J. D. NEUHAUS Profi 025Ti Page 2 Operation Manual Download

Page: 2 / 218

Please enter the Fabr. No. of your JDN Air Hoist here.

This operation manual, edition 4/2005,
covers the following JDN Air Hoists:

Before operating any hoist, carefully read the
entire manual. For hoists mounted in trolleys,
refer also to the

JDN Trolleys

Operation Manual.

Page 2

Fabr. No.

Summary of Contents for Profi 025Ti

Page 1: ...powered by air J D N O P E R A T I O N M A N U A L A I R H O I S T S...

Page 2: ...eration manual edition 4 2005 covers the following JDN Air Hoists Before operating any hoist carefully read the entire manual For hoists mounted in trolleys refer also to the JDN Trolleys Operation Ma...

Page 3: ...ed shutdown 37 Storage 37 Dismantling 37 Disposal 37 Maintenance and inspection intervals 38 Cleaning and care 38 Spare parts 38 Lubricants 38 Inspection and maintenance work 38 Instructions on the mo...

Page 4: ...with BGV D6 Accident Prevention Regulations for Cranes in the respective currently applicable version Operators must also initiate the prescribed tests see also Principles for the Testing of Cranes B...

Page 5: ...y and hazard awareness during work Ensure that only properly trained personnel are entrust ed with operation maintenance inspection and repair Properly trained in this case means that the operator has...

Page 6: ...operation manual are classified in three categories DANGER Safety warnings which if not followed can result in hazard to life and limb are indicated by this symbol The symbol indicates an immediate d...

Page 7: ...g operation of JDN Air Hoists which are not addressed in this opera tion manual please contact us at the following address J D NEUHAUS GMBH CO KG Windenstra e 2 4 D 58455 Witten Heven Germany Phone 49...

Page 8: ...tioning of the load series JDN Air Hoists conform to driving mechanism classification as indicated in the following table JDN Air Hoist motors feature rotors with grease chambers These contain JDN hig...

Page 9: ...XPLO SIVE DUSTS Following separate tests especially with regard to ambient temperatures and type of operation use in the presence of carbon disulphide or dusts with particularly low glow or ignition t...

Page 10: ...al handling of the devices in mining applications special mining hoists are available from J D NEUHAUS The maximum permissible surface temperature of 150 C in accordance with EN 13463 15 for coal dust...

Page 11: ...ks must be earthed on site Running wheels and rail surfaces must never be painted as this can result in unacceptably high earth leakage resistance values Earthing of the load hook is via the chain see...

Page 12: ...alcohol Fuel oil 1 2 Dichlorobenzene 1 Butylene n Hexane Acetic acid 1 2 Dichloroethane Jet fuels Ethane Di i Propyl ether Ethyl acetate Natural gas Ethyl bromide Acetic anhydride Ethyl chloride n Pr...

Page 13: ...used for the extremely slow running chain drives of large hoists so that the sliding velocity for potential friction points between the chain and the surroundings remains well below 1 m s FS Hoists w...

Page 14: ...s of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres 2 DIN EN 1127 1 Explosive atmospheres Explosion prevention and protection Part...

Page 15: ...onal regulations In combination with trolleys JDN Air Hoists are also suitable for the floorless horizontal movement of loads Any other use or use outside these stipulations is deemed to be impermissi...

Page 16: ...meplate If the system pressure is too low important functions of the hoist will be impaired The brake will drag and is thus subject to a high degree of wear An impermissibly high degree of warming cou...

Page 17: ...which the hoist is operated depends upon the weight of the load and the direction of movement of the load When lifting the nominal load load carrying capacity the actual pressure p2 must not fall belo...

Page 18: ...r force is created at the leading larger vane surface 4 1 than that at the trailing smaller vane surface 4 2 The difference in force generates the rotor torque As the chamber passes the outlet apertur...

Page 19: ...ure regulation of the compressed air can be installed with out an oiler If required the service unit is also avail able with an oiler Synthetic lubricants must not be used when operating with a servic...

Page 20: ...ION In the case of longer operational breaks coat the chain and hook with a light oil film Motor conservation If the motor lubrication is not renewed at the speci fied intervals a protective coating m...

Page 21: ...THE CHAIN SECTION PAGE 44 Mounting the trolley see trolley operation manual DANGER JDN Air Hoists must only be installed by qualified persons A defective installation can result in the most serious o...

Page 22: ...ond to the actual direction of movement CONNECTING THE E CONTROLS Pushbutton valve hand control Guide the strain relief cable through the eye on the pushbutton valve and secure using the cable clamp P...

Page 23: ...oses through the bellows frame secure the strain relief cable connect the hoses to the hose nipples and secure the one ear hose clamps using crimping tool Insert the bellows frame into the profile of...

Page 24: ...just the strain relief ropes accordingly Insert the bellows frame into the profile of the bellows insert bellows clamps long end pointing inward and secure to the control valve using bolts 2 x M5 CONN...

Page 25: ...clamp Installation facilitation Heat the protective sleeve hose sheathing with a hot air gun and grease the hose carrier Slightly bend open the ring of the eye bolt in order to attach the hose carrie...

Page 26: ...r Further see section Connecting the rope controls page 22 Check air connection for contamination and clean if necessary Blow through compressed air hose in order to remove foreign bodies Attach the c...

