J. D. NEUHAUS Profi 05Ti, Profi 1Ti, Profi 2Ti Operation Manual

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

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

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

Fabr. No.

Fabr. No.

Fabr. No.

Fabr. No.

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

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TA B L E O F CO N T E N T S

S A F E T Y I N S T R U C T I O N S

Organisational measures . . . . . . . . . . . . . . . . . . 5

Personnel safety . . . . . . . . . . . . . . . . . . . . . . . . 5

Preventing property damage . . . . . . . . . . . . . . . 5

P RO D U C T I N F O R M AT I O N

The operation manual . . . . . . . . . . . . . . . . . . . . 6

Warnings and symbols . . . . . . . . . . . . . . . . . . . . 6

Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Assembly overview . . . . . . . . . . . . . . . . . . . . . . 8

Product description . . . . . . . . . . . . . . . . . . . . . . 8

Explosion protection . . . . . . . . . . . . . . . . . . . . . 9

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . 15

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operating conditions . . . . . . . . . . . . . . . . . . . . 16

Energy requirements . . . . . . . . . . . . . . . . . . . 17

Principle of operation of

JDN air vane motors . . . . . . . . . . . . . . . . . . . . 18

Operation without chain box . . . . . . . . . . . . . . 19

Motor lubrication/ operation with service unit . 19

CE certification/ manufacturer's declaration . . . 19

Certification . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . 19

T R A N S P O R TAT I O N A N D S T O R AG E

Safe transportation . . . . . . . . . . . . . . . . . . . . . 20

Storage conditions . . . . . . . . . . . . . . . . . . . . . 20

S E T T I N G U P

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Installing the hoist . . . . . . . . . . . . . . . . . . . . . 21

Connecting the controls . . . . . . . . . . . . . . . . . . 22

Replacing controls . . . . . . . . . . . . . . . . . . . . . . 25

Connecting to the main air supply . . . . . . . . . . 26

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Pre-start checks . . . . . . . . . . . . . . . . . . . . . . . 28

O P E R AT I O N

Rules for safe operation of hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Emergency stop device . . . . . . . . . . . . . . . . . . 34

Overload protection . . . . . . . . . . . . . . . . . . . . . 34

Attaching the load . . . . . . . . . . . . . . . . . . . . . 35

Lifting the load . . . . . . . . . . . . . . . . . . . . . . . 36

Lowering the load . . . . . . . . . . . . . . . . . . . . . . 36

Detaching the load . . . . . . . . . . . . . . . . . . . . . 36

Interrupting working . . . . . . . . . . . . . . . . . . . 36

TA K I N G O U T O F O P E R AT I O N

Prolonged shutdown . . . . . . . . . . . . . . . . . . . . 37

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

M A I N T E N A N C E

Maintenance and inspection intervals . . . . . . . . 38

Cleaning and care . . . . . . . . . . . . . . . . . . . . . . 38

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Inspection and maintenance work . . . . . . . . . . 38

Instructions on the “model for determining the actual operating time” . . . . . . . . . . . . . . . . 40

Lubricating the chain . . . . . . . . . . . . . . . . . . . 44

Checking braking function . . . . . . . . . . . . . . . . 44

Checking lifting and lowering limiters . . . . . . . 45

Checking controls and emergency stop . . . . . . . 45

Checking direction of movement . . . . . . . . . . . 45

Checking the silencer for permeability . . . . . . . 45

Service unit . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Motor installation/checking brake linings and vanes/motor lubrication . . . . . . . . . . . . . . 49

Removing and installing load sleeve, bottom block, clamp and buffer . . . . . . . . . . . . 52

Checking chain, chain sprocket and chain guides 54

Check dimensions . . . . . . . . . . . . . . . . . . . . . . 54

Checking axial play . . . . . . . . . . . . . . . . . . . . . 56

Removing and installing chain . . . . . . . . . . . . . 57

Replacing chain and chain sprocket . . . . . . . . . 58

Overload protection . . . . . . . . . . . . . . . . . . . . . 59

FAU LT S , C AU S E A N D R E M E DY

Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

AC C E S S O R I E S

Filter silencer . . . . . . . . . . . . . . . . . . . . . . . . . 61

Booster unit . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Chain box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

A P P E N D I X

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 63

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 64


Please note:

Within the Federal Republic of Germany operators of air hoists must comply with trade association accident prevention regulations and rules, as well as state occupational safety regulations, in particular

BGV A1 accident prevention regulations “Principles of

Prevention”

BGV D8 accident prevention regulations “Winches,

Lifting and Pulling Devices”

BGR 258 trade association regulations “Operation of

Load-Carrying Devices Used with Lifting Equipment” and, for air hoists installed in trolleys, additionally 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” BGG 905

(ZH 1/27).

When operating air hoists in areas with explosive atmospheres, the operator must comply with the relevant explosion protection regulations, e.g.

BGR 104 “Explosion Protection Regulations” and

BGR 132 “Prevention of Ignition Hazards due to

Electrostatic Charges”

In all other countries, the operator shall comply with local regulations as applicable.

Special regulations may apply when incorporating air hoists into other installations or using air hoists under unusual conditions.




O RG A N I S AT I O N A L M E A S U R E S

JDN hoists are designed in accordance with current technological standards and accepted safety practice.

Nonetheless, the use of an air hoist may be associated with risk of injury or fatality to the user or to third parties or with the risk of damage to the hoist or to other items, if safety rules are disregarded.

All personnel charged with operating air hoists must have read and understood the operation manual, especially the section entitled “Rules for safe operation of hoists”, before commencing work.

This is particularly important for personnel who only occasionally operate the hoist, e.g. for maintenance or retrofitting work.

Operators of JDN hoists are also under obligation to ensure safe and hazard-free operation. This can be achieved through the following measures: keep the operation manuals available at the hoist operating site, carry out regular training, implement an inspection log and make regular entries, regularly check personnel for safety and hazard awareness during work.

P E R S O N N E L S A F E T Y

Ensure that only properly trained personnel are entrusted with operation, maintenance, inspection and repair.

“Properly trained” in this case means that the operator has appropriate training and experience in working with hoists. They are sufficiently familiar with the relevant occupational safety and accident prevention regulations that they are able to assess the condition of hoists with regard to working safety.

Follow the operating instructions for your workplace.

Comply with the accident prevention regulations.

Ensure that you are properly informed regarding working with hazardous materials.

Follow the safety instructions set out in the operation manuals.

P R E V E N T I N G P RO P E R T Y DA M AG E

Operators of JDN hoists are under obligation to ensure that entries in the accompanying inspection log are made properly and regularly.

Comply with the prescribed maintenance intervals.

Only use JDN hoists for work which is described as intended use.

Observe the operating conditions for JDN hoists as described in this manual.

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T H E O P E R AT I O N M A N UA L

This operation manual is intended to help the operator familiarise himself with JDN Air Hoists and to take full advantage of their designated areas of application.

This operation manual contains important information for the safe, proper and economic operation of JDN Air

Hoists. Observance of the manual helps to avoid hazardous situations, to reduce repair costs and downtimes and to extend the service life of the JDN Air Hoists.

WA R N I N G S A N D S Y M B O L S

Safety warnings in this operation manual are classified in three categories:

DA N G E R !

Safety warnings, which if not followed can result in hazard to life and limb, are indicated by this symbol.

The symbol indicates an immediate danger.

The possible consequences of non-observance may be severe or even fatal injuries.

WA R N I N G !

This symbol indicates situations, which may become hazardous. Failure to follow the instructions could result in injuries.

C AU T I O N !

This symbol indicates that failure to follow the relevant instructions may result in damage to the device or other equipment.



D E S I G N AT I O N

The nameplate mounted on the housing cover identifies the type of JDN Air Hoist and contains all important rating data.

If you have any questions concerning 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

Windenstraße 2-4

D - 58455 Witten-Heven Germany

Phone +49 2302 208-0

Fax +49 2302 208-286 www.jdn.de

e-mail: [email protected]

Example of nameplate on housing cover powered by air !

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A S S E M B LY O V E R V I E W assemblies: series air hoists consist of the following

1 Gearbox with chain sprocket

2 Centre section

3 Motor with integral brake function

4 Controls with main air EMERGENCY STOP and overload protection

5 Chain

6 Load hook with load sleeve or bottom block and buffer

P RO D U C T D E S C R I P T I O N

The series JDN Air Hoists described here are designed for load-carrying capacities from 0.25 t ( ) to 2 t (

Various control devices are available for the different requirements.

) .

The air vane motor of the hoist, together with the appropriate controls, is capable of sensitive movement.

This enables precise positioning of the load.

series JDN Air Hoists conform to driving mechanism classification as indicated in the following table:

025 TI

05 TI

1 TI

2 TI

ISO 4301 / FEM 9.5.11

Air Hoist

M5 / 2 m

M4 / 1 Am

M4 / 1 Am

M4 / 1 Am

Chain

M8 / 5 m

M7 / 4 m

M3 / 1 Bm

M3 / 1 BM

JDN Air Hoist motors feature rotors with grease chambers. These contain JDN high-performance grease which enables operation with oil-free compressed air. It remains effective for an operating period of approx. 250 hours and should be renewed when required, but after five years at the latest (see Motor lubrication, page 19). Additional lubrication with oilbearing compressed air by means of a service unit with oiler is possible.


series JDN Air Hoist


E X P L O S I O N P RO T E C T I O N

The basis for the following information is an expert statement by the DMT Gas & Fire Division on the use of

JDN Hoists, Trolleys and Crane Systems in explosionhazardous areas, based upon European Guideline

94/9/EC 1 (“ATEX 100a”). DMT is accredited for the testing of devices and protection systems for intended use in explosion-hazardous areas.

B A S I C E X P L O S I O N P RO T E C T I O N F O R T H E

S TA N DA R D V E R S I O N S

Standard version JDN air hoists are category 2 devices

(Guideline 94/9/EC, DIN EN 1127-1 2 ), for use in zone 1 and 2 for gases of explosion group IIA. (See also IEC

60079-12 3 and IEC 60079-20 4 .) These devices are also suitable for use in zone 2, in the presence of gases of explosion group IIB, provided that the substances hydrogen sulphide and ethylene oxide can be excluded and additionally in zones 21 and 22 for dusts with glow temperatures above 210°C or ignition temperatures above 202°C, provided that no light metal or other impact-sensitive dusts are present.

These devices are designated by:

II 2 GD IIA T4(X)/II 3 GD IIB T4(X)

Additional marking “X”, see page 10.

J D N H O I S T S

“W I T H I N C R E A S E D S PA R K P RO T E C T I O N ”

JDN hoists in the “with increased spark protection” version (FS) fulfil further explosion protection requirements. With the exception of carbon disulphide (temperature class T6), they can be used in the presence of all gases in zones 1 and 2 and dusts with glow temperatures above 210° or ignition temperatures above 202° in zones 21 and 22, and can be designated with

II 2 GD IIC T4(X) for installation in a trolley, depending upon the trolley version (see below), but also with II 2 GD IIB T4(X) . For further operating conditions, see Instructions for safe operation (Notes

D and E ).

JDN HOIS T S FOR USE IN THE PRESENCE OF TEM-

PER ATURE CL ASS T6 GASES OR EXTREMELY EXPLO-

SIVE DUS T S

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 temperatures may be possible with designation II 2 GD IIC T6(X) , which includes the additional marking “X” for special conditions (see

Additional marking “X”).

Please contact us with regard to these requirements.

S TA N DA R D J D N T RO L L E Y A N D C R A N E

R U N N I N G G E A R

JDN trolleys and cranes can be used in zone 2 with standard running wheels (made of steel or cast metal) with all dusts and the presence of gases up to explosion group IIC. Due to the low running speeds, the possible friction velocities on the running wheels are less than 1 m/s, which means that standard running wheels can also be used in zone 1 up to explosion group IIB. The highest possible designation for these devices is:

II 2 GD IIB T4(X)/II 3 GD IIC T4(X) .

Depending on the hoist version, designations

II 2 GD IIA T4(X)/II 3 GD IIB T4(X) or

II 2 GD IIB T4(X) are also used.

J D N T RO L L E Y A N D C R A N E R U N N I N G G E A R

“W I T H I N C R E A S E D S PA R K P RO T E C T I O N ”

For use in zone 1 in the presence of gases in explosion group IIC, bronzed running wheels or running wheels made of bronze are also used. The highest possible designation for this version (FSR) is

II 2 GD IIC T4(X) (the same as for JDN hoists

“with increased spark protection”).

J D N T RO L L E Y A N D C R A N E R U N N I N G G E A R F O R

U S E I N T H E P R E S E N C E O F T E M P E R AT U R E C L A S S

T 6 G A S E S O R D U S T S

As is the case with JDN hoists “with increased spark protection”, temperature class T6 could also be possible in this case too in the event of a special investigation of applicability, so that the highest possible designation for standard wheels and for bronzed or bronze wheels is

II 2 GD IIB T6(X)/II 3 GD IIC T6(X) and

II 2 GD IIC T6(X) respectively, i.e. each including the additional designation “X” for special conditions.



G E N E R A L N O T E O N D E S I G N AT I O N

The highest possible respective designations for lifting equipment and running gear are usually replaced by a designation which corresponds to the normal assembly of a compact complete device (trolley or crane system).

A D D I T I O N A L M A R K I N G “X”

This designation refers to explosion protection details in the operation manual.


II 3 GD IIA T4(X) :

This designation does not permit use in the presence of the extremely flammable substances hydrogen sulphide and ethylene oxide or in the presence of light metal or other impact-sensitive dusts, or in the presence of dusts with glow temperatures below 210° C or ignition temperatures below 202° C. The permissible ambient temperature range (Ta) extends from - 20° C to + 70° C.

II 2 GD IIC T4(X) or II 2 GD IIB T4(X) :

The permissible ambient temperature range (Ta) extends from - 20° C to + 70° C.

...II C T6(X) :

This designation permits use in the presence of carbon disulphide or other temperature class T6 substances only under special conditions, which have been agreed with the manufacturer and which are described in the crane documentation and which stipulate the maximum surface temperatures for the device.

U S E I N M I N I N G A P P L I C AT I O N S

Standard versions of JDN hoists, trolleys and crane systems may generally also be used for underground mining operations as well as for the associated surface facilities, which are hazardous due to firedamp and/or combustible dusts. Within this equipment group I they belong to category M2.

They constitute devices that can be switched off in cases where an explosive atmosphere forms. They are equipped with protective measures offering a high degree of safety. The protective measures with which products of this category are equipped 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 other difficult conditions in addition to explosion protection prevailing with regard to the general 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 13463-1 5 for coal dust atmospheres is not reached. For mining applications, the relevant designation for hoists, trolleys and crane systems is I M2 .

L OA D C H A I N

In order to guarantee the required degree of earthing, rusty chains must no longer be used in zones 1 and 21.

This is due to the fact that, depending upon the degree of corrosion, the leakage capability of the chain may be impaired to a level that is no longer adequate.

CO M P R E S S E D A I R H O S E S

In zone 1, compressed air hoses must have a sufficiently low surface resistance of less than 10 9 Ω

, in order to prevent electrostatic ignition hazards. Otherwise (resistance >10 9 Ω

), for explosion groups I, IIA and IIB the hoses must be

∅ ≤

30 mm and for explosion group IIC

∅ ≤

20 mm, or proof must be provided that they cannot become dangerously charged.

M AT E R I A L S F O R F R I C T I O N A N D I M PAC T H A Z A R D S

Friction and impacts can give rise to individual sparks presenting a danger of ignition in the presence of explosion group IIC gases, hydrogen sulphide, ethylene oxide, or light-metal or other impact-sensitive dusts.

Accordingly, spark formation caused by mechanical influences must be prevented.

The chain and load must always be moved in such a way that sliding and/or frictional contact with other plants or components is excluded. If circumstances do not permit this, it is necessary to ensure an absence of explosive atmospheres during operation.

Impact between particular materials results in an increased ignition hazard. Such material combinations include corrosion-susceptible steel or cast iron against aluminium, magnesium or corresponding alloys.

This applies in particular in the presence of rust or rust film. Rust (also rust film) formation is possible, especially on the chain and on the load hook, at the friction points. The following holds true for all zones: For the intended use of hoists it must be ensured that no rust is present at the above-mentioned friction points and that material combinations of the above-named light metals with steel (exceptions being stainless steel


P RO D U C T I N F O R M AT I O N or cast iron) are not used in the working area of the hoists, at potential friction, impact or sliding points. It is thus possible to exclude sparking due to mechanical influences with these material combinations.

E A R T H I N G

Electrostatic ignition hazards can be prevented by means of safe earthing. In zones 1 and 21, earthing of the hoists is required. This must be achieved via the load hook or the load eyes if the lifting equipment is connected to correspondingly earthed parts (earth leakage resistance less than 10 6 Ω

). This also applies to operation with trolleys or cranes. Their tracks 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 also Load chain , page 10).

Loads must be earthed during transportation.

A separate earth is required, for example, when using non-conducting sling gear.

AC E T Y L E N E A N D CO P P E R

When operating JDN products in explosion-hazardous areas, in which an acetylene-containing atmosphere can occur, it must be ensured that copper-plated parts are kept dry in order to exclude the possibility of oxidation of the metallic copper and the formation of an aqueous phase, which is capable of reacting with acetylene and which can result in an explosion hazard.

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EXPLOSION GROUPS AND TEMPER ATURE CL ASSES OF THE MOS T IMPOR TANT G ASES AND VAPOURS

(-SELECTION-)

(according to DIN VDE 0165 6 , Redeker 7 , Nabert, Schön 8 , IEC 60079-12 3 and IEC 60079-20 4 )

Ex group

II A

II B

T1 T2

Temperature class

T3 T4

Ignition temperature

300-200° C 200-135° C

T5

> 450° C 450-300° C 135-100° C

450° C

Maximum permissible surface temperature of operating facilities

300° C 200° C

Acetone

Ammonia

Aniline

Benzol

(Ethyl alcohol)

(Ethylene glycol) i-Amyl acetate n-Butane n-Amyl alcohol

Benzene

(petrol)

Diesel

Chlorobenzene n-Butyl alcohol

1,2-Dichlorobenzene 1-Butylene

Acetic acid

Ethane

1,2-Dichloroethane

Di-i-Propyl ether

Fuel oil n-Hexane

Jet fuels

Ethyl acetate

(Ethyl bromide)

Natural gas

Acetic anhydride

Ethyl chloride n-Propyl acetate

(Carbon monoxide) (n-Propyl alcohol) o-Cresol

Methane

Methyl acetate

Methyl alcohol*1 i-Propyl alcohol

Vinyl chloride

Methyl bromide

Methyl chloride

Methylene chloride

Naphthalene

(nitrobenzene)

Phenol

Propane

Toluene o-Xylene

135° C

Acetaldehyde

100° C

Hydrocyanic acid Butadiene-1,3

(Ethyl bromide) Dioxane-1,4

(carbon monoxide) Divinyl ether

(Nitrobenzene)

Town gas

(Ethyl alcohol)

Ethylene

(ethylene glycol)

**Ethylene oxide

Isoprene

(n-Propyl alcohol)

Dimethylether

**Hydrogen sulphide

Ethyl ether

Ether

Anaesthetic ether

Diethyl ether

T6

100-85° C

85° C

II C

**Hydrogen **Acetylene **Carbon disulphide

( ): The measured values for the substances placed in brackets are close to the limit for the next group or class when classified in the explosion groups or temperature classes. For this reason, they have been included in both.

**: Extremely flammable substances (cf. additional marking “X”)

*1 (Methanol = Methyl alcohol)



DECISION CRITERIA FOR SELECTING THE CORRECT JDN HOIS T S IN EXPLOSION-HAZARDOUS AREAS

Explosion groups of gases and vapours

(cf. Explosion groups and temperature classes of the most important gases and vapours)

II A

II B (X)

II B

II C / T4 except hydrogen sulphide, ethylene oxide

(particularly flammable)

II C / T6(X)

Explosion-hazardous dusts

Usual industrial dusts

Light-metal or impact-sensitive dusts

1

1

1

1

1

Zone

21

21

Zone

2

2

2

2

2

22

22

Version* 1

Manufacturer's responsibility

A

A

A

A FS

A FS

A FS

A FS

A FS FSR

A FS

A FS FSR

Version* 1

A

A

A FS

A FS

Operation* 2

Operator's responsibility

D

D

E

E

E

E

E

E

D

D

D

D

D

E

E

E T

D E T

Operation *2

E

E

E

E

*1: Version features (under the responsibility of the manufacturer):

A: The chain is made of zinc-plated steel; metal controls are conductively connected to the hoist. This is part of the standard equipment. For technological reasons, a zinc-plated version of chain size 31.5 x 90 is not available.

This is only 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 “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 bronzed or are made of bronze.

*2: Instructions for safe operation (operator's responsibility):

D

E

T

: Ignition hazards are not to be expected if hoists or cranes are used in the normal manner. Friction and impacts in the working area of the chain, not resulting from intended use of the hoist or crane and which result in sparking, must be excluded, or an absence of gas in the operating area must be ensured. This means, for example, that the chain, the bottom block and the load hook must be prevented from swinging against surrounding objects or that a gas-free environment must be ensured.

: Friction, impact and sliding points involving combinations of light metal and steel or cast iron must not be present in the hoist's operating area.

: Ambient temperature and the type of operation must be examined separately.



T E M P E R AT U R E L I M I T S F O R

E X P L O S I O N - H A Z A R D O U S D U S T S

In areas which are explosion-hazardous due to combustible dusts, the surface temperature must not exceed two-thirds of the ignition temperature in ° C of the dust/air mixture. The temperatures of surfaces, on which hazardous deposits of combustible dusts can be formed, must not exceed the glow temperature of the relevant dust minus 75°K. Greater safety margins are required if the thickness of the dust layer exceeds

5 mm.

The corresponding surface temperatures can be derived from the lowest values for glow and ignition temperatures of dusts specified in the HVBG/BIA Report 12/97 10

“Combustion and explosion characteristics of dusts”:

Synthetic rubber, soot-containing:

Glow temperature 220° C - 75° C = 145° C max. permissible surface temperature

Stearic acid:

Ignition temperature 190° C x 2/3 =126° C max. permissible surface temperature.

P L E A S E A L S O O B S E R V E Y O U R

CO R R E S P O N D I N G N AT I O N A L

R E G U L AT I O N S .

1 Guideline 94/9/EC of the European Parliament and the Council of 23 March 1994 on the approximation of the laws 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 1: Basic concepts and methodology, 1997-10.

3 IEC 60079-12: Electrical apparatus for explosive gas atmospheres, Part 12: Classification of mixtures of gases and vapours with air according to their maximum experimental safe gaps and minimum igniting currents, 1978.

4 IEC 60079-20: Electrical apparatus for explosive gas atmospheres,

Part 20: Data for flammable gases and vapours relating to the use of electric apparatus, 1996-10.

5 EN 13463-1: Non-electrical devices intended for use in explosive areas - part 1: Basic methodology and requirements

6 DIN VDE 0165: Installation of electrical systems in areas with explosion hazard, 1991

7 Redeker, Schön: 6. Supplement to safety-related characteristic values for flammable gases and vapours, 1990

8 Nabert, Schön: Safety-related characteristic values for flammable gases and vapours, 2nd edition, 1978

9 DIN EN 50014 (VDE 0170/0171 part 1): 2000-02

Electrical apparatus for use in explosion hazardous areas: General provisions

10 HVBG/BIA report 12/97: Central association of German employer's liability associations /trade association institute for industrial safety


I N T E N D E D U S E

JDN Air Hoists are designed for lifting and lowering loads within the specified load-carrying capacities, with a vertically-arranged chain. JDN Air Hoists from the ranges PROFI 025 TI to 2 TI are also suited to pulling loads horizontally. In exceptional circumstances, the lifting of personnel-carrying equipment is also permitted under certain conditions. Please also observe the individual national 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 impermissible. Oblique pulling, see section Operation , page 29. J.D. NEUHAUS GMBH & CO. KG cannot be held liable for any resultant damage.

The entire risk is borne by the user (see also Rules for safe operation of hoists , page 29).

Intended use also includes observance of the operation manuals and compliance with the inspection and maintenance conditions.

P RO D U C T I N F O R M AT I O N powered by air !

Page 15


E M I S S I O N S

The noise emission data can be found in the Technical data table, page 63.

The noise pressure level of the measurement area at a distance of 1 m from the machine surface was measured in accordance with DIN 45 635, Part 20, at the operating air pressure specified by us. In the hall, the noise pressure level drops by approx. 3 dB (A) every time the distance is doubled.

If the device is operated with motor oil lubrication, small amounts of lubrication oil will be released into the environment with the outlet air.

Oil emissions can be prevented by using a filter silencer

(see Filter silencer section, page 61). This also results in a reduction of the noise emission values.

O P E R AT I N G CO N D I T I O N S

JDN air hoists are extremely robust and require little maintenance. They are suitable for use in explosionhazardous areas, as well as in areas with increased concentrations of soot and dust, high humidity and at ambient temperatures of - 20° C to + 70° C if they are not heated above this level due to external influences. The thermal endurance of chains and hooks is + 150° C.

WA R N I N G !

When touching metallic hand controls which are colder than 0° C, the skin could freeze within a few seconds, and for temperatures above 43° C, burns can occur. As a protective measure, please wear suitable gloves.

For stationary outdoor operation, hoists must be protected against weathering and the maintenance intervals must be shortened.

Depending upon the version, JDN air hoists 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 thus subject to a high degree of wear. An impermissibly high degree of warming could take place.

The controls become noticeably less sensitive.

DA N G E R !

Warning against excessive system pressures

Operating with excessive system pressures results in danger due to overloading.

Therefore, the pressure must be limited to that specified on the nameplate.

JDN air hoists must be operated with a sufficiently clean and dry air supply. The air supply must fulfil the following quality requirements:

Particle size less than 40 µm

Particle density less than 10 mg/m3

(corresponds to Class 7 according to

ISO 8573 - 1:2001)

In order to provide adequate compressed air quality, operation with a service unit is recommended. Usually, an oiler is not required in the service unit, as the motor is provided with internal permanent lubrication.

Pressure dew point at least 10° C below the lowest expected ambient temperature

Do not operate JDN Air Hoists with other gases.

With moist air and ambient temperatures at or below

0° C, there is a danger of icing in the motor.

Icing can be prevented by using an upstream air dryer or using a service unit with oiler, adding anti-icing agent to the lubrication oil

(depending upon moisture content of compressed air) using compressed air oil (Art. no. 11900) with antiicing agent for relevant temperatures.

In case your JDN Air Hoist is operated in combination with a trolley, please read also the trolley operation manual and the relevant accident-prevention regulations for operation with trolleys.



E N E RG Y R E Q U I R E M E N T S

For air pressure, air quantity and connections, see the Technical data table in the hoist operation manual concerned.

A I R P R E S S U R E CO N D I T I O N S I N O P E R AT I O N

The system pressure in the air line must correspond to the nominal pressure. Higher pressures must be reduced.

After switching on, the nominal pressure p1 drops to the actual pressure p2.

The value of the actual pressure p2 at 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 below a value of

10 % below the specified nominal pressure of the hoist.

Example:

A hoist with a nominal pressure of 6 bar lifts its nominal load at the specified lifting speed, at an actual pressure of 5.4 bar.

The value of the actual pressure depends upon … … the weight of the load …

… and the direction of movement of the load.

powered by air !

Page 17


P R I N C I P L E O F O P E R AT I O N O F

J D N A I R VA N E M O T O R S

The vane motor consists of a cylinder liner 1 with two side bearing plates and an internal rotor 2 .

The rotor is mounted eccentrically in the cylinder liner and is provided with slots 3 for installation of the vanes 4 .

The vanes can move freely and make contact with the inner wall 5 of the cylinder liner. Each chamber is formed by two vanes 6 .

Due to the incoming compressed air, a greater 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 aperture 7 , the compressed air can escape.

Lubricant chambers 8 are provided between the vane slots of the rotor. They ensure continual motor lubrication.

The arrows in the illustration indicate the direction of rotation of the rotor and the corresponding path of the compressed air.

4.2

1 6 4.1

2 5

8 3 4 7



O P E R AT I O N W I T H O U T C H A I N B OX

DA N G E R !

If JDN air hoists are operated without a chain box it must be ensured that the idle chain (unloaded chain end) running up or down at the chain sprocket does not present a hazard, e.g. due to catching, impacting or falling.

Danger due to falling chain can also arise if the idle chain is first deposited on a load with a large surface and then slides off and drops.

M O T O R L U B R I C AT I O N /

O P E R AT I O N W I T H S E R V I C E U N I T

JDN air hoists are provided with motor lubrication, which must be renewed when required, but every

5 years at the latest.

Therefore, the service unit for filtration and pressure regulation of the compressed air can be 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. Alcohols are not permitted for use as anti-icing agents.

- C E R T I F I C AT I O N /

M A N U FAC T U R E R ' S D E C L A R AT I O N

Only hoists which have a designation may be operated within the EU.

C E R T I F I C AT I O N

Each JDN air hoist is delivered with a factory certificate.

S PA R E PA R T S

Only use original JDN spare parts . J.D. NEUHAUS

GMBH & CO. KG accepts no liability for the use of non-original components and/or modifications by unauthorised persons.


T R A N S P O R T A N D S T O R AG E


S A F E T R A N S P O R TAT I O N

If you wish to transport your JDN Air Hoist to another site, please observe the following points:

Carefully dismount trolley (if available).

Set the entire hoist down carefully; do not allow it to drop. For weights see Technical data , page 63.

Lay control and supply hoses together in such a way that they are not kinked.

Make sure that the controls are not damaged.

Failure to do so could lead to malfunctions.

Draw in the hoist's chain in such a way that loops cannot form and the chain cannot become twisted.

Secure the chain.

S T O R AG E CO N D I T I O N S

B R E A K S I N O P E R AT I O N

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 specified intervals, a protective coating must be applied to the motor. For this purpose, use a non-resinous and non-sticky conserving oil with conserving protection duration, which corresponds to the length of the planned operational break.

S T O R AG E

Close off the air supply hose connection using adhesive tape or a suitable cap, in order to prevent dirt ingress.

Protect connection for the air supply hose from being damaged.

Store your JDN Air Hoist in a clean and dry place.


SETTING UP

SETTING UP

U N PAC K I N G

WA R N I N G !

When unpacking, take account of the weight of the hoist. See Technical data , page 63.

C AU T I O N !

Do not kink the control lines. Kinked control lines can result in malfunctions.

Keep the accompanying documents in the place provided, near the operating site.

Lift the hoist carefully out of the packaging.

Recycle packaging materials in accordance with local regulations.

A S S E M B LY

JDN Air Hoists are usually delivered pre-assembled.

If not, first read the following sections:

Connecting the controls, page 22

Removing and installing chain, page 57

Chain box, page 62.

In the event that the chain is included unattached, a short auxiliary chain is drawn into the hoist. In order to draw in the chain, the hoist must be connected to the main air supply and must be ready for operation.

P R I O R T O I N I T I A L O P E R AT I O N , T H E

C H A I N M U S T B E L U B R I C AT E D

( S E E L U B R I C AT I N G T H E C H A I N S E C T I O N ,

PAG E 4 4 ) .

I N S TA L L I N G T H E H O I S T

Mounting the trolley, see trolley operation manual.

DA N G E R !

JDN Air Hoists must only be installed by qualified persons.

A defective installation can result in the most serious of accidents.

DA N G E R !

The attachment points for JDN Air Hoists must be able to safely withstand the expected forces. Ensure that your JDN Air Hoist is capable of alignment under load, otherwise inadmissible additional stresses may occur.

DA N G E R !

The supporting structure of the air hoist must form a rigid mounting. Vibration damages the chain and can lead to chain fracture. Furthermore, external vibration must on no account be transmitted to the hoist (lifting gear). (e.g. from the suspended load).

Provide a suitable working platform.

Attach the hoist at the suspension hook (or suspension eye) to running gear or stationary fixing.

Ensure that the hook safety catch closes automatically.

Attach the hoist securely at the suspension hook or suspension eye.


SETTING UP

C O N N E C T I N G T H E CO N T RO L S

C O N N E C T I N G T H E RO P E CO N T RO L S

Knot both control ropes at the ends of the control lever.

Knot the green pin into the rope which activates

“lift” mode, with the pointed end upwards

(see also illustration Rope control, page 22).

