J. D. NEUHAUS JDN mini Series Manuel de service

JDN OPERATION AND ASSEMBLY

INSTRUCTIONS AIR HOISTS

Original Operation and

Assembly Instructions

Distributed by Ergonomic Partners

[email protected]

www.ErgonomicPartners.com

Tel: (314) 884-8884

Page 2

This operation manual edition 8/2010,

covers the following 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.

mini 500

Page 3

TABLE OF CONTENTS

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 . . 38

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

APPENDIX

FAULTS, CAUSE AND REMEDY

MAINTENANCE

TAKING OUT OF OPERATION

OPERATION

INITIAL OPERATION

TRANSPORT AND STORAGE

PRODUCT INFORMATION

SAFETY MEASURES

Please note:

Within the Federal Republic of Germany operators of

air hoists must comply with trade association accident

prevention regulations and rules, as well as state

occupational safety regulations, in particular

BGV A1 accident prevention regulations ˝Principles of

Prevention˝

BGV D8 accident prevention regulations ˝Winches,

Lifting and Pulling Devices˝

BGR 258 trade association regulations ˝Operation of

Load-Carrying Devices Used with Lifting Equipment˝

and, for air hoists installed in trolleys and for the

operation of monorail hoists, additionally with

BGV D6 ˝Accident Prevention 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 explosion protection regulations, e.g.

BGR 104 ˝Explosion Protection Regulations˝ and

BGR 132 ˝Prevention of Ignition Hazards due to

Electrostatic Charges˝

In all other countries, the operator shall comply with

local regulations as applicable.

Special regulations may apply when incorporating air

hoists into other installations or using air hoists under

unusual conditions.

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JDN Hoists are designed in accordance with current

technological standards and accepted safety practice.

Nonetheless, the use of an air hoist may be associated

with risk of injury or fatality to the user or to third

parties or with the risk of damage to the hoist or to

other items, if safety rules are disregarded.

All personnel charged with operating air hoists, must

have read and understood the operation manual, espe-

cially the section entitled ˝Rules for the safe operation

of hoists˝, before commencing work.

This is particularly important for personnel who only

occasionally operate the hoist, e.g. for maintenance or

retrofitting work.

Operators of JDN Hoists are also under obligation to

ensure safe and hazard-free operation. This can be

achieved through the following measures:

keep the operation manuals available at the hoist

operating site,

performing regular training,

Perform regular inspections (at least once annually),

implement an inspection log and make regular

entries,

and regularly check personnel for safety and hazard

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 and accident prevention regulations that

they are able to assess the condition of hoists with

regard to working safety.

Follow the operating instructions for your workplace.

Comply with the accident prevention regulations.

Ensure that you are properly informed regarding

working with hazardous materials.

Follow the safety instructions set out in the

operation manuals.

Operators of JDN Hoists are under obligation to ensure

that entries in the accompanying inspection log are

made properly and regularly.

Comply with the prescribed maintenance intervals.

Only use JDN hoists for work which is described as

intended use.

Observe the operating conditions for JDN Hoists as

described in this manual.

PREVENTING PROPERTY DAMAGE

PERSONNEL SAFETYORGANISATIONAL MEASURES

SAFETY INSTRUCTIONS

Page 5

SAFETY INSTRUCTIONS

This operation manual is intended to help the operator

to become familiar with JDN air hoists and their

intended use.

This operation manual contains important information

for the safe, proper and efficient operation of JDN Air

Hoists. Observance of the manual helps to avoid haz-

ardous situations, to reduce repair costs and downtimes

and to ensure the specified service life of the JDN Air

Hoists.

Safety warnings in this operation 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!

This symbol indicates that failure to follow

the relevant instructions may result in dam-

age to the hoist or other equipment.

WARNINGS AND SYMBOLSTHE OPERATION MANUAL

PRODUCT INFORMATION

Page 6

PRODUCT INFORMATION

The nameplate mounted on the housing cover identifies

the type of JDN Air Hoist and contains all

important rating data.

If you have any questions 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

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

PRODUCT INFORMATION

Page 7

MINI series air hoists consist of the

following assemblies:

1Motor

2Gearbox with chain drive

3Controls

4Chain and hook

5Chain box

MINI series JDN Air Hoists are chain air hoists for load-

carrying capacities of 125 kg, 250 kg, 500 kg and 980

kg in the EU version. Outside of the EU the maximum

load-carrying capacity is 1000 kg. All models lift using

a single chain. They are equipped with direct controls

and an EMERGENCY STOP device.

