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Otis Mbm-2® Manual - Condition Module With Shaft, Controller, Machine and Door Modules For Otis Gen2 and Otis 2000 Elevators

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0% found this document useful (0 votes)

2K views143 pages

Otis Mbm-2® Manual - Condition Module With Shaft, Controller, Machine and Door Modules For Otis Gen2 and Otis 2000 Elevators

Uploaded by

Dony Dons

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 143

OTIS Gen2 | OTIS 2000

Maintenance Guideline

OTIS MBM-2® MANUAL — CONDITION MODULE WITH

SHAFT,CONTROLLER, MACHINE AND DOOR MODULES FOR
OTIS GEN2 AND OTIS 2000 ELEVATORS

1409E814

© 2024 KONE Corporation 1 (143) ASG-21.01.031-AP3

© 2024 KONE Corporation

Important Notice
This guidelines and instructions document and its contents (the “Instructions”) are for training
purposes, KONE technician use, and other authorized internal use. The Instructions do not contain all
the relevant information regarding the performance of the maintenance for the equipment in question
and the installation or replacement of associated components (the “Work”). Any person engaging
in the Work must follow all instructions related to the respective equipment and all applicable
KONE safety rules. Further, such persons must be qualified and authorized to perform the Work,
which includes possessing licenses required by law and training provided by KONE for the specific
equipment.

Authorized Use - License

Only technicians who perform the Work and their supervisors, as well as other individuals KONE
may from time to time designate in writing (“Authorized User”), are intended to possess and use
the Instructions. KONE grants the Authorized User a limited, revocable license to possess and use
the Instructions during the Authorized User’s term of employment with KONE to perform the Work
(“License”). Possession or use of the Instructions in a manner inconsistent with the License granted
is strictly prohibited. Under no circumstances is the Authorized User permitted to copy, disclose,
publish, or disseminate the Instructions to anyone, unless prior written consent has been obtained
from the KONE legal function. The Authorized User shall return the Instructions to KONE upon
separation of employment with KONE. Violation of this paragraph may result in disciplinary action, up
to and including termination of employment, and legal action against the Authorized User.

Prohibited Possession or Use by Others

Possession, use, copying, disclosure, publication, or dissemination of the Instructions by an individual
who or entity that is not an Authorized User is strictly prohibited (“Prohibited Use”), unless prior
written consent is obtained from the KONE legal function. KONE disclaims any and all liability for
loss or damage including without limitation, indirect or consequential loss or damage, resulting from
or in connection with Prohibited Use. Prohibited Use shall result in legal or equitable action by KONE
against violators.

Proprietary, Confidential, Intellectual Property

The Instructions are owned by KONE Corporation, its affiliates, and its subsidiaries (“KONE”). The
Instructions are proprietary, confidential, and contain KONE intellectual property and trade secrets.
The Instructions are protected by international and local intellectual property laws, including but not
limited to copyright law. Unless otherwise expressly mentioned, all trademarks and product names
in the Instructions are trademarks or registered trademarks of KONE. Unauthorized possession, use,
copying, disclosure, publication, or dissemination of the Instructions infringes upon KONE’s legal
rights and shall result in legal or equitable action by KONE against violators.

© 2024 KONE Corporation 2 (143) ASG-21.01.031-AP3

TABLE OF CONTENTS

1 ABOUT THIS DOCUMENT......................................................................................................................7

1.1 Purpose of this document..........................................................................................................7
1.2 Audience....................................................................................................................................7
1.3 Abbreviations.............................................................................................................................7
1.4 Related documents....................................................................................................................8
1.5 Approval and changes...............................................................................................................8
2 SAFETY AND MAINTENANCE TARGETS............................................................................................10
2.1 Refuge space.......................................................................................................................... 10
2.2 Access to pit............................................................................................................................ 12
2.2.1 Take safety measures before entering pit..............................................................12
2.2.2 Multiple cars in same shaft.................................................................................... 12
2.2.3 Go to pit................................................................................................................. 12
2.2.4 Exit the pit..............................................................................................................16
2.3 Access to car roof....................................................................................................................16
2.3.1 General safety checks before going onto the car roof...........................................16
2.3.2 Go to elevator car roof...........................................................................................18
2.3.3 Exit the car roof..................................................................................................... 21
2.4 Environmental issues.............................................................................................................. 22
2.5 Customer experience.............................................................................................................. 22
3 ELEVATOR PLATFORMS......................................................................................................................23
3.1 OTIS Gen 2............................................................................................................................. 23
3.2 OTIS 2000............................................................................................................................... 24
4 VISUAL CHARACTERISTICS OF EN 81-20/50 COMPLIANT ELEVATORS........................................ 25
5 TOOLS...................................................................................................................................................28
6 MBM-2 MODULAR BASED MAINTENANCE........................................................................................ 31
6.1 General instructions for an MBM visit......................................................................................31
6.2 Safety related signs................................................................................................................. 31
7 CONDITIONAL MODULE WITH SHAFT, CONTROLLER, MACHINE AND DOOR MODULES........... 34
7.1 Tasks on bottom landing..........................................................................................................34
7.1.1 Entrance and corridor (condition check)................................................................34
7.1.2 Load labels for goods-passenger elevators on landing (condition check).............35
7.1.3 Landing signalization (condition check).................................................................35
7.1.4 Landing door panels and landing door running (condition check)......................... 36
7.1.5 Landing door sill (condition check)........................................................................ 38
7.1.6 Elevator car door sill (condition check)..................................................................38
7.2 Tasks in elevator car on landing.............................................................................................. 38
7.2.1 Door open button and car door running (condition check).................................... 39
7.2.2 Car door running (condition check)....................................................................... 40
7.2.3 Door protective devices (condition check).............................................................40

© 2024 KONE Corporation 3 (143) ASG-21.01.031-AP3

7.2.4 Check door closing force....................................................................................... 40

7.2.5 Elevator car lighting (condition check)...................................................................43
7.3 Tasks in car moving up............................................................................................................ 43
7.3.1 Signs (condition check)......................................................................................... 44
7.3.2 Elevator car interior (condition check)................................................................... 44
7.3.3 Car signalization (condition check)........................................................................45
7.3.4 Elevator car door panels (condition check)........................................................... 45
7.3.5 Check car door bottom guides...............................................................................46
7.4 Tasks on all intermediate landings and on topmost landing.................................................... 47
7.4.1 Landing door sill (condition check)........................................................................ 48
7.4.2 Entrance and corridor (condition check)................................................................48
7.4.3 Landing signalization (condition check).................................................................49
7.4.4 Landing door panels and landing door running (condition check)......................... 50
7.4.5 Load labels for goods-passenger elevators on landing (condition check).............52
7.4.6 Door coupler to landing door lock roller interface (condition check)......................52
7.4.7 Switch on the MAP/shaft light................................................................................52
7.5 Test the ride comfort................................................................................................................ 53
7.6 Tasks on bottom landing..........................................................................................................55
7.6.1 Elevator shaft pit (condition check)........................................................................56
7.6.2 Refuge space labels in shaft pit (condition check)................................................ 57
7.6.3 Check the lower sliding guide shoes..................................................................... 57
7.6.4 Steel rope diverting pulleys (condition check)....................................................... 58
7.6.5 Suspension belts diverting pulleys (condition check)............................................ 59
7.6.6 Lower roller guide shoes (condition check)........................................................... 60
7.6.7 Lower car retainers (condition check)....................................................................60
7.6.8 Polyurethane buffers under car (condition check)................................................. 60
7.6.9 Traveling cable (condition check).......................................................................... 61
7.7 Tasks in pit...............................................................................................................................61
7.7.1 Oil collectors (condition check)..............................................................................63
7.7.2 Overspeed governor rope length (condition check)...............................................64
7.7.3 Counterweight overspeed governor rope length and switch (condition check)..... 64
7.7.4 Oil buffers (condition check).................................................................................. 66
7.7.5 Polyurethane buffers in pit (condition check).........................................................66
7.7.6 Compensation chain guide (condition check)........................................................68
7.7.7 Overtravel (condition check)..................................................................................68
7.7.8 Counterweight screen (condition check)............................................................... 69
7.7.9 Earthquake device fixings (condition check)......................................................... 69
7.7.10 Inspection control station (condition check)...........................................................70
7.8 Tasks at MAP floor...................................................................................................................70
7.8.1 Battery operated brake releasing device............................................................... 73
7.8.2 Overspeed governor mechanical reset (condition check)..................................... 75
7.9 Tasks for car roof..................................................................................................................... 77
7.9.1 Elevator car roof (condition check)........................................................................ 78
7.9.2 Shaft lighting (condition check)..............................................................................79

© 2024 KONE Corporation 4 (143) ASG-21.01.031-AP3

7.9.3 Refuge space labels on car roof (condition check)................................................79

7.9.4 Emergency alarm battery (condition check).......................................................... 79
7.9.5 Electrical brake release device battery (condition check)......................................80
7.9.6 Check safety gear linkage..................................................................................... 80
7.9.6.1 Safety gear linkage (condition check)..................................................81
7.9.7 Check the upper sliding guide shoes.....................................................................82
7.9.8 Upper roller guide shoes (condition check)........................................................... 83
7.10 Tasks on car roof for shaft headroom...................................................................................... 84
7.10.1 Hoisting machine (condition check).......................................................................84
7.10.2 Guide rail lubrication (condition check)..................................................................86
7.10.3 Suspension rope anchors (condition check)..........................................................86
7.10.4 Suspension belt fixings (condition check)..............................................................86
7.10.5 Steel suspension ropes (condition check)............................................................. 87
7.10.6 Suspension belts (condition check)....................................................................... 88
7.10.7 Overspeed governor rope (condition check)......................................................... 89
7.10.8 Check overspeed governor................................................................................... 90
7.10.9 Upper car retainers (condition check)....................................................................90
7.11 Tasks on car roof for hoisting machine.................................................................................... 90
7.11.1 Hoisting machine (condition check).......................................................................91
7.11.2 Mechanical isolation and fastening of the machine (condition check)...................92
7.11.3 Check suspension steel belt traction sheave........................................................ 92
7.11.4 Check brake air gap.............................................................................................. 93
7.12 Tasks on car roof for drive module.......................................................................................... 99
7.12.1 Emergency battery drive (EBD) unit (condition check)..........................................99
7.12.2 Drive module (condition check)........................................................................... 100
7.12.3 Group cabling (condition check).......................................................................... 101
7.13 Tasks on car roof for topmost landing door - upper part........................................................101
7.13.1 Landing door railing (condition check).................................................................101
7.13.2 Landing door lock (condition check).................................................................... 102
7.13.3 Landing door contact and lock contact (condition check)....................................103
7.13.4 Landing door lock rollers (condition check)......................................................... 104
7.13.5 Closing weight or spring (condition check).......................................................... 104
7.14 Tasks on car roof for topmost landing door - lower part........................................................ 104
7.14.1 Landing door bottom guides (condition check)....................................................105
7.14.2 Landing door closed gap (condition check)......................................................... 105
7.14.3 Sill connection to frame (condition check)........................................................... 106
7.15 Tasks on car roof for all intermediate floors...........................................................................106
7.15.1 Door coupler to landing door lock roller interface (condition check)....................107
7.15.2 Landing door railing (condition check).................................................................108
7.15.3 Landing door lock (condition check).................................................................... 108
7.15.4 Landing door contact and lock contact (condition check)....................................109
7.15.5 Landing door lock rollers (condition check)......................................................... 110
7.15.6 Closing weight or spring (condition check).......................................................... 110
7.15.7 Landing door bottom guides (condition check).................................................... 111

