MASTER INDEX VOLUME 01: CIVIL ELEMENTS
OPERATION AND MAINTENANCE MANUAL
1.1
CIVIL & STRUCTURAL ELEMENTS:
1.1.1 1.1.1 CHAIN LINK FENCE 1.1.2 SIGNAGE 1.1.3 1.1.3 TRAFFIC MANAGEMENT SYSTEM
AIRPORT A IRPORT STAFF STA FF ACCESS A CCESS CONTROL FACILITY PACKAGE PACK AGE - 6201
1.1.4 1.1.4
PARKING MANAGEMENT SYSTEM
1.1.5 1.1.5
TAXI DISPATCH SYSTEM
1.1.6 1.1.6
BUS TERMINAL SYSTEM
1.1.7 1.1.7
SBS ROOFING SYSTEM
1.1.8 1.1.8
ROOF DECKING
1.1.9 1.1.9
FALL PROTECTION SYSTEM
1.1.10 1.1.10
TREES, SHRUBS, GROUND COVERS, LAWNS & GRASSES
1.1.11 1.1.11 IRRIGATION SYSTEM 1.2
ARCHITECTURAL ELEMENTS:
1.2.1 1.2.1
STEEL DOORS
1.2.2 1.2.2
ALUMINUM & GLAZING WORKS
1.2.3 1.2.3
ACOUSTIC/ METAL PAN CEILING/ CEILING/ CORIAN COUNTERS
1.2.4 1.2.4
COMPOSITE STONE TILE/ FLOOR MATS
1.2.5 1.2.5
METAL LOCKERS/ SHELVING
1.2.6 1.2.6
TOILET ACCESSORIES
1.2.7 1.2.7
EPOXY FLOORING
1.2.8 1.2.8
RAISED ACCESS FLOOR
1.2.9 1.2.9
CARPET FLOORING
1.2.10 1.2.10
CARPET TILE FLOORING
O&M MANUAL S- ELEVATORS. ELEVATORS. AIR A IRPORT STAFF ACCESS CONTROL FACIL ILIT ITY-6201
O&M MANUALS- ELEVATORS. AIR AIRPORT STAFF ACCESS CONTROL FACIL ILIT ITY-6201
INDEX: Sr. Item
Description
Page No.
A.
How to use the manual…………………………………………………..3 - 6
1
System Description……………………………………………………. ...7- 13
2
Equipment Schedule…………………………………………………….14-16
3
Field Operation Structure……..……………………………………….. 17-18
4
Safety………………………………………………………………………19-25
5
Operation Manual………………………………………………………..26-27
6
Maintenance Manual…………………………………………………….28-29
7
Disposal Instruction…………………………………………………….3 0-31
8
Trouble shooting………………………………………………………... 32-39
9
Manufacturer contact details………………………………………….40-41
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O&M MANUALS- ELEVATORS. AIRPORT STAFF ACCESS CONTROL FACILITY-6201
Standard safety devices for ASME A17.1-2010/CSA B44-10 Optional safety devices
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8. TROUBLESHOOTING
O&M MANUALS- ELEVATORS. AIRPORT STAFF ACCESS CONTROL FACILITY-6201
8.
8.1
TROUBLESHOOTING
Fault Code Details
O&M MANUALS- ELEVATORS. AIRPORT STAFF ACCESS CONTROL FACILITY-6201
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COMMISSIONING CHECK LIST FOR FUNCTIONAL TESTING SYSTEM NO.:
SUB-SYSTEM NO.:
FM NO:
BUILDING NO.:
DESCRIPTION:
TAG NO:
DATE:
REF DOC/DRWS:
Page no: 1 of 6
of 4
GENERAL INFORMATION Customer:: Customer
SAP NO:
Site Address
Site Contact person Name: Tel No: Mobile No: Fax No: e- mail:
TECHNICAL DATA SAP NO:
Vertical Rise:
Step width :
m
Inclinaison:
mm
Level steps at upper end: Level steps at lowr end:
Rated speed: Supply Voltage:
m/s V
COMMISSIONING CHECK LIST FOR FUNCTIONAL TESTING SYSTEM NO.:
SUB-SYSTEM NO.:
FM NO:
BUILDING NO.:
DESCRIPTION:
TAG NO:
DATE:
REF DOC/DRWS:
Page no: 1 of 6
EQUIPMENT TEST Pre- Installation
YES
NO
YES
NO
N/A
Remark
N/A
Remark
Are the split trusses trusses undamaged ?
Are the standard mounting mounting bolts used?
Is the step chain pin inserted towards out side of escalator?
Is the temporary protection provided at site
In order
Bottom Pit Electrical Operation Is the electrical plug operating correctly?
Is the traffic light operating correctly?
YES
Adjusted/ Repaired NO
YES
NO
COMMISSIONING CHECK LIST FOR FUNCTIONAL TESTING SYSTEM NO.:
SUB-SYSTEM NO.:
FM NO:
BUILDING NO.:
DESCRIPTION:
TAG NO:
DATE:
REF DOC/DRWS:
Page no: 1 of 6
Access cover switch switch correctly installed and adjusted? adjusted?
Is the key start s witch operating correctly?
Is Is the step chain tension device operating correctly?
Inside Truss Are the step sag devices detector operating operating correctly? (Top and and bottom)
Is the guidance system set correctly and clean?
Is the handrail guidance and tension system set correctly? Drive Station Is the emergency switch operating c orrectly?
Is gear box oil level c orrect? Brake Are the gaps between between steps / skirts skirts correct (4mm on one side
COMMISSIONING CHECK LIST FOR FUNCTIONAL TESTING SYSTEM NO.:
SUB-SYSTEM NO.:
FM NO:
BUILDING NO.:
DESCRIPTION:
TAG NO:
DATE:
REF DOC/DRWS:
Page no: 1 of 6
Is the electrical drawing inside the electrical cabinet?
Is the 501 correctly parameted?
Is the electrical cabinet operating correctly?
Electrical Operation Is the electrical plug operating correctly?
Are the comb lights operating correctly?
Is the Diagnostic Display operating correctly?
Is the stop switch operating correctly?
Is the main switch operating correctly?
Is the plug for handheld pendant operating correctly?
Safety Device
COMMISSIONING CHECK LIST FOR FUNCTIONAL TESTING SYSTEM NO.:
SUB-SYSTEM NO.:
FM NO:
BUILDING NO.:
DESCRIPTION:
TAG NO:
DATE:
REF DOC/DRWS:
Page no: 1 of 6
Handrail Are all handrail inlets and brush brush plates adjusted centrally to the handrail?
Are handrails in newels newels are correctly guide without without abrasion?
Step Band Are all steps undamaged? undamaged?
Are all steps screws screws secured?
Are the gaps between between steps / skirts correct correct (4mm on one side and 7mm combined)?
Are the gaps between between steps/ combs correct (maxi 4 mm)?
Are the combs undamaged? undamaged?
COMMISSIONING CHECK LIST FOR FUNCTIONAL TESTING SYSTEM NO.:
SUB-SYSTEM NO.:
FM NO:
BUILDING NO.:
DESCRIPTION:
TAG NO:
DATE:
REF DOC/DRWS:
Page no: 1 of 6
S No
Equipment name
Acceptance / Representative Name Signature Date
Model Number
Equipment Serial Number
KONE
Type
AMANA
Calibration Due date
Witnessed by KEO
ELEVATORS ESCALATORS
Appendix: A
OPERATION MANUAL OF ESCALATOR & AUTOWALK
KONE Escalators and Autowalks Operating Instructions
Allrights Escalators UM-51.01.008 Owner'sGuide © (E) KONE Version2.0 2012KONE 2012-03-30 Corporation reserved andCorporation autowalks
Operating Instructions
KONE Escalators and Autowalks Operating Instructions
This publication is for informational purposes to support support the operator operator how and when an an escalator or autowalk / ramp should be checked to provide for the maximum safety of end users. The illustration in this manual is generic and may differ in some cases from the material used for the actual system. KONE reserves the right at any time to alter the product design, specifications and procedures reflected in this document. NO STATEMENT CONTAINED IN THIS DOCUMENT SHALL BE CONSTRUED AS A WARRANTY OR CONDITION, EXPRESS OR IMPLIED AS TO ANY PRODUCT, SPECIFICATION OR PROCEDURE, ITS MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OR QUALITY, OR AS A MODIFICATION OR REPRESENTATION OF THE TERMS OF ANY PURCHASE AGREEMENT. KONE DISCLAIMS ANY LIABILITY RESULTING FROM OR IN CONNECTION CONNECTION WITH THE USE OR DISCLOSURE OF INFORMATION IN THIS DOCUMENT. KONE HAS NO LIABILITY FOR TYPOGRAPHICAL OR OTHER ERRORS OR OMISSIONS CONTAINED IN THIS DOCUMENT OR ANYONE'S INTERPRETATION OF THE INSTRUCTIONS. THE USER OF THIS DOCUMENT ASSUMES ALL RISKS ASSOCIATED WITH THE USE OR DISCLOSURE OF THIS DOCUMENT. KONE, MonoSpace, MiniSpace, EcoDisc, TranSys, Alta, KoneXion, KONE TravelMaster, KONE TransitMaster and all other product names are trademarks or registered trademarks of KONE Corporation in various countries.