Knot the yellow pin into the rope which activates

“lower” mode, with the pointed end downwards.

Knot the handle into the rope so that the arrow markings correspond to the actual direction of movement.

C O N N E C T I N G T H E E - CO N T RO L S

Pushbutton valve (hand control)

Guide the strain-relief cable through the eye on the pushbutton valve and secure using the cable clamp.

Push the one-ear clamps onto the hose ends.

Attach the hoses to the hose nipples.

The one-ear hose clamp must lie in the middle of the hose nipple clamping range. The best clamping characteristics are achieved in this range.

Rope control, motor side

Pushbutton valve with nipples and rope with designation lift and lower


Secure the hoses using the one-ear hose clamps and crimping tool.

C AU T I O N !

To ensure perfect sealing, the “ear” must be fully closed on installation.

Pinched one-ear clamp and crimping tool

SETTING UP

Removal

The bellows must be pulled over the other end of the hose bundle including the strain-relief cable (coat hose bundle with oil for ease of fitting). Pull the bellows back far enough to permit further installation.

Push the one-ear clamps onto the free ends of the hoses. Guide the hoses 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 the bellows, insert bellows clamps

(long end pointing inward) and secure to the control valve using bolts (2 x M5).

C AU T I O N !

The strain-relief cable must be installed with the correct length in order to prevent loading of the hoses.

lift (green) lower (red)

Compressed air supply colour "white"

Illustration of bellows with hoses and strain-relief cable


SETTING UP

C O N N E C T I N G F - CO N T RO L S

Pull the bellows over the hose bundle for F-control.

For F-dual-control (for lifting and lowering only), remove approximately 50 mm of hose bundle protective sheathing.

Insert the control hoses into the connection nipples

(see illustration on page 23, bottom):

• Compressed air supply with hose designation 1 or colour: white

• Movement direction “lift” hose designation 2 or colour: green

• Movement direction “lower” hose designation 3 or colour: red

For F-control with additional functions (trolley, crane movement) remove approx. 50 mm of protective sheathing and slit open the protective hose a further

50 mm in order to route the control hoses for compressed-air connection, trolley and crane movement outwards in front of the bellows. (Close off compressed-air connection at the control valve using screw plug G 1/8). Pull both strain-relief cables through the eye bolt and secure using rope clamps.

The control hoses for the drive motors (trolley, crane movement) and for the compressed air supply must be extended, outside of the bellows, by means of plug-in connectors and additional control hoses.

Connection see “Trolley” operation manual.

C AU T I O N !

The control hoses must not be subject to tensile load; adjust 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).

C O N N E C T I N G F I - CO N T RO L S

Pull the bellows over the hose bundle for FI-control.

Remove approx. 50 mm of hose bundle protective sheathing. With this type of control, strain-relief of the hand controls takes place via the protective sleeve of the hose bundle. For this purpose, the protective sleeve is pushed onto the hose carrier and is secured using a one-ear 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 carrier. Close the ring again to prevent detaching.

Insert the control hoses into the connection nipples

(see illustration on page 23, bottom):

• Compressed air supply with hose designation 1 or colour: white



(see illustration on page 23, bottom)

C AU T I O N !

The control hoses must not be subject to tensile load; adjust the length of the protective sleeve 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).


SETTING UP

R E P L AC I N G C O N T R O L S

If you wish to exchange air controls E, F or FI, proceed as follows, (see illustrations in section

Connecting the controls ).

CO N V E R S I O N F RO M E T O F CO N T RO L

Control valve housing (on motor)

Removal of E-controls

Pull the bellows back over the hose until the hose nipples with the one-ear clamps are exposed and further removal is possible.

Detach the strain-relief cable and remove the one-ear clamps (see illustration Removal, page 23).

Cut off the hoses below the hose nipples using a knife. Unscrew the hose nipples (A/F 13).

Pull the bellows over the hoses of the E-controls.

This is also required for the F-controls.

Installation of F-controls

See page 24, Connecting F-controls.

CO N V E R S I O N F RO M E T O F I CO N T RO L

Removal of E-controls as previously described

Installation of FI-controls

Pull the bellows over the hose bundle for

FI-control. Remove approx. 80 mm of hose bundle protective sheathing.

Screw the “straight screw connections” (Steck-fix) for

4 mm hoses into the hose adapter (A/F 16).

With this type of control, strain-relief of the hand controls takes place via the protective sleeve of the hose bundle. For this purpose, the protective sleeve is pushed onto the hose carrier and is secured using a one-ear clamp.


(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 carrier. Close the ring again to prevent detaching.

Insert the control hoses into the connection nipples:

(see illustration on page 23, bottom).

• Compressed air with hose designation 1 or colour: white



C AU T I O N !

The control hoses must not be subject to tensile load; adjust the protective sleeve 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) (see illustration on page 23, bottom).

CONVERSION FROM AIR CONTROL

TO ROPE CONTROL

C AU T I O N !

Only air controls without protective sleeve main-stream valve can be converted to rope control.

Removal of E-controls, as previously described.

Removing air controls (F or FI)

Pull the bellows back over the hose until the hose connections are exposed. Pull all hoses out of the connectors (see illustration Plug-in connection ).

R E M O V I N G T H E H O S E P I E C E S

Press down the locking ring 1 with a suitable tool

(for example screwdriver), pulling out the hose piece 2 at the same time.

1

2

Plug-in connection


SETTING UP

Installation of rope controls

Close off the centre air connection using a screw plug

G1/8. Silencers G1/8 are screwed into the two outer connections. Unscrew main-stream valve or connecting plate, screw on rope control valve with an appropriate flat seal. Guide the control ropes through the bores in the lever and knot them. Rope colour: “green” lift,

“red” lower. Further, see section Connecting the rope controls, page 22.

Main-stream valve or air connection G 1 /

2

CO N N E C T I N G T O T H E M A I N A I R S U P P LY

Check air connection for contamination and clean if necessary.

Blow through compressed air hose in order to remove foreign bodies.

Attach the compressed air hose to the connection on the hoist or on the service unit. Tighten the union nut.

Air connection (white) lift (green) lower (red)

Rope control valve

Installation of rope controls

Attach the compressed air hose and tighten the union nut.


SETTING UP

L U B R I C A N T S

The following lubricants are intended for normal environmental influences.

In the case of wear-promoting environmental influences, please contact J.D. NEUHAUS to receive the appropriate instructions.

WA R N I N G !

Oils and greases can cause skin irritation.

Wear protective gloves.

C AU T I O N !

Potential damage! Do not mix synthetic oils or greases with mineral oils, as the properties may be impaired.

Also, never mix different types of lubricating grease within the synthetic or mineral lubricant groups.

Synthetic lubricants must not be used when operating with oilers.

Alcohols are not permitted for use as anti-icing agents.

Application

Motor lubrication

- from factory

- when operating with oiler

Lubricant

- JDN high-performance grease,

Art. no. 11901 (1 kg)

Art. no. 11902 (40 g)

- Compressed air oil “D”, kinematic viscosity approx. 30 mm 2 /s (cSt) at 40° C, with anti-icing agent where applicable

Chain lubrication chain oil or motor vehicle engine oil, kinematic viscosity approx. 150 mm 2 /s

(cSt) at 40° C, or special lubricant from J.D. NEUHAUS

In areas with very high corrosion potential, e.g. offshore, a lubricant with extremely strong anti-corrosion properties must be used.

Motor conservation

(not applicable when using

Non resinous Conservation oil with appropriate period of

JDN high-performance grease) effectiveness

Motor cleaning


JDN high-performance grease)

Lubrication of bearings and gearbox (also for exposed gears)

Pure petroleum

Lithium-thickened grease, worked penetration 265-295

(0.1mm), basic oil viscosity:

190 cSt (mm2/s) at 40° C, drop point: 180° C,

Working temperatures:

- 20° C to + 120° C, designation in accordance with DIN 51825: KP2K-20, active agents: EP additives

(for wear-reduction) and ageing protection; water resistant and corrosion protection powered by air !

Page 27

SETTING UP

P R E - S TA R T C H E C K S

Hoists, including the supporting structure, must be inspected by an appropriately trained and qualified person before initial operation and before re-commissioning after significant modifications. Hoists and lifting gear which are installed in trolleys must be inspected by a specialist.

The inspection covers the proper mounting, equipment level and operational-readiness, 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 the supporting structure.

Safety devices are braking devices, overload protection devices, EMERGENCY STOP devices, lifting and lowering limiters (emergency end-stop devices).

A description of the inspections can be found in the

Maintenance section, page 38.




R U L E S F O R S A F E O P E R AT I O N

O F H O I S T S

As an operator of hoists, you are responsible for your own safety and for that of your colleagues in the working area of the hoist.

Hoists may only be operated by persons charged with this task by their company.

Before using the JDN Air Hoist for the first time, familiarise yourself with all permissible operating conditions. For this purpose, read through this operation manual thoroughly and perform the described actions on the hoist, step by step.

Report each malfunction to your safety officer immediately, so that the fault can be remedied without delay.

Adhere to the regulations of the accident prevention authorities (e.g. Berufsgenossenschaft regulations in

Germany).

Observe the section Intended use , page 15.

Improper use includes, but is not limited to, any and all of the following:

Changing load-carrying capacities with the load position: JDN Air Hoists are not equipped with load-carrying capacity indicators, they may therefore 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 pulling is the deviation of the load chain and the chain hoist 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.

Oblique pulling

Under special safety provisions relevant to the particular situation, JDN Air Hoists may be used for oblique pulling (see Intended use , page 15).

In this case, a chain box must not be used as the chain may fall out or become knotted.

Oblique pulling is not permitted for hoists installed in trolleys or running gear. Please contact us, if required.

Detaching or dragging of loads.

Loading of the hook at the tip.

Catching of falling loads.

Carrying persons

(see Intended use , page 15).

Jog control with load on the hook.

Switching to the opposite direction wit load in motion.

Operational reaching of lifting and lowering limiters.



JDN Air Hoists must not be used for the following applications, for example:

Critical areas of nuclear plants.

Over acid baths or other plants with corrosive substances.

In areas in which organic acids are present.

To ensure the safety of personnel and property when using JDN Air Hoists, it is essential that the following points are observed:

Lift the load carefully at the beginning.

Never touch a running chain.

Never use the hoist chain for attaching loads.

Never allow loads to fall into the hoist chain.

If the chain is slack, do not take up the load at maximum speed.

Only use original JDN chain boxes .

Do not exceed the permissible capacity of the chain box.

When operating without a chain box, avoid hazards due to idle chain (falling, catching, impacting), see section Operation without chain box, page 19.

Never apply bending to chains.

Do not join or repair hoist chains.

Do not operate with a chain which is drawn tight, bent or extended.

Check blocked chains for damage.

Straighten twisted chains (defective bottom block)

Do not operate with damaged or worn or rusty chains.

Permissible operating temperature for chain and hook:

- 20° C to + 150° C, permissible ambient temperature:

- 20° C to + 70° C, permissible heat absorption of the hoist body: max. 90° C.

Never allow persons to enter the area below the suspended load.

Never attempt to remedy a fault with a load suspended from the hoist.

Only use suitable and approved attaching aids; do not jam the hook at the point of attachment.

Please ensure that the operator is not put at risk within the operating area by the sling gear or the load.

Follow the relevant instructions for attaching loads.

Before attaching, accurately position the load vertically below the hoist. The chain must hang vertically before lifting.

Ensure that the hook safety catch is closed.

Repair damaged hook safety catches.

Before lifting loads, ensure that the maximum permissible load is not exceeded. Attaching aids must be included in the weight of the load.

When taking up and setting down, ensure stable positioning of the load, to prevent accidents due to tilting or falling loads.

Never drive against jammed loads.

Only lift one load at a time; never several loads simultaneously.

Never lock the control elements of control devices.

In the case of stiff actuating elements, have the hoist repaired.

In the case of power failure, secure the load and the surrounding area, until the power is restored.

Never use or repair bent, open or deformed load hooks. The hoist must be repaired and the hook must be replaced.

Never anneal the hook.

Only operate JDN Air Hoists with original JDN controls .

Uncontrolled, external force factors (such as due to hydro cylinders, falling loads) are not permitted.

Repair stiff hook bearings.

Do not kink or pinch control hoses.

Have loosened bolted connections tightened by the

Repairs department.

Before removing compressed air hoses, shut off the compressed air.

Repair the hoist if the braking distance is excessive.

If a load is lifted using several air hoists, prevent overloading due to incorrect weight distribution.

Select a safe operating location.

Ensure the correct system pressure.

Never touch metallic hand controls which are colder than 0° C or hotter than 43° C, without suitable protective gloves.

Do not make modifications to the hoist.

Only use original JDN spare parts.

J.D. Neuhaus GmbH & Co. KG accepts no liability for the use of non-original components and/or modifications by unauthorised persons.

If, in the case of multi-chain hoists, the bottom block is lying on the floor, move it back to a hanging position in a controlled manner (evenly-loaded chains).



DA N G E R !

For all air hoist applications, ensure that the load hook can be lowered all the way to the ground, in order to prevent a load being moved to the lower limit position, without reaching the ground. Danger due to overloading.

DA N G E R !

Never use hoists on the ground if they are not specifically intended for horizontal pulling.

DA N G E R !

The fatigue strength of chains is significantly impaired due to extreme corrosion (pitting corrosion). There is a danger of fracture .

Hydrogen-induced embrittlement with resultant stress cracks due to highly corrosive media (e.g. seawater) may affect highstrength steels (e.g. 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 for operational reasons, crack inspections are to be carried out at intervals of three months.

Company operating instructions

In the case of particularly difficult lifting equipment applications, the company must provide comprehensible operating instructions in the language of the operator, within the framework of this operation manual. Here, measures for safe operation are stipulated in accordance with prevailing operating conditions.

Furthermore, it is essential that all the regulations set out in sections Intended use , page 15 and Operating conditions, page 16 are observed.

powered by air !

Page 31


CO N T RO L S

JDN Air Hoists can be equipped with various control devices.

All are suitable for use in explosion-hazardous areas.

All control switches return to the zero position when released.

CO N T RO L VA LV E O N M O T O R

Air control (E, F, FI controls) with upstream main-stream valve

The control valve consists of:

1. Main-stream valve

2. Direction control valve as flat slide valve

3. Load-limiting valve connection housing

The main-stream valve lies upstream from the direction control valve. If no control pressure is present, the valve is closed and the direction control valve is depressurised. If control 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 main-stream valve is closed.

Air control (E, F, FI controls) without upstream main-stream valve


1. Connecting plate

2. Direction control valve as flat slide valve

3. Load-limiting valve or connection housing

E CO N T RO L

With E-control, lifting and lowering movements can be controlled via two pushbuttons. The direction of movement of the load hook is marked on the upper side of the valve housing, above the pushbuttons.

Lift: Press the right pushbutton.

Lower: Press the left pushbutton.

E-control with EMERGENCY STOP button



P U S H B U T T O N F - C O N T R O L

With pushbutton F-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.

Lift: Press the upper pushbutton.

Lower: Press the lower pushbutton.

F-control with EMERGENCY STOP button

P U S H B U T T O N F I - C O N T R O L

With pushbutton FI-control, lifting and lowering movements can be controlled via two pushbuttons arranged side by side. The control pressure is infinitely variable, enabling precise 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 further down, in order to increase the lifting speed.

Release the pushbutton slightly, in order to reduce the lifting speed.

Lower: Carefully press the left pushbutton.

The load is lowered slowly.

Press the pushbutton further down, in order to increase the lowering speed.

Release the pushbutton slightly, in order to reduce the lowering speed.

EMERGENCY STOP button

FI-control with EMERGENCY STOP button



E M E RG E N C Y S T O P D E V I C E

Within the EU, these controls are equipped with an

EMERGENCY STOP device (optional outside the EU).

In order to avert danger arising from the lifting movement as quickly as possible, the pushbuttons must be released; the movement of the load is interrupted immediately.

Only in the case of failure of this stop function, must the red EMERGENCY STOP button be firmly pressed.

The EMERGENCY STOP button engages. This results in the closing of a separate check valve and the load hook comes to rest instantaneously. The pushbuttons for lifting and lowering now no longer function.

The EMERGENCY STOP button can be released again by turning clockwise. It jumps back into place.

DA N G E R !

Never release the EMERGENCY STOP button before the danger is eliminated and the stop function via the pushbuttons has been restored.

RO P E CO N T RO L

With rope control, the lifting and lowering movements 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 elements for rope control and the energyswitching component of the control valve on the motor

(reversing valve) are positively connected to one another. 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 EMERGENCY STOP device is required.

Lift: Carefully pull on the green rope with the green handle pin. The load is lifted slowly.

Pull harder on the rope, in order to increase the lifting speed.

Release the rope slightly, in order to reduce the lifting speed.

Lower: Carefully pull on the red rope with the red handle pin.

The load is lowered slowly.

Pull harder on the rope, in order to increase the lowering speed.

Release the rope slightly, in order to reduce the lowering speed.

Rope control

O V E R L OA D P RO T E C T I O N

The overload protection limits the operating pressure of the compressed air supplied. It responds as a function of load and is set to a limit value of approx. 125 % of the nominal load. The force limiting factor then has a value of 1.25.

When the overload protection is activated, the lifting movement is possible again once the lowering movement has been switched (unloading the hoist).

The overload protection may also respond when moving 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.


AT TAC H I N G T H E L OA D

DA N G E R !

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 load.

In Germany, the trade association 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 attached at the lowest point of the hook. Never load the point of the hook.



Attach the load safely powered by air !

Page 35


L I F T I N G T H E L OA D

C AU T I O N !

JDN Air Hoists must be capable of alignment under load. Otherwise impermissible additional forces can occur, which can damage the hoist components.

First, lift the load hook, in order to pull the slack chain tight. With the chain tight, briefly interrupt the lifting procedure. The hoist can align itself and the material is protected.

Then lift the load.

The overload protection system aborts the 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).

L OW E R I N G T H E L OA D

DA N G E R !

Ensure that there are no persons below the load.

Then lower the load and ground it carefully.

DA N G E R !

For all air hoist applications, ensure that the load hook can be lowered all the way to the ground in order to prevent a load being moved to the lower limit position, without reaching the ground. Danger due to overloading.

D E TAC H I N G T H E L OA D

Lower the load hook far enough, so that the load can be easily detached.

Move the load hook out of the lifting area, in order to avoid hazardous situations.

I N T E R R U P T I N G W O R K I N G

If you wish to interrupt working with your

JDN Air Hoist:

Set down and detach the load.





P RO L O N G E D S H U T D OW N

If the hoist is to be taken out of operation for a longer period of time it must be protected against corrosion and dirt.

Coat the chain and hook with a light oil film.

Move the load hook out of the lifting area in order to avoid hazardous situations.

Do not move against the lifting and lowering limiters/buffers (emergency end stop devices).

Depressurise the air line.

S T O R AG E

(see section Storage conditions, page 20)

D I S M A N T L I N G

DA N G E R O F I N J U R Y !

JDN Air Hoists may only be dismantled by qualified personnel.



Loosen the union nut and remove the air hose.

Protect the air connection against the dirt ingress.

Detach the control hoses from the hoist.

Do not kink the control hoses.

Mark the connections.

Detach the strain relief and hose carrier and 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).

D I S P O S A L

JDN hoists contain a range of materials which, on expiry of the service life, must be disposed of or recycled where appropriate, in accordance with statutory regulations.

Please note the following list of materials used:

H O I S T

Ferrous materials

Steel

Cast steel

Nodular cast iron

Non-ferrous metals

Bronze

Aluminium

Plastics

Polyethylene

Polyurethane

Polyoxymethylene

Polyvinyl chloride

Polyamide, glass-fibre reinforced

Natural rubber

Epoxy resin

Polyacetal

Polypropylene

Phenol resin

Thermoset moulding compound

(Asbestos-free brake lining)

Polyester

Synthetic rubber

Wool felt

F I LT E R S I L E N C E R /

S E R V I C E U N I T:

Zinc diecast

Brass

Nitrile rubber

Aluminium

Polypropylene

Polyurethane

Glass-fibre reinforced plastic

Steel

Polyacetal

Polyethylene


M A I N T E N A NC E


M A I N T E N A N C E A N D

I N S P E C T I O N I N T E R VA L S

JDN air hoists are extremely robust and require little maintenance. Compliance with maintenance and inspection intervals is of great importance in order that the hoist operates safely and reliably over a period of many years.

WA R N I N G !

Maintenance work on JDN Air Hoists must only be performed by trained and qualified personnel.

C L E A N I N G A N D C A R E

If your JDN Air Hoist is often used at different locations, particularly in dirty and damp environments, clean any dirt off the hoist and the chain, seal off the air supply connections, protect the hoist and, in particular, the chain from corrosion, store the hoist in a clean and dry place.


If, during repair work, the replacement of components is necessary, only original JDN spare parts may be installed.


(see section Lubricants, page 27)

I N S P E C T I O N A N D

M A I N T E N A N C E W O R K

Series lifting equipment is classified into groups and dimensioned according to the type of operation (Driving mechanism classification according to ISO/FEM). The classification (M4/1 Am) is determined by the average daily operating time (max. 1 hour) and the load spectrum. The theoretical operating time for load spectrum

2 (average) is 3200 hours. This corresponds to 800 fullload hours. This is assuming that the lifting and lowering paths are approximately the 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.

Therefore, the determined portion of the theoretical operating time must be multiplied by a factor of f v

.

The factor f v has a value of 1 to 50 % of the nominal load, increasing linearly to 1.5 at 100 % of the nominal load (nominal load percentage P).

f v

= 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 once annually. The inspection log is only supplied in the Federal Republic of Germany. Instructions and a model for determining the actual operating time can be found from page 40 onwards.

When the theoretical operating time has been reached, a general overhaul must be performed. Detailed explanations for the determination of the actual operating time and its documentation can be found in the national safety regulations. Alternatively, the calculation model in this operation manual can be used. The general overhaul must be initiated by the operator and must be documented in the inspection log. Information on general overhaul can be requested from the manufacturer.


Only if the group classification corresponds to the actual type of operation of the lifting equipment does a safe operating period conform to the theoretical operating time. Deviations of the actual type 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 be made to the hoist.

The hoist must be disconnected from the main air supply during assembly work.

Dismantling the hoist, see page 37.

WA R N I N G !

Following each repair, the hoist must be checked for operational readiness.

M A I N T E N A NC E powered by air !

Page 39


I N S T R U C T I O N S O N T H E

O P E R AT I N G T I M E ”

“ M O D E L

F O R D E T E R M I N I N G T H E AC T UA L

The formula given for the cubic average k does not take the weight of the harness into account. This is permissible if the ratio

Weight of harness

Load-bearing capacity

≤

0.05

The decisive factors for the type of operation are the collective loads with different cubic averages k .

The collective load indicates to what degree a driving mechanism, or a part of one, is subjected to its maximum stress or only to smaller stresses. The cubic average (factor of the load spectrum) is calculated using the following formula.

To determine the type of operation for calculating the partial operating times (actual operating time), the following collective load diagrams can also be used.

Collective load 1

Definitions:

=

Maximum or ultimate load


=

Dead load


=

Operating time with maximum load or partial load and dead load

Total operating time

=

Operating time with dead load


0.4

t

1

0 10 t

2

50

0.1

t

∆

100

Collective load 3

0 t

1

50

0.4

t

∆

100

The FEM* 9.511 rule differentiates between four collective loads, which are identified by the definitions and by the ranges of the cubic averages k . This classification complies with ISO 4301/1.

*FEM = Federation Europeene de la Manutention (European Federation of Materials Handling and Storage Equipment)

Collective load

1

(low)

Definition

Cubic average

L1 Driving mechanisms or parts thereof, which are only subject k

≤

0.50

to the maximum stress in exceptional circumstances, and are only subject to very lowstresses continuously.

2

(average)

L2 Driving mechanisms or parts thereof, which are subject to 0.50 < k the maximum stress often, and are only subject to low

≤

0.63

stresses continuously.

3

(high)

4

(very high)

L3 Driving mechanisms or parts thereof, which are subject to 0.63 < k the maximum stress often, and are subject to average

≤

0.80

stresses continuously.

L4 Driving mechanisms or parts thereof, which are subject to the maximum stress of adjacent stresses regularly.

0.80 < k

≤

1,00

Collective load 2

0.733

0.467

t

1 t

2 t

3

0 16.7 33.3

50

0.2

t

∆

100

0

Collective load 4 k k m k m m t

1

= k 3

= k 3

= k 3

= 0.25

= 0.5

= 1

0.8

t

∆

90 100

Collective load factor k m

= k 3 = 0.125



MODEL FOR DETERMINING THE ACTUAL OPER ATING TIME

The following calculation compares the actual operating time with the theoretical operating time in collective load 4 (very heavy).

1

_

2

Operating site

Average daily operating time in hours

0

3

Collective load factor in accordance withcollective load for the type of operation

L1 L2 L3

Low Average High

L4

Very high

4 5

Partial deployment

Remaining theoretical use in collective load 4

Column 2 x column 3 x operating days x factor 1.2

(When zero has been reached a general overhaul must be performed)

6

Date

Delivery

Initial operation

Inspections

7

Specialist inspector

Signature

Existing driving mechanism group, see nameplate

Delivery date J.D. NEUHAUS

GmbH & Co.KG

0,125 0,25 0,5 1 0 M2 (1Cm) 200 hours

M3 (1Bm) 400 hours

M4 (1Am) 800 hours

M5 (2m) 1600 hours

Initial operation

C ALCUL ATION MODEL (DRIVING MECHANISM CL ASSIFIC ATION M3)

Slewing crane assembly site

1,5 0,25

1.5 x 0.25 x 250 x 1.2

= 113 hours

(400 - 113)

287 hours

2. August

2004

A.N. Other



The specified inspection intervals are valid for use in accordance with the classification (see driving mechanism classification on the nameplate). The service life is approx. 10 years if the device is used in accordance with its classification.

If the hoist is used more intensively the intervals are to be shortened accordingly. The intensity of use must be assessed using the model for determining the actual operating time (see page 40). All operating hours are translated into full load hours. The theoretical operating time and the interval hours are indicated in full load hours.

Maintenance measure

Check oil level for motor lubrication (when operating with oiler)

Lubricate chain

Interval

Daily

As required

Comment

(Section

(Section

Filling and adjusting oiler,

Lubricating the chain, page 48) page 44)

Inspection measure

Check control equipment

Check braking function

Check direction of movement

Lifting and lowering limiters

(buffers), visual check

Check EMERGENCY STOP function

Check chain

Check lifting and lowering limiters

Check brake with load

Check all bolted and pin connections

Check load hook on the load and carrying side

Check the motor, check, clean and grease the control valve

(JDN high-performance grease)

Check the axial movement of hooks and eyes

Check service unit 1

Check silencer for permeability

Check overload protection

Check compressed air connections for damage

1 If available

Yearly

Yearly

Yearly

Yearly

Yearly

Yearly

Yearly

Yearly

Yearly

Annually

Interval

Daily

Daily

Daily

Daily

Daily

Every 3 months

Comment

(Section Checking controls, page 45)

(Section Checking braking function, page 44)

(Section Checking direction of movement, page 45)

Replace buffer immediately if damaged, otherwise replace every 5 years

(Section Checking chain, chain sprocket and chain guides, page 54) in the case of wear pro moting conditions, reduce interval between checks

(Section Checking lifting and lowering limiters, page 45)

The load must be braked reliably (Section

Checking braking function, page 44)

(Section

(Section

Check dimensions,

Measure the lifting speed

Checking axial play, page 54) page 56)

(Section Service unit, page 46)

(Section Checking the silencer for for permeability, page 45)

(Section Checking and adjusting overload protection, page 59)



Inspection measure Interval Comment

Check sealing efficiency and function Yearly of control valve

Check condition of chain box 1 including mountings

Yearly

Check brake wear and motor wear Every 200 hours,

At least every 5 years

Every 5 years In off-shore areas and other similar corrosive environments, replace the chain regularly

Check gearbox and perform lubricant Every 5 years change

(Section

(Section page 49)

Chain box, page 62)

Checking brake linings and vanes,

Check the rotor/pinion shaft connecEvery 5 years tion and lubricate with gear grease

Check the sprocket wheel bearings and Every 5 years lubricate if necessary

Check chain and chain guides changed Each time the chain is (Section Wear dimensions, page 55)

Renew grease lubrication of motor As required,

At least every 5 years

(Section Motor lubrication, page 49)

1 If available powered by air !

Page 43


L U B R I C AT I N G T H E C H A I N

The chains of JDN Air Hoist must be lubricated in the links, in unloaded condition.

Clean heavily contaminated chains.

Lay the chain in a suitable container.

Spray the chain with special lubricant or motor vehicle engine oil.

If you wish to lubricate the hanging chain, ensure that the chain links are oiled at the points of contact.

For this purpose, move the chain to and fro.

A high-performance lubricant in an aerosol can is available from JDN, which adheres well to the chain after the solvent has evaporated and does not drip off, Art.

no. 12066 (aerosol 400 ml).

For operation in areas with high corrosion potential, e.g. in the off-shore sector, the chain can be largely protected against corrosion by the use of special lubricants. These types of lubricants are characterised by weathering resistance, water insolubility, good adhesion properties etc. Relubrication intervals must be stipulated in accordance with the loading.

Please contact us, if required.

C H E C K I N G B R A K I N G F U N C T I O N

Check the function of the brake daily as follows:

Switch the unloaded air hoist alternately between lifting and lowering modes.

If a control element is released, the chain must be seen not to run on.

DA N G E R !

If the chain runs on, 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 be perceptible.

When checking the braking function under nominal load, the following braking distances must not be exceeded:

B R A K I N G D I S TA N C E S U N D E R N O M I N A L L OA D

( L OA D - C A R R Y I N G C A PAC I T Y ) A F T E R L OW E R I N G

H A S B E E N S T O P P E D

Type

Rope control

025 TI 05 TI 1 TI

7 6 3 all other controls with hose lengths 18 of 2 m

Dimensions in mm

9.5

8

2 TI

1.5

4

If the control hoses are long the braking distances will increase due to longer air evacuation times.



C H E C K I N G L I F T I N G A N D

L OW E R I N G L I M I T E R S

Move the unloaded load hook until just short of the upper and lower end positions.

Stop immediately before reaching the end position and then carefully (by repeatedly pressing the control element) move to the end position.

The movement of the chain must be stopped due to deformation of the buffer. For hoists with overload protection, the lifting movement is additionally limited by shutting off the motor.

Following successful testing, the buffer must be unloaded.

DA N G E R !

If the buffer is damaged, do not use the hoist. The hoist must be repaired (replace the buffer).

C H E C K I N G C O N T R O L S A N D

E M E RG E N C Y S T O P F U N C T I O N

All control elements of the controls must always be free-moving.

Unload the JDN Air Hoist.

Briefly actuate and release all control elements of the controls one after another. The control elements must return to their initial positions immediately. The switching on and off function must operate correctly.

PRESS the EMERGENCY STOP button. Each movement of the hoist must stop. Actuation of the control elements must not cause a lifting or lowering movement.

RELEASE the EMERGENCY STOP button by turning.

DA N G E R !

If a control element is stiff or remains in the actuated position, do not use the hoist. The controls must be repaired.

C H E C K I N G D I R E C T I O N

O F M O V E M E N T

Check that the direction of movement of the load hook corresponds to the direction indicated by the arrows on the control elements.

C H E C K I N G T H E S I L E N C E R

F O R P E R M E A B I L I T Y

Irrespective of the stipulated inspection intervals, the silencer must be checked for permeability if the hoist does not achieve the specified lifting speed (see section

Technical data, page 63).

The test is performed by comparing the lifting speeds under nominal load, with and without the silencer.

The speed with standard silencer or filter silencer must be at least 80 % of the lifting speed without a silencer element.

In the case of lower values, the silencer elements must be cleaned or replaced.



S E R V I C E U N I T

AT T E N T I O N !

If a hoist is operated with a service unit, this should not be mounted further than 5 m away from the hoist.

The ambient temperature must be a minimum of

0° C. It must not exceed 50° C.

N O T E : If, at the request of the customer, a service unit is installed in hoists in motorised trolleys and lifting gear, it will be configured at the factory.

The service unit in the Air Hoists PROFI O25 TI to

PROFI 2 TI consists either of two elements, filter controller and oiler, or of the filter controller only.

