JDN OPER ATION MANUAL

AIR HOISTS

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Please enter the Fabr. No. of your JDN Air Hoist here.

This operation manual, edition 4/2005,

covers the following JDN Air Hoists:

Fabr. No. Fabr. No.

Fabr. No. Fabr. No.

Before operating any hoist, carefully read the

entire manual. For hoists mounted in trolleys,
refer also to the JDN Trolleys Operation Manual.

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TABLE OF CONTENT S
Lowering the load . . . . . . . . . . . . . . . . . . . . . . 36
SAFET Y INSTRUCTIONS
Detaching the load . . . . . . . . . . . . . . . . . . . . . 36
Organisational measures . . . . . . . . . . . . . . . . . . 5 Interrupting working . . . . . . . . . . . . . . . . . . . 36
Personnel safety . . . . . . . . . . . . . . . . . . . . . . . . 5
Preventing property damage . . . . . . . . . . . . . . . 5 TA K I N G O U T O F O P E R AT I O N
Prolonged shutdown . . . . . . . . . . . . . . . . . . . . 37
P RO D U C T I N F O R M AT I O N
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
The operation manual . . . . . . . . . . . . . . . . . . . . 6 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Warnings and symbols. . . . . . . . . . . . . . . . . . . . 6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly overview . . . . . . . . . . . . . . . . . . . . . . 8 M A I N T E N A NC E
Product description. . . . . . . . . . . . . . . . . . . . . . 8 Maintenance and inspection intervals . . . . . . . . 38
Explosion protection . . . . . . . . . . . . . . . . . . . . . 9 Cleaning and care . . . . . . . . . . . . . . . . . . . . . . 38
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . 15 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operating conditions . . . . . . . . . . . . . . . . . . . . 16 Inspection and maintenance work . . . . . . . . . . 38
Energy requirements . . . . . . . . . . . . . . . . . . . 17 Instructions on the “model for determining
Principle of operation of the actual operating time” . . . . . . . . . . . . . . . . 40
JDN air vane motors . . . . . . . . . . . . . . . . . . . . 18 Lubricating the chain . . . . . . . . . . . . . . . . . . . 44
Operation without chain box . . . . . . . . . . . . . . 19 Checking braking function . . . . . . . . . . . . . . . . 44
Motor lubrication/ operation with service unit . 19 Checking lifting and lowering limiters . . . . . . . 45
CE certification/ manufacturer's declaration . . . 19 Checking controls and emergency stop . . . . . . . 45
Certification . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Checking direction of movement . . . . . . . . . . . 45
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Checking the silencer for permeability . . . . . . . 45
Service unit . . . . . . . . . . . . . . . . . . . . . . . . . . 46
T R A N S P O R TAT I O N A N D S T O R AG E
Motor installation/checking brake linings
Safe transportation . . . . . . . . . . . . . . . . . . . . . 20 and vanes/motor lubrication . . . . . . . . . . . . . . 49
Storage conditions . . . . . . . . . . . . . . . . . . . . . 20 Removing and installing load sleeve,
bottom block, clamp and buffer . . . . . . . . . . . . 52
SETTING UP Checking chain, chain sprocket and chain guides 54
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check dimensions . . . . . . . . . . . . . . . . . . . . . . 54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Checking axial play . . . . . . . . . . . . . . . . . . . . . 56
Installing the hoist . . . . . . . . . . . . . . . . . . . . . 21 Removing and installing chain . . . . . . . . . . . . . 57
Connecting the controls . . . . . . . . . . . . . . . . . . 22 Replacing chain and chain sprocket . . . . . . . . . 58
Replacing controls. . . . . . . . . . . . . . . . . . . . . . 25 Overload protection . . . . . . . . . . . . . . . . . . . . . 59
Connecting to the main air supply . . . . . . . . . . 26
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FAU LT S , C AU S E A N D R E M E DY
Pre-start checks . . . . . . . . . . . . . . . . . . . . . . . 28 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

O P E R AT I O N AC C E S S O R I E S
Rules for safe operation Filter silencer . . . . . . . . . . . . . . . . . . . . . . . . . 61
of hoists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Booster unit . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Chain box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Emergency stop device . . . . . . . . . . . . . . . . . . 34
APPENDIX
Overload protection . . . . . . . . . . . . . . . . . . . . . 34
Attaching the load . . . . . . . . . . . . . . . . . . . . . 35 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 63
Lifting the load . . . . . . . . . . . . . . . . . . . . . . . 36 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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Please note:

Within the Federal Republic of Germany operators of

air hoists must comply with trade association accident
prevention regulations and rules, as well as state occu-
pational safety regulations, in particular

 BGV A1 accident prevention regulations “Principles of

Prevention”
 BGV D8 accident prevention regulations “Winches,
Lifting and Pulling Devices”
 BGR 258 trade association regulations “Operation of
Load-Carrying Devices Used with Lifting Equipment”

and, for air hoists installed in trolleys, additionally with

 BGV D6 “Accident Prevention Regulations for Cranes”

in the respective currently applicable version.

Operators must also initiate the prescribed tests
(see also “Principles for the Testing of Cranes” BGG 905
(ZH 1/27).

When operating air hoists in areas with explosive

atmospheres, the operator must comply with the rele-
vant explosion protection regulations, e.g.

 BGR 104 “Explosion Protection Regulations” and

 BGR 132 “Prevention of Ignition Hazards due to
Electrostatic Charges”

In all other countries, the operator shall comply with

local regulations as applicable.

Special regulations may apply when incorporating air

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

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SAFET Y INS TRUCTIONS
O RG A N I S AT I O N A L M E A S U R E S
JDN hoists are designed in accordance with current
technological standards and accepted safety practice.
Nonetheless, the use of an air hoist may be associated
with risk of injury or fatality to the user or to third
parties or with the risk of damage to the hoist or to
other items, if safety rules are disregarded.
All personnel charged with operating air hoists must
have read and understood the operation manual, espe-
cially the section entitled “Rules for safe operation of
hoists”, before commencing work.
This is particularly important for personnel who only
occasionally operate the hoist, e.g. for maintenance or
retrofitting work.
Operators of JDN hoists are also under obligation to
ensure safe and hazard-free operation. This can be
achieved through the following measures:

keep the operation manuals available at the hoist
operating site,
 carry out regular training,
 implement an inspection log and make regular
entries,
 regularly check personnel for safety and hazard
awareness during work.
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SAFET Y INS TRUCTIONS
PERSONNEL SAFET Y
Ensure that only properly trained personnel are entrust-
ed with operation, maintenance, inspection and repair.
“Properly trained” in this case means that the operator
has appropriate training and experience in working with
hoists. They are sufficiently familiar with the relevant
occupational safety and accident prevention regulations
that they are able to assess the condition of hoists with
regard to working safety.
 Follow the operating instructions for your workplace.
 Comply with the accident prevention regulations.
 Ensure that you are properly informed regarding
working with hazardous materials.
 Follow the safety instructions set out in the
operation manuals.
P R E V E N T I N G P RO P E R T Y DA M AG E
Operators of JDN hoists are under obligation to ensure
that entries in the accompanying inspection log are
made properly and regularly.
 Comply with the prescribed maintenance intervals.
 Only use JDN hoists for work which is described as
intended use.
 Observe the operating conditions for JDN hoists as
described in this manual.
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PRODUCT INFORMATION
PRODUCT INFORMATION
T H E O P E R AT I O N M A N UA L
This operation manual is intended to help the operator
familiarise himself with JDN Air Hoists and to take full
advantage of their designated areas of application.
This operation manual contains important information
for the safe, proper and economic operation of JDN Air
Hoists. Observance of the manual helps to avoid haz-
ardous situations, to reduce repair costs and downtimes
and to extend the service life of the JDN Air Hoists.
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WA R N I N G S A N D S Y M B O L S
Safety warnings in this operation manual are classified
in three categories:
DA NG E R !
Safety warnings, which if not followed
can result in hazard to life and limb, are
indicated by this symbol.
The symbol indicates an immediate danger.
The possible consequences of non-observance
may be severe or even fatal injuries.
WA R N I N G !
This symbol indicates situations, which
may become hazardous. Failure to follow the
instructions could result in injuries.
C AU T I O N !
This symbol indicates that failure to follow
the relevant instructions may result in dam-
age to the device or other equipment.
 PRODUCT INFORMATION

D E S I G N AT I O N

The nameplate mounted on the housing cover

identifies the type of JDN Air Hoist and contains
all important rating data.

If you have any questions concerning operation of

JDN Air Hoists, which are not addressed in this opera-
tion manual, please contact us at the following address:

J.D. NEUHAUS GMBH & CO. KG

Windenstraße 2-4
D - 58455 Witten-Heven Germany

Phone +49 2302 208-0

Fax +49 2302 208-286
www.jdn.de
e-mail: info@jdn.de

Example of nameplate on housing cover

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PRODUCT INFORMATION

A S S E M B LY O V E R V I E W

series air hoists consist of the following

assemblies:

1 Gearbox with chain sprocket

2 Centre section
3 Motor with integral brake function
4 Controls with main air EMERGENCY STOP
and overload protection
5 Chain
6 Load hook with load sleeve or bottom block
and buffer

P RO D U C T D E S C R I P T I O N

The series JDN Air Hoists described

here are designed for load-carrying capacities
from 0.25 t ( ) to 2 t ( ).
Various control devices are available for the
different requirements.

The air vane motor of the hoist, together with the

appropriate controls, is capable of sensitive movement.
This enables precise positioning of the load.

series JDN Air Hoists conform to

driving mechanism classification as indicated
in the following table: series JDN Air Hoist

Air Hoist Chain

025 TI M5 / 2 m M8 / 5 m
05 TI M4 / 1 Am M7 / 4 m
1 TI M4 / 1 Am M3 / 1 Bm
2 TI M4 / 1 Am M3 / 1 BM
ISO 4301 / FEM 9.5.11

JDN Air Hoist motors feature rotors with

grease chambers. These contain JDN high-performance
grease which enables operation with oil-free compressed
air. It remains effective for an operating period of
approx. 250 hours and should be renewed when
required, but after five years at the latest (see Motor
lubrication, page 19). Additional lubrication with oil-
bearing compressed air by means of a service unit with
oiler is possible.

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E X P L O S I O N P RO T E C T I O N
The basis for the following information is an expert
statement by the DMT Gas & Fire Division on the use of
JDN Hoists, Trolleys and Crane Systems in explosion-
hazardous areas, based upon European Guideline
94/9/EC1 (“ATEX 100a”). DMT is accredited for the test-
ing of devices and protection systems for intended use
in explosion-hazardous areas.
BA S I C E X P L O S I O N P RO T E C T I O N F O R T H E
S TA N DA R D V E R S I O N S
Standard version JDN air hoists are category 2 devices
(Guideline 94/9/EC, DIN EN 1127-12), for use in zone 1
and 2 for gases of explosion group IIA. (See also IEC
60079-123 and IEC 60079-204.) These devices are also
suitable for use in zone 2, in the presence of gases of
explosion group IIB, provided that the substances
hydrogen sulphide and ethylene oxide can be excluded
and additionally in zones 21 and 22 for dusts with glow
temperatures above 210°C or ignition temperatures
above 202°C, provided that no light metal or other
impact-sensitive dusts are present.
These devices are designated by:
II 2 GD IIA T4(X)/II 3 GD IIB T4(X)
Additional marking “X”, see page 10.
JDN HOISTS
“W I T H I NC R E A S E D S PA R K P RO T E C T I O N ”
JDN hoists in the “with increased spark protection”
version (FS) fulfil further explosion protection require-
ments. With the exception of carbon disulphide (tem-
perature class T6), they can be used in the presence of
all gases in zones 1 and 2 and dusts with glow tempera-
tures above 210° or ignition temperatures above 202°
in zones 21 and 22, and can be designated with
II 2 GD IIC T4(X) for installation in a trolley,
depending upon the trolley version (see below), but
also with II 2 GD IIB T4(X). For further operating
conditions, see Instructions for safe operation (Notes
D and E ).
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PRODUCT INFORMATION
JDN HOIS T S FOR USE IN THE PRESENCE OF TEM-
PER ATURE CL ASS T6 GASES OR EXTREMELY EXPLO-
SIVE DUS T S
Following separate tests, especially with regard to
ambient temperatures and type of operation, use in the
presence of carbon disulphide or dusts with particularly
low glow or ignition temperatures may be possible with
designation II 2 GD IIC T6(X), which includes the
additional marking “X” for special conditions (see
Additional marking “X”).
Please contact us with regard to these requirements.
S TA N DA R D J D N T RO L L E Y A N D C R A N E
RUNNING GEAR
JDN trolleys and cranes can be used in zone 2 with
standard running wheels (made of steel or cast metal)
with all dusts and the presence of gases up to explosion
group IIC. Due to the low running speeds, the possible
friction velocities on the running wheels are less than 1
m/s, which means that standard running wheels can
also be used in zone 1 up to explosion group IIB. The
highest possible designation for these devices is:
II 2 GD IIB T4(X)/II 3 GD IIC T4(X).
Depending on the hoist version, designations
II 2 GD IIA T4(X)/II 3 GD IIB T4(X) or
II 2 GD IIB T4(X) are also used.
J D N T RO L L E Y A N D C R A N E R U N N I N G G E A R
“W I T H I NC R E A S E D S PA R K P RO T E C T I O N ”
For use in zone 1 in the presence of gases in explosion
group IIC, bronzed running wheels or running wheels
made of bronze are also used. The highest possible
designation for this version (FSR) is
II 2 GD IIC T4(X) (the same as for JDN hoists
“with increased spark protection”).
J D N T RO L L E Y A N D C R A N E R U N N I N G G E A R F O R
U S E I N T H E P R E S E NC E O F T E M P E R AT U R E C L A S S
T6 GASES OR DUSTS
As is the case with JDN hoists “with increased spark
protection”, temperature class T6 could also be possible
in this case too in the event of a special investigation
of applicability, so that the highest possible designation
for standard wheels and for bronzed or bronze wheels is
II 2 GD IIB T6(X)/II 3 GD IIC T6(X) and
II 2 GD IIC T6(X) respectively, i.e. each including
the additional designation “X” for special conditions.
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PRODUCT INFORMATION
G E N E R A L N O T E O N D E S I G N AT I O N
The highest possible respective designations for lifting
equipment and running gear are usually replaced by a
designation which corresponds to the normal assembly
of a compact complete device (trolley or crane system).
A D D I T I O N A L M A R K I N G “X”
This designation refers to explosion protection details
in the operation manual.
II 2 GD IIA T4(X)/II 3 GD IIB T4(X) or
II 3 GD IIA T4(X):
This designation does not permit use in the presence of
the extremely flammable substances hydrogen sulphide
and ethylene oxide or in the presence of light metal or
other impact-sensitive dusts, or in the presence of dusts
with glow temperatures below 210° C or ignition tempe-
ratures below 202° C. The permissible ambient tempera-
ture range (Ta) extends from - 20° C to + 70° C.
II 2 GD IIC T4(X) or II 2 GD IIB T4(X):
The permissible ambient temperature range (Ta)
extends from - 20° C to + 70° C.
...II C T6(X):
This designation permits use in the presence of carbon
disulphide or other temperature class T6 substances
only under special conditions, which have been agreed
with the manufacturer and which are described in the
crane documentation and which stipulate the maximum
surface temperatures for the device.
U S E I N M I N I N G A P P L I C AT I O N S
Standard versions of JDN hoists, trolleys and crane sys-
tems may generally also be used for underground min-
ing operations as well as for the associated surface facil-
ities, which are hazardous due to firedamp and/or com-
bustible dusts. Within this equipment group I they
belong to category M2.
They constitute devices that can be switched off in
cases where an explosive atmosphere forms. They are
equipped with protective measures offering a high
degree of safety. The protective measures with which
products of this category are equipped provide the nec-
essary degree of safety for normal operation as well as
operation under difficult conditions, in particular rough
treatment and changing environmental influences. For
other difficult conditions in addition to explosion pro-
tection prevailing with regard to the general handling
of the devices in mining applications, special mining
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hoists are available from J. D. NEUHAUS.
The maximum permissible surface temperature of 150° C
in accordance with EN 13463-15 for coal dust
atmospheres is not reached. For mining applications,
the relevant designation for hoists, trolleys and crane
systems is I M2.
L OA D C H A I N
In order to guarantee the required degree of earthing,
rusty chains must no longer be used in zones 1 and 21.
This is due to the fact that, depending upon the degree
of corrosion, the leakage capability of the chain may be
impaired to a level that is no longer adequate.
CO M P R E S S E D A I R H O S E S
In zone 1, compressed air hoses must have a sufficient-
ly low surface resistance of less than 109 Ω, in order to
prevent electrostatic ignition hazards. Otherwise (resis-
tance >109 Ω), for explosion groups I, IIA and IIB the
hoses must be ∅ ≤ 30 mm and for explosion group IIC
∅ ≤ 20 mm, or proof must be provided that they cannot
become dangerously charged.
M AT E R I A L S F O R F R I C T I O N A N D I M PAC T H A Z A R D S
Friction and impacts can give rise to individual sparks
presenting a danger of ignition in the presence of
explosion group IIC gases, hydrogen sulphide, ethylene
oxide, or light-metal or other impact-sensitive dusts.
Accordingly, spark formation caused by mechanical
influences must be prevented.
The chain and load must always be moved in such a way
that sliding and/or frictional contact with other plants
or components is excluded. If circumstances do not per-
mit this, it is necessary to ensure an absence of explo-
sive atmospheres during operation.
Impact between particular materials results in an
increased ignition hazard. Such material combinations
include corrosion-susceptible steel or cast iron against
aluminium, magnesium or corresponding alloys.
This applies in particular in the presence of rust or rust
film. Rust (also rust film) formation is possible, espe-
cially on the chain and on the load hook, at the fric-
tion points. The following holds true for all zones: For
the intended use of hoists it must be ensured that no
rust is present at the above-mentioned friction points
and that material combinations of the above-named
light metals with steel (exceptions being stainless steel
 PRODUCT INFORMATION

or cast iron) are not used in the working area of the

hoists, at potential friction, impact or sliding points. It
is thus possible to exclude sparking due to mechanical
influences with these material combinations.

EARTHING
Electrostatic ignition hazards can be prevented by
means of safe earthing. In zones 1 and 21, earthing of
the hoists is required. This must be achieved via the
load hook or the load eyes if the lifting equipment is
connected to correspondingly earthed parts (earth leak-
age resistance less than 106 Ω). This also applies to
operation with trolleys or cranes. Their tracks must be
earthed on site. Running wheels and rail surfaces must
never be painted, as this can result in unacceptably
high earth leakage resistance values.

Earthing of the load hook is via the chain

(see also Load chain, page 10).

Loads must be earthed during transportation.

A separate earth is required, for example, when using
non-conducting sling gear.

AC E T Y L E N E A N D CO P P E R
When operating JDN products in explosion-hazardous
areas, in which an acetylene-containing atmosphere can
occur, it must be ensured that copper-plated parts are
kept dry in order to exclude the possibility of oxidation
of the metallic copper and the formation of an aqueous
phase, which is capable of reacting with acetylene and
which can result in an explosion hazard.

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PRODUCT INFORMATION

EXPLOSION GROUPS AND TEMPER ATURE CL ASSES OF THE MOS T IMPOR TANT GASES AND VAPOURS
(-SELECTION-)
(according to DIN VDE 01656, Redeker7, Nabert, Schön8, IEC 60079-123 and IEC 60079-204)
Ex group Temperature class
T1 T2 T3 T4 T5 T6
Ignition temperature
> 450° C 450-300° C 300-200° C 200-135° C 135-100° C 100-85° C
Maximum permissible surface temperature of operating facilities
450° C 300° C 200° C 135° C 100° C 85° C
II A Acetone (Ethyl alcohol) n-Amyl alcohol Acetaldehyde
Ammonia (Ethylene glycol) Benzene
Aniline i-Amyl acetate (petrol)
Benzol n-Butane Diesel
Chlorobenzene n-Butyl alcohol Fuel oil
1,2-Dichlorobenzene 1-Butylene n-Hexane
Acetic acid 1,2-Dichloroethane Jet fuels
Ethane Di-i-Propyl ether
Ethyl acetate Natural gas
(Ethyl bromide) Acetic anhydride
Ethyl chloride n-Propyl acetate
(Carbon monoxide) (n-Propyl alcohol)
o-Cresol i-Propyl alcohol
Methane Vinyl chloride
Methyl acetate
Methyl alcohol*1
Methyl bromide
Methyl chloride
Methylene chloride
Naphthalene
(nitrobenzene)
Phenol
Propane
Toluene
o-Xylene
II B Hydrocyanic acid Butadiene-1,3 Dimethylether Ethyl ether
(Ethyl bromide) Dioxane-1,4 **Hydrogen Ether
(carbon monoxide) Divinyl ether sulphide Anaesthetic ether
(Nitrobenzene) (Ethyl alcohol) Diethyl ether
Town gas Ethylene
(ethylene glycol)
**Ethylene oxide
Isoprene
(n-Propyl alcohol)

II C **Hydrogen **Acetylene **Carbon

disulphide

( ): The measured values for the substances placed in brackets are close to the limit for the next group or class when classified
in the explosion groups or temperature classes. For this reason, they have been included in both.
**: Extremely flammable substances (cf. additional marking “X”)
*1 (Methanol = Methyl alcohol)

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 PRODUCT INFORMATION

DECISION CRITERIA FOR SELECTING THE CORRECT JDN HOIS T S IN EXPLOSION-HAZARDOUS AREAS

Explosion groups of gases and vapours Zone Version*1 Operation*2

(cf. Explosion groups and temperature classes of the most important gases Manufacturer's Operator's
and vapours) responsibility responsibility

II A 2 A E
1 A E
II B (X) except hydrogen sulphide, ethylene oxide 2 A E
(particularly flammable) 1 A FS E
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
Explosion-hazardous dusts Zone Version*1 Operation*2
22 A E
Usual industrial dusts
21 A E
22 A FS D E
Light-metal or impact-sensitive dusts
21 A FS D E

*1: Version features (under the responsibility of the manufacturer):

A: The chain is made of zinc-plated steel; metal controls are conductively connected to the hoist. This is part of
the standard equipment. For technological reasons, a zinc-plated version of chain size 31.5 x 90 is not available.
This is only used for the extremely slow-running chain drives of large hoists, so that the sliding velocity for
potential friction points between the chain and the surroundings remains well below 1 m/s.
FS: Hoists “with increased spark protection”:
Copper-plated load hook and bottom block with brass safety catch.
FSR: Running gear “with increased spark protection”:
Running wheels for trolleys and cranes are bronzed or are made of bronze.
*2: Instructions for safe operation (operator's responsibility):
D : Ignition hazards are not to be expected if hoists or cranes are used in the normal manner. Friction and impacts in
the working area of the chain, not resulting from intended use of the hoist or crane and which result in sparking,
must be excluded, or an absence of gas in the operating area must be ensured. This means, for example, that the
chain, the bottom block and the load hook must be prevented from swinging against surrounding objects or that
a gas-free environment must be ensured.
E : Friction, impact and sliding points involving combinations of light metal and steel or cast iron must not be pre-
sent in the hoist's operating area.
T : Ambient temperature and the type of operation must be examined separately.

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 PRODUCT INFORMATION

T E M P E R AT U R E L I M I T S F O R The corresponding surface temperatures can be derived

EXPLOSION-HAZARDOUS DUSTS
In areas which are explosion-hazardous due to
combustible dusts, the surface temperature must not
exceed two-thirds of the ignition temperature in ° C
of the dust/air mixture. The temperatures of surfaces,
on which hazardous deposits of combustible dusts can
be formed, must not exceed the glow temperature of
the relevant dust minus 75°K. Greater safety margins
are required if the thickness of the dust layer exceeds
5 mm.
from the lowest values for glow and ignition tempera-
tures of dusts specified in the HVBG/BIA Report 12/9710
“Combustion and explosion characteristics of dusts”:
Synthetic rubber, soot-containing:
Glow temperature 220° C - 75° C = 145° C max. permissible
surface temperature
Stearic acid:
Ignition temperature 190° C x 2/3 =126° C max. permis-
sible surface temperature.

P L E A S E A L S O O B S E R V E YO U R
CO R R E S P O N D I N G N AT I O N A L
R E G U L AT I O N S .

1 Guideline 94/9/EC of the European Parliament and the Council of 23 March 1994 on the approximation of the laws of
the Member States concerning equipment and protective systems intended for use in
potentially explosive atmospheres
2 DIN EN 1127-1: Explosive atmospheres - Explosion prevention and protection - Part 1: Basic concepts and methodolo-
gy, 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 for flammable gases and vapours relating to the use of electric apparatus, 1996-10.
5 EN 13463-1: Non-electrical devices intended for use in explosive areas - part 1: Basic methodology and requirements
6 DIN VDE 0165: Installation of electrical systems in areas with explosion hazard, 1991
7 Redeker, Schön: 6. Supplement to safety-related characteristic values for flammable gases and vapours, 1990
8 Nabert, Schön: Safety-related characteristic values for flammable gases and vapours, 2nd edition, 1978
9 DIN EN 50014 (VDE 0170/0171 part 1): 2000-02
Electrical apparatus for use in explosion hazardous areas: General provisions
10 HVBG/BIA report 12/97: Central association of German employer's liability associations/trade association institute for
industrial safety

Page 14

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 PRODUCT INFORMATION

INTENDED USE

JDN Air Hoists are designed for lifting and lowering

loads within the specified load-carrying capacities, with
a vertically-arranged chain. JDN Air Hoists from the
ranges PROFI 025 TI to 2 TI are also suited to pulling
loads horizontally. In exceptional circumstances, the
lifting of personnel-carrying equipment is also permit-
ted under certain conditions. Please also observe the
individual national regulations. In combination with
trolleys, JDN Air Hoists are also suitable for the floorless
horizontal movement of loads.

Any other use or use outside these stipulations is

deemed to be impermissible. Oblique pulling, see sec-
tion Operation, page 29. J.D. NEUHAUS GMBH & CO. KG
cannot be held liable for any resultant damage.
The entire risk is borne by the user (see also Rules for
safe operation of hoists, page 29).

Intended use also includes observance of the operation

manuals and compliance with the inspection and main-
tenance conditions.

Page 15
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PRODUCT INFORMATION
EMISSIONS
The noise emission data can be found in the Technical
data table, page 63.
The noise pressure level of the measurement area at a
distance of 1 m from the machine surface was measured
in accordance with DIN 45 635, Part 20, at the operat-
ing air pressure specified by us. In the hall, the noise
pressure level drops by approx. 3 dB (A) every time the
distance is doubled.
If the device is operated with motor oil lubrication,
small amounts of lubrication oil will be released into
the environment with the outlet air.
Oil emissions can be prevented by using a filter silencer
(see Filter silencer section, page 61). This also results
in a reduction of the noise emission values.
O P E R AT I N G CO N D I T I O N S
JDN air hoists are extremely robust and require little
maintenance. They are suitable for use in explosion-
hazardous areas, as well as in areas with increased
concentrations of soot and dust, high humidity
and at ambient temperatures of - 20° C to + 70° C if
they are not heated above this level due to external
influences. The thermal endurance of chains
and hooks is + 150° C.
WA R N I N G !
When touching metallic hand controls which
are colder than 0° C, the skin could freeze
within a few seconds, and for temperatures
above 43° C, burns can occur. As a protective
measure, please wear suitable gloves.
For stationary outdoor operation, hoists must be pro-
tected against weathering and the maintenance inter-
vals must be shortened.
Depending upon the version, JDN air hoists must be
operated at a system pressure of 4 bar or 6 bar (see
information on the nameplate). If the system pressure
is too low, important functions of the hoist will be
impaired:
Page 16
powered by air!
 The brake will drag and is thus subject to a
high degree of wear. An impermissibly high degree
of warming could take place.
 The controls become noticeably less sensitive.
DA NG E R !
Warning against excessive system pres-
sures
Operating with excessive system pressures
results in danger due to overloading.
Therefore, the pressure must be limited to
that specified on the nameplate.
JDN air hoists must be operated with a sufficiently
clean and dry air supply. The air supply must fulfil the
following quality requirements:
 Particle size less than 40 µm
 Particle density less than 10 mg/m3
(corresponds to Class 7 according to
ISO 8573 - 1:2001)
In order to provide adequate compressed air quality,
operation with a service unit is recommended. Usually,
an oiler is not required in the service unit, as the motor
is provided with internal permanent lubrication.
 Pressure dew point at least 10° C below the lowest
expected ambient temperature
Do not operate JDN Air Hoists with
other gases.
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
 using an upstream air dryer or using a service unit
with oiler,
 adding anti-icing agent to the lubrication oil
(depending upon moisture content of compressed air)
 using compressed air oil (Art. no. 11900) with anti-
icing agent for relevant temperatures.
In case your JDN Air Hoist is operated in combination
with a trolley, please read also the trolley operation
manual and the relevant accident-prevention regulations
for operation with trolleys.

E N E RG Y R E Q U I R E M E N T S
For air pressure, air quantity and connections,
see the Technical data table in the hoist operation
manual concerned.
A I R P R E S S U R E CO N D I T I O N S I N O P E R AT I O N
The system pressure in the air line must correspond
to the nominal pressure. Higher pressures must be
reduced.
After switching on, the nominal pressure p1 drops to
the actual pressure p2.
The value of the actual pressure depends upon …
… and the direction of movement of the load.
powered by air!
PRODUCT INFORMATION
The value of the actual pressure p2 at which the hoist
is operated depends upon
 the weight of the load and
 the direction of movement of the load.
When lifting the nominal load (load-carrying capacity),
the actual pressure p2 must not fall below a value of
10% below the specified nominal pressure of the hoist.
Example:
A hoist with a nominal pressure of 6 bar lifts
its nominal load at the specified lifting speed, at an
actual pressure of 5.4 bar.
… the weight of the load …
Page 17
PRODUCT INFORMATION

P R I NC I P L E O F O P E R AT I O N O F
4.2 1 6 4.1 2 5
J D N A I R VA N E M O T O R S

The vane motor consists of a cylinder liner 1 with

two side bearing plates and an internal rotor 2.

The rotor is mounted eccentrically in the cylinder

liner and is provided with slots 3 for installation
of the vanes 4.

The vanes can move freely and make contact with

the inner wall 5 of the cylinder liner. Each chamber
is formed by two vanes 6.

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 the rotor torque.

As the chamber passes the outlet aperture 7, the com-

pressed air can escape.

Lubricant chambers 8 are provided between the vane slots

of the rotor. They ensure continual motor lubrication.
8 3 4 7
The arrows in the illustration indicate the direction of
rotation of the rotor and the corresponding path of the
compressed air.

Page 18

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 PRODUCT INFORMATION

O P E R AT I O N W I T H O U T C H A I N B OX S PA R E PA R T S

DA N G E R ! Only use original JDN spare parts. J.D. NEUHAUS

If JDN air hoists are operated without a GMBH & CO. KG accepts no liability for the use of
chain box it must be ensured that the idle non-original components and/or modifications by
chain (unloaded chain end) running up or unauthorised persons.
down at the chain sprocket does not present
a hazard, e.g. due to catching, impacting or
falling.

Danger due to falling chain can also arise if

the idle chain is first deposited on a load
with a large surface and then slides off and
drops.

M O T O R L U B R I C AT I O N /
O P E R AT I O N W I T H S E R V I C E U N I T

JDN air hoists are provided with motor lubrication,

which must be renewed when required, but every
5 years at the latest.
Therefore, the service unit for filtration and pressure
regulation of the compressed air can be installed with-
out an oiler. If required, the service unit is also avail-
able with an oiler. Synthetic lubricants must not be
used when operating with a service unit. Alcohols are
not permitted for use as anti-icing agents.

- C E R T I F I C AT I O N /
M A N U FAC T U R E R ' S D E C L A R AT I O N

Only hoists which have a designation

may be operated within the EU.

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

Each JDN air hoist is delivered with a factory certificate.

Page 19
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TR ANSPOR T AND S TOR AGE

TR ANSPOR T AND S TOR AGE

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

If you wish to transport your JDN Air Hoist to

another site, please observe the following points:

 Carefully dismount trolley (if available).

 Set the entire hoist down carefully; do not allow it to
drop. For weights see Technical data, page 63.
 Lay control and supply hoses together in such a way
that they are not kinked.
 Make sure that the controls are not damaged.
Failure to do so could lead to malfunctions.
 Draw in the hoist's chain in such a way that loops
cannot form and the chain cannot become twisted.
 Secure the chain.

S T O R AG E CO N D I T I O N S

B R E A K S I N O P E R AT I O N
 In the 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 applied to
the motor. For this purpose, use a non-resinous and
non-sticky conserving oil with conserving protection
duration, which corresponds to the length of the
planned operational break.

S T O R AG E
 Close off the air supply hose connection using
adhesive tape or a suitable cap, in order to prevent
dirt ingress.
 Protect connection for the air supply hose from being
damaged.
 Store your JDN Air Hoist in a clean and dry place.

Page 20

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SETTING UP
U N PAC K I NG
WA R N I N G !
When unpacking, take account of the weight
of the hoist. See Technical data, page 63.
C AU T I O N !
Do not kink the control lines. Kinked
control lines can result in malfunctions.
 Keep the accompanying documents in the place pro-
vided, near the operating site.
 Lift the hoist carefully out of the packaging.
 Recycle packaging materials in accordance with local
regulations.
A S S E M B LY
JDN Air Hoists are usually delivered pre-assembled.
If not, first read the following sections:
 Connecting the controls, page 22
 Removing and installing chain, page 57
 Chain box, page 62.
In the event that the chain is included unattached, a
short auxiliary chain is drawn into the hoist. In order
to draw in the chain, the hoist must be connected to
the main air supply and must be ready for operation.
P R I O R T O I N I T I A L O P E R AT I O N , T H E
C H A I N M U S T B E L U B R I C AT E D
( S E E L U B R I C AT I N G T H E C H A I N S E C T I O N ,
PAG E 4 4 ) .
powered by air!
SETTING UP
I N S TA L L I N G T H E H O I S T
Mounting the trolley, see trolley operation manual.
DA NG E R !
JDN Air Hoists must only be installed
by qualified persons.
A defective installation can result in
the most serious of accidents.
DA NG E R !
The attachment points for JDN Air Hoists
must be able to safely withstand the expect-
ed forces. Ensure that your JDN Air Hoist is
capable of alignment under load, otherwise
inadmissible additional stresses may occur.
DA NG E R !
The supporting structure of the air hoist
must form a rigid mounting. Vibration dam-
ages the chain and can lead to chain frac-
ture. Furthermore, external vibration must on
no account be transmitted to the hoist (lift-
ing gear). (e.g. from the suspended load).
 Provide a suitable working platform.
 Attach the hoist at the suspension hook (or suspen-
sion eye) to running gear or stationary fixing.
 Ensure that the hook safety catch closes automatically.
Attach the hoist securely at the suspension hook
or suspension eye.
Page 21
SETTING UP

CO N N E C T I N G T H E CO N T RO L S

CO N N E C T I N G T H E RO P E CO N T RO L S
 Knot both control ropes at the ends of the
control lever.
 Knot the green pin into the rope which activates
“lift” mode, with the pointed end upwards
(see also illustration Rope control, page 22).
 Knot the yellow pin into the rope which activates
“lower” mode, with the pointed end downwards.
 Knot the handle into the rope so that the arrow mark-
ings correspond to the actual direction of movement.

Rope control, motor side

CO N N E C T I N G T H E E - CO N T RO L S
Pushbutton valve (hand control)
 Guide the strain-relief cable through the eye on the
pushbutton valve and secure using the cable clamp.
 Push the one-ear clamps onto the hose ends.
 Attach the hoses to the hose nipples.
 The one-ear hose clamp must lie in the middle of the
hose nipple clamping range. The best clamping char-
acteristics are achieved in this range.

Pushbutton valve with nipples and rope

with designation lift and lower

Page 22

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 SETTING UP

 Secure the hoses using the one-ear hose clamps and

crimping tool.

C AU T I O N !
To ensure perfect sealing, the “ear” must be
fully closed on installation.

Pinched one-ear clamp and crimping tool

Removal

 The bellows must be pulled over the other end of the

hose bundle including the strain-relief cable (coat
hose bundle with oil for ease of fitting). Pull the bel-
lows back far enough to permit further installation.
Push the one-ear clamps onto the free ends of the
hoses. Guide the hoses through the bellows frame,
secure the strain-relief cable, connect the hoses to
lift (green) lower (red)
the hose nipples and secure the one-ear hose
clamps using crimping tool. Insert the bellows frame
into the profile of the bellows, insert bellows clamps
(long end pointing inward) and secure to the control
valve using bolts (2 x M5). Compressed air supply
colour "white"

C AU T I O N !
The strain-relief cable must be installed with
the correct length in order to prevent loading
of the hoses.
Illustration of bellows with hoses and strain-relief cable

Page 23
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SETTING UP
CO N N E C T I N G F - CO N T RO L S
 Pull the bellows over the hose bundle for F-control.
For F-dual-control (for lifting and lowering only),
remove approximately 50 mm of hose bundle protec-
tive sheathing.
 Insert the control hoses into the connection nipples
(see illustration on page 23, bottom):
• Compressed air supply
with hose designation 1 or colour: white
• Movement direction “lift”
hose designation 2 or colour: green
• Movement direction “lower”
hose designation 3 or colour: red
 For F-control with additional functions (trolley,
crane movement) remove approx. 50 mm of protective
sheathing and slit open the protective hose a further
50 mm in order to route the control hoses for com-
pressed-air connection, trolley and crane movement
outwards in front of the bellows. (Close off com-
pressed-air connection at the control valve using
screw plug G 1/8). Pull both strain-relief cables
through the eye bolt and secure using rope clamps.
The control hoses for the drive motors (trolley,
crane movement) and for the compressed air supply
must be extended, outside of the bellows, by means
of plug-in connectors and additional control hoses.
Connection see “Trolley” operation manual.
C AU T I O N !
The control hoses must not be subject
to tensile load; adjust the strain-relief
ropes accordingly.
 Insertthe bellows frame into the profile of the
bellows, insert bellows clamps (long end pointing
inward) and secure to the control valve using bolts
(2 x M5).
Page 24
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CO N N E C T I N G F I - CO N T RO L S
 Pull the bellows over the hose bundle for FI-control.
Remove approx. 50 mm of hose bundle protective
sheathing. With this type of control, strain-relief of
the hand controls takes place via the protective
sleeve of the hose bundle. For this purpose, the pro-
tective sleeve is pushed onto the hose carrier and is
secured using a one-ear clamp.
Installation facilitation: Heat the protective sleeve
(hose sheathing) with a hot-air gun and grease the
hose carrier. Slightly bend open the ring of the eye bolt
in order to attach the hose carrier. Close the ring again
to prevent detaching.
 Insert the control hoses into the connection nipples
(see illustration on page 23, bottom):
• Compressed air supply
with hose designation 1 or colour: white
• Movement direction “lift”
hose designation 2 or colour: green
• Movement direction “lower”
hose designation 3 or colour: red
(see illustration on page 23, bottom)
C AU T I O N !
The control hoses must not be subject
to tensile load; adjust the length of the
protective sleeve accordingly.
 Insert the bellows frame into the profile of the bel-
lows, insert bellows clamps (long end pointing inward)
and secure to the control valve using bolts (2 x M5).
 SETTING UP

R E P L AC I N G CO N T RO L S
If you wish to exchange air controls E, F or FI,
proceed as follows, (see illustrations in section
Connecting the controls).
CO N V E R S I O N F RO M E T O F CO N T RO L
Control valve housing (on motor)
Removal of E-controls
 Pull the bellows back over the hose until the hose
nipples with the one-ear clamps are exposed and
further removal is possible.
 Detach the strain-relief cable and remove the one-ear
clamps (see illustration Removal, page 23).
 Cut off the hoses below the hose nipples using a
knife. Unscrew the hose nipples (A/F 13).
 Pull the bellows over the hoses of the E-controls.
This is also required for the F-controls.
Installation of F-controls
See page 24, Connecting F-controls.
CO N V E R S I O N F RO M E T O F I CO N T RO L
Removal of E-controls as previously described
• Compressed air
with hose designation 1 or colour: white
• Movement direction “lift”
hose designation 2 or colour: green
• Movement direction “lower”
hose designation 3 or colour: red
C AU T I O N !
The control hoses must not be subject
to tensile load; adjust the protective
sleeve accordingly.
• Insert the bellows frame into the profile of the
bellows, insert bellows clamps (long end pointing
inward) and secure to the control valve using bolts
(2 x M5) (see illustration on page 23, bottom).
CONVERSION FROM AIR CONTROL
TO ROPE CONTROL
C AU T I O N !
Only air controls without protective sleeve
main-stream valve can be converted to rope
control.
Removal of E-controls, as previously described.

Installation of FI-controls Removing air controls (F or FI)

 Pull the bellows over the hose bundle for
FI-control. Remove approx. 80 mm of hose bundle
protective sheathing.
 Screw the “straight screw connections” (Steck-fix) for
4 mm hoses into the hose adapter (A/F 16).
Pull the bellows back over the hose until the hose
connections are exposed. Pull all hoses out of the
connectors (see illustration Plug-in connection).
R E M OV I N G T H E H O S E P I E C E S
 Press down the locking ring 1 with a suitable tool

With this type of control, strain-relief of the hand con- (for example screwdriver), pulling out the hose
trols takes place via the protective sleeve of the hose piece 2 at the same time.
bundle. For this purpose, the protective sleeve is pushed
onto the hose carrier and is secured using a one-ear
clamp.