Page 27: ...902 40 g Compressed air oil D kinematic viscosity approx 30 mm2 s cSt at 40 C with anti icing agent where applicable Chain lubrication chain oil or motor vehicle engine oil kinematic viscosity approx...

Page 28: ...proper mounting equipment level and operational readiness in the main the com pleteness suitability and effectiveness of the safety devices as well as the condition of the device the har ness the equ...

Page 29: ...d in those applications in which the load carrying capacity does not change with the position of the load Oblique pulling of loads in general Definition of oblique pulling Oblique pulling is the devia...

Page 30: ...ust hang vertically before lifting Ensure that the hook safety catch is closed Repair damaged hook safety catches Before lifting loads ensure that the maximum per missible load is not exceeded Attachi...

Page 31: ...ins Danger of frac ture This process is promoted by so called recombination poisons Examples of these are hydrogen sulphide cyanide arsenic com pounds and rhodanide If rusty chains are not replaced fo...

Page 32: ...l pressure is applied from the hand control the valve opens and releases the main stream If the red EMERGENCY STOP button on the hand control is pressed all control lines are depressurised and the mai...

Page 33: ...ecise positioning of the load The direction of movement of the load hook is marked by arrows on the pushbuttons Lift Carefully press the right pushbutton The load is lifted slowly Press the pushbutton...

Page 34: ...reversing valve are positively connected to one anoth er This connection is designed in such a way that in an emergency the control valve can be reset to a stable neutral position Thus no additional E...

Page 35: ...ciation regulations Operation of Load carrying Devices Used with Lifting Equipment must be observed BVR 259 In other countries the relevant national regulations are applicable Attaching aids must be a...

Page 36: ...59 DANGER Ensure that there are no persons below the load Then lower the load and ground it carefully DANGER For all air hoist applications ensure that the load hook can be lowered all the way to the...

Page 37: ...detach dismount the hoist and remove For trolleys proceed in reverse order to that described in the section on mounting trolleys in the trolley operation manual JDN hoists contain a range of materials...

Page 38: ...n from 75 of on time the theoretical operating time is reduced due to the higher lowering speed in the range from 50 to 100 of the nominal load Therefore the determined portion of the theoretical oper...

Page 39: ...n from that used for calculation extend or shorten the safe operating period For all inspection work which is not a part of the daily inspection suitable access must be made to the hoist The hoist mus...

Page 40: ...40 Weight of harness Load bearing capacity 0 05 Collective load Definition Cubic Collective load factor average 1 L1 Driving mechanisms or parts thereof which are only subject k 0 50 low to the maxim...

Page 41: ...perating time in hours Collective load factor in accor dance withcollective load for the type of operation Partial deploy ment Remaining theoretical use in collective load 4 When zero has been reached...

Page 42: ...aily Section Checking direction of movement page 45 Lifting and lowering limiters Daily Replace buffer immediately if damaged buffers visual check otherwise replace every 5 years Check EMERGENCY STOP...

Page 43: ...49 In off shore areas and other similar Every 5 years corrosive environments replace the chain regularly Check gearbox and perform lubricant Every 5 years change Check the rotor pinion shaft connec Ev...

Page 44: ...rication intervals must be stipulated in accordance with the loading Please contact us if required Check the function of the brake daily as follows Switch the unloaded air hoist alternately between li...

Page 45: ...movement of the hoist must stop Actuation of the control ele ments must not cause a lifting or lowering movement RELEASE the EMERGENCY STOP button by turning DANGER If a control element is stiff or r...

Page 46: ...e regulator knob Turn the regulator knob until the manometer indicates a pressure of 5 4 bar 3 6 bar Clockwise higher pressure Anti clockwise lower pressure Lock the regulator knob by pressing it down...

Page 47: ...sing soap solution The filter element must be cleaned once annually For this purpose proceed as follows Drain the water Shut off the main air supply and carefully allow the residual pressure to dissip...

Page 48: ...a screwdriver until the desired number of drops per minute is achieved Turning clockwise reduces the amount of oil turning anti clockwise increases the amount of oil Oil drop rate lifting without load...

Page 49: ...prings 4 is fully released Remove the brake springs Remove the brake piston 5 from the internal cylinder integrated in the motor housing Pull out the rotor 6 removing the vanes 7 and starting aids 8 C...

Page 50: ...g lightly with high performance grease Coat the entire rotor lightly with high performance grease and insert into the front rotor bearing with the clutch side first Coat the vanes lightly with high pe...

Page 51: ...ion bolts Install the control valve CAUTION Tightening torques see E list WARNING Check the braking action of the hoist under load run in the brake by performing several hoisting cycles then assess pr...

Page 52: ...ive in a new roll pin to secure the chain link in the load sleeve REMOVING AND INSTALLING BOTTOM BLOCK AND BUFFERS DUAL CHAIN HOIST 2 TI Removal Move the bottom block as close as possible to the hoist...

Page 53: ...push the chain link pin through the chain link to be attached position of the weld must align with that of the following links Drive in a new roll pin to secure the end link pin REMOVING AND INSTALLI...

Page 54: ...next checking date must be taken into account If the chain dimension values are outside the limit val ues specified in the table when checked the chain has reached its replacement limit and must be re...

Page 55: ...r wear and when the wear dimension of 0 9 mm is reached with regard to chain guide diameters or hook mounts in the centre section of the device Replace the housing The wear dimension must be measured...

