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GEDA 300 Z Assembly And Operating Manual

Construction hoist for material transport
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Assembly and Operating Manual
Construction hoist
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Original Operating Manual

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Summary of Contents for GEDA 300 Z

  • Page 1 Assembly and Operating Manual Construction hoist for material transport Original Operating Manual...

  • Page 3: Eu Declaration Of Conformity

    Designation: Construction hoist for material transport (for temporary use on construction sites by authorised persons) Type: 300 Z Serial number: 16430 / 000670..., 14770 / 000672... Year of construction: Refer to name plate on the machine is in compliance with all pertinent provisions of the following directives at the time of being put on the market.

  • Page 5: Table Of Contents

    300 Z Table of contents Table of contents General information Information on the operating manual Abbreviations Identification data Manufacturer's name and address Information about the author and industrial property rights Information for the employer Intended use 1.7.1 Requirements for assembly personnel 1.7.1.1...
  • Page 6 Table of contents 300 Z Stop bars 5.7.1 EMERGENCY-LIMIT stop bar 5.7.2 LANDING LEVEL stop bar Special features when using as a scaffold hoist Securing loading and unloading points 5.10 Check after assembly and before each operation Operation Safety during operation Commissioning 6.2.1...
  • Page 7 300 Z Table of contents Replenishment and Inspection Tasks 9.4.1 Lubrication of the gear rack/drive pinion 9.4.1.1 Manual lubrication 9.4.1.2 Automatic lubrication device 9.4.2 Coating the trailing cable with lubricant 9.4.3 Gearboxes 9.4.4 Checking the threaded connections Checking for wear 9.5.1...
  • Page 9 300 Z Table of figures Table of figures Fig. 1: Mast section Fig. 2: Space required in front of scaffolding Fig. 3: Space required in front of a wall Fig. 4: Crane lug Fig. 5: Transport with single axle trailer Fig.
  • Page 10 Table of figures 300 Z Fig. 48: Assembly for load platform with ramp 3 Fig. 49: Assembling the pipe bracket Fig. 50: Overrun protection Fig. 51: Aligning the base unit with spindles Fig. 52: Transport frame Fig. 53: 1.10 m base enclosure with barrier Fig.

  • Page 11: General Information

    300 Z General information General information Information on the operating manual This operating manual is an essential aid to operating the machine successfully and hazard-free (refer to chapter 2.1 Residual risks, page 18). This operating manual contains important instructions on how to operate the machine safely, correctly and efficiently.

  • Page 12: Safe Working

    General information 300 Z DANGER Type and source of the hazard: Danger to life Consequence: Death/serious injury Probability: imminent  Measure for preventing the hazard WARNING Type and source: Risk of injury Consequence: Serious injury Probability: possible  Measure for avoiding...

  • Page 13: Abbreviations

    > greater than gal. gallons < less than kip. kilopound ± plus/minus Identification data Machine type: GEDA 300 Z Serial number: 16430 / 000670..., 14770 / 000672... Year of construction: Refer to name plate Documentation version: 2024-09 BL131 GB 2024-09...

  • Page 14: Manufacturer's Name And Address

    Violations are an offence and incur an obligation to pay compensation. All rights to exercise industrial property rights are reserved by GEDA . BL131 GB 2024-09...

  • Page 15: Information For The Employer

    Any replacement and wearing 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.

  • Page 16: Intended Use

    Any other locations or intended uses require written approval from the manufacturer. The 300 Z is a material hoist that is temporarily erected and • which may only be operated after the landing level safety gates are installed at each loading and unloading point •...

  • Page 17: Assembly, Service/Maintenance Specialist

    • observe national rules and regulations. 1.7.3 Improper use The 300 Z • is not designed for permanent installation • must not be set up to be free-standing (without anchoring) • must not be installed as a free-standing unit above 6.0 m without load weights on the foot sections - Use the front fall protection.

  • Page 18: General Safety Information

    General safety information 300 Z General safety information The machine has been designed and built according to the state of the art and recognised safety 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: •...

  • Page 19: Safety Instructions For Operating Personnel

    300 Z General safety information Safety instructions for operating personnel The operating manual must be kept within reach at all times at the location where the machine is used. The machine may only be used in a technically flawless condition, in...

