J. D. NEUHAUS JDN mini 125 User manual

Doc.No.: D0000201 Rev. 0 / 24.05.2019
JDN AIR HOISTS
MINI 125 // MINI 250 // MINI 500 // MINI 1000
// INSTALLATION AND OPERATION MANUAL

Doc.No.: D0000201 Rev. 0 / 24.05.2019 EN // 1
CONTENTS
English
CONTENTS
1GENERAL ................................................................................................................................................2
About these operating instructions .........................................................................................................2 1.1
Copyright protection.............................................................................................................................2 1.2
Contact data........................................................................................................................................2 1.3
Limitation of liability .............................................................................................................................3 1.4
Further documents...............................................................................................................................3 1.5
Definition of terms ...............................................................................................................................3 1.6
marking.........................................................................................................................................3 1.7
2SAFETY INFORMATION .............................................................................................................................4
Qualification of personnel ......................................................................................................................4 2.1
Operating company obligations ..............................................................................................................4 2.2
Proper use ..........................................................................................................................................4 2.3
Improper use ......................................................................................................................................5 2.4
Oblique pulling.....................................................................................................................................5 2.5
Personal protective equipment...............................................................................................................6 2.6
Spare parts .........................................................................................................................................6 2.7
3TECHNICAL DESCRIPTION ........................................................................................................................7
Marking / identification .........................................................................................................................7 3.1
Assembly overview...............................................................................................................................7 3.2
Load capacity ....................................................................................................................................10 3.3
Service life – Group of mechanism according to FEM / ISO ......................................................................10 3.4
Information on explosion protection .....................................................................................................11 3.5
Compressed air requirement ...............................................................................................................11 3.6
Sound pressure level ..........................................................................................................................12 3.7
Operating conditions...........................................................................................................................13 3.8
NFC chip / QR code ............................................................................................................................13 3.9
4TRANSPORT AND STORAGE.....................................................................................................................14
Transporting......................................................................................................................................14 4.1
Storage conditions .............................................................................................................................14 4.2
5INITIAL OPERATION ...............................................................................................................................15
Unpacking .........................................................................................................................................15 5.1
Shortening the control length if necessary.............................................................................................15 5.2
Suspending the hoist ..........................................................................................................................16 5.3
Connecting the air supply....................................................................................................................17 5.4
Emptying the chain container and running the chain into the chain container.............................................17 5.5
Lubricating the chain ..........................................................................................................................18 5.6
Setting the maximum speed................................................................................................................18 5.7
Tests before commissioning.................................................................................................................19 5.8
6OPERATION...........................................................................................................................................20
Checks before each start of work .........................................................................................................20 6.1
Attaching the load ..............................................................................................................................21 6.2
Moving the load .................................................................................................................................22 6.3
Releasing / detaching the load.............................................................................................................23 6.4
Operating the emergency stop.............................................................................................................24 6.5
Interrupting work...............................................................................................................................24 6.6
7MAINTENANCE AND REPAIR ....................................................................................................................25
Maintenance and inspection intervals....................................................................................................26 7.1
Determining the actual use in full load hours .........................................................................................26 7.2
Oils and greases ................................................................................................................................28 7.3
Checking the brake with nominal load...................................................................................................29 7.4
Checking the chain .............................................................................................................................30 7.5
Checking the chain inlet......................................................................................................................32 7.6
Checking the hook .............................................................................................................................33 7.7
Checking the chain box and lowering limiter ..........................................................................................34 7.8
Checking the chain guide, chain sprocket and pinion shaft ......................................................................35 7.9
Checking the vanes and brake lining.....................................................................................................36 7.10
Checking the silencer..........................................................................................................................37 7.11
Checking the gear lubrication ..............................................................................................................38 7.12
8FAULTS, CAUSES AND REMEDIES ............................................................................................................39
9DECOMMISSIONING...............................................................................................................................40
Disassembly ......................................................................................................................................40 9.1
Disposal............................................................................................................................................40 9.2
10 APPENDIX .............................................................................................................................................41
Dimensions .......................................................................................................................................41 10.1
Technical data ...................................................................................................................................42 10.2
Flow sheet ........................................................................................................................................43 10.3

