Shanghai Zhenhua Port Machinery Longchan

SHANGHAI ZHENHUA PORT MACHINERY
LONGCHANG LIETING RIG CO.,LTD Elevator Manual
ZPMC Elevator
Installation, Operation and Maintenance Manual
LONGCHANG LIFTING EQUIPMENT CO., LTD.

SHANGHAI ZHENHUA PORT MACHINERY (GROUP) CO., LTD.
Company address: Gate 4, Zhenhua Port Machinery, No.3800, Pan Garden Highway,
Changxing Island, Chongming County, Shanghai
Company tel.:021-56858559 E-mail:wangyan@zpmc.net
Page 1 of 36 pages
TABLE OF CONTENTS
1. DESCRIPTION Page 3
2. BRIEF TECHNICAL DESCRIPTION Page 3
3. IMPORTANT SAFETY INSTRUCTIONS Page 3
4. EXPLANATION ON ALLOCATION OF TYPE TO LIFT Page 8
5. TECHNICAL DATA AND SPECIFICATIONS Page10
6. DESCRIPTION OF TECHNICAL FEATURES AND STRUCTURE Page 10
7. INSTALLATION AND COMMISSIONING Page 19
8. RUNNING TEST Page 29
9. OPERATING PROCEDURE Page 31
10. SERVICE AND MAINTENANCE Page 32
11. COMMON TROUBLES AND CORRECTIVE SOLUTIONS Page 35
Page 2 of 36 pages
1. DESCRIPTION
Before use of this lift, the customer must carefully read this instruction. The installation,
commissioning, maintenance and service of the lift must be performed by the personnel
who have received special training or by the experts sent by Lift Plant.
All the figures used herein are not for production purposes and just serve as explanations
and directions.
2. BRIEF TECHNICAL DESCRIPTION
This lift employs the frequency conversion and transformation speed governing system,
having compact structure and reasonable configuration and making the passengers feel
stable and comfortable and nicely solving the problem of protection of the traveling cable
from being against wind.
This lift is mainly intended to operate on the container cranes, dock-side portal cranes,
tower cranes or buildings.
3. IMPORTANT SAFETY INSTRUCTIONS
Before installation, use, maintenance and service of the lift, the customer must to the best
of its capabilities understand the safety rules and regulations. The operators must be
familiar with and seriously observe the contents of this section.
3.1 General Safety Responsibilities
Each operator using the lift must take the responsibilities and obligations for safety.
During the operation, the operators must always bear safety consciousness and the sense
of the safety responsibilities and strictly observe the following regulations.
a. The operators must hold the on-job certificate for safety operation.
b. The operators must quickly react, be imperturbable and make no mistakes.
c. The operators must be familiar with the operating instructions and safety instructions.
d. The operators must understand how to use the safe equipment and assure the safe
equipment act accurately and always in good working condition.
e. The operators must conduct the necessary maintenance and service on the lift on a
regular basis.
f. The department using the lift must educate and train the operators on safety and
operation.
3.2 Requirements for Safety in Installation Period
Page 3 of 36 pages
3.2.1 Responsibilities
Customer and manufacturer assume all the responsibilities for safety, the performance
of the responsibilities shall be on the basis of the state or the local safety law and
regulations as well as conventional prevention measures. Before erection of the lift,
the personnel concerned must carefully study the safety regulations specified herein,
or the dedicated personnel must be authorized to monitor and manage the erection
work where necessary.
3.2.2 Safety Measures Taken during Installation

a. The sufficient area shall be available for operation in the erection site.
b. Keep the work area clear and free of obstructions, transportation convenient, and the
necessary installation equipment available.
c. The lift must not be erected in wind speeds exceeding 15m/sec..
d. During installation and commissioning, no other personnel are allowed to operate the
lift except for the authorized persons.
e. No persons are allowed to stand on the lift car or under the suspended load.
f. When working inside the safety enclosure or between the rails, the power supply
must be cut off.
g. The Emergency Stop button must be depressed when working on the top of the car.
h. After completion of work, make sure that the power supply is cut off.
i. Can the lift be started only after making certain that all the bolts are reliably and
securely tightened.
3.2.3 Safety Measures Taken After Installation

Can the lift be put into service only after it has been tested and accepted by the
relevant authority according to the state and local law and regulations.
3.3 Acceptance Test
In order to ensure that the lift runs safely, can it be put into service only after it has been
subject to the acceptance test in all aspects following the completion of the installation.
The content described in this section serves as reference when the customer tests and
accepts the lift. The test personnel or other special personnel designed by the department
concerned must witness the acceptance test.
3.3.1 Test and Inspection of Overall Installation

The overall installation must be performed according to the instructions regarding all
aspects outlined in this instruction, the test and inspection of the overall installation
covers the following aspects:
3.3.1.1 Lift Car

a. The dimensions and materials of the car must meet the requirements specified.
b. The door interlock device must function safely and reliably and move freely.
c. The strength of the car carriage must be sufficient; the accuracy of the position must
Page 4 of 36 pages
be able to ensure the precision running clearance.

d. The car door must be opened and closed freely without retarding.
e. The roller guide shoe must be installed in the right position and move freely.
f. The safety enclosure on the top of the car must meet the safety requirements.
g. The protection of the entire lift car must meet the requirements specified and free of
rust and corrosion and leakage of rain.
3.3.1.2 Guide Rail

a. The bottom frame supporting the guide rail must have sufficient bearing capacity.
b. The guide rail must be correctly installed, all the sections are precisely end-to-end
jointed and the bolts are firmly secured.
c. The linearity and verticality of the guide rail over the full length must meet the
requirements specified.
3.3.1.3 Traction Machine

a. The traction machine must be installed in the correct position.
b. The traction machine must always be in good working condition, the brake acts
precisely and the braking moment of force meets the requirements specified.
c. The redactor does not leak.
3.3.1.4 Landing Door and Safety Railing

a. The landing door must be installed firmly and reliably in the right position without
deflection.
b. The interlock device of the landing door must meet the requirements specified.
c. The landing door must open and close freely without jamming.
d. The safety railing must meet the requirements regarding the height and strength and
be installed securely and reliably.
3.3.1.5 Traveling Cable

a. The traveling cable must be reliably secured at both ends.
b. The trolley protecting the cable must be installed tidily and no mismatch and loose is
allowed.
c. The cable must move freely inside the cable chute without scratching and touching.
3.3.1.6 Control System

a. The whole control system must be in good working condition and the protective
grade meets the specified requirement.
b. The controlling device must be installed in the right position enabling to work safely
and be convenient for maintenance.
3.3.1.7 Buffer System

