J D N O P E R AT I O N M A N UAL

AIR HOISTS
MONORAIL HOISTS
Please fill in here the Fabr.-No. of your JDN air hoist.

This manual edition 4/2002 covers the

operation of the following JDN Air Hoists:

3 6 10
Fabr.-No. Fabr.-No. Fabr.-No.

15 20 25
Fabr.-No. Fabr.-No. Fabr.-No.

37 100
Fabr.-No. Fabr.-No. Fabr.-No.

the following JDN Monorail Hoists (EH)

only in connection with the Operation Manual ”trolleys“

EH 20 EH 25 EH 37
Fabr.-No. Fabr.-No. Fabr.-No.

EH 50 EH 75 EH 100
Fabr.-No. Fabr.-No. Fabr.-No.

and the following JDN Ultra-Low Monorail Hoists (UH)

only in connection with the Operation Manual “trolleys”

UH 05 UH 1 UH 2
Fabr.-No. Fabr.-No. Fabr.-No.

UH 4 UH 6 UH 8
Fabr.-No. Fabr.-No. Fabr.-No.

UH 12 UH 75 UH 100
Fabr.-No. Fabr.-No. Fabr.-No.

Before operating any hoist, carefully read the entire

manual. For trolley mounted hoists refer to the
manual JDN Trolleys.

Page 2
CONTENTS

SA F E T Y I N S T R U C T I O N S OP E R AT I O N

Organisational measures . . . . . . . . . . . . . . . . . . 5 Safety instructions . . . . . . . . . . . . . . . . . . . . . 20

Personnel safety . . . . . . . . . . . . . . . . . . . . . . . . 5 Operating materials . . . . . . . . . . . . . . . . . . . . . 23
Preventing equipment damage . . . . . . . . . . . . . . 5 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
P R O D U C T I N F O R M AT I O N
Load hook . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
The operation manual . . . . . . . . . . . . . . . . . . . . 6 Starting operation . . . . . . . . . . . . . . . . . . . . . . 26
Warnings and symbols . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 27
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating mode . . . . . . . . . . . . . . . . . . . . . . . . 8 MAINTENANCE
Explosion Protection . . . . . . . . . . . . . . . . . . . . . 8 Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service unit . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . 13
Checking the control elements . . . . . . . . . . . . . 33
Conditions of use . . . . . . . . . . . . . . . . . . . . . . 13
Testing the brake function . . . . . . . . . . . . . . . . 33
Certification . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Testing the limit switch . . . . . . . . . . . . . . . . . . 33
Lubrication of the chain . . . . . . . . . . . . . . . . . 34
A P P L I C AT I O N
Inspections and maintenance work . . . . . . . . . . 34
Application areas . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance list . . . . . . . . . . . . . . . . . . . . . . . 35
Suspension points . . . . . . . . . . . . . . . . . . . . . . 14
Inspection list . . . . . . . . . . . . . . . . . . . . . . . . 35
Energy requirements . . . . . . . . . . . . . . . . . . . . 14
Test dimensions . . . . . . . . . . . . . . . . . . . . . . . 36

T R A N S P O R TAT I O N A N D S TO R AG E
AC C E S S O R I E S
Transportation . . . . . . . . . . . . . . . . . . . . . . . . 15
Chain container . . . . . . . . . . . . . . . . . . . . . . . 37
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Filter silencer . . . . . . . . . . . . . . . . . . . . . . . . . 38

SETTING UP Overload protection . . . . . . . . . . . . . . . . . . . . . 39

Booster valve . . . . . . . . . . . . . . . . . . . . . . . . . 41
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Axial bearing . . . . . . . . . . . . . . . . . . . . . . . . . 41

Installing the hoist . . . . . . . . . . . . . . . . . . . . . 16

ANNEX
Fastening the pendant control . . . . . . . . . . . . . 17
Connecting the main air supply . . . . . . . . . . . . 18 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 42
Initial operating checks . . . . . . . . . . . . . . . . . . 19 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Page 3
Please note !

Within the Federal Republic of Germany

operators of air hoists must observe the currently
applicable

 UVV Winches, Lifting and Pulling Devices

(VBG 8), and
 UVV Load carrying Devices Used with Lifting
Equipment (VBG 9a),

and users of trolley mounted hoists must additionally

comply with the currently applicable

 UVV Cranes (VBG 9).

Users must also initiate the prescribed tests.

In all other countries the user shall comply with local

regulations as applicable.

Additional regulations may apply when incorporating

air hoists into other installations or using air hoists
in unusual conditions.

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 SA F E T Y I N S T R U C T I O N S

SA F E T Y I N S T R U C T I O N S

O R GA N I SAT I O N AL M E A S U R E S P E R S O N N E L SA F E T Y

JDN Air Hoists / Monorail Hoists (in the following called Ensure that only properly trained personnel are
JDN Air Hoists) are manufactured in accordance with entrusted with the operation, maintenance and repair
the latest state of the art and accepted safety practice. of the air hoist.
Nonetheless, the use of an air hoist may be associated
with the risk of injury or death of the user or of some „Properly trained“ in the present case means that the
third party, or with the risk of property damage. operator has appropriate training and experience in
working with air hoists and is sufficiently versed in
All personnel involved with the safe operation of the air occupational safety and accident prevention regulations
hoist must carefully read and understand the operation to be able to determine whether or not it is safe to
manual, especially the present section dealing with operate the air hoist.
safety. This is particularly important when personnel
 Follow the applicable regulations for the workplace
not normally working with air hoists are charged with
maintenance, repair or other additional works. in question.
 Observe all relevant accident prevention regulations,
The user is obliged to ensure that the air hoist is in particular VBG 8 (Winches, Lifting and Pulling
operated in a safe manner. The following measures Devices) and VBG 9a (Load-carrying Devices Used with
are requested as a minimum: Lifting Equipment).
 Ensure that you are properly informed about any
 keep this manual readily available at the air hoist hazardous materials you may be working with.
operating site,  Follow the safety instructions given in this manual.
 carry out training on air hoist operation on a
regular basis,
 set up an inspection log and keep it up to date, and

P R E VE N T I N G E Q U I P M E N T DA M AG E
on a regular basis, check up on the personnel wor-
king with the air hoist to ensure that it is being used
in a safe and proper manner. The user of JDN Air Hoists is responsible for ensuring
that the inspection log delivered with the hoist is
correctly used and kept up to date.

 Ensure that the scheduled maintenance is performed

as prescribed.
 Do not use the air hoist for any other purpose than
its intended design use.
 Ensure that the conditions of use as detailed below
are met.

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P R O D U C T I N F O R M AT I O N

P R O D U C T I N F O R M AT I O N

T H E OP E R AT I O N M A N UAL WA R N I N G S A N D SY M B O L S

The present manual is intended to help the operator In this manual warnings about safety are classified in
to inform himself about JDN Air Hoists and how to use three categories:
them properly.
DANGER!
This manual contains important information on the Indicates that failure to follow these instruc-
safe, proper, and economic operation of the JDN Air tions can cause a hazard to life and limb.
Hoists. By following this information the risk of safety The symbol indicates the immediate danger
hazards, repair costs and machinery downtime can be of severe and possibly fatal injuries.
reduced and the useful lifetime of the air hoist can be
extended. WA R N I N G !
Indicates a situation that could become
Always keep the manual readily available at the location
hazardous. Failure to follow the instructions
where the JDN Air Hoist is being used.
could result in injuries.
All persons charged with operating, maintaining, or
repairing JDN Air Hoists must read and follow the C AU T I O N !
instructions in this manual. Indicates that failure to follow the instruc-
tions could cause property damage.

Page 6
 P R O D U C T I N F O R M AT I O N

I D E N T I F I C AT I O N

The nameplate fixed to the hoist cover identifies

the type of JDN Air Hoist and gives important rating J.D. NEUHAUS
GmbH & Co. KG
information. D - 58449 Witten
http.//www.jdn.de · e-mail: [email protected]
If you have any questions concerning the operation of Typ
Profi 3 TI
Kette
13 x 36 TN
Type Chain
the air hoist which are not mentioned in this manual, Tragfähigkeit Baujahr
3t 2002
please contact us at the following address: Lifting capacity Year of constr.
Triebwerkgruppe Nenndruck
1 Bm 6 bar
Group of mechanisms Nom.pressure
J.D. NEUHAUS GMBH & CO. KG Fabr.-Nr.
0601745
Windenstraße Serial-No.

D - 58449 Witten-Heven Ex-Schutz

Explosion proof II 2 GD IIA T4(X)/II 3 GD IIB T4(X)

Phone + 49 - 23 02 - 20 80
Fax + 49 - 23 02 - 20 82 86
Made in Germany
http://www.jdn.de
e-mail: [email protected]

Example of a nameplate fixed to the hoist cover

Page 7
P R O D U C T I N F O R M AT I O N

nor in light metal dusts and dusts sensitive to impacts.

OP E R AT I N G M O D E
... IIC T6(X): This marking allows the application in
the media hydrogen sulphide and other materials of
JDN Air Hoists are manufactured in accordance temperature class T6 only under special conditions
with the driving mechanism group 1 Bm/M3 which have to be agreed with the manufacturer and
(according FEM/ISO)1). which have to bedescribed in the crane documentation
Hoists manufactured in series have a limited life time. (in Europe: in the crane check book) determinating the
After reaching the theoretical service time special tests maximum surface temperatures of the devices.
have to be carried out (see the section entitled JDN HOISTS WITH
Inspections and maintenance work, page 34). " I N C R E A S E D S PA R K P R OT E C T I O N "
1) FEM: Fédération Européenne de la Manutention – JDN hoists in the version "with increased spark protec-
European Materials Handling Federation tion" (FS) fulfil further requirements of the explosion
protection. They can be used in all gases of zones 1 and
2 with the exception of hydrogen sulphide as well as in
E X P L O S I O N P R OT E C T I O N dusts with glowing temperatures above 210°C and igni-
tion temperatures above 202°C and they can be marked
as a maximum with depending on the
The following information base on the attestation of
construction of the trolley (see below)- but also with
the DMT Company Gas & Fire Division with regard to the
. For further conditions of use please
application of JDN hoists, trolleys and cranes in areas
refer to the information for a safe operation (references
with danger of explosion following the European
D and E ).
Guideline 94/9/EG1 ("ATEX 100a"). DMT is certified to
test devices and protective Systems for its designed use J D N H O I S T S F O R T H E A P P L I C AT I O N I N GA S E S
in hazardous areas. O F T E M P E R AT U R E C L A S S T 6 O R I N E X T R E M E LY
G E N E R AL E X P L O S I O N P R OT E C T I O N DANGEROUS DUSTS
O F J D N P R O D U C T S A S S TA N DA R D After separate checks especially with regard to ambient
JDN air hoists in Standard version are devices of cate- temperatures and operating mode the hoists can also be
gory 2 (guideline 94/9/EG, EN 1127-12) to be used in used in media at the presence of hydrogen sulphide or
zones 1 and 2 at the presence of gases of explosion of dusts with especially low glowing and ignition tem-
group IIA (please also refer to IEC 60079-123 and IEC peratures, getting the marking ,
60079-204). These devices can also be used in zone 2 at containing the special smark "X" for special conditions
the presence of gases of explosion group IIB as long as (refer to Additional Mark "X"). In case of demand please
hydrogen sulphide and ethylene oxide are excluded, fur- contact us.
thermore in zones 21 and 22 at the presence of dusts as JDN TROLLEYS AND CRANES
far as no light metal dusts and dusts sensitive to impacts I N S TA N DA R D VE R S I O N
are present. In zone 1 and 21 frictions and impacts in
JDN trolleys and cranes can be operated with standard
the working area of the chain have to be excluded.
running wheels (made of steel or cast iron) in all types
These devices get the explosion proof marking: of dusts as well as at the presence of gases up to explo-
sion group IIC in zone 2. The possible friction speeds at
.
the running wheels are less than 1 m/s due to the low
A D D I T I O N AL M A R K " X " travelling speed so that standard running wheels can be
used even up to explosion group IIB of zone 1.
This spezial mark refers to notes about explosion
protection in the Operation Manual. The maximum marking for these devices is:
II 2 GD IIA T4(X)/ II 3 GD IIB T4(X): This marking
.
does not allow the application in the extremely high
ignitable media hydrogen sulphide and ethylene oxide

