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MASTER INDEX

VOLUME 01: CIVIL ELEMENTS

1.1 CIVIL & STRUCTURAL ELEMENTS:

1.1.1 CHAIN LINK FENCE

1.1.2 SIGNAGE

1.1.3 TRAFFIC MANAGEMENT SYSTEM

1.1.4 PARKING MANAGEMENT SYSTEM

1.1.5 TAXI DISPATCH SYSTEM

1.1.6 BUS TERMINAL SYSTEM

1.1.7 SBS ROOFING SYSTEM

1.1.8 ROOF DECKING

1.1.9 FALL PROTECTION SYSTEM

1.1.10 TREES, SHRUBS, GROUND COVERS, LAWNS & GRASSES

1.1.11 IRRIGATION SYSTEM

1.2 ARCHITECTURAL ELEMENTS:

1.2.1 STEEL DOORS

1.2.2 ALUMINUM & GLAZING WORKS

1.2.3 ACOUSTIC/ METAL PAN CEILING/ CORIAN COUNTERS

1.2.4 COMPOSITE STONE TILE/ FLOOR MATS

1.2.5 METAL LOCKERS/ SHELVING

1.2.6 TOILET ACCESSORIES

1.2.7 EPOXY FLOORING

1.2.8 RAISED ACCESS FLOOR

1.2.9 CARPET FLOORING

1.2.10 CARPET TILE FLOORING

1.2.11 ROLLER SHADES

1.2.12 ELEVATORS/ ESCALATORS/ AUTO-WALKS

1.2.13 GENIE ARIEL LIFT

VOLUME 02: MEP SYSTEMS

2.1 MECHANICAL SYSTEMS

2.1.1 FIRE PROTECTION SYSTEM

2.1.2 PLUMBING & DRAINAGE SYSTEM

2.1.3 HVAC SYSTEM

2.2 ELECTRICAL SYSTEMS

OPERATION AND

MAINTENANCE MANUAL

AIRPORT STAFF ACCESS

CONTROL FACILITY

PACKAGE - 6201

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O&M MANUALS- ELEVATORS.

AIRPORT STAFF ACCESS CONTROL FACILITY-6201

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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 Safety19-25

5 Operation Manual..26-27

6 Maintenance Manual.28-29

7 Disposal Instruction.30-31

8 Trouble shooting...32-39

9 Manufacturer contact details.40-41

10 Guaranties & Warranties.42-43

11 Emergency Information...44-45

12 As Built Drawing46-48

13 Manufacturer literature49-50

14 Testing & commissioning.51- 57

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Standard safety devices for ASME A17.1-2010/CSA B44-10

Optional safety devices

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8. TROUBLESHOOTING

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8. TROUBLESHOOTING

8.1 Fault Code Details

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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

GENERAL INFORMATION of 4Customer: SAP NO:

Site Address Site Contact personName:

Tel No:

Mobile No:

Fax No:e- mail:

TECHNICAL DATA

SAP NO:

Vertical Rise: m

Step width : mm

Inclinaison:

Level steps atupper end:

Level steps atlowr end:

Rated speed: m/s

Supply Voltage: V

EQUIPMENT TESTS ( SUMMARY)

In Order Comments

Bottom Pit ______________________________________

______________________________________

Inside Truss ______________________________________

______________________________________

Top Pit _______________________________________

Visual Features ___________________________________

Other Comments Tested By:Name:

WITNESSED BY:Name:

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EQUIPMENT TEST

YES NO YES NO N/A RemarkPre- InstallationAre the split trusses undamaged ?

Are the standard mounting bolts used?

Is the step chain pin inserted towards out side of escalator?

Is the temporary protection provided at site

In order Adjusted/ Repaired

Bottom Pit YES NO YES NON/A Remark

Electrical Operation

Is the electrical plug operating correctly?

Is the traffic light operating correctly?

Is the comb plate impact device operating correctly?

Is the comb light operating correctly?

Is the buzzer on stop switch operating correctly?

Is the lug for handheld pendant operating correctly?

Is the step guard correctly adjusted?

Safety Device

Are the handrail inlet safety switches operating correctly?

I th t ti tl

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Access cover switch correctly installed and adjusted?

Is the key start switch operating correctly?

Is Is the step chain tension device operating correctly?

Inside Truss

Are the step sag devices detector operating correctly? (Top 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 correctly?

Is gear box oil level correct?

Brake

Are the gaps between steps / skirts correct (4mm on one side

and 7 mm combined) ?

Are the gaps between steps / combs correct (maxi 4mm)?

Are the combs undamaged?

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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 DeviceAre the handrail inlet safety switches operating correctly?

Is the handrail pressure roller well adjusted?

Is the step guard correctly adjusted?

Is the comb plate impact device operating correctly?

Is the step band lock operating correctly?

Visual Features

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Handrail

Are all handrail inlets and brush plates adjusted centrally to the

handrail?

Are handrails in newels are correctly guide without abrasion?

Step Band

Are all steps undamaged?

Are all steps screws secured?

Are the gaps between steps / skirts correct (4mm on one side

and 7mm combined)?

Are the gaps between steps/ combs correct (maxi 4 mm)?

Are the combs undamaged?

Claddings

Are outside deckings correctly adjusted and joined?

Are soffit claddings undamaged?