Page 56: ...e increased HAZARDS IN THE CASE OF INSUFFICIENT MAINTENANCE LUBRICATION DANGER In the event of insufficient maintenance lubrication the extent of wear may be so high that there is a danger of loads fa...

Page 57: ...he old chain after aligning the welds and the first chain link by means of an open chain link The welds on the upright chain links must face outwards when running over the chain sprockets If the first...

Page 58: ...dle chain side The first chain link 4 must run upright over the drive sprocket with the weld facing outwards Switch the hoist to the lower rotational direction and detach the assembly chain from the c...

Page 59: ...is attached Attach overload of 125 of the load carrying capacity If this overload is lifted the adjusting bolt must be adjusted clockwise until it is no longer possible to lift the overload If the ove...

Page 60: ...operly Cross section of air line too small Use air line with sufficiently large diameter check air pressure Dirt in the service unit Clean the service unit ensure better air Filter blocked quality Sil...

Page 61: ...t Turn the drain valve 4 90 and allow the fluid to drain out Close the drain valve The filter must be replaced after approx 2500 hours of operation Turn the collecting container 3 slightly and detach...

Page 62: ...ng see section Removing and installing chain page 57 ATTENTION Never allow the chain to pile up in the chain box The chain must only enter the container via the chain drive If it falls out of the cont...

Page 63: ...peed at nominal load m min 38 17 11 5 5 Air consumption at nominal load m3 min 1 2 1 2 1 2 1 2 lifting Air consumption at nominal load m3 min 1 5 1 5 1 5 1 5 lowering Air connection G1 2 G1 2 G1 2 G1...

Page 64: ...e 025 TI 05 TI 1 TI 2 TI A Minimum headroom 450 450 450 498 B 288 288 288 336 C 145 145 145 145 D 297 297 297 297 E1 28 28 28 28 E2 28 28 28 28 F to centre of hook without chain box 137 137 137 137 G...

Page 65: ...powered by air NOTES Page 65...

Page 66: ...powered by air NOTES Page 66...

Page 67: ...powered by air NOTES Page 67...

Page 68: ...D Neuhaus GmbH Co KG_D 58449 Witten Heven Phone 49 2302 208 0_Fax 49 2302 208 286 Web site www jdn de_E mail info jdn de is a registered trade mark of our company BA 817 GB Issue April 2005 Subject t...

Page 69: ...powered by air J D N O P E R A T I O N A N D A S S E M B LY I N S T R U C T I O N S A I R H O I S T S 3 Original Operation and Assembly Instructions...

Page 70: ...tion manual edition 12 2009 covers the following JDN Air Hoists It must be read carefully and in its entirety before operating any hoist For hoists installed in trolleys please also refer to the opera...

Page 71: ...Storage 38 Dismantling 38 Disposal 38 Maintenance and inspection intervals 39 Cleaning and care 39 Spare parts 39 Lubricants 39 Inspection and repairs 39 Instructions concerning the model for determi...

Page 72: ...Regulations for Cranes in the respective currently applicable version Operators must also initiate the prescribed tests see also Principles for the Testing of Cranes BGG 905 ZH 1 27 To document the t...

Page 73: ...zard awareness during work Personnel who operate maintain inspect and perform setting up work on the hoist must be properly trained or must receive an introduction from properly trained personnel befo...

Page 74: ...nings in this operation manual are classified in three categories DANGER Safety warnings which if not followed can result in danger to life and limb are indicated by this symbol The symbol indi cates...

Page 75: ...286 www jdn de e mail info jdn de Example of nameplate on housing cover 1 5TI 1 2 1 6 t 3 2 t 4 6m min 2 3 m min 2009 6200001 4 6 bar M3 1Bm 9 x 27 TN II 2 GD IIA T4 X II 3 GD IIB T4 X Typ Type Baujah...

Page 76: ...ovement This enables precise positioning of the load PROFI TI series JDN Air Hoists conform to driving mechanism classification in the following table PROFI TI JDN Air Hoists feature rotors with greas...

Page 77: ...HOISTS FOR USE IN THE PRESENCE OF TEMPERATURE CLASS T6 GASES OR EXTREMELY EXPLOSIVE DUSTS Following separate tests especially with regard to ambient temperatures and type of operation use in the prese...

Page 78: ...ing environmental influences For other difficult conditions in addition to explosion protection prevailing with regard to the general handling of the devices in mining applications special mining hois...

Page 79: ...inted as this can result in unacceptably high earth leakage resistance values Earthing of the load hook is via the chain see also Load chain page 10 Loads must be earthed during transportation A separ...

Page 80: ...Butyl alcohol Heating oil 1 2 Dichlorbenzene 1 Butylene n Hexane Acetic acid 1 2 Dichlorethane Jet fuels Ethane Di i propyl ether Ethyl acetate Natural gas ethyl bromide Acetic anhydride Ethyl chlorid...

Page 81: ...nly used for the extremely slow running chain drives of large hoists so that the sliding velocity for potential friction points between the chain and the surroundings remains well below 1 m s SP Hoist...

Page 82: ...the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres 2 DIN EN 1127 1 Explosive atmospheres Explosion prevention and protection Part 1 Ba...

Page 83: ...onal regulations In combination with trolleys JDN Air Hoists are also suitable for the floorless horizontal movement of loads Any other use or use outside these stipulations is deemed to be impermissi...

