GEDA 200Z User instructions

Original operating manual
Assembly and Operating Manual
Rack and pinion hoist
For loads

Rack and pinion hoist
Assembly and Operating Instructions 3 / 100 BL108 GB Edition 03.2018 Rev. 02

Rack and pinion hoist
Assembly and Operating Instructions 4 / 100 BL108 GB Edition 03.2018 Rev. 02

Rack and pinion hoist
Assembly and Operating Instructions 5 / 100 BL108 GB Edition 03.2018 Rev. 02
Table of Contents:
Section Page
1General information........................................................................................................................... 7
1.1 Information about the instruction manual.................................................................................... 7
1.2 Information about the machine ................................................................................................... 8
1.3 Name and address of the manufacturer ..................................................................................... 9
1.4 Notes about the author and industrial property rights ................................................................. 9
1.5 Instructions for the operating company..................................................................................... 10
1.6 Intended use ............................................................................................................................. 11
1.6.1 Requirements of assembly personnel .............................................................................. 12
1.6.2 Operating personnel ......................................................................................................... 12
1.6.3 Improper use .................................................................................................................... 12
2General safety information ............................................................................................................. 13
2.1 Residual risks............................................................................................................................ 13
2.2 Safety instructions for operating personnel............................................................................... 14
2.3 Safety instructions for transport ................................................................................................ 15
2.4 Safety instructions for operation ............................................................................................... 16
2.5 Safety instructions for servicing, maintenance and troubleshooting......................................... 17
2.6 Safety whilst working on the electrics ....................................................................................... 19
3Technical description ...................................................................................................................... 20
3.1 Description of function............................................................................................................... 20
3.2 Machine equipment................................................................................................................... 21
3.2.1 Operating and control elements ....................................................................................... 23
3.3 Equipment as accessories ........................................................................................................ 25
3.3.1 Retainer for scaffolding .................................................................................................... 25
3.3.2 Landing level control......................................................................................................... 26
3.3.3 Small on-site main cabinet ............................................................................................... 28
3.4 Technical Data .......................................................................................................................... 29
3.4.1 Operating and environmental conditions.......................................................................... 29
3.4.2 Speeds ............................................................................................................................. 30
3.4.3 Electrics ............................................................................................................................ 30
3.4.4 Assembly height / Lifting height........................................................................................ 30
3.4.5 Emissions ......................................................................................................................... 30
3.4.6 Ladder section .................................................................................................................. 31
3.4.7 Load capacity, dimensions and weights........................................................................... 32
3.5 Anchoring and spatial requirement ........................................................................................... 33
3.5.1 Anchoring forces............................................................................................................... 34
3.6 Requirements of the installation site ......................................................................................... 37
3.6.1 Foundation........................................................................................................................ 37
3.6.2 Soil pressure..................................................................................................................... 37
3.6.3 Mains connection.............................................................................................................. 38
4Transport .......................................................................................................................................... 39
5Installation ........................................................................................................................................ 40
5.1 Safety during installation ........................................................................................................... 40
5.2 Assembly procedure ................................................................................................................. 41
5.3 Assembling the base unit .......................................................................................................... 42
5.3.1 Install the rail bracket and anchor .................................................................................... 43
5.3.2 Fitting the turning unit ....................................................................................................... 46
5.3.3 Assembling the platform ................................................................................................... 48
5.4 Installing the ladder sections..................................................................................................... 49
5.4.1 Limit switch, approach bar................................................................................................ 52
5.5 Securing loading and unloading points ..................................................................................... 53
5.5.1 Limit switch approach bar for landing stop....................................................................... 53
5.6 Check after assembly and before each operation .................................................................... 54
6Operation .......................................................................................................................................... 55
6.1 Safety during operation ............................................................................................................. 55
6.2 Safety check before starting work ............................................................................................. 56
6.3 Using the platform access point................................................................................................ 57

