GEDA 300 Z User manual

GEDA®300 Z / ZP
Page 1 of 101 Rev.: 001
BL 121 EN Translation of the original operating manual 2011 / 05
Operating Manual
Construction Hoist / Transport Platform
For loads and persons

GEDA®300 Z / ZP
Page 2 of 101 Rev.: 001
BL 121 EN Translation of the original operating manual 2011 / 05

GEDA®300 Z / ZP
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BL 121 EN Translation of the original operating manual 2011 / 05
INSTRUCTION MANUAL
EC Declaration of Conformity
1GUIDE ..........................................................................................................................7
1.1 IMAGES .............................................................................................................................................. 7
1.2 WARNING NOTICES ............................................................................................................................. 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 in the event of 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 / platform / cable box: ................................................................................................ 15
3.5.2 Mast section............................................................................................................................... 15
3.5.3 Landing-level safety gates......................................................................................................... 15
3.6 MAST ............................................................................................................................................... 16
3.6.1 Inclination of mast...................................................................................................................... 16
3.7 TECHNICAL INFORMATION ON ASSEMBLY ............................................................................................ 16
3.7.1 Foundation................................................................................................................................. 16
3.7.2 Soil pressure.............................................................................................................................. 16
3.8 TIGHTENING TORQUES ...................................................................................................................... 17
3.8.1 Mechanical screw connections without torque control .............................................................. 17
3.8.2 Mechanical screw connections with torque control ................................................................... 17
3.8.3 Electrical screw connections (metal screw connections)........................................................... 17
3.9 SAFETY DISTANCE FROM LIVE WIRES.................................................................................................. 17
3.9.1 European wind regions.............................................................................................................. 18
3.9.2 Assembly geometry ................................................................................................................... 19
3.9.3 Anchoring forces........................................................................................................................ 22
3.9.4 Stiffener tubes............................................................................................................................ 24
3.9.5 Operating materials.................................................................................................................... 25
3.9.6 Electrics...................................................................................................................................... 25
3.9.7 Tests .......................................................................................................................................... 26
3.9.8 Operating and environmental conditions................................................................................... 26