  • Page 20: Safety Instructions For Transport

    General safety information 300 Z Safety instructions for transport Immediately report transport damage and/or missing parts to the supplier. During transport tasks, wear a safety helmet, safety shoes and protective gloves! Never walk below suspended loads! Only use appropriate, standardised and tested lifting devices (forklifts, cranes) and load attachment gear (lifting beam, round slings, lifting straps, rope slings, chains) for transport at the assembly site.

  • Page 21: Safety Instructions For Operation

    300 Z General safety information Safety instructions for operation Only operate the machine in accordance with the operating manual, when it is in full working order, and in a safety and hazard- conscious manner. If work is interrupted, switch the machine off at the main switch and secure it with a padlock against being switched on again.

  • Page 22: Safety Instructions For Maintenance And Troubleshooting

    General safety information 300 Z Safety instructions for maintenance and troubleshooting Operating personnel must be informed about how to carry out special work and repair work before starting. Deadlines that are stipulated or stated in the maintenance manual for recurring tests/inspections must be adhered to.
  • Page 23 300 Z General safety information 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 information and warning signs, as well as safety labels.

  • Page 24: Safety When Working On The Electric System

    General safety information 300 Z Safety when working on the electric system 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 padlock or the mains plug must be disconnected!

  • Page 25: Technical Data

    300 Z Technical data Technical data Operating and environmental conditions The machine may only be operated when the following operating and environmental conditions are adhered to: • Storage in dry rooms, in order to prevent corrosion. • No jolts or vibrations.

  • Page 26: Electrical Connected Loads

    Technical data 300 Z Electrical connected loads 300 Z with 230 V drive Power 1.8 kW Rated current 10.5 A Duty cycle S3 (60%) Base unit Operating voltage 230 V / 50 Hz / 1 x 16 A / 1 Ph...

  • Page 27: Mains Connection

    300 Z Technical data 300 Z with 400 V drive Power 2.5 kW Power consumption 5.4 A Duty cycle (DC) S3 (60%) Base unit Operating voltage 400 V / 50 Hz / 3 x 16 A / 3 Ph Protective system...

  • Page 28: Mast

    Technical data 300 Z Mast Use only original GEDA mast sections! Fig. 1: Mast section Ladder section 1 m (with gear rack and captive screws) Weight: 14 kg Ladder section 2 m (with gear rack and captive screws) Weight: 25 kg...

  • Page 29: Load Capacity, Dimensions And Weights

    Landing level stop bar 2.6 kg Accessories 20 m extension lead for control (5-pole) 5 kg 300 Z with 230 V drive Weights Cable bin with 25 m trailing cable 27 kg Cable bin with 50 m trailing cable 37 kg Accessories Cable drum 33 m, 3x2,5 mm²...

  • Page 30: Fig. 2: Space Required In Front Of Scaffolding

    Technical data 300 Z Dimensions/required space Fig. 2: Space required in front of scaffolding 0.50 m 1.70 m 2.03 m Fig. 3: Space required in front of a wall 0.50 m 1.88 m 2.20 m BL131 GB 2024-09...

  • Page 31: Transport

    300 Z Transport Transport ATTENTION Damage to the machine  The machine has to be transported by experienced and competent personnel. Inspection on receiving the machine • Check the shipment for transport damage and completeness according to the purchase order.

  • Page 32: Transport With Single Axle Trailer

    Transport 300 Z 4.2.1 Transport with single axle trailer Fig. 5: Transport with single axle trailer Transport and loading is described in the Operating Manual for the single axle trailer. BL131 GB 2024-09...

  • Page 33: Assembly

    • At loading positions from 2,0 m height protection to prevent persons from falling must be provided (only use original GEDA landing-level safety doors). • Observe the load capacity of the hoist.
  • Page 34 Assembly 300 Z • During assembly, the protruding mast/ladder sections must only be moved a max. 3 m over the last anchorage point! (Upper edge of trolley to rail bracket). • During assembly, never do the following from the load platform: - reach or lean into the travel path during travel.

  • Page 35: Requirements For The Assembly Site

    300 Z Assembly Requirements for the assembly site 5.2.1 Substructure • 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.

  • Page 36: Anchoring Requirements

    Assembly 300 Z Anchoring requirements Mast projection above the top mast bracket [during operation and assembly] Maximum distance between the lower edge of the car/platform and the top mast bracket Installed height Vertical distance between mast brackets Vertical distance between ground...