Installation facilitation: Heat the protective sleeve 1

(hose sheathing) with a hot-air gun and grease the
hose carrier.

Slightly bend open the ring of the eye bolt in order to

attach the hose carrier. Close the ring again to prevent
detaching.
Insert the control hoses into the connection nipples: 2
(see illustration on page 23, bottom).
Plug-in connection

Page 25
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SETTING UP

Installation of rope controls

CO N N E C T I N G T O T H E M A I N A I R S U P P LY
Close off the centre air connection using a screw plug
G1/8. Silencers G1/8 are screwed into the two outer
 Check air connection for contamination and clean if
connections. Unscrew main-stream valve or connecting
plate, screw on rope control valve with an appropriate necessary.
 Blow through compressed air hose in order to remove
flat seal. Guide the control ropes through the bores
in the lever and knot them. Rope colour: “green” lift, foreign bodies.
 Attach the compressed air hose to the connection on
“red” lower. Further, see section Connecting the
rope controls, page 22. the hoist or on the service unit. Tighten the union
nut.

Main-stream valve or air connection G 1/2

Air connection (white) lift (green)

lower (red)

Rope control valve

Installation of rope controls

Attach the compressed air hose and tighten the union

nut.

Page 26

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 SETTING UP

LUBRIC ANTS Application Lubricant

Motor lubrication - JDN high-performance grease,
The following lubricants are intended for normal - from factory Art. no. 11901 (1 kg)
- when operating with oiler Art. no. 11902 (40 g)
environmental influences.
- Compressed air oil “D”,
In the case of wear-promoting environmental influ- kinematic viscosity
ences, please contact J.D. NEUHAUS to receive the approx. 30 mm2/s (cSt)
appropriate instructions. at 40° C, with anti-icing
agent where applicable
WA R N I N G ! Chain lubrication chain oil or motor vehicle
Oils and greases can cause skin irritation. engine oil, kinematic
Wear protective gloves. viscosity approx. 150 mm2/s
(cSt) at 40° C, or special
lubricant from J.D. NEUHAUS
C AU T I O N ! In areas with very high
Potential damage! Do not mix synthetic oils corrosion potential, e.g.
or greases with mineral oils, as the properties offshore, a lubricant with
extremely strong anti-corrosion
may be impaired. properties must be used.

Also, never mix different types of lubricating Motor conservation
grease within the synthetic or mineral lubri- (not applicable when using
JDN high-performance grease)
cant groups.
Motor cleaning
Synthetic lubricants must not be used (not applicable when using
when operating with oilers. JDN high-performance grease)
Alcohols are not permitted for use as Lubrication of bearings
anti-icing agents. and gearbox (also for
exposed gears)
Non resinous Conservation oil
with appropriate period of
effectiveness
Pure petroleum
Lithium-thickened grease,
worked penetration 265-295
(0.1mm), basic oil viscosity:
190 cSt (mm2/s) at 40° C,
drop point: 180° C,
Working temperatures:
- 20° C to + 120° C,
designation in accordance
with DIN 51825: KP2K-20,
active agents: EP additives
(for wear-reduction) and
ageing protection; water resis-
tant and corrosion protection

Page 27
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SETTING UP

P R E - S TA R T C H E C K S

Hoists, including the supporting structure, must be

inspected by an appropriately trained and qualified per-
son before initial operation and before re-commission-
ing after significant modifications. Hoists and lifting
gear which are installed in trolleys must be inspected by
a specialist.

The inspection covers the proper mounting, equipment

level and operational-readiness, in the main, the com-
pleteness, suitability and effectiveness of the safety
devices as well as the condition of the device, the har-
ness, the equipment and the supporting structure.

Safety devices are braking devices, overload protection

devices, EMERGENCY STOP devices, lifting and lowering
limiters (emergency end-stop devices).

A description of the inspections can be found in the

Maintenance section, page 38.

Page 28

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 OPER ATION

OPER ATION

R U L E S F O R S A F E O P E R AT I O N
OF HOISTS

As an operator of hoists, you are responsible for

your own safety and for that of your colleagues in
the working area of the hoist.

 Hoists may only be operated by persons charged with

this task by their company.
 Before using the JDN Air Hoist for the first time,
familiarise yourself with all permissible operating
conditions. For this purpose, read through this opera-
tion manual thoroughly and perform the described
actions on the hoist, step by step.
 Report each malfunction to your safety officer imme-
diately, so that the fault can be remedied without
delay.
 Adhere to the regulations of the accident prevention
authorities (e.g. Berufsgenossenschaft regulations in
Germany). Oblique pulling
 Observe the section Intended use, page 15. Under special safety provisions relevant to the partic-
ular situation, JDN Air Hoists may be used for oblique
Improper use includes, but is not limited to, any pulling (see Intended use, page 15).
and all of the following: In this case, a chain box must not be used as the
 Changing load-carrying capacities with the load chain may fall out or become knotted.
position: JDN Air Hoists are not equipped with Oblique pulling is not permitted for hoists installed
load-carrying capacity indicators, they may therefore in trolleys or running gear. Please contact us,
only be used in those applications in which the if required.
load-carrying capacity does not change with the  Detaching or dragging of loads.
position of the load.  Loading of the hook at the tip.
 Oblique pulling of loads in general.  Catching of falling loads.
Definition of oblique pulling  Carrying persons
(see Intended use, page 15).
Oblique pulling is the deviation of the load chain and
 Jog control with load on the hook.
the chain hoist from the vertical position, for a force
 Switching to the opposite direction wit
acting in a straight-line between the point of force
load in motion.
application of the load on the load hook and the
 Operational reaching of lifting and lowering limiters.
point of suspension on the supporting structure.

Page 29
powered by air!
OPER ATION
JDN Air Hoists must not be used for the following
applications, for example:
 Critical areas of nuclear plants.
 Over acid baths or other plants with
corrosive substances.
 In areas in which organic acids are present.
To ensure the safety of personnel and property
when using JDN Air Hoists, it is essential that the
following points are observed:
 Lift the load carefully at the beginning.
 Never touch a running chain.
 Never use the hoist chain for attaching loads.
 Never allow loads to fall into the hoist chain.
 If the chain is slack, do not take up the load at
maximum speed.
 Only use original JDN chain boxes.
 Do not exceed the permissible capacity of
the chain box.
 When operating without a chain box, avoid hazards
due to idle chain (falling, catching, impacting), see
section Operation without chain box, page 19.
 Never apply bending to chains.
 Do not join or repair hoist chains.
 Do not operate with a chain which is drawn tight,
bent or extended.
 Check blocked chains for damage.
 Straighten twisted chains (defective bottom block)
 Do not operate with damaged or worn or rusty chains.
 Permissible operating temperature for chain and hook:
- 20° C to + 150° C, permissible ambient temperature:
- 20° C to + 70° C, permissible heat absorption of the
hoist body: max. 90° C.
 Never allow persons to enter the area below the sus-
pended load.
 Never attempt to remedy a fault with a load suspend-
ed from the hoist.
 Only use suitable and approved attaching aids; do not
jam the hook at the point of attachment.
 Please ensure that the operator is not put at risk
within the operating area by the sling gear or the
load.
 Follow the relevant instructions for attaching loads.
 Before attaching, accurately position the load verti-
cally below the hoist. The chain must hang vertically
before lifting.
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 Ensure that the hook safety catch is closed.
 Repair damaged hook safety catches.
 Before lifting loads, ensure that the maximum per-
missible 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 prevent accidents due to
tilting or falling loads.
 Never drive against jammed loads.
 Only lift one load at a time; never several loads
simultaneously.
 Never lock the control elements of
control devices.
 In the case of stiff actuating elements,
have the hoist repaired.
 In the case of power failure, secure the load and
the surrounding area, until the power is restored.
 Never use or repair bent, open or deformed load
hooks. The hoist must be repaired and the hook
must be replaced.
 Never anneal the hook.
 Only operate JDN Air Hoists with original JDN con-
trols.
 Uncontrolled, external force factors (such as due to
hydro cylinders, falling loads) are not permitted.
 Repair stiff hook bearings.
 Do not kink or pinch control hoses.
 Have loosened bolted connections tightened by the
Repairs department.
 Before removing compressed air hoses, shut off the
compressed air.
 Repair the hoist if the braking distance is excessive.
 If a load is lifted using several air hoists, prevent
overloading due to incorrect weight distribution.
 Select a safe operating location.
 Ensure the correct system pressure.
 Never touch metallic hand controls which are colder
than 0° C or hotter than 43° C, without suitable
protective gloves.
 Do not make modifications to the hoist.
 Only use original JDN spare parts.
J.D. Neuhaus GmbH & Co. KG accepts no liability for
the use of non-original components and/or modifica-
tions by unauthorised persons.
 If, in the case of multi-chain hoists, the bottom block
is lying on the floor, move it back to a hanging posi-
tion in a controlled manner (evenly-loaded chains).
 OPER ATION

DA N G E R !
For all air hoist applications, ensure that
the load hook can be lowered all the way
to the ground, in order to prevent a load
being moved to the lower limit position,
without reaching the ground. Danger due
to overloading.

DA N G E R !
Never use hoists on the ground if they are
not specifically intended for horizontal
pulling.

DA N G E R !
The fatigue strength of chains is significantly
impaired due to extreme corrosion (pitting
corrosion). There is a danger of fracture.
Hydrogen-induced embrittlement with resul-
tant stress cracks due to highly corrosive
media (e.g. seawater) may affect high-
strength steels (e.g. chains). Danger of frac-
ture! This process is promoted by so-called
recombination poisons. Examples of these are
hydrogen sulphide, cyanide, arsenic com-
pounds and rhodanide.
If rusty chains are not replaced for opera-
tional reasons, crack inspections are to be
carried out at intervals of three months.

Company operating instructions

In the case of particularly difficult lifting equipment
applications, the company must provide comprehensible
operating instructions in the language of the operator,
within the framework of this operation manual. Here,
measures for safe operation are stipulated in accordance
with prevailing operating conditions.

Furthermore, it is essential that all the regulations set

out in sections Intended use, page 15 and Operating
conditions, page 16 are observed.

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OPER ATION

E CO N T RO L
CO N T RO L S
With E-control, lifting and lowering movements can be
controlled via two pushbuttons. The direction of move-
JDN Air Hoists can be equipped with various control
ment of the load hook is marked on the upper side of
devices.
the valve housing, above the pushbuttons.
All are suitable for use in explosion-hazardous areas.
 Lift: Press the right pushbutton.
All control switches return to the zero position when  Lower: Press the left pushbutton.
released.

CO N T RO L VA LV E O N M O T O R
Air control (E, F, FI controls) with
upstream main-stream valve

The control valve consists of:

1. Main-stream valve
2. Direction control valve as flat slide valve
3. Load-limiting valve connection housing

The main-stream valve lies upstream from the direction

control valve. If no control pressure is present, the
valve is closed and the direction control valve is depres-
surised. If control pressure is applied from the hand
control, the valve opens and releases the main stream.

If the red EMERGENCY STOP button on the hand control

is pressed, all control lines are depressurised and the
main-stream valve is closed. E-control with EMERGENCY STOP button

Air control (E, F, FI controls) without

upstream main-stream valve

The control valve consists of:

1. Connecting plate
2. Direction control valve as flat slide valve
3. Load-limiting valve or connection housing

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 OPER ATION

P U S H B U T T O N F - CO N T RO L
With pushbutton F-control, lifting and lowering move-
ments can be controlled via two pushbuttons.
The direction of movement of the load hook is marked
by arrows next to the pushbuttons.

 Lift: Press the upper pushbutton.

 Lower: Press the lower pushbutton.

F-control with EMERGENCY STOP button

P U S H B U T T O N F I - CO N T RO L
With pushbutton FI-control, lifting and lowering move-
ments can be controlled via two pushbuttons arranged
side by side. The control pressure is infinitely variable,
enabling precise positioning of the load. The direction
of movement of the load hook is marked by arrows on
the pushbuttons.

 Lift: Carefully press the right pushbutton.

The load is lifted slowly.
 Press the pushbutton further down,
in order to increase the lifting speed.
 Release the pushbutton slightly,
in order to reduce the lifting speed. EMERGENCY STOP button
 Lower: Carefully press the left pushbutton.
The load is lowered slowly.
 Press the pushbutton further down,
in order to increase the lowering speed.
 Release the pushbutton slightly, in order to reduce
the lowering speed. FI-control with EMERGENCY STOP button

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OPER ATION

 Lower: Carefully pull on the red rope with the red

E M E RG E NC Y S T O P D E V I C E
handle pin.
The load is lowered slowly.
Within the EU, these controls are equipped with an  Pull harder on the rope, in order to increase the
EMERGENCY STOP device (optional outside the EU). lowering speed.
 Release the rope slightly, in order to reduce the
In order to avert danger arising from the lifting move-
ment as quickly as possible, the pushbuttons must be lowering speed.
released; the movement of the load is interrupted
immediately.

Only in the case of failure of this stop function, must

the red EMERGENCY STOP button be firmly pressed.
The EMERGENCY STOP button engages. This results in
the closing of a separate check valve and the load hook
comes to rest instantaneously. The pushbuttons for lift-
ing and lowering now no longer function.

The EMERGENCY STOP button can be released again by

turning clockwise. It jumps back into place.

DA N G E R !
Never release the EMERGENCY STOP
button before the danger is eliminated and
the stop function via the pushbuttons
has been restored.

RO P E CO N T RO L
With rope control, the lifting and lowering movements
are controlled directly. Both rope ends are connected to
one another via a handle, enabling precise one-hand
operation. The direction of movement is marked by
arrows on the handle.
The control elements for rope control and the energy-
switching component of the control valve on the motor
(reversing valve) are positively connected to one anoth-
er. This connection is designed in such a way that, in
an emergency, the control valve can be reset to a stable
neutral position. Thus, no additional EMERGENCY STOP
device is required.
 Lift: Carefully pull on the green rope with the green
handle pin. The load is lifted slowly.
 Pull harder on the rope, in order to increase the
lifting speed.
 Release the rope slightly, in order to reduce the
lifting speed.
Rope control
OV E R L OA D P RO T E C T I O N
The overload protection limits the operating pressure of
the compressed air supplied. It responds as a function
of load and is set to a limit value of approx. 125 % of
the nominal load. The force limiting factor then has a
value of 1.25.
When the overload protection is activated, the lifting
movement is possible again once the lowering move-
ment has been switched (unloading the hoist).
The overload protection may also respond when moving
at full unloaded speed against a load to be lifted, even
when it is below the load size set. We therefore recom-
mend tensioning the slack chain before lifting the load.

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 OPER ATION

AT TAC H I N G T H E L OA D

DA N G E R !
Only use attaching cables or attaching chains
which are suitable for the load. Attaching
must not be attempted by winding with the
lifting chain around the load.

In Germany, the trade association regulations

“Operation of Load-carrying Devices Used with Lifting
Equipment” must be observed (BVR 259).
In other countries, the relevant national regulations are
applicable.

 Attaching aids must be attached at the lowest point

of the hook. Never load the point of the hook.
 Ensure that the hook safety catch is closed.

Attach the load safely

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 OPER ATION

L I F T I N G T H E L OA D D E TAC H I N G T H E L OA D

C AU T I O N !  Lower the load hook far enough, so that the

JDN Air Hoists must be capable of alignment load can be easily detached.
under load. Otherwise impermissible addition-  Move the load hook out of the lifting area,
al forces can occur, which can damage the in order to avoid hazardous situations.
hoist components.

 First, lift the load hook, in order to pull the slack

chain tight. With the chain tight, briefly interrupt
the lifting procedure. The hoist can align itself and
the material is protected.
 Then lift the load.
I N T E R R U P T I N G WO R K I N G
If you wish to interrupt working with your
JDN Air Hoist:

 Set down and detach the load.

The overload protection system aborts the lifting opera-
 Move the load hook out of the lifting area,
tion in the event of loads whose weight is more than the
pre-defined limit value for the overload protection (see in order to avoid hazardous situations.
Overload protection section, page 59).

L OW E R I N G T H E L OA D

DA N G E R !
Ensure that there are no persons below
the load.

 Then lower the load and ground it carefully.

DA N G E R !
For all air hoist applications, ensure that the
load hook can be lowered all the way to the
ground in order to prevent a load being
moved to the lower limit position, without
reaching the ground. Danger due to overload-
ing.

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 TAKING OUT OF OPER ATION

TAKING OUT OF OPER ATION

P RO L O N G E D S H U T D OW N DISPOSAL

If the hoist is to be taken out of operation for a longer JDN hoists contain a range of materials which, on
period of time it must be protected against corrosion expiry of the service life, must be disposed of or recy-
and dirt. cled where appropriate, in accordance with statutory
regulations.
 Coat the chain and hook with a light oil film.
 Move the load hook out of the lifting area in order Please note the following list of materials used:
to avoid hazardous situations.
 Do not move against the lifting and lowering HOIST
limiters/buffers (emergency end stop devices).  Ferrous materials
 Depressurise the air line. Steel
Cast steel
Nodular cast iron
S T O R AG E  Non-ferrous metals
Bronze
(see section Storage conditions, page 20) Aluminium
 Plastics
Polyethylene
DISMANTLING Polyurethane
Polyoxymethylene
DA N G E R O F I N J U R Y ! Polyvinyl chloride
JDN Air Hoists may only be dismantled Polyamide, glass-fibre reinforced
by qualified personnel. Natural rubber
Epoxy resin
 Depressurise the air line. Polyacetal
 Provide a suitable working platform. Polypropylene
 Loosen the union nut and remove the air hose. Phenol resin
 Protect the air connection against the dirt ingress. Thermoset moulding compound
 Detach the control hoses from the hoist. (Asbestos-free brake lining)
Do not kink the control hoses. Polyester
 Mark the connections. Synthetic rubber
 Detach the strain relief and hose carrier and remove Wool felt
the control device.
 Carefully detach/dismount the hoist and remove. F I LT E R S I L E NC E R /
 For trolleys, proceed in reverse order to that described S E R V I C E U N I T:
in the section on mounting trolleys (in the trolley
Zinc diecast
operation manual).
Brass
Nitrile rubber
Aluminium
Polypropylene
Polyurethane
Glass-fibre reinforced plastic
Steel
Polyacetal
Polyethylene

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MAINTENANCE
MAINTENANCE
M A I N T E N A NC E A N D
I N S P E C T I O N I N T E R VA L S
JDN air hoists are extremely robust and require little
maintenance. Compliance with maintenance and inspec-
tion intervals is of great importance in order that the
hoist operates safely and reliably over a period of many
years.
WA R N I N G !
Maintenance work on JDN Air Hoists must
only be performed by trained and qualified
personnel.
CLEANING AND C ARE
If your JDN Air Hoist is often used at different loca-
tions, particularly in dirty and damp environments,
 clean any dirt off the hoist and the chain,
 seal off the air supply connections,
 protect the hoist and, in particular, the chain from
corrosion,

store the hoist in a clean and dry place.
S PA R E PA R T S
If, during repair work, the replacement of components
is necessary, only original JDN spare parts may be
installed.
LUBRIC ANTS
(see section Lubricants, page 27)
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INSPECTION AND
M A I N T E N A NC E WO R K
Series lifting equipment is classified into groups and
dimensioned according to the type of operation (Driving
mechanism classification according to ISO/FEM). The
classification (M4/1 Am) is determined by the average
daily operating time (max. 1 hour) and the load spec-
trum. The theoretical operating time for load spectrum
2 (average) is 3200 hours. This corresponds to 800 full-
load hours. This is assuming that the lifting and lower-
ing paths are approximately the same.
For devices used mainly in vertical operation (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
operating time must be multiplied by a factor of fv.
The factor fv has a value of 1 to 50 % of the nominal
load, increasing linearly to 1.5 at 100 % of the nominal
load (nominal load percentage P).
P-50 (for P > 50%)
fv = 1+0.5
50
In order to achieve safe operating periods, the company
must check that the theoretical operating time has been
achieved during each inspection, by the person respon-
sible. This must be documented in the inspection log at
least once annually. The inspection log is only supplied
in the Federal Republic of Germany. Instructions and a
model for determining the actual operating time can be
found from page 40 onwards.
When the theoretical operating time has been reached,
a general overhaul must be performed. Detailed expla-
nations for the determination of the actual operating
time and its documentation can be found in the nation-
al safety regulations. Alternatively, the calculation
model in this operation manual can be used. The gener-
al overhaul must be initiated by the operator and must
be documented in the inspection log. Information on
general overhaul can be requested from the manufactur-
er.
 MAINTENANCE

Only if the group classification corresponds to the actu-

al type of operation of the lifting equipment does a safe
operating period conform to the theoretical operating
time. Deviations of the actual type of operation 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 must be disconnected from the main air sup-
ply during assembly work.

Dismantling the hoist, see page 37.

WA R N I N G !
Following each repair, the hoist must
be checked for operational readiness.

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MAINTENANCE

I N S T R U C T I O N S O N T H E “M O D E L
F O R D E T E R M I N I N G T H E AC T UA L
O P E R AT I N G T I M E ”
The decisive factors for the type of operation are the
collective loads with different cubic averages k .
The collective load indicates to what degree a driving
mechanism, or a part of one, is subjected to its maxi-
mum stress or only to smaller stresses. The cubic aver-
age (factor of the load spectrum) is calculated using the
following formula.
The formula given for the cubic average k does not take
the weight of the harness into account. This is permissi-
ble if the ratio
Weight of harness
≤ 0.05
Load-bearing capacity
To determine the type of operation for calculating the
partial operating times (actual operating time), the fol-
lowing collective load diagrams can also be used.

Load proportions Collective load 1 Collective load 2

0.733

0.467
Definitions:
1

0.4

0.1 0.2

Maximum or ultimate load

= t1 t2 t∆ t1 t2 t3 t∆
Load-bearing capacity
0 10 50 100 0 16.7 33.3 50 100

Dead load
=
Load-bearing capacity Collective load 3 Collective load 4
Load proportions

0.8

Operating time with maximum

load or partial load and dead load
1

0.4
=
Total operating time
t1 t∆ t1 t∆
Operating time with dead load 0 0 90 100
= 50 100
Total operating time

The FEM* 9.511 rule differentiates between four collec-

tive loads, which are identified by the definitions and
by the ranges of the cubic averages k. This classification
complies with ISO 4301/1.
*FEM = Federation Europeene de la Manutention (European Federation
of Materials Handling and Storage Equipment)

Collective load Definition Cubic Collective load factor

average
1 L1 Driving mechanisms or parts thereof, which are only subject k ≤ 0.50 km = k3 = 0.125
(low) to the maximum stress in exceptional circumstances, and
are only subject to very lowstresses continuously.
2 L2 Driving mechanisms or parts thereof, which are subject to 0.50 < k km = k3 = 0.25
(average) the maximum stress often, and are only subject to low ≤ 0.63
stresses continuously.
3 L3 Driving mechanisms or parts thereof, which are subject to 0.63 < k km = k3 = 0.5
(high) the maximum stress often, and are subject to average ≤ 0.80
stresses continuously.
4 L4 Driving mechanisms or parts thereof, which are subject to 0.80 < k km = k3 = 1
(very the maximum stress of adjacent stresses regularly. ≤ 1,00
high)

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 MAINTENANCE

MODEL FOR DETERMINING THE ACTUAL OPER ATING TIME

The following calculation compares the actual operating time with the theoretical operating time
in collective load 4 (very heavy).

1 2 3 4 5 6 7
Remaining
Average Collective load factor in accor- Partial deploy- theoretical Date
daily dance withcollective load for ment use in
Delivery
Operating operating the type of operation Column 2 collective load 4 Specialist
Initial
site time x column 3 (When zero has been reached operation inspector
L1 L2 L3 L4
Very x operating days a general overhaul must be Inspections Signature
in hours x factor 1.2 performed)
Low Average High high
Existing driving mechanism Delivery date J.D. NEUHAUS
group, see nameplate GmbH & Co.KG
_ 0 0,125 0,25 0,5 1 0 M2 (1Cm) 200 hours Initial
M3 (1Bm) 400 hours operation
M4 (1Am) 800 hours
M5 (2m) 1600 hours

C ALCUL ATION MODEL (DRIVING MECHANISM CL ASSIFIC ATION M3)

Slewing
1.5 x 0.25 (400 - 113)
crane 2. August
1,5 0,25 x 250 x 1.2 A.N. Other
assembly 287 hours 2004
= 113 hours
site

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MAINTENANCE

The specified inspection intervals are valid for use in accordance with the classification (see driving mechanism classifi-
cation on the nameplate). The service life is approx. 10 years if the device is used in accordance with its classification.
If the hoist is used more intensively the intervals are to be shortened accordingly. The intensity of use must be assessed
using the model for determining the actual operating time (see page 40). All operating hours are translated into full
load hours. The theoretical operating time and the interval hours are indicated in full load hours.

Maintenance measure Interval Comment

Check oil level for motor Daily (Section Filling and adjusting oiler, page 48)
lubrication (when operating with oiler)
Lubricate chain As required (Section Lubricating the chain, page 44)

Inspection measure Interval Comment

Check control equipment Daily (Section Checking controls, page 45)
Check braking function Daily (Section Checking braking function, page 44)
Check direction of movement Daily (Section Checking direction of movement,
page 45)
Lifting and lowering limiters Daily Replace buffer immediately if damaged,
(buffers), visual check otherwise replace every 5 years
Check EMERGENCY STOP function Daily
Check chain Every 3 months (Section Checking chain, chain sprocket and
chain guides, page 54) in the case of wear pro
moting conditions, reduce interval between checks
Check lifting and lowering limiters Yearly (Section Checking lifting and lowering limiters,
page 45)
Check brake with load Yearly The load must be braked reliably (Section
Checking braking function, page 44)
Check all bolted and pin Yearly
connections
Check load hook on the load Yearly (Section Check dimensions, page 54)
and carrying side
Check the motor, check, clean Yearly Measure the lifting speed
and grease the control valve
(JDN high-performance grease)
Check the axial movement of hooks Yearly (Section Checking axial play, page 56)
and eyes
1
Check service unit Yearly (Section Service unit, page 46)
Check silencer for Yearly (Section Checking the silencer for
permeability for permeability, page 45)
Check overload protection Yearly (Section Checking and adjusting overload
protection, page 59)
Check compressed air connections Annually
for damage
1
If available

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 MAINTENANCE

Inspection measure Interval Comment

Check sealing efficiency and function Yearly
of control valve
Check condition of chain box1 Yearly (Section Chain box, page 62)
including mountings
Check brake wear and motor wear Every 200 hours, (Section Checking brake linings and vanes,
At least every 5 years page 49)
In off-shore areas and other similar Every 5 years
corrosive environments, replace the
chain regularly
Check gearbox and perform lubricant Every 5 years
change
Check the rotor/pinion shaft connec- Every 5 years
tion and lubricate with gear grease
Check the sprocket wheel bearings and Every 5 years
lubricate if necessary
Check chain and chain guides changed Each time the chain is (Section Wear dimensions, page 55)

Renew grease lubrication of motor As required, (Section Motor lubrication, page 49)
At least every 5 years
1
If available

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MAINTENANCE

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

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.
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.

If you wish to lubricate the hanging chain, ensure DA NG E R !

that the chain links are oiled at the points of contact. If the chain runs on, do not use the hoist.
For this purpose, move the chain to and fro. The hoist must be repaired.
A high-performance lubricant in an aerosol can is avail-
able from JDN, which adheres well to the chain after For physical reasons, the braking distance cannot have
the solvent has evaporated and does not drip off, Art. the value zero. However, for the purpose of this func-
no. 12066 (aerosol 400 ml). tional check, running on of the chain must not be
perceptible.
For operation in areas with high corrosion potential,
e.g. in the off-shore sector, the chain can be largely When checking the braking function under nominal
protected against corrosion by the use of special load, the following braking distances must not be
lubricants. These types of lubricants are characterised exceeded:
by weathering resistance, water insolubility, good adhe-
B R A K I N G D I S TA NC E S U N D E R N O M I N A L L OA D
sion properties etc. Relubrication intervals must be
( L OA D - C A R R Y I N G C A PAC I T Y ) A F T E R L OW E R I N G
stipulated in accordance with the loading.
HAS BEEN STOPPED
Please contact us, if required.
Type 025 TI 05 TI 1 TI 2 TI
Rope control 7 6 3 1.5
all other controls
with hose lengths 18 9.5 8 4
of 2 m
Dimensions in mm

If the control hoses are long the braking distances will

increase due to longer air evacuation times.

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 MAINTENANCE

CHECKING LIFTING AND CHECKING DIRECTION

L OW E R I N G L I M I T E R S O F M OV E M E N T

 Move the unloaded load hook until just short of the
upper and lower end positions.
 Stop immediately before reaching the end position
and then carefully (by repeatedly pressing the control
element) move to the end position.
 The movement of the chain must be stopped due to
deformation of the buffer. For hoists with overload
protection, the lifting movement is additionally limit-
ed by shutting off the motor.
 Following successful testing, the buffer must be
unloaded.
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 CO N T RO L S A N D
E M E RG E NC Y S T O P F U NC T I O N
 Check that the direction of movement of the load
hook corresponds to the direction indicated by the
arrows on the control elements.
C H E C K I N G T H E S I L E NC E R
FOR PERMEABILIT Y
Irrespective of the stipulated inspection intervals, the
silencer must be checked for permeability if the hoist
does not achieve the specified lifting speed (see section
Technical data, page 63).
The test is performed by comparing the lifting speeds
under nominal load, with and without the silencer.
The speed with standard silencer or filter silencer must
be at least 80 % of the lifting speed without a silencer
element.
In the case of lower values, the silencer elements
must be cleaned or replaced.

All control elements of the controls must always be

free-moving.

 Unload the JDN Air Hoist.

 Briefly actuate and release all control elements of the
controls one after another. The control elements must
return to their initial positions immediately. The
switching on and off function must operate correctly.
 PRESS the EMERGENCY STOP button. Each movement
of the hoist must stop. Actuation of the control ele-
ments must not cause a lifting or lowering movement.
 RELEASE the EMERGENCY STOP button by turning.

DA N G E R !
If a control element is stiff or
remains in the actuated position,
do not use the hoist. The controls must
be repaired.

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MAINTENANCE

If the nominal pressure of 5.4 bar (3.6 bar) cannot be

SERVICE UNIT
achieved despite a sufficiently high pressure upstream
of the service unit, then the air line cross-section is too
AT T E N T I O N ! small.
If a hoist is operated with a service unit,
*)
this should not be mounted further than 5 m Values for 4-bar hoists in brackets
away from the hoist.

The ambient temperature must be a minimum of

0° C. It must not exceed 50° C.

N O T E : If, at the request of the customer, a service unit

is installed in hoists in motorised trolleys and lifting
gear, it will be configured at the factory.

The service unit in the Air Hoists PROFI O25 TI to

PROFI 2 TI consists either of two elements, filter
controller and oiler, or of the filter controller only.

C H E C K I N G A N D A D J U S T I N G T H E F I LT E R
CO N T RO L L E R * )
The filter controller is set to an actual pressure of 5.4
bar (3.6 bar) in the factory (actual pressure with motor
running).
In this setting, the manometer can indicate a pressure
of over 6 bar (4 bar) with the motor switched off. For
correct adjustment, a pressure of at least 7 bar (5 bar) Filter controller and oiler
upstream of the service unit is required.

 Lift the regulator knob. adjusting knob

 Turn the regulator knob until the manometer
indicates a pressure of 5.4 bar (3.6 bar).
Clockwise: higher pressure
Anti-clockwise: lower pressure
 Lock the regulator knob by pressing it down.

Alternatively, the filter controller can be set to a pres-

sure of 6 bar (4 bar) in the absence of an air stream.
This setting is only correct for a pressure of at least 7
bar (5 bar) upstream of the service unit.

 Depressurise the air line downstream of the service

unit and close it again. lubricator
 Turn the regulator knob anti-clockwise, in order to
release the adjusting spring.
 Turn the regulator knob until the manometer indi- filter-regulator
cates a pressure of 6 bar (4 bar).
Clockwise: higher pressure
Anti-clockwise: lower pressure
 Lock the regulator knob by pressing it down.

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 MAINTENANCE

D R A I N I N G WAT E R
After a certain time, liquid collects in the filter con-
troller container, which must be regularly drained. For
this purpose, proceed as follows:

 Check the water level through the sight glass in the

filter container. The water level must not reach the
separating plate.
 Fit the accompanying hose (instead of this, a ∅ 8 x 1
soft PVC hose of the required length can be fitted).
install
 Collect the escaping water and ensure proper dispos- hose
al, as possibly oil-containing. drain the liquid:
by pressing grips
C L E A N I N G T H E F I LT E R E L E M E N T on both sides
AT T E N T I O N !
Do not use alcohol for cleaning the service
Draining water
unit. Alcohol can damage parts of service
unit. Transparent components must only be
cleaned using soap solution.

The filter element must be cleaned once annually.

For this purpose, proceed as follows:

 Drain the water.

 Shut off the main air supply and carefully allow the
residual pressure to dissipate.
 Unlock the filter controller container, turn anti-clock-
wise to the stop and remove.
 Unscrew the separating plate. The filter is located
loosely on the separating plate centring device.
 Clean the filter element using soap solution and blow
through forcefully. filter element
 Reinstall the clean filter element and fasten the
separating disc
separating plate.
 Insert the filter controller container in the housing
and turn clockwise. The container locks automatically.

sight glass

filter receptacle

Cleaning the filter element

Page 47
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MAINTENANCE

FILLING AND ADJUSTING OILER

The oiler ensures that the hoist air supply is consistent-
ly provided with a precisely-metered quantity of oil.
Regular checking of the oiler is very important, as the
vane motor may be damaged in the case of lubricant
deficiency. The oiler can also be refilled under pressure.

 Check the oil level through the sight glass in the

container. The oil level must not fall below the mini-
mum mark.
 Remove the oil filler screw.
 Fill the container with oil up to the maximum mark maximum
and refit the oil filler screw. oil level
 Check the oil drop rate at the sight glass with the
motor running.
 Turn the oil throttle screw using a screwdriver until minimum
the desired number of drops per minute is achieved. oil level
Turning clockwise reduces the amount of oil; turning
anti-clockwise increases the amount of oil.

Oil drop rate (lifting without load):

2 drops per minute.

C AU T I O N !
Operation of service units with synthetic
oils is not permissible.
They must also not be connected to com-
Check the oil level and top up if necessary
pressed air circuits, which are supplied by
compressors lubricated with synthetic oil.
Sight glass
WA R N I N G !
J.D. Neuhaus only supplies standard spray
Oil filler screw
oilers.
Oil throttle screw
Do not use microspray oilers as very finely
secreted oil spray could adversely effect the
surrounding air and therefore the respiratory
system.

Check oil drop rate at sight glass and adjust

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M O T O R I N S TA L L AT I O N /
CHECKING BRAKE LININGS AND
VA N E S / M O T O R L U B R I C AT I O N
12 13 11
Replacing brake discs, brake piston and vanes /Motor installation
The motor and brake functions are achieved in part by
means of shared components. The braking action is
applied at the lateral surfaces of the rotor. The rotor is
pressed via spring force from the cover-side of the
motor against a second braking surface located on the
opposite side by means of a piston on which braking
material is bonded.
R E M OVA L
The hoist must first be unloaded and disconnected from
the main air supply.
Note: The following operations can be performed from
the nameplate side after the motor has been removed.
 Checking vane wear, replacing the vanes
with starting aids if necessary.
 Checking brake wear, replacing the brake piston
if necessary.
 Renewing the motor lubrication.
The replacement of the centre section halves with brake
lining is described under a separate item.
 Unscrew the nameplate 1.
 Remove the motor cover bolts 2 and pull out the
motor cover 3 (when the cover bolts are removed,
tension of the brake springs 4 is fully released).
powered by air!
MAINTENANCE
7 8 6 10 9 5 4 3 2 1
14/15
 Remove the brake springs.
 Remove the brake piston 5 from the internal cylinder
integrated in the motor housing.
 Pull out the rotor 6, removing the vanes 7 and
starting aids 8.
Checking vane wear:
(See illus. Checking vane wear, page 50).
Worn vanes reduce the motor
power and consequently the lifting performance.
Replacing the
vanes together with the starting aids.
Checking braking surfaces of the brake piston and
the centre section half with brake lining for wear and
damage:
The circular wear pattern in the braking surfaces must
not be deeper than 0.2 mm (see also illustration
page 50). The extremely low-wear braking material will
not reach the wear limit of 0.2 mm within the design-
dependent service life of the hoist, under intended use.
Should the wear limit be reached prematurely, the actual
pressure must be checked with the device switched on
(the brake drags in the event of insufficient pressure).
Page 49
MAINTENANCE

 Detach the motor with centre section half on the

Rotor motor-side from the hoist.
Cylinder liner
 Remove the bolts 12 and pull out the centre section
V1 max. = 0.2 mm V2 max. = 0.2 mm
Brake piston half with the brake lining 13.
•

Motor installation with additional basic lubrication:

 Apply high-performance grease lightly to braking
•
Brake disc •
surface and rotor bearing (needle bush) in the
•

R
centre section half and slide this into the motor
housing. At the same time, insert the anti-twist
device (pin).
 Bolt centre section half to motor housing.
 Coat the internal cylinder of the motor housing
lightly with high-performance grease.
 Coat the entire rotor lightly with high-performance
Lh

•
grease and insert into the front rotor bearing with
the clutch side first.
 Coat the vanes lightly with high-performance grease
L Vane
and insert into the rotor slots with the starting aids.
Lmax = R – (V1 + V2)  Coat the braking surface and the outer diameter
Lmin = R – (V1 + V2) – 0.3 mm = Lmax – 0.3 mm
including the brake piston seal lightly with high-
performance grease and push the brake piston with
Checking vane wear
the braking surface first into the internal cylinder.
Note the position of the eccentric bore.
Renewing motor lubrication:
 Insert the brake springs into the bores of the
Note: The grease packing in the rotor chambers is
brake piston.
sufficient for approx. 250 hours of normal operation.  Loosen adjusting bolts 14 and lock nuts 15.
The rotor chambers are only emptied by approx. 75%.
Screw back adjusting bolts.
In this condition, refilling must be performed.
 Apply high-performance grease lightly to rotor bearing
The retaining rings 9 and Vyon washers 10 must be
(needle bush) in the motor cover and install motor
removed in order to refill the chambers.
cover. Ensure correct seating of the brake springs and
Then pack the chambers with high-performance lubri-
the locating pins to the motor housing and to the
cant (JDN Art. no 11901) without forming cavities.
brake piston. Do not tighten the four adjusting bolts
Use new Vyon washers to close off the lubricant cham- after bolting the motor cover in place, only screw
bers and secure these using retaining rings.
them in loosely by hand to the stop in the cover.
Replace centre section halves with brake lining. Screw back the lock nuts sufficiently beforehand.
 Then screw back the adjusting bolts 45° from the
If the centre section half with brake lining is to be
replaced, the following removal operation is also stop, hold, and lock with the nuts. For lifting heights
required. of 10 m and more, a setting of up to 60° is required.
For operation in areas with ambient temperatures
 Detach the hoist from the point of attachment and
exceeding 30° C, the adjustment has to be carried out
set down carefully.
with the device warmed up accordingly.
 Detach the chain box if necessary.
 Remove the control valve.
 Unscrew centre section bolts 11.

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 MAINTENANCE

 Screw on the nameplate.

 Push motor with centre section half on the motor
side onto the hoist – install load hooks at same time –
and tighten centre section bolts.
 Install the control valve.

C AU T I O N !
Tightening torques, see E-list.

WA R N I N G !
Check the braking action of the hoist under
load (run in the brake by performing several
hoisting cycles, then assess) prior to initial
operation. Check the motor power. In the
event of low motor power, regulate the
adjusting bolts again.

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MAINTENANCE

REMOVING AND INS TALLING BO TTOM BLOCK

REMOVING AND INSTALLING LOAD SLEEVE,
AND BUFFERS
BOTTOM BLOCK, CLAMP AND BUFFER
- D UA L C H A I N H O I S T (2 TI)

R E M OV I N G A N D I N S TA L L I N G L OA D S L E E V E
AND BUFFER
- SINGLE CHAIN HOIS T S (025 TI, 05 TI, 1 TI)

3
14
3
2

1 12

11
5 13
2
9
10

5 8 6

7
1
8

4 4

Removal
 Drive out the roll pin 1 for securing the chain from
the load sleeve 3.
 Remove the chain link 2 from the chain pocket.
 Detach the buffer 4 and buffer discs 5 from the
chain.
Assembly
 Push the buffer discs (edge encloses buffer) and the
buffer onto the chain.
 Insert the chain link into the chain pocket of the
load sleeve (position of the weld must align with
that of the following links).
 Drive in a new roll pin to secure the chain link in the
load sleeve.
Removal
 Move the bottom block as close as possible to the
hoist body.
 Position the bottom block securely in order to
prevent the chain from unravelling uncontrollably
causing the bottom block to fall.
 Remove the chain link 1 of the bottom block from
the chain mount on the hoist body; drive out the roll
pin 2 and the end chain link pin 3 for this purpose.
 Draw the spacer pipe 4 from the chain.