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 P R O D U C T I N F O R M AT I O N

JDN TROLLEYS AND CRANES A C E T Y L E N E A N D C OP P E R

" W I T H I N C R E A S E D S PA R K P R OT E C T I O N " When operating JDN products in hazardous areas with
When working in zone 1 at the presence of gases of the presence of acetylene in the atmosphere it has to
explosion group IIC bronze coated running wheels or be safeguarded that copper plated parts are kept dry in
running wheels made of bronze are additionally used. order to exclude an oxidation of the metallic copper and
This Version (FSR) has the maximum marking the formation of an aqueous phase which could react
(same as the JDN hoists in version with acetylene and which could lead to dangers of
"with increased spark protection"). explosion.

JDN TROLLEYS AND CRANES FOR THE L OA D C H A I N

A P P L I C AT I O N I N GA S E S A N D D U S T S O F Chain and load are always to be guided in such a way
T E M P E R AT U R E C L A S S T 6 that a sliding and/or grinding friction with neighbou-
The same as with JDN hoists in the version "with ring structural members is avoided. Depending on the
increased spark protection" JDN trolleys and cranes can degree of corrosion the leaking ability of the chain can
also be operated in temperature class T6 after having deterioate in such a way that it is not sufficient any
carried out separate checks resulting in the maximum more. This means for the proper use of hoists that rusty
markings with standard running wheels chains may not be used any more.
and with bronze
coated running wheels or running wheels made of EARTHING
bronze that means with the addi- By a safe earthing electrostatic dangers of ignition can
tional character "X" standing for special conditions. be avoided. The hoists have to be connected to earth
which can be obtained via the load hook or load eye if
Please also refer to "Additional Mark "X", page 8. they are connected to a corresponding earthed part
(resistance to earth less than 106 Ω). The same applies
M AT E R I AL S W I T H DA N G E R
for the use of trolleys or cranes. Their travel way has to
O F F R I C T I O N A N D I M PA C T S
be earthed by the customer. As a matter of principle
An increased danger of ignition arises when special running wheels and surfaces of running rails may not be
material combinations run across one another as for covered with coats of lacquer as otherwise the earth
example non corrosion-proof steel or cast iron against leaks could obtain inadmissibly high values. The earth
aluminium, magnesium or corresponding alloys especially connection of the load hook is obtained via the chain
in connection with rust or rust films. Especially at the (please also refer to "Load Chain").
friction points of chains and load hooks rust or rust
films may occur. Therefore for the destined use of the Loads have to be earthed too during transport. A sepa-
hoists it has to be safeguarded that no rust may arise at rate connection to earth for example is necessary when
theses friction points and that in the operating area of no-conducting harnesses are used.
the hoists at possible friction impact or grinding points
no material combinations of above mentioned light
metals or steel (exception: stainless steel) are present
so that sparking with these material combinations due
to mechanical influences can be excluded.

COMPRESSED AIR HOSES

Air hoses used in zone 1 must have a sufficiently low
surface resistance of less than 109 Ω to avoid electrostatic
dangers of ignition. Otherwise (at >109 Ω) the hoses of
explosion group IIA and IIB must have a diameter of
≤ 30 mm and in explosion group IIC a diameter of
≤ 20 mm or it has to be proven that they cannot be
dangerously charged.

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P R O D U C T I N F O R M AT I O N

CLASSIFICATION OF THE MOST IMPORTANT GASES AND VAPOURS IN EXPLOSION GROUPS AND TEMPERATURE CLASSES
(extract acc. DIN VDE 01655, Redeker6, Nabert, Schön7, IEC 60079-12 und IEC 60079-20)

explosion temperature class

group 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 admissible surface temperature of the operating devices
450°C 300°C 200°C 135°C 100°C 85°C
II A Acetone (Ethyl Alcohol) n-Amyl Alcohol Acetaldehyd
Ammonia (Ethylene Glycol) Benzine/Gasoline
Aniline i-Amyl Acetate Diesel Fuel
Benzole n-Butane Heating Oil
Benzol Chloride n-Butyl Alcohol n-Hexane
1,2-Dichlor Benzole 1-Butylene Jet Propulsion Fuel
Acetic Acid 1,2-Dichlorethane
Natural Gas Di-i-Propyl Ether
Ethane Natural Gas
Ethyl Acetate Acetic Anhydride
(Ethyl Bromide) n-Propyl Acetate
Ethyl Chloride (n-Propyl Alcohol)
(Carbon Monoxide) i-Propyl Alcohol
O-Kresol Vinyl Chloride
Methane
Methyl Acetate
Methyl Alcohol*1
Methyl Bromide
Methyl Chloride
Methylene Chloride
Naphthalene
(Nitro Benzole)
Phenole
Propane
Toluene
O-Xylol
II B Cyan Hydrogen Butadiene-1,3 Dimethyl Ether Ethyl Ether
(Ethyl Bromide) Dioxane-1,4 **Hydrogen
(Carbon Monoxide) Divinyl Ether Sulphide
(Nitro Benzole) (Ethyl Alcohol)
City Gas Ethylene
(Ethylene Glycol)
**Ethylene Oxide
Isoprene
(n-Propyl Alcohol)

II C **Hydrogen **Acetylene **Carbon Disuphilde

( ): The measured values for classifying the media in brackets into explosion group or temperature class are near the
next group or class and are therefore mentioned in both.
**: media getting very easily into ingition
*1 (Methanol = Methylalcohol)

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 P R O D U C T I N F O R M AT I O N

D E C I S I VE C R I T E R I A TO C H O O S E T H E R I G H T VE R S I O N O F J D N H O I S T S O R C R A N E S F O R T H E U S E I N
E X P L O S I VE AT M O S P H E R E S A N D U S E O F T H E J D N H O I S T M I N I

Explosion Groups of Gases and Vapours Zone version*1 way of use*2

(see Classification of the most important gases and vapours in explosion groups
and temperature classes)

II A 2 A mini*3
1 A D
II B(X) without hydrogen sulphide and ethylene oxide, 2 A
which can get very easily into ignition 1 A FS D
II B 2 A FS D E
1 A FS D E
II C / T4 2 A FS D E
1 A FS FSR D E
II C/ T6(X) 2 A FS D E T
1 A FS FSR D E T
explosive dusts Zone version*1 way of use*2
22 A mini*3
normal industrial dusts
21 A D
22 A FS D
light metal dusts or dusts sensitive to impacts
21 A FS D

*1: versions:
A: Chain made of galvanised steel, metal control panels get earthing to the holst; these are standard features.
The load chain type 31,5 x 90 made of galvanised steel is not available because of technological reasons.
This chain is only to be used for our heavy hoists with very slow chain movements, so that possible friction
velocities are very much less than 1 m/s.
FS : Hoists with increased spark protection:
Load hook and housing of bottom hook block made of copper plated steel with safety latch made of brass.
FSR: Driving Units with increased spark protection:
wheels of trolleys and travelling gears are made of bronze.
*2: Notes for safe working:
D : At destined use of the hoist or the crane, there will no ignition dangers to be expected. Hitting and friction move-
ments in the working area of the load chain, which are not a result of the destined use of the hoist or the crane,
and make ignitions occur, are to be prevented. This is most important working with light metals resp. their alloys
(stainless steel excluded).
E : It has to be safeguarded that the working area is free of gas or sparks. That means, that e.g. swaying of the load
chain, of the bottom hook block or the load hook against part of the environment is to be prevented.
T : Temperature of the environment and the way of use have particularly to be checked.
*3: Use of the JDN hoist mini:
JDN-hoist mini cannot be delivered in a version with increased spark protection (FS).

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P R O D U C T I N F O R M AT I O N

The surface temperatures depend upon the operating According to the „HVBG/BIA-Report 12/979 „Brenn-
mode and the ambient temperature. Therefore when und Explosionskenngrößen von Stäuben (Characteristic
working in media of temperature class T5 and T6 special values of dusts)“ the given minimum values for glow
checks are necessary. and ignition temperatures of dusts allow to give the
corresponding surface temperatures:
The temperature classes given on the air hoists base on
a maximum ambient temperature of 40°C (refer to DIN Synthetic caoutchouc, containing soot:
EN500148). Glow temperature 220°C -75°C = 145°C maximum
admissible surface
T E M P E R AT U R E L I M I T S temperature
OF COMBUSTIBLE DUSTS
In areas with danger of explosion due to combustible Stearin acid:
dusts the surface temperature must not exceed two Ignition temperature 190°C x 2/3 = 126°C maximum
thirds of the ignition temperature in °C of the dust/air admissible surface
mixture. Temperatures of surfaces, on which hazardous temperature.
substances of dusts may settle down capable to glow,
may not exceed the glowing temperature of the respec-
tive dust reduced by 75 K. Longer safety distances are
necessary in case the thickness of the dust layer
exceeds 5 mm.

P L E A S E AL S O O B S E R VE T H E
C O R R E S P O N D I N G R E G U L AT I O N S I N YO U R
COUNTRY!

