Escalator 702456

MASTER INDEX
VOLUME 01: CIVIL ELEMENTS

1.1 CIVIL &STRUCTURAL ELEMENTS:
1.1.1 CHAIN LINK FENCE
1.1.2 SIGNAGE
1.1.3 TRAFFIC MANAGEMENT SYSTEM
1.1.4 PARKING MANAGEMENT SYSTEM
1.1.5 TAXI DISPATCH SYSTEM
1.1.6 BUS TERMINAL SYSTEM
1.1.7 SBS ROOFING SYSTEM
1.1.8 ROOF DECKING
1.1.9 FALL PROTECTION SYSTEM
1.1.10 TREES, SHRUBS, GROUND COVERS, LAWNS & GRASSES
1.1.11 IRRIGATION SYSTEM
1.2 ARCHITECTURAL ELEMENTS:
1.2.1 STEEL DOORS
1.2.2 ALUMINUM & GLAZING WORKS
1.2.3 ACOUSTIC/ METAL PAN CEILING/ CORIAN COUNTERS
1.2.4 COMPOSITE STONE TILE/ FLOOR MATS
1.2.5 METAL LOCKERS/ SHELVING
1.2.6 TOILET ACCESSORIES
1.2.7 EPOXY FLOORING
1.2.8 RAISED ACCESS FLOOR
1.2.9 CARPET FLOORING
1.2.10 CARPET TILE FLOORING
1.2.11 ROLLER SHADES
1.2.12 ELEVATORS/ ESCALATORS/ AUTO-WALKS
1.2.13 GENIE ARIEL LIFT
VOLUME 02: MEP SYSTEMS
2.1 MECHANICAL SYSTEMS
2.1.1 FIRE PROTECTION SYSTEM
2.1.2 PLUMBING & DRAINAGE SYSTEM
2.1.3 HVAC SYSTEM
2.2 ELECTRICAL SYSTEMS
2.2.1 LIGHTNING POTECTION & EARTHING
2.2.2 UNINTERUPTED POWER SUPPLY
2.2.3 INTERIOR LIGHTING SYSTEM
2.2.4 EXTERIOR LIGHTING SYSTEM
2.2.5 SWITCHBOARDS AND PANELBOARDS
2.2.6 PACKAGED ENGINE GENERATORS
2.2.7 POWER FACTOR CORRECTION
CAPACITORS
2.2.8 MOTOR CONTROL CENTER
2.2.9 DRY TYPE DISTRIBUTION TRANSFORMER
2.3 SPECIAL SYSTEMS
2.3.1 FIRE ALARM SYSTEM
2.3.2 BUILDING MANAGEMENT SYSTEMS
2.3.3 PUBLIC ADDRESS SYSTEMS
2.3.4 TELECOMMUNICATION & DATA SYSTEM
2.3.5 WIRELESS LAN
OPERATION AND
MAINTENANCE MANUAL
AIRPORT STAFF ACCESS
CONTROL FACILITY
PACKAGE - 6201
O&MMANUALS- ELEVATORS.
AIRPORT STAFF ACCESS CONTROL FACILITY-6201

NDA-6201-ASACF-AWA-OMM/CV-023 REV-0 VOL. 1.2.12, Page 1 OF 57

AIRPORT STAFF ACCESS CONTROL
FACILITY

OPERATION & MAINTENANCE MANUAL
For
ESCALATORS & AUTOWALKS
NDA-6201-ASACF-AWA-OMM/CV-023 Rev.00

VoIume 1.2.12 Book 1
Issued: 01 Feb. 2014
MAIN CONTRACTOR:

DESIGN CONSULTANT: PROJECT MANAGER:

O&MMANUALS- ELEVATORS.

NDIA-6201-ASACF-AWA-OMM/CIV-023, REV-0 VOL. 1.2.12, Page 2 OF 57

INDEX:
Sr. Item Description Page No.

A. How to use the manual..3 - 6

1 System Description....7- 13

2 Equipment Schedule.14-16

3 Field Operation Structure....17-18

4 Safety19-25

5 Operation Manual..26-27

6 Maintenance Manual.28-29

7 Disposal Instruction.30-31

8 Trouble shooting...32-39

9 Manufacturer contact details.40-41

10 Guaranties & Warranties.42-43

11 Emergency Information...44-45

12 As Built Drawing46-48

13 Manufacturer literature49-50

14 Testing & commissioning.51- 57

Appendix:-

A Operation manual of Escalator & Auto walk

B Maintenance Manual of Escalator & Auto walk

C Wiring Diagram

O&M MANUALS- ELEVATORS.

NDA-6201-ASACF-AWA-OMM/CV-023 REV-0 VOL. 1.2.12, Page 3 OF 57

I. HOW TO USE THE MANUAL

NDA-6201-ASACF-AWA-OMM/CV-023, REV-0 VOL. 1.2.12, Page 4 OF 57

I. HOW TO USE THE MANUAL

I.i THE SECTIONS

The operating and maintenance manual for Uninterruptabl e Power Supply Sy stem consists of
fourteen sectional divisions which are described below.

Each section number can be easily identified by the corresponding numbered 'tab' divider at the
beginning of each section.

Section A - How to use the ManuaI

This manual is organized to intervals at which maintenance on your engine is to be performed. A
maintenance schedule that states the required intervals and maintenance checks is located in
Maintenance Procedures (Section 6). Locate the interval at w hich you are performing
maintenance then follow the steps given in that section for all the procedures to be performed.

Keep a record of all the checks and inspections made. A maintenance record form i s located in
Maintenance Procedures (Section 6).

Section 1 - System Description

This section provides a general overview of the original design intent and a detailed description of
the installation including types of equipment installed. Location of each system and the area it
serves. The level of detail includes design parameters and data and the expected service life of
the various components.