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 MAINTENANCE

Note: For assembly, it is helpful to fasten a short R E M OV I N G A N D I N S TA L L I N G C L A M P A N D B U F F E R

assembly chain 5 to the end of the chain by means of Removal (see illus. page 52)
an open chain link 6 before pulling the chain out of
 In the case of operation with chain box, run the
the bottom block. This assembly is pulled into the bot-
chain out of the chain box and detach it from the
tom block as the chain is pulled out and remains there
hoist.
until assembly is completed.
 Remove the chain link of the idle chain from the

 Pull out the chain from the bottom block. chain mount on the hoist body. Unscrew the Allen
The buffer 7 and buffer discs 8 are thereby screws 14 for this purpose.
 Loosen screw connections 9 of the clamp 10.
pulled from the chain.
 Remove the clamp from the chain.
 Detach the buffer 11 and buffer discs 12 + 13 from
Assembly
 Push the buffer discs (edge encloses buffer) and the
the chain.
buffer onto the chain.
Assembly
 Align the chain and fasten it to the assembly chain
 Push the buffer disc with edge (edge encloses buffer),
in the bottom block by means of the open chain link.
 Pull the chain through the bottom block and detach buffer and buffer disc without edge onto the chain.
 Insert the tenth chain link into the chain pocket of
the assembly chain and the open chain link from the
chain. If no assembly chain has been used, the end the clamp (chain pocket away from hoist body, point-
of the chain must be inserted into the bottom block ing outwards).
 Introduce a screw connection to secure the chain link
and pulled through by turning the sprocket wheel
using an auxiliary tool. in the clamp.
 Align the idle chain and fasten the end chain link to
 Push the spacer pipe onto the chain, align the bot-
tom block chain and push the chain link pin through the hoist body.
 Attach the chain box.
the chain link to be attached (position of the weld
must align with that of the following links). C AU T I O N !
 Drive in a new roll pin to secure the end link pin.
Do not twist the chain! The chain is subject-
ed to impermissible stresses if the chain is
twisted.

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MAINTENANCE

CHECKING CHAIN, CHAIN CHECK DIMENSIONS

S P RO C K E T A N D C H A I N G U I D E S
HOIST CHAIN
See also Check dimensions, page 54. Note: When checking the replacement limit, future wear
If the chain of the JDN Air Hoist displays one of the to the next checking date must be taken into account.
following features, it must be replaced with a new one: If the chain dimension values are outside the limit val-
ues specified in the table when checked, the chain has
 Corrosion scars reached its replacement limit and must be replaced by a
 Bent or damaged chain links new one. The chain sprockets must also be replaced
 Chain drawn stiff together with the chain, as otherwise the new chain
 Wear over 11 pitches (Amax) will be subjected to increased wear. Each chain replace-
 Single pitch wear (Bmax) ment must be documented in the inspection log.
 Elongation of a single link (Dmax)

Check the entire length of the chain.

Please observe the information contained in DIN 685,

part 5 when checking chains. For further instructions,
see ISO 7592.

11 x t

d1

d1 + d2
d2

c=
2

Check dimensions of hoist chain

Chain d x t 7 x 21
Dimension A max. 249.2
11 x t inside max. 235.8
Dimension B max. 22,1
Dimension C min. 6,3
Dimension D max. 36,1
Dimensions in mm

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 MAINTENANCE

L OA D H O O K W E A R D I M E N S I O N S F O R C H A I N S P RO C K E T S
If the measured distance y and the height h of the load
hook are outside the wear limits, the hook must be
replaced.

a
x
Wear dimensions for chain sprockets
h

Chain size
Check dimensions of the load hook dxt z a x
mm x mm (1) mm mm

Type Maximum Minimum 7 x 21 4 19.1 0.15

permis. dimension permis.
of measured dimension a, x = limit dimensions after maximum permissible
distance of height “h“ wear
PROFI 025 TI - 2 TI 63 22.8 z = number of teeth of the chain sprocket
d x t = nominal diameter times pitch of chain link
Dimensions in mm

WEAR DIMENSIONS FOR CHAIN GUIDES AND

HOOK MOUNTS
Check the chain guides for wear and when the wear
dimension of 0.9 mm is reached with regard to chain
guide diameters or hook mounts in the centre section
of the device: Replace the housing.
The wear dimension must be measured at the points on
the guide surfaces which have been worn down by the
chain.

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MAINTENANCE

C H E C K I N G A X I A L P L AY

Maintenance and lubrication

Please ensure that load hooks and/or load eye mounts
are regularly checked, at least once a year. Especially
important: in areas where wear-promoting conditions
such as high ambient temperatures or corrosive sub-
stances in the atmosphere are present, or where lubri-
cants may be washed out, the frequency of mainte-

max. 2.5 mm
nance and inspection intervals must always be
increased.

HAZARDS IN THE C ASE OF INSUFFICIENT

M A I N T E N A NC E / L U B R I C AT I O N
DA N G E R !
In the event of insufficient maintenance/
lubrication the extent of wear may be so
high that there is a danger of loads falling.

P R E V E N T I O N O F DA N G E R S
Dangers are avoided by regular maintenance/lubrication Load sleeve with load hook or load eye
in suitable intervals.

When the axial play of the installed hook or load

eye exceeds the maximum play specified, the worn
parts must be replaced.
max. 2.5 mm

Bottom block with load hook or load eye

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R E M OV I N G A N D I N S TA L L I N G C H A I N
C AU T I O N !
The chain supplied together with this JDN
hoist is matched to the chain sprocket
according to strict tolerances. In order to
ensure optimum function of the chain and in
order to prevent hazards, only genuine JDN
chains must be installed.
Note: When a chain is replaced, the buffers must also
be replaced. For information on changing buffers at the
chain ends, see Removing and installing load sleeve,
bottom block, clamp and buffer section.
Buffers which are not located at the chain ends are
most easily replaced when the open chain link between
the old and new chains passes the buffer to be replaced.
C AU T I O N !
Do not twist the chain ends.
 In the case of operation with a chain box:
switch the hoist in the “lower” rotational direction
and run the old chain out of the chain box.
Then remove the chain box.
 Move the bottom block as close as possible to the
hoist body and position it securely.
 Detach the idle chain from the chain mount on
the hoist body (see also section Removing and
installing load sleeve, bottom block, clamp and
buffer).
 Detach the clamp, buffer and buffer discs from the
end of the idle chain.
For single chain hoists, also detach the load sleeve,
buffer and buffer discs from the load chain.
For dual chain hoists, detach the bottom block from
the hoist body (see also Removing and installing
load sleeve, bottom block, clamp and buffer sec-
tion).
powered by air!
MAINTENANCE
 Attach the new chain to the end link of the load sec-
tion of the old chain after aligning the welds and the
first chain link by means of an open chain link. The
welds on the upright chain links must face outwards
when running over the chain sprockets. If the first
link of the new chain is not correctly positioned, it
must be removed.
Note: It is possible that the first chain link of the other
chain end is correctly positioned.
Switch the hoist to the “lift” rotational direction. The
new chain will now run into the hoist while the
 old chain is simultaneously run out on the idle chain
side.
Run the chain until the join between the old and new
chain has run sufficiently (approx. 1m) out of the
centre section on the idle chain side.
 Detach the connection between the old and new
chains.
 Install the clamp (at the 10th chain link), buffer
and buffer discs on the idle chain section of the
new chain.
Align the idle chain and attach to the fastening point
on the hoist (see also Removing and installing load
sleeve, bottom block, clamp and buffer section)
 Attach the chain box if necessary.
 Switch the hoist in the “lift” rotational direction
until the as yet free end of the aligned load chain is
the correct length for attaching the chain link,
– for single chain hoists in the load sleeve after the
buffer and buffer discs have been pushed on,
– for dual chain hoists at the fastening point of the
hoist body (see also Removing and installing load
sleeve, bottom block, clamp and buffer section).
Note: If the chain link of the load chain is positioned
incorrectly, it must be removed, the following chain link
will be positioned correctly.
Page 57
MAINTENANCE

REPL ACING CHAIN AND CHAIN SPROCKET

Note: If the chain jams in the hoist and can no longer

be run out, the gearbox must be dismantled (see spare
parts list for “Gearbox”).

For dual chain hoists, when removing the old chain, an

assembly chain 1 is brought into position on the deflec-
tion sprocket of the bottom block by means of an open
chain link (see also Removing and installing load
3
sleeve, bottom block, clamp and buffer section and 2
Removing and installing chain section). 4

5
Following replacement of the chain sprocket (see spare
parts list) an assembly chain 2 is run carefully
1
– with low air pressure – over the drive sprocket.

Fasten the new chain 5 to the assembly chain on the

drive sprocket by means of one or two open links 3 to
the idle chain side. The first chain link 4 must run
upright over the drive sprocket with the weld facing
outwards.

Switch the hoist to the “lower” rotational direction and

detach the assembly chain from the chain after it comes
out of the centre section.

For dual chain hoists the new chain, after it has been
aligned, is pulled over the deflection sprocket of the Drawing in the chain
bottom block using the assembly chain.

Note: If the chain link on the idle chain side is posi-

tioned incorrectly, it must be removed, the following
chain link will be positioned correctly.

Fastening of the chains and installation of the load

sleeve, clamp, buffer and buffer discs is carried out in
accordance with the Removing and installing load
sleeve, bottom block, clamp and buffer section and
the Removing and installing chain section.

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 MAINTENANCE

OV E R L OA D P RO T E C T I O N

The hoists Profi 025 TI to 2 TI are available with an

overload protection. Hoists for use within the EU are
equipped with this as standard from a carrying capacity
of 1 t and above.

A D J U S T I N G OV E R L OA D P RO T E C T I O N
The adjustment method described here is based on the
attachment of test loads.

DA N G E R !
If the overload protection is set too high,
impermissibly high stresses may arise if a
load exceeding the permissible load carrying
capacity is attached.

 Attach overload of 125% of the load-carrying capacity.

 If this overload is lifted, the adjusting bolt must be
adjusted clockwise until it is no longer possible to lift
the overload. If the overload is not lifted, the adjust-
ing bolt must be adjusted anticlockwise until it is
possible to lift the overload. Then it must be adjusted
back until it is no longer possible for it to lift the
overload.
 After the adjustment process, it must be possible to
lift 110% of the nominal load. A dynamic overload
test of 110% of the nominal load is thus possible.

(+) (-)

Adjusting overload protection

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FAULT S, C AUSE AND REMEDY
FAULT S, C AUSE AND REMEDY
FAU LT TA B L E
Fault
Lifting not possible
Only very slow lifting is possible
Excessive running on during braking
Loud chain noise at chain sprocket
Lifting or lowering speed reduced at
higher lifting heights or motor comes
to a standstill
*if installed
Page 60
Possible cause
Overload protection has shut off
Air pressure too low
EMERGENCY STOP switch is
pressed
Hand control is faulty
Brake does not release fully
Brake lining worn or uneven
Motor cover bolts loose
Air supply hoses are leaking or
loose
Cross section of air line too small
Dirt in the service unit*
Filter blocked
Silencer is clogged
Motor vanes worn
Motor has run dry
Control valve on motor
Brake disc and/or brake piston
worn
Chain dry
Chain worn
Chain sprocket worn
Wrong chain drawn in
Adjustment of brake piston
too tight
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Remedy
Lower hook briefly, limit load to permissible
load carrying capacity, then lift again
Increase air pressure to the required value
When the danger has passed, release the
EMERGENCY STOP switch
Have hand control repaired
Set air pressure to the relevant value,
Check seal of brake piston and change seal
if necessary
Check the adjustment of the brake piston
(see E-list)
Replace brake lining
Tighten bolts
Check connections of air supply hose and
control hoses and connect properly
Use air line with sufficiently large diameter
(check air pressure)
Clean the service unit, ensure better air
quality
Replace the silencer elements or clean,
improve air quality if necessary
Replace motor vanes
Lubricate motor,
Check oiler*
Have the control valve repaired
Replace brake disc and/or brake piston
Lubricate chain
Replace chain with new JDN chain
Replace chain sprocket, check chain guide,
replace if necessary
Identify chain and replace with JDN chain
if necessary
Correct adjustment of brake piston. At high
ambient temperatures perform adjustment
with the device warmed up accordingly
 ACCESSORIES

ACCESSORIES

F I LT E R S I L E NC E R

With the use of a filter silencer, oil aerosols can be

avoided and noise insulation improved:

 99.9 % of oil aerosols during oil lubrication of

the motor are absorbed by the filter element.
 The noise insulation reduces noise levels by 3 to
4 dB (A) compared with the standard silencer
(sinter plate).
1
The ambient temperature must not be lower than -10° C.

M A I N T E N A NC E O F F I LT E R S I L E NC E R
The filtered oil runs into the transparent collecting
container 3. This container must be emptied before 2
the fluid level reaches the filter element.

 Turn the drain valve 4 90° and allow the fluid to

drain out.
 Close the drain valve.

The filter must be replaced after approx. 2500 hours

of operation. 3
 Turn the collecting container 3 slightly and detach.
 Unscrew the filter element 2.
 Insert a new filter element, with sealing ring 1 and 4
push on collecting container until it engages.

Filter silencer
BOOSTER UNIT

In the case of a control hose length exceeding 10 m,

the reaction times of the pushbutton controls increase
significantly.

Consequently, a booster unit is generally installed on

the motor for controls E, F and FI, enabling normal
reaction times.

The operating temperature range is from 0° C to 80° C.

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ACCESSORIES
C H A I N B OX
For various areas of application, a chain box enhances
operational safety, i.e. when a chain which is hanging
down could become caught up with the load.
JDN chain boxes are available in various sizes, corre-
sponding to the chain lengths.
AT T E N T I O N !
Do not exceed the permissible filling
capacity. Danger of chain dropping.
AT T E N T I O N !
Loads must not be moved against the chain
box during lifting. If necessary, attach a
clamp to the chain.
The clamp must be attached above the load hook so
that it functions as a preliminary end stop. With the
(dual chain) the clamp must be posi-
tioned as far as necessary downwards on the reeved
chain in order to support the bottom block (stationary
chain).
In addition, a spacer must be attached to the opposite
(moving) chain above the buffer in order to relocate the
stroke limiter. Please contact us, if required.
For greater clarity, see the illustration on the right
on page 52.
In all cases, a clamp is attached in the 10th chain link
of the unloaded chain end so that a length of chain
remains in the chain box when the bottom load hook
position is reached. Thus, the chain cannot run next to
the chain box during subsequent lifting (see section
Removing and installing chain, page 57).
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AT T E N T I O N !
Never allow the chain to pile up in the
chain box.
The chain must only enter the container via
the chain drive. If it falls out of the contain-
er, e.g. during transportation, it must be run
out completely on the load hook side and
then run back into the container via the
chain drive, in the air hoist operating posi-
tion.
 After installing the chain box, lower the load hook
to the bottom position once.
 Then activate lifting movement and run the
complete chain into the chain box.
DA NG E R !
During operation with the chain box, lubrica-
tion of the chain is particularly important in
order to prevent it from piling up and falling
out.Do not install longer chains when chang-
ing chains.
Furthermore, hazards arise due to rusty
chains when operating with chain boxes,
as the chain can form a heap and fall over
the edge of the container rim. In addition,
rusty chains are subject to extreme wear.
If the hoist has been transported with the
chain in the chain box, the chain box must
be emptied manually before initial operation
(if necessary, remove the chain box from the
hoist). The entire chain must then be allowed
to run to the load side and, subsequently, be
driven back into the chain box. The hoist
must be kept in a hanging position during
this procedure.
 APPENDIX

APPENDIX

T E C H N I C A L DATA

J D N P RO F I T I A I R H O I S T S

Type 025 TI 05 TI 1 TI 2 TI
Load-carrying capacity t 0.25 0.5 1 2
Number of chains 1 1 1 2
Motor rating kW 1.0 1.0 1.0 1.0
Air pressure bar 6 6 6 6
Lifting speed at nominal load m/min 20 11 5.5 2.7
Lifting speed without load m/min 42 19 11 5.5
Lowering speed at nominal load m/min 38 17 11 5.5
Air consumption at nominal load
- lifting m3/min 1.2 1.2 1.2 1.2
Air consumption at nominal load
- lowering m3/min 1.5 1.5 1.5 1.5

Air connection G 1/2 G 1/2 G 1/2 G 1/2

Hose size ( inside) mm 13 13 13 13
Weight for standard lift, kg 27 27 28
2
34
2
rope control
Chain dimensions mm 7 x 21 7 x 21 7 x 21 7 x 21
Weight of 1 m chain kg 1.0 1.0 1.0 1.0
Standard lift m 3 3 3 3
Control length for standard lift m 2 2 2 2
Noise pressure level with nominal load1 74 75 76 76
with standard silencer - lifting dB(A)
1
Noise pressure level with nominal load 78 78 78 78
with standard silencer - lowering dB(A)
1 measured from 1 m distance according to DIN 45635 part 20 2 with overload protection

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 APPENDIX

DIMENSIONS

J D N P RO F I T I A I R H O I S T S

G D
C
F

E1
A

E2

Type 025 TI 05 TI 1 TI 2 TI
A Minimum headroom* 450 450 450 498
B 288 288 288 336
C 145 145 145 145
D 297 297 297 297
E1 28 28 28 28
E2 28 28 28 28
F to centre of hook, without chain box 137 137 137 137
G maximum width 176 176 176 183

*Chain boxes increase the required headroom Dimensions in mm

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 NO TES

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 is a registered trade mark of our company.
BA 817 GB· Issue: April 2005 · Subject to changes · 42005

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

Phone: +49 2302 208-0_Fax: +49 2302 208-286
Web site: www.jdn.de_E-mail: info@jdn.de

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 J D N O P E R AT I O N A N D A S S E M B LY
INSTRUCTIONS AIR HOISTS
3

Original Operation and

Assembly Instructions

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Please enter the Serial No. of your JDN Air Hoist here.

This operation manual edition 12/2009, covers the

following JDN Air Hoists:

3
Fabr. No. Fabr. No.

It must be read carefully and in its entirety before

operating any hoist. For hoists installed in trolleys,
please also refer to the operation manual JDN Trolleys.

Page 2

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TABLE OF CONTENT S
SAFET Y MEASURES
Organisational measures . . . . . . . . . . . . . . . . . . . 5
Personnel safety . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preventing property damage . . . . . . . . . . . . . . . . 5
P RO D U C T I N F O R M AT I O N
About this operation manual. . . . . . . . . . . . . . . . 6
Warnings and symbols. . . . . . . . . . . . . . . . . . . . . 6
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly overview . . . . . . . . . . . . . . . . . . . . . . . 8
Product description. . . . . . . . . . . . . . . . . . . . . . . 8
Explosion protection . . . . . . . . . . . . . . . . . . . . . . 9
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operating conditions . . . . . . . . . . . . . . . . . . . . . 16
Energy requirements . . . . . . . . . . . . . . . . . . . . 17
Principle of operation of JDN air vane motors . . 18
Operation without chain box . . . . . . . . . . . . . . . 19
Motor lubrication/operation with a service unit . 19
CE marking / declaration of incorporation . . . . . 19
Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
T R A N S P O R T A N D S T O R AG E
Safe transportation . . . . . . . . . . . . . . . . . . . . . . 20
Storage conditions . . . . . . . . . . . . . . . . . . . . . . 20
I N I T I A L O P E R AT I O N
Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installing the hoist . . . . . . . . . . . . . . . . . . . . . . 21
Connecting the controls. . . . . . . . . . . . . . . . . . . 22
Replacing controls . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting to the main air supply. . . . . . . . . . . 27
Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection before initial operation . . . . . . . . . . 29
O P E R AT I O N
Rules for the safe operation of hoists . . . . . . . . 30
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . 35
Overload protection . . . . . . . . . . . . . . . . . . . . . . 36
Attaching the load. . . . . . . . . . . . . . . . . . . . . . . 36
Lifting the load . . . . . . . . . . . . . . . . . . . . . . . . 37
Lowering the load . . . . . . . . . . . . . . . . . . . . . . 37
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Detaching the load . . . . . . . . . . . . . . . . . . . . . . 37
Interrupting working . . . . . . . . . . . . . . . . . . . . 37
TA K I N G O U T O F O P E R AT I O N
Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . 38
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
M A I N T E N A NC E
Maintenance and inspection intervals . . . . . . . . 39
Cleaning and care . . . . . . . . . . . . . . . . . . . . . . . 39
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Inspection and repairs . . . . . . . . . . . . . . . . . . . . 39
Instructions concerning the “model for
determining the actual operating time” . . . . . . . 41
Lubricating chain . . . . . . . . . . . . . . . . . . . . . . . 45
Checking braking function . . . . . . . . . . . . . . . . 45
Checking lifting and lowering limiters . . . . . . . . 46
Checking controls and emergency stop function . 46
Checking direction of movement . . . . . . . . . . . . 46
Checking silencer for permeability . . . . . . . . . . 46
Service unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Motor installation/checking brake linings
and vanes/Motor lubrication . . . . . . . . . . . . . . . 50
Removing and installing load sleeve,
bottom block, clamp and buffer . . . . . . . . . . . . . 53
Checking chain, chain sprocket and chain guides . 55
Check dimensions . . . . . . . . . . . . . . . . . . . . . . . 55
Checking axial play . . . . . . . . . . . . . . . . . . . . . . 57
Removing and installing chain . . . . . . . . . . . . . 58
Replacing chain and chain sprocket . . . . . . . . . . 59
Overload protection . . . . . . . . . . . . . . . . . . . . . . 59
FAU LT S , C AU S E S A N D R E M E D I E S
Troubleshooting guide . . . . . . . . . . . . . . . . . . . . 61
AC C E S S O R I E S
Filter silencer . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Booster unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Chain box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
APPENDIX
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . 66
Page 3
Please note:

Within the Federal Republic of Germany operators of

air hoists must comply with trade association accident
prevention regulations and rules, as well as state
occupational safety regulations, in particular

 BGV A1 accident prevention regulations “Principles

of Prevention”
 BGV D8 accident prevention regulations “Winches,
Lifting and Pulling Devices”
 BGR 258 trade association regulations “Operation of
Load-Carrying Devices Used with Lifting Equipment”

and, for air hoists installed in trolleys and for the

operation of monorail hoists, additionally with

 BGV D6 “Accident Prevention Regulations for Cranes”

in the respective currently applicable version.

Operators must also initiate the prescribed tests
(see also “Principles for the Testing of Cranes”
BGG 905 (ZH 1/27).

To document the tests we recommend the

“Inspection log for cranes” BGG 943 (ZH 1/29)
from the trade association.

When operating air hoists in areas with explosive

atmospheres, the operator must comply with the
relevant explosion protection regulations, e.g.

 BGR 104 “Explosion Protection Regulations” and

 BGR 132 “Prevention of Ignition Hazards due to
Electrostatic Charges”

In all other countries, the operator must observe the

relevant national regulations.

Special regulations may apply when incorporating air

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

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SAFET Y MEASURES
O RG A N I S AT I O N A L M E A S U R E S
JDN Hoists are designed in accordance with current
technological standards and accepted safety practice.
Nonetheless, the use of a hoist may be associated with
risk of injury or fatality to the user or to third parties
or with the risk of damage to the hoist or to other
items, if safety rules are disregarded.
All personnel charged with operating hoists, must have
read and understood the operation manual, especially
the section entitled “Rules for the safe operation of
hoists”, before commencing work. This is particularly
important for personnel who only occasionally operate
the hoist, e.g. for maintenance or retrofitting work.
Operators of JDN Hoists are also under obligation to
ensure safe and hazard-free operation. This can be
achieved through the following measures:
 keep the operation manuals available at the
hoist operating site,
 performing regular training,

performing regular inspections (at least once
annually),
 implement an inspection log and make regular
entries,
 and regularly check personnel for safety and
hazard awareness during work.
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SAFET Y MEASURES
PERSONNEL SAFET Y
Personnel who operate, maintain, inspect and perform
setting-up work on the hoist must be properly trained
or must receive an introduction from properly trained
personnel before commencing work.
Due to their technical training and experience, properly
trained personnel have adequate knowledge of hoists.
They are sufficiently familiar with the relevant occupa-
tional safety and accident prevention regulations that
they are able to assess the condition of hoists with
regard to working safety.
 Follow the operating instructions for your workplace.
 Comply with the accident prevention regulations.
 Ensure that you are properly informed regarding
working with hazardous materials.
 Follow the safety instructions set out in the
operation manuals.
P R E V E N T I N G P RO P E R T Y DA M AG E
Operators of JDN Hoists are under obligation to ensure
that entries in the accompanying inspection log are
made properly and regularly.
 Comply with the prescribed maintenance intervals.
 Only use JDN hoists for work which is described as
intended use.
 Observe the operating conditions for JDN Hoists as
described in this manual.
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PRODUCT INFORMATION
PRODUCT INFORMATION
A B O U T T H I S O P E R AT I O N M A N UA L
This operation manual is intended to help the operator
familiarise himself with JDN Air Hoists and to take full
advantage of their designated areas of application.
This operation manual contains important information
for the safe, proper and efficient operation of JDN
Air Hoists. Observance of the manual helps to avoid
hazardous situations, to reduce repair costs and
downtimes and to ensure the specified service life
of the JDN Air Hoists.
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WA R N I N G S A N D S Y M B O L S
Safety warnings in this operation manual are classified
in three categories:
DA N G E R !
Safety warnings which, if not followed,
can result in danger to life and limb, are
indicated by this symbol. The symbol indi-
cates an immediate danger. The possible
consequences of non-observance may be
death or severe injuries.
C AU T I O N !
This symbol indicates potentially hazardous
situations. Failure to observe may result in
minor injuries.
AT T E N T I O N !
This symbol indicates that failure to follow
the relevant instructions may result in
damage to the device or other items.
 PRODUCT INFORMATION

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

The nameplate mounted on the housing cover identifies

the type of JDN Air Hoist and contains all important
rating data.

If you have any questions concerning operation of JDN

Typ Baujahr
Air Hoists, which are not addressed in this operation Type PROFI 1,5 TI 3TI/2 Year of constr. 2009
Anzahl der Stränge Fabr.-Nr.
1 2 6200001
manual, please contact us at the following address: No. of chain strands
Tragfähigkeit
Serial-No.
Nenndruck
Lifting capacity 1,6 t 3,2 t Nom.pressure 4-6 bar
Nennhubgeschw. Triebwerkgruppe
4-6 m/min 2-3 M3/1Bm
J.D. NEUHAUS GMBH & CO. KG Rated hoisting speed
Kette
m/min Group of mechani.

Chain 9 x 27 TN
Windenstraße 2-4 Ex-Schutz
Ex-proof II 2 GD IIA T4(X)
D - 58455 Witten-Heven II 3 GD IIB T4(X)

Phone 0 23 02/208-0 J.D. Neuhaus GmbH & Co. KG

58449 Witten_Germany_www.jdn.de
E-mail: info@jdn.de
Fax 0 23 02/208-286
www.jdn.de
e-mail: info@jdn.de

Example of nameplate on housing cover

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PRODUCT INFORMATION

A S S E M B LY OV E R V I E W

PROFI TI series air hoists consist of the following

assemblies:
2
1 Gearbox with chain sprocket and overload protection 3 1
2 Centre section
3 Motor with integral brake function
4
4 Controls with main air EMERGENCY STOP
5
5 Chain
6 Load hook with load sleeve or bottom block
and buffer

P RO D U C T D E S C R I P T I O N 6

The PROFI TI series JDN Air Hoists described here are

designed for load-carrying capacities of 1.6 t (PROFI
1.5 TI) and 3.2 t (PROFI 3 TI/2). Various control devices
are available for the different requirements.

The air vane motor of the hoist, together with the

appropriate controls, is capable of sensitive movement.
This enables precise positioning of the load.
PROFI TI series JDN Air Hoists conform to driving
mechanism classification in the following table:

Hoist Chain
PROFI TI series JDN Air Hoist
1.5 TI M3 / 1 Bm M3/ 1 Bm
3 TI/2 M3 / 1 Bm M3/ 1 Bm
ISO 4301 / FEM 9.5.11

PROFI TI JDN Air Hoists feature rotors with grease

chambers. These contain JDN high-performance grease
which enables operation with oil-free compressed air.
It remains effective for an operating period of approx.
250 hours and should be renewed when required, but
after five years at the latest (see Motor lubrication,
page 19). Additional lubrication with oil-bearing
compressed air by means of a service unit with oiler
is possible.

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 PRODUCT INFORMATION

JDN HOISTS FOR USE IN THE PRESENCE OF TEMPERATURE

E X P L O S I O N P RO T E C T I O N
CLASS T6 GASES OR EXTREMELY EXPLOSIVE DUSTS
Following separate tests, especially with regard to
The basis for the following information is an expert
ambient temperatures and type of operation, use in the
statement by the DMT Gas & Fire Division on the use of
presence of carbon disulphide or dusts with particularly
JDN Hoists, Trolleys and Crane Systems in potentially
low glow or ignition temperatures may be possible with
explosive areas and is based on European Directive
designation II 2 GD IIC T6(X), which includes the
94/9/EC1 (“ATEX 100a”). DMT is accredited with the
additional designation “X” for special conditions (see
testing of devices and protection systems for intended
Additional designation “X”). Please contact us with
use in explosion-hazardous areas.
regard to these requirements.
BASIC EXPLOSION PROTECTION
STANDARD JDN TROLLEY AND CRANE RUNNING GEAR
FOR THE STANDARD VERSIONS
JDN trolleys and cranes can be used in zone 2 with
Standard version JDN air hoists are category 2 devices
standard running wheels (made of steel or cast metal)
(Guideline 94/9/EC, DIN EN 1127-12), for use in zone
with all dusts and the presence of gases up to explosion
1 and 2 for gases of explosion group IIA. (Also see IEC
group IIC. Due to the low running speeds, the possible
60079-123 and IEC 60079-204). These devices are also
friction velocities on the running wheels are less than
suitable for use in zone 2, in the presence of gases of
1 m/s, which means that standard running wheels can
explosion group IIB, provided that the substances
also be used in zone 1 up to explosion group IIB. The
hydrogen sulphide and ethylene oxide can be excluded
highest possible designation for these devices is:
and additionally in zones 21 and 22 for dusts with glow
II 2 GD IIB T4(X)/II 3 GD IIC T4(X). Depending
temperatures above 210° C or ignition temperatures
on the hoist version, it may have the designations
above 202° C, provided that no light metal or other
II 2 GD IIA T4(X)/II 3 GD IIB T4(X) or
impact-sensitive dusts are present.
II 2 GD IIB T4(X).
These devices are designated by:
II 2 GD IIA T4(X)/II 3 GD IIB T4(X) Additional JDN TROLLEY AND CRANE RUNNING GEAR
designation “X” see page 10. “WITH INCREASED SPARK PROTECTION”
JDN HOISTS For use in zone 1 in the presence of gases in explo-
“WITH INCREASED SPARK PROTECTION” sion group IIC, bronzed running wheels or running
wheels made of bronze are also used. The highest
JDN hoists of the version “with increased spark protec-
possible designation for this version (FSR) is
tion” (FS) satisfy additional explosion protection
II 2 GD IIC T4(X) (the same as for JDN hoists
requirements. With the exception of carbon disulphide
“with increased spark protection”).
(temperature class T6), they can be used in the pre-
sence of all gases in zones 1 and 2 and dusts with glow JDN TROLLEY AND CRANE RUNNING GEAR FOR USE IN THE
temperatures above 210° or ignition temperatures above PRESENCE OF TEMPERATURE CLASS T6 GASES OR DUSTS
202° in zones 21 and 22, and can be marked
As is the case with JDN hoists “with increased spark
II 2 GD IIC T4(X) for installation in a trolley,
protection”, temperature class T6 is also possible here
depending upon the trolley version (see below), but
in the case of a special investigation of applicability,
also with II 2 GD IIB T4(X). For further operating
permitting the highest possible designation for standard
conditions, see Instructions for safe operation (Notes
wheels II 2 GD IIB T6(X)/II 3 GD IIC T6(X)
D and E ).

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PRODUCT INFORMATION
and for bronzed or bronze wheels
II 2 GD IIC T6(X), i.e. each including the additional
designation “X” for special conditions.
GENERAL NOTE ON DESIGNATION
The highest possible respective designations for lifting
equipment and running gear are usually replaced by a
designation which corresponds to the normal assembly
of a compact complete device (trolley or crane system).
ADDITIONAL DESIGNATION “X”
This designation refers to explosion protection details
in the operation manual.
II 2 GD IIA T4(X)/II 3 GD IIB T4(X) or.
II 3 GD IIA T4(X):
This designation does not permit use in the presence of
the extremely flammable substances hydrogen sulphide
and ethylene oxide or in the presence of light metal or
other impact-sensitive dusts, or in the presence of dusts
with glow temperatures below 210° C or ignition tempe-
ratures below 202° C. The permissible ambient tempera-
ture range (Ta) extends from - 20° C to + 70° C.
II 2 GD IIC T4(X) or II 2 GD IIB T4(X):
The permissible ambient temperature range (Ta) extends
from - 20° C to + 70° C.
... II C T6(X):
This designation permits use in the presence of carbon
disulphide or other temperature class T6 substances
only under special conditions, which have been agreed
with the manufacturer and which are described in the
crane documentation and which stipulate the maximum
surface temperatures for the device.
USE IN MINING APPLICATIONS
Standard versions of JDN hoists, trolleys and crane
systems may generally also be used for underground
mining operations as well as for the associated surface
facilities, which are hazardous due to firedamp and/or
combustible dusts. Within this equipment group I they
belong to category M2. They constitute devices which
can be switched off in cases where an explosive
atmosphere forms. They are equipped with protective
measures offering a high degree of safety. The
protective measures with which products of this
category are equipped provide the necessary degree of
safety for normal operation as well as operation under
difficult conditions, in particular rough treatment and
changing environmental influences. For other difficult
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conditions in addition to explosion protection prevailing
with regard to the general handling of the devices in
mining applications, special mining hoists are available
from J. D. NEUHAUS. The maximum permissible
temperature of 150° C in accordance with EN 13463-15
for coal dust atmospheres is not reached. For mining
applications, the relevant designation for hoists, trolleys
and crane systems is I M2.
LOAD CHAIN
In order to guarantee the required degree of earthing,
rusty chains must no longer be used in zones 1 and 21.
This is due to the fact that, depending upon the degree
of corrosion, the leakage capability of the chain may be
impaired to a level that is no longer adequate.
COMPRESSED AIR HOSES
In zone 1, compressed air hoses must have a suffi-
ciently low surface resistance of less than 109 Ω in
order to prevent electrostatic ignition hazards.
Otherwise (resistance >109 Ω), for explosion groups
I, IIA and IIB ∅ ≤ the hoses must be 30 mm and for
explosion group IIC ∅ ≤ 20 mm, or proof must be pro-
vided that they cannot become dangerously charged.
MATERIALS FOR FRICTION AND IMPACT HAZARDS
Friction and impacts can give rise to individual sparks
presenting a danger of ignition in the presence of
explosion group IIC gases, hydrogen sulphide, ethylene
oxide, or light-metal or other impact-sensitive dusts.
Accordingly, spark formation caused by mechanical
influences must be prevented.
The chain and load must always be moved in such a
way that sliding and/or frictional contact with other
plants or components is excluded. If circumstances do
not permit this, it is necessary to ensure an absence
of explosive atmospheres during operation.
Impacts between particular materials result in an
increased ignition hazard. This does not apply to
corrosion-resistant steel or cast iron against alumi-
nium, magnesium or corresponding alloys.
This applies especially in the presence of rust or rust
film. Rust (also rust film) formation is possible,
especially on the chain and on the load hook, at the
friction points. The following holds true for all zones:
For the intended use of hoists it must be ensured, that
no rust is present at the above-mentioned friction
 PRODUCT INFORMATION

points and that material combinations of the above-
named light metals with steel (exception: stainless
steel) are not used in the working area of the hoists,
at potential friction, impact or sliding points. It is
thus possible to exclude sparking due to mechanical
influences with these material combinations.
The external housing of the service units is made of
aluminium. Therefore the installation position is to be
selected so as to ensure that there is no risk from
impact sparks.
ACETYLENE AND COPPER
When operating JDN products in explosion-hazardous
areas, in which an acetylene-containing atmosphere can
occur, it must be ensured that copper-plated parts are
kept dry in order to exclude the possibility of oxidation
of the metallic copper and the formation of an aqueous
phase, which is capable of reacting with acetylene and
which can result in an explosion hazard.

EARTHING
Electrostatic ignition hazards can be prevented by
means of safe earthing. In zones 1 and 21, earthing
of the hoists is required. This must be achieved via
the load hook or the load eyes if the lifting equipment
is connected to correspondingly earthed parts (earth
leakage resistance less than 106 Ω). This also applies to
operation with trolleys or cranes. Their tracks must be
earthed on site. Running wheels and rail surfaces must
never be painted, as this can result in unacceptably
high earth leakage resistance values.

Earthing of the load hook is via the chain (see also

Load chain, page 10).

Loads must be earthed during transportation.

A separate earth is required, for example, when using
non-conducting sling gear.

CLEANING PLASTIC SURFACES

Where JDN Air Hoists or JDN Air Winches feature plastic
parts, these surfaces must only be cleaned using a damp
cloth (cleaning cloth with water). This reduces electro-
static charging that can arise due to mechanical friction
at the plastic surface.

DANGER!
Electrostatic charging may occur at the
plastic surfaces, potentially leading to
electrostatic discharge that can ignite gases
and air mixtures.

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PRODUCT INFORMATION

EXPLOSION GROUPS AND TEMPERATURE CLASSES OF THE MOST IMPORTANT GASES AND VAPOURS (-SELECTION-)
(in accordance with DIN VDE 01656, Redeker7, Nabert, Schön8, IEC 60079-123 and IEC 60079-204)

Explosion Temperature class

protection T1 T2 T3 T4 T5 T6
group
Ignition temperature
> 450° C 450-300° C 300-200° C 200-135° C 135-100° C 100-85° C
Maximum permissible surface temperature of operating facilities
450° C 300° C 200° C 135° C 100° C 85° C
II A Acetone (ethyl alcohol) n-Amyl alcohol Acetaldehyde
Ammonia (ethylene glycol) Petrol
Aniline i-Amyl acetate (fuel)
Benzene n-Butane Diesel
Chlorbenzene n-Butyl alcohol Heating oil
1.2-Dichlorbenzene 1-Butylene n-Hexane
Acetic acid 1.2-Dichlorethane Jet fuels
Ethane Di-i-propyl ether
Ethyl acetate Natural gas
(ethyl bromide) Acetic anhydride
Ethyl chloride n-Propyl acetate
(carbon monoxide) (n-Propyl alcohol)
o-Cresol i-Propyl alcohol
Methane Vinyl chloride
Methyl acetate
Methyl alcohol*1
Methyl bromide
Methyl chloride
Methylene chloride
Naphthalene
(nitrobenzene)
Phenol
Propane
Toluene
o-Xylene
II B Hydrocyanic acid Butadiene-1.3 Dimethyl ether Ethyl ether
(ethyl bromide) Dioxane-1.4 **Hydrogen sulphide Ether
(carbon monoxide) Divinyl ether Anaesthetic ether
(nitrobenzene) (ethyl alcohol) Diethyl ether
Town gas Ethylene
(ethylene glycol)
**Ethylene oxide
Isoprene
(n-Propyl alcohol)

II C **Hydrogen **Acetylene **Carbon disulphide

( ): The measured values for the substances placed in brackets are close to the limit or the next group or class when
classified in the explosion groups or temperature classes. For this reason, they have been included in both.
**: Extremely flammable substances (cf. additional designation “X”)
*1 (Methanol = Methyl alcohol)

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 PRODUCT INFORMATION

DECISION CRITERIA FOR SELECTING THE CORRECT JDN HOIS T S

IN EXPLOSION-HAZARDOUS AREAS

Explosion groups for gases and vapours (cf. explosion group Zone Version*1 Operation*2
and temperature classes for the most important gases and vapours) Manufacturer responsibility Operator responsibility

II A 2 A E
1 A E
II B (X) except hydrogen sulphide, ethylene oxide 2 A E
(highly flammable) 1 A SP E
II B 2 A SP D E
1 A SP D E
II C / T4 2 A SP D E
1 A SP FSR D E
II C/ T6(X) 2 A SP D E T
1 A SP FSR D E T
Potentially explosive dusts Zone Version*1 Operation*2
22 A E
Usual industrial dusts
21 A E
22 A SP D E
Light metal or impact-sensitive dusts
21 A SP D E

*1: Version features (under the responsibility of the manufacturer):

A: The chain is made of zinc-plated steel; metal controls are conductively connected to the hoist. This is part of the
standard equipment. For technological reasons, a zinc-plated version of chain size 31.5 x 90 is not available. This
is only used for the extremely slow-running chain drives of large 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 and bottom flange with brass safety catch.
FSR: Running gear “with increased spark protection”:
Running wheels for trolleys and cranes are made of bronze.
*2: Instructions for safe operation (operator’s responsibility):
D : Ignition hazards are not to be expected if hoists or cranes are used in the normal manner. Friction and impacts in
the working area of the chain, not resulting from intended use of the hoist or crane and which result in sparking,
must be excluded, or an absence of gas in the operating area must be ensured. This means, for example, that the
chain, the bottom block and the load hook must be prevented from swinging against surrounding objects or that
a gas-free environment must be ensured.
E : Friction, impact and sliding points involving combinations of light metal and steel or cast iron must not be pre-
sent in the hoist’s operating area.
T : Ambient temperature and the type of operation must be examined separately.

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 PRODUCT INFORMATION

T E M P E R AT U R E L I M I T S The corresponding surface temperatures can be derived

FOR EXPLOSION-HAZARDOUS DUSTS from the lowest values for glow and ignition tempera-
In areas that are potentially explosive due to tures of dusts specified in the HVBG/BIA Report 12/9710
combustible dusts, the surface temperature must “Combustion and explosion characteristics of dusts”:
not exceed two-thirds of the ignition temperature
Synthetic rubber, soot-containing:
in ° C of the dust/air mixture. The temperatures of
Glow temperature 220° C – 75° C = 145° C max.
surfaces on which hazardous deposits of combustible
permissible surface
dusts can be formed, must not exceed the glow
temperature
temperature of the relevant dust minus 75°K.
Greater safety margins are required if the thickness Stearic acid:
of the dust layer exceeds 5 mm. Ignition temperature 190° C x 2/3 = 126° C max.
permissible surface
temperature

P L E A S E A L S O O B S E R V E YO U R
CO R R E S P O N D I N G N AT I O N A L
R E G U L AT I O N S .