Page 84: ...If the system pressure is too low important functions of the hoist will be impaired The brake will drag and is thus subject to a high degree of wear An impermissibly high degree of warming could take...

Page 85: ...which the hoist is operated depends upon the weight of the load and the direction of movement of the load When lifting the nominal load load carrying capacity the actual pressure p2 must not fall belo...

Page 86: ...er force is created at the leading larger vane surface 4 1 than that at the trailing smaller vane surface 4 2 The difference in force generates the rotor torque As the chamber passes the outlet apertu...

Page 87: ...available with an oiler Synthetic lubricants must not be used when operating with a service unit Alcohols are not permitted for use as anti icing agents ATTENTION During operation with oil the grease...

Page 88: ...ION In the case of longer operational breaks coat the chain and hook with a light oil film Motor conservation If the motor lubrication is not renewed after the specified intervals the motor must be co...

Page 89: ...ATING THE CHAIN PAGE 45 Mounting the trolley see trolley operation manual DANGER JDN Air Hoists must only be installed by qualified personnel Faulty installation can lead to serious accidents DANGER T...

Page 90: ...to the actual direction of movement CONNECTING THE E CONTROLS Pushbutton valve hand control Guide the strain relief cable through the eye on the pushbutton valve and secure using the cable clamp Push...

Page 91: ...r enough to permit further installa tion Push the one ear clamps onto the free ends of the hoses Illustration of bellows with hoses and strain relief rope Removal Pinched one ear clamp and crimping to...

Page 92: ...the three hoses through the middle of the bellows and inserted into the hexagon socket of the bolt CONNECTING F CONTROLS Pull the bellows over the hose bundle for F control For F control for lifting a...

Page 93: ...lt see illustration on page 24 bottom Conversion to another type of control is a significant modification to a hoist Following conversion national safety regulations including testing regulations must...

Page 94: ...thing with a hot air gun and grease the hose carrier Slightly bend open the ring of the eye bolt in order to attach the hose carrier Close the ring again to prevent detaching Insert the control hoses...

Page 95: ...e rope control lever onto the control lever and secure with the M6 x 12 bolt and washer It must be ensured that the both ends of the control lever point downwards in the direction of the load hook and...

Page 96: ...r motor oil type D kinematic viscosity approx 30 mm2 s cSt at 40 C anti icing additive if required Chain lubrication Chain oil or motor vehicle engine oil kinematic viscosi ty approx 150 mm2 s cSt at...

Page 97: ...g equipment level and operational readiness etc in the main the completeness suitability and effectiveness of the safety devices as well as the condition of the device the harness the equipment and th...

Page 98: ...ith the position of the load Oblique pulling of loads in general Definition of oblique pulling Oblique pulling is the deviation of the load chain and the chain hoist from the vertical position for a f...

Page 99: ...hook safety catch is closed Repair damaged hook safety catches Before lifting loads ensure that the maximum permitted load is not exceeded Sling gear must be included in the weight of the load When ta...

Page 100: ...sk of fracture This process is promoted by so called recombination poisons Examples of these are hydrogen sulphide cyanide arsenic compounds and rhodanide If rusty chains are not replaced for operatio...

Page 101: ...button on the hand control is pressed all control lines are depressurised and the main stream valve is closed Air control E F FI controls without upstream main stream valve The control valve consists...

Page 102: ...cise positioning of the load The direction of movement of the load hook is marked by arrows on the pushbuttons Lift Carefully press the right pushbutton The load is lifted slowly Press the pushbutton...

Page 103: ...vements are controlled directly Both rope ends are connected to one another via a handle enabling precise one hand operation The direction of movement is marked by arrows on the handle The control ele...

Page 104: ...elow the load size set We therefore re commend tensioning the slack chain before lifting the load DANGER Only use attaching cables or attaching chains which are suitable for the load Attaching must no...

Page 105: ...59 DANGER Ensure that there are no persons below the load Then lower the load and ground it carefully DANGER For all air hoist applications ensure that the load hook can be lowered all the way to the...

Page 106: ...arefully detach dismount the hoist and remove For trolleys proceed in reverse order to that described in the section on mounting trolleys in the trolley operation manual JDN Hoists contain a range of...

Page 107: ...to the higher lowering speed in the range from 50 to 100 of the nominal load Therefore the determined portion of the theoretical operating time must be multiplied by a factor of fv The factor fv has...

Page 108: ...n from that used for calculation extend or shorten the safe operating period For all inspection work which is not a part of the daily inspection suitable access must be made to the hoist The hoist mus...

Page 109: ...of operation for calculating the partial operating times actual operating time the following load spectrum diagrams can also be used INSTRUCTIONS CONCERNING THE MODEL FOR DETERMINING THE ACTUAL OPERA...

Page 110: ...age daily opera ting time in hours Load spectrum factor in accordance with load spectrum for the type of operation Partial deployment Remaining theoretical use in load spectrum 4 When zero has been re...

Page 111: ...aily Checking direction of movement section page 46 Check lifting and lowering limiters Daily Replace buffer immediately if damaged otherwise buffers visually replace every 5 years Check EMERGENCY STO...

Page 112: ...50 replace motor vanes every 5 years In off shore areas and other similar Every 5 years corrosive environments replace the chain regularly Check gearbox and perform Every 5 years lubricant change Chec...

Page 113: ...adhesion properties Re lubrication intervals must be stipulated in accor dance with the loading Please contact us if required Check the function of the brake daily as follows Switch the unloaded air h...

