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

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JDN OPERATION AND ASSEMBLY
INSTRUCTIONS FOR AIR HOISTS
Original operation and assembly instructions

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  • Page 1 JDN OPERATION AND ASSEMBLY INSTRUCTIONS FOR AIR HOISTS Original operation and assembly instructions...
  • Page 2 Please enter the Serial No. of your JDN Air Hoist here. These operation instructions, edition 02/2011, cover the following JDN Air Hoists: Serial No. Serial No. Serial No. The operation instructions must be read carefully in their entirety before operating any hoist. For hoists installed in trolleys, also refer to the JDN Trolley operation instructions.

  • Page 3: Table Of Contents

    CONTENTS OPERATION Rules for safe operation SAFETY MEASURES Controls Organisational measures Emergency stop Personnel safety Overload protection Preventing property damage Load hook mount Chain PRODUCT INFORMATION Load hook About these operation instructions Attaching the load Warnings and symbols Lifting the load Identification Lowering the load Assembly overview...
  • Page 4 MAINTENANCE Check dimensions Checking axial play Checking and adjusting overload protection FAULTS, CAUSES AND REMEDIES Troubleshooting guide ACCESSORIES Filter silencer Booster unit Chain box APPENDIX Technical data Dimensions Circuit diagram powered by air! Page 4...
  • Page 5 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”...

  • Page 6: Safety Measures

    SAFETY MEASURES SAFETY MEASURES ORGANISATIONAL MEASURES PERSONNEL SAFETY JDN Hoists are designed in accordance with current technological Personnel who operate, maintain, inspect and perform setting-up standards and accepted safety practice. Nonetheless, the use of a work on the hoist must be properly trained or must receive an hoist may be associated with risk of injury or fatality to the user or to introduction from properly trained personnel before commencing third parties or with the risk of damage to the hoist or to other items,...

  • Page 7: Product Information

    P R O D U C T I N F O R M A T I O N PRODUCT INFORMATION ABOUT THESE OPERATION INSTRUCTIONS WARNINGS AND SYMBOLS These operation instructions are intended to help the operator to Safety warnings in these operation instructions are classified in become familiar with JDN Air Hoists and their intended use.

  • Page 8: Identification

    P R O D U C T I N F O R M A T I O N MARKING 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 these operation instructions, please contact us at the following address: J.D.

  • Page 9: Assembly Overview

    P R O D U C T I N F O R M A T I O N ASSEMBLY OVERVIEW PROFI TI series air hoists consist of the following assemblies: Gearbox with outlet air cooling Centre section with chain sprocket Motor with integrated braking function Control valve with integrated main-stream valve Load hook with bottom block and buffer...

  • Page 10: Type Of Operation

    P R O D U C T I N F O R M A T I O N EXPLOSION PROTECTION JDN HOISTS FOR USE IN THE PRESENCE OF TEMPERATURE CLASS T6 GASES OR EXTREMELY The basis for the following information is an expert statement by EXPLOSIVE DUSTS the DMT Gas &...
  • Page 11 J. D. NEUHAUS. The maximum permissible temperature of 150°C (trolley or crane system). in accordance with EN 13463-1 for coal dust atmospheres is not reached.
  • Page 12 P R O D U C T I N F O R M A T I O N DANGER! This applies especially in the presence of rust or rust film. Rust Electrostatic charging may occur at the plastic (also rust film) formation is possible, especially on the chain and surfaces, potentially leading to electrostatic on the load hook, at the friction points.
  • Page 13 P R O D U C T I N F O R M A T I O N EXPLOSION GROUPS AND TEMPERATURE CLASSES OF THE MOST IMPORTANT GASES AND VAPOURS (-SELECTION-) (according to DIN VDE 01656, Redeker , Nabert, Schön , IEC 60079-12 and IEC 60079-20 Explosion...
  • Page 14 P R O D U C T I N F O R M A T I O N DECISION CRITERIA FOR SELECTING THE CORRECT JDN HOISTS IN EXPLOSION-HAZARDOUS AREAS Explosion groups for gases and vapours Zone Version Operation (cf. explosion groups and temperature classes for the most important gases and vapours) II A II B (X) except hydrogen sulphide, ethylene oxide (highly...
  • Page 15 P R O D U C T I N F O R M A T I O N TEMPERATURE LIMITS FOR EXPLOSION-HAZARDOUS DUSTS In areas that are potentially explosive due to combustible dusts, the The corresponding surface temperatures can be derived from the surface temperature must not exceed two-thirds of the ignition lowest values for glow and ignition temperatures of dusts specified temperature in °C of the dust/air mixture.

  • Page 16: Intended Use

    P R O D U C T I N F O R M A T I O N INTENDED USE 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 25 TI to 50 TI ranges are also suitable for pulling loads horizontally.