© 2024 KONE Corporation 5 (143) ASG-21.01.031-AP3

7.15.8 Landing door closed gap (condition check)..........................................................111

7.15.9 Sill connection to frame (condition check)........................................................... 112
7.16 Tasks on car roof for counterweight - upper part................................................................... 112
7.16.1 Steel suspension ropes (condition check)........................................................... 113
7.16.2 Suspension belts (condition check)..................................................................... 113
7.16.3 Counterweight upper sliding guide shoes (condition check)................................114
7.16.4 Guide rail (condition checks)............................................................................... 115
7.16.5 Guide rail lubricator (condition check)................................................................. 115
7.16.6 Suspension belts counterweight frame, pulleys and filler weights (condition
check).................................................................................................................. 116
7.16.7 Upper car retainers (condition check)..................................................................117
7.17 Tasks on car roof for counterweight - lower part....................................................................118
7.17.1 Counterweight safety gear linkage (condition check).......................................... 118
7.17.2 Counterweight lower sliding guide shoes (condition check)................................ 118
7.17.3 Guide rail (condition checks)............................................................................... 119
7.17.4 Compensation chain (condition check)................................................................119
7.18 Tasks on car roof for shaft - lower part.................................................................................. 119
7.18.1 Suspension belts (condition check)..................................................................... 120
7.18.2 Overspeed governor rope (condition check)....................................................... 121
7.18.3 Car door operation (condition check).................................................................. 122
7.19 Tasks on car roof for the lowest landing door........................................................................ 122
7.20 Tasks on bottom landing for lowest landing door...................................................................122
7.20.1 Landing door closed gap (condition check)......................................................... 123
7.20.2 Landing door bottom guides (condition check)....................................................124
7.20.3 Check the car door bottom guides.......................................................................124
7.20.4 Sill connection to frame (condition check)........................................................... 125
7.20.5 Car door emergency opening rope (condition check)..........................................126
7.21 Tasks in car for lowest landing door...................................................................................... 126
7.21.1 Landing door railing (condition check).................................................................127
7.21.2 Landing door lock (condition check).................................................................... 127
7.21.3 Landing door contact and lock contact (condition check)....................................128
7.21.4 Landing door lock rollers (condition check)......................................................... 129
7.21.5 Closing weight or spring (condition check).......................................................... 129
7.21.6 Pit exit device (condition check).......................................................................... 130
7.22 Tasks on one floor above bottommost landing...................................................................... 130
7.23 Task at MAP floor.................................................................................................................. 130
7.23.1 Test earth leakage circuit breaker........................................................................131
7.23.2 Emergency light in car (condition check).............................................................132
7.23.3 Remote / local alarm system and telephone / intercom connection with back-
up power (condition check)..................................................................................132
7.23.4 CHECK DOOR ZONE INDICATOR (DZ).............................................................133
7.24 Finalize the maintenance visit............................................................................................... 134
8 CORRECTIVE ACTIONS FOR NON-CONFORMITIES...................................................................... 136

© 2024 KONE Corporation 6 (143) ASG-21.01.031-AP3

1 ABOUT THIS DOCUMENT

1.1 Purpose of this document

This document describes preventive maintenance standards and actions based on KONE
MBM-2® (Modular Based Maintenance) method. It is valid for the following EN 81–20/50
compliant elevator platforms with MCS/GCS control system:
‒ OTIS Gen2
‒ OTIS 2000
Each of the KONE MBM-2® module combinations is described in its own document. The
maintenance checks are organized in an optimized way, mixing the checks from different
modules instead of listing all checks "module by module."
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1.2 Audience

This information is intended to be used by people who are familiar with elevator
maintenance and have received proper training on methods and safety as specified by
KONE.
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1.3 Abbreviations

CCBL Call to lowest floor

CCTL Call to top most floor
CHCS Disable landing calls
DDO Disable Door Opening
DIS Re-level DOWN sensor
DZI Door Zone Indicator
ERO Emergency rescue operation
LPT Low Pit and Top devices
MAP Maintenance Access Panel
RBO Electrical brake release device
REM5 Remote Monitoring generation 5
SEP Shaft Electrification Panel
SPB Service panel board
SVT OTIS Service tool
UIB User Interface Board
UIS Re-level UP sensor

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© 2024 KONE Corporation 7 (143) ASG-21.01.031-AP3

1.4 Related documents

‒ AM-01.03.001 Use of fall prevention systems when working on elevators & escalators.
‒ AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and
autowalks.
‒ AM-01.03.010 Safe working in elevator shaft and machine room areas.
‒ AS-01.03.101 On-site maintenance safety manual.
‒ AS-01.01.004 Take Care, End user safety focal points in elevator maintenance.
‒ AS-01.03.004-AP3 KONE Global Safety Manual
‒ AR-21.01.001 Spare Parts Manual for OTIS GEN.
‒ AR-21.01.012 OTIS SPARE PARTS.
‒ AR-21.01.005 KONE spare parts manual for OTIS2000 type of elevators.
‒ AS-21.01.001 Rescue instruction for OTIS GEN2 type elevator.
‒ AS-21.04.001 Brake replacement instruction for OTIS GEN2 elevator.
‒ AS-21.09.001 Instruction for OTIS GEN2 suspension belt shortening.
‒ AS-21.09.002 Instruction for OTIS GEN2 suspension belt replacement.
‒ AS-21.10.001 Troubleshooting instruction for control cabinet of OTIS GEN2 elevator.
‒ AS-21.11.002 Maintenance instruction for OVFWW drive cabinet with MCBIII in OTIS
GEN2 elevator.
‒ AS-21.01.033 TECHNICAL INFORMATION FOR OTIS GEN2.
‒ AS-21.03.002 OTIS GEN2 - PAX (AT120) CAR DOOR.
‒ AS-21.03.001 OTIS GEN2 - TECHNA DO2000 CAR DOOR.
‒ AS-21.01.005 Rescue instruction for OTIS 2000 hydraulic elevator.
‒ AS-21.01.006 Rescue instruction for OTIS 2000 traction elevators.
‒ AS-01.05.007 Maintenance tool catalog.
‒ ASG-21.01.001 Preventive maintenance instruction for OTIS GEN2 type elevators.
‒ ASG-21.01.002 KONE maintenance pocket book for OTIS GEN2 elevator.
‒ ASG-21.04.001 Preventive maintenace instruction for OTIS GEN2 brake.
‒ ASG-21.07.001 Preventive maintenance instruction for OTIS GEN2 safety gear (SPB
control board).
‒ ASG-21.09.001 Preventive maintenance instruction for OTIS GEN2 suspension belts.
‒ ASG-21.03.010 OTIS GEN2 - TECHNA DO2000 CAR DOOR.
‒ ASG-21.03.001 OTIS GEN2 - PAX (AT120) CAR DOOR.
‒ ASG-21.01.009 Rescue instruction for OTIS 2000 traction elevators.
‒ ASG-21.01.010 KONE maintenance pocket book for OTIS 2000 elevator.
‒ TC000153 OTIS GEN2 For Experts Core Learning Guide
‒ TC000144 OTIS GEN2 With Service Tool Core Learning Guide
‒ TC000132 OTIS GEN2 Without Service Tool Core Learning Guide
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1.5 Approval and changes

Issue: A
Date: 2024-02-15

© 2024 KONE Corporation 8 (143) ASG-21.01.031-AP3

Changes:
‒ Update in section 7.11.4 Check brake air gap
Compiled by:
‒ Guingant Philippe, Technical Support Senior Specialist
‒ Manivannan D, Technical Support Senior Engineer
Checked by:
‒ T.Sridharan, Manager, Offering, NKE, NPR and THD Support
Approved by:
‒ Enholm Tony, Head of Service Operations
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© 2024 KONE Corporation 9 (143) ASG-21.01.031-AP3

2 SAFETY AND MAINTENANCE TARGETS

Note the following safety items:
‒ Refer to AS-01.03.101 Elevator Maintenance, Safety Manual for general safety
precautions and personal safety issues.
‒ General KONE safety regulations must be followed during the work. All normal
safety measures required in elevator maintenance must be implemented. Local safety
regulations must also be followed.
‒ Notice that the stop switch location and number may vary according to the shaft depth.
‒ Be aware of possible roll back when the elevator starts to move.
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2.1 Refuge space

Refuge space provides a safe working area above or below the elevator car for installation
and maintenance.
‒ Refuge space above the elevator car is the space when the counterweight rests on its
fully compressed buffer or buffers.
‒ Refuge space below the elevator car is the space when the elevator car rests on its fully
compressed buffer or buffers.
Refuge space labels in the pit and in the car top (balustrade) indicate the maximum number
of people refuge space accommodates. The label shows the person laying on one side,
crouching, or standing in the refuge space. The right posture depends on the height of the
refugee space.

WARNING:
There are no other refuge spaces available in the pit or on the car top than what the
site-specific refuge labels indicate. The layout of the elevator determines the available
refuge spaces. The refuge spaces are not optional or interchangeable.

The following figures show example refuge spaces according to EN 81–20 standard, with
their respective refuge space labels

© 2024 KONE Corporation 10 (143) ASG-21.01.031-AP3

Figure 1: 500 mm high refuge space and its label, pit

Figure 2: 1000 mm high refuge space and its label, pit or headroom

© 2024 KONE Corporation 11 (143) ASG-21.01.031-AP3

Figure 3: 2000 mm high refuge space and its label, headroom

Some inspection and maintenance tasks require more persons on the car roof or in the
pit than what refuge space label indicates. Extra refuge space must be provided for each
additional person. Mechanically prevent the unexpected movement of the elevator car. Use,
for example, parking chains attached to car sling and guide rail brackets.
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2.2 Access to pit

2.2.1 Take safety measures before entering pit

1. Place a safety fence around the entrance.

2. Before switching on the pit light, ensure that no gas smell comes from the pit to avoid
explosion danger.
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2.2.2 Multiple cars in same shaft

1. Be aware of moving and fixed objects in the shaft while driving on inspection.
2. Where there are no partitioning screens do not walk between pits unless all elevators
have been isolated, locked and tagged off.
3. Ensure that no maintenance work is done at the same time on adjacent elevators at
different levels, to avoid injury caused by falling materials.
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2.2.3 Go to pit

Before this procedure, check from the refuge space signage how many persons are
simultaneously allowed in the pit.

© 2024 KONE Corporation 12 (143) ASG-21.01.031-AP3

WARNING:

Move safely between pit and landing.

NOTE:
The pit ladders can be either fixed, movable or foldable.

1. If needed, use safety fences to prevent unauthorized access to the working area.
2. Send the car up (two car calls).
3. Open the landing door using the emergency opening key.
4. In case of foldable ladders, block the door open using the door blocking tool.
5. Switch on the stop switch.
Test operation of the stop switch.
6. Switch on the shaft lights.
7. If needed, move or unfold the pit ladder from the shaft wall.
Foldable ladder:

a) Release the ladder.