Page 114: ...repaired The main air emergency stop valve is opened with each actuation of the controls It closes when the controls are released Main air emergency stop valve With each check the working order of the...

Page 115: ...f For correct adjustment a pressure of at least 1 bar above the nominal pressure is required upstream of the service unit Lift the regulator knob Turn the regulator knob until the manometer indicates...

Page 116: ...sure upstream of the servi ce unit falls below 0 2 bar the container empties automatically With this setting it must be ensured that a suitable container is in place to collect the escaping condensate...

Page 117: ...ng a screwdriver until the desired number of drops per minute is achieved Turning clockwise reduces the amount of oil turning anti clockwise increases the amount of oil Oil drop rate lifting without l...

Page 118: ...Remove the brake springs Remove the brake piston 5 from the internal cylinder integrated in the motor housing Pull out the rotor 6 removing the vanes 7 and starting aids 8 Checking vane wear See Fig...

Page 119: ...high performance grease Coat the entire rotor lightly with high performance grease and insert into the front rotor bearing with the clutch side first Coat the vanes lightly with high performance grea...

Page 120: ...n bolts Install the control valve ATTENTION Tightening torques see E list CAUTION Check the braking action of the hoist under load run in the brake by performing several hoisting cycles then assess pr...

Page 121: ...the shaped element into the chain pocket install and tighten the bolt with the retaining washer change tightening torque to 8 Nm REMOVING AND INSTALLING BOTTOM BLOCK AND BUFFER DUAL CHAIN HOIST 3 TI 2...

Page 122: ...push the chain link pin through the chain link to be attached position of the weld must align with that of the following links Drive in a new roll pin to secure the end link pin REMOVING AND INSTALLI...

Page 123: ...the next inspection date must be taken into account If the chain dimension values are outside the limit values specified in the table when checked the chain has reached its replacement limit and must...

Page 124: ...nsion of 1 mm is reached with regard to chain guide diameters or hook mounts in the centre section of the device Replace the housing The wear dimension must be measured at the points on the guide surf...

Page 125: ...increased HAZARDS IN THE CASE OF INSUFFICIENT MAINTENANCE LUBRICATION DANGER In the event of insufficient mainte nance lubrication the extent of wear may be so high that there is a danger of loads fal...

Page 126: ...in after aligning the welds and the first chain link by means of an open chain link The welds on the upright chain links must face outwards when running over the chain sprockets If the first link of t...

Page 127: ...er it has been aligned is pulled over the deflection sprocket of the bottom block using the assembly chain Note If the chain link on the idle chain side is positioned incorrectly it must be removed th...

Page 128: ...more as the setting will be altered Check the limit value for correct setting Install the gearbox cover RESETTING THE LIMIT VALUE Loosen the lock nuts Screw out the threaded pins anti clockwise until...

Page 129: ...loose Tighten the bolts Air supply hoses leaking or Check connections of air supply hose and loose control hoses and connect properly Cross section of air line too small Use air line with sufficiently...

Page 130: ...Turn the drain valve 4 90 and allow the fluid to drain out Close the drain valve The filter must be replaced after approx 2500 hours of operation Turn the collecting container 3 slightly and detach U...

Page 131: ...oist position This is facilitated by a suspension point on the rear of the box We will be happy to answer any questions on this matter Modifications may only be made to the chain box on agreement with...

Page 132: ...at nominal load m min 11 to 12 5 5 to 6 Air consumption at nominal load lifting m3 min 1 5 to 2 6 1 5 to 2 6 Air consumption at nominal load lowering m3 min 2 2 to 3 6 2 2 to 3 6 Air connection G1 2...

Page 133: ...X Page 65 Type 1 5 TI 3 TI 2 A minimum headroom 480 544 B mm 293 356 C mm 200 200 D mm 412 412 E1 mm 28 28 E2 mm 26 28 F to centre of hook without chain box mm 170 140 G maximum width mm 215 215 Chain...

Page 134: ...ENDIX Page 66 ROPE CONTROL WITHOUT MAIN AIR EMERGENCY STOP VALVE CIRCUIT DIAGRAM silencer brake lifting motor A B motor A B control valve 2 BI rope control valve lifting lowering main air connection s...

Page 135: ...CTION WITHOUT EMERGENCY STOP DEVICE WITHOUT MAIN AIR EMERGENCY STOP VALVE NOT FOR EEA CIRCUIT DIAGRAM silencer brake lifting motor A B motor A B control valve 2 BI air Steuerventil main air connection...

Page 136: ...TH EMERGENCY STOP DEVICE WITH MAIN AIR EMERGENCY STOP VALVE CIRCUIT DIAGRAM silencer brake lifting motor A B motor A B control valve 2 BI air HS control valve main air connection service unit P E P Y...

Page 137: ...Y STOP DEVICE WITHOUT MAIN AIR EMERGENCY STOP VALVE NOT FOR EEA CIRCUIT DIAGRAM silencer brake lifting motor A B motor A B control valve 2 BI air control valve main air connection service unit P E P Y...

Page 138: ...TH EXTERNAL MAIN AIR EMERGENCY STOP VALVE CIRCUIT DIAGRAM brake lifting motor A B motor A B control valve 2 BI air control valve main air connection service unit P E P Y Z push button valve E 4fold em...