1 Richtlinie 94/9/EG des Europäischen Parlamentes und des Rates vom 23. März 1994 zur Angleichung der
Rechtsvorschriften der Mitgliedsstaaten für Geräte und Schutzsysteme zur bestimmungsgemäßen Verwendung in
explosionsgefährdeten Bereichen
2 DIN EN 1127-1: Explosionsfähige Atmosphären - Explosionsschutz, Teil 1: Grundlagen und Methodik, 1997-10.
3 IEC 60079-12: Electrical apparatus for explosive gas atmospheres, Part 12: Classification of mixtures of gases and
vapours with air according to their maximum experimental safe gaps and minimum igniting currents, 1978.
4 IEC 60079-20: Electrical apparatus for explosive gas atmospheres, Part 20: Data forflammable gases and vapours, rela-
ting to the use of electric apparatus, 1996-10.
5 DIN VDE 0165: Errichten elektrischer Anlagen in explosionsgefährdeten Bereichen, 1991
6 Nabert, Schön: Sicherheitstechnische Kennzahlen brennbarer Gase und Dämpfe 2. Auflage,1978
7 Redeker, Schön: 6. Nachtrag zu Sicherheitstechnische Kennzahlen brennbarer Gase und Dämpfe, 1990
8 DIN EN 50014 (VDE 0170/0171 Teil 1): 2000-02
Elektrische Betriebsmittel für explosionsgefährdete Bereiche: Allgemeine Bestimmungen
9 Hauptverband der Deutschen Berufsgenossenschaften/Berufsgenossenschaftliches Institut für Arbeitssicherheit

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 P R O D U C T I N F O R M AT I O N

EMISSION CONDITIONS OF USE

The sound emission figures are shown in table The JDN Air Hoists are sturdy and require very little
Technical data, page 42. maintenance. They are suitable for use in locations
The sound pressure level at the measuring surface at 1 m subject to explosion hazards, as well as locations expo-
distance from the machine surface was determined acc. sed to soot, dust, humidity and extreme temperatures
to DIN 45635, Part 20 with an air pressure acc. to our between -20°C and approximately +70°C. Permitted
instructions. The reduction of the sound level under chain and hook temperatures: -40°C up to +150°C.
indoor conditions is approx. 3 dB (A) per each doubled
distance. WA R N I N G !
When in operation – due to motor lubrication – small When touching metallic hand controls being
amounts of lubricating oil are discharged with the colder than 0°C frostbites of the skin may
exhaust air into the ambient atmosphere. occur within a few seconds, at temperatures
When using a filter silencer (see the section entitled above 55°C burnings may occur. Protective
Overload protection, page 39) the oil emission can be measures: use suitable safety gloves.
avoided. Additionally the sound emission will be reduced.

C E R T I F I C AT I O N
INTENDED USE
Every JDN Air Hoist is issued with a works certificate.
The JDN Air Hoists are designed for lifting loads with
vertically arranged chain. Under special conditions they
can also be used for lifting people. When incorporated
in trolleys they are also suited for moving elevated
loads in a horizontal direction.

Any other use shall be deemed improper. Such improper

use is at the customer’s own risk, and the company
J.D. NEUHAUS GMBH & CO. KG shall not be liable for
any resulting damages.

Please also see Safety Instructions, page 20.

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A P P L I C AT I O N

A P P L I C AT I O N
When calculating the lifting capacity of the hoists we
A P P L I C AT I O N A R E A S
have therefore considered a loss of 10 % of the nominal
air pressure for lifting the maximum load. In other
Hoists intended for permanent outdoors operation must words: A hoist with a nominal pressure of 6 bar reaches
be protected against the influences of weather and the the stated parameters at a working pressure of 5.4 bar.
intervals between maintenance must be reduced.
DANGER!
Working with system pressures of more than
SUSPENSION POINTS 6 bar may cause risks of overloading.
Therefore the pressure has to be limited
to 6 bar.
DANGER!
Suspension points for JDN Air Hoists are JDN Air Hoists must have sufficient supply of clean and
to be constructed in such a way that the dry working air (to fulfill this requirement an air dryer
expected forces can be safely held. must, if necessary, be connected to the air supply).
Ensure that your JDN Air Hoist can come
free into alignment under load, otherwise Do not drive JDN Air Hoists with other gases (contact
unallowed additional forces can occur. supplier).

DANGER! Working air must have sufficient of the following

The supporting structure of air hoists must qualities:
have a rigid bedding. Vibrations damage Solid particle content:
the chain and may lead to chain cracks.  Size of particles, smaller than 40 µm
Furthermore no vibrations must be trans-  Density of particles, less than 5 mg/m3
mitted from the outside to the hoist
(as for example by the suspended load). Pressure dew point:
At least 10 °C under the lowest expected temperature in
surrounding area of application.
ENERGY REQUIREMENTS
For lubrication of the motor, the working air must
contain lubricating oil in the following quantities:
Air pressure, amounts and connections, see the table
entitled Technical data, page 42. Oil content:
 10 mg per m3 air consumption
D E TA I L S O F T H E A I R P R E S S U R E The adjustable oiler, which is built into the connected
JDN Air Hoists are also identified by the nominal air service unit, ensures that the operating air
pressure (overpressure) stated on the hoist itself. contains the required amount of oil (see the section
With this value we want to coordinate the hoist to entitled Service unit, page 29).
a corresponding air pressure system.
In working areas where the surrounding temperature is
When connected but not working the hoist receives the 0 °C or under and in case of longer periods of operation
pressure of the air circuit. After starting operation the (e. g. several minutes) particular attention must be paid
pressure decreases to the actual value i.e. working pres- that the working air is not too damp. Danger of icing
sure which varies according to the load figure and the up of air hoses, control valves, motor and brake!
direction of the load movement (up or down). With the connection of an air dryer icing up can be
Furthermore it depends upon the hose section, the hose avoided. Under certain conditions it is sufficient to feed
length as well as upon the diameter of the air circuit lubricating oil with anti-freeze protection (see the section
and its length. Operating materials, page 23) to the working air
(see the section entitled Service unit, page 29).

Page 14
 T R A N S P O R TAT I O N A N D S TO R AG E

T R A N S P O R TAT I O N A N D S TO R AG E

T R A N S P O R TAT I O N

DANGER!
Do not throw or drop your JDN Air Hoist.

Make sure that load hook, chain loops and control hoses
do not hang down.

Control hoses and switches must not be damaged

when handling JDN Air Hoists.
– Danger of incorrect functioning!

S TO R AG E

Store your JDN Air Hoist in a clean and dry place.

Take care that the control elements and control hoses

cannot be damaged.

Protect the connection for the air intake hose against

damage or intake of dirt or foreign bodies.

In case of longer periods of non operation protect your

JDN Air Hoist including chain and load hook against
corrosion. To protect the motor against corrosion inject
conservating oil into the air supply hose after the last
use (see the section entitled Operating materials,
page 23), then run your JDN Air Hoist for a short period.

After longer periods of non operation clean the motor

by pouring about 30 cm3 of petroleum into the air hose
and then run your JDN Air Hoist for approximately half
a minute. Then, straight away, pour a little lubricating
oil into the air hose – further lubrication is carried out
by the service unit.

Page 15
SETTING UP

SETTING UP

U N PAC K I N G I N S TAL L I N G T H E H O I S T

WA R N I N G ! DANGER! RISK OF INJURY!

Be careful when unpacking the hoist. Observe The JDN Air Hoists must be installed by
the weight (see Technical Data, page 42) suitably trained personnel. An incorrectly
installed hoist can lead to serious injuries.
C AU T I O N !
Take care to prevent twisting the control DANGER!
hoses which could lead to incorrect The points from which the JDN Air Hoist is
functioning of the hoist. suspended must be capable of withstanding
the forces that may be expected to arise.
 Keep the hoist documentation in the appropriate
place provided at site.  Set up a suitable working platform.
 Carefully lift the hoist out of the carton (if existing).  Suspend the hoist to the stationary point or to the
 Recycle packaging materials in accordance trolley, using the provided hook or eye.
with local regulations.  Ensure that the hook safety latch snaps back into
position.

MOUNTING

The JDN Air Hoists are generally delivered in fully-

assembled condition.

If not, then proceed to the sections entitled

 Fastening the pendant control (page 17)

 Connecting the rope control (page 18)
 Chain container (page 37)

T H E C H A I N M U S T B E L U B R I C AT E D
B E F O R E S TA R T I N G OP E R AT I O N
( S E E PAG E 3 4 ).

Suspend the hoist using the provided hook or eye

Page 16
 SETTING UP

C AU T I O N !
FA S T E N I N G T H E P E N DA N T C O N T R O L
Please take care that the hose is not bent
when plugging in.
F A S T E N I N G T H E C O M P L E T E P E N DA N T
C O N T R O L TO T H E H O I S T  Put the end of the corresponding hose into the hole
FI control: of the corresponding plug-in connection.
 Press the hose down to the limit making sure that
 First, fasten the hose carrier by unscrewing the cap
screw and screwing on the hose carrier. the hose is not bent.
 Please check the proper connection by pulling at the
E, F and HT controls: hose.
 Hang up the loop of the wire rope into the
existing ring bolt. In case air is coming out of the connections during ope-
ration please try to press down the corresponding hose
CONNECTING THE CONTROL HOSES even deeper.
For your help short hose pieces have been put into the
plug-in connexion the colours of which correspond to H OW TO E S TA B L I S H T H E P L U G - I N C O N N E C T I O N
those of the hoses to be connected enabling you to
connect the hoses one after the other.

R E M OV I N G T H E H O S E P I E C E S FI control: E, F and
Cap screw for HT control:
 Press down the locking ring 1 with a suitable tool
fasting the Ring bolt for
(for example screw driver), pulling out the hose piece hose carrier fastening the
wire rope
2 at the same time.

1
Air connection LOWERING
Air connection LIFTING

Control hose GREEN

Control hose RED

Auxiliary air connection
Main air connection

Control hose WHITE

Plug-in connection Motor side of hoist

Page 17
SETTING UP

C O N N E C T I N G T H E R OP E C O N T R O L
 Tie the ends of the control rope to the two ends of
the control lever.
 Thread the UP rope into green wood pin so that the
pin’s tapered end points up.
 Thread the DOWN rope into yellow wood pin so that
the pin’s tapered end points down.
 Thread the rope through the wooden grip in such a
way that the arrows on the grip correspond to the
direction of hook travel.

Rope control, motor side

C O N N E C T I N G T H E M A I N A I R S U P P LY

C AU T I O N !
When operating a hoist with service unit,
the unit should be not more than 5 m away
from the hoist.

