TKC40升降机维修说明书TKC Man Lift Maintenance Manual

Maintenance Manual Project: PSA, Belgium
TKC Man Lift

Maintenance Manual
S&C HEAVY EQUIPMENT CO., LTD

Maintenance Manual Project:GMK-Doosan Vina
Contents
1. Foreword .............................................................................................................. 2
2. Technical Description .......................................................................................... 2
3. Man Lift Operation and Maintenance Instructions .............................................. 3
3.1 Run operation of the Man Lift ............................................................................. 3
3.2 Matters needing attention during the operation of Man Lift ................................ 3
3.3 When the following situations occur, the Man Lift must not be used. ................ 5
3.4 Handling in case of emergency ............................................................................ 6
4. Inspection and Maintenance................................................................................. 8
4.1 Routine inspection contents and requirements .................................................... 9
4.2 Inspection and adjustment.................................................................................. 11
4.3 Wear/tear and inspection .................................................................................... 16
4.4 Replacement of parts/components ..................................................................... 18
4.5 Lubrication ......................................................................................................... 21
5. Operation Test of the Man Lift........................................................................... 23
5.1 Preparations before the test run.......................................................................... 23
5.2 No-load test ........................................................................................................ 23
5.3 Rated-load test.................................................................................................... 24
5.4 Overload test ...................................................................................................... 24
6. Dropping Test and Reset of Safety Device ........................................................ 25
6.1 Dropping test ...................................................................................................... 25
6.2 Reset of anti-dropping safety device .................................................................. 26
7. Accompanied Tools ............................................................................................ 27
8. Commonly Used Tools ....................................................................................... 28
9. Parts Catalog ...................................................................................................... 28
10. Electrical System................................................................................................ 29
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.
Fig.1
2
3. Man Lift Operation and Maintenance Instructions
3.1 Run operation of the Man Lift
Caution!
Users must ensure that all Man Lift operators are familiar with the chapters
related to "Safety rules", "Man Lift operation" and "Emergency handling " in this
operating manual.
Users must inform all Man Lift operators how to handle in case of emergency; and
if any malfunction occurs, it is their responsibility to report them to the relevant
departments immediately.
Users shall regularly train the Man Lift operators and make the training records.
1） Confirm that the power circuit breaker and lighting switch operating handle
inside the power box are closed or not.
2） Press the call button on the landing door to call the Man Lift to this landing.
When the Man Lift stops stably, open the landing/car door, and then enter the
Man Lift car.
3） After the Man Lift doors (landing/car door) have been completely closed, press
the button of landing zone for the Man Lift to arrive at on the operation panel;
at this time, the Man Lift will start running automatically.
4） After the Man Lift reaches the selected floor, it will automatically decelerate
and then stop. When the Man Lift stops stably, open the landing/car door.
5） After leaving the Man Lift, the passengers shall close the Man Lift doors
(landing/car door).
6） When stopping using the Man Lift, the power circuit breaker, lighting switch
and key switch inside the car shall be turned off.
3.2 Matters needing attention during the operation of Man Lift

1） The Man Lift cannot operate under the following conditions:
3
Check whether the car/landing door is closed tightly.

Check whether the car roof skylight is closed or not
(See Fig. 2). Check whether (2) Skylight lock is closed, and whether (1) Interlock switch
is closed.
Check whether the circuit breaker in the power box of main landing and the key
switch on the operation panel inside the car are in the position of "ON";
Check whether each emergency stop button is pressed;
The Man Lift has four emergency stop buttons on the operation panel inside the car,
the inspection box on the car roof, the power box and the panel of pit box respectively (See
Fig. 3).
Fig.2 Fig.3
Check whether "Operation/inspection" switch on the car roof inspection box is in

the position of "Operation";
1） Check if there are any problems affecting safe operation.
2） Check whether the leveling dimensions (horizontal height difference between the
landing door sill and the car door sill) changes when the Man Lift runs to this landing.
3） Check whether the functions of emergency stop button and alarm button inside
the Man Lift car are normal.
4） Check whether the landing/car door lock devices are normal.
5） Check whether the noise and vibration during the Man Lift operation are
normal.
6） Check whether the brake is released by monitoring before the Man Lift moves
downward. During the Man Lift operation, if hearing an impact sound when the brake
attracts the electromagnet, which indicates that the brake has been released.
4
Caution!
If there are any problems affecting work safety, do not operate the Man Lift.
In case of any emergency, quickly press down the emergency stop button, and let
the Man Lift stop working, then timely notify the maintenance personnel for
handling.
Only after having confirmed that the faults have been troubleshot, can the
emergency stop button be pulled out, and then the button head will be reset.
Users shall assign a professional person to carry out routine inspection and
maintenance, meanwhile make detailed record of the daily problems found. The
contents of the record shall include date, problems found and maintenance and
troubleshooting methods, which will provide some reference for periodic inspection
and maintenance.
3.3 When the following situations occur, the Man Lift must not
be used.
1） The personnel have not been trained on use/operation;
2） The wind speed exceeds 20 m/s (72 km/h);
3） The load of the Man Lift exceeds the rated weight and the number of passengers
loaded.
4） When there are any abnormal noise, vibration, collision sound, leakage of
electricity, abnormal smell or sound in the operation of the Man Lift, the emergency
stop button shall be immediately pressed, and the alarm signal shall be sent out by
pressing down the alarm button.
5） When the Man Lift continues to slip down for a period of time after it runs to the
landing and then levels (the motor has been powered off);
6） When the Man Lift continues to climb up about 50 mm after it runs to the top
landing;
5
7） When the Man Lift continues to slip down for about 50 mm after it runs to the
main landing;
Warning! Caution!
If not comply with the above requirements, it will cause serious casualties and
property damage.
For Item 1 - 2), the Man Lift shall be inspected and handled by professionals before
use.
3.4 Handling in case of emergency

