J. D. NEUHAUS PROFI 25 TI, Operating And Assembly Instruction Manual

Page 1: ...PERATING AND ASSEMBLY INSTRUCTIONS Hoist PROFI 25 TI Serial No 3101649 3101650 Doc No VA049318 10 OM EN 0319 64 2 ORIGINAL OPERATING AND ASSEMBLY INSTRUCTIONS Representation may differ from actual pro...

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Page 3: ...l ity for damage due to Non observance of the instructions Inappropriate use Use by untrained personnel Unauthorised conversions Technical changes Use of unauthorised spare parts Copyright protection...

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Page 5: ...reaks in operation 27 4 2 2 Storage 27 5 Initial operation 29 5 1 Unpacking 29 5 2 Attach the hoist 29 5 3 Connecting the power supply 30 5 4 Lubricating the chain 30 5 5 Tests before commissioning 30...

Page 6: ...CONTENTS 8 18 Check silencer 56 8 19 Check lifting motor 56 8 20 Replace chain 58 9 Faults causes and remedies 61 A Technical data 63 B Dimensions 64 Page 6 of 64 Doc No VA049318 10 OM EN 0319 64 2...

Page 7: ...e classified in four stages in these operating instructions DANGER Indicates an imminently hazardous situation that will result in death or serious injury if not avoided WARNING Indicates a possibly h...

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Page 9: ...xplosion protection regu lations are to be observed such as BGR 104 Explosion protection regulations BGR 132 Preventing ignition hazards due to electrostatic charges In other countries the correspondi...

Page 10: ...the prescribed maintenance inter vals I Only use the product for work that is de scribed as intended I Observe the conditions of use described in these instructions for your product Page 10 of 64 Doc...

Page 11: ...perating instructions and compliance with the inspection and maintenance conditions 3 2 Improper use Among others the following are considered im proper uses Changing load capacities with the load pos...

Page 12: ...sed as the chain could fall out here or become knotted Please contact us if necessary For other foreseeable misuses Rules for safe operation page 35 Your product PROFI 25 TI may not be used in the fol...

Page 13: ...load capacity of your product PROFI 25 TI is 25t 3 5 2 Driving mechanism classification Your PROFI 25 TI corresponds to the driving mechanism classification M3 1Bm according to ISO 4301 FEM 9 511 The...

Page 14: ...d capacities from 25t no continuous oper ation of the hoists is permitted if the ambient tem perature exceeds 50 C 122 F In these cases cooling times are to be met so as not to exceed the permissible...

Page 15: ...compressed air Figure 4 Functioning of the compressed air vane motor 3 5 5 Motor lubrication The JDN high performance grease contained in the motor allows for operation with oil free com pressed air...

Page 16: ...the overload protection is set too high unac ceptably high stresses can occur if a load is sus pended above the maximum load capacity There is a danger of the chain and device breaking I Do not transp...

Page 17: ...lock load sleeve If the buffer is moderately deformed in the boundary layer the overload protection switches the motor off Figure 6 Lifting limiter 3 5 10 Lowering limiter WARNING Danger from chain fr...

Page 18: ...en induced embrittlement with subsequent stress corrosion from highly corrosive media e g sea water may appear on high strength alloys e g on the chain There is a danger of break age So called recombi...

Page 19: ...ring the nominal load the sound pressure level is 82 dB A The decrease of the sound pressure level in the hall is about 3 dB A per distance doubling 3 6 2 Oil emissions When operating with oil lubrica...

Page 20: ...ee specification on the nameplate Air pressure conditions during operation Figure 9 The system pressure existing in the line must cor respond to the nominal pressure Higher pres sures must be reduced...

Page 21: ...nach ISO 8573 1 2001 To provide a sufficient compressed air quality we recommend operation with a filter regulator The pressure condensation point must be at least 10K below the lowest expected ambien...

Page 22: ...s may no longer be used in zones 1 and 21 as well as in devices of category M2 For depending on the degree of corrosion the conductivity of the chain may deteriorate so that it is no longer sufficient...

