J. D. NEUHAUS PROFI 25TI Original Operation And Assembly Instructions Download Page 1

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JDN OPERATION AND ASSEMBLY
INSTRUCTIONS FOR AIR HOISTS

Original operation and assembly instructions

Summary of Contents for PROFI 25TI

Page 1: ...JDN OPERATION AND ASSEMBLY INSTRUCTIONS FOR AIR HOISTS Original operation and assembly instructions...

Page 2: ...peration instructions edition 02 2011 cover the following JDN Air Hoists Serial No Serial No Serial No The operation instructions must be read carefully in their entirety before operating any hoist Fo...

Page 3: ...initial operation 29 Initial operation 29 OPERATION Rules for safe operation 30 Controls 33 Emergency stop 35 Overload protection 35 Load hook mount 35 Chain 36 Load hook 37 Attaching the load 37 Lift...

Page 4: ...ons 58 Checking axial play 60 Checking and adjusting overload protection 61 FAULTS CAUSES AND REMEDIES Troubleshooting guide 62 ACCESSORIES Filter silencer 63 Booster unit 63 Chain box 64 APPENDIX Tec...

Page 5: ...nt 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 BGG 905 ZH 1 27 To d...

Page 6: ...annually Providing an inspection log and updating regularly Checking personnel regularly for safety and hazard awareness during work PERSONNEL SAFETY Personnel who operate maintain inspect and perform...

Page 7: ...at the JDN Air Hoist operating site All persons charged with operating maintaining or repairing JDN Air Hoists must read and follow these operation instructions WARNINGS AND SYMBOLS Safety warnings i...

Page 8: ...tant rating data If you have any questions concerning operation of JDN Air Hoists which are not addressed in these operation instructions please contact us at the following address J D NEUHAUS GMBH CO...

Page 9: ...precise positioning of the load The motors of the PROFI 25 50 TI JDN Air Hoists feature rotors with patented grease chambers These contain JDN high performance grease which enables operation with oil...

Page 10: ...ation Notes D and E JDN 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 op...

Page 11: ...d provide the necessary degree of safety for normal operation as well as operation under difficult conditions in particular rough treatment and changing environmental influences For hazardous conditio...

Page 12: ...spondingly earthed parts earth leakage resistance less than 106 This also applies to operation with trolleys or cranes Their tracks must be earthed on site Running wheels and rail surfaces must never...

Page 13: ...opane Toluene o Xylene ethyl alcohol ethylene glycol i Amyl acetate n Butane n Butyl alcohol 1 Butylene 1 2 Dichlorethane Di i propyl ether Natural gas Acetic anhydride n Propyl acetate n Propyl alcoh...

Page 14: ...P Hoists with increased spark protection Copper plated load hook and bottom block with brass safety catch FSR Running gear with increased spark protection Running wheels for trolleys and cranes are br...

Page 15: ...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 16: ...s 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 impermissible Oblique pul...

Page 17: ...must be operated at a system pressure of 4 bar or 6 bar see information on the nameplate If the system pressure is too low important functions of the hoist will be impaired The brake will drag and is...

Page 18: ...h chamber 6 is formed by two vanes Due to the incoming compressed air a greater force is created at the leading larger vane surface 4 1 than at the trailing smaller vane surface 4 2 The difference in...

Page 19: ...installed without 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 If the JDN Air Hoist is to be converted...

Page 20: ...ual pressure depends on the cross section and length of the hose For this reason when calculating the performance of the air hoist we have allowed for a 10 drop in nominal pressure when lifting the ma...

Page 21: ...ot form and the chain cannot become twisted Secure the chain STORAGE CONDITIONS BREAKS IN OPERATION In the case of longer operational breaks coat the chain and hook with a light film of oil Motor cons...

Page 22: ...CTION PAGE 46 INSTALLING THE HOIST DANGER JDN Air Hoists must only be installed by qualified personnel Faulty installation can lead to serious accidents DANGER The attachment points for JDN Air Hoists...

Page 23: ...The actuating elements pushbuttons levers return to the zero position automatically after being released The EMERGENCY STOP function is activated by pressing the EMERGENCY STOP button Once the button...

Page 24: ...s at the ends of the control lever using shackles and eyebolts Cut the knotted link chain to the required length Fasten one handle to the free end of either knotted link chain The green handle is inte...

