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J. D. NEUHAUS PROFI 2 TI Operating And Assembly Instruction Manual

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JDN OPERATING AND ASSEMBLY INSTRUCTIONS
Hoist
PROFI 2 TI
Serial No.: P408756-P408757
Representation may differ from actual product!
ORIGINAL OPERATING
AND ASSEMBLY INSTRUCTIONS
Doc.-No.: VA058498-50-OM-EN-1021-62-2

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Summary of Contents for J. D. NEUHAUS PROFI 2 TI

  • Page 1 JDN OPERATING AND ASSEMBLY INSTRUCTIONS Hoist PROFI 2 TI Serial No.: P408756-P408757 Representation may differ from actual product! ORIGINAL OPERATING AND ASSEMBLY INSTRUCTIONS Doc.-No.: VA058498-50-OM-EN-1021-62-2...
  • Page 3 Contact data These operating instructions are a part of the product. Always keep the instructions If you have questions about handling your product on site. that are not answered in these operating instruc- The operating instructions are to be tions, please contact read carefully and in their entirety before handling any product.

  • Page 5: Table Of Contents

    ONTENTS Contents 4.2.2. Storage ... . 5. Initial operation 1. User information 5.1. Unpacking ....1.1. About these operating instructions . 5.2.
  • Page 6 ONTENTS A. Technical data B. Dimensions Page 6 of 62 Doc.-No.: VA058498-50-OM-EN-1021-62-2...

  • Page 7: User Information

    Listings without specified sequence These operating instructions should make it easy Reference to other sections in these operation for you to get to know your product PROFI 2 TI instructions or applicable documents and to take advantage of the intended application possibilities.

  • Page 9: Safety Information

    2.1. General safety instructions When installing your product PROFI 2 TI in sys- Your product PROFI 2 TI is built according to cur- tems as well as in exceptional cases of use, spe- rent technological standards and the recognised cial regulations may apply.
  • Page 10 AFETY INFORMATION Adhere to the prescribed maintenance inter- vals. Only use the product for work that is de- scribed as intended. Observe the conditions of use described in these instructions for your product. Page 10 of 62 Doc.-No.: VA058498-50-OM-EN-1021-62-2...

  • Page 11: Product Information

    Among others, the following are considered im- 3.1. Proper use proper uses Your product PROFI 2 TI is designed for lifting and Changing load capacities with the load posi- lowering loads in the range of the rated load ca- tion: Your product is not equipped with a load pacity with a vertically arranged chain.

  • Page 12: Labelling (Nameplate)

    Using special safety precautions that are ap- propriate for the respective situation, your prod- uct PROFI 2 TI can be used for diagonal pull. In the process, a chain box may not be used, as the chain could fall out here or become knotted.

  • Page 13: Module Overview

    Your product PROFI 2 TI consists of the following In the following, you will receive a description of main modules ( Figure 3): your product PROFI 2 TI and its modules or com- ponents. You will find other technical data in the 1. Gear mechanism appendix.

  • Page 14: Explosion Protection Classification

    RODUCT INFORMATION 3.5.3. Explosion protection classification 3.5.4. Vane motor Your product PROFI 2 TI is marked according to The vane motor ( Figure 4) consists of a cylin- der liner (1) with two lateral bearing washers and EC directive 2014/34/EU and DIN EN 1127-1 as follows: an inner rotor (2).

  • Page 15: Motor Lubrication

    RODUCT INFORMATION 3.5.5. Motor lubrication All control switches automatically return to the neutral position when released. All movements are The JDN high performance grease contained in stopped instantaneously and the load is securely the motor allows for operation with oil-free com- held in its current position.

  • Page 16: Lifting Limiter

    RODUCT INFORMATION 3.5.8. Lifting limiter 3.5.9. Lowering limiter WARNING WARNING Danger from chain fracture Danger from chain fracture If the buffers are damaged, unacceptably high If the buffer is damaged, unacceptably high loads loads may act on the chain when starting the may act on the chain when starting the lowering lifting limiter.

  • Page 17: Load Hook

    JDN chains may be installed. Your product PROFI 2 TI has 2 falls and the chain size 7 x 21. Your product was shipped without a chain. Assem- bly chains are inserted for the installation of the chain.