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GENERAL
English
1GENERAL
About these operating instructions 1.1
These operating instructions should make it easy for you to get to know your hoist and to take advantage
of the intended application possibilities.
These operating instructions contain important information to be able to operate your hoist safely,
properly and efficiently. Your observance helps to avoid dangers, reduced repair costs and downtimes
and to achieve the specified service life of the product.
1.1.1 Symbols and notations used
Safety instructions are classified in four stages in these operating instructions:
DANGER
Indicates an imminently hazardous situation that will result in death or serious injury if not avoided.
WARNING
Indicates a possibly hazardous situation that may result in death or serious injury if not avoided.
CAUTION
Indicates a potentially hazardous situation that may result in minor or moderate injury if not avoided.
NOTICE
Indicates a potentially hazardous situation that may lead to property and environmental damage if not
avoided.
Different bullet points are used for the following cases:
Instructions for behaviour
1) Instructions for behaviour with specified sequence
Listings without specified sequence
→Reference to other sections in these operation instructions or applicable documents
Copyright protection 1.2
All rights reserved by the manufacturer. Neither the operating instructions as a whole nor individual
sections may be reproduced, distributed or processed using electronic systems in any form without
written permission from J.D. Neuhaus GmbH & Co. KG.
All of the brands mentioned in these operating instructions are the property of their respective
manufacturers and are hereby acknowledged.
Contact data 1.3
If you have questions about handling your hoist that are not answered in these operating instructions,
please contact
J.D. Neuhaus GmbH & Co. KG
Windenstraße 2-4
D-58455 Witten-Heven
Telephone [phone] / 208-0
Fax [phone] / 208-286
www.jdngroup.com
E-mail: [e-mail]

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GENERAL
English
Limitation of liability 1.4
All information and instructions in this manual were compiled in accordance with the applicable standards
and regulations, current technological standards as well as many years of experience.
J.D. Neuhaus GmbH & Co. KG assumes no liability for damage due to:
Non-observance of the instructions
Inappropriate use
Use by untrained personnel
Unauthorised conversions
Technical changes
Use of unauthorised spare parts
Further documents 1.5
In addition to these operating and assembly instructions, the following documents may be part of the
hoist documentation:
Declaration of conformity, declaration of incorporation
Factory certificate, chain and hook certificate
Spare parts lists (English)
Inspection log for the hoist: This can be used to document the results of periodic inspections and
the replacement of components or assemblies (German/English).
Definition of terms 1.6
Operating company:
The operating company is defined as the company which has the actual or legal means to take the
necessary decisions with regard to the safety of the hoist. The operating company bears the responsibility
and at the same time is liable in the event of damage due to non-compliance with a regulation.
(Operating company obligations → section 2.2, page 4)
Operator:
The operator has been instructed by the operating company to operate the hoist.
(Qualification of personnel → section 2.1, page 4)
marking 1.7
The hoist is marked with . This marking indicates compliance with one or more EU/EG directives. In
such cases, a declaration of conformity is supplied with the hoist. This declaration is not part of these
operating instructions but is supplied separately. A document reproducing the contents of this declaration
can be found in the appendix.
Machinery Directive 2006/42/EC
The JDN mini hoist is supplied either ready for operation as a complete machine or as an incomplete
machine according to the Machinery Directive 2006/42/EC. For a complete machine that is ready for
operation, an EC declaration of conformity is issued for the delivery condition; for an incomplete machine,
a declaration of incorporation is issued. The completed hoist must then be checked for conformity with
the Machinery Directive and a declaration of conformity issued.
If a complete hoist ready for operation is installed in a higher order machine in accordance with
Machinery Directive 2006/42/EC, the new risks arising from the installation must be reassessed by the
machine manufacturer and conformity must be determined again.
Likewise, in the case of unauthorised modifications to a complete hoist, a check of conformity with the
Machinery Directive must be carried out and a declaration of conformity issued.
ATEX Directive 2014/34/EU
The JDN mini hoist when delivered complies as standard with the ATEX Directive 2014/34/EU in the
classification listed in section 3.5, page 11. If the condition of the hoist supplied by JDN is modified or
extended, conformity with the ATEX Directive must be checked and declared again.

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SAFETY INFORMATION
English
2SAFETY INFORMATION
Your hoist is built according to current technological standards and the recognised technical safety
regulations. Nevertheless, dangers to life and limb of the user or third parties or impairments to their
product and other property may result if the safety rules are disregarded during the product's use.
Qualification of personnel 2.1
The personnel responsible for operation, maintenance, inspection and set-up work must be competent or
be instructed by a competent person before beginning work.
Due to their technical training and experience, properly trained personnel have adequate knowledge of
pneumatic hoists. They are familiar with the relevant health and safety regulations, explosion protection
regulations as well as accident prevention regulations to the extent that they can assess the safe working
condition of your product.
Observe the operating instructions for your workplace.
Comply with the accident prevention regulations and explosion protection regulations.
Receive instruction on dealing with hazardous materials.
Follow the operating instructions in their entirety and in particular this Chapter 2 and the
warnings in the “Operation” section.
Operating company obligations 2.2
The operating company of the hoist is obliged to ensure a safe and hazard-free operation. This also
includes the necessary training/instruction of the operating personnel.
Within the Federal Republic of Germany the operating company is obliged, among other things, to
observe accident prevention regulations and rules of the employers' liability insurance association,
relevant explosion protection regulations and state occupational health and safety regulations, in
particular
DGUV regulation 1 – Principles of prevention
DGUV regulation 54 – Winches, lifting and pulling equipment
DGUV principle 309-001 – Inspection of cranes
DGUV regulation 113-001 – Explosion protection regulations
TRGS 727 – Preventing ignition hazards due to electrostatic charges
in the respective, currently applicable versions and initiate the specified, related tests.
In other countries, the corresponding national regulations on work safety, explosion protection and
health protection are to be observed.
In exceptional cases of use, special regulations may apply.
In addition, the operating company must take at least the following measures, among others, to ensure
safe and hazard-free operation:
providing operating instructions on site at all times
drafting work instructions, operating safety instructions and hazard assessments
carrying out regular training sessions
carrying out initial commissioning and periodic inspections, and keeping the inspection log
regularly checking personnel work in a safety and hazard-conscious manner.
If a load is lifted together by several hoists / cranes, the work sequence must be determined beforehand
by the operating company and monitored by a supervisor.
Proper use 2.3
The hoist is designed for lifting and lowering loads in the range of the rated load capacity with a vertically
arranged chain.
In combination with a JDN trolley, the hoist is also suitable for overhead horizontal movement of loads.
Proper use also includes the observance of the operating conditions and the entire operating instructions
and compliance with the inspection and maintenance conditions.
Any other or exceeding use is considered improper. J.D. Neuhaus GmbH & Co. KG assumes no liability for
damage resulting from this improper use. The risk is borne solely by the user. Please observe the
following national legal provisions.