Page 139: ...FUNCTION WITH EMERGENCY STOP DEVICE WITH MAIN AIR EMERGENCY STOP VALVE CIRCUIT DIAGRAM silencer brake lifting motor A B motor A B control valve 2 BI air HS control valve main air connection service un...

Page 140: ...EXTERNAL MAIN AIR EMERGENCY STOP VALVE CIRCUIT DIAGRAM brake lifting motor A B motor A B 2 2 way valve for emergency stop control valve main air connection service unit P E P Y Z multi button pendent...

Page 141: ...ton pendent switches 7 fold driving motor silencer emergency stop control valve 2 BI air A B A B brake motor Y P X Z silencer A B lifting motor brake motor Y P X Z silencer A B driving motor brake mot...

Page 142: ...by air J D Neuhaus GmbH Co KG D 58449 Witten Heven Phone 49 2302 208 0 Fax 49 2302 208 286 web site www jdn de e mail info jdn de is a registered trade mark of our company BA 820 GB Subject to changes...

Page 143: ...powered by air J D N O P E R AT I O N A N D A S S E M B LY I N S T R U C T I O N S A I R H O I S T S M O N O R A I L H O I S T S E H 1 0 E H 1 6 E H 2 0 20 Original Operation and Assembly Instructions...

Page 144: ...nd the following JDN Monorail Hoists EH only in conjunction with the operation manual JDN Trolleys It must be read carefully and in its entirety before operating any air hoist For hoists installed in...

Page 145: ...down 36 Storage 36 Dismantling 36 Disposal 36 Maintenance and inspection intervals 37 Cleaning and care 37 Spare parts 37 Lubricants 37 Inspection and repairs 37 Instructions concerning the model for...

Page 146: ...egulations for Cranes in the respective currently applicable version Operators must also initiate the prescribed tests see also Prin ciples for the Testing of Cranes BGG 905 ZH 1 27 To document the te...

Page 147: ...ety and hazard awareness during work Personnel who operate maintain inspect and perform setting up work on the hoist must be properly trained or must receive an introduction from properly trained pers...

Page 148: ...nings in this operation manual are classified in three categories DANGER Safety warnings which if not followed can result in hazard to life and limb are indicated by this symbol The symbol indicates a...

Page 149: ...operation of JDN Air Hoists which are not addressed in this operation manual please contact us at the following address J D NEUHAUS GMBH CO KG Windenstra e 2 4 D 58455 Witten Heven Phone 49 2302 208 0...

Page 150: ...the hoist together with the appropriate controls is capable of sensitive movement This enables precise positioning of the load PROFI TI JDN Air Hoist and EH motors feature rotors with grease chambers...

Page 151: ...MELY EXPLOSIVE DUSTS Following separate tests especially with regard to ambient temperatures and type of operation use in the presence of carbon disulphide or dusts with particularly low glow or ignit...

Page 152: ...the general handling of the devices in mining applications special mining hoists are available from J D NEUHAUS The maximum permissible temperature of 150 C in accordance with EN 13463 15 for coal du...

Page 153: ...ing of the load hook is via the chain see also Load chain page 10 Loads must be earthed during transportation A separate earth is required for example when using non conducting sling gear CLEANING PLA...

Page 154: ...cohol Fuel oil 1 2 Dichlorobenzene 1 Butylene n Hexane Acetic acid 1 2 Dichloroethane jet fuels Ethane Di i Propyl ether Ethyl acetate Natural gas Ethyl bromide Acetic anhydride Ethyl chloride n Propy...

Page 155: ...s of large hoists so that the sliding velocity for potential friction points between the chain and the surroundings remains well below 1 m s SP Hoists with increased spark protection Copper plated loa...

Page 156: ...the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres 2 DIN EN 1127 1 Explosive atmospheres Explosion prevention and protection Part 1 Ba...

Page 157: ...ission values JDN Air Hoists are extremely robust and require little maintenance They are suitable for use in explosion hazardous areas as well as in areas with increased concentrations of soot and du...

Page 158: ...or below 0 C there is a danger of icing in the motor Icing can be prevented by the use of an upstream air dryer or using a service unit with oiler adding anti icing agent to the lubrication oil depen...

Page 159: ...which the hoist is operated depends upon the weight of the load and the direction of movement of the load When lifting the nominal load load carrying capacity the actual pressure p2 must not fall belo...

Page 160: ...r force is created at the leading larger vane surface 4 1 than that at the trailing smaller vane surface 4 2 The difference in force generates the rotor torque As the chamber passes the outlet apertur...

Page 161: ...thout an oiler If required the service unit is also available with an oiler Synthetic lubricants must not be used when operating with a service unit Alcohols are not permitted for use as anti icing ag...

Page 162: ...hain BREAKS IN OPERATION In the case of longer operational breaks coat the chain and hook with a light oil film Motor conservation If the motor lubrication is not renewed after the specified intervals...

Page 163: ...re accidents DANGER The attachment points for JDN Air Hoists must be able to safely withstand the expected forces DANGER The supporting structure of the air hoist must form a rigid mounting Vibration...

Page 164: ...nd to the actual direction of movement E CONTROL CONNECTION Pushbutton valve hand control Guide the strain relief cable through the eye on the pushbutton valve and secure using the cable clamp Push th...

Page 165: ...r enough to permit further installation Push the one ear clamps onto the free ends of the hoses Illustration of bellows with hoses and strain relief rope Removal Pinched one ear clamp and crimping too...

