GEDA 500Z User instructions

Original assembly and operating manual
Assembly and Operating Manual
Rack and pinion hoist
For loads

Rack and pinion hoist
Assembly and Operating Manual 3 / 92 BL054 GB Edition 08.2015

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Assembly and Operating Manual 4 / 92 BL054 GB Edition 08.2015

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Assembly and Operating Manual 5 / 92 BL054 GB Edition 08.2015
Table of Contents:
Chapter Page
1General Information........................................................................................................................... 7
1.1 Information about the instruction manual ..................................................................................... 7
1.2 Information about the machine ..................................................................................................... 7
1.3 Name and address of the manufacturer....................................................................................... 8
1.4 Notes about the author and industrial property rights .................................................................. 8
1.5 Instructions for the operating company ........................................................................................ 9
1.6 Intended use ............................................................................................................................... 10
1.6.1 Requirements of assembly personnel ................................................................................ 11
1.6.2 Operating personnel ........................................................................................................... 11
1.6.3 Improper use....................................................................................................................... 11
2General safety information ............................................................................................................. 12
2.1 Residual risks ............................................................................................................................. 12
2.2 Safety instructions for operating personnel ................................................................................ 13
2.3 Safety instructions for transport.................................................................................................. 14
2.4 Safety instructions for operation ................................................................................................. 15
2.5 Safety instructions for servicing, maintenance and troubleshooting .......................................... 16
2.6 Safety whilst working on the electrics......................................................................................... 18
3Tests.................................................................................................................................................. 19
3.1 Documenting the results............................................................................................................. 19
3.2 Checks before initial commissioning .......................................................................................... 20
3.3 Checks after assembly / daily before starting operation ............................................................ 20
3.4 Recurring inspections: ................................................................................................................ 20
3.5 Dynamic tests ............................................................................................................................. 21
3.6 Static tests .................................................................................................................................. 21
3.7 Checks after extreme weatherconditions ................................................................................... 22
4Technical description ...................................................................................................................... 23
4.1 Description of function ................................................................................................................ 23
4.2 Machine equipment .................................................................................................................... 25
4.2.1 Operating and control elements ......................................................................................... 27
4.3 Equipment as accessories.......................................................................................................... 29
4.3.1 Electric module for landinglevel safety door....................................................................... 29
4.3.2 Standard push-on frame for the load platform.................................................................... 30
4.3.3 Single axle trailer ................................................................................................................ 31
4.3.4 Cold package...................................................................................................................... 31
4.3.5 Operating time indicator ..................................................................................................... 31
4.4 Technical Data............................................................................................................................ 32
4.4.1 Operating and environmental conditions............................................................................ 34
4.5 Anchoring and spatial requirement............................................................................................. 35
4.6 Requirements of the installation site .......................................................................................... 42
4.6.1 Foundation.......................................................................................................................... 42
4.6.2 Ground pressure................................................................................................................. 42
4.6.3 Mains connection................................................................................................................ 43
5Transport .......................................................................................................................................... 44
6Installation ........................................................................................................................................ 45
6.1 Safety during installation ............................................................................................................ 45
6.2 Assembling the base unit ........................................................................................................... 46
6.3 Extending mast sections and anchoring to the building ............................................................. 47
6.3.1 Trailing cable guide ............................................................................................................ 52
6.3.2 Emergency limit switch approach bar................................................................................. 53
6.4 Securing loading and unloading points ...................................................................................... 54
6.4.1 Electric module for the landing-level safety door................................................................ 54
6.4.2 Limit switch approach bar for landing level stop................................................................. 55
6.5 Check after assembly and before each operation...................................................................... 56

