Rack and pinion hoist Table of Contents: Chapter Page General Information ........................... 7 Information about the instruction manual ..................7 Information about the machine ..................... 7 Name and address of the manufacturer ..................8 Notes about the author and industrial property rights ..............8 Instructions for the operating company ..................
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Rack and pinion hoist Operation ............................57 Safety during operation ....................... 57 Safety check before starting work ....................58 Using the platform access point, turning lever and landing-level safety door ......59 7.3.1 Ramp ..........................59 7.3.2 Turning lever ........................59 7.3.3 “ECO”...
This is found at points where information is given about using the machine economically or instructions are given regarding correct working procedures. Information about the machine Machine model GEDA 500 Z Works number: 14830 (400 V) 21900 (230 V 300 kg 21901 (230 V 500 kg))
Violations are an offence and incur an obligation to pay compensation. All rights to exercise industrial property rights are reserved by GEDA. Assembly and Operating Manual 8 / 92...
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.
Rack and pinion hoist Intended use The GEDA 500 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 doors) for transporting items and materials during construction work.
Rack and pinion hoist 1.6.1 Requirements of assembly personnel The machine may only be assembled, operated and maintained by qualified persons who, based on their training, knowledge and practical experience, can guarantee proper handling and who are aware of the risks associated with the construction hoist.
Rack and pinion hoist 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, −...
Rack and pinion hoist 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 may only be used in a technically fault-free condition, as well as in accordance with the intended use, in a safety conscious manner aware of the hazards, and while observing the operating manual! In particular rectify faults immediately that could impair safety! In addition to this, the machine may only be operated when all safety...
Rack and pinion hoist 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.
Rack and pinion hoist 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.
Rack and pinion hoist Safety instructions for servicing, maintenance and troubleshooting Operating personnel must be informed about how to carry out special work and maintenance work before they start. Deadlines that are stipulated or stated in the operating manual for recurring tests/inspections must be adhered to.
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Rack and pinion hoist 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.
Rack and pinion hoist 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...
Rack and pinion hoist Tests The GEDA 500 Z is a machine in compliance with the EC machinery directive 2006/42/EC. A copy of the conformity declaration is reproduced in this operating manual. Inspections before commissioning, recurring inspections and intermediate inspections must be carried out according to national regulations.
Recurring inspections must be carried out in accordance with national regulations. GEDA recommends that you carry out a recurring check on an annual basis. In the case of increased use and strain (e.g. multi- shift operation) carry out inspections at shorter intervals.
Rack and pinion hoist Dynamic tests With empty platform/car • Drop test each time after assembly. • Drop test after replacing the safety gear With loaded platform/car • Drop test before commissioning (refer to Chapter 3.2) • Drop test at recurring inspections (refer to national regulations). At recurring inspections, we recommend to carry out the drop test with the nominal load (refer to the max.
Rack and pinion hoist Checks after extreme weatherconditions Special check after temperatures of – 40 °C [-40 °F] NOTE If it is unclear if the temperature was less than – 40 °C [-40 °F], when recommissioning, proceed as if the temperature was attained. Before performing the special test, temperatures must be more than -30 °C [-22 °...
Rack and pinion hoist Technical description Description of function The GEDA 500 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 using 1.5 m-long mast sections up to a maximum installation height of 50 m (230 V) or 100 m (400 V).
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Rack and pinion hoist Use as a scaffold hoist A specific use of the hoist is for scaffold assembly, the scaffold and hoist are installed alternately (hoist and scaffolding are in assembly state). • A mobile ground control is used for operation or only the assembly control in the platform is used during assembly.
Rack and pinion hoist Machine equipment 1 = Foot section with base mast 2 = Cable bin with switch box, ground station 3 = Load platform 4 = Ramp 5 = Assembly guard plate 6 = Mast section 1.5 m 7 = Landing-level safety door Assembly and Operating Manual 25 / 92...
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Rack and pinion hoist 8 = Drive motor 9 = Safety gear 10 = Cable bin 11 = Switch box Ground station 12 = Switch box on trolley 13 = Manual control (ground control) 14 = Electric socket (blue) for manual control 15 = Socket (red) for electric module on the landing level doors (or dummy...
Rack and pinion hoist 4.2.1 Operating and control elements Main switch On the ground-station switch box Serves the purpose of switching On/Off at the start/end of work. In the event of malfunctions or maintenance/repair work and at the end of work the master switch must be secured with a padlock to prevent it being switched on.
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Rack and pinion hoist Platform control / Assembly control 1 = EMERGENCY STOP button 2 = UP button 3 = DOWN button 4 = Overload control lamp 5 = Key switch - Position left external control - Position right assembly control Platform access / ramp The interlock hook (1) must engage twice.