© 2024 KONE Corporation 13 (143) ASG-21.01.031-AP3

b) Unfold the ladder from the shaft wall.

c) Place the ladder against the fixing bracket.

The ladder securing device must sit firmly in the fixing bracket.
8. Enter the pit ladder and climb into the pit.
9. Activate the inspection control station by picking it up from the holder.
10. Switch on the inspection drive.
11. If needed, place the pit ladder back to the holder.
Foldable ladder:

© 2024 KONE Corporation 14 (143) ASG-21.01.031-AP3

12. Close the landing door.

13. Release the stop button from the inspection control station.
14. Move the car up or down with inspection control station, if needed.

WARNING:

While moving the car, stay in the refuge space.

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© 2024 KONE Corporation 15 (143) ASG-21.01.031-AP3

2.2.4 Exit the pit

WARNING:

Move safely between pit and landing.

1. Move the car high enough for pit exit, if needed.

2. Activate stop switch from the inspection control station.
3. Place the inspection control station to the holder.
4. Using the pit exit device (PED) open the landing door lock and block the door to a
partially open position using the door blocking tool.
5. If needed, take or unfold the pit ladder from storage position and place it against the
sill.
The ladder securing device must sit firmly in the sill groove.
6. Deactivate LPT (Low Pit and Top) devices, If needed
Refer related information for more details
7. Switch off the inspection drive in the inspection control station.
8. Go to the landing.
9. If needed, remove or fold the pit ladder, place and secure it into storage position.
10. Release the pit stop switch.
11. Remove the door blocking tool.
12. Close the landing doors.
Ensure that the landing doors are mechanically locked.
13. Check that the elevator returns to normal.
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2.3 Access to car roof

2.3.1 General safety checks before going onto the car roof

WARNING:
Move safely between car roof and landing.

NOTE:
Switch ON the shaft lights from the elevator shaft or controller before going onto the car
roof.

1. Press the landing button to call the elevator to the topmost floor. Allow the doors to
open and ensure that there are no passengers in the elevator car.

© 2024 KONE Corporation 16 (143) ASG-21.01.031-AP3

2. Use two car calls to drive the elevator downwards.

3. Open the landing doors using the emergency opening key. Block the landing doors in a
slightly open position using the door blocking tool.
4.

Operate the stop switch on inspection drive unit.

Remove the door blocking tool. Close the landing doors and ensure they are
mechanically locked.
Press the landing button: If the elevator moves, do not get on the car roof. If the
elevator does not move, then reopen the landing doors.
5. Ensure that the elevator has not moved. Block the landing door in a slightly open
position using the door blocking tool.
6. Switch the Normal/Inspection switch to Inspection. Release the stop switch.
7. Remove the door blocking tool. Close the landing doors and ensure they are

mechanically locked.
Press the landing button: If the elevator moves, do not get on the car roof. If the
elevator does not move, then reopen the landing doors.
8. Ensure that the elevator has not moved. Block the landing door in a slightly open
position using the door blocking tool.
9.

Operate the Stop switch on the car roof.

Get onto the car roof. Close the landing doors behind you and ensure they are
mechanically locked.
10. Push simultaneously run and down buttons of the inspection station: The elevator
should not move.
11. Release the Stop switch but be prepared to activate it again. Push simultaneously
the run and down buttons of the inspection station: The elevator should start to move
downwards.

Operate the Stop switch: The elevator should stop immediately.

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© 2024 KONE Corporation 17 (143) ASG-21.01.031-AP3

2.3.2 Go to elevator car roof

WARNING:
Move safely between car roof and landing. Use work positioning equipment or restraint
system if needed.

1. Press the landing button to call the elevator to the topmost floor. Allow the doors to
open and ensure that there are no passengers in the elevator car.
2. Send the car two floor down with two car calls.
3. Open the landing door slightly (maximum 90 mm) with an emergency opening key to
inspect car position.
‒ Use door blocking tool to block the landing door.

4. Check that the landing door contact is open.

‒ Call the elevator car to a floor below.
The elevator car must not move.

© 2024 KONE Corporation 18 (143) ASG-21.01.031-AP3

5. Check that the car roof stop switch is working.

A. Standing on the landing, push down the car roof stop switch (inspection drive switch
in position normal).

B. Close the landing doors. Check that the landing doors are mechanically locked.
C. Make a landing call.
The elevator car must not move.
D. Open the landing door with emergency opening key.
E. Check that the car is not moved.

NOTE:
If the car moves, do not enter the car roof. Find out the reason for the fault and
repair it immediately or take the elevator out of use.

6. Check that the inspection drive switch is working.

A. Standing on the landing, switch the inspection drive switch in position

inspection.

© 2024 KONE Corporation 19 (143) ASG-21.01.031-AP3

B. Release the stop switch.

C. Close the landing doors. Check that they are mechanically locked.
D. Make a landing call.
The elevator car must not move.
E. Open the landing door with emergency opening key.
F. Check that the car is not moved.

NOTE:
If the car moves, do not enter the car roof. Find out the reason for the fault and
repair it immediately or take the elevator out of use.

7. Standing on the landing, press down the car roof stop switch.

NOTE:
Always keep the stop switch in locked down position when working on the car roof. It
must be released only during the movement of the car.

8. Make sure that the fall prevention balustrades are installed. Raise and lock the foldable
balustrades, if applicable.
9. Go safely to the elevator car roof.
Close the landing doors behind you. Check that the landing doors are mechanically
locked.

© 2024 KONE Corporation 20 (143) ASG-21.01.031-AP3

10.

Operate the Stop switch on the car roof.

Get onto the car roof. Close the landing doors behind you and ensure they are
mechanically locked.
11. Push simultaneously run and down buttons of the inspection station: The elevator
should start to move downwards.
12. Release the Stop switch but be prepared to activate it again. Push simultaneously the
run and down buttons of the inspection station: The elevator should start to move.

Operate the Stop switch: The elevator should stop immediately.

184eaab9

2.3.3 Exit the car roof

WARNING:
Move safely between car roof and landing.

1. Drive the elevator car to same floor where you started to step onto the landing safely.
2.

Operate the Stop switch on the car roof.

3. Open the landing door. Ensure that there is no possibility for building users to enter the
elevator shaft from the landing.
4. Exit the car roof. Switch the Normal/Inspection switch to normal position.
5. Release the Stop switch.
6.

Close the landing doors and ensure they are mechanically locked.

NOTE:
After the landing door is closed, the elevator will do an automatic synchronization drive.

© 2024 KONE Corporation 21 (143) ASG-21.01.031-AP3

NOTE:
If these instructions are not followed, the elevator will assume that an unauthorized person
has entered the elevator shaft. It can be reanimated by switching to ERO and back to
Normal again.
bc0c68eb

2.4 Environmental issues

Dispose of hazardous substances, other waste and components according to local

regulations and environmental strategy of KONE.

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ab0a442d

2.5 Customer experience

The focus of your work must always be customer satisfaction. To reach and exceed the
expectations of the customers, be polite, constructive and co-operative, and communicate
clearly. Remember that for customers, you represent KONE, so make sure that you handle
or at least communicate all customer requests and feedback to the correct persons.
0f413dcc

© 2024 KONE Corporation 22 (143) ASG-21.01.031-AP3

3 ELEVATOR PLATFORMS
3.1 OTIS Gen 2

Electrification MCS/GCS
Car Otis Car
Signalization LCD screen, 7 segments, dot matrix
Hoisting machine Traction machines
Drive module OVF
Doors PAX or DO2000

1409e814
55a40ef0

© 2024 KONE Corporation 23 (143) ASG-21.01.031-AP3

3.2 OTIS 2000

Electrification MCS/GCS
Car Otis Car
Signalization LCD screen, 7 segments, dot matrix
Hoisting machine Traction machines
Drive module OVF
Doors DO2000
1feb734a

© 2024 KONE Corporation 24 (143) ASG-21.01.031-AP3

4 VISUAL CHARACTERISTICS OF EN 81-20/50 COMPLIANT ELEVATORS

EN 81-20/50 compliant elevators can be identified visually by the following characteristics:
1. Elevator platform and version identification sticker attached to the controller
2. EN 81-20 compliance stated in the layout drawings
3. Inspection control station in the pit

cc0f0010

1 = Inspection control station

2 = Shaft light control unit and socket outlet
3 = Additional stop push (pit depth > 1.6m)
4. Electrical brake release device (RBO) in the maintenance access panel (MAP)

© 2024 KONE Corporation 25 (143) ASG-21.01.031-AP3

5. By-pass switches in the MAP

‒ Car door contact by-pass = 264
‒ Landing door contact by-pass = 266

26
4
26
6

6. Refuge space labels on car roof and in pit

© 2024 KONE Corporation 26 (143) ASG-21.01.031-AP3

7. Pit exit device (PED) in the lowest landing door

f1065667

© 2024 KONE Corporation 27 (143) ASG-21.01.031-AP3

5 TOOLS
Number of Part number Tool
pieces
1 Standard maintenance tool kit
KM50009502R01

1 Step ladder
KM52000717

07726ae0

1 Multimeter with adequate test

KM985805

NOTE:
To prevent short circuits and
arcing, the maximum length of
bare metal probe tips is 4 mm.
(CAT III, IEC/EN 61010-031)
Fluke 179 (or equivalent) with
1000 V insulated test probes and
at least 100 mm long leads.

© 2024 KONE Corporation 28 (143) ASG-21.01.031-AP3

Number of Part number Tool

pieces

Safety fences
(Locally delivered)

Ratchet belt, rated load 250 kg

(locally delivered)

1 Feeler gauge set

KM959667

1 Stopping accuracy tool

KM268278
(optional)

1- 2 pairs Cut-resistant gloves, DY 008

T.10
KM964698

© 2024 KONE Corporation 29 (143) ASG-21.01.031-AP3

Number of Part number Tool

pieces

Maintenance signs
Locally delivered

3a2effe5

1 Door blocking tool

KM871952G01

1 Emergency opening key

KM982000

1 Closing force gauge

KM50068644

1 Service tool
KM50082009

1 MATO oil pump SFP500 for

emptying the oil cups
KM1369306

1 LV magnet 170x90x8 mm
KM50065019
b0e89fef

© 2024 KONE Corporation 30 (143) ASG-21.01.031-AP3

6 MBM-2 MODULAR BASED MAINTENANCE

KONE MBM-2® (Modular Based Maintenance) approach focuses on the equipment’s
actual need for maintenance. It means that maintenance is divided into modules of
preventive maintenance checks. These modules and corresponding actions are tailored
to the particular equipment. MBM-2 includes planning, and operating processes, as well as
defining a maintenance profile specific to each single installation. The purpose of this profile
is to maximize the availability of the equipment by performing the right maintenance tasks at
the right intervals.