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4SAFETY INFORMATION ...........................................................................................27
4.1 PROPER USE.................................................................................................................................... 27
4.2 MACHINE LIMITS ............................................................................................................................... 27
4.3 MODIFICATIONS /ALTERATIONS ......................................................................................................... 27
4.4 LINKING TO OTHER MACHINERY.......................................................................................................... 28
4.5 PROHIBITION OF CERTAIN ACTIVITIES ................................................................................................. 28
4.6 MACHINE OPERATION........................................................................................................................ 28
4.7 FORESEEABLE MISUSE...................................................................................................................... 28
4.8 MACHINE HAZARDS........................................................................................................................... 29
4.9 HAZARD SOURCES /EXISTING RESIDUAL HAZARDS.............................................................................. 29
4.9.1 Moving, rotating, pointed and sharp-edged parts...................................................................... 29
4.9.2 Energies..................................................................................................................................... 29
4.9.3 Operating materials.................................................................................................................... 29
4.9.4 Emergency................................................................................................................................. 29
4.10 OTHER RELEVANT DOCUMENTS ......................................................................................................... 30
4.11 EXPORT LICENCE.............................................................................................................................. 30
4.12 WARRANTY ...................................................................................................................................... 30
4.13 GEDA TRAINING SESSIONS............................................................................................................... 30
5OBLIGATIONS OF THE OPERATING COMPANY ...................................................31
5.1 OBLIGATION OF TRAINING /QUALIFICATION......................................................................................... 31
5.2 ACCESSIBILITY TO NECESSARY INFORMATION..................................................................................... 32
5.3 CHECKING THE CORRECT AND PROPER CONDITION AND USE ............................................................... 32
5.4 IDENTIFYING HAZARDS AT THE PLACE OF USE ..................................................................................... 32
5.5 MACHINES /SYSTEMS REQUIRING REGISTRATION ............................................................................... 32
5.6 RECURRING INSPECTIONS................................................................................................................. 32
5.7 TRANSPORTING SUSPENDED LOADS OVER THE MACHINE..................................................................... 33
5.8 PREPARING AN EMERGENCY /EVACUATION PLAN................................................................................ 33
5.9 TRAINING ASSEMBLY ENGINEERS FROM OTHER COMPANIES................................................................. 33
5.10 FOLLOWING THE INSTRUCTIONS OF GEDA ASSEMBLY ENGINEERS ...................................................... 33
5.11 PROVISION OF PERSONAL PROTECTIVE EQUIPMENT ............................................................................ 33
6REGARDING USE BY AUTHORISED PEOPLE .......................................................34
6.1 OPERATOR....................................................................................................................................... 34
6.2 ATTENDANT /PLATFORM OPERATOR .................................................................................................. 34
6.3 PROFESSIONALS FOR MAINTENANCE /SERVICING ............................................................................... 34
6.4 PROTECTION OF PARTICULAR GROUPS OF PEOPLE.............................................................................. 34
6.4.1 Young people, pregnant women, disabled persons .................................................................. 34
6.4.2 People with pacemakers and metal implants ............................................................................ 34
7OBLIGATORY SAFETY INSTRUCTIONS.................................................................35
7.1 BASIC CONDUCT WHEN WORKING WITH THE MACHINE ......................................................................... 35
7.2 TRANSPORTING THE MACHINE /DISPOSING OF THE MACHINE............................................................... 36
7.3 SET-UP AND CONNECTION /INSTALLATION.......................................................................................... 37
7.4 FIRST COMMISSIONING /DAILY COMMISSIONING.................................................................................. 38
7.5 TRANSPORTING PEOPLE.................................................................................................................... 39
7.6 TRANSPORTING MATERIAL................................................................................................................. 40
7.7 SERVICING /REPAIRS /MAINTENANCE /WORK ON ELECTRICAL COMPONENTS....................................... 41
7.8 CLEANING ........................................................................................................................................ 42
7.9 CONDUCT IN AN EMERGENCY............................................................................................................. 42
7.9.1 Hazard area can be left.............................................................................................................. 43
7.9.2 Hazard area cannot be left......................................................................................................... 43
7.10 SUPPLEMENTARY SAFETY INSTRUCTIONS -COMPONENTS FROM OTHER MANUFACTURERS.................... 43