Anti-dropping safety device acts;
Phenomenon: After the Man Lift suddenly stalls during the down-motion, it stops
running.
1） It is necessary to press the emergency stop button immediately, and turn off the key
switch.
2） Press the alarm button to send out a signal through the alarm horn or lamp; meanwhile,
ask the relevant departments for rescue through the telephone or mobile phone set
inside the car, and then wait for professionals to handle with.
3） The passengers shall be guided by professionals for evacuation, and report the
situations to the management department in a timely manner.
4） Only after the professionals inspect the Man Lift to find out the reasons for why the
anti-dropping safety device acts, and then troubleshoot them, can the Man Lift be used.
Power failure or electrical failure;
Phenomenon: The Man Lift suddenly stopped running during its normal operation.
1） It is necessary to press the emergency stop button immediately, and turn off the key
switch.
6
2） Press the alarm button to send out a signal through the alarm horn or lamp; meanwhile,
ask the relevant departments for rescue through the telephone or mobile phone set
inside the car.
3） Alternatively, through the hand release device inside the Man Lift car, make the car
slowly move down to the nearest landing, and open the car/landing door to enter the
landing platform, then close the car/landing door.
Caution!
When the running distance through the hand release device exceeds 20 meters, it shall
stop for 5 minutes before moving down once again.
The friction plate of motor brake fails due to wear/tear;
Phenomenon: After the Man Lift has run to the landing, and then levels (the motor has
been powered off), it continues to slip down faster and faster gradually.
At this time, the passengers shall not be panic, but shall press the floor-selection button
to the main landing, so that the Man Lift can enter the normal operation state. When
approaching the main landing, the Man Lift will land onto the buffer inside the pit at the
speed of deceleration section.
If there is no passenger in the car, when the slip speed reaches 1.15-1.35 times of the
rated operating speed, these overspeed governor installed on the Man Lift will not
increase the slip speed any more, until the Man Lift lands onto the buffer inside the pit
by collapsing to the bottom of pit .
Caution!
The friction plate of motor brake shall be replaced by professionals. Only after
testing, can the Man Lift be used.
Upper limit switch acts;
Phenomenon: When the Man Lift runs to the top landing, but does not stop running, it
continues to climb up 200 mm or so until stopping running( the power supply is cut off);
At this time, the passengers shall not be panic, but shall press the alarm button to send
out a signal through the alarm horn or lamp, and then wait for rescue; or go up to the top
7
of the car through the ladder inside the car, and raise the car's landing door lock plate to
open the car's landing door, then enter the landing platform.
Lower limit switch acts;
Phenomenon: When the Man Lift runs to the top landing, but does not stop running, it
continues to slip down 200 mm or so until stopping running( the power supply is cut
off);
At this time, the passengers shall not be panic, but shall press the alarm button to send
out a signal through the alarm horn or lamp, and then wait for rescue; or climb up to the
top of the car through the ladder inside the car, and raise the car's landing door lock plate
to open the car's landing door, then enter the landing platform.
Caution:
When the upper / lower limit switch acts, the Man Lift shall be handled by
professionals before use.
4. Inspection and Maintenance

The main service object of this Man Lift is human. In order to avoid any accidents, the Man Lift
must be inspected and maintained to ensure that it can meet all operational and safety requirements.
Users must assign special personnel (who must have relevant qualification certification) for
inspection and maintenance work, and specify their specific responsibilities.
Note: The contents of this section are mainly written in accordance with standard configuration.
If special handling, replacement of equipment and accessories that need to be specially produced are
involved in the maintenance process, please contact the manufacturer or supplier.
8
4.1 Routine inspection contents and requirements

