J. D. NEUHAUS JDN mini 1000 Operation And Assembly Instructions Download

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

Organisational measures

. . . . . . . . . . . . . . . . . . 5

Personnel safety

. . . . . . . . . . . . . . . . . . . . . . . . 5

Preventing property damage

. . . . . . . . . . . . . . . 5

The operation manual

. . . . . . . . . . . . . . . . . . . . . 6

Warnings and symbols

. . . . . . . . . . . . . . . . . . . . . 6

Designation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Assembly overview

. . . . . . . . . . . . . . . . . . . . . . . 8

Product description

. . . . . . . . . . . . . . . . . . . . . . . 8

Explosion protection

. . . . . . . . . . . . . . . . . . . . . . 9

Intended use

. . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Emissions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operating conditions

. . . . . . . . . . . . . . . . . . . . . 13

Energy requirements

. . . . . . . . . . . . . . . . . . . . 15

Principle of operation of

JDN air vane motors

. . . . . . . . . . . . . . . . . . . . . 16

Operation without chain box

. . . . . . . . . . . . . . . 17

Motor lubrication/operation with service unit

. 17

CE marking / declaration of incorporation

. . . . . 17

Spare parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safe transportation

. . . . . . . . . . . . . . . . . . . . . 18

Storage conditions

. . . . . . . . . . . . . . . . . . . . . . 18

Unpacking

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Installing the hoist

. . . . . . . . . . . . . . . . . . . . . . 19

Connecting the controls

. . . . . . . . . . . . . . . . . . . 20

Connecting to the main air supply

. . . . . . . . . . . 21

Lubricants

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pre-start checks

. . . . . . . . . . . . . . . . . . . . . . . . 22

Rules for safe operation

of hoists

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Controls

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Emergency stop device

. . . . . . . . . . . . . . . . . . . 26

Attaching the load

. . . . . . . . . . . . . . . . . . . . . . . 27

Lifting the load

. . . . . . . . . . . . . . . . . . . . . . . . . 27

Lowering the load

. . . . . . . . . . . . . . . . . . . . . . . 27

Detaching the load

. . . . . . . . . . . . . . . . . . . . . . 27

Interrupting working

. . . . . . . . . . . . . . . . . . . . 27

Shutting down

. . . . . . . . . . . . . . . . . . . . . . . . . 28

Storage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Dismantling

. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Disposal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Maintenance and inspection intervals

. . . . . . . . 29

Cleaning and care

. . . . . . . . . . . . . . . . . . . . . . . 29

Spare parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Lubricants

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Inspection and repairs

. . . . . . . . . . . . . . . . . . . . 29

Instructions on the

model for determining

the actual operating time

˝ . . . . . . . . . . . . . . . . . 31

Lubricating the chain

. . . . . . . . . . . . . . . . . . . . 34

Checking braking function

. . . . . . . . . . . . . . . . 34

Checking the direction of movement

. . . . . . . . . 34

Checking lifting and lowering limiters

. . . . . . . . 34

Checking controls and emergency stop

. . . . . . . . 35

Checking the silencer for permeability

. . . . . . . 35

Replacing brake discs, brake pistons and vanes

/Motor installation

. . . . . . . . . . . . . . . . . . . . . . 36

Adjusting the brake

. . . . . . . . . . . . . . . . . . . . . . 36

Checking axial play

. . . . . . . . . . . . . . . . . . . . . . 38

Checking and replacing load hook and buffer . .

Checking chain

. . . . . . . . . . . . . . . . . . . . . . . . . 39

Replacing chain and chain sprocket

. . . . . . . . . . 40

Chain box

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Fault table

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Technical data

. . . . . . . . . . . . . . . . . . . . . . . . . . 43

Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Tightening torques

. . . . . . . . . . . . . . . . . . . . . . 45

Air flow sheet

. . . . . . . . . . . . . . . . . . . . . . . . . . 46

A P P E N D I X

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

M A I N T E N A N C E

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

O P E R AT I O N

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

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

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

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

Summary of Contents for JDN mini 1000

Page 1: ...P E R A T I O N A N D A S S E M B LY I N S T R U C T I O N S AIR HOIS T S Original Operation and Assembly Instructions Distributed by Ergonomic Partners Sales ErgonomicPartners com www ErgonomicPartners com Tel 314 884 8884 ...