C H E C K I N G A N D A D J U S T I N G T H E F I LT E R

CO N T RO L L E R

* )

The filter controller is set to an actual pressure of 5.4

bar (3.6 bar) in the factory (actual pressure with motor running).

In this setting, the manometer can indicate a pressure of over 6 bar (4 bar) with the motor switched off. For correct adjustment, a pressure 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

Anti-clockwise: lower pressure

Lock the regulator knob by pressing it down.

Alternatively, the filter controller can be set to a pressure of 6 bar (4 bar) in the absence of an air stream.

This setting is only correct for a pressure of at least 7 bar (5 bar) upstream of the service unit.

Depressurise the air line downstream of the service unit and close it again.

Turn the regulator knob anti-clockwise, in order to release the adjusting spring.

Turn the regulator knob until the manometer indicates a pressure of 6 bar (4 bar).

Clockwise: higher pressure

Anti-clockwise: lower pressure


If the nominal pressure of 5.4 bar (3.6 bar) cannot be achieved despite a sufficiently high pressure upstream of the service unit, then the air line cross-section is too small.

* )

Values for 4-bar hoists in brackets

Filter controller and oiler filter-regulator adjusting knob lubricator



D R A I N I N G WAT E R

After a certain time, liquid collects in the filter controller container, which must be regularly drained. For this purpose, proceed as follows:

Check the water level through the sight glass in the filter container. The water level must not reach the separating plate.

Fit the accompanying hose (instead of this, a

∅

8 x 1 soft PVC hose of the required length can be fitted).

Collect the escaping water and ensure proper disposal, as possibly oil-containing.

C L E A N I N G T H E F I LT E R E L E M E N T


Do not use alcohol for cleaning the service unit. Alcohol can damage parts of service unit. Transparent components must only be cleaned using 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 dissipate.

Unlock the filter controller container, turn anti-clockwise to the stop and remove.

Unscrew the separating plate. The filter is located loosely on the separating plate centring device.

Clean the filter element using soap solution and blow through forcefully.

Reinstall the clean filter element and fasten the separating plate.

Insert the filter controller container in the housing and turn clockwise. The container locks automatically.

install hose

Draining water drain the liquid: by pressing grips on both sides filter element separating disc sight glass filter receptacle

Cleaning the filter element powered by air !

Page 47


F I L L I N G A N D A D J U S T I N G O I L E R

The oiler ensures that the hoist air supply is consistently provided with a precisely-metered quantity of oil.

Regular checking of the oiler is very important, as the vane motor may be damaged in the case of lubricant deficiency. The oiler can also be refilled under pressure.

Check the oil level through the sight glass in the container. The oil level must not fall below the minimum mark.

Remove the oil filler screw.

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 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):

2 drops per minute.

C AU T I O N !

Operation of service units with synthetic oils is not permissible.

They must also not be connected to compressed air circuits, which are supplied by compressors lubricated with synthetic oil.

WA R N I N G !

J.D. Neuhaus only supplies standard spray oilers.

Do not use microspray oilers as very finely secreted oil spray could adversely effect the surrounding air and therefore the respiratory system.

maximum oil level minimum oil level

Check the oil level and top up if necessary

Sight glass

Oil filler screw

Oil throttle screw

Page 48

Check oil drop rate at sight glass and adjust powered by air !


M O T O R I N S TA L L AT I O N /

C H E C K I N G B R A K E L I N I N G S A N D

VA N E S / M O T O R L U B R I C AT I O N

12 13 11 7 8 6 10 9 5 4 3 2 1

14/15

Replacing brake discs, brake piston and vanes /Motor installation

The motor and brake functions are achieved in part by means of shared components. The braking action is applied at the lateral surfaces of the rotor. The rotor is pressed via spring force from the cover-side of the motor against a second braking surface located on the opposite side by means of a piston on which braking material is bonded.

R E M O VA L

The hoist must first be unloaded and disconnected from the main air supply.

Note: The following operations can be performed from the nameplate side after the motor has been removed.

Checking vane wear, replacing the vanes with starting aids if necessary.

Checking brake wear, replacing the brake piston if necessary.

Renewing the motor lubrication.

The replacement of the centre section halves with brake lining is described under a separate item.

Unscrew the nameplate 1 .

Remove the motor cover bolts 2 and pull out the motor cover 3 (when the cover bolts are removed, tension of the brake springs 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 .

Checking vane wear:

(See illus. Checking vane wear, page 50).

Worn vanes reduce the motor power and consequently the lifting performance.

Replacing the vanes together with the starting aids.

Checking braking surfaces of the brake piston and the centre section half with brake lining for wear and damage:

The circular wear pattern in the braking surfaces must not be deeper than 0.2 mm (see also illustration page 50). The extremely low-wear braking material will not reach the wear limit of 0.2 mm within the designdependent service life of the hoist, under intended use.

Should the wear limit be reached prematurely, the actual pressure must be checked with the device switched on

(the brake drags in the event of insufficient pressure).



V1 max. = 0.2 mm

Rotor

Cylinder liner

V2 max. = 0.2 mm

Brake piston

•

•

Brake disc

•

•

R

L h

•

L Vane

Lmax = R – (V1 + V2)

Lmin = R – (V1 + V2) – 0.3 mm = Lmax – 0.3 mm

Checking vane wear

Renewing motor lubrication:

Note: The grease packing in the rotor chambers is sufficient for approx. 250 hours of normal operation.

The rotor chambers are only emptied by approx. 75%.

In this condition, refilling must be performed.

The retaining rings 9 and Vyon washers 10 must be removed in order to refill the chambers.

Then pack the chambers with high-performance lubricant (JDN Art. no 11901) without forming cavities.

Use new Vyon washers to close off the lubricant chambers and secure these using retaining rings.

Replace centre section halves with brake lining.

If the centre section half with brake lining is to be replaced, the following removal operation is also required.

Detach the hoist from the point of attachment and set down carefully.

Detach the chain box if necessary.

Remove the control valve.

Unscrew centre section bolts 11 .

Detach the motor with centre section half on the motor-side from the hoist.

Remove the bolts 12 and pull out the centre section half with the brake lining 13 .

Motor installation with additional basic lubrication:

Apply high-performance grease lightly to braking surface and rotor bearing (needle bush) in the centre section half and slide this into the motor housing. At the same time, insert the anti-twist device (pin).

Bolt centre section half to motor housing.

Coat the internal cylinder of the motor housing 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-performance grease and insert into the rotor slots with the starting aids.

Coat the braking surface and the outer diameter including the brake piston seal lightly with highperformance grease and push the brake piston with the braking surface first into the internal cylinder.

Note the position of the eccentric bore.

Insert the brake springs into the bores of the brake piston.

Loosen adjusting bolts 14 and lock nuts 15 .

Screw back adjusting bolts.

Apply high-performance grease lightly to rotor bearing

(needle bush) in the motor cover and install motor cover. Ensure correct seating of the brake springs and the locating pins to the motor housing and to the brake piston. Do not tighten the four adjusting bolts after bolting the motor cover in place, only screw them in loosely by hand to the stop in the cover.

Screw back the lock nuts sufficiently beforehand.

Then screw back the adjusting bolts 45° from the stop, hold, and lock with the nuts. For lifting heights of 10 m and more, a setting of up to 60° is required.

For operation in areas with ambient temperatures exceeding 30° C, the adjustment has to be carried out with the device warmed up accordingly.


Screw on the nameplate.

Push motor with centre section half on the motor side onto the hoist – install load hooks at same time – and tighten centre section bolts.

Install the control valve.

C AU T I O N !

Tightening torques, see E-list.

WA R N I N G !

Check the braking action of the hoist under load (run in the brake by performing several hoisting cycles, then assess) prior to initial operation. Check the motor power. In the event of low motor power, regulate the adjusting bolts again.

M A I N T E N A NC E powered by air !

Page 51


REMOVING AND INSTALLING LOAD SLEEVE,

BOTTOM BLOCK, CLAMP AND BUFFER

R E M O V I N G A N D I N S TA L L I N G L OA D S L E E V E

A N D B U F F E R

- SINGLE CHAIN HOIS T S (025 TI, 05 TI, 1 TI)

R E M OV I N G A N D I N S TA L L I N G B O T T O M B L O C K

A N D B U F F E R S

- D UA L C H A I N H O I S T (2 TI)

2

5

4

3

1

5

10

8

7

8

3

2

5

Removal

Drive out the roll pin 1 for securing the chain from the load sleeve 3 .

Remove the chain link 2 from the chain pocket.

Detach the buffer 4 and buffer discs 5 from the chain.

Assembly

Push the buffer discs (edge encloses buffer) and the buffer onto the chain.

Insert the chain link into the chain pocket of the load sleeve (position of the weld must align with that of the following links).

Drive in a new roll pin to secure the chain link in the load sleeve.

Removal

Move the bottom block as close as possible to the hoist body.

Position the bottom block securely in order to prevent the chain from unravelling uncontrollably causing the bottom block to fall.

Remove the chain link 1 of the bottom block from the chain mount on the hoist body; drive out the roll pin 2 and the end chain link pin 3 for this purpose.

Draw the spacer pipe 4 from the chain.

14

6

1

4

12

11

13

9



Note: For assembly, it is helpful to fasten a short assembly chain 5 to the end of the chain by means of an open chain link 6 before pulling the chain out of the bottom block. This assembly is pulled into the bottom block as the chain is pulled out and remains there until assembly is completed.

Pull out the chain from the bottom block.

The buffer 7 and buffer discs 8 are thereby pulled from the chain.

Assembly


Align the chain and fasten it to the assembly chain in the bottom block by means of the open chain link.

Pull the chain through the bottom block and detach the assembly chain and the open chain link from the chain. If no assembly chain has been used, the end of the chain must be inserted into the bottom block and pulled through by turning the sprocket wheel using an auxiliary tool.

Push the spacer pipe onto the chain, align the bottom block chain and 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.

R E M O V I N G A N D I N S TA L L I N G C L A M P A N D B U F F E R

Removal (see illus. page 52)

In the case of operation with chain box, run the chain out of the chain box and detach it from the hoist.

Remove the chain link of the idle chain from the chain mount on the hoist body. Unscrew the Allen screws 14 for this purpose.

Loosen screw connections 9 of the clamp 10 .

Remove the clamp from the chain.

Detach the buffer 11 and buffer discs 12 + 13 from the chain.

Assembly

Push the buffer disc with edge (edge encloses buffer), buffer and buffer disc without edge onto the chain.

Insert the tenth chain link into the chain pocket of the clamp (chain pocket away from hoist body, pointing outwards).

Introduce a screw connection to secure the chain link in the clamp.

Align the idle chain and fasten the end chain link to the hoist body.

Attach the chain box.

C AU T I O N !

Do not twist the chain! The chain is subjected to impermissible stresses if the chain is twisted.

powered by air !

Page 53


C H E C K I N G C H A I N , C H A I N

S P RO C K E T A N D C H A I N G U I D E S

See also Check dimensions, page 54.

If the chain of the JDN Air Hoist displays one of the following features, it must be replaced with a new one:

Corrosion scars

Bent or damaged chain links

Chain drawn stiff

Wear over 11 pitches (A max

)

Single pitch wear (B max )

Elongation of a single link (D max )

Check the entire length of the chain.

Please observe the information contained in DIN 685, part 5 when checking chains. For further instructions, see ISO 7592.

C H E C K D I M E N S I O N S

H O I S T C H A I N

Note: When checking the replacement limit, future wear to the next checking 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 be replaced by a new one. The chain sprockets must also be replaced together with the chain, as otherwise the new chain will be subjected to increased wear. Each chain replacement must be documented in the inspection log.


d

1

Check dimensions of hoist chain

Chain d x t

Dimension A max.

11 x t inside max.

Dimension B max.

Dimension C min.

Dimension D max.

Dimensions in mm c = d 1 + d 2

2

7 x 21

249.2

235.8

22,1

6,3

36,1


L OA D H O O K

If the measured distance y and the height h of the load hook are outside the wear limits, the hook must be replaced.

y

W E A R D I M E N S I O N S F O R C H A I N S P RO C K E T S x

Check dimensions of the load hook

Type

PROFI 025 TI - 2 TI

Dimensions in mm

Maximum Minimum permis. dimension permis. of measured distance dimension of height “ h “

63 22.8

Wear dimensions for chain sprockets

Chain size d x t mm x mm

7 x 21 z

(1)

4 a mm

19.1

x mm

0.15

a, x = limit dimensions after maximum permissible wear z = number of teeth of the chain sprocket d x t = nominal diameter times pitch of chain link

W E A R D I M E N S I O N S F O R C H A I N G U I D E S A N D

H O O K M O U N T S

Check the chain guides for 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 at the points on the guide surfaces which have been worn down by the chain.



C H E C K I N G A X I A L P L AY

Maintenance and lubrication

Please ensure that load hooks and/or load eye mounts are regularly checked, at least once a year. Especially important: in areas where 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 intervals must always be increased.

H A Z A R D S I N T H E C A S E O F I N S U F F I C I E N T

M A I N T E N A N C E / L U B R I C AT I O N

DA N G E R !

In the event of insufficient maintenance/ lubrication the extent of wear may be so high that there is a danger of loads falling.

P R E V E N T I O N O F DA N G E R S

Dangers are avoided by regular maintenance/lubrication in suitable intervals.

When the axial play of the installed hook or load eye exceeds the maximum play specified, the worn parts must be replaced.

Load sleeve with load hook or load eye

Page 56

Bottom block with load hook or load eye powered by air !


R E M O V I N G A N D I N S TA L L I N G C H A I N

C AU T I O N !

The chain supplied together with this JDN hoist is matched to the chain sprocket according to strict tolerances. In order to ensure optimum function of the chain and in order to prevent hazards, only genuine JDN chains must be installed.

Note: When a chain is replaced, the buffers must also be replaced. For information on changing buffers at the chain ends, see Removing and installing load sleeve, bottom block, clamp and buffer section.

Buffers which are not located at the chain ends are most easily replaced when the open chain link between the old and new chains passes the buffer to be replaced.

C AU T I O N !

Do not twist the chain ends.

In the case of operation with a chain box: switch the hoist in the “lower” rotational direction and run the old chain out of the chain box.

Then remove the chain box.

Move the bottom block as close as possible to the hoist body and position it securely.

Detach the idle chain from the chain mount on the hoist body (see also section Removing and installing load sleeve, bottom block, clamp and buffer ).

Detach the clamp, buffer and buffer discs from the end of the idle chain.

For single chain hoists, also detach the load sleeve, buffer and buffer discs from the load chain.

For dual chain hoists, detach the bottom block from the hoist body (see also Removing and installing load sleeve, bottom block, clamp and buffer section).

Attach the new chain to the end link of the load section of the 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 link of the new chain is not correctly positioned, it must be removed.

Note: It is possible that the first chain link of the other chain end is correctly positioned.

Switch the hoist to the “lift” rotational direction. The new chain will now run into the hoist while the old chain is simultaneously run out on the idle chain side.

Run the chain until the join between the old and new chain has run sufficiently (approx. 1m) out of the centre section on the idle chain side.

Detach the connection between the old and new chains.

Install the clamp (at the 10th chain link), buffer and buffer discs on the idle chain section of the new chain.

Align the idle chain and attach to the fastening point on the hoist (see also Removing and installing load sleeve, bottom block, clamp and buffer section)

Attach the chain box if necessary.

Switch the hoist in the “lift” rotational direction until the as yet free end of the aligned load chain is the correct length for attaching the chain link,

– for single chain hoists in the load sleeve after the buffer and buffer discs have been pushed on,

– for dual chain hoists at the fastening point of the hoist body (see also Removing and installing load sleeve, bottom block, clamp and buffer section).

Note : If the chain link of the load chain is positioned incorrectly, it must be removed, the following chain link will be positioned correctly.



R E P L AC I N G C H A I N A N D C H A I N S P RO C K E T

Note: If the chain jams in the hoist and can no longer be run out, the gearbox must be dismantled (see spare parts list for “Gearbox”).

For dual chain hoists, when removing the old chain, an assembly chain 1 is brought into position on the deflection sprocket of the bottom block by means of an open chain link (see also Removing and installing load sleeve, bottom block, clamp and buffer section and

Removing and installing chain section).

Following replacement of the chain sprocket (see spare parts list) an assembly chain 2 is run carefully

– with low air pressure – over the drive sprocket.

Fasten the new chain 5 to the assembly chain on the drive sprocket by means of one or two open links 3 to the idle 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 chain after it comes out of the centre section.

For dual chain hoists the new chain, after 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, the following chain link will be positioned correctly.

Fastening of the chains and installation of the load sleeve, clamp, buffer and buffer discs is carried out in accordance with the Removing and installing load sleeve, bottom block, clamp and buffer section and the Removing and installing chain section.

2

1

Drawing in the chain

3

4

5




The hoists Profi 025 TI to 2 TI are available with an overload protection. Hoists for use within the EU are equipped with this as standard from a carrying capacity of 1 t and above.

A D J U S T I N G O V E R L OA D P RO T E C T I O N

The adjustment method described here is based on the attachment of test loads.

DA N G E R !

If the overload protection is set too high, impermissibly high stresses may arise if a load exceeding the permissible load carrying capacity 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 overload is not lifted, the adjusting bolt must be adjusted anticlockwise until it is possible to lift the overload. Then it must be adjusted back until it is no longer possible for it to lift the overload.

After the adjustment process, it must be possible to lift 110% of the nominal load. A dynamic overload test of 110% of the nominal load is thus possible.

(+) (-)

Adjusting overload protection powered by air !

Page 59



FAU LT TA B L E

Fault

Lifting not possible

Only very slow lifting is possible

Possible cause Remedy

Overload protection has shut off Lower hook briefly, limit load to permissible load carrying capacity, then lift again

Air pressure too low Increase air pressure to the required value

EMERGENCY STOP switch is pressed

Hand control is faulty

Brake does not release fully

When the danger has passed, release the

EMERGENCY STOP switch

Have hand control repaired

Brake lining worn or uneven

Set air pressure to the relevant value,

Check seal of brake piston and change seal if necessary

Check the adjustment of the brake piston

(see E-list )

Replace brake lining

Excessive running on during braking

Loud chain noise at chain sprocket

Motor cover bolts loose

Air supply hoses are leaking or loose

Tighten bolts

Check connections of air supply hose and control hoses and connect properly

Cross section of air line too small Use air line with sufficiently large diameter

(check air pressure)

Dirt in the service unit*

Filter blocked

Silencer is clogged

Motor vanes worn

Motor has run dry

Clean the service unit, ensure better air quality

Replace the silencer elements or clean, improve air quality if necessary

Replace motor vanes

Control valve on motor

Brake disc and/or brake piston worn

Lubricate motor,

Check oiler*

Have the control valve repaired

Replace brake disc and/or brake piston

Chain dry

Chain worn

Chain sprocket worn

Wrong chain drawn in

Lubricate chain

Replace chain with new JDN chain

Replace chain sprocket, check chain guide, replace if necessary

Identify chain and replace with JDN chain if necessary

Lifting or lowering speed reduced at Adjustment of brake piston higher lifting heights or motor comes too tight to a standstill

Correct adjustment of brake piston. At high ambient temperatures perform adjustment with the device warmed up accordingly

*if installed




F I LT E R S I L E N C E R

With the use of a filter silencer, oil aerosols can be avoided and noise insulation improved:

99.9 % of oil aerosols during oil lubrication of the motor are absorbed by the filter element.

The noise insulation reduces noise levels by 3 to

4 dB (A) compared with the standard silencer

(sinter plate).

The ambient temperature must not be lower than -10° C.

M A I N T E N A N C E O F F I LT E R S I L E N C E R

The filtered oil runs into the transparent collecting container 3.

This container must be emptied before the fluid level reaches the filter 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 and detach.

Unscrew the filter element 2 .

Insert a new filter element, with sealing ring 1 and push on collecting container until it engages.

B O O S T E R U N I T

In the case of a control hose length exceeding 10 m, the reaction times of the pushbutton controls increase significantly.

Consequently, a booster unit is generally installed on the motor for controls E, F and FI, enabling normal reaction times.

The operating temperature range is from 0° C to 80° C.

Filter silencer

1

2

3

4



C H A I N B OX

For various areas of application, a chain box enhances operational safety, i.e. when a chain which is hanging down could become caught up with the load.

JDN chain boxes are available in various sizes, corresponding to the chain lengths.


Do not exceed the permissible filling capacity. Danger of chain dropping.


Loads must not be moved against the chain box during lifting. If necessary, attach a clamp to the chain.

The clamp must be attached above the load hook so that it functions as a preliminary end stop. With the

(dual chain) the clamp must be positioned as far as necessary downwards on the reeved chain in order to support the bottom block (stationary chain).

In addition, a spacer must be attached to the opposite

(moving) chain above the buffer in order to relocate the stroke limiter. Please contact us, if required.

For greater clarity, see the illustration on the right on page 52.

In all cases, a clamp is attached in the 10th chain link of the unloaded chain end so that a length of chain remains in the chain box when the bottom load hook position is reached. Thus, the chain cannot run next to the chain box during subsequent lifting (see section

Removing and installing chain, page 57).


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 completely on the load hook side and then run back into the container via the chain drive, in the air hoist operating position.

After installing the chain box, lower the load hook to the bottom position once.

Then activate lifting movement and run the complete chain into the chain box.

DA N G E R !

During operation with the chain box, lubrication of the chain is particularly important in order to prevent it from piling up and falling out.Do not install longer chains when changing chains.

Furthermore, hazards arise due to rusty chains when operating with chain boxes, as the chain can form a heap and fall over the edge of the container rim. In addition, rusty chains are subject to extreme wear.

If the hoist has been transported with the chain in the chain box, the chain box must be emptied manually before initial operation

(if necessary, remove the chain box from the hoist). The entire chain must then be allowed to run to the load side and, subsequently, be driven back into the chain box. The hoist must be kept in a hanging position during this procedure.


A P P E N D I X

T E C H N I C A L DATA

J D N P RO F I T I A I R H O I S T S

Type

Load-carrying capacity

Number of chains

Motor rating

Air pressure

Lifting speed at nominal load

Lifting speed without load

Lowering speed at nominal load

Air consumption at nominal load

- lifting

Air consumption at nominal load

- lowering m m kW bar m/min m/min m/min

3

3 t

/min

/min

Air connection

Hose size ( inside)

Weight for standard lift, rope control mm kg

Chain dimensions

Weight of 1 m chain mm kg

Standard lift m

Control length for standard lift

Noise pressure level with nominal load

1 with standard silencer - lifting m dB(A)

Noise pressure level with nominal load

1 with standard silencer - lowering dB(A)

025 TI

0.25

1

1.0

6

20

42

38

1.2

1.5

G 1/2

13

27

7 x 21

1.0

3

2

74

78

05 TI

0.5

1

1.0

6

11

19

17

1.2

1.5

G 1/2

13

27

7 x 21

1.0

3

2

75

78

1 measured from 1 m distance according to DIN 45635 part 20

2 with overload protection

1.5

G 1/2

13

28

2

7 x 21

1.0

3

2

76

1 TI

1

1

1.0

6

5.5

11

11

1.2

78

1.5

G 1/2

13

34

2

7 x 21

1.0

3

2

76

2 TI

2

2

1.0

6

2.7

5.5

5.5

1.2

78

A P P E N D I X powered by air !

Page 63

A P P E N D I X

D I M E N S I O N S

J D N P RO F I T I A I R H O I S T S

F

G

C

D

E1

E2

C

D

E1

Type

A Minimum headroom*

B

E2

F to centre of hook, without chain box

G maximum width

*Chain boxes increase the required headroom

025 TI

450

288

05 TI

450

288

145 145

297 297

28 28

28 28

137 137

176 176

Dimensions in mm

1 TI

450

288

145

297

28

28

137

176

2 TI

498

336

145

297

28

28

137

183


NO TES powered by air !

Page 65

NO TES


NO TES powered by air !

Page 67

is a registered trade mark of our company.

BA 817 GB · Issue: April 2005 · Subject to changes · 42005

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: [email protected]

powered by air !

J D N O P E R A T I O N A N D A S S E M B L Y

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 powered by air !

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

This operation manual edition 12/2009, covers the following JDN Air Hoists:

Fabr. No.

Fabr. No.

3

It must be read carefully and in its entirety before operating any hoist. For hoists installed in trolleys, please also refer to the operation manual JDN Trolleys.


TA B L E O F CO N T E N T S

S A F E T Y M E A S U R E S

Organisational measures . . . . . . . . . . . . . . . . . . . 5

Personnel safety . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preventing property damage . . . . . . . . . . . . . . . . 5


About this operation manual . . . . . . . . . . . . . . . . 6

Warnings and symbols . . . . . . . . . . . . . . . . . . . . . 6

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Assembly overview . . . . . . . . . . . . . . . . . . . . . . . 8

Product description . . . . . . . . . . . . . . . . . . . . . . . 8

Explosion protection . . . . . . . . . . . . . . . . . . . . . . 9

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operating conditions . . . . . . . . . . . . . . . . . . . . . 16

Energy requirements . . . . . . . . . . . . . . . . . . . . 17

Principle of operation of JDN air vane motors . . 18

Operation without chain box . . . . . . . . . . . . . . . 19

Motor lubrication/operation with a service unit . 19

CE marking / declaration of incorporation . . . . . 19

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19


Safe transportation . . . . . . . . . . . . . . . . . . . . . . 20

Storage conditions . . . . . . . . . . . . . . . . . . . . . . 20

I N I T I A L O P E R AT I O N

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Installing the hoist . . . . . . . . . . . . . . . . . . . . . . 21

Connecting the controls . . . . . . . . . . . . . . . . . . . 22

Replacing controls . . . . . . . . . . . . . . . . . . . . . . . 25

Connecting to the main air supply . . . . . . . . . . . 27

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Inspection before initial operation . . . . . . . . . . 29


Rules for the safe operation of hoists . . . . . . . . 30

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . 35

Overload protection . . . . . . . . . . . . . . . . . . . . . . 36

Attaching the load . . . . . . . . . . . . . . . . . . . . . . . 36

Lifting the load . . . . . . . . . . . . . . . . . . . . . . . . 37

Lowering the load . . . . . . . . . . . . . . . . . . . . . . 37

Detaching the load . . . . . . . . . . . . . . . . . . . . . . 37

Interrupting working . . . . . . . . . . . . . . . . . . . . 37


Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . 38

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38



Cleaning and care . . . . . . . . . . . . . . . . . . . . . . . 39

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Inspection and repairs . . . . . . . . . . . . . . . . . . . . 39

Instructions concerning the “ model for determining the actual operating time ” . . . . . . . 41

Lubricating chain . . . . . . . . . . . . . . . . . . . . . . . 45


Checking lifting and lowering limiters . . . . . . . . 46

Checking controls and emergency stop function . 46

Checking direction of movement . . . . . . . . . . . . 46

Checking silencer for permeability . . . . . . . . . . 46

Service unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Motor installation/checking brake linings and vanes/Motor lubrication . . . . . . . . . . . . . . . 50

Removing and installing load sleeve, bottom block, clamp and buffer . . . . . . . . . . . . . 53

Checking chain, chain sprocket and chain guides . 55

Check dimensions . . . . . . . . . . . . . . . . . . . . . . . 55

Checking axial play . . . . . . . . . . . . . . . . . . . . . . 57


Replacing chain and chain sprocket . . . . . . . . . . 59


FAU LT S , C AU S E S A N D R E M E D I E S

Troubleshooting guide . . . . . . . . . . . . . . . . . . . . 61


Filter silencer . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Booster unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chain box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

A P P E N D I X

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . 66


Please note:


BGV A1 accident prevention regulations “Principles of Prevention”

BGV D8 accident prevention regulations “Winches,


BGR 258 trade association regulations “Operation of

Load-Carrying Devices Used with Lifting Equipment” and, for air hoists installed in trolleys and for the operation of monorail hoists, additionally 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”

BGG 905 (ZH 1/27).

To document the tests we recommend the

“Inspection log for cranes” BGG 943 (ZH 1/29) from the trade association.


BGR 104 “Explosion Protection Regulations” and

BGR 132 “Prevention of Ignition Hazards due to


In all other countries, the operator must observe the relevant national regulations.





O RG A N I S AT I O N A L M E A S U R E S

JDN Hoists are designed in accordance with current technological standards and accepted safety practice.

Nonetheless, the use of a hoist may be associated with risk of injury or fatality to the user or to third parties or with the risk of damage to the hoist or to other items, if safety rules are disregarded.

All personnel charged with operating hoists, must have read and understood the operation manual, especially the section entitled “Rules for the safe operation of hoists”, before commencing work. This is particularly important for personnel who only occasionally operate the hoist, e.g. for maintenance or retrofitting work.

Operators of JDN Hoists are also under obligation to ensure safe and hazard-free operation. This can be achieved through the following measures: keep the operation manuals available at the hoist operating site, performing regular training, performing regular inspections (at least once annually), implement an inspection log and make regular entries, and regularly check personnel for safety and hazard awareness during work.

P E R S O N N E L S A F E T Y

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 before commencing work.

Due to their technical training and experience, properly trained personnel have adequate knowledge of hoists.

They are sufficiently familiar with the relevant occupational safety and accident prevention regulations that they are able to assess the condition of hoists with regard to working safety.




Follow the safety instructions set out in the operation manuals.

P R E V E N T I N G P R O P E R T Y DA M AG E

Operators of JDN Hoists are under obligation to ensure that entries in the accompanying inspection log are made properly and regularly.


Only use JDN hoists for work which is described as intended use.

Observe the operating conditions for JDN Hoists as described in this manual.

powered by air !

Page 5



A B O U T T H I S O P E R AT I O N M A N UA L


This operation manual contains important information for the safe, proper and efficient operation of JDN

Air Hoists. Observance of the manual helps to avoid hazardous situations, to reduce repair costs and downtimes and to ensure the specified service life of the JDN Air Hoists.

WA R N I N G S A N D S Y M B O L S

Safety warnings in this operation manual are classified in three categories:

DA N G E R !

Safety warnings which, if not followed, can result in danger to life and limb, are indicated by this symbol. The symbol indicates an immediate danger. The possible consequences of non-observance may be death or severe injuries.

C AU T I O N !

This symbol indicates potentially hazardous situations. Failure to observe may result in minor injuries.


This symbol indicates that failure to follow the relevant instructions may result in damage to the device or other items.



I D E N T I F I C AT I O N


If you have any questions concerning operation of JDN

Air Hoists, which are not addressed in this operation manual, please contact us at the following address:


Windenstraße 2-4

D - 58455 Witten-Heven

Phone 0 23 02/208-0

Fax 0 23 02/208-286 www.jdn.de


T y p

T y pe

PROFI

Anzahl der Stränge

No. of chain strands

1,5 TI 3TI/2

1 2

Tragfähigkeit

Lifting capacit y

1,6 t 3,2 t

Nennhubgeschw.

Rated hoisting speed

4-6 m/min

2-3 m/min

Baujahr

Year of constr.

Fabr.-Nr.

Serial-No.

Nenndruck

Nom.pressure

Triebwerkgruppe

Group of mechani.

Kette

Chain

E x -Schutz

E x -proof

9 x 27 TN

II 2 GD IIA T4(X)

II 3 GD IIB T4(X)

6200001

4-6 bar

M

200 9

3/1Bm

J.D. Neuhaus GmbH & Co. KG

5 8 44 9 W itten_German y _www.jdn.de

E-mail: [email protected]


Page 7


A S S E M B LY O V E R V I E W

PROFI TI series air hoists consist of the following assemblies:

1 Gearbox with chain sprocket and overload protection

2 Centre section


4 Controls with main air EMERGENCY STOP

5 Chain


P RO D U C T D E S C R I P T I O N

The PROFI TI series JDN Air Hoists described here are designed for load-carrying capacities of 1.6 t (PROFI

1.5 TI) and 3.2 t (PROFI 3 TI/2). Various control devices are available for the different requirements.



PROFI TI series JDN Air Hoists conform to driving mechanism classification in the following table:

1.5 TI

Hoist

M3 / 1 Bm

3 TI/2

ISO 4301 / FEM 9.5.11

M3 / 1 Bm

Chain

M3/ 1 Bm

M3/ 1 Bm

PROFI TI JDN Air Hoists feature rotors with grease chambers. These contain JDN high-performance grease which enables operation with oil-free compressed air.