Loads can be moved and positioned with precision.

The highest and lowest load hook position is limited

by buffers (emergency end stop).

DANGER!

Hook travel limit buffers are for emergency

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 enables operation with

oil-free compressed air. It remains effective for an

operating period of approx. 100 hours and should be

renewed after five years, at the latest (see Motor lubri-

cation, page 17). Additional lubrication with oil-bearing

compressed air by means of a service unit with oiler

is possible.

MINI series JDN Air Hoist

PRODUCT DESCRIPTION

ASSEMBLY OVERVIEW

PRODUCT INFORMATION

Page 8

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-

hazardous areas, based upon European Guideline

94/9/EC1(˝ATEX 100a˝). DMT is accredited with the

testing of devices and protection systems for intended

use in explosion-hazardous areas.

MINI type JDN Air Hoists are category 3 devices for

general industrial use and for use in zone 2 for gases

of explosion group IIA. They are also suitable for use

in zone 22 for dusts, provided that no light metal or

other impact-sensitive dusts are present.

They are designated by II 3 GD IIA T4(X)

ADDITIONAL MARKING ˝X˝

This designation refers to explosion protection details

in the operation manual.

II 3 GD IIA T4(X):

This designation does not permit use in the presence of

light metal or other impact-sensitive dusts, or in the

presence of dusts with glow temperatures below 210° C

or ignition temperatures below 202° C. The permissible

ambient temperature range (Ta) extends from - 20° C to

+ 50° C.

MATERIALS FOR FRICTION AND IMPACT HAZARDS

Impacts between particular materials result in an

increased ignition hazard. This does not apply to

corrosion-resistant 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 points and that material

combinations of the above-named light metals with

steel (exception being stainless steel) or cast iron are

not used in the working area of the hoists, at potential

friction, impact or sliding points.

It is thus possible to exclude sparking due to mechani-

cal influences with these material combinations.

The external housing of the service units is made of

aluminium. Therefore the installation position is to be

selected so as to ensure that there is no risk from

impact sparks.

CLEANING PLASTIC SURFACES

Where JDN Air Hoists or JDN Air Winches feature plastic

parts, these surfaces must only be cleaned using a damp

cloth (cleaning cloth with water). This reduces electro-

static charging that can arise due to mechanical friction

at the plastic surface.

DANGER!

Electrostatic charging may occur at the

plastic surfaces, potentially leading to

electrostatic discharge that can ignite

gases and air mixtures.

EXPLOSION PROTECTION

PRODUCT INFORMATION

Page 9

PRODUCT INFORMATION

Page 10

EXPLOSION GROUPS AND TEMPERATURE CLASSES OF THE MOST IMPORTANT GASES AND VAPOURS (-SELECTION)

(in accordance with DIN VDE 01656, Redeker7, Nabert, Schön8, IEC 60079-123and IEC 60079-204)

( ): The measured values for the substances placed in brackets are close to the limit or the next group or class when classified

in the explosion groups or temperature classes. For this reason, they have been included in both.

**: Extremely flammable substances

*1 (Methanol = Methyl alcohol)

Ex group Temperature class

T1 T2 T3 T4 T5 T6

Ignition temperature

> 450° C 450-300° C 300-200° C 200-135° C 135-100° C 100-85° C

Maximum permissible surface temperature of operating facilities

450° C 300° C 200° C 135° C 100° C 85° 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-Propyl alcohol)

o-Cresol i-Propyl alcohol

Methane Vinyl chloride

Methyl acetate

Methyl alcohol*1

Methyl bromide

Methyl chloride

Methylene chloride

Naphthalene

(nitrobenzene)

Phenol

Propane

Toluene

o-Xylene

II B Hydrocyanic acid Butadiene-1,3 Dimethylether Ethyl ether

(Ethyl bromide) Dioxane-1,4 **Hydrogen Ether

(carbon monoxide) Divinyl ether sulphide Anaesthetic ether

(Nitrobenzene) (Ethyl alcohol) Diethyl ether

Town gas Ethylene

(ethylene glycol)

**Ethylene oxide

Isoprene

(n-Propyl alcohol)

II C **Hydrogen **Acetylene **Carbon

disulphide

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