Section 2 - Equipment ScheduIe

This section contains schedules of the following:

a) Type of system
b) Name of Manufacturer
c) Equipment model number of each component

Section 3 - Parts Identification and Spares

This section provides a guide to the Parts identification listing including recommendations for both
spares and running spares for the first year and second year period.

Section 4 - Safety

This section provides a d escription of the spe cific system safet y instruction and rescuing the
trapped passengers from the elevator incase of emergency.



Section 5 - Operation

This section contains information on the operation of systems in a safe and efficient condition in
both normal and emergency circumstances

Section 6 - Maintenance

This section provides manufacturer's recommendations and instructions for all corre ctive and
routine maintenance procedures relating to each item of th e generator. For preve ntive
maintenance and cleaning task, the instructions are in the form of a schedule

Section7 -DisposaI Instructions

This section contains comprehensive details of the methods to be employed for the safe disposal
of all equipment, materials and consumable items, e.g. oils, grease etc.

Section 8 - TroubIeshooting

This section provides information on problems that may arise during the operation of the elevator
and information on the system checks that should be completed to establish the fault.

Section 9 - Manufacturers

This section includes details of the equ ipment, the manufacturer's name, address and contact
details.

Section 10 - Guarantees and Warranties

This section includes copy of warranty.

Section 11 - Emergency Information

This section contains names, addresses, telephone and fax numbers of appropriate contacts for
assistance in the event of fire, theft or burglary and gas leaks, electricity failure or water leaks.

Section 12 - As BuiIt Drawing Index

This section includes AS BULT drawings list.

Section 13 - Manufacturer's Literature

This section contains an alphabetical index of all manufa cturers and equipment suppliers
associated with the installation. The literature provides the following:
Description of the product as purchased
Drawings and diagrams required for maintenance
Maintenance Specifications
Precautions against improper use and maintenance
Sources of required maintenance materials and related services
System Flow Diagrams
Engineering Data and Test



Section 14 - Commissioning Data

This section contains testing and commissioning template.



1. SYSTEM DESCRIPTION


1. SYSTEM DESCRIPTION

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o on nl ly y a a f fr ra ac ct ti io on n o of f t th he e o oi il l u us se ed d b by y c co om mp pe et ti it to or rs s u un ni it ts s a an nd d c co on ns su um me e s su ub bs st ta an nt ti ia al ll ly y l le es ss s e en ne er rg gy y. .
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d di ia ag gn no os se e p po ot te en nt ti ia al l p pr ro ob bl le em ms s a an nd d e en na ab bl le e o ou ur r h hi ig gh hl ly y t tr ra ai in ne ed d s se er rv vi ic ce e s sp pe ec ci ia al li is st ts s t to o e el li im mi in na at te e
p pr ro ob bl le em ms s b be ef fo or re e t th he ey y m ma at te er ri ia al li is se e. . T Th he e s so op ph hi is st ti ic ca at te ed d m mi ic cr ro op pr ro oc ce es ss so or r b ba as se ed d c co on nt tr ro ol ll le er r c co on ns st ta an nt tl ly y
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u ut ti il li is sa at ti io on n o of f t th he e e eq qu ui ip pm me en nt t a an nd d h hi ig gh h l le ev ve el ls s o of f p pe er rf fo or rm ma an nc ce e
O Op pt ti io on na al l s st ta an nd d- -b by y o op pe er ra at ti io on n a ad dj ju us st ts s s sp pe ee ed d b ba as se ed d o on n u us sa ag ge e, , r re ed du uc ci in ng g e en ne er rg gy y c co on ns su um mp pt ti io on n b by y u up p t to o
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o ou ut tp pu ut t t to o p pa as ss se en ng ge er r d de em ma an nd d. .
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s so ou un nd d d de es si ig gn n. . L Le ea ad di in ng g e ed dg ge e s st ty yl le e a an nd d s sa af fe e, , r re el li ia ab bl le e p pe er rf fo or rm ma an nc ce e a al ll l b ba ac ck ke ed d b by y t th he e e ex xp pe er ri ie en nc ce e
o of f a a w wo or rl ld d l le ea ad de er r i in n v ve er rt ti ic ca al l t tr ra an ns sp po or rt ta at ti io on n. .













2. EQUIPMENT SCHEDULE


2. EQUIPMENT SCHEDULE

2.1 EQUIPMENT INFORMATION

The Elevators installed for the Staff access control facility in New Doha nternational Airport is KONE
EscaIators (table 2-1) & Auto waIks (table 2-2)

Sl.
No.

KONE lift type

KONE Escalator
1

CIient Lift Code and
Use

ESC 1- ESC 4
EscaIators Numbers E1 ~ E4
1 EscaIators Arrangement Single
2 Capacity 9000 Persons / Hour
3 Quantity 4 units
4 Speed 0.5 Mps
5 Step Width 1000 mm
7 AngIe of IncIination 35 degree
8 Rise for EscaIator 5.15 Mts
9 Operation System UP/DOWN Travel Arrangements
10 Operation Mode Automatic / Stand By speed with photo cells
11 Interior PaneI
Vertical, flat, tempered safety glass panel -
clear glass, 10 mm thick
12 Height of BaIustrade 1000 mm
13 Decking ProfiIes Hairline stainless steel
14 Skirting Stain less steel w clear anti
15 Moving HandraiI Black
16 Soffit CIadding Hairline finish stainless steel
17 Side CIadding Hairline finish stainless steel on Both Side
18 Landing PIate Stainless Steel with anti slip pattern
19 Steps
One piece diecast Black Aluminium Step, with
yellow painted demarcation
20 Comb Segment MateriaI Aluminium


Table 2-1,Escalator Equipment Schedule

For further details, refer to the detailed packing list in Appendix D.