NOTE:
Minimum maintenance interval is once a year for all components.
56438063

6.1 General instructions for an MBM visit

The responsibility of the maintenance technician during the maintenance visit is to ensure
that the equipment fulfils requirements of maintenance and quality standards.
1. Start the visit with a talk to the customer, if possible.
2. Perform the checks defined in the module.
Write down all the non-conformities.
3. Make quick adjustments where instructed (not necessarily immediately after the check).
4. In case of any non-conformity, initiate immediately corrective actions or replacements to
correct the problem, or proactive replacement to prevent a problem.
‒ If you have the spare part available, replace the part according to the relevant
maintenance instruction.
‒ If you don’t have the needed spare part, create a service order.
5. If you must leave the elevator out of service, record the date and reason to log book.
Inform the customer and your supervisor.
6. Complete the reporting. Back report the visit according to the local process.
7. End the visit with a talk to the customer, if possible.
31bce772

6.2 Safety related signs

Warning: Danger of falling

While moving the car, stay in the refuge space.

General warning: Caution, Danger, Risk

© 2024 KONE Corporation 31 (143) ASG-21.01.031-AP3

Warning: Risk of electric shock

Warning: Rotating part

Warning: Crushing hazard

Keep landing calls and door opening disabled. Elevator car

must be empty.

Do not lubricate.

Wear personal fall protection.

Keep a stop switch activated. The switch can be on the

elevator car roof, in the pit or in the machine room.

Keep main power and other possible power sources switched

off, and prevent their reconnection.

Ensure de-energization with multimeter.

General mandatory action

Safety barrier

Eye protection

© 2024 KONE Corporation 32 (143) ASG-21.01.031-AP3

Recommended situation

Unwanted situation

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© 2024 KONE Corporation 33 (143) ASG-21.01.031-AP3

7 CONDITIONAL MODULE WITH SHAFT, CONTROLLER, MACHINE AND

DOOR MODULES
7.1 Tasks on bottom landing

1. Go to the bottom landing.

2. Place Under maintenance -sign to the landing.

3. Check:
a) Entrance and corridor
b) Load labels for goods-passenger elevators
c) Landing signalization
d) Landing door panels
e) Landing door running condition
f) Landing door sill
g) Car door sill
e19146d5

7.1.1 Entrance and corridor (condition check)

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© 2024 KONE Corporation 34 (143) ASG-21.01.031-AP3

On floor level, the light must be efficient enough for a user to see ahead and enter the car,
even if the car light had failed.
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7.1.2 Load labels for goods-passenger elevators on landing (condition check)

f95ee3c1

7.1.3 Landing signalization (condition check)

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e2f15dec

© 2024 KONE Corporation 35 (143) ASG-21.01.031-AP3

224d2d67
5038a1ed

7.1.4 Landing door panels and landing door running (condition check)

fa95a10e

4278955b

NOTE:
Do not let the doors close.

© 2024 KONE Corporation 36 (143) ASG-21.01.031-AP3

ae1d7e67

Gap (*) = 3 — 6 mm (for glass doors, 3 — 4 mm)

b801a9a9

7.1.4.1 Finger protection strips with glass doors (condition check)

* = critical area

1,6m

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caa7bb6c

© 2024 KONE Corporation 37 (143) ASG-21.01.031-AP3

7.1.5 Landing door sill (condition check)

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7.1.6 Elevator car door sill (condition check)

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a6889f70

7.2 Tasks in elevator car on landing

1. Go into the elevator car.

2. Check:
a) Door open button (DOB)
b) Car door running condition
c) Door protective devices
d) Car lighting
e) Remote / local alarm system and telephone / intercom connection
0ac4be1f

© 2024 KONE Corporation 38 (143) ASG-21.01.031-AP3

7.2.1 Door open button and car door running (condition check)

6e2ded7c

4a6612be

c7c24052
2e42d6af

© 2024 KONE Corporation 39 (143) ASG-21.01.031-AP3

7.2.2 Car door running (condition check)

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7.2.3 Door protective devices (condition check)

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7.2.4 Check door closing force

1. From the landing, open the car doors using the car door operator test buttons.

© 2024 KONE Corporation 40 (143) ASG-21.01.031-AP3

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2. Drive the doors in the close direction. Leave them open just enough for the closing force
gauge to fit into the gap between the door panels (centre opening door) or the door
panel and door frame (side opening door).

1d05ebe2

3. Hold the closing force gauge at the door panel (centre opening door) or at the door
frame (side opening door). Simultaneously drive the door in the close direction using the
car door operator test buttons.

© 2024 KONE Corporation 41 (143) ASG-21.01.031-AP3

WARNING:
Risk of door panel hitting your hand, if the closing force gauge slips. Hold the closing
force gauge tightly.

bc79287d

0ca87519

4. Read the value from the closing force gauge.

Table 1: Door closing force limits

Door opening Fmax

Center opening 70
Side opening 140

If the local requirements are more demanding, follow the local requirements.
03141011

© 2024 KONE Corporation 42 (143) ASG-21.01.031-AP3

7.2.5 Elevator car lighting (condition check)

cc802cc0
59b8f989

7.2.6 Alarm systems, remote and local (condition check)

WARNING:
If the elevator does not pass the test, take the elevator out of use. Do not return the elevator
into normal use until the problem is solved.

X >= 5 sec or check local regulation.

In case of local voice connection, check its functioning respectively.

abab7e97

7.3 Tasks in car moving up

1. Make a car call upwards.

2. During the travel, check:
a) Signs
b) Car interior
c) Car signalization
d) Car door panels

© 2024 KONE Corporation 43 (143) ASG-21.01.031-AP3

e) Car door bottom guides

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7.3.1 Signs (condition check)

1234567 1234 2005 1234567 1234 2005

64006841
0413ed02

7.3.2 Elevator car interior (condition check)

f1376d18

NOTE:
Apply the thread lock onto the screw threads using hex key.
8e2c9db5

© 2024 KONE Corporation 44 (143) ASG-21.01.031-AP3

7.3.3 Car signalization (condition check)

d628c322
9dca2843

7.3.4 Elevator car door panels (condition check)

e1379903
e4b3fcfd

7.3.4.1 Finger protection strips with glass doors (condition check)

* = critical area

© 2024 KONE Corporation 45 (143) ASG-21.01.031-AP3

1,6m

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caa7bb6c

7.3.5 Check car door bottom guides

1. Push lower part of the panel towards the door frame or the other door panel.

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© 2024 KONE Corporation 46 (143) ASG-21.01.031-AP3

2. Check the gap from lowest part of the panel.

95ebed37

Gap = 3 — 6 mm (for glass doors, 3 — 4 mm)

131ba1a9

7.4 Tasks on all intermediate landings and on topmost landing

NOTE:
Do not let the doors close when performing the checks on landings.

1. Travel upwards and make a stop on each landing.

2. Place “Under maintenance” -sign to each landing.
3. Check on each landing, until the topmost one:
a) Landing door sill
b) Entrance floor and light
c) Landing signalization
d) Landing door panels
e) Landing door running condition
f) Load labels for goods-passenger elevators
4. On the topmost landing, check the door coupler clearance.
5. Go to the maintenance access panel (MAP) and open it.
6. Switch on the MAP/shaft lights. (268)
7. Close and lock the MAP.
ec1b3872

© 2024 KONE Corporation 47 (143) ASG-21.01.031-AP3

7.4.1 Landing door sill (condition check)

160801f6
86c0bf63

7.4.2 Entrance and corridor (condition check)

e378898f

On floor level, the light must be efficient enough for a user to see ahead and enter the car,
even if the car light had failed.
2cd7fef4

© 2024 KONE Corporation 48 (143) ASG-21.01.031-AP3

7.4.3 Landing signalization (condition check)

56da4222

e2f15dec

224d2d67
5038a1ed

© 2024 KONE Corporation 49 (143) ASG-21.01.031-AP3

7.4.4 Landing door panels and landing door running (condition check)

fa95a10e

4278955b

NOTE:
Do not let the doors close.

© 2024 KONE Corporation 50 (143) ASG-21.01.031-AP3

ae1d7e67

Gap (*) = 3 — 6 mm (for glass doors, 3 — 4 mm)

b801a9a9

7.4.4.1 Finger protection strips with glass doors (condition check)

* = critical area

1,6m

78a21f4f
caa7bb6c

© 2024 KONE Corporation 51 (143) ASG-21.01.031-AP3

7.4.5 Load labels for goods-passenger elevators on landing (condition check)

f95ee3c1

7.4.6 Door coupler to landing door lock roller interface (condition check)

5584dee7
7e587fa5

7.4.7 Switch on the MAP/shaft light

1. Go to the maintenance access panel (MAP).

2. Open the MAP.
3. Switch ON the MAP/shaft lights (A).

© 2024 KONE Corporation 52 (143) ASG-21.01.031-AP3

83af6e0a

4. Close and lock the MAP.

53d31150

7.5 Test the ride comfort

NOTE:
While travelling in the elevator car and observing the ride comfort, you can proceed with
other preventive maintenance tasks, if needed.

NOTE:
Drive the car whole travel both directions.

© 2024 KONE Corporation 53 (143) ASG-21.01.031-AP3

© 2024 KONE Corporation 54 (143) ASG-21.01.031-AP3

6b8f9386

7.6 Tasks on bottom landing

1. Exit the car at the bottom landing.

2. Send the car two floors up with two car calls.
3. Apply KONE safety procedure to access to the pit (Guarding, Operating Pit Stop switch,
Pit ladder).
4. Stop the elevator by using emergency opening key before the elevator car reaches the
next floor.
5. Place the safety fence and maitenance signs to retrict others.
6. Switch ON the shaft lights.
7. Check:
a) Elevator Shaft Pit (Condition check)
b) Refuge space labels

© 2024 KONE Corporation 55 (143) ASG-21.01.031-AP3

c) Sliding guide shoes of elevator car

d) Steel rope diverting pulleys
e) Belt diverting pulleys (Condition check)
f) Lower roller guide shoes of the car
g) Car retainers (if applicable)
h) Car bottom buffers
i) Traveling cable
For details information, refer related information.
8. Remove the door blocking tool.
9. Close the landing door and ensure that it is mechanically locked.
6fff2258

7.6.1 Elevator shaft pit (condition check)

WARNING:
If you find used needles, follow the local policy for hazardous waste disposal. Never touch a
used needle without adequate personal protective equipment.
45df9b8b

© 2024 KONE Corporation 56 (143) ASG-21.01.031-AP3

7.6.2 Refuge space labels in shaft pit (condition check)

5a9df6e0
105af5e1

7.6.3 Check the lower sliding guide shoes

1. Grab the car apron.

2. Rock the elevator car by applying manual force to the car apron.
There must not be excessive movement of the car between the guide rails (Distance
between guide rails) or in the front to back dimension.
2c3ee404

7.6.3.1 Sliding guide shoes of OTIS Gen2 elevator car (condition check)

Swing the car.

Check the permitted clearance between the guide rail and the guide shoe according to
sling/guide shoe type.
In case of roller guides, the spring pressure should be high enough to keep the rollers
always on the guiding faces.
0mm

0mm

2mm

0mm
2mm

4mm

99d1b458
588d69be

7.6.3.2 Sliding guide shoes of OTIS 2000 elevator car (condition check)

Swing the car.

© 2024 KONE Corporation 57 (143) ASG-21.01.031-AP3

0mm

2mm
0mm
2mm

4mm

99d1b458
9b157b31

7.6.4 Steel rope diverting pulleys (condition check)

e3b4641c

© 2024 KONE Corporation 58 (143) ASG-21.01.031-AP3

3mm

d0ba16f3
777296da

7.6.5 Suspension belts diverting pulleys (condition check)

All belts must be in the middle of the traction sheaves.