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S No Equipment name Model Number Equipment Serial

Number

Type Calibration Due date

Acceptance / Representative KONE AMANA Witnessed by KEO

Name

Signature

Date

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ELEVATORS ESCALATORS

Appendix: A

OPERATION MANUAL OFESCALATOR & AUTOWALK

KONE Escalators and AutowalksOperating Instructions

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Escalators and autowalksOwner'sGuideUM-51.01.008 2012KONE CorporationAllrights reserved(E) 2012-03-30KONE CorporationVersion2.0

Operating Instructions


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This publication is for informational purposes to support the operator how and when anescalator 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 andprocedures reflected in this document. NO STATEMENT CONTAINED IN THIS DOCUMENT

SHALL BE CONSTRUED AS A WARRANTY OR CONDITION, EXPRESS OR IMPLIED ASTO 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 WITH THE

USE OR DISCLOSURE OF INFORMATION IN THIS DOCUMENT. KONE HAS NO

LIABILITY FOR TYPOGRAPHICAL OR OTHER ERRORS OR OMISSIONS CONTAINED INTHIS DOCUMENT OR ANYONE'S INTERPRETATION OF THE INSTRUCTIONS. THE

USER OF THIS DOCUMENT ASSUMES ALL RISKS ASSOCIATED WITH THE USE ORDISCLOSURE 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.

Copyright 2012 KONE Corporation

All rights reserved. No part of the contents of this document may be copied, reproduced or

transmitted in any form or by any means, or translated into another language or format, in

whole or part, without prior written permission of KONE Corporation.


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1 INSTRUCTIONS FOR THE OPERATOR...................................................................4

1.1 Organizational measures .............................................................................................. 4

1.2 Personnel ...................................................................................................................... 5

1.3 Regular inspection and maintenance ............................................................................ 5

2 MAIN COMPONENTS................................................................................................6

3 SAFETY INSTRUCTIONS FOR ESCALATORS AND AUTOWALKS........................ 8

3.1 Safe behavior in the vicinity of and on escalators or autowalks .................................... 8

4 SAFETY NOTICES (PICTOGRAMS)......................................................................... 9

5 FREE AREA FOR END USERS - EN 115................................................................ 11

6 REGULAR INSPECTION AND TESTING ................................................................ 12

7 CLEANING ...............................................................................................................13

7.1 Stainless steel surfaces............................................................................................... 13

7.2 Push-buttons and switches ......................................................................................... 13

7.3 Handrail surfaces ........................................................................................................ 13

8 CHAIN LUBRICATION BY HAND (STANDARD) .....................................................13

9 INFORMATION DISPLAY 501 (OPTIONAL)............................................................14

10 SWITCHING ON (OPERATING MODE VARIANTS) ...............................................15

10.1 Prior to switching on.................................................................................................... 15

10.2 Switching on Smart star-delta (standard) .................................................................... 16

10.3 Switching on Stand-by speed with inverter (optional).................................................. 17

10.4 Switching on Automatic start / stop (optional) ............................................................. 18

10.5 Switching on Automatic start and Stand-by (optional) ................................................. 19

11 SWITCHING OFF ....................................................................................................19

11.1 Operational stop.......................................................................................................... 19

11.2 Emergency stop .......................................................................................................... 19

12 SWITCHING OFF THE MAIN POWER SUPPLY.....................................................20

12.1 Recovering the auxiliary brake.................................................................................... 20

13 SAFETY CHECK PRIOR TO RESTARTING THE ESCALATOR OR AUTOWALK. 21

14 VERSION HISTORY.................................................................................................2215 FEEDBACK ..............................................................................................................23


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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, 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 operatinginstructions. Which operating mode is used is dependent on the specific configuration of your

unit. For more information on all operating modes, see section 10 Switching on (operating

mode 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 to 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:

Directions relating to existing national regulations for accident prevention and protection,

Directions concerning responsibilities, supervisory duties and reporting duties, for

example, for the personnel deployed.

Directions concerning action in emergency situations, for example, notification of location

and instructions for use of fire extinguishers.

In the event of any safety-related changes to the unit or the related operating behaviour, the

unit must be shut down immediately. No modifications to, or conversion of the unit are

allowed without the permission of KONE.

Replacement parts must correspond to the technical requirements specified by the

manufacturer. Therefore, use only original KONE replacement and wearing parts.Contact the KONE Customer Service for the performance of servicing and repair work.


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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.

Personnel with long hair must wear head covering. Loose clothing or jewellery, includingrings, 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 andbefore 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 regulations, 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.


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The KONE escalator or autowalk consists of the following main components:

the support system of the escalator or autowalk.

moving components 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 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, gear box, operational brake,

handrail drive wheels and step chain sprockets by means of which the step band andhandrails are driven.

optional electrical components for illumination of the

escalator or autowalk in various positions. The lighting system can comprise the balustrade

lighting, comb bearing plate lighting, and step gap lighting.

various electrical safety devices (safety limit

switches, speed monitoring device) are connected to the control unit in the form of a safety

chain for the purpose of monitoring. The escalator or autowalk is switched off upon activation

of one of these safety devices.

NOTE! The illustrations in your operating instructions may deviate from the design of your

escalator or autowalk.

NOTE! The side specification (left or right) always refers to an escalator viewed from the


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um5100002d

3

8

24, 6

5

6

7

12

11

9


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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 unattended children to play in the vicinity of or on the unit

Do not allow end users with prams or pushchairs, people in wheelchairs, or end users with

walking aids to use the unit. Ask them to use the elevator. Do not allow end users with bulky or heavy luggage to enter the escalator. Ask them to

use the elevator.

Do not allow anyone to ride on the handrail, or place heavy or bulky objects on the

handrail.

Do not allow anyone to pull on the handrail or pull it out of the handrail guide.

Do not allow anyone to use a downwards travelling unit in an upward direction or anupwards travelling unit in a downward direction.

Do not allow anyone to run up or down the unit.

Do not allow anyone to press the Emergency Stop button, except in an emergency.

Do not allow end users to use the unit barefooted.

Encourage end users to lift their feet when they enter or leave the unit.

Encourage end users to stand in the middle of the step and not to drag their shoes along

the skirts.

Do not allow end users to sit, kneel, or support themselves with their hands on a step

during operation of the unit. Leaning over the balustrade while the unit is in operation is

not allowed.