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SAFETY INFORMATION
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αα
Improper use 2.4
The following are regarded as improper use:
Changing load capacities with the load position: Your hoist is not equipped with a load capacity
display, which is why it may only be used in such cases where the load capacity does not change
with the load position.
Exceeding the load capacity
Trying to dislodge stuck loads
Loading of the hook at the tip
Catching falling loads
Carrying people
Holding stationary loads above persons
Jog controls
For ongoing motion, switch in the opposite direction
In the upper or lower limit position of the load hook, keep the chain taught in the area of the
central part
Transport of changing masses
Transport of molten masses
Transport over pipelines carrying dangerous substances
Use outside of the operating conditions
Use in explosion hazardous areas outside the permissible classification
Operation after expiration of theoretical service life (service life)
Starting the lowering limiter under normal operating conditions
Use of the hoist as sling gear
Oblique pulling (→section 2.5, page 5).
Your hoist may not be used in the following areas:
• critical areas in nuclear plants
• over acid baths or systems with aggressive substances
• in areas where there are organic acids
• in areas outside of the permissible ambient temperatures
Oblique pulling 2.5
Oblique pulling is the deviation from the vertical position of the load chain and the chain hoist in the
straight course of the force line between the point of application of force of the load on the load hook and
the suspension on the carrying structure (α ≠ 0°).
Oblique pulling is permitted in
exceptional
cases under the following conditions:
The hoist must be hung stationary, it must
not be in any trolley.
The hoist must be able to align itself freely
in all directions under load, rigid
suspension is not permitted.
The hooks must not be loaded at the tip.
If the angle of inclination is too large, the
chain box must be removed, otherwise the
chain may fall next to the chain box
(section 3.2.3, page 8).
The suspension must be suitable for the
transverse forces that occur.
If several hoists are used to lift a common
load, the increase in load on the hoist and
its suspension due to the spread angle
must be taken into account.
Shorten the maintenance intervals.
Observe the specifications in the complete
operating instructions.
Contact J.D. Neuhaus if you have any
questions!


Fig. 1: Oblique pulling

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SAFETY INFORMATION
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Personal protective equipment 2.6
The protective equipment required for the operation, maintenance and inspection of the hoist is
determined by the operating company’s risk assessment. As manufacturer we recommend the following
protective equipment:
Safety helmet in the danger area
Safety footwear
Hearing protection for continuous use
Tight-fitting work clothing
Spare parts 2.7
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.

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TECHNICAL DESCRIPTION
English
3TECHNICAL DESCRIPTION
Marking / identification 3.1
For accurate identification you will find a nameplate on your hoist containing all relevant information
(→Fig. 2: Nameplate).
Fig. 2: Nameplate
Assembly overview 3.2
J.D.Neuhaus GmbH & Co. KG 58449 Witten Germany www.jdngroup.com
Description
Type
Rated hoisting speed Chain
Lifting capacity
Nom. pressure
Year of construction Serial number
Group of mechanisms
Explosion proof class
Air Hoist
Gearbox
Chain
Buffer package
Load sleeve
with load hook
Support hook
Air connection
Motor with
integrated brake
Chain box
Control hose
with strain relief
Hand control
with emergency stop
function
Fig. 3: Assembly overview