Page 2: ...ng JDN MINI Air Hoists It must be read carefully and in its entirety before operating any MINI air hoist For hoists installed in trolleys refer also to the JDN Trolleys Operation Manual Please enter the Fabr No of your JDN Air Hoist here Fabr No Fabr No Fabr No Fabr No mini 500 ...

Page 3: ...load 27 Lowering the load 27 Detaching the load 27 Interrupting working 27 Shutting down 28 Storage 28 Dismantling 28 Disposal 28 Maintenance and inspection intervals 29 Cleaning and care 29 Spare parts 29 Lubricants 29 Inspection and repairs 29 Instructions on the model for determining the actual operating time 31 Lubricating the chain 34 Checking braking function 34 Checking the direction of mov...

Page 4: ...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 asso ciation When operating air hoists in areas with explosive atmospheres the operator must comply with the relevant expl...

Page 5: ...azard awareness during work 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 occupa tional safety an...

Page 6: ...n manual are classified in three categories DANGER Safety warnings which if not followed can result in hazard to life and limb are indicat ed by this symbol The symbol indicates an immediate danger The possible consequences of non observance may be severe or even fatal injuries CAUTION This symbol indicates potentially hazardous situations Failure to observe may result in light injuries ATTENTION ...

Page 7: ...ncerning 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 Phone 49 2302 208 0 Fax 49 2302 208 286 www jdn de e mail info jdn de Example of nameplate on housing cover LABELLING powered by air PRODUCT INFORMATION Page 7 ...

Page 8: ...y use only repetitive impact of buffers is not allowed Operator must monitor hook travel to prevent impact of the buffer against the hoist body JDN MINI Air Hoists conform to driving mechanism clas sification 1 Bm in accordance with FEM corresponding to M3 as per ISO The motors for the JDN MINI air hoists are treated dur ing installation with a JDN high performance grease Art No 11901 This grease ...

Page 9: ...tant steel or cast iron against aluminium magnesium or corresponding alloys It applies in partic ular to the presence of rust or of rust film Rust also rust film formation is possible especially on the chain and on the load hook at the friction points The follow ing 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 po...

Page 10: ...5 C II A Acetone Ethyl alcohol n Amyl alcohol Acetaldehyde Ammonia Ethylene glycol Benzene Aniline i Amyl acetate petrol Benzol n Butane Diesel Chlorobenzene n Butyl alcohol Fuel oil 1 2 Dichlorobenzene 1 Butylene n Hexane Acetic acid 1 2 Dichloroethane jet fuels Ethane Di i Propyl ether Ethyl acetate Natural gas Ethyl bromide Acetic anhydride Ethyl chloride n Propyl acetate Carbon monoxide n Prop...

Page 11: ...rge 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 respons...

Page 12: ...f the Member States concerning equipment and protective systems intended for use in potentially explosive atmos pheres 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 exp...

Page 13: ...ased concentrations of soot and dust high humidity and at ambient temperatures of 20 C up to approx 50 C if they are not heated above this level due to external influences The thermal endurance of chains and hooks is 150 C CAUTION When touching metallic hand controls which are colder than 0 C the skin could freeze within a few seconds and at temperatures above 43 C burns may occur As a protec tive...

Page 14: ...s 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 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 Art no 11900 with anti icing agent for relevant temperatures In the event that your...

Page 15: ... 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 b...

Page 16: ... by two vanes 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 The arrows in the illustration indicate the direction of rotation of the rotor and the corresponding path of ...

Page 17: ...ion 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 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 o...

Page 18: ...he 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 speci fied intervals a protective coating must be applied to the motor For this purpose use a non resinous and non sticky conserving oil with conserving protec tion duration which corresponds to the length of the planned operational break STORAGE Clos...

Page 19: ...lation can result in the most serious of accidents DANGER The attachment points for JDN Air Hoists must be able to safely withstand the expected forces DANGER The supporting structure of the air hoist must form a rigid mounting Vibration dam ages the chain and can lead to chain frac ture Furthermore external vibration must on no account be transmitted to the hoist lift ing gear e g from the suspen...

