J. D. NEUHAUS PROFI 6 Ti Customer'S Operating And Assembly Instructions Download Page 6

Page: 6 / 62

ONTENTS

8.13.Check lowering limiter . . . . . . . .

8.14.Check chain . . . . . . . . . . . . . .

8.15.Check chain sprocket

. . . . . . . .

8.16.Check the chain guide and hook

mount . . . . . . . . . . . . . . . . .

8.17.Check the hook, shackle and eyelets

8.18.Check silencer . . . . . . . . . . . .

8.19.Check lifting motor . . . . . . . . . .

8.20.Replace chain

. . . . . . . . . . . .

9. Faults, causes and remedies

A. Technical data

B. Dimensions

Page

of 62

Doc.-No.: VA057988-10-OM-EN-0821-62-1

Summary of Contents for PROFI 6 Ti

Page 1: ...JDN OPERATING AND ASSEMBLY INSTRUCTIONS Hoist PROFI 6 TI Serial No P706448 Doc No VA057988 10 OM EN 0821 62 1 ORIGINAL OPERATING AND ASSEMBLY INSTRUCTIONS Representation may differ from actual product ...

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Page 3: ... liabil ity for damage due to Non observance of the instructions Inappropriate use Use by untrained personnel Unauthorised conversions Technical changes Use of unauthorised spare parts Copyright protection All rights reserved by the manufacturer Neither the operating instructions as a whole nor individual sections may be reproduced distributed or pro cessed using electronic systems in any form wit...

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Page 5: ...age conditions 27 4 2 1 Breaks in operation 27 4 2 2 Storage 27 5 Initial operation 29 5 1 Unpacking 29 5 2 Attach chain container 29 5 2 1 Insert the chain into the chain container 29 5 3 Attach the hoist 30 5 4 Connecting the power supply 31 5 5 Lubricating the chain 31 5 6 Tests before commissioning 31 5 6 1 Check control device 32 5 6 2 Check direction of movement 32 5 6 3 Check the braking fu...

Page 6: ...ket 53 8 16 Check the chain guide and hook mount 53 8 17 Check the hook shackle and eyelets 54 8 18 Check silencer 55 8 19 Check lifting motor 55 8 20 Replace chain 57 9 Faults causes and remedies 59 A Technical data 61 B Dimensions 62 Page 6 of 62 Doc No VA057988 10 OM EN 0821 62 1 ...

Page 7: ...e classified in four stages in these operating instructions DANGER Indicates an imminently hazardous situation that will result in death or serious injury if not avoided WARNING Indicates a possibly hazardous situation that may result in death or serious injury if not avoided CAUTION Indicates a potentially hazardous situation that may result in minor or moderate injury if not avoided NOTICE Indic...

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Page 9: ... explosion protection regu lations are to be observed such as BGR 104 Explosion protection regulations BGR 132 Preventing ignition hazards due to electrostatic charges In other countries the corresponding national regulations are to be observed When installing your product PROFI 6 TI in sys tems as well as in exceptional cases of use spe cial regulations may apply 2 2 Qualification of personnel Th...

Page 10: ... the prescribed maintenance inter vals I Only use the product for work that is de scribed as intended I Observe the conditions of use described in these instructions for your product Page 10 of 62 Doc No VA057988 10 OM EN 0821 62 1 ...

Page 11: ...operating instructions and compliance with the inspection and maintenance conditions 3 2 Improper use Among others the following are considered im proper uses Changing load capacities with the load posi tion Your product is not equipped with a load capacity display which is why it may only be used in such cases where the load capacity does not change with the load position Exceeding the load capac...

Page 12: ...be used as the chain could fall out here or become knotted Please contact us if necessary For other foreseeable misuses Rules for safe operation page 35 Your product PROFI 6 TI may not be used in the following areas critical areas in nuclear plants over acid baths or systems with aggressive substances in areas where there are organic acids in areas outside of the permissible ambient temperatures 3...

Page 13: ...rmissible load capacity of your product PROFI 6 TI is 6 3t 3 5 2 Driving mechanism classification Your PROFI 6 TI corresponds to the driving mech anism classification M3 1Bm according to ISO 4301 FEM 9 511 The daily running time and the load spectrum de termine the classification A safe operating period only corresponds to the theoretical use if the group classification correlates with the actual ...