Sl.
No.

KONE lift type

KONE Autowalk
1

CIient Lift Code and
Use

AW1 -AWB
1 AutowaIk arrangement Parallel
2 Capacity 9000 Persons / Hour
3 Quantity 8 units
4 Speed 0.65 Mps
5 Step Width 1400 mm
6 AngIe of IncIination 0 degree
7 Height BaIustratd 1000 mm
8 Skirt brush defIector With silver aluminium holder
9 Moving HandraiI Black
10 PaIIet Natural Aluminum
11 Steps Natural Aluminium

Table 2-2 Auto walk Equipment
Schedule



3. FIELD OPERATION STRUCTURE



ELEVATORS ESCALATORS

KONE ELEVATORS (LLC)

'FIELD OPERATIONS STRUCTURE'

MaiIing Address in Qatar : KONE ELEVATOR L.L.C.
P.O. Box 37143,
Doha, Qatar.
TeI. No. 44552150
Fax No. 44552403

MaiIing Address of SuppIier : KONE EscaIators SuppIy Line
KrefeId Gmbh
Sterkenhofweg 27
47807 KREFELD
Germany

Managing Director : Mr. AIchaI NicoIas

FieId Operation Manager : Mr. IIIman Kari

InstaIIation Manager : Mr. RadhaKrishnan

Maintenance Manager : Mr. Jaffer. C.T

Emergency caII out No. : 800 5663 (ToII free number)



4. SAFETY



4.1 EscaIator safety

Escalator safety is very important. t is the Owner's responsibility to actively enforce safe
behavior around escalators, enforce posted safety signs and make sure official periodic
safety inspections and tests are performed annually. Additionally, a daily check of escalator
equipment is required in the daily start-up and shut-down of escalators.

Safe behaviour around escaIators

Escalator emergencies can be prevented by actively enforcing posted safety precautions.
Maintain passenger safety around your escalator(s) by making sure every passenger follows
posted Safety Rules and Cautions. n addition, watch for the following and actively try to
prevent their occurrence.

Do not allow unattended children to play around or on the escalator.
Do not allow pushchairs (baby strollers), wheelchairs or people using crutches on an
escalator. Recommend they ride the nearest elevator.
Do not allow passengers to ride the escalator when carrying too many packages or
luggage. Recommend they ride the nearest elevator.
Do not allow anyone to ride on the handrail or transport heavy items on the handrail.
Do not allow anyone to pull the handrail up from the handrail guide or drag the handrail on
the handrail guide.
Do not allow anyone to walk up the down or down the up escalator.
Do not allow anyone to run up or down the escalator.
Do not allow anyone to play with emergency stop buttons.
Do not allow shoes to be run along the skirts when the escalator is moving.
Do not allow anyone with bare feet to ride on the escalator.
Encourage people to pick up their feet and step carefully on and off the escalator and to
avoid dragging or sliding their feet off the edge of the escalator.
Encourage people to stand upright when riding an escalator. Do not allow anyone to sit,
kneel, ride with their hands on a moving step or lean on the side of the escalator.
Encourage people to keep hands, feet, clothing and shoe laces clear of the escalator
skirts.
Encourage people to exit promptly from the escalator landing. When someone stops on
the landing, they can cause a dangerous pile-up of the people behind them.
Heavy or bulky goods must not be transported on the escalator.

8-000418 (2012-06)

4.2 Safety signs

Your unit should be equipped with Safety signs (1). f at any time these signs are missing or
damaged, have them replaced as soon as possible.

8-000419 (2007-06)


1

5001943(2009-09)

4.3 Periodic inspections and tests

Make sure official periodic safety inspections and tests are performed annually. t is
recommended that all escalator work be done by qualified escalator personnel with an
elevator/escalator service company through a comprehensive maintenance program.

Periodic inspections and tests, for escalators, are done in addition to regular preventive
maintenance. Periodic inspections and tests are done annually, and are normally witnessed
by the local authority's authorized nspector.

The nspector responsible for inspecting the escalator equipment, may request certain tests
be performed by a qualified Service Technician.

NOTE! For specific information on periodic inspections and tests, refer to the most recent
version of ASME/ANS A17.1 Safety Code for Elevators and Escalators; or call your
local elevator/escalator nspection authority.
NOTE! Standards set by the ASME/ANS A17.1 and A17.3 Safety Code are considered
minimum requirements. Local codes may have additional standards for periodic
inspections and tests. Check with the local governing authority for complete details of
nspections and Tests required in your area.

707-084 (2003-11)


4.2 TRAVELMASTER 110 OVERVIEW

4.2.1 Description of main components

Truss (1) main supporting structure of the escalator.

Tracks (2) the main guide and support system of the step band in its journey around the
escalator truss. There are three main areas of the tracking system. They are the upper end
track, lower end track and inclined track.

Drive station machinery composed of the drive motor (3), gear box (4), brake (5), handrail
drive wheels (6) and step chain sprockets (7) that drive the step band and handrails.

Step band and handraiIs rotating components used to convey passengers on the
escalator. The step band consists of steps (8) and step chain (9) mechanically linked together
and driven by the drive through step chain sprockets. The handrail (10) travels in sync with
the step band and provides a handhold for passengers as they are conveyed by the
escalator. The handrail travels around the balustrade and is driven by handrail drive wheels.

Lower reversing station (11) turnaround area at the lower end for the step band. Step
chain tension is provided by compression springs acting on the return station.

BaIustrade area above the step band consisting of balustrade panels (12), decks (13),
newel ends (14) and skirts (15).