Period/freq
Parts/components Requirements
uency
1. Anti-dropping Safety devices shall be intact, without any internal
safety device noise during the operation.
2. Landing/car door The electromechanical interlocking device is flexible
lock device and reliable.
Check whether there are any frictional sounds or
3. Electromagnetic
odors; when the car lands under full load, its leveling
brake of motor
accuracy shall be less than 30 mm
Monthly 4. Speed reducer There is no oil leakage in the speed reducer.
maintenance 5. Man Lift car There is no water leakage in the car.
(Net The meshing clearance between the output gear and
working 6. Gear-rack meshing rack of speed reducer is 0.3-0.5 mm.
time: 50 clearance The meshing clearance between the gear and rack of
hours) anti-dropping safety device is 0.5-0.75 mm.
There is no hanging/collision with the inner wall of
7. Traveling cable
cable draught-proofing channel
Check whether the bolts for rolling roller, pressure
8. Connecting bolt roller and safety stop lever on the driving device and
Man Lift car bracket are tightened or not
9. Lubrication
According to the lubrication interval.
interval
Quarterly 10. Anti-dropping A Man Lift dropping test is carried out according to
maintenance safety device "9 Dropping test ".
(Net Tighten all the connecting bolts between the mast
working section and the rack, the mast section and the bracket,
11. Guide rail
time: 150 the mast section and the mast section, which have
hours) been loosened.
9
Period/freq
Parts/components Requirements
uency
Check whether the cable is worn /torn, and check the
12. Cable
clearance between the running wire rack and the
installations
draught-proofing channel of traveling cable.
13. Rack and gear Check the wear/tear of rack and gear
14. Guide roller and
Check the wear/tear, and carry out some adjustment
pressure roller
15. Overspeed Check the speed limiting effect, and inspect the
governor wear/tear of brake pad by observation
Ensure that all the texts on safety label and sign are
16. Sign
clear and visible.
Check the conditions of shock absorber; if necessary,
17. Coupling
replace it.
Check the conditions of worm and gear; clean them
18. Speed reducer
and change the oil according to lubrication table
19. Guide roller and Clean them and change the oil according to
pressure roller lubrication table
Annual
20. Corrosion Check all components/parts of the Man Lift that may
inspection
damage and wear/tear be corroded and worn/torn; replace them if necessary.
21. Inspection on the
In accordance with "5. Operation test of the Man Lift
operation of whole
".
machine
Note: Monthly maintenance: Items 1-9; Quarterly maintenance: Items 1-17; Annual inspection:
Items 1-21.
For anti-dropping safety device, a no-load dropping test shall be carried out every three
months, and an additional drop test with rated load shall be carried out every six months.
The service life of anti-dropping safety device is 5 years, counting from the date of leaving
the factory.
10
4.2 Inspection and adjustment

1） Motor brake;
Structure of motor brake
See Fig.4
When the brake has some frictional sound or
odor after powering on the motor:
The motor brake shall be inspected (see Fig. 5).
Check whether there is sufficient degree of freedom
in the connection between Release brake lever (1) and
Release lever (3), Release lever and Support rod (2)
Fig.4
and that there shall be no jamming between Release
brake lever and Motor cover.
When the Man Lift can't stop reliably, and still slips
down for a while after cutting off the power supply
It may be due to the rotating brake disc is worn/
torn or the armature iron of the brake is not flexible to Fig.5
be reset or the spring is jammed, which shall be
adjusted by referring to the brake maintenance manual.
Land the Man Lift car onto the buffer, cut off the power supply, disassemble the protective
cover, and loosen the coordination adjustment to make the clearance between the electromagnet
and the armature iron be 0.35-0.4 mm, with the circumference balanced. After that, power it on
for test until the brake works normally.
If the rotating brake disc is damaged or the clearance between the fixed brake disc and the
armature iron is ≤8mm (after stopping at the landing, the car’s slip speed gradually increases
until it lands onto the buffer, from which it can be preliminarily judged that the rotating brake
disc may be damaged); at this time, the rotating brake disc shall be replaced, whose specific
steps are as follows:
Land the Man Lift car onto the buffer, cut off the power supply, disassemble the protective
cover, remove six bolts, take down the electromagnet assembly, and remove the rotating brake
11
disc from the spline housing, then replace it with a new one; loosen the adjusting sleeve by 3-4
turns, reset the electromagnet assembly and fasten it with bolts, adjust six adjusting sleeves and
six bolts until the clearance between the armature iron and the electromagnet is balanced to
0.35-0.4 mm; after that, mount the protective cover, and then power it on for test.
If the brake is not working properly, please check the following items:
Check whether the rectifier is intact, and has been powered on; whether the brake switch
is intact; whether the current passing through the coil is sufficient; whether the coil
resistance meets the requirements.
Warning!
When adjusting the clearance between the armature iron of the brake and the brake
pad, or replacing the brake, the Man Lift must be landed onto the buffer.
2） Adjustment of overspeed governor
See Fig.6, and Fig.7
Fig.6 Fig.7
The overspeed governor consists of (1) Adjusting bolt (2) Stop washer (3)Lock nut (4)Brake
(5)Brake assembly (6) Adjusting washer (7)Housing (8)Disc spring (9), Connecting plate
(10)Main body, etc. in Fig. 7.
Clearance between the brake pad and the housing:
The clearance is related to the operation speed of the Man Lift. The higher the speed, the
larger the clearance. During the factory debugging, the clearance is controlled at 1-1.5 mm.
When some friction occurs between the housing and the brake pad of speed governor:
Loosen the bolt, disassemble the housing, open the fuse, remove the bolt baffle, unscrew
12
the lock nut, and tighten the adjusting bolt to increase the clearance.
When the speed governor loses its normal function:
Loosen the bolt, disassemble the housing, open the fuse, remove the bolt baffle, unscrew
the lock nut, and tighten the adjusting bolt to decrease the clearance.
If the speed limiting effect cannot be restored, it is necessary to loosen all adjusting bolts,
and take down the brake pad assembly, then increase the thickness or number of adjusting
washers on the small shaft to compensate for the increase in clearance.
3） Adjustment of pressure roller