Encourage end users to keep their hands, feet, clothing items, and shoelaces away fromthe skirts. There is a danger of entrapment.

Encourage end users to promptly step onto and off of the unit when entering and exiting

so that no congestion occurs.

Do not allow heavy or bulky objects to be transported on the unit.


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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.

Pictograms in accordance with EN 115:1995 and GB 16899-1997


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Pictograms in accordance with EN 115-1:2008+A1:2010 and GB 16899-2011


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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 centerlines (A). The depth must be at least 2500 mm,measured from the end of the balustrade.

A = Distance between the handrail center lines

The free area may be reduced to 2000 mm, if

the area is increased in width 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). Thedepth must be at least 2500 mm, measured fromthe end of the balustrade.

A = Distance between the outer edges of the

handrails plus 80 mm on each side

The free area may be reduced to 2000 mm, if

the area is increased in width by at least twice

the distance between the outer edges of thehandrails plus 80 mm on each side (B).

B = Twice the distance between the outer edges

of the handrails plus 80 mm on each side


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C = common crossing area for adjacent units

Make sure that regular safety inspections and tests are performed at least once per quarter

and after each repair. It is recommended that all work on the escalator or autowalk be

performed by KONE service personnel only.

The annual safety inspection and testing is usually monitored by a local inspector who is

authorized by the licensing authority.

The inspector responsible for checking the escalator or autowalk components can demand

the performance of additional tests by a skilled KONE erector.

NOTE! For more information on regular inspections and testing consult the latest version of

EN 115 or the local licensing authority.

NOTE! The safety standards required in EN 115 are the minimum requirements. Local

directives can make additional requirements of the regular inspections and tests


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Clean escalator or autowalk parts as described in section 7.1 Stainless 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 steel cleaner to

clean and protect the surfaces.

Wipe push-buttons and switches with alcohol or water / soap-based cleaning agents.

Wipe down the handrails with a cloth moistened with a cleaning agent.

It is recommended that you use a special handrail cleaning agent or mild soap and warm

water. Then wipe the handrail with a dry cloth.

Fill the oil into the cup (1L).

Open the regulating valve and drop oil into chains with proper flux. Ensure that the whole

chain length is lubricated.

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.


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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, the corresponding 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.


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The operating mode variants available for escalator or autowalk are described 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 push-button, 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 safety of

personnel traffic is not allowed.

Check also whether skirts, inner and outer decks, frontplates, or combplates have 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 10.2 to section 10.5.


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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, insert the key into the key-

operated switch (1).

The key-operated switch is located at

the lower right and upper left of theinner side of the handrail entry.

2 Start the unit in the operational direction

you require by turning the key.

Key switch at lower right side: Turn

clockwise to run the unit downwards

and counter-clockwise to run the unit

upwards.

Key switch at upper left side (optional):Turn clockwise to run the unit upwards

and counter-clockwise to run the unit

downwards.

The unit starts up immediately.

3 After actuation of the key, turn it immediately back to the middle position and pull it out of

the key-operated switch (1).

The direction can only be changed after actuation of stop switch (2).

Simultaneously with unit start-up the operational direction is indicatedoptically by traffic lights

(optional).

NOTE! After start-up, only allow the public to use the unit after ensuring that the step band

and handrails are running correctly. Observe at least two revolutions of the step

band. In particular, make sure there are no damaged or missing steps.

The transport of bulky or heavy goods is not permissible.

Free areas at the unit entry and exit points must be kept clear at all times

Do not start / stop the unit if persons or objects are on the unit, otherwise there is a

danger of falling.


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Each time before switching on the unit, perform avisual and functional check in accordance withsection 10.1 Prior to switching on.

1 To switch on, insert the key into the key-operated

switch (1).

The key-operated switch is located at the lower

right and upper left of the inner side of thehandrail entry.

2 Pre-select the operational direction by turning thekey.

Key switch at lower right side: Turn clockwise to

pre-select down running direction and counter-

clockwise to pre-select up running direction.

Key switch at upper left side: Turn clockwise to

pre-select up running direction and counter-

clockwise to pre-select down running direction.

The unit starts immediately when the light barrier is interrupted.




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.

Upon expiration of the normal run-time (travel time plus after-run-time) the step band is

switched automatically back to stand-by mode for energy saving reasons.

NOTE! After start-up, only allow the public to use the unit after ensuring that the step band

and handrails are running correctly. Observe at least two revolutions of the step

band. In particular, make sure there are no damaged or missing steps.

The transport of bulky or heavy goods is not permissible


danger of falling.


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Each time before switching on the unit, perform a visual and functional check in accordancewith section 10.1 Prior to switching on.

1 To switch on, insert the key into the key-operated switch (1).

The key-operated switch is located at the lower right and upper left of the inner side of

the handrail entry.2 Pre-select the operational direction by turning the key.

Key switch at lower right side: Turn clockwise to pre-select down running direction and

counter-clockwise to pre-select up running direction.

Key switch at upper left side: Turn clockwise to pre-select up running direction and

counter-clockwise to pre-select down running direction.

The unit starts immediately when the light barrier is interrupted.




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 canbe adjusted on the radar amplifiers. If the adjustment is needed, call the KONE maintenance

personnel. For more information, see section 13 Safety check prior to restarting the escalator

or autowalk.

When the sensing distance is set, a detection area is set up in front of the unit entrance

accordingly. Once an end user walks into the area from any direction, he / she should be

detected by the radar sensors. The control system makes the unit start running.

The step band runs a prescribed length of time and stops until the sensors are detected again

by a passenger walking through the detection area.

Units with the radar sensors are preset to run only in one direction (either up or down). If an

end user tries to enter from the wrong direction, the unit starts to run for a defined time to

prevent the user from using the unit as a stairway.


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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).

Press stop button (1) to switch off the unit

(operational stop).

