J. D. NEUHAUS PROFI 3 Ti, Customer'S Operating And Assembly Instructions

Page 1: ...OPERATING AND ASSEMBLY INSTRUCTIONS Hoist PROFI 3 TI Serial No P604247 P604248 Doc No VA053957 40 OM EN 0720 60 2 ORIGINAL OPERATING AND ASSEMBLY INSTRUCTIONS Representation may differ from actual pro...

Page 2: ......

Page 3: ...il 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...

Page 4: ......

Page 5: ...ation 25 4 2 2 Storage 25 5 Initial operation 27 5 1 Unpacking 27 5 2 Attach the hoist 27 5 3 Connecting the power supply 28 5 4 Lubricating the chain 28 5 5 Tests before commissioning 28 5 5 1 Check...

Page 6: ...k mount 51 8 17 Check the hook shackle and eyelets 52 8 18 Check silencer 53 8 19 Check lifting motor 53 8 20 Replace chain 55 9 Faults causes and remedies 57 A Technical data 59 B Dimensions 60 Page...

Page 7: ...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 ha...

Page 8: ......

Page 9: ...explosion 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 correspond...

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 60 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: ...used as the chain could fall out here or become knotted Please contact us if necessary For other foreseeable misuses Rules for safe operation page 33 Your product PROFI 3 TI may not be used in the fo...

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

Page 14: ...Page 21 3 5 4 Vane motor The vane motor Figure 4 consists of a cylin der liner 1 with two lateral bearing washers and an inner rotor 2 The rotor is mounted eccentrically in the cylinder liner and is p...

Page 15: ...return to the neutral position when released All movements are stopped instantaneously and the load is securely held in its current position 3 5 7 EMERGENCY STOP device Your control system is equippe...

Page 16: ...ment in due time Striking the buffer against the housing is to be avoided This may result in damage to the buffers Your product is equipped with a limiter that stops the lowering movement Figure 7 In...

Page 17: ...only genuine JDN chains may be installed Your product PROFI 3 TI has 1 falls and the chain size 13 x 36 The chain is manufactured according to DIN EN 818 7 The permissible temperature range is 40 C 4...

Page 18: ...ower requirement 3 8 1 Connections The connection for the compressed air supply has the size G 3 4 Please use the corresponding hose lines for the selected pressure 3 8 2 Pressure WARNING Danger of ex...

Page 19: ...he com pressed air add an anti icing agent to the lubri cating oil or use an air lubricator type no 11900 with an anti icing addictive for the corresponding temperatures Your product PROFI 3 TI must b...

Page 20: ...oiler Air lubricator D kine matic viscosity about 30mm2 s cSt at 40 C possibly with anti icing agent Chain lubrication Chain oil or vehi cle motor oil kine matic viscosity about 150mm2 s cSt at 40 C o...

Page 21: ...e working area of the hoists at potential friction impact or grinding points It is therefore possible to exclude sparking due to mechanical influences with these material combinations The external hou...

Page 22: ...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 23: ...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 24: ...126 C max permissible surface temperature For further information 6789 6Guideline 2014 34 EU of the European Parliament and the Council 7DIN EN 1127 1 Explosive atmospheres Explosion preven tion and...

Page 25: ...trol 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 limiter is...

Page 26: ......

Page 27: ...product PROFI 3 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 a ri...

Page 28: ...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 3 TI must be lubricated in the links...

Page 29: ...elease 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 contr...

Page 30: ...e engaged briefly in order to prevent unnecessary wear and overheating of the drive The testing of the overload protection is based on the attachment of test loads 1 Attach 125 of load capacity If thi...

Page 31: ...ill stall in the process 4 Following successful testing the buffer must be unloaded 5 5 7 Check lowering limiter WARNING Danger from chain fracture If the buffers are damaged inadmissibly high loads m...

Page 32: ......

Page 33: ...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 catch...

Page 34: ...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 35: ...ruck 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 overloading Ensure that for all appli cations of your product PROFI 3...

Page 36: ...ement will be stopped immediately Only in the case of failure of this stop function the red EMERGENCY STOP button 1 is to be pressed down firmly The EMERGENCY STOP button clicks into place Your produc...

Page 37: ...emove the control device 8 Carefully hang up your product PROFI 3 TI and transport away 7 2 Disposal Your product PROFI 3 TI contains a series of ma terials that you may have to dispose of or have re...

Page 38: ......

Page 39: ...or 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 op...

Page 40: ...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 41: ...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 42: ...8 Page 48 Check brake function without load Daily 8 9 Page 48 Visually inspect the buffer of Daily 8 11 Page 49 lifting and lowering limiters Check the function of the Daily 8 10 Page 49 EMERGENCY STO...

Page 43: ...ge 51 chain is replaced Check chain guide Whenever the 8 16 Page 51 and hook mount chain is replaced Lubricate lifting motor When required 8 6 3 Page 46 at least every 5 years Check gearbox and perfor...

Page 44: ...rt 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 protec...

Page 45: ...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 46: ...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 47: ...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 48: ...gs 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 3 TI between lifting and l...

Page 49: ...buffer The buffer of the lifting limiter optional and low ering limiter must be visually inspected daily If the buffers have cracks permanent deformations or other damage they must be replaced 8 12 C...

Page 50: ...ne 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 damaged chain links Chain drawn tight Wear over 11 pitches d...

Page 51: ...chain sprocket z amin xmax 4 32 8 mm 0 25 mm 5 32 1 mm 0 25 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 52: ...ensions of load hook sup port hook Dimension xmax Dimension ymin Dimension hmin 60 9 mm 42 0 mm 35 5 mm Checking axial clearance If the axial clear ance of the installed load hook or clevis exceeds th...

Page 53: ...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 54: ...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 55: ...es then assess prior 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 s...

Page 56: ...sleeve 4 to secure the chain end link 7 Mount the components on the idle chain a Push the buffer discs 3 edge encloses buffer and the buffer 2 onto the chain b Insert the 12th chain link into the chai...

Page 57: ...Supply hoses leaking or loose Check connections Cross section of the line too small Use line with sufficient cross section Brake does not release fully Bring the inlet pressure to the required value c...

Page 58: ...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 59: ...nominal load 4 m3 min 142 cfm Air consumption at lowering with nominal load 5 5 m3 min 195 cfm Hose connection G 3 4 Hose dimension inside 19 mm 3 4 inch Motor output lifting motor 3 5 kW Lifting spe...

Page 60: ...DIMENSIONS B Dimensions mm inch A 593 23 3 B 373 14 7 C 233 9 2 D 483 19 0 E1 40 1 6 E2 30 1 2 F 187 7 4 G 233 9 2 Page 60 of 60 Doc No VA053957 40 OM EN 0720 60 2...