  • Page 18: Dead End Chain Mount

    Your product PROFI 2 TI is very sturdy and re- uations listed above. quires very little maintenance. It is suitable for ap-...

  • Page 19: Power Requirement

    The load capacity of the device is reduced. The response of the control system decreases notice- ably. Comply with the specified pressure. Your product PROFI 2 TI must be operated with a nominal pressure of 6bar (85psi) (see specification on the nameplate). Air pressure conditions during operation (...

  • Page 20: Quality Of The Compressed Air

    The following operating materials and lubricants are intended for normal environmental influences. Your product PROFI 2 TI must be operated with a In the event of environmental influences that pro- sufficiently clean and dry working air. The working mote wear, please contact J.D. Neuhaus to obtain air must meet the following quality requirements: appropriate information.

  • Page 21: Explosion Protection

    RODUCT INFORMATION 3.10. Explosion protection Application area Operating material Motor lubrication JDN high performance Load chain To ensure the required earthing, grease, item no. 11904 badly rusted chains may no longer be used in (250ml) zones 1 and 21 as well as in devices of category Engine lubrication for Air lubricator “D”, kine- M2.
  • Page 22 RODUCT INFORMATION impact sparks. Emergency lowering DANGER Earthing Electrostatic ignition hazards can be avoided by means of safe earthing. In zones 1 Risk of explosion and 21, it is required to earth the hoists. This must There is an increased danger of explosion during be achieved via load hooks or load eyes if the lift- emergency lowering.
  • Page 23 RODUCT INFORMATION Emergency lowering DANGER Risk of explosion There is an increased danger of explosion during emergency lowering. Heat is generated in the en- gine that cannot be sufficiently dissipated due to the lack of compressed air supply (see “General information on explosion protection”).
  • Page 24 RODUCT INFORMATION Explosion groups and temperature classes of the most important gases and vapours (-selection-) in accordance with (DIN VDE 0165 , Redeker , Nabert , IEC 60079-12 und IEC 60079-20 Explosion pro- Temperature class tection group Ignition temperature >450 C 450-300 C 300-200 C 200-135 C...
  • Page 25 RODUCT INFORMATION Decision criteria for selecting the correct JDN products 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 flammable) II B II C...

  • Page 26: Declaration Of Incorporation

    3.11. Declaration of incorporation Temperature limits for explosion-hazardous dusts In areas that are potentially explosive Your product PROFI 2 TI is an incomplete ma- due to combustible dusts, the surface temperature chine in the sense of the EC machinery directive must not exceed two-thirds of the ignition temper- 2006/42/EC.

  • Page 27: Transport And Storage

    4. Motor conservation: If the motor lubrication could lead to malfunctions. is not renewed at the specified intervals, a If you want to transport your product PROFI 2 TI protective coating must be applied to the mo- to another site of application, please observe the tor.

  • Page 29: Initial Operation

    Do not twist the chain! dard lift of 3m (10 ft), each 1m (1ft) of additional lift increases the weight by 2x 1,0kg (2x 0.67lbs)) of your product PROFI 2 TI during transport. En- NOTICE sure that the control system is not damaged. This could lead to malfunctions.

  • Page 30: Attach The Hoist

    The attachment points and supporting struc- ture for your product PROFI 2 TI must be able to securely absorb the forces ( table 1) to be expected.

  • Page 31: Connecting The Power Supply

    5.5. Lubricating the chain Before tests can be carried out, the chain must be lubricated. The chain of your product PROFI 2 TI must be lubricated in the links in an unloaded state. Clean heavily soiled chains. Place the chain in a suitable container.

  • Page 32: Check Control Device

    Have the product repaired ment and the load-bearing medium. 1. Relieve the product PROFI 2 TI. Safety devices are: 2. Briefly actuate and release all control ele- ments of the controls one after the other. The Brake assemblies ( Section 5.6.3)

  • Page 33: Check Lifting Limiter

    NITIAL OPERATION Check with nominal load 5.6.4. Check lifting limiter Alternatively switch your product PROFI 2 TI WARNING loaded with a nominal load to lifting and low- ering Danger from chain fracture If you release a control device, the chain must...