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TECHNICAL DESCRIPTION
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3.2.1 Motor with integrated brake
The pneumatic motor is designed as a vane motor with integrated brake.
Fig. 4: Sectional view of the compressed air vane motor
The vane motor consists of a cylinder liner with two lateral bearing washers and an inner rotor. The
bearing washers are spring preloaded and also serve as brake discs. The rotor is mounted eccentrically in
the cylinder liner and is provided with slots for installation of the vanes. The vanes can move freely and
make contact with the inner wall of the cylinder liner. Each chamber is formed by two vanes.
Due to the incoming compressed air, a greater force is created at the leading, larger vane surface than at
the trailing, smaller vane surface. The rotor's torque results from the difference in force. As the chamber
passes the outlet opening, the compressed air can escape. A throttle is located at the outlet opening with
which a maximum speed can be set (section 5.7, page 18). There are two connected lubricant chambers
in the rotor. Continuous motor lubrication takes place via permeable discs embedded in the rotor at the
front. The lubricant chamber can easily be refilled from the outside via a grease nipple (section 7.3.3,
page 29).
3.2.2 Gearbox
The gearbox is designed as a two-stage planetary gearbox. The mini 250 and mini 1000 have one double
stage each.
3.2.3 Hook, chain and chain container
Hook:
NOTICE
Load hooks/support hooks must not be loaded at the tip. They may not be directed or annealed. This
may result in damage to the hook.
The hoist is equipped with either a hook with a safety catch or a hook with a twist lock safety device. The
different hook types are interchangeable.
The permissible temperature range of the load hook is -20°C (-4°F) to +150°C (302°F).
Cylinder liner
Rotor
Vane with
starting aids
Outlet opening
Throttle
Lubricant chamber
Inlet opening “Lifting”
Inlet opening “Lowering”
Fig. 5: Hook with safety catch
Fig. 6: Hook with twist lock safety device

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TECHNICAL DESCRIPTION
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Chain and chain inlet:
WARNING
Danger from chain fracture
The fatigue strength of chains is significantly impaired by extreme corrosion (pitting corrosion). In
addition, rusty chains result in heavy wear. There is a danger of breakage!
Hydrogen-induced embrittlement with subsequent stress corrosion from highly corrosive media (e.g.
sea water) may appear on high-strength alloys (e.g. on the chain). There is a danger of breakage! So-
called recombination toxins promote this process. Hydrogen sulphides, cyanide, arsenic compounds
and thiocyanates are known for this.
Protect the chain against strong corrosion
Do not use rusty chains
NOTICE
Chains from JDN are matched to the chain sprocket in close tolerances. In order to ensure an
optimum function of the chain and in order to prevent risks, only genuine JDN chains may be installed.
Do not use chains measuring 4mm x 12mm, 5mm x 15mm (mini 125/250) or 7mm x 21mm (mini
500/1000)!
The hoist is designed as a single chain hoist and has a chain size of 4.7mm x 14.1mm (mini 125/250) or
7.4mm x 22.0mm (mini 500/1000).
The chain is manufactured in accordance with DIN EN 818-7 and corresponds to DAT quality (standard
chain) or quality 6 (stainless chain). The permissible temperature range of the chain is -20°C (-4°F) to
+150°C (302°F).
The chain inlet on the load and idle chain side is equipped with replaceable wear parts (→Checking the
chain inlets, page 32).
Chain container:
WARNING
Danger from falling chain
When operating without a chain container, it is important to ensure that the idle chain (unloaded chain
end) accumulating on or sagging from the sprocket does not cause any hazard, such as from catching,
impacting or falling. There may be hazards from the chain falling if the idle chain is first deposited on
a load with a large surface or on-site occurrences when lifting and then slides off and drops.
When operating with other chain boxes or overfilled chain containers, the chain may fall out of the
chain box.
When operating without a chain container, ensure that the chain does not get caught, hit
anything or fall down.
Only use original JDN chain boxes.
When replacing the chain (section 7.5.1, page 30), do not insert a longer chain than the original
chain so as not to exceed the capacity of the chain box.
3.2.4 Control with emergency stop device
The lifting and lowering motion is controlled via the push buttons. In the process, the control pressure is
continuously adjustable so that a sensitive positioning of the load is possible. The direction of movement
of the load hook is indicated by arrows on the hand control.
Lifting: Gently push down the right push button. The load will be lifted slowly.
Depress the push button further to increase the lifting speed.
Ease up on the push button slightly to reduce the lifting speed.
Lowering: Gently depress the left push button. The load will be lowered slowly.
Depress the push button further to increase the lowering speed.
Ease up on the push button slightly to reduce the lowering speed.
The push buttons automatically return to the neutral position when released. All movements are stopped
instantaneously and the load is securely held in its current position.
By pressing the red EMERGENCY STOP button, a separate blocking valve closes; the hoist instantly comes
to a halt and the load is held securely in its current position. The control system is now inoperable.

