GEDA 1500z Installation instructions

BL 076 GB Edition 07.2015 Original operating manual
Operating Manual
Construction Hoist / Transport Platform
For persons and loads

General Information GEDA®1500 Z/ZP
Operating Manual 2 / 84 BL076 GB Edition 07.2015

GEDA®1500 Z/ZP General Information
BL076 GB Edition 07.2015 3 / 84 Operating Manual
Table of Contents:
Chapter Page
1General Information ...............................................................................................5
1.1 Information about the instruction manual ..........................................................5
1.2 Abbreviations ....................................................................................................7
1.3 Information about the machine..........................................................................7
1.4 Name and address of the manufacturer............................................................8
1.5 Notes about the author and industrial property rights........................................8
1.6 Instructions for the operating company .............................................................9
1.7 Intended use ...................................................................................................10
1.7.1 Requirements of assembly personnel......................................................12
1.7.2 Operating personnel.................................................................................12
1.7.3 Improper use............................................................................................12
2General safety information..................................................................................13
2.1 Residual risks..................................................................................................13
2.2 Safety instructions for operating personnel.....................................................14
2.3 Safety instructions for transport.......................................................................15
2.4 Safety instructions for operation......................................................................16
2.5 Safety instructions for servicing, maintenance and troubleshooting................17
2.6 Safety whilst working on the electrics..............................................................19
3Technical description...........................................................................................20
3.1 Description of function.....................................................................................20
3.1.1 Use as a material hoist.............................................................................21
3.1.2 Use as a transport platform / climbing platform.......................................21
3.2 Machine equipment.........................................................................................22
3.2.1 Ground station switch box........................................................................25
3.2.2 Platform control........................................................................................25
3.2.3 Ground control (manual control)...............................................................26
3.2.4 Drop test control.......................................................................................26
3.2.5 Platform access, ground station...............................................................27
3.2.6 Platform access, building.........................................................................28
3.2.7 Overrun and cable protection...................................................................30
3.2.8 Document box..........................................................................................31
3.2.9 Operating time indicator...........................................................................31
3.3 Equipment as accessories ..............................................................................32
3.3.1 1.1 m base enclosure with barrier............................................................32
3.3.2 Underride protection.................................................................................33
3.3.3 Securing loading and unloading points ....................................................34
3.3.4 Electric module for landing level equipment.............................................35
3.3.5 Assembly bridge.......................................................................................36
3.3.6 Roofs........................................................................................................37
3.3.7 Scaffold bracket .......................................................................................40
3.3.8 Holder for individual support frames.........................................................42
3.3.9 Cable bin cover........................................................................................43
3.3.10 Cold package...........................................................................................43

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Chapter Page
3.4 Technical Data................................................................................................ 44
3.4.1 Operating and environmental conditions................................................. 44
3.4.2 Speeds.................................................................................................... 45
3.4.3 Electrical connected loads....................................................................... 45
3.4.4 Assembly height...................................................................................... 45
3.4.5 Emissions................................................................................................ 45
3.4.6 Mast ........................................................................................................ 46
3.4.7 Load capacity, Dimensions and weights ................................................. 47
4Operation.............................................................................................................. 56
4.1 Safety during operation .................................................................................. 56
4.1.1 Special safety instructions for operation as a material hoist.................... 57
4.1.2 Special safety instructions for operation as a transport platform............. 57
4.1.3 Safety check before starting work ........................................................... 58
4.2 Operation of the platform access points and the landing-level safety doors... 59
4.2.1 1.1 m base enclosure with barrier (option).............................................. 59
4.2.2 Platform access, ground station.............................................................. 60
4.2.3 Platform access, building/landing level.................................................... 61
4.2.4 Landing-level safety doors....................................................................... 62
4.3 Operating as a material hoist.......................................................................... 63
4.4 Operating as transport platform...................................................................... 66
4.5 Operation for assembly .................................................................................. 69
4.6 Emergency shutdown..................................................................................... 71
4.7 Interrupting work – end of work ...................................................................... 71
5Malfunctions - Diagnosis – Repair..................................................................... 72
5.1 Diagnostic system (option)............................................................................. 73
5.2 Fault table....................................................................................................... 74
5.3 Fault rectification ............................................................................................ 75
5.3.1 Motor is not producing full output ............................................................ 75
5.3.2 Platform moved too high.......................................................................... 75
5.3.3 Platform has run too low.......................................................................... 76
5.3.4 Overload warning device has triggered................................................... 77
5.3.5 Safety gear has triggered........................................................................ 77
5.4 Retrieving the platform ................................................................................... 79
5.4.1 Basic conduct in the event of a rescue/malfunction................................. 79
5.4.2 Rescue action plan.................................................................................. 80
5.5 Repair............................................................................................................. 83
6Disposal of the machine ..................................................................................... 84

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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.
You will come across a series of illustrations and symbols while reading
this manual which are intended to help you navigate through and
understand this manual. The different meanings are explained below.
Text display
Meaning
Bold type
Emphasises particularly important
words/passages
•List 1
Denotes lists
−
List 2
Denotes lists
(brackets)
Position numbers
Instruction
Instruction to personnel. Always given in
chronological order
Images
The illustrations used refer to a specific machine type. They may only
constitute a schematic representation with other machine types.
The fundamental function and operation is not affected by this.

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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!
Warning level
Consequence
Probability
DANGER
Death / serious injury
is imminent
WARNING serious injury possible
CAUTION minor injury possible
CAUTION tangible damage possible

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.