KONE Escalators and Autowalks Operating Instructions
1
INSTRU INS TRUCTI CTIONS ONS FOR FOR THE OPERATO OPERATOR.... R....... ....... ........ ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... ........ ....... ....... ........4 ....4 1.1 1.2
Organizational measur Organizational measures es ......... ................. ................. .................. ................. ................. ................. ................. ................. ................ ................ .......... 4 Personnel Person nel ......... .................. .................. .................. ................. ................. .................. ................. ................. .................. ................. ................. .................. ............. .... 5
1.3
Regular inspect inspection ion and maintenan maintenance ce ......... .................. .................. .................. ................. ................. .................. ................. .............. ...... 5
2
MAIN MAI N COM COMPON PONENT ENTS...... S.......... ....... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ........ ........ ........ ....... ....... ........ ....... ...... ....... ...... .. 6
3
SAFETY SAF ETY INS INSTRU TRUCTI CTIONS ONS FOR ESC ESCALA ALATOR TORS S AND AUT AUTOWA OWALKS. LKS..... ........ ....... ....... ....... ....... ...... 8 3.1
Safe behavi behavior or in the vicinity vicinity of and on escalat escalators ors or autowalk autowalks s .... ........ ........ ........ ........ ........ ....... ....... ........ ...... 8
4
SAFETY SAF ETY NOTICE NOTICES S (PI (PICTO CTOGRA GRAMS)...... MS).......... ....... ....... ....... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ........ ........ ........ ....... ..... 9
5
FREE FRE E AREA AREA FOR END END USERS USERS - EN 115... 115....... ........ ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ........ ........ ........ ........ .... 11
6
REG RE GUL ULAR AR IN INSP SPEC ECTI TIO ON AND TE TEST STIN ING G ............................ .................................... 12
7
CLEANI CLE ANING NG .... ........ ........ ....... ....... ........ ........ ....... ....... ........ ....... ...... ....... ........ ....... ....... ........ ........ ........ ........ ........ ....... ....... ........ ....... ....... ........ ....... ....... .......13 ...13 7.1
Stainless St ainless steel surfac surfaces................. es......................... ................. .................. .................. .................. .................. ................. ................. ................. ........ 13
7.2 7.3
Push-buttons and switche Push-buttons switches s ......... ................. ................. .................. ................. ................. .................. .................. ................. ................. ........... .. 13 Handraill surfac Handrai surfaces es ......... .................. .................. ................. ................. .................. ................. ................. .................. ................. ................. ................. ........ 13
8
CHAIN CHA IN LUBR LUBRICA ICATIO TION N BY HAN HAND D (STA (STANDA NDARD) RD) ... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ........ ........ ....... ..... .. 13
9
INFORM INF ORMATI ATION ON DISPLAY DISPLAY 501 (OPTI (OPTIONA ONAL).. L)...... ........ ........ ....... ....... ....... ....... ........ ........ ........ ....... ....... ........ ....... ....... ...... .. 14
10
SWITCH SWI TCHING ING ON (OPERATI (OPERATING NG MODE VARIANT VARIANTS) S) ... ....... ........ ....... ....... ........ ........ ....... ....... ........ ....... ....... .......15 ...15 10.1 10.2 10.3 10.4 10.5
Prior to switc switching hing on ........ ................. ................. ................. .................. ................. ................. .................. .................. ................. ................. .............. ..... 15 Switching Switchi ng on Smart starstar-delta delta (standa (standard) rd) ........ ................. ................. ................. ................. ................. ................. ................ .......... 16 Switching Switchi ng on Stand-by Stand-by speed with with inverter (optiona (optional)............ l).................... ................. ................. ................. ............. .... 17 Switching Switchi ng on Automatic start / stop stop (optional) (optional) ........ ................. .................. .................. .................. .................. ................ ......... 18 Switching Switch ing on Automati Automatic c start start and St Stand-by and-by (optional (optional)) 19
KONE Escalators and Autowalks Operating Instructions
Congratulations on purchasing your KONE escalator or autowalk. The escalator or autowalk installation is manufactured in conformity with the latest findings and will provide a long service life at low operating costs. The following instructions inform you of your responsibilities, as an operator, operator, for the operation of this unit. Read the introductory instructions before you pass the operating instructions onto your operating personnel. All operating modes available for escalators and autowalks are described in these operating instructions. Which operating mode is used is dependen dependentt on the specific configuration of your unit. For more information on all operating modes, see section 10 Switching on (operating mode variants). variants). Upon handover of the installation, the responsible KONE employee explains for you in detail the relevant operating mode for your unit. This can enable you to refer specifically to the relevant information at any time and to quickly be able t o cope with your unit.
The operating instructions for your unit cannot take into account of the conditions valid at the installation site. Therefore, supplement the operating instructions with: • Direc Direction tions s relating to existing existing national national regulat regulations ions for accident accident preventi prevention on and protection protection,, • Direction Directions s concerning concerning responsib responsibilitie ilities, s, supervisory supervisory duties duties and reporting reporting duties, duties, for example, for the personnel deployed.
KONE Escalators and Autowalks Operating Instructions
Operating instructions are intended for escalator or autowalk operators who have been instructed. Personnel who operate or clean the escalator or autowalk must first receive training from the manufacturer. Personnel receiving training or instruction may only perform operations on the escalator or autowalk under the constant supervision of an experienced person. The operating personnel must have the operating instructions available at all times. This applies to all personnel operating the escalator or autowalk including part-time operators. operators. Personnel with long hair must wear head covering. Loose clothing or jewellery, including rings, must not be worn. There is an injury hazard of being caught up in or pulled into the machinery.
The operator must inspect the condition of each escalator or autowalk several times daily and before each start-up, if the escalator or autowalk is in operation. The inspection includes a visual and functional check and is described in section . . According to current statutory regulation regulations, s, the condition of escalators or autowalks must be additionally checked at least once every 3 months and after each repair by a KONE professional fitter. Allow the KONE Customer Service to perform this legally prescribed work according to the time schedule.
KONE Escalators and Autowalks Operating Instructions
The KONE escalator or autowalk consists of the following main components: – – the support system of the escalator or autowalk. – moving component components s for conveyance of users on the escalator or autowalk. The handrails (3) run synchronously with the step band (2) and provide the users with a good hold as they are conveyed by the escalator or autowalk. – area above the step band (2) consisting of skirts (5), glass panels (6), balustrade heads (7), inner decks (8), and outer decks (9). – – removable covers for the upper and lower maintenance areas. These enable access to the components installed in the upper and lower areas and provide a transition to the floor of the building structure. – – plates at the t he upper and lower escalator or autowalk accesses. Combplates contain removable comb segments (12) that engage into the grooved profile of the steps. – – form the ends of the inner and outer decks and of the balustrade skirts at the lower and upper escalator or autowalk accesses. – – the central unit of the electrical system. It contains all the electronic components required for monitoring and diagnostics, and for the control unit. – – the main guide and support system for the step band on its way through the truss. There are three areas of the guide system: the guides at the top end, the guides at the bottom end and the guides in the incline section. – consisting of drive motor motor,, gear box, operationa operationall brake, handrail drive wheels and step chain sprockets by means of which the step band and
KONE Escalators and Autowalks Operating Instructions
KONE Escalators and Autowalks Operating Instructions
Compliance with safety regulations is of the greatest importance with escalators and autowalks. It is the responsibility of the operator to actively work towards achieving the safe behaviour of end users, to draw attention to the attached safety notices and to make provision for regular (quarterly) servicing and inspections. In addition, daily checking of the escalator or autowalk is required before switching on and off.
Accidents on escalators or autowalks can be avoided by attaching clear safety notices. Maintain the safety of end users in the vicinity of the unit by making sure that users always comply with the safety notices and safety rules. • Do not allow allow unatte unattended nded childr children en to play play in the vicini vicinity ty of or on the the unit unit • Do not allow allow end users users with prams prams or pushcha pushchairs, irs, people people in wheelch wheelchairs, airs, or end users users with walking aids to use the unit. Ask them to use the elevator. • Do not allow allow end users users with bulky bulky or heavy heavy luggage luggage to enter enter the escalator escalator.. Ask them to use the elevator. • Do not allow allow anyone anyone to ride on the the handrail handrail,, or place heavy heavy or bulky bulky objects objects on the handrail. • Do not allow allow anyon anyone e to pull pull on the hand handrail rail or or pull it out out of the handra handrailil guide. guide. • Do not allow allow anyone anyone to use a downwa downwards rds travellin travelling g unit in an upward upward directi direction on or an upwards travelling unit in a downward direction. • Do not not allow allow anyo anyone ne to run run up up or down down the the unit. unit.
KONE Escalators and Autowalks Operating Instructions
Your escalator or autowalk is equipped with safety notices (pictograms). If these safety notices are missing or if they are damaged, they must be replaced immediately. immediately.
KONE Escalators and Autowalks Operating Instructions
Pictograms in accordance with EN 115-1:2008+A1:2010 and GB 16899-2011
KONE Escalators and Autowalks Operating Instructions
In order that escalator or autowalk users can safely enter and leave the unit, there must be free (clear) areas for unit exits and entries to handle end user congestion. For all conversions always take into consideration the dimensions required by EN 115 and GB 16899 for the end user. the width of the free area must at least comply with the distance between the handrail center lines (A). The depth must be at least 2500 mm, measured from the end of the balustrade. A = Distance between between the handrail handrail center lines The free area may be reduced to 2000 mm, if the area is increased in width by by at least twice the distance between the handrail center lines (B). B = Twice the distance between the handrail center lines
The width of the free area must at least comply with the distance between the outer edges of the handrails plus 80 mm on each side (A). The
KONE Escalators and Autowalks Operating Instructions
C = common crossing area for adjacent units
KONE Escalators and Autowalks Operating Instructions
Clean escalator or autowalk parts as described in section 7.1 Sta Stainless inless steel surfaces, section 7.2 Push-buttons and switches, and section 7.3 Handrail surfaces.
Clean stainless steel surfaces with mild soap and water. Then use a stainless st eel cleaner to clean and protect the surfaces.
Wipe push-buttons and switches with alcohol or water / soap-based cleaning agents.
If plastic parts (for example, made of polycarbonate) are treated with corrosive cleaning agents (for example, with chlorinated hydrocarbon cleaners), the plastic parts can get damaged. Push-buttons and switches made of poly-carbonate plastic dissolve in chlorinated hydrocarbon cleaners. Therefore use only approved cleaning agents.
KONE Escalators and Autowalks Operating Instructions
The information display indicates in plain text any faults that occur. The information display is located in the inner deck on the upper left side of the escalator or autowalk. Should the step band stop unexpectedly, unexpectedly, the corresponding corr esponding text for the fault is displayed. In this case, try to restart the escalator or autowalk. If this is not possible, inform KONE Customer Service. Quote the serial number of your unit. This can be found on the type identification plate which fixed on the handrail front plate.
KONE Escalators and Autowalks Operating Instructions
The operating mode variants available for escalator or autowalk are described below. below.