 Inspect the air connector and clean it if required.

 Blow through the air hose with compressed air to
remove any debris that may have lodged there.
 Plug the main air supply hose into the hoist-side fit-
ting and secure it by tightening down the union nut.

Plug the main air supply hose in and secure it with

the union nut.

Page 18
 SETTING UP

C H E C K I N G T H E E M E R G E N C Y S TO P S W I TC H
I N I T I AL OP E R AT I N G C H E C K S
 Actuate lifting process and press down red emergency
stop switch whilst lever is still pressed down. Lifting
Prior to initial use the hoist and supporting structure
process must come to a halt immediately. Release
must be checked by a qualified person. Checking must
emergency stop switch.
also be carried out after any major modification. The
 Actuate lowering process and press down red emer-
object of such testing is to determine that the lifting
gency stop switch whilst lever is still pressed down.
equipment is correctly installed and ready for operation.
Lowering process must come to a halt immediately.
TESTING THE BRAKE Release emergency stop switch.
The correct functioning of the brake must be tested
before starting to use the hoist. Proceed as follows:

 Operate the hoist with no load, alternating between

lifting and lowering.

The chain must stop running immediately after relea-

sing a control button.

DANGER!
If you notice that the chain running does
not stop immediately stop using the hoist at
once! The hoist must be repaired before any
further use.

C H E C K I N G T H E D I R E C T I O N O F OP E R AT I O N
 Check that the load hook moves up and down in
accordance with the markings on the hoist controls.

C H E C K I N G T H E OVE R R U N P R OT E C T I O N
 Lift the load hook with no load until it almost
reaches the upper end.
 Carefully lift it still further until the hook or the
chain stop strikes the overrun switch.

The lifting operation must stop when the control lever

has reached its central position.

DANGER!
In case the hoisting movement is not stopped
with the control lever in its central position
and the control lever blocks in the down
position, stop using the hoist at once !
The hoist must be repaired before any
further use.

Page 19
O P E R AT I O N

O P E R AT I O N
Improper use includes but is not limited to any and
SA F E T Y I N S T R U C T I O N S
all of the following:

F O L L OW T H E S E R U L E S F O R SA F E  exceeding the rated load capacity

H O I S T OP E R AT I O N  hoisting loads at a non-vertical angle (Oblique Lifting)
Whenever you operate a hoist, you are responsible for Definition of Oblique Lifting
your own safety and the safety of your fellow workers.
Oblique lifting means the deviation from the vertical
 Only persons duly authorised by the management position of the load chain and the hoist at rectilinear
shall operate the hoist. course of the power line between the point of appli-
 Before beginning to use the JDN Air Hoist you should cation of the load at the hook and the suspension at
inform yourself thoroughly about the correct method the supporting structure.
of operation. Read this manual carefully and carry out
the indicated procedures on the hoist step by step.
 Report any malfunctioning to your safety representa-
tive at once, so that it can be corrected.
 Follow the instructions issued by the responsible acci-
dent prevention authorities (in Germany, these
instructions are known as UVV’s and are issued by the
trade associations).

As a prerequisite for proper use the instructions in the

operation manual must be observed and the recommen-
ded inspection and maintenance procedures must be
carried out.

Hoists have to be checked by trained staff at least once

a year or after a service time of 160 hours (see the sec-
tion entitled Inspections and maintenance work,
page 34).

In addition to the annual inspection by an expert

JDN Air Hoists should be checked according to the
service and inspection lists (see the sections entitled
Oblique Lifting
Maintenance list and Inspection list, page 35).

For example JDN Air Hoists may not be used in the Under special safety precautions and considering the
following areas: corresponding situation at site JDN Air Hoists can be
used for oblique lifting whereby the hoists Profi 3 TI, 6
 critical surroundings in atomic plants.
TI, 10 TI and 15 TI have to be additionally equipped
 above acid baths or similar plants with aggressive
with special emergency end switches whereby the use
substances.
of a chain container is not allowed as the chain may
 in areas where organic acids can be found.
fall out or form knots. Hoist mounted trolleys are not
 operating the hoist whilst lying on the floor or
allowed for oblique lifting. Please contact us in case
moving loads horizontally.
of application.
On the following pages some important points for the  dragging or pulling loads or trying to dislodge
safe operation of your JDN Air Hoist are listed. They
stuck loads.
should help you to avoid hazards.  load the hook at its tip.
 catching a falling load.

Page 20
 O P E R AT I O N

 using the hoist for transporting people.  Do not take up the load at full speed if the chain is
 hoisting by tipping the control buttons or levers. initially slack.
 reversing the hoist while it is in motion.  Ensure that the load is in a stable position when lif-
 deliberately ramming the end stop switch. ting or lowering it down to avoid accidents caused by
a toppling or falling load.
For the safety of all personnel it is vital to follow  Never use the hoist in an attempt to dislodge a load
the instructions given below whenever operating a that has become stuck.
JDN Air Hoist.  Never lift more than one load at a time.
 Never allow the chain to be bent.
 Never touch a running chain.
 Save the load in case of loss of energy.
 Never allow any person to stay under a raised/sus-
 Do not join or mend hoist chain.
pended load.
 Exchange deformed load hook.
 When hooking loads observe appropriate regulations.
 Repair damaged hook safety latch.
 Make sure that the operating place is without any
 Repair tight hook bearing.
danger for the operator due to suspension or load.
 Do not bend or squeeze control hoses.
 Start carefully when lifting loads.
 Loose screws must be fastened by repair shop.
 Never try to correct a fault or damage while the hoist
 Shut off air supply before taking off air hoses.
is under load.
 Do not exceed allowed quantity of chain
 Never operate the hoist whilst lying on the floor or
move loads horizontally. in the chain container.
 When working without chain container avoid dangers
 Never run to end positions under normal working
conditions. caused by the idle chain: falling down, interlocking,
 Never use bent, open or twisted hooks. striking (see section Chain Container, page 37).
 Repair hoist in case of a too long braking distance.
Hoist to repair, never straighten, change hook.
 Check blocked chain for damages.
 Never use stiff moving hook at the chain. Inspection.
 Check chain for damage if hoist blocks in switched
 Never use stiff moving hook in the housing without
load. Inspection. on position.
 In case of lifting a load with several hoists avoid
 Never load hook on the tip, only on deepest part of
hook saddle. overloading by wrong load distribution.
 Never lock hook at connecting point. Avoid unacceptable load distribution.
 Choose safe place of control.
 Never anneal the hook.
 Do not exceed operating pressure.
 Never block operating elements.
 Put in order twisted chain (capsized bottom block).
 Never use stiff operating elements. Repair shop.
 Do not work with damaged or worn or rusty chain.
 Operate JDN Air Hoists only with original JDN con-
 Do not work with chain pulled rigid, bent or
trols.
 Uncontrollable external power influences extended chain.
 Do not use the load chain as a sling for suspension.
(e.g. through hydrocylinder, falling loads) are not
 It is not permitted to connect or repair hoist chains
permitted.
 Use only suitable and approved harness, do not jam (e.g. with bolts, emergency links or otherwise).
 Remove chain accumulated in front of chain intake.
hook at the fixing point of the harness.
 Do not bend the chain.
 Never use the hoist chain for wrapping around a load
 Admissible temperature range for chain and hook:
to be lifted.
 Position the load vertically under the hoist before -40°C up to +150°C, permitted heat bearing capacity
lifting. The chain should be hanging straight down. of the body of the air hoist max. 90 °C, permitted
 Never allow a load to drop into the harness. ambient temperature: -20°C up to +70°C.
 Never touch metallic hand controls being colder than
 Before lifting a load, ensure that it does not exceed
the rated capacity of the hoist including the weight 0°C or warmer than 55°C without using suitable
of the load and the harness. safety gloves.

Page 21
O P E R AT I O N

 Do not carry out any modifications on the air hoist.

 It is not allowed to use other than JDN components
with JDN Air Hoists because of the dangers connected
therewith.
 Only use original JDN spare parts. When using foreign
components and/or carrying out changes by non
authorised persons J.D. Neuhaus GmbH & Co. KG does
not undertake any responsilbility.
 If the air supply is cut protect area around the load
until power is restored.
 Turn off the compressed air before detaching the air
hoist from the compressed air system.
 Do not start a double or multiple fall chain hoist
when the bottom block is still supported.

DANGER!
Make sure that the load hook can be lowered
up to the floor at all operating conditions of
the air hoist in order to avoid that a load is
lowered to its lowest position without rea-
ching the floor. Danger of overloading.

In case of using hoists in extremely difficult conditions

the user has to work out a directive on the basis of this
Operation Manual understandable for and in the language
of the operator. In this directive regulations for the safe
operation are stipulated considering the special conditi-
ons at site.

In addition, it is essential to follow all instructions

given in the sections entitled Intended use and
Conditions of use, page 13.

JDN Air Hoists are equipped with round steel chains as

load chains. When in use section 5 of DIN 685 should be
observed.

Extract: “At the instigation of the operator chains in

use should be checked and tested at regular intervals by
a responsable expert” (see the section entitled
Inspection list, page 35).

Page 22
 O P E R AT I O N

F O R M OT O R C L E A N I N G :
OP E R AT I N G M AT E R I AL S
 Pure petroleum.

F O R M OT O R L U B R I C AT I O N : F O R C H A I N L U B R I C AT I O N :
 lubricating oil ”D” (pneumatic oil), DIN 51502,  Motor oil, kinematic viscosity
kinematic viscosity approx. 32 mm2/s (cST) at 40 °C approx. 150 mm2/s (cST) at 40 °C.
(ISO VG 32, DIN 51519).
If the environmental conditions at the working site are
Additives: Anticorrosive, wear protection and cleaning such that they induce wear please consult the manufac-
turer about the appropriate motor and chain lubricant.
If surrounding temperatures are 0 °C or below and
according to the humidity of the pressurised air an
anti-freeze additive to the lubricating oil or pneumatic
oil with anti-freeze additive for the appropriate
temperatures is recommended.

WA R N I N G !
Oil and grease may cause skin irritation.
Wear protective gloves at all times.

C AU T I O N !
Risk of motor damage! Never mix synthetic
oil with mineral oil as the physical and ther-
mal properties may be adversely affected.

If a service unit is in use no synthetic lubricants should

be used at all. Do not use alcohol-based products for
anti-icing protection.

F O R M OT O R P R E S E R VA T I O N :
 Use a non resinous and non sticking conserving oil.
The preservation protection duration should be in
accordance with the intended period of non operation.

F O R L U B R I C AT I O N O F B E A R I N G S A N D G E A R :
 Roller bearing grease, lithium saponified, walk pene-
tration 265 – 295 (0.1 mm). Dropping point: 190 °C.

