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

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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

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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.

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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.

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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 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

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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

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1.4 Name and address of the manufacturer
GEDA Dechentreiter GmbH & Co. KG
Mertinger Strasse 60
86663 Asbach-Bäumenheim
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Web: www.geda.de
Representatives of the manufacturer
Bergkamen Subsidiary
Gera Subsidiary
GEDA Dechentreiter GmbH & Co.
KG
North-West
Marie-Curie-Strasse 11
59192 Bergkamen-Rünthe
Tel. [phone]
Fax. [phone]
GEDA Dechentreiter GmbH & Co.
KG
East
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
Korea 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
Phone: [phone]
Fax: [phone]
Web: www.geda.com.tr
GEDA KOREA
1708, (MetroDioVill Bldg.,
Singongdeok-dong)
199, Baekbeom-ro, Mapo-gu,
Seoul
04195, Korea
Tel.: [phone]
Fax: [phone]
www.geda-korea.com
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 instruction 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 instruction 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 approval from the manufacturer! This also applies to
installing and adjusting safety devices, as well as welding onto load-
bearing components.
Any replacement and wearing parts that are used must correspond to
the technical requirements stipulated by GEDA. This is guaranteed 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 rope winches GEDA AB 450 and GEDA AB 650 constitute
incomplete machines and are intended only for incorporation into a
complete machine.
An incomplete machine constitutes an entirety nearly forming a
machine but which in itself is not able to meet a specific function.
The sole purpose of an incomplete machine is its incorporation
into other machines or other incomplete machines or equipment
or to be joined with the same in order to jointly form a machine
according to the Machinery Directive.
Observe and comply with the instructions in Chapter 3, “Technical
data”.
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 instruction 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.

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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 scaffolding lifts. These
persons must be appointed to the tasks of installation, dismantling and
maintenance by the operating company.
1.7.2 Improper use
The rope winch GEDA£AB 450 / AB 650
must not be operated without incorporation into a complete machine.
must not be operated by people who have not been briefed on the
machine, who are not familiar with the instruction manual 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 incomplete 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 incomplete
machine 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
Hazard from moving, rotating, pointed and sharp-edged parts such
as ropes and cables.
Do not remove safety stickers; replace any safety instructions that
have become illegible.
Hazard from energies:
oWorking on the electrical system.
oHot surfaces.
oPotential energy (raised components/tipping/falling loads/
falling tools).
Hazard from damage.
Hazards from a malfunction in the control system.
Injuries due to uncoordinated work methods.

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2.2 Safety instructions for transport
Immediately report transport damage and/or missing parts to the
supplier.
During transport work, wear a safety helmet, safety footwear 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, rope slings, chains)
for transport at the assembly site.
When selecting lifting equipment, always take into account the
maximum suspended loads!
Please refer to the dimensions and weights in the technical
specifications chapter (3).
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 to the designated slinging points.
Always secure transported loads against falling or tipping over!

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2.3 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 instruction 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,
disconnect the mains plug.
All servicing and maintenance tasks are only permitted when the
mains plug is 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 Chapter Maintenance.
If the machine has been completely shut down for these tasks, it must
be secured against switching on unintentionally:
xActivate the EMERGENCY STOP button,
xPlace a warning sign at the mains plug.
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
system must be worn! Keep all handles, railings and the scaffolding
from dirt and contamination.

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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, short-out or bridge safety devices.
If it is necessary to dismantle 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 10)
)The aforementioned safety measures apply equally for work in the
context of eliminating faults.

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2.4 Safety whilst working on the electrics
In the event of malfunctions of the electrical installations on the
machine, immediately stop it by disconnecting the mains plug!
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 covers /
switch boxes closed as soon as they are left unattended.
Never work on live parts! Machine parts on which inspection,
maintenance or repair tasks are 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 it is necessary to carry out tasks on energized components (only in
exceptional situations), an additional person is required to activate the
EMERGENCY STOP button or disconnect the mains plug in 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 data
CAUTION
General overhaul of the rope winches
The rope winches GEDA£AB 450 / AB 650 must undergo general
overhaul every 500 hours of operation!
The general overall must only be performed by the manufacturer or by
a person authorised by the manufacturer.
3.1 Operating and environmental conditions
The machine may only be operated when the following operating
and environmental conditions are adhered to:
Temperature range: minimum - 20 °C [- -4 °F]
maximum +40 °C [104 °F]
Air humidity (relative): 80% RH.
xStoring in dry rooms, in order to prevent corrosion.
xNo jolts or vibrations.
xNo abrasive, corrosive substances.
xThe machine must be protected against pest damage (insects,
rodents, etc.).
xBefore transportation/storage, the machine must be cleaned and
checked for signs of damage.
Weather conditions:
No storms with risk of lightning.
It may be necessary to cease/prohibit operation of the machine under
extreme weather conditions, even if the operating and environmental
conditions are within the conditions stated; for example, by the
combined occurrence of heavy frost and storm. Here, the operating
company must provide appropriate regulations.
Atmosphere:
No concentration of aggressive / corrosive substances, as well as
(potentially explosive (fine particulate matter) must occur. If this cannot
be safely excluded, then the corrosion protection and/or the functional
reliability of the electrical components must be checked at regular
intervals and they should, if necessary, be replaced. Fine particulate
matter must be removed.
Location of storage:
In order to prevent corrosion, if possible the machine should be stored
in dry air.