Rack and pinion hoist Equipment as accessories 4.3.1 Electric module for landinglevel safety door The electric module must be installed on the landing level equipment when local regulations specify electrical monitoring of the landing-level sliding door or control of an upper stop is required. ...
Rack and pinion hoist 4.3.2 Standard push-on frame for the load platform 1 = Standard push-on frame for safe Tools required: 2 ring or open-jaw spanners - width across flats 13/17 1 screwdriver Assembly Remove the plastic cap from the −...
Rack and pinion hoist 4.3.3 Single axle trailer A special single axle trailer is available for road transport. This single axle trailer can be fitted with a trailer coupling ring for cars or alternatively with a trailer coupling ring for lorries. ...
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Rack and pinion hoist Mast inclination Assembly height (H) max. when erected vertically in X and Y direction Example 1 Example 2 Assembly height = 50 m Assembly height = 100 m 50 m 100 m = 0.1 m = 0.2 m ...
Rack and pinion hoist 4.4.1 Operating and environmental conditions The machine must only be operated when the following operating and environmental conditions are adhered to: Temperature range minimum - 20 °C maximum +40 °C Wind speed Operation/maintenance/servicing maximum of 72 km/h Installation maximum 45 km/h No storms with a risk of lightning.
Rack and pinion hoist Anchoring and spatial requirement Assembly and Operating Manual 35 / 92 BL054 GB Edition 08.2015...
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Rack and pinion hoist Assembly and Operating Manual 36 / 92 BL054 GB Edition 08.2015...
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Rack and pinion hoist Legend Distance between wall fixtures See the anchoring forces below Distance from the centre of the circular See the anchoring mast tube to the wall forces below Width of the load platform 1.6 m Depth of the load platform 0.4 m Height of base unit 2.3 m...
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Rack and pinion hoist Tie forces The anchoring forces can be found in the following tables, depending on the respective location (see wind map), assembly height and assembly situation. Details are given of the peak forces occurring for the assembly geometry shown; they do not include any safety factors. The appropriate anchoring forces must be requested if the assembly geometry shown is changed.
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Rack and pinion hoist Assembly in front of a wall A = 1.2 m, B = 0.7 m Anchoring distance V = 6m Load capacity = max. 300kg (only for the 500 Z with 230V drive at 13m/min.) Upper anchoring mast Other anchorages or projection 4.5 m uppermost anchoring...
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Rack and pinion hoist Assembly in front of a scaffolding A = 2.5 m, B = 1.9 m (with a scaffold field depth of approx. 0.7m) Anchoring distance V = 6 m Load capacity = max. 300kg (only for the 500 Z with 230V drive at 13m/min.) Upper anchoring mast Other anchorages or projection 4.5 m...
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Rack and pinion hoist Reinforcing tubes For certain assembly situations (very large distances to fixing points) it may be necessary to protect the anchoring tubes against buckling. Buckling Permissible The actual pressure forces in the tube length pressure must be calculated using the forces stated force in the tables.
Rack and pinion hoist Requirements of the installation site 4.6.1 Foundation • The foundation must be horizontal and have sufficient load bearing capacity. The foundation must be compacted according to the ground load − [kN/m²] (refer to assembly height). • Depending on the assembly height, for example, wooden planks or steel sheeting, can be used as load distributing base supports.
Rack and pinion hoist 4.6.3 Mains connection A building site main cabinet (according to IEC 60439-4:2004) with fuse protection of the supply point with min. fusing of 16A slow-to-blow is required on site. 500 Z with 230 V drive Supply point: 230V/50Hz −...
Rack and pinion hoist Transport Have the hoist transported by experienced and competent persons. Inspection on receiving the hoist • Check the shipment for transport damage and for completeness according to the purchase order. • Immediately notify the freight carrier (haulage company) and dealer of any transport damage.
• Install the equipment on a stable foundation, align it in a precisely vertical position and anchor it to the building. • At loading heights above 2.0 m, protection to prevent persons from falling must be provided (only use original GEDA landing-level safety doors). • Observe the load capacity of the hoist.
Rack and pinion hoist Assembling the base unit • Set the base unit at the support points (spindle support plates and especially on the foot section support beneath the mast) onto load distributing, even base supports and align (refer to Chapter 4.5). Observe load-bearing capacity of the foundation! ...
Rack and pinion hoist Extending mast sections and anchoring to the building If the equipment is erected in front of scaffolding it must be anchored to the building. It can also be anchored directly to the scaffolding if the scaffolding has been designed for the additional load (see anchoring forces).