Page 25: ...fter another REMOVING THE HOSE PIECES Press down the locking ring 1 with a suitable tool for example a screwdriver pulling out the hose piece 2 at the same time Detaching connections MAKING CONNECTION...

Page 26: ...utton valve hand control Guide the strain relief rope through the eye on the pushbutton valve and secure it using the cable clamp Push the one ear clamps onto the hose ends Attach the hoses to the hos...

Page 27: ...for contamination and clean if necessary Blow through the compressed air hose in order to remove foreign bodies Attach the compressed air hose to the connection on the hoist Secure using a hose clamp...

Page 28: ...y approx 30 mm2 s cSt at 40 C anti icing additive if required Chain lubrication Chain oil or motor vehicle engine oil kinematic viscosity approx 150 mm2 s cSt at 40 C or special lubricant from J D NEU...

Page 29: ...ready adjusted Filling the optional oiler see Lubricants page 28 and Service unit page 48 It is especially important for the operator to lubricate the chain before initial operation of the hoist see L...

Page 30: ...re only be used 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 pullin...

Page 31: ...fore attaching the load accurately position it vertically below the hoist The chain must hang vertically before lifting Ensure that the hook safety catch is closed Repair damaged hook safety catches B...

Page 32: ...of fracture Hydrogen induced embrittlement with resultant stress cracks due to highly corrosive media e g sea water may affect high strength steels e g chains Risk of fracture This process is encoura...

Page 33: ...stream If the red EMERGENCY STOP button on the hand control is pressed all control lines are depressurised and the main stream valve is closed Rope control Control valve with upstream main stream valv...

Page 34: ...control lifting and lowering movements can be controlled via two pushbuttons The direction of movement of the load hook is marked by arrows next to the pushbuttons Lifting Press the upper pushbutton L...

Page 35: ...e main stream valve is closed simultaneously No additional EMERGENCY STOP device is required Lifting Carefully pull on the chain with the green handle The load is lifted slowly Pull harder on the chai...

Page 36: ...ompounds and rhodanide Furthermore hazards arise due to rusty chains when using chain boxes as the chain can drop out of the chain box if it forms a heap In addition rusty chains are subject to extrem...

Page 37: ...is 40 C to 150 C ATTACHING THE LOAD DANGER Only use attaching cables or attaching chains which are suitable for the load Attaching must not be attempted by winding with the lifting chain around the l...

Page 38: ...ection page 35 and Checking and adjusting overload protection page 61 LOWERING THE LOAD DANGER Ensure that there are no persons below the load Then lower the load and set it down carefully DANGER For...

Page 39: ...l hoses Detach the strain relief and hose carrier and remove the control device Carefully detach dismount the hoist and remove In the case of trolleys proceed in reverse order as described in the sect...

Page 40: ...he same For devices used mainly in vertical operation 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 Ther...

Page 41: ...ions of the actual mode of operation 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...

Page 42: ...ation of Materials Handling and Storage Equipment The formula given for the cubic average k does not take the weight of the harness into account This is permissible if the ratio 05 0 capacity bearing...

Page 43: ...deployment Column 2 x Column 3 x Operating days x factor1 2 Remaining theoretical use in load spectrum 4 When zero has been reached a general overhaul must be performed Date Delivery Initial operation...

Page 44: ...rection of movement Daily Checking direction of movement page 47 Check lifting and lowering limiters buffers visually Daily Replace buffer immediately if damaged otherwise replace every 5 years Check...

Page 45: ...vanes every 5 years In off shore areas and other similar corrosive environments replace the chain regularly Every 5 years Check gearbox and perform lubricant change Every 5 years Check the rotor pini...

Page 46: ...istance water insolubility and good adhesion properties Re lubrication intervals must be stipulated in accordance with the loading Please contact us if required CHECKING BRAKING FUNCTION Check the fun...

Page 47: ...utton All movement of the hoist must stop Actuating the control elements must not cause a lifting or lowering movement Turn the EMERGENCY STOP button to reset it DANGER If a control element is stiff o...

Page 48: ...be set to a pressure of 6 bar in the absence of an air stream This setting is only correct for a pressure of at least 7 bar upstream of the service unit Depressurise the air line downstream of the se...