1 Guideline 94/9/EC of the European Parliament and the Council dated 23 March 1994 on the adaptation of the
laws of the Member States concerning equipment and protective systems intended for use in potentially explosive
atmospheres
2 DIN EN 1127-1: Explosive atmospheres - Explosion prevention and protection - Part 1: Basic concepts and
methodology, 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 for flammable gases and vapours
relating to the use of electric apparatus, 1996-10.
5 EN 13463-1: Non-electrical devices intended for use in explosive areas - Part 1: Basic methodology and requirements,
07/2009
6 DIN VDE 0165: Installation of electrical systems in areas with explosion hazard, 1991
7 Redeker, Schön: 6. Supplement to safety-related characteristic values for flammable gases and vapours, 1990
8 Nabert, Schön: Safety-related characteristic values for flammable gases and vapours, 2nd edition, 1978
9 DIN EN 50014 (VDE 0170/0171 part 1): 2000-02 Electrical apparatus for use in explosion hazardous areas:
General provisions
10 HVBG/BIA report 12/97: Central association of German employer’s liability associations/trade association institute
for industrial safety

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 PRODUCT INFORMATION

INTENDED USE

JDN Air Hoists are designed for lifting and lowering

loads within the specified load-carrying capacities, with
a vertically-arranged chain. JDN Air Hoists from the
PROFI 1.5 TI and 3 TI/2 ranges are also suitable for
pulling loads horizontally. In exceptional circumstances,
the lifting of personnel-carrying equipment is also
permitted under certain conditions. Please also observe
the individual national regulations. In combination with
trolleys, JDN Air Hoists are also suitable for the floorless
horizontal movement of loads.

Any other use or use outside these stipulations is

deemed to be impermissible. Oblique pulling, see
Operation section, page 29. J.D. NEUHAUS GMBH &
CO.KG cannot be held liable for any resulting damage.
The entire risk is borne by the user (see also section
Rules for safe operation of hoists, page 30).

Intended use also includes observance of the operation

manuals and compliance with the inspection and
maintenance conditions.

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PRODUCT INFORMATION
EMISSIONS
The noise emission data can be found in the Technical
data table, pages 64.
The noise pressure level of the measurement area at a
distance of 1 m from the machine surface was measured
in accordance with DIN 45 635, Part 20, at the
operating air pressure specified by us. In the hall, the
noise pressure level drops by approx. 3 dB (A) every
time the distance is doubled.
If the device is operated with motor oil lubrication,
small amounts of lubrication oil will be released into
the environment with the outlet air.
Oil emissions can be prevented by using a filter silencer
(see Filter silencer section, page 62). This also results
in a reduction of the noise emission values.
O P E R AT I N G CO N D I T I O N S
JDN Air Hoists are extremely robust and require little
maintenance. They are suitable for use in explosion-
hazardous areas, as well as in areas with increased
concentrations of soot and dust, high humidity and at
ambient temperatures from – 20° C to approx. + 70° C
if they are not heated above this level due to external
influences. The thermal endurance of chains and hooks
is + 150° C.
C AU T I O N !
When touching metallic hand controls which
are colder than 0° C, skin could freeze within
a few seconds, and at temperatures above
43° C, burns may occur. As a protective
measure, please wear suitable gloves.
For stationary outdoor operation, hoists must be
protected against weathering and the maintenance
intervals must be shortened.
Depending upon the version, JDN Air Hoists must be
operated at a system pressure of at least 4 bar (see
information on the nameplate). If the system pressure
is too low, important functions of the hoist will be
impaired:
Page 16
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 The brake will drag and is thus subject to a high
degree of wear. An impermissibly high degree of
warming could take place.
 The controls become noticeably less sensitive.
DA N G E R !
Warning against excessive system
pressures Operating with excessive system
pressures results in danger due to over-
loading. Therefore, the pressure must be
limited to that specified on the nameplate.
JDN Air Hoists must be operated with a sufficiently
clean and dry air supply. The air supply must fulfil the
following quality requirements:
 Particle size less than 40 µm
 Particle density less than 10 mg/m3
(corresponds to Class 7 in accordance with ISO 8573-1: 2001)
In order to provide adequate compressed air quality,
operation with a service unit is recommended. Usually,
an oiler is not required in the service unit, as the motor
is provided with internal permanent lubrication.
 Pressure dew point at least 10° C below the lowest
expected ambient temperature
Do not operate JDN Air Hoists with other gases.
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 anti-icing agent to the lubrication oil
(depending upon moisture content of compressed
air),
 or using compressed air oil (Part No. 11900) with
anti-icing agent for relevant temperatures.
In case your JDN Air Hoist is operated in combination
with a trolley, please read also the trolley operation
manual and the relevant accident-prevention regulations
for operation with trolleys.

E N E RG Y R E Q U I R E M E N T S
For air pressure, air quantity and connections, see the
Technical data table in the hoist operation manual
concerned.
A I R P R E S S U R E CO N D I T I O N S I N O P E R AT I O N
The system pressure in the air line must correspond
to the nominal pressure. Higher pressures must be
reduced.
After switching on, the nominal pressure p1 drops to
the actual pressure p2.
The value of the actual pressure depends upon …
… and the direction of movement of the load.
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PRODUCT INFORMATION
The value of the actual pressure p2 at which the hoist
is operated, depends upon
 the weight of the load and
 the direction of movement of the load.
When lifting the nominal load (load-carrying capacity),
the actual pressure p2 must not fall below a value of
10% below the specified nominal pressure of the hoist.
Example:
A hoist with a nominal pressure of 6 bar lifts its
nominal load at the specified lifting speed, at an actual
pressure of 5.4 bar.
… the weight of the load …
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PRODUCT INFORMATION

P R I NC I P L E O F O P E R AT I O N O F
4.2 1 6 4.1 2 5
J D N A I R VA N E M O T O R S

The vane motor consists of a cylinder liner 1 with two

side bearing plates and an internal rotor 2.

The rotor is mounted eccentrically in the cylinder

liner and is provided with slots 3 for installation of the
vanes 4.

The vanes can move freely and make contact with the
inner wall 5 of the cylinder liner. Each chamber 6 is
formed 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 the rotor torque.

As the chamber passes the outlet aperture 7, the

compressed air can escape.

Lubricant chambers 8 are provided between the vane

slots of the rotor. They ensure continual motor
lubrication. 3 4 7

The arrows in the illustration indicate the direction of

rotation of the rotor and the corresponding path of the
compressed air.

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 PRODUCT INFORMATION

O P E R AT I O N W I T H O U T C H A I N B OX S PA R E PA R T S

DA N G E R ! Only use original JDN spare parts. J.D. NEUHAUS

If JDN Air Hoists are operated without a GMBH & CO. KG accepts no liability for the use of
chain box it must be ensured that the idle non-original components and/or modifications by
chain (unloaded chain end) running up unauthorised persons.
or down at the chain sprocket, does not
present a hazard, e.g. due to catching,
impacting or falling.

Danger due to falling chain can also arise,

if the idle chain is first deposited on a load
with a large surface and then slides off and
drops.

M O T O R L U B R I C AT I O N / O P E R AT I O N
WITH A SERVICE UNIT

JDN air hoists are provided with motor lubrication,

which must be renewed when required, but every
5 years at the latest.
Therefore, the service unit for filtration and pressure-
regulation 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. Alcohols
are not permitted for use as anti-icing agents.

AT T E N T I O N !
During operation with oil, the grease
chambers for motor lubrication are
emptied more quickly.

M A R K I N G / D E C L A R AT I O N O F
I NCO R P O R AT I O N

Only hoists for which EC conformity in accordance with

EC Machinery Directive 2006/42/EC has been declared
may be operated within the EU.

In the case of a designation, only the EC conformity

declaration provides information on which EC directive
has been met.

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TR ANSPOR T AND S TOR AGE

TR ANSPOR T AND S TOR AGE

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

If you wish to transport your JDN Air Hoist to another

site, please observe the following points:

 Carefully dismount trolley (if fitted).

 Set the entire hoist down carefully; do not allow it
to drop. For weights see Technical data, page 64.
 Lay control and supply hoses together in such a way
that they are not kinked.
 Please ensure that the controls are not damaged.
Risk of malfunction.
 Draw in the hoist’s chain in such a way that loops
cannot form and the chain cannot become twisted.
 Secure the chain.

S T O R AG E CO N D I T I O N S

B R E A K S I N O P E R AT I O N
 In the case of longer operational breaks, coat the
chain and hook with a light oil film.
 Motor conservation

If the motor lubrication is not renewed after the

specified intervals, the motor must be conserved.
For this purpose, use a non-resinous and non-sticky
conserving oil with conserving protection duration,
which corresponds to the length of the planned
operational break.

S T O R AG E
 Close off the air supply hose connection using
adhesive tape or a suitable cap in order to prevent
dirt ingress.
 Protect connection for the air supply hose against
damage.
 Store your JDN Air Hoist in a clean and dry place.

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 INITIAL OPER ATION

INITIAL OPER ATION

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

C AU T I O N ! Mounting the trolley, see trolley operation manual.

When unpacking, take account of the weight
of the hoist. See Technical data, page 64. DA N G E R !
JDN Air Hoists must only be installed by
AT T E N T I O N ! qualified personnel. Faulty installation can
Do not bend the control lines. Kinked control lead to serious accidents.
lines can result in malfunctions.
DA N G E R !
 Keep the accompanying documents in the place The attachment points for JDN Air Hoists
provided, near the operating site. must be able to safely withstand the
 Lift the hoist carefully out of the packaging. expected forces. Ensure that your JDN Air
 Dispose of packaging in the local recycling system. Hoist is capable of alignment under load,
otherwise inadmissible additional stresses
may occur.
A S S E M B LY
DA N G E R !
The supporting structure of the air hoist
JDN Air Hoists are usually delivered pre-assembled. must form a rigid mounting. Vibration
damages the chain and can lead to chain
If not, first read the following sections:
fracture. Furthermore, external vibration
 Connecting the controls, page 22 must on no account be transmitted to
 Removing and installing chain, page 58 the hoist (lifting gear). (e.g. from the
 Chain box, page 63 suspended load).

In the event that the chain is included unattached, a  Provide a suitable working platform.
short auxiliary chain is drawn into the hoist. In order  Attach the hoist at the suspension hook (or suspen-
to draw in the chain, the hoist must be connected to sion eye) to running gear or stationary fixing.
the main air supply and must be ready for operation.  Ensure that the hook safety catch closes
automatically.
P R I O R T O I N I T I A L O P E R AT I O N , T H E
C H A I N M U S T B E L U B R I C AT E D ( S E E
S E C T I O N L U B R I C AT I N G T H E C H A I N ,
PAG E 4 5 ) .

Attach the hoist securely at the suspension hook or

suspension eye.

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INITIAL OPER ATION

CO N N E C T I N G T H E CO N T RO L S

CO N N E C T I N G T H E RO P E CO N T RO L
 Knot both control ropes at the ends of the
control lever.
 Knot the green pin into the rope which activates
“lift” mode, with the pointed end upwards (see
also illustration Rope control, page 22).
 Knot the yellow pin into the rope which activates
“lower” mode, with the pointed end upwards.
 Knot the handle into the rope so that the arrow
markings correspond to the actual direction of
movement.

Rope control, motor side

CO N N E C T I N G T H E E - CO N T RO L S
Pushbutton valve (hand control)
 Guide the strain-relief cable through the eye on the
pushbutton valve and secure using the cable clamp.
 Push the one-ear clamps onto the hose ends.
 Attach the hoses to the hose nipples.
 The one-ear hose clamp must lie in the middle of
the hose nipple clamping range. The best clamping
characteristics are achieved in this range.

Pushbutton valve with nipple and rope with

designation lift and lower

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 INITIAL OPER ATION

 Secure the hoses using the one-ear hose clamps and  The bellows must be pulled over the other end of the
crimping tool. hose bundle including the strain-relief cable (coat
hose bundle with oil for ease of fitting). Pull the
AT T E N T I O N ! bellows back far enough to permit further installa-
To ensure perfect sealing, the “ear” must be tion. Push the one-ear clamps onto the free ends of
fully closed on installation. the hoses.

Installation example
Position the clamp on the hose with nipple.
Crimp the clamp ear until fully closed.

Permissible aperture after

crimping

Use of the normal

crimping tool...

Pinched one-ear clamp and crimping tool

...in order to remove the

clamp, set the crimping tool
transversely to the clamp ear Illustration of bellows with hoses and strain-relief rope
and cut the ear open...

Removal

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INITIAL OPER ATION

Control valve (on motor)

Note: In order to connect the hoses to the control
valve, we recommend removal of the hose adapter. Dowel pin
 Remove the hose adapter (secured via central bolt).
 Attach the hoses to the corresponding nipples (see
designation in illustration)
 Secure the hoses using the one-ear hose clamps and
crimping tool.
 Secure the strain-relief cable.

Lift
AT T E N T I O N !
The strain-relief rope must be installed with Lower
the correct length in order to prevent loading
of the hoses.

 Pull the bellows over the hose adapter. The upper Compressed-air
collar of the bellows fits into the recess of the hose connection
adapter.
 In order to secure the hose adapter to the control
valve, a long A/F 6 socket spanner must be guided
between the three hoses, through the middle of Hose adapter with nipples designation lift, lower
the bellows and inserted into the hexagon socket
of the bolt.

CO N N E C T I N G F - CO N T RO L S
Pull the bellows over the hose bundle for F-control.
For F-control for lifting and lowering only, remove
approx. 80 mm of hose bundle protective sheathing;
for F-controls with additional functions (trolley/crane
movement) remove approx. 160 mm from end of
protective sheathing.

Pull the strain-relief cables through the eye bolt and

secure using cable clamps.

Insert the control hoses: See illustration above

Compressed air with hose designation 1 or colour: white

Direction of movement “lift”

with hose designation 2 or colour: green

Direction of movement “lower”

with hose designation 3 or colour: red

Bellows with A/F 6 socket spanner

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The control hoses for the drive motors (trolley/crane
movement) must be extended, outside of the bellows,
by means of plug-in connectors and additional control
hoses.
Connection see “Trolley” operation manual.
AT T E N T I O N !
The control hoses must not be subject to
tensile load; adjust the strain-relief cables
accordingly.
Pull the bellows over the hose adapter and secure via the
central bolt (see illustration on page 24, bottom).
CO N N E C T I N G F I - CO N T RO L S
Pull the bellows over the hose bundle for F-control.
Remove approx. 80 mm of hose bundle protective
sheathing.
With this type of control, strain-relief of the hand
controls takes place via the protective sleeve of the hose
bundle. For this purpose, the protective sleeve is pushed
onto the hose carrier and is secured using a one-ear
clamp.
Installation facilitation: Heat the protective sleeve
(hose sheathing) with a hot-air gun and grease the
hose carrier.
Slightly bend open the ring of the eye bolt in order to
attach the hose carrier.
Close the ring again to prevent detaching.
Insert the control hoses:
See illustration on page 24, top.
Compressed air
with hose designation 1 or colour: white
Direction of movement “lift”
with hose designation 2 or colour: green
Direction of movement “lower”
with hose designation 3 or colour: red
AT T E N T I O N !
The control hoses must not be subject to
tensile load; adjust the protective sleeve
accordingly.
Pull the bellows over the hose adapter and secure via
the central bolt (see illustration on page 24, bottom).
powered by air!
INITIAL OPER ATION
R E P L AC I N G CO N T RO L S
Conversion to another type of control is a significant
modification to a hoist. Following conversion, national
safety regulations, including testing regulations, must
be observed. If you wish to exchange air controls E,
F or FI, proceed as follows (see illustrations in Connec-
ting the controls section)
CO N V E R S I O N F RO M E T O F
Control valve housing (on motor)
Removal of E-controls
Remove the hose adapter (secured by central bolt).
For removal of the hose adapter, a long A/F 6 socket
spanner must be guided through the middle of the
bellows and inserted into the hexagon socket of the
bolt (illustration on page 24, bottom).
Pull the bellows back over the hose until the hose
nipples with the one-ear clamps are exposed and
further removal is possible.
Detach the strain-relief rope and remove the one-ear
clamps (see Removal illustration, page 23).
Cut off the hoses below the hose nipples using a knife.
Unscrew the hose nipples (A/F 17).
Pull the bellows over the hoses of the E-controls. This is
also required for the F-controls.
Installation of F-controls
Pull the bellows over the hose bundle for F-control.
Remove approx. 80 mm of the hose bundle protective
sheathing or 160 mm for additional movements.
Screw the “straight screw connections” (Steck-fix) for 4
mm hoses into the hose adapter (A/F 16).
Pull the strain-relief cables through the eye bolt and
secure using cable clamps.
Insert the control hoses:
See illustration on page 24, top.
Compressed air
with hose designation 1 or colour: white
Direction of movement “lift”
with hose designation 2 or colour: green
Page 25
INITIAL OPER ATION

Direction of movement “lower” AT T E N T I O N !

with hose designation 3 or colour: red
AT T E N T I O N !
The control hoses must not be subject to
tensile load; adjust the strain-relief cables
accordingly.
The control hoses must not be subject to
tensile load; adjust the protective sleeve
accordingly.
Pull the bellows over the hose adapter and secure via
the central bolt (see illustration on page 24, bottom).

Pull the bellows over the hose adapter and secure via
the central bolt, (see page 24, bottom).
CO N V E R S I O N F RO M E T O F I
Removal of E-controls as previously described (page 25).
Installation of FI-controls
Pull the bellows over the hose bundle for FI-control.
Remove approx. 80 mm of hose bundle protective
sheathing.
Conversion from rope control to air control:
Remove the rope control lever by removing the
M6 x 12 bolt from the control shaft.
The connecting surface of the hose adapter on the
valve housing is closed off by means of a disc with an
M8 x 16 countersunk screw. Following removal of the
countersunk screw and of the disc and dowel pin
(5 x 12 dowel pin), the hose adapter of air control can
be installed as described in the previous section.

Screw the “straight screw connections” (Steck-fix)

for 4 mm hoses into the hose adapter (A/F 16).

With this type of control, strain-relief of the hand

controls takes place via the protective sleeve of the
hose bundle. For this purpose, the protective sleeve
is pushed onto the hose carrier and is secured using
a one-ear clamp.

Installation facilitation: Heat the protective sleeve

(hose sheathing) with a hot-air gun and grease the
hose carrier.

Slightly bend open the ring of the eye bolt in order to

attach the hose carrier.
Close the ring again to prevent detaching.

Insert the control hoses:

See illustration on page 24, top.

Compressed air
with hose designation 1 or colour: white

Direction of movement “lift”

with hose designation 2 or colour: green

Direction of movement “lower”

with hose designation 3 or colour: red

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 INITIAL OPER ATION

CONVERSION FROM AIR CONTROL TO ROPE CONTROL

CO N N E C T I N G T O T H E M A I N A I R S U P P LY
Air controls can only be installed on rope controls that
feature a control shaft.
 Check air connection for contamination and clean
if necessary.
Removal of air controls
 Blow through compressed air hose in order to remove
Remove the hose adapter (secured by central bolt).
foreign bodies.
For removal of the hose adapter, a long A/F 6 socket
 Attach the compressed air hose to the connection
spanner must be guided through the middle of the
on the hoist or on the service unit. Tighten the
bellows (illustration on page 27).
union nut.
Installation of rope controls
The connecting surface of the hose adapter on the valve
housing is closed off by means of a disc and is secured
with the M8 x 16 countersunk screw. The dowel pin
(roll pin) must be inserted in the bore provided.

Push the rope control lever onto the control lever and
secure with the M6 x 12 bolt and washer. It must be
ensured that the both ends of the control lever point
downwards (in the direction of the load hook and not
in the direction of the motor). Guide the control ropes
from the side facing the valve through the bores in the
control lever and knot them. Rope colour: “green” lift,
“red” lower. Further, see section Connecting the rope
control.

Attach the compressed air hose and tighten

the union nut.

Installation of rope controls

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INITIAL OPER ATION

LUBRIC ANTS Application Lubricant

Motorlubrication - JDN high-performance grease
The following lubricants are intended for normal - at factory Part No. 11901 (250 ml)
environmental influences. If the trolley is operated - for operation with oiler - Air motor oil type “D”,
kinematic viscosity
under adverse conditions that induce increased wear, approx. 30 mm2/s (cSt)
consult J.D. NEUHAUS, for further information. at 40° C, anti-icing
additive if required
C AU T I O N ! Chain lubrication Chain oil or motor vehicle
Oil and grease can cause skin irritation. engine oil, kinematic viscosi
Wear protective gloves at all times. ty approx. 150 mm2/s (cSt)
at 40° C, or special lubricant
from J.D. NEUHAUS
AT T E N T I O N !
In areas with very high
Potential damage! Do not mix synthetic oils corrosion potential, e.g. off-
or greases with mineral oils, as the properties shore, a lubricant with
may be impaired. especially high-performance
anti-corrosion properties must
Also, never mix different types of lubricating be used.
grease within the synthetic or mineral Motor conservation (not Non-resinous protective
lubricant groups. applicable when using JDN oil rated for the durati
high-performance grease) on of the storage period
Synthetic lubricants must not be used when Motor cleaning (not appli- Pure petroleum
operating with oilers. Alcohols are not cable when using JDN high-
permitted for use as anti-icing agents. performance grease)
Lubrication of bearings Saponified lithium grease,
and gearboxes (also for felting penetration 265-295
exposed gears) (0.1 mm), ground oil viscosi
ty: 190 cSt (mm2/s) at 40° C,
dripping point: 180° C,
operating temperatures:
– 20° C to + 120° C,
designation in accordance
with DIN 51825: KP2K-20,
active agents: EP additives
(for wear-reduction) and
ageing protection; water
resistant and corrosion
protection

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 INITIAL OPER ATION

INSPECTION BEFORE INITIAL OPER ATION

Hoists, including the supporting structure, must be

inspected by an appropriately trained and qualified
person before initial operation and before re-
commissioning after significant modifications. Hoists
and lifting gear which are installed in trolleys must be
inspected by a specialist.

The inspection covers the proper mounting, equipment

level and operational-readiness etc., in the main, the
completeness, suitability and effectiveness of the safety
devices as well as the condition of the device, the
harness, the equipment and the supporting structure.

Safety devices are braking devices, overload protection

devices, EMERGENCY STOP devices, lifting and lowering
limiters (emergency end-stop devices).

A description of the inspections can be found in the

Maintenance section, page 39.

Page 29
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OPER ATION

OPER ATION

RULES FOR SAFE

O P E R AT I O N O F H O I S T S

As a hoist operator, you are responsible for your

own safety and that of your colleagues in the
working area of the hoist.

 Hoists may only be operated by persons charged

with this task by their company.
 Before using the JDN Air Hoist for the first time,
familiarise yourself with all permissible operating
conditions. For this purpose, read through this
operation manual thoroughly and carry out the
described actions on the hoist, step by step.
 Report each malfunction to your safety officer
immediately, so that the fault can be remedied
without delay.
 Adhere to the regulations of the accident prevention
authorities (e.g. trade association regulations in
Germany). Oblique pulling
 Read the section Intended use, page 15. Under special safety provisions relevant to the particu-
lar situation, JDN Air Hoists may be used for oblique
The following situations, among others, are regarded pulling (see Intended use, page 15). In this case, a
as improper use: chain box must not be used, as the chain may fall out
 Changing load-carrying capacity depending on load or become knotted. Oblique pulling is not permitted for
position: JDN Air Hoists are not equipped with load- hoists installed in trolleys or in running gears. Please
carrying capacity indicators, they may therefore only contact us, if required.
be used in those applications in which the load-  Breaking loads free or dragging loads.
carrying capacity does not change with the position  Loading of the hook at the tip.
of the load.  Catching falling loads.
 Oblique pulling of loads in general.  Carrying persons (see Intended use, page 15).
Definition of oblique pulling  Jog control with load on the hook.
 Switching to the opposite direction with the load
Oblique pulling is the deviation of the load chain and
in motion.
the chain hoist from the vertical position, for a force
 Reaching lifting and lowering limiters as part of
acting in a straight line between the force’s point of
normal operation.
application of the load on the load hook and the
 Never hold the centre section of the chain under
suspension on the supporting structure.
tension when the load hook is in the upper or lower
limit position.

Page 30

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JDN Air Hoists must not be used for the following
applications, for example:
 Critical areas of nuclear plants.
 Over acid baths or other plants with corrosive
substances.
 In areas in which organic acids are present.
To ensure the safety of personnel and property
when using JDN Air Hoists, it is essential that the
following points are observed:
 Lift the load carefully at first.
 Never touch a running chain.
 Never use the hoist chain for attaching loads.
 Never allow loads to fall into the hoist chain.
 If the chain is slack, do not take up the load at
maximum speed.
 Only use original JDN chain boxes.
 Do not exceed the permitted filling capacity of the
chain box.
 When operating without a chain box, avoid hazards
due to idle chain (falling, catching, impacting), see
section Operation without chain box, page 19.
 Never apply bending loads to chains.
 Do not join or repair chains.
 Do not operate with a chain which is drawn tight,
bent or extended.
 Check jammed chains for damage.
 Straighten twisted chains (defective bottom block)
 Do not operate with damaged, worn or rusty chains.
 Permitted operating temperature for chain and hook:
- 20° C to + 150° C, permissible ambient temperature:
- 20° C to + 70° C, permitted heat absorption of hoist
body: max. 90° C.
 Never allow persons to enter the area below the
suspended load.
 Never attempt to remedy a fault with a load
suspended from the hoist.
 Only use suitable and approved sling gear; do not jam
the hook at the point of attachment.
 Ensure that the operator is not put at risk within the
operating area by attaching aids or the load.
 Follow the relevant instructions for attaching loads.
 Before attaching, accurately position the load
vertically below the hoist. The chain must hang
vertically before lifting.
 Ensure that the hook safety catch is closed.
 Repair damaged hook safety catches.
powered by air!
OPER ATION
 Before lifting loads, ensure that the maximum
permitted load is not exceeded. Sling gear must be
included in the weight of the load.
 When taking up and setting down, ensure stable
positioning of the load, to prevent accidents due to
tilting or falling loads.
 Never force jammed loads.
 Only lift one load at a time, never several loads
simultaneously.
 Never lock the control elements of control devices.
 If the control elements become difficult to operate,
have the hoist repaired.
 In the case of power failure, secure the load and the
surrounding area until the power is restored.
 Never use or repair bent, open or deformed load
hooks. The hoist must be expertly repaired and the
hook replaced.
 Never anneal the hook.
 Only operate JDN Air Hoists with original JDN
controls.
 Uncontrolled, external force factors (e.g. due to
hydraulic cylinders, falling loads) are not permitted.
 Repair stiff hook bearings.
 Do not kink or pinch control hoses.
 Have loosened bolted connections tightened by the
Repairs department.
 Before removing compressed air hoses, shut off the
main air supply.
 If the braking distance is excessive, repair the hoist.
 If a load is lifted using several air hoists, prevent
overloading due to incorrect weight distribution.
 Select a safe operating location.
 Ensure the correct system pressure.
 Never touch metallic hand controls which are colder
than 0° C or hotter than 43° C, without suitable
protective gloves.
 Do not make modifications to the hoist.
 Only use original JDN spare parts. J.D. NEUHAUS
GMBH & CO. KG accepts no liability for the use of
non-original components and/or modifications.
 If, in the case of multi-chain hoists, the bottom block
is lying on the floor, move it back to a hanging
position in a controlled manner (evenly-loaded
chains).
 Special safety precautions must be taken when loads
are being hoisted into areas that are out of sight.
Page 31
BETRIEB

DA N G E R ! Furthermore, it is essential that all the regulations set

For all air hoist applications, ensure that the out in sections Intended use, page 15 and Operating
load hook can be lowered all the way to the conditions, page 16 are observed.
ground, in order to prevent a load being
moved to the lower limit position, without
reaching the ground. Danger due to
overloading

DA N G E R !
Never use hoists lying on the ground if they
are not specifically intended for horizontal
pulling.

DA N G E R !
The fatigue strength of chains is significantly
impaired due to extreme corrosion (pitting
corrosion). Risk of fracture. Hydrogen-
induced embrittlement with resultant stress
cracks due to highly corrosive media (e.g. sea
water) may affect high-strength steels (e.g.
chains). Risk 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 for operational
reasons, crack inspections are to be carried
out at intervals of three months.

Company operating instructions

Where hoists are to be employed under particularly
difficult conditions, the company must provide
operating instructions in easily comprehensible form, in
the language of the operator, based on the instructions
in this manual. Here, measures for safe operation are
stipulated in accordance with prevailing operating
conditions.

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 OPER ATION

E CO N T RO L
CO N T RO L S
With E-control, lifting and lowering movements can be
controlled via two pushbuttons. The direction of
JDN Air Hoists can be equipped with a variety of
movement of the load hook is marked on the upper side
control devices. They are all suitable for use in
of the valve housing, above the pushbuttons.
explosion-hazardous areas.
 Lift: Press the right pushbutton.
All control switches return to the zero position when  Lower: Press the left pushbutton.
released.

CO N T RO L VA LV E O N M O T O R
Air control (E, F, FI controls) with upstream main-
stream valve

The control valve consists of:

1. Main-stream valve
2. Direction control valve as slider with sleeve

The main-stream valve lies upstream from the direction

control valve. If no control pressure is present, the
valve is closed and the direction control valve is
depressurised. If control pressure is applied from the
hand control, the valve opens and releases the main
stream.

If the red EMERGENCY STOP button on the hand control

is pressed, all control lines are depressurised and the
main-stream valve is closed. E-control with EMERGENCY STOP button

Air control (E, F, FI controls) without upstream

main-stream valve

The control valve consists of:

Direction control valve as slider with sleeve

Rope control
valve without upstream main-stream

The control valve consists of:

1. Direction control valve as slider with sleeve
2. Positioner

The direction control valve positioner (sleeve with

slider) is connected directly to the control lever via the
control shaft.

Page 33
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OPER ATION

P U S H B U T T O N F - CO N T RO L
With pushbutton F-control, lifting and lowering
movements can be controlled via two pushbuttons. The
direction of movement of the load hook is marked by
arrows next to the pushbuttons.

 Lift: Press the upper pushbutton.

 Lower: Press the lower pushbutton.

F-control with EMERGENCY STOP button

P U S H B U T T O N F I - CO N T RO L
With pushbutton FI-control, lifting and lowering
movements can be controlled via two pushbuttons
arranged side by side. The control pressure is infinitely
variable, enabling precise positioning of the load. The
direction of movement of the load hook is marked by
arrows on the pushbuttons.

 Lift: Carefully press the right pushbutton. The load is

lifted slowly.
 Press the pushbutton further down, in order to
increase the lifting speed.
 Release the pushbutton slightly in order to reduce
the lifting speed. EMERGENCY STOP
 Lower: Carefully press the left pushbutton. The load button
is lowered slowly.
 Press the pushbutton further down in order to
increase the lowering speed.
 Release the pushbutton slightly in order to reduce
the lowering speed. FI-control with EMERGENCY STOP button

Page 34

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 OPER ATION

 Lowering: Carefully pull on the red rope with the

E M E RG E NC Y S T O P D E V I C E
yellow handle pin. The load is lowered slowly.
 Pull harder on the rope, in order to increase the
Within the EU, these controls are equipped with an
lowering speed.
EMERGENCY STOP device (optional outside the EU).  Release the rope slightly, in order to reduce the
In order to avert danger produced by the lifting lowering speed.
movement as quickly as possible, release the
pushbuttons - the movement of the load is then
interrupted immediately.

Only press the red EMERGENCY STOP button firmly if

this Stop function fails. The EMERGENCY STOP button
engages. This results in the closing of a separate check
valve and the load hook comes to rest instantaneously.
The pushbuttons for lifting and lowering now no longer
function.

The EMERGENCY STOP button can be released again by

turning clockwise. It jumps back into place.

DA N G E R !
Never release the EMERGENCY STOP button
before the danger has been eliminated and
the stop function via the pushbuttons has
been restored. Rope control
RO P E CO N T RO L
With rope control, the lifting and lowering movements
are controlled directly. Both rope ends are connected to
one another via a handle, enabling precise one-hand
operation. The direction of movement is marked by
arrows on the handle.

The control elements for rope control and the energy-

switching component of the control valve on the motor
(reversing valve) are positively connected to one
another. This connection is designed in such a way
that, in an emergency, the control valve can be reset to
a stable neutral position. Thus, no additional
EMERGENCY STOP device is required.

 Lift: Carefully pull on the green rope with the green

handle pin. The load is lifted slowly.
 Pull harder on the rope, in order to increase the
lifting speed.
 Release the rope slightly in order to reduce the
lowering speed.

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BETRIEB
OV E R L OA D P RO T E C T I O N
The overload protection limits the operating pressure of
the compressed air supplied. It responds as a function
of load and is set to a limit value of approx. 125 % of
the nominal load. The force limiting factor then has a
value of 1.25.
When the overload protection is activated, the lifting
movement is possible again once the lowering
movement has been switched (unloading the hoist).
The overload protection may also respond when moving
at full unloaded speed against a load to be lifted, even
when it is below the load size set. We therefore re-
commend tensioning the slack chain before lifting the
load.
Page 36
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AT TAC H I N G T H E L OA D
DA N G E R !
Only use attaching cables or attaching chains
which are suitable for the load. Attaching
must not be attempted by winding with the
lifting chain around the load.
In Germany, the trade association regulations
“Operation of load carrying devices used with lifting
equipment” (BGR 258) must be adhered to. In other
countries, the relevant local regulations must be
observed.
 Attaching aids must be attached at the lowest point
of the hook. Never load the tip of the hook.
 Ensure that the hook safety catch is closed.
Attach the load safely
 OPER ATION

L I F T I N G T H E L OA D D E TAC H I N G T H E L OA D

AT T E N T I O N !
JDN Air Hoists must be capable of alignment
under load. Otherwise impermissible additio-
nal forces can occur, which can damage the
hoist components.
 Lower the load hook far enough, so that the load can
be easily detached.
 Move the load hook out of the lifting area, in order
to avoid hazardous situations.

 First, lift the load hook, in order to pull the slack

chain tight. With the chain tight, briefly interrupt
the lifting procedure. The hoist can align itself and
the material is protected.
 Then lift the load.
I N T E R R U P T I N G WO R K I N G
If you wish to interrupt working with your JDN Air
Hoist:

 Set down and detach the load.

The overload protection system aborts the lifting
 Move the load hook out of the lifting area, in order
operation in the event of loads whose weight is more
than the pre-defined limit value for the overload to avoid hazardous situations.
protection (see Overload protection section,
page 59).

L OW E R I N G T H E L OA D

DA N G E R !
Ensure that there are no persons below
the load.

 Then lower the load and ground it carefully.

DA N G E R !
For all air hoist applications, ensure that
the load hook can be lowered all the way
to the ground, in order to prevent a load
being moved to the lower limit position
without reaching the ground. Danger due
to overloading!

Page 37
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TAKING OUT OF OPER ATION

TAKING OUT OF OPER ATION

S H U T T I N G D OW N DISPOSAL

If the hoist is to be taken out of operation for a longer JDN Hoists contain a range of materials which, on
period of time it must be protected against corrosion expiry of the service life, must be disposed of or
and dirt. recycled where appropriate, in accordance with
statutory regulations.
 Coat the chain and hook with a light oil film.
 Move the load hook out of the lifting area, in order Please note the following list of materials used:
to avoid hazardous situations.
 Do not move against the lifting and lowering HOIST
limiters/buffers (emergency end stop devices).  Ferrous materials
 Depressurise the air line. Steel
Nodular cast iron
 Non-ferrous metals
S T O R AG E Bronze
Aluminium
(see section Storage conditions, page 20)  Plastics
Polyethylene
Polyurethane
DISMANTLING Polyoxymethylene
Polyvinyl chloride
DA N G E R O F I N J U R Y ! Polyamide, glass-fibre reinforced
JDN Air Hoists must only be dismantled by Natural rubber
qualified personnel. Epoxy resin
Polyacetal
 Depressurise the air line. Polypropylene
 Provide a suitable working platform. Phenol resin
 Loosen the union nut and remove the air hose. Thermoset moulding compound (asbestos-free brake
 Protect the air connection against the dirt ingress. lining)
 Detach the control hoses from the hoist. Do not kink Polyester
the control hoses. Synthetic rubber
 Mark the connections. Wool felt
 Detach the strain-relief and hose carrier and remove
the control device. F I LT E R S I L E NC E R / S E R V I C E U N I T:
 Carefully detach/dismount the hoist and remove. Zinc diecast
 For trolleys, proceed in reverse order to that described Brass
in the section on mounting trolleys (in the trolley Nitrile rubber
operation manual). Aluminium
Polypropylene
Polyurethane
Glass-fibre reinforced plastic
Steel
Polyacetal
Polyethylene

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MAINTENANCE
M A I N T E N A NC E A N D
I N S P E C T I O N I N T E R VA L S
JDN Air Hoists are extremely robust and require little
maintenance. Compliance with maintenance and
inspection intervals is of great importance in order
that the hoist operates safely and reliably over a
period of many years.
C AU T I O N !
Maintenance work on JDN Air Hoists must
only be performed by trained and qualified
personnel.
CLEANING AND C ARE
If your JDN Air Hoist is often used at different
locations, particularly in dirty and damp environments,
 clean any dirt off the hoist and the chain,
 seal off the air supply connections,
 protect the hoist and, in particular, the chain
from corrosion,
 store the hoist in a clean and dry place.
S PA R E PA R T S
If, during repair work, the replacement of components
is necessary, only original JDN spare parts may be
installed.
LUBRIC ANTS
(see section Lubricants, page 28)
powered by air!
MAINTENANCE
I N S P E C T I O N A N D R E PA I R S
Series lifting equipment is classified into groups and
dimensioned according to the type of operation (Driving
mechanism classification according to ISO/FEM). The
average daily operating time and the load spectrum
determine the classification. This is assuming that the
lifting and lowering paths are approximately the same.
For devices used mainly in vertical operation (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
operating time must be multiplied by a factor of fv.
The factor fv has a value of 1 to 50 % of the nominal
load, increasing linearly to 1.5 at 100 % of the nominal
load (nominal load percentage P).
fv = 1+0.5 P-50 (for P > 50%)
50
In order to achieve safe operating periods, the company
must check that the theoretical operating time has been
achieved during each inspection, by the person respon-
sible. This must be documented in the inspection log at
least once annually. The inspection log is only supplied
in the Federal Republic of Germany. Instructions and a
model for determining the actual operating time can be
found from page 41 onwards.
When the theoretical operating time has been reached,
a general overhaul must be performed. Detailed expla-
nations for the determination of the actual operating
time and its documentation can be found in the natio-
nal safety regulations. Alternatively, the calculation
model in this operation manual can be used. The
general overhaul must be initiated by the operator and
must be documented in the inspection log. Information
on general overhaul can be requested from the
manufacturer.
Page 39
MAINTENANCE

Only if the group classification corresponds to the

actual type of operation of the lifting equipment, does
a safe operating period conform to the theoretical
operating time. Deviations of the actual type of
operation 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 must be disconnected from the main air
supply during assembly work.

Dismantling the hoist, see page 38.

C AU T I O N !
Following each repair, the hoist must
be checked for operational readiness.

Page 40

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 MAINTENANCE

The formula given for the cubic average k does not

INSTRUCTIONS CONCERNING THE “MODEL FOR
take the weight of the harness into account. This is
DETERMINING THE ACTUAL OPERATING TIME” permissible if the ratio

The decisive factors for the type of operation are the

load spectrums with different cubic averages k. The load
spectrum indicates to what degree a driving mechanism,
or a part of one, is subjected to its maximum stress or
To determine the type of operation for calculating the
only to smaller stresses. The cubic average (factor of the
partial operating times (actual operating time), the
load spectrum) is calculated using the following
following load spectrum diagrams can also be used.
formula.

The FEM* 9.511 rule differentiates between four load

spectrums, which are identified by the definitions and
by the ranges of the cubic averages k. This classification
complies with ISO 4301/1.
*FEM = Federation Europeene de la Manutention (European Federation
of Materials Handling and Storage Equipment)

Load spectrum Definition Cubic Load spectrum factor

average
1 L1 Driving mechanisms or parts thereof, which are only subject k ≤ 0.50 km = k3 = 0.125
(Low) to the maximum stress in exceptional circumstances, and
are only subject to very low stresses continuously.
2 L2 Driving mechanisms or parts thereof, which are subject to 0.50 < k km = k3 = 0.25
(Average) the maximum stress fairly often, and are only subject to ≤ 0.63
low stresses continuously.
3 L3 Driving mechanisms or parts thereof, which are often 0.63 < k km = k3 = 0.5
(High) subject to the maximum stress, and are continuously ≤ 0.80
subject to average stresses.
4 L4 Driving mechanisms or parts thereof, which are regularly 0.80 < k km = k3 = 1
(Very high) subject to the maximum stress of adjacent stresses. ≤ 1.00

Page 41
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MAINTENANCE

MODEL FOR DETERMINING THE ACTUAL OPER ATING TIME

The following calculation compares the actual operating time with the theoretical operating time
in load spectrum 4 (Very high).