Page 23: ...ing of the load hook takes place via the chain Loads must be earthed during transportation A separate earthing is required for example when using non conductive sling gear Cleaning plastic surfaces DA...

Page 24: ...nitrobenzene Town gas Butadine 1 3 Dioxane 1 4 Divinyl ether Ethyl alcohol Ethylene Ethyle glycol Ethylen oxide Isoprene n Propylalkohol Dimethyl ether Hydrogen sulphide Ethyl ether Ether Schwefel et...

Page 25: ...s so that the sliding velocities for potential friction points between the chain and the surroundings remain well below 1 m s FS Hoists with increased spark protection Copper plated load hook and bott...

Page 26: ...emperature 190 C x 2 3 126 C max permissible surface temperature For further information 678 6Guideline 94 9 EC of the European Parliament and the Council dated 23 March 1994 on the adaptation of the...

Page 27: ...e control and supply hoses together so that they are not kinked 4 2 Storage conditions 4 2 1 Breaks in operation 1 Bring the load hook clevis into the upper end position Ensure that the lifting limite...

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Page 29: ...Your product PROFI 25 TI may only be installed by qualified personnel WARNING Danger from chain fracture Vibrations damage the chain and can lead to chain breakage I The supporting structure must form...

Page 30: ...rmly mount the hose clamp Screw on the union nut 5 4 Lubricating the chain Before tests can be carried out the chain must be lubricated The chain of your product PROFI 25 TI must be lubricated in the...

Page 31: ...release all control ele ments of the controls one after the other The control elements must return to their initial po sitions immediately The on and off function must operate without problem All con...

Page 32: ...In case this information should not be observed you damage the high tensile chain in your hoist already during testing prior to initial use for which the manufacturer does not undertake any liability...

Page 33: ...break I Do not use the product I Have the product repaired replace buffer 1 Move the unloaded load hook until just short of the upper end position 2 Stop immediately before reaching the end po sition...

Page 34: ...paired replace buffer 1 Move the unloaded load hook until just short of the lower end position 2 Stop immediately before reaching the end po sition and then carefully by repeatedly press ing the contr...

Page 35: ...s too long Only use an original JDN chain container Do not exceed the permissible fill capacity of the chain container When operating the chain container avoid dangers from an empty chain falling catc...

Page 36: ...rm in the operator s language while taking this user manual into con sideration These instructions shall regulate measures for safe operation according to the operational con ditions In addition all i...

Page 37: ...he load DANGER Danger to life from being struck People can be struck and killed from lowering loads I Make sure that no one is below the load or in the hazard area of the load NOTICE Danger from overl...

Page 38: ...nterrupting work If you want to interrupt work with your product I Set down and release the load I Move the load hook clevis out of the traffic area to avoid dangers Page 38 of 64 Doc No VA049318 10 O...

Page 39: ...move the control device 8 Carefully hang up your product PROFI 25 TI and transport away 7 2 Disposal Your product PROFI 25 TI contains a series of ma terials that you may have to dispose of or have re...

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Page 41: ...tor of fv The factor fv has a value of 1 at 50 of the nom inal load increasing linearly to 1 5 at 100 of the nominal load nominal load percentage P fv 1 0 5 P 50 50 for P 50 In order to achieve safe o...

Page 42: ...ke the weight of the harness into account This is permissible if the ratio W eight of the harness Load capacity 0 05 To determine the mode of operation for calculating the partial operating times actu...

Page 43: ...ate Specialist inspector in hours L1 light L2 med ium L3 heavy L4 very heavy column 2 x column 3 x operating days x factor 1 2 When zero has been reached a general overhaul must be performed Signature...

Page 44: ...ily 8 8 Page 50 Check brake function without load Daily 8 9 Page 50 Visually inspect the buffer of Daily 8 10 Page 51 lifting and lowering limiters Visually inspect the chain Weekly 8 14 Page 53 Check...

