GEDA 1500 Z/ZP User manual

Page 1 of 114 Rev.: 004
BL 076 GB Translation of the original operating manual 2011 / 03
Operating Manual
Construction hoist / transport platform
For persons and loads

GEDA®1500 Z / ZP
Page 2 of 114 Rev.: 004
BL 076 GB Translation of the original operating manual 2011 / 03

GEDA®1500 Z / ZP
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BL 076 GB Translation of the original operating manual 2011 / 03
EC Declaration of Conformity
1GUIDE..........................................................................................................................7
1.1 IMAGES .............................................................................................................................................. 7
1.2 WARNINGS......................................................................................................................................... 7
1.3 OVERVIEW OF WARNINGS IN THE MANUAL............................................................................................. 8
1.3.1 Electric shock............................................................................................................................... 8
1.3.2 Crushing by car............................................................................................................................ 8
1.3.3 Do not use the hoist if there is a fire ............................................................................................ 8
1.3.4 Reaching into the travel path during operation............................................................................ 8
1.3.5 Secure machine against being switched on ................................................................................ 9
1.3.6 Falling tools/parts......................................................................................................................... 9
1.3.7 Fall and trip hazard...................................................................................................................... 9
1.3.8 Suspended loads......................................................................................................................... 9
1.3.9 Prevent access for unauthorised persons ................................................................................... 9
1.3.10 Wear safety clothing.............................................................................................................. 10
1.4 ABBREVIATIONS................................................................................................................................11
1.5 IMPRINT ........................................................................................................................................... 11
2IDENTIFICATION DATA............................................................................................12
2.1 MACHINE.......................................................................................................................................... 12
2.2 MANUFACTURER............................................................................................................................... 12
2.3 GEDA REPRESENTATIVES ................................................................................................................ 13
2.4 ORDERING SPARE PARTS .................................................................................................................. 13
3TECHNICAL DATA....................................................................................................14
3.1 SPEEDS ........................................................................................................................................... 14
3.2 DRIVES ............................................................................................................................................ 14
3.3 ASSEMBLY HEIGHT............................................................................................................................ 14
3.4 EMISSIONS ....................................................................................................................................... 14
3.5 DIMENSIONS AND WEIGHT ................................................................................................................. 15
3.5.1 Base unit:................................................................................................................................... 15
3.5.2 Platform A .................................................................................................................................. 15
3.5.3 Platform B .................................................................................................................................. 15
3.5.4 Platform BL ................................................................................................................................ 16
3.5.5 Platform BS................................................................................................................................ 16
3.5.6 Platform BLL .............................................................................................................................. 16
3.5.7 Platform C.................................................................................................................................. 17
3.5.8 Platform D.................................................................................................................................. 17
3.5.9 Platform E .................................................................................................................................. 17
3.5.10 Platform F.............................................................................................................................. 18
3.5.11 Platform G.............................................................................................................................. 18
3.5.12 Platform H.............................................................................................................................. 18
3.5.13 Platform I ............................................................................................................................... 19
3.5.14 Mast....................................................................................................................................... 19
3.5.15 Inclination of mast.................................................................................................................. 19
3.6 LANDING LEVEL SAFETY GATES.......................................................................................................... 19
3.7 TIGHTENING TORQUES ...................................................................................................................... 20
3.7.1 Mechanical fittings without tightening-torque control................................................................. 20
3.7.2 Mechanical screw connections with torque control ................................................................... 20
3.7.3 Electrical screw connections (metal screw connections)........................................................... 20
3.8 SAFETY DISTANCE TO LIVE WIRES ...................................................................................................... 20
3.9 TECHNICAL INFORMATION FOR ASSEMBLY .......................................................................................... 21
3.9.1 Foundation................................................................................................................................. 21
3.9.2 Ground pressure........................................................................................................................ 21
3.9.3 European wind regions.............................................................................................................. 22
3.9.4 Assembly geometry ................................................................................................................... 23
3.9.5 Anchoring forces........................................................................................................................ 25
3.9.6 Reinforcing tubes....................................................................................................................... 28
3.9.7 Operating materials.................................................................................................................... 29
3.9.8 Electrics...................................................................................................................................... 29
3.9.9 Tests .......................................................................................................................................... 30