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7Operation .......................................................................................................................................... 57
7.1 Safety during operation............................................................................................................... 57
7.2 Safety check before starting work .............................................................................................. 58
7.3 Using the platform access point, turning lever and landing-level safety door ............................ 59
7.3.1 Ramp .................................................................................................................................. 59
7.3.2 Turning lever ....................................................................................................................... 59
7.3.3 “ECO” landing-level safety door.......................................................................................... 60
7.4 Operating the hoist ..................................................................................................................... 61
7.5 Emergency shutdown ................................................................................................................. 63
7.6 Interrupting work – end of work .................................................................................................. 63
8Dismantling (disassembly) ............................................................................................................. 64
9Maintenance and cleaning .............................................................................................................. 65
9.1 Daily cleaning ............................................................................................................................. 65
9.2 Weekly servicing ......................................................................................................................... 65
9.3 Monthly servicing ........................................................................................................................ 66
9.4 Quarterly servicing ...................................................................................................................... 67
9.5 Annual maintenance ................................................................................................................... 68
9.6 Servicing every 6 years .............................................................................................................. 69
9.7 Checking the safety gear ............................................................................................................ 70
10 Malfunctions - Diagnosis – Repair ................................................................................................. 71
10.1 Potential malfunctions during operation ..................................................................................... 73
10.1.1 Power failure or defective motor ......................................................................................... 73
10.1.2 Load platform has been driven too high ............................................................................. 74
10.1.3 Platform has descended too low......................................................................................... 74
10.1.4 Overload warning device has triggered .............................................................................. 75
10.2 Safety gear has triggered ........................................................................................................... 76
10.3 Repair ......................................................................................................................................... 77
11 Disposal of the machine.................................................................................................................. 77
12 Appendix A Summary of instruction notices............................................................................... 78
13 Appendix B Test Documentation ................................................................................................... 80

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1 General Information
1.1 Information about the instruction manual
This operating manual is an essential aid to operating the machine
successfully and hazard-free.
This operating manual contains important instructions on how to
operate the machine safely, correctly and efficiently. Compliance
with these instructions helps to avoid hazards and increases the
reliability and service life of the machine.
The operating manual must be available at the machine at all times
and must be read and applied by every person commissioned to work
on/with the machine, e.g.:
−Operating, fault rectification during work, disposal of operating
materials and auxiliary supplies,
−assembly, maintenance (servicing, general maintenance, repairs)
and/or transport
The structural elements in this operating manual appear as follows
and have the following meaning:
Health and safety symbol
This symbol is found next to all safety instructions where there is a risk
of injury or a fatality. Observe these instructions and be very cautious!

Attention information
This is found at points where special information or instructions and
restrictions regarding damage prevention are given in order to prevent
damage to the equipment.

Note
This is found at points where information is given about using the
machine economically or instructions are given regarding correct
working procedures.
1.2 Information about the machine
Machine model GEDA

500 Z
Works number:
14830 (400 V)
21900 (230 V 300 kg
21901 (230 V 500 kg))
Year of construction:
Refer to identification plate on the
machine
Documentation version:
04/2015

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1.3 Name and address of the manufacturer
GEDA Dechentreiter GmbH & Co. KG
Mertinger Strasse 60
86663 Asbach-Bäumenheim
Tel.: +49 (0)9 06 / 98 09-0
Fax: +49 (0)9 06 / 98 09-50
E-Mail: [e-mail]
Web: www.geda.de
Representatives of the manufacturer
Bergkamen Subsidiary
Gera Subsidiary
GEDA Dechentreiter
GmbH & Co. KG
Niederlassung Nord-West
Marie-Curie-Strasse 11
59192 Bergkamen-Rünthe
Tel. [phone]
Fax. [phone]
GEDA Dechentreiter
GmbH & Co. KG
East branch
Ernst-M.-Jahr Strasse 5
07552 Gera
Tel. [phone]
Fax. [phone]
USA Subsidiary
Russia Subsidiary
GEDA USA, LLC
1151 Butler Road
USA 77573 League City, Texas
Tel. [phone]
Fax. [phone]
Web: www.gedausa.com
GEDA RUS, LLC
Yaroslavskoe shosse 42
129337 Moscow
Russian Federation
Tel. [phone]
Fax. [phone]
Web: www.geda-ru.com
Turkey Subsidiary
GEDA MAJOR
IS VE INSAAT MAKINALARI SAN. TIC. LTD. STI.
Semsettin Günaltay Cad. No:224 A Blok K:2 D:5
Tüccarbasi/Erenköy
TR-34734 Istanbul/Turkey
Tel.: [phone]
Fax: [phone]
Web: www.geda.com.tr
1.4 Notes about the author and industrial property rights
All documents are protected in terms of copyright law. Dissemination
and reproduction of documents (even parts thereof), as well as
recycling or communication of their contents are prohibited unless
expressly permitted in writing.
Violations are an offence and incur an obligation to pay compensation.
All rights to exercise industrial property rights are reserved by GEDA.