Page 20: ...e middle of the hose grommet clamping range The best clamping characteristics are achieved in this range Secure the hoses using the one ear hose clamps and crimping tool Push up bellows and allow them to snap into the groove provided on the valve housing ATTENTION To ensure perfect sealing the ear must be fully closed on installation Removal Connecting the controls Pinched one ear clamp and crimpi...

Page 21: ...to receive the appropriate instructions CAUTION Oils and greases can cause skin irritation Wear protective gloves ATTENTION 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 lubri cant groups Synthetic lubricants must not be used when operating with oilers Al...

Page 22: ...ION Page 22 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 mm2 s cSt at 40 C with anti icing agent where applicable Chain lubrication chain oil or motor vehicle engine oil kinematic viscosity approx 150 mm2 s cSt at 40 C or special lubricant from J D NEUHAUS In areas w...

Page 23: ... 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 Under special safety provisions relevant to the particular situation JDN Air Hoists may be used for oblique pulling see Intended use page 13 In this case a chain box must not ...

Page 24: ...ting 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 use original JDN chain boxes Only lift one load at a time never several loads simultaneously Never lock the contr...

Page 25: ...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 opera tional reasons crack inspections are to be performed at intervals of three months Company operating instructions In the case of particularly difficult lifting equipment applications the compa...

Page 26: ...to slow lowering allow operated pushbutton to return slowly Each control is equipped with an EMERGENCY STOP device In order to avert danger arising from the lifting move ment 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 ...

Page 27: ...ith the chain tight briefly interrupt the lifting procedure The hoist can align itself and the material is protected Then lift the load DANGER Ensure that there are no persons below the load Then lower the load and ground it carefully DANGER 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 po...

Page 28: ...ection 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 JDN Hoists contain a range of mate...

Page 29: ...eration 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 fv The factor fv 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 In order ...

Page 30: ...on 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 sup ply during assembly work Dismantling the hoist see page 28 CAUTION Following each repair the hoist must be checked for operational readiness powered by air MAI...

Page 31: ...age 31 Weight of harness Load bearing capacity 0 05 Maximum or ultimate load Load bearing capacity Definitions Dead load Load bearing capacity Operating time with maximum load or partial load and dead load Total operating time Operating time with dead load Total operating time Collective load 1 Collective load 2 Load proportions t2 t1 tΔ t3 0 4 0 1 0 733 0 467 0 2 0 10 50 100 0 16 7 33 3 50 100 t2...

Page 32: ... daily operating time in hours Collective load factor in accor dance withcollective load for the type of operation Partial deploy ment Remaining theoretical use in collective load 4 When zero has been reached a general overhaul must be performed Date Delivery Initial operation Inspections Specialist inspector Signature 1 2 3 4 5 6 7 L1 Low L3 High L4 Very high L2 Average 0 0 125 0 25 0 5 1 0 Exist...

Page 33: ...therwise replace at least once a year Section Checking lifting and lowering limiters page 34 Check chain Every 3 months Section Checking chain page 39 Shorten inspection intervals in the case of wear promoting operating conditions Check sprocket wheel and chain guides Each time the chain is changed Check all bolted and pin connections Yearly Check load hook on the load and Yearly Section Checking ...

Page 34: ...leased the chain must be seen not to run on DANGER 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 If the control hoses are long the braking distances will increase due to longer air evacuation times Check that th...

Page 35: ...irectly into the outlet air chamber If the ball in the inner seat of the control piston does not close outlet air escapes at the hand control valve DANGER If a control element is stiff or remains in the actuated position do not use the hoist The controls must be repaired The silencer must be checked for permeability if the hoist does not achieve the specified lifting speed see section Technical da...

Page 36: ...e cover bolts are removed the tension of the brake springs 4 is fully released Remove the springs 4 Remove the brake piston 7 from the cylinder liner 8 Pull out the rotor 9 collecting the vanes 10 and starting aids 11 NOTE If you only wish to replace the vanes with the starting aids please continue with the section Checking for vane wear Pull out the cylinder liner 8 Remove the brake disc 12 Check...