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3.2.5 Operational limit stop for lifting and lowering limiter
WARNING
Danger of chain breakage due to damage to the lowering limiter
The lowering limiter must not be started under normal operating conditions. Before using the hoist,
make sure that the length of the chain is sufficient so that the lifted load can be placed on the ground
at its final destination.
Make sure that the installed chain length exceeds the chain length required for the application.
WARNING
Risk of chain breakage due to damage to the lifting limiter buffer
The operational limit stop for lifting may be started under normal operating conditions. However, a
damaged buffer and/or a damaged shut-off valve can exert unacceptably high forces on the chain if
the hook is moved to the end position.
Use the hoist only with functioning buffer and end stop
Check buffer and end stop regularly (→ section 6.1.4, page 21)
The hoist is equipped with limiters which switch off the lifting or lowering movement.
To achieve this, valves are integrated in the hoist. These are switched by the buffer discs. The control
circuit is interrupted in the appropriate direction. The load is held securely in its current position. The
opposite direction remains functional.
Fig. 7: Shut-off valves
Load capacity 3.3
The permissible load capacity of the hoist is shown in the following table:
Type mini 125 mini 250 mini 500 mini 1000
Load capacity 125 kg (275 lbs) 250 kg (550 lbs) 500 kg (1100 lbs) 980 kg (2200 lbs)
Service life – Group of mechanism according to FEM / ISO 3.4
Hoists from the mini series are classified in group of mechanism M4 / 1Am according to ISO 4301 / FEM
9.511. The theoretical service life is therefore 800 full load hours or a maximum of 10 years if the
approved theoretical full load hours have not been reached before.
Measures must be taken during the service life to reach the safe operating period (→ section 7.1, page
26).
Special tests within the scope of a general overhaul are required after the theoretical service lift has
expired. The general overhaul must be initiated by the operating company and must be documented in
the inspection log. The general overhaul is used to assess the condition of the components and to
determine all defective or near-defective components. As a result, the replacement of individual
components or entire assemblies may be necessary. The scope of general overhauls shall be determined
taking into account the specifications of JDN. Please contact us, if required.
Shut-off valve

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TECHNICAL DESCRIPTION
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Information on explosion protection 3.5
Hoists from the mini series are marked as follows in accordance with EU Directive 2014/34/EU and DIN
EN 13463-1:
II 3 GD IIA T4(X)
The additional marking "X" refers to the explosion protection in the operating instructions.
Your product mini 500 is a device in category 3, can be used in general industry, in zone 2 for gases of
the explosion group IIA with an ignition temperature over 135°C (275°F).
Your product can also be used in zone 22 for dusts with smouldering temperatures above 210°C (410°F)
or ignition temperatures above 203°C (398°F). Use for light metal or other impact-sensitive dusts is not
permitted. The thickness of the dust layer must not exceed 5 mm.
The permissible ambient temperature range is from -20°C (-4°F) to +50°C (+122°F).
Load chain:
To ensure the required earthing, badly rusted chains may no longer be used. For, depending on the
degree of corrosion, the conductivity of the chain may deteriorate so that it is no longer sufficient. The
chain and load are always to be moved in such a way that sliding and/or frictional contact with other
systems and components is excluded. If circumstances do not permit this, it necessary to ensure an
absence of explosive atmospheres during operation.
Earthing:
The hoist is earthed via the suspension (support hook). The hand control is conductively connected to the
hoist body via the strain relief and the final cable lug.
Assembly, maintenance and disassembly work:
WARNING
Risk of explosion
Observe the national regulations and work instructions at your workplace when carrying out
assembly, maintenance and disassembly work in explosion-hazardous areas.
Cleaning plastic surfaces:
WARNING
Risk of explosion
Electrostatic charging may occur at the plastic surfaces due to mechanical friction, potentially leading
to brushing discharges that can ignite gases and air mixtures.
Only clean the surfaces with a damp cloth (cleaning cloth with water) to reduce the electrostatic
charging.
Compressed air requirement 3.6
3.6.1 Connection
To connect the hoist to the on
-
site compressed air supply, a hose nozzle
with union nut is screwed loosely onto the sealed double nipple. The hose
nozzle with union nut is suitable for compressed air hoses with an inside
diameter of di=13mm (1/2"). The double nipple has the connection size
G1/2".
Fig. 8: Compressed air
connection
Air connection