Page 166: ...etween the three hoses through the middle of the bellows and inserted into the hexagon socket of the bolt F CONTROL CONNECTION Pull the bellows over the hose bundle for F control For F control for lif...

Page 167: ...tom Conversion to another type of control is a significant modification to a hoist Following conversion national safety regulations including testing regulations must be observed If you wish to exchan...

Page 168: ...ed ATTENTION The control hoses must not be subject to tensile load adjust the protective sleeve accordingly Pull the bellows over the hose adapter and secure via the central bolt see illustration on p...

Page 169: ...o receive the appropriate instructions CAUTION Oils and greases can cause skin irritation Wear protective gloves ATTENTION Potential damage Do not mix synthetic oils or greases with mineral oils as th...

Page 170: ...Page 28 Application Lubricant Motor lubrication JDN high performance grease from factory Art No 11901 250 ml when operating with oiler Compressed air oil D kinematic viscosity approx 30 mm2 s cSt at...

Page 171: ...st from the vertical position for a force acting in a straight line between the point of force application of the load on the load hook and the point of suspension on the supporting structure Under sp...

Page 172: ...loads ensure that the maximum per missible load is not exceeded Attaching aids must be included in the weight of the load During lifting and lowering prevent accidents by ensuring that the load remai...

Page 173: ...chains Danger of fracture This process is promoted by so called recombination poisons Examples of these are hydrogen sulphide cyanide arsenic compounds and rhodanide If rusty chains are not replaced...

Page 174: ...positioner is mechanically connected to the rotary valve drive The positioner is actuated by the control air Air control E F FI control Control valve without upstream main stream valve The control va...

Page 175: ...cise positioning of the load The direction of movement of the load hook is marked by arrows on the pushbuttons Lift Carefully press the right pushbutton The load is lifted slowly Press the pushbutton...

Page 176: ...ws on the handle The control elements for rope control and the energy switching component of the control valve on the motor reversing valve are positively connected to one another This connection is d...

Page 177: ...e lifting operation in the event of loads whose weight is more than the pre defined limit value for the overload protection see Overload protection section page 59 DANGER Ensure that there are no pers...

Page 178: ...remove the control device Carefully detach dismount the hoist and remove For trolleys proceed in reverse order to that described in the section on mounting trolleys in the trolley operation manual JDN...

Page 179: ...due to the higher lowering speed in the range from 50 to 100 of the nominal load Therefore the determined portion of the theoretical operating time must be multiplied by a factor of fv The factor fv...

Page 180: ...n from that used for calculation extend or shorten the safe operating period For all inspection work which is not a part of the daily inspection suitable access must be made to the hoist The hoist mus...

Page 181: ...ge 39 Collective load 1 Collective load 2 Load proportions t2 t1 t t3 0 4 0 1 0 733 0 467 0 2 0 10 50 100 0 16 7 33 3 50 100 t2 t1 t 1 Collective load 3 Collective load 4 Load proportions t1 t 0 4 0 8...

Page 182: ...daily operating time in hours Collective load factor in accor dance withcollective load for the type of operation Partial deployment Remaining theoretical use in collective load 4 When zero has been...

Page 183: ...l valve JDN high performance grease Check the axial movement of the hooks and eyes Check the service unit 1 Check the silencer for permeability Check overload protection Check compressed air connectio...

Page 184: ...ularly Check gearbox and perform lubricant change Check the rotor pinion shaft connec tion and lubricate with gear grease Check the chain sprocket bearings and lubricate if necessary Check chain sproc...

Page 185: ...do not use the hoist The hoist must be repaired For physical reasons the braking distance cannot have the value zero However for the purpose of this functional check running on of the chain must not...

Page 186: ...he line Remove retaining ring 1 Pull out cover 2 Press plunger 3 inwards against the force of spring 4 It must return again due to the spring force If the plunger does not move the valve must be repai...

Page 187: ...of at least 7 bar 5 bar upstream of the service unit is required Lift the regulator knob Turn the regulator knob until the manometer indicates a pressure of 5 4 bar 3 6 bar Clockwise higher pressure A...

Page 188: ...ure upstream of the service unit falls below 0 2 bar the container empties automatically With this setting it must be ensured that a suitable container is in place to collect the escaping condensate w...

Page 189: ...screwdriver until the desired number of drops per minute is achieved Turning clockwise reduces the amount of oil turning anti clockwise increases the amount of oil Oil drop rate lifting without load 1...

Page 190: ...lace the vanes with the starting aids please continue with the section Checking for vane wear Remove the cover bolts 9 and remove the cover with the brake lining 10 brake disc Check the braking surfac...

Page 191: ...surface first into the internal cylinder note the position of the eccentric bore Insert the brake springs into the bores of the brake piston Detach the nameplate from the motor cover Loosen adjusting...

Page 192: ...n the load sleeve LOAD SLEEVE IN SPECIAL DESIGN WITH CLAMPING PIECE Removal Loosen screw 7 and take it out of the chain pocket together with locking washer 6 and clamping piece 1 Remove the chain link...

Page 193: ...n from the bottom block The buffer 7 and buffer discs 8 are thereby pulled from the chain Assembly Push the buffer discs edge encloses buffer and the buffer onto the chain Align the chain and fasten i...

Page 194: ...ments 8 and 9 are thereby pulled from the chain Assembly Push the buffer assembly buffer 6 plus buffer discs 7 edge encloses buffer onto the chain Align the chain and fasten it to the assembly chain i...