The buffer spring is reasonable in its strength and be able to restore to its original state
after compressed.
3.3.2 Test and Inspection of Safety
Page 5 of 36 pages
After the overall installation has successfully passed the test and inspection, at least the
following checks must be performed to ensure that the lift operates safely:
3.3.2.1 Safety Device (Over-speed Governor – Safety Gear)

a. Over-speed governor—safety gear is correctly installed.
b. The gate of the safety gear, the rope duct of the over-speed governor must be free of
smear.
c. According to the requirement of the instructions, no-load over speed test must be
conducted once with the lift approximately 4m away from the main landing. The lift
runs downward by acting the over-speed governor manually. During the test, no
person is allowed inside the lift car.
d. After the over-speed governor has acted, the safety gear is able to make the car
braked and stopped, and in the meantime, the control electric circuit is cut off.
3.3.2.2 Over landing limit protective device acts agilely, precisely and reliably.
3.3.2.3 Indication Plate, Warning Plate and Instructions

a. The indication plate and warning plate must give the adequate instructions and the
safety instruction of the lift is right and usable.
b. The operators must read and understand the instructions as well as the instructions
shown on the warning plate and indication plate.
3.3.2.4 Running Test

a. No-load: over the full distance, reciprocating three times, it runs smoothly with the
floor correctly selected and the leveling accurately.
b. Rated load: over the full distance, reciprocating three times, it runs reliably and
smoothly with the accurate leveling.
c. Over load: take 125% of the rated load, running twice over the full distance, it runs
normally.
3.3.2.5 The results of the acceptance test and check must be recorded on the test report
which should be forwarded to the customer of the lift. The record must cover all the
problems discovered during the check and state the requirements. And the problems must be
solved before the lift is put into service.
3.3.3 Safety Measures Taken during Acceptance Test and Check

During the acceptance test and check, it is extremely important to ensure the personnel
safety by harmonious and coincident action and centralized and uniform direction, the test
of the safety device must be performed with no persons inside the lift car and on the
landing.
3.4 Periodic Inspection and Test
Page 6 of 36 pages
3.4.1 Inspection and Test Requirements

The periodic inspection and test of the lift must meet the local safety law, regulations.
In case of no such regulations to follow, the inspection and test must be performed at least
every three months and the test must cover the followings:
3.4.1.1 Responsibilities
Customer must assure that the periodic inspection and test is performed normally to
ensure the safety of the passengers in the lift.
3.4.1.2 Inspector
The full time person must be appointed to do such a job.
3.4.1.3 Safety Measures Taken during Inspection and Test

The safety measures must ensure the safety of the persons who directly access and
touch the lift and the test of bearing capacity and the inspection of the safety device must be
conducted with no persons inside the car and on the landing.
3.4.1.4 Check and Test of the Whole Body

All the parts on the equipment must be checked to ensure that they are safe and usable
and the check must meet the requirements of the maintenance and service regulations. The
defect parts must be replaced with new ones.
3.4.1.5 Inspection and Test of Safety Device

The inspection and test of the safety device shall be performed according to the
instructions on the overspeed test provided by this instruction. For the purpose of safety, be
sure that:
a. Prior to the overspeed test, the brake of the traction machine is in good condition.
b. Prior to the overspeed test, the lift shall be driven to a safety height to ensure the
buffer is not to be impacted.
c. During the test, make sure that no person is inside the car.
d. After each test, the safety device must be returned to the original state.
3.5 Daily Safety Check
In order to ensure that the lift operates safely, the customer must make certain that the
daily safety check be conducted every day.
3.5.1 Important Safety Measures during Daily Safety Check

a. Do not operate the lift in the wind speed exceeding 20m/sec..
b. Do not start the lift before making certain that the periodic check and maintenance
and service is performed.
c. Do not operate the lift unless it is ascertain that there is no obstruction in the lift rail
and nobody is working near by.
d. Operate the lift only after the safety check of the car is performed on the ground
Page 7 of 36 pages
landing.
e. Be very careful when conducting the safety check on the moving lift.
3.6 Safety Operation
Customer must take the responsibility for the safety in operation. Operators must
diligently study the section ―Operation‖ of ―Operating Procedure‖ before operating the lift.
Never forget the following safety measures in operation:
a. Overload is never allowed, the number of the passengers must correspond with that
specified on the nameplate.
b. It is not allowed to transport the goods on the top of the lift car.
c. Operate the lift only when making sure that all the protective devices work normally.
d. Nobody is allowed to stand on the top of the lift car when the lift is running (other
than repair).
e. Report the problem and the hidden safety trouble to the relevant department in a
timely manner.
3.7 Safety in “Maintenance and Service” and “Replacing parts”
a. Can ―Repair‖, ―Replacement‖ be done only after the power supply is cut off or the
emergency stop button is depressed.
b. When changing hoist ropes, lower the car onto the buffer spring at the bottom, the
counterweight should be hung up by manually pulling jib chain hoist or by means of
other lifting tools.
4. EXPLANATION ON ALLOCATING TYPE TO LIFT
The type of the lift is shown on the nameplate inside the lift car, where,
The first capital letter ―T‖ represents the lift
The second capital letter ―K‖ represents the passenger lift.
The third capital letter ―J‖ represents Alternating Current.
The digit following ―J‖ represents the load capacity (kg).
The capital letter following the digit represents the major improvement sequence
SSD in the parentheses represents that the transmission of the steel hoist ropes of the
lifting machine for the construction has the counterweight.
The digit following the slash represents the speed (m/s).
The capital letter A following represents button-operated.
The capital letter S represents manually operated door.
For example: TKJ (SSD) 400A/1.0-AS means:

Button-type manually operated door AC passenger lift, speed 1.0m, load capacity
400kg, the first improvement derived from the lift type TKJ (SSD) 400/1.0-AS.
Page 8 of 36 pages
Fig. 1
Page 9 of 36 pages
5. TECHNICAL SPECIFICATIONS (See Table 1)
Rated capacity kg 400,500

Rated number of persons 3 persons, 4 persons or 5 persons
Rated speed m/s 0.5,1
Rated voltage, frequency 380V,50Hz; 440V, 60Hz
Power of traction motor kW 5.5kw,7.5kw
The internal dimension of the car 10008002150 100010002150 as
required by customer
Width  height of the door 6502000
Traveling height of the lift As required by customer
Number of the landings As required by customer
6. DESCRIPTION OF TECHNICAL FEATURES AND STRUCTURE
The environment where the lift is used relies on its own technical features. Since it is
erected along with the bank-and-bridge crane at the dock of the river and the sea, the
moisture and salt spray environment requires it possess very strong corrosion resistance
property. According to this requirement, all the parts (except for aluminum alloy, stainless
steel parts) have been subject to corrosion protection treatment so it is the desirable lift to be
used outside.
The product consists of the two parts, which are metal structure, and electrical devices.
6.1 Metal Structure
The metal structure comprises bottom frame, safety netting, landing door, car, guide rail,
traveling cable and protecting chute, counterweight, traction machine, overspeed brake
system, buffer device, etc..
6.1.1 Bottom frame

The bottom frame is the place where the lift guide rail is connected with the foundation
and the buffer is located for the car, which bears all the impact force when the car is
descending toward the bottom.
6.1.2 Landing Door and Safety Netting (See Fig. 2)