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Rack and pinion hoist Inspection before mast assembly Raise the empty load platform (manual control) and check if the proximity shuts down the unit at the end of the mast. − the last (on the gear rack side) eye bolt of the hook has been −...
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Rack and pinion hoist • Place the 1.5 m mast section (7) with the eye bolts up onto the base mast (6). The guide sections on the rectangular tubes of the mast are designed in such a way that the mast to be attached can be suspended and tipped up by both assembly engineers until it slips into the guides.
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Rack and pinion hoist Insert the mast bracket (9) from the front into the mast (10) and − secure the scaffold coupling (11) to the round mast tube. (Tightening torque 50 Nm). Open scaffold clamps (13) and insert the telescopic tube (12). Close −...
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Rack and pinion hoist Secure telescoping tube (14) with a starred frame coupling to the − inner side of the mast tube (torque moment 50 Nm), extend towards the wall and anchor likewise. Select the furthest possible horizontal distance between the two anchoring tubes against the wall. (The minimum distance between the two attachment plates is dependent upon the distance between the mast and building, for greater distances use extension tubes).
Rack and pinion hoist 6.3.1 Trailing cable guide Trailing cable guides must be installed to ensure that the trailing cable runs freely into the cable bin. Recommended distance to each other: max. 6 m The more sensitive the hoist location is to wind forces, the shorter the distances should be between trailing cable guides.
Rack and pinion hoist 6.3.2 Emergency limit switch approach bar An approach bar (1) must be installed at the top stop point, before the drive pinion leaves the gear rack. Adhere to a minimum distance to the top of the mast end of 1.25 m. ...
Rack and pinion hoist Securing loading and unloading points To prevent persons falling, fall protection must be installed at all loading and unloading points where there is a risk of falling from a height of more than 2m. The “ECO” landing-level safety door, together with the loading ramp on the load platform, provides safe transfer to the building or scaffold.
Rack and pinion hoist 6.4.2 Limit switch approach bar for landing level stop A limit switch approach bar for a landing level stop can be placed at each stop position so that the platform stops at the same level as the landing-level safety door.
• The key on the assembly control has been switched to “Operation” and removed. Check the GEDA 500 Z according to national regulations after assembly and before initial commissioning, as well as after each assembly at a new construction site or any other new site.
Rack and pinion hoist Operation The GEDA 500 Z may only be operated by a qualified person appointed by the operating company. This person must be familiar with the operating manual, have sufficient experience and be informed about the risks involved in handling the hoisting equipment.
The load platform must emit a warning tone in both travel directions when it is near to the ground (approx. 2 m). When near to the ground (approx. 2 m), the GEDA 500 Z must not be able to be operated from the landing gate. Assembly and Operating Manual 58 / 92 BL054 GB Edition 08.2015...
Rack and pinion hoist Using the platform access point, turning lever and landing-level safety door 7.3.1 Ramp Open • Unlatch the ramp (1) at the interlock hook (2) and lower the ramp. Close • Raise the ramp (1) and press against the platform until the interlock hook (2) clicks into place twice.
Rack and pinion hoist 7.3.3 “ECO” landing-level safety door • Turn the load platform towards the landing-level safety door. Open the landing-level safety door Remove the key (1) from the − holder (2) on the load platform. Insert the key (1) into the lock on −...
Rack and pinion hoist Operating the hoist The platform must be turned towards the trolley and latched into place. The ramp must be closed and the assembly guard plate must be up and secured. • Rotate the main switch to the position “I”. •...
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Rack and pinion hoist The platform can be only be operated above the initial 2 m safety height with the “UP” (3) or “DOWN” (4) buttons using the electric module. 5 = STOP button (does not engage) Automatic travel to a landing level •...
Rack and pinion hoist Emergency shutdown • In situations that present a risk to operating personnel or the hoist, the platform can be shutdown by pressing the EMERGENCY STOP button. There is an EMERGENCY STOP button on the manual control. −...
Rack and pinion hoist Dismantling (disassembly) The rack and pinion hoist must be disassembly according to the assembly and operating manual under supervision by a qualified person, specifically appointed by the operating company! Assembly personnel, refer to section 1.6.1 For disassembly, the same regulations and safety instructions are applicable as described in Chapter 6.
Immediately report any changes or malfunctions to the company management or their authorised representative. If necessary, shut down and secure the GEDA 500 Z immediately. Before cleaning and maintenance work, first lower the platform and remove the mains plug.
Rack and pinion hoist • Check the overload control light on the platform control by manually pressing the overload limit switch (1). Monthly servicing • Check that the mast connection bolts, limit switch approach bars and mast anchors/bolts are secured to the mast and the building, tighten if necessary.