The stop button is located at the lower rightand upper left of the inner side of the

handrail entry.

The unit makes a controlled stop.

If, while the unit is in operation an unforeseenemergency situation occurs, the unit must be

switched off immediately.

Only in this emergency situation should the

stop button (1) be pressed independently of


danger of falling.


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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 maintenance chamber on the

control cabinet of your escalator or autowalk.

2 Turn the main power switch to OFF ("0") to disconnect the main power supply.

3 Lock the switch in the position OFF ("0") with a padlock.

An auxiliary brake is mandatory for vertical rises above 6 m, and optional for vertical rises 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.

Directly turn the key switch to let the unit operate upward for around 3 seconds. The auxiliary

brake block is pushed down when you hear a crash sound. After that, the unit enters the

normal operation mode.

After performing the same operation as above, press the stop button to stop the escalator.

Turn the key switch to let the unit operate downward, and then the unit enters the normal

operation mode.

Always switch off the unit before opening the maintenance chamber, otherwise 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.

Before the auxiliary brake is recovered, the unit can not work if directly turning the key


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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 described below should be performed only by KONE's service

department or by skilled personnel who have been qualified by the manufacturer of

the unit.

1 Read the fault message on the info display in the PCB control unit.

2 Check the following points on the escalator or autowalk.

whether two or more teeth of a comb segment are damaged or broken

whether there are any foreign bodies in the comb segment or in the step band

whether a safety device has been activated a damaged step in the step band

an increased gap between two steps

the distance between the steps and the skirts

drive chain and step chain lubrication

whether auxiliary brake looses or recovers (if provided)

check the handrail surface quality and isochronous step speed

faults in the electrical system

whether any switches are loose

whether any cables are loose whether the coating on the balustrade skirt is worn through

3 Reset the error message on the control unit by pressing the reset button. The reset button

is located on top of the control cabinet.

4 Connect the handheld pendant control.

5 Start the unit in travel direction.

6 Check the input voltage.

7 Check the inspection travel.

If the unit does not start up, read the fault display and proceed in compliance with thefault code indicated.

8 Remove the handheld pendant control.

9 Restart the unit.

10 Check the running step band for abnormal sounds (for example: at the step inlet) and for

Cordon off both escalator entries by erecting personnel traffic barriers. Removal of thebarrier is not allowed until the maintenance chamber has been closed, otherwise there is

a personal injury hazard.


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Compiled by: Technical Illustrator / Guo Li Li

Checked by: Escalator PCM Assistant Manager / Shang Rui

Approved by: Escalator Platform Category & PCM Manager / Weber Ralf

- 2012-07-05 First issue Weber Ralf


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Click one of the star buttons in the PDF version to rate the document and report errors or

suggest improvements. This opens your default e-mail client. Users of printed documents can

send feedback directly to [email protected]

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Appendix: B

MAINTENANCE MANUALOF ESCALATOR &

AUTOWALK


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MAINTENANCE MANUAL

OF ESCALATOR

MBM-2 Manual Add-ons forKONE TravelMaster110 Escalator

Maintenance Instructions

MBM-2 ManualAdd-onsfor KONETravelMaster 110Escalator(EJVR1.2/1.3/1.4/1.4.1)Maintenance InstructionsASG-51.05.001 2006KONE CorporationAllrights reserved(H)2011-01-28KONE CorporationEJV 1.5

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KONE TRAVELMASTER 110 ESCALATORMBM-2 (Modular Based Maintenance)



TABLE OF CONTENTS

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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MBM-2 modular based maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

STANDARD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY DEVICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Location of safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step band lock device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

BASIC MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Product-specific instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

STEP MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Removing steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Reinstalling steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

BRAKE MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Auxiliary brake (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

COMB PLATE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DRIVE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

GUIDE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

HANDRAIL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Handrail drive system overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Handrail guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



STANDARD TOOLS

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Toshiba pulling tool (TE4Z6KZ802P001, for lifting the access cover)

Handle for lifting landing (DEE0075707)

Label - Proactive oil replacement (KM987329G01)

Callipers for motor brake lining check (KM167619)

SAFETY DEVICES

Location of safety devices



Name Explanation

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Additional safety switches:

Name ExplanationB 20 Water level switch (for outdoor) (if equipped)

B 36 Missing step monitor, lower (if equipped)

B 37 Missing step monitor, upper (if equipped)

B 50 Handrail speed monitor, left (if equipped)

B 51 Handrail speed monitor, right (if equipped)

S 1 Control current circuit breaker, lower

S 5 Emergency stop switch, lower

S 6 Emergency stop switch, upper

S 60-61 Comb plate impact switch lower left and right

S 62-63 Comb plate impact switch upper left and right

S 65-66 Handrail inlet switch lower left and right

S 67-68 Handrail inlet switch upper left and right

S 70 Step sag switch, lower

S 72 Step sag switch, upper

S 75-76 Broken step-chain switch lower left and rightS 80 Step band lock (upper pit left) (if equipped)

S 100-101 Skirting switch, lower left and right

S 102-103 Skirting switch, upper left and right

S 104-105 Skirting switch, inclined section (if equipped)

S 130 Access cover switch, lower

S 131 Access cover switch, upper

S 145 Broken drive chain switch

EJV EJV Explanation

S 84 S 85 Auxiliary brake lift monitor

S 85 S 85.1 Auxiliary brake lift monitor (the second motor)

S 183 S 83 The first motor brake lift monitor

S 184 S 84 The first motor brake lift monitor

S 181 S 83.1 The second motor brake lift monitor S 182 S 84.1 The second motor brake lift monitor

S 187 S 81 The first motor brake wearing monitor

S 188 S 82 The first motor brake wearing monitor

S 185 S 81 1 Th d t b k i it



Step band lock device

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Step band lock device

The step band lock device must be activated any time you are working in the step band.