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3.6.2 Pressure
WARNING
Risk of explosion
Operating at higher pressures may result in hazards due to overload. When operating at lower
pressures, the brake can grind and is therefore subject to very high wear. Inadmissibly high heating
may result. The load carrying capacity of the device is reduced. The response of the control system
decreases noticeably.
Comply with the specified pressure.
Note the possible pressure loss with long hose lines.
Your hoist must be operated with a nominal pressure of 6 bar (85psi) (see specification on the
nameplate). The pressure existing in the line must correspond to the nominal pressure.
Use the corresponding hose lines for the pressure.
Higher pressures must be reduced to nominal pressure.
After switching on, the adjoining nominal pressure p1reduces to the flow pressure p2. The extent of the
flow pressure p2at 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 the flow pressure p2may at a maximum be 10% below the specified
nominal pressure of the hoist (measured immediately before the lifting motor)!
3.6.3 Volume
The air consumption of the hoist is shown in the following table:
Type mini 125 mini 250 mini 500 mini 1000
Air consumption
when
lifting with nominal load m³/min (cfm) 0,95 (33.5) 0,95 (33.5) 1,7 (60.0) 1,7 (60.0)
Air consumption when
lowering with nominal load m³/min (cfm) 0,95 (33.5) 0,95 (33.5) 1,7 (60.0) 1,7 (60.0)
3.6.4 Quality of the compressed air
NOTICE
There is a danger of icing in the motor if there is moist air and ambient temperatures at or below 0°C
(32°F)! You can avoid icing by:
the use of an upstream air dryer
when using a service unit with an oiler, depending on the moisture content of the compressed air,
add an anti-icing agent to the lubricating oil or use an air lubricator with an anti-icing addictive
for the corresponding temperatures.
Your hoist must be operated with a sufficiently clean and dry working air. The air supply must fulfil the
following quality requirements:
Particle size less than 40 µm (1.57 mils)
Particle density lower than 10mg/m³
Pressure dew point at least 10K below the lowest expected ambient temperature
To provide a sufficient compressed air quality, we recommend operation with a filter regulator.
Do not operate your product with other gases!
Sound pressure level 3.7
The sound pressure level was determined on the basis of EN ISO 11201. Since the operator location is
flexible due to different control lengths, the measurement was carried out according to standard at a
distance of 1m from the hoist.
Type mini 125 mini 250 mini 500 mini 1000
A-weighted
emission sound
pressure level L
p1
Lifting with nominal load dB 78 78 78 78
Lowering with nominal load dB 80 80 80 80
The above values were determined on a test bench. On-site occurrences such as reflections from
surrounding structures can influence the values.

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TECHNICAL DESCRIPTION
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The following formula can be used to determine the emission sound pressure level Lpr at the operator site
for buildings of common structural design:
 = −10 ∙lg(d) with d=distance from operator site to hoist body
Operating conditions 3.8
CAUTION
Safe and proper operation of the hoist is only possible if the specified operating conditions are
observed.
Adhere to the specified operating conditions.
If other operating conditions are present, please contact JDN.
Your hoist is very sturdy and low-maintenance. It is suitable for use in explosion-hazardous areas, as well
as in areas with increased concentrations of soot, dust and humidity.
Permissible
ambient temperature
Permissible
air humidity Explosion hazardous areas
-20°C (-4°F) to +50°C (+122°F)
if the hoist is not heated above this level due to
external influences
0% to 100% Zone 2
(→section 3.5, page 11)
For stationary use outdoors, you must protect your hoist against the effects of weather and shorten the
maintenance intervals.
Stopping and securing against the wind is required upon reaching a critical wind surge pressure. The
critical wind surge pressure depends on the mass and shape of the load to be lifted and must be
determined by the operating company.
Your hoist may not be used in the following areas, among others (for further areas →section 2.4, page
5):
critical areas in nuclear plants
• over acid baths or systems with aggressive substances
• in areas where there are organic acids
• in areas outside of the permissible ambient temperatures
NFC chip / QR code 3.9
The NFC chip located in the motor cover below the NFC symbol or the QR code on the nameplate provides
you with access to all relevant technical data and documents of your hoist as well as their updates.

14 // EN Rev. 0 / 24.05.2019 Doc.No.: D0000201
TRANSPORT AND STORAGE
English
4TRANSPORT AND STORAGE
Transporting 4.1
NOTICE
Note the weight of the hoist of 10kg (22lbs) for the mini 125/250 or 20,5/21kg (45/46lbs) for the mini
500/1000. This weight applies for a lift of 3m (10ft), each metre (ft) of additional lifting height
increases the weight by 0.5kg (0.35lbs) for the mini 125/250 or 1.2kg (0.81lbs) for the mini
500/1000.
4.1.1 Change of operating site
WARNING
Danger from the load falling
A chain that becomes knotted in the chain box during transport can cause a chain breakage during
subsequent operation if the chain knot blocks the entry of the chain into the hoist.
After each change of operating site, empty the chain box by hand and run the chain via the chain
drive back into the chain box (→section 5.5, page 17).
If you want to transport your hoist to another site, please observe the following points:
1) Reel the chain so that so that no loops can form and the chain cannot become twisted.
2) Depressurise the power supply and disconnect the air connection from the device.
3) Close the air connection in order to prevent dirt ingress.
4) Remove hoist from suspension and carefully set the hoist down and do not allow it to fall.
5) Lay the control hose so that it cannot be kinked.
6) When operating the hoist at a new site, observe the chapter “Commissioning”.
Storage conditions 4.2
4.2.1 Breaks in operation
1) Bring the load hook into the upper end position. Ensure that the lifting limiter is not triggered and
the buffer does not come into contact with the housing.
2) Depressurise the power supply.
3) In the case of longer operational breaks, coat the chain and hook with a light film of oil.
4.2.2 Storage
NOTE
The original packaging is not intended for storing the hoist for a period longer than 12 months.
1) Motor conservation: Lubricate the motor shortly before storing the device (→section 7.3.3, page
29).
2) Coat all bare components with a light oil film.
3) Reel the chain so that so that no loops can form and the chain cannot become twisted.
4) Depressurise the power supply and disconnect the air connection from the device, close the air
connection in order to prevent dirt ingress.
5) Remove hoist from suspension and carefully set the hoist down and do not allow it to fall.
6) Lay the control hose so that it cannot be kinked.
7) Store the hoist in a dry and clean location.