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3.9.10 Operating and environmental conditions............................................................................... 30
4SAFETY INFORMATION...........................................................................................31
4.1 PROPER USE.................................................................................................................................... 31
4.2 MACHINE LIMITS ............................................................................................................................... 31
4.3 CONVERSIONS/ALTERATIONS............................................................................................................. 31
4.4 LINKING TO OTHER MACHINERY.......................................................................................................... 32
4.5 PROHIBITION OF CERTAIN ACTIVITIES ................................................................................................. 32
4.6 MACHINE OPERATION........................................................................................................................ 32
4.7 FORESEEABLE MISUSE...................................................................................................................... 32
4.8 MACHINE HAZARDS........................................................................................................................... 33
4.9 HAZARD SOURCES/RESIDUAL HAZARDS.............................................................................................. 33
4.9.1 Mobile, rotating, pointed and sharp-edged parts....................................................................... 33
4.9.2 Power sources/energy............................................................................................................... 33
4.9.3 Operating materials.................................................................................................................... 33
4.9.4 Emergency................................................................................................................................. 33
4.10 OTHER APPLICABLE DOCUMENTS....................................................................................................... 34
4.11 EXPORT LICENCE.............................................................................................................................. 34
4.12 WARRANTY ...................................................................................................................................... 34
4.13 GEDA TRAINING SESSIONS............................................................................................................... 34
5OBLIGATIONS OF THE OPERATING COMPANY...................................................35
5.1 DUTY TO INSTRUCT/PROVIDE QUALIFICATIONS.................................................................................... 35
5.2 ACCESSIBILITY TO NECESSARY INFORMATION..................................................................................... 36
5.3 INSPECTING CORRECT AND PROPER CONDITION AND USE.................................................................... 36
5.4 ESTABLISHING HAZARDS AT THE PLACE OF USE .................................................................................. 36
5.5 MACHINES/INSTALLATIONS THAT ARE SUBJECT TO REGISTRATION........................................................ 36
5.6 RECURRING INSPECTIONS................................................................................................................. 36
5.7 TRANSPORTING SUSPENDED LOADS OVER THE MACHINE..................................................................... 37
5.8 PREPARING AN EMERGENCY/EVACUATION PLAN ................................................................................. 37
5.9 INSTRUCTING ASSEMBLY ENGINEERS FROM OTHER COMPANIES........................................................... 37
5.10 FOLLOW THE INSTRUCTIONS OF GEDA ASSEMBLY ENGINEERS............................................................ 37
5.11 PROVISION OF PERSONAL PROTECTIVE GEAR ..................................................................................... 37
6FOR USE BY AUTHORISED PEOPLE......................................................................38
6.1 OPERATOR....................................................................................................................................... 38
6.2 SUPERVISOR.................................................................................................................................... 38
6.3 SPECIALISTS FOR MAINTENANCE/SERVICING....................................................................................... 38
6.4 PROTECTION OF PARTICULAR GROUPS............................................................................................... 38
6.4.1 Young people, pregnant women, disabled people .................................................................... 38
6.4.2 People with pacemakers and metal implants ............................................................................ 38
7OBLIGATORY SAFETY INSTRUCTIONS.................................................................39
7.1 BASIC CONDUCT WHILE WORKING WITH THE MACHINE ......................................................................... 39
7.2 SUPPLEMENTARY SAFETY INSTRUCTIONS -TRANSPORTING THE MACHINE/DISPOSING OF THE MACHINE.. 40
7.3 SUPPLEMENTARY SAFETY INSTRUCTIONS -SET UP AND CONNECTION/INSTALLATION............................. 41
7.4 SUPPLEMENTARY SAFETY INSTRUCTIONS -FIRST COMMISSIONING/DAILY COMMISSIONING .................... 42
7.5 SUPPLEMENTARY SAFETY INSTRUCTIONS –TRANSPORTING PERSONS ................................................. 43
7.6 SUPPLEMENTARY SAFETY INSTRUCTIONS -TRANSPORTING MATERIALS................................................ 44
7.7 SUPPLEMENTARY SAFETY INSTRUCTIONS SERVICING/REPAIRS/MAINTENANCE...................................... 45
7.8 SAFETY INSTRUCTIONS FOR CLEANING............................................................................................... 46
7.9 SAFE CONDUCT IN AN EMERGENCY .................................................................................................... 47
7.9.1 Hazard area can be left.............................................................................................................. 47
7.9.2 Hazard area cannot be left......................................................................................................... 47
7.10 SUPPLEMENTARY SAFETY INSTRUCTIONS -COMPONENTS FROM OTHER MANUFACTURERS.................... 47
7.11 EXTREME WEATHER CONDITIONS....................................................................................................... 48
8BRIEF DESCRIPTION OF THE MACHINE................................................................50
9OPERATING AND CONTROL ELEMENTS ..............................................................53
9.1 MAIN SWITCH ................................................................................................................................... 53
9.2 PLATFORM CONTROL ........................................................................................................................ 53
9.3 MANUAL CONTROL............................................................................................................................ 54
9.4 CONTROL LIGHT,OVERLOAD AND ELECTRIC SOCKET........................................................................... 54
9.5 PLATFORM ACCESS GROUND STATION............................................................................................... 55
9.6 DROP TEST CONTROL ....................................................................................................................... 57