The landing door and the safety netting form a sealed space.
The landing door is the entrance of the car. The landing door and the car are
mechanically and electrically interlocked. The interlock makes it impossible to open the
landing door unless the car is at that landing and because of the electrical interlocking
system the car will stop at once if the door is opened or will not start unless the door is
closed.
The safety netting plays the function of the protection. The safety netting and the
Page 10 of 36 pages
landing door form the space which makes it possible that the people cannot touch the
moving car when they are standing in any location of the landing and cause no danger to the
people when the car is passing through any landing.
Fig 2
6.1.3 Car and Car Frame
6.1.3.1 Car (Fig. 3)
The car is installed on the car frame and the area of the car is determined as required by
customer providing that the standard is met. There are two kinds of structure of the car,
which are the metal frame and stainless steel setting up type and the upper and lower parts
are sealed with textured aluminum sheet. The car can come equipped with one bi-folding
door, which is electrically and mechanically interlocked. There is a trapdoor in the car roof
so that the inspection persons can easily access the roof to do inspection and repair or it
serves as the emergency exit for the passengers to escape from the car in case of the lift
being in trouble.
Page 11 of 36 pages
Fig.3
6.1.3.2 Car frame (Fig. 4)
Page 12 of 36 pages
The car frame is the frame structure welded with the channel steel sections, and the four
ends of the car frame are equipped with the roller guide shoes, which are driven by the
traction machine to run along the guide rail. On both sides of the car frame on the lower part
are installed two safety gears that brake the car to stop when the lift is running at the speed
beyond the normal traveling speed.
Fig. 4 Fig. 5
6.1.4 Guide Rail
Page 13 of 36 pages
Guide rail, the rail along which the car and the counterweight move up and down,
consists of several guide rails.
6.1.5 Counterweight (Fig.5)
The counterweight, consisting of counterweight frame and counterweight block, is
connected with the car by means of the steel hoist ropes. It plays the function of the weight
balance while the lift is moving.
6.1.6 Traveling Cable and Protective Chute
The traveling cable, with its upper end connected with the control cabinet and its lower
end with the car, is a free-hanging cable that runs inside the cable chute and moves along
with the car when the car is moving. And the cable chute protects the cable against the
inter-faience of the wind and other factors when the cable is moving in the wind.
6.1.7 Traction Machine
The traction machine, which is the main driving body, consists of worm wheel, worm,
rope sheave, brake and motor and the hoist ropes round the V-groove and drive the car and
the counterweight to move up and down by means of the friction.
6.1.8 Over Speed Brake Device
The over speed brake device consists of the
over speed governor and the safety gear. Machine room floor
The over-speed governor (Fig.6) comprises
the three parts such as the over-speed governor,
steel hoist ropes and tensioned with the over-speed Safety gear linkage
governor installed at the top, i.e. at the bottom
frame of the traction machine room. And the
steel hoist ropes round the rope sheave of the
over-speed governor and tensioned with both
ends fixed at the handle of the pull rod of the
safety gear. When the lift is moving at the speed
exceeding the normal driving speed by30%, the
over-speed governor acts and the over speed
ropes are seized pulling the pull rod of the
safety gear upward and locking the guide rail
by the gate of the safety gear so that the car is Bottom frame plate
braked to stop and in the same time the speed
limit switch is triggered thus bringing the Fig.6
traction machine to a stop.
6.1.9 Buffer Device
On the bottom frame is installed the buffer for the car and the counterweight. When the
control fails or the lift is descending toward the bottom under special circumstance, the
buffer spring can absorb all the energy produced when the car and the counterweight are
descending toward the bottom to prevent the parts from being damaged and the people from
being injured or death.
6.2 Electrical Control System (Refer to Fig. 7)
Page 14 of 36 pages
Fig.7
Page 15 of 36 pages
6.2.1 General
The electrical control system consists of the power control cabinet with the electrical
elements installed, control board, inspection box on the car roof, landing calling board,
deceleration and leveling magneto switch, limit and final limit switches. They are installed
in the respective locations of the lift so as to accomplish the normal motion of the lift and
safety control of the lift.
The speed governing device includes the frequency and voltage controller, PLC and the
external hardware that enable the lift to have good control characteristics and safety
protection functions.
6.2.2 Block Diagram of Electrical System of Lift
Inspection
Switch
External
calling
Address
Traction
PLC Recognition
machine
switch
Internal
selection Frequency
converter
Fig. 8 Block Diagram of Electrical System
6.2.3 Internal floor Selection and External Call Floor Selection

The internal floor selector is inside the car, which is used for the passenger to select the
floor. The electric switch lock which is on the control cabinet inside the car is used for
controlling the main power supply switch, alarm button, fan switch, light switch, emergency
stop button and floor selecting button. And the internal floor selection has precedence over
the external calling floor selection and the time is not less than 5 seconds.
The external-calling device is the call buttons provided for the passengers at all
landings outside the car to call the car go upstairs and come downstairs. No matter what
landing the lift is on, it will come to the floor where the passenger is as long as the call
button is depressed.
6.2.4 Programmable Controller (PLC)

The programmable controller is the logic control system consisting of hardware and
software, and its external hardware comprises the selection button, inspection switch as well
as deceleration and leveling switch.
6.2.4.1 The landing selection and direction finding device includes the memory switch
MCS1 and MCS2 and the floor selection button, PLC tests the condition of MCS1 and
MCS2 and determines whether the lift go up or go down. For example, the lift is at the first
Page 16 of 36 pages
landing and MCS1 is closed while MCS2 is off, if now the second landing is selected, the
lift will be in up motion. If MCS1 is off while MCS2 is closed and the lift is at the second
landing and up, when the first landing is selected, then the lift will be in down motion. If the
lift is at the second landing or the first landing, when the third landing is selected, the lift
will definitely be in up motion. Also, if the lift is at the second landing or the third landing,
when the first landing is selected, the lift will definitely be in down motion. But when the
lift is at the landing and that landing is selected, the lift will not respond. And it should be
pointed out that the software is designed in such a way that when MCS1 and MCS2 are all
ON, i.e. they are in ―1‖ state, it means that the lift is in trouble, which needs to be fixed.
Also when MCS1 and MCS2 are all OFF, i.e. they are in ―0‖ state, it is equivalent to that
the lift is at the second landing, PLC will not respond, the lift only goes up to the third
landing or goes down to the first landing.
6.2.4.2 Inspection switch

The inspection switches are provided in two places, one is inside the electrical control
cabinet, the other one is in the box on the top of the car for adjustment purpose. The
inspection switches SA2, SA3 are hardware interlocked to ensure that the two inspection
switches cannot be operated at the same time and insure the commissioning is safe. The
inspection switch has two buttons which are Up and Down buttons and when any of the two
buttons are depressed, the signal as a low frequency 15Hz will be input into the frequency
converter to make the lift move up or down.
6.2.4.3 Deceleration and leveling

To optimize the design, minimize the quantity of the hardware as much as possible and
adequately bring the function of the software of PLC into full play, in this lift, only at the
first and the third landings are provided the deceleration points. While at the intermediate
landings are utilized the memory switches MCS1 and MCS2 which serve as the landing
selection and the direction finding as well as deceleration switches. And the deceleration
and leveling accuracy can be obtained by adjusting the position of the deceleration and
leveling switches.
6.2.4.4 The emergency stop buttons are provided for this lift for any emergency situation or
troubleshooting. When the lift is moving and the emergency stop is needed to fix the trouble,
the lift can be stopped by depressing any of the emergency stop buttons that are in such
three different places as in the power supply control cabinet, the box on the top of the car
and inside the car.
6.2.5 Variable frequency speed controller

Variable frequency speed controller is the core part of the lift, which determines the
motion characteristics of the lift. To simplify the structure of the lift circuit, the variable
frequency speed controller employs the control method without PG vector and for the
driving part; the variable frequency motor of the special traction machine is utilized. Its
number of revolution is depended on the frequency of the power supply and the number of
poles, so that changing the frequency enables the revolution speed of the motor to be
Page 17 of 36 pages
regulated. However, when the frequency changes, the internal impedance of the motor
varies as well. Just changing the frequency, the motor will generate weak excitation
resulting in the inadequate torque or the magnetic saturation caused by the over excitation
and etc. making the power factor efficiency of the motor significantly decrease. To
eliminate this disadvantage, the variable frequency speed controller using the control
method with vector is adopted, but such a control method makes the circuit more
complicated.
6.2.5.1 Control terminal of frequency converter (See Fig. 9)