  • Page 37: Anchoring Forces

    300 Z Assembly 5.3.1 Anchoring forces The stated values apply: • Per anchoring point. • For the assembly geometry shown. In the event of differing structures, the corresponding values must be requested! The stated values do not include any safety factors. The wind loads used to determine the anchoring forces refer to the European wind regions according to EN 12158 / EN 12159.

  • Page 38: Fig. 8: Assembly In Front Of A Wall

    Assembly 300 Z Erection height H Wind forces for geographical regions [N/m Wind region 0˂H≤10 1225 10˂H≤20 1114 1410 20˂H≤50 1031 1347 1704 50˂H≤100 1196 1562 1977 100˂H≤150 1306 1706 2159 150˂H≤200 1023 1393 1819 2303 Assembly in front of a wall Fig.
  • Page 39 300 Z Assembly Anchoring forces [kN] with maximum mast projection AP ≥ BP x 1.2 Top anchor point Other anchor points Assembly height Wind region A/B 0 < H ≤ 10 m ± 3.5 ± 2.7 ± 2.6 ± 2.2 10 <...

  • Page 40: Fig. 9: Assembly In Front Of A Scaffolding

    Assembly 300 Z Assembly in front of a scaffolding Fig. 9: Assembly in front of a scaffolding Scaffold field depth = 0,70 m AP = approx. 2.5 m, BP = approx. 1.38 m Anchoring forces [kN] with maximum mast projection AP ≥...
  • Page 41 300 Z Assembly Anchoring forces [kN] without projecting mast AP ≥ BP x 1.7 Top anchor point Other anchor points Assembly height Wind region 0 < H ≤ 10 m ± 2.2 ± 2.1 ± 1.8 ± 1.9 10 < H ≤ 20 m ±...

  • Page 42: Assembly Plan

    Assembly 300 Z Assembly plan The assembly plan shows the basic assembly stages and their chronological sequence. However, installation is always based on the detailed instructions in this manual and the approved installation drawings. Depending on the working equipment available / number of installation engineers, and the construction-site conditions (e.g.

  • Page 43: Assembling The Base Unit

    300 Z Assembly Assembling the base unit The machine may only be installed and used vertically! The base unit must be aligned parallel to the building or scaffolding. Place the foot section on the support points (support plate of the spindles and, above all, on the foot section support beneath the masts) on load-distributing, level base supports and align.

  • Page 44: Assembling Switch Cabinet With Main Switch

    Assembly 300 Z 5.5.1 Assembling switch cabinet with main switch 1. Place the bracket with switch cabinet onto the foot section and screw down. 2. Plug in the trailing cable plug (coming from the cable bin below), and connect the plug socket bar.

  • Page 45: Replacing The Cable Bin

    300 Z Assembly 5.5.2 Replacing the cable bin When installing the cable bin, ensure that the trailing cable maintains the correct twist. If rotation is necessary, turn the cable bin only together with the cable holder. The cable holder must not be rotated in the opposite direction to...
  • Page 46 Assembly 300 Z 6. Release the nuts (4) on the cable bin mount and turn the screw with the clamp (5) until the mount can be removed from the groove of the mast. Fig. 12: Replacing the cable bin 2 7.

  • Page 47: Extending The Mast

    300 Z Assembly Extending the mast 5.6.1 Anchoring the mast 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 (refer to Anchoring forces).

  • Page 48: Fig. 14: Anchoring To A Wall 2

    Assembly 300 Z 2. Peg the fixing tube to the wall or bolt using through bolts. 3. Clamp bracing tube (3) into the mobile coupling on the mast bracket and guide it to the wall.  Choose the widest possible distance between both anchoring points on the wall (at least 0.80 m).

  • Page 49: Fig. 15: Anchoring To Scaffolding

    300 Z Assembly Anchoring to scaffolding Pipe dimensions: Ø 48,3 x 3,2 mm St 37, length depending on scaffold width  Clamp the fixing tube (1) into both rigid couplings on the mast bracket (2) ); the pipe is secured to the scaffold by two scaffold couplings.

  • Page 50: Installing The Mast Elements

    Assembly 300 Z 5.6.2 Installing the mast elements Inspection before mast assembly Raise the empty load platform (manual control) and check if • the proximity switch shuts the unit down at the end of the mast. • the last (platform side) lowered mast fixing device actuates the emergency stop limit switch.

  • Page 51: Fig. 18: Key Switch In Assembly Position

    300 Z Assembly  Push key into the key switch on the sliding carriage switch cabinet (5) and turn to the right (assembly position). Fig. 18: Key switch in assembly position WARNING Risk of injury  Before the platform ascends, ensure that the base unit is standing securely.