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10 SAFETY AND EMERGENCY EQUIPMENT ..............................................................58
10.1 EMERGENCY STOP...................................................................................................................... 59
10.2 TRIGGERING AN EMERGENCY STOP/SHUTTING DOWN THE MACHINE IN AN EMERGENCY................... 59
10.3 FINISHING THE EMERGENCY STOP SITUATION............................................................................... 59
10.4 DEFECT AFTER AN EMERGENCY STOP SITUATION ......................................................................... 59
10.5 LOCATION OF THE EMERGENCY STOP BUTTONS ........................................................................... 60
10.6 SAFETY STOP ................................................................................................................................... 61
10.7 SAFETY GEAR................................................................................................................................... 61
10.8 EMERGENCY LIMIT SWITCHES........................................................................................................ 61
10.9 LOCKS TO PREVENT UNAUTHORISED USE ........................................................................................... 61
10.10 EMERGENCY LOWER ................................................................................................................ 62
11 COUNTRY-SPECIFIC EQUIPMENT VARIANTS/ACCESSORIES............................63
11.1 COLLISION GRILLE ............................................................................................................................ 63
11.2 ROOF............................................................................................................................................... 63
11.3 ENCLOSURE WITH BARRIER ............................................................................................................... 64
11.4 COLD PACKAGE ................................................................................................................................65
11.5 OPERATING TIME INDICATOR ............................................................................................................. 65
12 OPERATION ..............................................................................................................66
12.1 DAILY INSPECTIONS BEFORE STARTING WORK .................................................................................... 66
12.1.1 Visual inspections.................................................................................................................. 66
12.1.2 Function tests ........................................................................................................................ 67
12.1.3 Test run by platform operator/person authorised to carry out tests and inspections............ 67
12.2 OPERATION OF THE PLATFORM ACCESS POINTS AND THE LANDING LEVEL SAFETY DOORS..................... 68
12.2.1 Base enclosure barrier (optional) .......................................................................................... 68
12.2.2 Platform access Ground station ............................................................................................ 68
12.2.3 Barrier with unloading ramp................................................................................................... 69
12.2.4 Landing gate.......................................................................................................................... 69
12.2.5 Operating as a material hoist................................................................................................. 70
12.2.6 Operating as transport platform............................................................................................. 74
13 RECOVERY OF PEOPLE LOCKED INSIDE.............................................................76
13.1 BASIC CONDUCT IN THE EVENT OF A RESCUE/MALFUNCTION................................................................ 76
13.2 RESCUE MEASURES PLAN.................................................................................................................. 77
13.3 RESCUING PEOPLE FROM THE PLATFORM........................................................................................... 77
14 CLEANING.................................................................................................................78
14.1 INTERNAL/EXTERNAL CLEANING OF THE MACHINE................................................................................ 78
14.2 CLEANING THE AREA AROUND THE MACHINE....................................................................................... 78
15 ASSEMBLY................................................................................................................79
15.1 TRANSPORT TO ASSEMBLY SITE......................................................................................................... 81
15.1.1 Unloading / loading the base unit using a forklift................................................................... 81
15.1.2 Unloading / loading the base unit using a crane ................................................................... 81
15.2 ASSEMBLY PLAN............................................................................................................................... 82
15.3 ASSEMBLING THE BASE UNIT.............................................................................................................. 83
15.4 ASSEMBLE CABLE BIN AND TRAILING CABLE BRACKET.......................................................................... 84
15.5 ASSEMBLY /ANCHORING THE MAST.................................................................................................... 85
15.5.1 Assemble mast bracket......................................................................................................... 86
15.5.2 Use of the assembly bridge................................................................................................... 89
15.5.3 Assemble trailing cable guide................................................................................................ 89
15.5.4 Assemble EMERGENCY limit switch bar.............................................................................. 90
15.5.5 Safeguarding loading and unloading points.......................................................................... 91
15.5.6 Assembly of landing level, limit switch bar............................................................................ 91
15.5.7 Tests after assembly / tests before initial commissioning..................................................... 91
16 DISMANTLING...........................................................................................................92
17 DISPOSAL OF THE MACHINE .................................................................................92
18 MAINTENANCE.........................................................................................................93
18.1 WARNINGS AND SAFETY INSTRUCTIONS TO BE COMPLIED WITH DURING SERVICING/REPAIRS................. 93
18.2 MAINTENANCE SCHEDULE ................................................................................................................. 95
18.3 TESTS.............................................................................................................................................. 96
18.4 REPLENISHMENT AND INSPECTION TASKS........................................................................................... 98
18.4.1 Lubrication device.................................................................................................................. 98
18.5 CHECKING FOR WEAR ....................................................................................................................... 99