Visible damages on the sheave surfaces must not exist.

7c8d3b4d
f1688aa5

© 2024 KONE Corporation 59 (143) ASG-21.01.031-AP3

7.6.6 Lower roller guide shoes (condition check)

3e1d5bed
1a61ec50

7.6.7 Lower car retainers (condition check)

4c54ce81
9c92b3da

7.6.8 Polyurethane buffers under car (condition check)

WARNING:
If the buffer is not in full working order (it does not last until the next scheduled maintenance
visit), arrange the replacement of the buffer immediately. If the buffer has failed already,
take the elevator out of use until the buffer has been replaced.

© 2024 KONE Corporation 60 (143) ASG-21.01.031-AP3

97c44edf

7.6.9 Traveling cable (condition check)

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14d97f36

7.7 Tasks in pit

WARNING:
Move safely between landing and pit. Follow the method approved by your local unit.

© 2024 KONE Corporation 61 (143) ASG-21.01.031-AP3

1. Go to the bottom landing.

2. Put safety fences in front of the bottom landing.
3. Make a landing call.
4. Send the car to topmost landing with a car call.
5. Open the doors with emergency opening key, when the car has reached the topmost
floor.
6. Press the stop switch.

NOTE:
Check operation of pit stop switch, before going to the pit.

7. Go to the pit.

NOTE:
In case of foldable ladder, keep the landing door open and blocked with door blocking
tool.

8. Check:
a) Oil collectors, if applicable
b) Overspeed governor
‒ Distance between the overspeed governor tension weight and pit floor
‒ Car and counterweight overspeed governor tension weight assembly
c) Car and counterweight buffers
d) Compensation chain guides
e) Clearance and overtravel of counterweight buffer
f) Counterweight screen
g) Earthquake device fixings, if applicable
h) Snag point protection devices, if applicable
i) Inspection control station

NOTE:
For detailed instructions, refer to the related information.

9. Exit the pit.

Leave the shaft lights ON.
10. Release the stop switch.
11. Remove the door blocking tool.
12. Close the landing door.
Make sure that the door is mechanically locked.

© 2024 KONE Corporation 62 (143) ASG-21.01.031-AP3

WARNING:
If any of the safety components does not operate correctly and cannot be repaired
immediately, take the equipment out of use. Inform your supervisor and arrange the repair
immediately. If the equipment is in use, also inform the customer.
ec5695d9

7.7.1 Oil collectors (condition check)

>2/3
<2/3

5c67d6ed
d3848d80

7.7.1.1 Empty oil collectors

1. Check the level of collected oil.

2. Empty the oil collectors, if they are more than 2/3 full.
Depending on the oil collector design, use the oil pump or remove the collector and pour
the oil to the container.

babc5156

© 2024 KONE Corporation 63 (143) ASG-21.01.031-AP3

4e7e5e0a

3. Clean spilled oil immediately.

4. Collect the oily rags for disposal.

NOTE:
Collect and treat waste oil properly and according to local hazardous waste oil regulations.
54d0951e

7.7.2 Overspeed governor rope length (condition check)

WARNING:
If the component does not operate correctly and cannot be repaired immediately, take the
equipment out of use. Inform your supervisor and arrange the repair immediately. If the
equipment is in use, also inform the customer.

x
x

Distance between the weight and pit floor must allow enough rope elongation before the
switch operates. Tension weight must fully tense the rope.
a464c8d6

7.7.3 Counterweight overspeed governor rope length and switch (condition check)

© 2024 KONE Corporation 64 (143) ASG-21.01.031-AP3

Figure 4: Example of a counterweight OSG

52b88df2

© 2024 KONE Corporation 65 (143) ASG-21.01.031-AP3

7.7.4 Oil buffers (condition check)

WARNING:
Before entering the pit, make sure that the pit is free from water/oil and other debris.

ab0942e6

fe18f6e2
2b3f3fa5

7.7.5 Polyurethane buffers in pit (condition check)

© 2024 KONE Corporation 66 (143) ASG-21.01.031-AP3

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8d63e76c
fe199852

© 2024 KONE Corporation 67 (143) ASG-21.01.031-AP3

7.7.6 Compensation chain guide (condition check)

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7.7.7 Overtravel (condition check)

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© 2024 KONE Corporation 68 (143) ASG-21.01.031-AP3

7.7.8 Counterweight screen (condition check)

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7.7.9 Earthquake device fixings (condition check)

f56ca5eb
3fc2e0b4

© 2024 KONE Corporation 69 (143) ASG-21.01.031-AP3

7.7.10 Inspection control station (condition check)

S TOP

NO RMAL

INSP ECTIO N
UP

ENABLE

DOW N

c3cbb179

NOTE:
Do not remove the station from the hanger, if you don't need to move the car with it. If the
station is removed, reset must be done when returning to the landing.
53915680

7.8 Tasks at MAP floor

1. Using the User Interface Board (UIB) call the car to the topmost floor (CCTL), where
the Maintenance Access Panel (MAP) exists.
2. Open the MAP.
Ensure that the MAP/shaft light is ON.

83af6e0a

3. Disable landing calls by pressing the CHCS button on the user interface board (UIB)
and car door opening by pressing the DDO button.

© 2024 KONE Corporation 70 (143) ASG-21.01.031-AP3

b1b1918b

4. Connect the OTIS service tool.

08ca074d

5. Check stopping accuracy in each floor by driving the elevator up – down –up with OTIS
service tool (KM50082009).
6. Disconnect the OTIS service tool. (KM50082009)

© 2024 KONE Corporation 71 (143) ASG-21.01.031-AP3

7. Switch ON Electrical Recall Switch ERO (electrical emergency operation RDF)

51f0c313

8. Drive the car up/down using UDB (Electrical UP recall Button) / DDB (Electrical DOWN
recall Button) to a suitable position for checking the car door railing.
9. When the elevator car is at a suitable position, open the landing door slightly (max. 100
mm) with the emergency opening key.
Keep the landing door open and blocked with door blocking tool.
10. Check:
a) Battery operated brake release device
b) Overspeed governor reset

NOTE:
For detailed instructions, refer to the related information.

11. Fully open the landing door.

Keep the landing door open and blocked with door blocking tool.
12. Check:
a) Car door operator
b) Car door operation
c) Door operator belt
d) Car door contact and lock contact

NOTE:
For detailed instructions, refer to the related information.

13. Remove the door blocking tool.

14. Close the landing door and ensure that it is mechanically locked.
15. Enable landing calls by pressing the CHCS button on the user interface board (UIB)
and car door opening by pressing the DDO button.

© 2024 KONE Corporation 72 (143) ASG-21.01.031-AP3

16. Switch OFF Electrical Recall Switch ERO (electrical emergency operation RDF)
17. Close and lock the MAP.
63eda5d9

7.8.1 Battery operated brake releasing device

NOTE:
The battery operated brake releasing devices is operated with a key switch and a button.
The location of the controls inside the maintenance access panel varies between elevator
models!

1. Ensure that the power is OFF!

2. Insert the brake release key into the brake release key switch (BRB2), and then turn the
key 1/4 turn clockwise.

765a0c27

© 2024 KONE Corporation 73 (143) ASG-21.01.031-AP3

3. Keep holding the brake release key in position and press the BRB1 button to open the
brake.

f9f8183a

Car should start moving upwards. Check the speed and direction indicator (SDI) Leds on
the user interface.
When the elevator reaches the rated speed, a buzzer sounds, CON SPEED Led is lit
and the elevator stops.

© 2024 KONE Corporation 74 (143) ASG-21.01.031-AP3

94f38f68
Then it starts again and continues moving in a similar manner until the car reaches a
door zone.
4. Release the BRB1 button and BRB2 key switch.
5. Remove the brake release key and put it in its storage place in maintenance access
panel.
6. Switch ON the power.
Elevator should do synchronization drive to the bottom floor.
7. If the check fails, check the date of the battery. Replace the battery if it has been in
use for more than three years or the date is unknown. Repeat the checks with the new
battery.
Refer to AR-21.01.001 for the updated spare part information.
60e4e9c6

7.8.2 Overspeed governor mechanical reset (condition check)

1. Push “REB” (6) and “RRB” (7) buttons to reset the speed limiter.

© 2024 KONE Corporation 75 (143) ASG-21.01.031-AP3

55d32bc2

2. If applicable, mechanically reset the speed limiter using the lever at the top of the
maintenance access panel.

© 2024 KONE Corporation 76 (143) ASG-21.01.031-AP3

3cdf4b71

1b7ba098

7.9 Tasks for car roof

WARNING:
Move safely between landing and elevator car roof. Follow the method approved by your
local unit.

© 2024 KONE Corporation 77 (143) ASG-21.01.031-AP3

1. Check visually from the landing:

a) Overall cleanliness of the car roof
b) Shaft light functioning
c) Refuge space labels on car roof
2. Remove the door blocking tool.
3. Check operation of car roof stop switch.
4. Check operation of inspection switch.
5. Go to the car roof.
Make sure that the landing doors are mechanically closed.
6. Check:
a) Next replacement date of the emergency alarm battery
b) Next replacement date of electrical brake release device (RBO) battery
c) Safety gear linkage, if applicable
d) Upper sliding or roller guide shoes of the car
e) Overspeed governor reset stick
7. Release the stop switch.
d297a5c4

7.9.1 Elevator car roof (condition check)

b8fbac8c
c1f5b3b5

© 2024 KONE Corporation 78 (143) ASG-21.01.031-AP3

7.9.2 Shaft lighting (condition check)

e84c5766

7.9.3 Refuge space labels on car roof (condition check)

b5faf2d8
59488c47

7.9.4 Emergency alarm battery (condition check)

> <

* = next maintenance visit

468d9dcf

© 2024 KONE Corporation 79 (143) ASG-21.01.031-AP3

7.9.5 Electrical brake release device battery (condition check)

024e9853

* = next maintenance visit

976e0b13

7.9.6 Check safety gear linkage

1. Pull overspeed governor rope slightly.

© 2024 KONE Corporation 80 (143) ASG-21.01.031-AP3

2. Move the rope up and down.

3. Verify the function of the safety gear linkage.

a090165d

7.9.6.1 Safety gear linkage (condition check)

© 2024 KONE Corporation 81 (143) ASG-21.01.031-AP3

5eb5992a

7.9.7 Check the upper sliding guide shoes

1. If needed, remove the lubricator, to see the guide shoe.

2. Select a suitable position on the elevator car roof.
3. Take a steady posture.

© 2024 KONE Corporation 82 (143) ASG-21.01.031-AP3

4. Push the guide rail with hands and push the elevator car with your feet towards the
opposite guide rail so that it is slightly pressed against the sliding guide shoe.

NOTE:
Checking point is at the guide rail brackets.