See Fig.8
Fig.8
The pressure roller is composed of (1) Gasket (2) Seat plate (3) Eccentric sleeve (4)
Pressure roller shaft (5) Pressure roller (6) Bearing (7) Retainer ring (8) End cover (9)
Retainer ring (10) Screw (11) Nut (12) Thin nut (13) Locking bolt and so on.
The pressure roller is installed at the gear of speed reducer for the drive assembly and
the gear of anti-dropping safety device for the car bracket (See Fig. 9). The inner and outer
diameters of pressure roller shaft are concentric, while the inner and outer diameters of
eccentric sleeve are eccentric. By rotating, the angle of the eccentric sleeve can change from
-3 to 0- +3mm.
13
4） Adjustment of gear-rack meshing clearance

Fig.9 Fig.10
In Fig. 9: (1) Seat cover (2) Pressure roller (3) Drive board/brake board (4) Rack (5)
Gear
In Fig. 10: (1) Pressure roller (2) Washer (3) Eccentric sleeve (4) Nut (5) Wrench 3 (6)
Drive board/brake board (7) Screw (8) Thin nut (9) Screw.
When adjusting, loosen the connecting screw between the pressure roller and the seat
cover. The angle of eccentric sleeve rotated with a special wrench is as shown in Fig. 10; the
meshing clearance between the gear and the rack is shown in Fig. 9. The normal meshing
clearance between the output gear and rack of speed reducer is 0.3-0.5 mm; the normal
meshing clearance between the gear and rack of anti-dropping safety device is 0.5-0.75 mm
(measured by using a feeler gauge).
5） Adjustment of rolling roller

Fig.11 Fig.12
14
In Fig. 11: (1) Washer (2) Seat cover (3) Eccentric shaft (4) Dust ring (5) Roller (6)
Bearing (7) Retainer ring (8) Retainer ring (9) End cover (10) Oil nozzle (11) Bolt (12) Washer.
In Fig. 12: (1) Wrench 2 (2) Roller (3) Drive board/brake board (4) Eccentric shaft (5)
Bolt (6) Washer.
There are two rollers in the front and rear of the drive
assembly respectively, and two rollers in the front and rear of
the Man Lift car bracket respectively. By rotating, the angle of
the eccentric sleeve can change from -3 to 0- +3mm.
When adjusting, loosen the connecting screw between the
pressure roller and the seat cover (the angle of eccentric sleeve
rotated with a special wrench is as shown in Fig. 12); attach the
Fig.13
front and rear rollers of the drive assembly and the front and
rear rollers of the Man Lift car bracket onto to the surface of
main tube for the mast section(the clearance between the left and right rollers of the Man Lift
car bracket and the surface of main tube for the mast section is 0.1-0.5 mm, as shown in Fig.
13).
6） Adjustment of the clearance between the bump iron and the roller of car door lock
See Fig.14
Fig.14 Fig.15
In Fig. 14: (1) Bump iron of car door (2) Rolling roller of car door lock.
By adjusting the relative position between the bracket and the bump iron of car door on
the landing door, the clearance between the roller and the bump iron can be changed, which
15
shall be between 0.2-0.5mm.

7） Adjustment of the clearance between the bump iron and the roller of landing door lock
See Fig.15
In Fig. 15: (1) Bump iron of landing door (2) Roller of landing door lock (3) Roller support
plate (4) Lock plate.
By adjusting the relative position between the lock plate and the roller support plate on
the landing door lock, the clearance between the roller and the bump iron of landing door
fixed on the Man Lift car can be changed, which shall be between 0.5-2mm.
4.3 Wear/tear and inspection

1） Measurement of torque value for motor brake
See Fig.16
The motor power is 11 kw; the braking moment of the
brake is not less than 126 Nm when the spindle is not
moving. Fig.16
Warning!
When measuring the brake torque value, the Man Lift must be landed onto the
buffer.
2） Limit value of gear wear/tear
See Fig.17
Number of 15 teeth for M8 gear. Measuring and checking instruments: Tooth pitch
measuring caliper
Standard value 37.1

Wear/tear limit value 35.8
Wear/tear limit value
60.5
Fig.17 Fig.18
16
3） Limit value of rack wear/tear

See Fig.18

Limit value of M8 rack wear/tear.

Measuring and checking instruments: φ 14 measuring
rod and 150 mm caliper.
4） Limit value of speed-reducer wear/tear
See Fig.19
When measuring, land the car onto the buffer, cut off
the power supply, push the motor brake handle to release
the brake, and open the end cover of the overspeed Fig.19
governor to rotate the brake assembly, then measure β value
in the figure; if greater than 20°, it indicates that the worm gear of speed reducer has reached
the wear/tear limit.

Warning:
When measuring the wear/tear limit of speed
reducer, the Man Lift must be landed onto the buffer.
5） Wear/tear limit for brake pad of overspeed governor
See Fig.20
Wherein (1) Brake assembly (2) Brake pad (3) Main body.

When the brake pad is worn/torn out to the point where Fig.20
rivets will be exposed (rivets will be rubbed against the
housing), the brake pad need to be replaced.
6） Wear/tear limit of guide rail (main tube of mast section)
The measuring position is shown in Fig. 21. The original wall thickness is 4.5mm. The
wall thickness of the contact area between the roller and the main tube shall be measured by
using ultrasonic thickness gauge; if less than 3.4mm, it shall be replaced in time, especially
the bottom main tube of mast section.
7） Wear/tear limit of pressure roller
17
See Fig.22
The original dimensions is 120mm, and the limit is 119mm.
8） Wear/tear limit of rolling roller

The rolling rollers installed on the position of drive assembly are as shown in Fig. 23.
The original dimension is 80mm, and the limit is 78mm.