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Assembly and Operating Instructions 6 / 100 BL108 GB Edition 03.2018 Rev. 02
6.3.1 Loading gate ..................................................................................................................... 57
6.3.2 Turning lever..................................................................................................................... 57
6.3.3 “ECO” landing level safety gate........................................................................................ 58
6.4 Operating the hoist .................................................................................................................... 59
6.5 Emergency shutdown................................................................................................................ 60
6.6 Interrupting work – end of work................................................................................................. 60
7Dismantling (disassembly) ............................................................................................................. 61
8Maintenance and cleaning .............................................................................................................. 62
8.1 Maintenance schedule .............................................................................................................. 63
8.2 Checks....................................................................................................................................... 64
8.2.1 Documenting the results ................................................................................................... 64
8.2.2 Checks before initial commissioning ................................................................................ 65
8.2.3 Checks after assembly / daily before starting operation................................................... 65
8.2.4 Recurring checks .............................................................................................................. 65
8.2.5 Checks after extreme weather conditions ........................................................................ 66
8.3 Replenishment and Inspection Tasks ....................................................................................... 67
8.3.1 Lubrication of the gear rack / drive pinion ........................................................................ 67
8.3.2 Trailing cable / cable guide profile .................................................................................... 67
8.3.3 Check/replace gearbox oil ................................................................................................ 67
8.3.4 Check the ladder interlocks and bolted connections ........................................................ 68
8.4 Checking for wear ..................................................................................................................... 69
8.4.1 Drive pinion....................................................................................................................... 69
8.4.2 Rack.................................................................................................................................. 69
8.4.3 Tracks rollers .................................................................................................................... 70
8.4.4 Motor brake....................................................................................................................... 72
8.5 Function checks ........................................................................................................................ 74
8.5.1 Check the overload triggering........................................................................................... 74
8.5.2 Test the safety gear .......................................................................................................... 75
8.5.3 Safety gear replacement .................................................................................................. 78
9Malfunctions - Diagnosis – Repair ................................................................................................. 82
9.1 Fault table.................................................................................................................................. 83
9.1.1 Motor is not producing full output ..................................................................................... 84
9.1.2 Load platform moved too high .......................................................................................... 84
9.1.3 Platform has descended too low ...................................................................................... 84
9.1.4 Overload warning device has triggered............................................................................ 85
9.2 Retrieving the platform .............................................................................................................. 86
9.2.1 Basic conduct in the event of a rescue/malfunction ......................................................... 86
9.2.2 Rescue action plan ........................................................................................................... 87
9.3 Repair ........................................................................................................................................ 89
10 Disposal of the machine.................................................................................................................. 89
11 Appendix A Summary of instruction notices................................................................................ 90
12 Appendix B Test Documentation ................................................................................................... 91

Rack and pinion hoist
Assembly and Operating Instructions 7 / 100 BL108 GB Edition 03.2018 Rev. 02
1 General information
1.1 Information about the instruction 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, correctly and efficiently. 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, fault rectification during work, disposal of operating
materials and auxiliary supplies,
−assembly, maintenance (servicing, general maintenance, repairs)
and/or transport.
You will see a series of illustrations and symbols whilst reading this
manual which are intended to help you navigate through and
understand this manual. The different meanings are explained below.
Text display
Meaning
Bold type
Emphasises particularly important
words/passages
•List 1
Denotes lists
−
List 2
Denotes lists
(brackets)
Item numbers
Instruction
Instruction to personnel. Always given in
chronological order
Images
The illustrations used refer to a specific machine type. They may only
constitute a schematic representation with other machine types. The
fundamental function and operation is not affected by this.

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Assembly and Operating Instructions 8 / 100 BL108 GB Edition 03.2018 Rev. 02
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
of injury or a fatality. Observe these instructions and be very cautious!
Warning level
Consequence
Probability
DANGER Death / serious injury is imminent
WARNING serious injury possible
CAUTION minor injury possible
CAUTION tangible damage possible
Attention note
This is found at points where special information or instructions and
restrictions regarding damage prevention are given in order to prevent
damage to the equipment.
Note
This is found at points where information is given about using the
machine economically or instructions are given regarding correct
working procedures.
1.2 Information about the machine
Works number:
29220 / 50790
Year of manufacture:
See identification plate on the machine
Documentation version:
03/2018

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Assembly and Operating Instructions 9 / 100 BL108 GB Edition 03.2018 Rev. 02
1.3 Name and address of the manufacturer
GEDA- Dechentreiter GmbH & Co. KG
Mertinger Strasse 60
86663 Asbach-Bäumenheim
Phone: +49 (0)9 06 / 98 09-0
Fax: +49 (0)9 06 / 98 09-50
E-Mail: [e-mail]
Web: www.geda.de
Representatives of the manufacturer
Bergkamen Subsidiary
Gera Subsidiary
GEDA Dechentreiter GmbH & Co.
KG
Niederlassung Nord-West
Marie-Curie-Strasse 11
59192 Bergkamen-Rünthe
Phone: [phone]
Fax: [phone]
GEDA Dechentreiter GmbH & Co.
KG
East branch
Ernst-M.-Jahr Strasse 5
07552 Gera
Phone: [phone]
Fax: [phone]
USA Subsidiary
Russia Subsidiary
GEDA USA, LLC
1151 Butler Road
USA 77573 League City, Texas
Phone: [phone]
Fax: [phone]
Web: www.gedausa.com
GEDA RUS, LLC
Yaroslavskoe shosse 42
129337 Moscow
Russian Federation
Phone: [phone]
Fax: [phone]
Web: www.geda-ru.com
Turkey Subsidiary
Korea Subsidiary
GEDA MAJOR
IS VE INSAAT MAKINALARI SAN.
TIC. LTD. STI.
Semsettin Günaltay Cad. No:224 A
Blok K:2 D:5
Tüccarbasi/Erenköy
TR-34734 Istanbul/Turkey
Phone: [phone]
Fax: [phone]
Web: www.geda.com.tr
GEDA KOREA
1708, (MetroDioVill Bldg.,
Singongdeok-dong)
199, Baekbeom-ro, Mapo-gu,
Seoul, 04195, Korea
Tel.: [phone]
Fax: [phone]
Web: www.geda-korea.com
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.

