Maintenance Manual

SAFETY AND
GENERAL NOTES

GOODS /
PASSENGER LIFT
GPL 25
GPL 40
GPL 40F
GPL 80F

Instruction: M:0.2 EN
Date: 09-03-23
Sign: JM
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 Instruction: M:0.2 EN
Date: 09-03-23
EN
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0 GENERAL PART
0.1 INTRODUCTION INFORMATIONS
0.1.1 DEFINITIONS
Maintenance:
All the necessary operations to ensure the safe and intended functioning of the installation and its components after the
completion of the installation and throughout its life cycle.
Maintenance includes:
A) lubrication, cleaning, etc.;
However, the following cleaning operations can be not considered as maintenance :
- cleaning of the external parts of the well,
- cleaning of the inside of the car;
B) checks;
C) passenger rescue operations;
D) the operations of setting and adjustment;
E) repair or changing of components which may occur due to wear or tear and do not affect the characteristics of the
installation.
The following are not considered as maintenance operations:
F) changing of a major component such as the machine, the car, the control panel, etc., or safety component
such as safety gear, etc., even if the characteristics of the new component are the same as the original;
G) replacement of the installation;
H) modernisation of the installation, including the changing of any characteristic of the installation (such as
speed, load, etc.);
I) rescue operations carried out by Fire Brigades.
maintenance organization:
Company or part of company where competent maintenance person(s) carry out maintenance operations on
behalf of the owner of the installation.
competent maintenance person:
a designated person, suitably trained (see EN ISO 9000 series), qualified by knowledge and practical
experience, provided with necessary instructions and supported within his maintenance organization to enable
the required maintenance operations to be safely carried out
manufacturer: Natural or legal person who takes responsibility for the design, manufacture and placing on the
market either of lifts.
installer:
Natural or legal person who takes responsibility for the design, manufacture, installation and placing on the
market of lifts
owner of the installation:
Natural or legal person who has the power of disposal of the installation and takes the responsibility for its
operation and use
rescue operation:
Operation starting after receiving notification of a person(s) trapped in a lift and finishing by releasing the
trapped person(s)
0.1.2 SYMBOLS USED
NOTE
Indicates information which contents must be seriously taken in consideration.
WARNING
Indicates that the described operation is likely to cause, damages to the system or physical damages if
performed without complying with the safety standards.
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0.2 DOCUMENTS RELATED WITH MAINTENANCE

The documents to use for the maintenance of the lift are those required by the EN81-2:1998 and by the rules in
force, particularly the following:
- THIS LIFT MAINTENANCE MANUAL
- THE INSTALLATION MANUAL
· A provided book according with EN81-2:1998 16.2, which should contain:
- INSTALLATION PROJECT DRAWS (EN81-2:1998 16.2.A.5).
- W IRING AND HYDRAULIC DIAGRAMS (EN81-2:1998 16.2.A.6 AND 7).
- PERIODICAL AND EXTRA MAINTAINING CHECKS RESULTS (EN81-2:1998 16.2.B).
- DATED COPIES OF EXAMINATIONS AND INSPECTIONS REPORTS, WITH OBSERVATIONS (EN81-2:1998 16.2.B).
- DECLARATION OF CONFORMITY COPY
- COPY OF THE LIFT ACTIVATION REQUEST, THAT, ACCORDING TO LOCAL LAWS, OWNER OR LEGAL
REPRESENTATIVE SEND TO THE PROPER OFFICE,
- COPY OF THE LIFT ACTIVATION COMMUNICATION, WITH REGISTER NUMBER, THAT THE PROPER OFFICE ,
ACCORDING TO LOCAL LAWS, SEND TO OWNER OR LEGAL REPRESENTATIVE
All the documentation for a correct and safe maintenance of the lift, must be stored by the installation
responsible.
Please remember that this documentation is considered part of the plant and must be complete, well stored and
unabridged in every part.
In order to maintain the readability, the documentation shouldn’t be damaged and shouldn’t have missing parts.
Moreover, do not tear or deteriorate sheets during consulting.