5. Check visually that the guide shoe housings are centralized properly and housings are
not touching to guide rails.
6. Refix the lubricator, if removed.
4b1f9256

7.9.8 Upper roller guide shoes (condition check)

4e8f2d30
9d7f090d

© 2024 KONE Corporation 83 (143) ASG-21.01.031-AP3

7.10 Tasks on car roof for shaft headroom

1. Drive on inspection up to a suitable position for checking the suspension rope anchors, if
needed.
2. Switch ON the car roof stop switch.
3. Check:

NOTE:
For detailed instructions, refer to the related information.

a) Suspension rope tension in the rope anchors

b) Suspension ropes
c) Overspeed governor rope
d) Overspeed governors’ mechanism
e) Snag point protections, if applicable

NOTE:
Snag point protections need to be checked throughout the shaft.
a4121298

7.10.1 Hoisting machine (condition check)

1. Drive the elevator on inspection drive and listen to the machinery.

Check the hoisting unit for abnormal noise.

4a8caff3

2. Ensure that the power is switched off from the main switch in the shaft.

1a8d2913

3. Check the hoisting unit.

© 2024 KONE Corporation 84 (143) ASG-21.01.031-AP3

04464737

4. Check the condition of the traction sheaves.

daef79fa
All belts must be in the middle of the traction sheaves. No visible damages on the
sheave surfaces should exist
5. Check the tachometer.

eba8da17

6. Check that the tachometer fixing is tight and the wires are properly fixed (must not be
tangled with any moving object in the elevator shaft).
7. Check the connections of all motor supply cables.

0d6b26db

ae5df32e

© 2024 KONE Corporation 85 (143) ASG-21.01.031-AP3

7.10.2 Guide rail lubrication (condition check)

NOTE:
Do not lubricate, if the elevator has roller guide shoes.

Check that the guide rails have a thin layer of grease.

If necessary, lubricate 1 meter of guide rails at three different heights in the elevator shaft
(top, middle, bottom).
This ensures that there is enough grease until the next maintenance visit.
Use vaseline without EP additives (Cecalubes Bordeaux).

NOTE:
Avoid skin contact with lubricant.
deb36ad8

7.10.3 Suspension rope anchors (condition check)

X>3mm
X<3mm

dc001012

7.10.4 Suspension belt fixings (condition check)

Check the belt suspension fixings.

The washers must be in the same level.

© 2024 KONE Corporation 86 (143) ASG-21.01.031-AP3

Otherwise belt tension equalization is necessary. Maximum deviation is 3 mm.

a3bcb1f9

f7690db5

7.10.5 Steel suspension ropes (condition check)

6c1e95bd

WARNING:
If the elevator does not pass the test, take the elevator out of use. Do not return the elevator
into normal use until the problem is solved.

© 2024 KONE Corporation 87 (143) ASG-21.01.031-AP3

f28bc3a3
78147679

7.10.6 Suspension belts (condition check)

NOTE:
Check the replacement date of the belts. Schedule a belt replacement according to the
manufacturer's instructions. Make sure that the date of the latest belt check is updated in
elevator logbook.

e74206ec

1. Check the belts for visible cable marks in the polyurethane compound caused by wear.

© 2024 KONE Corporation 88 (143) ASG-21.01.031-AP3

2. Check the belts for cuts in the polyurethane compound. Cuts may be result of incorrect
pulley alignment, or the belt is not plumb.
3. Check the belts for rust. Rust on the belt may be due to, for example, an unfavorable
operating environment.
4. Check the belts for cable strands which protrude through the polyurethane compound.
5. Check the belts for polished sections due to wear or slipping.
6. Check the belts for cables which have pierced the polyurethane and are exposed.

NOTE:
Take the elevator out of service and replace the belts, if necessary!
c7249c03

7.10.7 Overspeed governor rope (condition check)

WARNING:
Do not lubricate the overspeed governor rope.

6c1e95bd
0afd95e7

© 2024 KONE Corporation 89 (143) ASG-21.01.031-AP3

7.10.8 Check overspeed governor

1. Check the overspeed governor mechanism and its electrical contact.

d844e6ea

2. Check the overall cleanliness of the overspeed governor.

9efbf9d6

7.10.9 Upper car retainers (condition check)

6c434ca2

7.11 Tasks on car roof for hoisting machine

1. Drive on inspection to suitable position for checking the hoisting machine.

2. Switch on the car roof stop button.
3. Check:
a) Overall condition of the machine
b) Mechanical isolation and fastening of the machine
c) Traction sheave
d) Brake air gap
e) Rope gripper, if applicable
e0760b9a

© 2024 KONE Corporation 90 (143) ASG-21.01.031-AP3

7.11.1 Hoisting machine (condition check)

1. Drive the elevator on inspection drive and listen to the machinery.

Check the hoisting unit for abnormal noise.

4a8caff3

2. Ensure that the power is switched off from the main switch in the shaft.

1a8d2913

3. Check the hoisting unit.

04464737

4. Check the condition of the traction sheaves.

daef79fa
All belts must be in the middle of the traction sheaves. No visible damages on the
sheave surfaces should exist
5. Check the tachometer.

© 2024 KONE Corporation 91 (143) ASG-21.01.031-AP3

eba8da17

6. Check that the tachometer fixing is tight and the wires are properly fixed (must not be
tangled with any moving object in the elevator shaft).
7. Check the connections of all motor supply cables.

0d6b26db

ae5df32e

7.11.2 Mechanical isolation and fastening of the machine (condition check)

Check mechanical isolation and fastening of the machine.

Verify that the mechanical isolations are in place and in good condition.
8f0c77b5

7.11.3 Check suspension steel belt traction sheave

1. Check the cleanliness of the traction sheave.

2. Dirt, especially oil or grease (or other substances), are not allowed on sheave..
3. Check that all belts are in the middle of the traction sheaves. Visible damages on the
sheave surfaces should not exist.

NOTE:
The centred suspension belt position on traction sheaves is shown below,

© 2024 KONE Corporation 92 (143) ASG-21.01.031-AP3

daef79fa
63425dec

7.11.4 Check brake air gap

1. Secure the working spaces with barriers on the top most floor and protect the walls and
the floor to avoid damages.
2. Place the “Out of Service” stickers at every landing.
3. Through the user interface, call the car to the floor with the maintenance panel to the
top most floor (CCTL).
a) Ensure that the car is empty.
b) Allow the doors to close.
c) On the UIB: Press the “CHCS” to disable the landing call commands.
d) Press the “DDO” to disable door operation.

b1b1918b

4. Set the inspection drive switch in the MAP to ERO position.

a) Use the “Down” button to bring the car down to have the top of the car at 0.80
meters above the top most floor.

© 2024 KONE Corporation 93 (143) ASG-21.01.031-AP3

69b09936

5. Switch the main power off.

653ef55a

6. Close the MAP to go to the top of the car.

Use the step ladder.

© 2024 KONE Corporation 94 (143) ASG-21.01.031-AP3

7. If the machine brake is inaccessible while standing on car roof, install platform LOBO
to work safely. Ensure that the technician works on the car roof with body harness.

cbb75590

8. Ensure that the window on each side of the brake is accessible for the control of the air
gaps.

9c7ec571

© 2024 KONE Corporation 95 (143) ASG-21.01.031-AP3

9. Check the air gaps on - T..20222BC/BD/BD/BF/BG and T..20236G/H/L/K brake (See

name plate for identification).

1 - Fixing plate
2 - Lining holder
3 - Release plate
4 - Magnet coil housing
5 - Metric feeler guage
10. Put the metric feeler gauge in the first window of the brake and control the air gap. Do
the same for the other side of the brake.

b3a13a55
If one of the air gaps measured DIM1 is higher than 0.35 mm, shut down the unit. The
brake must be replaced.

© 2024 KONE Corporation 96 (143) ASG-21.01.031-AP3

a55e5e29

NOTE:
For T..20222BC/BD/BD/BF/BG - If one of the air gaps measured DIM1 is higher than
0.55 mm, shut down the unit. The brake must be replaced.

NOTE:
For T..20236G/H/L/K - If one of the air gaps measured DIM1 is higher than 0.65 mm,
shut down the unit. The brake must be replaced

11. Record the measurement in the maintenance book.

© 2024 KONE Corporation 97 (143) ASG-21.01.031-AP3

12. After the control on both sides of the brake, remove the platform “LOBO” from the car
roof.

cbb75590

13. Go back to the landing door. Open the MAP.

14. Switch on the main power.
15. Drive the car with the ERO in the up and down direction to observe any abnormal
noise.
16. If there is no abnormal noise, return the car back to normal.
Press the buttons corresponding to the functions on the UIB to:
‒ Enable the landing call commands (CHCS)
‒ Enable car door operation (DDO)
‒ Call the car to the top most level (CCTL)
‒ Ensure that the installation operates correctly

b1b1918b

© 2024 KONE Corporation 98 (143) ASG-21.01.031-AP3

17. Remove the “out of service” stickers at every landing.

05a821ef

7.12 Tasks on car roof for drive module

1. Drive on inspection to suitable position for checking the drive module, if needed.
2. Switch on the car roof stop switch.
3. Check:
a) Emergency battery drive (EBD) unit
b) Drive module
c) Group controller
2b220bde

7.12.1 Emergency battery drive (EBD) unit (condition check)

> >

1a1b2af1

© 2024 KONE Corporation 99 (143) ASG-21.01.031-AP3

> >

fad85b68

Figure 5: KDX drive

* = next maintenance visit

31bff9f4

7.12.2 Drive module (condition check)

c58faa3e
0852e179

© 2024 KONE Corporation 100 (143) ASG-21.01.031-AP3

7.12.3 Group cabling (condition check)

dbcd6dee

7.13 Tasks on car roof for topmost landing door - upper part

1. Drive on inspection to suitable position for checking the upper part of the topmost
landing door.
2. Switch ON the car roof stop button.
3. Check:
a) Landing door railing
b) Landing door synchronization rope
c) Landing door lock
d) Landing door lock contact
e) Landing door lock rollers
f) Closing weight or spring
ab03cf44

7.13.1 Landing door railing (condition check)

ceec3d60
33bea6a3

7.13.2 Landing door lock (condition check)

WARNING:
If the elevator does not pass the test, take the elevator out of use. Do not return the elevator
into normal use until the problem is solved.

b12dcd8d
5b6356d6

7.13.3 Landing door contact and lock contact (condition check)

3−5 mm

< 3 mm

45f87774

7.13.4 Landing door lock rollers (condition check)

c2a0b164
498cdf53

7.13.5 Closing weight or spring (condition check)

1
100mm

cbd6d59d
5180901c

7.14 Tasks on car roof for topmost landing door - lower part

1. Drive the elevator car on inspection drive downwards to a suitable position for checking
the lower part of the topmost landing door.
2. Switch ON the car roof stop switch.
3. Check:
a) Landing door bottom guides
b) Landing door closed gap

c) Sill connection to the frame

f68c4cdb

7.14.1 Landing door bottom guides (condition check)

* *

bcf1eb0e

Gap (*) = 3 — 6 mm (for glass doors, 3 — 4 mm)

0e54a37c

7.14.2 Landing door closed gap (condition check)

Max. 30 mm Max. 45mm

629f1f03

NOTE:
The door closed gap with moderate force applied for one panel must be max. 30 mm for the
side opening door and max. 45 mm for the centre opening door.
d2a3cd5f

7.14.3 Sill connection to frame (condition check)

8b6eddf8
a410208d

7.15 Tasks on car roof for all intermediate floors

NOTE:
Do the landing door checks on all intermediate floors until reaching the counterweight.
Then do the counterweight checks and continue the landing door checks until reaching the
second floor.