In order to assess the operational safety of the escalator or autowalk, the operator must check the condition of the escalator or autowalk several times daily and before each start-up. The check consists of a visual and a functional check (for example: emergency stop pushbutton, comb segments, and optional equipment such as step demarcation lights) The visual check determines the presence of any externally recognizable deviations. For example, the removal of components such as panelling or covers that can affect the s afety of personnel traffic is not allowed. • Check also also whether whether skirts, skirts, inner inner and outer outer decks, frontplat frontplates, es, or combplate combplates s have loose loose fastening elements or need cleaning. If necessary, have the fastening elements secured and components cleaned by KONE customer service department before switching on. During the functional check the escalator or autowalk must revolve several times. To do so it must be switched on as described in section 10.2 to section 10.5. Observe the step band and handrails in the process and make sure the unit runs fault free, particularly with respect to damaged or missing steps. After performance of the aforementioned tests the unit can be switched on as described in section secti on 10.2 to section section 10.5.
KONE Escalators and Autowalks Operating Instructions
Each time before switching on the unit, perform a visual and functional check in accordance with section 10.1 Prior to switching on. 1 To switch switch on, on, insert insert the key into into the keyoperated switch (1). (1). • The key key-op -opera erated ted swi switch tch is is locat located ed at at the low lower er rig right ht and up upper per lef leftt of of the the inner side of the handrail entry. 2 Start Start the unit in in the oper operation ational al directio direction n you require by turning the key. • Key swi switch tch at at lower lower righ rightt side: side: Turn Turn cloc clo ckwise to run the unit downwards and counter-clockwise to run the unit upwards. • Key swit switch ch at uppe upperr left left side side (optio (optiona nal): l): Turn clockwise to run the unit upwards and counter-clockwise to run the unit downwards. • The un unit it start starts s up imm immed ediat iately ely.. 3 After actuation of the key, key, turn it immediately immediately back to the middle position position and pull it out of the key-operated switch (1). The direction can only be changed after actuation of stop switch (2).
KONE Escalators and Autowalks Operating Instructions
Each time before switching on the unit, perform a visual and functional check in accordance with section 10.1 Prior to switching on. 1 To switch on, on, insert insert the key key into the the key-opera key-operated ted switch (1). • The key-o key-opera perated ted switch is locate located d at at the the lower lower right and upper left of the inner side of the handrail entry. 2 Pre-se Pre-select lect the opera operationa tionall direction direction by turnin turning g the key. • Key switc switch h at lower lower right right side: side: Turn Turn cloc clockwi kwise se to pre-select down running direction and counterclockwise to pre-select up running direction. • Key switch switch at upper upper left side: Tu Turn rn clockwis clockwise e to pre-select pre-se lect up runni running ng directio direction n and count countererclockwise to pre-select down running direction. • The unit unit starts starts immed immediatel iately y when the light light barrier barrier is interr interrupte upted. d. 3 After actuation of of the key, key, turn it immediately immediately back to the middle position position and pull it out of the key-operated switch (1). The direction can only be changed after actuation of stop switch (2). Simultaneously to unit start-up the operational direction is indicated optically by traffic lights (optional). Initially the unit runs in stand-by mode (approximately 50% travel speed). If an end user walks through the light barrier (3) in the area of the bottom or top unit entries, the step band speed is increased to the full travel speed.
KONE Escalators and Autowalks Operating Instructions
Each time before switching on the unit, perform a visual and functional check in accordance with section 10.1 Prior to switching on. 1 To switch on, on, insert the the key into the the key-operate key-operated d switch (1). (1). • The key-ope key-operated rated switch switch is located located at at the lower lower right right and upper upper left left of the inner inner side of of the handrail entry. 2 Pre-se Pre-select lect the operat operationa ionall direction direction by turning turning the key key. • Key switch switch at lower lower right side: side: Turn clockwi clockwise se to pre-select pre-select down down running running direction direction and and counter-clockwise to pre-select up running direction. • Key switch switch at upper upper left side: side: Turn clockwi clockwise se to pre-select pre-select up running running directio direction n and counter-clockwise to pre-select down running direction. • The unit unit starts starts immediate immediately ly when the light light barrier barrier is interrup interrupted. ted. 3 After actuation of the key, key, turn it immediately immediately back to the middle position position and pull it out of the key-operated switch (1). The direction can only be changed after actuation of stop switch (2). Simultaneously to unit start-up the operational direction is indicated optically by traffic lights (optional required by the code). The unit in this operating mode is equipped with radar sensors. The radar sensors consist of two parts: radar heads and radar amplifiers. Both the sensitivity and the sensing distance can
KONE Escalators and Autowalks Operating Instructions
Switching on automatic start and stand-by is a combined feature. In this mode the unit starts as described in automatic start / stop mode. After expiration of the normal run-time, it switches to stand-by mode (about half of normal speed). After a pre-determined time of 10 seconds (time is adjustable) during which there is no passenger, the unit comes to a complete stop. The cycle repeats when the next end user passes the sensor. Traffic lights are standard with this feature. For more information on starting and setting, see section 10.4 Switching on Automatic start / stop (optional). (optional).
Do not start / stop the unit if persons or objects are on the unit, otherwise there is a danger of falling. Press stop button (1) to switch off the unit (operational stop). • The stop stop butt button on is loca located ted at at the lower lower righ rightt
KONE Escalators and Autowalks Operating Instructions
If required, switch off the main power supply of the unit as follows: 1 Go to the main power switch. It is located in the upper upper maintenance maintenance chamber chamber on the control cabinet of your escalator or autowalk. 2 Turn the main power switch to OFF ("0") ("0") to disconnect disconnect the main main power supply supply.. 3 Lock the the switch switch in the positi position on OFF ("0") ("0") with with a padlock. padlock.
Always switch off the unit before opening opening the maintenance maintenance chamber, chamber, otherwise there there is a personal injury hazard.
Cordon off both unit entries by erecting personnel traffic barriers. Removal of the barrier is not allowed until the maintenance chamber has been closed, otherwise there is a personal injury hazard.
An auxiliary brake is mandatory for vertical vertical rises above 6 m, and and optional for vertical rises not not greater than 6 m. When the main power of the unit is switched off, the auxiliary brake will be activated. After the main power is switched on again and before the unit can operate normally,, firstly recover the auxiliary brake with the following method. normally
KONE Escalators and Autowalks Operating Instructions
If the escalator or autowalk is switched off during operation due to a fault (for example: by a safety device or power failure), have the following points checked before restarting: NOTE! The procedure procedure described below should be performed performed only by KONE's service department or by skilled personnel who have been qualified by the manufacturer of the unit.
Cordon off both escalator entries by erecting personnel traffic barriers. Removal of the barrier is not allowed until the maintenance chamber has been closed, otherwise there is a personal injury hazard. 1 Read the the fault message message on on the info displa display y in the PCB control control unit. unit. 2 Check tthe he followin following g points points on the the escalato escalatorr or autowalk. autowalk. • wheth whether er two or or more teeth of a comb comb segmen segmentt are damag damaged ed or broke broken n • wheth whether er there there are any any foreign foreign bodies bodies in the the comb segmen segmentt or in the step step band band • whe whethe therr a safety safety devi device ce has has been been activa activated ted • a dama damaged ged ste step p in in the the step step ban band d • an incr increa eased sed ga gap p betwe between en two two step steps s • the dist distance ance betwe between en the step steps s and and the skirts • dri drive ve chain chain an and d step step chain chain lub lubrica ricatio tion n • wheth whether er auxiliar auxiliary y brake brake looses looses or recovers recovers (if provided provided)) • check the the handrai handraill surface surface quality quality and and isochron isochronous ous step step speed speed • fau faults lts in the ele electri ctrical cal sys system tem • whe whethe therr any any swi switch tches es are loo loose se
KONE Escalators and Autowalks Operating Instructions
Compiled by:
Technical Illust Illustrator rator / Guo Li Li
Checked by:
Escalator PCM Assistant Manager / Shang Rui
Approved by:
Escalator Platform Category Category & PCM Manager / Weber Weber Ralf
-
2012-07-05 First issue
Weber Ralf
KONE Escalators and Autowalks Operating Instructions
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ELEVATORS ESCALATORS
Appendix: B
MAINTENANCE MANUAL OF ESCALATOR & AUTOWALK
ELEVATORS ESCALATORS
MAINTENANCE MANUAL OF ESCALATOR
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
ASG-51.05.001 Allrights MBM-2 Maintenance © KONE EJV (H)2011-01-28 2006KONE 1.5 Corporation ManualAdd-onsfor reserved Instructions Corporation KONETravelMaster™ 110Escalator(EJVR1.2/1.3/1.4/1.4.1)
KONE TRAVELMASTER™ 110 ESCALATOR MBM-2 (Modular Based Maintenance)
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
TABLE OF CONTENTS •
GENE GE NERAL RAL IN INFO FORM RMAT ATION ION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 • MBMMB M-2 2 modu modular lar bas based ed ma maint intena enanc nce e . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 3
•
STA TAND NDAR ARD D TOO TOOLS LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
•
SAFETY SAFET Y DEVI DEVICE CES. S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 • Locati Loc ation on of of safe safety ty dev devic ices. es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 •
Step ban band d lock lock dev devic ice e. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . 6
•
BASIC MOD BASIC MODUL ULE E . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..8 • Lower Low er end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 • Upper Upp er end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 • Produc Pro ductt-sp spec ecifi ific c ins instr truc uctio tions ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
•
STE TEP PM MOD ODUL ULE E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 • Remov Rem oving ing st step eps. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 • Reins Rei nsta talli lling ng step steps s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
•
BRAKE MO BRAKE MODU DULE. LE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 • Auxil Aux iliar iary y brak brake e (if (if equip equipped ped)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
