GEDA 300 Z User instructions

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

Rack and pinion hoist
Assembly and operating manual 3 / 92 BL131 GB Edition 08.2015

Rack and pinion hoist
Assembly and operating manual 4 / 92 BL131 GB Edition 08.2015

Rack and pinion hoist
Assembly and operating manual 5 / 92 BL131 GB Edition 08.2015
Table of Contents:
Section Page
1General information........................................................................................................................... 7
1.1 Information about the operating manual ..................................................................................... 7
1.2 Information about the machine ................................................................................................... 7
1.3 Name and address of the manufacturer ..................................................................................... 8
1.4 Notes about the author and industrial property rights ................................................................. 8
1.5 Instructions for the operating company....................................................................................... 9
1.6 Proper use................................................................................................................................. 10
1.6.1 Requirements of assembly personnel .................................................................................. 11
1.6.2 Operating personnel ............................................................................................................. 11
1.6.3 Improper use......................................................................................................................... 11
2General safety information ............................................................................................................. 12
2.1 Residual risks............................................................................................................................ 12
2.2 Safety instructions for operating personnel............................................................................... 13
2.3 Safety instructions for transport ................................................................................................ 14
2.4 Safety instructions for operation ............................................................................................... 15
2.5 Safety instructions for servicing, maintenance and troubleshooting......................................... 16
2.6 Safety during work on the electrics ........................................................................................... 18
3Checks .............................................................................................................................................. 19
3.1 Documenting the results ........................................................................................................... 19
3.2 Checks before initial commissioning......................................................................................... 20
3.3 Checks after assembly / daily before starting operation ........................................................... 20
3.4 Recurring inspections................................................................................................................ 20
3.5 Dynamic tests............................................................................................................................ 21
3.6 Static test................................................................................................................................... 21
3.7 Checks after extreme weather conditions................................................................................. 22
4Technical description ...................................................................................................................... 23
4.1 Description of function............................................................................................................... 23
4.2 Machine equipment................................................................................................................... 25
4.3 Equipment as accessories ........................................................................................................ 30
4.3.1 Standard push-on frame for the load platform...................................................................... 30
4.3.2 Special push-on frames ........................................................................................................ 31
4.3.3 Spindle .................................................................................................................................. 33
4.3.4 Manoeuvrable bogie ............................................................................................................. 33
4.3.5 Single axle trailer .................................................................................................................. 34
4.3.6 Small on-site main cabinet.................................................................................................... 34
4.4 Technical data ........................................................................................................................... 35
4.4.1 Data for 230 V drive .............................................................................................................. 36
4.4.2 Data for 400 V drive .............................................................................................................. 36
4.4.3 Load platform ........................................................................................................................ 36
4.4.4 Extension to base unit .......................................................................................................... 37
4.5 Anchoring and spatial requirement ........................................................................................... 38
4.6 Requirements for the site of installation.................................................................................... 44
4.6.1 Foundation ............................................................................................................................ 44
4.6.2 Ground pressure................................................................................................................... 44
4.6.3 Mains connection .................................................................................................................. 45
5Transport .......................................................................................................................................... 46