Access cover (16) removable floor plates covering the upper and lower end pits that allow
access to the upper end and lower end equipment. Access covers provide the transition from
the surrounding floor area at each landing.

CombpIates (17) plates at both landings where passengers enter and exit the step band.
The combplates contain removable comb segments (18) that mesh with the rotating steps.

FrontpIates (19) attached to the access cover and newel end and containing the handrail
inlet where the handrail enters into and exits from the interior of the escalator.

ControI cabinet (20) the central point for the electrical system. The control cabinet
contains electrical components that control and monitor the unit's operation. The control
cabinet is normally located in the upper end pit, but may also be located externally, either due
to customer requirements or the size of the electrical inverter at higher vertical rises.

EIectricaI safety devices (not shown) various electrical safety devices are connected in
series to safety relays in the control cabinet. Activation of any one of the electrical safety
devices will trigger the safety relays and shut down the unit.

Lighting systems (not shown) optional electrical components, which are used to provide
light at various points of the escalator. Available lighting systems include under step
demarcation, skirt, handrail and comb lighting.

7-002454 (2012-02)


18
17

15

20

8

7
1

3
6

5
4

13
2

10

5

12
9

3
14

16

4

17
11
19

5024986(2012-04)


4.2.2 Location of safety devices

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

Combplate impact devices (1)
Handrail inlet switches (2)
Out-of-level step switches (3)
Broken step-chain switches (4)
Encoder (5)
Motor thermal protection (6)
Main supply isolator (7)
Emergency stop switches (8)
Pit stop switches (9)
Key start switch (10)
Handrail speed sensor (11)
Step band lock (12)
Missing step detector (13)
Broken drive chain device (14)
Skirt switches (15)
Step upthrust switch (16)

Optional safety devices

Access cover safety switches (17)
Brake wear monitor (18)
Water level switch (19)

7-002456 (2012-06)




5. OPERATION


NDA-6201-ASACF-AWA-OMM/CV-022, REV-0 VOL. 1.2.12, BOOK 27 OF 57

5.1 Operation manuaI for EscaIator and AutowaIk

Refer to Appendix: 1


NDA-6201-ASACF-AWA-OMM/CV-022, REV-0 VOL. 1.2.12, BOOK 28 OF 57

6. MAINTENANCE



6.1 Maintenance Instruction of EscaIator and AutowIak
Refer the Appendix: B



7. DISPOSAL INSTRUCTION



7. DISPOSAL INSTRUCTION

No waste management involved in this activity except empty cases and carton boxes to be collected
and dispose them to the location specified by the main contractor.



8. TROUBLESHOOTING



8. TROUBLESHOOTING

8.1 Fault Code Details

Description of Event/FauIt Codes
Code No. Description Reset Type *Times of Generation
**00 Power Up Mode Non-manual When Power Loss
Mode is entered
01 Upper Comb mpact Switches Manual 1 & 2
**02 Upper E-Stop Switch Non-Manual 1 & 2
03 Upper Left Handrail nlet Switch Manual 1 & 2
04 Upper Right Handrail nlet Switch Manual 1 & 2
05 Upper Level Step Switches Manual 1 & 2
06 Upper Left Skirt Switch Non-Manual 1 & 2
07 Upper Right Skirt Switch Non-Manual 1 & 2
08 S145 Chain Breakage Monitor Manual 1 & 2
**09 Upper Pit Switch Non-Manual 1 & 2
10 Upper Left Vertical Comb mpact Switch Manual 1 & 2
11 Upper Right Vertical Comb mpact Switch Manual 1 & 2
12 Upper Left ncline Skirt Switch Non-Manual 1 & 2
13 Upper Right ncline Skirt Switch Non-Manual 1 & 2
14 Seismic Switch Non-Manual 1 & 2
15 Upper Access Cover Switch Non-Manual 1 & 2
16 Step Band Lock Switch Non-Manual 1 & 2
17 Lower Comb mpact Switches Manual 1 & 2
**18 Lower E-Stop Switch Non-Manual 1 & 2
19 Lower Left Handrail nlet Switch Manual 1 & 2
20 Lower Right Handrail nlet Switch Manual 1 & 2
21 Lower Level Step Switches Manual 1 & 2
22 Lower Left Skirt Switch Non-Manual 1 & 2
23 Lower Right Skirt Switch Non-Manual 1 & 2
24 Lower Upthrust Switches Non-Manual 1 & 2
**25 Lower Pit Switch Non-Manual 1 & 2
26 Lower Chain Tension Switches Manual 1 & 2


27 Lower Left Vertical Comb mpact Switch Manual 1 & 2
28 Lower Right Vertical Comb mpact Switch Manual 1 & 2
29 Water Level Switch Non-Manual 1 & 2
30 Frequency Drive Switch Non-Manual 1 & 2
31 Lower Access Cover Switch Non-Manual 1 & 2
32 Handrail Drive Switch Non-Manual 1 & 2
NOTE! *Generation Time Notes:
NOTE! 1 = Whenever fault or event causes the Stop Mode to be entered.
NOTE! 2 = Whenever fault prevents Ready Mode from being entered.
NOTE! ** = recorded in Event Log
7T-000064 (2012-06)