It remains effective for an operating period of approx.

250 hours and should be renewed when required, but after five years at the latest (see Motor lubrication, page 19). Additional lubrication with oil-bearing compressed air by means of a service unit with oiler is possible.

2

3

4

PROFI TI series JDN Air Hoist

1

5

6



E X P L O S I O N P R O T E C T I O N


JDN Hoists, Trolleys and Crane Systems in potentially explosive areas and is based on European Directive

94/9/EC 1 (“ATE X 100a”). DMT is accredited with the testing of devices and protection systems for intended use in explosion-hazardous areas.

BASIC EXPLOSION PROTECTION

FOR THE STANDARD VERSIONS

Standard version JDN air hoists are category 2 devices

(Guideline 94/9/EC, DIN EN 1127-1 2 ), for use in zone

1 and 2 for gases of explosion group IIA. (Also see IEC

60079-12 3 and IEC 60079-20 4 ). These devices are also suitable for use in zone 2, in the presence of gases of explosion group IIB, provided that the substances hydrogen sulphide and ethylene oxide can be excluded and additionally in zones 21 and 22 for dusts with glow temperatures above 210° C or ignition temperatures above 202° C, provided that no light metal or other impact-sensitive dusts are present.


II 2 GD IIA T4(X)/II 3 GD IIB T4(X) Additional designation “ X ” see page 10.

JDN HOISTS

“WITH INCREASED SPARK PROTECTION”

JDN hoists of the version “with increased spark protection” (FS) satisfy additional explosion protection requirements. With the exception of carbon disulphide

(temperature class T6), they can be used in the presence of all gases in zones 1 and 2 and dusts with glow temperatures above 210° or ignition temperatures above

202° in zones 21 and 22, and can be marked

II 2 GD IIC T4(X) for installation in a trolley, depending upon the trolley version (see below), but also with II 2 GD IIB T4(X) . For further operating conditions, see Instructions for safe operation (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 operation, use in the presence of carbon disulphide or dusts with particularly low glow or ignition temperatures may be possible with designation II 2 GD IIC T6(X) , which includes the additional designation “ X ” for special conditions (see

Additional designation “ X ”). Please contact us with regard to these requirements.

STANDARD JDN TROLLEY AND CRANE RUNNING GEAR

JDN trolleys and cranes can be used in zone 2 with standard running wheels (made of steel or cast metal) with all dusts and the presence of gases up to explosion group IIC. Due to the low running speeds, the possible friction velocities on the running wheels are less than

1 m/s, which means that standard running wheels can also be used in zone 1 up to explosion group IIB. The highest possible designation for these devices is:

II 2 GD IIB T4(X)/II 3 GD IIC T4(X) . Depending on the hoist version, it may have the designations


II 2 GD IIB T4(X) .

JDN TROLLEY AND CRANE RUNNING GEAR

“WITH INCREASED SPARK PROTECTION”

For use in zone 1 in the presence of gases in explosion group IIC, bronzed running wheels or running wheels made of bronze are also used. The highest possible designation for this version (FSR) is

II 2 GD IIC T4(X) (the same as for JDN hoists

“with increased spark protection”).

JDN TROLLEY AND CRANE RUNNING GEAR FOR USE IN THE

PRESENCE OF TEMPERATURE CLASS T6 GASES OR DUSTS

As is the case with JDN hoists “with increased spark protection”, temperature class T6 is also possible here in the case of a special investigation of applicability, permitting the highest possible designation for standard wheels II 2 GD IIB T6(X)/II 3 GD IIC T6(X)


P RO D U C T I N F O R M AT I O N and for bronzed or bronze wheels

II 2 GD IIC T6(X) , i.e. each including the additional designation “ X ” for special conditions.

GENERAL NOTE ON DESIGNATION

The highest possible respective designations for lifting equipment and running gear are usually replaced by a designation which corresponds to the normal assembly of a compact complete device (trolley or crane system).

ADDITIONAL DESIGNATION “X”


II 2 GD IIA T4(X)/II 3 GD IIB T4(X) or.

II 3 GD IIA T4(X) :




... II C T6(X) :


USE IN MINING APPLICATIONS

Standard versions of JDN hoists, trolleys and crane systems may generally also be used for underground mining operations as well as for the associated surface facilities, which are hazardous due to firedamp and/or combustible dusts. Within this equipment group I they belong to category M2. They constitute devices which can be switched off in cases where an explosive atmosphere forms. They are equipped with protective measures offering a high degree of safety. The protective measures with which products of this category are equipped 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 other difficult conditions in addition to explosion protection prevailing with regard to 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 13463-1 5 for coal dust atmospheres is not reached. For mining applications, the relevant designation for hoists, trolleys and crane systems is I M2 .

LOAD CHAIN

In order to guarantee the required degree of earthing, rusty chains must no longer be used in zones 1 and 21.

This is due to the fact that, depending upon the degree of corrosion, the leakage capability of the chain may be impaired to a level that is no longer adequate.

COMPRESSED AIR HOSES

In zone 1, compressed air hoses must have a sufficiently low surface resistance of less than 10 9 Ω in order to prevent electrostatic ignition hazards.

Otherwise (resistance >10 9 Ω ), for explosion groups

I, IIA and IIB ∅ ≤ the hoses must be 30 mm and for explosion group IIC ∅ ≤ 20 mm, or proof must be provided that they cannot become dangerously charged.

MATERIALS FOR FRICTION AND IMPACT HAZARDS


Accordingly, spark formation caused by mechanical influences must be prevented.

The chain and load must always be moved in such a way that sliding and/or frictional contact with other plants or components is excluded. If circumstances do not permit this, it is necessary to ensure an absence of explosive atmospheres during operation.

Impacts between particular materials result in an increased ignition hazard. This does not apply to corrosion-resistant steel or cast iron against aluminium, magnesium or corresponding alloys.

This applies especially in the presence of rust or rust film. Rust (also rust film) formation is possible, especially on the chain and on the load hook, at the friction points. The following holds true for all zones:

For the intended use of hoists it must be ensured, that no rust is present at the above-mentioned friction


P RO D U C T I N F O R M AT I O N points and that material combinations of the abovenamed light metals with steel (exception: stainless steel) are not used in the working area of the hoists, at potential friction, impact or sliding points. It is thus 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 selected so as to ensure that there is no risk from impact sparks.

EARTHING

Electrostatic ignition hazards can be prevented by means of safe earthing. In zones 1 and 21, earthing of the hoists is required. This must be achieved via the load hook or the load eyes if the lifting equipment is connected to correspondingly earthed parts (earth leakage resistance less than 10 6 Ω ). This also applies to operation with trolleys or cranes. Their tracks 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 also

Load chain , page 10).



CLEANING PLASTIC SURFACES

Where JDN Air Hoists or JDN Air Winches feature plastic parts, these surfaces must only be cleaned using a damp cloth (cleaning cloth with water). This reduces electrostatic charging that can arise due to mechanical friction at the plastic surface.

DANGER!

Electrostatic charging may occur at the plastic surfaces, potentially leading to electrostatic discharge that can ignite gases and air mixtures.

ACETYLENE AND COPPER

When operating JDN products in explosion-hazardous areas, in which an acetylene-containing atmosphere can occur, it must be ensured that copper-plated parts are kept dry in order to exclude the possibility of oxidation of the metallic copper and the formation of an aqueous phase, which is capable of reacting with acetylene and which can result in an explosion hazard.



EXPLOSION GROUPS AND TEMPERATURE CLASSES OF THE MOST IMPORTANT GASES AND VAPOURS (-SELECTION-)

(in accordance with DIN VDE 0165 6 , Redeker 7 , Nabert, Schön 8 , IEC 60079-12 3 and IEC 60079-20 4 )

Explosion protection group

II A

II B

II C

T1 T2


T3 T4


300-200° C 200-135° C

T5

> 450° C 450-300° C 135-100° C

450° C


300° C 200° C 135° C 100° C

Acetone

Ammonia

Aniline

Benzene

(ethyl alcohol)

(ethylene glycol) i-Amyl acetate n-Butane

Chlorbenzene n-Butyl alcohol

1.2-Dichlorbenzene 1-Butylene

Acetic acid

Ethane

1.2-Dichlorethane

Di-i-propyl ether

Ethyl acetate

(ethyl bromide)

Natural gas

Acetic anhydride

Ethyl chloride n-Propyl acetate

(carbon monoxide) (n-Propyl alcohol) o-Cresol

Methane

Methyl acetate

Methyl alcohol*1 i-Propyl alcohol

Vinyl chloride

Methyl bromide

Methyl chloride

Methylene chloride

Naphthalene

(nitrobenzene)

Phenol

Propane

Toluene oX ylene

Hydrocyanic acid

(ethyl bromide)

Butadiene-1.3

Dioxane-1.4


(nitrobenzene) (ethyl alcohol)

Town gas Ethylene

(ethylene glycol)

**Ethylene oxide

Isoprene

(n-Propyl alcohol) n-Amyl alcohol

Petrol

(fuel)

Diesel

Heating oil n-Hexane

Jet fuels

Acetaldehyde

Dimethyl ether Ethyl ether

**Hydrogen sulphide Ether

Anaesthetic ether

Diethyl ether

**Hydrogen **Acetylene

T6

100-85° C

85° C

**Carbon disulphide

( ): The measured values for the substances placed in brackets are close to the limit or the next group or class when classified in the explosion groups or temperature classes. For this reason, they have been included in both.

**: Extremely flammable substances (cf. additional designation “ X ”)




DECISION CRITERIA FOR SELECTING THE CORRECT JDN HOIS T S

IN EXPLOSION-HAZARDOUS AREAS

Explosion groups for gases and vapours

II A

II B (X)

II B except hydrogen sulphide, ethylene oxide

(highly flammable)

(cf. explosion group and temperature classes for the most important gases and vapours)

II C / T4

II C / T6(X)

Potentially explosive dusts


Light metal or impact-sensitive dusts

1

1

1

1

1

21

21

Zone Version* 1 Operation* 2

Manufacturer responsibility Operator responsibility

2 A

A

2 A

A SP

2 A SP

A SP

2 A SP

A SP FSR

2 A SP

A SP FSR

Zone

22 A

Version* 1

A

22 A SP

A SP

D

D

E

E

E

E

E

E

D

D

D

D

D

E

E

E T

D E T

Operation *2

E

E

E

E


A: The chain is made of zinc-plated steel; metal controls are conductively connected to the hoist. This is part of the standard equipment. For technological reasons, a zinc-plated version of chain size 31.5 x 90 is not available. This is only 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: 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.

*2:

D

Instructions for safe operation (operator’s responsibility):


E

T

: Friction, impact and sliding points involving combinations of light metal and steel or cast iron must not be present in the hoist’s operating area.




T E M P E R AT U R E L I M I T S

F O R E X P L O S I O N - H A Z A R D O U S D U S T S

In areas that are potentially explosive due to combustible dusts, the surface temperature must not exceed two-thirds of the ignition temperature in ° C of the dust/air mixture. The temperatures of surfaces on which hazardous deposits of combustible dusts can be formed, must not exceed the glow temperature of the relevant dust minus 75°K.

Greater safety margins are required if the thickness of the dust layer exceeds 5 mm.

The corresponding surface temperatures can be derived from the lowest values for glow and ignition temperatures of dusts specified in the HVBG/BIA Report 12/97 10

“Combustion and explosion characteristics of dusts”:


Glow temperature 220° C – 75° C = 145° C max. permissible surface temperature

Stearic acid:

Ignition temperature 190° C x 2/3 = 126° C max. permissible surface temperature

P L E A S E A L S O O B S E R V E Y O U R

CO R R E S P O N D I N G N AT I O N A L


1 Guideline 94/9/EC of the European Parliament and the Council dated 23 March 1994 on the adaptation of the laws 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 1: Basic concepts and methodology, 1997-10

3 IEC 60079-12: Electrical apparatus for explosive gas atmospheres, Part 12: Classification of mixtures of gases and vapours with air according to their maximum experimental safe gaps and minimum igniting currents, 1978.

4 IEC 60079-20: Electrical apparatus for explosive gas atmospheres, Part 20: Data for flammable gases and vapours relating to the use of electric apparatus, 1996-10.

5 EN 13463-1: Non-electrical devices intended for use in explosive areas - Part 1: Basic methodology and requirements,

07/2009




9 DIN EN 50014 (VDE 0170/0171 part 1): 2000-02 Electrical apparatus for use in explosion hazardous areas:

General provisions

10 HVBG/BIA report 12/97: Central association of German employer’s liability associations /trade association institute for industrial safety



JDN Air Hoists are designed for lifting and lowering loads within the specified load-carrying capacities, with a vertically-arranged chain. JDN Air Hoists from the

PROFI 1.5 TI and 3 TI/2 ranges are also suitable for pulling loads horizontally. In exceptional circumstances, the lifting of personnel-carrying equipment is also permitted under certain conditions. Please also observe the individual national 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 impermissible. Oblique pulling, see

Operation section, page 29. J.D. NEUHAUS GMBH &

CO.KG cannot be held liable for any resulting damage.

The entire risk is borne by the user (see also section

Rules for safe operation of hoists , page 30).


P RO D U C T I N F O R M AT I O N powered by air !

Page 15



The noise emission data can be found in the Technical data table, pages 64.





O P E R AT I N G C O N D I T I O N S

JDN Air Hoists are extremely robust and require little maintenance. They are suitable for use in explosionhazardous areas, as well as in areas with increased concentrations of soot and dust, high humidity and at ambient temperatures from – 20° C to approx. + 70° C if they are not heated above this level due to external influences. The thermal endurance of chains and hooks is + 150° C.

C AU T I O N !

When touching metallic hand controls which are colder than 0° C, skin could freeze within a few seconds, and at temperatures above

43° C, burns may occur. As a protective measure, please wear suitable gloves.


Depending upon the version, JDN Air Hoists must be operated at a system pressure of at least 4 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 thus subject to a high degree of wear. An impermissibly high degree of warming could take place.

The controls become noticeably less sensitive.

DA N G E R !

Warning against excessive system pressures Operating with excessive system pressures results in danger due to overloading. Therefore, the pressure must be limited to that specified on the nameplate.

JDN Air Hoists must be operated with a sufficiently clean and dry air supply. The air supply must fulfil the following quality requirements:


Particle density less than 10 mg/m 3

(corresponds to Class 7 in accordance with ISO 8573-1 : 2001)


Pressure dew point at least 10° C below the lowest expected ambient temperature

Do not operate JDN Air Hoists with other gases.



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

(depending upon moisture content of compressed air), or using compressed air oil (Part No. 11900) with anti-icing agent for relevant temperatures.

In case your JDN Air Hoist is operated in combination with a trolley, please read also the trolley operation manual and the relevant accident-prevention regulations for operation with trolleys.



E N E RG Y R E Q U I R E M E N T S

For air pressure, air quantity and connections, see the

Technical data table in the hoist operation manual concerned.

A I R P R E S S U R E C O N D I T I O N S I N O P E R AT I O N



The value of the actual pressure p2 at which the hoist is operated, depends upon the weight of the load and the direction of movement of the load.



Example:


The value of the actual pressure depends upon …

… the weight of the load …


powered by air !

Page 17


P R I N C I P L E O F O P E R AT I O N O F

J D N A I R VA N E M O T O R S



The vanes can move freely and make contact with the inner wall 5 of the cylinder liner. Each chamber 6 is formed by two vanes.







4.2

1 6 4.1

2 5

3 4 7



O P E R AT I O N W I T H O U T C H A I N B OX

DA N G E R !

If JDN Air Hoists are operated without a chain box it must be ensured that the idle chain (unloaded chain end) running up or down at the chain sprocket, does not present a hazard, e.g. due to catching, impacting or falling.

Danger due to falling chain can also arise, if the idle chain is first deposited on a load with a large surface and then slides off and drops.

M O T O R L U B R I C AT I O N / O P E R AT I O N

W I T H A S E R V I C E U N I T

JDN air hoists are provided with motor lubrication, which must be renewed when required, but every

5 years at the latest.

Therefore, the service unit for filtration and pressureregulation of the compressed air can be 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. Alcohols are not permitted for use as anti-icing agents.


During operation with oil, the grease chambers for motor lubrication are emptied more quickly.

M A R K I N G / D E C L A R AT I O N O F

I N CO R P O R AT I O N

Only hoists for which EC conformity in accordance with

EC Machinery Directive 2006/42/EC has been declared may be operated within the EU.

In the case of a designation, only the EC conformity declaration provides information on which EC directive has been met.



GMBH & CO. KG accepts no liability for the use of non-original components and/or modifications by unauthorised persons.




S A F E T R A N S P O R TAT I O N


Carefully dismount trolley (if fitted).

Set the entire hoist down carefully; do not allow it to drop. For weights see Technical data, page 64.

Lay control and supply hoses together in such a way that they are not kinked.

Please ensure that the controls are not damaged.

Risk of malfunction.

Draw in the hoist’s chain in such a way that loops cannot form and the chain cannot become twisted.

Secure the chain.

S T O R AG E C O N D I T I O N S

B R E A K S I N O P E R AT I O N

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 conserved.

For this purpose, use a non-resinous and non-sticky conserving oil with conserving protection duration, which corresponds to the length of the planned operational break.

S T O R AG E

Close off the air supply hose connection using adhesive tape or a suitable cap in order to prevent dirt ingress.

Protect connection for the air supply hose against damage.





U N PAC K I N G

C AU T I O N !

When unpacking, take account of the weight of the hoist. See Technical data , page 64.


Do not bend the control lines. Kinked control lines can result in malfunctions.

Keep the accompanying documents in the place provided, near the operating site.


Dispose of packaging in the local recycling system.

A S S E M B LY



Connecting the controls, page 22

Removing and installing chain, page 58

Chain box, page 63


P R I O R T O I N I T I A L O P E R AT I O N , T H E

C H A I N M U S T B E L U B R I C AT E D ( S E E

S E C T I O N L U B R I C AT I N G T H E C H A I N ,

PAG E 4 5 ) .

I N S TA L L I N G T H E H O I S T

Mounting the trolley, see trolley operation manual.

DA N G E R !

JDN Air Hoists must only be installed by qualified personnel. Faulty installation can lead to serious accidents.

DA N G E R !

The attachment points for JDN Air Hoists must be able to safely withstand the expected forces. Ensure that your JDN Air

Hoist is capable of alignment under load, otherwise inadmissible additional stresses may occur.

DA N G E R !

The supporting structure of the air hoist must form a rigid mounting. Vibration damages the chain and can lead to chain fracture. Furthermore, external vibration must on no account be transmitted to the hoist (lifting gear). (e.g. from the suspended load).


Attach the hoist at the suspension hook (or suspension eye) to running gear or stationary fixing.

Ensure that the hook safety catch closes automatically.




C O N N E C T I N G T H E CO N T RO L S

C O N N E C T I N G T H E RO P E CO N T RO L

Knot both control ropes at the ends of the control lever.

Knot the green pin into the rope which activates

“lift” mode, with the pointed end upwards (see also illustration Rope control, page 22).

Knot the yellow pin into the rope which activates

“lower” mode, with the pointed end upwards.


C O N N E C T I N G T H E E - CO N T RO L S


Guide the strain-relief cable through the eye on the pushbutton valve and secure using the cable clamp.





Pushbutton valve with nipple and rope with designation lift and lower





To ensure perfect sealing, the “ear” must be fully closed on installation.

Installation example

Position the clamp on the hose with nipple.

Crimp the clamp ear until fully closed.

Permissible aperture after crimping

Use of the normal crimping tool...

Pinched one-ear clamp and crimping tool

The bellows must be pulled over the other end of the hose bundle including the strain-relief cable (coat hose bundle with oil for ease of fitting). Pull the bellows back far enough to permit further installation. Push the one-ear clamps onto the free ends of the hoses.

...in order to remove the clamp, set the crimping tool transversely to the clamp ear and cut the ear open...

Illustration of bellows with hoses and strain-relief rope

Removal powered by air !

Page 23


Control valve (on motor)

Note: In order to connect the hoses to the control valve, we recommend removal of the hose adapter.

Remove the hose adapter (secured via central bolt).

Attach the hoses to the corresponding nipples (see designation in illustration)


Secure the strain-relief cable.


The strain-relief rope must be installed with the correct length in order to prevent loading of the hoses.

Pull the bellows over the hose adapter. The upper collar of the bellows fits into the recess of the hose adapter.

In order to secure the hose adapter to the control valve, a long A/F 6 socket spanner must be guided between the three hoses, through the middle of the bellows and inserted into the hexagon socket of the bolt.

C O N N E C T I N G F - C O N T R O L S


For F-control for lifting and lowering only, remove approx. 80 mm of hose bundle protective sheathing; for F-controls with additional functions (trolley/crane movement) remove approx. 160 mm from end of protective sheathing.

Pull the strain-relief cables through the eye bolt and secure using cable clamps.

Insert the control hoses: See illustration above

Compressed air with hose designation 1 or colour: white

Direction of movement “lift” with hose designation 2 or colour: green

Direction of movement “lower” with hose designation 3 or colour: red

Lower

Compressed-air connection

Dowel pin

Hose adapter with nipples designation lift, lower

Lift

Bellows with A /F 6 socket spanner



The control hoses for the drive motors (trolley/crane movement) must be extended, outside of the bellows, by means of plug-in connectors and additional control hoses.

Connection see “Trolley” operation manual.


The control hoses must not be subject to tensile load; adjust the strain-relief cables accordingly.

Pull the bellows over the hose adapter and secure via the central bolt (see illustration on page 24, bottom).

C O N N E C T I N G F I - C O N T R O L S


Remove approx. 80 mm of hose bundle protective sheathing.




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:

See illustration on page 24, top.







R E P L AC I N G C O N T RO L S

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 exchange air controls E,

F or FI, proceed as follows (see illustrations in Connecting the controls section)

C O N V E R S I O N F R O M E T O F



Remove the hose adapter (secured by central bolt).

For removal of the hose adapter, a long A/F 6 socket spanner must be guided through the middle of the bellows and inserted into the hexagon socket of the bolt (illustration on page 24, bottom).


Detach the strain-relief rope and remove the one-ear clamps (see Removal illustration, page 23).

Cut off the hoses below the hose nipples using a knife.

Unscrew the hose nipples (A/F 17).

Pull the bellows over the hoses of the E-controls. This is also required for the F-controls.



Remove approx. 80 mm of the hose bundle protective sheathing or 160 mm for additional movements.

Screw the “straight screw connections” (Steck-fix) for 4 mm hoses into the hose adapter (A/F 16).

Pull the strain-relief cables through the eye bolt and secure using cable clamps.










Pull the bellows over the hose adapter and secure via the central bolt, (see page 24, bottom).

C O N V E R S I O N F R O M E T O F I

Removal of E-controls as previously described (page 25).


Pull the bellows over the hose bundle for FI-control.

Remove approx. 80 mm of hose bundle protective sheathing.

Screw the “straight screw connections” (Steck-fix) for 4 mm hoses into the hose adapter (A/F 16).




Slightly bend open the ring of the eye bolt in order to attach the hose carrier.

Close the ring again to prevent detaching.









Conversion from rope control to air control:

Remove the rope control lever by removing the

M6 x 12 bolt from the control shaft.

The connecting surface of the hose adapter on the valve housing is closed off by means of a disc with an

M8 x 16 countersunk screw. Following removal of the countersunk screw and of the disc and dowel pin

(5 x 12 dowel pin), the hose adapter of air control can be installed as described in the previous section.



CONVERSION FROM AIR CONTROL TO ROPE CONTROL

Air controls can only be installed on rope controls that feature a control shaft.

Removal of air controls


For removal of the hose adapter, a long A/F 6 socket spanner must be guided through the middle of the bellows (illustration on page 27).


The connecting surface of the hose adapter on the valve housing is closed off by means of a disc and is secured with the M8 x 16 countersunk screw. The dowel pin

(roll pin) must be inserted in the bore provided.

Push the 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 not in the direction of the motor). Guide the control ropes from the side facing the valve through the bores in the control lever and knot them. Rope colour: “green” lift,

“red” lower. Further, see section Connecting the rope control .

C O N N E C T I N G T O T H E M A I N A I R S U P P LY

Check air connection for contamination and clean if necessary.

Blow through compressed air hose in order to remove foreign bodies.







The following lubricants are intended for normal environmental influences. If the trolley is operated under adverse conditions that induce increased wear, consult J.D. NEUHAUS, for further information.

C AU T I O N !

Oil and grease can cause skin irritation.

Wear protective gloves at all times.




Synthetic lubricants must not be used when operating with oilers. Alcohols are not permitted for use as anti-icing agents.

Application

Motorlubrication

- at factory

- for operation with oiler

Lubricant

- JDN high-performance grease

Part No. 11901 (250 ml)

- Air motor oil type “D”, kinematic viscosity approx. 30 mm 2 /s (cSt) at 40° C, anti-icing additive if required

Chain lubrication Chain oil or motor vehicle engine oil, kinematic viscosi ty approx. 150 mm 2 /s (cSt) at 40° C, or special lubricant from J.D. NEUHAUS

In areas with very high corrosion potential, e.g. offshore, a lubricant with especially high-performance anti-corrosion properties must be used.

Motor conservation (not Non-resinous protective applicable when using JDN oil rated for the durati high-performance grease) on of the storage period

Motor cleaning (not appliPure petroleum cable when using JDN highperformance grease)

Lubrication of bearings and gearboxes (also for exposed gears)

Saponified lithium grease, felting penetration 265-295

(0.1 mm), ground oil viscosi ty: 190 cSt (mm 2 /s) at 40° C, dripping point: 180° C, operating temperatures:

– 20° C to + 120° C, designation in accordance with DIN 51825: KP2K-20, active agents: EP additives

(for wear-reduction) and ageing protection; water resistant and corrosion protection


I N S P E C T I O N B E F O R E I N I T I A L O P E R AT I O N

Hoists, including the supporting structure, must be inspected by an appropriately trained and qualified person before initial operation and before recommissioning after significant modifications. Hoists and lifting gear which are installed in trolleys must be inspected by a specialist.

The inspection covers the proper mounting, 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 the supporting structure.


A description of the inspections can be found in the


I N I T I A L O P E R AT I O N powered by air !

Page 29



R U L E S F O R S A F E

O P E R AT I O N O F H O I S T S

As a hoist operator, you are responsible for your own safety and that of your colleagues in the working area of the hoist.

Hoists may only be operated by persons charged with this task by their company.

Before using the JDN Air Hoist for the first time, familiarise yourself with all permissible operating conditions. For this purpose, read through this operation manual thoroughly and carry out the described actions on the hoist, step by step.

Report each malfunction to your safety officer immediately, so that the fault can be remedied without delay.

Adhere to the regulations of the accident prevention authorities (e.g. trade association regulations in

Germany).

Read the section Intended use , page 15.

The following situations, among others, are regarded as improper use:

Changing load-carrying capacity depending on load position: JDN Air Hoists are not equipped with loadcarrying capacity indicators, they may therefore only be used in those applications in which the loadcarrying capacity does not change with the position of the load.

Oblique pulling of loads in general.


Oblique pulling is the deviation of the load chain and the chain hoist from the vertical position, for a force acting in a straight line between the force’s point of application of the load on the load hook and the suspension on the supporting structure.

Oblique pulling

Under special safety provisions relevant to the particular situation, JDN Air Hoists may be used for oblique pulling (see Intended use , page 15). In this case, a chain box must not be used, as the chain may fall out or become knotted. Oblique pulling is not permitted for hoists installed in trolleys or in running gears. Please contact us, if required.

Breaking loads free or dragging loads.


Catching falling loads.

Carrying persons (see Intended use , page 15).


Switching to the opposite direction with the load in motion.

Reaching lifting and lowering limiters as part of normal operation.

Never hold the centre section of the chain under tension when the load hook is in the upper or lower limit position.





Over acid baths or other plants with corrosive substances.



Lift the load carefully at first.






Do not exceed the permitted filling capacity of the chain box.

When operating without a chain box, avoid hazards due to idle chain (falling, catching, impacting), see section Operation without chain box, page 19.

Never apply bending loads to chains.

Do not join or repair chains.


Check jammed chains for damage.


Do not operate with damaged, worn or rusty chains.

Permitted operating temperature for chain and hook:

- 20° C to + 150° C, permissible ambient temperature:

- 20° C to + 70° C, permitted heat absorption of hoist body: max. 90° C.


Never attempt to remedy a fault with a load suspended from the hoist.

Only use suitable and approved sling gear; do not jam the hook at the point of attachment.

Ensure that the operator is not put at risk within the operating area by attaching aids or the load.


Before attaching, accurately position the load vertically below the hoist. The chain must hang vertically before lifting.



Before lifting loads, ensure that the maximum permitted load is not exceeded. Sling gear must be included in the weight of the load.

When taking up and setting down, ensure stable positioning of the load, to prevent accidents due to tilting or falling loads.

Never force jammed loads.

Only lift one load at a time, never several loads simultaneously.

Never lock the control elements of control devices.

If the control elements become difficult to operate, have the hoist repaired.

In the case of power failure, secure the load and the surrounding area until the power is restored.

Never use or repair bent, open or deformed load hooks. The hoist must be expertly repaired and the hook replaced.


Only operate JDN Air Hoists with original JDN controls .

Uncontrolled, external force factors (e.g. due to hydraulic cylinders, falling loads) are not permitted.




Repairs department.

Before removing compressed air hoses, shut off the main air supply.

If the braking distance is excessive, repair the hoist.




Never touch metallic hand controls which are colder than 0° C or hotter than 43° C, without suitable protective gloves.



J.D. NEUHAUS

GMBH & CO. KG accepts no liability for the use of non-original components and/or modifications.

If, in the case of multi-chain hoists, the bottom block is lying on the floor, move it back to a hanging position in a controlled manner (evenly-loaded chains).

Special safety precautions must be taken when loads are being hoisted into areas that are out of sight.


B E T R I E B

DA N G E R !

For all air hoist applications, ensure that the load hook can be lowered all the way to the ground, in order to prevent a load being moved to the lower limit position, without reaching the ground. Danger due to overloading

DA N G E R !

Never use hoists lying on the ground if they are not specifically intended for horizontal pulling.

DA N G E R !

The fatigue strength of chains is significantly impaired due to extreme corrosion (pitting corrosion). Risk of fracture . Hydrogeninduced 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 promoted by so-called recombination poisons.

Examples of these are hydrogen sulphide, cyanide, arsenic compounds and rhodanide. If rusty chains are not replaced for operational reasons, crack inspections are to be carried out at intervals of three months.


Where hoists are to be employed under particularly difficult conditions, the company must provide operating instructions in easily comprehensible form, in the language of the operator, based on the instructions in this manual. Here, measures for safe operation are stipulated in accordance with prevailing operating conditions.

Furthermore, it is essential that all the regulations set out in sections Intended use , page 15 and Operating conditions, page 16 are observed.



C O N T R O L S

JDN Air Hoists can be equipped with a variety of control devices. They are all suitable for use in explosion-hazardous areas.


C O N T R O L VA LV E O N M O T O R

Air control (E, F, FI controls) with upstream mainstream valve



2. Direction control valve as slider with sleeve

The main-stream valve lies upstream from the direction control valve. If no control pressure is present, the valve is closed and the direction control valve is depressurised. If control pressure is applied from the hand control, the valve opens and releases the main stream.


Air control (E, F, FI controls) without upstream main-stream valve


Direction control valve as slider with sleeve

Rope control valve without upstream main-stream


1. Direction control valve as slider with sleeve

2. Positioner

The direction control valve positioner (sleeve with slider) is connected directly to the control lever via the control shaft.

E C O N T R O L




E-control with EMERGENCY STOP button



P U S H B U T T O N F - C O N T R O L

With pushbutton F-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.




P U S H B U T T O N F I - C O N T R O L


Lift: Carefully press the right pushbutton. The load is lifted slowly.

Press the pushbutton further down, in order to increase the lifting speed.

Release the pushbutton slightly in order to reduce the lifting speed.

Lower: Carefully press the left pushbutton. The load is lowered slowly.

Press the pushbutton further down in order to increase the lowering speed.

Release the pushbutton slightly in order to reduce the lowering speed.





E M E RG E N C Y S T O P D E V I C E



In order to avert danger produced by the lifting movement as quickly as possible, release the pushbuttons - the movement of the load is then interrupted immediately.