  • Page 34: Check Lowering Limiter

    NITIAL OPERATION 5.6.5. Check lowering limiter WARNING Danger from chain fracture If the buffers are damaged, inadmissibly high loads may act on the chain upon actuation of the lowering limiter. The chain may break. Do not use the product Have the product repaired (replace buffer) 1.

  • Page 35: Operation

    For the safety of persons and property when deal- Always only lift one load, never several loads ing with your product PROFI 2 TI, it is crucial to simultaneously. observe the following points: When lifting and setting down, ensure a stable position of the load to avoid accidents from Never stress the chain to where it bends.

  • Page 36: Attaching The Load

    PERATION 6.2. Attaching the load Have detached screw connections from repair attached. When lifting loads in non-visible areas, special WARNING safety precautions must be taken. Danger to life from being struck Uncontrolled external force impacts (such as Improper attaching the load can lead to the load from hydraulic cylinder, falling loads) are not crashing down.

  • Page 37: Lifting The Load

    The hoist can be aligned and the material is Danger from overloading! Ensure that for all appli- protected. cations of your product PROFI 2 TI the load hook Then lift the load. / clevis can be lowered all the way to the ground to avoid a load being driven into the lower limit position without reaching the ground.

  • Page 38: Interrupting Work

    PERATION 6.6. Interrupting work If you want to interrupt work with your product: Set down and release the load. Move the load hook / clevis out of the traffic area to avoid dangers. Page 38 of 62 Doc.-No.: VA058498-50-OM-EN-1021-62-2...

  • Page 39: Decommissioning

    ECOMMISSIONING 7. Decommissioning 7.2. Disposal Your product PROFI 2 TI contains a series of ma- 7.1. Disassembly terials that you may have to dispose of or have re- cycled after the end of their useful lives according CAUTION to statutory provisions.

  • Page 41: Maintenance

    PROFI 2 TI operates safely and operating time. Deviations of the actual mode of reliably over a period of many years.

  • Page 42: Model For Determining The Actual Use

    AINTENANCE 8.2. Model for determining the actual use The decisive factors for the type of operation are the The FEM 9.511 rule differentiates between four load load spectrums with different cubic averages k. spectrums, which are identified by the definitions The load spectrum indicates to what extent a driving and by the ranges of the cubic averages k.
  • Page 43 AINTENANCE The following calculation compares the actual operating time with the theoretical operating time in load spec- trum L4 (very heavy). Collective load factor in accor- dance Operating Average Partial Remaining Date Specialist with collective load for the type site daily deployment theoretical use in...

  • Page 44: Maintenance And Inspection Intervals

    AINTENANCE 8.3. Maintenance and inspection intervals The specified inspection intervals are valid for use in accordance with the classification. The service life is approx. 10 years if the device is used in accordance with its classification. If your product is used more intensively, the intervals are to be shortened accordingly. All operating hours are translated into full load hours.
  • Page 45 AINTENANCE Replace chain at least every 5 years (in corrosive environment) Check chain sprocket Whenever the 8.13, Page 52 chain is replaced Check chain guide Whenever the 8.14, Page 52 and hook mount chain is replaced Lubricate lifting motor When required, 8.6.3, Page 48 at least every 5 years Check gearbox and perform...

  • Page 46: Spare Parts

    Alcohols are not (cleaning cloth with water). permitted as de-icing agents. If your product PROFI 2 TI is often used at differ- The following operating materials and lubricants ent locations, particularly in dirty and damp envi- are intended for normal environmental influences.

  • Page 47: Lubricating The Chain

    11904 lubricated. (250ml) Engine lubrication for Air lubricator “D”, kine- The chain of your product PROFI 2 TI must be operation with oiler matic viscosity about lubricated in the links in an unloaded state. (cSt) bei 40 C, Clean heavily soiled chains.

  • Page 48: Re-Lubricate The Lifting Motor

    AINTENANCE 8.6.3. Re-lubricate the lifting motor the lubricant chambers and secure these us- ing retaining rings. 3. Engine assembly with additional basic lubrica- CAUTION tion of the engine: Danger of injury from pre-tensioned a) Provide the braking surface and rotor springs bearing (needle bush) of the cover with Pre-tensioned springs are released when disas-...
  • Page 49 AINTENANCE carried out with the device warmed up 4. Check the braking action under nominal load accordingly. (run in the brake by performing several hoist- ing cycles, then assess) prior to initial opera- j) Tighten the nameplate (1) . tion. Check the motor power. In the event of low motor power, regulate the adjusting bolts again.