Page 14: ... Page 22 3 5 4 Vane motor The vane motor Figure 4 consists of a cylin der liner 1 with two lateral bearing washers and an inner rotor 2 The rotor is mounted eccentrically in the cylinder liner and is provided with slots 3 for holding the slats 4 The slots can move freely and are on the inner wall 5 of the cylinder liner Two slots form a chamber 6 The incoming compressed air creates a greater force...

Page 15: ...gloves With E control Figure 5 you can control the movements via push buttons The directions of movement are marked on the top of the valve housing Figure 5 Control The control system is suitable for use in explosive areas All control switches automatically return to the neutral position when released All movements are stopped instantaneously and the load is securely held in its current position 3...

Page 16: ...ve If the buffer is moderately deformed in the boundary layer the overload protection switches the motor off Figure 6 Lifting limiter 3 5 9 Lowering limiter WARNING Danger from chain fracture If the buffer is damaged unacceptably high loads may act on the chain when starting the lowering limiter The chain may break I Do not use product I Have product repaired replace buffer NOTICE The lowering lim...

Page 17: ...ogen induced embrittlement with subsequent stress corrosion from highly corrosive media e g sea water may appear on high strength alloys e g on the chain There is a danger of break age So called recombination toxins promote this process Hydrogen sulphides cyanide arsenic compounds and thiocyanates are known for this I Protect the chain against strong corrosion NOTICE JDN chains are matched in clos...

Page 18: ... chain container Damage may occur to the chain con tainer A chain container contributes to operational safety in various application areas such as when the hanging chain can be hooked onto the load Your product is equipped with a chain container that is tailored to your chain length Changes may only be made to the chain container with the approval of J D Neuhaus GmbH Co KG 3 5 13 Operation without...

Page 19: ...Power requirement 3 8 1 Connections The connection for the compressed air supply has the size G 3 4 Please use the corresponding hose lines for the selected pressure 3 8 2 Pressure WARNING Danger of explosion Operating at higher system pressures may result in hazards due to overload When operating at lower system pressures the brake can grind and is therefore subject to very high wear Inadmissibly...

Page 20: ...the com pressed air add an anti icing agent to the lubri cating oil or use an air lubricator type no 11900 with an anti icing addictive for the corresponding temperatures Your product PROFI 6 TI must be operated with a sufficiently clean and dry working air The working air must meet the following quality requirements Particle size less than 40µm 1 57mils Particle density smaller than 10mg m3 entsp...

Page 21: ... oiler Air lubricator D kine matic viscosity about 30mm2 s cSt at 40 C possibly with anti icing agent Chain lubrication Chain oil or vehi cle motor oil kine matic viscosity about 150mm2 s cSt at 40 C or special lubricant from J D Neuhaus In areas with extreme corrosion potential such as offshore a lubricant with a particu larly powerful corrosion protection is to be used Motor corrosion pro tectio...

Page 22: ...the working area of the hoists at potential friction impact or grinding points It is therefore possible to exclude sparking due to mechanical influences with these material combinations The external housing of the service units is made of aluminium Therefore the installation position is to be chosen so that there is no danger from impact sparks Earthing Electrostatic ignition hazards can be avoide...

Page 23: ... this device the maximum surface temperature of the engine can be above the maximum permissible surface temperature of the specified temperature class Emergency lowering DANGER Risk of explosion There is an increased danger of explosion during emergency lowering Heat is generated in the en gine that cannot be sufficiently dissipated due to the lack of compressed air supply see General information ...

Page 24: ...e nitrobenzene Town gas Butadine 1 3 Dioxane 1 4 Divinyl ether Ethyl alcohol Ethylene Ethyle glycol Ethylen oxide Isoprene n Propylalkohol Dimethyl ether Hydrogen sulphide Ethyl ether Ether Schwefel ether Diethyl ether II C Hydrogen Acetylene Carbon disulphide For the substances placed in the brackets the measured values for the classification in the ex plosion group or temperature class are near ...

Page 25: ...ves of large hoists so that the sliding velocities for potential friction points between the chain and the surroundings remain well below 1 m s FS Hoists with increased spark protection Copper plated load hook and bottom flange with brass safety catch FSR Running gear with increased spark protection Running wheels for trolleys and cranes are made of bronze Instructions for safe operation operator ...