Operable temperature range: -30 °C to +130 °C, ground

oil viscosity at 40 °C 190 mm2/s, DIN 51502, additives:
anticorrosive and ageing protection.

Page 23
O P E R AT I O N

The operating elements (push buttons, lever) return

CONTROLS
automatically to zero position when released.

JDN Air Hoists are operated by: The emergency stop function is operated by pressing
the red stop button, immediately stopping all operati-
Control sensitive emergency stop switch ons of the hoist and trolley. Movement of the load hook
alternatively is also stopped. By simply releasing the emergency stop
yes no yes no button the emergency stop function is reset.
E control x x
F control x1) x x
Option

HT control x x
FI control x1) x
Cord control x X
1) Up to 20 t lifting capacity

E control F control HT control

FI control Cord control

Page 24
 O P E R AT I O N

Apart from that rusty chains increase wear.

CHAIN
Before operation ensure that the chain of your JDN Air
RULES FOR RUNNING IN HOIST CHAINS Hoist is in perfect condition.
B E F O R E C A R R Y I N G O U T T H E OVE R L OA D T E S T
 Order any twisted chain.
C AU T I O N !  Ensure that the chain can run straight so that
In case this information should not be blocking of the chain intake at the mid section
observed you damage the high tensile chain is avoided.
in your hoist/lifting gear already during
testing prior to initial use for which the The chain has to be checked in regular intervals
manufacturer does not undertake (see the section entitled Inspection list, page 35)
any liability.
In case of any of the following defects:
Hoisting chains with a load capacity of over 25 metric  Extended chain links
tons have to be run in before carrying out the overload  Bent chain links
test so that they can withstand the high surface pressure  Externally damaged links
at the contact points of the chain links (in the joints).  Chain pulled rigid
 Severe wear in the link joints
For preparing the test with overload the following pre-  Corrosion scars
requisites have to be fulfilled: the JDN Air Hoist must be sent for overhaul immediately
1. The chain has to be carefully lubricated in the joints. (see the section entitled Test dimensions, page 36).
Please observe the relevant information in the The chain must be lubricated when not under load
Operation Manual. (see the section entitled Lubrication of the chain,
2. The chain has to be loaded five times by lifting and page 34).
lowering with approximately 50% the nominal load
thus sufficiently increasing the load bearing capacity Appropriate lubricants see the section entitled
of the joints. Operating materials, page 23.
3. Especially the part of the chain which will be tested
with overload has to be carefully lubricated once The lubrication intervals depend on the daily
again. running time.

Only now the overload test can be carried out. Increased wear can occur due to aggressive
environmental influences.
DANGER!  Shorten maintenance intervals.
Extreme corrosions (pitting corrosion)
heavily reduces the resistance against vibra- For safety reasons please note that the chain may not be
tions of chains. Danger of cracks!
Hydrogen induced brittleness with following  used as a sling round the load for suspension.
stress corrosion cracking due to corroding  handled while running.
media (as for example sea water) can occur  run at an angle so that the links can be bent on entry.
at high tensile steels (as for example at the  repaired or attached to other hoist chains
chain). Danger of cracks! (e. g. with bolts, emergency links or otherwise).

So-called recombination poisons as for example hydro- The allowed chain temperature range is from
gen sulphide, cyanides, arsenic compounds and rhoda- – 40 °C to +150 °C.
nides favour this procedure.
If you use a chain container the permitted filling
Furthermore dangers arise due to rusty chains when capacity may not be exceeded (see the section entitled
using chain containers as the chain may fall out of the Chain container, page 37).
box when piling up.

Page 25
O P E R AT I O N

A well ordered running-in of the chain is a must for a

L OA D H O O K
proper functioning of the JDN Air Hoist. Before every
operation, please check that the chain is not twisted or
Check the throat width “a” and the height “h” of the the bottom block – if applicable – has not been flipped
load hook of the JDN Air Hoist in use at least once a through the chain falls. Order the chain if necessary.
year (see the section entitled Test dimensions, page 36).
The throat width “a” can be checked with the JDN load Observe all appropriate regulations when attaching
hook gauge. the load!

Load hooks may not be Before every operation and after longer idle periods
 Loaded on the tip action should be taken in the following order:
 Straightened
 Annealed 1. Check power requirements (air pressure and air
consumption see the section entitled Technical data,
If the hook is bent the JDN Air Hoist should be sent for page 42) and the setting of the regulator in the
inspection. service unit.

The allowed load hook temperature range is from 2. Check the oil level in the oiler of the service unit
– 40°C to +150°C. and if necessary replenish (see the section entitled
Service unit, page 29).

3. Lubricate the chain if necessary.

S TA R T I N G OP E R AT I O N
4. Blow through the air hose before connecting.
JDN Air Hoists including their supporting structure are
to be checked by trained staff prior to being placed in 5. Connect air supply hose (for size of hose and air
service. connection screw see the section entitled Technical
data, page 42).
In case JDN Hoists are mounted by the user into trolleys
or cranes, these powered cranes have to be checked by 6. Test the brake function and – at the same time –
trained staff prior to being placed in service or prior to the control unit and the limit switch (see the section
being placed in service again after a substantial modifi- entitled Testing the limit switch, page 33).
cation. Switch the JDN Air Hoist (without load) for short periods
For preparation of the compressed air JDN Air Hoists alternatively to raise and lower. When the control element
must be operated with an air service unit. is released the chain should not continue to run.
The air service unit must not be more than 10 m away If the chain continues to run and/or the operating
from the hoist. element does not automatically return to the zero
position, your JDN Air Hoist must be sent for repair!
The air service unit is supplied without the oil.
Oiler and regulator are already preset.

For filling the oiler, see the sections entitled Operating

materials, page 23, and Service unit, page 29.

Lubrication of the chain by the client before initial use

is especially important (see the sections entitled
Lubrication of the chain, page 34, and Operating
materials, page 23).

Page 26
 O P E R AT I O N

T R O U B L E S H O OT I N G

Symptom Remedy

motor has too little power – check air pressure, increase if necessary
or stops – check diameter of air hose
(see the section entitled Technical data, page 42)
– check hose for free passage of air
– check tightness of control hose connections
– check oil level
– silencer plate clogged,
wash out or change.

All other problems must be corrected by

maintenance repairs.

Page 27
MAINTENANCE

MAINTENANCE
If maintenance measures exceed care and servicing
please contact the manufacturer.

With regard to the qualification of maintenance

personnel see the section entitled Safety instructions,
page 5.

CARE

If your JDN Air Hoist is not suspended, connected or

installed stationary but frequently changing working
place – especially in contaminated or humid surroun-
dings – ensure that for periods of non operation it is
stored in a clean and dry place (see the section entitled
Storage, page 15).

Page 28
 MAINTENANCE

SERVICE UNIT

C AU T I O N !
When operating a hoist with service unit,
the unit should be installed within 5 m of
the hoist.

The service unit for air hoists PROFI 3 TI up to PROFI 50 TS

consists of the two components filter-regulator and
lubricator. The service unit for air hoists PROFI 50 TI
and PROFI 100 TI as well as for the monorail hoists
consists of the three components filter, regulator and
lubricator.

VE R S I O N O F T WO C O M P O N E N T S
Inspecting and adjusting the filter-regulator

The filter regulator is preset in the factory at an opera-

ting pressure of 5,4 bar (operating pressure with run-
ning motor). If the pressure gauge shows a different
reading you should first check the accuracy of the
gauge. If the gauge is in order, then re-adjust the filter-
regulator with running motor with rated load. A fault-
less adjustment is only reached at a pressure upstream Version of two components filter-regulator and lubricator
the service unit of at least 7 bar.

 Lift the adjusting knob.

 Turn the regulator knob until the pressure gauge
shows 5,4 bar operating pressure.
Turn clockwise to increase the pressure or counter-
clockwise to decrease it.
 Latch the adjusting knob by pressing it down.

Alternatively you can set the filter regulator to 6 bar

with halted motor which will require a pressure of at
least 7 bar upstream the service unit.

 Relieve all pressure from the air line behind the

service unit and close it again.
 Turn the adjusting knob counter-clockwise to
detension the adjusting spring.
 Turn the adjusting knob until the pressure gauge
shows a pressure of 6 bar. Turn clockwise to increase
the pressure or counter-clockwise to decrease it.
 Latch the adjusting knob by pressing it down.

If the operating pressure does not reach 5,4 bar despite

a sufficiently high pressure upstream the service unit
then the cross section of the air feeding hose is too small!

Page 29
MAINTENANCE

Draining the moisture

In the course of time moisture is gathered in the

receptacle of the filter-regulator which has to be
drained in regular intervals. Please proceed as follows:

 Check the water level visible through the sight glass

in the receptacle. The water level may not reach the
separating disc.
 Mount the enclosed drain hose (instead of this a soft
PVC-hose of a diameter of 8 x 1 of corresponding Mount
length may be used). the hose
 Collect the drained water and dispose it in a suitable Drain moisture
manner as it may contain oil. by pressing
both handles
Cleaning the filter element
Draining the moisture
C AU T I O N !
Do not use any alcohols for cleaning the ser-
vice unit! Alcohol may damage parts of the
service unit. Transparent parts may only be
cleaned with soap.

The filter element must be cleaned yearly as follows:

 Drain the water.

 Shut off the compressed air supply, carefully relieve
any remaining pressure.
 Unlock the receptacle of the filter-regulator,
turn it to the left until it stops and remove it.
 Unscrew the separating disc. The filter element is loo-
sely positioned on the centre of the separating disc.
 Clean the filter element with soap water and blow
through it firmly.
 Remount the clean filter element and tighten the
separating screw.
 Put receptacle of the filter regulator back into the
hosuing and turn it to the right. The receptacle locks
by itself.

Version of two components filter-regulator and lubricator

Page 30
 MAINTENANCE

Filling and adjusting the lubricator

The function of the lubricator is to ensure that the air

supplied to the hoist receives a constant and precisely
metered quantity of oil. It is very important to check
the lubricator regularly as the vane motor could be
damaged in case of insufficient lubrication. The lubrica-
tor can be replenished even when it is under pressure.

 Check the oil level through the sight glass of the

receptacle. The oil level may not fall short of the
minimum marking!
 Unscrew the oil filling plug.
 Fill the lubricator with oil up to the maximum marking
and replace the oil filling plug.
 Check the oil dripping rate through the sight glass
with running motor.
 Turn the oil throttle screw with a screw driver until
reaching the required number of oil drops per minute.
Turn clockwise to reduce the dripping rate, counter-
clockwise to increase it.