For EJV

Step Action Note

1 Place barricades at both ends of the

escalator, remove access cover and

turn main power supply OFF.2 Take out controller from upper pit using

controller lifting tool.

3 Remove flywheel cover.

4 Remove step guard.

5 Raise handlebar (3) of step band lockfrom slot (1).

6 Keep pushing step band lock (4) to

drive wheel disc (5) while runningflywheel manually.

Stop until step band lock is

engaged.

7 Put handlebar into slot (2).

The step band lock switch should be

actuated (10 displayed on main

board).

8 After finishing work, release the step

band lock by moving handlebar (3) fromslot (2) to slot (1).

9 Reinstall the parts in reverse order ofremoval. Turn main power supply ON,

reinstall access cover, and removebarricades.



For EJV

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Step Action Note

1 Place barricades at both ends of the

escalator, remove access cover and

turn main power supply OFF.

2 Take out controller from upper pit using

controller lifting tool if needed.

3 Lift and push the handle (2) until bolts

(3) and teeth of the sprocket (4) areengaged. If necessary, release the

main brake manually.

The step band lock switch (1) should

be actuated ("10" displayed on main

board).

4 After finishing work, release the step

band lock.

Release the handle (2) to separate

the bolts (3) from sprockets.

5 Put the controller back in pit, turn main

power supply ON, reinstall access

cover, and remove barricades.



BASIC MODULE

Lower end

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Lower endStep Maintenance task Method and standard

1 Check step chain tension. In the lower end pit, check step chain

tension by measuring the compressedspring length between washers. Spring

length should be 95 mm.

2 Check function of skirt

switches (if equipped).

1 Make sure the main power supply is

OFF.

2 Remove the inner upper and lower

curve decking.

3 Change the blind plug to the hand-held

pendant control. Turn the main power

supply ON.4 Place a thickness gauge 3.2 mm

between the switch actuator (1) and

the inside surface of the skirt (2) so

that the switch actuates.

NOTE! Do not place a thickness gauge

on the step side of the skirt.

Try to normally run the escalator in

both directions on inspection.

The escalator should not start.

5 Repeat the procedure for the opposite

side of the escalator.

3 Check LED light electric

cabinet (if equipped).

1 Check the LED lighting in lower pit.

2 Open the electric cabinet.3 Check the fan function.

4 Clean the air filter, replace it if needed.

4 Check the inverter cabinet (if

equipped)

1 Check the fan condition.

2 Turn the main power supply OFF



Upper end

St M i t t k M th d d t d d

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Step Maintenance task Method and standard

1 Check function of skirt switches. Refer to the method and standard for

function of skirt switches in Basic

Module>Lower end.

2 Check automatic oilers (if

equipped).

Lubricate step chain with the

recommended lubricant.

[lubricate only from upper end

equipment driving down]

If lubrication is not suitable, reset the

parameter of pump, refer to Product-

specific instructions>Automatic oiler.

Lubricate connection area 1 and area 2

on every link

3 Check LED light electric cabinet(if equipped). 1 Check the LED lighting in upper pit.2 Open the electric cabinet.

3 Check the fan function.

4 Clean the air filter, replace it if

needed.

4 Check the inverter cabinet (if

equipped).

1 Check the fan condition.

2 Turn the main power supply OFF.

3 Open the inverter cabinet.

4 Check and clean the air filter, replace

it if needed.5 Lift the controller back in the pit.

6 Check the fall protection barrier (if

equipped).

1 Manually check if the fall protection

barrier is fastened securely.

2 Check if the screws are loose.



Product-specific instructions

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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 Action Note

1 Check the oil level in the oil tank.

Fill with clean oil.

NOTE! Make sure oil is absolutely

clean when filling theautomatic oiler.

2 Turn the switch F62 (24 V AC) OFF

inside the controller, the pump willstart.

The oil should come out from the

nozzles or oil brushes.

The pressure value of oil pump is

displayed on the pressure indicator

(if equipped) and should not be

below 1.0 Mpa.

NOTE! Clean the pump filter and

lubrication port filter yearly.



3 If the chain is not lubricated properly,dj h l il b h

Step Action Note

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adjust the nozzles or oil brushes.

4 Check every joint for oil leakage.

Tighten the joints, if necessary. Turn

the switch F62 ON.5 Check and adjust the electrical

parameter setting according to

lubrication quality (just for first

maintenance visit).

If lubrication of chains is not sufficient,

readjust the pulse length parameters.

WARNING! Basic parameters may not

be valid for all escalators.

For more information on the lubrication

parameters, refer to the tables named:

pulse length (lubrication pump on time)

and delay between pulses (lubrication

pump off time).

Pulse length (Lubrication pump on time)a)

a) The pulse length means one circle time.

Vertical rise(m) 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5

Parameter 19

(minute)00 00 00 00 00 00 00 01 01 01 01 01 01 01 01 01

Parameter 20

(second)33 38 41 46 49 54 57 2 5 10 13 18 21 26 29 34

Delay between pulses (Lubrication pump off time)

Indoor escalators Outdoor escalators



For EJV

Step Action Note

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Step Action Note

1 Check the oil level in the oil tank.

Fill with clean oil.

NOTE! Make sure oil is absolutely

clean when filling the

automatic oiler.

2 Check that the chain is lubricated

properly. If needed, adjust the nozzles

or oil brushes.

3 Check every joint for oil leakage.

Tighten the joints if needed.



4 If needed, set the Ton and Toff on thetime relay in the control cabinet again

Step Action Note

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time relay in the control cabinet again

according to current status.

For Ton and Toff parameter setting,

refer to the following table.

NOTE! Parameters must be checked

after first maintenance iscompleted. If necessary,

adjust parameters slightly

according to the actual

humidity and temperature.