Page 26: ...3 126 C max permissible surface temperature For further information 6789 6Guideline 2014 34 EU of the European Parliament and the Council 7DIN EN 1127 1 Explosive atmospheres Explosion preven tion and protection Part 1 Basic concepts and methodol ogy 1997 10 8EN ISO 80079 36 Explosive atmospheres Part 36 Non electrical equipment for explosive atmospheres Basic method and requirements 9EN ISO 80079...

Page 27: ...e control and supply hoses together so that they are not kinked 4 2 Storage conditions 4 2 1 Breaks in operation 1 Bring the load hook clevis into the upper end position Ensure that the lifting limiter is not triggered 2 Depressurise the power supply 3 In the event of longer breaks in operation coat the chain and hook eyelets with a light oil film 4 Motor conservation If the motor lubrication is n...

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Page 29: ...or the tightening torque Figure 9 Attach chain container 5 2 1 Insert the chain into the chain container WARNING Danger from chain crash If the chain is in the chain holder haphazardly it may become blocked when lowering a load I Never place the chain in the chain container haphazardly 1 After mounting the chain container lower the load hook once into the lowest position 2 Then switch on the lifti...

Page 30: ...at high lifting speeds impact forces result that can be several times the load weight I The attachment points and supporting struc ture for your product PROFI 6 TI must be able to securely absorb the forces table 1 to be expected I Ensure that your product can be freely aligned under load as otherwise impermissible additional loads may occur Load case Shock force factor Force to support constructi...

Page 31: ...ve the chain back and forth to do this During operation in areas with a high corrosion po tential such as offshore the chain can be largely protected against corrosion by using speciality lubricants These types of lubricants are char acterised among other things by a weathering resistance water insolubility and good adhesion properties The re lubrication intervals are to be set depend ing on the e...

Page 32: ...lags it may be due to a faulty brake The load may fall I Do not use product I Have the product repaired Check without load I Alternatively switch your unloaded product PROFI 6 TI to lifting and lowering If you release a control device the chain must come to a standstill in an acceptable time after the brake has been applied For physical reasons however the braking distance cannot have the value ze...

Page 33: ... 5 Check lifting limiter WARNING Danger from chain fracture If the buffers are damaged inadmissibly high loads may act on the chain upon actuation of the lifting limiter The chain may break I Do not use the product I Have the product repaired replace buffer 1 Move the unloaded load hook until just short of the upper end position 2 Stop immediately before reaching the end po sition and then careful...

Page 34: ...epaired replace buffer 1 Move the unloaded load hook until just short of the lower end position 2 Stop immediately before reaching the end po sition and then carefully by repeatedly press ing the control element move to the end posi tion 3 The movement of the chain must be stopped due to deformation of the buffer The engine will stall in the process 4 Following successful testing the buffer must b...

Page 35: ...s too long Only use an original JDN chain container Do not exceed the permissible fill capacity of the chain container When operating the chain container avoid dangers from an empty chain falling catch ing striking Never touch metallic hand controls that are colder than 0 C 32 F or hotter than 43 C 109 F without suitable protective gloves Repair the product if the operating controls are difficult ...

Page 36: ...orm in the operator s language while taking this user manual into con sideration These instructions shall regulate measures for safe operation according to the operational con ditions In addition all information must be strictly ob served that is listed in the sections of Proper use Improper use und Operating conditions aufgefu hrt sind 6 2 Attaching the load WARNING Danger to life from being stru...

Page 37: ...truck and killed from lowering loads I Make sure that no one is below the load or in the hazard area of the load NOTICE Danger from overloading Ensure that for all appli cations of your product PROFI 6 TI the load hook clevis can be lowered all the way to the ground to avoid a load being driven into the lower limit position without reaching the ground I Lower the load and carefully set it down 6 5...

Page 38: ...vement will be stopped immediately Only in the case of failure of this stop function the red EMERGENCY STOP button 1 is to be pressed down firmly The EMERGENCY STOP button clicks into place Your product PROFI 6 TI will come to a stop instantly The push buttons or press buttons are now inoperable The EMERGENCY STOP button can now be un locked again It springs back The push buttons or press buttons ...

Page 39: ...remove the control device 8 Carefully hang up your product PROFI 6 TI and transport away 7 2 Disposal Your product PROFI 6 TI contains a series of ma terials that you may have to dispose of or have re cycled after the end of their useful lives according to statutory provisions Please note the following list of materials used Ferrous materials Steel spheroidal graphite iron Non ferrous metals Bronz...