1. Drive the elevator car on inspection drive down to a position where car and landing door
are engaged with door coupler and coupler rollers, in door zone level.
2. Switch on the car roof stop switch.
3. Check:
a) Door coupler and lock rollers
b) All landing door items as on the topmost floor.
4. Drive the elevator car on inspection drive downwards to a suitable position for checking
the upper part of the landing door.
5. Check:
a) Landing door railing
b) Landing door synchronization rope
c) Landing door lock
d) Landing door contact and lock contact
e) Landing door lock rollers
f) Closing weight or spring

6. Drive the elevator car on inspection drive downwards to a suitable position for checking
the lower part of the landing door.
7. Check:
a) Landing door bottom guides
b) Landing door closed gap
c) Sill connection to the frame
d) Snag point protections, if applicable
8d312d3c

7.15.1 Door coupler to landing door lock roller interface (condition check)

WARNING:
Do not check this while driving or moving the car.

NOTE:
Press door close button when checking.

b66d66b3

NOTE:
The tool can not be used at the bottommost landing.

= =

D D

f0af6e34

Figure 6: Checking the door coupler with landing door roller adjustment tool
0f9c7b2c

7.15.2 Landing door railing (condition check)

ceec3d60
33bea6a3

7.15.3 Landing door lock (condition check)

WARNING:
If the elevator does not pass the test, take the elevator out of use. Do not return the elevator
into normal use until the problem is solved.

b12dcd8d
5b6356d6

7.15.4 Landing door contact and lock contact (condition check)

3−5 mm
< 3 mm

45f87774

7.15.5 Landing door lock rollers (condition check)

c2a0b164
498cdf53

7.15.6 Closing weight or spring (condition check)

1
100mm

cbd6d59d
5180901c

7.15.7 Landing door bottom guides (condition check)

* *

bcf1eb0e

Gap (*) = 3 — 6 mm (for glass doors, 3 — 4 mm)

0e54a37c

7.15.8 Landing door closed gap (condition check)

Max. 30 mm Max. 45mm

629f1f03

NOTE:
The door closed gap with moderate force applied for one panel must be max. 30 mm for the
side opening door and max. 45 mm for the centre opening door.
d2a3cd5f

7.15.9 Sill connection to frame (condition check)

8b6eddf8
a410208d

7.16 Tasks on car roof for counterweight - upper part

1. Drive the car to the same level with the counterweight on inspection drive.
2. Switch on the car roof stop switch.
3. Check:
a) Suspension rope
b) Overspeed governor rope
c) Counterweight upper guide shoes and guide rails
d) Guide rail lubricator, if applicable
e) Counterweight frame
f) Upper car and counterweight retainers, if applicable
20ed442e

7.16.1 Steel suspension ropes (condition check)

6c1e95bd

WARNING:
If the elevator does not pass the test, take the elevator out of use. Do not return the elevator
into normal use until the problem is solved.

f28bc3a3
78147679

7.16.2 Suspension belts (condition check)

e74206ec

1. Check the belts for visible cable marks in the polyurethane compound caused by wear.
2. Check the belts for cuts in the polyurethane compound. Cuts may be result of incorrect
pulley alignment, or the belt is not plumb.
3. Check the belts for rust. Rust on the belt may be due to, for example, an unfavorable
operating environment.
4. Check the belts for cable strands which protrude through the polyurethane compound.
5. Check the belts for polished sections due to wear or slipping.
6. Check the belts for cables which have pierced the polyurethane and are exposed.

NOTE:
Take the elevator out of service and replace the belts, if necessary!
c7249c03

7.16.3 Counterweight upper sliding guide shoes (condition check)

Maximum values allowed

0mm

2mm
0mm
2mm

2mm

b0c11650

7.16.4 Guide rail (condition checks)

‒ Guide rails must be smooth and free of marks caused by operation of the safety gear.
‒ Guide rail fixings must be correctly tightened.

NOTE:
Use milled file KM254337 and frame for milled file KM254336 for removing the marks from
the rails
98534459

7.16.5 Guide rail lubricator (condition check)

‒ Lubricator must be free of any dirt built up.

‒ Lubricator felt pads must be in contact with the guide rails but without exerting excessive
pressure.
‒ Lubricator must be 2 — 3 degrees inclined towards the guide rail.

64de56d6

‒ Oil level must be correct in the lubricators. The cups must be 2/3 full.

2/3

a845ea79

7cadc2cf

7.16.6 Suspension belts counterweight frame, pulleys and filler weights (condition check)

1. Listen for noise from counterweight pulley bearings during the down direction in
inspection drive.

84b9cf12

2. Check the counterweight frame, pulleys and filler weights.

8d1071a2

3. Check the clearance between the counterweight guide shoes and the guide rails visually
and/or by swinging the counterweight.

80fc5817

4. Check the counterweight guide rail lubrication.

5. Check the clearance between the lower guide shoes and the guide rails visually and/or
by swinging the counterweight.

b2e846ab

df13251c

7.16.7 Upper car retainers (condition check)

6c434ca2

7.17 Tasks on car roof for counterweight - lower part

1. Drive the elevator car on inspection drive downwards to a suitable position for checking
the counterweight bottom parts.
2. Switch on the car roof stop switch.
3. Check:
a) Counterweight safety gear
b) Counterweight lower guide shoes
c) Guide rail lubricator, if applicable
d) Compensation chain
e) Lower counterweight retainers, if applicable
267f3b88

7.17.1 Counterweight safety gear linkage (condition check)

3bde39ed

7.17.2 Counterweight lower sliding guide shoes (condition check)

Maximum values allowed

0mm

2mm
0mm
2mm

2mm

8e106895

7.17.3 Guide rail (condition checks)

‒ Guide rails must be smooth and free of marks caused by operation of the safety gear.
‒ Guide rail fixings must be correctly tightened.

NOTE:
Use milled file KM254337 and frame for milled file KM254336 for removing the marks from
the rails
98534459

7.17.4 Compensation chain (condition check)

ac7acb75

7.18 Tasks on car roof for shaft - lower part

1. Drive the elevator car on inspection drive down to a position where car and landing door
are engaged with coupler and coupler rollers, in door zone level.

2. Switch ON the car roof stop switch.

3. Check:
a) Suspension rope
b) Overspeed governor rope
789680f7

7.18.1 Suspension belts (condition check)

e74206ec

6. Check the belts for cables which have pierced the polyurethane and are exposed.

NOTE:
Take the elevator out of service and replace the belts, if necessary!
c7249c03

7.18.2 Overspeed governor rope (condition check)

WARNING:
Do not lubricate the overspeed governor rope.

6c1e95bd
0afd95e7

7.18.3 Car door operation (condition check)

8cf72f72
e24ad0fa

7.19 Tasks on car roof for the lowest landing door

WARNING:

Move safely between car roof and landing.

1. Drive upwards on inspection to a position where the car sill is about 800 mm above the
floor sill.

WARNING:
Be careful when driving upwards on inspection drive.

2. Activate car top stop push.

3. Go to the landing.
4. Use OSG reset button for opening the landing door lock, if needed.
5. Switch ON the car roof stop button.
6. Switch to ERO using the Electrical recal switch to leave the inspection control station to
Inspection-position
7. Close the landing door and ensure that it is mechanically locked.
8. Exit to the landing.
2c19f8d1

7.20 Tasks on bottom landing for lowest landing door

Before you start this task, the elevator car must be at a suitable height, max. 700 mm above
the landing.

NOTE:
The procedure described here is only for normal floor to floor distance (HF) between the
lowest and the second floor.

1. Walk to the bottom landing.

2. Check:
a) Landing door bottom guides
b) Landing door closed gap
3. Open the landing door with emergency opening key.
Keep the landing door open and blocked with door blocking tool.
4. Check:
a) Apron fixings
b) Car door emergency opening rope
5. Remove the door blocking tool.
48042dd2

7.20.1 Landing door closed gap (condition check)

Max. 30 mm Max. 45mm

629f1f03

NOTE:
The door closed gap with moderate force applied for one panel must be max. 30 mm for the
side opening door and max. 45 mm for the centre opening door.
d2a3cd5f

7.20.2 Landing door bottom guides (condition check)

7c2d1cab

Gap (*) = 3 — 6 mm (for glass doors, 3 — 4 mm)

7448178f

7.20.3 Check the car door bottom guides

1. Push lower part of the panel towards the door frame or the other door panel.

2. Check the gap from lowest part of the panel.

Gap = 3 — 6 mm (for glass doors, 3 — 4 mm)

d4556921

7.20.4 Sill connection to frame (condition check)

8b6eddf8
a410208d

7.20.5 Car door emergency opening rope (condition check)

5c38cf77
0f86f9c7

7.21 Tasks in car for lowest landing door

NOTE:
The procedure described here is only for normal floor to floor distance (HF) between the
lowest and the second floor.

1. Open the car door.

Block the door fully open with door blocking device.
2. Climb inside the elevator car. Use work stool if needed.

3. Check:

NOTE:
For detailed instructions, refer to the related information.

a) Landing door railing

b) Landing door synchronization rope

c) Landing door lock

d) Landing door lock contact
e) Landing door lock rollers
f) Closing weight or spring
4. Exit the car.

5. Remove the door blocking device.

6. Close the landing door and ensure that it is mechanically locked.
5d52234f

7.21.1 Landing door railing (condition check)

ceec3d60
33bea6a3

7.21.2 Landing door lock (condition check)

WARNING:
If the elevator does not pass the test, take the elevator out of use. Do not return the elevator
into normal use until the problem is solved.

b12dcd8d
5b6356d6

7.21.3 Landing door contact and lock contact (condition check)

3−5 mm

< 3 mm

45f87774

7.21.4 Landing door lock rollers (condition check)

c2a0b164
498cdf53

7.21.5 Closing weight or spring (condition check)

1
100mm

cbd6d59d
5180901c

7.21.6 Pit exit device (condition check)

ab0498a3
36be82b2

7.22 Tasks on one floor above bottommost landing

1. Walk to the next floor above the bottommost landing.

2. Open the landing door.
3. Switch off the car roof stop switch.
4. Switch off the inspection drive from the car roof.
5. Close the landing door.
Make sure that the door is mechanically locked.
ba533b23

7.23 Task at MAP floor

1. Make a landing call.

2. Travel to the MAP floor.
3. Go to the MAP. Open the MAP.
4. Make a landing call to open the doors.

5. Switch ON the Electrical Recall Switch ERO (electrical emergency operation RDF).

51f0c313

6. Check the earth leakage circuit breaker.

NOTE:
For detailed instructions, refer to the related information.

7. Switch OFF the car light power supply.

Switch OFF the car lighting.
8. Check:

NOTE:
For detailed instructions, refer to the related information.

a) Emergency light
b) Remote / local alarm system and telephone / intercom connection (if applicable) with
back-up power
c) Door Zone Indicator (DZ)
9. Switch ON the car light power supply.
67f6cd04

7.23.1 Test earth leakage circuit breaker

1. Press the test button of the earth leakage circuit breaker.

The circuit breaker has to switch OFF.
2. Reset earth leakage circuit breaker by switching it ON.

4c221106

3. Test other earth leakage switches same way.

ec6d48e5

7.23.2 Emergency light in car (condition check)

Switch off the car light to check the emergency light.