0.3 SAFETY PRECAUTION DURING MAINTENANCE

0.3.1 MAINTENANCE ADVICES
For a correct and safe maintenance of the plant, it is advisable to follow this safety precautions:
· Always wear the necessary individual protection devices (IPD) (particularly see Fig. 0.1)
· Never wear draping clothes and/or objects (necklaces, watches, tie…)
· Not let long hair free.
· Do not keep cutting or sharp object in the shirt-pocket (screwdriver, scissors…).
· Do not tamper with, damage or hide the warning shields/labels: in case of wear replace immediately.
· To lift heavy weights, always use adequate devices, to limit the damage to the spine.
WARNING
Before start all kind of maintenance operation.
ALWAYS verify that al the safety devices, mechanical or electrical, are active and working properly.
Fig. 0.1 - Individual Protection Devices (IPD)

Overall closed on wrists Helmet

Safety belt Gloves

Hearing protection Safety shoes

0.3.2 TOOLING
Use standard building-yard tooling for the maintenance of the plant.
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0.4 GENERAL ORDERS

The installations shall be maintained in good working order in accordance with the European Standards.
To this effect, regular maintenance of the installation shall be carried out, to ensure, in particular, the safety of
the installation.
The safety of an installation shall take into account the ability to be maintained without causing injury or
damage to health.
Regular maintenance of the installation shall be carried out to ensure the reliability of the installation.
The access and the associated environment shall be maintained in good working order.
The competence of the maintenance person within the maintenance organization shall be continuously
updated.
Note
We inform the owner of the installation that the qualification of the maintenance organization needs to
be in conformity with the rules applicable in the country in which the installation operates; if no rules
exist, the qualification can be ensured by a certified EN ISO 9001 quality system supplemented if
necessary to take into account the specific features of the installation.

0.5 GENERAL INFORMATIONS

0.5.1 INFORMATION TO THE OWNER OF THE INSTALLATION
It’s necessary for the owner :
A) to keep the installation in a safe operating condition.
- To obtain this the owner shall use a maintenance organization complying with the requirements of the
Standard and with adequate and proper insurance cover.
B) to take care of any regulations and other requirements, where relevant, and their implications on
maintenance.
C) for planned maintenance to carry out by a maintenance organization, when the installation is put into
service or if the installation is to remain unused for a long period of time.
D) to have the same maintenance organization in the case of several installations having common well/spaces
and/or machine room.
E) to keep the two-way means of communication efficient and linked to a 24 hours rescue service for the
whole of the time that the installation can be used, as described in prEN 81-28.
F) to remove the lift from service:
- when the two-way means of communication is out of order.
- in case of dangerous situations.
G) to inform the maintenance organization:
- immediately about any abnormal operation of the installation
- about any abnormal change in its direct environment
- immediately after putting the installation out of service in the case of a dangerous situation
- after any rescue
- before any modification related to the installation and/or its environment or use
- before any third party inspection or works other than maintenance works are carried out on the
installation
- before taking the installation out of service for a prolonged period of time
- before putting the installation back into service after a prolonged period of non operating time.
Note
The owner of the installation should obtain from the company carrying out the relevant modification the
maintenance instructions for the maintenance organization.
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H) to take into consideration the consequences of the risk assessment carried out by the maintenance
organization.
I) to make sure that the risk assessment for maintenance is carried out:
- if the maintenance organization is replaced
- if the use of the building and/or the installation changes;
- after a major modification of the installation or of the building
- after an accident involving the installation.
J) to ensure, through a risk assessment, that :
- their premises are safe and free from risk to health as far as is practicable. This includes access to the
premises and installation equipment, and articles or substances used according to the regulation for the
use of work equipment at the workplace
- the persons using the premises are informed about any remaining risks
- any action to be done as a consequence of his risk assessment is carried out.
K) to inform the maintenance organization, regarding the access ways to areas reserved to maintenance
persons, about:
- the access ways to be used and fire evacuating procedures from the building
- the place where the keys of the reserved areas can be found
- if necessary, the persons who shall accompany the maintenance persons to the installation
- if necessary, personal protective equipment to be used in the access ways, and, possibly, where this
equipment can be found.) the informtion shall be made available also on site to the maintenance
organization.
L) the information shall be made available also on site to the maintenance organization.
M) o ensure that the name and the telephone number of the maintenance organisation are always available to
the user of the installation, permanently affixed and clearly visible.
N) to ensure that the keys of machine and pulley room doors (trap doors) and of inspection and emergency
doors (trap doors) are permanently available in the building and are used only by persons authorized to
gain access
O) to provide, in all circumstances, safe access to the building and to the installation for the maintenance
organization
P) to keep the access to working areas and working rooms safe and free for the maintenance persons
Q) to inform the maintenance organization about any hazard or change in the workplace and/or the access ways
(lighting, obstructions, ground conditions, etc.)
R) to carry out periodically, in his own interests, in addition to those examinations and tests entrust to the
maintenance organization, the following:
- A full ascent and descent to assess any changes in the quality of the ride or damage to the equipment.
Typical items to be checked to ensure that they are in place, undamaged and functioning correctly are:
- landing doors and bottom door tracks
- stopping accuracy
- indicators that are not located in a reserved area
- landing push controls, car push controls, door open controls
- two-way means of communication in the car which provides permanent contact with a rescue service
- normal car lighting
- door reversal device
- safety signs/pictograms.