1 2 3 4 5 6 7
Load spectrum factor in accordance Partial Remaining theoretical
Average with load spectrum for the type of deployment use in load spectrum 4 Date
daily operation
Column 2 Delivery
Operating opera- (When zero has been Specialist ins-
x column 3 Initial
site ting reached a general pector
L1 L2 L3 L4 x operating operation
time in overhaul must be
Very days Inspections Signature
hours performed)
Low Average High high x factor 1.2
Existing driving mechanism Delivery
group, see nameplate GmbH & Co.KG

– 0 0.125 0.25 0.5 1 0 M2 (1Cm) 200 hours Initial

M3 (1Bm) 400 hours operation
M4 (1Am) 800 hours
M5 (2m) 1600 hours

C ALCUL ATION MODEL (DRIVING MECHANISM CL ASSIFIC ATION M3)

Slewing
1.5 x 0.25 (400 - 113)
crane 2nd August
1.5 0.25 x 250 x 1.2 A.N. Other
assembly 287 hours 2004
= 113 hours
site

Page 42

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 MAINTENANCE

The specified inspection intervals are valid for use in accordance with the classification (see driving mechanism classi-
fication on the nameplate). The service life is approx. 10 years if the device is used in accordance with its classification.
If the hoist is used more intensively the intervals are to be shortened accordingly. The intensity of use must be assessed
using the model for determining the actual operating time (see page 41). All operating hours are translated into full
load hours. The theoretical operating time and the interval hours are indicated in full load hours.

Maintenance measure Interval Comment

Check oil level for motor lubrication Daily (Filling and adjusting oiler section, page 49)
(when operating with oiler)
Lubricate chain As required (Lubricating the chain section, page 45)
Visually check the chain Weekly

Inspection measure Interval Comment

Check control device Daily (Checking controls section, page 46)
Check the braking function Daily (Checking braking function section, page 45)
Checking direction of movement Daily (Checking direction of movement section,
page 46)
Check lifting and lowering limiters Daily Replace buffer immediately if damaged, otherwise
(buffers) visually replace every 5 years
Check EMERGENCY STOP function Daily
Check chain Every 3 months (Checking chain, chain sprocket and chain
guides section, page 55) In the event of wear-
promoting operating conditions, reduce intervals
between checks
Checking lifting and lowering limiters Annually (Checking lifting and lowering limiters, section,
page 46)
Check brakes with load Annually Load must be braked reliably (Checking braking
function section, page 45)
Check all the bolted and- Annually
pin connections
Check load hook on the load and Annually (Check dimensions section, page 55)
carrying side
Check the motor, check, clean and Annually Measure the lifting speed
rgrease the control valve
(JDN high-performance grease)
Check the axial movement of the hooks Annually (Checking axial play section, page 57)
and eyes
1
Check the service unit Annually (Service unit section, page 47)
Check the silencer for permeability Annually (Checking silencer for permeability section,
page 46)
Check overload protection Annually (Checking and adjusting overload protection
section, page 59)
Check compressed air connections Annually
for damage
1
if fitted

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MAINTENANCE

Inspection measure Interval Comment

Check sealing efficiency and function Annually
of control valve
Check condition of the chain box1 Annually (Chain box section, page 63)
including mountings
Check for brake wear and motor Every 200 hours, (Checking brake linings and vanes section,
vane wear at least every 5 years page 50), replace motor vanes every 5 years.
In off-shore areas and other similar Every 5 years
corrosive environments, replace
the chain regularly
Check gearbox and perform Every 5 years
lubricant change
Check the rotor/pinion shaft connec- Every 5 years
tion and lubricate with gear grease
Check the chain sprocket bearings and Every 5 years
lubricate if necessary
Check chain sprocket and chain guides Whenever the chain is (Wear dimensions section, page 56)
replaced
Renew grease lubrication of motor When required, (Motor lubrication section, page 50)
at least every 5 years
1
if fitted

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 MAINTENANCE

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

The chain of the JDN Air Hoist must be lubricated
in the links when not under load.
 Clean heavily contaminated chains.
 Lay the chain in a suitable container.
 Spray the chain with special lubricant or motor
vehicle engine oil.
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.

If you wish to lubricate the hanging chain, ensure DA N G E R !

that the chain links are oiled at the points of contact. If the chain runs on, do not use the hoist.
For this purpose, move the chain to and fro. The hoist must be repaired.
A high-performance lubricant in an aerosol can is
available from JDN, which adheres well to the chain For physical reasons, the braking distance cannot have
after the solvent has evaporated and does not drip off, the value zero. However, for the purpose of this
Part No. 12066 (spray can 400 ml). functional check, running on of the chain must not be
perceptible.
For operation in areas with high corrosion potential,
e.g. in the offshore sector, the chain can be largely When checking the braking function under nominal
protected against corrosion by the use of special load, the following braking distances must not be
lubricants. exceeded:
These types of lubricants are characterised among
B R A K I N G D I S TA NC E S U N D E R N O M I N A L L OA D
other things by weathering resistance, water insolubility
( L OA D - C A R R Y I N G C A PAC I T Y ) A F T E R L OW E R I N G
and good adhesion properties.
HAS BEEN STOPPED
Re-lubrication intervals must be stipulated in accor-
dance with the loading. Please contact us, if required. Type 1.5 TI 3 TI/2
Rope control 10 5
all other controls
with length of 33 16
2m
Dimensions in mm

If the control hoses are long the braking distances will

increase due to longer air evacuation times.

Page 45
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MAINTENANCE

CHECKING LIFTING AND

L OW E R I N G L I M I T E R S 4

 Move the unloaded load hook until just short of the

upper and lower end positions. 2
 Stop immediately before reaching the end position
and then carefully (by repeatedly pressing the control
element) move to the end position.
 The movement of the chain must be stopped due to
deformation of the buffer. For hoists with overload 3 1
protection, the lifting movement is additionally
limited by shutting off the motor. Main air emergency-stop valve
 Following successful testing, the buffer must be
unloaded. With each check, the working order of the valve must
be examined as follows:
DA N G E R !
If the buffer is damaged, do not use the  Shut off the compressed air supply and unload the
hoist. The hoist must be repaired (replace line.
the buffer).  Remove the safety ring 1.
 Pull out the cover 2.
 Press plunger 3 inwards against the force of spring 4.
C H E C K I N G CO N T RO L S A N D It must return again due to the spring force.
 If the plunger does not move, the valve must be
E M E RG E NC Y S T O P F U NC T I O N
repaired.

All control elements of the controls must always be

free-moving.
C H E C K I N G D I R E C T I O N O F M OV E M E N T
 Unload the JDN Air Hoist.
 Briefly actuate and release all control elements of the  Check that the direction of movement of the load
controls one after the other. The control elements hook corresponds to the direction indicated by the
must return to their initial positions immediately. The arrows on the control elements.
on and off function must operate without problem.
 PRESS THE EMERGENCYSTOP. All movement of the
hoist must stop. Actuating the control elements must C H E C K T H E S I L E NC E R F O R
not cause a lifting or lowering movement. PERMEABILIT Y
 RELEASE THE EMERGENCY STOP button by turning.

DA N G E R ! Independent of the stipulated inspection intervals, the

If a control element is stiff or remains in the silencer must be checked for permeability if the hoist
actuated position, do not use the hoist. The does not achieve the specified lifting speed (see section
control must be repaired. Technical data, page 64).

The test is performed by comparing the lifting speeds

under nominal load, with and without the silencer. The
CHECKING THE MAIN AIR speed with standard silencer or filter silencer must be
E M E RG E NC Y S T O P VA LV E at least 80 % of the lifting speed without a silencer
element. In the event of lower values, the silencer
The main air emergency-stop valve is opened with each elements must be cleaned or replaced.
actuation of the controls. It closes when the controls
are released.

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 MAINTENANCE

 Turn the regulator knob until the manometer indi-

SERVICE UNIT
cates the nominal pressure. Clockwise: higher
pressure Anti-clockwise: lower pressure
AT T E N T I O N !  Lock the regulator knob by pressing it down.
If a hoist is operated with a service unit,
this should not be mounted further than If the nominal pressure cannot be achieved despite a
5 m away from the hoist. sufficiently high pressure upstream of the service unit,
then the air line cross-section is too small.
The ambient temperature must be a minimum of 0° C. It
must not exceed 50° C.

N O T E : If, at the request of the customer, a service unit

is installed in hoists in motorised trolleys and lifting
gear, it will be configured at the factory.

A maximum connecting pressure of 10 bar is permitted

for the service units supplied by JDN. Higher pressures
must be reduced to a permitted amount upstream of the
service unit.

The service unit in the PROFI 1.5 TI and PROFI 3 TI/2

Air Hoists consists either of two elements, filter
controller and oiler, or of the filter controller only.

C H E C K I N G A N D A D J U S T I N G T H E F I LT E R
CO N T RO L L E R * )
The filter controller is set to an actual pressure in the
factory (actual pressure when lifting the nominal load).
In this setting, the manometer can indicate a pressure Filter regulator and oiler
above the nominal pressure with the motor switched
off. For correct adjustment, a pressure of at least 1 bar
above the nominal pressure is required upstream of the Regulator knob
service unit.

 Lift the regulator knob.

 Turn the regulator knob until the manometer
indicates the nominal pressure. Clockwise: higher
pressure Anti-clockwise: lower pressure
 Lock the regulator knob by pressing it down.

Alternatively, the filter regulator can be set to the

nominal pressure in the absence of an air stream. This
setting is only correct for a pressure of at least 1 bar
above the nominal pressure upstream of the service
unit. Oiler

 Depressurise the air line downstream of the service

unit and close it again.
 Turn the regulator knob anti-clockwise, in order to Filter regulator
release the adjusting spring.

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MAINTENANCE
D R A I N I N G CO N D E N S AT E
After a certain time, condensate collects in the filter
regulator container, which must be regularly drained.
Check the condensate level through the sight glass in
the filter container. The condensate level must not
reach the separating plate.
The container can be emptied manually or semi-automa-
tically, depending on the setting of the drain valve:
 OFF position
The drain valve is closed in this position.
The OFF position is generally set at the factory.
 ON position
The condensate can be drained manually in this posi-
tion. Operate the drain valve by pressing upwards
(see Figure).
When the compressed air supply is connected, the
drain valve is under pressure. We recommend using
suitable splash protection (cloth, fleece) as the con-
densate will otherwise escape uncontrollably.
Collect the escaping condensate and dispose of it as
it may contain oil.
 AUTO position
In this position, semi-automatic condensate drainage
takes place. When the pressure upstream of the servi-
ce unit falls below 0.2 bar, the container empties
automatically. With this setting it must be ensured
that a suitable container is in place to collect the
escaping condensate when drainage occurs.
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C L E A N I N G T H E F I LT E R E L E M E N T
AT T E N T I O N
Do not use alcohol for cleaning the service
unit. Alcohol can damage parts of service
unit. Transparent components must only be
cleaned using soap solution.
The filter element must be cleaned once annually.
For this purpose, proceed as follows:
 Drain the water.
 Shut off the main air supply and carefully allow the
residual pressure to dissipate.
 Unlock the filter regulator container, turn anti-clock-
wise to the stop and remove.
 Unscrew the separating plate. The filter is located
loosely on the separating plate centring device.
 Clean the filter element using soap solution and blow
through forcefully.
 Reinstall the clean filter element and fasten the
separating plate.
 Insert the filter regulator container in the housing
and turn clockwise. The container locks
automatically.
filter element
separating disc
sight glass
filter receptacle
Cleaning the filter element
 MAINTENANCE

FILLING AND ADJUSTING OILER

The oiler ensures that the hoist air supply is consistent-
ly provided with a precisely-metered quantity of oil.
Regular checking of the oiler is very important, as the
vane motor may be damaged in the case of lubricant
deficiency. The oiler can also be refilled under pressure.

 Check the oil level through the sight glass in the

container. The oil level must not fall below the
minimum mark.
 Remove the oil filler screw.
 Fill the container with oil up to the maximum mark
and refit the oil filler screw. Max. oil level
 Check the oil drop rate at the sight glass with the
motor running.
 Turn the oil throttle screw using a screwdriver until
the desired number of drops per minute is achieved. Min. oil level
Turning clockwise reduces the amount of oil; turning
anti-clockwise increases the amount of oil.

Oil drop rate (lifting without load):

2 drops per minute.

AT T E N T I O N !
Operation of service units with synthetic oils
is not permissible. They must also not be
connected to compressed air circuits, which
Check the oil level and top up if necessary
are supplied by compressors lubricated with
synthetic oil.
Sight glass
C AU T I O N !
J.D. Neuhaus only supplies standard spray Oil filler screw
oilers. Do not use microspray oilers as very
Oil throttle screw
finely secreted oil spray could adversely
effect the surrounding air and therefore the
respiratory system.

Check oil drop rate at sight glass and adjust

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MAINTENANCE
M O T O R I N S TA L L AT I O N / C H E C K I N G
BRAKE LININGS AND
VA N E S / M O T O R L U B R I C AT I O N
12 13 11
Replacing brake discs, brake piston and vanes /Motor installation
The motor and brake functions are achieved in part by
means of shared components. The braking action is
applied at the lateral surfaces of the rotor. The rotor is
pressed via spring force from the cover-side of the motor
against a second braking surface located on the opposite
side by means of a piston on which braking material is
bonded.
R E M O VA L
The hoist must first be unloaded and disconnected from
the main air supply.
Note: The following operations can be performed from
the nameplate side after the motor has been removed.
 Checking vane wear, replacing the vanes with starting
aids if necessary.
 Checking brake wear, replacing the brake piston if
necessary.
 Renewing the motor lubrication.
The replacement of the centre section halves with brake
lining is described under a separate item.
 Unscrew 1 the nameplate.
 Remove the motor cover bolts 2 and detach the motor
cover 3 (when the cover bolts are removed, the brake
springs 4 are fully released).
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7 8 6 10 9 5 4 3 2 1
14/15
 Remove the brake springs.
 Remove the brake piston 5 from the internal cylinder
integrated in the motor housing.
 Pull out the rotor 6, removing the vanes 7 and starting
aids 8.
Checking vane wear:
(See Fig. Checking vane wear, page 51). When the vanes
are worn, the motor power and consequently the lifting
performance of the JDN Air Hoist are reduced. Replacing
the vanes together with the starting aids.
Checking braking surfaces of the brake piston and
the centre section half with brake lining for wear
and damage:
The circular wear pattern in the braking surfaces must
not be deeper than 0.2 mm (also see illustration on
page 51). The extremely low-wear braking material will
not reach the wear limit of 0.2 mm within the design-
dependent service life of the hoist, under intended use.
Should the wear limit be reached prematurely, the actual
pressure must be checked with the device switched on
(the brake drags in the event of insufficient
pressure).
 MAINTENANCE

 Detach the motor with centre section half on the

Rotor Cylinder liner (internal cylinder)
motor-side from the hoist.
V1max. = 0.2 mm V2max. = 0.2 mm  Remove the bolts 12 and pull out the centre section
Brake piston
half with the brake lining 13.
Motor installation with additional basic lubrication:
Brake disc
R  Apply high-performance grease lightly to braking
surface and rotor bearing (needle bush) in the centre
section half and slide this into the motor housing. At
the same time, insert the anti-twist device (pin).
 Bolt centre section half to motor housing.
 Coat the internal cylinder of the motor housing
Lh

lightly with high-performance grease.

 Coat the entire rotor lightly with high-performance
L grease and insert into the front rotor bearing with
Lmax = R - (V1 + V2) Vane
Lmin = R - (V1 + V2) - 0.5 mm = Lmax - 0.5 mm the clutch side first.
Lhmin = 23 mm  Coat the vanes lightly with high-performance grease
and insert into the rotor slots with the starting aids.
Checking vane wear
 Coat the braking surface and the outer diameter
including the brake piston seal lightly with high-
Renewing motor lubrication:
performance grease and push the brake piston with
Note: The grease packing in the rotor chambers is
the braking surface first into the internal cylinder.
sufficient for approx. 250 hours of normal operation.
The rotor chambers are only emptied by approx. 75%. Note the position of the eccentric bore.
 Insert the brake springs into the bores of the brake
In this condition, refilling must be performed.
piston.
The retaining rings 9 and Vyon washers 10 must be
 Loosen adjusting bolts 14 and lock nuts 15. Screw
removed in order to refill the chambers.
back adjusting bolts.
Then pack the chambers with high-performance
 Apply high-performance grease lightly to rotor
lubricant (JDN Art. no 11901) without forming cavities.
bearing (needle bush) in the motor cover and install
Use new Vyon washers to close off the lubricant
motor cover. Ensure correct seating of the brake
chambers and secure these using retaining rings.
springs and the locating pins to the motor housing
Replace centre section halves with brake lining. and to the brake piston. Do not tighten the four
If the centre section half with brake lining is to be adjusting bolts after bolting the motor cover in place,
replaced, the following removal operation is also only screw them in loosely by hand to the stop in the
required. cover. Screw back the lock nuts sufficiently

beforehand.
Detach the hoist from the point of attachment and
 Then screw back the adjusting bolts 45° from the
set down carefully.

stop, hold, and lock with the nuts. For lifting heights
Detach the chain box if necessary.

of 10 m and more, a setting of up to 60° is required.
Remove the control valve.

For operation in areas with ambient temperatures
Remove centre section bolts 11.
exceeding 30° C, the adjustment must be carried out
with the device warmed up accordingly.

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MAINTENANCE

 Attach the nameplate.

 Push motor with centre section half on the motor
side onto the hoist – install load hooks at same time
– and tighten centre section bolts.
 Install the control valve.

AT T E N T I O N !
Tightening torques, see E-list.

C AU T I O N !
Check the braking action of the hoist under
load (run in the brake by performing several
hoisting cycles, then assess) prior to initial
operation. Check the motor power. In the
event of low motor power, regulate the
adjusting bolts again.

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 MAINTENANCE

REMOVING AND INS TALLING BO TTOM BLOCK AND

REMOVING AND INSTALLING LOAD SLEEVE,
BUFFER - D UA L C H A I N H O I S T (3 TI/2)
BOTTOM BLOCK, CLAMP AND BUFFER

R E M OV I N G A N D I N S TA L L I N G L OA D S L E E V E A N D
B U F F E R – S I N G L E - C H A I N H O I S T 1. 5 T I

3 14
1
2
3
12
11
5 13
9
10

8 6
2
7 1
5 8
6
7
4

Removal
 Unscrew bolt 7 and remove it from the chain pocket to-
gether with retaining washer 6 and shaped element 1.
 Remove the chain link 2 from the chain pocket.
Removal
 Detach the buffer 4 and buffer discs 5 from the  Move the bottom block as close as possible to the

chain. hoist body.

 Position the bottom block securely in order to
Assembly prevent the chain from unravelling uncontrollably
 Push the buffer discs (edge encloses buffer) and the causing the bottom block to fall.
 Remove the chain link 1 of the bottom block from
buffer onto the chain.
 Insert the chain link into the chain pocket of the the chain mount on the hoist body; drive out the roll
load sleeve (position of the weld must align with that pin 2 and the end chain link pin 3 for this purpose.
of the following links).
 Insert the shaped element into the chain pocket,
install and tighten the bolt with the retaining washer
(change tightening torque to 8 Nm).

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MAINTENANCE
Note: For assembly, it is helpful to fasten a short
assembly chain 5 to the end of the chain by means of
an open chain link 6 before pulling the chain out of
the bottom block. This assembly is pulled into the
bottom block as the chain is pulled out and remains
there until assembly is completed.
 Pull out the chain from the bottom block. The
buffer 7 and buffer discs 8 are thereby pulled from
the chain.
Assembly
 Push the buffer discs (edge encloses buffer) and the
buffer onto the chain.
 Align the chain and fasten it to the assembly chain
in the bottom block by means of the open chain link.
 Pull the chain through the bottom block and detach
the assembly chain and the open chain link from the
chain. If no assembly chains have been used, the end
of the chain must be inserted into the bottom block
and pulled through by turning the sprocket wheel
using an auxiliary tool.
 Push the spacer pipe onto the chain.
 Align the bottom block chain and push the chain link
pin through the chain link to be attached (position
of the weld must align with that of the following
links).
 Drive in a new roll pin to secure the end link pin.
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R E M OV I N G A N D I N S TA L L I N G C L A M P A N D B U F F E R
Removal (see illus. page 53)
 In the case of operation with chain box, run the
chain out of the chain box and detach it from the
hoist.
 Remove the chain link of the idle chain from the
chain mount on the hoist body. Unscrew the Allen
screws 14 for this purpose.
 Loosen screw connections 9 of the clamp 10.
 Remove the clamp from the chain.
 Detach the buffer 11 and buffer discs 12 + 13 from
the chain.
Assembly
 Push the buffer disc with edge (edge encloses buffer),
buffer and buffer disc without edge onto the chain.
 Insert the tenth chain link into the chain pocket of
the clamp (chain pocket away from hoist body,
pointing outwards).
 Introduce a screw connection to secure the chain link
in the clamp.
 Align the idle chain and fasten the end chain link to
the hoist body.
 Attach the chain box.
AT T E N T I O N !
Do not twist the chain! The chain is
subjected to impermissible stresses if the
chain is twisted.
 MAINTENANCE

CHECKING CHAIN, CHAIN CHECK DIMENSIONS

S P RO C K E T A N D C H A I N G U I D E S
See also Check dimensions, page 55. If the chain of
the JDN Air Hoist displays one of the following
characteristics, it must be replaced with a new one:
 Corrosion pitting
 Bent or damaged chain links
 Chain drawn tight
 Wear over 11 pitches (Amax)
 Single pitch wear (Bmax)
 Elongation of a single link (Dmax)
HOIST CHAIN
Note: When checking the replacement limit, future wear
up until the next inspection date must be taken into
account. If the chain dimension values are outside the
limit values specified in the table when checked, the
chain has reached its replacement limit and must be
replaced by a new one. The chain sprockets must also be
replaced together with the chain, as otherwise the new
chain will be subjected to increased wear. Each chain
replacement must be documented in the inspection log.

Check the entire length of the chain.

Please observe the information contained in DIN 685,

B
part 5 when checking chains. For further instructions
see ISO 7592.

11 x t
A
D

d1

d1 + d2
c=
d2

Check dimensions of hoist chain

Chain d x t 9 x 27
Dimension A max. 320.5
11 x t inside max. 303.2
Dimension B max. 28.4
Dimension C min. 8.1
Dimension D max. 46.4
Dimensions in mm

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MAINTENANCE

L OA D H O O K W E A R D I M E N S I O N S F O R C H A I N S P RO C K E T S
If the measured distance y and the height h of the
load hook are outside the wear limits, the hook must
be replaced.

a
x

Wear dimensions for chain sprockets

h

Chain size
dxt z a x
Check dimensions of load hook mm x mm (1) mm mm
9 x 27 4 25 0.2
Type Permissible maximum Permissible minimum
dimension of dimension of
measured distance "y" height "h" a, x = Limit dimensions after maximum permitted
wear
PROFI 1.5 TI
Load sleeve 57.8 28.2 z = Number of teeth of the chain sprocket
Centre section 63.0 36.1 d x t = Nominal diameter times pitch of chain link
PROFI 3 TI/2 63.0 36.1
Dimensions in mm WEAR DIMENSIONS FOR CHAIN GUIDES AND
HOOK MOUNTS
Check the chain guides for wear and when the wear
dimension of 1 mm is reached with regard to chain
guide diameters or hook mounts in the centre section
of the device: Replace the housing.
The wear dimension must be measured at the points on
the guide surfaces which have been worn down by the
chain.

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 MAINTENANCE

C H E C K I N G A X I A L P L AY

Maintenance and lubrication

Please ensure that load hooks and/or load eye mounts

max. 2.5 mm
are regularly checked, at least once a year. Especially
important: in areas where wear-promoting conditions
such as high ambient temperatures or corrosive
substances in the atmosphere are present, or where
lubricants may be washed out, the frequency of
maintenance and inspection intervals must always
be increased.

HAZARDS IN THE C ASE OF INSUFFICIENT

M A I N T E N A NC E / L U B R I C AT I O N
DA N G E R !
In the event of insufficient mainte-
nance/lubrication the extent of wear may
be so high that there is a danger of loads
falling.

P R E V E N T I O N O F DA N G E R S
Dangers are avoided by regular maintenance/lubrication Load sleeve with load hook or load eye
in suitable intervals.

When the axial play of the installed hook or load

eye exceeds the maximum play specified, the worn
parts must be replaced.
max. 2.5 mm

Bottom block with load hook or load eye

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MAINTENANCE
R E M OV I N G A N D I N S TA L L I N G C H A I N
AT T E N T I O N !
The chain supplied together with this JDN
hoist is matched to the chain sprocket
according to strict tolerances. In order to
ensure optimum function of the chain and
in order to prevent hazards, only genuine
JDN chains must be installed.
Note: When a chain is replaced, the buffers must also
be replaced. For changing buffers at the chain ends, see
section Removing and installing load sleeve, bottom
block, clamp and buffer.
Buffers not located on the chain ends are most easily
replaced when the open chain link between the old and
new chains passes the buffer to be replaced.
AT T E N T I O N !
Do not twist the chain ends.
 In the case of operation with chain box: switch the
hoist in the “lower” rotational direction and run the
old chain out of the chain box. Then remove the
chain box.
 Move the bottom block as close as possible to the
hoist body and position it securely.
 Detach the idle chain from the chain mount on the
hoist body (see also section Removing and
installing load sleeve, bottom block, clamp and
buffer).
 Detach the clamp, buffer and buffer discs from the
end of the idle chain. For single chain hoists also
detach the load sleeve, buffer and buffer discs from
the load chain. For dual chain hoists detach the
bottom block chain from the hoist body (see also
Removing and installing load sleeve, bottom
block, clamp and buffer section).
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 Attach the new chain to the end link of the load
section of the old chain after aligning the welds and
the first chain link by means of an open chain link.
The welds on the upright chain links must face
outwards when running over the chain sprockets. If
the first link of the new chain is not correctly
positioned, it must be removed.
Note: It is possible that the first chain link of the other
chain end is correctly positioned. Switch the hoist to
the “lift” rotational direction. The new chain will now
run into the hoist while the
 old chain is simultaneously run out on the idle chain
side.
Run the chain until the join between the old and new
chain has run sufficiently (approx. 1 m) out of the
centre section on the idle chain side.
 Detach the connection between the old and new
chains.
 Install the clamp (at the 10th chain link), buffer
and buffer discs on the idle chain section of the
new chain.
Align the idle chain and attach to the fastening point
on the hoist (see also Removing and installing load
sleeve, bottom block, clamp and buffer section)
 Attach the chain box if necessary.
 Switch the hoist in the “lift” rotational direction
until the as yet free end of the aligned load chain is
the correct length for attaching the chain link
– for single chain hoists in the load sleeve after the
buffer and buffer discs have been pushed on,
– for dual chain hoists at the fastening point of the
hoist body (see also Removing and installing load
sleeve, bottom block, clamp and buffer section).
Note: If the chain link of the load chain is positioned
incorrectly, it must be removed, the following chain link
will be positioned correctly.
 MAINTENANCE

REPL ACING CHAIN AND CHAIN SPROCKET

Note: If the chain jams in the hoist and can no longer

be run out, the gearbox must be dismantled (see spare
parts list for “Gearbox”).

For dual chain hoists, when removing the old chain, an

assembly chain 1 is brought into position on the
deflection sprocket of the bottom block by means of an
open chain link (see also Removing and installing
load sleeve, bottom block, clamp and buffer section 3
2
and Removing and installing chain section). 4

Following replacement of the chain sprocket (see spare 5

parts list) an assembly chain 2 is run carefully – with
low air pressure – over the drive sprocket. 1

Fasten the new chain 5 to the assembly chain on the

drive sprocket by means of one or two open links 3 to
the idle chain side. The first chain link 4 must run
upright over the drive sprocket with the weld facing
outwards.

Switch the hoist to the “lower” rotational direction and

detach the assembly chain from the chain after it comes
out of the centre section.

For dual chain hoists, the new chain, after it has been
aligned, is pulled over the deflection sprocket of the Drawing in the chain
bottom block using the assembly chain.

Note: If the chain link on the idle chain side is OV E R L OA D P RO T E C T I O N

positioned incorrectly, it must be removed, the
following chain link will be positioned correctly.
Fastening of the chains and installation of the load
sleeve, clamp, buffer and buffer discs is carried out in
accordance with the Removing and installing load
sleeve, bottom block, clamp and buffer section and
the Removing and installing chain section.
The PROFI 1.5 TI and 3 TI/2 hoists are equipped with a
new type of safety clutch as standard. This prevents
loads exceeding the limit values set from being lifted.
The limit value is set so that loads of 125 % of the load
carrying capacity cannot be lifted. 110 % can be lifted
in order to perform the dynamic overload test.

AT T E N T I O N !
The safety clutch must only be engaged for a
short time in order to prevent unnecessary
wear and overheating of the drive.

When the safety clutch is activated, the hoist should be

unloaded by switching to a lowering movement.

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The overload protection can also be activated when
moving at full unloaded speed against a load to be
lifted, even when it is below the load size set. We
therefore recommend tensioning the slack chain before
lifting the load.
A D J U S T I N G OV E R L OA D P RO T E C T I O N
The adjustment method described here is based on the
attachment of test loads.
DA N G E R !
If the overload protection is set too high,
impermissibly high stresses may arise if a
load exceeding the permissible load carrying
capacity is attached.
Then let the load hook run for approx. 10 seconds
without a load so that the outlet air cools the clutch
down.
 Secure threaded pins with the lock nuts. Hold the
threaded pins tightly in the process.
 Check the limit value for correct setting, correct if
necessary.
 Install the gearbox cover.
 The adjusting and inspection result arrived at by
qualified personnel must be entered in the lifting
gear inspection log (limit value: see Overload
protection, page 36).

 Unload the hoist.

 Detach the gearbox cover 1 from the gearbox in
order to gain access to the threaded pins 2 with lock
nuts 3 located behind it.

CORRECTING THE SET LIMIT VALUE

 Loosen the lock nuts. It must be ensured that the
threaded pins are not turned.
 During each readjustment, adjust the threaded pins
to the same degree in order to adjust the disc springs 3
evenly: turning clockwise – limit value is increased, 2
turning anti-clockwise – limit value is reduced. 4
 Secure threaded pins with the lock nuts. Do not turn
the threaded pins any more as the setting will be
altered.
 Check the limit value for correct setting.
 Install the gearbox cover. 1

R E S E T T I N G T H E L I M I T VA L U E Gearbox 1.6 t
 Loosen the lock nuts. Screw out the threaded pins –
anti-clockwise – until the disc springs 4 are
completely free of pre-tension.
 Then loosely screw in the threaded pins by hand –
clockwise – to the stop, unscrew the lock nuts
sufficiently far back beforehand.
 The limit value for reaching at least 110 % of the
load-carrying capacity is set at approx. 2.5 turns.
Screw in the three threaded pins successively in
small steps by approx. 1/2 turn. With this pre-
adjustment after re-assembly, first let the safety
clutch take effect for approx. 5 seconds (load hook
on the upper end position with the motor running).

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FAULT S, C AUSE AND REMEDY
FAU LT TA B L E
Fault
Lifting not possible
Only very slow lifting possible
Excessive running on during braking Replace brake disc and/or
brake piston worn
Loud chain noise
on the chain sprocket
Lifting or lowering speed declines
with high lifting heights or the
motor comes to a standstill
*if fitted
Possible cause
Overload protection has
caused deactivation
Air pressure too low
EMERGENCY STOP button
is pressed
Hand control is faulty
Brake does not release fully
Brake lining worn or uneven
Motor cover bolts loose
Air supply hoses leaking or
loose
Cross section of air line too small Use air line with sufficiently large cross
Dirt in the service unit*, filter
filter blocked
Silencer is clogged
Motor vanes worn
Motor has run dry
Control valve on motor
Chain dry
Chain worn
Chain sprocket worn
Wrong chain drawn in
Brake piston setting too tight
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FAULT S, C AUSE AND REMEDY
Remedy
Lower hook briefly, limit load to permissible
load carrying capacity, then lift again. If loads
within the load carrying capacity range are
not lifted, the overload protection must be
adjusted.
Set the air pressure correctly. Air pressures
which are too high can cause deactivation
within the load carrying capacity range.
Increase air pressure to the required value
Release the EMERGENCY STOP button once the
danger has been rectified
Have hand control repaired
Set air pressure to the relevant value, check
seal of brake piston and change seal if
necessary. Check the adjustment of the brake
piston (see E-list)
Replace brake lining
Tighten the bolts
Check connections of air supply hose and
control hoses and connect properly
section (check air pressure)
Clean the service unit
Ensure better air quality
Replace or clean silencer elements, improve
air quality if necessary
Replace motor vanes
Lubricate motor, check oiler*
Have control valve repaired
Replace brake disc and/or
brake piston
Lubricate chain
Replace chain with a new JDN Chain
Replace chain sprocket, check chain guide,
replace if necessary
Identify chain and replace with JDN Chain if
necessary
Correct adjustment of brake piston. At high
ambient temperatures, perform adjustment
with the device warmed up accordingly.
Page 61
ACCESSORIES

ACCESSORIES

F I LT E R S I L E NC E R

With the use of a filter silencer, oil aerosols can be

avoided and noise insulation improved:

 99.9 % of oil aerosols during oil lubrication of the

motor are absorbed by the filter element.
 The noise insulation reduces noise levels by 3 to 4 dB
(A) compared with the standard silencer (sinter
plate).
1
The ambient temperature must not be lower
than -10° C.

M A I N T E N A NC E O F F I LT E R S I L E NC E R
The filtered oil runs into the transparent collecting 2
container 3. This container must be emptied before the
fluid level reaches the filter element.

 Turn the drain valve 4 90° and allow the fluid to

drain out.
 Close the drain valve.

The filter must be replaced after approx. 2500 hours of 3

operation.

 Turn the collecting container 3 slightly and detach.

 Unscrew the filter element 2. 4
 Insert a new filter element, with sealing ring 1 and
push on collecting container until it engages.
Filter silencer

BOOSTER UNIT

In the event of a control hose length exceeding 10 m,

the reaction times of the pushbutton controls increase
significantly.

Consequently, a booster unit is generally installed on

the motor for controls E, F and FI, enabling normal
reaction times.

The operating temperature range is from 0° C to 80° C.

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C H A I N B OX
For various areas of application, a chain box enhances
operational safety, i.e. when a chain which is hanging
down could become caught up with the load.
JDN chain boxes are available in various sizes,
corresponding to the chain lengths.
AT T E N T I O N !
Do not exceed the permissible filling
capacity. Danger of chain falling.
AT T E N T I O N !
Loads must not be moved against the chain
box during lifting. If necessary, attach a
clamp to the chain.
The clamp must be attached above the load hook so
that it functions as a preliminary end stop. With the
PROFI 2 TI (dual chain) the clamp must be positioned as
far as necessary downwards on the reeved chain in order
to support the bottom block (stationary chain). In
addition, a spacer must be attached to the opposite
(moving) chain above the buffer in order to relocate the
load hook stroke limiter. Please contact us, if required.
For greater clarity, see the illustration on the right
on page 53.
In all cases, a clamp is attached in the 10th chain link
of the unloaded chain end so that a length of chain
remains in the chain box when the bottom load hook
position is reached. Thus, the chain cannot run next to
the chain box during subsequent lifting (see section
Removing and installing chain page 58).
Depending on the ratio of the size of the hoist (without
running gear) and the chain box, the chain box may
have to be stabilised by the customer due to an
acceptable vertical hoist position. This is facilitated by a
suspension point on the rear of the box. We will be
happy to answer any questions on this matter.
Modifications may only be made to the chain box on
agreement with J.D. Neuhaus GmbH & Co. KG.
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ACCESSORIES
AT T E N T I O N !
Never allow the chain to pile up in the chain
box.
The chain must only enter the container via
the chain drive. If it falls out of the container,
e.g. during transportation, it must be run
out completely on the load hook side and
then run back into the container via the
chain drive, in the air hoist operating
position.
 After installing the chain box, lower the load hook to
the bottom position once.
 Then activate lifting movement and run the complete
chain into the chain box.
DA N G E R !
When operated with a chain box, lubrication
of the chain is particularly important in
order to prevent it from piling up and falling
out. Do not install longer chains when
changing chains.
Furthermore, hazards arise due to rusty
chains when operating with chain boxes, as
the chain can form a heap and fall over the
edge of the container rim. In addition, rusty
chains are subject to extreme wear.
If the hoist has been transported with the chain in the
chain box, the chain box must be emptied manually
before initial operation (if necessary, remove the chain
box from the hoist). The entire chain must then be
allowed to run to the load side and, subsequently, be
driven back into the chain box. The hoist must be kept
in a hanging position during this procedure. This
process will ensure that the chain does not lock when
loads are being lowered.
Page 63
APPENDIX

APPENDIX

T E C H N I C A L DATA

J D N P RO F I T I A I R H O I S T S

Type 1.5 TI 3 TI/2

Air pressure bar 4 to 6 4 to 6
Load-bearing capacity t 1.6 3.2
Number of chain sections 1 2
Motor power kW 1.3 to 2 1.3 to 2
Lifting speed at nominal load m/min 4 to 6 2 to 3
Lifting speed without load m/min 8.4 to 10 4.2 to 5
Lowering speed at nominal load m/min 11 to 12 5.5 to 6
Air consumption at nominal load, lifting m3/min 1.5 to 2.6 1.5 to 2.6
Air consumption at nominal load, lowering m3/min 2.2 to 3.6 2.2 to 3.6
Air connection G 1/2 G 3/4 G 3/4
Hose dimension ( inside) mm 19 19
Weight for standard lift, kg 56 66
rope control
Chain dimensions mm 9 x 27 9 x 27
Weight for 1 m chain kg 1.8 1.8
Standard lift m 3 3
Control length for standard liftm 2 2
Noise pressure level with nominal load1 dB(A) 73 to 77 73 to 77
with standard silencer - lifting
Noise pressure level with nominal load1 dB(A) 78 to 80 78 to 80
with standard silencer - lowering
1 measured from 1 m distance according to DIN 45635 part 20

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 APPENDIX

DIMENSIONS
J D N P RO F I T I A I R H O I S T S

G D
F
A C E1
B

E2

Type 1.5 TI 3 TI/2

A minimum headroom* 480 544
B mm 293 356
C mm 200 200
D mm 412 412
E1 mm 28 28
E2 mm 26 28
F to centre of hook, without chain box mm 170 140
G maximum width mm 215 215
*Chain boxes increase the required headroom

Page 65
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APPENDIX

C I RC U I T D I AG R A M

RO P E CO N T RO L ,
W I T H O U T M A I N A I R E M E RG E NC Y S T O P VA LV E
lifting motor

motor
brake silencer

A B

A B

control valve 2 BI rope control valve

lifting lowering

P
E

main air connection service unit

Page 66

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 APPENDIX

C I RC U I T D I AG R A M

E - CO N T RO L , D UA L - F U NC T I O N , lifting motor
W I T H O U T E M E RG E NC Y S T O P D E V I C E
W I T H O U T M A I N A I R E M E RG E NC Y S T O P VA LV E motor
(NOT FOR EEA) brake silencer

A B

A B
control valve 2 BI air

Steuerventil

P Y Z

P
E
main air connection service unit

push button valve E-2fold

Page 67
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APPENDIX

C I RC U I T D I AG R A M

E - CO N T RO L , D UA L - F U NC T I O N , lifting motor
W I T H E M E RG E NC Y S T O P D E V I C E
W I T H M A I N A I R E M E RG E NC Y S T O P VA LV E motor
brake silencer

A B

A B
control valve 2 BI air HS

control valve

P Y Z

P
E
main air connection service unit

emergency
stop push button valve
E-2fold emergency stop

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 APPENDIX

C I RC U I T D I AG R A M

E - CO N T RO L , 4 - F U NC T I O N ,
W I T H O U T E M E RG E NC Y S T O P D E V I C E
W I T H O U T M A I N A I R E M E RG E NC Y S T O P VA LV E
(NOT FOR EEA)
lifting motor
motor
brake silencer

driving motor

A B motor
brake silencer
A B
control valve 2 BI air
control valve

P Y Z Y P Z

P
E

main air connection service unit

push button valve

E-4fold

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APPENDIX

C I RC U I T D I AG R A M

E - CO N T RO L , 4 - F U NC T I O N ,
W I T H E M E RG E NC Y S T O P D E V I C E
WITH EXTERNAL MAIN AIR
E M E RG E NC Y S T O P VA LV E

lifting motor
motor
brake silencer

driving motor
A B motor
brake silencer
control valve 2 BI air A B
control
valve A B

P Y Z Y P Z
service unit
P
E
main air connection

emergency push button valve

stop
E-4fold emergency stop

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 APPENDIX

C I RC U I T D I AG R A M

F I - CO N T RO L , D UA L - F U NC T I O N , lifting motor
W I T H E M E RG E NC Y S T O P D E V I C E
W I T H M A I N A I R E M E RG E NC Y S T O P VA LV E motor
brake silencer

A B

A B
control valve 2 BI air HS

control valve

P Y Z

P
E
main air connection service unit

hand valve FI-3fold

emergency
stop

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APPENDIX

C I RC U I T D I AG R A M

F - CO N T RO L , 5 - F U NC T I O N
( D E V I C E W I T H T RO L L E Y ) ,
W I T H E M E RG E NC Y S T O P D E V I C E ,
WITH EXTERNAL MAIN AIR
lifting motor driving motor
E M E RG E NC Y S T O P VA LV E
motor motor
brake silencer brake silencer

A B

A B
control
control valve 2 BI air valve Y P X Z

P Y Z
2/2 way-valve for emergency stop
service unit
P
E
main air connection

multi button pendent

switches 5 fold
emergency
stop

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 APPENDIX

C I RC U I T D I AG R A M

F - CO N T RO L , 7 - F U NC T I O N ( D E V I C E W I T H T RO L L E Y C R A N E ) ,
W I T H E M E RG E NC Y S T O P D E V I C E
W I T H E X T E R N A L M A I N A I R E M E RG E NC Y S T O P VA LV E

lifting motor driving motor lifting motor driving motor

motor motor motor motor
brake silencer brake silencer brake brake silencer
silencer

A B A B A B

A B

control A B
control valve 2 BI air valve Y P X Z Y P X Z Y P X Z

P Y Z
service unit 2/2 way-valve for emergency stop
P
E
main air connection

multi button pendent

switches 7 fold
emergency
stop

Page 73
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 is a registered trade mark of our company.
BA 820 GB · Subject to changes · 122009

J.D. Neuhaus GmbH & Co. KG / D-58449 Witten-Heven

Phone: +49 2302 208-0 / Fax: +49 2302 208-286
web site: www.jdn.de / e-mail: info@jdn.de

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 J D N O P E R AT I O N A N D A S S E M B LY
INSTRUCTIONS AIR HOISTS
, , , ,
20

MONORAIL HOISTS
EH 10, EH 16, EH 20

Original Operation and

Assembly Instructions

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Please enter the Fabr. No. of your JDN Air Hoist here.