Doc.No.: D0000201 Rev. 0 / 24.05.2019 EN // 15
INITIAL OPERATION
English
5INITIAL OPERATION
WARNING
Risk of explosion
Observe the national regulations and work instructions at your workplace when carrying out assembly,
maintenance and disassembly work in explosion-hazardous areas.
Unpacking 5.1
NOTICE
Note the weight of the hoist of 10kg (22lbs) for the mini 125/250 or 20,5/21kg (45/46lbs) for the mini
500/1000. This weight applies for a lift of 3m (10ft), each metre (ft) of additional lifting height
increases the weight by 0.5kg (0.35lbs) for the mini 125/250 or 1.2kg (0.81lbs) for the mini
500/1000.
The hoist is packaged in environmentally friendly cardboard packaging. Immediately after opening the
packaging, check the delivery for completeness and damage. To unpack, proceed as follows:
1) Keep the accompanying documents in the place provided near the site of application.
2) Lift the hoist carefully out of the packaging.
3) Dispose of packaging in the local recycling system.
Shortening the control length if necessary 5.2
WARNING
Risk of explosion
By removing the cable lug, the conductive connection between the hand control and the hoist is
removed and the hand control can become electrostatically charged.
If possible, do not remove the cable lug when shortening the control length. In case of removal,
reattach a new cable lug to the end of the shortened wire rope.
At the end of the installation, it is essential that you reconnect the cable lug of the wire rope to
the motor housing.
CAUTION
Danger due to escaping compressed air
When releasing the supply hose of the hand control, compressed air flows out if the hoist is under
pressure.
Block the compressed air supply and depressurise the device.
NOTICE
Do not damage the individual compressed air hoses when shortening. This can result in functional
losses.
1) Depressurise the hoist and open the motor cover.
2) Detach the control hoses, the cable lug and unscrew the motor cover.
3) Push the hose casing upwards out of the motor cover, pull the cone out of the hose, remove the
wire rope barrel from the motor cover and pull the complete control hose out of the motor cover.
4) Shorten the sheathing to the desired length. Take care not to damage the compressed air hoses.
Shorten the compressed air hoses and the wire rope according to the illustration.
5) Push the hose back through the motor cover and insert the cone flush. Pull the hose briefly so
that it becomes wedged in the motor cover.Insert the wire rope barrel into the motor cover and
secure the wire rope over the screw in the wire rope barrel.
6) Screw the motor cover back onto the motor housing, reconnect the cable lug to the motor
housing and connect the hoses. Observe the designations on the motor cover.
7) Attach the motor housing cover.

16 // EN Rev. 0 / 24.05.2019 Doc.No.: D0000201
INITIAL OPERATION
English
Fig. 9: Shortening the control length
Suspending the hoist 5.3
WARNING
Danger due to inadequate qualifications
A faulty installation may result in serious accidents.
The hoist may only be installed by qualified personnel in compliance with all applicable national
safety regulations (→chapter 2).
WARNING
Danger from the load falling
Vibrations damage the chain and can lead to chain breakage.
The supporting structure must form a rigid support.
Furthermore, no external vibrations may be transferred to your hoist (e.g. from the attached
load).
WARNING
Danger from the load falling
Due to the dynamic behaviour of the hoist, impact forces can occur which can be several times the load
weight. The supporting structure must be sufficiently dimensioned for this. The hoist has no overload
protection.
The attachment point and the supporting structure for your hoist must be able to safely absorb
the forces to be expected according to the following table (DIN EN 14492-2:2010).
Ensure that your product can be freely aligned under load, as otherwise impermissible additional
loads may occur.
Type mini 125 mini 250 mini 500 mini 1000
Impact factor
- 4,6 2,2 2,0 1,6
Load capacity kg
(lbs)
125
(275)
250
(550)
500
(1100)
980
(2200)
Maximum dynamic force on supporting
structure at rated load
(without oblique pulling)
kN
(lbf)
5,65
(1270)
5,40
(1215)
9,81
(2205)
15,40
(3460)
170
27
155
M5
mini125/250:
M5 / 5Nm
mini500/1000: M6 / 8Nm
1) 2)
3)
M6 / 8Nm