0.5.2 INFORMATION FOR THE MAINTENANCE ORGANIZATION

It’s necessary for the maintenance organization :
A) to carry out the work of maintenance in conformity with the maintenance instructions and based on
systematic maintenance checks.
- After these checks, the maintenance organization shall decide in conformity with the maintenance
instructions what is required to be done
- A list of typical examples of maintenance checks to maintain the installation is shown in annex A.
B) to update the original maintenance instructions if the installation changes its intended use and/or the
environmental conditions existing on the completion of the installation.
Note
The maintenance organization should be provided by the owner of the installation with the relevant
maintenance instructions where modifications are carried out on the installation.
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C) to ensure that a risk assessment for any working area and for any maintenance operation has been carried
out taking into account the installer's maintenance instructions and all information supplied by the owner of
the installation.
D) to inform the owner of the installation about any work to be carried out as a consequence of a risk
assessment especially for the access and/or the environment related to the building/installation.
E) to carry out a maintenance plan so that preventive maintenance is suitable for the installation and
maintenance time is as short as reasonably practicable, without reducing the safety of persons, in order to
minimize the non-operational time of the installation.
F) to adapt the plan for maintenance so as to take account of any predictable failures, e.g. those due to
misuse, mishandling, deterioration, etc.
G) to carry out maintenance operations by competent maintenance persons and provided with the necessary
tools and equipment.
H) to maintain the competency of maintenance persons.
I) to carry out the maintenance periodically.
J) to provide a 24 hour, all year round call-out service for rescue of persons
K) to keep records of the result of each intervention due to a failure of the installation.
- These records shall include the type of failures in order to detect any repetition. They shall be available
to the owner of the installation on request.
L) to put out of service the installation if the maintenance organization is aware of a dangerous situation,
detected during the maintenance, which cannot be eliminated immediately, and to inform the owner of the
installation of the need to keep it out of service until repaired.
M) to be organized to provide the necessary spare parts for any repair
N) to ensure the attendance of a competent maintenance person, given reasonable notice, for any inspection
carried out by an authorized third party or for building maintenance works to be carried out in the areas
reserved for the maintenance organization.
O) to inform in due time the owner of the installation about necessary progressive upgrading of the installation.
P) to organize rescue operations, even with subcontractor, and to make provision for circumstances such as
fire, panic, etc.

ANNOTAZIONI
"
 Instruction: M:0.2 EN
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Maintenance Manual

MAINTENANCE OPERATION

GOODS /
PASSENGER LIFT
GPL 25
GPL 40
GPL 40F
GPL 80F
VL 30 & VL 35
 Instruction: M:0.2 EN
Date: 09-03-23
EN
Sign: JM
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1 MAINTEINING OPERATIONS
1.1 PROGRAMMED MAINTENANCE
For a correct and safe lift use, it is necessary to make a preventive programmed maintenance, following a fixed
plan.
To define the periodical maintenance frequency, you should consider more events, particularly :
- Number of travel per year
- Travelling and stopping periods
- Age and condition of the lift
- Site and type of the building in which the lift travel
- Passengers and goods demand
- Inside and outside working condition (climate, vandalism, etc.)
In the next table, parts are shared in groups and for each group is shown the type of check and its longest
frequency recommended. Checks operative instructions are detailed in the maintenance schedules on chapter.
Please, note that all checks are applicable only if the part is really installed.

