate contains the following information:
Device type
Device number
Order number
Year of construction
Maximum load
Device weight
The device type, device number and year of construction are important for
identifying the device. They must always be quoted when ordering spare parts,
making warranty claims or other queries regarding the device.
Danger
The maximum load indicates the maximum load for which the device is
designed. The maximum load must not be exceeded.
The device weight indicated on the type plate must be taken into account when
using the device on a hoist (e.g. crane, chain hoist).