Page 45: ...ge 54 chain is replaced Check chain guide Whenever the 8 16 Page 54 and hook mount chain is replaced Lubricate lifting motor When required 8 6 3 Page 48 at least every 5 years Check gearbox and perfor...

Page 46: ...irt from your product I protect your product from corrosion 8 6 Lubricate and grease 8 6 1 Operating materials CAUTION Danger of skin irritation Oils and greases may cause skin irritation I Wear prote...

Page 47: ...dropping point 180 C Application temper atures 20 C bis 120 C Designation according to DIN 51825 KP2K 20 active ingredients EP additives to reduce wear and ageing pro tection water resistant and anti...

Page 48: ...s ing retaining rings 3 Engine assembly with additional basic lubrica tion of the engine a Provide the braking surface and rotor bearing needle bush of the cover with the brake pad with a thin layer o...

Page 49: ...the braking action under nominal load run in the brake by performing several hoist ing cycles then assess prior to initial opera tion Check the motor power In the event of low motor power regulate the...

Page 50: ...s it may be due to a faulty brake The load may fall I Do not use the product I Have the product repaired Check without load I Alternately switch your unloaded product PROFI 25 TI between lifting and l...

Page 51: ...rs are damaged inadmissibly high loads may act on the chain upon actuation of the lifting limiter The chain may break I Do not use the product I Have the product repaired replace buffer 1 Move the unl...

Page 52: ...8 13 Check overload protection WARNING Danger due to overloading If the overload protection is set too high imper missibly high stresses may arise if a load exceed ing the permissible load capacity i...

Page 53: ...fracture If the chain of your product PROFI 25 TI has one of the features listed below the chain may break upon further use I Do not use the product I Replace the chain Corrosion pitting Bent or dama...

Page 54: ...chain sprocket z amin xmax 4 60 0 mm 0 45 mm 5 59 6 mm 0 45 mm z Number of teeth of the chain sprocket a x Limit dimensions after maximum permitted wear 8 16 Check the chain guide and hook mount Chec...

Page 55: ...it must be assumed that the hardened surfaces of the mount are worn The worn parts of the mount must then be replaced immediately The actual dimensions of the mount must be measured and recorded befor...

Page 56: ...tensioned springs Pre tensioned springs are released when disas sembling the engine covers I Carefully loosen and remove the engine cover NOTICE See the spare parts list for tightening torques In orde...

Page 57: ...extremely low wear braking material will not reach the wear limit of 0 02mm within the design dependent service life of the hoist under intended use Should the wear limit be reached prematurely the a...

Page 58: ...to initial opera tion Check the motor power In the event of low motor power regulate the adjusting bolts again 8 20 Replace chain WARNING Danger from chain fracture The chain is subjected to impermis...

Page 59: ...buffer 2 onto the chain b Fasten clamping piece 1 to the 12th chain link and secure with screws c Fasten the chain end link in the dead end chain mount 8 The replacement of the chain for a new chain...

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Page 61: ...high can cause deactivations within the load capacity range Hand control is faulty Have hand control repaired Supply hoses leaking or loose Check connections Cross section of the line too small Use l...

Page 62: ...in with a new JDN chain Wrong chain drawn in Identify chain and replace with JDN chain if necessary Defective gearbox bearing Have product repaired LIFTING AND LOWERING SPEED DECLINES OR ENGINE STOPS...

Page 63: ...nominal load 6 5 m3 min 230 cfm Air consumption at lowering with nominal load 2 9 m3 min 102 cfm Hose connection G 1 1 2 Hose dimension inside 35 mm 1 1 2 inch Motor output lifting motor 6 3 kW Liftin...

Page 64: ...DIMENSIONS B Dimensions mm inch A 1260 49 6 B 827 32 6 C 450 17 7 D 900 35 4 E1 75 3 0 E2 75 3 0 F 270 10 6 G 445 17 5 Page 64 of 64 Doc No VA049318 10 OM EN 0319 64 2...