Oil dripping rates (lifting with no load):

For UH 05, UH 1 and UH 2:

2 drops each per minute

For PROFI 3 TI, 6 TI, 10 TI, 15 TI, 20 TI, EH 20,

UH 4, UH 6, UH 8 and UH 12:
10 drops each per minute Check the oil level and replenish if necessary

For PROFI 25 TI, 37 TI and 50 TS:

15 drops each per minute sight glass

C AU T I O N ! oil filling screw

It is not allowed to fill the lubricator with oil throttle screw
synthetic oils. It may neither be connected
to an air system fed by a compressor which is
lubricated with synthetic oils.

Checking and adjusting the oil dripping rate

through sight glass

Page 31
MAINTENANCE

VE R S I O N O F T H R E E C O M P O N E N T S
Inspecting and adjusting the regulator

see description of the version of two components.

adjusting screw
stop nut •

;Q¢;Q¢;Q¢;Q¢;Q¢;Q¢;Q¢;Q¢
¢Q;¢Q;¢Q;;Q¢ ¢Q;¢Q;;¢Q;Q¢;Q¢¢Q;¢Q;;Q¢;Q¢
¢Q;¢Q;¢Q;¢Q;¢Q;¢Q;¢Q;;¢Q;Q¢;Q¢¢Q;¢Q;;Q¢;Q¢
¢Q; ;Q¢¢Q;;Q¢;Q¢;Q¢;Q¢;Q¢;Q¢;Q¢
Q;¢¢Q;¢Q;¢Q;
¢Q;
Draining the moisture •

;Q¢ ;Q¢ ;Q¢ ;Q¢

The receptacle is drained automatically.

¢
Q
;
adjusting spring spring cover
• •

Cleaning the filter element aspirating tube

Q
;¢
opening for
readjusting
C AU T I O N !

;¢
Q
Do not use any alcohols for cleaning the •

¢Q;¢¢QQ;;¢Q;¢¢QQ;;¢Q;¢¢QQ;;¢Q;
¢Q;¢Q;¢Q;¢Q;¢Q;¢Q;¢Q;
¢Q;¢Q;¢Q;¢Q;¢Q;¢Q;¢Q;
¢Q;¢Q;¢Q;¢Q;¢Q;¢Q;¢Q;
service unit! Alcohol may damage parts of

Q
¢
;
•
the service unit. Transparent parts may only inlet outlet

¢Q; ¢Q;
be cleaned with soap.
valve seat
• valve rod
•
The filter element must be cleaned yearly as follows: bottom screw recuperating spring
• •

 Shut off the compressed air supply, carefully relieve

any remaining pressure.
 Unscrew the receptacle by turning the cap nut
Regulator
to the left.
 Unscrew the separating cap.
 Remove the filter element from the stud bolt.
 Clean the filter element with soap water and blow
through it firmly. inlet outlet
 Place the clean filter element back on the stud bolt housing
•
and screw the separating disc tight.
twist cap
 Screw the receptacle tight by turning the cap nut •

to the right.
filter element
•
stud bolt
•

separating disc
•
setting zone
•

receptacle automatic
• •
draining

Filter

Page 32
 MAINTENANCE

Filling and adjusting the lubricator

CHECKING THE CONTROL ELEMENTS
See description Version of two components.
The lubricator can be replenished under pressure. The control elements of your JDN Air Hoist must return
automatically to the off position when they
 Check the oil level through the sight glass of the are released.
receptacle. The oil level may not fall short of the
minimum marking! Check once a day whether the control elements
 Unscrew the oil filling plug. work smoothly.
 Replenish the lubricator with oil up to the maximum
marking and replace the oil filling plug.
 Check the oil dripping rate through the sight glass TESTING THE BRAKE
with running motor.
 Adjust the oil dripping rate by turning the adjusting
The correct functioning of the brake must be tested
knob until reaching the required number of drops per
as follows:
minute. Turn clockwise to reduce the dripping rate,
counter-clockwise to increase it.  Operate the hoist with no load, alternating between
lifting and lowering.
Oil dripping rates (lifting with no load):
When you release a control element it must not be
For EH 25 up to EH 50:
visibly noticed that the chain slows down.
15 drops each per minute

For PROFI 50 TI, 100 TI, EH 75, EH 100, DANGER!

UH 75 and UH 100: If you notice that the chain does not stop
25 drops each per minute running immediately, stop using the hoist at
once! The hoist must be repaired before any
further use.

housing adjusting knob Due to physical reasons the stopping distance cannot
•

venturi nozzle adjusting needle reach the value zero but during this function test it
•
•
• lubricator must not be visibly noticed the chain slows down.
sight glass
•
inlet outlet
T E S T I N G T H E L I M I T S W I TC H

Move the hooks in succession into the upper and

sight glass
lower end position. Stop just before the end positions
aspiration tube • are reached and carefully (e. g. by pressing the control
•
elements several times) move the hook into the end
receptacle position.
•

Lubricator

Page 33
MAINTENANCE

In order to obtain safe working periods the client has to

L U B R I C AT I O N O F T H E C H A I N
check at each inspection whether the theoretical service
time has been reached. This has to be documentated at
The links of the chain of your JDN Air Hoist must be least once a year in the check book which contains an
lubricated in unloaded position. example of how to calculate the actual service time.
 Place the chain in an appropriate container. When the theoretical service time is reached a general
 Spray the chain with so much car oil that it is overhaul has to be carried out. Local (national) safety
completely covered with an oil film (see the section regulations detail the precise method to be used for cal-
entitled Operating materials, page 23). culating and recording the actual service time. It is the
 If there is no container available for carrying out customer’s responsibility to initiate the overhaul which
lubrication the chain can be lubricated while it is must be recorded in the check book. For information on
hanging. Ensure that the links are completely coated the general overhaul consult the manufacturer.
with oil (e. g. by moving).
It is only when the assumption for the group classifica-
You can get from JDN a high duty lubricator in a tion is in accordance with the practical operation of the
sprayer which sticks well to the chain and does not hoist that a safe working period corresponds to the
drop after the solvent has evaporated, article No. 12066 theoretical service time. Any deviation between the
(sprayer 400 ml). actual working time and the theoretical service time
increases or decreases the safe working period.

I N S P E C T I O N S A N D M A I N T E N A N C E WO R K Apart from the daily inspection all inspection procedures

require removing the hoist from its operating position.
Hoists are classified into groups and designed according  Release all pressure from the air lines.
to their planned operating method according FEM/ISO.  Set up a suitable working platform.
The daily running time and the load collective determine  Disconnect the air supply and control hoses
the classification (1 Bm/M3). The theoretical service from the hoist.
time is 1600 hours in the load collective 2, correspon-  Take the hoist out and remove it to a location suita-
ding to 400 hours of full load. ble for conducting the work required.
Whereby it is supposed that the distance for lifting and
WA R N I N G !
lowering is more or less the same.
Every time repairs have been carried out the
The life time of hoists used mainly for lowering purposes setting up checks must be done on the hoist.
(approx. 75% of the duty cycle) would be reduced
because of the higher lowering speed in the range of
50% to 100% of the nominal load. The reduction factor
fv has the value 1 at 50% nominal load linearly ascen-
ding to 1,5 at 100% nominal load (P = percentage of
nominal load).

fv = 1+0,5 P-50 (for P > 50%)

50

Page 34
 MAINTENANCE

MAINTENANCE LIST

No. Measures to be taken Frequency see the section entitled

1 Check oil level for motor lubrication daily Service unit, page 29
2 Check control elements daily Checking the control elements, page 33
3 Test brake function daily Testing the brake function, page 33
4 Test limit switch daily Testing the limit switch, page 33
5 Lubricate the chain in case of need Operating materials, page 23, and
Lubrication of the chain, page 34
6 Check emergency stop daily Controls, page 24
7 Check buffers of the emergency stop device daily
(if there is no end switch)

All these measures are described in the section entitled

Service Unit, page 29.

INSPECTION LIST

The mentioned frequencies refer to normal operation The frequencies have to be increased in dependence on
(see the section entitled Operating mode, page 8). higher stress.

No. Measures to be taken Frequency

1 Check chain every three months at least
2 Check chain sprocket and chain guide at every chain change
3 Check wear on brakes every 250 hours*
4 Check all screw and bolt connections every 250 hours*
5 Check seating and condition of load hook and eye every 250 hours*
(load and suspension sections)
6 Check motor every 250 hours*
7 Check gears and change lubrication every 800 hours**
8 Check shaft coupling every 800 hours**
9 Check load coupling every 800 hours**
10 Check control daily
11 Check service unit yearly
12 Check silencer yearly
13 Check overload protection yearly
14 Check and lubricate the axial bearing of the hooks yearly
and the bearing of the sprocket wheels
15 Change buffers of the emergency stop device at least every 5 years
16 Check air connections for damages yearly
17 In Offshore and similar corrosive applications the chain at least after 5 years
has to be exchanged on a regular basis
* at least yearly ** at least after 5 years

Page 35
MAINTENANCE

The chain sprocket should be exchanged at the same

TEST DIMENSIONS
time when exchanging the chain, as otherwise the new
chain will be subject to increased wear. Each chain
Note: When checking the extent of wear, the wear change has to be documented in the check book.
which will occur in the period until the next examinati-
on must be taken into consideration.

Chain d x t 7 x 21 13 x 36 16 x 45 22 x 66 31.5 x 90
Dimension A max. 249.2 429.2 536 783.4 518.3*
11 x t inside 235.8 404.3 505.3 741.2 457.8*
Dimension B max. 22.1 37.9 47.4 69.5 93.8
Dimension C min. 6.3 11.7 14.4 19.8 28.35
Dimension D max. 36.1 63.9 79.3 113.3 157.6
Dimensions in mm * Measuring length referred to 5 x t

Type Max. permissible dimension Min. permissible dimension

of throat width a1) of height h
UH 05, UH 1 31.5 mm 21.4 mm
UH 2 36.5 mm 28.5 mm
3 TI 35.7 mm 36.1 mm
6 TI, UH 4, UH 6 46.0 mm 41.3 mm
10 TI, UH 8, UH 12 50.4 mm 58.9 mm
15 TI 60.6 mm 71.3 mm
20 TI, 25 TI
83.4 mm 80.8 mm
EH 20, EH 25,
37 TI, 50 TI, 50 TS
110.2 mm 116.9 mm
EH 37, EH 50,
100 TI, EH 75, EH 100,
131.0 mm 152.0 mm
UH 75, UH 100

1) With safety latch the plate thickness of the safety

latch has to be subtracted from the max. permissable
dimension a.

d1

C = d1 + d2
d2

Page 36
 ACCESSORIES

ACCESSORIES
DANGER!
C H A I N C O N TA I N E R
When using a chain container the lubrication
of the chain is of special importance to avoid
Use only JDN chain containers with JDN Air Hoists. the chain to fall out.
Other constructions could be a high safety risk.
C AU T I O N !
Never exceed the permitted filling capacity for The chain container must be protected
a chain container. against impacts from the load when lifting.
For chains in containers lubrication is of utmost Fit a chain stop to the chain if required.
importance for making full use of the bucket capacity.
C AU T I O N !
Rust on chains assist high piling up of the chain in
Do not allow the chain to pile up in
the bucket and is therefore not allowed.
the chain container.
When the chain runs into the container it has to be
observed that between lower edge of mid section and
chain pile at least 5 chain links can hang without
obstruction.