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Section Page
6Installation ........................................................................................................................................ 47
6.1 Safety during installation ........................................................................................................... 47
6.2 Assembling the base unit .......................................................................................................... 48
6.3 Extending mast sections and anchoring to the building............................................................ 50
6.3.1 Trailing cable guide............................................................................................................... 55
6.3.2 Limit switch approach bar ..................................................................................................... 56
6.4 Safeguarding loading and unloading points .............................................................................. 57
6.4.1 Electric module for the landing level safety gate .................................................................. 57
6.5 Limit switch approach bar for landing level stop ....................................................................... 58
6.6 Inspections after assembly and before commissioning ............................................................ 59
6.7 Special features when using as a scaffold hoist ....................................................................... 60
7Operation .......................................................................................................................................... 61
7.1 Safety during operation ............................................................................................................. 61
7.2 Safety inspection before starting work ...................................................................................... 62
7.3 Using the platform access point, turning lever and landing level safety gate ........................... 63
7.3.1 Ramp..................................................................................................................................... 63
7.3.2 Turning lever ......................................................................................................................... 63
7.3.3 "ECO" landing level safety gate ............................................................................................ 64
7.4 Operating the hoist .................................................................................................................... 65
7.5 Emergency shutdown................................................................................................................ 67
7.6 Interrupting work - end of work.................................................................................................. 67
8Dismantling (disassembly) ............................................................................................................. 68
9Servicing and cleaning.................................................................................................................... 69
9.1 Daily cleaning ............................................................................................................................ 69
9.2 Weekly servicing ....................................................................................................................... 69
9.3 Monthly servicing....................................................................................................................... 70
9.4 Quarterly servicing .................................................................................................................... 71
9.5 Six monthly maintenance .......................................................................................................... 72
9.6 Annual maintenance.................................................................................................................. 72
9.7 Servicing every 6 years ............................................................................................................. 72
9.8 Inspecting the overspeed safety brake in the context of the recurring inspection .................... 73
10 Faults - diagnosis - repairs ............................................................................................................. 74
10.1 Potential faults during operation................................................................................................ 76
10.1.1 Power failure or defective motor....................................................................................... 76
10.1.2 Load platform has been driven too high ........................................................................... 77
10.1.3 Platform has descended too low ...................................................................................... 77
10.1.4 Overload warning device has triggered ............................................................................ 78
10.2 Overspeed safety brake has been triggered ............................................................................. 79
10.3 Repairs ...................................................................................................................................... 80
11 Disposing of the machine ............................................................................................................... 80
12 Appendix A Summary of instruction notices............................................................................... 81
13 Appendix B Entries for recurring inspections .............................................................................. 83

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1 General information
1.1 Information about the operating 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, properly and economically. 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, troubleshooting during work, disposal of operating
materials and auxiliary supplies,
−assembly, maintenance (servicing, general maintenance, repairs)
and/or transport.
The structural elements in this operating manual appear as follows
and have the following meaning:
Health and safety symbol
This symbol is found next to all safety instructions where there is a risk
to a person's life and limbs. Observe these instructions and conduct
yourself with care!
Attention note
This is found at points where special information or rules and
prohibitions regarding damage prevention are given in order to prevent
damage to the equipment.
Note
This is found at points where information is given about using the
machine economically or instructions are given regarding correct
working procedures.
1.2 Information about the machine
Type of machine GEDA300 Z
Serial number:
14770 (400 V)
16430 (230 V)
Year of manufacture:
see type plate of the machine
Documentation version:
08/2015

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1.3 Name and address of the manufacturer
GEDA-Dechentreiter GmbH & Co. KG
Mertinger Straße 60
86663 Asbach-Bäumenheim
Tel.: +49 (0)9 06 / 98 09-0
Fax: +49 (0)9 06 / 98 09-50
E-Mail: [e-mail]
Web: www.geda.de
GEDA representatives
Bergkamen Subsidiary
Gera Subsidiary
GEDA-Dechentreiter GmbH & Co.
KG
Northwest branch
Marie-Curie-Straße 11
59192 Bergkamen-Rünthe
Tel. [phone]
Fax. [phone]
GEDA-Dechentreiter GmbH & Co.
KG
Subsidiary Eastern
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/Türkiye
Tel.: [phone]
Fax: [phone]
Web: www.geda.com.tr
1.4 Notes about the author and industrial property rights
All documents are protected in terms of copyright law. Dissemination
and reproduction of documents (even parts thereof), as well as
recycling or communication of their contents are prohibited unless
expressly permitted in writing.
Violations are an offence and incur an obligation to pay compensation.
All rights to exercise industrial property rights are reserved by GEDA.