33 Lower Missing Step Detector
[Lower Missing Pallet Detector]
Manual 1 & 2
34 Upper Missing Step Detector
[Upper Missing Pallet Detector]
Manual 1 & 2
35 Left Handrail Speed Sensor Manual 1 & 2 Alarm is turned on
immediately and escalator shuts
down if deviation continues for 6
seconds. f deviation is corrected
alarm is turned off.)
36 Right Handrail Speed Sensor Manual Same as 35.
37 5%> Left Handrail Speed <15% Deviation must exist for 10
seconds. No shut down.
38 5%>Right Handrail Speed <15% Deviation must exist for 10
seconds. No shut down.
39 No Safety String Voltage Manual 1 & 2
40 CPU Safety Relays Non-manual 1 & 2
41 115% > Overspeed <125% Manual 1
42 Underspeed Non-manual 1
43 Reverse Direction Manual 1 & 2
44 Speed Monitor Hardware or
Software Fault
Non-manual 1 & 2
45 Encoder Fault Non-manual 1 & 2
46 Motor #1 Temp Non-manual 1 & 2
47 PTC #1 Fault Non-manual 1 & 2
48 Motor #2 Temp Non-manual 1 & 2
49 PTC #2 Fault Non-manual 1 & 2
*Generation Time Notes:
1 = Whenever fault or event causes the Stop Mode to be entered.
2 = Whenever fault prevents Ready Mode from being entered.

7T-000044 (2012-06)


50 Missing Start Signal Non-manual 1 & 2
51 More Than One Start Signal Non-manual 2
52 K1 Not Released Non-manual 2
53 K1 De-energized Non-manual 1 & 2
58 Start Monitor Closed Non-manual 1 & 2
59 Start Monitor Open Non-manual 1 & 2
60 Speed Monitor DP Switches Do
Not Match
Non-manual 1 & 2
61 Overspeed > 125% Manual 1 & 2
62 Stop Distance >457 mm [18 in.] Manual 1 & 2
63 Security Gate Fault Non-manual 1 & 2
64 Brake #1 Wear Manual 1 & 2
65 Brake #2 Wear Manual 1 & 2
66 Brake #1 Under Current Non-manual 1 & 2
67 Brake #2 Under Current Non-manual 1 & 2
68 Brake #1 Over Current Non-manual 1 & 2
69 Brake #2 Over Current Non-manual 1 & 2
70 Brake #1 Communication Loss Non-manual 1 & 2
71 Brake #2 Communication Loss Non-manual 1 & 2
72 Brake #1 Hardware Fault Non-manual 1 & 2
73 Brake #2 Hardware Fault Non-manual 1 & 2
74 Brake #1 Backup Timer Fault Non-manual 1 & 2
75 Brake #2 Backup Timer Fault Non-manual 1 & 2
76 Brake #1 Encoder Fault Non-manual 1 & 2
77 Brake #2 Encoder Fault Non-manual 1 & 2
78 Controller Over Temperature Non-manual 1 & 2
79 Stop Distance Too Short Manual 1 & 2
80 No 24 VAC on Main Board
Terminal 30
Non-manual 1 & 2
81 Main Board Terminals 63 and 64
Fault
Non-manual 1 & 2

7T-000027 (2012-06)


**82 Construct Enabled

1 & 2
83 Motor Overload Fault Non-manual 1 & 2
84 Service Tool Stop Non-manual 1 & 2
85 Upper Safety Extension Board
Communication Fault
Non-manual 1 & 2
86 Lower Safety Extension Board
Communication Fault
Non-manual 1 & 2
87 Smoke Alarm Fault Non-manual 1 & 2 (Shut down only in ENTERNG
direction. Alarm sounds 15 seconds
before shut down occurs.)
88 Aux nput Fault Non-manual 1 & 2
89 Not Ready Mode When Not Ready Mode entered
90 Ready Mode When Ready Mode entered
91 Begin Start Mode When Begin Start Mode entered
92 nspect Start Mode When nspect Start Mode entered
93 Normal Start Mode (Up Direction) When Normal Start Mode Up entered
94 Normal Start Mode (Down
Direction)
When Normal Start Mode Down
entered
**95 Run Mode When Run Mode entered
96 Stop Mode When Stop Mode entered
97 EPROM Fault Non-manual Power Up and Stop Modes Start
disallowed until cleared.
98 EEPROM Fault Non-manual Power Up and Stop Modes Start
disallowed until cleared.
**99 Power Loss Mode When Power Loss Mode is entered

7T-000065 (2012-06)


Code
No.
Description Reset Type *Times of Generation
**100 nspect Enabled When main board terminal 39
loses 24VAC
**101 nspect Disabled When main board terminal 39
regains 24VAC
**102 Construct Disabled When Construct Mode is exited
**103 Sleep Mode Entered When 24vdc applied to EMB
terminal 36
**104 Sleep Mode Exited When 24vdc removed from EMB
terminal 36
105 (A5
on EMB
Display)
Not used Not
applicable
Not applicable
106 (A6
on EMB
Display
Reserved for Band Brake Lift
Switch on Motor #1.
Not used with PM Warner
Brake.
Reserved input: EMB/33
Reserved function: Brake not
following brake command.
Manual Reserved for Band Brake Lift
Switch on Motor #1.
Not used with PM Warner Brake.
107 (A7
on EMB
Display
Reserved for Band Brake Lift
Switch on Motor #2.
Not used with PM Warner
Brake.
Reserved input: EO/06
Reserved function: Brake not
following brake command.
Manual Reserved for Band Brake Lift
Switch on Motor #2.
Not used with PM Warner Brake.


7T-000058 (2012-04)


Code
No.
Description Reset Type *Times of Generation
108 (A8
on EMB
Display
Auxiliary Brake Monitor - U-
ESE/19
Used only with chain drive
and not GOSD.
Manual Fault will occur if:
Auxiliary brake is not
engaged when not running.
Auxiliary brake is not
disengaged when starting or
running.
NOTE! f the drive chain switch
is tripped, then the
auxiliary brake will
engage.
109 (A9
on EMB
Display
Light Beam Fault, Top
Not used with ANS version
of controller
Not
applicable
Not applicable
110 (AA
on EMB
Display
Light Beam Fault, Bottom
Not used with ANS version
of controller
Not
applicable
Not applicable

NOTE! 1 = Whenever fault or event causes the Stop Mode to be
entered. NOTE! 2 = Whenever fault prevents Ready Mode from being
entered.