1.2 PERIODICAL MAINTENANCE AND CHECKS TABLE

OPERATION CHECKS RECOMMENDED MAXIMAL FREQUENCY
I. Group : General checks INSTALLATION 6 MONTH 5 YEARS
I.a General cleaning þ þ
II. Group : Guide rails and pit elements INSTALLATION 6 MONTH 5 YEARS
II.a Grease guide rails þ þ
II.b Guide rails verticality þ þ
II.c Buffers þ þ
II.d Pit cleaning þ þ
III. Group : Car frame INSTALLATION 6 MONTH 5 YEARS
III.a Shoes þ þ
III.b Cleaning þ þ
IV. Group : Power unit and jack INSTALLATION 6 MONTH 5 YEARS
IV.a Valve gaskets seal þ þ
IV.b Oil level check up þ þ
IV.c Characteristics of the oil þ
IV.d Motor protection operation þ þ
IV.e Filters þ þ
IV.f Pressure check þ þ
IV.g Pressure gauge shut off (6) þ þ
IV.h Pressure test (static pressure x2) þ þ
IV.i Ball valve seal þ
IV.j Labels, signs and schemes þ þ
IV.k Overall check-up þ
IV.l Jack and Chain wheels þ þ
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V. Group : Doors and operator INSTALLATION 6 MONTH 5 YEARS

V.a Landing locks and landing doors þ
V.b Landing doors and car door working þ
V.c Coupling landing doors and car doors þ
V.d Chains and belts þ
V.e Door shoes and hanger rollers þ
V.f Safety edge þ
V.g Photocells þ
VI. Group : Other components INSTALLATION 6 MONTH 5 YEARS
VI.a Ride quality þ
VI.b Relevelling þ
VI.c Pushbuttons and signals þ
VI.d Communication devices þ
VI.e Emergency floor return þ
VI.f Emergency operation þ
VI.g Labels and schemes þ
VI.h Travelling cables þ
VI.i Control panel grounding þ

1.3 MAINTENANCE SCHEDULES

I. Group : General checks
What to do:
I.a General cleaning
- Check, for their correct working, all components are sufficiently clean and kept free from corrosion and stay in
good conditions.
· Change or restore all components that don’t work properly.

II. Group : Guide rails and pit elements

What to do:
II.a Grease guide rails
- Lubricate the guide rails, eliminate excess from the end of the guides
- Check level and correct working of guide lubricator. (if installed)
- For the lower piece of guide, lubricate directly from the pit.
II.b Guide Rails Verticality
- Use a template to check guides verticality and their position.
- Check all the bolts are well tights to fishplates and guides.
II.c Buffers
- Make sure that the buffers are placed into the original position and that they are not damaged.
- Check, for safety, fixing of the supports and the basements of the buffers
II.d Pit cleaning
· At the operations end check the pit area is clean, dry and free from debris
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III. Group : Car frame

What to do:
III.a Shoes
- Check preservation, wear and free from dust of the car guide shoes, car frame and pulley-frame.
III.b Devices Cleaning
- Check all elements are well oiled and free in their movements
· Replace or restore all the components not correctly working.

