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Table of Contents
Related Manuals for J. D. NEUHAUS JDN mini Series
Summary of Contents for J. D. NEUHAUS JDN mini Series
- Page 1 Distributed by Ergonomic Partners Sales@ErgonomicPartners.com www.ErgonomicPartners.com Tel: (314) 884-8884 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 Original Operation and Assembly Instructions...
- Page 2 This operation manual edition 8/2010, covers the following JDN MINI Air Hoists: Fabr. No. Fabr. No. Please enter the Fabr. No. of your JDN Air Hoist here. mini 500 Fabr. No. Fabr. No. It must be read carefully and in its entirety before operating any MINI air hoist.
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Page 3: Table Of Contents
TABLE OF CONTENT S Emergency stop device ....26 S A F E T Y M E A S U R E S Attaching the load . - Page 4 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˝...
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Page 5: Organisational Measures
SAFET Y INS TRUCTIONS SAFET Y INS TRUCTIONS O RG A N I S AT I O N A L M E A S U R E S P E R S O N N E L S A F E T Y JDN Hoists are designed in accordance with current Personnel who operate, maintain, inspect and perform technological standards and accepted safety practice. -
Page 6: Product Information
PRODUCT INFORMATION PRODUCT INFORMATION T H E O P E R AT I O N M A N UA L WA R N I N G S A N D S Y M B O L S This operation manual is intended to help the operator Safety warnings in this operation manual are classified to become familiar with JDN air hoists and their in three categories:... -
Page 7: Designation
PRODUCT INFORMATION L A B E L L I N G 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. -
Page 8: Assembly Overview
PRODUCT INFORMATION A S S E M B LY OV E R V I E W MINI series air hoists consist of the following assemblies: 1 Motor 2 Gearbox with chain drive 3 Controls 4 Chain and hook 5 Chain box P RO D U C T D E S C R I P T I O N MINI series JDN Air Hoists are chain air hoists for load- carrying capacities of 125 kg, 250 kg, 500 kg and 980... -
Page 9: Explosion Protection
PRODUCT INFORMATION 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 E X P L O S I O N P RO T E C T I O N Impacts between particular materials result in an increased ignition hazard. - Page 10 PRODUCT INFORMATION EXPLOSION GROUPS AND TEMPER ATURE CLASSES OF THE MOST IMPORTANT GASES AND VAPOURS (-SELECTION) (in accordance with DIN VDE 0165 , Redeker , Nabert, Schön , IEC 60079-12 and IEC 60079-20 Ex group Temperature class Ignition temperature > 450° C 450-300°...
- Page 11 PRODUCT INFORMATION DECISION CRITERIA FOR SELECTING THE CORRECT JDN HOIS T S IN EXPLOSION-HAZARDOUS AREAS Explosion groups of gases and vapours Zone Version* Operation* (cf. Explosion groups and temperature classes of the most important gases and vapours) Manufacturer's responsibility Operator's responsibility II A II B (X) except hydrogen sulphide, ethylene oxide (particularly flammable)
- Page 12 PRODUCT INFORMATION The corresponding surface temperatures can be derived T E M P E R AT U R E L I M I T 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 from the lowest values for glow and ignition tempera- tures of dusts specified in the HVBG/BIA Report 12/97 In areas which are explosion-hazardous due to com-...
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Page 13: Intended Use
PRODUCT INFORMATION I N T E N D E D U S E O P E R AT I N G CO N D I T I O N S JDN Air Hoists are designed for lifting and lowering JDN Air Hoists are extremely robust and require little loads within the specified load-carrying capacities, with maintenance. - Page 14 PRODUCT INFORMATION 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.
