GEDA AB 450 User manual

Original operating manual
Assembly and Instruction Manual
Rope winch for incorporation in a machine

Rope winch GEDA®AB 450 / AB 650
BL094 GB Edition 03/2016 3 / 72 Assembly and Instruction Manual

Rope winch GEDA®AB450 / AB 650
Assembly and Instruction Manual 4 / 72 BL094 GB Edition 03/2016

Rope winch GEDA®AB 450 / AB 650
BL094 GB Edition 03/2016 5 / 72 Assembly and Instruction Manual
Table of Contents:
Chapter Page
1General information ...............................................................................................7
1.1 Information about the instruction manual ..........................................................7
1.2 Abbreviations ....................................................................................................9
1.3 Information about the machine........................................................................10
1.4 Name and address of the manufacturer..........................................................11
1.5 Notes about the author and industrial property rights......................................11
1.6 Instructions for the operating company ...........................................................12
1.7 Intended use ...................................................................................................13
1.7.1 Requirements of assembly personnel ......................................................14
1.7.2 Improper use ............................................................................................14
2General safety information ..................................................................................15
2.1 Residual risks..................................................................................................15
2.2 Safety instructions for transport.......................................................................16
2.3 Safety instructions for servicing, maintenance and troubleshooting................17
2.4 Safety whilst working on the electrics..............................................................19
3Technical data ......................................................................................................20
3.1 Operating and environmental conditions .........................................................20
3.2 Rope winch GEDA£AB 450 Item No. 24100 ..................................................21
3.3 Rope winch GEDA£AB 450 Item No. 23152 ..................................................22
3.4 Rope winch GEDA£AB 650 Item No. 23100 ..................................................23
3.5 Wire rope.........................................................................................................24
3.6 Rope reel.........................................................................................................24
3.7 Noise emissions ..............................................................................................24
4Transport...............................................................................................................25
4.1 Inspection on receiving the scaffolding lift .......................................................25
4.2 Transport of rope winch...................................................................................25
4.2.1 Transportation by persons .......................................................................25
5Assembly ..............................................................................................................26
5.1 Mounting the rope winch .................................................................................26
5.1.1 Mounting on the C-clamp .........................................................................27
5.1.2 Mounting to the winch retainer .................................................................28
5.2 Electrical connection of the winch ...................................................................29
5.3 Assembling the wire rope ................................................................................31
5.4 Inspection after assembly and before each operation .....................................33
6Operation ..............................................................................................................34
6.1 Functional description .....................................................................................34
6.2 Safety during operation ...................................................................................35
6.2.1 Checks before starting work.....................................................................35
6.3 Operation of the rope winch ............................................................................36
7Disassembly .........................................................................................................36

Rope winch GEDA®AB450 / AB 650
Assembly and Instruction Manual 6 / 72 BL094 GB Edition 03/2016
Chapter Page
8Maintenance - Checking - Cleaning ................................................................... 37
8.1 Inspections ..................................................................................................... 37
8.1.1 Documenting the results.......................................................................... 38
8.1.2 Checks before initial operation ................................................................ 38
8.1.3 Checks after assembly / daily before starting operation .......................... 38
8.1.4 Recurring checks..................................................................................... 38
8.1.5 Checks after extreme weather conditions................................................ 39
8.2 Maintenance schedule.................................................................................... 40
8.3 Replenishment and inspection tasks .............................................................. 41
8.3.1 Lubricate drive sprocket of winch ............................................................ 41
8.3.2 Visual checks .......................................................................................... 41
8.4 Wear and Function Checks ............................................................................ 42
8.4.1 Motor / Motor brake ................................................................................. 42
8.4.2 Inspecting / lubricating wire ropes ........................................................... 44
8.4.3 Guide bushes at the rope inlet................................................................. 47
8.4.4 Check rope end control ........................................................................... 47
8.4.5 Check for overload .................................................................................. 47
8.4.6 Handwheel cover..................................................................................... 47
8.4.7 Check EMERGENCY LIMIT limit switch.................................................. 48
8.4.8 Inspect rope stop..................................................................................... 49
9Malfunctions - Diagnosis – Repair ..................................................................... 50
9.1 Malfunction table ............................................................................................ 51
9.2 Malfunction rectification .................................................................................. 52
9.2.1 Motor is not producing full output ............................................................ 52
9.2.2 Overload warning device has triggered ................................................... 52
9.2.3 Rope stop has triggered .......................................................................... 53
9.2.4 Checks and release of rope stop after rope break................................... 54
9.2.5 Emergency lowering................................................................................ 57
9.3 Repair............................................................................................................. 59
10 Disposal of the machine.................................................................................. 60
11 Summary of instruction plates........................................................................ 60
12 Documenting the checks................................................................................. 61

Rope winch GEDA®AB 450 / AB 650
BL094 GB Edition 03/2016 7 / 72 Assembly and Instruction Manual
1 General information
1.1 Information about the instruction manual
This instruction manual is an essential aid to operating the machine
successfully and hazard-free.
This instruction 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 instruction 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 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
xList 1
Denotes lists

List 2
Denotes lists
(brackets)
Position numbers
¾Handling 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 are not affected by this.

Rope winch GEDA®AB450 / AB 650
Assembly and Instruction Manual 8 / 72 BL094 GB Edition 03/2016
The structural elements in this instruction 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
danger 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
1Attention 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.

Rope winch GEDA®AB 450 / AB 650
BL094 GB Edition 03/2016 9 / 72 Assembly and Instruction Manual
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 millilitres
mm millimetres
°C degrees Celsius
°F degrees Fahrenheit
ft. feet
ft/m feet per minute
m/min metres per minute
in inch
etc. et cetera
lb. 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

Rope winch GEDA®AB450 / AB 650
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1.3 Information about the machine
Machine model
Serial number: (400 V)
(230 V)
(400 V)
Rope winch GEDA®AB450
23152 ________________
24100 ________________
24340 ________________
(for side suspension and rope winding)
Machine model
Serial number:
Rope winch GEDA®AB 650
23100 ________________
34740 ________________
(for side suspension and rope winding)
Year of construction: Refer to identification plate
Documentation version: 03/2016