•
COMB CO MB PL PLAT ATE E MOD MODUL ULE E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
•
DRIVE DRIV E MOD MODULE ULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 • Driv Dr ive e unit unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
•
GUIDE GU IDE MO MODU DULE LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
•
HANDRA HAND RAIL IL MOD MODULE. ULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 • Handra Han drail il driv drive e sys syste tem m over overvi view. ew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Handr Han drail ail gu guide ides s
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
STANDARD TOOLS • Toshib oshiba a pulling pulling tool (TE4Z6KZ (TE4Z6KZ802P 802P001, 001, for for lifting lifting the access access cover) cover) • Han Handle dle for for lifting lifting landi landing ng (DEE0 (DEE0075 075707 707)) • Labe Labell - Proa Proactive ctive oil repla replacemen cementt (KM987 (KM987329G 329G01) 01) • Calli Callipers pers for motor motor brak brake e lining lining check check (KM1 (KM16761 67619) 9)
SAFETY DEVICES Location of safety devices
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Name B 20 B 36 B 37 B 50 B 51 S1 S5 S6 S 60-61 S 62-63 S 65-66 S 67-68 S 70 S 72 S 75-76 S 80 S 100-101 S 102-103 S 104-105 S 130 S 131 S 145
Explanation Water level switch (for outdoor) (if equipped) Missing step monitor, lower (if equipped) Missing step monitor, upper (if equipped) Handrail speed monitor, left (if equipped) Handrail speed monitor, right (if equipped) Control current circuit breaker, lower Emergency stop switch, lower Emergency stop switch, upper Comb plate impact switch lower left and right Comb plate impact switch upper left and right Handrail inlet switch lower left and right Handrail inlet switch upper left and right Step sag switch, lower Step sag switch, upper Broken step-chain switch lower left and right Step band lock (upper pit left) (if equipped) Skirting switch, lower left and right Skirting switch, upper left and right Skirting switch, inclined section (if equipped) Access cover switch, lower Access cover switch, upper Broken drive chain switch
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Step band lock device The step band lock device must be activated any time you are working in the step band. For EJV Step 1
2 3 4 5 6
7
8
Action Place ba barricades at at bo both en ends of of th the escalator,, remove access cover and escalator turn main power supply OFF. Take out co cont ntrrol olle lerr fr from om upp ppe er pit us usin ing g controller lifting tool. Remove flywheel cover. Remove step guard. Raise handlebar (3) of step band lock from slot (1). Keep pushing step band lock (4) to drive wheel disc (5) while running flywheel manually. • Sto top p unti untill step step band band loc lock k is engaged. Put handlebar into slot (2). • The ste step p band band lock lock swi switch tch sho should uld be actuated (“10” displayed on main board). After fifinishing work, re release the st step
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
For EJV Step 1
2 3
4
5
Action Place ba barricades at at bo both en ends of of th the escalator , remove access cover and turn main power supply OFF. Take out co cont ntrrol olle lerr fr from om upp ppe er pit us usin ing g controller lifting tool if needed. Lift an and push th the handle (2) un until bo bolts (3) and teeth of the sprocket (4) are engaged. If necessary, release the main brake manually. • The ste step p band band lock lock swit switch ch (1) (1) shou should ld be actuated ("10" displayed on main board). After fifinishing wo work, re release th the e st ste ep band lock. • Rel Releas ease e the ha handl ndle e (2) (2) to sep separ arate ate the bolts (3) from sprockets. Put th the controller ba back in in pi pit, tu turn ma main power supply ON, reinstall access cover, and remove barricades.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
BASIC MODULE Lower end Step 1
Maintenance task Check step chain tension.
Method and standard In the lower end pit, check step chain tension by measuring the compressed spring length between washers. Spring length should be 95 mm.
2
Check function of skirt switches (if equipped).
1 Make Make sure sure the main main pow power er supp supply ly is OFF. 2 Rem Remove ove the the inner inner upper upper and and lower lower curve decking. 3 Chan Change ge the the blind blind plug plug to to the hand hand-hel -held d pendant control. Turn the main power supply ON. 4 Pla Place ce a thic thickne kness ss gauge gauge 3.2 mm between the switch actuator (1) and the inside surface of the skirt (2) so that the switch actuates. NOTE! NOT E! Do not not place place a thick thicknes ness s gauge gauge
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Upper end Step 1
Maintenance task Check function of skirt switches.
Method and standard Refer to the method and standard for function of skirt switches in Basic Module>Lower end.
2
Check au automatic oi oilers (i (if equipped).
If lubrication is not suitable, reset the parameterr of pump, refer to Product paramete specific instructions>Automatic oiler.
Lubricate step chain with the recommended lubricant. [lubricate only from upper end equipment driving down]
3
Check LED light electric cabinet (if equipped).
4
Check th the inverter ca cabinet (i (if equipped).
Lubricate connection area 1 and area 2 on every link 1 Che Check ck the LED LED lighti lighting ng in upp upper er pit. pit. 2 Op Open en the the elec electri tric c cabin cabinet. et. 3 Ch Chec eck k the fan fan fun funct ctio ion. n. 4 Clea Clean n the the air air filter filter,, replace replace it if needed. 1 Che Check ck the the fan con condit dition ion.. 2 Tu Turn rn the the main main power power suppl supply y OFF. OFF. 3 Op Open en the the inve inverte rterr cabin cabinet. et. 4 Check and clean the air air filter filter,, replace replace
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Product-specific instructions Automatic oiler Automatic oiler lubricates drive chains, handrail drive chains and step chains automatically and regularly. Maintenance task: Check operation of automatic oilers Maintenance method and standards: For EJV Step 1
Action Check the oil level in the oil tank.
Note
• Fi Fill ll wi with th cl clea ean n oil oil.. NOTE! NOT E! Make Make sure sure oil oil is abs absolu olutel tely y clean when filling the automatic oiler.
2
Turn the switch F62 (24 V AC) OFF inside the controller, the pump will
NOTE! NOT E! Cle Clean an the the pum pump p filte filterr and and
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Step 3
Action If th the ch chain is is no not lu lubricated pr properly, adjust the nozzles or oil brushes.
4
Check every jo joint fo for oil leakage. Tighten the joints, if necessary. Turn the switch F62 ON. Check and adjust the electrical parameterr setting according to paramete lubrication quality (just for first maintenance visit). If lubrication of chains is not sufficient, readjust the pulse length parameters.
5
WARNING! Basic parameters may not WARNING! be valid for all escalators.
Note
For more information on the lubrication parameters, parameter s, refer to the tables tables named: pulse length (lubrication (lubrication pump on time) and delay between pulses (lubrication pump off time).
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
For EJV Step 1
Action Check the oil level in the oil tank. • Fi Fill ll wi with th cl clea ean n oil oil.. NOTE! NOT E! Make Make sure sure oil oil is abs absolu olutel tely y clean when filling the automatic oiler.
2
Check th that th the ch chain is is lu lubricated properly.. If needed, adjust the nozzles properly or oil brushes.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Step 4
Action If ne needed, se set th the Ton and Toff on on th the time relay in the control cabinet again according to current status. • For Ton Ton and and Toff Toff par paramete ameterr setting, setting, refer to the following table.
NOTE! NOT E! Parame Parameter ters s must must be check checked ed after first maintenance is completed. If necessary necessary,, adjust parameters slightly according to the actual humidity and temperature temperature..
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
STEP MODULE Removing steps Escalator steps usually should be removed at the lower escalator pit. Maintenance task: Remove task: Remove steps to open the maintenance access in step band Maintenance method and standards: Step 1
2
3
Action Remove spring pin (2). • Use a hook hook or or a set set of of plier pliers s to pu pullll spring pin out of mounting hole. Remove screw (1) and retaining plate (3). • Use a scr screw ew driv driver er to to straig straighte hten n the the end of of the retaining plate. Use the hand-held pendant contr tro ol to drive the step band. • The lef leftt step step rolle rollerr is acces accessib sible le from from the hole on the turnaround plate.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Step 4
Action Slide the connecto torr (4) to towards ce center of the step.
5
Remove the step. • Take the the left left step step roll roller er first first out out of the hole in turnaround plate.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Reinstalling steps The steps can be interchanged as a result of their modular design. Maintenance task: Check task: Check and reinstall steps Maintenance method and standards: Step 1
Action Position step in step band. • Positi Position on the the righ rightt side side of step step in the the step band. • Positio Position n the the left left side side of step step in the the step band by placing the left step roller through the hole in the turnaround plate. NOTE! NOT E! Make Make sure sure tha thatt the the step step guidance pin (A) is installed in step.
2
Slide co connector (1 (1) to towards ch chain ro roller (2). NOTE! NOT E! Make Make sure sure tha thatt the the washe washerr stays on the step chain pin.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Step 5 6 7 8
Action Secure scr cre ews by bending retaining plate (4). Inst sta all re remaining st steps us using th the same procedure. Check step for alignment. Install step guards.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
BRAKE MODULE Adjustment and checking checking are needed needed if stopping distance distance is not correct. Maintenance task: Check motor brake lining Maintenance method and standards: For EJV Step 1
2 3 4 5
Action Open upper acc cce ess cover, switch OFF power supply, and engage step band lock (if equipped equipped). ). Measure the actual le length of sp springs at at both sides of the brake and record it. Loosen fifixing nu nuts (1 (1) fo for on one si side, th then remove springs. Turn br brake ar arm (2 (2) un until th the br brake lining thickness can be measured. Check br brake lilining (3 (3) th thickness. If the brake lining thickness is less t han 3 mm, replace brake arms and lining. NOTE! NOT E! If the bra brake ke lin lining ing is contaminated, contaminate d, always replace it.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
For EJV (without brake wearing monitor) Step 1 2 3
4 5
Action Open upper access cover, switch OFF power supply. Measure the depth D of brake arm from measurementt hole (1) by callipers. measuremen If th the brake lining th thiickness is below 3 mm, replace brake arms and lining. • Brake Brake lini lining ng thic thickne kness ss = Mea Measur sured ed data D - 29 Check th the brake lilining fo for another si side. If needed, replace the brake arm according to the section Replacing brake arms”
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Maintenance task: Check main brake spring length Maintenance method and standards: Step 1
2
Action Tighten th the sp spring to to ma make th the sto stop pping distance shorter and loosen the spring to make the distance longer. Lock the adjusting nuts.
Note Both springs (1) must be equally adjusted to ensure the spring length L is the same on both sides.