Page 49: ...Fill the container with oil up to the maximum mark and refit the oil filler screw Check the oil drop rate at the sight glass with the motor running Turn the oil throttle screw using a screwdriver unti...

Page 50: ...ng is described under a separate item Remove the nameplate 1 Remove the motor cover bolts 2 and detach the motor cover 3 when the cover bolts are removed tension in the brake springs 4 is fully releas...

Page 51: ...to the front rotor bearing with the clutch side first Coat the vanes lightly with high performance grease and insert into the rotor slots with the starting aids Coat the braking surface and the outer...

Page 52: ...embly is completed Pull out the chain from the bottom block The buffers buffer discs and spacer are thereby pulled from the chain Assembly Push the buffer discs in the correct alignment edge encloses...

Page 53: ...scs and spacers are thereby pulled from the chain Assembly Push the buffer assembly in the correct alignment buffer plus buffer discs edge encloses buffer onto the chains Align the chain and fasten it...

Page 54: ...ly Push the buffer assembly in the correct alignment buffer plus buffer discs edge encloses buffer onto the chains Align the chain and fasten it to the assembly chain in the bottom block by means of t...

Page 55: ...in box the spacer must also be removed from the chain Assembly In the case of operation with chain box Push the buffer discs with edge in the correct alignment edge encloses buffer together with the b...

Page 56: ...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 For this reason the weld...

Page 57: ...ain side The first chain link must run upright over the drive sprocket with the weld facing outwards The welds of the chain links which lie flat in the drive sprocket must face towards the gearbox in...

Page 58: ...ISO 7592 CHECK DIMENSIONS HOIST CHAIN Note When checking the replacement limit future wear up until the next inspection date must be taken into account If the chain dimension values are outside the l...

Page 59: ...WEAR DIMENSIONS FOR CHAIN SPROCKETS Check dimensions for chain sprockets Chain size d x t mm x mm z a mm x mm 4 60 0 0 45 23 5 x 66 5 59 6 0 45 a x Limit dimensions after max permitted wear z Number o...

Page 60: ...is a danger of loads falling PREVENTING RISKS Dangers are avoided by regular maintenance lubrication in suitable intervals When the axial play of the installed hook and bottom block increases rapidly...

Page 61: ...t After the test screw the screw plug back in and ensure that it fits tightly ADJUSTING OVERLOAD PROTECTION The adjustment method described here is based on the attachment of test loads The adjustment...

Page 62: ...r pressure Dirt in the service unit filter blocked Clean service unit ensure better air quality Silencer is clogged Replace or clean silencer elements improve air quality if necessary Motor vanes worn...

Page 63: ...before the fluid level reaches the filter element Turn the drain valve 4 by 90 and allow the fluid to drain out Close the drain valve again by turning back The filter must be replaced after approx 250...

Page 64: ...KG 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 container e g during transportation it must be run out...

Page 65: ...ing speed at nominal load m min 2 8 2 0 1 6 Air consumption at nominal load lifting m min 6 5 Air consumption at nominal load lowering m min 2 9 Air connection G 1 Hose size inside outside mm 35 51 We...

Page 66: ...TI 37 TI 50 TI A minimum headroom 2 mm 1260 1470 1485 B mm 827 935 950 C mm 450 540 540 D mm 900 1080 1080 E1 mm 75 100 100 E2 mm 75 100 100 F to centre of hook without chain box mm 270 285 250 G mm...

Page 67: ...powered by air Page 67 APPENDIX CIRCUIT DIAGRAM Rope control...

Page 68: ...powered by air Page 68 APPENDIX Dual control...

Page 69: ...powered by air Page 69 APPENDIX Dual control with pin valve Lower side OPTIONAL...

Page 70: ...powered by air Page 70 APPENDIX Quadruple control...

Page 71: ...powered by air Page 71 APPENDIX Quadruple control with pin valve Lower side OPTIONAL...

Page 72: ...NEUHAUS GmbH Co KG D 58449 Witten Heven PHONE 49 0 2302 208 0 FAX 49 0 2302 208 286 website www jdn de e mail info jdn de is a registered trade mark of our company BA 822 EN Issue February 2011 Subjec...

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J. D. NEUHAUS PROFI 25TI, Original Operation And Assembly Instructions

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