Only press the red EMERGENCY STOP button firmly if this Stop function fails. The EMERGENCY STOP button engages. This results in the closing of a separate check valve and the load hook comes to rest instantaneously.

The pushbuttons for lifting and lowering now no longer function.


DA N G E R !

Never release the EMERGENCY STOP button before the danger has been eliminated and the stop function via the pushbuttons has been restored.

RO P E CO N T RO L



(reversing valve) are positively connected to one another. 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

EMERGENCY STOP device is required.

Lift: Carefully pull on the green rope with the green handle pin. The load is lifted slowly.

Pull harder on the rope, in order to increase the lifting speed.

Release the rope slightly in order to reduce the lowering speed.

Lowering: Carefully pull on the red rope with the yellow handle pin. The load is lowered slowly.

Pull harder on the rope, in order to increase the lowering speed.


Rope control


B E T R I E B


The overload protection limits the operating pressure of the compressed air supplied. It responds as a function of load and is set to a limit value of approx. 125 % of the nominal load. The force limiting factor then has a value of 1.25.

When the overload protection is activated, the lifting movement is possible again once the lowering movement has been switched (unloading the hoist).

The overload protection may also respond when moving 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.


DA N G E R !


In Germany, the trade association regulations

“Operation of load carrying devices used with lifting equipment” (BGR 258) must be adhered to. In other countries, the relevant local regulations must be observed.

Attaching aids must be attached at the lowest point of the hook. Never load the tip of the hook.


Page 36

Attach the load safely powered by air !





First, lift the load hook, in order to pull the slack chain tight. With the chain tight, briefly interrupt the lifting procedure. The hoist can align itself and the material is protected.

Then lift the load.

The overload protection system aborts the 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).


DA N G E R !


Then lower the load and ground it carefully.

DA N G E R !

For all air hoist applications, ensure that the load hook can be lowered all the way to the ground, in order to prevent a load being moved to the lower limit position without reaching the ground. Danger due to overloading!


Lower the load hook far enough, so that the load can be easily detached.


I N T E R R U P T I N G W O R K I N G

If you wish to interrupt working with your JDN Air

Hoist:






S H U T T I N G D OW N




Do not move against the lifting and lowering limiters/buffers (emergency end stop devices).


S T O R AG E




JDN Air Hoists must only be dismantled by qualified personnel.





Detach the control hoses from the hoist. Do not kink the control hoses.


Detach the strain-relief and hose carrier and remove the control device.

Carefully detach/dismount the hoist and remove.


D I S P O S A L

JDN Hoists contain a range of materials which, on expiry of the service life, must be disposed of or recycled where appropriate, in accordance with statutory regulations.


H O I S T

Ferrous materials

Steel

Nodular cast iron

Non-ferrous metals

Bronze

Aluminium

Plastics

Polyethylene

Polyurethane

Polyoxymethylene

Polyvinyl chloride

Polyamide, glass-fibre reinforced

Natural rubber

Epoxy resin

Polyacetal

Polypropylene

Phenol resin

Thermoset moulding compound (asbestos-free brake lining)

Polyester

Synthetic rubber

Wool felt

F I LT E R S I L E N C E R / S E R V I C E U N I T:

Zinc diecast

Brass

Nitrile rubber

Aluminium

Polypropylene

Polyurethane


Steel

Polyacetal

Polyethylene





I N S P E C T I O N I N T E R VA L S

JDN Air Hoists are extremely robust and require little maintenance. Compliance with maintenance and inspection intervals is of great importance in order that the hoist operates safely and reliably over a period of many years.

C AU T I O N !



If your JDN Air Hoist is often used at different locations, particularly in dirty and damp environments, clean any dirt off the hoist and the chain, seal off the air supply connections, protect the hoist and, in particular, the chain from corrosion, store the hoist in a clean and dry place.





I N S P E C T I O N A N D R E PA I R S

Series lifting equipment is classified into groups and dimensioned according to the type of operation (Driving mechanism classification according to ISO/FEM). The average daily operating time and the load spectrum determine the classification. This is assuming that the lifting and lowering paths are approximately the same.




.


f v

= 1+ 0.5

P-50

50

(for P > 50%)





Only if the group classification corresponds to the actual type of operation of the lifting equipment, does a safe operating period conform to the theoretical operating time. Deviations of the actual type of operation from that used for calculation extend or shorten the safe operating period.




C AU T I O N !




INSTRUCTIONS CONCERNING THE “MODEL FOR

DETERMINING THE ACTUAL OPERATING TIME

”

The decisive factors for the type of operation are the load spectrums with different cubic averages k. The load spectrum indicates to what degree a driving mechanism, or a part of one, is subjected to its maximum stress or only to smaller stresses. The cubic average (factor of the load spectrum) is calculated using the following formula.


To determine the type of operation for calculating the partial operating times (actual operating time), the following load spectrum diagrams can also be used.

The FEM* 9.511 rule differentiates between four load spectrums, which are identified by the definitions and by the ranges of the cubic averages k . This classification complies with ISO 4301/1.

*FEM = Federation Europeene de la Manutention (European Federation of Materials Handling and Storage Equipment)

Load spectrum

1

(Low)

Definition

Cubic average


≤

0.50

to the maximum stress in exceptional circumstances, and are only subject to very low stresses continuously.

2

(Average)

0.50 < k

≤ 0.63

3

(High)

4

(Very high)

L2 Driving mechanisms or parts thereof, which are subject to the maximum stress fairly often, and are only subject to low stresses continuously.

L3 Driving mechanisms or parts thereof, which are often subject to the maximum stress, and are continuously subject to average stresses.

L4 Driving mechanisms or parts thereof, which are regularly subject to the maximum stress of adjacent stresses.

0.63 <

≤

0.80

0.80 <

≤ 1.00

k k

Load spectrum factor k m

= k 3 = 0.125

k k m k m m

= k

= k

3

= k

3

3

= 0.25

= 0.5

= 1



MODEL FOR DETERMINING THE ACTUAL OPER ATING TIME

The following calculation compares the actual operating time with the theoretical operating time in load spectrum 4 (Very high).

1 2 3

Operating site


Load spectrum factor in accordance with load spectrum for the type of operation

L1

Low

L2

Average

L3

High

L4

Very high

4

Partial deployment


– 0 0.125

0.25

0.5

1 0

5

Remaining theoretical use in load spectrum 4

6 7


Date

Delivery

Initial operation

Inspections


Signature


Delivery

M2 (1Cm) 200 hours

M3 (1Bm) 400 hours

M4 (1Am) 800 hours

M5 (2m) 1600 hours

Initial operation

GmbH & Co.KG

C ALCUL ATION MODEL (DRIVING MECHANISM CL ASSIFIC ATION M3)


1.5

0.25

1.5 x 0.25 x 250 x 1.2

= 113 hours

(400 - 113)

287 hours

2nd August

2004

A.N. Other






Check oil level for motor lubrication

(when operating with oiler)

Lubricate chain

Visually check the chain


Check control device

Check the braking function

Checking direction of movement


(buffers) visually


Check chain

Interval

Daily

As required

Weekly

Interval

Daily

Daily

Daily

Daily

Daily

Every 3 months

Comment

( Filling and adjusting oiler section, page 49)

( Lubricating the chain section, page 45)

Comment

( Checking controls section, page 46)

( Checking braking function section, page 45)

( Checking direction of movement section, page 46)


( Checking chain, chain sprocket and chain guides section, page 55) In the event of wearpromoting operating conditions, reduce intervals between checks

( Checking lifting and lowering limiters, section, page 46)

Load must be braked reliably ( Checking braking function section, page 45)

Checking lifting and lowering limiters Annually

Check brakes with load Annually

Check all the bolted andpin connections

Check load hook on the load and carrying side

Annually

Annually

Check the motor, check, clean and rgrease the control valve

(JDN high-performance grease)

Annually

Check the axial movement of the hooks Annually and eyes

Check the service unit 1 Annually

Check the silencer for permeability Annually

Check overload protection Annually

Annually Check compressed air connections for damage

1 if fitted

(


(

Check dimensions section, page 55)

Checking axial play section, page 57)

( Service unit section, page 47)

( Checking silencer for permeability section, page 46)

( Checking and adjusting overload protection section, page 59)



Inspection measure Interval Comment

Check sealing efficiency and function Annually of control valve

Check condition of the chain box 1 Annually including mountings

Check for brake wear and motor vane wear

In off-shore areas and other similar corrosive environments, replace the chain regularly

Check gearbox and perform lubricant change

Every 200 hours, at least every 5 years

Every 5 years

Every 5 years

(

(

Chain box section, page 63)

Checking brake linings and vanes section, page 50), replace motor vanes every 5 years.

Check the rotor/pinion shaft connecEvery 5 years tion and lubricate with gear grease

Check the chain sprocket bearings and Every 5 years lubricate if necessary

Check chain sprocket and chain guides Whenever the chain is ( Wear dimensions section, page 56) replaced

Renew grease lubrication of motor When required, at least every 5 years

( Motor lubrication section, page 50)

1 if fitted



L U B R I C AT E C H A I N

The chain of the JDN Air Hoist must be lubricated in the links when not under load.




If you wish to lubricate the hanging chain, ensure that the chain links are oiled at the points of contact.

For this purpose, move the chain to and fro.

A high-performance lubricant in an aerosol can is available from JDN, which adheres well to the chain after the solvent has evaporated and does not drip off,

Part No. 12066 (spray can 400 ml).

For operation in areas with high corrosion potential, e.g. in the offshore sector, the chain can be largely protected against corrosion by the use of special lubricants.

These types of lubricants are characterised among other things by weathering resistance, water insolubility and good adhesion properties.

Re-lubrication intervals must be stipulated in accordance with the loading. Please contact us, if required.

C H E C K T H E B R A K I N G F U N C T I O N


Switch the unloaded air hoist alternately between lifting and lowering modes.


DA N G E R !



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 be perceptible.

When checking the braking function under nominal load, the following braking distances must not be exceeded:

B R A K I N G D I S TA N C E S U N D E R N O M I N A L L OA D


H A S B E E N S T O P P E D

Type

Rope control all other controls with length of

2 m

Dimensions in mm

1.5 TI 3 TI/2

10 5

33 16






4

Move the unloaded load hook until just short of the upper and lower end positions.


The movement of the chain must be stopped due to deformation of the buffer. For hoists with overload protection, the lifting movement is additionally limited by shutting off the motor.


DA N G E R !



E M E RG E N C Y S T O P F U N C T I O N

2

3 1

Main air emergency-stop valve

With each check, the working order of the valve must be examined as follows:

Shut off the compressed air supply and unload the line.

Remove the safety ring 1 .

Pull out the 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 repaired.



Briefly actuate and release all control elements of the controls one after the other. The control elements must return to their initial positions immediately. The on and off function must operate without problem.

PRESS THE EMERGENCYSTOP. All movement of the hoist must stop. Actuating the control elements must not cause a lifting or lowering movement.

RELEASE THE EMERGENCY STOP button by turning.

DA N G E R !

If a control element is stiff or remains in the actuated position, do not use the hoist. The control must be repaired.

C H E C K I N G T H E M A I N A I R

E M E RG E N C Y S T O P VA LV E

C H E C K I N G D I R E C T I O N O F M O V E M E N T

Check that the direction of movement of the load hook corresponds to the direction indicated by the arrows on the control elements.

C H E C K T H E S I L E N C E R F O R

P E R M E A B I L I T Y

The main air emergency-stop valve is opened with each actuation of the controls. It closes when the controls are released.


Independent of the stipulated inspection intervals, the silencer must be checked for permeability if the hoist does not achieve the specified lifting speed (see section

Technical data, page 64).

The test is performed by comparing the lifting speeds under nominal load, with and without the silencer. The speed with standard silencer or filter silencer must be at least 80 % of the lifting speed without a silencer element. In the event of lower values, the silencer elements must be cleaned or replaced.




If a hoist is operated with a service unit, this should not be mounted further than

5 m away from the hoist.

The ambient temperature must be a minimum of 0° C. It must not exceed 50° C.

N O T E : If, at the request of the customer, a service unit is installed in hoists in motorised trolleys and lifting gear, it will be configured at the factory.

A maximum connecting pressure of 10 bar is permitted for the service units supplied by JDN. Higher pressures must be reduced to a permitted amount upstream of the service unit.

The service unit in the PROFI 1.5 TI and PROFI 3 TI/2

Air Hoists consists either of two elements, filter controller and oiler, or of the filter controller only.


C O N T R O L L E R

* )

The filter controller is set to an actual pressure in the factory (actual pressure when lifting the nominal load).

In this setting, the manometer can indicate a pressure above the nominal pressure with the motor switched off. For correct adjustment, a pressure of at least 1 bar above the nominal pressure is required upstream of the service unit.


Turn the regulator knob until the manometer indicates the nominal pressure. Clockwise: higher pressure Anti-clockwise: lower pressure


Alternatively, the filter regulator can be set to the nominal pressure in the absence of an air stream. This setting is only correct for a pressure of at least 1 bar above the nominal pressure upstream of the service unit.

Depressurise the air line downstream of the service unit and close it again.

Turn the regulator knob anti-clockwise, in order to release the adjusting spring.

Turn the regulator knob until the manometer indicates the nominal pressure. Clockwise: higher pressure Anti-clockwise: lower pressure


If the nominal pressure cannot be achieved despite a sufficiently high pressure upstream of the service unit, then the air line cross-section is too small.

Filter regulator and oiler

Filter regulator

Regulator knob

Oiler



D R A I N I N G CO N D E N S AT E

After a certain time, condensate collects in the filter regulator container, which must be regularly drained.

Check the condensate level through the sight glass in the filter container. The condensate level must not reach the separating plate.

The container can be emptied manually or semi-automatically, depending on the setting of the drain valve:

OFF position

The drain valve is closed in this position.

The OFF position is generally set at the factory.

ON position

The condensate can be drained manually in this position. Operate the drain valve by pressing upwards

(see Figure).

When the compressed air supply is connected, the drain valve is under pressure. We recommend using suitable splash protection (cloth, fleece) as the condensate will otherwise escape uncontrollably.

Collect the escaping condensate and dispose of it as it may contain oil.

AUTO position

In this position, semi-automatic condensate drainage takes place. When the pressure 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 when drainage occurs.


AT T E N T I O N




Drain the water.

Shut off the main air supply and carefully allow the residual pressure to dissipate.

Unlock the filter regulator container, turn anti-clockwise to the stop and remove.

Unscrew the separating plate. The filter is located loosely on the separating plate centring device.

Clean the filter element using soap solution and blow through forcefully.

Reinstall the clean filter element and fasten the separating plate.

Insert the filter regulator container in the housing and turn clockwise. The container locks automatically.

filter element separating disc sight glass filter receptacle

Cleaning the filter element




The oiler ensures that the hoist air supply is consistently provided with a precisely-metered quantity of oil.

Regular checking of the oiler is very important, as the vane motor may be damaged in the case of lubricant deficiency. The oiler can also be refilled under pressure.

Check the oil level through the sight glass in the container. The oil level must not fall below the minimum mark.


Fill the container with oil up to the maximum mark and refit the oil filler screw.


Turn the oil throttle screw using a screwdriver until the desired number of drops per minute is achieved.



2 drops per minute.


Operation of service units with synthetic oils is not permissible. They must also not be connected to compressed air circuits, which are supplied by compressors lubricated with synthetic oil.

C AU T I O N !

J.D. Neuhaus only supplies standard spray oilers. Do not use microspray oilers as very finely secreted oil spray could adversely effect the surrounding air and therefore the respiratory system.

Max. oil level

Min. oil level

Check the oil level and top up if necessary

Sight glass

Oil filler screw

Oil throttle screw


Page 49


M O T O R I N S TA L L AT I O N / C H E C K I N G

B R A K E L I N I N G S A N D

VA N E S / M O T O R L U B R I C AT I O N

12 13 11 7 8 6 10 9 5 4 3 2 1

14/15



R E M O VA L

The hoist must first be unloaded and disconnected from the main air supply.

Note: The following operations can be performed from the nameplate side after the motor has been removed.

Checking vane wear, replacing the vanes with starting aids if necessary.

Checking brake wear, replacing the brake piston if necessary.

Renewing the motor lubrication.

The replacement of the centre section halves with brake lining is described under a separate item.

Unscrew 1 the nameplate.

Remove the motor cover bolts 2 and detach the motor cover 3 (when the cover bolts are removed, the brake springs 4 are fully released).

Remove the brake springs.

Remove the brake piston 5 from the internal cylinder integrated in the motor housing.


Checking vane wear:

(See Fig. Checking vane wear, page 51). When the vanes are worn, the motor power and consequently the lifting performance of the JDN Air Hoist are reduced. Replacing the vanes together with the starting aids.

Checking braking surfaces of the brake piston and the centre section half with brake lining for wear and damage:

The circular wear pattern in the braking surfaces must not be deeper than 0.2 mm (also see illustration on page 51). The extremely low-wear braking material will not reach the wear limit of 0.2 mm within the designdependent service life of the hoist, under intended use.

Should the wear limit be reached prematurely, the actual pressure must be checked with the device switched on

(the brake drags in the event of insufficient pressure).



Rotor Cylinder liner (internal cylinder)

V

1 max. = 0.2 mm V

2 max. = 0.2 mm

Brake piston

Brake disc

R

= R - (V

1

L

L max

= R - (V

1

+ V

2

)

L min

L hmin

= 23 mm

+ V

2

) - 0.5 mm = L max

Vane

- 0.5 mm


Renewing motor lubrication:

Note: The grease packing in the rotor chambers is sufficient for approx. 250 hours of normal operation.

The rotor chambers are only emptied by approx. 75%.

In this condition, refilling must be performed.

The retaining rings 9 and Vyon washers 10 must be removed in order to refill the chambers.

Then pack the chambers with high-performance lubricant (JDN Art. no 11901) without forming cavities.

Use new Vyon washers to close off the lubricant chambers and secure these using retaining rings.

Replace centre section halves with brake lining.

If the centre section half with brake lining is to be replaced, the following removal operation is also required.

Detach the hoist from the point of attachment and set down carefully.

Detach the chain box if necessary.

Remove the control valve.

Remove centre section bolts 11 .

Detach the motor with centre section half on the motor-side from the hoist.

Remove the bolts 12 and pull out the centre section half with the brake lining 13 .

Motor installation with additional basic lubrication:

Apply high-performance grease lightly to braking surface and rotor bearing (needle bush) in the centre section half and slide this into the motor housing. At the same time, insert the anti-twist device (pin).

Bolt centre section half to motor housing.

Coat the internal cylinder of the motor housing lightly with high-performance grease.


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 diameter including the brake piston seal lightly with highperformance grease and push the brake piston with the braking surface first into the internal cylinder.

Note the position of the eccentric bore.

Insert the brake springs into the bores of the brake piston.

Loosen adjusting bolts 14 and lock nuts 15 . Screw back adjusting bolts.

Apply high-performance grease lightly to rotor bearing (needle bush) in the motor cover and install motor cover. Ensure correct seating of the brake springs and the locating pins to the motor housing and to the brake piston. Do not tighten the four adjusting bolts after bolting the motor cover in place, only screw them in loosely by hand to the stop in the cover. Screw back the lock nuts sufficiently beforehand.

Then screw back the adjusting bolts 45° from the stop, hold, and lock with the nuts. For lifting heights of 10 m and more, a setting of up to 60° is required.

For operation in areas with ambient temperatures exceeding 30° C, the adjustment must be carried out with the device warmed up accordingly.



Attach the nameplate.

Push motor with centre section half on the motor side onto the hoist – install load hooks at same time

– and tighten centre section bolts.

Install the control valve.


Tightening torques, see E-list.

C AU T I O N !






R E M O V I N G A N D I N S TA L L I N G L OA D S L E E V E A N D

B U F F E R – S I N G L E - C H A I N H O I S T 1. 5 T I

R E M OV I N G A N D I N S TA L L I N G B O T T O M B L O C K A N D

B U F F E R - D UA L C H A I N H O I S T (3 TI/2)

1

3

3

2

2

5

4

5

7

6

Removal

Unscrew bolt 7 and remove it from the chain pocket together with retaining washer 6 and shaped element 1.



Assembly


Insert the chain link into the chain pocket of the load sleeve (position of the weld must align with that of the following links).

Insert the shaped element into the chain pocket, install and tighten the bolt with the retaining washer

(change tightening torque to 8 Nm).

5

10

8

7

8

Removal

Move the bottom block as close as possible to the hoist body.


Remove the chain link 1 of the bottom block from the chain mount on the hoist body; drive out the roll pin 2 and the end chain link pin 3 for this purpose.

14

6

1

12

11

13

9




Pull out the chain from the bottom block. The buffer 7 and buffer discs 8 are thereby pulled from the chain.

Assembly


Align the chain and fasten it to the assembly chain in the bottom block by means of the open chain link.

Pull the chain through the bottom block and detach the assembly chain and the open chain link from the chain. If no assembly chains have been used, the end of the chain must be inserted into the bottom block and pulled through by turning the sprocket wheel using an auxiliary tool.

Push the spacer pipe onto the chain.

Align the bottom block chain and 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.

R E M O V I N G A N D I N S TA L L I N G C L A M P A N D B U F F E R


In the case of operation with chain box, run the chain out of the chain box and detach it from the hoist.

Remove the chain link of the idle chain from the chain mount on the hoist body. Unscrew the Allen screws 14 for this purpose.

Loosen screw connections 9 of the clamp 10 .


Detach the buffer 11 and buffer discs 12 + 13 from the chain.

Assembly

Push the buffer disc with edge (edge encloses buffer), buffer and buffer disc without edge onto the chain.

Insert the tenth chain link into the chain pocket of the clamp (chain pocket away from hoist body, pointing outwards).

Introduce a screw connection to secure the chain link in the clamp.

Align the idle chain and fasten the end chain link to the hoist body.







S P RO C K E T A N D C H A I N G U I D E S

See also Check dimensions, page 55. If the chain of the JDN Air Hoist displays one of the following characteristics, it must be replaced with a new one:

Corrosion pitting


Chain drawn tight

Wear over 11 pitches (A max )

Single pitch wear (B max )

Elongation of a single link (D max )


Please observe the information contained in DIN 685, part 5 when checking chains. For further instructions see ISO 7592.

C H E C K D I M E N S I O N S


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 limit values specified in the table when checked, the chain has reached its replacement limit and must be replaced by a new one. The chain sprockets must also be replaced together with the chain, as otherwise the new chain will be subjected to increased wear. Each chain replacement must be documented in the inspection log.

d1


Chain d x t

Dimension A max.

11 x t inside max.

Dimension B max.

Dimension C min.

Dimension D max.

Dimensions in mm c = d 1 + d 2

2

9 x 27

320.5

303.2

28.4

8.1

46.4



L OA D H O O K

If the measured distance y and the height h of the load hook are outside the wear limits, the hook must be replaced.

y

W E A R D I M E N S I O N S F O R C H A I N S P R O C K E T S x

Check dimensions of load hook

Type

PROFI 1.5 TI

Load sleeve

Centre section

PROFI 3 TI/2

Dimensions in mm

Permissible maximum Permissible minimum dimension of dimension of measured distance "y" height "h"

57.8

63.0

63.0

28.2

36.1

36.1



9 x 27 z

(1)

4 a mm

25 x mm

0.2

a, x = Limit dimensions after maximum permitted wear z = Number of teeth of the chain sprocket d x t = Nominal diameter times pitch of chain link



Check the chain guides for wear and when the wear dimension of 1 mm is reached with regard to chain guide diameters or hook mounts in the centre section of the device: Replace the housing.



C H E C K I N G A X I A L P L AY





DA N G E R !

In the event of insufficient maintenance/lubrication the extent of wear may be so high that there is a danger of loads falling.

P R E V E N T I O N O F DA N G E R S





Bottom block with load hook or load eye powered by air !

Page 57


R E M O V I N G A N D I N S TA L L I N G C H A I N


The chain supplied together with this JDN hoist is matched to the chain sprocket according to strict tolerances. In order to ensure optimum function of the chain and in order to prevent hazards, only genuine

JDN chains must be installed.

Note: When a chain is replaced, the buffers must also be replaced. For changing buffers at the chain ends, see section Removing and installing load sleeve, bottom block, clamp and buffer.

Buffers not located on the chain ends are most easily replaced when the open chain link between the old and new chains passes the buffer to be replaced.



In the case of operation with chain box: switch the hoist in the “lower” rotational direction and run the old chain out of the chain box. Then remove the chain box.

Move the bottom block as close as possible to the hoist body and position it securely.

Detach the idle chain from the chain mount on the hoist body (see also section Removing and installing load sleeve, bottom block, clamp and buffer ).

Detach the clamp, buffer and buffer discs from the end of the idle chain. For single chain hoists also detach the load sleeve, buffer and buffer discs from the load chain. For dual chain hoists detach the bottom block chain from the hoist body (see also

Removing and installing load sleeve, bottom block, clamp and buffer section).

Attach the new chain to the end link of the load section of the 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 link of the new chain is not correctly positioned, it must be removed.

Note: It is possible that the first chain link of the other chain end is correctly positioned. Switch the hoist to the “lift” rotational direction. The new chain will now run into the hoist while the old chain is simultaneously run out on the idle chain side.

Run the chain until the join between the old and new chain has run sufficiently (approx. 1 m) out of the centre section on the idle chain side.

Detach the connection between the old and new chains.


Align the idle chain and attach to the fastening point on the hoist (see also Removing and installing load sleeve, bottom block, clamp and buffer section)


Switch the hoist in the “lift” rotational direction until the as yet free end of the aligned load chain is the correct length for attaching the chain link

– for single chain hoists in the load sleeve after the buffer and buffer discs have been pushed on,

– for dual chain hoists at the fastening point of the hoist body (see also Removing and installing load sleeve, bottom block, clamp and buffer section).




REPL ACING CHAIN AND CHAIN SPROCKET

Note: If the chain jams in the hoist and can no longer be run out, the gearbox must be dismantled (see spare parts list for “Gearbox”).

For dual chain hoists, when removing the old chain, an assembly chain 1 is brought into position on the deflection sprocket of the bottom block by means of an open chain link (see also Removing and installing load sleeve, bottom block, clamp and buffer section and Removing and installing chain section).

Following replacement of the chain sprocket (see spare parts list) an assembly chain 2 is run carefully – with low air pressure – over the drive sprocket.

Fasten the new chain 5 to the assembly chain on the drive sprocket by means of one or two open links 3 to the idle 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 chain after it comes out of the centre section.

For dual chain hoists, the new chain, after it has been aligned, is pulled over the deflection sprocket of the bottom block using the assembly chain.



2

1

3

4

5



The PROFI 1.5 TI and 3 TI/2 hoists are equipped with a new type of safety clutch as standard. This prevents loads exceeding the limit values set from being lifted.

The limit value is set so that loads of 125 % of the load carrying capacity cannot be lifted. 110 % can be lifted in order to perform the dynamic overload test.


The safety clutch must only be engaged for a short time in order to prevent unnecessary wear and overheating of the drive.

When the safety clutch is activated, the hoist should be unloaded by switching to a lowering movement.


The overload protection can also be activated when moving 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.

A D J U S T I N G O V E R L OA D P R O T E C T I O N


DA N G E R !


Unload the hoist.

Detach the gearbox cover 1 from the gearbox in order to gain access to the threaded pins 2 with lock nuts 3 located behind it.

CORRECTING THE SET LIMIT VALUE

Loosen the lock nuts. It must be ensured that the threaded pins are not turned.

During each readjustment, adjust the threaded pins to the same degree in order to adjust the disc springs evenly: turning clockwise – limit value is increased, turning anti-clockwise – limit value is reduced.

Secure threaded pins with the lock nuts. Do not turn the threaded pins any more as the setting will be altered.

Check the limit value for correct setting.

Install the gearbox cover.

R E S E T T I N G T H E L I M I T VA L U E

Loosen the lock nuts. Screw out the threaded pins – anti-clockwise – until the disc springs 4 are completely free of pre-tension.

Then loosely screw in the threaded pins by hand – clockwise – to the stop, unscrew the lock nuts sufficiently far back beforehand.

The limit value for reaching at least 110 % of the load-carrying capacity is set at approx. 2.5 turns.

Screw in the three threaded pins successively in small steps by approx. 1/2 turn. With this 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).

3

2

4

Then let the load hook run for approx. 10 seconds without a load so that the outlet air cools the clutch down.

Secure threaded pins with the lock nuts. Hold the threaded pins tightly in the process.

Check the limit value for correct setting, correct if necessary.


The adjusting and inspection result arrived at by qualified personnel must be entered in the lifting gear inspection log (limit value: see Overload protection , page 36).

1

Gearbox 1.6 t




FAU LT TA B L E

Fault


Only very slow lifting possible

Possible cause

Overload protection has caused deactivation

Remedy

Lower hook briefly, limit load to permissible load carrying capacity, then lift again. If loads within the load carrying capacity range are not lifted, the overload protection must be adjusted.

Set the air pressure correctly. Air pressures which are too high can cause deactivation within the load carrying capacity range.

Air pressure too low

EMERGENCY STOP button is pressed



Increase air pressure to the required value

Release the EMERGENCY STOP button once the danger has been rectified




Set air pressure to the relevant value, check seal of brake piston and change seal if necessary. Check the adjustment of the brake piston (see E-list )


Tighten the bolts

Air supply hoses leaking or loose


Cross section of air line too small Use air line with sufficiently large cross section (check air pressure)

Dirt in the service unit*, filter Clean the service unit filter blocked Ensure better air quality

Silencer is clogged Replace or clean silencer elements, improve air quality if necessary

Motor vanes worn

Motor has run dry

Replace motor vanes

Lubricate motor, check oiler*

Loud chain noise on the chain sprocket


Excessive running on during braking Replace brake disc and/or brake piston worn

Chain dry

Chain worn

Chain sprocket worn


Have control valve repaired

Replace brake disc and/or brake piston

Lubricate chain

Replace chain with a new JDN Chain


Identify chain and replace with JDN Chain if necessary

Lifting or lowering speed declines Brake piston setting too tight Correct adjustment of brake piston. At high with high lifting heights or the motor comes to a standstill ambient temperatures, perform adjustment with the device warmed up accordingly.

*if fitted






99.9 % of oil aerosols during oil lubrication of the motor are absorbed by the filter element.

The noise insulation reduces noise levels by 3 to 4 dB

(A) compared with the standard silencer (sinter plate).

The ambient temperature must not be lower than -10° C.




Turn the drain valve 4 90° and allow the fluid to drain out.





Insert a new filter element, with sealing ring 1 and push on collecting container until it engages.


In the event of a control hose length exceeding 10 m, the reaction times of the pushbutton controls increase significantly.



Filter silencer


1

2

3

4


C H A I N B OX




Do not exceed the permissible filling capacity. Danger of chain falling.




PROFI 2 TI (dual chain) the clamp must be positioned as far as necessary downwards on the reeved chain in order to support the bottom block (stationary chain). In addition, a spacer must be attached to the opposite

(moving) chain above the buffer in order to relocate the load hook stroke limiter. Please contact us, if required.

For greater clarity, see the illustration on the right on page 53.


Removing and installing chain page 58).

Depending on the ratio of the size of the hoist (without running gear) and the chain box, the chain box may have to be stabilised by the customer due to an acceptable vertical hoist 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 J.D. Neuhaus GmbH & Co. KG.




After installing the chain box, lower the load hook to the bottom position once.

Then activate lifting movement and run the complete chain into the chain box.

DA N G E R !

When operated with a chain box, lubrication of the chain is particularly important in order to prevent it from piling up and falling out. Do not install longer chains when changing chains.


If the hoist has been transported with the chain in the chain box, the chain box must be emptied manually before initial operation (if necessary, remove the chain box from the hoist). The entire chain must then be allowed to run to the load side and, subsequently, be driven back into the chain box. The hoist must be kept in a hanging position during this procedure. This process will ensure that the chain does not lock when loads are being lowered.