Ton and Toff parameter setting

Vertical rise (m) 2 3 4 5 6 7 8 9 9.5

TonWhite button 660 minutes

Black button 3 3 4 4 5 5 6 6 7

Toff

IndoorWhite button 10100 hours

Black button 2

Outdoor

White button 10100 hours

Black button 1



STEP MODULE

Removing steps

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Removing steps

Escalator steps usually should be removed at the lower escalator pit.

Maintenance task:Remove steps to open the maintenance access in step band

Maintenance method and standards:

Step Action Note1 Remove spring pin (2).

Use a hook or a set of pliers to pull

spring pin out of mounting hole.

2 Remove screw (1) and retaining plate

(3).

Use a screw driver to straighten the

end of the retaining plate.

3 Use the hand-held pendant control to

drive the step band.

The left step roller is accessible from

the hole on the turnaround plate.



4 Slide the connector (4) towards centerof the step

Step Action Note

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of the step.

5 Remove the step.

Take the left step roller first out of

the hole in turnaround plate.

Take the right step roller out of thestep band.

NOTE! Make sure that the washer

stays on step chain pin.

6 Remove other steps using the same

procedure.

NOTE! On the first maintenance visit,

mark all steps using red spraypaint. Mark the first step in its

corner as number one. Then

run the unit in up direction,

5012864(2006-06)



Reinstalling steps

The steps can be interchanged as a result of their modular design.

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Maintenance task:Check and reinstall steps


Step Action Note

1 Position step in step band.

Position the right side of step in the

step band.

Position the left side of step in the

step band by placing the left step

roller through the hole in the

turnaround plate.

NOTE! Make sure that the step

guidance pin (A) is installed instep.

2 Slide connector (1) towards chain roller

(2).

NOTE! Make sure that the washer

stays on the step chain pin.

NOTE! Add grease into the connector

if needed.

3 Mount spring pin to the connector.

Use a hammer to insert spring pin

into the mounting hole.

4 Install and fasten screw (3) with new

retaining plate (4).

Tightening torque for screws (3): MA= 22 Nm

Retaining plate: DEE2191072



5 Secure screws by bending retainingplate (4).

Step Action Note

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p ( )

6 Install remaining steps using the same

procedure.

7 Check step for alignment.

8 Install step guards.



BRAKE MODULE

Adjustment and checking are needed if stopping distance is not correct.

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Maintenance task: Check motor brake lining


For EJV

Step Action Note1 Open upper access cover, switch OFF

power supply, and engage step band

lock (if equipped).

2 Measure the actual length of springs at

both sides of the brake and record it.

3 Loosen fixing nuts (1) for one side, then

remove springs.

4 Turn brake arm (2) until the brake lining

thickness can be measured.

5 Check brake lining (3) thickness.

If the brake lining thickness is less than

3 mm, replace brake arms and lining.

NOTE! If the brake lining is

contaminated, always replace

it.

6 Check that the surface of the brake

should be free from grease and oil.

Clean if needed.

7 Reinstall brake arms in reverse order of

removal and check that brake arms can

move freely.

8 Adjust springs to the measured length

in step 2. Then lock nuts (1).

9 Check the brake lining for another side.



For EJV (without brake wearing monitor)

Step Action Note1 Open upper access cover, switch OFF

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For EJV (with brake wearing monitor)

power supply.

2 Measure the depth D of brake arm from

measurement hole (1) by callipers.

3 If the brake lining thickness is below 3

mm, replace brake arms and lining.

Brake lining thickness = Measured

data D - 29

4 Check the brake lining for another side.

5 If needed, replace the brake arm

according to the section Replacing

brake arms

Step Action Note

1 Open upper access cover, switch OFF

power supply.

2 Visually check that the brake wearingmonitor is fixed tight.



Maintenance task: Check main brake spring length


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Maintenance task: Check clearance between brake arm and brake solenoid piston


Step Action Note

1 Tighten the spring to make the stopping

distance shorter and loosen the spring

to make the distance longer.

Both springs (1) must be equally

adjusted to ensure the spring length L is

the same on both sides.

2 Lock the adjusting nuts.

Step Action Note

1 Push the piston (2) to C direction.

Measure the clearance between brake

arm (1) and brake solenoid piston (2).

It is very important that there is 1.5 mm

clearance between the brake solenoid

piston (2) and brake arm (1).

2 If adjustment is needed, turn screw (3)to adjust for 1.5 mm clearance between

brake arm and brake solenoid piston.



Maintenance task: Check brake lift monitor (normal open) (if equipped)


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Maintenance task:Check function of safety latch (if equipped)


Step Action Note

1 Check the switch actuator (1).

Actuate manual handle (4) by 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.

Release manual handle (4), the brake

is closed, the switch actuator (1) must

be actuated by the bolt (3) of the

bracket (2).

2 Adjust the bolt (3) if needed.

3 Release step band lock (if equipped),

switch ON power supply, and reinstall the

access cover.

Step Action Note

1 Switch off the main power



2 Take out the splint to remove the bolt(3).

3 Remove the slider (4)

Step Action Note

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3 Remove the slider (4).

4 Pull the bar (5) to adjust the distance

between the arm (1) and the ratchet

wheel (2) to 10 mm.

5 Check that the detecting switch (6) is

activated in this position.

6 Check that the arm (1) can accesscompletely in the ratchet wheel without

pressing the tappet of the switch to itsend position.

7 Check the slider surface, replacement

is needed if severe wear.

8 If necessary, adjust the switch.

9 Reset the bar and reinstall the slider

(4) after adjustment.

Make sure the slider is in place.



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

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drive chain.

Brake trigger device (1)

Brake disc (2)

Sprocket for drive chain (3)

Sprocket for step chain (4)

Brake shoe (5)

Step Action Note

1 Confirm that no personnel and tools are on the step band.

2 Stop the equipment normally.

3 Switch OFF the main power.

Auxiliary brake should be released, and the auxiliary

brake stopper is stopping brake wheel.

