J D N O P E R A T I O N M A N U A LA I R H O I S T S
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Page 1: ...J D N O P E R A T I O N M A N U A L A I R H O I S T S 16 10 6 3...
Page 2: ...ing JDN Air Hoists Before operating any hoist carefully read the entire manual For hoists mounted in trolleys refer also to the JDN Trolleys Operation Manual Please enter the Fabr No of your JDN Air H...
Page 3: ...Interrupting working 32 Shutting down 33 Storage 33 Dismantling 33 Disposal 33 Maintenance and inspection intervals 34 Cleaning and care 34 Spare parts 34 Lubricants 34 Inspection and repairs 34 Chec...
Page 4: ...d in trolleys additionally with UVV Cranes BGV D6 in the respective currently applicable version Operators must also initiate the prescribed tests see also Principles for the Testing of Cranes BGG 905...
Page 5: ...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 person...
Page 6: ...y warnings in this operation manual are classified in three categories DANGER Safety warning which if not followed can result in a hazard to life and limb are indi cated by this symbol The symbol indi...
Page 7: ...ons concerning 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 Windenstra e D 58449 Witten Heven Phone 49...
Page 8: ...ns of a service unit with oiler is possible The basis for the following information is an expert statement by the DMT Gas Fire Division on the use of JDN Hoists Trolleys and Crane Systems in explosion...
Page 9: ...o ambient temperatures and type of operation use in the presence of carbon disulphide or dusts with particularly low glow or ignition temperatures may be possible with designation which includes the a...
Page 10: ...rthed on site Running wheels and rail surfaces must never be painted as this can result in unacceptably high earth leakage resistance values Earthing of the load hook is via the chain see also Load ch...
Page 11: ...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 ace...
Page 12: ...alloys exception stainless steel A gas free or spark free environment must be ensured in the working area This means for example that the chain the bottom block and the load hook must be prevented fro...
Page 13: ...l of 23 March 1994 on the approximation of the laws of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres 2 DIN EN 1127 1 Explosive atm...
Page 14: ...ust be shortened Depending upon the version JDN Air Hoists must be operated at a system pressure of 4 bar or 6 bar If the system pressure is too low important functions of the hoist will be impaired T...
Page 15: ...ctual pressure p2 at 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...
Page 16: ...eading 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 com pressed air can...
Page 17: ...r lubrication which is sufficient for approx 250 operating hours Therefore the service unit for filtration and pressure regulation of the compressed air can be installed without an oiler If required t...
Page 18: ...longer operational breaks coat the chain and hook with a light oil film Motor conservation If the grease packing of the rotor is not renewed after 250 operating hours the motor must be conserved For t...
Page 19: ...be connected to the main air supply and must be ready for operation PRIOR TO INITIAL OPERATION THE CHAIN MUST BE LUBRICATED SEE PAGE 38 DANGER JDN Air Hoists must only be installed by qualified person...
Page 20: ...that the arrow markings correspond to the actual direction of movement E CONTROL CONNECTION Pushbutton valve hand control Guide the strain relief rope through the eye on the pushbutton valve and secu...
Page 21: ...The bellows must be pulled over the other end of the hose bundle including the strain relief rope coat hose bundle with oil for ease of fitting Pull the bellows back far enough to permit further inst...
Page 22: ...F 6 socket spanner must be guided between the three hoses through the middle of the bellows and inserted into the hexagon socket of the bolt F CONTROL CONNECTION Pull the bellows over the hose bundle...
Page 23: ...opes accordingly Pull the bellows over the hose adapter and secure via the central bolt see illustration on page 22 bottom If you wish to exchange air controls E F or FI proceed as follows see illustr...
Page 24: ...se designation 3 or colour red ATTENTION The control hoses must not be subject to tensile load adjust the strain relief ropes accordingly Pull the bellows over the hose adapter and secure via the cent...
Page 25: ...on nut LUBRICANTS CONNECTING TO THE MAIN AIR SUPPLY Application Consumable Motor lubrication JDN high performance grease from factory Art no 11901 1 kg Art no 11902 40 g when operating with oiler Comp...
Page 26: ...oper mounting equipment level and operational readiness in the main the com pleteness suitability and effectiveness of the safety devices as well as the condition of the device the har ness the equipm...
Page 27: ...f loads in general Definition of oblique pulling Oblique pulling is the deviation of the load chain and the chain hoist from the vertical position for a force acting in a straight line between the poi...
Page 28: ...ply bending loads to chains Never lock the control elements of control devices In the case of stiff actuating elements have the hoist repaired In the case of power failure secure the load and the surr...
Page 29: ...from the hand control the valve opens and releases the main stream If the red EMERGENCY STOP button on the hand control is pressed all control lines are depressurised and the main stream valve is clos...
Page 30: ...is infinitely variable enabling pre cise positioning of the load The direction of movement of the load hook is marked by arrows on the levers Lift Carefully press the right lever The load is lifted s...
Page 31: ...he control elements for rope control and the energy switching component of the control valve on the motor reversing valve are positively connected to one ano ther This connection is designed in such a...