The rolling rollers installed on the position of Man Lift car bracket are as shown in Fig.
24.
The original dimension is 80mm, and the limit is 98mm.
Standard valueΦ120
Wear/tear limit valueΦ119 Standard valueΦ100
Wear/tear limit valueΦ98
Standard valueΦ80
Wear/tear limit valueΦ78
Fig.21 Fig.22 Fig.23 Fig.24
4.4 Replacement of parts/components

1） Replacement of motor
See Fig.25
Fig.25
Wherein (1) Overspeed governor (2) Speed reducer (3) Drive board (4) Coupling (5)
(6) Coupling (7) Motor bracket (8) Motor
The disassembly and assembly procedures are as follows:

Land the Man Lift onto the buffer.
18

Disconnect the main power switch and remove the three-phase power line of the
motor.

Disassemble the hand release device at the tail of the motor.

Remove the motor brake band.

Disassemble the flange bolt of the motor.

Take down the motor.

Remove the motor coupling.

Install/assemble a new motor in reverse order.
2） When the anti-dropping safety device needs annual inspection or replacement
See Fig.26
Fig.26 Fig.27
(1) Brake board (2) Connector (3) Anti-dropping safety device (4) Gear of anti-dropping
safety device.
When the safety device needs to be replaced due to it is newly calibrated or damaged, the
procedures are as follows:

19

Loosen the back gear behind the rack, and adjust the eccentricity to the maximum
position, so that the gear and the rack are out of contact.

Remove four bolts of the safety device and the brake board.

Remove the safety device.

Install/assemble a new safety device in reverse order.

Wiring.

Adjust the gear-rack meshing clearance to 0.5-0.75 mm
3） Replacement of drive gear
See Fig.27
Wherein (1) Drive board (2) Gear (3) Connector (4) Speed reducer.


Loosen the back gear behind the rack, and adjust the eccentricity to the maximum
position, so that the gear and rack are out of contact.

Remove the rand at the end of the gear shaft.

Disassemble the gear with a gripper.

Re-install/re-assemble a new gear.

Adjust the gear-rack meshing clearance to 0.3-0.5mm.

Tighten the back gear.
4） Replacement of rack for mast section;

Loosen the mast section with the rack to be replaced, and then all the bolts connecting
the bracket to the mast section on the upper position, but don't remove the nuts.

Remove the bolts connecting the mast section with the rack to be replaced to the mast
section on the upper position

Lift the loosened mast section to separate the rack to be replaced from the rack of mast
section on the upper position.

Remove the rack to be replaced, and then replace it with a new one. Do not tighten the
connecting screw.

Lower the mast section that has been lifted, and then adjust its correct position.

Adjust the position of new rack, and tighten all bolts that have been loosened and
removed.
20
5） Replacement of speed reducer

See Fig.27

Lift up the car so that the gear and rack are out of contact.

Remove the motor.

Disassemble the overspeed governor.

Remove the gear.

Remove the connecting bolts between the speed reducer and the drive board.

Take down the speed reducer.

Re-install/assemble a new speed reducer in reverse order.

Re-install/re-assemble a new gear.

Adjust the gear-rack meshing clearance to 0.3-0.5mm.
4.5 Lubrication
The positions/parts to be lubricated, lubrication intervals and used lubricants are as
shown in the table below.
Positions/parts
Period /
to be Used lubricants Requirements
frequency
lubricated
Check the oil
Monthly Speed reducer
level (oil gauge)
Apply from top

Molybdenum to bottom, with
Rack
disulphide grease the coating thin
and uniform
Anti-dropping Lithium base Grease-gun

safety device grease lubrication
Lithium base Grease-gun

Rolling roller
grease lubrication
21
Positions/parts
Period /
frequency
lubricated
Hinge
position/part Lithium base Grease-gun
Quarterly
of car door grease lubrication
lock
Hinge
position/part Electromechanical
Drop lubrication
of landing N22 with oil pot
door lock
Car door axle Electromechanical

Drop lubrication
and roller N22 with oil pot
Landing door Electromechanical

Drop lubrication
axle N22 with oil pot
Hinge
position/part Electromechanical
Drop lubrication
of release N22 with oil pot
device
Apply along the

contact surface
Main tube of Molybdenum
of rolling roller
mast section disulphide grease
from top to
bottom
Clean and
Synthetic worm
replace the
gear lubricant
N32 or Mobil worm gear
Annually Speed reducer Glygoy HE320
lubricant, with
and Shell tivla Oil
ScGH6-320 the oil quantity
Synthetic gear oil
of 10L
22
Positions/parts
Period /
frequency
lubricated
Clean, lubricate
Motor or replace the
bearings
Clean, lubricate
Pressure roller Lithium base or replace the
grease
bearings
5. Operation Test of the Man Lift
5.1 Preparations before the test run:

1） Before test run, grease the drive gear, and rack, mast section rail and roller.
2） Check that all emergency switches and ultimate limit switches are functioning
properly.
3） Check that all electrical and mechanical interlocking devices are normal.
4） Check that all mechanical parts/components are firm and reliable.
5） When the wind speed is over 15 m/s. no test is allowed.
6） The test run shall be completed by the manufacturer's professionals or
authorized personnel.
7） No unrelated personnel shall enter the test site during the test run.
5.2 No-load test

The whole test run of the Man Lift shall include not less than three working cycles of
up/down-motion test. During each working cycle, one up/down-motion brake must be carried
out.
1） The Man Lift levels accurately.
2） The function of electrical and mechanical interlocking is normal. If opening any
one of the landing doors, the car doors and the safety windows in any position
and state, the Man Lift shall not operate.
23
3） The function of electrical system device and operating system is normal.