Rack and pinion hoist
Assembly and Operating Instructions 10 / 100 BL108 GB Edition 03.2018 Rev. 02
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 obligatory regulations for accident prevention and
industrial safety that apply both in the country of use and at the place
of use, accepted professional rules for working safely and competently
must also be observed.
The operating company must 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 must not make any
changes, additions or modifications to 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 employ qualified and/or trained personnel for the tasks
described in this manual.
The operating company clearly defines the responsibilities of the
personnel for operation/installation/maintenance. The operating
company is obliged to train all persons authorised to use the machine in
the correct handling of the machine before using it for the first time,
according to the respective area of activity and responsibility of the
authorised individual and using practical exercises.
These instructions must be documented and repeated at regular
intervals.
The legally permissible minimum age must be observed!

Rack and pinion hoist
Assembly and Operating Instructions 11 / 100 BL108 GB Edition 03.2018 Rev. 02
1.6 Intended use
The GEDA 200 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 doors 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 load 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.
•Must only be controlled in operation using the manual control and
outside the hazard area.
Only authorised persons are permitted to travel on the load platform
and only for the purposes of assembly and servicing tasks. Special
measures are required for such operations.
•Use fall protection on the front side.
•During assembly, the hoist shall only be operated from the load
platform (use an extension lead for the controls).
Observe and comply with the instructions in Chapter 3.3.3, “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.
Intended use includes
−That the assembly, operating 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 200 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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Assembly and Operating Instructions 12 / 100 BL108 GB Edition 03.2018 Rev. 02
1.6.1 Requirements of assembly personnel
The machine must only be assembled, operated and maintained by
competent persons who, based on their training or knowledge and
practical experience, can ensure correct handling and who are
instructed about 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 acquainted with the assembly and operating manual.
−observe national regulations
1.6.3 Improper use
•Transporting persons is prohibited!
−Only authorised persons are permitted to travel on the load platform
and only for the purposes of assembly and servicing tasks. 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 200 Z is not designed for permanent installation.
•The 200 Z must 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 machine.
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.

Rack and pinion hoist
Assembly and Operating Instructions 13 / 100 BL108 GB Edition 03.2018 Rev. 02
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 handling 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 load 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.

Rack and pinion hoist
Assembly and Operating Instructions 14 / 100 BL108 GB Edition 03.2018 Rev. 02
2.2 Safety instructions for operating personnel
The operating manual must be within reach at all times at the location
where the machine is used.
The machine must only be used when fully serviceable, as well as in
accordance with the intended use, in a safety conscious manner
aware of the hazards and whilst 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 rules for prevention of accidents 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 equipment 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.

Rack and pinion hoist
Assembly and Operating Instructions 15 / 100 BL108 GB Edition 03.2018 Rev. 02
2.3 Safety instructions for transport
Immediately report transport damage and/or missing parts to the
supplier.
During transport work, wear a safety helmet, safety shoes and safety
gloves!
Never step under suspended loads!
Only use appropriate, standardised and tested lifting gear, forklifts,
cranes) and sling gear (round slings, lifting straps, sling ropes, chains)
for transport at the assembly site.
When selecting hoisting equipment, always take into account the
maximum suspended loads!
Please refer to the dimensions and weights in the technical
specifications section (3.4) and spatial requirements (3.5).
Only carefully load and transport equipment that has been
disassembled, packaged and lashed.
Always ensure that the machine is transported without being knocked
or jolted.
Observe the pictograms on the packaging.
Only attach gear to the designated sling points.
Always secure transported loads against falling or tipping over!

Rack and pinion hoist
Assembly and Operating Instructions 16 / 100 BL108 GB Edition 03.2018 Rev. 02
2.4 Safety instructions for operation
Only operate the machine, under consideration of the operating manual,
when it is fully serviceable and in a safety and hazard conscious
manner.
If work is interrupted, switch off the machine at the main switch and
secure it with a padlock against switching on.
Fundamentally, the machine must be secured against unauthorised
use (disconnect from power)!
In situations that present a risk to the operating personnel or machine,
shut down the machine by pressing the EMERGENCY STOP button.
Shut down and lower the machine if the 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 doors.)