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Page 15: Energy Requirements
PRODUCT INFORMATION The value of the actual pressure p2 at which the E N E RG Y R E Q U I R E M E N T S hoist is operated, depends upon For air pressure, air quantity and connections, see the weight of the load and the Technical data table in the hoist operation the direction of movement of the load. -
Page 16: Principle Of Operation Of Jdn Air Vane Motors
PRODUCT INFORMATION P R I NC 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. -
Page 17: Operation Without Chain Box
PRODUCT INFORMATION O P E R AT I O N W I T H O U T C H A I N B OX S PA R E PA R T S DA N G E R ! Only use original JDN spare parts. J.D. NEUHAUS If JDN Air Hoists are operated without a GMBH &... -
Page 18: Tr Anspor T And S Tor Age
TR ANSPOR T AND S TOR AGE TR ANSPOR T AND S TOR AGE 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 fitted). -
Page 19: Initial Oper Ation
INITIAL OPER ATION INITIAL OPER ATION DA N G E R ! U N PAC K I NG The supporting structure of the air hoist must form a rigid mounting. Vibration dam- C AU T I O N ! ages the chain and can lead to chain frac- When unpacking, take account of the weight ture. -
Page 20: Connecting The Controls
INITIAL OPER ATION CO N N E C T I N G T H E CO N T RO L S If the controls were delivered at the same time but groove for main air unattached, connect them as follows (see also illustra- bellows connection tion Connecting the controls):... -
Page 21: Connecting To The Main Air Supply
INITIAL OPER ATION 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. -
Page 22: Pre-Start Checks
INITIAL OPER ATION CHECKING PRIOR TO INITIAL OPER AT I O N Application Lubricant Motor lubrication - JDN high-performance Hoists, including the supporting structure, must be grease, - from factory Art. no. 11901 (250 ml) inspected by an appropriately trained and qualified - when operating with oiler - Compressed air oil ˝D˝, person before initial operation and before re-commis-... -
Page 23: Oper Ation
OPER ATION OPER ATION 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. - Page 24 OPER ATION JDN Air Hoists must not be used for the following When taking up and setting down, ensure stable applications, for example: positioning of the load, to prevent accidents due to tilting or falling loads. Critical areas of nuclear plants. Never drive against jammed loads.
- Page 25 OPER ATION 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.
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Page 26: Controls
OPER ATION CO N T RO L S E M E RG E NC Y S T O P D E V I C E All MINI series JDN Air Hoists are equipped with Each control is equipped with an direct controls. -
Page 27: Attaching The Load
OPER ATION First, lift the load hook, in order to pull the slack AT TAC H I N G T H E L OA D chain tight. With the chain tight, briefly interrupt the lifting procedure. The hoist can align itself and DA N G E R ! the material is protected. -
Page 28: Taking Out Of Oper Ation
TAKING OUT OF OPER ATION TAKING OUT OF OPER ATION S H U T T I N G D OW N D I S P O S A L If the hoist is to be taken out of operation for a longer JDN Hoists contain a range of materials which, on period of time it must be protected against corrosion expiry of the service life, must be disposed of or recy-... -
Page 29: Maintenance
MAINTENANCE MAINTENANCE M A I N T E N A NC E A N D I N S P E C T I O N A N D R E PA I R S I N S P E C T I O N I N T E R VA L S Series lifting equipment is classified into groups and dimensioned according to the type of operation (Driving JDN Air Hoists are extremely robust and require little... - Page 30 MAINTENANCE Only if the group classification corresponds to the actu- al type of operation of the lifting equipment, does a safe operating period conform to the theoretical operat- ing time. Deviations of the actual type of operation from that used for calculation extend or shorten the safe operating period.
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Page 31: Instructions On The ˝Model For Determining The Actual Operating Time
MAINTENANCE The formula given for the cubic average k does not take I N S T R U C T I O N S CO NC E R N I N G T H E the weight of the harness into account. This is permissi- ˝... - Page 32 MAINTENANCE 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). Remaining Average Collective load factor in accor- Partial deploy- Date theoretical daily dance withcollective load for ment use in...