Maintenance task: Check clearance between brake arm and brake solenoid piston Maintenance method and standards: Step 1
Action Push th the pi piston (2) to to C di direction. Measure the clearance between brake arm (1) and brake solenoid piston (2).
Note It is very important that there is 1.5 mm clearance between the brake solenoid piston (2) and brake arm (1).
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Maintenance task: Check brake lift monitor (normal open) (if equipped) Maintenance method and standards: Step 1
Action Check the switch actuator (1). • Actuat Actuate e manu manual al handl handle e (4) (4) by hand, hand, the switch actuator (1) must be released from the bolt (3) of the bracket (2) and there are no fault codes “68”, “70” displayed on main board.
2 3
• Releas Release e manual manual han handle dle (4), (4), the the bra brake ke is closed, the switch actuator (1) must be actuated by the bolt (3) of the bracket (2). Adjust the bolt (3) if needed. Release st ste ep band lock (if equipped), switch ON power supply, and reinstall the access cover.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Step 2 3 4
5 6
7 8 9
Action Take out th the splint to remove the bolt (3). Remove the slider (4). Pull the bar (5) to adjust th the e distance between the arm (1) and the ratchet wheel (2) to 10 mm. Check that the detecting sw swiitch (6) is activated in this position. Check that the arm (1) can access completely in the ratchet wheel without pressing the tappet of the switch to its end position. Check th the slider su surface ce,, re replacement is needed if severe wear. If necessary, adjust the switch. Reset th the bar and reinst sta all the slider (4) after adjustment. • Mak Make e sure sure the sli slide derr is in pla place. ce.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Auxiliary brake (if equipped) Auxiliary brake is located in upper landing. It is activated in case of escalator power off, escalator overspeed (over 1.4 times the rated speed), step band reverse direction, broken drive chain. • • • • •
Brake Brak e tri trigg gger er de devi vice ce (1 (1)) Brake disc (2 (2) Spro procke ckett for for driv drive e cha chain in (3 (3)) Spr proc ocke kett for for step step ch chai ain n (4) (4) Brake shoe (5 (5)
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
COMB PLATE MODULE Maintenance task: Check comb plate impact device if adjustment is needed Maintenance method and standards: Step 1
2
Action Remove th the access co cover an and ch change the blind plug to the hand-held pendant control. Then turn the control current OFF. Remove end inner decks (left and right) located above the comb plate. Check th the length of of th the compressed spring (4). • The ini initia tiall lengt length h of the spr spring ing is 60± 1 mm.
3
• If neces necessar sary y, adjus adjustt the nu nutt (5) to set set the spring length. Check the position of comb plate impact switch. • The The gap gap betwe between en the the swi switc tch h actuator (1) and the trip arm (2) should not be above 1 mm. • If neede needed, d, turn turn the the nut nut (3) (3) to adju adjust st the gap.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
DRIVE MODULE Drive unit Maintenance task: Check oil level of gearbox Maintenance method and standards: Step 1
Action Check oil level of of gearbox by removi vin ng the filler cap of the dipstick (1).
Note
• Oil sho should uld be be betwe tween en the upp upper er and lower marks on dipstick. Maintenance task: Check air breather Maintenance method and standards: Step 1
Action Check that air breather (2) is clean.
Note
Maintenance task: Add task: Add oil Maintenance method and standards: Step 1
Action If the oil is under the lower mark, add the oil at filler cap (3) until the oil is between the upper and lower marks.
Note For more information on oil type, oil volume and so on, refer to the table Oil specification”.
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Maintenance task: Check oil replacement date Maintenance method and standards standards:: Step 1
Action According to oil replacement information stick, confirm oil replacement date.
Note Detailed method, see AS51.05.002>Minor Repairs>Changing oil.
COMPONENT:
R EP EP LA LA CE CE ME ME NT NT I NT NT ER ER VA VA L: L: REPLACE MENT
Y EA EA RS RS
NEXT REPLACE MENT
M o n t h / Ye a r
M o n t h / Ye a r
/ 20
/20
Oil specification Drive Type
Oil viscosity
5.5 kW with CG35B gear
VG460
7.5, 9.2,11 kW with CRW160B gear
VG460
Oil Type Synthetic oil Synthetic oil
Oil volume (L)
Oil change interval 1st time Regular (h) (h)
9
1800
20000
17.5
1800
2000 0
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Oil specification Drive Type 8 kW motor with FTJ160D gear (China only) 11 kW motor with FTJ160D gear (China only) 15 kW motor with FTJ160D gear (China only) 5.5, 7.5 kW motor, with FJ125 gear (China only) 8 kW motor, with FJ160 gear (China only) 11 kW motor, with FJ160 gear (China only) 15 kW motor, with FJ160 gear (China only) 5.5, 7.5, 9.2 kW with K87 gear
Oil change interval 1st time Regular (h) (h)
Oil viscosity
Oil Type
Oil volume (L)
VG460
Synthetic oil
15.0
1800
20000
VG460
Synthetic oil
15.0
1800
20000
VG460
Synthetic oil
12.0
1800
20000
6.0
1800
20000
12.0
1800
20000
12.0
1800
20000
12.0
1800
20000
10.9
1800
20000
20
1800
20000
33.5
1800
20000
VG 460 VG 460 VG 460 VG 460 VG220
11,15 kW with K97 gear
VG220
11 kW motor with K107 gear
VG220
Synthetic oil Synthetic oil Synthetic oil Synthetic oil Synthetic oil Synthetic oil Synthetic oil
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Maintenance task: Check drive unit mounting bolts and drive chain slack Maintenance method and standards: Step 1
Action Check drive unit mounting bolts (1).
2
• Check Check the the drive drive uni unitt moun mountin ting g bolts bolts are tight. Remove the fl fly ywheel cover, tu turrn the flywheel down direction, make sure the upper side of drive chain is slack. • When When the the ten tensio sion n is on the upp upper er side of chain, the slack amount (X) is 10 mm +/-5 mm (25/64 in.+/- 3/16 in.).
3
4
If dr drive ch chain sl slack ad adjusting is is ne needed, loosen the four fixing bolts (1) on motor base, loosen the nut (2) and turn the limiting bolt (3) so that the drive chain can be tightened appropriately. Tig igh hten th the fifixing bo bolts (1 (1) an and lo lock th the nut (2).
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
For EJV
For EJV
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
For EJV
1 2
3 1
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Maintenance task: Check the gap of broken drive chain switch Maintenance method and standards: Step 1
2 3
Action Turn th the ma main po power su supply OF OFF, ch check the gap between drive chains (3) and the detecting bar (1). • The ga gap p sho should uld be 25 – 35 35 mm. mm. Adjust the sw swiitch (2), if necessary. Physica callly move the detecting bar to depress the switch. Listen for audible click of switch.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
GUIDE MODULE WARNING
If equipped missing step/pallet monitor, run the unit with step/pallet opening, please keep the step/pallet opening on the upside of step/pallet band, otherwise need to reset the fault code (58 59) on cabinet. Maintenance task: Make adjustment if missing step detector does not work Maintenance method and standards: Step 1
2
3
Action Remove fifive st steps in in a ro row, an and mo move the step opening to missing step detector area in inspection mode. Actuate the stop button on the handheld pendant control. Check clearance between proxi xim mity sensor (1) and tapered flat head screw of trailing wheel (2). • The sen sensor sor sho should uld be cen center tered ed and and approximately 5 mm from the tapered flat head screw of trailing wheel. If ad adjustment is is ne needed, lo loosen nu nuts (3 (3) and adjust until the sensor (1) is
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Maintenance task: Check the oil groove of handrail drive chain Maintenance method and standards: Step 1
Action Run unit in inspecti tio on mode in the UP
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions Maintenance task: Check handrail drive chain tension Maintenance method and standard standards: s: Step 1
2
Action Check ha handrail dr drive chain te ten nsion (A (A) in the center between the handrail drive chain sprockets (1) and main drive sprocket (2).
Note
• Handr Handrail ail dri drive ve cha chain in tens tension ion:: A = 9 to 15 mm Adjust handrail drive chain tension if needed.
Maintenance task: Adjust task: Adjust handrail handrail drive chain tension tension if needed Maintenance method and standard standards: s: Step 1
2 3 4
Action Find out the slack side of chain. • If unit unit is runn running ing up befo before re itit stops stops,, then the n the slack side is Up, vice versa. Remove the upper curve inner deck by loosening fixing bolts. Release th the e handrail pressure spring on two sides. Loosen bearing mounting bolts (2) of handrail drive wheel shaft (four on right
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Step 5
Action Loosen lo lock nu nut (3 (3), an and ad adjust ha handrail drive chain tension with jack bolt (4). • Set han handra drailil driv drive e chain chain sla slack ck from from 9 to 15 mm – measured at the drive chain center between drive chain sprockets (1). • For EJV 1.1/ 1.1/1.2 1.2/1. /1.3/1 3/1.4/ .4/1.4 1.4.1, .1, mak make e sure measurement B on both s ides of escalator are the same. Otherwise the handrail wheels are inclined.
Note NOTE! To increa NOTE! increase se the the handr handrail ail chain chain tension, tighten jack bolt (4) equally for right hand and left hand sides. NOTE!! To decrea NOTE decrease se the the handr handrail ail chain tension, loosen jack bolt (4) and pull handrail drive wheel shaft (5) to set tension dimension. NOTE! NOT E! Empty Empty the the oil oil conta containe inerr if needed.
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Step 6 7
8
Action Tig igh hten mounting bolt (2) and lock nut (3). Reinstall th the pa parts in in re reverse or order of removal, release the step band lock device. Check th the position of th the handrail pressure roller cluster and check handrail traction on both sides of escalator in UP and DOWN directions.
Note
Maintenance task: Lubricate track in case of lube-free step chain (if equipped) Maintenance method and standards: If required, the step chain lip track may be moistened by a spray in the running surface area (1). Step 1
2 3
Action Spray application may be required if noise is generated between step chain roller (2) and lip track. Spray ap application ma may be be al along th the entire length of lip track. Spray ap application should be done on once before putting the unit into operation.