  • Page 17: Emissions

    P R O D U C T I N F O R M A T I O N EMISSIONS The brake will drag and is thus subject to a high degree of wear. An impermissibly high degree of heating may occur. N o i s e e m i s s i o n s The controls become noticeably less sensitive.

  • Page 18: Principle Of Operation Of Jdn Air Vane Motors

    P R O D U C T I N F O R M A T I O N PRINCIPLE OF OPERATION OF JDN AIR VANE MOTORS The vane motor consists of a cylinder liner 1 with two side bearing plates and an internal rotor 2. The rotor 2 is mounted eccentrically in the cylinder liner 1 and is provided with slots 3 for installation of the vanes 4.

  • Page 19: Operation Without Chain Box

    P R O D U C T I N F O R M A T I O N OPERATION WITHOUT CHAIN BOX SPARE PARTS D A N G E R ! Only use original JDN spare parts. J.D. NEUHAUS GMBH & CO. If JDN Air Hoists are operated without a chain box, it KG accepts no liability for the use of non-original components must be ensured that the idle chain (unloaded chain...

  • Page 20: Application

    A P P L I C A T I O N For this reason, when calculating the performance of the air hoist, APPLICATION we have allowed for a 10% drop in nominal pressure when lifting the maximum load specified for the hoist. AREA OF APPLICATION Specifically: An air hoist designed for 6 bar achieves the specified For permanent stationary outdoor operation, hoists must be...

  • Page 21: Transport And Storage

    T R A N S P O R T A N D S T O R A G E SAFE TRANSPORTATION If you wish to transport your JDN Air Hoist to another site, please observe the following points: Carefully dismount trolley (if fitted). Set the entire hoist down carefully;...

  • Page 22: Initial Operation

    I N I T I A L O P E R A T I O N D A N G E R ! INITIAL OPERATION The supporting structure of the air hoist must form a rigid mounting. Vibration damages the chain and can lead to chain fracture.

  • Page 23: Controls

    I N I T I A L O P E R A T I O N CONTROLS JDN Air Hoists are actuated via the following The actuating elements (pushbuttons, levers) return to the controls: zero position automatically after being released. Controls Emergency-stop Sensitive...

  • Page 24: Connecting The Controls

    I N I T I A L O P E R A T I O N CONNECTING THE CONTROLS CONNECTING THE ROPE CONTROLS The control ropes are designed as knotted link chains. Fasten both knotted link chains at the ends of the control lever using shackles and eyebolts.
  • Page 25 I N I T I A L O P E R A T I O N MAKING CONNECTIONS CONNECTING THE AIR CONTROLS A T T E N T I O N ! FASTENING THE COMPLETE CONTROL UNIT TO THE HOIST Please ensure that the hose is not bent when inserted.
  • Page 26 I N I T I A L O P E R A T I O N ATTACHING STRAIN RELIEF E and F controls: Insert the loop of the strain relief (wire rope) in the eyebolt provided. E-CONTROL CONNECTION Pushbutton valve (hand control) Guide the strain-relief rope through the eye on the pushbutton valve and secure it using the cable clamp.

  • Page 27: Connecting To The Main Air Supply

    I N I T I A L O P E R A T I O N CONNECTING TO THE MAIN AIR SUPPLY Check the air connection for contamination and clean if necessary. Blow through the compressed air hose in order to remove foreign bodies.

  • Page 28: Lubricants

    I N I T I A L O P E R A T I O N LUBRICANTS Application Lubricant The following lubricants are intended for normal environmental Motor lubrication - JDN high-performance influences. - at factory grease, Part No. 11901 If operating under adverse conditions that induce increased wear, - for operation with oiler (250 ml)

  • Page 29: Inspection Before Initial Operation

    I N I T I A L O P E R A T I O N CHECKING PRIOR TO INITIAL OPERATION Ensure that the chain is running into the hoist properly before working with the JDN Air Hoist. Before each operation, check that the chain is not twisted and that the bottom block, if fitted, is not Hoists, including the supporting structure, must be inspected by an defective.

  • Page 30: Operation

    O P E R A T I O N OPERATION RULES FOR THE SAFE OPERATION OF HOISTS 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.
  • Page 31 O P E R A T I O N Before attaching the load, accurately position it vertically JDN Air Hoists must not be used for the following applications, for example: below the hoist. The chain must hang vertically before lifting. Ensure that the hook safety catch is closed.
  • Page 32 O P E R A T I O N 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.

  • Page 33: Controls

    O P E R A T I O N CONTROLS E-CONTROL With E-control, lifting and lowering movements can be controlled JDN Air Hoists can be equipped with a variety of control devices. via two pushbuttons. They are all suitable for use in explosion-hazardous areas. The direction of movement of the load hook is marked on the upper side of the valve housing, above the pushbuttons.
  • Page 34 O P E R A T I O N 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.