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Page 41: ...tor of fv The factor fv has a value of 1 at 50 of the nom inal load increasing linearly to 1 5 at 100 of the nominal load nominal load percentage P fv 1 0 5 P 50 50 for P 50 In order to achieve safe operating periods the company must check that the theoretical operating time has been achieved during each inspection by the person responsible This must be documented in the inspection log at least on...

Page 42: ...not take the weight of the harness into account This is permissible if the ratio W eight of the harness Load capacity 0 05 To determine the mode of operation for calculating the partial operating times actual operating time the following load spectrum diagrams can also be used Figure 13 Diagram of the load spectrums Load spectrum Definition Cubic average Collective load factor L1 light Driving mec...

Page 43: ...Date Specialist inspector in hours L1 light L2 med ium L3 heavy L4 very heavy column 2 x column 3 x operating days x factor 1 2 When zero has been reached a general overhaul must be performed Signature 0 0 125 0 25 0 5 1 0 Existing driving mechanism group see nameplate or section 3 5 2 M2 1Cm 200h M3 1Bm 400h M4 1Am 800h M5 2m 1600h Calculation example driving mechanism classification group M3 1Bm...

Page 44: ... 8 Page 50 Check brake function without load Daily 8 9 Page 50 Visually inspect the buffer of Daily 8 11 Page 51 lifting and lowering limiters Check the function of the Daily 8 10 Page 51 EMERGENCY STOP Visually inspect the chain Weekly 8 14 Page 52 Check chain Every 3 months 8 14 Page 52 Lubricating the chain As required 8 6 2 Page 47 Check lifting limiter Annually 8 12 Page 51 Check lowering lim...

Page 45: ...hain sprocket Whenever the 8 15 Page 53 chain is replaced Check chain guide Whenever the 8 16 Page 53 and hook mount chain is replaced Lubricate lifting motor When required 8 6 3 Page 48 at least every 5 years Check gearbox and perform Every 5 years Spare parts list lubricant change Check and lubricate the Every 5 years Spare parts list rotor pinion shaft connection Check the chain sprocket Every ...

Page 46: ...irt from your product I protect your product from corrosion 8 6 Lubricate and grease 8 6 1 Operating materials CAUTION Danger of skin irritation Oils and greases may cause skin irritation I Wear protective gloves NOTICE Do not mix synthetic oils or greases with mineral oils or greases as the properties may deterio rate Also never mix different types of lubricating grease within the synthetic or mi...

Page 47: ... dropping point 180 C Application temper atures 20 C bis 120 C Designation according to DIN 51825 KP2K 20 active ingredients EP additives to reduce wear and ageing pro tection water resistant and anti corrosive 8 6 2 Lubricating the chain Before tests can be carried out the chain must be lubricated The chain of your product PROFI 6 TI must be lubricated in the links in an unloaded state I Clean he...

Page 48: ...us ing retaining rings 3 Engine assembly with additional basic lubrica tion of the engine a Provide the braking surface and rotor bearing needle bush of the cover with the brake pad with a thin layer of high performance lubricant b Coat the internal cylinder of the motor housing lightly with high performance grease c Coat the entire rotor lightly with high performance grease and insert into the fr...

Page 49: ... the braking action under nominal load run in the brake by performing several hoist ing cycles then assess prior to initial opera tion Check the motor power In the event of low motor power regulate the adjusting bolts again Figure 14 Lifting motor Doc No VA057988 10 OM EN 0821 62 1 Page 49 of 62 ...

Page 50: ...ags it may be due to a faulty brake The load may fall I Do not use the product I Have the product repaired Check without load I Alternately switch your unloaded product PROFI 6 TI between lifting and lowering If you release a control device the chain must come to a standstill in an acceptable time after the brake has been applied For physical reasons however the braking distance cannot have the va...

Page 51: ...e buffer The buffer of the lifting limiter optional and low ering limiter must be visually inspected daily If the buffers have cracks permanent deformations or other damage they must be replaced 8 12 Check lifting limiter WARNING Danger from chain fracture If the buffers are damaged inadmissibly high loads may act on the chain upon actuation of the lifting limiter The chain may break I Do not use ...