− operating hours at normal operation. The grease reservoir must be replenished before it is empty. Filling capacity: 1.2l Recommended lubricant: Multi-purpose grease/cartridge for grease gun, GEDA Item No. − 16744. Attach manual lever grease gun − to the filling nipple (1) (below the grease reservoir) and pump grease into the reservoir.
Secure tools/parts against falling. Servicing every 6 years GEDA safety gears must be replaced by new GEDA safety gears (replacement safety gears) at the latest after 6 years. The obligation to replace safety gear applies to both material hoists and personnel hoists.
Rack and pinion hoist Checking the safety gear WARNING Danger to life The drop test must only be carried out by a qualified person specifically appointed by the operating company who, on account of his/her training, knowledge and practical experience, is able to evaluate the risks and assess the safe condition of the safety gear.
Rack and pinion hoist Malfunctions - Diagnosis – Repair Malfunctions must only be rectified by competent persons! Before troubleshooting, if possible, lower the platform and unload! Before working on the electrical system of the rack and pinion lift, switch off and secure the main switch. For safety reasons, remove the mains plug.
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Rack and pinion hoist *If the green control light lit is not lit, check the following points (only on machines with 400 V drive): Is there a phase failure? − Is the phase sequence incorrect? − If the phase sequence is incorrect, correct it −...
Rack and pinion hoist 10.1 Potential malfunctions during operation 10.1.1 Power failure or defective motor If this happens the load platform must be lowered to the ground by releasing the motor brake. The brake release lever (1) can stick in the holder (2) on the motor guard cover.
Rack and pinion hoist 10.1.2 Load platform has been driven too high The platform-facing eye bolt on the top mast section actuates the rocker switch of the Emergency limit switch before the drive pinion leaves the gear rack. Cause The Emergency limit switch is operated, if The up limit switch is defective.
Rack and pinion hoist The lower area of the base mast has a rack and pinion segment (4) with predetermined breaking point. This rack and pinion segment (4) prevents the drive unit being damaged in the event of any impact against the foot section.
Rack and pinion hoist 10.2 Safety gear has triggered The GEDA 500 Z is equipped with a safety gear which stops the platform in the event of it overspeeding. Further travel is not possible once the safety gear has been triggered.
The nameplate is located on the trolley of the base unit. Spare parts must conform to the technical specifications of the manufacturer! Only use original spare parts from GEDA. For service or repair work, please contact our customer service department: For the sales and customer service address, refer to Chapter 1.3...
Rack and pinion hoist Appendix B Test Documentation Documentation for regular checks in accordance with the maintenance schedule unplanned check after specific events Name: Serial number: Year of construction: Works number: The machine was checked on______________. As a result none ...
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Rack and pinion hoist Documentation for regular checks in accordance with the maintenance schedule unplanned check after specific events Name: Serial number: Year of construction: Works number: The machine was checked on______________. As a result none the following Defects determined: Scope of inspection:...
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Rack and pinion hoist Documentation for regular checks in accordance with the maintenance schedule unplanned check after specific events Name: Serial number: Year of construction: Works number: The machine was checked on______________. As a result none the following Defects determined: Scope of inspection:...
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Rack and pinion hoist Documentation for regular checks in accordance with the maintenance schedule unplanned check after specific events Name: Serial number: Year of construction: Works number: The machine was checked on______________. As a result none the following Defects determined: Scope of inspection:...
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Rack and pinion hoist Documentation for regular checks in accordance with the maintenance schedule unplanned check after specific events Name: Serial number: Year of construction: Works number: The machine was checked on______________. As a result none the following Defects determined: Scope of inspection:...
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Rack and pinion hoist Documentation for regular checks in accordance with the maintenance schedule unplanned check after specific events Name: Serial number: Year of construction: Works number: The machine was checked on______________. As a result none the following Defects determined: Scope of inspection:...
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Rack and pinion hoist Documentation for regular checks in accordance with the maintenance schedule unplanned check after specific events Name: Serial number: Year of construction: Works number: The machine was checked on______________. As a result none the following Defects determined: Scope of inspection:...
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Rack and pinion hoist Documentation for regular checks in accordance with the maintenance schedule unplanned check after specific events Name: Serial number: Year of construction: Works number: The machine was checked on______________. As a result none the following Defects determined: Scope of inspection:...
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Rack and pinion hoist Space for notices Notice entered Name: / Date Position Assembly and Operating Manual 88 / 92 BL054 GB Edition 08.2015...
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Rack and pinion hoist Space for notices Notice entered Name: / Date Position Assembly and Operating Manual 89 / 92 BL054 GB Edition 08.2015...
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Rack and pinion hoist Assembly and Operating Manual 90 / 92 BL054 GB Edition 08.2015...
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