Related Manuals for J. D. NEUHAUS MINI 125
Summary of Contents for J. D. NEUHAUS MINI 125
- Page 1 JDN AIR HOISTS MINI 125 // MINI 250 // MINI 500 // MINI 1000 // INSTALLATION AND OPERATION MANUAL Doc.No.: D0000201 Rev. 0 / 24.05.2019...
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Page 2: Table Of Contents
CONTENTS CONTENTS GENERAL ..............................2 About these operating instructions ......................2 Copyright protection ..........................2 Contact data............................2 Limitation of liability ..........................3 Further documents ..........................3 Definition of terms ..........................3 marking ............................3 SAFETY INFORMATION ..........................4 Qualification of personnel ........................4 Operating company obligations ...................... -
Page 3: General
GENERAL 1 GENERAL About these operating instructions These operating instructions should make it easy for you to get to know your hoist and to take advantage of the intended application possibilities. These operating instructions contain important information to be able to operate your hoist safely, properly and efficiently. -
Page 4: Limitation Of Liability
GENERAL Limitation of liability All information and instructions in this manual were compiled in accordance with the applicable standards and regulations, current technological standards as well as many years of experience. J.D. Neuhaus GmbH & Co. KG assumes no liability for damage due to: Non-observance of the instructions ... -
Page 5: Safety Information
SAFETY INFORMATION 2 SAFETY INFORMATION Your hoist is built according to current technological standards and the recognised technical safety regulations. Nevertheless, dangers to life and limb of the user or third parties or impairments to their product and other property may result if the safety rules are disregarded during the product's use. Qualification of personnel The personnel responsible for operation, maintenance, inspection and set-up work must be competent or be instructed by a competent person before beginning work. -
Page 6: Improper Use
SAFETY INFORMATION Improper use The following are regarded as improper use: Changing load capacities with the load position: Your hoist is not equipped with a load capacity display, which is why it may only be used in such cases where the load capacity does not change with the load position. -
Page 7: Personal Protective Equipment
SAFETY INFORMATION Personal protective equipment The protective equipment required for the operation, maintenance and inspection of the hoist is determined by the operating company’s risk assessment. As manufacturer we recommend the following protective equipment: Safety helmet in the danger area ... -
Page 8: Technical Description
TECHNICAL DESCRIPTION 3 TECHNICAL DESCRIPTION Marking / identification For accurate identification you will find a nameplate on your hoist containing all relevant information (→Fig. 2: Nameplate). Description Air Hoist Type Lifting capacity Rated hoisting speed Chain Group of mechanisms Nom. pressure Year of construction Serial number Explosion proof class... - Page 9 TECHNICAL DESCRIPTION 3.2.1 Motor with integrated brake The pneumatic motor is designed as a vane motor with integrated brake. Cylinder liner Throttle Rotor Outlet opening Vane with starting aids Lubricant chamber Inlet opening “Lifting” Inlet opening “Lowering” Fig. 4: Sectional view of the compressed air vane motor The vane motor consists of a cylinder liner with two lateral bearing washers and an inner rotor.
- Page 10 Do not use chains measuring 4mm x 12mm, 5mm x 15mm (mini 125/250) or 7mm x 21mm (mini 500/1000)! The hoist is designed as a single chain hoist and has a chain size of 4.7mm x 14.1mm (mini 125/250) or 7.4mm x 22.0mm (mini 500/1000).
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Page 11: Load Capacity
Shut-off valve Fig. 7: Shut-off valves Load capacity The permissible load capacity of the hoist is shown in the following table: Type mini 125 mini 250 mini 500 mini 1000 Load capacity 125 kg (275 lbs) -
Page 12: Information On Explosion Protection
TECHNICAL DESCRIPTION Information on explosion protection Hoists from the mini series are marked as follows in accordance with EU Directive 2014/34/EU and DIN EN 13463-1: II 3 GD IIA T4(X) The additional marking "X" refers to the explosion protection in the operating instructions. Your product mini 500 is a device in category 3, can be used in general industry, in zone 2 for gases of the explosion group IIA with an ignition temperature over 135°C (275°F). -
Page 13: Sound Pressure Level
10% below the specified nominal pressure of the hoist (measured immediately before the lifting motor)! 3.6.3 Volume The air consumption of the hoist is shown in the following table: Type mini 125 mini 250 mini 500 mini 1000 Air consumption when m³/min (cfm) 0,95 (33.5) -
Page 14: Operating Conditions
TECHNICAL DESCRIPTION The following formula can be used to determine the emission sound pressure level at the operator site for buildings of common structural design: − 10 ∙ lg ( d) with d=distance from operator site to hoist body Operating conditions CAUTION Safe and proper operation of the hoist is only possible if the specified operating conditions are observed. -
Page 15: Transport And Storage
Transporting NOTICE Note the weight of the hoist of 10kg (22lbs) for the mini 125/250 or 20,5/21kg (45/46lbs) for the mini 500/1000. This weight applies for a lift of 3m (10ft), each metre (ft) of additional lifting height increases the weight by 0.5kg (0.35lbs) for the mini 125/250 or 1.2kg (0.81lbs) for the mini 500/1000. -
Page 16: Initial Operation