  • Page 35: Emergency Stop

    O P E R A T I O N EMERGENCY STOP DEVICE These controls are always equipped with an EMERGENCY STOP device. 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.

  • Page 36: Chain

    O P E R A T I O N CHAIN In addition, rusty chains are subject to extreme wear. Protect the chain from corrosion. RUNNING-IN INSTRUCTIONS FOR HOIST CHAINS PRIOR TO OVERLOAD TESTING Ensure that the chain is in perfect condition before initial operation of the JDN Air Hoist.

  • Page 37: Load Hook

    O P E R A T I O N LOAD HOOK Check the hook opening “a” and the height “h” of the load hook of JDN Air Hoists that are in use at least once a year (see Check dimensions, page 58ff). Load hooks should not be loaded at the tip, be adjusted,...

  • Page 38: Lifting The Load

    O P E R A T I O N LIFTING THE LOAD ATTENTION! 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 to tighten the slack chain. With the chain tight, briefly interrupt the lifting procedure.

  • Page 39: Taking Out Of Operation

    T A K I N G O U T O F O P E R A T I O N SHUTTING DOWN DISPOSAL If the hoist is to be taken out of operation for a longer period of time, JDN Hoists contain a range of materials which, on expiry of the it must be protected against corrosion and dirt.

  • Page 40: Maintenance

    M A I N T E N A N C E MAINTENANCE INSPECTION AND REPAIRS MAINTENANCE AND INSPECTION INTERVALS Series lifting equipment is classified into groups and dimensioned according to the type of operation (Driving mechanism classification JDN Air Hoists are extremely robust and require little maintenance. according to ISO/FEM).
  • Page 41 M A I N T E N A N C E Only if the group classification corresponds to the actual mode of operation of the lifting equipment, does a safe operating period conform to the theoretical operating time. Deviations of the actual mode of operation from that used for calculation extend or shorten the safe operating period.

  • Page 42: Instructions Concerning The "Model For Determining The Actual Operating Time

    M A I N T E N A N C E The formula given for the cubic average k does not take the weight INSTRUCTIONS CONCERNING THE “MODEL FOR of the harness into account. This is permissible if the ratio DETERMINING THE ACTUAL OPERATING TIME”...
  • Page 43 M A I N T E N A N C E MODEL FOR DETERMINING THE ACTUAL OPERATING TIME The following calculation compares the actual operating time with the theoretical operating time in load spectrum 4 (very heavy). Average Load spectrum factor relative to Partial Date Remaining...
  • Page 44 M A I N T E N A N C E 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.
  • Page 45 M A I N T E N A N C E Inspection measure Interval Comment Check sealing efficiency and function of control Annually valve Check the state of the chain box Annually (Chain box, page 64) including mounting Check for brake wear and motor vane wear Every 200 hours, at least (Motor installation and inspection, page 50), replace every 5 years...

  • Page 46: Lubricating The Chain

    M A I N T E N A N C E LUBRICATING THE CHAIN CHECKING BRAKING FUNCTION The chain of the JDN Air Hoist must be lubricated in the links when Check the function of the brake daily as follows: not under load.

  • Page 47: Checking Lifting And Lowering Limiters

    M A I N T E N A N C E CHECK LIFTING AND LOWERING LIMITERS CHECKING SILENCER FOR PERMEABILITY Move the unloaded load hook until just short of the upper and Irrespective of the stipulated inspection intervals, the silencer must lower end positions.

  • Page 48: Service Unit

    M A I N T E N A N C E SERVICE UNIT CLEANING THE FILTER ELEMENT ATTENTION! ATTENTION! Do not use alcohol for cleaning the service unit. If a hoist is operated with a service unit, this should Alcohol can damage parts of service unit. not be mounted further than 5m away from the hoist.

  • Page 49: Filling And Adjusting Oiler

    M A I N T E N A N C E FILLING AND ADJUSTING THE OILER The oiler can also be filled 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.

  • Page 50: Motor Installation And Inspection

    M A I N T E N A N C E MOTOR INSTALLATION AND INSPECTION CHECKING THE Brake linings Vanes Motor lubrication Motor installation / Replacing brake discs, brake piston and vanes integrated in the motor housing. The motor and brake functions are achieved in part by means of Remove the rotor 6 together with vanes 7 and starting aids 8.

  • Page 51: Motor Lubrication

    M A I N T E N A N C E 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).