It adopts the switching value control, the control terminal 1 is positive phase sequence
running, the control terminal 2 is negative phase sequence running, the control terminal 7 is
step-by-step control, the control terminal 6 is multi-segment speed and the control terminal
3 is the fault signal.
R U
3 phase 380V S V M
T W
Positive direction 9
1
10 In motion
Negative direction 2
Multi-segment speed 18
6
Step-by-step 19 Trouble
7
Common port 20
11
Fig. 9 Wiring Diagram of Terminal of Frequency Converter
6.2.5.2 Setting of parameters of the frequency converter (See Fig. 10)
V S Characteristics 0.5
(1) 0.61/S.47Hz
(2) 0.2/S15Hz
1.5S Deceleration point 2S Leveling point
Fig. 10
Page 18 of 36 pages
To make the lift run steady and the passengers feel comfortable, take Fig.10 as example,
the lift utilize the following parameters:
Curve (1) is the running parameter
Curve (2) is the inspection parameter
6.2.6 Protective Circuit of lift
6.2.6.1 Protective circuit
No-voltage contactor KM1 is controlled by main stop switchSQ1, lock switch SA1,
rope broken switch SQ7, safety gear switch SQ8 and over-speed governor SQ9. Switching
off any of these switches can cut off the power and the lift cannot run. Up and Down limit
switches are backed up by the final limit switch QS which is provided in the machine room.
Should Up and Down limit switches not function, the final limit switch QS is knocked open,
which cuts off the main power supply and stops the car.
The lift will never run when the car interlock switch SQ6 and the landing door interlock
switches 1SQ, 2SQ, 3SQ and the roof trapdoor SQ5 are not closed.
The Up limit switch SQ10 and Down limit switch SQ11 are provided for this lift. When
the Up leveling or Down leveling switches do not function, the Up limit switch will cut off
the up-motion signal of the frequency converter through KA1 to make the frequency
converter stop. Likewise, when the down-motion does not work, SQ11 will cut off through
KA2 the down-motion signal of the frequency converter. In the mean time, PLC inputs the
limit signal through the normal-open point of KA1 and KA2 to make PLC stop working.
And since the frequency converter stops working, KM2 cuts off the power to the brake of
the traction machine to bring the car to a stop immediately.
6.2.6.2 Other auxiliary circuit of the lift
Exhaust fan is provided inside the car of the lift to ensure that the air displacement of
the volume of the car is to be replaced at least three times per minute. And the fan is opened
and closed by the fan switch on the control board. And the fan inside the electrical cabinet is
controlled by the temperature inside the cabinet and works automatically when the
temperature inside the cabinet exceeds 35C.
There is emergency light in the lift. In normal operation, the lighting is supplied by the
lamp, which has the bulb 36V, 40W. When there is no electricity, the bulb 12V, 8W will
light. There is also an alarm button inside the car, which is used before start the lift or when
the lift is in trouble. 12V is DC power supplied by the battery 6.5Ah, which is always
floating charged by a charger.
7. INSTALLATION AND COMMISSIONING
7.1 Preparation before Installation

a. Set up a erection team of 4-6 persons, among which there must be fitter, electrician,
welder, one for each, who have rich experience so that they can be responsible for
erection and commissioning work.
b. Check the packing case of the lift for the release documents or ask for the release
documents for the lift, which includes: general drawing for structure of the lift,
arrangement plan for the lift and installation drawing for the guide rail, the
instructions for installation, use, maintenance and service, electrical schematic
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diagram, electrical wiring diagram, packing list, certificate of conformity, etc..

c. Carefully read all the release documents and understand the type, major parameters,
beat out the installation and arrangement drawing of the lift, electrical schematic
diagram, electrical wiring diagram, read up the instructions for the installation, use,
maintenance and service of the lift and the following work needs to be done:
Verify the specifications and dimensions
Verify the location, type, dimension of the machine room and the bearing capacity of
the floor
Verify the location and direction of the traction machine in the machine room and the
locations of each hole
Verify the locations of the power cord led into the machine room and its capacity,
determine the location of the control cabinet and verify and determine the location
for installation of over-speed governor
Determine the construction program and centralize the management
d. Get all the tools and equipment necessary for erection of the lift ready, see Table 2.
e.
List of Tools Table 2
Ser. Ser.
Description Size Remarks Description Size Remarks
No. No.
1 Box spanner Set 11 Mega meter
2 Socket wrench 150-200mm 12 Steel saw
Monkey
3 13 Jib chain hoist 2 ton
spanner
Sharp nose
4 L-square 14
pliers
5 Steel tape 15 Wire cutter
Steel board Wire stripping
6 16
rule pliers
7 Plug gage 17 Universal meter
Flat, round, Electric hand
8 File 18
half round drill
Electrician’s
9 Flush light 19
knife
10 Screwdriver 20 Grinding wheel
The tools mentioned above are for reference, they are to be selected or added it all depends.
f. The adequate operation area and space and three-phase power supply must be
available in the erection place.
g. Prior to erection, make sure the safety permission has been obtained from the safety
and inspection authorities and the necessary safety check has been conducted.
h. Unpack the packing case and check the delivery against the packing lists. Should
there be any damage and shortages caused during the transportation, report the same
to the responsible transportation insurance company within 7 days from the date of
arrival of the goods.
7.2 Installation of Lift
Page 20 of 36 pages
7.2.1 To Install Guide Rail SUPPORT (See Fig.11)
Top landing
Operation height
Bottom landing
TH5
(TH3)
T89
(T75)
Fig.11
Page 21 of 36 pages
The guide rail support must be welded according to the location dimensions as shown
in Fig.11: scribe the location line of the bottom frame and each guide rail support on the
installation door legs. The spacing parameter n of the support determines the running height
of the lift (given on the installation drawing of the guide rail of each lift). The horizontal
space of the support is L2. It is recommended that the supports at the top and the bottom are
to be welded first followed by welding the rest guide rail supports by pulling the steel wire
after alignment of the location.
Ⅱ Ⅰ
1:3 1:3
Platen Platen
Angle iron Angle iron
Fig. 12
7.2.2 To Install Guide Rail

a. Weld the bottom frame according to the location line of the bottom frame. Make sure
that the upper plane of the bottom frame becomes the horizontal state with the
tolerance not more than 2mm.
b. Scribe the location line of the master and auxiliary guide rails and ensure that the
dimensions L1, H0, H1 are correct and the dimension L1 must be consistent all the
way down, the tolerance is + 2, the tolerance of H0 and H1 is 1.5.
c. Start the installation with the first guide rail at the bottom, lean the corner profile
against the rear of the guide rail and connect them with each other by means of the
press plate and the bolts (See Fig. 12). Verify the location dimensions L1, H0, H1
and check to see if the deviation of the verticality is less than 0.7mm/5m, and then
tighten the connecting bolts. The guide rails are to be connected by means of
Page 22 of 36 pages
connection plate and the local gap at the faying faces between the guide rails must
not be more than 0.5mm. For the rest guide rails, they are to be installed one by one
from the bottom to the top ensuring that the dimensions L1, H0, H1 and the deviation
of the verticality meet the requirement. And also make sure that the requirement for
the common plane of the side working surfaces of the corresponding guide rails is
met, which can be checked by means of special snap gauges and plug gauges. (See
Fig. 13)
Side working surface Special snap guage Side working surface
Fig. 13
7.2.3 To Install Car Frame
a. Fix the roller guide shoes on both ends of the car frame with bolts and set the roller
of the guide shoes in the maximum space position.
b. Remove the second guide rail under the master guide rail.
c. Lift the car frame by means of winding tackle or crane, (the car and frame have been
formed into one piece when delivered) and install it on the first guide rail and lift the
car frame using jib chain hoist.
d. Fit the removed guide rail.
e. Adjust each roller of the roller guide rail to make them in proper working position
with each roller being against the top face and the side face of the guide rail. The
clearance between the wedge block of the safety gear and the guide rail must be
symmetric and equal to 2-2.5mm and tighten the all adjusting nuts.
7.2.4 To Install Counterweight