  • Page 52: Fig. 21: Place The First Mast Element Onto The Base Mast

    Assembly 300 Z  Place the first mast element (10) onto the base mast (9) by hand.  Raise the three eyebolts (11A) and fully tighten.  Tightening torque approx. 90 Nm 3 9A Fig. 21: Place the first mast element onto the base mast The adjustable connecting plate (9B) of the base mast must be pushed up and secured with the eye bolt.

  • Page 53: Trailing Cable Guides

    300 Z Assembly  Install other mast anchors as described previously.  Mount trailing cable guides at distances of approx. 8 m (refer to chapter 5.6.3 Trailing cable guides, page 53).  Assemble the hoist until the desired height is reached (max. 50 m with 230 V drive or 100 m with a 400 V drive).

  • Page 54: Stop Bars

    Assembly 300 Z Stop bars 5.7.1 EMERGENCY-LIMIT stop bar An EMERGENCY-LIMIT stop bar has to be installed at the top stopping point, before the drive pinion exits the gear rack. Installation The limit switch tag must point to the motor side.

  • Page 55: Landing Level Stop Bar

    300 Z Assembly 5.7.2 LANDING LEVEL stop bar A LANDING LEVEL stop bar can be installed at each stop position, so that the platform stops at the same level as the landing level safety gate. Installation The limit switch tag must point to the motor side.

  • Page 56: Special Features When Using As A Scaffold Hoist

    Assembly 300 Z Special features when using as a scaffold hoist The overrun protection (proximity switch) shuts down the ascend function during assembly. It can be minimally adjusted in height to match the scaffold level with the load platform floor.

  • Page 57: Securing Loading And Unloading Points

    300 Z Assembly 5. At the impact point between foot section and base mast (2) and the first attached mast section (3), release the eye bolt (4) and push the connecting plate (5) down. 6. Loosen the three eye bolts (6) and open.

  • Page 58: Check After Assembly And Before Each Operation

    300 Z 5.10 Check after assembly and before each operation Check the GEDA 300 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.

  • Page 59: Operation

    300 Z Operation Operation The 300 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 lifting gear.

  • Page 60: Commissioning

    Operation 300 Z Commissioning Main switch Control light, ready for operation Fig. 27: Ground station switch box Socket [blue] for ground control/manual control Socket [red] for electric module on the landing level doors (or dummy plug during assembly)  Turn the main switch to the "I" position [ON] .

  • Page 61: Safety Check Before Starting Work

    300 Z Operation 6.2.1 Safety check before starting work Perform a test run with an empty platform and check that the entire travel path of the platform is clear. The platform must immediately stop when • an EMERGENCY STOP button is pressed.

  • Page 62: Operation/Function

    Operation 300 Z Operation/function Fig. 29: Overview 1 Foot section with base mast Mast section 2 m (1 m) Stop bar lowest stop position Stop bar for UP-END limit switch Cable bin Anchoring tubes Load platform Trailing cable guide Assembly guard plate...

  • Page 63: Fig. 30: Overview 2

    300 Z Operation Fig. 30: Overview 2 Drive motor Switch box on trolley Safety gear Switch cabinet with main switch BL131 GB 2024-09...

  • Page 64: Functional Description

    Operation 300 Z 6.3.1 Functional description • The base unit can be extended with 0.7 m, 1.0 m and 2.0 m long mast sections up to a max. installed height of 50 m (230 V) / 100 m (400 V).

  • Page 65: Platform Access Ramp

    300 Z Operation • A mobile ground control is used for operation or only the assembly control in the platform is used during assembly. • Following scaffolding work, dismantle the hoist or equip it for further operation (install landing level safety gates).

  • Page 66: Securing The Lowest Stop Position (Ground Station)

    Operation 300 Z 6.3.3 Securing the lowest stop position (ground station) The lowest stop position must be secured and marked to prevent unauthorized access. DANGER Danger to life from lowering platform  Never remain inside the cordoned-off area during operation.

  • Page 67: Controls For Normal Operation

    300 Z Operation 6.3.4 Controls for normal operation 6.3.4.1 Ground control/manual control The platform can be summoned to the ground station from higher stop positions or moved up to a landing level using the ground control. The platform must be turned towards the trolley and engaged. The ramp must be closed and the assembly guard plate must be secured at the top.
  • Page 68 Operation 300 Z Selector switch (13) to "II" position (automatic travel) Travelling UP  Press and hold the UP button (3). → The platform moves in the lower safety area only while the UP button (3) is pressed.  After exceeding this safety area, release the UP button (3).