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1.5 Instructions for the operating company
This operating manual is an essential component of the machine. The
operating company must ensure that operating personnel are informed
about these guidelines.
The operating company must supplement the operating manual with
operating instructions based on existing national regulations for
accident prevention and for the protection of the environment,
including information regarding supervisory and reporting duties that
take account of company-related specifics, e.g. with reference to work
organisation, work procedures and the personnel employed.
In addition to the binding 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 appropriately
must also be observed.
The operating company must obligate operating personnel to wear
personal protective gear as appropriate to the local conditions.
First aid facilities (first aid kit, etc.) must be kept within reach!
The operating company/user of the machine may not undertake any
changes, attachments or conversions to/on 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 use qualified and/or instructed personnel for the activities
described in this manual. Clearly establish the responsibilities for
personnel in respect of operating, servicing and repairs! Comply with
the legally permissible minimum age!

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1.6 Proper use
The GEDA 300 Z rack and pinion hoist is a construction hoist that is
temporarily erected and
•which is intended exclusively for putting up scaffolding and as
additional equipment (landing level safety gates) for transporting
items and materials during construction work.
•which may only be operated after the landing level safety gates are
installed at each transfer point to the building or scaffolding.
•which may only be operated at wind speeds of up to 72 km/s
(20 m/sec. ≈wind force 7-8 according to the Beaufort scale).
−which must have its platform parked on the ground and taken out of
operation at higher wind speeds.
•which may only be operated from outside the cordoned-off and
signposted hazard area using the ground control, and/or operated
from the landing level control above the 2 m safety height.
Observe and comply with the instructions in section 4.3.6, "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.
Proper 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 300 Z is suitable for temporary use on construction
sites. Any other locations or intended uses require written
approval from the manufacturer.

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1.6.1 Requirements of assembly personnel
The machine may only be assembled, operated and maintained by
qualified persons who, based on their training, knowledge and practical
experience, can guarantee proper handling and who are aware of the
risks associated with the construction hoist. These persons must be
appointed to the tasks of installation, dismantling and maintenance by
the operating company.
1.6.2 Operating personnel
The machine may be operated only by persons who, based on their
training, knowledge and practical experience, can guarantee proper
handling.
These persons must
−have been appointed by the operating company,
−have been appropriately instructed and informed about the risks,
−be familiar with the assembly and operating manual,
−observe national regulations.
1.6.3 Improper use
•Transporting persons is prohibited!
−Only authorised persons are permitted to ride the platform, and only
for the purposes of assembly and servicing work. Special measures
are required for such operations.
−Use the front fall protection.
−Operation during assembly work may only be carried out using the
assembly control from the load platform.
•The 300 Zis not designed for permanent installation.
•The 300 Z may not be constructed to be free-standing (without
anchors).
•Persons who have not been instructed in the machine and who are
not acquainted with the operating manual, and children, may not
operate the hoist.
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 working with the machinery
even when all safety conditions are complied with.
Everyone who works on and with the machine must be aware of these
hazards and follow instructions that prevent these residual risks leading
to accidents or damage.
Caution
−Do not remove safety stickers; replace any safety instructions that
have become illegible.
−Hazards due to toppling of an improperly secured load.
−Hazards due to high wind speeds (> 72 km/h)
−Hazards when accessing and exiting the platform.
−Hazards from damage to the load carrying device.
−Hazards when working on the electrical system.
−Hazards from a malfunction in the control system.
−Injuries due to uncoordinated work methods.

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2.2 Safety instructions for operating personnel
The operating manual must be within reach at all times at the place
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 accident prevention rules 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 gear 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
Report transport damage and/or missing parts immediately to the
supplier.
Wear a hard hat, safety shoes and safety gloves during transport
work!
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.
Always take account of the maximum bearing loads when selecting
lifting and sling gear!
Please refer to the dimensions and weights in the technical
specifications section (4.3.6) and spatial requirements (4.5).
Only load and transport equipment that has been carefully
dismantled, packed and securely lashed down.
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
Use the machine only in a technically fault-free condition, in a safety
conscious manner and aware of the hazards, while also observing
the operating manual.
If work is interrupted, switch the machine off at the main switch
and secure it with a padlock against being switched back on.
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.
Shutdown and lower the machine when wind speeds are >72 km/h.
(Wind force 7-8, wind breaks branches off trees, makes walking very
difficult!)
No one is allowed to stand under the machine. Ensure that the danger
zone is suitably cordoned off at the customer's site.
Protection to prevent persons from falling must be provided at loading
heights above 2.0 m. (Install landing level safety gates.)