This operation manual edition 12/2009, covers the

following JDN Air Hoists:

Fabr. No. Fabr. No.

Fabr. No. Fabr. No.

20
Fabr. No.

and the following JDN Monorail Hoists (EH), only in

conjunction with the operation manual JDN Trolleys:

EH 10 EH 16
Fabr. No. Fabr. No.

EH 20
Fabr. No.

It must be read carefully and in its entirety before

operating any air hoist. For hoists installed in trolleys,
please also refer to the operation manual JDN Trolleys.

Page 2

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TABLE OF CONTENTS
SA F E T Y M E A S U R E S
Organisational measures . . . . . . . . . . . . . . . . . . 5
Personnel safety . . . . . . . . . . . . . . . . . . . . . . . . 5
Preventing property damage . . . . . . . . . . . . . . . 5
P R O D U C T I N F O R M AT I O N
The operation manual . . . . . . . . . . . . . . . . . . . . 6
Warnings and symbols . . . . . . . . . . . . . . . . . . . . 6
Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly overview. . . . . . . . . . . . . . . . . . . . . . . 8
Product description . . . . . . . . . . . . . . . . . . . . . . 8
Explosion protection . . . . . . . . . . . . . . . . . . . . . 9
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operating conditions . . . . . . . . . . . . . . . . . . . . 15
Energy requirements . . . . . . . . . . . . . . . . . . . . 17
Principle of operation of
JDN air vane motors. . . . . . . . . . . . . . . . . . . . . 18
Operation without chain box . . . . . . . . . . . . . . 19
Motor lubrication / operation with service unit . 19
CE marking / declaration of incorporation . . . . 19
Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
T R A N S P O R T A N D S TO R AG E
Safe transportation . . . . . . . . . . . . . . . . . . . . . 20
Storage conditions . . . . . . . . . . . . . . . . . . . . . . 20
I N I T I AL OP E R AT I O N
Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installing the hoist . . . . . . . . . . . . . . . . . . . . . . 21
Connecting the controls. . . . . . . . . . . . . . . . . . . 22
Replacing controls . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting to the main air supply. . . . . . . . . . . 27
Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Checking prior to initial operation . . . . . . . . . . 28
OP E R AT I O N
Rules for safe operation of hoists . . . . . . . . . . . 29
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Emergency stop device . . . . . . . . . . . . . . . . . . . 34
Overload protection . . . . . . . . . . . . . . . . . . . . . . 34
Attaching the load. . . . . . . . . . . . . . . . . . . . . . . 34
Lifting the load . . . . . . . . . . . . . . . . . . . . . . . . 35
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Lowering the load . . . . . . . . . . . . . . . . . . . . . . . 35
Detaching the load . . . . . . . . . . . . . . . . . . . . . . 35
Interrupting working . . . . . . . . . . . . . . . . . . . . 35
TA K I N G O U T O F OP E R AT I O N
Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . 36
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
MAINTENANCE
Maintenance and inspection intervals . . . . . . . . 37
Cleaning and care . . . . . . . . . . . . . . . . . . . . . . . 37
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Inspection and repairs . . . . . . . . . . . . . . . . . . . . 37
Instructions concerning the ”model for
determining the actual operating time” . . . . . . . 39
Lubricate the chain . . . . . . . . . . . . . . . . . . . . . . 43
Checking braking function . . . . . . . . . . . . . . . . 43
Checking lifting and lowering limiters . . . . . . . . 43
Checking controls and emergency stop function . 44
Checking the main air emergency-stop valve . . . 44
Checking direction of movement . . . . . . . . . . . . 44
Checking the silencer for permeability . . . . . . . 44
Service unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Replacing brake disc, brake piston and vanes
/motor installation/motor lubrication . . . . . . . . 48
Removing and installing load sleeve,
bottom block, clamp and buffer . . . . . . . . . . . . . 50
Checking chain, chain sprocket and chain guides 54
Check dimension . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking axial play . . . . . . . . . . . . . . . . . . . . . . 56
Removing and installing chain . . . . . . . . . . . . . 57
Replacing chain and chain sprocket . . . . . . . . . . 58
Overload protection . . . . . . . . . . . . . . . . . . . . . . 59
FAU LT S , C AU S E A N D R E M E DY
Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AC C E S S O R I E S
Filter silencer . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Booster unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Chain box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
APPENDIX
Technical data . . . . . . . . . . . . . . . . . . . . . . . 64, 66
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 65, 67
Air flow sheets . . . . . . . . . . . . . . . . . . . . . . . . . 68
Page 3
Please note:

Within the Federal Republic of Germany operators

of air hoists must comply with trade association
accident prevention regulations and rules, as well as
state occupational safety regulations, in particular

왘 BGV A1 accident prevention regulations ”Principles

of Prevention”
왘 BGV D8 accident prevention regulations ”Winches,
Lifting and Pulling Devices”
왘 BGR 258 trade association regulations ”Operation of
Load-Carrying Devices Used with Lifting Equipment”

and, for air hoists installed in trolleys and for the

operation of monorail hoists, additionally with

왘 BGV D6 ”Accident Prevention Regulations for Cranes”

in the respective currently applicable version. Operators

must also initiate the prescribed tests (see also ”Prin-
ciples for the Testing of Cranes” BGG 905 (ZH 1/27).

To document the tests we recommend the “Inspection

log for cranes” BGG 943 (ZH 1/29) from the trade
association.

When operating air hoists in areas with explosive

atmospheres, the operator must comply with the
relevant explosion protection regulations, e.g.

왘 BGR 104 ”Explosion Protection Regulations” and

왘 BGR 132 ”Prevention of Ignition Hazards due to
Electrostatic Charges”

In all other countries, the operator shall comply with

local regulations as applicable.

Special regulations may apply when incorporating air

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

Page 4

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SAFETY INSTRUCTIONS
O R GA N I SAT I O N AL M E A S U R E S
JDN Hoists are designed in accordance with current
technological standards and accepted safety practice.
Nonetheless, the use of an air hoist may be associated
with risk of injury or fatality to the user or to third
parties or with the risk of damage to the hoist or to
other items, if safety rules are disregarded.
All personnel charged with operating air hoists, must
have read and understood the operation manual,
especially the section entitled ”Rules for the safe
operation of hoists”, before commencing work. This
is particularly important for personnel who only
occasionally operate the hoist, e.g. for maintenance
or retrofitting work.
Operators of JDN Hoists are also under obligation to
ensure safe and hazard-free operation. This can be
achieved through the following measures:
왘 keeping the operation manual available at the hoist’s
operating site at all times
왘
performing regular training,
왘 perform regular inspections (at least once annually),
왘 implement an inspection log and make regular entries,
왘 and regularly check personnel for safety and hazard
awareness during work.
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SAFETY INSTRUCTIONS
P E R S O N N E L SA F E T Y
Personnel who operate, maintain, inspect and perform
setting-up work on the hoist must be properly trained
or must receive an introduction from properly trained
personnel, before commencing work.
Due to their technical training and experience, properly
trained personnel have adequate knowledge of hoists.
They are sufficiently familiar with the relevant occu-
pational safety and accident prevention regulations,
that they are able to assess the condition of hoists,
with regard to working safety.
왘 Follow the operating instructions for your workplace.
왘 Comply with the accident prevention regulations.
왘 Ensure that you are properly informed regarding
working with hazardous materials.
왘 Follow the safety instructions set out in the
operation manuals.
P R E VE N T I N G P R OP E R T Y DA M AG E
Operators of JDN Hoists are under obligation to ensure
that entries in the accompanying inspection log are
made properly and regularly.
왘 Comply with the prescribed maintenance intervals.
왘 Only use JDN Hoists for work which is described as
intended use.
왘 Observe the operating conditions for JDN Hoists as
described in this manual.
Page 5
PRODUCT INFORMATION
PRODUCT INFORMATION
T H E OP E R AT I O N M A N UAL
This operation manual is intended to help the operator
familiarise himself with JDN Air Hoists and to take full
advantage of their designated areas of application.
This operation manual contains important information
for the safe, proper and efficient operation of JDN
Air Hoists. Observance of the manual helps to avoid
hazardous situations, to reduce repair costs and
downtimes and to ensure the specified service life
of the JDN Air Hoists.
Page 6
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WA R N I N G S A N D SY M B O L S
Safety warnings in this operation manual are classified
in three categories.
DA N G E R !
Safety warnings, which if not followed
can result in hazard to life and limb, are
indicated by this symbol. The symbol
indicates an immediate danger. The possible
consequences of non-observance may be
severe or even fatal injuries.
C AU T I O N !
This symbol indicates potentially hazardous
situations. Failure to observe may result in
light injuries.
AT T E N T I O N !
This symbol indicates that failure to follow
the relevant instructions may result in
damage to the device or other equipment.
 PRODUCT INFORMATION

LABELLING

The nameplate mounted on the housing cover identifies

the type of JDN Air Hoist and contains all important
rating data.

If you have any questions concerning operation of JDN powered by air!

Air Hoists, which are not addressed in this operation

manual, please contact us at the following address:

J.D. NEUHAUS GMBH & CO. KG

Windenstraße 2-4
D - 58455 Witten-Heven

Phone +49 2302 208-0

Fax +49 2302 208-286
www.jdn.de
e-mail: info@jdn.de

Example of nameplate on housing cover

Page 7
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PRODUCT INFORMATION

A S S E M B LY OVE R V I E W
2
PROFI TI air hoists and monorail hoists consist of the
following assemblies: 3 1

1 Gearbox with chain sprocket and overload protection

2 Centre section
3 Motor with integral brake function
4 Controls with main air EMERGENCY STOP
5 Chain
6 Load hook with load sleeve or bottom block and buffer 5

PRODUCT DESCRIPTION

The PROFI TI series JDN Air Hoists and EHs described

here are designed for load-carrying capacities from 3.2 t 32

6
(PROFI 3TI ) to 20 t (PROFI 20TI/EH 20).
Various control devices are available for the different
requirements. 4

The air vane motor of the hoist, together with the

appropriate controls, is capable of sensitive movement.
This enables precise positioning of the load.

PROFI TI JDN Air Hoist and EH motors feature rotors

with grease chambers. These contain JDN highperfor-
mance grease which enables operation with oilfree
compressed air. It remains effective for an operating PROFI TI series JDN Air Hoists
period of approx. 250 hours and should be renewed
when required, but after five years at the latest (see
Motor lubrication, page 19). Additional lubrication
with oil-bearing compressed air by means of a service
unit with oiler is possible.

1
2 3

JDN monorail hoists EH

Page 8

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E X P L O S I O N P R OT E C T I O N
The basis for the following information is an expert
statement by the DMT Gas & Fire Division on the use of
JDN Hoists, Trolleys and Crane Systems in explosion-
hazardous areas, based upon European Guideline
94/9/EC1 (”ATEX 100a”). DMT is accredited with the
testing of devices and protection systems for intended
use in explosion-hazardous areas.
BA S I C E X P L O S I O N P R OT E C T I O N F O R T H E
S TA N DA R D VE R S I O N S ( E XC L U D I N G M I N I )
Standard version JDN Air Hoists are category 2 devices
(Guideline 94/9/EC, DIN EN 1127-12), for use in zone 1
and 2 for gases of explosion group IIA. (See also IEC
60079-123 and IEC 60079-204). These devices are also
suitable for use in zone 2, in the presence of gases of
explosion group IIB, provided that the substances
hydrogen sulphide and ethylene oxide can be excluded
and additionally in zones 21 and 22 for dusts with glow
temperatures above 210° C or ignition temperatures
above 202° C, provided that no light metal or other
impact-sensitive dusts are present.
These devices are designated by:
II 2 GD IIA T4(X)/ II 3 GD IIB T4(X)
Additional marking ”X”, see page 10.
JDN HOISTS
” 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 ”
JDN Hoists in the ”with increased spark protection”
version (SP), fulfil further explosion protection
requirements. With the exception of carbon disulphide
(temperature class T6), they can be used in the presence
of all gases in zones 1 and 2 and dusts with glow
temperatures above 210° C or ignition temperatures
above 202° C in zones 21 and 22, and can be designated
with II 2 GD IIC T4(X) for installation in a trolley,
depending upon trolley version (see below), but also
with II 2 GD IIB T4(X). For further operating
conditions, see Instructions for safe operation (Notes
D and E ).
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PRODUCT INFORMATION
JDN HOISTS FOR USE IN THE PRESENCE OF
TEMPERATURE CLASS T6 GASES OR EXTREMELY
EXPLOSIVE DUSTS
Following separate tests, especially with regard to
ambient temperatures and type of operation, use in the
presence of carbon disulphide or dusts with particularly
low glow or ignition temperatures may be possible with
designation II 2 GD IIC T6(X), which includes the
Additional marking ”X” for special conditions (see
Additional marking ”X”). Please contact us with regard
to these requirements.
S TA N DA R D J D N T R O L L E Y A N D C R A N E
RUNNING GEAR
JDN Trolleys and Cranes can be used in zone 2 with
standard running wheels (made of steel or cast metal)
with all dusts and the presence of gases up to explosion
group IIC. Due to the low running speeds, the possible
friction velocities on the running wheels are less than
1 m/s, so that standard running wheels can also be
used in zone 1 up to explosion group IIB. The highest
possible designation for these devices is:
II 2 GD IIB T4(X)/ II 3 GD IIC T4(X).
Depending on the hoist version, designations
II 2 GD IIA T4(X)/ II 3 GD IIB T4(X) or
II 2 GD IIB T4(X) are also used.
JDN TROLLEY AND CRANE RUNNING GEAR ”WITH
I N C R E A S E D S PA R K P R OT E C T I O N ”
For use in zone 1 in the presence of gases in explosion
group IIC, bronzed running wheels or running wheels
made of bronze will also be used. The highest possible
designation for this version (FSR) will be
II 2 GD IIC T4(X) (the same as for JDN Hoists
”with increased spark protection”).
JDN TROLLEY AND CRANE RUNNING GEAR FOR
U S E I N T H E P R E S E N C E O F T E M P E R AT U R E C L A S S
T 6 GA S E S O R D U S T S
As is the case with JDN Hoists ”with increased spark
protection”, temperature class T6 could also be possible
in this case too in the event of a special investigation
of applicability, so that the highest possible designation
for standard wheels and for bronzed or bronze wheels
are II 2 GD IIB T6(X)/ II 3 GD IIC T6(X) and
II 2 GD IIC T6(X) respectively, i.e. each including
the additional designation ”X” for special conditions.
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PRODUCT INFORMATION

G E N E R AL N OT E O N D E S I G N AT I O N J.D. NEUHAUS. The maximum permissible temperature

The highest possible respective designations for lifting of 150° C in accordance with EN 13463-15 for coal dust
equipment and running gear are usually replaced by a atmospheres is not reached. For mining applications,
designation, which corresponds to the normal assembly the relevant designation for hoists, trolleys and crane
of a compact complete device (trolley or crane system). systems is I M2.

A D D I T I O N AL M A R K I N G ” X ” L OA D C H A I N
This designation refers to explosion protection details In order to guarantee the required degree of earthing,
in the operation manual. extremely rusty chains must no longer be used in zones
II 2 GD IIA T4(X)/ II 3 GD IIB T4(X) or 1 and 21 or in category M2 devices. As, depending upon
the degree of corrosion, the leakage capability of the
II 3 GD IIA T4(X):
chain may be impaired to a level that is no longer ade-
This designation does not permit use in the presence of
quate.
the extremely flammable substances hydrogen sulphide
and ethylene oxide or in the presence of light metal or COMPRESSED AIR HOSES
other impact-sensitive dusts, or in the presence of dusts
In zone 1, compressed air hoses must have a sufficiently
with glow temperatures below 210° C or ignition
low surface resistance of less than 109  , in order to
temperatures below 202° C. The permissible ambient
prevent electrostatic ignition hazards. Otherwise
temperature range (Ta) extends from - 20° C to + 70° C.
(resistance >109 ), for explosion groups I, IIA and IIB
II 2 GD IIC T4(X) or II 2 GD IIB T4(X):
the hoses must be ∅  30 mm and for explosion group
The permissible ambient temperature range (Ta)
IIC ∅  20 mm, or proof must be provided that they
extends from - 20° C to + 70° C.
cannot become dangerously charged.
...IIC T6(X):
M AT E R I AL S F O R F R I C T I O N A N D I M PAC T H A Z A R D S
This designation permits use in the presence of carbon
Friction and impacts can give rise to individual sparks
disulphide or other temperature class T6 substances
presenting a danger of ignition in the presence of
only under special conditions, which have been agreed
explosion group IIC gases, hydrogen sulphide, ethylene
with the manufacturer and which are described in the
oxide, or light-metal or other impact-sensitive dusts.
crane documentation and which stipulate the maximum
Accordingly, spark formation caused by mechanical
surface temperatures for the device.
influences must be prevented. The chain and load must
U SAG E I N M I N I N G A P P L I C AT I O N S always be moved in such a way that sliding and/or
Standard versions of JDN Hoists, Trolleys and Crane frictional contact with other plants or components is
Systems may generally also be used for underground excluded. If circumstances do not permit this, it is
mining operations as well as for the associated surface necessary to ensure an absence of explosive
facilities, which are hazardous due to firedamp and/or atmospheres during operation.
combustible dusts. Within this equipment group I they
Impacts between particular materials result in an
belong to category M2. The devices must be switched
increased ignition hazard. This does not apply to
off in the event of an explosive atmosphere being
corrosion-resistant steel or cast iron against aluminium,
formed. They are equipped with protective measures
magnesium or corresponding alloys. This applies
offering a high degree of safety. The protective measures
especially in the presence of rust or rust film. Rust (also
with which products of this category are equipped
rust film) formation is possible, especially on the chain
provide the necessary degree of safety for normal
and on the load hook, at the friction points. The
operation as well as operation under difficult
following holds true for all zones: For the intended use
conditions, in particular rough treatment and changing
of hoists it must be ensured that no rust is present at
environmental influences. For other difficult conditions
the above-mentioned friction points and that material
in addition to explosion protection prevailing with
combinations of the above-named light metals with
regard to the general handling of the devices in mining
steel (exception being stainless steel) or cast iron are
applications, special mining hoists are available from
not used in the working area of the hoists, at potential

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 PRODUCT INFORMATION

friction, impact or sliding points. It is thus possible to

exclude sparking due to mechanical influences with
these material combinations.

The external housing of the service units is made of

aluminium. Therefore the installation position is to be
selected so as to ensure that there is no risk from
impact sparks.

EARTHING
Electrostatic ignition hazards can be prevented by
means of safe earthing. In zones 1 and 21, earthing of
the hoists is required. This must be achieved via the
load hook or the load eyes, if the lifting equipment is
connected to correspondingly earthed parts (earth
leakage resistance less than 106 ). This also applies to
operation with trolleys or cranes. Their tracks must be
earthed on site. Running wheels and rail surfaces must
never be painted, as this can result in unacceptably
high earth leakage resistance values.

Earthing of the load hook is via the chain (see also

Load chain, page 10).

Loads must be earthed during transportation.

A separate earth is required, for example, when
using non-conducting sling gear.

C L E A N I N G P L A S T I C S U R FAC E S
Where JDN Air Hoists or JDN Air Winches feature plastic
parts, these surfaces must only be cleaned using a damp
cloth (cleaning cloth with water). This reduces
electrostatic charging that can arise due to mechanical
friction at the plastic surface.
DA N G E R !
Electrostatic charging may occur at the
plastic surfaces, potentially leading to
electrostatic discharge that can ignite
gases and air mixtures.

AC E T Y L E N E A N D C OP P E R
When operating JDN products in explosion-hazardous
areas, in which an acetylene-containing atmosphere can
occur, it must be ensured that copper-plated parts are
kept dry, in order to exclude the possibility of oxidation
of the metallic copper and the formation of a aqueous
phase, which is capable of reacting with acetylene and
which can result in an explosion hazard.

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PRODUCT INFORMATION

EXPLOSION GROUPS AND TEMPERATURE CLASSES OF THE MOST IMPORTANT GASES AND VAPOURS (-SELECTION-)
(in accordance with DIN VDE 01656, Redeker7, Nabert, Schön8, IEC 60079-123 and IEC 60079-204)

Ex group Temperature class

T1 T2 T3 T4 T5 T6
Ignition temperature
> 450° C 450-300° C 300-200° C 200-135° C 135-100° C 100-85° C
Maximum permissible surface temperature of operating facilities
450° C 300° C 200° C 135° C 100° C 85° C
II A Acetone (Ethyl alcohol) n-Amyl alcohol Acetaldehyde
Ammonia (Ethylene glycol) Benzene
Aniline i-Amyl acetate (petrol)
Benzol n-Butane Diesel
Chlorobenzene n-Butyl alcohol Fuel oil
1,2-Dichlorobenzene 1-Butylene n-Hexane
Acetic acid 1,2-Dichloroethane jet fuels
Ethane Di-i-Propyl ether
Ethyl acetate Natural gas
(Ethyl bromide) Acetic anhydride
Ethyl chloride n-Propyl acetate
(Carbon monoxide) (n-Propyl alcohol)
o-Cresol i-Propyl alcohol
Methane Vinyl chloride
Methyl acetate
Methyl alcohol*1
Methyl bromide
Methyl chloride
Methylene chloride
Naphthalene
(nitrobenzene)
Phenol
Propane
Toluene
o-Xylene
II B Hydrocyanic acid Butadiene-1,3 Dimethylether Ethyl ether
(Ethyl bromide) Dioxane-1,4 **Hydrogen Ether
(carbon monoxide) Divinyl ether sulfide Anaesthetic ether
(Nitrobenzene) (Ethyl alcohol) Diethyl ether
Town gas Ethylene
(ethylene glycol)
**Ethylene oxide
Isoprene
(n-Propyl alcohol)

II C **Hydrogen **Acetylene **Carbon

disulphide

( ): The measured values for the substances placed in brackets are close to the limit or the next group or class when classified
in the explosion groups or temperature classes. For this reason, they have been included in both.
**: Extremely flammable substances (cf. additional marking ”X”)
*1 (Methanol = Methyl alcohol)

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 PRODUCT INFORMATION

DECISION CRITERIA FOR SELECTING THE CORRECT JDN HOISTS

IN EXPLOSION-HAZARDOUS AREAS

Explosion groups of gases and vapours Zone Version*1 Operation*2

(See Explosion groups and temperature classes of the most important gases and vapours) Manufacturer’s Operator’s
responsibility responsibility
II A 2 A E
1 A E
II B (X) except hydrogen sulphide, ethylene oxide 2 A E
(particularly flammable) 1 A FS E
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
Explosion-hazardous dusts Zone Version*1 Operation*2
22 A E
Usual industrial dusts
21 A E
22 A FS D E
Light-metal or impact-sensitive dusts
21 A FS D E

*1: Version features (under the responsibility of the manufacturer):

A: The chain is made of zinc-plated steel; metal controls are conductively connected to the hoist. This is part of the
standard equipment. For technological reasons, a zinc-plated version of chain size 31.5 x 90 is not available. This
is only used for the extremely slow-running chain drives of large 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 and bottom block with brass safety catch.
FSR: Running gear ”with increased spark protection”:
Running wheels for trolleys and cranes are made of bronze.
*2: Instructions for safe operation (operator’s responsibility):
D : Ignition hazards are not to be expected if hoists or cranes are used in the normal manner. Friction and impacts in
the working area of the chain, not resulting from intended use of the hoist or crane and which result in sparking,
must be excluded, or an absence of gas in the operating area must be ensured. This means, for example, that the
chain, the bottom block and the load hook must be prevented from swinging against surrounding objects or that
a gas-free environment must be ensured.
E : Friction, impact and sliding points involving combinations of light metal and steel or cast iron must not be
present in the hoist’s operating area.
T : Ambient temperature and the type of operation must be examined separately.

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 PRODUCT INFORMATION

T E M P E R AT U R E L I M I T S F O R E X P L O S I O N - The corresponding surface temperatures can be derived

HAZARDOUS DUSTS from the lowest values for glow and ignition
In areas which are explosion-hazardous due to com- temperatures of dusts specified in the HVBG/BIA Report
bustible dusts, the surface temperature must not exceed 12/9710 ”Combustion and explosion characteristics of
two-thirds of the ignition temperature in ° C of the dusts”:
dust/air mixture. The temperatures of surfaces on which
Synthetic rubber, soot-containing:
hazardous deposits of combustible dusts can be formed,
Glow temperature 220° C – 75° C = 145° C max.
must not exceed the glow temperature of the relevant
permissible surface
dust minus 75K. Greater safety margins are required if
temperature
the thickness of the dust layer exceeds 5 mm.
Stearic acid:
Ignition 190° C x 2/3 = 126° C max.
temperature temperature
permissible surface.

P L E A S E AL S O O B S E R VE YO U R
C O R R E S P O N D I N G N AT I O N AL
R E G U L AT I O N S .
1 Guideline 94/9/EC of the European Parliament and the Council dated 23rd March 1994 on the adaptation of the laws
of the Member States concerning equipment and protective systems intended for use in potentially explosive
atmospheres
2 DIN EN 1127-1: Explosive atmospheres - Explosion prevention and protection - Part 1: Basic concepts and
methodology, 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 for flammable gases and vapours relating to the use of electric apparatus, 1996-10
5 EN 13463-1: Non-electrical devices intended for use in explosive areas - part 1: Basic methodology and requirements,
07/2009
6 DIN VDE 0165: Installation of electrical systems in areas with explosion hazard, 1991
7 Redeker, Schön: 6. Supplement to safety-related characteristic values for flammable gases and vapours, 1990
8 Nabert, Schön: Safety-related characteristic values for flammable gases and vapours, 2nd edition, 1978
9 DIN EN 50014 (VDE 0170/0171 part 1): 2000-02
Electrical apparatus for use in explosion hazardous areas: General provisions
10 HVBG/BIA report 12/97: Central association of German employer’s liability associations/trade association institute
for industrial safety

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INTENDED USE
JDN Air Hoists are designed for lifting and lowering
loads within the specified load-carrying capacities, with
a vertically-arranged chain. JDN Air Hoists from the
ranges PROFI 3 TI to 20 TI are also suited to pulling
loads horizontally. Please also observe the individual
national regulations. In combination with trolleys, JDN
Air Hoists are also suitable for the floorless horizontal
movement of loads.
Any other use or use outside these stipulations is
deemed to be impermissible. Oblique pulling, see
Operation section, page 29. J.D. NEUHAUS GMBH & CO.
KG cannot be held liable for any resulting damage. The
entire risk is borne by the user (see also Rules for safe
operation of hoists, page 29).
Intended use also includes observance of the operation
manuals and compliance with the inspection and
maintenance conditions.
EMISSIONS
The noise emission data can be found in the Technical
data table, pages 64 and 66.
The noise pressure level of the measurement area at a
distance of 1 m from the machine surface was measured
in accordance with DIN 45 635, Part 20, at the
operating air pressure specified by us. In the hall, the
noise pressure level drops by approx. 3 dB (A) every
time the distance is doubled.
If the device is operated with motor oil lubrication,
small amounts of lubrication oil will be released into
the environment with the outlet air.
Oil emissions can be prevented by using a filter silencer
(see Filter silencer section, page 62). This also results
in a reduction of the noise emission values.
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PRODUCT INFORMATION
OP E R AT I N G C O N D I T I O N S
JDN Air Hoists are extremely robust and require little
maintenance. They are suitable for use in explosion-
hazardous areas, as well as in areas with increased
concentrations of soot and dust, high humidity and at
ambient temperatures of -20° C up to approx. +70° C if
they are not heated above this level due to external
influences. The thermal endurance of chains and hooks
is +150° C.
C AU T I O N !
When touching metallic hand controls which
are colder than 0° C, the skin could freeze
within a few seconds, and for temperatures
above 43° C, burns can occur. As a protective
measure, please wear suitable gloves.
For stationary outdoor operation, hoists must be
protected against weathering and the maintenance
intervals must be shortened.
Depending upon the version, JDN Air Hoists must be
operated at a system pressure of 4 bar or 6 bar (see
information on the nameplate). If the system pressure
is too low, important functions of the hoist will be
impaired:
왘 The brake will drag and is thus subject to a high
degree of wear. An impermissibly high degree of
warming could take place.
왘 The controls become noticeably less sensitive.
DA N G E R !
Warning against excessive system pressures
Operating with excessive system pressures
results in danger due to overloading.
Therefore, the pressure must be limited to
that specified on the nameplate.
JDN Air Hoists must be operated with a sufficiently
clean and dry air supply. The air supply must fulfil
the following quality requirements:
왘 Particle size less than 40 µm
왘 Particle density less than 10 mg/m3
(corresponds to Class 7 in accordance with ISO 8573-1:2001)
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PRODUCT INFORMATION

In order to provide adequate compressed air quality,

operation with a service unit is recommended. Usually,
an oiler is not required in the service unit, as the motor
is provided with internal permanent lubrication.

왘 Pressure dew point at least 10° C below the lowest

expected ambient temperature.

Do not operate JDN Air Hoists with other gases!

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:

왘 the use of an upstream air dryer or using a service

unit with oiler,
왘 adding anti-icing agent to the lubrication oil
(depending upon moisture content of compressed air)
왘 or using compressed air oil (Art. no. 11900) with
anti-icing agent for relevant temperatures.

In the event that your JDN Air Hoist is operated in

combination with a trolley, please also read the trolley
operation manual and the relevant accident prevention
regulations for operation with trolleys.

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ENERGY REQUIREMENTS
For air pressure, air quantity and connections, see the
Technical data table in the hoist operation manual
concerned.
A I R P R E S S U R E C O N D I T I O N S I N OP E R AT I O N
The system pressure in the air line must correspond
to the nominal pressure. Higher pressures must be
reduced.
After switching on, the nominal pressure p1 drops to
the actual pressure p2.
The value of the actual pressure depends upon …
… and the direction of movement of the load.
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PRODUCT INFORMATION
The value of the actual pressure p2 at which the hoist
is operated, depends upon
왘 the weight of the load and
왘 the direction of movement of the load.
When lifting the nominal load (load-carrying capacity),
the actual pressure p2 must not fall below a value of
10% below the specified nominal pressure of the hoist.
Example:
A hoist with a nominal pressure of 6 bar lifts its
nominal load at the specified lifting speed, at an actual
pressure of 5.4 bar.
… the weight of the load …
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PRODUCT INFORMATION

P R I N C I P L E O F OP E R AT I O N O F
4.2 1 6 4.1 2 5
J D N A I R VA N E M OTO R S

The vane motor consists of a cylinder liner 1 with two

side bearing plates and an internal rotor 2.

The rotor is mounted eccentrically in the cylinder

liner and is provided with slots 3 for installation of
the vanes 4.

The vanes can move freely and make contact with the
inner wall 5 of the cylinder liner. Each chamber is
formed by two vanes 6.

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 the rotor torque.

As the chamber passes the outlet aperture 7, the

compressed air can escape.

Lubricant chambers 8 are provided between the vane

slots of the rotor. They ensure continual motor
lubrication. 8 3 4 7

The arrows in the illustration indicate the direction of

rotation of the rotor and the corresponding path of the
compressed air.

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 PRODUCT INFORMATION

OP E R AT I O N W I T H O U T C H A I N B OX S PA R E PA R T S

DA N G E R ! Only use original JDN spare parts. J.D. NEUHAUS

If JDN Air Hoists are operated without a GMBH & CO. KG accepts no liability for the use of
chain box it must be ensured that the idle non-original components and/ or modifications by
chain (unloaded chain end) running up or unauthorised persons.
down at the chain sprocket, does not present
a hazard, e.g. due to catching, impacting or
falling.

Danger due to falling chain can also arise, if

the idle chain is first deposited on a load with
a large surface and then slides off and drops.

M OTO R L U B R I C AT I O N /
OP E R AT I O N W I T H A S E R V I C E U N I T

JDN Air Hoists are provided with motor lubrication

which must be renewed when required, but every 5
years at the latest. Therefore, the service unit for
filtration and pressure-regulation 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. Alcohols are not permitted for use as
anti-icing agents.

M A R K I N G / D E C L A R AT I O N O F
I N C O R P O R AT I O N

Only hoists for which EC conformity in accordance with

EC Machinery Directive 2006/42/EC has been declared
may be operated within the EU.

In the case of a designation, only the EC conformity

declaration provides information on which EC directive
has been met.

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TRANSPORT AND STORAGE

TRANSPORT AND STORAGE

SA F E T R A N S P O R TAT I O N

If you wish to transport your JDN Air Hoist to another

site, please observe the following points:

왘 Carefully dismount trolley (if available).

왘 Set the entire hoist down carefully; do not allow it
to drop. See Technical data, page 64 and 66 for
information on weights.
왘 Lay control and supply hoses together in such a way
that they are not kinked.
왘 Please ensure that the controls are not damaged.
Could lead to malfunctions.
왘 Draw in the hoist’s chain in such a way that loops
cannot form and the chain cannot become twisted.
왘 Secure the chain.

S TO R AG E C O N D I T I O N S

B R E A K S I N OP E R AT I O N
왘 In the case of longer operational breaks, coat the
chain and hook with a light oil film.
왘 Motor conservation
If the motor lubrication is not renewed after the
specified intervals, the motor must be conserved. For
this purpose, use a non-resinous and non-sticky
conserving oil with a conserving protection duration
which corresponds to the length of the planned
operational break.

S TO R AG E
왘 Close off the air supply hose connection using
adhesive tape or a suitable cap, in order to prevent
dirt ingress.
왘 Protect the air supply hose from being damaged.
왘 Store your JDN Air Hoist in a clean and dry place.

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 INITIAL OPERATION

INITIAL OPERATION
U N PAC K I N G
C AU T I O N !
When unpacking, take account of the weight
of the hoist. See Technical data, page 64
and 66.
AT T E N T I O N !
Do not kink the control lines. Kinked control
lines can result in malfunctions.
왘 Keep the accompanying documents in the place
provided, near the operating site.
왘 Lift the hoist carefully out of the packaging.
왘 Dispose of packaging in the local recycling system.
DA N G E R !
The supporting structure of the air hoist must
form a rigid mounting. Vibration damages the
chain and can lead to chain fracture.
Furthermore, external vibration must on no
account be transmitted to the hoist (lifting
gear). (e.g. from the suspended load).
왘 Provide a suitable working platform.
왘 Attach the hoist at the suspension hook
(or suspension eye) to the running gear or a
stationary fixing.
왘 Ensure that the hook safety catch closes
automatically.

A S S E M B LY

JDN Air Hoists are usually delivered pre-assembled.

If not, first read the following sections:

왘 Connecting the controls, page 22

왘 Removing and installing chain, page 57
왘 Chain box, page 63

In the event that the chain is included unattached, a

short auxiliary chain is drawn into the hoist. In order
to draw in the chain, the hoist must be connected to
the main air supply and must be ready for operation.
Attach the hoist securely at the suspension hook or
PRIOR TO INITIAL OPERATION, THE CHAIN suspension eye.
MUST BE LUBRICATED (SEE LUBRICATING
THE CHAIN SECTION, PAGE 43). DA N G E R !
When loads are taken up suddenly on slack
chain, especially using hoists with high
I N S TAL L I N G T H E H O I S T lifting speeds, forces are generated which
may be equivalent to several times the load
weight.
DA N G E R !
JDN Air Hoists must only be installed by Type Force
qualified personnel. Faulty installation can PROFI 3TI 1.4-times load-carrying capacity
lead to severe accidents.
PROFI 6TI 1.3-times load-carrying capacity
DA N G E R ! PROFI 10TI, EH10 1.25-times load-carrying capacity
The attachment points for JDN Air Hoists
PROFI 16TI, EH16 1.2-times load-carrying capacity
must be able to safely withstand the
expected forces. PROFI 20TI, EH20 1.15-times load-carrying capacity

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INITIAL OPERATION

CONNECTING THE CONTROLS

C O N N E C T I N G T H E R OP E C O N T R O L S
왘 Knot both control ropes at the ends of the control
lever.
왘 Knot the green pin into the rope which activates
”lift” mode, with the pointed end upwards (also see
Rope control illustration, page 34).
왘 Knot the yellow pin into the rope which activates
"lower" mode, with the pointed end upwards.
왘 Knot the handle into the rope so that the arrow
markings correspond to the actual direction of
movement.

Rope control, motor side

E-CONTROL CONNECTION
Pushbutton valve (hand control)
왘 Guide the strain-relief cable through the eye on the
pushbutton valve and secure using the cable clamp.
왘 Push the one-ear clamps onto the hose ends.
왘 Attach the hoses to the hose nipples.
왘 The one-ear hose clamp must lie in the middle of
the hose nipple clamping range. The best clamping
characteristics are achieved in this range.

Pushbutton valve with nipple and rope with

designation lift and lower

Page 22

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 INITIAL OPERATION

왘 Secure the hoses using the one-ear hose clamps and

crimping tool. Installation example
Position the clamp on the hose with nipple.
Crimp the clamp ear until fully closed.
AT T E N T I O N !
To ensure perfect sealing, the ”ear” must be
fully closed on installation.
Permissible aperture
after crimping

Use of the normal

crimping tool ...

Pinched one-ear clamp and crimping tool

in order to remove the clamp,

set the crimping tool
transversely to the clamp ear
and cut the ear open …

Removal

왘 The bellows must be pulled over the other end of the

hose bundle including the strain-relief cable (coat
hose bundle with oil for ease of fitting). Pull the
bellows back far enough to permit further
installation. Push the one-ear clamps onto the free
ends of the hoses.

Illustration of bellows with hoses and strain-relief rope

Page 23
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INITIAL OPERATION

Control valve (on motor)

Note: In order to connect the hoses to the control
valve, we recommend removal of the hose adapter. Dowel pin
왘 Remove the hose adapter (secured via central bolt).
왘 Attach the hoses to the corresponding nipples (see
designation in illustration).
왘 Secure the hoses using the one-ear hose clamps and
crimping tool.
왘 Secure the strain-relief cable.
Raise
AT T E N T I O N !
The strain-relief rope must be installed with Lower
the correct length in order to prevent loading
of the hoses.

왘 Pull the bellows over the hose adapter. The upper

collar of the bellows fits into the recess of the hose Compressed air
adapter. connection
왘 In order to secure the hose adapter to the control
valve, a long A/F 6 socket spanner must be guided
Hose adapter with nipples designation lift, lower
between the three hoses, through the middle of
the bellows and inserted into the hexagon socket
of the bolt.

F-CONTROL CONNECTION
Pull the bellows over the hose bundle for F-control.
For F-control for lifting and lowering only, remove
approx. 80 mm of hose bundle protective sheathing;
for F-controls with additional functions (trolley/crane
movement) remove approx. 160 mm from end of
protective sheathing.

Pull the strain-relief ropes through the eye bolt and

secure them using rope clamps.