The chain may only pass into the container over the
chain drive. Should it have fallen out of the container
for example during transportation it must be completely
extended at the load hook side and then returned into
the container over the chain drive with running hoist.

In case a load is fastened directly under the load hook

it has to be safeguarded that it cannot be driven
against the chain container. If necessary a clamping
sleeve has to be mounted on the chain above the load
hook acting as an emergency stop at the control lever.

DANGER!
When operating JDN Air Hoists without a
chain container it has to be made certain
that the idle chain running up and down the
chain sprocket (unloaded chain end) does
not cause any risks for example by
interlocking, striking or falling down.

Crash dangers may also arise when during

the lifting process the idle chain at first
settles on large surface loads or other
surfaces above the transport level and then
slides or falls down.

DANGER!
Do not exceed the admissible filling capacity!
Danger of a chain drop!

Page 37
ACCESSORIES

O P E R AT I O N
F I LT E R S I L E N C E R
The function of the fine filter silencer takes place
in three steps:
1 Distribution system 1. The oil containing exhaust air flows over the inlet
2 Filter silencer element
3 Upper housing into a conical distribution system (1) to flow uni-
4 Drip pan formly against the filter element and reduce the flow
5 Fastening bolt rate.
6 Divertor
2. When flowing through the filter element made of
micro glass fibre the oil particles form larger drops –
because of the “coalescing effect” – which are collec-
ted in the outer foam coating and can drop from
there into the transparent drip pan (4).
The degree of efficiency achieved is > 99.99 % of all
oil particles according to the DOP Test.

3. The compressed air, which is now clean, can expand

Filter silencer to ambient pressure. The reduced flow speed leads to
a sound absorption of > 4 dB (A). The noise level of
expanding from 7 bar to atmosphere can reach
approx. 125 dB (A).

4. – Result: Clean and quiet ambient air.

As the structure of the filtering material (2) has a high

hollow volume (approx. 90 %) there is considerable
retention of solid particles. Therefore the service life is
correspondingly high and the pressure drop very low.

MAINTENANCE
Care must be taken that the filtered out oil or the
emulsion which has accumulated in the drip pan, are
drained. This should be carried out by turning the knob
of the divertor (6) by 90 ° before the fluid level reaches
the filter silencer element (2).

Depending on the amount of solid particles, the element

needs to be replaced by a new one after approx. 2500
hours of operation with the filter silencer still mounted
in the air line. The bottom tray fastened to the upper
housing with 4 snap connections can be easily removed,
the same as the element which is held in place by the
fastening bolt (5).

Page 38
 ACCESSORIES

OVE R L OA D P R OT E C T I O N

;Q¢;;QQ¢¢;Q¢;;QQ¢¢;Q¢;;QQ¢¢;Q¢;;QQ¢¢¢Q;¢Q;¢Q;¢Q;
;Q¢;Q¢;Q¢¢Q;;Q¢¢Q;¢Q;;Q¢¢Q;¢Q;;Q¢;Q¢;Q¢¢Q;¢Q;¢Q;
;Q¢¢Q;¢Q;¢Q;;Q¢¢Q;¢Q;¢Q;;Q¢¢Q;;Q¢¢Q;;Q¢¢Q;;Q¢¢Q;;Q¢;Q¢¢Q;¢Q;¢Q; Q
;¢
;Q¢;Q¢;Q¢;Q¢¢Q;¢Q;;Q¢;Q¢¢Q;¢Q;¢Q;
;Q¢;Q¢;Q¢;Q¢¢Q;¢Q;;Q¢;Q¢¢Q;¢Q;¢Q;
Q¢Q¢;QÀ;€À@€@¢Q;À€@¢Q;À€@¢Q;¢Q;¢Q;¢Q; ;Q¢
;Q¢ ;Q¢ ;Q¢;Q¢;Q¢ ¢Q;¢Q;¢Q;
JDN Air Hoists have the overload protection as a stan- Locking screw

¢Q;¢Q; ;Q¢
¢
Q
;
•
dard feature for the EU market. The overload protection

Q;¢¢Q;¢Q;¢Q;¢Q;
Q
¢
;
Q;¢Q;À€@¢Q;À€@¢Q;¢Q;¢Q;¢Q;
¢Q; ¢;Q
automatically stops the lifting operation if the load

Q;À€@¢¢Q;À€@¢Q;À€@¢Q;À€@ ¢Q;À€@Q;À€@¢¢Q;À€@¢Q;À€@ Q;À€@¢¢Q;À€@¢Q;À€@¢Q;À€@¢Q;À€@ Q;À€@¢¢Q;À€@¢Q;À€@¢Q;À€@

;
Q
¢
Retaining
•
reaches or is greater than the maximum setting. screw

¢Q;À€@ ¢ ;
Q
The shutoff setting is between 110% and 125% of the

¢Q;À€@¢Q;¢ÀQ€;@À€@¢Q;À€@¢Q;À¢€Q@;À€@¢Q;À€@; Q
¢
¢Q;À€@ ¢Q;À€@¢
¢Q;À€@¢Q;À€@¢Q;À€@; Q
¢ Q
¢
;
¢Q;À€@¢¢QQ;;ÀÀ€€@@¢Q;À€@;
¢Q;À€@¢Q;À€@¢Q;À€@¢
Q;À€@¢¢Q;À€@¢Q;À€@¢Q;À€@ ¢Q;À€@¢Q;¢ÀQ€;@À€@¢Q;À€@

Q;À€@¢¢Q;À€@¢Q;À€@¢Q;À€@ ¢Q;À€@Q;À€@¢¢Q;À€@Q;À€@¢
hoist’s rated maximum load capacity.

¢Q ;À € @
When the overload protection has actuated only the
“Down” motion can be initiated.

The overload protection can also respond to a load that

weighs less than the shutoff setting. This may happen
when with full speed and a slack chain a load is abrupt- Overload protection (at the motor)
ly lifted. We therefore recommend to tighten the slack
chain slowly before lifting the load.

If you wish to retrofit the overload protection to your

air hoist consult the customer service of J.D. NEUHAUS
GMBH & CO. KG.

O VE R L OA D T E S T I N G W I T H P R O F I 3 T I T H R O U G H
PROFI 20 TI AND MONORAIL HOIST EH 20
When testing the hoist with overload without causing
the hoist to shut-off the locking screw has to be removed.

DANGER!
After completing the overload test, always
tighten the locking screw until it seats firmly.

A D J U S T I N G T H E OVE R L OA D P R OT E C T I O N
DANGER!
If the overload protection is incorrectly
adjusted the chain may break.

 Loosen the retaining screw in order to reach the

threaded lug underneath it.
 Turn the threaded lug to adjust the overload protec-
tion setting. Turn the lug clockwise to increase
the shutoff setting or counterclockwise to decrease
the setting.
 Replace the retaining screw and tighten it down before
testing the overload protection for correct functioning.

Page 39
ACCESSORIES

O VE R L OA D T E S T I N G W I T H P R O F I 2 5 T I O VE R L OA D T E S T I N G W I T H U H 0 5 T H R O U G H U H 2
THROUGH PROFI 100 TI AND MONORAIL When testing the hoist with overload without causing
HOISTS EH 25 THROUGH EH 100 the hoist to shut-off the locking screw has to be removed.
When testing the hoist with overload without causing
the hoist to shut-off the locking screw has to be removed. DANGER!
After completing the overload test, always
DANGER! tighten the plug screw until it seats firmly.
After completing the overload test, always
 Loosen the plug screw.
tighten the locking screw until it seats firmly.
 Now the pressure balance piston is not activated at
 Loosen the locking screw. the “UP” side, and the overload protection is out of
 Now the pressure balance piston is not activated function.
at the “UP” side, and the overload protection is out  After completing the overload protection test,
of function. tighten the plug screw until it seats firmly.
 After completing the overload protection test
tighten the locking screw until it seats firmly. A D J U S T I N G T H E OVE R L OA D P R OT E C T I O N
DANGER!
A D J U S T I N G T H E OVE R L OA D P R OT E C T I O N If the overload protection is incorrectly
DANGER! adjusted the chain may break.
If the overload protection is incorrectly
 Loosen the retaining screw in order to reach the
adjusted the chain may break.
threaded lug underneath it.
 Loosen the retaining screw in order to reach the  Turn the threaded lug to adjust the overload protec-
threaded lug underneath it. tion. Turn the lug clockwise to increase the shutoff
 Turn the threaded lug to adjust the overload protec- setting, or counterclockwise to decrease the setting.
tion setting. Turn the lug clockwise to increase  Replace the retaining screw and tighten it down
the shutoff setting or counterclockwise to decrease before testing the overload protection for correct
the setting. functioning.
 Replace the retaining screw and tighten it down
before testing the overload protection for correct
functioning. Locking screw
•

Section A - A

•
.
.

Retaining
•
( ( (

screw
. . . .

Retaining screw
A
.

. . . . . .

. . . . . . .

Locking screw Overload Protection (at the motor)

. . . .

. . . . . .
•
Loosen the retaining screw to reach the threaded lug
A
underneath it.

Overload protection (at the motor)

Page 40
 ACCESSSORIES

O VE R L OA D T E S T I N G W I T H U H 4 T R O U G H U H 1 2  Replace the retaining screw and tighten it down

When testing the hoist with overload without causing before testing the overload protection for correct
the hoist to shut-off the locking screw has to be removed. functioning.
 Replace the cover screw (2) at the housing.
DANGER!
After completing the overload test,
always tighten the plug screw until it B O O S T E R VALVE
seats firmly.