Page 32: ...protected Then lift the load For loads in excess of 120 of load carrying capacity the overload protection interrupts the lifting procedure DANGER Ensure that there are no persons below the load Then...
Page 33: ...ntrol 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 the hoist and remove JDN Air Hois...
Page 34: ...onds to 400 full load hours This is provided that the lifting and lowe ring paths are approximately the same For devices used mainly in vertical operation from 75 of on time the theoretical operating...
Page 35: ...uipment does a safe operating period conform to the theoretical ope rating time Deviations of the actual type of operation from that used for calculation extend or shorten the safe operating period Di...
Page 36: ...50 hours The load must be braked reliably At least once annually Section Checking brake function page 37 Check all bolted and pin Every 250 hours connections At least once annually Check load hook Eve...
Page 37: ...ition and then carefully by repeatedly pressing the control element move to the end position The movement of the chain must be stopped due to deformation of the buffer and activation of the safety clu...
Page 38: ...he off shore sector the chain can be largely pro tected against corrosion by the use of special lubricants These types of lubricants are characterised by weathering resistance water insolubility good...
Page 39: ...4 bar 3 6 bar Clockwise higher pressure Anti clockwise lower pressure Lock the regulator knob by pressing it down Alternatively the filter controller can be set to a pres sure of 6 bar 4 bar in the a...
Page 40: ...of service unit Transparent components must only be cleaned using soap solution The filter element must be cleaned once annually For this purpose proceed as follows Drain the water Shut off the main a...
Page 41: ...ximum mark and refit the oil filler screw Check the oil drop rate at the sight glass with the motor running Turn the oil throttle screw using a screwdriver until the desired number of drops per minute...
Page 42: ...heck for vane wear or repla ce the vanes with the starting aids please continue with the section Checking for vane wear Remove the cover bolts 9 and pull out the cover with the brake lining 10 Check t...
Page 43: ...ing the brake piston seal lightly with high per formance grease and push the brake piston with the braking surface first into the internal cylinder note the position of the eccentric bore Insert the b...
Page 44: ...ll pin to secure the chain link in the load sleeve REMOVING AND INSTALLING BOTTOM BLOCK AND BUFFERS DOUBLE FALL HOISTS 6 TI 10 TI Removal Move the bottom block as close as possible to the hoist body P...
Page 45: ...ely pulled out only align the bottom block chain and push the chain link pin through the chain link to be attached position of the weld must align with that of the fol lowing links If the chain link p...
Page 46: ...case of hoists without chain box detach the chain link of the idle chain for double fall hoists also the end link of the bottom block chain 1 from the chain mount on the hoist body Drive out the roll...
Page 47: ...K If die hook opening a and the height h of the load hook are outside the wear limits the hook must be replaced 1 If a safety catch is fitted the thickness of the safety catch must be subtracted from...
Page 48: ...or load eye mounts are regularly checked and lubricated at least once annually Especially important in areas where wear promoting conditions such as high ambient temperatures or corrosive substances i...
Page 49: ...hen the axial play of the installed hook or load eye exceeds the maximum play specified the worn parts must be replaced Load sleeve with load hook or load eye max 2 5 mm Bottom block with load hook or...
Page 50: ...and the first chain link by means of an open chain link The welds on the upright chain links must face out wards when running over the chain sprockets For this reason the welds of the chain links whic...
Page 51: ...en the new chain to the assembly chain on the drive sprocket by means of one or two open links 3 to the idle chain side The first chain link 4 must run upright over the drive sprocket with the weld fa...
Page 52: ...om the gearbox in order to gain access to the threaded pins 2 with lock nuts 3 located behind it CORRECTING THE LIMIT VALUE SET Loosen the lock nuts It must be ensured that the threaded pins are not t...
Page 53: ...r line Use air line with sufficiently 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 silen...
Page 54: ...ILENCER The filtered oil runs into the transparent collecting con tainer 3 This container must be emptied before the fluid level reaches the filter element Turn the drain valve 4 90 and allow the flui...
Page 55: ...ary downwards on the reeved chain in order to support the bottom block stationary chain In addition a spacer must be attached to the opposite moving chain above the buffer in order to relocate the str...
Page 56: ...consumption at nominal load Lowering m3 min 2 8 3 8 2 8 3 8 2 8 3 8 2 8 3 8 Air connection G3 4 G3 4 G3 4 G3 4 Hose size inner outer mm 19 31 19 31 19 31 19 31 Weight for standard lifting distance ro...
Page 57: ...E1 G F Type 3 TI 6 TI 10 TI 16 TI A Minimum headroom 593 674 813 898 B 373 454 548 598 C 233 233 308 382 D 483 483 575 692 E1 40 40 44 53 E2 30 40 44 53 F to centre of hook without chain box 187 154 1...
Page 58: ...NOTES Page 58...
Page 59: ...6 GB Issue July 2003 Alterations reserved With the issue of this edition all previous versions are null and void 72003 J D Neuhaus GmbH Co KG_D 58449 Witten Heven Phone 49 0 2302 208 0_Fax 49 0 2302 2...