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8BRIEF DESCRIPTION OF THE MACHINE................................................................44
9OPERATING AND CONTROL ELEMENTS ..............................................................46
9.1 MASTER SWITCH............................................................................................................................... 46
9.2 CAR CONTROL.................................................................................................................................. 46
9.3 MANUAL CONTROL............................................................................................................................ 47
9.4 OVERLOAD CONTROL LAMP AND SOCKET OUTLET ............................................................................... 47
9.5 GROUND STATION CAR ACCESS RAMP................................................................................................ 48
9.6 BUILDING CAR ACCESS RAMP............................................................................................................. 49
9.7 DROP-TEST CONTROL UNIT................................................................................................................ 50
10 SAFETY AND EMERGENCY EQUIPMENT ..............................................................51
10.1 EMERGENCY STOP...................................................................................................................... 52
10.2 TRIGGERING AN EMERGENCY STOP /MACHINE SHUT-DOWN IN EVENTS OF EMERGENCY.................. 52
10.3 ENDING THE EMERGENCYSTOP SITUATION .................................................................................. 52
10.4 DEFECT AFTER AN EMERGENCY STOP SITUATION ......................................................................... 52
10.5 LOCATION OF THE EMERGENCY STOP BUTTONS ........................................................................... 53
10.6 SAFETY STOP ................................................................................................................................... 54
10.7 SAFETY GEAR................................................................................................................................... 54
10.8 EMERGENCY LIMIT SWITCH............................................................................................................ 54
10.9 LOCKS TO PREVENT UNAUTHORISED USE ........................................................................................... 54
10.10 EMERGENCY LOWERING (BRAKE RELEASE LEVER).......................................................................... 55
11 COUNTRY-SPECIFIC EQUIPMENT VARIANTS / ACCESSORIES..........................56
11.1 COLLISION GRILLE ............................................................................................................................ 56
11.2 ROOF............................................................................................................................................... 56
11.3 ASSEMBLY BRIDGE............................................................................................................................ 57
11.4 REPLACE THE CABLE BOX.................................................................................................................. 57
11.5 CONVERTING ACCESS TO THE FRONT END /ADDING A SECOND ACCESS ............................................... 58
11.6 ENCLOSURE WITH BARRIER ............................................................................................................... 59
11.7 HOLDER FOR INDIVIDUAL SUPPORT FRAMES ....................................................................................... 60
11.8 COLD PACKAGE ................................................................................................................................60
11.9 OPERATING TIME INDICATOR ............................................................................................................. 60
12 DAILY INSPECTIONS BEFORE STARTING WORK ................................................61
12.1 VISUAL INSPECTIONS ........................................................................................................................ 61
12.2 FUNCTION TESTS.............................................................................................................................. 62
12.2.1 Test run with an empty car.................................................................................................... 62
12.2.2 Test run by platform operator / person authorised to carry out tests and inspections.......... 62
13 RESCUING PEOPLE TRAPPED INSIDE ..................................................................63
13.1 BASIC CONDUCT IN THE EVENT OF A RESCUE /MALFUNCTION .............................................................. 63
13.2 RESCUE MEASURES PLAN.................................................................................................................. 64
13.3 RESCUING PEOPLE FROM THE CAR .................................................................................................... 65
14 CLEANING.................................................................................................................66
14.1 CLEANING THE MACHINE INSIDE AND OUT ........................................................................................... 66
14.2 CLEANING THE AREA AROUND THE MACHINE....................................................................................... 66

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15 ASSEMBLY................................................................................................................67
15.1 TRANSPORT TO THE ASSEMBLY LOCATION.......................................................................................... 69
15.2 ASSEMBLY PLAN............................................................................................................................... 70
15.3 ASSEMBLING THE BASE UNIT.............................................................................................................. 71
15.4 MOUNTING THE FIRST MAST TIE ......................................................................................................... 71
15.5 TRANSPORT THROUGH NARROW SPACES ........................................................................................... 72
15.5.1 Dismantling the accesses...................................................................................................... 73
15.5.2 Dismantling the front wall ......................................................................................................74
15.5.3 Folding up the car.................................................................................................................. 74
15.5.4 Remove protective buffers..................................................................................................... 75
15.5.5 Unscrew foot section ............................................................................................................. 75
15.5.6 Installation at the assembly location...................................................................................... 75
15.5.7 Inspection after assembly...................................................................................................... 75
15.6 ASSEMBLY /ANCHORING OF THE MAST............................................................................................... 76
15.6.1 Assembling the mast fixture .................................................................................................. 77
15.6.2 Trailing cable guide ............................................................................................................... 78
15.6.3 Using the assembly bridge.................................................................................................... 79
15.6.4 Assembling the EMERGENCY limit switch bar..................................................................... 80
1.1 LANDING-LEVEL LIMIT SWITCH BAR................................................................................................ 80
15.6.5 Securing loading and unloading points ................................................................................. 80
15.6.6 Checks after assembly / checks prior to initial commissioning ............................................. 81
16 DISASSEMBLY..........................................................................................................81
17 DISPOSING OF THE MACHINE ................................................................................81
18 MAINTENANCE .........................................................................................................82
18.1 WARNINGS AND SAFETY INSTRUCTIONS TO BE COMPLIED WITH DURING MAINTENANCE /SERVICING ....... 82
18.2 MAINTENANCE PLAN.......................................................................................................................... 83
18.3 INSPECTIONS.................................................................................................................................... 84
18.4 VISUAL INSPECTIONS ........................................................................................................................ 85
18.4.1 Test run with an empty car.................................................................................................... 86
18.4.2 Test run by platform operator / person authorised to carry out tests and inspections.......... 86
18.5 REFILLING AND INSPECTION JOBS ...................................................................................................... 87
18.5.1 Lubrication device.................................................................................................................. 87
18.6 CHECKING FOR WEAR ....................................................................................................................... 88
18.6.1 Drive pinion............................................................................................................................ 88
18.6.2 Gear rack............................................................................................................................... 88
18.6.3 Tracks rollers......................................................................................................................... 89
18.6.4 Motor brake............................................................................................................................ 90
18.7 FUNCTION TESTS.............................................................................................................................. 91
18.7.1 Safety gear ............................................................................................................................ 91
18.7.2 Drop test passed ................................................................................................................... 92
18.7.3 Drop test not passed ............................................................................................................. 92
18.7.4 Check safety gear for damage .............................................................................................. 93
18.7.5 Safety gear replacement ....................................................................................................... 93
18.8 FAULT TABLE.................................................................................................................................... 94
19 DOCUMENTING THE CHECKS ................................................................................95