  • Page 69: Assembly Control/Maintenance Control

    300 Z Operation 6.3.5 Assembly control/maintenance control The platform must be turned towards the trolley and engaged. The ramp must be closed and the assembly guard plate must be secured at the top. For installation or maintenance, the platform can only be controlled with the dead man’s control.
  • Page 70 Operation 300 Z Travelling DOWN  Press and hold the DOWN button (7).  The platform moves only while the DOWN button is pressed and stops at the DOWN limit switch . WARNING Risk of injury from platform moving downwards ...

  • Page 71: Swivelling The Platform

    300 Z Operation 6.3.6 Swivelling the platform For loading and unloading, the platform has to be swivelled by 90° towards the scaffolding/building. Swivelling the platform out  Turn the swivel lever (2) down and swivel out the platform (1) towards the...

  • Page 72: Securing Loading And Unloading Points

    Operation 300 Z 6.3.7 Securing loading and unloading points To prevent persons from 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 2 m.

  • Page 73: Fig. 39: Unlocking The Landing Level Safety Gate

    300 Z Operation  Turn the key (1) to the right to unlock the sliding door (2A).  Push open the sliding door (2A). Fig. 39: Unlocking the landing level safety gate  Open the ramp of the platform.  The platform can be loaded/unloaded.

  • Page 74: Landing Level Module

    Operation 300 Z 6.3.8 Landing level module The landing level module must be installed on the landing level safety gates if local regulations specify electrical monitoring of the landing level safety gate or control from an upper stop position is required.

  • Page 75: Emergency Shutdown

    300 Z Operation 6.3.10 Emergency shutdown In situations that present a risk to operating personnel or the machine, the machine can be shut down by pressing an EMERGENCY STOP button. An EMERGENCY STOP button is located at each control point.

  • Page 76: Equipment

    Equipment 300 Z Equipment Standard push-in frame for the platform Transported items (e.g. scaffolding tubes) which are higher than the platform can be secured against falling over during transport with this device. Fig. 44: Push-in frame for scaffolding parts Tools required:...

  • Page 77: Special Push-On Frames

    300 Z Equipment Special push-on frames Fig. 45: Special push-on frames for scaffold components 1 / 2 Special push-on frames for safe transport of scaffold components Pipe bracket Tools required: 2 ring or open-jaw spanners - width across flats 13/17...

  • Page 78: Fig. 48: Assembly For Load Platform With Ramp 3

    Equipment 300 Z Assembly for platform with ramp 1. Assemble the lateral push-on frame (refer to chapter 7.1 Standard push-in frame for the platform, page 76) 2. Dismantle the fall protection lever (7) on the right-hand corner strut (4). → screw M 8 with compression spring Fig.

  • Page 79: Overrun Protection

    300 Z Equipment Assembly for load platform with door 1. Assemble the lateral push-on frame (refer to chapter 7.1 Standard push-in frame for the platform, page 76) 2. Remove the plastic cap from the corner strut (4). 3. Remove the top door hinge screws (4A) on the corner strut (4).

  • Page 80: Accessories

    Accessories 300 Z Accessories Spindle Spindle for easy alignment of the base unit. Spindles can be installed on the foot section. Fig. 51: Aligning the base unit with spindles Manoeuvrable bogie The transport frame facilitates manoeuvring at the construction site or storage area if no crane or forklift is available.

  • Page 81: Operating Hours Counter

    300 Z Accessories 3. Use the brake release lever to carefully lower the load platform. 4. While operating the brake release lever, tip the base mast backwards, then release the brake release lever. → When the unit is tipped forwards, the base unit will rest on the wheels.

  • Page 82: M Base Enclosure With Barrier

    Accessories 300 Z 1.10 m base enclosure with barrier With use of the base enclosure, the 300 Z meets the safety requirements specified in the standard. Fig. 53: 1.10 m base enclosure with barrier Height = 1.10 m Distance to moving hoist parts = min. 0.5 m / max. 2,0 m Opening ...