9. MANUFACTURER'S CONTACT
DETAILS



9. MANUFACTURER'S CONTACT DETAILS

9.1 Manufacturer's Address

KONE Escalators Supply Line
Krefeld Gmbh
Sterkenhofweg 27
47807 KREFELD
Germany

9.2 LocaI Address

KONE ELEVATOR L.L.C.
P.O. Box 37143,
Doha, Qatar.
Tel. No. +974 44552150
Fax No. +974 44552403

E-mail : Qatar@kone.com
Contact person: Mr. Radha Krishnan nstallation Manager



10. GUARANTIES & WARRANTIES



10.1 Guaranties & Warranties



11. EMERGENCY INFORMATION



11. EMERGENCY INFORMATION
11.1 Contact detaiIs in case of emergency

Contact details in case of emergency

n Case of Contact Telephone
Breakdown Kone Elevators 00974 -44655260
Theft/Burglary Police 999
Fire Police 999
Accident Police 999
Power Failure Kahrama 991

11.2 Contact detaiIs of Kone EIevators

Mailing Address in Qatar : KONE ELEVATOR L.L.C.
P.O. Box 37143,
Doha, Qatar.
Tel. No. 44552150
Fax No. 44552403

Mnaging Director : Mr. Nicolas Elkhal
Field Operation Manager : Mr. llman Kari
nstallation Manager : Mr. Radha Krishnan
Maintenance Manager : Mr. Jaffer C T
Maintenance Engineer : Mr. Kulanthai Sami

Emergency call out No. : 8005663 (24Hrs Toll free)



12. AS BUILT DRAWINGS



12. AS BUILT DRAWINGS

12.1 Drawings Iist



SL
NO.
DESCRPTON DRAWNG NO.
SHEET
NO.
1
Layout for Escalator-1 Grid12-11-1
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-ES-0001
001
2
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-ES-0002
002
3
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-ES-0003
003
4
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-ES-0004
004
5
Layout for Escalator-3&4 Grid 31& B-C-1
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-ES-0005
005
6
Layout for Escalator-3&4 Grid 31& B-C-2
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-ES-0006
006
7
Moving walk-AW1 & AW2 Grid between 5
& 10
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-MW-0001
007
8
Moving walk-AW1 & AW2 Grid between 5
& 10
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-MW-0002
008
9
Moving walk-AW3 & AW4 Grid between
11 & 16
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-MW-0003
009
10
11 & 16
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-MW-0004
010
11
17 & 22
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-MW-0005
011
12
17 & 22
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-MW-0006
012
13
23 & 28
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-MW-0007
013
14
23 & 28
NDA-6201-ASACF-AWA-
AB-P1210-X-AR-MW-0008
014


13. MANUFACTURERS LITERATURE



13. MANUFACTURER LITERATURE

13.1 Wiring diagram

Refer to appendix-C



14. TESTING AND COMMISSIONING

COMMISSIONING CHECK LIST FOR FUNCTIONAL TESTING
SYSTEM NO.: SUB-SYSTEM NO.: FM NO:
BUILDING NO.: DESCRIPTION: TAG NO:
DATE: REF DOC/DRWS: Pageno:1of6
Doc. No. NDIA-6201-ASACF-AWA-OMM/CIV-023 REV. No. 0
Page # 52 of 57
GENERAL INFORMATION of4
Customer: SAPNO:
SSiteAddress SiteContactperson
Name:
TelNo:
MobileNo:
FaxNo:
e-mail:
TECHNICALDATA
SAP NO:
Vertical Rise: m
Step width : mm
Inclinaison:
Level steps at
upper end:
Level steps at
lowr end:
Rated speed: m/s
Supply Voltage: V
EQUIPMENT TESTS ( SUMMARY)
In Order Comments
Bottom Pit ______________________________________
______________________________________
Inside Truss ______________________________________
______________________________________
Top Pit _______________________________________
Visual Features ___________________________________
Other Comments
Tested By:
Name:
Signature:
Date:
WITNESSED BY:
Name:
Signature:
Date:

Page # 53 of 57
EQUIPMENT TEST (continued)
Bottom Pit & Safety Device (continued) YES NO YES NO N/A Remark
EQUIPMENT TEST
YES NO YES NO N/A Remark
Pre- Installation
Arethesplittrussesundamaged?
Arethestandardmountingboltsused?
Isthestepchainpininsertedtowardsoutsideofescalator?
Isthetemporaryprotectionprovidedatsite
In order Adjusted/ Repaired
Bottom Pit YES NO YES NO
N/A Remark
Electrical Operation
Istheelectricalplugoperatingcorrectly?
Isthetrafficlightoperatingcorrectly?
Isthecombplateimpactdeviceoperatingcorrectly?
Isthecomblightoperatingcorrectly?
Isthebuzzeronstopswitchoperatingcorrectly?
Isthelugforhandheldpendantoperatingcorrectly?
Isthestepguardcorrectlyadjusted?
Safety Device
Arethehandrailinletsafetyswitchesoperatingcorrectly?
Istheemergencystopoperatingcorrectly