GEDA®300 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 under-
stand this manual. The different meanings are explained below.
Text display Meaning
Bold type Emphasises particularly important words /
passages
List 1 Denotes lists
oList 2 Denotes lists
(brackets) Item numbers
Instruction Instruction to personnel Always given in
chronological order
The masculine form of address is mostly 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 func-
tion and operation is not affected by this.
1.2 Warning notices
Activities with specific hazards (to life and limb or potential damage to the
machine) are indicated by warning notices. The instructions given in the
warning notices must be observed.
Warning level Consequence Probability
death / serious injury is imminent
serious injury possible
minor injury possible
material damage possible

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1.3 Overview of warnings in the manual
1.3.1 Electric shock
1.3.2 Crushing by car
DANGER
Danger to life
by crushing.
Never stand underneath the car / 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 in the event of fire
1.3.4 Reaching into the travel path during operation
DANGER
Electric shock
Parts remain live even after actuating the
EMERGENCY STOP or after switching off the
machine at the master switch.
Applies to all work on electrical parts.
Disconnect mains supply upstream from the
master switch.
DANGER
Danger to life
Do not use the hoist in the case of fire.
DANGER
Danger to life
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
DANGER
Danger to life
Due to the machine being switched on during
servicing / repair work or when there is a defect.
Secure master switch with a padlock to prevent
it from being switched on.
DANGER
Danger to life
Falling tools / parts.
Secure tools / parts against falling.
Use the car roof.
WARNING
Fall and trip hazard
Look out for steps and objects on the ground
when entering / exiting the car.
WARNING
Danger to life
Raised load.
Do not stand under suspended loads.
Do not stand on suspended loads.
Only lift loads at the suspension points.
Only use suitable lifting gear.
WARNING
Danger to life
Access only for authorised individuals.
No access for unauthorised individuals.

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1.3.10 Wear safety clothing
DANGER
Danger to life
Risk of fire and explosion as a result of using
combustible cleaning materials.
Only use suitable, non-combustible cleaning
agents.
Do not use steam-jet equipment / high-pressure
cleaners. This can damage electrical components.
Do not touch sockets, cables or electrical compo-
nents with wet or damp hands.
Cleaning work on live components must only be
carried out by qualified electrical personnel.
Wear personal protective equipment.