 Loosen the cover screw (1) at the housing To shorten the reaction times of indirect controls
 Loosen the plug screw. (E, F, HT) where the control hose length is over 10 m,
 Now the pressure balance piston is not activated at an additional valve is fitted on the motor.
the „UP“ side, and the overload protection is out of This also prevents a pressure drop in the control
function. cylinder of the motor valve.
 After completing the overload protection test, tigh-
ten the plug screw until it seats firmly.
 Replace the cover screw (1) at the housing.
A X I AL B E A R I N G
A D J U S T I N G T H E OVE R L OA D P R OT E C T I O N
As standard the top hooks of JDN Air Hoists can only
DANGER! be turned around its longitudinal axle without load
If the overload protection is incorrectly as there is no roller bearing in the housing.
adjusted the chain may break. In case the top hook has to be turned around smoothly
 Loosen the cover screw (2) at the housing. under load an axial bearing with own housing can be
 Loosen the retaining screw in order to reach the mounted between hoist housing and top hook.
threaded lug underneath. This additional device increases the headroom of JDN
 Turn the threaded lug to adjust the overload protec- Air Hoists.
tion. Turn the lug clockwise to increase the shutoff
setting, or counterclockwise to decrease the setting.

Plug screw

A-A
A
•
•

•
•

Cover screw (1) Cover screw (2)

Loosen the retaining screw to Threaded lug Retaining screw Loosen the plug screw to
reach the threaded lug underneath. override the overload protection.

Overload protection (in the motor housing)

Page 41
ANNEX

D I M E N S I O N S / T E C H N I C AL DATA

S P E C I F I C AT I O N S O F J D N A I R H O I S T S
G D
C
E1

A
B
E2

Type 025 TS 05 TS 1 TS 2 TS 3 TI 6 TI 10 TI 15 TI 20 TI 25 TI 37 TI 50 TS 50 TI 100 TI

A min. headroom* 452 395 410 544 540 650 800 910 1090 1282 1466 1700 1700 2200
B 298 238 238 370 320 430 535 585 708 948 935 1144 1144 1475
C 141 144 183 183 200 200 240 240 390 393 377 475 538 705
D 302 308 348 348 480 480 528 528 768 839 807 1005 1124 1417
E1 26 26 30 30 40 40 42 55 75 75 100 100 100 120
E2 26 26 26 30 30 40 42 55 75 75 100 100 100 120
F 132 136 142 116 198.5 198.5 220 322 250 466 518 310 310 440
G max. width 217 217 217 217 275 275 340 465 360 610 745 539 539 767
* Chain container increases the headroom Dimensions in mm

Type 025 TS 05 TS 1 TS 2 TS 3 TI 6 TI 10 TI 15 TI 20 TI 25 TI 37 TI 50 TS 50 TI 100 TI

Rated capacity metric tons 0.25 0.5 1 2 3 6 10 15 20 25 37.5 50 50 100
Number of chain falls 1 1 1 2 1 2 2 3 4 2 3 4 4 4
Motor output kw 1.0 1.0 1.0 1.0 2.2 2.2 2.2 2.2 2.5 6.0 6.0 6.0 10.0 10.0
Air pressure bar 6 6 6 6 6 6 6 6 6 6 6 6 6 6
Lifting speed with rated load m/min 20 10 5 2.5 3.5 1.7 1.0 0.7 0.5 1.1 0.65 0.45 0.7 0.35
Lifting speed with no load m/min 44 22 11 5.5 7 3.5 2.6 1.7 1.0 2.3 1.6 1.3 1.3 0.7
Lowering speed with rated load m/min 40 24 12 6 8.5 4.2 3 2 1.3 1.9 1.5 1.4 1.5 0.8
Air consumption Lifting 1.4 1.4 1.4 1.4 2.4 2.4 2.4 2.4 2.9 5.5 5.5 5.5 11 11
m3/min
with rated load Lowering 1.2 1.2 1.2 1.2 3.1 3.1 3.1 3.1 3.7 6.5 6.5 6.5 12 12
Air connection G 1⁄2 G 1⁄2 G 1⁄2 G 1⁄2 G 3⁄4 G 3⁄4 G 3⁄4 G 3⁄4 G 3⁄4 G1 G1 G1 G11⁄2 G11⁄2
Hose dimension mm 15/27 15/27 15/27 15/27 19/31 19/31 19/31 19/31 19/31 25/39 25/39 25/39 35/51 35/51
( inside/ outside)
Weight with standard lift. kg 21.5 24 27.5 34.5 67 88 125 190 285 498 880 855 940 2460
rope control. without ∆p
Chain size mm 5x15 7x21 7x21 7x21 13x36 13x36 16x45 16x45 16x45 22x66 22x66 22x66 22x66 31.5x90
Weight of chain per metre kg 0.54 1.0 1.0 1.0 3.8 3.8 5.8 5.8 5.8 10.8 10.8 10.8 10.8 21.3
Standard lift m 3 3 3 3 3 3 3 3 3 3 3 3 3 3
Length of control with standard lift m 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Sound level with rated load1 dB (A) 75 75 75 75 86 86 86 86 76 83 83 83 88 88
with standard silencer - Lifting
Sound level with rated load1
with standard silencer - Lowering dB (A) 80 80 80 80 88 88 88 88 82 83 83 83 89 89

1 measured in 1 m distance acc. to DIN 45635 part 20

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 ANNEX

S P E C I F I C AT I O N S O F J D N M O N O R A I L H O I S T S
A b+B C
K
D b

E
H

F
J G
L M

Type EH 20 EH 25 EH 37 EH 50 EH 75 EH 100
A 162 146 100 125 100 125
B 68 70 68 68 68 68
C 287 277 287 292 287 292
D 35 25 35 40 35 40
E 220 198 220 283 220 283
F* 850 998 1070 1150 1480 1535
G 275 170 190 420 286 575
H 75 75 100 100 120 120
J 210 350 455 340 740 470
K 720 1185 1730 1680 3210 3130
L 390 377 379 462 640 762
M 407 434 430 560 655 750
* Chain container increases the headroom Dimensions in mm

Type EH 20 EH 25 EH 37 EH 50 EH 75 EH 100
Rated capacity t 20 25 37.5 50 75 100
Number of chain falls 4 2 3 4 3 4
Motor output Trolley kw 0.7 1.4 1.4 1.4 2.8 2.8
Motor output Hoist kw 2.5 6 6 6 10 10
Air pressure bar 6 6 6 6 6 6
Lifting speed with rated load m/min 0.5 1.1 0.65 0.5 0.45 0.35
Lifting speed with no load m/min 1.0 2.3 1.6 1.1 0.85 0.65
Lowering speed with rated load m/min 1.3 1.9 1.5 0.9 1.0 0.75
Travelling speed with rated load m/min 12 12 12 12 12 12
Travelling speed with no load m/min 13.5 13.5 13.5 13.5 13.5 13.5
Air consumption Trolley m3/min 1.3 2.6 2.6 2.6 5.2 5.2
Air consumption Hoist 2.9 5.5 5.5 5.5 11 11
Air connection G 3⁄4 G 11⁄2 G 11⁄2 G 11⁄2 G 11⁄2 G 11⁄2
Hose dimension mm 19/31 25/39 25/39 25/39 35/51 35/51
( inside/ outside)
Weight with standard lift kg 620 950 1450 1780 4000 5700
Chain size mm 16x45 22x66 22x66 22x66 31.5x90 31.5x90
Weight of chain per metre kg 5.8 10.8 10.8 10.8 21.3 21.3
Standard lift m 3 3 3 3 3 3
Length of control with standard lift m 2 2 2 2 2 2
Sound level with rated load1 dB (A) 76 83 83 83 88 88
with standard silencer - Lifting
Sound level with rated load1 dB (A) 82 83 83 83 89 89
with standard silencer - Lowering
1 measured in 1 m distance acc. to DIN 45635 part 20

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ANNEX

S P E C I F I C AT I O N S O F J D N U LT R A- L OW M O N O R A I L H O I S T S
L A b+B C
E b
D

G
K

H
M

F N

Type UH 05 UH 1 UH 2 UH 4 UH 6 UH 8 UH 12
A 155 155 155 246 317 246 317
B 140 140 140 200 200 200 200
C 252 252 252 315 315 315 315
D 84 84 84 165 165 165 165
E 136 136 136 236 236 236 236
F 182 182 148 330 330 270 270
G 114 114 114 197.5 197.5 197.5 197.5
H* min. 58 <=b <=125 120 120 120
H* min. 125 <=b <=210 125 125 135
H* min. 150 <=b <=230 210 210 260 260
H* min. 210 <=b <=310 130 130 140
H* min. 230 <=b <=310 220 220 235 235
J 257 257 257 400 400 400 400
K 339 339 339 500 500 500 500
L 625 625 625 970 970 970 970
M 26 26 30 30 40 40 42
N 38 38 53 53 55 55 76
* Chain container increases the headroom Dimensions in mm

Type UH 05 UH 1 UH 2 UH 4 UH 6 UH 8 UH 12
Rated capacity t 0.5 1.0 2.0 4.0 6.0 8.0 12.0
Number of chain falls 2 2 4 2 2 4 4
Motor output kw 1.0 1.0 1.0 2.5 2.5 2.5 2.5
Air pressure bar 6 6 6 6 6 6 6
Lifting speed with rated load m/min 10 5 2.5 2.2 1.5 1.0 0.7
Lifting speed with no load m/min 24 12 6 4.4 3 2 1.4
Lowering speed with rated load m/min 24 12 6 7.5 5.2 3.6 2.5
Air consumption Lifting -rated load- m3/min 1.4 1.4 1.4 2.9 2.9 2.9 2.9
Air consumption Lowering -rated load- m3/min 1.2 1.2 1.2 3.7 3.7 3.7 3.7
Air connection G 1⁄2 G 1⁄2 G 1⁄2 G 3⁄4 G 3⁄4 G 3⁄4 G 3⁄4
Hose dimension mm 15/27 15/27 15/27 19/31 19/31 19/31 19/31
( inside/ outside)
Weight with standard lift kg 105 106 120 450 470 495 520
without control
Chain size mm 7x21 7x21 7x21 13x36 13x36 13x36 13x36
Weight of chain per metre kg 1.1 1.1 1.1 3.8 3.8 3.8 3.8
Standard lift m 3 3 3 3 3 3 3
Lenght of control with standard lift m 2 2 2 2 2 2 2
Sound level with rated load1
dB (A) 75 75 75 76 76 76 76
with standard silencer - Lifting
Sound level with rated load1
dB (A) 80 80 80 82 82 82 82
with standard silencer - Lowering
1 measured in 1 m distance acc. to DIN 45635 part 20

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 is a registered trademark of our company.
BA 811 GB · Issue: September 2002 · Alterations reserved · With the issue
of this edition all previous versions are null and void · 9200205

J.D. Neuhaus GmbH & Co. KG_D-58449 Witten-Heven

Phone: +49(0)23 02-2 08-0_Fax: +49(0)23 02-2 08-286
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