Unpacking NOTICE Note the weight of the hoist of 10kg (22lbs) for the mini 125/250 or 20,5/21kg (45/46lbs) for the mini 500/1000. This weight applies for a lift of 3m (10ft), each metre (ft) of additional lifting height increases the weight by 0.5kg (0.35lbs) for the mini 125/250 or 1.2kg (0.81lbs) for the mini 500/1000. -
Page 17: Suspending The Hoist
(DIN EN 14492-2:2010). Ensure that your product can be freely aligned under load, as otherwise impermissible additional loads may occur. Type mini 125 mini 250 mini 500 mini 1000 Impact factor... -
Page 18: Connecting The Air Supply
INITIAL OPERATION 5.3.1 Hoist with support hook with hook safety catch 1) Hang the hoist in the on-site suspension. 2) Make sure that a) the on-site suspension is on the central axis of the support hook. b) the hook safety catch is closed. c) the support hook can swing slightly in all directions. -
Page 19: Lubricating The Chain
Adjusting the Max. lifting speed at nominal Max. lowering speed at Hoist throttle load nominal load minimal 100% 100% mini 125 / 250 maximal ~55% ~70% minimal 100% 100% mini 500 / 1000 maximal ~50% ~65% 2-3) Fig. -
Page 20: Tests Before Commissioning
INITIAL OPERATION Tests before commissioning WARNING Danger to life If the hoist is put into operation without proper testing (e.g. in accordance with the currently applicable accident prevention regulations), there is a danger to life and health. The hoist, including the supporting structure, must be inspected by an appropriately trained and qualified person before... -
Page 21: Operation
OPERATION 6 OPERATION As an operator, you are responsible for your own safety and the safety of your colleagues in the working area of the hoist. The hoist may only be operated by persons authorised by the operating company. ... -
Page 22: Attaching The Load
OPERATION the control elements must not cause any movement. The load must be held securely in its present position. Then release the emergency stop button. 6.1.4 Checking the operational limit stop for lifting and the buffers WARNING Danger from chain fracture A damaged buffer or non-functioning end stop can lead to a fracture of the chain if the upper hook end position is met. -
Page 23: Moving The Load
OPERATION Fig. 15: Examples of incorrect attachment of the load 6.2.1 Load attachment for load hooks with hook safety catch Press on the hook safety catch and connect the sling gear at the lowest point of the hook. Never load the tip of the hook! ... -
Page 24: Releasing / Detaching The Load
OPERATION WARNING Danger of chain breakage due to knot formation in the chain When a load is taken up suddenly on slack chain, the chain may knot in the chain box. In rare cases, this may result in the load hook no longer being able to be lowered across the full hook path. A knot has formed in the idle chain strand which was driven against the lowering chain inlet during lowering and blocked the chain. -
Page 25: Operating The Emergency Stop
OPERATION Operating the emergency stop WARNING Danger from maintaining hazardous situations Danger persists by maintaining a dangerous situation. Never release the emergency stop button before the danger is eliminated and, if necessary, the stop function is restored via the push buttons or press buttons. In order to avert a danger caused by the movement, the push buttons are to be let go as quickly as possible. -
Page 26: Maintenance And Repair
MAINTENANCE AND REPAIR 7 MAINTENANCE AND REPAIR CAUTION Risk of explosion Observe the national regulations and work instructions at your workplace when carrying out assembly, maintenance and disassembly work in explosion-hazardous areas. CAUTION Dangers due to improper repair Improper repair can lead to errors on the product and thus to hazardous situations. ... -
Page 27: Maintenance And Inspection Intervals
MAINTENANCE AND REPAIR Maintenance and inspection intervals The following maintenance and inspection intervals must be observed. The intervals are determined by two criteria, full load hours and period. The criterion which is reached first is decisive for the maintenance or inspection measures. Maintenance and inspection measures Interval Section... - Page 28 MAINTENANCE AND REPAIR ∙ The factors must be determined for individual payloads and added to the totals. For determining the actual use, it is permissible to use the nominal speeds at nominal load throughout for the speeds. For devices used mainly in vertical operation (from 75% of on-time), the factor must also be multiplied by the factor = 1 + 0,5 ∙...
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Page 29: Oils And Greases
MAINTENANCE AND REPAIR Oils and greases Motor and chain must be lubricated during operation. 7.3.1 Lubricants CAUTION Danger of skin irritation Oils and greases may cause skin irritation. Wear protective gloves. Observe the safety data sheet of the lubricant used. NOTE Do not mix synthetic oils or greases with mineral oils or greases, as the properties may deteriorate. -
Page 30: Checking The Brake With Nominal Load
MAINTENANCE AND REPAIR 7.3.3 Lubricate motor NOTICE A dry-running motor leads to heavy wear and performance losses. Adhere to the specified relubrication intervals. Do not use too much lubricant. This can clog the motor and silencer and ultimately lead to a loss of performance or a malfunction. -
Page 31: Checking The Chain
Each chain replacement must be documented in the inspection log. Wear mark Fig. 22: Example for wear mark and check dimensions of chain Type mini 125/250 mini 500/1000 Dimension A max. 167,1 261,4 Dimension 11xt internal max. - Page 32 Chains from JDN are matched to the chain sprocket in close tolerances. In order to ensure an optimum function of the chain and in order to prevent risks, only genuine JDN chains may be installed. Do not use chains measuring 4mm x 12mm, 5mm x 15mm (mini 125/250) or 7mm x 21mm (mini 500/1000)! mini 125/250: M6...