4 Switch ON the main power.

Auxiliary brake should be actuated and removed from

auxiliary brake wheel



COMB PLATE MODULE

Maintenance task: Check comb plate impact device if adjustment is needed


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Step Action Note

1 Remove the access cover and changethe blind plug to the hand-held pendant

control. Then turn the control current

OFF. Remove end inner decks (left andright) located above the comb plate.

2 Check the length of the compressed

spring (4).

The initial length of the spring is

601 mm.

If necessary, adjust the nut (5) to set

the spring length.

3 Check the position of comb plateimpact switch.

The gap between the switch

actuator (1) and the trip arm (2)should not be above 1 mm.

If needed, turn the nut (3) to adjust

the gap.

4 Check the function of the impactdevice.



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DRIVE MODULE

Drive unit

Maintenance task: Check oil level of gearbox

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Maintenance task: Check air breather


Maintenance task:Add oil


Step Action Note

1 Check oil level of gearbox by removing

the filler cap of the dipstick (1).

Oil should be between the upperand lower marks on dipstick.

Step Action Note

1 Check that air breather (2) is clean.

Step Action Note

1 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.

For more information on oil type, oil

volume and so on, refer to the table Oil

specification.



Maintenance task: Check oil replacement date


Step Action Note

1 According to oil replacement Detailed method, see AS-

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g p

information stick, confirm oil

replacement date.

,

51.05.002>Minor Repairs>Changing oil.

Oil specification

Drive TypeOil

viscosityOil Type

Oil

volume

(L)

Oil change interval

1st time

(h)

Regular

(h)

5.5 kW with CG35B gear VG460Synthetic

oil9 1800 20000

7.5, 9.2,11 kW with

CRW160B gearVG460

Synthetic

oil17.5 1800 20000

15 kW with CRW180Bgear

VG460 Syntheticoil

23.5 1800 20000

5.5, 7.5 kW with FJ125Rgear

VG460Synthetic

oil6 1800 20000

9.2, 11 kW with FJ160R

gearVG460

Synthetic

oil12 1800 20000

15 kW with FJ160R gear VG460Synthetic

oil12 1800 20000

7.5 kW motor, with CG35gear

VG460 Syntheticoil

9 1800 20000

8 kW motor with CRW160

gearVG460

Synthetic

oil17.5 1800 20000

COMPONENT:

REPLACEMENT INTERVAL: YEARS

REPLACE MENT NEXT REPLACE MENT

Month/Year Month/Year

/20 /20



8 kW motor with

FTJ160D gear (China VG460Synthetic

15 0 1800 20000

Oil specification

Drive TypeOil

viscosityOil Type

Oil

volume

(L)

Oil change interval

1st time

(h)

Regular

(h)

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FTJ160D gear (China

only)

VG460oil

15.0 1800 20000

11 kW motor with

FTJ160D gear (China

only)

VG460Synthetic

oil15.0 1800 20000

15 kW motor with

FTJ160D gear (Chinaonly)

VG460 Syntheticoil 12.0 1800 20000

5.5, 7.5 kW motor, with

FJ125 gear (China only)VG 460

Synthetic

oil6.0 1800 20000

8 kW motor, with FJ160

gear (China only)VG 460

Synthetic

oil12.0 1800 20000

11 kW motor, with FJ160

gear (China only)VG 460

Synthetic

oil12.0 1800 20000

15 kW motor, with FJ160gear (China only)

VG 460 Syntheticoil

12.0 1800 20000

5.5, 7.5, 9.2 kW with K87

gearVG220

Synthetic

oil10.9 1800 20000

11,15 kW with K97 gear VG220Synthetic

oil20 1800 20000

11 kW motor with K107

gearVG220

Synthetic

oil33.5 1800 20000

15 kW motor with K107gear

VG220 Syntheticoil

33.5 1800 20000

NOTE! Synthetic oil is recommended to be used starting from first replacement.Mineral

oil can be replaced with synthetic oil, but synthetic oil can not be replaced with

mineral oil. Different oil types can not be mixed. If the oil is changed to other type,

the gear box must be cleaned.



Maintenance task: Check drive unit mounting bolts and drive chain slack


Step Action Note

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Step Action Note

1 Check drive unit mounting bolts (1).

Check the drive unit mounting bolts

are tight.

2 Remove the flywheel cover, turn the

flywheel down direction, make sure theupper side of drive chain is slack.

When the tension is on the upper

side of chain, the slack amount (X)

is 10 mm +/-5 mm (25/64 in.+/- 3/16

in.).

3 If drive chain slack adjusting is 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.

4 Tighten the fixing bolts (1) and lock the

nut (2).

5 Reinstall the flywheel cover, turn mainpower supply ON.



For EJV

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For EJV



For EJV

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3

2

1

1



Maintenance task: Check the gap of broken drive chain switch


Step Action Note

1 T th i l OFF h k

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1 Turn the main power supply OFF, check

the gap between drive chains (3) and

the detecting bar (1).

The gap should be 25 35 mm.

2 Adjust the switch (2), if necessary.

3 Physically move the detecting bar todepress the switch. Listen for audible

click of switch.



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

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Maintenance task: Make adjustment if missing step detector does not work


Maintenance task: Check tension carriage


the step/pallet opening on the upside of step/pallet band, otherwise need to reset the fault

code (58 59) on cabinet.

Step Action Note

1 Remove five steps in a row, and move

the step opening to missing step

detector area in inspection mode.

Actuate the stop button on the hand-

held pendant control.

2 Check clearance between proximity

sensor (1) and tapered flat head screwof trailing wheel (2).