A P P E N D I X

A P P E N D I X

T E C H N I C A L DATA

J D N P R O F I T I A I R H O I S T S

Type

Air pressure


Number of chain sections

Motor power




Air consumption at nominal load, lifting

Air consumption at nominal load, lowering

Air connection

Hose dimension ( inside)

Weight for standard lift, rope control

Chain dimensions

Weight for 1 m chain

Standard lift

Control length for standard liftm

Noise pressure level with nominal load 1 with standard silencer - lifting

Noise pressure level with nominal load 1 with standard silencer - lowering bar t kg mm kg m dB(A) dB(A)

1 measured from 1 m distance according to DIN 45635 part 20 kW m/min m/min m/min m

3

/min m

3

/min

G 1/2 mm

1.5 TI

4 to 6

1.6

1

1.3 to 2

4 to 6

8.4 to 10

11 to 12

1.5 to 2.6

2.2 to 3.6

G 3/4

19

56

9 x 27

1.8

3

2

73 to 77

78 to 80

3 TI/2

4 to 6

3.2

2

1.3 to 2

2 to 3

4.2 to 5

5.5 to 6

1.5 to 2.6

2.2 to 3.6

G 3/4

19

66

9 x 27

1.8

3

2

73 to 77

78 to 80




F

G

C

D

E1

Type

A minimum headroom*

B

C

D

E

1

E

2


G maximum width

*Chain boxes increase the required headroom

E2

1.5 TI

480

293 mm mm mm

200

412 mm 28 mm 26 mm mm

170

215

3 TI/2

544

356

200

412

28

28

140

215

A P P E N D I X


A P P E N D I X

C I RC U I T D I AG R A M

R O P E C O N T R O L ,

W I T H O U T M A I N A I R E M E RG E N C Y S T O P VA LV E lifting motor brake motor silencer control valve 2 BI rope

A B

A B control valve

P lifting lowering

P

E main air connection

Page 66 service unit powered by air !

A P P E N D I X


E - C O N T R O L , D UA L - F U N C T I O N ,

W I T H O U T E M E RG E N C Y S T O P D E V I C E

W I T H O U T M A I N A I R E M E RG E N C Y S T O P VA LV E

( N O T F O R E E A ) lifting motor brake motor silencer control valve 2 BI air

A B

Steuerventil

A B

P Y Z

P

E main air connection service unit push button valve E-2fold


A P P E N D I X


E - C O N T R O L , D UA L - F U N C T I O N ,

W I T H E M E RG E N C Y S T O P D E V I C E

W I T H M A I N A I R E M E RG E N C Y S T O P VA LV E lifting motor brake motor silencer control valve 2 BI air HS

A B

A control valve

B

P Y Z

P

E main air connection service unit emergency stop push button valve

E-2fold emergency stop


A P P E N D I X


E - C O N T R O L , 4 - F U N C T I O N ,

W I T H O U T E M E RG E N C Y S T O P D E V I C E

W I T H O U T M A I N A I R E M E RG E N C Y S T O P VA LV E

( N O T F O R E E A ) lifting motor brake motor silencer control valve 2 BI air

A B

A B control valve

P Y Z

P

E main air connection service unit driving motor brake motor silencer

Y P Z push button valve

E-4fold powered by air !

Page 69

A P P E N D I X


E - C O N T R O L , 4 - F U N C T I O N ,


W I T H E X T E R N A L M A I N A I R

E M E RG E N C Y S T O P VA LV E

P

E main air connection service unit lifting motor brake motor silencer control valve 2 BI air

A B control valve

A B

P Y Z driving motor motor brake

A B silencer

Y P Z emergency stop push button valve




F I - C O N T R O L , D UA L - F U N C T I O N ,


W I T H M A I N A I R E M E RG E N C Y S T O P VA LV E lifting motor brake motor silencer control valve 2 BI air HS control valve

A

A

B

B

P

E main air connection service unit hand valve FI-3fold emergency stop

P Y Z

A P P E N D I X


A P P E N D I X


F - C O N T R O L , 5 - F U N C T I O N

( D E V I C E W I T H T R O L L E Y ) ,

W I T H E M E RG E N C Y S T O P D E V I C E ,

W I T H E X T E R N A L M A I N A I R

E M E RG E N C Y S T O P VA LV E lifting motor motor brake silencer driving motor motor brake silencer control valve 2 BI air

A B control valve

A B

Y P X Z

P Y Z service unit

P


2/2 way-valve for emergency stop multi button pendent switches 5 fold emergency stop


A P P E N D I X


F - C O N T R O L , 7 - F U N C T I O N ( D E V I C E W I T H T R O L L E Y C R A N E ) ,


W I T H E X T E R N A L M A I N A I R E M E RG E N C Y S T O P VA LV E lifting motor motor brake silencer driving motor motor brake silencer

A B control valve 2 BI air

A B control valve

A B

Y P X Z service unit

P


2/2 way-valve for emergency stop

P Y Z multi button pendent switches 7 fold emergency stop lifting motor motor brake silencer

A B driving motor motor brake silencer

A B

Y P X Z Y P X Z powered by air !

Page 73

is a registered trade mark of our company.

BA 820 GB · Subject to changes · 122009

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: [email protected]

powered by air !

J D N O P E R A T I O N A N D A S S E M B L Y

I N S T R U C T I O N S A I R H O I S T S

, , , ,

20

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

Original Operation and

Assembly Instructions powered by air !

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

This operation manual edition 12/2009, covers the following JDN Air Hoists:

Fabr. No.

Fabr. No.

Fabr. No.

Fabr. No.

Fabr. No.

20 and the following JDN Monorail Hoists (EH), only in conjunction with the operation manual JDN Trolleys :

EH 10

Fabr. No.

EH 16

Fabr. No.

EH 20

Fabr. No.

It must be read carefully and in its entirety before operating any air hoist. For hoists installed in trolleys, please also refer to the operation manual JDN Trolleys.


TA B L E O F C O N T E N T S

SA F E T Y M E A S U R E S

Organisational measures . . . . . . . . . . . . . . . . . . 5

Personnel safety . . . . . . . . . . . . . . . . . . . . . . . . 5

Preventing property damage . . . . . . . . . . . . . . . 5

P R O D U C T I N F O R M AT I O N

The operation manual . . . . . . . . . . . . . . . . . . . . 6

Warnings and symbols . . . . . . . . . . . . . . . . . . . . 6

Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Assembly overview . . . . . . . . . . . . . . . . . . . . . . . 8

Product description . . . . . . . . . . . . . . . . . . . . . . 8

Explosion protection . . . . . . . . . . . . . . . . . . . . . 9

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Operating conditions . . . . . . . . . . . . . . . . . . . . 15

Energy requirements . . . . . . . . . . . . . . . . . . . . 17

Principle of operation of

JDN air vane motors . . . . . . . . . . . . . . . . . . . . . 18

Operation without chain box . . . . . . . . . . . . . . 19

Motor lubrication / operation with service unit . 19

CE marking / declaration of incorporation . . . . 19

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

T R A N S P O R T A N D S TO R AG E

Safe transportation . . . . . . . . . . . . . . . . . . . . . 20

Storage conditions . . . . . . . . . . . . . . . . . . . . . . 20

I N I T I AL OP E R AT I O N

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Installing the hoist . . . . . . . . . . . . . . . . . . . . . . 21

Connecting the controls . . . . . . . . . . . . . . . . . . . 22

Replacing controls . . . . . . . . . . . . . . . . . . . . . . . 25

Connecting to the main air supply . . . . . . . . . . . 27

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Checking prior to initial operation . . . . . . . . . . 28

OP E R AT I O N

Rules for safe operation of hoists . . . . . . . . . . . 29

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Emergency stop device . . . . . . . . . . . . . . . . . . . 34


Attaching the load . . . . . . . . . . . . . . . . . . . . . . . 34

Lifting the load . . . . . . . . . . . . . . . . . . . . . . . . 35

Lowering the load . . . . . . . . . . . . . . . . . . . . . . . 35

Detaching the load . . . . . . . . . . . . . . . . . . . . . . 35

Interrupting working . . . . . . . . . . . . . . . . . . . . 35

TA K I N G O U T O F OP E R AT I O N

Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . 36

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36



Cleaning and care . . . . . . . . . . . . . . . . . . . . . . . 37

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Inspection and repairs . . . . . . . . . . . . . . . . . . . . 37

Instructions concerning the ” model for determining the actual operating time ” . . . . . . . 39

Lubricate the chain . . . . . . . . . . . . . . . . . . . . . . 43


Checking lifting and lowering limiters . . . . . . . . 43

Checking controls and emergency stop function . 44

Checking the main air emergency-stop valve . . . 44

Checking direction of movement . . . . . . . . . . . . 44

Checking the silencer for permeability . . . . . . . 44

Service unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Replacing brake disc, brake piston and vanes

/motor installation/motor lubrication . . . . . . . . 48

Removing and installing load sleeve, bottom block, clamp and buffer . . . . . . . . . . . . . 50

Checking chain, chain sprocket and chain guides 54

Check dimension . . . . . . . . . . . . . . . . . . . . . . . . 55

Checking axial play . . . . . . . . . . . . . . . . . . . . . . 56


Replacing chain and chain sprocket . . . . . . . . . . 58



Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61


Filter silencer . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Booster unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chain box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

A P P E N D I X

Technical data . . . . . . . . . . . . . . . . . . . . . . . 64, 66

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 65, 67

Air flow sheets . . . . . . . . . . . . . . . . . . . . . . . . . 68


Please note:


왘 BGV A1 accident prevention regulations ”Principles

왘 of Prevention”

BGV D8 accident prevention regulations ”Winches,

왘


BGR 258 trade association regulations ”Operation of

Load-Carrying Devices Used with Lifting Equipment” and, for air hoists installed in trolleys and for the operation of monorail hoists, additionally with

왘 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” BGG 905 (ZH 1/27).

To document the tests we recommend the “Inspection log for cranes” BGG 943 (ZH 1/29) from the trade association.


왘

왘

BGR 104 ”Explosion Protection Regulations” and

BGR 132 ”Prevention of Ignition Hazards due to


In all other countries, the operator shall comply with local regulations as applicable.



SA F E T Y I N S T R U C T I O N S

SA F E T Y I N S T R U C T I O N S

O R GA N I SAT I O N AL M E A S U R E S

JDN Hoists are designed in accordance with current technological standards and accepted safety practice.

Nonetheless, the use of an air hoist may be associated with risk of injury or fatality to the user or to third parties or with the risk of damage to the hoist or to other items, if safety rules are disregarded.

All personnel charged with operating air hoists, must have read and understood the operation manual, especially the section entitled ”Rules for the safe operation of hoists”, before commencing work. This is particularly important for personnel who only occasionally operate the hoist, e.g. for maintenance or retrofitting work.

Operators of JDN Hoists are also under obligation to ensure safe and hazard-free operation. This can be achieved through the following measures:

왘 keeping the operation manual available at the hoist’s

왘

왘

왘

왘 operating site at all times performing regular training, perform regular inspections (at least once annually), implement an inspection log and make regular entries, and regularly check personnel for safety and hazard awareness during work.

P E R S O N N E L SA F E T Y

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, before commencing work.

Due to their technical training and experience, properly trained personnel have adequate knowledge of hoists.

They are sufficiently familiar with the relevant occupational safety and accident prevention regulations, that they are able to assess the condition of hoists, with regard to working safety.

왘

왘

왘




왘 Follow the safety instructions set out in the operation manuals.

P R E VE N T I N G P R OP E R T Y DA M AG E

Operators of JDN Hoists are under obligation to ensure that entries in the accompanying inspection log are made properly and regularly.

왘

왘


Only use JDN Hoists for work which is described as

왘 intended use.

Observe the operating conditions for JDN Hoists as described in this manual.

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Page 5



T H E OP E R AT I O N M A N UAL


This operation manual contains important information for the safe, proper and efficient operation of JDN

Air Hoists. Observance of the manual helps to avoid hazardous situations, to reduce repair costs and downtimes and to ensure the specified service life of the JDN Air Hoists.

WA R N I N G S A N D SY M B O L S

Safety warnings in this operation manual are classified in three categories.

DA N G E R !

Safety warnings, which if not followed can result in hazard to life and limb, are indicated by this symbol. The symbol indicates an immediate danger. The possible consequences of non-observance may be severe or even fatal injuries.

C AU T I O N !

This symbol indicates potentially hazardous situations. Failure to observe may result in light injuries.


This symbol indicates that failure to follow the relevant instructions may result in damage to the device or other equipment.



L A B E L L I N G


If you have any questions concerning operation of JDN

Air Hoists, which are not addressed in this operation manual, please contact us at the following address:


Windenstraße 2-4

D - 58455 Witten-Heven

Phone +49 2302 208-0

Fax +49 2302 208-286 www.jdn.de


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Page 7


A S S E M B LY OVE R V I E W

PROFI TI air hoists and monorail hoists consist of the following assemblies:

1 Gearbox with chain sprocket and overload protection

2 Centre section


4 Controls with main air EMERGENCY STOP

5 Chain


P R O D U C T D E S C R I P T I O N

The PROFI TI series JDN Air Hoists and EHs described here are designed for load-carrying capacities from 3.2 t

(PROFI 3TI ) to 20 t (PROFI 20TI/EH 20).

Various control devices are available for the different requirements.



PROFI TI JDN Air Hoist and EH motors feature rotors with grease chambers. These contain JDN highperformance grease which enables operation with oilfree compressed air. It remains effective for an operating period of approx. 250 hours and should be renewed when required, but after five years at the latest (see

Motor lubrication, page 19). Additional lubrication with oil-bearing compressed air by means of a service unit with oiler is possible.

4

3

32

PROFI TI series JDN Air Hoists

6

1

2

6

2

5

1

3

4

Page 8

JDN monorail hoists EH powered by air !


E X P L O S I O N P R OT E C T I O N


JDN Hoists, Trolleys and Crane Systems in explosionhazardous areas, based upon European Guideline

94/9/EC 1 (”ATEX 100a”). DMT is accredited with the testing of devices and protection systems for intended use in explosion-hazardous areas.

BA S I C E X P L O S I O N P R OT E C T I O N F O R T H E

S TA N DA R D VE R S I O N S ( E XC L U D I N G M I N I )

Standard version JDN Air Hoists are category 2 devices

(Guideline 94/9/EC, DIN EN 1127-1 2 ), for use in zone 1 and 2 for gases of explosion group IIA. (See also IEC

60079-12 3 and IEC 60079-20 4 ). These devices are also suitable for use in zone 2, in the presence of gases of explosion group IIB, provided that the substances hydrogen sulphide and ethylene oxide can be excluded and additionally in zones 21 and 22 for dusts with glow temperatures above 210° C or ignition temperatures above 202° C, provided that no light metal or other impact-sensitive dusts are present.


II 2 GD IIA T4(X)/ II 3 GD IIB T4(X)

Additional marking ”X”, see page 10.

J D N H O I S T S

” W I T H I N C R E A S E D S PA R K P R OT E C T I O N ”

JDN Hoists in the ”with increased spark protection” version (SP), fulfil further explosion protection requirements. With the exception of carbon disulphide

(temperature class T6), they can be used in the presence of all gases in zones 1 and 2 and dusts with glow temperatures above 210° C or ignition temperatures above 202° C in zones 21 and 22, and can be designated with II 2 GD IIC T4(X) for installation in a trolley, depending upon trolley version (see below), but also with II 2 GD IIB T4(X) . For further operating conditions, see Instructions for safe operation (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 operation, use in the presence of carbon disulphide or dusts with particularly low glow or ignition temperatures may be possible with designation II 2 GD IIC T6(X) , which includes the

Additional marking ”X” for special conditions (see

Additional marking ”X”). Please contact us with regard to these requirements.

S TA N DA R D J D N T R O L L E Y A N D C R A N E

R U N N I N G G E A R

JDN Trolleys and Cranes can be used in zone 2 with standard running wheels (made of steel or cast metal) with all dusts and the presence of gases up to explosion group IIC. Due to the low running speeds, the possible friction velocities on the running wheels are less than

1 m/s, so that standard running wheels can also be used in zone 1 up to explosion group IIB. The highest possible designation for these devices is:

II 2 GD IIB T4(X)/ II 3 GD IIC T4(X) .

Depending on the hoist version, designations

II 2 GD IIA T4(X)/ II 3 GD IIB T4(X) or

II 2 GD IIB T4(X) are also used.

J D N T R O L L E Y A N D C R A N E R U N N I N G G E A R ” W I T H

I N C R E A S E D S PA R K P R OT E C T I O N ”

For use in zone 1 in the presence of gases in explosion group IIC, bronzed running wheels or running wheels made of bronze will also be used. The highest possible designation for this version (FSR) will be

II 2 GD IIC T4(X) (the same as for JDN Hoists

”with increased spark protection”).

J D N T R O L L E Y A N D C R A N E R U N N I N G G E A R F O R

U S E I N T H E P R E S E N C E O F T E M P E R AT U R E C L A S S

T 6 GA S E S O R D U S T S

As is the case with JDN Hoists ”with increased spark protection”, temperature class T6 could also be possible in this case too in the event of a special investigation of applicability, so that the highest possible designation for standard wheels and for bronzed or bronze wheels are II 2 GD IIB T6(X)/ II 3 GD IIC T6(X) and

II 2 GD IIC T6(X) respectively, i.e. each including the additional designation ”X” for special conditions.



G E N E R AL N OT E O N D E S I G N AT I O N

The highest possible respective designations for lifting equipment and running gear are usually replaced by a designation, which corresponds to the normal assembly of a compact complete device (trolley or crane system).

A D D I T I O N AL M A R K I N G ” X ”


II 2 GD IIA T4(X)/ II 3 GD IIB T4(X) or

II 3 GD IIA T4(X) :




...IIC T6(X) :


U SAG E I N M I N I N G A P P L I C AT I O N S

Standard versions of JDN Hoists, Trolleys and Crane

Systems may generally also be used for underground mining operations as well as for the associated surface facilities, which are hazardous due to firedamp and/or combustible dusts. Within this equipment group I they belong to category M2. The devices must be switched off in the event of an explosive atmosphere being formed. They are equipped with protective measures offering a high degree of safety. The protective measures with which products of this category are equipped 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 other difficult conditions in addition to explosion protection prevailing with regard to 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 13463-1 5 for coal dust atmospheres is not reached. For mining applications, the relevant designation for hoists, trolleys and crane systems is I M2 .

L OA D C H A I N

In order to guarantee the required degree of earthing, extremely rusty chains must no longer be used in zones

1 and 21 or in category M2 devices. As, depending upon the degree of corrosion, the leakage capability of the chain may be impaired to a level that is no longer adequate.

C O M P R E S S E D A I R H O S E S

In zone 1, compressed air hoses must have a sufficiently low surface resistance of less than 10 9 , in order to prevent electrostatic ignition hazards. Otherwise

(resistance >10 9 ), for explosion groups I, IIA and IIB the hoses must be ∅ 30 mm and for explosion group

IIC ∅ 20 mm, or proof must be provided that they cannot become dangerously charged.

M AT E R I AL S F O R F R I C T I O N A N D I M PAC T H A Z A R D S


Accordingly, spark formation caused by mechanical influences must be prevented. The chain and load must always be moved in such a way that sliding and/or frictional contact with other plants or components is excluded. If circumstances do not permit this, it is necessary to ensure an absence of explosive atmospheres during operation.

Impacts between particular materials result in an increased ignition hazard. This does not apply to corrosion-resistant steel or cast iron against aluminium, magnesium or corresponding alloys. This applies especially in the presence of rust or rust film. Rust (also rust film) formation is possible, especially on the chain and on the load hook, at the friction points. The following holds true for all zones: For the intended use of hoists it must be ensured that no rust is present at the above-mentioned friction points and that material combinations of the above-named light metals with steel (exception being stainless steel) or cast iron are not used in the working area of the hoists, at potential


P R O D U C T I N F O R M AT I O N friction, impact or sliding points. It is thus 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 selected so as to ensure that there is no risk from impact sparks.

E A R T H I N G

Electrostatic ignition hazards can be prevented by means of safe earthing. In zones 1 and 21, earthing of the hoists is required. This must be achieved via the load hook or the load eyes, if the lifting equipment is connected to correspondingly earthed parts (earth leakage resistance less than 10 6 ). This also applies to operation with trolleys or cranes. Their tracks 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 also

Load chain , page 10).



C L E A N I N G P L A S T I C S U R FAC E S

Where JDN Air Hoists or JDN Air Winches feature plastic parts, these surfaces must only be cleaned using a damp cloth (cleaning cloth with water). This reduces electrostatic charging that can arise due to mechanical friction at the plastic surface.

DA N G E R !

Electrostatic charging may occur at the plastic surfaces, potentially leading to electrostatic discharge that can ignite gases and air mixtures.

AC E T Y L E N E A N D C OP P E R

When operating JDN products in explosion-hazardous areas, in which an acetylene-containing atmosphere can occur, it must be ensured that copper-plated parts are kept dry, in order to exclude the possibility of oxidation of the metallic copper and the formation of a aqueous phase, which is capable of reacting with acetylene and which can result in an explosion hazard.

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EXPLOSION GROUPS AND TEMPERATURE CLASSES OF THE MOST IMPORTANT GASES AND VAPOURS (-SELECTION-)

(in accordance with DIN VDE 0165 6 , Redeker 7 , Nabert, Schön 8 , IEC 60079-12 3 and IEC 60079-20 4 )

Ex group

II A

II B

II C

T1 T2


T3 T4


300-200° C 200-135° C

T5

> 450° C 450-300° C

Hydrocyanic acid

(Ethyl bromide)

Butadiene-1,3

Dioxane-1,4


(Nitrobenzene) (Ethyl alcohol)

Town gas Ethylene

(ethylene glycol)

**Ethylene oxide

Isoprene

(n-Propyl alcohol)

135-100° C

450° C


300° C 200° C

Acetone

Ammonia

Aniline

(Ethyl alcohol)

(Ethylene glycol) i-Amyl acetate n-Amyl alcohol

Benzene

(petrol)

Benzol

Chlorobenzene n-Butane n-Butyl alcohol

Diesel

Fuel oil

1,2-Dichlorobenzene 1-Butylene

Acetic acid 1,2-Dichloroethane n-Hexane jet fuels

Ethane

Ethyl acetate

(Ethyl bromide)

Ethyl chloride

Di-i-Propyl ether

Natural gas

Acetic anhydride n-Propyl acetate

(Carbon monoxide) (n-Propyl alcohol) o-Cresol i-Propyl alcohol

Methane

Methyl acetate

Vinyl chloride

Methyl alcohol*1

Methyl bromide

Methyl chloride

Methylene chloride

Naphthalene

(nitrobenzene)

Phenol

Propane

Toluene o-Xylene

135° C

Acetaldehyde

100° C

Dimethylether

**Hydrogen sulfide

Ethyl ether

Ether

Anaesthetic ether

Diethyl ether

**Hydrogen **Acetylene

T6

100-85° C

85° C

**Carbon disulphide

( ): The measured values for the substances placed in brackets are close to the limit or the next group or class when classified in the explosion groups or temperature classes. For this reason, they have been included in both.

**: Extremely flammable substances (cf. additional marking ”X”)




DECISION CRITERIA FOR SELECTING THE CORRECT JDN HOISTS

IN EXPLOSION-HAZARDOUS AREAS

Explosion groups of gases and vapours

(See Explosion groups and temperature classes of the most important gases and vapours)

II A

II B (X)

II B

II C / T4 except hydrogen sulphide, ethylene oxide

(particularly flammable)

II C / T6(X)

Explosion-hazardous dusts


Light-metal or impact-sensitive dusts

1

1

1

1

1

Zone

21

21

Zone

2

2

2

2

2

22

22

A

A

A

Version* 1

Manufacturer’s responsibility

A FS

A FS

A FS

A FS

A FS FSR

A FS

A FS FSR

Version* 1

A

A

A FS

A FS

D

D

Operation* 2

Operator’s responsibility

E

E

E

E

E

E

D

D

D

D

D

E

E

E T

D E T

Operation *2

E

E

E

E


A: The chain is made of zinc-plated steel; metal controls are conductively connected to the hoist. This is part of the standard equipment. For technological reasons, a zinc-plated version of chain size 31.5 x 90 is not available. This is only 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: 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 made of bronze.

*2: Instructions for safe operation (operator’s responsibility):

D

E

T


: Friction, impact and sliding points involving combinations of light metal and steel or cast iron must not be present in the hoist’s operating area.




T E M P E R AT U R E L I M I T S F O R E X P L O S I O N -

H A Z A R D O U S D U S T S

In areas which are explosion-hazardous due to combustible dusts, the surface temperature must not exceed two-thirds of the ignition temperature in ° C of the dust/air mixture. The temperatures of surfaces on which hazardous deposits of combustible dusts can be formed, must not exceed the glow temperature of the relevant dust minus 75K. Greater safety margins are required if the thickness of the dust layer exceeds 5 mm.

The corresponding surface temperatures can be derived from the lowest values for glow and ignition temperatures of dusts specified in the HVBG/BIA Report

12/97 10 ”Combustion and explosion characteristics of dusts”:


Glow temperature 220° C – 75° C = 145° C max. permissible surface temperature

Stearic acid:

Ignition temperature

190° C x 2/3 = 126° C max.

temperature permissible surface.

P L E A S E AL S O O B S E R VE YO U R

C O R R E S P O N D I N G N AT I O N AL


1 Guideline 94/9/EC of the European Parliament and the Council dated 23rd March 1994 on the adaptation of the laws 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 1: Basic concepts and methodology, 1997-10

3 IEC 60079-12: Electrical apparatus for explosive gas atmospheres, Part 12: Classification of mixtures of gases and vapours with air according to their maximum experimental safe gaps and minimum igniting currents, 1978

4 IEC 60079-20: Electrical apparatus for explosive gas atmospheres,

Part 20: Data for flammable gases and vapours relating to the use of electric apparatus, 1996-10

5 EN 13463-1: Non-electrical devices intended for use in explosive areas - part 1: Basic methodology and requirements,

07/2009




9 DIN EN 50014 (VDE 0170/0171 part 1): 2000-02

Electrical apparatus for use in explosion hazardous areas: General provisions

10 HVBG/BIA report 12/97: Central association of German employer’s liability associations /trade association institute for industrial safety




JDN Air Hoists are designed for lifting and lowering loads within the specified load-carrying capacities, with a vertically-arranged chain. JDN Air Hoists from the ranges PROFI 3 TI to 20 TI are also suited to pulling loads horizontally. Please also observe the individual national 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 impermissible. Oblique pulling, see

Operation section, page 29. J.D. NEUHAUS GMBH & CO.

KG cannot be held liable for any resulting damage. The entire risk is borne by the user (see also Rules for safe operation of hoists, page 29).



The noise emission data can be found in the Technical data table, pages 64 and 66.





OP E R AT I N G C O N D I T I O N S

JDN Air Hoists are extremely robust and require little maintenance. They are suitable for use in explosionhazardous areas, as well as in areas with increased concentrations of soot and dust, high humidity and at ambient temperatures of -20° C up to approx. +70° C if they are not heated above this level due to external influences. The thermal endurance of chains and hooks is +150° C.

C AU T I O N !

When touching metallic hand controls which are colder than 0° C, the skin could freeze within a few seconds, and for temperatures above 43° C, burns can occur. As a protective measure, please wear suitable gloves.


Depending upon the version, JDN Air Hoists 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:

왘 The brake will drag and is thus subject to a high degree of wear. An impermissibly high degree of warming could take place.

왘 The controls become noticeably less sensitive.

DA N G E R !

Warning against excessive system pressures

Operating with excessive system pressures results in danger due to overloading.

Therefore, the pressure must be limited to that specified on the nameplate.

JDN Air Hoists must be operated with a sufficiently clean and dry air supply. The air supply must fulfil the following quality requirements:

왘

왘


Particle density less than 10 mg/m 3

(corresponds to Class 7 in accordance with ISO 8573-1:2001)




왘 Pressure dew point at least 10° C below the lowest expected ambient temperature.

Do not operate JDN Air Hoists with other gases!



Icing can be prevented by:

왘 the use of an upstream air dryer or using a service

왘 unit with oiler, adding anti-icing agent to the lubrication oil

왘

(depending upon moisture content of compressed air) or using compressed air oil (Art. no. 11900) with anti-icing agent for relevant temperatures.

In the event that your JDN Air Hoist is operated in combination with a trolley, please also read the trolley operation manual and the relevant accident prevention regulations for operation with trolleys.



E N E R G Y R E Q U I R E M E N T S

For air pressure, air quantity and connections, see the

Technical data table in the hoist operation manual concerned.

A I R P R E S S U R E C O N D I T I O N S I N OP E R AT I O N



The value of the actual pressure p2 at which the hoist is operated, depends upon

왘

왘 the weight of the load and the direction of movement of the load.



Example:


The value of the actual pressure depends upon … … the weight of the load …


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Page 17


P R I N C I P L E O F OP E R AT I O N O F

J D N A I R VA N E M OTO R S



The vanes can move freely and make contact with the inner wall 5 of the cylinder liner. Each chamber is formed by two vanes 6 .







4.2

1 6 4.1

2 5

8 3 4 7



OP E R AT I O N W I T H O U T C H A I N B OX

DA N G E R !

If JDN Air Hoists are operated without a chain box it must be ensured that the idle chain (unloaded chain end) running up or down at the chain sprocket, does not present a hazard, e.g. due to catching, impacting or falling.

Danger due to falling chain can also arise, if the idle chain is first deposited on a load with a large surface and then slides off and drops.

M OTO R L U B R I C AT I O N /

OP E R AT I O N W I T H A S E R V I C E U N I T

JDN Air Hoists are provided with motor lubrication which must be renewed when required, but every 5 years at the latest. Therefore, the service unit for filtration and pressure-regulation of the compressed air can be 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. Alcohols are not permitted for use as anti-icing agents.

M A R K I N G / D E C L A R AT I O N O F

I N C O R P O R AT I O N

Only hoists for which EC conformity in accordance with

EC Machinery Directive 2006/42/EC has been declared may be operated within the EU.

In the case of a designation, only the EC conformity declaration provides information on which EC directive has been met.



GMBH & CO. KG accepts no liability for the use of non-original components and/ or modifications by unauthorised persons.




SA F E T R A N S P O R TAT I O N


왘

왘

Carefully dismount trolley (if available).

Set the entire hoist down carefully; do not allow it to drop. See Technical data, page 64 and 66 for information on weights.

왘 Lay control and supply hoses together in such a way that they are not kinked.

왘 Please ensure that the controls are not damaged.

Could lead to malfunctions.

왘 Draw in the hoist’s chain in such a way that loops cannot form and the chain cannot become twisted.

왘 Secure the chain.

S TO R AG E C O N D I T I O N S

B R E A K S I N OP E R AT I O N

왘 In the case of longer operational breaks, coat the

왘 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 conserved. For this purpose, use a non-resinous and non-sticky conserving oil with a conserving protection duration which corresponds to the length of the planned operational break.

S TO R AG E

왘 Close off the air supply hose connection using adhesive tape or a suitable cap, in order to prevent

왘

왘 dirt ingress.

Protect the air supply hose from being damaged.





U N PAC K I N G

C AU T I O N !

When unpacking, take account of the weight of the hoist. See Technical data, page 64 and 66.


Do not kink the control lines. Kinked control lines can result in malfunctions.

왘 Keep the accompanying documents in the place

왘

왘 provided, near the operating site.


Dispose of packaging in the local recycling system.

A S S E M B LY



왘

왘

왘

Connecting the controls

Chain box , page 63

, page 22

Removing and installing chain , page 57


P R I O R TO I N I T I AL OP E R AT I O N , T H E C H A I N

M U S T B E L U B R I C AT E D ( S E E L U B R I C AT I N G

T H E C H A I N S E C T I O N , PAG E 4 3 ) .

I N S TAL L I N G T H E H O I S T

DA N G E R !

JDN Air Hoists must only be installed by qualified personnel. Faulty installation can lead to severe accidents.

DA N G E R !

The attachment points for JDN Air Hoists must be able to safely withstand the expected forces.

DA N G E R !

The supporting structure of the air hoist must form a rigid mounting. Vibration damages the chain and can lead to chain fracture.

Furthermore, external vibration must on no account be transmitted to the hoist (lifting gear). (e.g. from the suspended load).

왘

왘


Attach the hoist at the suspension hook

(or suspension eye) to the running gear or a stationary fixing.

왘 Ensure that the hook safety catch closes automatically.


DA N G E R !

When loads are taken up suddenly on slack chain, especially using hoists with high lifting speeds, forces are generated which may be equivalent to several times the load weight.