Note NOTE! Use only NOTE! only a hig high h press pressure ure sem semiisynthetic grease (Rivolta SKD 3602), based on metal soap without solid additives for initial application. NOTE!! All lubr NOTE lubricatio ication-fr n-free ee chai chains ns are identified by SF or SFD in the
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions Maintenance task: Lubricate main shaft and handrail drive shaft Maintenance method and standards: Step 1 2
3 4 5
6 7 8
Action Run escalator normally fo forr several cycles. Move th the op opening of th the st step band to to the lubrication position of bearings in inspection mode. Press down stop button on hand-held pendant control. Add gr grease to th the grease nozzle (1) with an oil gun. Run th the escalator no normally fo for se sev veral cycles again in inspection mode. Add grease and cycle the escalator two more times. • Add gre grease ase an and d cycle cycle the esc escala alator tor totally for three separate times. time s. Add grease unti till old grease flows out from the bearing. Remove ol old grease from th the be bearing surface. Reinstall al all re removed pa parts in in re reverse order.
Note
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
HANDRAIL MODULE Handrail drive system overview • • • • • • • •
Handrail (1) Hand Ha ndra rail il dr driv ive e whe wheel el (2 (2)) Hand Ha ndra rail il dr driv ive e sha shaft ft (3 (3)) Hand Ha ndra rail il dri drive ve ch chai ain n (4) (4) Newel (5) Hand Ha ndra rail il gui guide de rol rolle lerr (6) (6) Handr Han drail ail pr press essure ure ro rolle llerr (7) (7) Hand Ha ndra rail il tens tensio ion n devi device ce (8) (8)
MBM-2 Manual Add-ons for KONE for KONE TravelMaster™ 110 Escalator Maintenance Instructions
Handrail guides Maintenance task: Check task: Check handrail tension Maintenance method and standards: Step 1
2
3
4
Action With ste step p ba band st stopped, titilt up up ha handrail in the lower curve balustrade on one side. Remove ha handrail fr from th the ha handrail guide, and observe handrail tension. • If tensi tension on is corre correct, ct, the han handra drailil section removed from the handrail guide must run straight over the balustrade. Press ha handrail ba back on onto ha handrail guide. • It must must be pos possib sible le to to pres press s the the handrail effortlessly back in place onto the handrail guide. Adjust ha handrail te tension if ne needed.
Note
ELEVATORS ESCALATORS
MAINTENANCE MANUAL OF AUTO WALK
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
ASG-51.00.001 Allrights MBM-2 Maintenance © (A) KONE RJV 2011 2012-04-16 1.3/AJV Corporation KONE ManualAdd-onsfor reserved Instructions 1.0 Corporation KONE TravelMaster™ 115InclinedAutowalk and TransitMaster™ 165/185HorizontalAutowalk
TRANSITMASTER™ 165/185 HORIZONTAL AUTOWALK (AJV 1.0) MBM-2 (Modular Based Maintenance)
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
TABLE OF CONTENTS •
GENE GE NERAL RAL IN INFO FORM RMAT ATION ION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 • MBMMB M-2 2 modu modular lar bas based ed ma maint intena enanc nce e . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 3
•
STA TAND NDAR ARD D TOO TOOLS LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
•
SAFETY SAFET Y DEVI DEVICE CES. S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 • Locati Loc ation on of of safe safety ty dev devic ices. es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 •
Pallet Pal let ban band d lock lock dev devic ice e . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . 5
•
BASIC MOD BASIC MODUL ULE E . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..6 • Retur Ret urn n end. end. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 • Driv Dr ive e end end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 • Produc Pro ductt-sp spec ecifi ific c inst instru ruct ction ions s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 .11 1
•
PALLET MO PALLET MODU DULE LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 • Remov Rem oving ing pa palle llets. ts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 • Reins Rei nsta talli lling ng pall pallet ets. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
•
BRAKE MO BRAKE MODU DULE. LE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 • Auxil Aux iliar iary y brak brake e (if (if equip equipped ped)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
•
DRIV DR IVE E MOD MODULE ULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
•
GUIDE MO GUIDE MODU DULE LE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 • Second Sec ond ha handr ndrail ail dri drive ve uni unitt (if (if equip equipped ped)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
•
HANDRA HAND RAIL IL MOD MODULE. ULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 • Handra Han drail il driv drive e sys syste tem m over overvi view. ew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 • Handr Han drail ail gu guide ides s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 RELAT REL ATED ED DOC DOCUM UMEN ENTS. TS. . . .
36
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
GENERAL INFORMATION MBM-2 modular based maintenance This document is meant to be used as an additional MBM-2 instruction for the Generic MBM-2 Manual ASG-51.01.001. NOTE! For RJV 1.0 to 1.2, 1.2, refer to Maintenance Maintenance Instructions Instructions for KONE TravelMaster™ TravelMaster™ 115 115 Inclined Autowalk ASG-51.08.00 ASG-51.08.001. 1.
STANDARD TOOLS No need of additional tools.
SAFETY DEVICES Location of safety devices
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Pos. 1 1 2 2 3 3 4 5 5 6 6 7 7 8 9 10 11 12, 13 14 14 15 16
Explanation Combplate impact switch return end left and right Combplate impact switch drive end left and right Handrail inlet switch return end left and right Handrail inlet switch drive end left and right pallet sag switch, return end pallet sag switch, drive end Broken pallet-chain switch return end left and right Emergency stop switch, return end Emergency stop switch, drive end Handrail speed monitor, left (if equipped) Handrail speed monitor, right (if equipped) Access cover switch, return end Access cover switch, drive end Pallet band lock (drive end pit left) (if equipped) Broken drive chain switch (if equipped) Auxiliary brake lift monitor (for RJV) Water level switch (for outdoor) (if equipped) Motor brake wearing monitor Missing pallet monitor, return end (if equipped) Missing pallet monitor, drive end (if equipped) Skirting switch (if equipped) Control current circuit breaker, return end
Name S 60-61 S 62-63 S 65-66 S 67-68 S 70 S 72 S 75-76 S5 S6 B 50 B 51 S 130 S 131 S 80 S 145 S 85 B 20 S 81-82 B 36 B 37 S 100-103 S1
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Pallet band lock device The pallet band lock device must be activated any time you are working in the pallet band. Step 1
2
3
4
5
Action Place ba barricades at at bo both en ends of of th the escalator,, remove drive end access escalator cover and turn main power supply OFF. Take ou out co contr tro oller fr fro om dr drive en end pi pit using controller lifting tool if needed. Turn main power supply ON. Lift an and push th the handle (2) un until bo bolts (3) and teeth of the sprocket (4) are engaged. If necessary, release the main brake manually. • The pa palle llett band band loc lock k switc switch h (1) (1) should be be actuated ("10" displayed on main board). After fi finishing wo work, re release th the pa pallet band lock. • Rel Releas ease e the the hand handle le (2) (2) to to sepa separat rate e the bolts (3) from sprockets. Put th the co contro rolller ba back in in pi pit, re reinstall access cover, and remove barricades.
Note NOTE! If there NOTE! there is no pall pallet et band band lock lock device, rated lifting slings and shackles must be used attaching the slings between the chain sprocket wheels and the lifting eye points on the truss. The slings must be fitted in such a manner that there is no free movement of the sprocket wheel.
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
BASIC MODULE Return end Step 1
Maintenance task Check pallet chain tension.
Method and standard In the return end pit, check pallet chain tension by measuring the compressed spring length between washers.
For RJV: 95 mm
For AJV: 95 mm (TransitMaster 165) 185 mm (TransitMa ( TransitMaster ster 185) to be changed to be changed
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Step 2
Maintenance task Check function of skirt switches (if equipped).
Method and standard 1 Cha Chang nge e the bli blind nd plug plug to the the maintenance handset. Actuate the stop button on the handset. 2 Rem Remove ove the the inner inner deck decking ing nea nearr the second balustrade panel from the drive and return ends. 3 Pla Place ce a thick thickne ness ss gauge gauge 3.2 mm mm between the switch actuator (1) and the inside surface of the skirt (2) so that the switch actuates. NOTE! NOT E! Do not not place place a thickn thickness ess gaug gauge e on the pallet side of the skirt. • Rele Releas ase e the the stop stop bu butto tton n on handset, try to inspecting run the autowalk in both directions on inspection. •
3
Check LED light electr triic cabinet (if equipped).
The Th e aut autow owal alk k shou should ld not not sta start rt..
4 Repeat Repeat the the proced procedure ure for the the oppos opposite ite side of the autowalk. 1 Check the LED light lighting ing in return return end pit. 2 Op Open en th the e cab cabin inet et.. 3 Ch Chec eck k the the fan fun funct ctio ion. n. 4 Clean the air filter filter,, replace replace it if
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Step 7
Maintenance task Adjust the combplate impact device if function test fails.
Method and standard Remove the access cover and change the blind plug to the hand held pendant control. Then turn the control current OFF. • Rem Remove ove end inn inner er deck decks s (lef (leftt and and right) located above the combplate. c ombplate. Check the length of the compressed spring (4). • Th The e initi initial al leng length th of of the the sprin spring g is 65 1 mm. • If nece necessa ssary ry,, adjus adjustt the the nut nut (5) (5) to set the spring length. Check the position of combplate impact switch. • Th The e gap gap betwe between en the the swi switch tch actuator (1) and the trip arm (2) should not be above 1 mm. • If nee needed ded,, turn turn nut nut (3) to adju adjust st the the gap.
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Drive end Step 1
Maintenance task Check function of skirt switches (if equipped).
Method and standard Refer to the method and standard for function of skirt switches in Basic Module> return end.
2
Lubricate th the chain ma manually (f (for gravity oiler).
3
Check automatic oilers.
Lubricate the main drive chain and handrail drive chain. • Fi Fill ll the the oi oill in th the e cup cup if nee need. d. • Ope Open n the the valve valve und under er the the oil oil cup, cup, inspecting run the unit for two cycles after oil falls down on the chain. Lubricate the step chain. • Put the oil nip nipple ple to the the step step cha chain in in upper pit. • In Insp spec ectin ting g run run the the uni unitt by maintenance handset and press the oil to the chain one cycle for pin 1, one cycle for pin 2. • Lub Lubrica ricate te the the othe otherr side side usin using g the the same method. If lubrication is not correct, refer to Product-specific instructions>Autom instructions>Automatic atic oiler.