Page # 54 of 57
Accesscoverswitchcorrectlyinstalledandadjusted?
Isthekeystartswitchoperatingcorrectly?
IsIsthestepchaintensiondeviceoperatingcorrectly?
Inside Truss
Arethestepsagdevicesdetectoroperatingcorrectly?(Topand
bottom)
Istheguidancesystemsetcorrectlyandclean?
Isthehandrailguidanceandtensionsystemsetcorrectly?
DriveStation
Istheemergencyswitchoperatingcorrectly?
Isgearboxoillevelcorrect?
Brake
Arethegapsbetweensteps/skirtscorrect(4mmononeside
and7mmcombined)?
Arethegapsbetweensteps/combscorrect(maxi4mm)?
Arethecombsundamaged?
EQUIPMENT TEST (continued)
TOP PIT InorderAdjusted/Repaired
YES NO YES NO N/A
Remark
Electrical Cabinet

Page # 55 of 57
Istheelectricaldrawinginsidetheelectricalcabinet?
Isthe501correctlyparameted?
Istheelectricalcabinetoperatingcorrectly?
Electrical Operation
Istheelectricalplugoperatingcorrectly?
Arethecomblightsoperatingcorrectly?
IstheDiagnosticDisplayoperatingcorrectly?
Isthestopswitchoperatingcorrectly?
Isthemainswitchoperatingcorrectly?
Istheplugforhandheldpendantoperatingcorrectly?

Safety Device
Arethehandrailinletsafetyswitchesoperatingcorrectly?
Isthehandrailpressurerollerwelladjusted?
Isthestepguardcorrectlyadjusted?
Isthecombplateimpactdeviceoperatingcorrectly?
Isthestepbandlockoperatingcorrectly?

Visual Features
YES NO YES NO N/A Remark
Balustrade
Aregapsbetweenbalustradepanelsnobiggerthan4mm?
Arejointsofbalustradeprofilescorrect?
Areallpanelswithoutdefect?

Page # 56 of 57
Handrail
Are all handrail inlets and brush plates adjusted centrally to the
handrail?
Are handrails in newels are correctly guide without abrasion?
Step Band
Are all steps undamaged?
Are all steps screws secured?
Are the gaps between steps / skirts correct (4mm on one side
and 7mm combined)?
Are the gaps between steps/ combs correct (maxi 4 mm)?
Are the combs undamaged?
Claddings
Are outside deckings correctly adjusted and joined?
Are soffit claddings undamaged?
Are the side claddings correctly adjusted and joined?
Deck guards correctly installed?

DATE: REF DOC/DRWS: Page no: 1 of 6
Page # 57 of 57
S No Equipment name Model Number Equipment Serial
Number
Type Calibration Due date

Acceptance / Representative KONE AMANA Witnessed by KEO
Name
Signature
Date
Appendix: A
OPERATION MANUAL OF
ESCALATOR & AUTOWALK
KONE Escalators and Autowalks
Operating Instructions
2012 KONE Corporation
AII rights reserved. 1 (23)
Escalators and autowalks Owner's Guide UM-51.01.008 2012 KONE Corporation All rights reserved (E) 2012-03-30 KONE Corporation Version 2.0
KONE ESCALATORS AND AUTOWALKS
um5100002b
Authorization Notice
This publication is for informational purposes to support the operator how and when an
escalator or autowalk / ramp should be checked to provide for the maximum safety of end
users.

IIIustration Notice
The illustration in this manual is generic and may differ in some cases from the material used
for the actual system.

DISCLAIMER OF WARRANTIES AND LIABILITIES
KONE reserves the right at any time to alter the product design, specifications and
procedures reflected in this document. NO STATEMENT CONTAINED IN THIS DOCUMENT
SHALL BE CONSTRUED AS A WARRANTY OR CONDITION, EXPRESS OR IMPLIED AS
TO ANY PRODUCT, SPECIFICATION OR PROCEDURE, ITS MERCHANTABILITY OR
FITNESS FOR ANY PARTICULAR PURPOSE OR QUALITY, OR AS A MODIFICATION OR
REPRESENTATION OF THE TERMS OF ANY PURCHASE AGREEMENT.

KONE DISCLAIMS ANY LIABILITY RESULTING FROM OR IN CONNECTION WITH THE
USE OR DISCLOSURE OF INFORMATION IN THIS DOCUMENT. KONE HAS NO
LIABILITY FOR TYPOGRAPHICAL OR OTHER ERRORS OR OMISSIONS CONTAINED IN
THIS DOCUMENT OR ANYONE'S INTERPRETATION OF THE INSTRUCTIONS. THE
USER OF THIS DOCUMENT ASSUMES ALL RISKS ASSOCIATED WITH THE USE OR
DISCLOSURE OF THIS DOCUMENT.