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1.5 Instructions for the operating company
This operating manual is an essential component of the machine. The
operating company must ensure that operating personnel are informed
about these guidelines.
The operating company must supplement the operating manual with
operating instructions based on existing national regulations for
accident prevention and for the protection of the environment,
including information regarding supervisory and reporting duties that
take account of company-related specifics, e.g. with reference to work
organisation, work procedures and the personnel employed.
In addition to the obligatory regulations for accident prevention and
industrial safety that apply both in the country of use and at the place
of use, accepted professional rules for working safely and competently
must also be observed.
The operating company must obligate operating personnel to wear
personal protective gear as appropriate to the local conditions.
First aid facilities (first aid kit, etc.) must be kept within reach!
The operating company/user of the machine must not make any
changes, additions or modifications to the machine that could impair
safety without permission from the manufacturer! This also applies to
installing and adjusting safety equipment, as well as welding onto load-
bearing components.
Any replacement and wear parts that are used must correspond to the
technical requirements stipulated by GEDA. This is ensured with
original replacement parts.
Only employ qualified and/or trained personnel for the tasks
described in this manual. The responsibilities of personnel in respect of
operating, servicing and repairs must be clearly established! The legally
permissible minimum age must be observed!

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1.6 Intended use
The GEDA 500 Z rack and pinion hoist is a construction hoist that is
temporarily erected and
•which is intended exclusively for putting up scaffolding and as
additional equipment (landing-level safety doors) for transporting
items and materials during construction work.
•which may only be operated after the landing-level safety doors are
installed at each transfer point to the building or scaffolding.
•which may only be operated at a wind speed of up to 72 km/s
(20 m/sec. ≈wind force 7-8 according to the Beaufort scale).
−which must have its platform parked on the ground and taken out of
operation at higher wind speeds.
•which may only be operated from outside the cordoned-off and
signposted hazard area using the ground control and / or operated
from the landing level control above the 2 m safety height.
Observe and comply with the instructions in Chapter 4.3.4, “Technical
specifications”.
Any other use or any use going beyond this is not considered proper
use.
The operating company/user of the machine is solely liable for any
damage resulting from such action. This applies equally to any arbitrary
changes to the machine.
Intended use includes
−That the assembly, operation and maintenance provisions (assembly
and operating manual) provided by the manufacturer are complied
with.
−That the foreseeable misconduct of other persons is taken into
consideration.
−That the corresponding national regulations are complied with.

The GEDA 500 Z is suitable for temporary use on construction
sites. Any other locations or intended uses require written
approval from the manufacturer.

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1.6.1 Requirements of assembly personnel
The machine may only be assembled, operated and maintained by
qualified persons who, based on their training, knowledge and practical
experience, can guarantee proper handling and who are aware of the
risks associated with the construction hoist. These persons must be
appointed to the tasks of installation, dismantling and maintenance by
the operating company.
1.6.2 Operating personnel
The machine may be operated only by persons who, based on their
training, knowledge and practical experience, can guarantee proper
handling.
These persons must
−have been appointed by the operating company.
−have been appropriately instructed and informed about the risks.
−be familiar with the assembly and operating manual.
−observe national regulations
1.6.3 Improper use
•Transporting persons is prohibited!
−Only authorised persons are permitted to ride the platform, and only
for the purposes of assembly and servicing work. Special measures
are required for such operations.
−Use the front fall protection.
−Operation during assembly work may only be carried out using the
assembly control from the load platform.
•The 500 Z is not designed for permanent installation.
•The 500 Z must not be constructed to be free-standing (without
anchors).
•Persons without instruction on the machine, who are not familiar with
the operating instructions or children must not operate it.
Consequences of improper use of equipment
−Danger to life and limb of the user or a third party.
−Damage to the machine and other tangible assets.

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2 General safety information
The machine has been designed and built according to the latest
standards of technology and recognised safety-related rules.
Nevertheless, hazards for personnel or third parties and/or damage to
machinery and other tangible assets can occur during use, e.g. if the
machine:
−Is operated by untrained or uninstructed personnel,
−Is used improperly,
−Is assembled, operated and serviced inappropriately.
Attached notices and warning signs must be observed!
Consequences of not complying with safety instructions
Non-compliance with safety instructions can result in danger both for
personnel as well as for the environment and the machine. Non-
compliance can lead to the forfeiture of any damage compensation
claims.
2.1 Residual risks
There are still residual risks remaining from handling the machinery
even when all safety conditions are complied with.
Everyone who works on and with the machine must be aware of these
hazards and follow instructions that prevent these residual risks leading
to accidents or damage.
Caution
−Do not remove safety stickers; replace any safety instructions that
have become illegible.
−Hazards due to toppling of an improperly secured load.
−Hazards due to high wind speeds (> 72 km/h).
−Hazards when accessing and exiting the platform.
−Hazards from damage to the load carrying device.
−Hazards when working on the electrical system.
−Hazards from a malfunction in the control system.
−Injuries due to uncoordinated work methods.