The sensor should be centered and

approximately 5 mm from the

tapered flat head screw of trailing

wheel.

3 If adjustment is needed, loosen nuts (3)

and adjust until the sensor (1) is

centered and the clearance is correctfrom the tapered flat head screw of the

trailing wheel (2).

4 Tighten nuts (3). Check the detector is

working correctly.

Step Action Note

1 Check the tension carriage for

movement with a small pry bar.



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Maintenance task: Check the oil groove of handrail drive chain


Step Action Note

1 Run unit in inspection mode in the UP

direction, stop unit by pressing the stopbutton on hand-held pendant control

when step opening is in handrail drive

chain area on upper level. Turn main

power supply OFF, and engage the

step band lock (if equipped).

2 Visually check the oil groove of handrail

drive chain, clean the groove if needed.

3 For EJV 1.5, check the oil drain pipe is

unblocked, clean the pipe if needed.



Maintenance task: Check handrail drive chain tension


Step Action Note

1 Check handrail drive chain tension (A)

in the center between the handrail drive

h i k t (1) d i d i

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Maintenance task:Adjust handrail drive chain tension if needed


chain sprockets (1) and main drivesprocket (2).

Handrail drive chain tension: A = 9

to 15 mm

2 Adjust handrail drivechain tension ifneeded.

Step Action Note

1 Find out the slack side of chain.

If unit is running up before it stops,then the slack side is Up, vice versa.

2 Remove the upper curve inner deck by

loosening fixing bolts.

3 Release the handrail pressure spring

on two sides.

4 Loosen bearing mounting bolts (2) of

handrail drive wheel shaft (four on right

hand and four on left hand).



5 Loosen lock nut (3), and adjust handrail

drive chain tension with jack bolt (4).

Set handrail drive chain slack from 9

to 15 mm measured at the drivechain center between drive chain

NOTE! To increase the handrail chain

tension, tighten jack bolt (4)equally for right hand and left

hand sides.

Step Action Note

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chain center between drive chain

sprockets (1).

For EJV 1.1/1.2/1.3/1.4/1.4.1, makesure measurement B on both sides

of escalator are the same.

Otherwise the handrail wheels areinclined.

For EJV 1.1, make sure

measurement C on both sides of

escalator are the same to ensure

the handrail drive is parallel to chain

drive.

NOTE! To decrease the handrail chain

tension, loosen jack bolt (4) and

pull handrail drive wheel shaft

(5) to set tension dimension.

NOTE! Empty the oil container if

needed.



6 Tighten mounting bolt (2) and lock nut(3).

7 Reinstall the parts in reverse order of

removal, release the step band lock

d i

Step Action Note

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Maintenance task: Lubricate track in case of lube-free step chain (if equipped)


If required, the step chain lip track may be moistened by a spray in the running surface area

(1).

device.

8 Check the position of the handrail

pressure roller cluster and check

handrail traction on both sides of

escalator in UP and DOWN directions.

Step Action Note

1 Spray application may be required ifnoise is generated between step chain

roller (2) and lip track.

NOTE! Use only a high pressure semi-synthetic grease (Rivolta SKD

3602), based on metal soap

without solid additives for initial

application.

NOTE! All lubrication-free chains are

identified by SF or SFD in the

chain designation.

2 Spray application may be along theentire length of lip track.

3 Spray application should be done once

before putting the unit into operation.



Maintenance task: Lubricate main shaft and handrail drive shaft


Step Action Note1 Run escalator normally for several

cycles.

2 Move the opening of the step band to

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the lubrication position of bearings in

inspection mode. Press down stop

button on hand-held pendant control.

3 Add grease to the grease nozzle (1)

with an oil gun.4 Run the escalator normally for several

cycles again in inspection mode.

5 Add grease and cycle the escalator two

more times.

Add grease and cycle the escalator

totally for three separate times.

6 Add grease until old grease flows out

from the bearing.7 Remove old grease from the bearing

surface.

8 Reinstall all removed parts in reverse

order.



HANDRAIL MODULE

Handrail drive system overview Handrail (1)

Handrail drive wheel (2)

Handrail drive shaft (3)

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Handrail drive shaft (3)

Handrail drive chain (4)

Newel (5)

Handrail guide roller (6)

Handrail pressure roller (7)

Handrail tension device (8)



Handrail guides

Maintenance task:Check handrail tension


St A ti N t

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Step Action Note

1 With step band stopped, tilt up handrail

in the lower curve balustrade on one

side.

2 Remove handrail from the handrailguide, and observe handrail tension.

If tension is correct, the handrail

section removed from the handrail

guide must run straight over the

balustrade.

3 Press handrail back onto handrail

guide.

It must be possible to press thehandrail effortlessly back in place

onto the handrail guide.

4 Adjust handrail tension if needed.

5 Reinstall all handrail onto guide, turnmain power ON.


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MAINTENANCE MANUAL

OF AUTO WALK

TransitMaster 165/185

Horizontal Autowalk Maintenance Instructions

MBM-2 ManualAdd-onsfor KONE TravelMaster 115InclinedAutowalk and TransitMaster 165/185HorizontalAutowalkMaintenance InstructionsASG-51.00.001 2011 KONE CorporationAllrights reserved(A) 2012-04-16KONE CorporationRJV 1.3/AJV 1.0

TRANSITMASTER 165/185 HORIZONTAL AUTOWALK

(AJV 1.0)

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( )MBM-2 (Modular Based Maintenance)

TransitMaster 165/185

Horizontal Autowalk Maintenance Instructions

TABLE OF CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MBM-2 modular based maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

STANDARD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SAFETY DEVICES 3

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SAFETY DEVICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Location of safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pallet band lock device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

BASIC MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Return end. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Drive end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Product-specific instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

PALLET MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Removing pallets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Reinstalling pallets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BRAKE MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . .

Escalator 702456

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