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1.4 Abbreviations
The following abbreviations may be used in the manual.
max. maximum
min. minimum
mins. minutes
etc. et cetera
poss. possible / possibly
e.g. for example
ml millilitre
mm millimetre
°C degrees Celsius
°F degrees Fahrenheit
ft. feet
ft/m feet per minute
m/min metres per minute
in. inch
etc. et cetera
lbs. pounds
lbf.-ft pounds per feet
kg kilogram
l litre
gal. gallons
kip kilopound
Nm Newton metre
km/h kilometres per hour
mph miles per hour
inc. including
if nec. if necessary
i.e. i.e.
reg. regarding
RH relative humidity
approx. approximately
Ø diameter
® registered trademark
© copyright
TM trademark (trade
name)
% per cent
‰ per mille
dB (A) sound pressure level
LWA sound power level
> greater than
< less than
± plus or minus
1.5 Imprint
GEDA Dechentreiter GmbH & Co. KG
Copyright ©
All rights reserved. No part may be reproduced in any form or processed,
duplicated or disseminated using electronic media without the written con-
sent of the manufacturer. The copyright and conditions of use of any soft-
ware products / user documentation from other manufacturers that may be
included with the scope of delivery must be observed.

GEDA®300 Z / ZP
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2 Identification data
2.1 Machine
Machine model 300 Z / ZP
Year of manufacture See nameplate
2.2 Manufacturer
GEDA Dechentreiter GmbH & Co. KG
Street: Mertinger Straße 60
Town / city: DE-86663 Asbach-Bäumenheim
Country: Germany
Tel.: +49 (0)9 06 / 98 09-0
Fax: +49 (0)9 06 / 98 09-50
Email: [email protected]
Home page: www.geda.de

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2.3 GEDA representatives
Northwest branch East branch
GEDA Dechentreiter GmbH & Co. KG
Marie-Curie-Straße 11
D-59192 Bergkamen-Rünthe
Tel. [phone]
Fax [phone]
GEDA Dechentreiter GmbH & Co. KG
Ernst-M.-Jahr Straße 5
D-07552 Gera
Tel. [phone]
Fax [phone]
GEDA USA, LLC GEDA RUSSIA
P.O. BOX 752086
USA 77275 Houston, Texas
Tel. [phone]
Fax [phone]
Yaroslavskoe shosse 42
129337 Moscow
Tel. [phone]
Fax [phone]
2.4 Ordering spare parts
Spare parts are ordered exclusively through the manufacturer / represen-
tative.
Only original GEDA spare parts may be used. Only original GEDA spare
parts guarantee full function as well as safety and reliability. The use of
unapproved spare parts releases us from any liability for damage arising
as a consequence of such use.
Please supply the following details with each order for spare parts:
Machine model
Year of manufacture
Serial No.
Name of the component
Item-No.
Order quantity
Operating voltage (if applicable)

GEDA®300 Z / ZP
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3 Technical data
3.1 Speeds
400 V
Travel: (12 m/min.)
In the safety area (0-2 m)
Car control unit (12 m/min. or 9 m/min#)
External control unit (12 m/min. or 9 m/min#)
Load capacity: Standard operation / assembly 500 kg / 300 kg
230 V
Travel: (12 m/min.)
In the safety area (0-2 m)
Car control unit (12 m/min. or 9 m/min#)
External control unit (12 m/min. or 9 m/min#)
Load capacity: Standard operation / assembly 300 kg / 300 kg
Safety gear
Triggering speed (22 m/min.)
3.2 Drives
400 V
Power 1.9 kW
Nominal current 4.6 A
Start-up current (max.) 23 A
230 V
Power 1.7 kW
Nominal current 11 A
Start-up current (max.) 31 A
3.3 Assembly height
230 V max. 50 m
3.4 Emissions
Sound power level LWA:
#9 m/min. may be stipulated by national provisions.