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2.2 Safety instructions for operating personnel
The operating manual must be within reach at all times at the location
where the machine is used.
The machine may only be used in a technically fault-free condition, as
well as in accordance with the intended use, in a safety conscious
manner aware of the hazards, and while observing the operating
manual! In particular rectify faults immediately that could impair safety!
In addition to this, the machine may only be operated when all safety
features are present and functioning!
Check the machine at least once each working day for externally
identifiable damage and defects! Immediately report any changes
(including changes to the operating behaviour) to the office/person in
charge. If necessary, shutdown and secure the machine immediately!
The responsibilities for different jobs within the context of operation,
servicing and maintenance of the machine must be clearly stipulated
and adhered to. This is the only way to avoid mistakes especially in
hazardous situations.
The pertinent rules for prevention of accidents as well as the other,
generally recognised, safety-related and industrial health related rules
must be adhered to.
The operator is obliged to wear personal protective equipment as
appropriate to the local conditions.
Switch-on and shutdown procedures, including emergency
shutdown, must be observed in accordance with the operating manual
for all work that affects operation, and for conversions and adjustments
to the machine and its safety features.

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2.3 Safety instructions for transport
Immediately report transport damage and/or missing parts to the
supplier.
During transport work, wear a safety helmet, safety shoes and safety
gloves!
Never step under suspended loads!
Only use appropriate, standardised and tested lifting gear, forklifts,
cranes) and sling gear (round slings, lifting straps, sling ropes, chains)
for transport at the assembly site.
When selecting hoisting equipment, always take into account the
maximum suspended loads!
Please refer to the dimensions and weights in the technical
specifications section (4.3.4) and spatial requirements (4.5).
Only carefully load and transport equipment that has been
disassembled, packaged and lashed.
Always ensure that the machine is transported without being knocked
or jolted.
Observe the pictograms on the packaging.
Only attach gear to the designated sling points.
Always secure transported loads against falling or tipping over!

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2.4 Safety instructions for operation
Only operate the machine, under consideration of the operating manual,
when it is fully serviceable and in a safety and hazard conscious
manner.
If work is interrupted, switch off the machine at the main switch and
secure it with a padlock against switching on.
Fundamentally, the machine must be secured against unauthorised
use (disconnect from power)!
In situations that present a risk to operating personnel or the
machine, shut down the machine by pressing the EMERGENCY STOP
button.
Shut down and lower the machine when wind speeds are >72 km/h.
(Wind force 7-8, wind breaks branches off trees, makes walking very
difficult!)
No one is allowed to stand under the machine. Ensure that the danger
zone is suitably cordoned off at the customer's site.
Protection to prevent persons from falling must be provided at loading
heights above 2.0 m. (Install landing level safety doors.)

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2.5 Safety instructions for servicing, maintenance and
troubleshooting
Operating personnel must be informed about how to carry out special
work and maintenance work before they start.
Deadlines that are stipulated or stated in the operating manual for
recurring tests/inspections must be adhered to.
The maintenance area must be cordoned off as extensively as
required!
Fundamentally, before any maintenance work on the machine
−unload,
−turn off the main switch.
All servicing and maintenance tasks are only permitted with the
master switch turned off or with the mains plug disconnected.
Manual intervention while the machine is running can lead to serious
injury and is therefore prohibited. If it is necessary to turn the machine
on during such work, then this must only be done while complying with
special safety measures.

For further instructions about maintenance / maintenance intervals
/ repair, refer to sections 9 and 10.
If the machine has been completely shut down for these tasks, it must
be secured against switching on unintentionally:
•Operate the emergency STOP button,
•Lock the main switch using a shackle lock and
•Attach a warning notice to the switch box (main switch).
Any faults that could impair safety must be rectified immediately.
Workshop equipment that is suitable for the specific work is
imperative for carrying out servicing and maintenance tasks. When
carrying out maintenance tasks at greater height, a fall-protection
device must be worn! Keep all handles, railings and the platform free
from dirt and contamination.
When working under the platform, secure it using appropriate means
(e.g. bolts, mast clamps, etc.).