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18.5.1 Drive pinion............................................................................................................................ 99
18.5.2 Gear rack............................................................................................................................... 99
18.5.3 Tracks rollers....................................................................................................................... 100
18.5.4 Drive brake .......................................................................................................................... 101
18.6 FUNCTION CHECKS ......................................................................................................................... 102
18.6.1 Safety gear .......................................................................................................................... 102
18.6.2 Drop test successful ............................................................................................................103
18.6.3 Drop test not successful ...................................................................................................... 103
18.6.4 Check the safety gear for damage ...................................................................................... 104
18.6.5 Safety gear replacement ..................................................................................................... 104
18.7 FAULT TABLE.................................................................................................................................. 105
19 DOCUMENTING THE TESTS..................................................................................107

GEDA®1500 Z / ZP
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1 Guide
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.
Textual notations Meaning
Bold Emphasises particularly important
words/passages
List 1 Designates lists
oList 2 Designates lists
(brackets) Item numbers
Practical instructions Practical instructions for personnel. Always
given in chronological order
The masculine form of address is used in this manual to make reading
easier. It goes without saying that both genders are always implied and
addressed.
1.1 Images
The images used refer to a specific machine type. They may only be
a schematic representation of other machine types. The fundamental
function and operation is not affected by this.
1.2 Warnings
Activities with specific hazards (to life and limb or potential damage to the
machine) are designated by warnings. You must observe the instructions
given in the warnings.
Warning level Consequence Probability
Death/serious injury is immediately pending
Serious injury possible
Slight injury possible
Material damage possible
HAZARD
W
ARNING
CAUTION
CAUTION

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1.3 Overview of warnings in the manual
1.3.1 Electric shock
1.3.2 Crushing by car
HAZARD
Life-threatening hazard
through crushing.
Never stand underneath the car (platform) / in
the hazard area during operation.
Turn the master switch off and secure against
being switched back on while working in the
hazard area.
1.3.3 Do not use the hoist if there is a fire
1.3.4 Reaching into the travel path during operation
HAZARD
Electric shock
Parts remain live even after pressing the
EMERGENCY STOP or after turning off the
machine at the main switch.
This applies to all work on electrical parts.
Disconnect mains supply upstream from the
main switch.
HAZARD
Life-threatening hazard
Do not use the hoist if there is a fire.
HAZARD
Life-threatening hazard
Crushing or amputation of limbs.
Never reach into the travel path of the machine
during operation.

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1.3.5 Secure machine against being switched on
1.3.6 Falling tools/parts
1.3.7 Fall and trip hazard
1.3.8 Suspended loads
1.3.9 Prevent access for unauthorised persons
HAZARD
Life-threatening hazard
Due to the machine being switched on during
servicing/repair work or when there is a defect.
Secure the main switch with a padlock to
prevent it being switched on.
HAZARD
Life-threatening hazard
Falling tools/parts
Secure tools / parts against falling
Use the platform.
WARNING
Fall and trip hazard
Look out for steps and objects on the ground
when entering/exiting the platform.
WARNING
Life-threatening hazard
Raised load.
Do not stand under a suspended load.
Do not stand on a suspended load.
Only raise the load at the sling points.
Only use suitable hoisting gear.
WARNING
Life-threatening hazard
Access only for authorised persons.
Access prohibited for unauthorised persons.

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1.3.10 Wear safety clothing
HAZARD
Life-threatening hazard
Risk of fire and explosion due to the use of
combustible cleaning agents.
Only use suitable, non-combustible cleaning
agents.
Do not use steam-jet equipment/high-pressure
cleaners. Electrical components can be damaged.
Do not touch sockets, cables or electrical
components with wet or damp hands.
Cleaning work on live components may only be
carried out by qualified electrical personnel.
Wear personal protective gear.