IV. Group : Power unit and jack

What to do: (see Fig. 1.3.1)
IV.a Valve gaskets seals
- At the end of installation, and during check-ups, verify the gasket seals, in
the following way: with the oil at room temperature close the ball valve (B)
and open the pressure gauge shut off (6). Check that the pressure gauge
reading on pressure gauge should not drop more than 4 bar in 5 minutes.
IV.b Oil level check-up.
- With the elevator at the highest floor, check, using dipstick (F) or level
indicator (L), that the oil level is above the minimum level and (the motor
should be fully covered in oil).
IV.c Oil Characteristics
- Check visually that no change are occurred in the oil conditions. Perform
this check after leaving the system down for a few hours. Once every year
it should be better to discharge a little amount of oil from cap (J) and to
check if it’s clean. If oil is not clean keep on discharging oil until you see to
flow clean oil.
IV.d Motor protection functionality
- Disconnect one terminal of the thermistors, and check that the motor
protection working properly.
IV.e Filter
- Check the main filter (FIL) mounted inside the silencer and clean it if is
Fig. 1.3.1- Pump unit
necessary.
Scheme
IV.f Pressures check
- Check static and dynamic (working) pressure at the end of installation. Check regularly that all values
of these parameters remain unchanged.
IV.g Pressure gauge shut off (6)
- Close the ball valve (B), open the pressure gauge shut off (6) and fully discharge the pressure using
electro-valve (VMD). Close the pressure gauge shut off (6) open the ball valve (B) and check that the
level shown on pressure gauge is zero.
IV.h Pressure test (static pressure x2)
- This test assures you about the integrity of parts under pressure, including those which can not be
visually checked.
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To correctly carry out this test follow these instructions and make reference to Fig. 1.3.1 and Fig. 1.3.2:
- Close the pressure gauge valve (6)
- Close the ball valve (B).
- Remove the pressure gauge (MAN).
- Connect the hand pump (M) in place of the pressure gauge (G1/4) as
shown on Fig. 1.3.2.
- Open the pressure gauge valve (6)
- Open the ball valve (B).
- Open the hand pump valve (N) for about 1 minute.
- Close the ball valve (B)
- Operate the hand pump (M) until the required pressure is reached,
checking it on hand pump pressure gauge (O).
- At the end of the test, discharge the pressure to zero by pressing the
push-button on (VMD) (see Fig. 1.3.1) using a screwdriver.
- Close the pressure gauge shut off (6) Fig. 1.3.2 - Components for
- Disconnect the hand pump (M) testing static pressure x 2
- Mount the pressure gauge (MAN).
LEGENDA:
IV.I Ball valve seal M – Hand pump
- Close the ball valve (B) and open the pressure gauge shut off (6). Fully N – Manual pump valve
discharge the pressure-using valve (VMD). check that the level shown on O – Pressure gauge
pressure gauge (MAN) is zero. P - Pump connection
Q - Copper washer
IV.j Labels, signs and schemes
- Check that all the tags and diagrams are in place and legible (oil data label, emergency operation
manual, electrical diagram and hydraulic power unit schemes).
IV.k Overall check-up
- Perform an overall check up of the power unit. When the overall check-up ends, check all the settings
for the power unit start-up.
IV.l Jack
- Check level in drip tray / plastic can, empty if needed.
- If needed re-tighten stop screws on the flanges (only 2, 3 and 4 stroke jacks)
- Control the status on the chain wheels and replace them if necessary.
- Clean with rag.
· Replace or restore all the components not correctly working.
NOTE
In case of oil replacement, do not throw the oil away in the environment, but give it to oil recycling
company.
NOTE
When the power unit in no longer required, don’t throw it away, but give it to a recycling company or to
the manufacturer.

V. Group : Operator and doors

What to do:
V.a Landing locks and landing doors
- Check that all the operator close contacts and landing doors are clean and working.
- Check the correct working of all the landing locks, performing the manual operation on the lift roof to let
the car travel up and down.
V.b Landing Doors and car doors working
- Check that the safety unlocking triangle work properly.
- Check correct operation at every floor and check if they are damaged.
- Check the doors opening and closing, they should be:
A) frictionless
B) quiet
V.c Coupling floor doors and car doors
- Check that the lock rollers couple correctly with the operator
- Check the good working of landing door lock and make sure that they are perfectly set.
- Oil the door-stop.
V.d Chains and belts
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- Check that belt and chain are tensioned and are not wear, check rope and cables integrity.
V.e Doors shoes and hanger rollers
- Check that are not wear
V.f Safety edge (if fitted)
- Check that the device works properly.
V.g Photocells
- Check that the photocells works properly
· Replace or restore all the components not correctly working.

VI. Group : Other components

What to do:
VI.a Ride quality
- Observe the car while is travelling and for each floor check (on upward travel and downward travel):
A) Acceleration; B) Slow down; C) Stop; D) Quietness; E) Frictionless.
VI.b Revelling
- Check the relevelling for each floor: perform the descent manual operation to check that the electrical
circuit and the relevelling contacts work properly.
VI.c Pushbuttons and signals
- Check that the pushbuttons and signals in car and at all landing floor are working.
VI.d Alarm and intercommunication devices
- Check that the intercommunication and the alarm devices are working properly.
VI.e Emergency floor return
- Check that the emergency light, the floor return device and the open doors device (if installed) work
properly in case of power failure.
VI.f Emergency operation
- Perform an emergency operation every year to check that all the elements work properly, according to
the instructions included in the use manual.
VI.g Labels and schemes
- Check the entirety and easy finding of warning signs, schemes signs and system documents..
VI.h Flexible cable
- Check cables wear and replace them when necessary.
VI.i Control panel and electrical wiring
- Verify that control panel and all electrical wiring are dry, free from dust and correctly insulated and
grounded
· Replace or restore all the components not correctly working.