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

Rack and pinion hoist
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.

Rack and pinion hoist
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

Rack and pinion hoist
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!