a. Assemble the counterweight frame and fit four guide shoes on both ends.
b. Remove the second guide rail of the counterweight underneath.
c. Lift the counterweight frame and fit it into the first guide rail.
d. Install the removed guide rail.
e. Adjust the guide shoes to make them in proper working position, that is, make the
counterweight frame at the symmetric position of the guide rail with the clearance on
both sides equal and tighten the guide shoes.
Lift the counterweight frame using jib chain hoist or place it on the counterweight
buffer temporarily.
7.2.5 To Install Buffer

Fix the two buffers with bolts as per the locations specified on the drawing.
Page 23 of 36 pages
7.2.6 To install Traction Machine (See Fig. 14)
Fig. 14
a. Assemble the traction machine and the traction machine frame together with the
rubber pad of 20 mm thick in between.
b. Scribe the location line of the hoist ropes and opening whole line on the traction
machine room floor.
To this end, find out the center line and the center a, b of the car and the
counterweight guide rail and connect a, b to be a line and extend the line. Take a, b two
points as the center points and then draw the rectangle of 80160 and the location line
is as shown in Fig.15.
Align the center of the pitch circle of the traction sheave (or deflector sheave) and
the points a, b to determine the location of the traction machine. Make sure that the
hoist ropes take on the state of the plumb bob. The deflection of the traction sheave in
the vertical direction must not be greater than 0.5mm.
The play between the brake shoe of the brake of the traction machine and the brake
pulley shall be even. When the brake shoe is released, the play on both sides shall be
symmetric and even and not greater than 0.7mm.
7.2.7 Installation Drawing of Over-speed Governor (Refer to Fig.6)
The over-speed governor has been strictly checked and tested when it leaves the
factory; it is not allowed to adjust the relevant parts of the over-speed governor at will
in installation.
a. According to the arrangement plan, place the over-speed governor on the floor in
the machine room, the direction of the arrow as shown on the over-speed
governor is the direction of the down motion of the car.
b. Install the tension device of the over-speed governor on the bracket or the guide
rail on the bottom frame of the lift as specified; the distance from the lowest
point of the tension device to the plane of the bottom frame is 360mm.
c. The over-speed governor rounds over the upper pulley groove and lower tension
pulley and is connected to the swinging arm of the pull rod and the upper and
lower pulley grooves must be aligned with each other. Make sure that the
over-speed governor ropes take on the state of the plumb bob with the deviation
not more than 3mm.
Page 24 of 36 pages
d. The deviation of the verticality of the over-speed governor tension pulley to the
horizontal plane of the machine room floor must not be greater than 0.5mm.
e. Wipe the over-speed governor ropes clean and make them round over the upper
and lower pulleys and hang them in the middle of the brake shoe without
scratching or touching the brake shoe. And then cut them to the required length
and stretch both ends and fix them on the swinging arm of the pull rod of the car
safety gear with the buckled ropes.
f. After installation, the tension device should move freely and the safety edges for
the door are in close state.
7.2.8 To install Steel Hoist Ropes (See Fig.15)
It must be taken into account that after
hanging the ropes, the distance from the lower
beam and the bottom face of the counterweight
frame to the buffer is 250~400.
With the car in the main landing position,
the bottom plane of the counterweight must be
flush with the leveling plane of the top landing.
The kinds of rope fastening:
a. Babbitt alloy filled conical sleeve way: Top landing
Install the rope fastening on the car frame and
the counterweight frame beforehand (install
one group only),use the steel wire of  2.5 to
measure the length X from the tapped rope exit
of the car to the tapped rope exit of the counter
weight according to the actual winding condition.
When using binding length Y as the rope end,
leave the length Z in advance. The total length of Bottom landing
the steel ropes is Q=X+2Y+2Z and cut the steel
ropes to the total length Q. When cutting the steel
ropes, stretch the steel ropes and make accurate
measurement and then bind the steel ropes up to
20mm wide with a steel wire (0.7~1mm) at a point
5mm away from both ends of the cut and leave the Fig.15
length Z and bind the length Y to prevent strands from being loose.
Make the steel ropes pass through the clean tapped body. Remove the steel wire at the cut
and release the strands and clean the core with gasoline after cut and bend it back and pull it
into the tapped sleeve.
Since the melting temperature of Babbitt alloy is 350C, the indirect heating method
should be used. Before pouring, heat the tapped sleeve to 40~50C and take out the residue
on the surface of Babbit alloy and pour it after evenly mixing it.
When pouring Babbit alloy, pour it once and pouring it twice is not allowed and gently
knock the ropes when pouring to make Babbit alloy firmly poured and do not move the
ropes until it is cooled.
Page 25 of 36 pages
The rope bent into the tapped sleeve is not allowed to come out of the tapped sleeve
and the height of the pouring port of Babbit alloy must be within the range of 10~15mm.
(See Fig. 16)
Fig.16
After hanging the rope, adjust the nut at the rope end to make the tension of each rope
end consistent and the different value must not be greater than 5%. And furthermore, the
double nut must be used to lock them and fit the pins in place.
b. Self-locking wedge shape bail (Fig.17)
The bail is divided into two parts, the jacket and the wedge block, the steel ropes
round over the wedge block and are sleeved into the jacket, with the help of the wedge
block and the slope inside the jacket and under the action of the pull force, the steel
ropes lock automatically. At the lower end of the wedge block there is a cotter pin
which has the function of preventing the wedge block from being loose and coming out.
At the joint of the steel ropes there are two rope clips to be fit in assembling and finally
tighten up after hanging the car or the counterweight.
This fastening way has the advantage of easily fitting and removing and the steel
ropes can obtain the strength of over 80% but the impact load resistance is poor.
1 2 3 4 5
Fig.17 Self-locking wedge rope sleeve