  • Page 83: Underrun Protection

    300 Z Accessories Underrun protection The underrun protection can be used as an alternative to the base enclosure. (Corresponds to the same safety level as the 1.10-m base enclosure.) For platforms with underrun protection, a barrier is sufficient for securing the ground station! Function: Protects the platform against damage from hitting obstacles.

  • Page 84: Cable Bin Cover

    Accessories 300 Z Cable bin cover For better protection against theft, a cover can be installed on the cable bin for the trailing cable. Assembly: Assembly of the cable bin cover is described in separate instructions. Fig. 55: Cable bin cover Single axle trailer A special single axle trailer is available for road transport.

  • Page 85: Maintenance - Checking - Cleaning

    300 Z Maintenance - Checking - Cleaning Maintenance - Checking - Cleaning Inspection schedule The inspections to be carried out on a daily basis before the start of operation are not included in the maintenance schedule. These are described in the Operation chapter in the instruction manual as these checks are carried out by the operating personnel.
  • Page 86 Maintenance - Checking - Cleaning 300 Z Mechanical components Platform from below Cable guides (threaded connections/rubber parts present) All covers fitted Motor brake Motors/gearboxes (oil leak/irregularities) Mast (threaded connections/deformation/cracks/wear) Mast brackets (threaded connections/flaking on building) Check that the gear rack is securely installed...

  • Page 87: Cleaning

    300 Z Maintenance - Checking - Cleaning Replacement intervals Replacing the impact buffers on every 3 years the foot section Changing the gearbox oil For replacement interval (refer to chapter 9.5.4 Motor/motor brake, page 100) Replacing the safety gear For replacement intervals refer to the assembly manual for the safety gear.

  • Page 88: Inspections

    Maintenance - Checking - Cleaning 300 Z Inspections Inspections prior to operation, recurring inspections and intermediate inspections must be carried out according to national regulations. During inspections, the relevant safety features of the hoist are checked by means of appropriate procedures according to the maintenance schedule or after specific incidents.

  • Page 89: Checks Before Initial Operation

    Recurring inspections must be carried out in accordance with national regulations. GEDA recommends that you carry out a recurring check at least once a year. In the event of increased use (e.g. multiple shift operation), carry out inspections at shorter intervals.

  • Page 90: Structural Testing

    Maintenance - Checking - Cleaning 300 Z During recurring checks, we recommend carrying out the drop test with the rated load (refer to the max. payload) of the loaded car. The drop test with rated load of the loaded platform/car should...

  • Page 91: Checks After Extreme Weather Conditions

    300 Z Maintenance - Checking - Cleaning 9.3.7 Checks after extreme weather conditions Special test after temperatures below -40 °C [-40 °F] If it is unclear if the temperature was below -40 °C [-40 °F] when recommissioning, proceed as if the temperature had been reached.

  • Page 92: Replenishment And Inspection Tasks

    Replenishment and Inspection Tasks 9.4.1 Lubrication of the gear rack/drive pinion CAUTION Increased wear If GEDA POWER GREASE is not used, higher wear can occur on the gear rack and drive pinion. Any warranty cover is therefore excluded. 9.4.1.1 Manual lubrication...

  • Page 93: Automatic Lubrication Device

    • Filling capacity: 1.2l [0.32 gall.] CAUTION Damage to the lubricant pump Do not use grease containing solid lubricants [z. B. GEDA POWER GREASE 7000]. This can damage the lubrication device.  Check gear racks for deposits every week.  Remove any deposits.

  • Page 94: Coating The Trailing Cable With Lubricant

    Recommended anti-friction lubricant • Talcum powder item no. B1156 CAUTION Increased wear of the trailing cable To prevent damage to the trailing cable, GEDA recommends using only this lubricant! Assembly  Shake talcum powder vigorously into the cable bin from outside the barrier/base enclosure.

  • Page 95: Gearboxes

    300 Z Maintenance - Checking - Cleaning 9.4.3 Gearboxes Check gearboxes at least every six months  Check for running noises that could indicate possible damage to bearings.  Carry out a visual check for leaks on the seals. Gearbox oil / change intervals...

  • Page 96: Checking For Wear

    Maintenance - Checking - Cleaning 300 Z Checking for wear WARNING Risk of injury from components failing  Parts must be replaced immediately if the specified wear limits are exceeded.  Hoist operation is prohibited until the parts have been replaced. All parts also have to be inspected for damage (deformation, cracks, cavities, etc.).