1 2

a260293b

NOTE:
The location of the emergency light can vary.
b52a7566

7.23.3 Remote / local alarm system and telephone / intercom connection with back-up
power (condition check)

WARNING:
If the elevator does not pass the test, take the elevator out of use. Do not return the elevator
into normal use until the problem is solved.

d48c491f
1874f852

7.23.4 CHECK DOOR ZONE INDICATOR (DZ)

Door zone LED must be ON.

1. Switch OFF the main switch.
2. Check that DZ is not illuminated.
3. Switch ON the main switch.

4. Check that DZ is illuminated.

80b1e058

246d3a77

7.24 Finalize the maintenance visit

1. Drive the elevator car on inspection drive upwards to a suitable position to exit from the
car roof.

WARNING:
Be careful when driving upwards on inspection drive.

2. Go to the landing.
3. Switch OFF the inspection drive.
4. Switch OFF the car roof stop switch.
5. Close the landing door and ensure that it is mechanically locked.

6. Ensure that MAP/shaft lights (A) are OFF.

83af6e0a

7. Fill in the maintenance logbook.

8. Close and lock the MAP.
9. Make a landing call.
10. Remove maintenance signs from all landings.
11. Return the elevator to normal service.
e6e1720f

8 CORRECTIVE ACTIONS FOR NON-CONFORMITIES

For correct replacement or repair instructions, see related information.

Component or behavior Corrective action

Alarm buttons If the alarm sound cannot be heard,
investigate the root cause.
Possible reasons for malfunction:
‒ Emergency battery in car top connection
box is defective.
‒ Components are damaged.

Car and counterweight buffers Add oil, if needed. Clean the buffer, if
needed.
If there is any concern that the buffer is not
in full working order or that it will not last to
the next scheduled maintenance visit based
on the checking routine, arrange buffer
replacement at the first possible opportunity.
In case the buffer has clearly failed, take the
elevator out of service until the buffer has
been replaced.

Car diverting pulleys (coated steel rope) If there is oil leakage from the bearings,
clean with a cloth or replace the diverting
pulley, if rope contamination is happened.
Car door bottom guides If the gap is out of defined range, replace
the bottom guides, or adjust with shims, if
possible. See door-specific instructions.
Car door contact and lock contact Replace or adjust, if any deviation from
standard.
Car door emergency opening rope Investigate the root cause and repair
according to the door-specific instructions.
Car door lock Adjust the door, if needed.
Car door operator Clean, if needed.
Car door panels Repair damaged panels and frames.
If the gap is out of defined range, replace
the guide shoes or the door hanger rollers.

Car door running condition Investigate the root cause and repair
according to the door-specific instructions.
Car door sill Remove obstacles from the sill groove, if
any. Use, for example, screwdriver or brush.

Component or behavior Corrective action

Car interior Replace or retighten the fixings, if needed.
One screw at both ends, use 3 mm hex key.
Car lighting Replace all fluorescent tubes, if one is
broken. Replace LEDs one at the time.
Car position devices Tighten or refix, if needed.
If the car encoder does not work well,
emergency slow down/stop happens during
normal running.
Replace car encoder, if needed.

Car roof cleanliness Clean the car roof, if needed.

Car signalization Replace devices which do not operate
normally.
Closing weight and spring Adjust the closing weight or spring, if
needed. Replace the components, if not in
acceptable condition. Tighten the fixings, if
needed.
Compensation chain's fixing Reattach or replace the fixings.
Cooling fan in control and drive cabinets Replace the defective components, if
needed.
Cooling fans of hoisting machine If the fans are not working correctly, repair
or replace, if needed.
Counterweight bottom guide shoes Replace worn out roller guide shoes.
Counterweight diverting pulleys (coated If there is oil leakage from the bearings,
steel rope) clean with a cloth or replace the diverting
pulley, if rope contamination is happened.
Counterweight frame, roller guide shoes Clean with cloth or replace the roller, if
needed.
Replace roller guide shoes according to
counterweight-specific instructions.

Counterweight screen Refix, if needed. Replace the sticker and

rewrite overtravel information to sticker.
Diverting pulleys Dirt, oil, grease or other substances must be
removed.
Door bottom guides If the gap is out of defined range, replace
the guide shoes.
Door closing force limiter Adjust the closing force potentiometer, if
needed.

Component or behavior Corrective action

Door coupler clearance Adjust, if needed.
Door open button (DOB) Replace the button assembly, if it does not
operate normally.
Door operator belt Adjust the tightness, if needed. Replace the
belt, if needed.
Door protective devices Replace damaged and inoperative
components.
Door Zone Indicator (DZI) If the DZI is not operative, investigate the
root cause and repair accordingly.
Earth leakage circuit breakers If the operation is not correct, replace the
earth leakage circuit breaker. Contact your
supervisor for replacement procedures.
Earthquake fixings Retighten or refix, if loosen.
Earthquake protection devices Investigate the root cause and repair
according to the component-specific
instructions.
Electrical brake release device (RBO or Replace the faulty parts.
EBR)
Electrical equipment sticker Replace the sticker, if needed.
Emergency alarm battery Replace the battery, if needed. Dispose of
the battery according to KONE environment
policy.
Emergency lighting Replace the light, if needed.
Entrance floor and light, corridor light Inform the customer, if the entrance light is
not on adequate level.
Finger protection strips Repair or replace immediately, if needed.
Guide rail lubricator Oil cups must be filled if they are less than
2/3 full. Waste oil must be properly collected
and treated according to local hazardous
waste oil regulations. Oily rags must be
properly collected for disposal. Spilled oil
must be cleaned immediately.
Handrail Replace or retighten the fixings, if needed.
One screw at both ends, use 3 mm hex key.
Hoisting motor bearing (coated steel rope) If there is oil leakage from the bearings,
clean with cloth or replace the motor if rope
contamination is happened.
Inspection control station Replace, if broken.

Component or behavior Corrective action

KCECPU/KCECPUc battery Replace the battery, if needed. Dispose of
the battery according to KONE environment
policy.
KCEGCL/KCEGCH battery Replace the battery, if needed. Dispose of
the battery according to KONE environment
policy.
KONE MediaScreen Replace devices which do not operate
normally.
Landing door bottom guides Adjust the door and replace the guides, if
needed, or adjust with shims, if possible.
See door-specific instructions.
Landing door closed gap Adjust the anti-tip rollers, if the gap is too
wide.
Landing door emergency opening device If the door does not open, check the
opening mechanism. Repair or replace, if
needed.
Landing door lock If the gap is less than 1 – 2 mm, check the
door panel gaps against other door or slam
post. The door panel gaps must be 2 mm.
Adjust the door panel, if needed. Check
the vertical straightness of the panels and
adjust accordingly, if needed.
If the gap is more than 2 mm, check the
condition of closing buffer: rotate the door
closing buffer to other position or replace
the buffer completely.
If the fault cannot be repaired immediately,
the elevator must be taken out of service
until the fault is repaired.
If you must leave the elevator out of service,
record the date and reason to log book.
Inform the customer and your supervisor.

Landing door lock rollers Replace or adjust, if any deviation from

standard.
Landing door panels Repair damaged panels and frames.
If the gap is out of defined range, replace
the guide shoes.

Landing door railing Clean the railing, if needed.

Component or behavior Corrective action

Landing door sill Remove obstacles from the sill groove, if
any. Use, for example, screwdriver or brush.
Landing signalization Replace damaged buttons and displays.
Landing door synchronization rope Replace or adjust, if any deviation from
standard.
Load labels for goods passenger elevators Replace the labels, if needed.
Lower roller guide shoes Clean with cloth, or repair or replace the
shoes, if worn out according to car sling
type instructions.
Machine brake air gap Adjust, if needed.
Machine brake contacts Adjust, if needed.
If the test fails, take the elevator out of use
until repaired.

Machine brake lining Adjust or replace the brakes.

Machine brake operation Adjust the brakes, if needed.
Machine running condition Investigate the root cause, if needed.
Manual brake release system and If the car does not move, check and readjust
relevelling or repair the manual opening system.
MAP light Replace the work light, if needed.
MX brake test Adjust the torque / replace the brakes, if
needed.
Oil collectors in pit Oil cups must be emptied if they are more
than 2/3 full. Waste oil must be properly
collected and treated according to local
hazardous waste oil regulations. Oily rags
must be properly collected for disposal.
Spilled oil must be cleaned immediately.
One-sided brake test If the test fails, take the elevator out of use
until repaired.
Overspeed governor and safety gear Adjust the safety gear, if needed.
linkage
Overspeed governor mechanism Clean the OSG, if needed.
Overspeed governor ropes Replace the ropes if wire breaks, wear
and/or tear exist.

WARNING:
Do not lubricate overspeed governor rope.

Component or behavior Corrective action

Overspeed governor running condition Investigate the root cause, if needed.
Overtravel If the clearance is on lower limit, turn buffer
extension block (spacer) to shorter position.
If the block is already turned, then the
suspension ropes must be shortened so
that the amount of overtravel matches value
marked to the sticker.
Refer to component-specific instructions.

Pit light and cleanliness Replace bulb(s) if needed. Clean the pit, if
needed.
Refuge space labels in pit Replace the labels, if needed.
Refuge space labels on car roof Replace the labels, if needed.
Remote / local alarm system and Replace the button assembly, if it does not
telephone / intercom connection work properly. If the fault cannot be repaired
immediately, the elevator must be taken
out of service until the fault is repaired. If
you must leave the elevator out of service,
record the date and reason to log book.
Inform the customer and your supervisor. If
the two-way communication link does not
work, investigate the root cause and repair
it.
Remote / local alarm system and Investigate the root cause and fix
telephone / intercom connection with back- accordingly.
up power
Ride comfort Investigate reason of possible abnormal
operation. Repair accordingly.
Rope guards Fix the rope guards, if needed.
Shaft lights Replace bulb(s) or tubes, if needed.
Signalization Replace damaged buttons and displays.
Signs Replace damaged and missing signs.
Sill connection to the frame If the sill is loose, tighten the fixings.
If the sill is corroded, distorted, worn or
damaged, replace the sill.

Stopping accuracy If stopping accuracy is not in the allowed

accuracy, do the shaft setup, if needed.

Component or behavior Corrective action

Suspension rope tension from the rope hitch If suspension rope tension deviation
exceeds 3 mm, rope tension must be
equalized:
1. Adjust by loosening or tightening the
nuts, if needed.
2. Drive the elevator twice between terminal
floors.
3. Check the tensions again.
4. Readjust, if needed.
Insert new split pins, if missing.
Tighten the rope clips, if needed.

Suspension ropes Replace the ropes if wire breaks, wear

and/or tear exist. Relubricate the ropes, if
needed.
Tension weight's vertical distance from pit Adjust the rope length, if needed.
bottom
Traction sheave If deviation among all of the ropes is more
than 0.2 mm, and the ropes are within
specification, the machine must be
replaced. Dirt, oil, grease or other
substances must be removed.
If the rope is so deep in the groove
that the liner touches the traction sheave,
immediate actions must be taken for
machine replacement.

Traveling cable Refix, if needed.

Upper roller guide shoes Clean with cloth, or repair or replace the
shoes if worn out according to car sling type
instructions.

2bb69b2f

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