Type

PROFI 3 TI

PROFI 6 TI

PROFI 10 TI, EH 10

PROFI 16 TI, EH 16

PROFI 20 TI, EH 20

Force

1.4-times load-carrying capacity







C O N N E C T I N G T H E C O N T R O L S

C O N N E C T I N G T H E R OP E C O N T R O L S

왘 Knot both control ropes at the ends of the control lever.

왘 Knot the green pin into the rope which activates

”lift” mode, with the pointed end upwards (also see

Rope control illustration, page 34).

왘 Knot the yellow pin into the rope which activates

왘

"lower" mode, with the pointed end upwards.


E - C O N T R O L C O N N E C T I O N


왘

왘

왘

왘 Guide the strain-relief cable through the eye on the pushbutton valve and secure using the cable clamp.





Pushbutton valve with nipple and rope with designation lift and lower



왘 Secure the hoses using the one-ear hose clamps and crimping tool.


To ensure perfect sealing, the ”ear” must be fully closed on installation.

Installation example

Position the clamp on the hose with nipple.

Crimp the clamp ear until fully closed.

Permissible aperture after crimping

Use of the normal crimping tool ...

Pinched one-ear clamp and crimping tool in order to remove the clamp, set the crimping tool transversely to the clamp ear and cut the ear open …

왘 The bellows must be pulled over the other end of the hose bundle including the strain-relief cable (coat hose bundle with oil for ease of fitting). Pull the bellows back far enough to permit further installation. Push the one-ear clamps onto the free ends of the hoses.

Removal

Illustration of bellows with hoses and strain-relief rope



Control valve (on motor)

Note: In order to connect the hoses to the control valve, we recommend removal of the hose adapter.

왘

왘

Remove the hose adapter (secured via central bolt).

Attach the hoses to the corresponding nipples (see designation in illustration).

왘 Secure the hoses using the one-ear hose clamps and crimping tool.

왘 Secure the strain-relief cable.


The strain-relief rope must be installed with the correct length in order to prevent loading of the hoses.

왘 Pull the bellows over the hose adapter. The upper collar of the bellows fits into the recess of the hose

왘 adapter.

In order to secure the hose adapter to the control valve, a long A/F 6 socket spanner must be guided between the three hoses, through the middle of the bellows and inserted into the hexagon socket of the bolt.

F - C O N T R O L C O N N E C T I O N


For F-control for lifting and lowering only, remove approx. 80 mm of hose bundle protective sheathing; for F-controls with additional functions (trolley/crane movement) remove approx. 160 mm from end of protective sheathing.

Pull the strain-relief ropes through the eye bolt and secure them using rope clamps.

Insert the control hoses: See illustration above


Movement direction ”lift” hose designation 2 or colour: green

Movement direction ”lower” hose designation 3 or colour: red

Lower

Dowel pin

Compressed air connection

Hose adapter with nipples designation lift, lower

Bellows with A/F 6 socket spanner

Raise



The control hoses for the drive motors (trolley/crane movement) must be extended, outside of the bellows, by means of plug-in connectors and additional control hoses.

Connection see ”Trolley” operation manual.




F I - C O N T R O L C O N N E C T I O N

Pull the bellows over the hose bundle for F-control. Remove approx. 80 mm of hose bundle protective sheathing.













R E P L AC I N G C O N T R O L S

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 exchange air controls E, F or FI, proceed as follows (see illustrations in Connecting the controls section)

C O N VE R S I O N F R O M E TO F






Detach the strain-relief rope and remove the one-ear clamps (see Removal illustration, page 23).

Cut off the hoses below the hose nipples using a knife.

Unscrew the hose nipples (A/F 17).

Pull the bellows over the hoses of the E-controls. This is also required for the F-controls.



Remove approx. 80 mm of the hose bundle protective sheathing or 160 mm for additional movements.

Screw the ”straight screw connections” (Steckfix) for


Pull the strain-relief ropes through the eye bolt and secure them using rope clamps.










Pull the bellows over the hose adapter and secure via the central bolt, (see page 24, bottom).

C O N VE R S I O N F R O M E TO F I

Removal of E-controls as previously described (page 25).


Pull the bellows over the hose bundle for FI-control. Remove approx. 80 mm of hose bundle protective sheathing.

Screw the ”straight screw connections” (Steckfix) for














CONVERSION FROM AIR CONTROL TO ROPE CONTROL


Only air controls without upstream mainstream valve can be converted to rope control.

Removal of air controls



The cover ”1” in the axis centre must be removed

(M 6 bolt, A/F 5).


The connecting surface of the hose adapter on the valve housing is closed off with a disc, (from conversion kit

Art. no.: 13590, item 10) and is secured with the M 8 x

16 countersunk screw (item 50).

The dowel pin (roll pin, item 70) must be inserted in the bore ”2” provided.

Insert the rope control lever connector (item 20) into the cover bore with the lug ”3” facing upwards; push on the control lever (item 30) and secure with the M6 x

35 bolt (item 40) and washer (item 60).

Guide the control ropes ”4" through the bores ”5" in the lever and knot them. Rope colour: ”green” lift,

”red” lower. Further, see section Connecting the rope controls , page 22.




C O N N E C T I N G TO T H E M A I N A I R S U P P LY

왘 Check air connection for contamination and clean if

왘 necessary.

Blow through compressed air hose in order to remove

왘 foreign bodies.



The following lubricants are intended for normal environmental influences.

In the case of wear-promoting environmental influences, please contact J.D. NEUHAUS, to receive the appropriate instructions.

C AU T I O N !

Oils and greases can cause skin irritation.

Wear protective gloves.




Synthetic lubricants must not be used when operating with oilers.

Alcohols are not permitted for use as antiicing agents.




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 mm 2 /s (cSt) at 40° C, with anti-icing agent where applicable

Chain lubrication chain oil or motor vehicle engine oil, kinematic viscosity approx. 150 mm 2 /s

(cSt) at 40° C, or special lubricant from J.D. NEUHAUS

In areas with very high corrosion potential, e.g. offshore, a lubricant with extremely strong anti-corrosion properties must be used.

Motor conservation


Non resinous

Conservation oil with

JDN high-performance grease) appropriate period of effectiveness

Motor cleaning


JDN high-performance grease)

Pure petroleum

Lubrication of bearings and gearbox (also for exposed gears)

Lithium-thickened grease, worked penetration 265-295

(0.1mm), basic oil viscosity:

190 cSt (mm 2 /s) at 40° C, drop point: 180° C,

Working temperatures:

- 20° C to + 120° C, designation in accordance with DIN 51825: KP2K-20, active agents:

EP additives (for wearreduction) and ageing protection; water resistant and corrosion protection

A copy of the special publication ”Recommended lubricants” is available on request.

C H E C K I N G P R I O R TO I N I T I AL OP E R AT I O N

Hoists, including the supporting structure, must be inspected by an appropriately trained and qualified person before initial operation and before recommissioning after significant modifications. Hoists and lifting gear which are installed in trolleys must be inspected by a specialist.

The inspection covers the proper mounting, equipment level and operational-readiness, 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 the supporting structure.


A description of the inspection can be found in the



OP E R AT I O N

OP E R AT I O N

R U L E S F O R SA F E OP E R AT I O N

O F H O I S T S

As an operator of hoists, you are responsible for your own safety and for that of your colleagues in the working area of the hoist.

왘 Hoists may only be operated by persons charged with this task by their company.

왘 Before using the JDN Air Hoist for the first time, familiarise yourself with all permissible operating conditions. For this purpose, read through this operation manual thoroughly and perform the

왘 described actions on the crane, step by step.

Report each malfunction to your safety officer immediately, so that the fault can be remedied

왘 without delay.

Adhere to the regulations of the accident prevention authorities (e.g. Berufsgenossenschaft regulations in

왘

Germany).

Always comply with the information in the Intended use section on page 15.

The following uses are classified as impermissible:

왘 Oblique pulling of loads in general.


Oblique pulling is the deviation of the load chain and the chain hoist 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.

Oblique pulling

Under special safety provisions relevant to the particular situation, JDN Air Hoists may be used for oblique pulling (see Intended use , page 15).

In this case, a chain box must not be used as the chain may fall out or become knotted.

Oblique pulling is not permitted for hoists installed in trolleys or in running gear. Please contact us, if required.

왘

왘

왘

왘

왘

왘

왘

왘

Detaching or dragging of loads.


Catching of falling loads.

Carrying persons (see Intended use


, page 13).

Switching to the opposite direction with load in motion.

Operational reaching of lifting and lowering limiters.

Allowing the safety clutch to slip following actuation due to overload (PROFI 3 TI - 20 TI, EH 10 - EH 20).

왘 Never hold the chain in the area of the centre section under tension at the upper or lower limit position of the load hook.


OP E R AT I O N


왘

왘


Over acid baths or other facilities containing corrosive

왘 substances.



왘

왘

왘

왘

왘

Lift the load carefully at the beginning.





왘 When operating without a chain box, avoid hazards due to idle chain (falling, catching, impacting), see section Operation without chain box, page 19.

왘

왘

왘

왘

왘

왘

왘

Never apply bending loads to chains.

Do not join or repair hoist chains.


Check blocked chains for damage.


Do not operate with damaged, worn or rusty chains.

Permissible operating temperature for chain and hook: - 40° C to + 150° C, permissible ambient temperature: - 20° C to + 70° C, permissible heat

왘 absorption of the hoist body: max. 90° C.


왘 Never attempt to remedy a fault with a load suspended from the hoist.

왘 Only use suitable and approved attaching aids; do not jam the hook at the point of attachment.

왘 Please ensure that the operator is not put at risk within the operating area by attaching aids or the load.

왘

왘


Before attaching, accurately position the load vertically below the hoist. The chain must hang vertically

왘

왘 before lifting.


Before lifting loads, ensure that the maximum permissible load is not exceeded. Attaching aids must be included in the weight of the load.

왘 During lifting and lowering, prevent accidents by ensuring that the load remains stable and does not

왘

왘

왘 tilt or fall.

Never drive against jammed loads.


Only lift one load at a time; never several loads

왘 simultaneously.

Never lock the control elements of the control devices.

왘 If the control elements become difficult to operate have the hoist repaired.

왘 In the case of power failure, secure the load and the surrounding area, until the power is restored.

왘 Never use or repair bent, open or deformed load hooks. The hoist must be repaired and the hook

왘

왘 must be replaced.


Only operate JDN Air Hoists with controls .

original JDN

왘

왘

왘

왘

왘

왘

왘

왘

왘

왘 Uncontrolled, external force factors (such as due to hydro cylinders, falling loads) are not permitted.





Repairs department.

왘 Before removing compressed air hoses, shut off the compressed air supply.

왘 Do not exceed the permissible capacity of the chain box.

Repair the hoist if the braking distance is excessive.




Never touch metallic hand controls which are colder than 0° C or hotter than 43° C, without suitable

왘

왘 protective gloves.



J.D. Neuhaus

GmbH & Co. KG accepts no liability for the use of non-original components and/or modifications by unauthorised persons.

왘 Do not switch on multi-chain hoists if the bottom block is supported.

왘 Special safety precautions must be taken when lifting loads into areas which are out of sight.


OP E R AT I O N

DA N G E R !

For all air hoist applications, ensure that the load hook can be lowered all the way to the ground, in order to prevent a load being moved to the lower limit position, without reaching the ground. Danger due to overloading.

DA N G E R !

Never use hoists on the ground if they are not specifically intended for horizontal pulling.

DA N G E R !

The fatigue strength of chains is significantly impaired due to extreme corrosion (pitting corrosion). This causes a danger of fracture .

Hydrogen-induced embrittlement with resultant stress cracks due to highly corrosive media (e.g. sea water) may affect highstrength steels (e.g. chains). Danger of fracture! This process is promoted by socalled recombination poisons. Examples of these are hydrogen sulphide, cyanide, arsenic compounds and rhodanide. If rusty chains are not replaced for operational reasons, crack inspections are to be carried out at intervals of three months.


In the case of particularly difficult lifting equipment applications, the company must provide comprehensible operating instructions in the language of the operator, within the framework of this operation manual. Here, measures for safe operation are stipulated in accordance with prevailing operating conditions.

Furthermore, it is essential that all the regulations set out in sections Intended use , page 15 and Operating conditions, page 15, are observed. powered by air !

Page 31

OP E R AT I O N

C O N T R O L S

JDN Air Hoists can be equipped with a variety of control devices. They are all suitable for use in explosion-hazardous areas.


C O N T R O L VALVE O N M OTO R

Air control (E-, F-, FI-control) with MS

Control valve with upstream main-stream valve



2. Direction control valve as rotary valve

3. Positioner (pneumatic actuation)

The main-stream valve lies upstream from the rotary valve. If no control pressure is present, this valve is closed and the rotary valve is depressurised. If control pressure is applied from the hand control, the valve opens and releases the main stream.


The rotary valve 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



2. Positioner (pneumatic actuation)


The positioner is actuated by the control air.

Rope control

Control valve without upstream main-stream valve



2. Positioner


For the purpose of actuation, the rotary valve is directly connected to the control lever.

E - C O N T R O L


왘

왘



Page 32

E-control with EMERGENCY STOP button powered by air !

OP E R AT I O N

P U S H B U T TO N F - C O N T R O L

With pushbutton F-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.

왘

왘




P U S H B U T TO N F I - C O N T R O L


왘 Lift: Carefully press the right pushbutton. The load is

왘 lifted slowly.

Press the pushbutton further down in order to

왘 increase the lifting speed.

Release the pushbutton slightly in order to reduce

왘 the lifting speed.

Lower: Carefully press the left pushbutton. The load

왘 is lowered slowly.

Press the pushbutton further down in order to

왘 increase the lowering speed.

Release the pushbutton slightly, in order to reduce the lowering speed.




OP E R AT I O N

E M E R G E N C Y S TOP D E V I C E



In order to avert danger arising from the lifting movement as quickly as possible, the pushbuttons must be released; the movement of the load is interrupted immediately.

Only in the case of failure of this stop function, must the red EMERGENCY STOP button be firmly pressed. The

EMERGENCY STOP button engages. This results in the closing of a separate check valve and the load hook comes to rest instantaneously. The pushbuttons for lifting and lowering now no longer function.


DA N G E R !

Never release the EMERGENCY STOP button before the danger has been eliminated and the stop function via the pushbuttons has been restored.

R OP E C O N T R O L



(reversing valve), are positively connected to one another. 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 EMERGENCY

STOP device is required.

왘 Lift: Carefully pull on the green rope with the green

왘 handle pin. The load is lifted slowly.

Pull harder on the rope, in order to increase the

왘 lifting speed.

Release the rope slightly in order to reduce the lifting speed.

왘 Lower: Carefully pull on the red rope with the yellow

왘 handle pin. The load is lowered slowly.

Pull harder on the rope, in order to increase the

왘 lowering speed.


Rope control

OVE R L OA D P R OT E C T I O N

Your hoist is equipped with a direct-acting overload protection in the form of a new type of safety clutch.

This safety clutch limits overload to 120 % of loadcarrying capacity, without the danger of failure due to the load running back.


DA N G E R !



OP E R AT I O N

In Germany, the trade association regulations ”Operation of load carrying devices used with lifting equipment”

(BGR 258) must be adhered to. In other countries, the relevant local regulations must be observed.

왘 Attaching aids must be attached at the lowest point

왘 of the hook. Never load the point of the hook.


Attach the load safely




왘 First, lift the load hook, in order to pull the slack chain tight. With the chain tight, briefly interrupt the lifting procedure. The hoist can align itself and

왘 the material is protected.

Then lift the load.

The overload protection system aborts the 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).


DA N G E R !


왘 Then lower the load and ground it carefully.

DA N G E R !

For all air hoist applications, ensure that the load hook can be lowered all the way to the ground, in order to prevent a load being moved to the lower limit position without reaching the ground. Danger due to overloading.


왘 Lower the load hook far enough, so that the load

왘 can be easily detached.


I N T E R R U P T I N G WO R K I N G

If you wish to interrupt working with your JDN Air

Hoist:

왘

왘






S H U T T I N G D OW N


왘

왘


Move the load hook out of the lifting area, in

왘 order to avoid hazardous situations.

Do not move against the lifting and lowering

왘 limiters/ buffer (emergency end-stop devices).


S TO R AG E




JDN Air Hoists must only be dismantled by qualified personnel.

왘

왘

왘

왘

왘

왘

왘





Detach the control hoses from the hoist. Do not kink the control hoses.


Detach the strain-relief and hose carrier and remove

왘

왘 the control device.

Carefully detach/ dismount the hoist and remove.


D I S P O SAL

JDN Hoists contain a range of materials which, on expiry of the service life, must be disposed of or recycled where appropriate, in accordance with statutory regulations.


H O I S T

왘 Ferrous materials

Steel

Nodular cast iron

왘 Non-ferrous metals

Bronze

Aluminium

왘 Plastics polyurethane polyoxymethylene polyvinyl chloride polyamide, glass-fibre reinforced natural rubber polypropylene phenol resin thermoset moulding compound

(asbestos-free brake lining) synthetic rubber

F I LT E R S I L E N C E R / S E R V I C E U N I T:

Zinc diecast

Brass

Nitrile rubber

Aluminium

Polypropylene

Polyurethane


Steel

Polyacetal

Polyethylene





I N S P E C T I O N I N T E R VAL S

JDN Air Hoists are extremely robust and require little maintenance. Compliance with maintenance and inspection intervals is of great importance in order that the hoist operates safely and reliably over a period of many years.

C AU T I O N !



If your JDN Air Hoist is often used at different locations, particularly in dirty and damp environments,

왘

왘

왘 clean any dirt off the hoist and the chain, seal off the air supply connections, protect the hoist and, in particular, the chain from corrosion,

왘 store the hoist in a clean and dry place.





I N S P E C T I O N A N D R E PA I R S

Series lifting equipment is classified into groups and dimensioned according to the type of operation (Driving mechanism classification according to ISO/FEM).

The classification is determined by the average daily operating time and the load spectrum. This is provided that the lifting and lowering paths are approximately the same.




.


f v

= 1+ 0.5

P-50

50

(for P > 50%)





Only if the group classification corresponds to the actual type of operation of the lifting equipment, does a safe operating period conform to the theoretical operating time. Deviations of the actual type of operation from that used for calculation extend or shorten the safe operating period.




C AU T I O N !




I N S T R U C T I O N S C O N C E R N I N G T H E

” M O D E L F O R D E T E R M I N I N G T H E

AC T UAL OP E R AT I N G T I M E

”


Weight of harness


≤ 0.05

The decisive factors for the type of operation are the collective loads with different cubic averages k .

The collective load indicates to what degree a driving mechanism, or a part of one, is subjected to its maximum stress or only to smaller stresses. The cubic average

(factor of the load spectrum) is calculated using the following formula.

To determine the type of operation for calculating the partial operating times (actual operating time), the following collective load diagrams can also be used.

Definitions:

=

Maximum or ultimate load


=

Dead load


=

Operating time with maximum load or partial load and dead load


=

Operating time with dead load


Collective load 1

0.4

t

1

0 10 t

2

50

0.1

t

Δ

100

Collective load 3

0

0.4

t

1

50 t

Δ

100

Collective load 2

0.733

0.467

t

1 t

2 t

3

0 16.7 33.3

50

0.2

t

Δ

100

0

Collective load 4 t

1

0.8

t

Δ

90 100

The FEM* 9.511 rule differentiates between four collective loads, which are identified by the definitions and by the ranges of the cubic averages k . This classification complies with ISO 4301/1.

*FEM = Federation Europeene de la Manutention (European

Federation of Materials Handling and Storage Equipment)

Collective load

1

(low)

Definition

Cubic average


≤

0.50

to the maximum stress in exceptional circumstances, and are only subject to very lowstresses continuously.

2

(average)

L2 Driving mechanisms or parts thereof, which are subject to the maximum stress often, and are only subject to low stresses continuously.

0.50 < k

≤ 0.63

3

(high)

4

(very high)

L3 Driving mechanisms or parts thereof, which are often subject to the maximum stress and are subject to average stresses continuously.

L4 Driving mechanisms or parts thereof, which are regularly subject to the maximum stress of adjacent stresses.

0.63 < k

≤

0.80

0.80 <

≤ 1.00

k

Collective load factor k m

= k 3 = 0.125

k k m k m m

= k 3

= k 3

= k 3

= 0.25

= 0.5

= 1



MODEL FOR DETERMINING THE ACTUAL OPERATING TIME

The following calculation compares the actual operating time with the theoretical operating time in collective load 4

(very heavy).

1 2 3 7

Operating site


Collective load factor in accordance withcollective load for the type of operation

L1 L2 L3

Low Average High

L4

Very high

4 5

Partial deployment


Remaining theoretical use in collective load 4


6

Date

Delivery

Initial operation

Inspections


Signature


Delivery date

GmbH & Co.KG

– 0 0.125

0.25

0.5

1 0 M2 (1Cm) 200 hours

M3 (1Bm) 400 hours

M4 (1Am) 800 hours

M5 (2m) 1600 hours

Initial operation

CALCULATION MODEL (DRIVING MECHANISM CLASSIFICATION M3)


1.5

0.25

1.5 x 0.25 x 250 x 1.2

= 113 hours

(400 - 113)

287 hours

2nd August

2004

A.N. Other






Check oil level for motor lubrication (when operating with oiler)

Lubricate the chain

Visually check the chain

Interval

Daily

As required

Weekly

(

(

Comment

Filling and adjusting oiler

Lubricating the chain section, page 47) section, page 43)


Check control device

Checking braking function

Checking direction of movement


(buffers) visually


Check chain

Interval

Daily

Daily

Daily

Daily

Comment

( Checking controls section, page 44)

( Checking braking function section, page 43)

( Checking direction of movement section, page 44)



Check brakes with load

Daily

Every 3 months

Annually

Annually

( Checking chain, chain sprocket and chain guides section, page 54) In the event of wear promoting operating conditions, reduce intervals between checks

( Checking lifting and lowering limiters section, page 43)

Load must be braked reliably ( Checking braking function section, page 43)

Check all the bolted and pin connections

Check load hook on load a. carrying side

Check the motor, check, clean and grease the control valve (JDN highperformance grease)

Check the axial movement of the hooks and eyes

Check the service unit 1

Check the silencer for permeability

Check overload protection

Annually

Annually

Annually

Annually

Annually

Annually

Annually

(


(

(

Check dimensions

Checking axial play

Service unit page 59) section, page 55) section, page 56) section, page 45)

( Checking silencer for permeability section, page 44)

( Checking and adjusting overload protection section,

Check compressed air connections for damage

1 If appropriate

Annually




Check sealing efficiency and function of control valve

Check condition of the chain box 1 including mountings

Check for brake wear and motor vane wear

In off-shore areas and other similar corrosive environments, replace the chainregularly

Check gearbox and perform lubricant change

Check the rotor/pinion shaft connection and lubricate with gear grease

Check the chain sprocket bearings and lubricate if necessary

Check chain sprocket and chain guides

Renew grease lubrication of motor

Interval

Annually

Annually (

Comment

Chain box section, page 63)

Every 200 hours, at least every 5 years

(Replacing brake disc, brake piston and vanes section, page 48), replace motor vanes every 5 years

Every 5 years

Every 5 years

Every 5 years

Every 5 years

Whenever chain is replaced

When required, at least every 5 years

( Wear dimensions section, page 56)

( Motor lubrication section, page 48)

1 If available

For monorail hoists, also refer to ”Maintenance and inspection measures” in the Trolley operation manual .



L U B R I C AT E T H E C H A I N

The chains of JDN Air Hoist must be lubricated in the links, in unloaded condition.

왘

왘

왘




If you wish to lubricate the hanging chain, ensure that the chain links are oiled at the points of contact. For this purpose, move the chain to and for.

A high-performance lubricant in an aerosol can is available from JDN, which adheres well to the chain after the solvent has evaporated and does not drip off,

Art. no. 12066 (aerosol 400 ml).

For operation in areas with high corrosion potential, e.g. in the off-shore sector, the chain can be largely protected against corrosion by the use of special lubricants.

These types of lubricants are characterised by weathering resistance, water insolubility, good adhesion properties etc.

Re-lubrication intervals must be stipulated in accordance with the loading.

Please contact us, if required.

C H E C K I N G B R A K I N G F U N C T I O N


왘 Switch the unloaded air hoist alternately between lifting and lowering modes.


DA N G E R !



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 be perceptible.When checking the braking function under nominal load, the following braking distances must not be exceeded:

B R A K I N G D I S TA N C E S U N D E R N O M I N AL L OA D


H A S B E E N S TOP P E D

Type 3 TI 6 TI 10 TI 16 TI 20 TI

EH 10 EH 16 EH 20

36 15 18 10 8 Rope control

All others

Controls with hose 48 lengths of 2 m

Dimensions in mm

22 26 14 11




왘 Move the unloaded load hook until just short of the

왘 upper and lower end positions.


왘 The movement of the chain must be stopped due to deformation of the buffer and activation of the safety clutch. The motor is however not switched off (only

왘 allow the safety clutch to act for a short time).


DA N G E R !





E M E R G E N C Y S TOP F U N C T I O N


왘

왘


Briefly actuate and release all control elements of the controls one after another. The control elements must return to their initial positions immediately. The switching on and off function must operate correctly.

왘 PRESS the EMERGENCY STOP button. Each movement of the hoist must stop. Actuation of the control elements must not cause a lifting or lowering

왘 movement.

RELEASE the EMERGENCY STOP button by turning.

DA N G E R !

If a control element is stiff or remains in the actuated position, do not use the hoist. The controls must be repaired.

C H E C K I N G T H E M A I N A I R

E M E R G E N C Y- S TOP VALVE

The main air emergency-stop valve is opened with each actuation of the controls. It closes when the controls are released.

With each check, the working order of the valve must be examined as follows:

왘

왘

왘

왘 Shut off the compressed air supply and unload the line.

Remove retaining ring

Pull out cover

Press plunger 3

2 .

1 .

inwards against the force of spring 4 .

왘

It must return again due to the spring force.

If the plunger does not move, the valve must be repaired.

C H E C K I N G D I R E C T I O N O F M OVE M E N T

왘 Check that the direction of movement of the load hook corresponds to the direction indicated by the arrows on the control elements.

C H E C K T H E S I L E N C E R

F O R P E R M E A B I L I T Y

Independent of the stipulated inspection intervals, the silencer must be checked for permeability if the hoist does not achieve the specified lifting speed

(see Technical data section, page 64 and 66).

The test is performed by comparing the lifting speeds under nominal load, with and without the silencer.

The speed with standard silencer or filter silencer must be at least 80 % of the lifting speed without a silencer element. In the event of lower values, the silencer elements must be cleaned or replaced.

4

2

Main air emergency-stop valve

3 1





If a hoist is operated with a service unit, this should not be mounted further than 5 m away from the hoist.

The ambient temperature must be a minimum of 0° C.

It must not exceed 50° C.

N OT E : If, at the request of the customer, a service unit is installed in hoists in motorised trolleys and lifting gear, it will be configured at the factory.

A maximum connecting pressure of 10 bar is permitted for the service units supplied by JDN. Higher pressures must be reduced to a permissible value, upstream of the service unit.

The service unit consists either of two elements, filter controller and oiler, or of the filter controller only.


C O N T R O L L E R

* )

The filter controller is set to an actual pressure of 5.4

bar (3.6 bar) in the factory (actual pressure when lifting the nominal load). In this setting, the manometer can indicate a pressure of over 6 bar (4 bar) with the motor switched off. For correct adjustment, a pressure of at least 7 bar (5 bar) upstream of the service unit is required.

왘

왘


Turn the regulator knob until the manometer indicates a pressure of 5.4 bar (3.6 bar). Clockwise: higher pressure, Anti-clockwise: lower pressure

왘 Lock the regulator knob by pressing it down.

Alternatively, the filter controller can be set to a pressure of 6 bar (4 bar) in the absence of an air stream. This setting is only correct for a pressure of at least 7 bar (5 bar) upstream of the service unit.

왘 Depressurise the air line downstream of the service

왘 unit and close it again.

Turn the regulator knob anti-clockwise, in order to

왘 release the adjusting spring.

Turn the regulator knob until the manometer indicates a pressure of 6 bar (4 bar). Clockwise: higher pressure Anti-clockwise: lower pressure

왘 Lock the regulator knob by pressing it down.

* )

Values for 4-bar hoists in brackets

If the nominal pressure of 5.4 bar (3.6 bar) cannot be achieved despite a sufficiently high pressure upstream of the service unit, then the air line cross-section is too small.

Filter regulator and oiler filter-regulator adjusting knob lubricator



D R A I N I N G C O N D E N SAT E

After a certain time, condensate collects in the filter regulator container, which must be regularly drained.

Check the condensate level through the sight glass in the filter container. The condensate level must not reach the separating plate.

The container can be emptied manually or semiautomatically, depending on the setting of the drain valve:

왘 OFF position

The drain valve is closed in this position.

The OFF position is generally set at the factory.

왘 ON position

The condensate can be drained manually in this position. Operate the drain valve by pressing upwards

(see Figure).

When the compressed air supply is connected, the drain valve is under pressure. We recommend using suitable splash protection (cloth, fleece) as the condensate will otherwise escape uncontrollably.

Collect the escaping condensate and dispose of it as it may contain oil.

왘 AUTO position

In this position, semi-automatic condensate drainage takes place. When the pressure 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 when drainage occurs.


AT T E N T I O N




왘

왘

Drain the water.

Shut off the main air supply and carefully allow the

왘 residual pressure to dissipate.

Unlock the filter regulator container, turn anti-

왘 clockwise to the stop and remove.

Unscrew the separating plate. The filter is located

왘 loosely on the separating plate centring device.

Clean the filter element using soap solution and blow

왘 through forcefully.

Reinstall the clean filter element and fasten the

왘 separating plate.

Insert the filter regulator container in the housing and turn clockwise. The container locks automatically.

filter element separating disc sight glass filter receptacle

Cleaning the filter element




The oiler ensures that the hoist air supply is consistently provided with a precisely-metered quantity of oil. Regular checking of the oiler is very important, as the vane motor may be damaged in the case of lubricant deficiency. The oiler can also be refilled under pressure.

왘

왘

왘 Check the oil level through the sight glass in the container. The oil level must not fall below the minimum mark.


Fill the container with oil up to the maximum mark

왘 and refit the oil filler screw.


왘 Turn the oil throttle screw using a screwdriver until the desired number of drops per minute is achieved.



10 drops per minute.


Operation of service units with synthetic oils is not permissible. They must also not be connected to compressed air circuits, which are supplied by compressors lubricated with synthetic oil.

C AU T I O N !

J.D. Neuhaus only supplies standard spray oilers. Do not use microspray oilers as very finely secreted oil spray could adversely effect the surrounding air and therefore the respiratory system.

Sight glass

Oil filler screw

Oil throttle screw

Check the oil level and top up if necessary maximum oil level minimum oil level


Page 47


R E P L AC I N G B R A K E D I S C , B R A K E P I S TO N

A N D VA N E S / M OTO R I N S TAL L AT I O N /

M OTO R L U B R I C AT I O N

9 10 8 7 6 1211 5 4 2 1 3

13/14



R E M OVAL

Proceed as follows when removing the motor with the brake:

왘 Unload the hoist and disconnect it from the main

왘 air supply.

Detach the control valve from the motor (in order

왘

왘 to permit removal of the motor retaining bolts).

Detach the motor from the hoist.

Remove the motor cover bolts 1 and remove the motor cover 2 with the nameplate 3 . (When the

왘

왘 cover bolts are removed, brake spring tension 4 is fully released).

Remove the springs.

Remove the brake piston 5 from the internal cylinder

왘 integrated in the motor housing.


Note: If you only wish to check for vane wear or replace the vanes with the starting aids, please continue with the section ”Checking for vane wear”.

왘 Remove the cover bolts 9 and remove the cover with

왘 the brake lining 10 (brake disc).

Check the braking surfaces of the brake piston and the cover with the brake lining for wear and damage, replace if necessary. The circular wear pattern in the braking surfaces must not be deeper than 0.2 mm.

The extremely low-wear braking material will not reach the wear limit of 0.2 mm within the designdependent 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

왘 event of insufficient pressure).

Checking vane wear (see illustration Checking vane wear, page 49). When the air motor vanes are worn, the motor power and consequently the lifting performance of the JDN Air Hoist are reduced. Replacing the vanes together with the starting aids.