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Before starting servicing/repair tasks clean the machine, in particular
connections and screw connections, from oil, operating fluids,
contamination and maintenance products. Abrasive cleaning agents
must not be used. Loosened screw connections during servicing and
maintenance tasks must always be tightened using the necessary
torques!
Do not change, remove, bypass or bridge safety devices.
If it is necessary to remove safety devices during servicing and
repairs, the safety devices must be installed and checked immediately
after completion of servicing and repair tasks!
Do not make any changes, additions or modifications to the machine.
This also applies to the installation and adjustment of safety devices
such as limit switches.
Immediately replace damaged or detached notices and warning signs,
as well as safety labels.
Ensure that auxiliary supplies, as well as replaced parts, are disposed
of safely and in an eco-friendly manner (also refer to Chapter 11).

The aforementioned safety measures apply equally for work in the
context of eliminating faults.

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2.6 Safety whilst working on the electrics
If there are faults on the electrical system of the machine, it must be
shut down immediately using the main switch and secured with a lock
or the mains plug must be removed!
Work on the electrical equipment of the machine must only be carried
out by qualified electricians working in accordance to electrical
engineering regulations! Only professional electricians may access the
machine's electrics and carry out work on it. Always keep the switch
boxes closed as soon as they are left unattended.
Never work on live parts! System parts on which inspection,
maintenance or repair work is to be carried out must be
disconnected from the mains. Operating fluids that have been
disconnected must be secured against being switched back on
unintentionally or automatically (lock away fuses, block isolating
switches, etc.). The disconnected, electrical components must first be
tested to ensure they are voltage-free, then earthed, short-circuited and
isolated from neighbouring live components.
If tasks must be carried out on live components (only in exceptional
circumstances) an additional person must be present to operate the
EMERGENCY STOP button or main switch in the event of an
emergency. Only use insulated tools!
When carrying out repairs, make sure that safety design features are
not changed (e.g. creeping distances, clearances and distances must
not be made smaller by insulation).
Fault-free earthing of the electrical system must be ensured by
a protective earth system.

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3 Tests
The GEDA 500 Z is a machine in compliance with the EC machinery
directive 2006/42/EC. A copy of the conformity declaration is
reproduced in this operating manual.

Inspections before commissioning, recurring inspections and
intermediate inspections must be carried out according to national
regulations.
During the checks, the condition, presence and function of all safety-
related features of the machine are checked using appropriate
procedures. Appropriate procedures are:
•Visual inspections
•Function and efficacy checks
•Checks using measurement and test equipment
For each test, the scope of the test, type of test and the execution of the
test by competent persons must be defined by the operating company.
Type of test
Inspection procedures
Check by a trained person
Basic visual inspection and function check
with few test steps and simple evaluation
Check by a competent person
Check due to special events / damage, e.g.
−Assembly
−Maintenance
−
Natural phenomena
Checking by an accredited
inspection body (technical specialist)
Recurring check
for systems / machines that
must be monitored.
Checking in accordance with national
regulations
3.1 Documenting the results
The operating company must document the results of the checks. The
documentation must be kept for a reasonable period of time – however
at least for the entire lifetime of the machine.
•The results of the recurring check can be recorded in writing in the
appendix of this manual.
•Verification of the execution of the last check must be attached to the
machine.

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3.2 Checks before initial commissioning
Checks at the factory
The following tests have already been carried out at the factory:
−Dynamic test with 1.1x useful load.
−Electrical tests according to EN 60204
−Function tests.
3.3 Checks after assembly / daily before starting operation
To ensure safety when handling the machine, the custodian / person
determined by the operating company must carry out a daily check of
certain areas of the machine / parts.
Defects detected must be immediately reported to the supervisor and
rectified. Defects may only be rectified by trained personnel responsible
for maintenance and servicing.
Always carry out visual inspections before function checks. Operation is
prohibited until the defects are rectified.
The following points must be checked daily
−Visual inspections before start of work
→refer to Chapter “Operation” in the operating manual
−Clean the cable bin (keep free from snow and ice in winter).
−Keep the work area around the machine clear and clean.
For inspections after each installation
→
refer to Chapter 6.5
3.4 Recurring inspections:
Recurring inspections must be carried out in accordance with national
regulations.

GEDA recommends that you carry out a recurring check on an
annual basis. In the case of increased use and strain (e.g. multi-
shift operation) carry out inspections at shorter intervals.