1. Pull rod 2. Jacket 3. Wedge block 4. Pin 5. Rope clip
Page 26 of 36 pages
7.2.9 Placement of Counterweight Block

Place the counterweight block and fix it after placement as required.
7.2.10 To Install Cable Chute and Cable
7.2.10.1 To install the cable chute
As per Fig. 18, install the cable chute. Start the installation with the second guide rail
support from the bottom to the top. It is required to align the joints of the cable chute and
mismatching is not allowed and makes connection with bolts after adjusting two chutes.
7.2.10.2 To install the cable
Let the cable go and hang it at the highest place for 3~4 hours to let the internal
winding force go. Connect one end of the cable to the terminal in the electric control cabinet
in the machine room and the other end to the terminal in the electric control cabinet in the
car by free-hanging through the cable chute and fix them through the cable support on the
car.
The length of the cable is that there is an allowance after the car moves beyond the
lower terminal landing and compresses the buffer.
Cable chute
Fig. 18
7.2.11 To install Landing Door and Safety Netting
a. Adjust the car to the leveling position of the main landing.
b. Install the small safety netting on the bottom frame as per the drawing.
c. Install the landing door to allow the landing door to be normal to the horizontal plane
of the landing with the dimension error not greater than 3mm.
d. Install the safety netting on both sides of the landing door and tighten the bolts and
the safety netting and the attached wall must be securely fixed.
e. The landing door and the safety netting on other landings are installed basically in
the same way as the main landing.
7.2.12 To install Electrical Devices and Auxiliary Electrical Devices
The electrical devices must be installed by strictly observing the regulations set forth by
the relevant state authorities.
a. Run the power cords and control wires according to the electric drawings (schematic
diagram, wiring diagram).
b. Install the landing calling boards, leveling switches, limit switches and final limit
Page 27 of 36 pages
switches according to the locations specified.

c. Connect the power cords and the control wires to each electric element according to
the electric drawings.
It is required that: the external connection lines are not allowed to be bare and the
cord less than 1 m in length must be covered with flexible tube and the cord over 1 m in
length must be covered with the metal conduit with the tip ends being rainproof.
d. Install other electric accessories and check every part for correct connection after all
cords and wires are connected and elements are installed as per the schematic
diagrams and wiring diagrams.
7.3 Adjustment
7.3.1 What to Adjust in Standstill and Hand Winding Device Condition
a. The deviation of the guide rail distance must meet the requirements.
The flatness of the side working surface of the guide rail must not deviate over the
full length by more than 1/1500.
The entire contact face of the guide rail joint shall be free of continuous gap, the local
gap a must not be greater than 0.5mm. The shoulder of the guide rail joint must not
be more than 0.04mm measured by placing 300 steel rules against the working
surfaces of the guide rail and using the plug gauge.
The unevenness of the surface the guide rail joint must not be more than 0.08mm.
The side working surfaces of the two guide rails must be in the same plane without
torsion.
b. To adjust the roller guide shoe
The roller guide shoe on the front working surface must be fit with the working face
of the guide rail.
After adjustment, the front working surface of the guide rail must be parallel with the
outer side face of the car frame.
c. To adjust the safety gear (See Fig. 19)
Adjust the lifting and pulling stem of the safety gear to allow the space length
between the safety gears on both sides and the top face of the guide rail to be 5 01 mm
and the gap of the two side working surfaces is 2.5mm and must be equal. As shown
in Fig.19.
Fig. 19
Page 28 of 36 pages
Adjust the balance spring to allow the lifting and pulling stem of the safety gear to have
the lift and pull force not exceeding 20kg and the safety switch of the lifting and pulling
system of the safety gear must act with the cam rotating within 12, which can be
accomplished by adjusting the installation position of the cam.
d. To adjust the over-speed governor

Adjust the over-speed governor to make the tension device tense the steel ropes.
When the over-speed governor acts, the contact of the safety gear must be
disconnected.
The rope broken protective switch installed on the movement weight of the tension
pulley must be ON in normal operation to prevent acting due to the less amount of
extending of the rope.
e. To adjust the band type brake

When the brake is braking, the brake shoe and the braking wheel must be tight fit.
When the brake is released, the gap between the surface of the brake wheel and the
working face of the brake shoe must not be greater than 0.7mm.
7.3.2 Adjustment with Lift in Inspection Operation

When the lift is in the inspection operation, the adjustment over the full travel is as
follows:
a. Adjust the roller guide shoe.
b. Adjust the cable support to allow it to run freely inside the cable notch without
scratching and touching.
c. The cable runs freely inside the cable chute without scratching and touching.
7.3.3 Adjustment with Lift in Operation

a. Adjust the leveling position to allow its leveling error to be 15mm.
b. Adjust the upper and the lower limit frogs.
c. Adjust the landing door interlocking and the car interlocking devices.
8. RUNNING TEST (COMMISSIONING OF LIFT)
8.1 Preparations before Commissioning
8.1.1 Normal Inspection before Test

a. Clean up the running pathway and ensure there are no any foreign objects that block
the traveling of the lift inside the pathway.
b. Make sure that all the points need to be lubricated are in good lubrication condition.
c. Make sure that the guide rails, traction pulley, hoist ropes and safety gears are free
from smear.
d. Check the redactor of the traction machine to see if there is adequate amount of
Page 29 of 36 pages
lubrication oil filled.

e. Check all the wires for correct connection without any error.
f. The temperature in the machine room must range between 5~40C.
g. Make sure that the wind speeds not exceed 15m/sec.
h. Check to see if all the coupling bolts are securely fixed.
i. Make sure that no persons are inside the car when conducting over speed test.
8.1.2 Inspection of Safety Devices before Test

a. Open-phase/error phase protection device of the power supply system
Cut off one phase or swap the phases sequence of the main power supply, the lift
cannot run.
b. Safety gear of over-speed governor
In the place 4m away from the main landing, the car travels downward at inspection
speed, manually operate the over-speed governor inside the machine room, now the
safety gear acts and seize the guide rail and the motor stops rotating and the car stops
traveling.
c. Buffer
Give the car the rated load, statically press the buffer of the counterweight and the
buffer of the car respectively for 5 minutes and release the buffers, the buffers are
able to restore to their original state.
d. Limit switch and final limit switch
Manually push the Up and Down limit switches and final limit switches and the lift
cannot run. And then make the lift run at inspection speed, make the limit frog and
final limit frog touch the limit switches and final limit switches, the lift will stop
running.
8.2 Running Test of Lift
8.2.1 Running Test of Lift with No-load, Half load (50% of the rated load), Rated Load
(100% of the rated load)
When running test is being performed with no-load, half load and full load, the lift must
run up and down for 1.5 hours. When the lift is started, running and stops,
a. There must no severe vibration and impact inside the car.
b. The brake acts agilely and reliably, the brake shoe of the brake does not rub the brake
during running and the temperature rise must not exceed 60C.
c. The temperature rise of the reductor oil must not exceed 60C and the temperature
must not be higher than 80C.
d. The lift has leveling accuracy with its error not exceeding 15mm.
e. Every part of the lift works normally and the elements work reliably and the function
meets the design requirements.
8.2.2 Overload Test
Having past the no-load and the full load test, the lift must be subject to the overload
test. When the overload test is being performed, the car must have 125% rated load. The lift
must move up and down over the full travel twice and the lift must be safely started and run
with the brake functioning reliably and the traction machine working normally.
Page 30 of 36 pages
8.2.3 Behavior Test of Safety Gear

With the lift moving downward in no-load and inspection condition, perform the
behavior test of the safety gear. When the lift travels to the proper position, manually make
the over-speed governor act to allow the steel ropes of the over-speed governor to pull the
safety gear, the wedge block of the safety gear must reliably clamp the guide rail and the lift
stops moving. And in the mean time, the linked switch of the safety gear will reliably cut off
the control circuit.
8.2.4 Reset of Safety Gear and Over-speed Governor

a. By manually operating the hand winding device, lift the lift to allow the over-speed
governor to return to its previous position, the safety gear will restore to its original
state.
b. Manually restore the linked switch of the safety gear to its original state.
9. OPERATING PROCEDURE
9.1 Safety Check
Prior to any use of this lift perform daily safety check procedures below:
a. In addition to filling the lubrication oil according to the requirement, the relevant
regulations of the maintenance and service must also be observed.
b. In case of storms, all the vital parts of the lift must be inspected and tested by an
expert prior to use of the lift.
c. Check all the mechanical/electrical interlock devices and the emergency stop
switches by making test runs with:
 the car door open.
 the landing door open.
 the trapdoor.
Note: The lift must not start. Be sure to open only one door at a time.
d. Close all the doors, depress the emergency stop switch, now the lift cannot operate.
e. When the lift is not in the leveling position, the landing door and the car door cannot
be opened.
f. There must be no any obstruct in the traveling pathway where the lift runs.
9.2 Operation
Before start the lift, the operator must perform the safety check as outlined in the above
Section ―Safety Check‖.
9.2.1 Running Operation

a. Switch on all the power switches.
b. Enter the car and close the doors.
c. Depress the button indicating the landing where you are going to, the lift will
Page 31 of 36 pages
automatically get to the destination landing.

d. Leave the car and close the doors.
e. When the lift is not in use, switch off the control power.
f. When the lift is not in use for a long time, switch off the main power switch.
9.2.2 Calling
If the lift is not on the landing where the operator is, just depress the call button on the
landing door, the lift will automatically get to the landing where you are.
9.2.3 Emergency Actions

a. In case that some abnormal situation occurs when the lift is running, depress the
emergency stop button immediately, investigate the cause for the abnormal situation
and conduct necessary remedy.
b. If any accident happens to the lift and the lift cannot move any more, the operator
should depress the alarm button to tell the personnel outside the car to go into the
machine room and manually operate the hand winding device to make the lift get to
the nearest landing.
How to do it: Open the band-type brake of the traction machine and rotate the
hand-wheel of the hand winding device at the tail end of the motor.
9.2.4 What to check when lift cannot move:

If the lift cannot be started, then check to see if:
a. The main switches are in ON position.
b. The emergency stop button is depressed.
c. ―Inspection‖, ―Running‖ switches in the electric control cabinet on the top of the car
are set to ―Running‖ position.
d. All the doors are closed.
If the lift still cannot be started even if the above-mentioned actions have been taken,
perform the inspection and repair according to the content of ―Electrical
Troubleshooting‖ herein.
10. MAINTENANCE AND SERVICE
In order to guarantee that the lift is able to run safely and reliably, to prevent the
accident from being occurred, extend the service life and avoid the death or serious personal
injury, the maintenance personnel must perform the maintenance and service on the lift
according to the following contents. And the interval for the maintenance and service
depends on the length of the lift’s service time and the maintenance personnel must perform
the maintenance items listed in the maintenance schedule unconditionally.
10.1 Maintenance personnel must lubricate the relevant parts of the lift according to the
lubrication schedule for the specific parts.
Page 32 of 36 pages
Lubrication Interval Table 3

Item of Points to be Interval for Filling Oil, Cleaning Type of Lube
Equipment lubricated & Changing Oil Grease
For a new lift, it must be checked
often within the first 6 months
and if any foreign impurities are
discovered in lube oil then the
Oil tank N320
lube oil must be changed in a
timely manner, and subsequently
Traction
the worm and gear oil must be
machine
changed yearly.
Rolling bearing of
Greased monthly and cleaned Lime base
the worm–wheel
and grease-changed yearly. grease
shaft
Machine oil
Shaft pin of the brake Filled Weekly
Brake of
traction In between the
Graphite
machine movable core of Checked every 6 months and
powder
electromagnet and lubricated yearly.
copper sleeve
Rolling bearing of Greased monthly, cleaned and Limebase
motor lube grease-changed half-yearly. grease
Traction
Clear lube oil
motor Bush bearing of Filled weekly, grease-changed
with viscosity
motor half-yearly.
30-45
Greased weekly, cleaned and Limebase
Guide pulley Rolling bearing
grease-changed half-yearly. grease
Roller guide Greased quarterly, cleaned and Limebase
Bearing
shoe grease-changed half-yearly. grease
Landing door
& car door Limebase
Reversible shaft pin Greased quarterly.
interlocking grease
device
Door shaft, slide Greased quarterly, cleaned Limebase
Door
track yearly. grease
Machine oil
Drive gear Lube oil filled monthly
Safety gear Suitable
Sliding points on the
Filled quarterly. amount of
safety gear jaw
vaseline oil
Rotary axle pin,
Over-speed tension pulley shaft Filled quarterly, cleaned and Limebase
governor and axle bush on the lube-grease changed yearly. grease
over-speed governor
Page 33 of 36 pages
10.2 Check, Repair and Adjustment of Main Parts
10.2.1 Traction Machine

a. The traction machine must be running steady without vibration and abnormal noise,
the axial play of the worm and the gear is 0.02-0.04 and 0.07-0.12 respectively. After
the lift has run for a long time, the flank play of the worm-gear conjugation increases
due to wearing or the axial play is out of tolerance due to the thrust bearing of the
worm-gear is worn, which makes the lift produce the greater impact when the lift is
running in reverse direction. If the inspection shows that the results are out of
tolerance, the central distance adjustment gasket and the gasket of the bearing cover
must be replaced in a timely manner or the bearings must be replaced.
b. Check to see if the reduction gearbox of the traction machine is leak. If any, replace
the seal washer.
c. The temperature rise of the lubrication oil in the reductor must not exceed 60C and
the temperature rise of the coil of the brake must not exceed 60C. If anything
abnormal happens, stop the lift immediately and investigate the cause and do not
start the lift until the trouble is removed.
d. The brake must act agilely and reliably and the brand-type brake shoe and the
working surface of the brake wheel must fit each other. When the brake is released,
the two side brake shoes must leave the working surface of the brake wheel
simultaneously and the play must be uniform and not be greater than 0.7mm. The
working surface of the brake rubber must be free of smear. And when the worn brake
rubber exceeds 1/4 of its thickness or the rivets come out, replace the brake rubber
immediately. If the play between the brake rubber and the working surface of the
brake wheel increases due to the brake rubber being worn too much and affects the
braking performance or produces the impact sound, adjust the nut for connecting the
armature and the brake shoe arm to make the play meet the requirement.
e. The temperature rise of the bearing of the motor must not exceed 80C. When the
uneven abnormal noise produces or the deflection amount of the motor rotator
exceeds 0.2mm due to the bearing being worn, replace the bearing immediately.
f. Check to see if the tension of the steel ropes is uniform and prevent that the wearing
amount of the hoist ropes chute is inconsistent due to the uneven tension of the steel
ropes. When the difference of the wearing amount exceeds 1.5mm, replace the
traction sheave immediately.
g. Check the distance from the bottom of the hoist ropes to the bottom of rope sheave
V-groove to prevent the hoist ropes from being fell down to the bottom of the
V-groove thus producing serious drift or reducing towing power. If the clearance
between the bottom of any of the hoist ropes and the bottom of the groove is 1mm,
turn the rope groove again or replace the traction sheave. After re-turning the rope
groove, the distance from the bottom of the rope groove to the lower rim of the rope
sheave must not less than the diameter of the corresponding hoist ropes.
Page 34 of 36 pages
10.2.2 Over-speed Governor and Safety Gear

a. The over-speed governor must act agilely and reliably. When it is running at the
rated speed, no abnormal sound is heard. When the rope of the over-speed
governor extends beyond the range specified and touches the rope broken switch,
truncate the ropes to prevent cutting off the control circuit and affecting the
normal running of the lift.
b. The drive gear of the safety gear must act agilely and the distance from the
wedge block to the working surface of the guide rail is 2.5 mm.
10.2.3 Guide Rail and Roller Guide Shoe

a. The working face of the guide rail must be clean without lubricant. The working
face of the guide rail must be free from damage. When the working surface is
damaged due to the action of the safety gear, it must be repaired. The nuts on
pressing guide plate for fixing the guide rail must not be loose.
b. Strictly check the rubber face of the roller guide shoe for wear condition, adjust
immediately the gap between the guide shoe and the working face of the guide
rail, caused by wearing. When the rubber face of the roller guide shoe is
discovered worn up to 2/3 of the original thickness, replace it immediately.
10.2.4 Steel Hoist Ropes

a. The steel hoist ropes must be properly lubricated to reduce the wear-and-tear
between the ropes and also protect the surface of the ropes from being rusted
and corroded. Do not apply too much lubrication oil and it is acceptable when
you have the sense of oil (do not apply the lubrication oil to the new steel ropes).
b. Frequently check to see if the tension of the steel ropes is uniform with the
D-value to each other not exceeding 5%.
c. If the broken strand of the steel wires on the surface of the steel ropes is
discovered or the diameter is less than 90% of the original, or the steel wires on
the surface are seriously worn or corroded, replace the steel ropes immediately.
10.2.5 Buffer
The top face of the spring buffer must have the unevenness not more than 4/1000mm
and vertical to the center of the buffering plate on the car platform or the center of the
buffering plate of the counterweight. The fixing bolts must not be loose.
10.2.6 Landing Door and Car door Interlocking Mechanism

The landing door and car door interlocking mechanism must work freely and reliably.
When opening the door, the control power must be cut off.
11. COMMON TROUBLES AND CORRECTIVE SOLUTION (See Table 4)
Common Troubles and Corrective Measures Table 4
Page 35 of 36 pages
Symptom of Trouble Probable Cause Corrective Measures

1.The traction machine vibrates greatly. 1. Tell the manufacturer of
the traction machine to
2.The guide rail is not installed in place
The car vibrates too fix the problem.
and there is mismatch at the joints.
much.
3.The bolts are loose at the joints of the 2. Align the guide rail.
guide rails. 3. Tighten the bolts.
The shaking occurs or
the impact sound is 1.The isolated joints of the guide rail are
heard in some mismatched with big error. 1.Align the guide rail.
isolation areas when 2.There is obstruction in the running 2.Clear up the obstruction.
most parts of the lift channel.
work stably.
The protruded end of 1. The lubrication oil in the reduction
the worm of the 1.Change the lubrication oil.
gearbox is too sticky.
traction machine is 2.Replace the seal ring.
overheated and seized. 2. The seal ring is damaged.
1.Seal ring at the protruded end of the
worm shaft of the reduction gearbox is
worn.
Traction machine is 1. Replace the seal washer.
2.The pad at the abutted face of the
leak. 2. Clean the oil slot.
reduction gearbox is damaged.
3.The oil slot of the oil seal at the worm
shaft end is blocked.
The lift cannot be Short circuit occurs in the power supply Switch on the power and
started. and the fuse is blown out. replace the fuse.
1. Replace the element and
1.The contact of the electric elements in
eliminate the dummy
The lift sometimes the control circuit is dummy connected.
connection.
moves and sometimes 2.The electric switch of the mechanical
stops. 2. Adjust the mechanical
and electrical interlocking mechanism
and electrical interlocking
is interfered.
mechanism.
1.Readjust the leveling
1. The leveling switch is not in its place.
switch.
Leveling is not 2. The contracting moment of the
accurate. 2.Adjust the contracting
band-type brake of the traction
moment of the band-type
machine is small.
brake.
The over-speed
governor and the 1. The adjusting bolt inside the 1. Tighten the adjusting bolt.
safety gear have over-speed governor is loose. 2. Clear away the foreign
abnormal sound and 2. There is a foreign object. object.
action.
Page 36 of 36 pages

Shanghai Zhenhua Port Machinery Longchan

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SHANGHAI ZHENHUA PORT MACHINERY

LONGCHANG LIETING RIG CO.,LTD Elevator Manual

LONGCHANG LIFTING EQUIPMENT CO., LTD.

Company tel.:021-56858559 E-mail:wangyan@zpmc.net

2. BRIEF TECHNICAL DESCRIPTION Page 3

3. IMPORTANT SAFETY INSTRUCTIONS Page 3

4. EXPLANATION ON ALLOCATION OF TYPE TO LIFT Page 8

5. TECHNICAL DATA AND SPECIFICATIONS Page10

6. DESCRIPTION OF TECHNICAL FEATURES AND STRUCTURE Page 10

7. INSTALLATION AND COMMISSIONING Page 19

8. RUNNING TEST Page 29

9. OPERATING PROCEDURE Page 31

10. SERVICE AND MAINTENANCE Page 32

11. COMMON TROUBLES AND CORRECTIVE SOLUTIONS Page 35

2. BRIEF TECHNICAL DESCRIPTION

3. IMPORTANT SAFETY INSTRUCTIONS

3.1 General Safety Responsibilities

3.2 Requirements for Safety in Installation Period

3.2.2 Safety Measures Taken during Installation

3.2.3 Safety Measures Taken After Installation

3.3 Acceptance Test

3.3.1 Test and Inspection of Overall Installation

3.3.1.1 Lift Car

be able to ensure the precision running clearance.

3.3.1.2 Guide Rail

3.3.1.3 Traction Machine

3.3.1.4 Landing Door and Safety Railing

3.3.1.5 Traveling Cable

3.3.1.6 Control System

3.3.1.7 Buffer System

3.3.2.1 Safety Device (Over-speed Governor – Safety Gear)

3.3.2.3 Indication Plate, Warning Plate and Instructions

3.3.2.4 Running Test

3.3.3 Safety Measures Taken during Acceptance Test and Check

3.4 Periodic Inspection and Test

3.4.1 Inspection and Test Requirements

3.4.1.3 Safety Measures Taken during Inspection and Test

3.4.1.4 Check and Test of the Whole Body

3.4.1.5 Inspection and Test of Safety Device

3.5 Daily Safety Check

3.5.1 Important Safety Measures during Daily Safety Check

3.6 Safety Operation

3.7 Safety in “Maintenance and Service” and “Replacing parts”

4. EXPLANATION ON ALLOCATING TYPE TO LIFT

For example: TKJ (SSD) 400A/1.0-AS means:

5. TECHNICAL SPECIFICATIONS (See Table 1)

Rated capacity kg 400,500

6. DESCRIPTION OF TECHNICAL FEATURES AND STRUCTURE

6.1 Metal Structure

6.1.1 Bottom frame

6.1.2 Landing Door and Safety Netting (See Fig. 2)

6.2 Electrical Control System (Refer to Fig. 7)

6.2.2 Block Diagram of Electrical System of Lift

Fig. 8 Block Diagram of Electrical System

6.2.3 Internal floor Selection and External Call Floor Selection

6.2.4 Programmable Controller (PLC)

6.2.4.2 Inspection switch

6.2.4.3 Deceleration and leveling

6.2.5 Variable frequency speed controller

6.2.5.1 Control terminal of frequency converter (See Fig. 9)

Fig. 9 Wiring Diagram of Terminal of Frequency Converter

6.2.5.2 Setting of parameters of the frequency converter (See Fig. 10)