Rack and pinion hoist
Assembly and Operating Instructions 17 / 100 BL108 GB Edition 03.2018 Rev. 02
2.5 Safety instructions for servicing, maintenance and
troubleshooting
Before they start work, operating personnel must be informed about
how to carry out special tasks and maintenance tasks.
Deadlines that are stipulated or stated in the operating manual for
recurring tests/inspections must be adhered to.
The maintenance area must be cordoned off as extensively as
required!
Fundamentally, before any maintenance work on the machine
−Unload,
−turn off the main switch.
All servicing and maintenance tasks are only permitted with the
master switch turned off or with the mains plug disconnected.
Manual intervention while the machine is running can lead to serious
injury and is therefore prohibited. If it is necessary to turn the machine
on during such work, then this must only be done while complying with
special safety measures.
For further instructions on servicing / servicing intervals /
maintenance, refer to Chapters 8 and 9.
If the machine has been completely shut down for these tasks, it must
be secured against switching on unintentionally:
•Activate the Emergency STOP button,
•Lock the main switch using a shackle lock and
•attach a warning sign to the switch box (main switch).
Any faults that could impair safety must be rectified immediately.
Workshop equipment suitable for the specific tasks is imperative for
carrying out servicing and maintenance tasks. When carrying out
maintenance tasks at greater height, a fall-protection device must be
worn! Keep all handles, railings and the load platform free from dirt and
contamination.
When working under the load platform, secure it using appropriate
means (e.g. bolts, mast clamps, etc.)
Before starting servicing/repair tasks clean the machine, in particular
connections and screw connections, from oil, operating fluids,
contamination and maintenance products. Abrasive cleaning agents
must not be used. Loosened screw connections during servicing and
maintenance tasks must always be tightened using the necessary
torques!
Do not change, remove, bypass or bridge safety devices.

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Assembly and Operating Instructions 18 / 100 BL108 GB Edition 03.2018 Rev. 02
If it is necessary to remove safety devices during servicing and
repairs, the safety devices must be installed and checked immediately
after completion of servicing and repair tasks!
Do not make any changes, additions or modifications to the machine.
This also applies to the installation and adjustment of safety devices
such as limit switches.
Immediately replace damaged or detached notices and warning signs,
as well as safety labels.
Ensure that auxiliary supplies, as well as replaced parts, are disposed
of safely and in an eco-friendly manner (also refer to Chapter 10)
The aforementioned safety measures apply equally for work in the
context of eliminating faults.

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Assembly and Operating Instructions 19 / 100 BL108 GB Edition 03.2018 Rev. 02
2.6 Safety whilst working 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 must only be carried
out by qualified electricians working in accordance to electrical
engineering regulations! Only professional electricians may access the
machine's electrics and carry out work on it. Always keep the switch
boxes closed as soon as they are left unattended.
Never work on live parts! System parts on which inspection,
maintenance or repair work is to be carried out must be
disconnected from the mains. Operating fluids that have been
disconnected must be secured against being switched back on
unintentionally or automatically (lock away fuses, block isolating
switches, etc.). The disconnected, electrical components must first be
tested to ensure they are voltage-free, then earthed, short-circuited and
isolated from neighbouring live components.
If work on live components is required (only in exceptional
circumstances) an additional 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, make sure that design features are not modified so
that they have a negative influence on safety. (e.g. creeping distances,
clearances and distances must not be made smaller by insulation).
Fault-free earthing of the electrical system must be ensured by a
protective earth system.

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Assembly and Operating Instructions 20 / 100 BL108 GB Edition 03.2018 Rev. 02
3 Technical description
3.1 Description of function
The GEDA 200 Z is a vertically installed rack and pinion hoist which is
used exclusively for transporting scaffold parts, objects and construction
material.
•The base unit can be extended with 1.0 m and 2.0 m long ladder
sections up to a max. installation height of 41 m.
•Complete installation of the construction hoist includes safety
equipment for the loading and unloading points (refer to Chapter 5.5).
−The danger zone, excluding the access point to the platform, must be
cordoned off and identified.
•The load bearing capacity is max. 200 kg.
−The machine has an overload device that disables movement in both
directions if the payload is exceeded. If switched off due to
overloading, a red warning lamp on the trolley switch box illuminates
and a alarm signal sounds.
•The lifting speed of the hoist is only approx. 25 m/min.
•The downward travel path of the platform is limited by a DOWN limit
switch and upwards by an UP limit switch.
•The turned load platform interrupts the safety circuit. The hoist is
unable to start with the load platform turned.
•Control is carried out using the ground control, from outside the
hazard area.
−The ground control is a mobile manual control plugged into the
switch box of the foot section. For installation purposes, the manual
control must be fitted with a special extension lead for this manual
control.
•The platform opening (loading ramp) is electrically monitored and
interrupts the movement in both directions (EMERGENCY STOP
safety circuit).