Page 37: ...d push it into the cylinder liner with the braking surface first note the correct position of the eccentric bore Lightly coat the outer rotor bearing needle bush with high performance grease as well Insert the brake springs into the bores of the brake piston Install the cover with bearing ensure correct seating of the brake springs and locating pins to the motor housing and to the brake piston scr...

Page 38: ...he sheet metal thickness of the safety catch must be subtracted from the maximum permissible hook opening dimension a Check dimensions of the load hook a h CHECKING AND REPLACING LOAD HOOK AND BUFFER max 2 5 mm CHECKING AXIAL PLAY powered by air MAINTENANCE Page 38 Load sleeve with load hook or load eye Load carrying Maximum Minimum capacity permis dimension height h of hook opening a 1 up to 250 ...

Page 39: ... connection Loosen screw connection 7 at the clamp 8 Remove the clamp 8 from the chain Detach the buffer 9 and buffer discs 10 11 from the chain ASSEMBLY Push the buffer disc 10 with edge edge encloses buffer the new buffer 9 and the buffer disc 11 without edge onto the chain For the version with chain box insert first chain link into the chain pocket of the clamping sleeve 8 for version without c...

Page 40: ...he chain box from the hoist body Then detach load sleeve clamp buffer and buffer discs from the chain as described in the section Replacing load hook including load sleeve and buffer page 39 and allow chain to run out of the hoist To replace the chain sprocket the gearbox must be removed see E list After replacing the chain sprocket and installing the hoist the chain can be drawn in DRAWING IN THE...

Page 41: ...ut completely on the load hook side and then run back into the container via the chain drive in the air hoist operating position DANGER 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 pre sent a hazard e g due to catching impact ing or falling Danger due to falling chain can also arise if...

Page 42: ...iciently large too small diameter check air pressure Dirt in the service unit Clean the service unit Filter blocked ensure better air quality Silencer is Replace the silencer elements clogged or clean improve air quality if necessary Motor vanes worn Replace motor vanes Motor has run dry Lubricate motor Check oiler Control valve on motor Have the control valve repaired Excessive running on during ...

Page 43: ...lifting distance and 2 m control length kg 9 5 10 5 21 23 Weight of 1 m chain kg 0 35 0 35 1 0 1 0 Chain dimensions mm 4x12 4x12 7x21 7x21 Air pressure nominal pressure bar 6 6 6 6 Air consumption at nominal load lifting m3 min 0 5 0 5 1 2 1 2 Air consumption at nominal load lowering m3 min 0 7 0 7 1 6 1 6 Air connection G3 8 G3 8 G1 2 G1 2 Hose size Ø inside mm mm 9 9 13 13 Lifting speed at nomin...

Page 44: ...rements in mm mini 125 mini 250 mini 500 mini 1000 A 328 328 458 458 B 232 232 316 316 C 367 367 505 505 D 92 92 122 122 E 213 213 292 292 F 109 109 148 148 G 104 104 144 144 H 177 177 234 234 J 148 148 194 194 K 83 83 119 119 L 29 29 40 40 M 19 19 28 28 ...

Page 45: ...2 Tightening torques in Nm Item Screw mini 125 250 mini 500 1000 1 1 hexagon socket screw for hoist housing 8 21 2 2 hexagon socket screws for hoist housing 8 21 3 4 hexagon socket screws for cover 4 9 8 4 4 hexagon socket screws for control valve housing 3 5 6 ...

Page 46: ...air supply heben lifting senken lowering p h s NOT STOPP emergency stop Hubmotor lifting motor B R A R Steuerventil mini control valve mini Handsteuerventil manual control valve Ventilblock am Hubmotor valve at the lifting motor p h s Hauptanschluss main air connection ...

Page 47: ...powered by air NOTES Page 47 ...

Page 48: ... are registered trademarks of our company BA 814 EN Subject to changes 82010 powered by air Distributed by Ergonomic Partners Sales ErgonomicPartners com www ErgonomicPartners com Tel 314 884 8884 ...

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J. D. NEUHAUS JDN mini 1000, Operation And Assembly Instructions

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