  • Page 97: Fig. 62: Wear Limit Rack

    300 Z Maintenance - Checking - Cleaning Gear rack Calculating wear Wear is calculated using a calibrated vernier calliper at the upper and lower end of the rack at 3 teeth respectively with the corresponding measuring pin. When checking the rack for wear, always carry out a visual inspection for cavities, flaking, groove formation/scoring and deformations.

  • Page 98: Gearwheels

    Maintenance - Checking - Cleaning 300 Z 9.5.2 Gearwheels Calculating wear Only use a calibrated vernier calliper to measure at three different locations within the visible wear area (1) (area of the gear wheel in contact with the gear rack).

  • Page 99: Track Rollers

    300 Z Maintenance - Checking - Cleaning Drive pinion/safety gear pinion Outer diameter: 83.6 mm Number of teeth: Module m: Wear limit Dimension X new 27.8 mm Dimension X min. 27.5 mm Fig. 69: Drive pinion Measure dimension X across two teeth (in at least three different locations) in the area in which wear is visible.

  • Page 100: Motor/Motor Brake

    Maintenance - Checking - Cleaning 300 Z Replacing the track rollers DANGER Lethal hazard from falling tools/objects  Secure tools/parts from falling during maintenance/assembly. Track roller installed with an eccentric shaft  Remove the screw (2) and track roller (1).

  • Page 101: Function Tests

    300 Z Maintenance - Checking - Cleaning Function tests 9.6.1 Overload adjustment The overload setting for the platform must be checked!  The load platform must not move, the red control light (1) on the trolley switch box must light up and an alarm signal must sound.

  • Page 102: Fig. 73: Releasing The Brake

    Maintenance - Checking - Cleaning 300 Z The main switch on the ground station switch box must be switched on (position "1" [ON]). The key switch on the platform must be set to “Operation” and the key has to be removed.

  • Page 103: Check The Safety Gear For Damage

    300 Z Maintenance - Checking - Cleaning Drop test not unsuccessful WARNING Risk of injury  Immediately replace the safety gear.  Operation of the hoist is prohibited until then. Ground control/manual control EMERGENCY stop button UP button DOWN button...
  • Page 104 Maintenance - Checking - Cleaning 300 Z DANGER Life hazard from incorrect repair of safety components  Repairs to the safety gear should only be carried out by the manufacturer. 1. Turn the main switch to the „0“ position. 2. Secure against switching on.

  • Page 105: Malfunctions - Diagnosis - Repair

    300 Z Malfunctions – diagnosis – repair Malfunctions – diagnosis – repair WARNING Risk of injury from incorrect troubleshooting and fault elimination  Troubleshooting and the fault elimination may only be carried out by persons specially trained and authorized for this purpose.
  • Page 106 Malfunctions – diagnosis – repair 300 Z Green control light off Is the DOWN limit switch Check/replace the DOWN limit functioning properly switch Platform only moves upwards Is the UP limit switch Check/replace the UP limit functioning properly switch Platform moved too high (refer to chapter 10.2.3 Platform has travelled too high,...

  • Page 107: Rectify Fault

    300 Z Malfunctions – diagnosis – repair 10.2 Rectify fault 10.2.1 Motor is not delivering full power • Voltage drop of more than 10 % of the rated voltage. • Select cable with larger cross-section. • The integrated thermal switches turn off the control current when overloaded.

  • Page 108: Platform Moved Too Low

    Malfunctions – diagnosis – repair 300 Z 10.2.4 Platform moved too low The platform moves too low, i.e. the EMERGENCY limit switch of the platform reaches the lower EMERGENCY STOP stop rail. Possible causes: • The brake clearance is too large.

  • Page 109: Overload Detection Device Has Triggered

    300 Z Malfunctions – diagnosis – repair 10.2.5 Overload detection device has triggered The material hoist is equipped with an overload warning device which prevents the platform from starting when it is overloaded. If the platform is overloaded, a red control light (8) on the platform lights up.

  • Page 110: Fig. 79: Resetting The Safety Gear

    Malfunctions – diagnosis – repair 300 Z Releasing the safety gear Downward travel is mechanically blocked by the safety gear and can be pressed again only after brief upward travel!  Release the lock nut (1) on the safety gear.

  • Page 111: Rescuing The Platform

    300 Z Malfunctions – diagnosis – repair 10.3 Rescuing the platform Rescue may become necessary in the event that, e.g. • there is no mains voltage. • the electrical system malfunctions. • the drive fails. • the safety gear has triggered.