Insert the control hoses: See illustration above

Compressed air
with hose designation 1 or colour: white

Movement direction ”lift”

hose designation 2 or colour: green

Movement direction ”lower”

hose designation 3 or colour: red
Bellows with A/F 6 socket spanner

Page 24

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The control hoses for the drive motors (trolley/crane
movement) must be extended, outside of the bellows,
by means of plug-in connectors and additional control
hoses.
Connection see ”Trolley” operation manual.
AT T E N T I O N !
The control hoses must not be subject to
tensile load; adjust the strain-relief cables
accordingly.
Pull the bellows over the hose adapter and secure via
the central bolt (see illustration on page 24, bottom).
FI-CONTROL CONNECTION
Pull the bellows over the hose bundle for F-control. Re-
move approx. 80 mm of hose bundle protective sheathing.
With this type of control, strain-relief of the hand
controls takes place via the protective sleeve of the
hose bundle. For this purpose, the protective sleeve is
pushed onto the hose carrier and is secured using a
one-ear clamp.
Installation facilitation: Heat the protective sleeve
(hose sheathing) with a hot-air gun and grease the
hose carrier.
Slightly bend open the ring of the eye bolt in order to
attach the hose carrier. Close the ring again to prevent
detaching.
Insert the control hoses:
See illustration on page 24, top.
Compressed air
with hose designation 1 or colour: white
Movement direction ”lift”
hose designation 2 or colour: green
Movement direction ”lower”
hose designation 3 or colour: red
AT T E N T I O N !
The control hoses must not be subject to
tensile load; adjust the protective sleeve
accordingly.
Pull the bellows over the hose adapter and secure via
the central bolt (see illustration on page 24, bottom).
powered by air!
INITIAL OPERATION
R E P L AC I N G C O N T R O L S
Conversion to another type of control is a significant
modification to a hoist. Following conversion, national
safety regulations, including testing regulations, must
be observed. If you wish to exchange air controls E, F
or FI, proceed as follows (see illustrations in Connecting
the controls section)
C O N VE R S I O N F R O M E TO F
Control valve housing (on motor)
Removal of E-controls
Remove the hose adapter (secured by central bolt).
For removal of the hose adapter, a long A/F 6 socket
spanner must be guided through the middle of the
bellows and inserted into the hexagon socket of the
bolt (illustration on page 24, bottom).
Pull the bellows back over the hose until the hose
nipples with the one-ear clamps are exposed and
further removal is possible.
Detach the strain-relief rope and remove the one-ear
clamps (see Removal illustration, page 23).
Cut off the hoses below the hose nipples using a knife.
Unscrew the hose nipples (A/F 17).
Pull the bellows over the hoses of the E-controls. This
is also required for the F-controls.
Installation of F-controls
Pull the bellows over the hose bundle for F-control.
Remove approx. 80 mm of the hose bundle protective
sheathing or 160 mm for additional movements.
Screw the ”straight screw connections” (Steckfix) for
4 mm hoses into the hose adapter (A/F 16).
Pull the strain-relief ropes through the eye bolt and
secure them using rope clamps.
Insert the control hoses:
See illustration on page 24, top.
Compressed air
with hose designation 1 or colour: white
Movement direction ”lift”
hose designation 2 or colour: green
Movement direction ”lower”
hose designation 3 or colour: red
Page 25
INITIAL OPERATION

AT T E N T I O N ! CONVERSION FROM AIR CONTROL TO ROPE CONTROL

The control hoses must not be subject to
tensile load; adjust the strain-relief cables
accordingly.
Pull the bellows over the hose adapter and secure via
the central bolt, (see page 24, bottom).
C O N VE R S I O N F R O M E TO F I
Removal of E-controls as previously described (page 25).
Installation of FI-controls
Pull the bellows over the hose bundle for FI-control. Re-
move approx. 80 mm of hose bundle protective sheathing.
Screw the ”straight screw connections” (Steckfix) for
4 mm hoses into the hose adapter (A/F 16).
With this type of control, strain-relief of the hand
controls takes place via the protective sleeve of the
hose bundle. For this purpose, the protective sleeve is
pushed onto the hose carrier and is secured using a
one-ear clamp.
Installation facilitation: Heat the protective sleeve
(hose sheathing) with a hot-air gun and grease the
hose carrier.
Slightly bend open the ring of the eye bolt in order to
attach the hose carrier. Close the ring again to prevent
detaching.
Insert the control hoses:
See illustration on page 24, top.
AT T E N T I O N !
Only air controls without upstream main-
stream valve can be converted to rope control.
Removal of air controls
Remove the hose adapter (secured by central bolt).
For removal of the hose adapter, a long A/F 6 socket
spanner must be guided through the middle of the
bellows and inserted into the hexagon socket of the
bolt (illustration on page 24, bottom).
The cover ”1” in the axis centre must be removed
(M 6 bolt, A/F 5).
Installation of rope controls
The connecting surface of the hose adapter on the valve
housing is closed off with a disc, (from conversion kit
Art. no.: 13590, item 10) and is secured with the M 8 x
16 countersunk screw (item 50).
The dowel pin (roll pin, item 70) must be inserted in
the bore ”2” provided.
Insert the rope control lever connector (item 20) into
the cover bore with the lug ”3” facing upwards; push
on the control lever (item 30) and secure with the M6 x
35 bolt (item 40) and washer (item 60).
Guide the control ropes ”4" through the bores ”5" in
the lever and knot them. Rope colour: ”green” lift,
”red” lower. Further, see section Connecting the rope
controls, page 22.

Compressed air
with hose designation 1 or colour: white

Movement direction ”lift”

hose designation 2 or colour: green

Movement direction ”lower”

hose designation 3 or colour: red

AT T E N T I O N !
The control hoses must not be subject to
tensile load; adjust the protective sleeve
accordingly.

Pull the bellows over the hose adapter and secure via Installation of rope controls
the central bolt (see illustration on page 24, bottom).

Page 26

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 INITIAL OPERATION

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

왘 Check air connection for contamination and clean if

necessary.
왘 Blow through compressed air hose in order to remove
foreign bodies.
왘 Attach the compressed air hose to the connection on
the hoist or on the service unit. Tighten the union nut.

LUBRICANTS

The following lubricants are intended for normal

environmental influences.
In the case of wear-promoting environmental
influences, please contact J.D. NEUHAUS, to receive
the appropriate instructions.

C AU T I O N !
Oils and greases can cause skin irritation.
Wear protective gloves.

AT T E N T I O N !
Potential damage! Do not mix synthetic oils Attach the compressed air hose and tighten
or greases with mineral oils, as the properties the union nut.
may be impaired.

Also, never mix different types of lubricating

grease within the synthetic or mineral
lubricant groups.

Synthetic lubricants must not be used when

operating with oilers.
Alcohols are not permitted for use as anti-
icing agents.

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INITIAL OPERATION

Application Lubricant C H E C K I N G P R I O R TO I N I T I AL OP E R AT I O N
Motor lubrication - JDN high-performance
grease, Hoists, including the supporting structure, must be
- from factory Art. No. 11901 (250 ml) inspected by an appropriately trained and qualified
- when operating with oiler - Compressed air oil ˝D˝,
person before initial operation and before re-
kinematic viscosity
approx. 30 mm2/s (cSt) commissioning after significant modifications. Hoists
at 40° C, with anti-icing and lifting gear which are installed in trolleys must be
agent where applicable inspected by a specialist.
Chain lubrication chain oil or motor vehicle
engine oil, kinematic The inspection covers the proper mounting, equipment
viscosity approx. 150 mm2/s level and operational-readiness, in the main, the
(cSt) at 40° C, or special completeness, suitability and effectiveness of the safety
lubricant from J.D. NEUHAUS
In areas with very high devices as well as the condition of the device, the
corrosion potential, e.g. harness, the equipment and the supporting structure.
offshore, a lubricant with
extremely strong anti-corro- Safety devices are braking devices, overload protection
sion properties must be used.
devices, EMERGENCY STOP devices, lifting and lowering
Motor conservation Non resinous limiters (emergency end-stop devices).
(not applicable when using Conservation oil with
JDN high-performance grease) appropriate period of
effectiveness A description of the inspection can be found in the
Maintenance section, page 37.
Motor cleaning Pure petroleum
(not applicable when using
JDN high-performance grease)
Lubrication of bearings Lithium-thickened grease,
and gearbox (also for worked penetration 265-295
exposed gears) (0.1mm), basic oil viscosity:
190 cSt (mm2/s) at 40° C,
drop point: 180° C,
Working temperatures:
- 20° C to + 120° C,
designation in accordance
with DIN 51825: KP2K-20,
active agents:
EP additives (for wear-
reduction) and ageing
protection; water resistant
and corrosion protection

A copy of the special publication ”Recommended

lubricants” is available on request.

Page 28

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 OPERATION

OPERATION

R U L E S F O R SA F E OP E R AT I O N
OF HOISTS

As an operator of hoists, you are responsible for

your own safety and for that of your colleagues in
the working area of the hoist.

왘 Hoists may only be operated by persons charged with

this task by their company.
왘 Before using the JDN Air Hoist for the first time,
familiarise yourself with all permissible operating
conditions. For this purpose, read through this
operation manual thoroughly and perform the
described actions on the crane, step by step.
왘 Report each malfunction to your safety officer
immediately, so that the fault can be remedied
without delay.
왘 Adhere to the regulations of the accident prevention
authorities (e.g. Berufsgenossenschaft regulations in
Germany). Oblique pulling
왘 Always comply with the information in the Intended Under special safety provisions relevant to the
use section on page 15. particular situation, JDN Air Hoists may be used
for oblique pulling (see Intended use, page 15).
The following uses are classified as impermissible: In this case, a chain box must not be used as the
왘 Oblique pulling of loads in general. chain may fall out or become knotted.
Oblique pulling is not permitted for hoists installed
Definition of oblique pulling in trolleys or in running gear. Please contact us,
Oblique pulling is the deviation of the load chain and if required.
the chain hoist from the vertical position, for a force
왘 Detaching or dragging of loads.
acting in a straight-line between the point of force
왘 Loading of the hook at the tip.
application of the load on the load hook and the
왘 Catching of falling loads.
point of suspension on the supporting structure.
왘 Carrying persons (see Intended use, page 13).
왘 Jog control with load on the hook.
왘 Switching to the opposite direction with load
in motion.
왘 Operational reaching of lifting and lowering limiters.
왘 Allowing the safety clutch to slip following actuation
due to overload (PROFI 3 TI - 20 TI, EH 10 - EH 20).
왘 Never hold the chain in the area of the centre
section under tension at the upper or lower limit
position of the load hook.

Page 29
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OPERATION
JDN Air Hoists must not be used for the following
applications, for example:
왘 Critical areas of nuclear plants.
왘 Over acid baths or other facilities containing corrosive
substances.
왘 In areas in which organic acids are present.
To ensure the safety of personnel and property
when using JDN Air Hoists, it is essential that the
following points are observed:
왘 Lift the load carefully at the beginning.
왘 Never touch a running chain.
왘 Never use the hoist chain for attaching loads.
왘 Never allow loads to fall into the hoist chain.
왘 If the chain is slack, do not take up the load at
maximum speed.
왘 When operating without a chain box, avoid hazards
due to idle chain (falling, catching, impacting), see
section Operation without chain box, page 19.
왘 Never apply bending loads to chains.
왘 Do not join or repair hoist chains.
왘 Do not operate with a chain which is drawn tight,
bent or extended.
왘 Check blocked chains for damage.
왘 Straighten twisted chains (defective bottom block)
왘 Do not operate with damaged, worn or rusty chains.
왘 Permissible operating temperature for chain and
hook: - 40° C to + 150° C, permissible ambient
temperature: - 20° C to + 70° C, permissible heat
absorption of the hoist body: max. 90° C.
왘 Never allow persons to enter the area below the
suspended load.
왘 Never attempt to remedy a fault with a load
suspended from the hoist.
왘 Only use suitable and approved attaching aids; do
not jam the hook at the point of attachment.
왘 Please ensure that the operator is not put at risk with-
in the operating area by attaching aids or the load.
왘 Follow the relevant instructions for attaching loads.
왘 Before attaching, accurately position the load verti-
cally below the hoist. The chain must hang vertically
before lifting.
왘 Ensure that the hook safety catch is closed.
왘 Before lifting loads, ensure that the maximum per-
missible load is not exceeded. Attaching aids must be
included in the weight of the load.
Page 30
powered by air!
왘 During lifting and lowering, prevent accidents by
ensuring that the load remains stable and does not
tilt or fall.
왘 Never drive against jammed loads.
왘 Only use original JDN chain boxes.
왘 Only lift one load at a time; never several loads
simultaneously.
왘 Never lock the control elements of the control
devices.
왘 If the control elements become difficult to operate
have the hoist repaired.
왘 In the case of power failure, secure the load and
the surrounding area, until the power is restored.
왘 Never use or repair bent, open or deformed load
hooks. The hoist must be repaired and the hook
must be replaced.
왘 Never anneal the hook.
왘 Only operate JDN Air Hoists with original JDN
controls.
왘 Uncontrolled, external force factors (such as due to
hydro cylinders, falling loads) are not permitted.
왘 Repair damaged hook safety catches.
왘 Repair stiff hook bearings.
왘 Do not kink or pinch control hoses.
왘 Have loosened bolted connections tightened by the
Repairs department.
왘 Before removing compressed air hoses, shut off the
compressed air supply.
왘 Do not exceed the permissible capacity of the chain
box.
왘 Repair the hoist if the braking distance is excessive.
왘 If a load is lifted using several air hoists, prevent
overloading due to incorrect weight distribution.
왘 Select a safe operating location.
왘 Ensure the correct system pressure.
왘 Never touch metallic hand controls which are colder
than 0° C or hotter than 43° C, without suitable
protective gloves.
왘 Do not make modifications to the hoist.
왘 Only use original JDN spare parts. J.D. Neuhaus
GmbH & Co. KG accepts no liability for the use of
non-original components and/or modifications by
unauthorised persons.
왘 Do not switch on multi-chain hoists if the bottom
block is supported.
왘 Special safety precautions must be taken when lifting
loads into areas which are out of sight.
 OPERATION

DA N G E R !
For all air hoist applications, ensure that
the load hook can be lowered all the way to
the ground, in order to prevent a load being
moved to the lower limit position, without
reaching the ground. Danger due to overloading.

DA N G E R !
Never use hoists on the ground if they are not
specifically intended for horizontal pulling.

DA N G E R !
The fatigue strength of chains is significantly
impaired due to extreme corrosion (pitting
corrosion). This causes a danger of fracture.
Hydrogen-induced embrittlement with re-
sultant stress cracks due to highly corrosive
media (e.g. sea water) may affect high-
strength steels (e.g. chains). 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 for operational reasons,
crack inspections are to be carried out at
intervals of three months.

Company operating instructions

In the case of particularly difficult lifting equipment
applications, the company must provide comprehensible
operating instructions in the language of the operator,
within the framework of this operation manual. Here,
measures for safe operation are stipulated in accordance
with prevailing operating conditions.

Furthermore, it is essential that all the regulations set

out in sections Intended use, page 15 and Operating
conditions, page 15, are observed.

Page 31
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OPERATION
CONTROLS
JDN Air Hoists can be equipped with a variety
of control devices. They are all suitable for use in
explosion-hazardous areas.
All control switches return to the zero position
when released.
C O N T R O L VALVE O N M OTO R
Air control (E-, F-, FI-control) with MS
Control valve with upstream main-stream valve
The control valve consists of:
1. Main-stream valve
2. Direction control valve as rotary valve
3. Positioner (pneumatic actuation)
The main-stream valve lies upstream from the rotary
valve. If no control pressure is present, this valve is
closed and the rotary valve is depressurised. If control
pressure is applied from the hand control, the valve
opens and releases the main stream.
If the red EMERGENCY STOP button on the hand control
is pressed, all control lines are depressurised and the
main-stream valve is closed.
The rotary valve positioner is mechanically connected
to the rotary valve drive.
The positioner is actuated by the control air.
Page 32
powered by air!
Air control (E-, F-, FI-control)
Control valve without upstream main-stream valve
The control valve consists of:
1. Direction control valve as rotary valve
2. Positioner (pneumatic actuation)
The rotary valve positioner is mechanically connected
to the rotary valve drive.
The positioner is actuated by the control air.
Rope control
Control valve without upstream main-stream valve
The control valve consists of:
1. Direction control valve as rotary valve
2. Positioner
The rotary valve positioner is mechanically connected
to the rotary valve drive.
For the purpose of actuation, the rotary valve is directly
connected to the control lever.
E-CONTROL
With E-control, lifting and lowering movements can be
controlled via two pushbuttons. The direction of
movement of the load hook is marked on the upper side
of the valve housing, above the pushbuttons.
왘 Lift: Press the right pushbutton.
왘 Lower: Press the left pushbutton.
E-control with EMERGENCY STOP button
 OPERATION

P U S H B U T TO N F - C O N T R O L
With pushbutton F-control, lifting and lowering
movements can be controlled via two pushbuttons. The
direction of movement of the load hook is marked by
arrows next to the pushbuttons.

왘 Lift: Press the upper pushbutton.

왘 Lower: Press the lower pushbutton.

F-control with EMERGENCY STOP button

P U S H B U T TO N F I - C O N T R O L
With pushbutton FI-control, lifting and lowering
movements can be controlled via two pushbuttons
arranged side by side. The control pressure is infinitely
variable, enabling precise positioning of the load. The
direction of movement of the load hook is marked by
arrows on the pushbuttons.

왘 Lift: Carefully press the right pushbutton. The load is

lifted slowly.
왘 Press the pushbutton further down in order to
increase the lifting speed.
왘 Release the pushbutton slightly in order to reduce
the lifting speed. EMERGENCY STOP button
왘 Lower: Carefully press the left pushbutton. The load
is lowered slowly.
왘 Press the pushbutton further down in order to
increase the lowering speed.
왘 Release the pushbutton slightly, in order to reduce
the lowering speed. FI-control with EMERGENCY STOP button

Page 33
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OPERATION

왘 Lower: Carefully pull on the red rope with the yellow

E M E R G E N C Y S TOP D E V I C E
handle pin. The load is lowered slowly.
왘 Pull harder on the rope, in order to increase the
Within the EU, these controls are equipped with an
lowering speed.
EMERGENCY STOP device (optional outside the EU). 왘 Release the rope slightly, in order to reduce the
In order to avert danger arising from the lifting move- lowering speed.
ment as quickly as possible, the pushbuttons must be
released; the movement of the load is interrupted
immediately.

Only in the case of failure of this stop function, must

the red EMERGENCY STOP button be firmly pressed. The
EMERGENCY STOP button engages. This results in the
closing of a separate check valve and the load hook
comes to rest instantaneously. The pushbuttons for
lifting and lowering now no longer function.

The EMERGENCY STOP button can be released again by

turning clockwise. It jumps back into place.

DA N G E R !
Never release the EMERGENCY STOP button
before the danger has been eliminated and
the stop function via the pushbuttons has
been restored.
Rope control
R OP E C O N T R O L
With rope control, the lifting and lowering movements
are controlled directly. Both rope ends are connected to OVE R L OA D P R OT E C T I O N
one another via a handle, enabling precise one-hand
operation. The direction of movement is marked by
Your hoist is equipped with a direct-acting overload
arrows on the handle.
protection in the form of a new type of safety clutch.
The control elements for rope control and the energy- This safety clutch limits overload to 120 % of load-
switching component of the control valve on the motor carrying capacity, without the danger of failure due
(reversing valve), are positively connected to one to the load running back.
another. This connection is designed in such a way, that
in an emergency, the control valve can be reset to a
stable neutral position. Thus, no additional EMERGENCY AT TAC H I N G T H E L OA D
STOP device is required.
DA N G E R !
왘 Lift: Carefully pull on the green rope with the green
Only use attaching cables or attaching chains
handle pin. The load is lifted slowly.
which are suitable for the load. Attaching
왘 Pull harder on the rope, in order to increase the
must not be attempted by winding with the
lifting speed.
lifting chain around the load.
왘 Release the rope slightly in order to reduce the lifting
speed.

Page 34

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In Germany, the trade association regulations ”Operation
of load carrying devices used with lifting equipment”
(BGR 258) must be adhered to. In other countries, the
relevant local regulations must be observed.
왘 Attaching aids must be attached at the lowest point
of the hook. Never load the point of the hook.
왘 Ensure that the hook safety catch is closed.
Attach the load safely
L I F T I N G T H E L OA D
AT T E N T I O N !
JDN Air Hoists must be capable of alignment
under load. Otherwise impermissible addi-
tional forces can occur, which can damage
the hoist components.
powered by air!
OPERATION
왘 First, lift the load hook, in order to pull the slack
chain tight. With the chain tight, briefly interrupt
the lifting procedure. The hoist can align itself and
the material is protected.
왘 Then lift the load.
The overload protection system aborts the lifting
operation in the event of loads whose weight is more
than the pre-defined limit value for the overload
protection (see Overload protection section, page 59).
L OW E R I N G T H E L OA D
DA N G E R !
Ensure that there are no persons below
the load.
왘 Then lower the load and ground it carefully.
DA N G E R !
For all air hoist applications, ensure that
the load hook can be lowered all the way
to the ground, in order to prevent a load
being moved to the lower limit position
without reaching the ground. Danger due
to overloading.
D E TAC H I N G T H E L OA D
왘 Lower the load hook far enough, so that the load
can be easily detached.
왘 Move the load hook out of the lifting area in order
to avoid hazardous situations.
I N T E R R U P T I N G WO R K I N G
If you wish to interrupt working with your JDN Air
Hoist:
왘 Set down and detach the load.
왘 Move the load hook out of the lifting area
in order to avoid hazardous situations.
Page 35
TAKING OUT OF OPERATION

TAKING OUT OF OPERATION

S H U T T I N G D OW N D I S P O SAL

If the hoist is to be taken out of operation for a longer JDN Hoists contain a range of materials which, on
period of time it must be protected against corrosion expiry of the service life, must be disposed of or
and dirt. recycled where appropriate, in accordance with
statutory regulations.
왘 Coat the chain and hook with a light oil film.
왘 Move the load hook out of the lifting area, in Please note the following list of materials used:
order to avoid hazardous situations.
왘 Do not move against the lifting and lowering HOIST
limiters/ buffer (emergency end-stop devices). 왘 Ferrous materials
왘 Depressurise the air line. Steel
Nodular cast iron
왘 Non-ferrous metals
S TO R AG E Bronze
Aluminium
(see section Storage conditions, page 20) 왘 Plastics
polyurethane
polyoxymethylene
DISMANTLING polyvinyl chloride
polyamide, glass-fibre reinforced
DA N G E R O F I N J U R Y ! natural rubber
JDN Air Hoists must only be dismantled polypropylene
by qualified personnel. phenol resin
thermoset moulding compound
왘 Depressurise the air line. (asbestos-free brake lining)
왘 Provide a suitable working platform. synthetic rubber
왘 Loosen the union nut and remove the air hose.
왘 Protect the air connection against the dirt ingress. F I LT E R S I L E N C E R / S E R V I C E U N I T:
왘 Detach the control hoses from the hoist. Do not Zinc diecast
kink the control hoses. Brass
왘 Mark the connections. Nitrile rubber
왘 Detach the strain-relief and hose carrier and remove Aluminium
the control device. Polypropylene
왘 Carefully detach/ dismount the hoist and remove. Polyurethane
왘 For trolleys, proceed in reverse order to that described
Glass-fibre reinforced plastic
in the section on mounting trolleys (in the trolley
Steel
operation manual).
Polyacetal
Polyethylene

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MAINTENANCE
MAINTENANCE AND
I N S P E C T I O N I N T E R VAL S
JDN Air Hoists are extremely robust and require little
maintenance. Compliance with maintenance and in-
spection intervals is of great importance in order that
the hoist operates safely and reliably over a period of
many years.
C AU T I O N !
Maintenance work on JDN Air Hoists must
only be performed by trained and qualified
personnel.
CLEANING AND CARE
If your JDN Air Hoist is often used at different locations,
particularly in dirty and damp environments,
왘 clean any dirt off the hoist and the chain,
왘 seal off the air supply connections,
왘 protect the hoist and, in particular, the chain
from corrosion,
왘 store the hoist in a clean and dry place.
S PA R E PA R T S
If, during repair work, the replacement of components
is necessary, only original JDN spare parts may be
installed.
LUBRICANTS
(see section Lubricants, page 27)
powered by air!
MAINTENANCE
I N S P E C T I O N A N D R E PA I R S
Series lifting equipment is classified into groups and
dimensioned according to the type of operation (Driving
mechanism classification according to ISO/FEM).
The classification is determined by the average daily
operating time and the load spectrum. This is provided
that the lifting and lowering paths are approximately
the same.
For devices used mainly in vertical operation (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
operating time must be multiplied by a factor of fv.
The factor fv has a value of 1 to 50 % of the nominal
load, increasing linearly to 1.5 at 100 % of the nominal
load (nominal load percentage P).
fv = 1+0.5 P-50 (for P > 50%)
50
In order to achieve safe operating periods, the company
must check that the theoretical operating time has been
achieved during each inspection, by the person respon-
sible. This must be documented in the inspection log at
least once annually. The inspection log is only supplied
in the Federal Republic of Germany. Instructions and a
model for determining the actual operating time can
be found from page 39 onwards.
When the theoretical operating time has been reached,
a general overhaul must be performed. Detailed expla-
nations for the determination of the actual operating
time and its documentation can be found in the national
safety regulations. Alternatively, the calculation model
in this operation manual can be used. The general
overhaul must be initiated by the operator and must
be documented in the inspection log. Information on
general overhaul can be requested from the manufacturer.
Page 37
MAINTENANCE

Only if the group classification corresponds to the

actual type of operation of the lifting equipment, does
a safe operating period conform to the theoretical
operating time. Deviations of the actual type of
operation 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 must be disconnected from the main air
supply during assembly work.

Dismantling the hoist, see page 36.

C AU T I O N !
Following each repair, the hoist must be
checked for operational readiness.

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 MAINTENANCE

The formula given for the cubic average k does not

INSTRUCTIONS CONCERNING THE
take the weight of the harness into account. This is
”MODEL FOR DETERMINING THE permissible if the ratio
AC T UAL OP E R AT I N G T I M E ”
Weight of harness
≤ 0.05
The decisive factors for the type of operation are the Load-bearing capacity
collective loads with different cubic averages k .
The collective load indicates to what degree a driving To determine the type of operation for calculating the
mechanism, or a part of one, is subjected to its maximum partial operating times (actual operating time), the
stress or only to smaller stresses. The cubic average following collective load diagrams can also be used.
(factor of the load spectrum) is calculated using the
following formula.

Collective load 1 Collective load 2

Load proportions
0.733

Definitions: 0.467
1

0.4

0.1 0.2
Maximum or ultimate load
=
Load-bearing capacity t1 t2 tΔ t1 t2 t3 tΔ

0 10 50 100 0 16.7 33.3 50 100

Dead load
=
Load-bearing capacity
Collective load 3 Collective load 4
Load proportions

0.8
Operating time with maximum
load or partial load and dead load
=
1

0.4
Total operating time

t1 tΔ t1 tΔ
Operating time with dead load
= 0 50 100 0 90 100
Total operating time

The FEM* 9.511 rule differentiates between four collec-

tive loads, which are identified by the definitions and
by the ranges of the cubic averages k. This classification
complies with ISO 4301/1.
*FEM = Federation Europeene de la Manutention (European
Federation of Materials Handling and Storage Equipment)

Collective load Definition Cubic Collective load factor

average
1 L1 Driving mechanisms or parts thereof, which are only subject k ≤ 0.50 km = k3 = 0.125
(low) to the maximum stress in exceptional circumstances, and
are only subject to very lowstresses continuously.
2 L2 Driving mechanisms or parts thereof, which are subject to 0.50 < k km = k3 = 0.25
(average) the maximum stress often, and are only subject to low ≤ 0.63
stresses continuously.
3 L3 Driving mechanisms or parts thereof, which are often 0.63 < k km = k3 = 0.5
(high) subject to the maximum stress and are subject to average ≤ 0.80
stresses continuously.
4 L4 Driving mechanisms or parts thereof, which are regularly 0.80 < k km = k3 = 1
(very subject to the maximum stress of adjacent stresses. ≤ 1.00
high)

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MAINTENANCE

MODEL FOR DETERMINING THE ACTUAL OPERATING TIME

The following calculation compares the actual operating time with the theoretical operating time in collective load 4
(very heavy).
1 2 3 4 5 6 7
Remaining
Average Collective load factor in accor- Partial theoretical Date
daily dance withcollective load for deployment use in
Delivery
Operating operating the type of operation Column 2 collective load 4 Specialist
Initial
site time x column 3 (When zero has been reached operation inspector
L1 L2 L3 L4
x operating days a general overhaul must be
Very Inspections Signature
in hours x factor 1.2 performed)
Low Average High high
Existing driving mechanism Delivery date
group, see nameplate GmbH & Co.KG

– 0 0.125 0.25 0.5 1 0 M2 (1Cm) 200 hours Initial

M3 (1Bm) 400 hours operation
M4 (1Am) 800 hours
M5 (2m) 1600 hours

CALCULATION MODEL (DRIVING MECHANISM CLASSIFICATION M3)

Slewing
1.5 x 0.25 (400 - 113)
crane 2nd August
1.5 0.25 x 250 x 1.2 A.N. Other
assembly 287 hours 2004
= 113 hours
site

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 MAINTENANCE

The specified inspection intervals are valid for use in accordance with the classification (see driving mechanism classi-
fication on the nameplate). The service life is approx. 10 years if the device is used in accordance with its classification.
If the hoist is used more intensively the intervals are to be shortened accordingly. The intensity of use must be assessed
using the model for determining the actual operating time (see page 39). All operating hours are translated into full
load hours. The theoretical operating time and the interval hours are indicated in full load hours.

Maintenance measure Interval Comment

Check oil level for motor Daily (Filling and adjusting oiler section, page 47)
lubrication (when operating with oiler)
Lubricate the chain As required (Lubricating the chain section, page 43)
Visually check the chain Weekly

Inspection measure Interval Comment

Check control device Daily (Checking controls section, page 44)
Checking braking function Daily (Checking braking function section, page 43)
Checking direction of movement Daily (Checking direction of movement section, page 44)
Check lifting and lowering limiters Daily Replace buffer immediately if damaged, otherwise replace
(buffers) visually every 5 years
Check EMERGENCY STOP function Daily
Check chain Every 3 months (Checking chain, chain sprocket and chain guides
section, page 54) In the event of wear promoting
operating conditions, reduce intervals between checks
Check lifting and lowering limiters Annually (Checking lifting and lowering limiters section, page 43)
Check brakes with load Annually Load must be braked reliably (Checking braking function
section, page 43)
Check all the bolted and pin Annually
connections
Check load hook on load a. carrying side Annually (Check dimensions section, page 55)
Check the motor, check, clean and Annually Measure the lifting speed
grease the control valve (JDN high-
performance grease)
Check the axial movement of the Annually (Checking axial play section, page 56)
hooks and eyes
1
Check the service unit Annually (Service unit section, page 45)
Check the silencer for Annually (Checking silencer for permeability
permeability section, page 44)
Check overload protection Annually (Checking and adjusting overload protection section,
page 59)
Check compressed air connections for Annually
damage
1
If appropriate

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MAINTENANCE

Inspection measure Interval Comment

Check sealing efficiency and function Annually
of control valve
Check condition of the chain box1 Annually (Chain box section, page 63)
including mountings
Check for brake wear and motor Every 200 hours, at least (Replacing brake disc, brake piston and vanes
vane wear every 5 years section, page 48), replace motor vanes every 5 years
In off-shore areas and other similar Every 5 years
corrosive environments, replace the
chainregularly
Check gearbox and perform lubricant Every 5 years
change
Check the rotor/pinion shaft connec- Every 5 years
tion and lubricate with gear grease
Check the chain sprocket bearings Every 5 years
and lubricate if necessary
Check chain sprocket and chain guides Whenever chain is replaced (Wear dimensions section, page 56)
Renew grease lubrication of motor When required, (Motor lubrication section, page 48)
at least every 5 years
1
If available

For monorail hoists, also refer to ”Maintenance and inspection measures” in the Trolley operation manual.

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 MAINTENANCE

For physical reasons, the braking distance cannot have the

L U B R I C AT E T H E C H A I N
value zero. However, for the purpose of this functional
check, running on of the chain must not be
The chains of JDN Air Hoist must be lubricated in the perceptible.When checking the braking function under
links, in unloaded condition. nominal load, the following braking distances must not
be exceeded:
왘 Clean heavily contaminated chains.
왘 Lay the chain in a suitable container. B R A K I N G D I S TA N C E S U N D E R N O M I N AL L OA D
왘 Spray the chain with special lubricant or motor ( L OA D - C A R R Y I N G C A PAC I T Y ) A F T E R L OW E R I N G
vehicle engine oil. H A S B E E N S TOP P E D
If you wish to lubricate the hanging chain, ensure that
Type 3 TI 6 TI 10 TI 16 TI 20 TI
the chain links are oiled at the points of contact. For EH 10 EH 16 EH 20
this purpose, move the chain to and for.
A high-performance lubricant in an aerosol can is Rope control 36 15 18 10 8
available from JDN, which adheres well to the chain All others
after the solvent has evaporated and does not drip off, Controls with hose 48 22 26 14 11
lengths of 2 m
Art. no. 12066 (aerosol 400 ml).
Dimensions in mm
For operation in areas with high corrosion potential,
If the control hoses are long the braking distances will
e.g. in the off-shore sector, the chain can be largely
increase due to longer air evacuation times.
protected against corrosion by the use of special
lubricants.
These types of lubricants are characterised by weathering CHECKING LIFTING AND
resistance, water insolubility, good adhesion properties
L OW E R I N G L I M I T E R S
etc.
Re-lubrication intervals must be stipulated in accordance
왘 Move the unloaded load hook until just short of the
with the loading.
upper and lower end positions.
Please contact us, if required.
왘 Stop immediately before reaching the end position
and then carefully (by repeatedly pressing the control
CHECKING BRAKING FUNCTION element) move to the end position.
왘 The movement of the chain must be stopped due to
deformation of the buffer and activation of the safety
Check the function of the brake daily as follows:
clutch. The motor is however not switched off (only
왘 Switch the unloaded air hoist alternately between allow the safety clutch to act for a short time).
왘 Following successful testing, the buffer must be
lifting and lowering modes.
unloaded.
If a control element is released, the chain must be seen
not to run on. DA N G E R !
If the buffer is damaged, do not use the
DA N G E R ! hoist. The hoist must be repaired (replace
If the chain runs on, do not use the hoist. the buffer).
The hoist must be repaired.

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MAINTENANCE

With each check, the working order of the valve must

CHECKING CONTROLS AND
be examined as follows:
E M E R G E N C Y S TOP F U N C T I O N
왘 Shut off the compressed air supply and unload
All control elements of the controls must always be the line.
free-moving. 왘 Remove retaining ring 1.
왘 Pull out cover 2.
왘 Unload the JDN Air Hoist. 왘 Press plunger 3 inwards against the force of spring 4.
왘 Briefly actuate and release all control elements of the It must return again due to the spring force.
controls one after another. The control elements must 왘 If the plunger does not move, the valve must be
return to their initial positions immediately. The repaired.
switching on and off function must operate correctly.
왘 PRESS the EMERGENCY STOP button. Each movement
of the hoist must stop. Actuation of the control C H E C K I N G D I R E C T I O N O F M OVE M E N T
elements must not cause a lifting or lowering
movement. 왘 Check that the direction of movement of the load
왘 RELEASE the EMERGENCY STOP button by turning. hook corresponds to the direction indicated by the
arrows on the control elements.
DA N G E R !
If a control element is stiff or remains in the
actuated position, do not use the hoist. The
controls must be repaired. CHECK THE SILENCER
FOR PERMEABILITY

CHECKING THE MAIN AIR Independent of the stipulated inspection intervals,

the silencer must be checked for permeability if the
E M E R G E N C Y- S TOP VALVE
hoist does not achieve the specified lifting speed
(see Technical data section, page 64 and 66).
The main air emergency-stop valve is opened with each
actuation of the controls. It closes when the controls The test is performed by comparing the lifting speeds
are released. under nominal load, with and without the silencer.
The speed with standard silencer or filter silencer must
be at least 80 % of the lifting speed without a silencer
element. In the event of lower values, the silencer
elements must be cleaned or replaced.
4

3 1

Main air emergency-stop valve

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 MAINTENANCE

왘 Lock the regulator knob by pressing it down.

SERVICE UNIT
*)
Values for 4-bar hoists in brackets
AT T E N T I O N !
If a hoist is operated with a service unit, this If the nominal pressure of 5.4 bar (3.6 bar) cannot be
should not be mounted further than 5 m achieved despite a sufficiently high pressure upstream
away from the hoist. of the service unit, then the air line cross-section is
too small.
The ambient temperature must be a minimum of 0° C.
It must not exceed 50° C.

N OT E : If, at the request of the customer, a service unit

is installed in hoists in motorised trolleys and lifting
gear, it will be configured at the factory.

A maximum connecting pressure of 10 bar is permitted

for the service units supplied by JDN. Higher pressures
must be reduced to a permissible value, upstream of the
service unit.

The service unit consists either of two elements, filter

controller and oiler, or of the filter controller only.

C H E C K I N G A N D A D J U S T I N G T H E F I LT E R
CONTROLLER*)
The filter controller is set to an actual pressure of 5.4
bar (3.6 bar) in the factory (actual pressure when lifting
the nominal load). In this setting, the manometer can
indicate a pressure of over 6 bar (4 bar) with the motor
switched off. For correct adjustment, a pressure of at Filter regulator and oiler
least 7 bar (5 bar) upstream of the service unit is
required.
adjusting knob
왘 Lift the regulator knob.
왘 Turn the regulator knob until the manometer
indicates a pressure of 5.4 bar (3.6 bar). Clockwise:
higher pressure, Anti-clockwise: lower pressure
왘 Lock the regulator knob by pressing it down.

Alternatively, the filter controller can be set to a

pressure of 6 bar (4 bar) in the absence of an air
stream. This setting is only correct for a pressure of
at least 7 bar (5 bar) upstream of the service unit.

왘 Depressurise the air line downstream of the service

unit and close it again. lubricator
왘 Turn the regulator knob anti-clockwise, in order to
release the adjusting spring.
왘 Turn the regulator knob until the manometer
filter-regulator
indicates a pressure of 6 bar (4 bar). Clockwise:
higher pressure Anti-clockwise: lower pressure

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MAINTENANCE
D R A I N I N G C O N D E N SAT E
After a certain time, condensate collects in the filter
regulator container, which must be regularly drained.
Check the condensate level through the sight glass in
the filter container. The condensate level must not
reach the separating plate.
The container can be emptied manually or semi-
automatically, depending on the setting of the drain
valve:
왘 OFF position
The drain valve is closed in this position.
The OFF position is generally set at the factory.
왘 ON position
The condensate can be drained manually in this
position. Operate the drain valve by pressing upwards
(see Figure).
When the compressed air supply is connected, the
drain valve is under pressure. We recommend using
suitable splash protection (cloth, fleece) as the
condensate will otherwise escape uncontrollably.
Collect the escaping condensate and dispose of it as
it may contain oil.
왘 AUTO position
In this position, semi-automatic condensate drainage
takes place. When the pressure upstream of the
service unit falls below 0.2 bar, the container empties
automatically. With this setting it must be ensured
that a suitable container is in place to collect the
escaping condensate when drainage occurs.
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C L E A N I N G T H E F I LT E R E L E M E N T
AT T E N T I O N
Do not use alcohol for cleaning the service
unit. Alcohol can damage parts of service
unit. Transparent components must only be
cleaned using soap solution.
The filter element must be cleaned once annually.
For this purpose, proceed as follows:
왘 Drain the water.
왘 Shut off the main air supply and carefully allow the
residual pressure to dissipate.
왘 Unlock the filter regulator container, turn anti-
clockwise to the stop and remove.
왘 Unscrew the separating plate. The filter is located
loosely on the separating plate centring device.
왘 Clean the filter element using soap solution and blow
through forcefully.
왘 Reinstall the clean filter element and fasten the
separating plate.
왘 Insert the filter regulator container in the housing
and turn clockwise. The container locks
automatically.
filter element
separating disc
sight glass
filter receptacle
Cleaning the filter element
 MAINTENANCE

FILLING AND ADJUSTING OILER Oil drop rate (lifting without load):
The oiler ensures that the hoist air supply is 10 drops per minute.
consistently provided with a precisely-metered quantity
AT T E N T I O N !
of oil. Regular checking of the oiler is very important,
Operation of service units with synthetic oils
as the vane motor may be damaged in the case of
is not permissible. They must also not be
lubricant deficiency. The oiler can also be refilled under
connected to compressed air circuits, which
pressure.
are supplied by compressors lubricated with
왘 Check the oil level through the sight glass in the synthetic oil.
container. The oil level must not fall below the
C AU T I O N !
minimum mark.
J.D. Neuhaus only supplies standard spray
왘 Remove the oil filler screw.
oilers. Do not use microspray oilers as very
왘 Fill the container with oil up to the maximum mark
finely secreted oil spray could adversely
and refit the oil filler screw.
effect the surrounding air and therefore the
왘 Check the oil drop rate at the sight glass with the
respiratory system.
motor running.
왘 Turn the oil throttle screw using a screwdriver until
the desired number of drops per minute is achieved. Sight glass
Turning clockwise reduces the amount of oil; turning Oil filler screw
anti-clockwise increases the amount of oil.
Oil throttle screw

maximum
oil level Check oil drop rate at sight glass and adjust

minimum
oil level

Check the oil level and top up if necessary

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MAINTENANCE
R E P L AC I N G B R A K E D I S C , B R A K E P I S TO N
A N D VA N E S / M OTO R I N S TAL L AT I O N /
M OTO R L U B R I C AT I O N
9 10
Replacing brake discs, brake piston and vanes /Motor installation
The motor and brake functions are achieved in part by
means of shared components. The braking action is applied
at the lateral surfaces of the rotor. The rotor is pressed
via spring force from the cover-side of the motor against
a second braking surface located on the opposite side by
means of a piston on which braking material is bonded.
R E M OVAL
Proceed as follows when removing the motor with
the brake:
왘 Unload the hoist and disconnect it from the main
air supply.
왘 Detach the control valve from the motor (in order
to permit removal of the motor retaining bolts).
왘 Detach the motor from the hoist.
왘 Remove the motor cover bolts 1 and remove the
motor cover 2 with the nameplate 3. (When the
cover bolts are removed, brake spring tension 4 is
fully released).
왘 Remove the springs.
왘 Remove the brake piston 5 from the internal cylinder
integrated in the motor housing.
왘 Pull out the rotor 6, removing the vanes 7 and
starting aids 8.
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8 7 6 1211 5 4 2 1 3
13/14
Note: If you only wish to check for vane wear or
replace the vanes with the starting aids, please
continue with the section ”Checking for vane wear”.
왘 Remove the cover bolts 9 and remove the cover with
the brake lining 10 (brake disc).
왘 Check the braking surfaces of the brake piston and
the cover with the brake lining for wear and damage,
replace if necessary. The circular wear pattern in the
braking surfaces must not be deeper than 0.2 mm.
The extremely low-wear braking material will not
reach the wear limit of 0.2 mm within the design-
dependent service life of the hoist, under intended
use. Should the wear limit be reached prematurely,
the actual compressed air pressure must be checked
with the device switched on (the brake drags in the
event of insufficient pressure).
왘 Checking vane wear (see illustration Checking vane
wear, page 49). When the air motor vanes are worn,
the motor power and consequently the lifting per-
formance of the JDN Air Hoist are reduced. Replacing
the vanes together with the starting aids.