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Page 33: Lubricating The Chain
MAINTENANCE The specified inspection intervals are valid for use in accordance with the classification (see driving mechanism classifi- cation 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 31). -
Page 34: Checking Braking Function
MAINTENANCE BR AKING DIS TANCE UNDER NOMINAL LOAD L U B R I C AT E T H E C H A I N (LOAD-C ARRYING C APACIT Y) AFTER LOWERING HAS BEEN S TOPPED The chains of JDN Air Hoist must be lubricated in the links, in unloaded condition. -
Page 35: Checking Controls And Emergency Stop
MAINTENANCE C H E C K I N G CO N T RO L S A N D E M E RG E NC Y S T O P The control elements of the controls must always be easily moving. Unload the JDN Air Hoist. -
Page 36: Replacing Brake Discs, Brake Pistons And Vanes /Motor Installation
MAINTENANCE 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 T O N A N D VA N E S / M O T O R I N S TA L L AT I O N 13/14 Replacing brake discs, brake piston and vanes / Motor installation The braking action is applied at the lateral surfaces of... - Page 37 MAINTENANCE Should the wear limit be reached prematurely, the Coat the vanes lightly with high-performance grease actual compressed air pressure must be checked with and push into the rotor slots with the starting aids. the device switched on (the brake drags in the event Lightly coat the entire brake piston surface including of insufficient pressure).
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Page 38: Checking Axial Play
MAINTENANCE C H E C K I N G A X I A L P L AY C H E C K I N G A N D R E P L AC I N G L OA D H O O K A N D B U F F E R When the axial play of the installed hook or load eye exceeds 2.5 mm (see drawing), the worn parts If die hook opening a and the height h of the load... -
Page 39: Checking Chain
MAINTENANCE R E P L AC I N G L OA D H O O K I NC L U D I N G L OA D R E P L AC I N G B U F F E R O N T H E E N D O F T H E C H A I N S L E E V E A N D B U F F E R R E M O VA L When operated with a chain box 12 the chain box... -
Page 40: Replacing Chain And Chain Sprocket
MAINTENANCE Corrosion pitting R E P L AC I N G C H A I N A N D Bent or damaged chain links C H A I N S P RO C K E T Chain drawn tight Wear over 11 pitches (A max ) R E M OV I N G C H A I N Single pitch wear (B max ) The chain sprocket must be replaced together with the... -
Page 41: Chain Box
MAINTENANCE AT T E N T I O N ! DA N G E R ! The chain supplied together with this JDN If JDN Air Hoists are operated without a hoist is matched to the chain sprocket chain box, it must be ensured that the according to strict tolerances. -
Page 42: Fault S, C Ause And Remedy
FAULT S, C AUSE AND REMEDY FAULT S, C AUSE AND REMEDY FAU LT TA B L E Fault Possible cause Remedy Lifting not possible Air pressure too low Increase air pressure to the relevant value EMERGENCY STOP switch When danger is eliminated, is pressed release the EMERGENCY STOP switch Hand control is faulty... -
Page 43: Appendix
APPENDIX APPENDIX T E C H N I C A L DATA Type mini 125 mini 250 mini 500 mini 1000 Load-carrying capacity 980* Number of chains Motor rating Weight at 3 m standard lifting distance and 2 m control length 10.5 Weight of 1 m chain 0.35... -
Page 44: Dimensions
APPENDIX D I M E N S I O N S All measurements mini 125 mini 250 mini 500 mini 1000 in mm Page 44 powered by air ! -
Page 45: Tightening Torques
APPENDIX T I G H T E N I N G T O R Q U E S Tightening torques in Nm Item Screw mini 125/250 mini 500/1000 1 hexagon socket screw for hoist housing 2 hexagon socket screws for hoist housing 4 hexagon socket screws for cover 4 hexagon socket screws for control valve housing Page 45... -
Page 46: Air Flow Sheet
APPENDIX A I R F L OW S H E E T Hubmotor lifting motor Hauptanschluss Ventilblock am Hubmotor main air connection valve at the lifting motor Steuerventil mini ” “ control valve “ mini ” Handsteuerventil manual control valve NOT-STOPP emergency stop Druckluftversorgung... - Page 47 NO TES Page 47 powered by air !
- Page 48 are registered trademarks of our company. BA 814 EN · Subject to changes · 82010 Distributed by Ergonomic Partners Sales@ErgonomicPartners.com www.ErgonomicPartners.com Tel: (314) 884-8884 powered by air!