  • Page 112: Rescue Action Plan

    Malfunctions – diagnosis – repair 300 Z 10.3.2 Rescue action plan Action 1: Check the EMERGENCY STOP button. It may have been actuated accidentally. 1. Unlock the EMERGENCY STOP button (1). 2. Press the UP- (3) or DOWN button (4) to continue travel.
  • Page 113 300 Z Malfunctions – diagnosis – repair CAUTION Risk of death due to inexpert maintenance The brake can become very hot. Free drop of the platform (until the safety gear is activated) when the motor brakes are fully opened.  The brake release lever must be operated extremely carefully to prevent the safety gear from engaging.

  • Page 114: Repair

    • Quantity required The name plate is located on the trolley of the base unit. Spare parts must conform to the manufacturer’s technical specifications! 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 1.4...

  • Page 115: Disassembly

    300 Z Disassembly Disassembly The same regulations and safety instructions apply to dismantling (refer to chapter 5 Assembly, page 33). Dismantling is generally carried out in reverse order to installation. Additionally observe the following instructions: • Dismantle the landing level safety gates first (mount the 3-part protection first).

  • Page 116: Disposal

    Disposal 300 Z Disposal At the end of its useful life, the machine may need to be inspected for operational safety in accordance with national regulations, disassembled correctly and scrapped in an environmentally friendly way according to national provisions. It is prohibited to use parts from a machine that is being scrapped in other machines or to assemble such parts to produce a new machine.

  • Page 117: Summary Of Instruction Signs

    300 Z Summary of instruction signs Summary of instruction signs Fig. 82: Item No.: 05242 (all Fig. 83: Item No.: 14657 switch boxes) Fig. 84: Item No.:33697(trolley) (trolley) Fig. 85: Item No.: 16688 (Manual Fig. 86: Item No.: 14523 (trolley switch box) control) Fig.

  • Page 118: Fig. 91: Item No. 14565 (Assembly Guard Plate)

    Summary of instruction signs 300 Z Fig. 92: Item No.16688 (manual control) Fig. 91: Item No. 14565 (assembly guard plate) BL131 GB 2024-09...

  • Page 119: Documenting The Checks

    300 Z Documenting the checks Documenting the checks Documentation for regular checks in accordance with the maintenance schedule recurring check in accordance with national rules unscheduled check after specific events Name: Serial number: Year of manufacture: The hoist was checked on ______________ .
  • Page 120 Documenting the checks 300 Z Documentation for regular checks in accordance with the maintenance schedule recurring check in accordance with national rules unscheduled check after specific events Name: Serial number: Year of manufacture: The hoist was checked on ______________ .
  • Page 121 300 Z Documenting the checks Documentation for regular checks in accordance with the maintenance schedule recurring check in accordance with national rules unscheduled check after specific events Name: Serial number: Year of manufacture: The hoist was checked on ______________ .
  • Page 122 Documenting the checks 300 Z Documentation for regular checks in accordance with the maintenance schedule recurring check in accordance with national rules unscheduled check after specific events Name: Serial number: Year of manufacture: The hoist was checked on ______________ .
  • Page 123 300 Z Documenting the checks Documentation for regular checks in accordance with the maintenance schedule recurring check in accordance with national rules unscheduled check after specific events Name: Serial number: Year of manufacture: The hoist was checked on ______________ .
  • Page 124 Documenting the checks 300 Z Documentation for regular checks in accordance with the maintenance schedule recurring check in accordance with national rules unscheduled check after specific events Name: Serial number: Year of manufacture: The hoist was checked on ______________ .
  • Page 125 300 Z Documenting the checks Documentation for regular checks in accordance with the maintenance schedule recurring check in accordance with national rules unscheduled check after specific events Name: Serial number: Year of manufacture: The hoist was checked on ______________ .
  • Page 126 Documenting the checks 300 Z Documentation for regular checks in accordance with the maintenance schedule recurring check in accordance with national rules unscheduled check after specific events Name: Serial number: Year of manufacture: The hoist was checked on ______________ .
  • Page 127 300 Z Documenting the checks BL131 GB 2024-09...
  • Page 128 GEDA GmbH Mertinger Strasse 60 86663 Asbach-Bäumenheim Tel.: +49 (0)9 06 / 98 09-0 Fax: +49 (0)9 06 / 98 09-50 E-Mail: info@geda.de Web: www.geda.de BL131 GB 2024-09...

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