4） The motor brakes reliably.
5） The safety device is stable and reliable.
5.3 Rated-load test

Place the rated load evenly in the car, and carry out three working cycles (total travel);
during each working cycle of up/down-motion, one normal braking is done. When testing, it
shall be guaranteed that:
1） The Man Lift levels accurately, and with the error not more than 25 mm.
2） The function of electrical and mechanical interlocking is normal.
3） The function of electrical system device and operating system is normal.
4） The motor brakes reliably.
5） There is no abnormal noise or vibration.
6） The safety device is stable and reliable.
5.4 Overload test

1） Static-load test
125% of the rated load is placed evenly in the car, and the distance between the car
and the buffer device is 1 m high. When it lasts 10 minutes, there shall be no down-slip.
2） Overload operation test
Place 125% of the rated load evenly in the car, carry out one working cycle (total
travel), and perform one normal braking. When testing, it shall be guaranteed that:
The function of electrical and mechanical interlocking is normal.
The function of electrical device and operating system is normal.
The safety device is stable and reliable.
Metal structural parts do not have any deformation or damage.
24
Note: The magnet of overload meter shall be

removed before the test.
Caution!
After the test, the magnet of overload meter shall be
mounted, and then debugged according to the requirements of its
operation manual.
6. Dropping Test and Reset of Safety Device
6.1 Dropping test

1） Before the test, stop the Man Lift at the main landing, cut off
the main power supply, insert the accompanied plug of dropping
test button box into the socket of "Dropping test" on the right side
of power box, and push the "Inspection/operation" switch on the
car roof inspection box to the position of "Inspection ".
2） Take down the position limit tool of the overspeed governor
from the car guard rail, disassemble the cover and gasket of the
overspeed governor, and unscrew five bolts to remove the baffle;
after that, take down the position limit tool from the car guard rail,
insert its four claws into the outer side of speed governor connecting
25
plate, and fix them with hexagonal flange bolts, so as to make the brake assembly and the main
body lose the function of speed limiting as a whole.
3） Straighten out the cables on the button box to ensure that they will be not scratched/ scrapped
during the process of testing.
4） Connect the main power switch, press the "up" button on the button junction box, and move
the Man Lift up to a height of 10m from the buffer.
5） Press the "Release the brake" button, and then hold it still; at this time, the motor brake coil is
powered on, and then opened, meanwhile the car of the Man Lift starts to drop faster and faster
under the action of potential energy load. When reaching the action speed of anti-dropping safety
device, the anti-dropping safety device will act to brake the car.
6） At this time, the position limit switch inside the anti-dropping safety device acts, and then the
braking distance and other data are measured. After that, press the bypass switch, meanwhile press
the button of up/down-motion. After the Man Lift moves up 0.5 meter, press the button of down-
motion once again to make the car move down to the 1st landing.
7） Disconnect the main power supply, remove the dropping test button box and test cable.
6.2 Reset of anti-dropping safety device

1） Remove the cover (3).
2） Take down the reset tool and lever (8) from the car roof guard rail.
3） Use the reset tool and lever to withdraw the copper nut until the tail of the pin flushes with the
end face of safety device shell. (At this time, the lower limit switch circuit of safety device
shall be turned on)
4） Remove the position limit tool on the speed governor, and then restore to its original state.
After connecting the main power supply, the Man Lift must first run upward more than 200
mm, so that the centrifugal block can be reset. Only after that, can the Man Lift operate
normally.
Caution:
26
When the Man Lift is 4m away from the buffer device, but the anti-dropping
safety device has not acted yet, it is necessary to release the button immediately, so that
the motor brake coil is powered off to make the Man Lift stop running.
The reasons for why the anti-dropping safety device does not act are as
follows:
The overspeed governor has not lost its speed limiting function. The reason is
that the pre-tightening force of the disc spring is small; when the down-motion speed
of the Man Lift has not reached the action speed of anti-dropping safety device, the
overspeed governor has played the role of speed limiting.
The brake pad of motor brake is not completely separated from the armature
iron.
The anti-dropping safety device fails.
After finding out the reasons, and troubleshooting them, carry out the test
once again.
7. Accompanied Tools
Special wrench
Special wrench 1
2
Position limiting
Special wrench 3
tool
Reset tool of anti- Key to landing

dropping safety device door
27
8. Commonly Used Tools
Hexagonal head
Spanner
wrench
Adjustable
Screwdriver
wrench
Clip-on
Pipe wrench
ammeter
Electrician's tools Multimeter
9. Parts Catalog
No. Name Quantity Specification/model