  • Page 52: Removing And Installing Bottom Block, Clamp And Buffer

    M A I N T E N A N C E Note: For assembly, it is helpful to fasten a short assembly chain to the end of the chain by means of an open chain link before pulling REMOVING AND INSTALLING BOTTOM the chain out of the bottom block.
  • Page 53 M A I N T E N A N C E - TREBLE CHAIN HOIST (37 TI) Assembly Push the buffer assembly in the correct alignment (buffer plus buffer discs, edge encloses buffer) onto the chains. Align the chain and fasten it to the assembly chain in the bottom block by means of the open chain link.
  • Page 54 M A I N T E N A N C E - QUADRUPLE CHAIN HOIST (50 TI) Note: For subsequent assembly, it is helpful to work with three short assembly chains which are fastened by means of an open chain link 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.
  • Page 55 M A I N T E N A N C E REMOVING AND INSTALLING CLAMP AND BUFFER Removal (see illustrations, page 52-54) 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 is not attached to the hoist body.

  • Page 56: Removing And Installing Chain

    M A I N T E N A N C E REMOVING AND INSTALLING CHAIN If the first link of the new chain is not correctly positioned, it ATTENTION! must be removed. The chain supplied together with this JDN hoist is matched to the chain sprocket according to strict Note: It is possible that the first chain link of the other chain end is tolerances.

  • Page 57: Replacing Chain And Chain Sprocket

    M A I N T E N A N C E REPLACING CHAIN AND CHAIN SPROCKET When removing the old chain and replacing the drive chain sprocket, assembly chains 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, page 52ff and Removing and installing chain, page 56.

  • Page 58: Checking Chain, Chain Sprocket

    M A I N T E N A N C E CHECK DIMENSIONS CHECKING THE CHAIN, CHAIN SPROCKET AND CHAIN GUIDES HOIST CHAIN Note: When checking the replacement limit, future wear up until the See also Check dimensions, page 58. next inspection date must be taken into account.
  • Page 59 “h” “a” a, x = Limit dimensions after max. permitted wear PROFI 25TI 83.4 80.8 = Number of teeth of the chain sprocket d x t = Nominal diameter times pitch of chain link PROFI 37TI / 50TI 116.9...

  • Page 60: Checking Axial Play

    M A I N T E N A N C E CHECKING AXIAL PLAY Maintenance and lubrication Please ensure that the load hooks and/or the 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...

  • Page 61: Checking And Adjusting Overload Protection

    M A I N T E N A N C E CHECKING AND ADJUSTING OVERLOAD PROTECTION Attach overload of 125% of the load-carrying capacity. If the overload is lifted, the adjusting bolt must be adjusted clockwise until it is no longer possible to lift the overload. All JDN Air Hoists are equipped with overload protection If the overload is not lifted, the adjusting bolt must be adjusted as standard.

  • Page 62: Faults, Causes And Remedies

    F A U L T S , C A U S E S A N D R E M E D I E S FAULT TABLE Fault Possible cause Remedy Lifting not possible Air pressure too low Increase air pressure to the required value Release the emergency-off switch if the danger has EMERGENCY STOP been rectified...

  • Page 63: Accessories

    A C C E S S O R I E S ACCESSORIES FILTER SILENCER 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.

  • Page 64: Chain Box

    A C C E S S O R I E S CHAIN BOX In various application situations, a chain box enhances operational ATTENTION! safety, e.g. if a chain that is hanging down could become caught up Never allow the chain to pile up in the chain box. with the load.

  • Page 65: Appendix

    A P P E N D I X APPENDIX TECHNICAL DATA Type 25 TI 37 TI 50 TI Load-bearing capacity 37.5 Number of chain sections Air pressure Lifting speed at nominal load m/min 1.25 0.75 0.55 Lifting speed without load m/min Lowering speed at nominal load m/min...

  • Page 66: Dimensions

    A P P E N D I X DIMENSIONS Dimensions 25 TI 37 TI 50 TI A minimum headroom 1260 1470 1485 1080 1080 F to centre of hook, without chain box Chain boxes increase the required headroom powered by air! Page 66...

  • Page 67: Circuit Diagram

    A P P E N D I X CIRCUIT DIAGRAM R o p e c o n t r o l powered by air! Page 67...
  • Page 68 A P P E N D I X D u a l c o n t r o l powered by air! Page 68...
  • Page 69 A P P E N D I X D u a l c o n t r o l w i t h p i n v a l v e , “ L o w e r ” s i d e ( O P T I O N A L ) powered by air! Page 69...
  • Page 70 A P P E N D I X Q u a d r u p l e c o n t r o l powered by air! Page 70...
  • Page 71 A P P E N D I X Q u a d r u p l e c o n t r o l w i t h p i n v a l v e , “ L o w e r ” s i d e ( O P T I O N A L ) powered by air! Page 71...
  • Page 72 is a registered trade mark of our company. BA 822 EN - Issue: February 2011 – Subject to changes – J.D. NEUHAUS GmbH & Co. KG / D-58449 Witten-Heven PHONE + 4 9 ( 0)2302 208-0 / FAX + 4 9 ( 0)2302 208-286 website: www.jdn.de / e-mail: info@jdn.de...

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