Page 195: ...ith chain box three additional run on elements are provided on the bottom block see spare parts list Assembly Push the buffer assembly buffer 9 plus buffer discs 10 edge encloses buffer onto the chain...

Page 196: ...On version PROFI 20TI with chain box it must be ensured that the three additional run on elements remain on the chain see spare parts list Assembly In the case of operation with chain box Push the bu...

Page 197: ...e load hook are outside the wear limits the hook must be replaced 1 If a safety catch is fitted the thickness of the safety catch must be subtracted from the maximum hook opening dimension a Check dim...

Page 198: ...ere wear promoting conditions such as high ambient temperatures or corrosive substances in the atmosphere are present or where lubricants may be washed out the frequency of maintenance and inspection...

Page 199: ...of hoists without chain box detach the idle chain from the chain mount _ for dual and quadruple chain hoists the bottom block chain is released simultaneously see also Removing and installing load sl...

Page 200: ...k will be positioned correctly Note If the chain jams in the hoist and can no longer be run out the gearbox must be dismantled The gear box retaining bolts must be removed for this purpose and the end...

Page 201: ...ving at full unloaded speed against a load to be lifted even when it is below the load size set We therefore recommend tensioning the slack chain before lifting the load ADJUSTING OVERLOAD PROTECTION...

Page 202: ...preadjustment after re assembly first let the safety clutch take effect for approx 5 seconds load hook on the upper end position with the motor running Then let the load hook run for approx 10 second...

Page 203: ...ity Replace or clean silencer elements improve air quality if necessary Replace motor vanes Lubricate motor check oiler Have control valve repaired Adjusting safety clutch Replace chain with a new JDN...

Page 204: ...lter element Turn the drain valve 4 90 and allow the fluid to drain out Close the drain valve The filter must be replaced after approx 2500 hours of operation Turn the collecting container 3 slightly...

Page 205: ...oist position This is facilitated by a suspension point on the rear of the box We will be happy to answer any questions on this matter Modifications may only be made to the chain box on agreement with...

Page 206: ...0 2 3 4 0 2 3 4 0 2 3 4 0 Air consumption at nominal load lowering m3 min 3 2 5 5 3 2 5 5 3 2 5 5 3 2 5 5 3 2 5 5 Air connection G 3 4 G3 4 G3 4 G3 4 G3 4 Hose size inner outer mm 19 31 19 31 19 31 1...

Page 207: ...I A Minimum headroom 593 674 813 898 1040 B 373 454 548 598 667 C 233 233 308 382 382 D 483 483 575 692 692 E1 40 40 44 53 75 E2 30 40 44 53 75 F to centre of hook without chain box 187 154 197 199 18...

Page 208: ...min 10 5 13 5 10 5 13 5 10 5 13 5 Air consumption at nominal load running gear m3 min 1 0 1 3 1 0 1 3 1 0 1 3 Air consumption at nominal load lifting gear lifting m3 min 2 2 3 2 2 2 3 2 2 2 3 2 Air c...

Page 209: ...105 130 130 B 70 68 68 C 284 294 294 D 25 35 35 E 198 220 220 F 705 750 820 G 138 213 202 H 44 53 75 J 192 185 266 K 580 600 600 L 308 367 367 M 266 325 325 Measurements in mm Chain boxes increase the...

Page 210: ...P VALVE Hubmotor lifting motor Steuerventil Seil control valve S R P B A heben lifting senken lowering heben lifting senken lowering Drehschieber Ventil rotary control valve Hauptanschluss main air co...

Page 211: ...ring p h s S R P B A Steuerventil Luft control valve Hubmotor lifting motor Druckknopfventil E 2fach NOT STOPP push button valve E 2fold emergency stop heben lifting senken lowering h s p NOT STOPP em...

Page 212: ...lifting Drehschieber Ventil rotary control valve Hauptanschluss main air connection Druckknopfventil E 4fach push button valve E 4fold li re Hauptanschluss main air connection Ventilblock am Motor va...

Page 213: ...re R B A Steuerventil Luft control valve S P Hubmotor lifting motor heben lifting senken lowering Druckknopfventil E 4fach NOT STOPP push button valve E 4fold emergency stop s h p li re NOT STOPP emer...

Page 214: ...fting motor Druckknopfventil FI 2fach NOT STOPP push button valve FI 2fold emergency stop heben lifting senken lowering h s p NOT Stopp emergency stop Drehschieber Ventil rotary control valve Ventilbl...

Page 215: ...til Luft control valve S R P B A Hubmotor lifting motor heben lifting senken lowering Steuerflasche F 5 fach NOT STOPP multi button pedent switches 5 fold emergency stop s h p li re NOT STOPP emergenc...

Page 216: ...ifting motor heben lifting senken lowering Steuerflasche F 7fach NOT STOPP multi button pedent switches 7 fold emergency stop s h p Drehschieber Ventil rotary control valve li re p NOT STOPP emergency...

Page 217: ......

Page 218: ...ed trademark of our company BA 816 GB Edition December 2009 Subject to changes 122009 J D NEUHAUS GMBH CO KG _ D 58449 WITTEN HEVEN PHONE 49 2302 208 0 _ FAX 49 2302 208 286 info jdn de _ www jdn de p...

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J. D. NEUHAUS Profi 025Ti, Operation Manual

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