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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/intervals that are stipulated or stated in the operating
manual for recurring tests/inspections must be adhered to.
The area of maintenance must be generously cordoned off as
required!
In principle, before any service work on the machine
−Unload,
−Turn off the main switch.
All servicing and maintenance work is only permitted with the main
switch turned off or with the mains plug removed. Manual
interventions while the machine is running can lead to severe injury and
are therefore prohibited. If it is necessary to turn the machine on
during such work, then this may only be done while complying with
special safety measures.
You will find further instructions on servicing/service
intervals/maintenance in sections 9 and 10.
If the machine has been completely shutdown for this work, it must also
be secured against being switched back on unintentionally:
•Operate the emergency STOP button,
•Lock the main switch with a shackle lock and
•Attach a warning notice to the switch cabinet (main switch).
Any faults that could impair safety must be rectified immediately.
Workshop equipment that is suitable for the specific work is absolutely
necessary for carrying out servicing and maintenance work. Wear fall
protection when doing service work at great heights! Keep all handles,
railings and the platform free from dirt and grime.
When working under the platform, secure it using appropriate means
(e.g. bolts, mast clamps, etc.).

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The machine, especially general connections and screw connections,
must be cleaned of any oil, working materials, dirt/grime and
maintenance products. Aggressive cleaning agents may not be used.
During servicing and maintenance work, loosened screw connections
must always be re-tightened with the necessary torques!
Do not change, remove, bypass or bridge safety devices.
If it is necessary to dismantle safety features during servicing and
repairs, the safety features must be reassembled and checked straight
after completion of servicing and repairs!
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 (see also section 11)
The aforementioned safety measures apply equally for work in the
context of eliminating faults.

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2.6 Safety during work on the electrics
If there are faults on the electrical system of the machine, it must be
shut down immediately using the main switch and secured with a lock
or the mains plug must be removed!
Work on the electrical equipment of the machine may only be carried
out by professional electricians working in accordance with electrical
engineering regulations! Only professional electricians may access the
machine's electrics and carry out work on it. Always keep the switch
cabinets closed as soon as they are left unattended.
Never work on live parts! System parts on which inspection,
servicing or repair work is to be carried out must be disconnected
from the power. Operating materials 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 work on live components is required (only in exceptional
circumstances) an extra person must be called who can operate the
EMERGENCY STOP button or main switch in the event of an
emergency. Only use insulated tools!
During repairs, ensure that design features are not altered in a way
that negatively affects 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 an
earth conductor system.

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

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3.2 Checks before initial commissioning
Checks at the factory
The following tests have already been carried out at the factory:
- Dynamic test with 1.1 times the safe working load.
- Electrical tests according to EN 60204.
- Function tests.
3.3 Checks after assembly / daily before starting operation
To ensure safety when handling the machine, the custodian / person
determined by the operating company must carry out a daily check of
certain areas of the machine / parts.
Any defects identified must be immediately reported to the supervisor
and rectified. Defects may only be rectified by trained personnel
responsible for maintenance and servicing.
Always carry out visual inspections before function checks. Operation is
prohibited until the defects are rectified.
The following points must be checked daily
- Visual inspections before start of work
→refer to Chapter “Operation” in the operating manual
- Clean the cable bin (keep free from snow and ice in winter).
- Keep the work area around the machine clear and clean.
For inspections after each installation →see section 6.6
3.4 Recurring inspections
Recurring checks must be carried out in accordance with national
regulations.
GEDA recommends that you carry out a recurring check on an
annual basis. In the event of increased demand (e.g. multiple shift
operation), carry out checks at shorter intervals.