Lubricate pallet chain with the recommended lubricant.
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Step 7
Maintenance task Check the fall protection barrier (if equipped).
8
Check th the fu function of of th the co combplate impact device. Refer to ASG-51.01.001 to ASG-51.01.001,, Generic MBM-2 Manual .
9
Adjust the combplate impact device if function test fails.
Method and standard Manually check if the fall protection barrier is fastened securely. Check if the screws are loose.
Remove the access cover and change the blind plug to the hand held pendant control. Then turn the control current OFF. • Rem Remove ove end inn inner er deck decks s (lef (leftt and and right) located above the combplate. Check the length of the compressed spring (4). • The ini initia tiall lengt length h of the spr spring ing is 65 1 mm. • If nece necessa ssary ry,, adjus adjustt the the nut nut (5) (5) to set the spring length. Check the position of combplate impact switch. • Th The e gap gap bet betwe ween en the the sw swit itch ch actuator (1) and the trip arm (2) should not be above 1 mm. • If nee needed ded,, turn turn nut nut (3) (3) to ad adjus justt the the gap.
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Product-specific instructions Automatic oiler Automatic oiler lubricates drive chains, handrail drive chains chain s and pallet chains automatically and regularly. Maintenance task: Check operation of automatic oilers Maintenance method and standards: Step 1
Action Check the oil level in the oil tank. • Fi Fill ll wi with th cl clea ean n oil oil.. NOTE! NOT E! Make Make sure sure oil oil is abs absolu olutel tely y clean when filling the automatic oiler.
2
Check that the chain is lubricated properly.. If needed, adjust the nozzles properly or oil brushes.
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Step 4
Action If ne needed, se set th the Ton and Toff on on th the time relay in the control cabinet again according to current status. • For Ton Ton and and Toff Toff para paramete meterr setting, setting, refer to the following table.
NOTE! NOT E! Parame Parameter ters s must must be che checke cked d after first maintenance is completed. If necessary necessary,, adjust parameters slightly according to the actual humidity and temperature.
For AJV
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
PALLET MODULE Removing pallets WARNING
If the missing pallet monitor is equipped, run the unit with pallet opening, keep the pallet opening on the upside of pallet band, otherwise reset the fault code(58 59) on cabinet. The pallets can be removed at the drive or return station. Maintenance task: Remove task: Remove pallets Maintenance method and standards: WARNING
In general, the pallet band must be locked using the pallet band lock when performing any work in or on an open pallet band.
Step 1
2
Action Remove access cover an and insert th the hand-held pendant control. Release the screws (1) and remove pallet guards (2). Run the pallet ba band using the handheld pendant control until screws (4)
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Step 4
5
6
7
Action Remove screws (4) with retaining plates (5), drag the slide connector (6) towards the center of the pallet. Raise pa pallet (7 (7) an and pu pull ou out pa pallet retaining forks (8) from the slider blocks (9) of the succeeding pallet (10). Lock unsecu curred slider blocks (11) in position by inserting a spreader bar (12). Remove ot other fo four pa pallets in in in insp spe ecti tio on mode.
Note
NOTE! NOT E! On the the first first mainte maintenan nance ce visit, visit, mark all pallets using red spray paint. Mark the first pallet in its corner as number one. Then run the unit towards the drive station, mark the next pallet as number two, and so on.
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Reinstalling pallets The pallets can be interchanged as a result of the modular design. Maintenance task: Check task: Check and reinstall pallets Maintenance method and standards: Step 1
2 3
4
Action Check the removed pallets for the following. • Warp • Cracks • Lo Loos ose e or or dam damag aged ed ro roll ller ers s • Lo Loos ose e or or dama damage ged d pal palle lett demarcation strips • Loo oose se har ard dwa ware re Check slider bl blocks for we wear or damage. Make sure the pallet band is cl cle ear of personnel and equipment. and equipment. WARNING! Serious injury or death can occur from rotating equipment. Make sure unit is clear of all personnel and equipment before attempting to start the unit. Start the unit and ru run n the pallet band
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Step 6
Action Slide pa pallet fo forks (8 (8) on onto sl slider bl blocks (9) of the next pallet (10). NOTE! NOT E! Make Make sure insta installa llatio tion n positio position n of the slider block is correct. The slider block is properly installed with the slider block protrusion (13) which is located towards the pallet chain (14) and facing the base of the forks (15).
7 8
9 10
NOTE! NOT E! Add gre grease ase ins inside ide the sli slide derr blocks and around slider connectors if needed. (Grease type: DEE1547522) Slide pallet co connector (6 (6) to toward rds s th the center of the pallet. Install sc screws (4 (4) an and re retaining pl plates (5), and tighten screws. • Tig ight hten en scr screw ews s (4) (4) to M A 22 Nm [18.75 lbf-ft]. Secure sc screws by by be bending re retaining plates (5). Inst In sta all re rem main inin ing g pa pall lle ets in in th the sam same e
Note
15
14
13 9
5016770(2007-11)
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
BRAKE MODULE Maintenance task: Check clearance between brake arm and brake solenoid piston Maintenance method and standards: Step 1
2
3
Action Change the blind plug to the maintenance handset. Actuate the stop button on the handset. Push the piston (2) to to C direction. Measure the clearance between brake arm (1) and brake solenoid piston (2). If ad adjustment is is ne needed, tu turn scre rew ws (3 (3) to adjust for 1.5 mm clearance between screws and brake solenoid piston.
Note
It is very important that there is 1.5 mm clearance between the brake solenoid piston (2) and brake arm (1).
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Step 2
Action Adjust the bolt (3) if needed.
Note
Maintenance task: Check motor brake lining Maintenance method and standards: Without brake wearing monitor Step 1 2
Action Measure the depth D of br brake ar arm fr from measurement me asurement hole (1) by callipers. If th the brake lining th thiickness is below 3 mm, replace brake arms and lining. • Bra Brake ke lini lining ng thic thickne kness ss = Mea Measur sured ed data D - 29
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
With brake wearing monitor Step 1
Action Visu sua ally check that the bra rak ke wearing monitor is fixed tight.
Note
Maintenance task: Check task: Check main brake spring length Maintenance method and standards: NOTE! Adjustment and and checking are needed needed if stopping stopping distance distance is not not correct. Step 1
2
Action Tighten th the sp spring to to ma make th the sto stop pping distance shorter and loosen the spring to make the distance longer. Lock the adjusting nuts.
Note Both springs (1) must be equally adjusted to ensure the spring length L is the same on both sides.
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Auxiliary brake (if equipped) NOTE! Auxil Auxiliary iary brake brake is only available available for RJV. RJV. Auxiliary brake is activated in case of autowalk autowalk power off, off, autowalk overspeed (over (over 1.4 times the rated speed), pallet band reverse direction, broken drive chain. Maintenance task: task: Check Check the auxiliary brake trigger device Maintenance method and standards: Step 1
Action Drag Dr ag th the e au auxi xili lia ary br bra ake sh shaf aftt manu nua all lly y. It must move freely and can reset automatically. • Swi Switch tch con contac tacts ts wit with h the the swi switch tch pusher curve part. • The swi switch tch pus pusher her and swi switch tch mus mustt be fixed tightly.
Note
Maintenance task: task: T est auxiliary brake function (once a year if no third party inspection) Te Maintenance method and standards: Step 1
2
Action Place th the barricades at at bo both ends, confirm that no personnel and tools are on the step band. Open the access cove verr, switch off main power, lift and take out the cabinet.
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
DRIVE MODULE Change the blind plug to the maintenance handset. Actuate the stop button on the handset. Maintenance task: Check oil level of gearbox Maintenance method and standards: Step 1
Action Check oil level of gearb rbo ox by removing the filler cap of the dipstick (1).
Note
• Oil sho should uld be be betwe tween en the upp upper er and lower marks on dipstick.
Maintenance task: Check air breather Maintenance method and standards: Step 1
Action Check th that a aiir br breather (2 (2) iis sc cllean
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Oil specification Drive type 5.5, 7.5kW motor, with FTJ125A gear 7.5,9.2, 11kW motor, with FTJ160D gear 5.5kW motor, with CG35B gear 7.5kW motor, with CG35B gear (Right side) 7.5kW motor, with CG35A gear (Left side) 7.5, 9.2, 11kW motor, with CRW160B gear (Right side) 7.5, 9.2, 11kW motor, with CRW160A gear (Left side) 5.5, 7.5, 9.2, 11kW motor, with CG26-112 gear 5.5, 7.5, 9.2kW motor, with K87 gear 7.5, 9.2, 11kW motor, with K97 gear
VG460
Synthetic oil
7.5
Oil change interval 1st ti time me (h (h)) Re Reg gul ula ar (h (h)) 3600 20000
VG460
Synthetic oil
15
3600
20000
VG460
Synthetic oil
9
3600
20000
VG460
Synthetic oil
9
3600
20000
VG460
Synthetic oil
7.5
3600
20000
VG460
Synthetic oil
17.5
3600
20000
VG460
Synthetic oil
12
3600
20000
VG460
Synthetic oil
14
3600
20000
VG220
Synthetic oil
10.9
3600
20000
VG220
Synthetic oil
20
3600
20000
Oil viscosity
Oil type
Oil volume (L)
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Maintenance task: Check drive unit mounting bolts and drive chain slack Maintenance method and standards: Step 1
2
Action Check dr drive un unit mo mounting b bo olts ((1 1). • The dri drive ve unit unit mou mounti nting ng bolt bolts s are are tightened. Remove th the e fl fly ywheel cover, tu turrn the flywheel in return end direction, make sure the upper side of drive chain is slack. • When When the the ten tensio sion n is on the upp upper er side of chain, the slack amount (X) is 10 mm +/-5 mm (25/64 in.+/- 3/16 in.).