Page 52: ...one of the features listed below the chain may break upon further use I Do not use the product I Replace the chain Corrosion pitting Bent or damaged chain links Chain drawn tight Wear over 11 pitches dimension A Single pitch wear dimension B Diameter reduction of a chain link dimension C Elongation of a chain link dimension D Check the entire length of the chain When check ing the replacement limi...

Page 53: ...h chain sprocket z amin xmax 4 32 8 mm 0 25 mm 5 32 1 mm 0 25 mm z Number of teeth of the chain sprocket a x Limit dimensions after maximum permitted wear 8 16 Check the chain guide and hook mount Check the chain guides for wear and when the wear dimension of 1 4mm is reached with regard to chain guide diameters or hook mounts in the centre section of the device Replace the housing The wear dimens...

Page 54: ...mensions of load hook sup port hook Dimension xmax Dimension ymin Dimension hmin 72 9 mm 56 0 mm 43 0 mm Checking axial clearance If the axial clear ance of the installed load hook or clevis exceeds the maximum clearance specified the worn parts must be replaced Figure 18 Permissible axial clearance Permissible maximum dimension of the axial clearance z 3 5 mm Page 54 of 62 Doc No VA057988 10 OM E...

Page 55: ... tensioned springs Pre tensioned springs are released when disas sembling the engine covers I Carefully loosen and remove the engine cover NOTICE See the spare parts list for tightening torques In order to check the lifting motor it must be re moved Figure 14 the lifting motor can be re moved from the hoist to simplify matters 1 Engine disassembly a Relieve the product and disconnect from the powe...

Page 56: ...e extremely low wear braking material will not reach the wear limit of 0 02mm within the design dependent service life of the hoist under intended use Should the wear limit be reached prematurely the actual compressed air pressure must be checked with the device switched on the brake drags in the event of insuffi cient pressure 4 Engine assembly with additional basic lubrica tion of the engine a P...

Page 57: ...al opera tion Check the motor power In the event of low motor power regulate the adjusting bolts again 8 20 Replace chain WARNING Danger from chain fracture The chain is subjected to impermissible stresses if the chain is twisted I Do not twist the chain NOTICE JDN chains are matched in close tolerances to the sprocket In order to ensure an optimum func tion of the chain and in order to prevent da...

Page 58: ...chain link into the chain pocket of the clamp sleeve 1 chain pocket away from the hoist body facing outward and secure with bolted connec tion or dowel pin 9 Assembly of the chain container 10 Insert the chain into the chain container 11 The replacement of the chain for a new chain is to be entered in the test book Figure 21 Replace chain Page 58 of 62 Doc No VA057988 10 OM EN 0821 62 1 ...

Page 59: ... Supply hoses leaking or loose Check connections Cross section of the line too small Use line with sufficient cross section Brake does not release fully Bring the inlet pressure to the required value check the brake piston seal and replace the seal if necessary Check the setting of the brake piston see spare parts list Brake lining worn Replace brake lining Motor cover bolts loose Tighten the bolt...

Page 60: ...ain with a new JDN chain Wrong chain drawn in Identify chain and replace with JDN chain if necessary Defective gearbox bearing Have product repaired LIFTING AND LOWERING SPEED DECLINES OR ENGINE STOPS WITH HIGHER LIFTING HEIGHTS Possible cause Remedy Brake piston setting too tight Correct adjustment of brake piston At high ambient temperatures perform adjustment with the device warmed up according...

Page 61: ...th nominal load 4 m3 min 142 cfm Air consumption at lowering with nominal load 5 5 m3 min 195 cfm Hose connection G 3 4 Hose dimension inside 19 mm 3 4 inch Motor output lifting motor 3 5 kW Lifting speed with nominal load 2 5 m min 8 2 ft min Lifting speed without load 5 m min 16 4 ft min Lowering speed at nominal load 5 4 m min 17 7 ft min Noise level at lifting with nominal load 78 dB A Noise l...

Page 62: ...DIMENSIONS B Dimensions mm inch A 674 26 5 B 454 17 9 C 233 9 2 D 483 19 0 E1 40 1 6 E2 40 1 6 F 154 6 1 G 233 9 2 Page 62 of 62 Doc No VA057988 10 OM EN 0821 62 1 ...

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J. D. NEUHAUS PROFI 6 Ti, Customer'S Operating And Assembly Instructions

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