  • Page 50: Check Control Device

    Have the product repaired Have the product repaired Check without load 1. Relieve the product PROFI 2 TI. 2. Briefly actuate and release all control ele- Alternately switch your unloaded product ments of the controls one after the other. The...

  • Page 51: Check The Buffer

    AINTENANCE 8.10. Check the buffer 8.11. Check lifting limiter WARNING WARNING Danger from chain fracture Danger from chain fracture A damaged or non-existent buffer can lead to a If the buffers are damaged, inadmissibly high fracture of the chain if the upper or lower hook loads may act on the chain upon actuation of the end position is met.

  • Page 52: Check Lowering Limiter

    AINTENANCE 8.12. Check lowering limiter 8.13. Check chain sprocket WARNING NOTICE Danger from chain fracture If the wear dimensions of a chain sprocket are If the buffers are damaged, inadmissibly high outside of the limit dimensions indicated below, loads may act on the chain upon actuation of the then the chain sprocket is to be replaced.

  • Page 53: Check The Hook, Shackle And Eyelets

    AINTENANCE 8.15. Check the hook, shackle and Checking axial clearance If the axial clear- ance of the installed load hook or clevis exceeds eyelets the maximum clearance specified, the worn parts Check load and support hook If the dimension must be replaced. x, y or h of the load hook (support hook) is outside of the limit value, the hook must be replaced.

  • Page 54: Check Silencer

    AINTENANCE 8.16. Check silencer 8.17. Check lifting motor CAUTION CAUTION Danger from noise Danger of injury from pre-tensioned By removing the silencer, the noise pressure level springs of the product increases. Pre-tensioned springs are released when disas- Always wear appropriate protection equipment sembling the engine covers.
  • Page 55 AINTENANCE 2. Checking vane wear: When the vanes (7) are worn, the engine power is reduced. Replace the vanes (7) and starting aids (8) together. Figure 19: Vane Vane dimensions after maximum permissible wear (measured at the thinnest point): 49,5 mm 19,0 mm 3,4 mm 3.

  • Page 56: Replace Chain

    Check the motor power. In the event of 5. Switch PROFI 2 TI to Lifting and run the new low motor power, regulate the adjusting bolts chain through the bottom block and drive again.
  • Page 57 AINTENANCE 7. Mount the components on the idle chain: a) Push the buffer disc with edge (3) (edge encloses the buffer), new buffer (2) and buffer disc without edge onto the chain. b) Insert the 10th chain link into the chain pocket of the clamp sleeve (1) (chain pocket away from the hoist body, facing outward) and secure with bolted connec-...

  • Page 59: Faults, Causes And Remedies

    AULTS CAUSES AND REMEDIES 9. Faults, causes and remedies LIFTING NOT POSSIBLE OR ONLY POSSIBLE VERY SLOWLY Possible cause Remedy Insufficient inlet pressure Increase inlet pressure to the required value. Input volume too low Increase input volume to the required value. Hand control is faulty Have hand control repaired.
  • Page 60 AULTS CAUSES AND REMEDIES LOUD NOISE AT THE CHAIN SPROCKET OR GEARBOX Possible cause Remedy Chain dry Lubricate the chain. Check wear. Chain sprocket worn Replace chain sprocket, check chain guide and replace if necessary. Chain worn Replace chain with a new JDN chain. Wrong chain drawn in Identify chain and replace with JDN chain if necessary.
  • Page 61 ECHNICAL DATA A. Technical data metric anglo-american Load capacity 2.2 tn.sh. Number of chain strands Weight with standard lift (3m (10ft)) and control 34 kg 75 lbs Chain dimension 7 x 21 mm Weight of chain 1,0 kg/m 0.67 lbs/ft Air pressure 6 bar 85 psi...
  • Page 62 IMENSIONS B. Dimensions inch 19.6 13.2 11.7 Page 62 of 62 Doc.-No.: VA058498-50-OM-EN-1021-62-2...

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