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Page 33: Checking The Chain Inlet
4) Reassemble the chain inlets. 5) Check that the shut-off valves on the load chain side and the idle chain side are working (→ section 6.1.4 and 7.8). Type mini 125/250 mini 500/1000 max. max. max. 32 // EN Rev. -
Page 34: Checking The Hook
Check for wear regularly. If one of the test dimensions of the load or support hook is outside a limit value, the hook must be replaced. Fig. 25: Checking the hook Type mini 125/250 mini 500/1000 40,9 60,9 max. 16,0 27,0 min. -
Page 35: Checking The Chain Box And Lowering Limiter
Check the function of the shut-off valve regularly. Check the condition of the buffer regularly. mini 125/250: M6 mini 500/1000: M8 Fig. 27: Checking the chain box and lowering limiter 1) Disassemble the chain box. 2) Inspect the chain box visually for cracks and check the bending of the clamping plate. The permissible maximum amount of bending must not be exceeded. -
Page 36: Checking The Chain Guide, Chain Sprocket And Pinion Shaft
The chain is subjected to impermissible stresses if the chain is twisted. Do not twist the chain when reassembling the hoist! mini 125/250: M6 / 8Nm mini 500/1000: M8 / 21Nm mini 125/250: M6 mini 500/1000: M8 mini mini 125/250 500/1000 Schnitt B-B min. -
Page 37: Checking The Vanes And Brake Lining
To check the vanes and brake lining, the motor unit must be removed from the motor and disassembled. This can be done while the hoist is suspended. M5 / 4,9Nm M4 / 2,5N mini 125/250: M4 / 2,5N mini 500/1000: M5 / 4,9Nm Fig. 29: Checking the vanes and brake lining 1) Depressurise the hoist and remove the motor housing cover. -
Page 38: Checking The Silencer
4) Remove the two motor and brake covers and pull the brake piston and rotor out of the cylinder liner. 5) Checking vane wear: When the vanes are worn, the motor power and consequently the lifting performance are reduced. Replace the vanes and starting aids together. Type mini 125/250 mini 500/1000 min. 12,8 19,0 min. -
Page 39: Checking The Gear Lubrication
MAINTENANCE AND REPAIR 1) Depressurise the hoist and remove the gearbox housing. A strong pull on the gear housing may be necessary. 2) Examine both the felt plate and the filter disc. In case of coarse soiling or blockage, replace both elements (→... -
Page 40: Faults, Causes And Remedies
FAULTS, CAUSES AND REMEDIES 8 FAULTS, CAUSES AND REMEDIES Lifting / lowering not possible or only possible very slowly Possible cause Remedy Insufficient inlet pressure Increase inlet pressure to the required value. Input volume too low Ensure sufficient volume. Cross section of the supply line too Use line with sufficient cross section. -
Page 41: Decommissioning
DECOMMISSIONING Excessive running on during braking Possible cause Remedy Brake cover and/or brake piston worn Replace brake cover and/or brake piston. Motor freshly lubricated Move the hoist without load until the fresh grease has spread. Chain box is knocked out Possible cause Remedy Chain box is bent / damaged... -
Page 42: Appendix
APPENDIX 10 APPENDIX 10.1 Dimensions Type mini 125/250 mini 500/1000 mm (inch) 370 / 422 (14.57 / 16.61) 510 / 542 (20.08 / 21.34) mm (inch) 252 / 277 (9.92 / 10.91) 370 / 399 (14.57 / 15.71) mm (inch) 401 / 452 (15.79 / 17.80) -
Page 43: Technical Data
APPENDIX 10.2 Technical data Type mini 125 mini 250 mini 500 mini 1000 Load capacity kg (lbs) 125 (275) 250 (550) 500 (1100) 980 (2200) Nominal pressure bar (psi) 6 (87) Number of chain sections Weight with 3m lift kg (lbs) -
Page 44: Flow Sheet
APPENDIX 10.3 Flow sheet Abschaltung Senken Limit switch lowering Motor Bremse motor Schalldämpfer brake silencer Abschaltung Heben Limit switch lifting Senken Heben Lifting Lowering Hauptluftanschluß main air connection transparent green Handventil FI hand valve FI Not-Halt emergency stop Doc.No.: D0000201 Rev. - Page 45 APPENDIX EC/EU Conformity Declaration (Original Conformity Declaration) We, J.D. Neuhaus GmbH & Co. KG, 58449 Witten, Germany, hereby declare that the Compressed air hoist: JDN mini Serial no.: Nxxxxxx in the version supplied conforms to all applicable provisions of the following EC/EU Directives: // 2006/42/EC, EC Machinery Directive // 2014/34/EU, ATEX Directive Directive 2006/42/EC, Machinery Directive...