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1.2 Abbreviations
The following abbreviations may be used in the manual.
max. maximum
min. minimum
mins. minutes
etc. et cetera
poss. possible/possibly
e.g. for example
ml millilitre
mm millimetre
°C degrees Celsius
°F degrees Fahrenheit
ft. feet
ft/m feet per minute
m/min metres per minute
in. inch
etc. et cetera
lbs. pounds
lbf.-ft pounds per feet
kg kilogram
l litre
gal. gallons
kip. kilopound
Nm Newton metre
km/h kilometres per hour
mph miles per hour
incl. including
if nec. if necessary
i.e. id est (that is)
reg. regarding
RH relative humidity
approx. approximately
Ø diameter
® registered trademark
© copyright
TM trademark
% per cent
‰ per thousand
dB (A) sound pressure level
LWA sound power level
> greater than
< less than
± plus or minus
1.3 Information about the machine
Machine model
with platform
GEDA 1500 Z/Z
A, B, BS, BL, BLL, C, D, E, ED, F, G,
GD, H-I
Works number: 17006
Year of construction: Refer to nameplate
Documentation version: 07/2015

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1.4 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
1.5 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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1.6 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 make sure that operating personnel 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 operating company clearly defines the responsibilities of the
personnel for operation/installation/maintenance.
The operating company is obliged to train all persons authorised to use
the machine in the correct handling of the machine before using it for
the first time, according to the respective area of activity and
responsibility of the authorised individual and using practical exercises.
This training must be documented and repeated at regular intervals.
The legally permissible minimum age must be observed!

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1.7 Intended use
The GEDA 1500 Z/ZP is a construction material hoist as well as a
transport platform that is temporarily erected and
•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.
as construction material hoist
•which is intended exclusively for putting up scaffolding and for
transporting items and materials during construction work.
•which may only be operated from outside the cordoned-off and
signposted hazard area using the ground control and/or operated
from the electric modules on the landing level control above the lower
safety area (2 m above the ground).
as transport platform and carrying persons
•Determined for the transport of material and a max. of 7 persons who
can exit the platform at installed and secured exit points.
•It must only be used by trained personnel (platform operator) on
construction sites.
•The equipment can only be operated from the platform in dead man's
control.
(Operation is not possible from other control locations.)
•There is the option to stop at any position (e.g. to unload bulky
components over the base enclosure).
As a mast climbing platform
•Determined for the transport of material and a max. of 7 persons who
can carry out tasks from the platform.
•The equipment can only be operated from the platform in dead man's
control.
(Operation is not possible from other control locations.)

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Observe and comply with the instructions in Chapter 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 1500 Z/ZP is suitable for temporary use on construction
sites. Any other locations or intended uses require written
approval from the manufacturer.

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1.7.1 Requirements of assembly personnel
The machine must only be assembled, operated and maintained by
competent persons who, based on their training, knowledge and
practical experience, can ensure correct handling of the machine and
who are aware of the risks associated with the transport platform.
These persons must be appointed to the tasks of installation,
dismantling and maintenance by the operating company.
1.7.2 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
1.7.3 Improper use
The GEDA 1500 Z/ZP
•is not designed for permanent installation.
•must not be set up to be free-standing (without anchors).
•must not be operated by people who have not been trained on the
machine, who are not familiar with the operating instructions or by
children.
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.
−Hazard of damage to the mast sections, anchors or base unit.
−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 chapter (3.4).
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. (Install the base
enclosure and underride protection).
Protection to prevent persons from falling must be provided at loading
heights above 2.0 m. (Install landing-level safety doors).
Accompanying persons must comply with the instructions of the
platform operator. Above all, they must not lean out over the sides of
the platform or step across material being carried.

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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,
−Switch off at the master 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
/ servicing, refer to the maintenance manual.
If the machine has been completely shut down for these tasks, it must
be secured against switching on unintentionally:
Activate 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 6)

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 in the electrical system of the machine, it must be
shut down immediately using the master 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!
During repairs, make sure that design features are not modified so
that they have a negative influence on safety. (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 Technical description
3.1 Description of function
The GEDA 1500 Z/ZP is a rack-and-pinion hoist constructed vertically
that, on the one hand, is used as a construction hoist for exclusive use
to transport construction material, on the other hand, used as a
transport platform for the transport of material and up to a max. of
7 persons. The platform can be entered and exited at secure exit points
installed (ground base enclosure and landing-level safety doors).
These operating modes are selected using a key switch on the platform
control.
•The machine is fitted with an overload device. If the load capacity is
exceeded, this switches off travel movement in both directions and
the overloading control light lights up.
•The lifting speed of the platform is approx. 12 m/min. or 24 m/min.
respectively.
•The lowest 2 m are specifically secured.
In this safety area,
−the lifting speed of the platform is approx. a max. of 12 m/min.
−travel is only possible using dead man's control.
−Stops the platform coming from the top. Before starting each time,
a signal is emitted in this area for approx. 3 seconds.
−Cannot be operated from the landing level control.
•The platform openings (barrier, door, assembly guard, assembly
frame) are electrically monitored and interrupts the safety circuit on
opening so that the platform immediately stops or does not move off.
−Access to the platform at the ground station can only be opened
when the platform is located at the ground station.
The downward travel path of the platform is limited by a DOWN limit
switch and the upward travel path is limited by an UP limit switch. If
there is movement beyond the limit switch, the EMERGENCY STOP
limit switch interrupts the EMERGENCY STOP safety circuit.
Further travel is possible in both directions from the landing-level limit
switch.
•The base unit can be extended by up to a construction height of
100 m.
•Installation of the hoist includes safety equipment for the loading and
unloading points (refer to the assembly instructions).