Rotor Cylinder liner

V

1 max. = 0,2 mm V

2 max. = 0,2 mm

Brake piston

Brake disc

R

L max

= R - (V

1

+ V

2

)

L

Vane

L min

= R - (V

1

+ V

2

) - 0,3 mm = L max

- 0,3 mm

L hmin

= 19 mm


왘 Renew grease lubrication of motor. The grease packing in the rotor chambers is sufficient for approx. 250 operating hours. For this time interval the load on the hoist (collective load) is immaterial. Note: The rotor chambers only empty by approx. 60 %. In this condition, refilling must be performed. The retaining rings 11 and Vyon washers 12 must be removed in order to refill the chambers. Then pack the lubricant chambers with high-performance lubricant (JDN Art.

no 11901) without forming cavities.

Use new round plates to close off the lubricant chambers and secure these using retaining rings.

A S S E M B LY W I T H A D D I T I O N AL BA S I C M OTO R

L U B R I C AT I O N

왘 Fit the cover with the brake lining, inserting the anti-twist device (pin). Coat the braking surface and rotor bearing (needle bush) lightly with high-

왘

왘 performance grease.

Tighten the cover bolts.

Coat the internal cylinder of the housing lightly with

왘 high-performance grease.


왘 Coat the vanes lightly with high-performance grease

왘 and insert into the rotor slots with the starting aids.

Coat the braking surface and the outer diameter including the brake piston seal lightly with highperformance grease and push the brake piston with the braking surface first into the internal cylinder; note the position of the eccentric bore.

왘 Insert the brake springs into the bores of the

왘

왘 brake piston.

Detach the nameplate from the motor cover.

Loosen adjusting bolts 13 and lock nuts 14 . Screw back adjusting bolts.

왘 Apply high-performance grease lightly to rotor bearing (needle bush)in the motor cover and install motor cover, ensure correct seating of the brake springs and locating pins to motor housing and brake piston.

왘 Do not tighten the 4 adjusting bolts after bolting the motor cover in place, only screw them in loosely to the stop in the cover. Screw back the lock nuts

왘 sufficiently beforehand.

Then screw back the adjusting bolts 45° to 60° from the stop, hold, and lock with the nuts. For operation in areas with ambient temperatures exceeding 30°C, the adjustment must be carried out with the device warmed up accordingly. For lifting heights of 10 m and more, the setting must be at least 60°C.

왘

왘

Screw on the nameplate.

Initially fasten the motor, then the control valve to the hoist.


Tightening torques , see E-list.

C AU T I O N !






R E M OV I N G A N D I N S TAL L I N G L OA D S L E E VE

A N D B U F F E R

- S I N G L E C H A I N H O I S T ( 3 T I )

L OA D S L E E VE I N S P E C I AL D E S I G N

W I T H C L A M P I N G P I E C E

1

3

1

3

4

5

2

5

Removal

왘 Drive out the roll pin 1 for securing the chain from

왘

왘 the load sleeve 3 .



Assembly

왘 Push the buffer discs (edge encloses buffer) and the

왘 buffer onto the chain.

Insert the end chain link into the chain pocket of the load sleeve (position of the weld must align with that of the following links).

왘 Drive in a new roll pin to secure the chain link in the load sleeve.

2

5

4

5

7

6

Removal

왘 Loosen screw 7 and take it out of the chain pocket

왘

왘 together with locking washer 6 and clamping piece 1



Assembly

왘 Push the buffer discs (edge encloses buffer)

왘 and the buffer onto the chain.

Insert the end chain link into the chain pocket of the load sleeve (position of the weld must align with that of the following links).

왘 Insert the clamping piece 1 into the chain pocket, tighten screw 7 with locking washer 6 (41 Nm).



R E M OV I N G A N D I N S TAL L I N G B OT TO M B L O C K

A N D B U F F E R S

- D O U B L E C H A I N H O I S T S (6 TI, 10 TI, EH 10)

2

1

8

7

8

5

9

10

12

13

11

6

3

4

Removal

왘 Move the bottom block as close as possible to the

왘 hoist body.


왘 Remove the chain link 1 of the bottom block from the chain mount on the hoist body by driving out the roll pin 2 and pull out the chain link pin 3 (the end chain link 4 of the idle chain is released simultaneously) or only pull out the chain link pin to the extent that the end chain link of the idle chain is not released from the hoist body. In versions with chain box, the idle chain is not attached to the hoist body.


왘 Pull out the chain from the bottom block. The buffer 7 and buffer discs 8 are thereby pulled from the chain.

Assembly

왘 Push the buffer discs (edge encloses buffer) and

왘 the buffer onto the chain.

Align the chain and fasten it to the assembly chain

왘 in the bottom block by means of the open chain link.

Pull the chain through the bottom block and detach the assembly chain and the open chain link from the chain. If no assembly chains have been used, the end of the chain must be inserted into the bottom block and pulled through by turning the sprocket wheel

왘 using an auxiliary tool.

If the chain link pin was not completely pulled out, only align the bottom block chain and push the chain link pin through the chain link to be attached

(position of the weld must align with that of the following links). If the chain link pin was pulled out completely, align the bottom block chain and the idle chain and push the chain link pin into the hoist. It must first be guided through the end link of the idle chain and then through the end link of the bottom block chain (position of the weld must align with that of the following links).

왘 Drive in a new roll pin to secure the end link pin.



- T R E B L E C H A I N H O I S T S ( 1 6 T I , E H 1 6 )

7

6

7

8

1

2

3

5

4

9

Removal

왘 Move the bottom block as close as possible to the hoist body. Position the bottom block securely in order to prevent the chain from unravelling

왘 uncontrollably causing the bottom block to fall.

Remove the bottom block end chain link 1 from the chain mount on the bottom block; drive out the roll pin 2 and remove the end chain link pin 3 for this purpose.

Note : For assembly, it is helpful to work with two short assembly chains 4 which are fastened by means of an open chain link 5 to the hoist chain being pulled out during removal of the chain and are pulled successively over the deflection sprocket of the centre section and the bottom block. They remain there until assembly is completed.

왘 Pull the chain from the deflection sprocket of the centre section and from the bottom block. The buffer

6, the buffer discs 7 and the run-on elements 8 and

9 are thereby pulled from the chain.

Assembly

왘 Push the buffer assembly (buffer 6 plus buffer discs

왘

7 , edge encloses buffer) onto the chain.


왘

왘


Pull the chain through the bottom block and detach the assembly chain and the open chain link from the chain.

Push the first run-on element 8 onto the chain.

Align the chain and pull through the centre section

왘 by means of the assembly chain.

Detach the assembly chain and the open chain link

왘 from the chain.

If no assembly chains have been used, the end of the

왘

왘 chain must be inserted into both the bottom block and the centre section and pulled through by turning the deflection sprockets using an auxiliary tool.

Push the second run-on element 9 onto the chain.

Align the chain and fasten the chain link to the bottom block by means of the end link pin (position of the weld must align with that of the following links).




Q UA D R U P L E C H A I N H O I S T S ( 2 0 T I , E H 2 0 )

3

2

4

5

10

9

10

6

1

8

7

Removal

왘 Move the bottom block as close as possible to the hoist body. Position the bottom block securely in order to prevent the chain from unravelling un-

왘 controllably causing the bottom block to fall.

Remove the bottom block end chain link 1 from the chain mount on the hoist body; drive out the roll pin

2 and remove the end chain link pin 3 for this purpose. In the case of the PROFI 20TI the end chain link 4 of the idle chain is released simultaneously or only remove the end chain link pin far enough to ensure that the end chain link of the idle chain is not released from the hoist body.

In versions with chain box, the idle chain is not attached to the hoist body.

Note : For subsequent assembly, it is helpful to work with three short assembly chains 5 which are fastened by means of an open chain link 6 to the hoist chain being pulled out during removal of the chain and are pulled successively over the deflection sprocket of the centre section and the bottom block. They remain there until assembly is completed.

왘 Pull the chain from the deflection sprocket of the centre section and from the bottom block.

The run-on elements 7 and 8 , as well as the buffer 9 and the buffer discs 10 are thereby pulled from the chain. On version PROFI 20 TI with chain box, three additional run-on elements are provided on the bottom block (see spare parts list).

Assembly

왘 Push the buffer assembly (buffer 9 plus buffer discs

10 , edge encloses buffer) onto the chain. On version

PROFI 20 TI with chain box, a run-on element must be pushed onto the chain before pushing on the buffer

왘 assembly (see spare parts list for adjustment).



Pull the chain through the bottom block and detach the assembly chain and the open chain link from the chain.

왘 Push the run-on element 8 onto the chain.

On version PROFI 20 TI with chain box, an additional run-on element must be pushed onto the chain (see

왘 spare parts list for adjustment).

Align the chain and pull through the centre section


Detach the assembly chain and the open chain link

왘 from the chain.

Push the run-on element 7 onto the chain.

On version PROFI 20 TI with chain box, an additional run-on element must be pushed onto the chain (see

왘 spare parts list for adjustment).

Align the chain and pull through the bottom block


Detach the assembly chain and the open chain link from the chain.

왘 If no assembly chains have been used, the end of the chain must be inserted into both the bottom block and the centre section and pulled through by turning the deflection sprockets using an auxiliary tool.



왘 Align the chain and fasten the end chain link to the hoist body by means of the end chain link pin.

(Position of the weld must align with that of the following links.)

In the case of the PROFI 20 TI

If the end chain link pin was pulled out completely, the bottom block chain link and the end chain link of the idle chain have to be aligned. (Position of the weld must align with that of the following links.)


R E M OV I N G A N D I N S TAL L I N G C L A M P A N D B U F F E R


왘 In the case of operation with chain box, run the chain out of the chain box and detach it from the hoist.

Note : In the case of hoists with chain box, the end chain link of the idle chain 4 is not attached to

왘 the hoist body.

In the case of hoists without chain box, detach the chain link of the idle chain (for double chain and quadruple chain hoists, except for EH 20, also the end link of the bottom block chain 1 ) from the chain mount on the hoist body. Drive out the roll pin 2

왘

왘

왘

왘 and remove the end chain link pin 3 .

Immediately fasten the end link of the bottom block chain to the hoist body in order to prevent the chain from becoming twisted.

Drive out the roll pin


Detach the buffer 11

9 from the clamp and buffer discs

10

12 +

.

13 from the chain. 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:

왘 Push the buffer disc with edge (edge encloses buffer),

왘 buffer and buffer disc without edge onto the chain.

Insert the tenth chain link into the chain pocket of the clamp (chain pocket away from hoist body, pointed outwards).

왘 Drive in a new roll pin to secure the chain link in

왘 the clamp.


In the case of operation without chain box:

왘 Align the chain link of the idle chain (for double chain and quadruple hoists, except for EH 20, also the end link of the bottom block chain) and fasten to the hoist body by means of the end chain link pin (position of the weld must align with that of

왘 the following links).

Drive in a new roll pin to secure the end chain link pin.




S P R O C K E T A N D C H A I N G U I D E S

See also Check dimensions, page 55. If the chain of the JDN Air Hoist displays one of the following features, it must be replaced with a new one:

왘

왘

왘

왘

왘

왘

Corrosion scars


Chain drawn stiff

Wear over 11 pitches (A max

)

Single pitch wear (B max

)

Elongation of a single link (D max

)


Please observe the information contained in DIN 685, part 5 when checking chains. For further instructions see ISO 7592.



C H E C K D I M E N S I O N


Note: When checking the replacement limit, future wear to the next checking 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 be replaced by a new one. The chain sprockets must also be replaced together with the chain, as otherwise the new chain will be subjected to increased wear. Each chain replacement must be documented in the inspection log.

L OA D H O O K

If die hook opening a and the height h of the load hook are outside the wear limits, the hook must be replaced.

Check dimensions of the load hook

Type

PROFI 3 TI

PROFI 6 TI

PROFI 10 TI, EH 10

PROFI 16 TI, EH 16

PROFI 20 TI, EH 20

Dimensions in mm

Maximum Minimum permis. dimension of permis. dimension hook opening ”a”

1) of height ”h”

35.7

46.0

36.1

44.7

50.4

60.6

83.4

58.9

71.3

80.8

1) If a safety catch is fitted, the thickness of the safety catch must be subtracted from the maximum hook opening dimension a.

d1


Chain d x t

Dimension A max.

11 x t inside max.

Dimension B max.

Dimension C min.

Dimension D max.

Dimensions in mm

13 x 36

429.2

404.3

37.9

11.7

63.9

c = d

1

+ d

2

2

16 x 45

536

505.3

47.4

14.4

79.3



W E A R D I M E N S I O N S F O R C H A I N S P R O C K E T S x



13 x 36

16 x 45 z

(1)

4

4 a mm

32.8

38.5

x mm

0.25

0.30

a, x = limit dimensions after maximum permissible wear z = number of teeth of the chain sprocket d x t = nominal diameter times pitch of chain link



Check the chain guides for wear and when the following wear dimensions are reached with regard to chain guide diameters or hook mounts in the centre section of the device: Replace the housing:

Chain diameter

Wear dimension

Dimensions in mm

13

1.4

16

1.7


C H E C K I N G A X I AL P L AY





DA N G E R !

In the event of insufficient maintenance/ lubrication the extent of wear may be so high that there is a danger of loads falling.

P R E VE N T I O N O F DA N G E R S





C H E C K D I M E N S I O N S F O R T H E A X I AL P L AY

Bottom block type Axial play ”x” max.

6.3 t, 10 t, 16 t

20 t

Max. 3.5 mm

Max. 11.5 mm

Bottom block with load hook or load eye


R E M OV I N G A N D I N S TAL L I N G C H A I N


The chain supplied together with this JDN hoist is matched to the chain sprocket according to strict tolerances. In order to ensure optimum function of the chain and in order to prevent hazards, only genuine

JDN chains must be installed.

Note: When a chain is replaced, the buffers must also be replaced. For information on changing buffers at the chain ends, see Removing and installing load sleeve, bottom block, clamp and buffer section.

Buffers and run-on elements not located on the chain ends are most easily replaced when the open chain link between the old and new chains passes the buffer to be replaced.



왘 In the case of operation with chain box: switch the hoist in the ”lower” rotational direction and run the old chain out of the chain box. Then remove the chain box.

왘 Move the bottom block as close as possible to the

왘 hoist body and position it securely.

In the case 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 sleeve, bottom block, clamp and

왘 buffer section).

Detach the clamp, buffer and buffer discs from the end of the idle chain. For single chain hoists also detach the load sleeve, buffer and buffer discs from the load chain. For dual and quadruple chain hoists with chain box, detach the bottom block from the hoist body.

For triple chain hoists, detach the bottom block chain from the mount on the bottom block. (See also

Removing and installing load sleeve, bottom

왘 block, clamp and buffer section.)

Attach the new chain to the end link of the load section of the 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. For this reason, the welds of the chain links which lie flat in the drive sprocket must face towards the gearbox in the case of treble and quadruple chain hoists. If the first link of the new chain is not correctly positioned, it must be removed.

Note: It is possible that the first chain link of the other chain end is correctly positioned. Switch the hoist to the ”lift” rotational direction. The new chain will now run into the hoist while the

왘 old chain is simultaneously run out on the idle chain side.

Run the chain until the join between the old and new chain has run sufficiently (approx. 1 m) out of the centre section on the idle chain side.

왘 Detach the connection between the old and new

왘 chains.


Only in the case of operation without chain box, align the idle chain and attach to the fastening point on the hoist - for dual and quadruple chain hoists, except for

EH 20, the bottom block chain is also attached here later. (See also Removing and installing load sleeve, bottom block, clamp and buffer section.)

왘

왘


Switch the hoist in the ”lift” rotational direction until the as yet free end of the aligned load chain is the correct length for attaching the chain link,

_ for single chain hoists in the load sleeve after the buffer and buffer discs have been pushed on,

_ for dual and quadruple chain hoists at the fastening point on the hoist body and

_ for triple chain hoists at the fastening point of the bottom block (see also Removing and installing load sleeve, bottom block, clamp and buffer section).


R E P L AC I N G C H A I N A N D

C H A I N S P R O C K E T

Note: If the chain jams in the hoist and can no longer be run out, the gearbox must be dismantled. The gearbox retaining bolts must be removed for this purpose, and the end chain link pin must be pulled out. The chain wiper must then be removed. The gearbox can now be pulled approx. 15 mm from the centre section.

In this position, the safety ring, item 440 (gearbox

3 TI/6 TI), item 500 (gearbox 10 TI/16 TI/20 TI/EH 10/

EH 16/EH 20) (see E-list, gearbox) must be removed in the vicinity of one of the exhaust air guides. The gearbox housing can then be removed and the gearbox can be dismantled down to the sprocket wheel.

When removing the old chain, assembly chains (1) are brought into position on all the deflection sprockets by means of open chain links (see also Removing and installing load sleeve, bottom block, clamp and buffer section and section Removing and installing chain section).

Following replacement of the chain sprocket (see spare parts list) an assembly chain (2) is run carefully – with low air pressure – over the drive sprocket.

Fasten the new chain to the assembly chain on the drive sprocket by means of one or two open links (3) on the idle chain side. The first chain link (4) 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 (5) must face towards the gearbox in the case of treble and quadruple chain hoists. (See illustration.)

Switch the hoist to the ”lower” rotational direction and detach the assembly chain from the chain after it comes out of the centre section.

Depending on the number of chains of hoist and after alignment, the new chain is pulled over the deflection sprocket of the bottom block and if necessary over the deflection sprocket of the centre section by means of further assembly chains.





2

3

4

5

1


OVE R L OA D P R OT E C T I O N

The PROFI 3 TI, 6 TI, 10 TI, 16 TI, 20 TI and EH 10,

EH 16, EH 20 hoists are equipped with a new type of safety clutch as standard. This prevents loads exceeding the limit values set from being lifted. The limit value is set so that loads of 125 % of the load carrying capacity cannot be lifted. 110 % can be lifted in order to perform the dynamic overload test.


The safety clutch must only be engaged for a short time in order to prevent unnecessary wear and overheating of the drive.

When the safety clutch is activated, the hoist should be unloaded by switching to a lowering movement.

The overload protection can also be activated when moving 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.

A D J U S T I N G OVE R L OA D P R OT E C T I O N


DA N G E R !


왘

왘

Unload the hoist

Detach the gearbox cover (1) from the gearbox in order to gain access to the threaded pins (2) with lock nuts (3) located behind it.

CORRECTING THE SET LIMIT VALUE

왘 Loosen the lock nuts. It must be ensured that the

왘 threaded pins are not turned.

During each readjustment adjust the threaded pins to the same degree in order to adjust the disc springs evenly: turning clockwise - limit value is increased, turning anti-clockwise - limit value is reduced.

왘 Secure threaded pins with the lock nuts. Do not turn

왘

왘 the threaded pins any more as the setting will be altered.

Check the limit value for correct setting.




R E S E T T I N G T H E L I M I T VAL U E

왘 Loosen the lock nuts. Screw out the threaded pins anti-clockwise - until the disc springs (4) are completely free of pre-tension.

왘 Then loosely screw in the threaded pins by hand – clockwise – to the stop, screw the lock nuts sufficiently far back beforehand.

왘 The limit value for reaching at least 110 % of the load-carrying capacity is set at approx. 2 turns. Screw in the three threaded pins successively in small steps by approx. 1/2 turn. With this preadjustment after reassembly, 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 seconds without a load so

왘 that the outlet air cools the clutch down.

Secure threaded pins with the lock nuts. Hold the

왘 threaded pins tightly in the process.

Check the limit value for correct setting, correct

왘

왘 if necessary.


The adjusting and inspection result arrived at by qualified personnel must be entered in the lifting gear inspection log (limit value: see Overload protection , page 34).

3

2

4

1

Gearbox 3.2 t




FAU LT TA B L E

Fault


Only very slow lifting possible

Excessive running on during braking

Loud chain noise on the chain sprocket

Lifting or lowering speed declines with high lifting heights or the motor comes to a standstill

Possible cause

Air pressure too low

EMERGENCY STOP button is pressed





Air supply hoses leaking or loose

Cross section of air line too small

Dirt in the service unit*, filter blocked

Silencer is clogged

Remedy

Increase air pressure to the required value

Release the EMERGENCY-OFF switch if the danger has been rectified


Set air pressure to the relevant value, check seal of brake piston and change seal if necessary Check the adjustment of the brake piston (see Spare Part List )


Tighten the bolts


Use air line with sufficiently large cross section (check air pressure)

Clean service unit, ensure better air quality

Motor vanes worn

Motor has run dry


Safety clutch slips

Safety clutch slips due to chain wear

Brake disc and/or brake piston worn

Chain dry

Chain worn

Chain sprocket worn


Brake piston setting too tight

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 brake disc and/ or brake piston

Lubricate chain



Identify chain and replace with JDN Chain if necessary

Correct adjustment of brake piston. At high ambient temperatures, perform adjustment with the device warmed up accordingly.

*if installed






왘 99.9 % of oil aerosols during oil lubrication of the

왘 motor are absorbed by the filter element.

The noise insulation reduces noise levels by 3 to

4 dB (A) compared with the standard silencer

(sinter plate).

The ambient temperature must not be lower than - 10° C.




왘 Turn the drain valve 4 90° and allow the fluid

왘 to drain out.



왘

왘

왘



Insert a new filter element, with sealing ring push on collecting container until it engages.

1 and


In the event of a control hose length exceeding 10 m, the reaction times of the pushbutton controls increase significantly.



Filter silencer


1

2

3

4


C H A I N B OX




Do not exceed the permissible filling capacity. Danger of chain dropping.




PROFI 6 TI and PROFI 10 TI (dual chain) the clamp must be positioned as far as necessary downwards on the reeved chain in order to support the bottom block

(stationary chain). In addition, a spacer must be attached to the opposite (moving) chain above the buffer in order to relocate the load hook stroke limiter.

Please contact us, if required. For greater clarity, see the lower illustration on page 50.


Removing and installing chain page 57).

Depending on the ratio of the size of the hoist (without running gear) and the chain box, the chain box may have to be stabilised by the customer due to an acceptable vertical hoist 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 J.D. Neuhaus GmbH & Co. KG.




왘 After installing the chain box, lower the load hook to

왘 the bottom position once.

Then activate the lifting movement and run the complete chain into the chain box.

DA N G E R !

During operation with the chain box, lubrication of the chain is particularly important in order to prevent it from piling up and falling out.

Do not install longer chains when changing chains.


If the hoist has been transported with the chain in the chain box, the chain box must be emptied manually before initial operation (if necessary, remove the chain box from the hoist). The entire chain must then be allowed to run to the load side and, subsequently, be driven back into the chain box. The hoist must be kept in a hanging position during this procedure.

This process will ensure that the chain does not lock when loads are being lowered.

Seite 63 powered by air !

A P P E N D I X

A P P E N D I X

T E C H N I C AL DATA


Type

Air pressure


Number of chains bar t

4

3 TI

3.2

1

6 4

6 TI

6.3

2

6 4

10 TI

6

10

2

4

16 TI

6

16

3

4

20 TI

6

20

4

Motor power

Lifting speed at nominal load kW m/ min

1.8

3.5

1.8

3.5

1.8

3.5

1.8

3.5

1.8

3.5

2.5

5 1.2

2.5

0.8

1.6

0.5

1 0.4

0.7


Air connection m/ min

Lowering speed at nominal load m/ min 5.5

10.8

2.8

5.4

1.8

3.4

1.1

2.1

0.85

1.6

Air consumption at nominal load – lifting m 3 /min 2.3

4.0

2.3

4.0

2.3

4.0

2.3

4.0

2.3

4.0

Air consumption at nominal load – lowering m 3 /min 3.2

5.5

3.2

5.5

3.2

5.5

3.2

5.5

3.2

5.5

mm

5 10 2.5

5 1.5

3.2

1

G 3

⁄

4

19/31

G 3

⁄

4

19/31

G 3

⁄

4

19/31

G 3

⁄

4

19/31

2 0.75

1.4

G 3

⁄

4

19/31 Hose size (Ø inner/Ø outer ¯)

Weight for standard lifting distance, rope control kg 86 110 156 240 285

Chain dimensions

Weight per 1 m chain

Standard lifting distance mm kg m

13 x 36

3.8

3

13 x 36

3.8

3

16 x 45

5.8

3

16 x 45

5.8

3

16 x 45

5.8

3

2 2 2 2 2 Control length for standard lifting distance m

Noise pressure level at nominal load 1 with standard silencer – lifting dB (A)

Noise pressure level at nominal load 1 with standard silencer – lowering dB (A)

76 78 76 78 76 78 76 78 76 78

78 80 78 80 78 80 78 80 78 80



A P P E N D I X



Type

C

D

A * Minimum headroom

B

E1

E2


G maximum width

Dimensions in mm

3 TI

40

30

187

233

593

373

233

483

6 TI

674

454

233

483

40

40

154

233

* Chain boxes increase the required headroom

10 TI

44

44

197

306

813

548

308

575

16 TI

53

53

199

308

898

598

382

692

20 TI

1040

667

382

692

75

75

182

324


A P P E N D I X

T E C H N I C AL DATA

J D N M O N O R A I L H O I S T S

Type

Air pressure


Number of chains

Motor power, running gear

Motor power, lifting gear


Lifting speed without load t bar kw kw m/min m/min


Travel speed at nominal load m/min m/min

Travel speed without load

Air consumption at nominal load, running gear m/min m

3

/min

Air consumption at nominal load, lifting gear(lifting) m 3 /min

Air connection

Hose size

( inner/ outer)

Weight for standard lifting distance

Chain dimensions

Weight per 1 m chain

Standard lifting distance

Control length for standard lifting distance

Noise pressure level at nominal load 1 with standard silencer - lifting

Noise pressure level at nominal load 1 with standard silencer - lowering mm kg mm kg m m dB (A) dB (A)


EH 10

4 6

10

2

0.3

1.8

0.8

2

2.5

10

10.5

1.0

2.2

G 3 ⁄

4

19/31

450

16 x 45

5.8

3

2

0.7

3.5

1.6

3.2

3.4

12

13.5

1.3

3.2

75 78

81 80

EH 16

4

16

3

0.3

1.8

0.5

1.3

1.6

10

10.5

1.0

2.2

G 3 ⁄

4

19/31

575

16 x 45

5.8

3

2

6

0.7

3.5

1

2

2.1

12

13.5

1.3

3.2

75 78

81 80

EH 20

4 6

20

4

0.3

1.8

0.4

0.9

1.2

10

10.5

1.0

2.2

G 3 ⁄

4

19/31

620

16 x 45

5.8

3

2

0.7

3.5

0.7

1.4

1.6

12

13.5

1.3

3.2

75 78

81 80



K D

A b + B b

C

A P P E N D I X

H

J

K

L

M

H

J

D

E

F*

G

B

C

Type

A

EH 10

105

70

284

25

198

705

138

44

192

580

308

266

Measurements in mm * Chain boxes increase the required headroom

L

G

EH 16

130

68

294

35

220

750

213

53

185

600

367

325

M

EH 20

130

68

294

35

220

820

202

75

266

600

367

325 powered by air !

Page 67

A P P E N D I X

A I R F L OW S H E E T S

R OP E C O N T R O L , W I T H O U T M A I N A I R E M E R G E N C Y- S TOP VALVE

Hubmotor lifting motor

Ventilblock am Hubmotor valve at the lifting motor

Steuerventil Seil control valve senken lowering

A B heben lifting

Drehschieber-Ventil rotary control valve

R P S

Hauptanschluss main air connection heben lifting senken lowering


A P P E N D I X

E - C O N T R O L , 2 - F O L D , W I T H E M E R G E N C Y S TOP F U N C T I O N

W I T H M A I N A I R E M E R G E N C Y- S TOP VALVE


Steuerventil Luft control valve senken lowering

A heben lifting

B

Drehschieber - Ventil rotary control valve

R P S

HS - Sperrventil

HS - stop valve

Ventilblock am Motor valve at the lifting motor

Druckknopfventil

E-2fach NOT-STOPP push button valve


NOT-STOPP emergency stop p

Hauptanschluss main air connection s h p = Druckversorgung

air supply h = heben

lifting s = senken

lowering powered by air !

Seite 69

A P P E N D I X

E - C O N T R O L , 4 - F O L D , W I T H O U T E M E R G E N C Y S TOP F U N C T I O N

W I T H O U T M A I N A I R E M E R G E N C Y- S TOP VALVE

( N OT F O R E W R )



A heben lifting

B


R P S

Fahrmotor

Bremse brake

Motor motor driving motor

Schalldämpfer silencer

A B

Y P Z


Hauptanschluss main air connection


Druckknopfventil

E-4fach push button valve

E-4fold p s h li re p = Druckversorgung


lifting s = senken

lowering li = Linksfahrt

travel left re = Rechtsfahrt

travel right


A P P E N D I X

E - C O N T R O L , 4 - F O L D , W I T H E M E R G E N C Y S TOP F U N C T I O N

W I T H E X T E R N AL M A I N A I R E M E R G E N C Y- S TOP VALVE



A B heben lifting


R P S

Ventilblock am Motor valve at the lifting motor verschlossen closed

Druckknopfventil

E-4fach NOT-STOPP push button valve


NOT-STOPP emergency stop p s h pö p li re p = Druckversorgung


lifting s = senken

lowering pö = Öffnungsdruck

opening pressure li


travel right

Fahrmotor

Bremse brake



A B

Y P

HS-Sperrventil

HS-stop valve


Z


A P P E N D I X

F I - C O N T R O L , 2 - F O L D , W I T H E M E R G E N C Y S TOP F U N C T I O N



Steuerventil Luft control valve senken lowering heben lifting


A B

R P S

Ventilblock am Hubmotor valve at the lifting motor

Druckknopfventil

FI-2fach NOT-STOPP push button valve

FI-2fold emergency stop

NOT-Stopp emergency stop p s h

HS-Sperrventil

HS-stop valve

Hauptanschluss main conection p = Druckluftversorgung


lifting s = senken

lowering


A P P E N D I X

F - C O N T R O L , 5 - F O L D , W I T H E M E R G E N C Y S TOP F U N C T I O N




A B heben lifting


R P S

Ventilblock am Motor valve at the lifting motor p

Steuerflasche

F-5 fach NOT-STOPP multi button pedent switches 5 fold emergency stop

NOT-STOPP emergency stop s h

HS-Sperrventil

HS-stop valve pö li re p = Druckversorgung


lifting s = senken


opening pressure li


travel right

Fahrmotor

Bremse brake



A B

Y P

HS-Sperrventil

HS-stop valve

Hauptanschluss

Z main air connection


A P P E N D I X

F - C O N T R O L , 7 - F O L D , W I T H E M E R G E N C Y S TOP F U N C T I O N




A B heben lifting


R P S

HS-Sperrventil

HS-stop valve


Fahrmotor

Bremse brake



Fahrmotor driving motor

Motor motor

Bremse brake


A B A B

Y P Z Y P Z p

Steuerflasche

F-7fach NOT-STOPP multi button pedent switches 7 fold emergency stop

NOT-STOPP emergency stop s h li re v z pö

HS-Sperrventil

HS-stop valve p = Druckversorgung


lifting s = senken


opening pressure li


travel right



is a registered 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 [email protected] _ www.jdn.de

powered by air !

J. D. NEUHAUS Profi 05Ti, Profi 1Ti, Profi 2Ti Operation Manual

powered by air !

powered by air !

Original Operation and

Assembly Instructions powered by air !

”

powered by air !

Original Operation and

Assembly Instructions powered by air !

”

1

2

⁄

⁄

⁄

⁄

⁄

powered by air !

Key Features

Related manuals

Frequently Answers and Questions

What is the lifting capacity of the Profi 05Ti?

What is the maximum lifting height of the Profi 05Ti?

What is the weight of the Profi 05Ti?

What is the voltage of the Profi 05Ti?

J. D. NEUHAUS Profi 05Ti, Profi 1Ti, Profi 2Ti Operation Manual

powered by air !

powered by air !

Original Operation and

Assembly Instructions powered by air !

”

powered by air !

Original Operation and

Assembly Instructions powered by air !

”

1

2

⁄

⁄

⁄

⁄

⁄

powered by air !

Key Features

Related manuals

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25/19

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VSM-01

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Frequently Answers and Questions

What is the lifting capacity of the Profi 05Ti?

What is the maximum lifting height of the Profi 05Ti?

What is the weight of the Profi 05Ti?

What is the voltage of the Profi 05Ti?