Doc.No.: D0000201 Rev. 0 / 24.05.2019 EN // 17
INITIAL OPERATION
English
5.3.1 Hoist with support hook with hook safety catch
1)
Hang the hoist in the on
-
site
suspension.
2) Make sure that
a) the on-site suspension is on the central
axis of the support hook.
b) the hook safety catch is closed.
c) the support hook can swing slightly in all
directions.
Fig. 10: Suspending the hoist
5.3.2 Hoist with support hook with twist-lock safety device
1)
Hang the hoist in the on
-
site suspension.
2) Make sure that
a) the on-site suspension is on the central
axis of the support hook.
a) the twist-lock is closed.
b) the support hook can swing slightly in all
directions.
Fig. 11: Suspending the hoist
Connecting the air supply 5.4
Technical connection data / requirements →section 3.6, page 11
1) Check air connection parts for dirt and clean them if necessary.
2) Sparge the compressed air hose to remove foreign bodies.
3) Connect the compressed air hose to the port and screw on the union nut.
4) Make sure that the connection is secure and tight.
Emptying the chain container and running the chain into the 5.5
chain container
WARNING
Danger from the load falling
A chain that becomes knotted in the chain box during transport can cause a chain breakage during
subsequent operation if the chain knot blocks the entry of the chain into the hoist.
Empty the chain box by hand and run the chain back into the chain box via the chain drive.
Fig. 12: Emptying the chain container and running the chain into the chain container

mini125/250:
M6
mini500/1000: M8
1) 3)

18 // EN Rev. 0 / 24.05.2019 Doc.No.: D0000201
INITIAL OPERATION
English
1) Loosen the chain container and remove the chain container a little away from the hoist.
2) Empty the chain from the chain container by hand. Make sure that nobody is under the hoist and
that nobody is hit by the chain.
3) Then lower the hook until just before the buffer of the idle chain touches the hoist body.
4) Secure the chain container and run the chain into the chain container by lifting.
Lubricating the chain 5.6
WARNING
Danger from chain fracture
An insufficiently lubricated chain can lead to increased wear during continued operation and ultimately
to chain breakage.
The chain must always be coated with a light lubricating film.
The contact points of the chain must be carefully lubricated.
The chain is delivered from the factory in slightly oiled condition. It is recommended to lubricate the
chain directly before commissioning. To lubricate the chain see section 7.3.2, page 28. It must be
ensured that the chain is always sufficiently lubricated during operation (check →section 6.1.1, page 20).
Setting the maximum speed 5.7
The maximum speed of the hoist can be adjusted via a throttle (→section 3.2.1, page 8). Unless ordered
otherwise, the maximum speed is set to the maximum possible value in the factory. The setting range is
between the following values:
Hoist Adjusting the
throttle
Max. lifting speed at nominal
load
Max. lowering speed at
nominal load
mini 125 / 250 minimal 100% 100%
maximal ~55% ~70%
mini 500 / 1000 minimal 100% 100%
maximal ~50% ~65%
Fig. 13: Setting the max. speed
1) Remove the motor housing cover.
2) The motor housing cover is connected to the motor cover so that it cannot be lost. The adjusting
screw of the throttle is located centrally at the top of the motor.
3) The maximum speed can be changed by turning the adjusting screw. Clockwise – max. speed is
reduced, counterclockwise – max. speed is increased. The adjusting screw has an adjustment
range of approx. 14 revolutions. The end positions are secured by a stop. Turn carefully, the
screw must be easy to turn by hand.
4) Refit the motor cover.
M5
1) 2-3)
M
4

Doc.No.: D0000201 Rev. 0 / 24.05.2019 EN // 19
INITIAL OPERATION
English
Tests before commissioning 5.8
WARNING
Danger to life
If the hoist is put into operation without proper testing (e.g. in accordance with the currently
applicable accident prevention regulations), there is a danger to life and health.
The hoist, including the supporting structure, must be inspected by an appropriately trained and
qualified person before initial operation and before re-commissioning after significant
modifications.
National regulations must be observed.
The testing extends from the installation, outfitting and operational ability under normal conditions,
mainly to check the completeness, suitability and effectiveness of the safety equipment, as well as to the
state of the device, the lifting gear, the equipment and the load-bearing medium. The testing must be
entered in the accompanying inspection log.
In addition to national regulations, the following points must be checked before commissioning:
Hoist suspension
Presence of the operating instructions at the workplace
Proper functioning of the emergency stop function (check →section 6.1.3, page 20)
Proper functioning of the lifting and lowering switch-off (check →section 6.1.4 and 7.8, page 21
and 33)
Air supply (→section 3.6, page 11)
Lubrication of the chain according to the intended application (lubricating the chain →section 5.6,
page 18)