3
4 5
If dr drive ch chain sl slack ad adjusting is is ne needed, loosen the four fixing bolts (1) on motor base, loosen the nut (2) and turn the limiting bolt (3) so that the drive chain can be tightened appropriately. Tig igh hten th the fifixing bo bolts (1 (1) an and lo lock th the nut (2). Reinstall the flywheel co cover.
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Maintenance task: Check the gap of broken drive chain switch Maintenance method and standards: Step 1
2 3
4
Action Turn th the flflywheel in in dri driv ve en end di direction manually.. Confirm the manually t he slack of chain is in lower side. Check the gap between drive chains (3) and the detecting bar (1). • Th The e gap gap mu must st be be 25 25 – 35 35 mm. mm. Adjust th the sw switch (2 (2), ifif ne necessary. Physically move the detecting bar to depress the switch. The fault code 12 must display on control board. (For 501 upgrade version, fault code is 14.) Remove the maintenance handset, insert blind plug.
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
GUIDE MODULE WARNING
If missing pallet monitor is equipped, the unit must be run with pallet opening on the upside of pallet band. Otherwise the fault code (58 59) on cabinet must be reset. Maintenance task: Make adjustment adjustment if missing pallet detector does not work Maintenance method and standards: Step 1
2
3
Action Remove five pallets in a ro row w, and move the pallet opening to missing pallet detector area in inspection mode. Actuate the stop button on the handheld pendant control. Check cl clearance be between pr proximity sensor (1) and the fork (2) of pallet. • The sen sensor sor sho should uld be cen center tered ed and and approximately 5 mm from the tapered flat head screw of trailing wheel. If ad adjustment is is ne needed, lo loosen nu nuts (3 (3) and adjust until the sensor (1) is centered and the clearance is correct from the fork (2) of pallet.
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Maintenance task: Check the oil groove of handrail drive chain Maintenance method and standards: Step 1
2 3 4
Action Run un unit in in in insp spe ection mode in th the dr drive end direction, actuate the stop button on maintenance handset when pallet opening is in handrail drive chain area on upper level. Turn main power supply OFF, and engage the pallet band lock (if equipped). Visually ch check th the oi oil gr groove of of ha handra raiil drive chain, clean the groove if needed. Check the oil drain pipe is unblocked, clean the pipe if needed. Check the lubrication brush is at the right position.
Note
Maintenance task: Check handrail drive chain tension Maintenance method and standards: Step 1
Action Check ha handrail dr drive ch chain te ten nsion (A (A)) in the center between the handrail drive chain sprocket (1) and main drive sprocket (2).
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Step 2 3
4 5
6
Action Loosen be bearing mo mounting bo bolt (3 (3) of of handrail drive wheel shaft. Loosen lo lock nu nut (4 (4), an and ad adjust ha handrail drive chain tension with jack bolt ( 5). • Set ha handr ndrail ail dri drive ve cha chain in slac slack k to be standard – measured at the drive chain center between the handrail drive chain sprocket (1) and main drive sprocket (2). • Mak Make e sure sure me measu asurem remen entt (dist (distan ance ce between axles) on both sides of autowalk are the same. Otherwise the handrail wheels are inclined. Tig igh hten mounting bolt (3 (3)) an and lock nut (4). Rein Re inst sta all al alll of th the e par artts in re reve vers rse e or ord der of removal. Release the step band lock device. Check th the po position of of th the ha handrail. • The ha handr ndrail ail dri drive ve whee wheell must must be be in handrail. the center of of the handrail. For RJV
Note NOTE! To increa NOTE! increase se the the handra handrailil tension, tighten jack bolt (5) equally for right hand and left hand sides. NOTE! NOT E! To decrea decrease se the hand handrai raill tension, loosen jack bolt (5) and pull handrail drive wheel shaft to set tension dimension. NOTE! NOT E! Empty Empty the the oil oil cont contain ainer er ifif needed. For AJV
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Maintenance task: Check the thickness of handrail drive wheel rubber (main handrail drive wheel and second handrail drive wheel) Maintenance method and standards: Step 1 2
3
Action Move th the pa pallet op opening to to re related handrail hand rail drive wheel position. Actuate th the st stop bu button on on ha handset, turn main power OFF, engage the step band lock device. Check the thickness of handra raiil drive wheel rubber on both sides.
Note
NOTE! NOT E! The The thickn thickness ess sho should uld no nott be less than 3 mm.
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Step 1
2 3
Action Spra ray y application may be re req quire red d if noise is generated between pallet chain roller (2) and lip track. Spray ap application ma may be be al along th the entire length of lip track. Spra ray y ap application should be done on once before putting the unit into operation.
Note NOTE! Use onl NOTE! only y a high high pres pressur sure e semisemisynthetic grease (Rivolta SKD 3602), based on metal soap without solid additives for initial application. NOTE! NOT E! All lubri lubricat cation ion-fre -free e chains chains are are identified by SF or LF in the chain designation.
to be added
Maintenance task: Grease the bearings of following shafts: • • • •
Main sh Main shaf aftt (dr (driv ive e en end) d) Handra Han drailil dri drive ve sha shaft ft (dr (drive ive end end)) Second Seco nd handra handrailil drive shaf shaftt (return end, ifif equipped equipped)) (only for for AJV) Return Retur n wheel wheel shaft shaft (return (return end, if equipp equipped) ed) (only (only for for AJV)
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Grease nozzle for main shaft and handrail drive shaft (AJV)
to be added 1
1
Grease nozzle for main shaft and handrail drive shaft (RJV)
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Grease nozzle for the second handrail drive shaft
to be changed
Grease nozzle for return wheel shaft
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Second handrail drive unit (if equipped) This device is usually installed in return end. Maintenance task: Check running noise Maintenance method and standards: Step 1 2 3 4
Action Remove the pallet opening to se sec cond handrail drive area in inspection mode. Inch chiing run the unit, visually check vibration and noise of the driver. If th the e op oper era ati tion on is not qu quie iet, t, in inve vest stig iga ate the cause of noise and correct it. If noise cannot be corr rre ect cte ed, contact your supervisor with all details.
Note
Maintenance task: Visually check the seals for leakage Maintenance method and standards: Step 1
Action Move the pallet opening to second handrail drive station, turn the control current OFF in the return end pit, actuate the emergency stop on maintenance handset. Actuate the pallet band lock device in drive end.
Note
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
HANDRAIL MODULE Handrail drive system overview • • • • • • • • •
Handra raiil (1 (1)) Hand Ha ndra rail il dr driv ive e whe wheel el (2 (2)) Hand Ha ndra rail il dr driv ive e sha shaft ft (3 (3)) Hand Ha ndra rail il dr driv ive e cha chain in (4 (4)) Newel (5 (5) Hand Ha ndra rail il gui guide de rol rolle lerr (6) (6) Hand Ha ndra rail il pre press ssur ure e roll roller er (7) (7) Hand Ha ndra rail il ten tensi sion on dev devic ice e (8) (8) Second Seco nd handr handrail ail drive drive (if equip equipped ped for AJV) AJV) (9) (9)
to be added, AJV + second handrail drive
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
Handrail guides Maintenance task: Check task: Check handrail tension Maintenance method and standards: Step 1
Action Remove one piece of inner deck ckiing in middle position on both sides.
2
Run the unit towards drive end for several seconds, actuate emergency stop on the hand-held pendant pendant control. Select one secti tio on of tru rus ss bar (1) and press the handrail in middle position.
3
Note NOTE! Rem NOTE! Remove ove the the inner inner deck decking ing from from the fourth balustrade panel relative to end.
• With With arou around nd 50 N forc force, e, sla slack ck is is about 10 – 20 mm.
to be added 4 5
Tension th the ha handrail in in re return en end pi pit if if needed. Run th the un unit in in in inspection mode towards return direction for several
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
RELATED DOCUMENTS The following documents are related with maintenance of KONE TravelMaster™ 115 (RJV) and TransitMaster™ 165/185 (AJV): • AS-51.00.0 AS-51.00.001 01 MBM-2 MBM-2 Manual Manual Add-ons Add-ons for KONE KONE TransitMaster™ 165/185 Autowalk Maintenance Instruction
TravelMaster™ TravelMa ster™
115 115
and
• AS-51.05.0 AS-51.05.004, 04, Control Control System: System: 501-B 501-B upgrade upgrade for for EJV R1.5 / E40 R1.1 R1.1 / AJV1.0 / RJV1.3 RJV1.3 Diagnostic Guide • AM-51.08.0 AM-51.08.001 01 KONE TravelMa TravelMaster™ ster™ 115 115 and TransitM TransitMaster™ aster™ 165/18 165/185 5 Autowalk Autowalk Installation Instruction • AR-51 AR-51.07.0 .07.002 02 KONE Transi TransitMast tMaster™ er™ 165/185 165/185 Horizont Horizontal al Autowalk Autowalk spare spare parts parts • AR-51 AR-51.08.0 .08.002 02 KONE Transi TransitMast tMaster™ er™ 115 115 Inclined Inclined Autowalk Autowalk spare spare parts parts • 5214 52141 110D2 10D21, 1, EMB_501 EMB_501 upgrade upgrade paramete parameterr setting for 0.4 m/s with VACON VACON Inverter Inverter • 1372 1372012D 012D21, 21, VACON VACON invert inverter er adjustm adjustment ent for for handrail handrail drive drive
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
APPROVALS AND VERSION HISTORY Compiled by:
PIA Technical Writer / Ma Yun Hui
Checked by:
CRD Escalat Escalator or Maintenance Specialist / Ye Zu Ling Escalator Platform Category & PCM Manager / Weber Ralf
Approved by:
SEB Maintenance Development Development Manager Manager / Seppo Valliovuo Valliovuo
Issue Date Description of change 2011-03-14 Document creation. A 2012-04-16 Automatic oil Toff Toff parameter parameter setting changed; checking the gap of broken drive chain switch added; oil specificaion changed; handrail guides checking added. The content for checking auxiliary brake trigger device changed. The content of complate module moved to basic module. The method for checking thickness of handrail drive wheel rubber and handrail track spring length added.
Ref CR
Approved by Seppo Valliovuo Seppo Valliovuo
TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions
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ELEVATORS ESCALATORS
Appendi x:C
WI RI NG DI AGRAM