QAEJ 132M-4 11Kw (400V 50Hz) with the protection
1 Motor 1 pcs class of IP55
Overspeed
2 governor 1 pcs MBQ01
Anti-dropping SAJ30-1.2 with the rated speed of 0.67m/s (gear modulus:
3 safety device 1 pcs 8; number of teeth: 15)
4 Rolling roller 4 pcs RB070400(G) Φ80
5 Rolling roller 4 pcs R547070700 Φ100
6 Rolling roller 4 pcs R547070800 Φ100

Pressure
7 roller 4 pcs R547070900
8 Gear 1 pcs RB0710
9 Coupling 1 pcs RB071100-1
10 Motor brake 1 pcs Matching with ABB 11kW motor, FDB20C
28
10. Electrical System

Overview
The electrical control section consists of two parts: Main circuit and Control circuit. The
electronic control devices are respectively installed in the power box near the main landing door, the
electronic control box on the top of the car, the pit box, the suspension box, the operation panel inside
the car and the call box on each landing door.
10.1 Main circuit

The main circuit consists of Circuit breaker QF1, Contactor KM1,KM2 and Leakage protection
circuit breaker FV. When three-phase AC passes through the main circuit breaker QF1, which
connects the power supply of main machine into the main circuit of the Man Lift, and the circuit
breaker QF1 in the main circuit can protect the motor from any short-circuit or overload; meanwhile,
the phase sequence relay K9 detects the phase sequence and phase loss of the input power supply.
Brake resistance R: When the elevator moves down, the brake resistance plays the role of releasing
energy.
10.2 Safety circuit

The contactor KM1 is the contactor at the incoming end of inverter, which is controlled by Phase
sequence relay (K11), Pit emergency stop (EMS2), Power box emergency stop (EMS1), Electronic
control box emergency stop (EMS3), Car emergency stop (EMS4) , One to four floor emergency
stop(EMS11-EMS44)，Safety locking pin relay(KA24), Hook Girder Home SW relay(KA23),Anti-
dropping safety switch (SQ5), Skylight switch (SQ7), Position limit switch (SQ9), Brake power
supply detection relay (KA14). If any one of the above switches is disconnected, the contactor KM1
will be disconnected, and the inverter will be powered off, so that the elevator can not run!
10.3 Door Interlocking control circuit

KM2 in the circuit are circuit breaker contactors. When all the landing doors (1SQ-4QS) and the
car door (SQ6), the up/down- crossing (SQS,SQX) and non- overload of the elevator (and KA12 in
the suction state) are in the position of “connection”, KM2 are connected, and the power supply on
the circuit will be transmitted to KM2. KT1 is a time relay. If the door interlocking contactors KM2
is disconnected, the main circuit will cut off the power supply between the inverter and the motor, so
29
that the elevator cannot operate!
10.4 Control circuit

This circuit consists of the switch devices such as inspection, operation, floor selection, call and
leveling control to car arrival chime.
10.4.1 Elevator inspection circuit

In the inspection/maintenance and operation section of control circuit, SA2 is an inspection
switch. When pushing SA2 to the position of “Inspection”, the elevator is in the inspection state. SB5
is slow up-motion switch, and SB6 is slow down-motion switch. When pressing SB5, the elevator
moves up. At the same time, a group of contacts (3, 4) in SB5 short-connect the down-crossing switch,
that is, after the down-crossing switch acts, the elevator still can run slowly upward by pressing the
button of SB5. Similarly, when pressing SB6, the elevator moves down. At the same time, a group of
contacts (3, 4) in SB6 short-connect the up- crossing switch, that is, after the up-crossing switch acts,
the elevator still can run slowly downward by pressing the button of SB6.
10.4.2 Elevator operation circuit

SB1-SB4 are the floor selection buttons inside the Man Lift car, and SD1-SD4 are the landing
call buttons. There are six deceleration switches in the elevator, all of which are magnetically
controlled bistable switches. When the magnet passes through the deceleration switch upward, the
switch will change to the opposite state, i.e., the switch changes from the open or closed point to the
closed or open point, and then maintains its state. When the magnet passes through the deceleration
switch downward, the state of the switch is just to that when the magnet passes through the
deceleration switch upward. MCS1 is the elevator’s 1st floor down-deceleration switch, MCS2 is the
elevator’s 2nd floor up-deceleration switch, MCS3 is the elevator’s 2nd floor down-deceleration
switch, and MCS4 is the elevator’s 3nd floor up-deceleration switch, MCS5 is the elevator’s 3nd floor
down-deceleration switch,and S86 the elevator’s 4rd floor up-deceleration switch.
30
YG is a leveling switch, which is installed on the car’s drive board. When the leveling switch
receives the signal from the leveling separator, the switch is changed from closed point to open point.
Elevator stopped running.
10.4.3 Inverter control section

DI1: Forward rotation, DI2: Reverse rotation, DI4: Inching operation, DI3: Deceleration
operation.When “DI1” is connected to “+”, the inverter runs forward at the frequency of 50HZ - that
is, the elevator moves upward at the rated speed; when “DI1” and “DI4” are connected to “+”, the
inverter runs forward at the frequency of 10HZ - that is, the elevator inches upward at the speed of
10HZ; when “DI1” and “DI3” are connected to “+”, the inverter runs forward at the frequency of
3HZ- that is, the elevator climb upward at the speed of 3HZ after deceleration. When “DI2” is
connected to “+”, the inverter runs reversely at the frequency of 50HZ - that is, the elevator moves
downward at the rated speed; when “DI2” and “DI4” are connected to “+”, the inverter runs reversely
at the frequency of 10HZ - that is, the elevator inches downward at the speed of 10HZ; when “DI2”
and “DI3” are connected to “+”, the inverter runs reversely at the frequency of 3HZ- that is, the
elevator slip downward at the speed of 3HZ after deceleration.
31
The operation procedures and parameters of the inverter are as follows:

Schneider inverter elevator parameter table
Level 1 Level 2 Level 3 Level 4
Parameter setting
parameter name parameter name parameter name parameter name
2 Access level Expert authority
5 LANGUAGE ENGLISH
1 Inverter menu
1.1 Simple start
（SIN)
Macro setting
Lifting lift(HST)
（CFG)
Standard motor Reference motor
frequency（bfr） nameplate
Motor rated Reference motor
power（npr） nameplate
voltage（UNS） nameplate
current（NCR) nameplate
frequency（FRS) nameplate
Motor rated
Reference motor
speed（NSP)
nameplate
Maximum output
60HZ
frequency（TFR)
complete
（DONE)
Request self-
VDF（TUN) undone（NO)
tuning（YES)
Need to learn
again
32
Change the If the motor turns

output phase to the opposite
sequence（ABC) ACB
Motor thermal
1.2 times rated
protection current
motor current
(ITH)
acceleration
2.5S
time(ACC)
deceleration
2.3S
time(DEC)
Low speed(LSP) 0HZ
High speed
60HZ
frequency(HSP)
1.4 motor control Motor control
SVC I(CUC)
（DRC) type(CTT)
1.5 Input/output Relay R1
Inverter fault
settings（I-O) distribution（R1)
Relay R2 Brake logic
distribution（R2) （BLC)
1.7 Application Slope type
S
function（FUN) （RPT)
2 preset
speeds(PS2) LI1
4 preset
LI2
speeds(PS4)
8 preset
LI3
speeds(PS8)
16 preset
LI4
speeds(PS16)
Preset speed(SP2) 50HZ
33

Preset
10HZ
speed(SP10)
Preset
10HZ
speed(SP11)
Preset
0HZ
speed(SP12)
Preset
speed(SP13) 0HZ
Preset
0HZ
speed(SP14)
Preset
0HZ
speed(SP15)
Preset
0HZ
speed(SP16)
Type of exercise Vertical motion
（BST) （UER)
Brake impulse 2lbr
Brake release
Reference motor
current
Brake logic rated current
(forward)(IBR)
control（BLC)
Brake release
0.5S
time(BRT)
Brake engage
0.2S
delay（TBE)
Brake engage 0.2S
34
time（BET)
1.8 Fault
Fault reset Unallocated
management
未分配
External fault
Unallocated
OUTPH TIME
Output phase loss 2S
DETECT
35

TKC40升降机维修说明书TKC Man Lift Maintenance Manual

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Maintenance Manual Project: PSA, Belgium

TKC Man Lift

S&C HEAVY EQUIPMENT CO., LTD

3. Man Lift Operation and Maintenance Instructions

3.1 Run operation of the Man Lift

3.2 Matters needing attention during the operation of Man Lift

Check whether the car/landing door is closed tightly.

Check whether "Operation/inspection" switch on the car roof inspection box is in

3.4 Handling in case of emergency

4. Inspection and Maintenance

4.1 Routine inspection contents and requirements

4.2 Inspection and adjustment

3） Adjustment of pressure roller

4） Adjustment of gear-rack meshing clearance

5） Adjustment of rolling roller

shall be between 0.2-0.5mm.

4.3 Wear/tear and inspection

Standard value 37.1

3） Limit value of rack wear/tear

Fig.21 Fig.22 Fig.23 Fig.24

4.4 Replacement of parts/components

5） Replacement of speed reducer

Apply from top

Anti-dropping Lithium base Grease-gun

Lithium base Grease-gun

Car door axle Electromechanical

Landing door Electromechanical

Apply along the

5. Operation Test of the Man Lift

5.1 Preparations before the test run:

5.2 No-load test

3） The function of electrical system device and operating system is normal.

5.3 Rated-load test

5.4 Overload test

Note: The magnet of overload meter shall be

6. Dropping Test and Reset of Safety Device

6.1 Dropping test

6.2 Reset of anti-dropping safety device

Reset tool of anti- Key to landing

8. Commonly Used Tools

Electrician's tools Multimeter

No. Name Quantity Specification/model

4 Rolling roller 4 pcs RB070400(G) Φ80

5 Rolling roller 4 pcs R547070700 Φ100

6 Rolling roller 4 pcs R547070800 Φ100

8 Gear 1 pcs RB0710

9 Coupling 1 pcs RB071100-1

10 Motor brake 1 pcs Matching with ABB 11kW motor, FDB20C

10. Electrical System

10.1 Main circuit

10.2 Safety circuit

10.3 Door Interlocking control circuit

that the elevator cannot operate!

10.4 Control circuit

10.4.1 Elevator inspection circuit

10.4.2 Elevator operation circuit

10.4.3 Inverter control section

The operation procedures and parameters of the inverter are as follows: