TKC40升降机操作说明书 TKC Man Lift Operation Manual

Operation
Manual Project: GMK‐Doosan Vina
TKC Man Lift

Operation Manual
S&C HEAVY EQUIPMENT CO., LTD

Operation Manual Project: GMK‐Doosan Vina
Contents
1. Foreword ..................................................................................................................... 2
2. Technical Description .................................................................................................. 2
3. Brief Introduction of Structure .................................................................................... 2
3.1 Drive assembly ............................................................................................................ 3
3.2 Man Lift car bracket .................................................................................................... 4
3.3 Man Lift car assembly ................................................................................................. 5
3.4 Landing door assembly ............................................................................................... 6
3.5 Mast section................................................................................................................. 7
3.6 Base ............................................................................................................................. 7
3.7 Landing protection net ................................................................................................ 8
3.8 Cable draught-proofing channel .................................................................................. 9
3.9 Running wire rack ..................................................................................................... 10
4. Run operation ............................................................................................................ 11
4.1 Operation on the operating panel inside the Man Lift car......................................... 11
4.2 Call operation on the landing call button box ........................................................... 11
4.3 Operation on the panel of car roof inspection box .................................................... 12
4.4 Operation of pit box .................................................................................................. 12
5. Safety Device ............................................................................................................ 13
5.1 Structure of anti-dropping safety device ................................................................... 13
5.2 Overspeed governor .................................................................................................. 14
5.3 Motor brake ............................................................................................................... 15
5.4 Landing lock device .................................................................................................. 16
5.5 Car door mechanical lock .......................................................................................... 17
5.6 Landing door mechanical lock .................................................................................. 18
5.7 Safety protection of car frame ................................................................................... 19
5.8 Hand release device ................................................................................................... 20
5.9 Buffer......................................................................................................................... 20
5.10 Overload device......................................................................................................... 21
5.11 Self-lubricating system .............................................................................................. 22
6. Safety locking system of elevator instruction ............................................................ 23
7. Important Description of Safety Rules ...................................................................... 24
7.1 Safety requirements during the run operation ........................................................... 25
7.2 Before the operation of this Man Lift, you shall be familiar with the requirements
on the sign of safety instructions: .......................................................................................... 25
8. Safety requirements for periodic inspection and maintenance.................................. 26

1
1. Foreword
TKC Man Lift is a kind of special lifting equipment
used for operation, maintenance and management
personnel of large bridge cranes, ship unloaders, ship
loaders, gantry cranes and portal cranes in port wharf to
go up/down.
Please read this manual carefully before operation.
Operation and maintenance must be carried out by
professionals in accordance with safety procedures. The
pictures in this manual are for reference only, which
does not represent the actual product on the site.
When using the product, it must conform to the
operation specifications and safety regulations.
2. Technical Description
TKC Man Lift and its Man Liftway accessories are
as shown in Fig. 1., wherein
(1) Upper-frame (2) Top landing (3) Intermediate
landing (4) Support column (5) Cable draught-proofing
channel (6) Man Lift car bracket (7) Drive assembly (8)
Bracket for mast section (9) Man Lift car assembly (10)
Mast section (11) Safety net (12) Landing door (13)
Buffer (14) Base (15) Base plate.
3. Brief Introduction of Structure
Fig.1
2
3.1 Drive assembly

See Fig.2
Fig.2
Wherein (1) Elastic connector (2) Overspeed governor (3) Speed reducer (4)
Coupling (5) Motor (6) Motor bracket (7) Rolling roller (8) Pressure roller (9) Gear
(10) Safety stop-lever (11) Drive plate assembly (12) Release brake wire (13) Release
mechanism.
3
3.2 Man Lift car bracket

See Fig.3
Fig.3
wherein(1) Fixing seat for car roof inspection box (2) Brake plate assembly (3)
Anti-dropping safety device (4) Fixing seat for Man Lift car (5) Release brake wire (6) Seat
plate of running wire rack (7) Gear of anti-dropping safety device (8) Pressure roller (9)
Rolling roller (10) Safety stop-lever (11) Side roller (12) Column of Man Lift car bracket
(13) Fixing seat for car platform.
4
3.3 Man Lift car assembly

See Fig.4
Detail view A
(rotation)
Fig.4
Wherein (1) Car roof guardrail (2) Special wrench (3) Reset tool of overspeed
governor (4) Reset tool of anti-dropping safety device (5) Car roof (6) Fan (8) Rear car
panel(10) Hand release (11) Left car panel (12) Car chassis (13) Movable platform of Man
Lift car (15) Guard plate (16) Lower doorway (17) Door leaf (18) Straight ladder (19) Left
door frame (20) Document box (21) Right door frame (22) C column (23) Operation panel
(24) Upper doorway (26) Right car panel (27) Bump iron of landing door (28) Car door
lock.
5
3.4 Landing door assembly
Landing door assembly is shown in Fig.5

1. Interlock switch of landing door
2. flatter
3. mechanical lock of landing door
4. folding plate
5. top beam of landing door
6. car door bumper
7. Interlock switch box
8. channel plate of landing door
9. mechanical lock box
10. right frame of landing door
11. calling box
12. left frame of landing door
13. door leaf
14. bottom beam of landing door
15. sill plate
Size:
Code H H1 L L1
Size 2550mm 2000mm 1130mm 670mm fig. 5

Note: Picture shows that parts of the locking
device are out of the landing door.
6
3.5 Mast section

See Fig.6
Fig.6
Wherein (1) S board (2) Main tube (3) Standard parts (4) Rack
Dimensions in drawing
Code H L L1
Dimensions 1,508mm 650 mm 434mm
3.6 Base
See Fig.7
Fig.7
Code W W1 L L1
Dimensions 380mm 550 mm 1,120 mm 650 mm
7
3.7 Landing protection net

See Fig.8
Fig.8
Code H H1 L
Dimensions 2,550mm 1,230 mm 1,130mm
Note: This figure shows the protection net of bottom landing. For other landings, their
protection net has no sections of H1 (1230).
8
3.8 Cable draught-proofing channel
See Fig.9
Fig.9
The left picture is the channel section, and the right picture is the open channel section,
wherein (1) Bending plate 2 (2) Bending plate 1 (3) Bending plate 3 (4) Cover plate for
installation process hole of traveling cable (5) Installation hole of traveling cable.
Code H L L1
Dimensions 2,000mm 490 mm 230mm
9
3.9 Running wire rack
See Fig.10
Fig.10
Wherein (1) Column of Man Lift car bracket (2) Running wire rack (3) Clamp plate (4)
Traveling cable
10
4. Run operation
4.1 Operation on the operating panel inside the Man Lift car
See Fig.11
(1) Emergency stop switch: When pressed in case
of emergency, the power supply can be disconnected
and the Man Lift will be stopped emergently;
(2) Key switch: Provide the function of locking
the elevator;
(3) Alarm button: When the Man Lift fails, it
provides alarm function.
(4) Lighting switch: Man Lift internal lighting
switch; Fig.11
(5) Fan switch: Man Lift internal exhaust fan switch;
(6)Floor selection button: By clicking the floor selection button, the Man Lift can run
to the selected landing.
(8) Sound-light alarm: Work under overload.
The Man Lift can be operated to the selected landing by clicking the floor selection
button on the operation panel; meanwhile, it can also carry out the operations such as
“Power on/off”, “Alarm” and “Emergency stop” through other components/parts.

4.2 Call operation on the landing call button box

See Fig.12
(1) Emergency stop switch: When pressed in case of emergency, the
power supply can be disconnected and the Man Lift will be stopped
emergently;
(2)Call button: When the Man Lift is not at the landing where it is located,
it can be operated to this landing by clicking the call button.
Fig.12
11
4.3 Operation on the panel of car roof inspection box

See Fig.13
(1) Emergency stop switch: When pressed in case of emergency,
the power supply can be disconnected and the Man Lift will be stopped
emergently;
(2) Inspection/operation switching switch: Adjust the operation
mode of the Man Lift, which is switched between inspection and
Fig.13
operation.
(3) Car roof lighting switch: Control the ON/OFF of the Man Lift
car roof lighting;
(4) Inspection up-motion button: Make the Man Lift move up at
the inspection speed (20% of the rated speed) under the inspection
mode;
(5) Inspection down-motion button: Make the Man Lift move
down at the inspection speed (20% of the rated speed) under the
Fig.13
inspection mode;
(6) Greasing pump start switch: When the elevator is in the inspection state, when the
elevator starts running, turn on the switch to lubricate the pump to start working.
When inspecting and maintaining on the Man Lift car roof, it is necessary to push the
inspection/operation switch on the panel to the position of “Inspection”, and then operate
the Man Lift at the inspection speed (20% of the rated speed) through the up/down-motion
button.
4.4 Operation of pit box

See Fig.14
(1) Emergency stop switch: When pressed in case of emergency,
the power supply can be disconnected and the Man Lift will be
stopped emergently; Fig.14
(2) Pit lighting switch: Control the ON/OFF of the pit lighting;
12
When inspecting and maintaining in the pit, press the emergency stop button on the pit
box, where there are the lighting switch and 230V power supply for maintenance personnel
to use.
5. Safety Device
5.1 Structure of anti-dropping safety device

See Fig.15
Fig.15
Wherein (1) Loading nut (2) Disc spring (3) Shell (4) Friction plate (5) Gear shaft (6)
Brake drum (7) End cover (8) Reset pin (9) Safety position-limit switch (10) Speed
regulating spring (11) Seat for centrifugal block (12) Centrifugal block, and etc.
When the Man Lift car stalls in the process of down-motion, the centrifugal force of
the centrifugal block on the gear shaft increases with the rise of the rotation speed; if the
centrifugal force is greater than the pre-adjusting force of the speed regulating spring on the
centrifugal block, the centrifugal block throws out the convex teeth on the inner side of the
brake drum, then the centrifugal block drives the brake drum to rotate together, and the
loading nut installed on the end screw of the brake drum cannot rotate because of structural
reasons, which will carry out an axial movement; at this time, the disc spring installed
between the loading nut and the outer shell is compressed. The reaction force of the disc
spring makes the positive pressure of the brake surface of the brake drum and the friction
disc glued on the inner cone of the outer shell increase gradually, and the braking friction
13
moment also increases, which will make the elevator car stop running. The movement of the
loading nut causes the control switch to disconnect, and cut off the control power supply.
5.2 Overspeed governor

See Fig.16
Fig.16
Wherein (1) End cover (2) Gasket (3) Fuse (4) Baffle (5) Brake assembly (6) Housing
(7) Reset tool
During the normal operation of the Man Lift, the brake pad on the brake assembly does
not contact the housing. When the release device is used, the fixed brake disc and the
rotating brake disc of the motor brake are separated from each other; at this time, the
braking action is relieved, and the Man Lift will accelerate downward. If the speed of
down-motion is greater than 1.15-1.35 times of the rated speed, the brake pad on the brake
assembly contacts with the housing to produce a braking moment, and then the speed of
down-motion decreases. When the brake pad on the brake assembly separates form the
housing, the speed of down-motion decreases; if the speed is 1.15-1.35 times higher than
the rated speed, the brake pad on the brake assembly contacts with the housing once again
to produce a braking moment, and then the speed of then the speed of down-motion
decreases. In this way, the speed governor guarantees that the Man Lift moves down at a
steady speed (1.15-1.35 times of the rated speed) when the hand (foot) release device is
14
used, so that the down-motion speed of the car can be controlled, and the safety of
personnel and equipment can be ensured.
5.3 Motor brake

See Fig.17
Fig.17
Wherein (1) Hand release lever (2) Compression spring (3) Adjusting sleeve (4) Motor
end cover (5) Fixed brake disc (6) Armature iron (7) Rotating brake disc (8) Adjusting bolt
/screw (9) Bolt (10) Coil (11) DC electromagnet (12) Electromagnet shell (13) Compression
spring (14) Bolt
When the coil is powered off, the compression spring pushes the rotating brake disc
along the axial direction through the armature iron to tighten the fixed brake disc, which
will provide a braking moment, so as to ensure that the car does not slip in the static state
(braking state).
When the coil is powered off, the armature iron is attracted, so that the fixed brake disc
and the rotating brake disc are separated from each other, and the braking action is relieved
(running state).
The brake is equipped with a manual release device. If necessary, the release lever
can be pushed to release the brake.
15
5.4 Landing lock device

See Fig.18
Fig.18
1. door lock 2. interlock switch of door 3. bump plate axle
4. bump plate of car door 5. bump plate of car door
6. car door bumper 7. door lock 8. fixed base of folded plate axle
9. folded plate axle of door 10. folded plate of door
11. fixed set of bumper axle 12. Interlock switch of door
The action process is as follows:

After the Man Lift car has stopped at the landing zone, when opening the car door, the
car door leaf pushes the bump plate of car door to turn upward. After the mechanical lock
roller at one end of the bump plate shaft collides with the bump iron of car door on the
landing door, it climbs up along the bump iron, and then the teeth of the lock plate pass over
the stop lever (the lock plate collides with the connecting lever of electrical switch, which
causes the switch to be powered off), so that the car door can be opened.
Similarly, when pushing the landing door, the folding plate of landing door turns
upward. After the mechanical lock roller at one end of the folding plate shaft collides with
the bump iron of landing door on the car roof, it climbs up along the bump iron, and then
the teeth of the lock plate pass over the stop lever (the lock plate collides with the
connecting lever of electrical switch, which causes the switch to be powered off), so that the
16
landing door can be opened. After the landing/car door has been completely closed, the Man
Lift can operate only when the switch contact is closed.
After the Man Lift car leaves the landing zone, the landing/car door cannot be opened at the
other positions of the Man Liftway.
The inspection/maintenance personnel can use a special key to open the
landing door as shown in Fig. 19,
wherein(1) Lock box (2) Lock plate (3) Key to landing door (4) Lock
core
Fig.19
5.5 Car door mechanical lock

See Fig.20
Fig.20
1. roller 2. pressure wheel
3. lever 4. lock set
5. lock plate 6. crank
7. turn arm 8. bracke

Interlock Switch of Car Door Fig.21
( see fig. 21 )

1. base plate 2. guide plate 1
3. guide pillar 4. spring
5. slider of insert plate switch
6. switch 7. slider
8. guide plate 2
17
5.6 Landing door mechanical lock
( see fig. 22 ) Fig.22

1. roller 2. flatter
3. lock plate assembly
4. lock core
5. spring
6. lever
Interlock Switch of Landing Door

( see fig. 23 ) Fig.23

1. base plate 2. guide pillar
3. guide plate 1 4. spring
5. slider 6. Insert plate
7. Switch 8. Guide plate 2

18
5.7 Safety protection of car frame

See Fig.24
Fig.24
Wherein (1) Front guide roller (2) Drive assembly (3) Gear of anti-dropping safety
device (4) Rear guide roller (5) Side guide roller (6) Man Lift car bracket (7) Mast section
(8) Safety stop-lever (9) Gear of speed reducer (10) Pressure roller
A safety stop-lever is installed on the drive assembly, one safety hook is installed on
the left /right side of Man Lift car bracket respectively, two rollers are installed on the
front/rear side of drive assembly respectively, two rollers are installed on the front/rear side
of Man Lift car bracket and four side rollers are installed on the front/rear side of Man Lift
car bracket, and two pressure rollers are installed on the gear-rack meshing positions/parts
of the speed reducer and anti-dropping safety device, all of which will play a protective
role.
19
5.8 Hand release device

See Fig.25

Fig.25
Wherein (1) Protection box for release brake wire (2) Car panel (3) Hand release brake
wire (4) Release handle (5) Protection cover for hand release handle (6) Motor brake (7)
Release brake bar (8) Support rod (9) Release lever (10) U connection block
Hand release is to separate the fixed brake disc and the rotating brake disc of the motor
brake from each other by pulling the release handle on the car panel through the brake wire,
release lever and release brake bar, and then relieve the brake, so that the Man Lift can
move downward under the action of the potential load.
5.9 Buffer
See Fig.26
There are two hydraulic buffers on the
floor of the pit. When the car collapses to
the bottom of pit, the anti-collision cushion
plate at the bottom of the elevator car frame
Fig.26 contacts the top cover of the buffer, and the

energy due to collapsing to the bottom of pit will be absorbed by the spring, which can
reduce its impact force.
20
Code H L L1
Dimensions 750mm 180 mm 520mm
5.10 Overload device

See Fig.27
Detail view A
Fig.27
Wherein (1) Man Lift car (2) Car chassis (3) Elastic elements (4) Alarm horn (5)
Movable platform of Man Lift car (6) Car chassis (7) Magnet (8) Sensor (9) Junction box
The device consists of Sensor, Magnet and Elastic elements. The distance between
magnet and sensor (6-8mm) decreases due to the compression deformation of elastic
elements. The sensor generates an alarm signal by detecting the distance change between
the sensor and the magnet. When this distance decreases to a certain value, the sensor
outputs an alarm signal.
21
5.11 Self-lubricating system
Lubrication pump system
Fig.28
The working principle of self-lubrication system: When the motor of the lubrication
pump starts up, the pump core sucks some lubricants in the oil tank, and then conveys them
to the lubrication pipeline through the safety valve. These lubricants flow into the pipeline in
this way. After that, the lubricants are then transported to the lubrication points during the
operation of the pump. Once the pressure accumulation process is completed, the system will
switch the relief valve controlled by the pressure switch. When the pipeline releases the
pressure, the system immediately begins to prepare for the next lubrication cycle.
Test instructions:
1. The tester stands at the top of the Man Lift car, sets/pushes the operating handle on the top
of the car into the inspection mode and opens the pump control switch, then the elevator
moves up. The lubrication pump motor will start after power up. Observe if the agitated oil
pan in the lubrication pump is rotating/moving. Stir the oil pan counterclockwise.
2. When the elevator moves up, the lubrication pump delivers the oil to the lubrication line
and then delivers it to the lubrication point of the lubrication line until the grease can
continue to flow out.
Operation steps: There is an oil pump control circuit breaker in the roof electric control box.
After connection, the oil pump is turned on and the elevator is set to check the state and the
oil pump control switch is turned on. After that, the elevator only needs to move up and down
one cycle to ensure that the contact surface of the gear and the rack is covered with an oil
film.
22
6.Safety locking system of elevator instruction

Function: Safety locking system is used for the purpose of ensure the maintenance
personnel in safe if the parts needs repair under the car bottom or other related parts in the 1st
landing in pit.
Procedure:
Operate the car up to the 2nd landing, the maintenance personnel shall climb to the car
top through the ladder inside the car, open the control box on top car, switch the maintenance
switch to the manual position,and then the personnel leave the car;
The maintenance personnel return to the 1st landing through the platform outside;
manually operate the handle of safety locking, pull the safety locking from the non-working
state (figure 1) to the working state (figure 2);and then go back to the control box of elevator
power supply, and reach the elevator general power control box, connect the falling test
controller to the power box, and then press the bypass and downward button on the controller
to lower the elevator to the location of safety locking.
After maintenance work completed, operate the car to the 2nd landing by the falling test
controller, reset the safety locking to the non-working state,at last, set the car to the automatic
state on top car.

Pic 1 non-working state (figure 1) Pic 2 working state (figure 2)
23
View A
7. Important Description of Safety Rules
Warning!
This identification represents danger! Be careful！ This sign indicates that it
may cause some personal casualties!
Caution!
This identification represents the behaviors that may cause some damage to
equipment.
Since the manufacturer is unable to predict the potential hazards under all
environmental conditions, the attention and warning information provided in this "Manual"
does not fully cover all situations, nor does it apply anywhere.
Users shall conduct pre-job safety and skills training for the operators.
Warning! Caution!

For your safety, it is necessary to read this manual before using, repairing and
installing the Man Lift. Misuse of this Man Lift may cause personal injury or property
damage, and randomly touching the control button may cause some accidents.

Repair and replacement can only be done when the power supply is cut off or
the emergency stop switch is pressed.

You can’t test the braking moment of the Man Lift or replace the speed
reducer, motor, brake (including adjustment) and anti-dropping safety device before
the car has landed on the buffer and the power supply has been cut off.
24
7.1 Safety requirements during the run operation

Users shall be responsible for all safety issues in the process of use.
7.2 Before the operation of this Man Lift, you shall be

familiar with the requirements on the sign of safety
instructions:
25
1） It is not allowed to operate the Man Lift when wind speed exceeds 20 m/s.
2） Do not overload. The rated load and the number of the rated load-bearing
personnel are indicated on the sign.
3） It is forbidden to carry goods on the top of the car.
4） No personnel are allowed to stand on the car top during normal operation.
5） If any abnormal situation occurs, please stop operation immediately and
notify the maintenance/repair department.
8. Safety requirements for periodic inspection and maintenance

The periodic inspection and maintenance unit shall be responsible for the safety
issues in the process of inspection and maintenance.
Warning! Caution!
 Repair and replacement can only be done when the power supply is cut off
or the emergency stop switch is pressed.
 Only when the car has landed steadily on the buffer, can it be allowed to do
relevant work.
1） When working on the top of the car, the safety belt must be fastened.
2） When carrying out operation inspection or maintenance/repair, the Man Lift
car shall move downwards from top to bottom.
3） No personnel are allowed to stand on the car top when the Man Lift is
running.
4） Overload operation is strictly prohibited.
5） It is strictly forbidden to operate in violation of regulations until the cause of
the failure has not been identified and eliminated.
6） When conducting the load-bearing test and anti-dropping safety device test,
no one can be in the car or at the landing.
7） Repair and replacement can only be done when the power supply is cut off or
the emergency stop switch is pressed.
8） You can’t test the braking moment of the Man Lift or inspect/replace the
26
motor and motor brake, speed reducer, anti-dropping safety device, etc.
9） before the car has landed on the buffer and the power supply has been cut off.
27

TKC40升降机操作说明书 TKC Man Lift Operation Manual

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Operation

TKC Man Lift

S&C HEAVY EQUIPMENT CO., LTD

3. Brief Introduction of Structure

3.1 Drive assembly

3.2 Man Lift car bracket

3.3 Man Lift car assembly

3.4 Landing door assembly

3.5 Mast section

3.7 Landing protection net

3.8 Cable draught-proofing channel

3.9 Running wire rack

4.2 Call operation on the landing call button box

4.3 Operation on the panel of car roof inspection box

4.4 Operation of pit box

5.1 Structure of anti-dropping safety device

5.2 Overspeed governor

5.3 Motor brake

5.4 Landing lock device

The action process is as follows:

5.5 Car door mechanical lock

Interlock Switch of Landing Door

5.7 Safety protection of car frame

5.8 Hand release device

Fig.26 contacts the top cover of the buffer, and the

5.10 Overload device

5.11 Self-lubricating system

Lubrication pump system

6.Safety locking system of elevator instruction

7. Important Description of Safety Rules

7.1 Safety requirements during the run operation

7.2 Before the operation of this Man Lift, you shall be

8. Safety requirements for periodic inspection and maintenance

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