Rotor Cylinder liner
V1max. = 0,2 mm V2max. = 0,2 mm
Brake piston
Brake disc
R 왘
Lh
L
Lmax = R - (V1 + V2) Vane
Lmin = R - (V1 + V2) - 0,3 mm = Lmax - 0,3 mm
Lhmin = 19 mm
Checking vane wear
왘 Renew grease lubrication of motor. The grease packing
in the rotor chambers is sufficient for approx. 250
operating hours. For this time interval the load on
the hoist (collective load) is immaterial. Note: The
rotor chambers only empty by approx. 60 %. In this
condition, refilling must be performed. The retaining
rings 11 and Vyon washers 12 must be removed in
order to refill the chambers. Then pack the lubricant
chambers with high-performance lubricant (JDN Art.
no 11901) without forming cavities.
Use new round plates to close off the lubricant
chambers and secure these using retaining rings.
A S S E M B LY W I T H A D D I T I O N AL BA S I C M OTO R
L U B R I C AT I O N
왘 Fit the cover with the brake lining, inserting the
anti-twist device (pin). Coat the braking surface and
rotor bearing (needle bush) lightly with high-
performance grease.
왘 Tighten the cover bolts.
왘 Coat the internal cylinder of the housing lightly with
high-performance grease.
왘 Coat the entire rotor lightly with high-performance
grease and insert into the front rotor bearing with
the clutch side first.
왘 Coat the vanes lightly with high-performance grease
and insert into the rotor slots with the starting aids.
왘 Coat the braking surface and the outer diameter
including the brake piston seal lightly with high-
powered by air!
MAINTENANCE
performance grease and push the brake piston with
the braking surface first into the internal cylinder;
note the position of the eccentric bore.
왘 Insert the brake springs into the bores of the
brake piston.
왘 Detach the nameplate from the motor cover.
Loosen adjusting bolts 13 and lock nuts 14. Screw
back adjusting bolts.
왘 Apply high-performance grease lightly to rotor
bearing (needle bush)in the motor cover and install
motor cover, ensure correct seating of the brake
springs and locating pins to motor housing and
brake piston.
왘 Do not tighten the 4 adjusting bolts after bolting
the motor cover in place, only screw them in loosely
to the stop in the cover. Screw back the lock nuts
sufficiently beforehand.
왘 Then screw back the adjusting bolts 45° to 60° from
the stop, hold, and lock with the nuts. For operation
in areas with ambient temperatures exceeding 30°C,
the adjustment must be carried out with the device
warmed up accordingly. For lifting heights of 10 m
and more, the setting must be at least 60°C.
왘 Screw on the nameplate.
왘 Initially fasten the motor, then the control valve
to the hoist.
AT T E N T I O N !
Tightening torques, see E-list.
C AU T I O N !
Check the braking action of the hoist under
load (run in the brake by performing several
hoisting cycles, then assess) prior to initial
operation. Check the motor power. In the
event of low motor power, regulate the
adjusting bolts again.
Page 49
MAINTENANCE

L OA D S L E E VE I N S P E C I AL D E S I G N
REMOVING AND INSTALLING LOAD SLEEVE,
WITH CLAMPING PIECE
BOTTOM BLOCK, CLAMP AND BUFFER

R E M OV I N G A N D I N S TAL L I N G L OA D S L E E VE
AND BUFFER
- SINGLE CHAIN HOIST (3 TI)

1
3 3

2
2
5
5
6
7
4 4
5
5

Removal
왘 Drive out the roll pin 1 for securing the chain from
the load sleeve 3.
왘 Remove the chain link 2 from the chain pocket.
왘 Detach the buffer 4 and buffer discs 5 from the chain.
Assembly
왘 Push the buffer discs (edge encloses buffer) and the
buffer onto the chain.
왘 Insert the end chain link into the chain pocket of the
load sleeve (position of the weld must align with that
of the following links).
왘 Drive in a new roll pin to secure the chain link in the
load sleeve.
Removal
왘 Loosen screw 7 and take it out of the chain pocket
together with locking washer 6 and clamping piece 1
왘 Remove the chain link 2 from the chain pocket.
왘 Detach the buffer 4 and buffer discs 5 from the chain.
Assembly
왘 Push the buffer discs (edge encloses buffer)
and the buffer onto the chain.
왘 Insert the end chain link into the chain pocket
of the load sleeve (position of the weld must align
with that of the following links).
왘 Insert the clamping piece 1 into the chain pocket,
tighten screw 7 with locking washer 6 (41 Nm).

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REMOVING AND INSTALLING BOTTOM BLOCK
AND BUFFERS
- D O U B L E C H A I N H O I S T S (6 TI, 10 TI, EH 10)
왘 Remove the chain link 1 of the bottom block from
the chain mount on the hoist body by driving out the
roll pin 2 and pull out the chain link pin 3 (the end
chain link 4 of the idle chain is released simulta-
neously) or only pull out the chain link pin to the
extent that the end chain link of the idle chain is
not released from the hoist body. In versions with
chain box, the idle chain is not attached to the
hoist body.

Note: For assembly, it is helpful to fasten a short

assembly chain 5 to the end of the chain by means of
an open chain link 6 before pulling the chain out of
2 3 the bottom block. This assembly is pulled into the
4
bottom block as the chain is pulled out and remains
there until assembly is completed.

왘 Pull out the chain from the bottom block. The

buffer 7 and buffer discs 8 are thereby pulled
5 from the chain.
9 10
12 Assembly
11
13 왘 Push the buffer discs (edge encloses buffer) and
the buffer onto the chain.
왘 Align the chain and fasten it to the assembly chain
1
8 6
in the bottom block by means of the open chain link.
7 왘 Pull the chain through the bottom block and detach
8 the assembly chain and the open chain link from the
chain. If no assembly chains have been used, the end
of the chain must be inserted into the bottom block
and pulled through by turning the sprocket wheel
using an auxiliary tool.
왘 If the chain link pin was not completely pulled out,
only align the bottom block chain and push the chain
link pin through the chain link to be attached
(position of the weld must align with that of the
following links). If the chain link pin was pulled out
Removal completely, align the bottom block chain and the idle
왘 Move the bottom block as close as possible to the chain and push the chain link pin into the hoist. It
hoist body. must first be guided through the end link of the idle
왘 Position the bottom block securely in order to chain and then through the end link of the bottom
prevent the chain from unravelling uncontrollably block chain (position of the weld must align with
causing the bottom block to fall. that of the following links).
왘 Drive in a new roll pin to secure the end link pin.

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MAINTENANCE

- TREBLE CHAIN HOISTS (16 TI, EH 16)
Note: For assembly, it is helpful to work with two short
assembly chains 4 which are fastened by means of an
open chain link 5 to the hoist chain being pulled out
during removal of the chain and are pulled successively
over the deflection sprocket of the centre section and
the bottom block. They remain there until assembly is
completed.

왘 Pull the chain from the deflection sprocket of the

centre section and from the bottom block. The buffer
6, the buffer discs 7 and the run-on elements 8 and
9 are thereby pulled from the chain.

Assembly
왘 Push the buffer assembly (buffer 6 plus buffer discs

7 8 7, edge encloses buffer) onto the chain.

1 왘 Align the chain and fasten it to the assembly chain
6
3 in the bottom block by means of the open chain link.
7
5 왘 Pull the chain through the bottom block and detach
2 the assembly chain and the open chain link from
the chain.
왘 Push the first run-on element 8 onto the chain.

4 왘 Align the chain and pull through the centre section

by means of the assembly chain.
왘 Detach the assembly chain and the open chain link

9 from the chain.

Removal
왘 Move the bottom block as close as possible to the
hoist body. Position the bottom block securely in
order to prevent the chain from unravelling
uncontrollably causing the bottom block to fall.
왘 Remove the bottom block end chain link 1 from the
chain mount on the bottom block; drive out the roll
pin 2 and remove the end chain link pin 3 for this
purpose.
왘 If no assembly chains have been used, the end of the
chain must be inserted into both the bottom block
and the centre section and pulled through by turning
the deflection sprockets using an auxiliary tool.
왘 Push the second run-on element 9 onto the chain.
왘 Align the chain and fasten the chain link to the
bottom block by means of the end link pin (position
of the weld must align with that of the following
links).
왘 Drive in a new roll pin to secure the end link pin.

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 MAINTENANCE

Q UA D R U P L E C H A I N H O I S T S ( 2 0 T I , E H 2 0 ) Note: For subsequent assembly, it is helpful to work

with three short assembly chains 5 which are fastened
by means of an open chain link 6 to the hoist chain
being pulled out during removal of the chain and are
pulled successively over the deflection sprocket of the
centre section and the bottom block. They remain there
until assembly is completed.

왘 Pull the chain from the deflection sprocket of the

centre section and from the bottom block.
The run-on elements 7 and 8, as well as the buffer 9
and the buffer discs 10 are thereby pulled from the
3
chain. On version PROFI 20 TI with chain box, three
2
additional run-on elements are provided on the bottom
4 6
block (see spare parts list).
5 1
8 Assembly
7 왘 Push the buffer assembly (buffer 9 plus buffer discs
10 10, edge encloses buffer) onto the chain. On version
9 PROFI 20 TI with chain box, a run-on element must be
10 pushed onto the chain before pushing on the buffer
assembly (see spare parts list for adjustment).
왘 Align the chain and fasten it to the assembly chain
in the bottom block by means of the open chain link.
왘 Pull the chain through the bottom block and detach
the assembly chain and the open chain link from
the chain.
왘 Push the run-on element 8 onto the chain.
On version PROFI 20 TI with chain box, an additional
run-on element must be pushed onto the chain (see
Removal spare parts list for adjustment).
왘 Move the bottom block as close as possible to the 왘 Align the chain and pull through the centre section

hoist body. Position the bottom block securely in by means of the assembly chain.
order to prevent the chain from unravelling un- 왘 Detach the assembly chain and the open chain link

controllably causing the bottom block to fall. from the chain.

왘 Remove the bottom block end chain link 1 from the 왘 Push the run-on element 7 onto the chain.

chain mount on the hoist body; drive out the roll pin On version PROFI 20 TI with chain box, an additional
2 and remove the end chain link pin 3 for this run-on element must be pushed onto the chain (see
purpose. In the case of the PROFI 20TI the end chain spare parts list for adjustment).
link 4 of the idle chain is released simultaneously or 왘 Align the chain and pull through the bottom block

only remove the end chain link pin far enough to by means of the assembly chain.
ensure that the end chain link of the idle chain is 왘 Detach the assembly chain and the open chain link

not released from the hoist body. from the chain.

왘 If no assembly chains have been used, the end of the
In versions with chain box, the idle chain is not chain must be inserted into both the bottom block
attached to the hoist body. and the centre section and pulled through by turning
the deflection sprockets using an auxiliary tool.

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MAINTENANCE

왘 Align the chain and fasten the end chain link to the 왘 Drive in a new roll pin to secure the chain link in
hoist body by means of the end chain link pin. the clamp.
(Position of the weld must align with that of the 왘 Attach the chain box.
following links.)
In the case of operation without chain box:
In the case of the PROFI 20 TI 왘 Align the chain link of the idle chain (for double
If the end chain link pin was pulled out completely, chain and quadruple hoists, except for EH 20, also
the bottom block chain link and the end chain link of the end link of the bottom block chain) and fasten
the idle chain have to be aligned. (Position of the weld to the hoist body by means of the end chain link
must align with that of the following links.) pin (position of the weld must align with that of
the following links).
왘 Drive in a new roll pin to secure the end link pin. 왘 Drive in a new roll pin to secure the end chain
link pin.
R E M OV I N G A N D I N S TAL L I N G C L A M P A N D B U F F E R
Removal (see illus. page 50) AT T E N T I O N !
왘 In the case of operation with chain box, run the chain Do not twist the chain! The chain is sub-
out of the chain box and detach it from the hoist. jected to impermissible stresses if the chain
is twisted.
Note: In the case of hoists with chain box, the end
chain link of the idle chain 4 is not attached to
the hoist body. CHECKING CHAIN, CHAIN
왘 In the case of hoists without chain box, detach the SPROCKET AND CHAIN GUIDES
chain link of the idle chain (for double chain and
quadruple chain hoists, except for EH 20, also the See also Check dimensions, page 55. If the chain of
end link of the bottom block chain 1) from the chain the JDN Air Hoist displays one of the following features,
mount on the hoist body. Drive out the roll pin 2 it must be replaced with a new one:
and remove the end chain link pin 3 .
왘 Immediately fasten the end link of the bottom block 왘 Corrosion scars
chain to the hoist body in order to prevent the chain 왘 Bent or damaged chain links
from becoming twisted. 왘 Chain drawn stiff
왘 Drive out the roll pin 9 from the clamp 10 . 왘 Wear over 11 pitches (A max)
왘 Remove the clamp from the chain. 왘 Single pitch wear (B max)
왘 Detach the buffer 11 and buffer discs 12 + 13 from 왘 Elongation of a single link (D max)
the chain. On version PROFI 20TI with chain box, it
must be ensured that the three additional run-on Check the entire length of the chain.
elements remain on the chain (see spare parts list).
Please observe the information contained in DIN 685,
Assembly part 5 when checking chains. For further instructions
see ISO 7592.
In the case of operation with chain box:
왘 Push the buffer disc with edge (edge encloses buffer),
buffer and buffer disc without edge onto the chain.
왘 Insert the tenth chain link into the chain pocket of
the clamp (chain pocket away from hoist body,
pointed outwards).

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 MAINTENANCE

L OA D H O O K
CHECK DIMENSION
If die hook opening a and the height h of the load
hook are outside the wear limits, the hook must be
HOIST CHAIN
replaced.
Note: When checking the replacement limit, future wear
to the next checking date must be taken into account.
If the chain dimension values are outside the limit
values specified in the table when checked, the chain
has reached its replacement limit and must be replaced
by a new one. The chain sprockets must also be replaced
together with the chain, as otherwise the new chain
will be subjected to increased wear. Each chain re-
placement must be documented in the inspection log.
B

Check dimensions of the load hook

Type Maximum Minimum

permis. dimension of permis. dimension
hook opening ”a”1) of height ”h”

PROFI 3 TI 35.7 36.1

11 x t
A

PROFI 6 TI 46.0 44.7

PROFI 10 TI, EH 10 50.4 58.9

PROFI 16 TI, EH 16 60.6 71.3
PROFI 20 TI, EH 20 83.4 80.8
D

Dimensions in mm

d1 1) If a safety catch is fitted, the thickness of the safety

catch must be subtracted from the maximum hook
opening dimension a.
d + d2
c= 1
d2

Check dimensions of hoist chain

Chain d x t 13 x 36 16 x 45
Dimension A max. 429.2 536
11 x t inside max. 404.3 505.3
Dimension B max. 37.9 47.4
Dimension C min. 11.7 14.4
Dimension D max. 63.9 79.3
Dimensions in mm

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MAINTENANCE

WEAR DIMENSIONS FOR CHAIN SPROCKETS

C H E C K I N G A X I AL P L AY

Maintenance and lubrication

Please ensure that load hooks and/or load eye mounts
are regularly checked, at least once a year. Especially
important: in areas where wear-promoting conditions
a such as high ambient temperatures or corrosive
substances in the atmosphere are present, or where
x

lubricants may be washed out, the frequency of

maintenance and inspection intervals must always
be increased.

Wear dimensions for chain sprockets HAZARDS IN THE CASE OF INSUFFICIENT

M A I N T E N A N C E / L U B R I C AT I O N
DA N G E R !
Chain size In the event of insufficient maintenance/
dxt z a x lubrication the extent of wear may be so
mm x mm (1) mm mm high that there is a danger of loads falling.
13 x 36 4 32.8 0.25
P R E VE N T I O N O F DA N G E R S
16 x 45 4 38.5 0.30 Dangers are avoided by regular maintenance/lubrication
in suitable intervals.
a, x = limit dimensions after maximum permissible
wear When the axial play of the installed hook or load
z = number of teeth of the chain sprocket eye exceeds the maximum play specified, the worn
d x t = nominal diameter times pitch of chain link parts must be replaced.

WEAR DIMENSIONS FOR CHAIN GUIDES AND

HOOK MOUNTS
Check the chain guides for wear and when the following
wear dimensions are reached with regard to chain guide
diameters or hook mounts in the centre section of the
device: Replace the housing:

Chain
diameter 13 16

Wear dimension 1.4 1.7

Dimensions in mm

The wear dimension must be measured at the points

on the guide surfaces which have been worn down by
the chain.

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 MAINTENANCE

C H E C K D I M E N S I O N S F O R T H E A X I AL P L AY
R E M OV I N G A N D I N S TAL L I N G C H A I N
Bottom block type Axial play ”x” max.
6.3 t, 10 t, 16 t Max. 3.5 mm AT T E N T I O N !
The chain supplied together with this JDN
20 t Max. 11.5 mm hoist is matched to the chain sprocket
according to strict tolerances. In order to
ensure optimum function of the chain and
in order to prevent hazards, only genuine
JDN chains must be installed.

Note: When a chain is replaced, the buffers must also

be replaced. For information on changing buffers at the
chain ends, see Removing and installing load sleeve,
bottom block, clamp and buffer section.

Buffers and run-on elements not located on the chain

ends are most easily replaced when the open chain link
x max.

between the old and new chains passes the buffer to be

replaced.

AT T E N T I O N !
Do not twist the chain ends.

왘 In the case of operation with chain box: switch the

hoist in the ”lower” rotational direction and run the
old chain out of the chain box. Then remove the
chain box.
Bottom block with load hook or load eye 왘 Move the bottom block as close as possible to the
hoist body and position it securely.
왘 In the case of hoists without chain box, detach the
idle chain from the chain mount _ for dual and
quadruple chain hoists, the bottom block chain is
released simultaneously – (see also Removing and
installing load sleeve, bottom block, clamp and
max. 2,5 mm

buffer section).
왘 Detach the clamp, buffer and buffer discs from the
end of the idle chain. For single chain hoists also
detach the load sleeve, buffer and buffer discs from
the load chain. For dual and quadruple chain
hoists with chain box, detach the bottom block from
the hoist body.
For triple chain hoists, detach the bottom block
chain from the mount on the bottom block. (See also
Removing and installing load sleeve, bottom
block, clamp and buffer section.)
왘 Attach the new chain to the end link of the load
section of the old chain after aligning the welds and
Load sleeve with load hook or load eye the first chain link by means of an open chain link.

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MAINTENANCE
The welds on the upright chain links must face out-
wards when running over the chain sprockets. For this
reason, the welds of the chain links which lie flat in
the drive sprocket must face towards the gearbox in
the case of treble and quadruple chain hoists. If the
first link of the new chain is not correctly positioned,
it must be removed.
Note: It is possible that the first chain link of the other
chain end is correctly positioned. Switch the hoist to
the ”lift” rotational direction. The new chain will now
run into the hoist while the
왘 old chain is simultaneously run out on the idle
chain side.
Run the chain until the join between the old and new
chain has run sufficiently (approx. 1 m) out of the
centre section on the idle chain side.
왘 Detach the connection between the old and new
chains.
왘 Install the clamp (at the 10th chain link), buffer and
buffer discs on the idle chain section of the new chain.
Only in the case of operation without chain box, align
the idle chain and attach to the fastening point on the
hoist - for dual and quadruple chain hoists, except for
EH 20, the bottom block chain is also attached here
later. (See also Removing and installing load sleeve,
bottom block, clamp and buffer section.)
왘 Attach the chain box if necessary.
왘 Switch the hoist in the ”lift” rotational direction
until the as yet free end of the aligned load chain
is the correct length for attaching the chain link,
_ for single chain hoists in the load sleeve after the
buffer and buffer discs have been pushed on,
_ for dual and quadruple chain hoists at the
fastening point on the hoist body and
_ for triple chain hoists at the fastening point of
the bottom block (see also Removing and
installing load sleeve, bottom block, clamp and
buffer section).
Note: If the chain link of the load chain is positioned
incorrectly, it must be removed, the following chain link
will be positioned correctly.
Page 58
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R E P L AC I N G C H A I N A N D
CHAIN SPROCKET
Note: If the chain jams in the hoist and can no longer
be run out, the gearbox must be dismantled. The gear-
box retaining bolts must be removed for this purpose,
and the end chain link pin must be pulled out. The
chain wiper must then be removed. The gearbox can
now be pulled approx. 15 mm from the centre section.
In this position, the safety ring, item 440 (gearbox
3 TI/6 TI), item 500 (gearbox 10 TI/16 TI/20 TI/EH 10/
EH 16/EH 20) (see E-list, gearbox) must be removed in
the vicinity of one of the exhaust air guides. The gear-
box housing can then be removed and the gearbox can
be dismantled down to the sprocket wheel.
When removing the old chain, assembly chains (1) are
brought into position on all the deflection sprockets by
means of open chain links (see also Removing and
installing load sleeve, bottom block, clamp and
buffer section and section Removing and installing
chain section).
Following replacement of the chain sprocket (see spare
parts list) an assembly chain (2) is run carefully – with
low air pressure – over the drive sprocket.
Fasten the new chain to the assembly chain on the
drive sprocket by means of one or two open links (3)
on the idle chain side. The first chain link (4) must run
upright over the drive sprocket with the weld facing
outwards. The welds of the chain links which lie flat in
the drive sprocket (5) must face towards the gearbox
in the case of treble and quadruple chain hoists. (See
illustration.)
Switch the hoist to the ”lower” rotational direction and
detach the assembly chain from the chain after it comes
out of the centre section.
Depending on the number of chains of hoist and after
alignment, the new chain is pulled over the deflection
sprocket of the bottom block and if necessary over the
deflection sprocket of the centre section by means of
further assembly chains.
Note: If the chain link on the idle chain side is posi-
tioned incorrectly, it must be removed, the following
chain link will be positioned correctly.

Fastening of the chains and installation of the load
sleeve, clamp, buffer and buffer discs is carried out in
accordance with the Removing and installing load
sleeve, bottom block, clamp and buffer section and
the Removing and installing chain section.
2
3 DA N G E R !
4 1
5 If the overload protection is set too high,
Drawing in the chain
OVE R L OA D P R OT E C T I O N
The PROFI 3 TI, 6 TI, 10 TI, 16 TI, 20 TI and EH 10,
EH 16, EH 20 hoists are equipped with a new type of
safety clutch as standard. This prevents loads exceeding
the limit values set from being lifted. The limit value
is set so that loads of 125 % of the load carrying capa-
city cannot be lifted. 110 % can be lifted in order to
perform the dynamic overload test.
powered by air!
MAINTENANCE
AT T E N T I O N !
The safety clutch must only be engaged for
a short time in order to prevent unnecessary
wear and overheating of the drive.
When the safety clutch is activated, the hoist should be
unloaded by switching to a lowering movement.
The overload protection can also be activated when mo-
ving at full unloaded speed against a load to be lifted,
even when it is below the load size set. We therefore
recommend tensioning the slack chain before lifting
the load.
A D J U S T I N G OVE R L OA D P R OT E C T I O N
The adjustment method described here is based on the
attachment of test loads.
impermissibly high stresses may arise if a
load exceeding the permissible load carrying
capacity is attached.
왘 Unload the hoist
왘 Detach the gearbox cover (1) from the gearbox in
order to gain access to the threaded pins (2) with
lock nuts (3) located behind it.
CORRECTING THE SET LIMIT VALUE
왘 Loosen the lock nuts. It must be ensured that the
threaded pins are not turned.
왘 During each readjustment adjust the threaded pins
to the same degree in order to adjust the disc springs
evenly: turning clockwise - limit value is increased,
turning anti-clockwise - limit value is reduced.
왘 Secure threaded pins with the lock nuts. Do not turn
the threaded pins any more as the setting will be
altered.
왘 Check the limit value for correct setting.
왘 Install the gearbox cover.
Page 59
MAINTENANCE

R E S E T T I N G T H E L I M I T VAL U E
왘 Loosen the lock nuts. Screw out the threaded pins -
anti-clockwise - until the disc springs (4) are
completely free of pre-tension.
왘 Then loosely screw in the threaded pins by hand –
clockwise – to the stop, screw the lock nuts
sufficiently far back beforehand.
왘 The limit value for reaching at least 110 % of the
load-carrying capacity is set at approx. 2 turns. Screw
in the three threaded pins successively in small steps
by approx. 1/2 turn. With this preadjustment after re-
assembly, first let the safety clutch take effect for
approx. 5 seconds (load hook on the upper end
position with the motor running). Then let the load 3
2
hook run for approx. 10 seconds without a load so
that the outlet air cools the clutch down. 4
왘 Secure threaded pins with the lock nuts. Hold the
threaded pins tightly in the process.
왘 Check the limit value for correct setting, correct
if necessary.
왘 Install the gearbox cover. 1
왘 The adjusting and inspection result arrived at by Gearbox 3.2 t
qualified personnel must be entered in the lifting
gear inspection log (limit value: see Overload
protection, page 34).

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FAULTS, CAUSE AND REMEDY
FAU LT TA B L E
Fault
Lifting not possible
Only very slow lifting possible
Excessive running on during braking
Loud chain noise
on the chain sprocket
Lifting or lowering speed declines
with high lifting heights or the
motor comes to a standstill
*if installed
Possible cause
Air pressure too low
EMERGENCY STOP button is
pressed
Hand control is faulty
Brake does not release fully
Brake lining worn or uneven
Motor cover bolts loose
Air supply hoses leaking or
loose
Cross section of air line too
small
Dirt in the service
unit*, filter blocked
Silencer is clogged
Motor vanes worn
Motor has run dry
Control valve on motor
Safety clutch slips
Safety clutch slips due to chain
wear
Brake disc and/or brake piston
worn
Chain dry
Chain worn
Chain sprocket worn
Wrong chain drawn in
Brake piston setting too tight
powered by air!
FAULTS, CAUSE AND REMEDY
Remedy
Increase air pressure to the required value
Release the EMERGENCY-OFF switch
if the danger has been rectified
Have hand control repaired
Set air pressure to the relevant value, check
seal of brake piston and change seal if
necessary Check the adjustment of the brake
piston (see Spare Part List)
Replace brake lining
Tighten the bolts
Check connections of air supply hose and
control hoses and connect properly
Use air line with sufficiently large cross
section (check air pressure)
Clean service unit, ensure better air quality
Replace or clean silencer elements, improve air
quality if necessary
Replace motor vanes
Lubricate motor,
check oiler*
Have control valve repaired
Adjusting safety clutch
Replace chain with a new JDN Chain
Replace brake disc and/ or brake piston
Lubricate chain
Replace chain with a new JDN Chain
Replace chain sprocket, check chain guide,
replace if necessary
Identify chain and replace with JDN Chain if
necessary
Correct adjustment of brake piston. At
high ambient temperatures, perform
adjustment with
the device warmed up accordingly.
Page 61
ACCESSORIES

ACCESSORIES

F I LT E R S I L E N C E R

With the use of a filter silencer, oil aerosols can be

avoided and noise insulation improved:

왘 99.9 % of oil aerosols during oil lubrication of the

motor are absorbed by the filter element.
왘 The noise insulation reduces noise levels by 3 to
4 dB (A) compared with the standard silencer
(sinter plate).
1
The ambient temperature must not be lower than - 10° C.

M A I N T E N A N C E O F F I LT E R S I L E N C E R
The filtered oil runs into the transparent collecting
container 3. This container must be emptied before 2
the fluid level reaches the filter element.

왘 Turn the drain valve 4 90° and allow the fluid

to drain out.
왘 Close the drain valve.

The filter must be replaced after approx. 2500 hours

of operation. 3

왘 Turn the collecting container 3 slightly and detach.

왘 Unscrew the filter element 2.
왘
4
Insert a new filter element, with sealing ring 1 and
push on collecting container until it engages.

Filter silencer
BOOSTER UNIT

In the event of a control hose length exceeding 10 m,

the reaction times of the pushbutton controls increase
significantly.

Consequently, a booster unit is generally installed on

the motor for controls E, F and FI, enabling normal
reaction times.

The operating temperature range is from 0° C to 80° C.

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C H A I N B OX
For various areas of application, a chain box enhances
operational safety, i.e. when a chain which is hanging
down could become caught up with the load.
JDN chain boxes are available in various sizes, corres-
ponding to the chain lengths.
AT T E N T I O N !
Do not exceed the permissible filling
capacity. Danger of chain dropping.
AT T E N T I O N !
Loads must not be moved against the chain
box during lifting. If necessary, attach a
clamp to the chain.
The clamp must be attached above the load hook so
that it functions as a preliminary end stop. With the
PROFI 6 TI and PROFI 10 TI (dual chain) the clamp must
be positioned as far as necessary downwards on the
reeved chain in order to support the bottom block
(stationary chain). In addition, a spacer must be
attached to the opposite (moving) chain above the
buffer in order to relocate the load hook stroke limiter.
Please contact us, if required. For greater clarity, see
the lower illustration on page 50.
In all cases, a clamp is attached in the 10th chain link
of the unloaded chain end so that a length of chain
remains in the chain box when the bottom load hook
position is reached. Thus, the chain cannot run next to
the chain box during subsequent lifting (see section
Removing and installing chain page 57).
Depending on the ratio of the size of the hoist (without
running gear) and the chain box, the chain box may
have to be stabilised by the customer due to an
acceptable vertical hoist position. This is facilitated
by a suspension point on the rear of the box. We will
be happy to answer any questions on this matter.
Modifications may only be made to the chain box
on agreement with J.D. Neuhaus GmbH & Co. KG.
powered by air!
ACCESSORIES
AT T E N T I O N !
Never allow the chain to pile up in the
chain box.
The chain must only enter the container via
the chain drive. If it falls out of the container,
e.g. during transportation, it must be run out
completely on the load hook side and then run
back into the container via the chain drive,
in the air hoist operating position.
왘 After installing the chain box, lower the load hook to
the bottom position once.
왘 Then activate the lifting movement and run the
complete chain into the chain box.
DA N G E R !
During operation with the chain box, lubri-
cation of the chain is particularly important
in order to prevent it from piling up and
falling out.
Do not install longer chains when changing
chains.
Furthermore, hazards arise due to rusty
chains when operating with chain boxes,
as the chain can form a heap and fall over
the edge of the container rim. In addition,
rusty chains are subject to extreme wear.
If the hoist has been transported with the chain in the
chain box, the chain box must be emptied manually
before initial operation (if necessary, remove the chain
box from the hoist). The entire chain must then be
allowed to run to the load side and, subsequently, be
driven back into the chain box. The hoist must be kept
in a hanging position during this procedure.
This process will ensure that the chain does not lock
when loads are being lowered.
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APPENDIX

APPENDIX

T E C H N I C AL DATA

JDN PROFI TI AIR HOISTS

Type 3 TI 6 TI 10 TI 16 TI 20 TI
Air pressure bar 4 6 4 6 4 6 4 6 4 6
Load-carrying capacity t 3.2 6.3 10 16 20
Number of chains 1 2 2 3 4
Motor power kW 1.8 3.5 1.8 3.5 1.8 3.5 1.8 3.5 1.8 3.5
Lifting speed at nominal load m/ min 2.5 5 1.2 2.5 0.8 1.6 0.5 1 0.4 0.7
Lifting speed without load m/ min 5 10 2.5 5 1.5 3.2 1 2 0.75 1.4
Lowering speed at nominal load m/ min 5.5 10.8 2.8 5.4 1.8 3.4 1.1 2.1 0.85 1.6
Air consumption at nominal load – lifting m3/min 2.3 4.0 2.3 4.0 2.3 4.0 2.3 4.0 2.3 4.0
Air consumption at nominal load – lowering m3/min 3.2 5.5 3.2 5.5 3.2 5.5 3.2 5.5 3.2 5.5
Air connection G 3⁄4 G 3⁄4 G 3⁄4 G 3⁄4 G 3⁄4
Hose size (Ø inner/Ø outer ¯) mm 19/31 19/31 19/31 19/31 19/31
Weight for standard lifting distance,
kg 86 110 156 240 285
rope control
Chain dimensions mm 13 x 36 13 x 36 16 x 45 16 x 45 16 x 45
Weight per 1 m chain kg 3.8 3.8 5.8 5.8 5.8
Standard lifting distance m 3 3 3 3 3
Control length for standard lifting distance m 2 2 2 2 2
Noise pressure level at nominal load1
dB (A) 76 78 76 78 76 78 76 78 76 78
with standard silencer – lifting
Noise pressure level at nominal load1
dB (A) 78 80 78 80 78 80 78 80 78 80
with standard silencer – lowering
1 measured from 1 m distance according to DIN 45635 part 20

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 APPENDIX

DIMENSIONS

JDN PROFI TI AIR HOISTS

Type 3 TI 6 TI 10 TI 16 TI 20 TI
A* Minimum headroom 593 674 813 898 1040
B 373 454 548 598 667
C 233 233 308 382 382
D 483 483 575 692 692
E1 40 40 44 53 75
E2 30 40 44 53 75
F to centre of hook, without chain box 187 154 197 199 182
G maximum width 233 233 306 308 324
Dimensions in mm * Chain boxes increase the required headroom

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APPENDIX

T E C H N I C AL DATA

JDN MONORAIL HOISTS

Type EH 10 EH 16 EH 20
Air pressure bar 4 6 4 6 4 6
Load-carrying capacity t 10 16 20
Number of chains 2 3 4
Motor power, running gear kw 0.3 0.7 0.3 0.7 0.3 0.7
Motor power, lifting gear kw 1.8 3.5 1.8 3.5 1.8 3.5
Lifting speed at nominal load m/min 0.8 1.6 0.5 1 0.4 0.7
Lifting speed without load m/min 2 3.2 1.3 2 0.9 1.4
Lowering speed at nominal load m/min 2.5 3.4 1.6 2.1 1.2 1.6
Travel speed at nominal load m/min 10 12 10 12 10 12
Travel speed without load m/min 10.5 13.5 10.5 13.5 10.5 13.5
Air consumption at nominal load, running gear m3/min 1.0 1.3 1.0 1.3 1.0 1.3
Air consumption at nominal load, lifting gear(lifting) m3/min 2.2 3.2 2.2 3.2 2.2 3.2
Air connection G 3⁄4 G 3⁄4 G 3⁄4
Hose size
mm 19/31 19/31 19/31
( inner/ outer)
Weight for standard lifting distance kg 450 575 620
Chain dimensions mm 16 x 45 16 x 45 16 x 45
Weight per 1 m chain kg 5.8 5.8 5.8
Standard lifting distance m 3 3 3
Control length for standard lifting distance m 2 2 2
Noise pressure level at nominal load1
dB (A) 75 78 75 78 75 78
with standard silencer - lifting
Noise pressure level at nominal load1
dB (A) 81 80 81 80 81 80
with standard silencer - lowering
1 measured from 1 m distance according to DIN 45635 part 20

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 APPENDIX

DIMENSIONS

A b+B C

K D b

E
F

J G

L M

Type EH 10 EH 16 EH 20
A 105 130 130
B 70 68 68
C 284 294 294
D 25 35 35
E 198 220 220
F* 705 750 820
G 138 213 202
H 44 53 75
J 192 185 266
K 580 600 600
L 308 367 367
M 266 325 325
Measurements in mm * Chain boxes increase the required headroom

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APPENDIX

A I R F L OW S H E E T S

R OP E C O N T R O L , W I T H O U T M A I N A I R E M E R G E N C Y- S TOP VALVE

Hubmotor
lifting motor

Steuerventil Seil senken heben

control valve lowering lifting

Drehschieber-Ventil
rotary control valve
A B

Ventilblock am Hubmotor
valve at the lifting motor
R P S

Hauptanschluss
main air connection

heben senken
lifting lowering

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E - C O N T R O L , 2 - F O L D , W I T H E M E R G E N C Y S TOP F U N C T I O N
W I T H M A I N A I R E M E R G E N C Y- S TOP VALVE

Hubmotor
lifting motor

Steuerventil Luft senken heben

control valve lowering lifting
Drehschieber - Ventil
rotary control valve
A B

RP S

HS - Sperrventil
HS - stop valve

Ventilblock am Motor
valve at the lifting motor

Hauptanschluss
main air connection
p s h

Druckknopfventil
E-2fach NOT-STOPP
push button valve
E-2fold emergency stop
NOT-STOPP
emergency stop

p = Druckversorgung
air supply

h = heben
lifting

s = senken
lowering

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E - C O N T R O L , 4 - F O L D , W I T H O U T E M E R G E N C Y S TOP F U N C T I O N
W I T H O U T M A I N A I R E M E R G E N C Y- S TOP VALVE
( N OT F O R E W R )

Fahrmotor driving motor

Hubmotor
lifting motor Motor motor
Schalldämpfer
Bremse brake silencer

Steuerventil Luft senken heben

control valve
lowering lifting A B
Drehschieber - Ventil
rotary control valve
A B

RP S
Y P Z

Ventilblock am Motor
valve at the lifting motor
Hauptanschluss
Hauptanschluss main air connection
main air connection

p s h li re

Druckknopfventil
E-4fach
push button valve
E-4fold

p = Druckversorgung
air supply

h = heben
lifting

s = senken
lowering

li = Linksfahrt
travel left

re = Rechtsfahrt
travel right

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E - C O N T R O L , 4 - F O L D , W I T H E M E R G E N C Y S TOP F U N C T I O N
W I T H E X T E R N AL M A I N A I R E M E R G E N C Y- S TOP VALVE

Hubmotor
lifting motor Fahrmotor driving motor
Motor motor
Schalldämpfer
Bremse brake silencer

Steuerventil Luft senken heben

control valve lowering lifting A B
Drehschieber - Ventil
rotary control valve
A B

RP S
Y P Z

Ventilblock am Motor HS-Sperrventil

valve at the lifting motor verschlossen HS-stop valve
closed
pö

p s h
Hauptanschluss
Druckknopfventil li main air connection
E-4fach NOT-STOPP
push button valve re
E-4fold emergency stop
NOT-STOPP
emergency stop
p = Druckversorgung
air supply

h = heben
lifting

s = senken
lowering

pö = Öffnungsdruck
opening pressure

li = Linksfahrt
travel left

re = Rechtsfahrt
travel right

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APPENDIX

F I - C O N T R O L , 2 - F O L D , W I T H E M E R G E N C Y S TOP F U N C T I O N
W I T H M A I N A I R E M E R G E N C Y- S TOP VALVE

Hubmotor
lifting motor

senken heben
Steuerventil Luft lowering lifting
control valve
Drehschieber - Ventil
rotary control valve
A B

RP S

HS-Sperrventil
HS-stop valve

Ventilblock am Hubmotor
valve at the lifting motor

p s h

Druckknopfventil
FI-2fach NOT-STOPP Hauptanschluss
push button valve main conection
FI-2fold emergency stop

NOT-Stopp
emergency stop

p = Druckluftversorgung
air supply

h = heben
lifting

s = senken
lowering

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F - C O N T R O L , 5 - F O L D , W I T H E M E R G E N C Y S TOP F U N C T I O N
W I T H M A I N A I R E M E R G E N C Y- S TOP VALVE

Hubmotor Fahrmotor driving motor

lifting motor
Motor motor
Bremse brake Schalldämpfer
silencer

Steuerventil Luft senken heben A B

control valve lowering lifting
Drehschieber - Ventil
rotary control valve
A B

RP S
Y P Z

HS-Sperrventil
HS-stop valve

Ventilblock am Motor
valve at the lifting motor
HS-Sperrventil
pö HS-stop valve

p s h

Steuerflasche li
F-5 fach NOT-STOPP
multi button pedent re
switches 5 fold emergency stop
NOT-STOPP
emergency stop
p = Druckversorgung
air supply
Hauptanschluss
h = heben main air connection
lifting

s = senken
lowering

pö = Öffnungsdruck
opening pressure

li = Linksfahrt
travel left

re = Rechtsfahrt
travel right

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F - C O N T R O L , 7 - F O L D , W I T H E M E R G E N C Y S TOP F U N C T I O N
W I T H M A I N A I R E M E R G E N C Y- S TOP VALVE

Hubmotor Fahrmotor driving motor Fahrmotor driving motor

lifting motor Motor motor Motor motor
Schalldämpfer Schalldämpfer
Bremse brake Bremse brake silencer
silencer

Steuerventil Luft senken heben

control valve lowering lifting A B A B
Drehschieber - Ventil
rotary control valve
A B

RP S
Y P Z Y P Z

HS-Sperrventil
HS-stop valve

Ventilblock am Motor
valve at the lifting
motor

p s h li re v z pö
Steuerflasche
F-7fach NOT-STOPP
multi button pedent
switches 7 fold emergency stop HS-Sperrventil
HS-stop valve
NOT-STOPP
emergency stop

Hauptanschluss
p = Druckversorgung main air connection
air supply

h = heben
lifting

s = senken
lowering

pö = Öffnungsdruck
opening pressure

li = Linksfahrt
travel left

re = Rechtsfahrt
travel right

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 is a registered trademark of our company.
BA 816 GB · Edition: December 2009 · Subject to changes · 122009

J.D. NEUHAUS GMBH & CO. KG _ D-58449 WITTEN-HEVEN

PHONE +49 2302 208-0 _ FAX +49 2302 208-286
info@jdn.de _ www.jdn.de

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