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M A I N T E N A NC E

Page 34

The chains of JDN Air Hoist must be lubricated 
in the links, in unloaded condition.

Clean heavily contaminated chains.

Lay the chain in a suitable container.

Spray the chain with special lubricant or 
motor vehicle engine oil.

If you wish to lubricate the hanging chain, ensure 
that the chain links are oiled at the points of contact.
For this purpose, move the chain to and fro.

A high-performance lubricant in an aerosol can is 
available from JDN, which adheres well to the chain
after the solvent has evaporated and does not drip off, 
Art. no. 12066 (aerosol 400 ml).

For operation in areas with high corrosion potential,
e.g. in the off-shore sector, the chain can be largely
protected against corrosion by the use of special 
lubricants.
These types of lubricants are characterised by 
weathering resistance, water insolubility, good 
adhesion properties etc. Re-lubrication intervals 
must be stipulated in accordance with the loading.
Please contact us, if required.

Check the function of the brake daily as follows:

Switch the unloaded air hoist alternately between
lifting and lowering modes.

If a control element is released, the chain must be 
seen not to run on.

DA N G E R !

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 the direction of movement of the load hook
corresponds to the direction indicated by the arrows on
the control elements.

Inspect buffers for damage daily. 
If considerable damage is found at the buffer, 
or if it is completely destroyed, a length of 20 cm 
must be cut from the chain directly above the 
load hook to prevent breakages.

Replace buffer at annual inspection, inspect 
buffer discs for damage, replace if necessary.

DA N G E R !

Hook travel limit buffers are for emergency
use only, repetitive impact of buffers is not
allowed!

DA N G E R !

If the buffer is damaged, do not use the 
hoist.
The hoist must be repaired 
(replace the buffer).

C H E C K I N G   L I F T I N G   A N D  
L OW E R I N G   L I M I T E R S

C H E C K I N G   D I R E C T I O N   O F   M O V E M E N T

C H E C K I N G   B R A K I N G   F U N C T I O N

L U B R I C AT E   T H E   C H A I N

Type

mini

mini mini

mini

125

250

500

1000

Pushbutton 

84

60

36

48

control with 
2 m hose length

Dimensions in mm

BR AKING DIS TANCE UNDER NOMINAL LOAD
(LOAD-C ARRYING C APACIT Y) AFTER LOWERING
HAS BEEN S TOPPED

Summary of Contents for JDN mini Series

Page 1: ...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 ErgonomicPartner...

Page 2: ...g 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 th...

Page 3: ...oad 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 part...

Page 4: ...egulations 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 tes...

Page 5: ...zard 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 befo...

Page 6: ...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...

Page 7: ...cerning 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 2 4 D 58455 Witten Heven Phone 49 23...

Page 8: ...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 sif...

Page 9: ...ant 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...

Page 10: ...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 Dichlorobenzen...

Page 11: ...ge 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 a...

Page 12: ...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 B...

Page 13: ...sed 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 chai...

Page 14: ...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 an...

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 belo...

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 t...

Page 17: ...on 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 Alcohol...

Page 18: ...e 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 ap...

Page 19: ...ation 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...

Page 20: ...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...

Page 21: ...o 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 th...

Page 22: ...ON 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 a...

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 t...

Page 24: ...ing 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 pr...

Page 25: ...hains 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 fo...

Page 26: ...o 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...

Page 27: ...th 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...

Page 28: ...ction 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 Carefu...

Page 29: ...ration 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...

Page 30: ...n 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 mus...

Page 31: ...Page 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 dea...

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...

Page 33: ...herwise 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 p...

Page 34: ...sed 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 th...

Page 35: ...ly 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 ac...

Page 36: ...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...

Page 37: ...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 In...

Page 38: ...e 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 m...

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...

Page 40: ...e 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...

Page 41: ...t 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 ens...

Page 42: ...ciently 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...

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...

Page 44: ...ements 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 14...

Page 45: ...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...

Page 46: ...ir 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...

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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