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3.5 Dimensions and weight
NOTE
The installation of optional equipment (such as e.g. roof, assembly bridge,
etc.) increases the dead weight. The useful load decreases accordingly.
3.5.1 Base unit /platform / cable box:
Weight 730 kg
Platform internal dimensions 1.32 m x 0.96 m
3.5.2 Mast section
Length 1.5 m
Weight 44 kg (52 kg with assem-
bly parts)
Mast oversail for operation max. 3 m
Mast oversail for assembly max. 5.5 m
Fixing distance 6 m
Vertical distance of mast fixtures max. 6 m
Vertical distance of travelling cable guide max. 6 m
3.5.3 Landing-level safety gates
The hoist GEDA 300 Z/ZP has been type-tested together with the GEDA
landing-level safety gates:
GEDA COMFORT Item-No.: 01212
GEDA STANDARD Item-No.: 01217
GEDA STANDARD Basic Item-No.: 01268
and fulfils the requirements for safe transfer between landing level and car.
GEDA lifts with type test certification must also only be used in combina-
tion with tested GEDA landing-level gates. For assembly of landing-level
safety gates see corresponding instruction manual.

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3.6 Mast
3.6.1 Inclination of mast
Vertical inclination of the mast max. 0.5°. Check inclination during and fol-
lowing installation using appropriate means.
3.7 Technical information on assembly
3.7.1 Foundation
The foundation must reliably transfer existing loads into the subsoil.
The following points must therefore be ensured before each installation operation.
Evidence of the load-bearing capacity of the foundation
Evidence of the load-bearing capacity of the subsoil
Since the load-bearing capacity of the subsoil is often very difficult to estimate, a specialist
soil investigator should be called on if there is even the slightest doubt, in particular for
high / complicated superstructures.
The following points must be taken into account when assessing the subsoil:
Maximum permissible soil pressure
Predicted settlement
Predicted groundwater levels
Predicted thawing and frost processes
Construction activities expected in direct proximity to the installation
site
Steel plates and concrete can be used as load-distributing base supports.
The foundation must be horizontal. The ground pressure data includes no safety factors.
3.7.2 Soil pressure
Assembly height
[m] 10 20 30 40 50
Weight
(kg) 1815 2130 2500 2870 3185
Load-bearing capacity
(kN/m²) 73 86 101 115 128

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3.8 Tightening torques
3.8.1 Mechanical screw connections without torque control
Data refers to bolts in strength class 8.8
Tightening torque Tightening torque
M 8 25 Nm M 16 210 Nm
M 10 49 Nm M 18 300 Nm
M 12 86 Nm M 20 425 Nm
M 14 135 Nm M 24 710 Nm
3.8.2 Mechanical screw connections with torque control
Mast elements to one another
150 Nm Tightening torque
Mast tubes
50 Nm Tightening torque
3.8.3 Electrical screw connections (metal screw connections)
Tightening torque Tightening torque
M 4 1.2 Nm M 12 15.5 Nm
M 5 2 Nm M 16 30 Nm
M 6 3 Nm M 20 52 Nm
M 8 6 Nm M 24 52 Nm
M 10 10 Nm M 30 52 Nm
3.9 Safety distance from live wires
The table below shows the minimum safety distances for each machine
component from live, non-insulated wires. Country-specific regulations
must be observed.
Voltage Minimum distance
0 – 300 V Avoid contact
> 300 V to 50 kV 3,0 m
> 50 kV to 200 kV 4,5 m
> 200 V to 350 kV 6,0 m
> 350 V to 500 kV 8,0 m
> 500 V to 750 kV 11,0 m
> 750 V to 1000 kV 14,0 m

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3.9.1 European wind regions
The operating company is responsible
for applying the correct wind region.
Local conditions such as:
mountains, bays, valleys,
house gullies, thoroughfares,
buildings, etc.
can create wind turbulences and make
it necessary to apply another wind re-
gion.
Assembly
height
metres
Wind pressures by
region (N/m²)
A/B C D E
0 – 10 544 741 968 1225
10 – 20 627 853 1114 1410
20 – 50 757 1031 1347 1704

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3.9.2 Assembly geometry

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