Trademark Notice
KONE, MonoSpace, MiniSpace, EcoDisc, TranSys, Alta, KoneXion, KONE TravelMaster,
KONE TransitMaster and all other product names are trademarks or registered trademarks of
KONE Corporation in various countries.
Copyright Notice
Copyright 2012 KONE Corporation
All rights reserved. No part of the contents of this document may be copied, reproduced or
transmitted in any form or by any means, or translated into another language or format, in
whole or part, without prior written permission of KONE Corporation.
TABLE OF CONTENTS
1 INSTRUCTIONS FOR THE OPERATOR................................................................... 4
1.1 Organizational measures .............................................................................................. 4
1.2 Personnel ...................................................................................................................... 5
1.3 Regular inspection and maintenance............................................................................ 5
2 MAIN COMPONENTS................................................................................................ 6
3 SAFETY INSTRUCTIONS FOR ESCALATORS AND AUTOWALKS........................ 8
3.1 Safe behavior in the vicinity of and on escalators or autowalks .................................... 8
4 SAFETY NOTICES (PICTOGRAMS) ......................................................................... 9
5 FREE AREA FOR END USERS - EN 115................................................................ 11
6 REGULAR INSPECTION AND TESTING................................................................ 12
7 CLEANING............................................................................................................... 13
7.1 Stainless steel surfaces............................................................................................... 13
7.2 Push-buttons and switches ......................................................................................... 13
7.3 Handrail surfaces ........................................................................................................ 13
8 CHAIN LUBRICATION BY HAND (STANDARD) ..................................................... 13
9 INFORMATION DISPLAY 501 (OPTIONAL)............................................................ 14
10 SWITCHING ON (OPERATING MODE VARIANTS) ............................................... 15
10.1 Prior to switching on.................................................................................................... 15
10.2 Switching on Smart star-delta (standard) .................................................................... 16
10.3 Switching on Stand-by speed with inverter (optional).................................................. 17
10.4 Switching on Automatic start / stop (optional) ............................................................. 18
10.5 Switching on Automatic start and Stand-by (optional) ................................................. 19
11 SWITCHING OFF .................................................................................................... 19
11.1 Operational stop.......................................................................................................... 19
11.2 Emergency stop .......................................................................................................... 19
12 SWITCHING OFF THE MAIN POWER SUPPLY..................................................... 20
12.1 Recovering the auxiliary brake.................................................................................... 20
13 SAFETY CHECK PRIOR TO RESTARTING THE ESCALATOR OR AUTOWALK. 21
14 VERSION HISTORY................................................................................................. 22
15 FEEDBACK.............................................................................................................. 23
1 INSTRUCTIONS FOR THE OPERATOR
Congratulations on purchasing your KONE escalator or autowalk. The escalator or autowalk
installation is manufactured in conformity with the latest findings and will provide a long
service life at low operating costs.
The following instructions inform you of your responsibilities, as an operator, for the operation
of this unit.
Read the introductory instructions before you pass the operating instructions onto your
operating personnel.
All operating modes available for escalators and autowalks are described in these operating
instructions. Which operating mode is used is dependent on the specific configuration of your
unit. For more information on all operating modes, see section 10 Switching on (operating
mode variants).
Upon handover of the installation, the responsible KONE employee explains for you in detail
the relevant operating mode for your unit. This can enable you to refer specifically to the
relevant information at any time and to quickly be able to cope with your unit.
1.1 OrganizationaI measures
The operating instructions for your unit cannot take into account of the conditions valid at the
installation site. Therefore, supplement the operating instructions with:
Directions relating to existing national regulations for accident prevention and protection,
Directions concerning responsibilities, supervisory duties and reporting duties, for
example, for the personnel deployed.
Directions concerning action in emergency situations, for example, notification of location
and instructions for use of fire extinguishers.
In the event of any safety-related changes to the unit or the related operating behaviour, the
unit must be shut down immediately. No modifications to, or conversion of the unit are
allowed without the permission of KONE.
Replacement parts must correspond to the technical requirements specified by the
manufacturer. Therefore, use only original KONE replacement and wearing parts.
Contact the KONE Customer Service for the performance of servicing and repair work.
1.2 PersonneI
Operating instructions are intended for escalator or autowalk operators who have been
instructed. Personnel who operate or clean the escalator or autowalk must first receive
training from the manufacturer.
Personnel receiving training or instruction may only perform operations on the escalator or
autowalk under the constant supervision of an experienced person.
The operating personnel must have the operating instructions available at all times. This
applies to all personnel operating the escalator or autowalk including part-time operators.
Personnel with long hair must wear head covering. Loose clothing or jewellery, including
rings, must not be worn. There is an injury hazard of being caught up in or pulled into the
machinery.
1.3 ReguIar inspection and maintenance
The operator must inspect the condition of each escalator or autowalk several times daily and
before each start-up, if the escalator or autowalk is in operation. The inspection includes a
visual and functional check and is described in section 10.1 Prior to switching on.
According to current statutory regulations, the condition of escalators or autowalks must be
additionally checked at least once every 3 months and after each repair by a KONE
professional fitter.
Allow the KONE Customer Service to perform this legally prescribed work according to the
time schedule.
2 MAIN COMPONENTS
The KONE escalator or autowalk consists of the following main components:
Truss (1) the support system of the escalator or autowalk.
Step band (2) and handraiIs (3) moving components for conveyance of users on the
escalator or autowalk. The handrails (3) run synchronously with the step band (2) and provide
the users with a good hold as they are conveyed by the escalator or autowalk.
BaIustrades (4) area above the step band (2) consisting of skirts (5), glass panels (6),
balustrade heads (7), inner decks (8), and outer decks (9).
Access cover (10) removable covers for the upper and lower maintenance areas. These
enable access to the components installed in the upper and lower areas and provide a
transition to the floor of the building structure.
CombpIate (11) plates at the upper and lower escalator or autowalk accesses. Combplates
contain removable comb segments (12) that engage into the grooved profile of the steps.
FrontpIates (13) form the ends of the inner and outer decks and of the balustrade skirts at
the lower and upper escalator or autowalk accesses.
ControI and diagnostic unit (not iIIus trated) the central unit of the electrical system. It
contains all the electronic components required for monitoring and diagnostics, and for the
control unit.
Guides (not iIIustrated) the main guide and support system for the step band on its way
through the truss. There are three areas of the guide system: the guides at the top end, the
guides at the bottom end and the guides in the incline section.
Drive station (not iIIustrated) consisting of drive motor, gear box, operational brake,
handrail drive wheels and step chain sprockets by means of which the step band and
handrails are driven.
Lighting system (not iIIustrated) optional electrical components for illumination of the
escalator or autowalk in various positions. The lighting system can comprise the balustrade
lighting, comb bearing plate lighting, and step gap lighting.
EIectricaI safety devices (not shown) various electrical safety devices (safety limit
switches, speed monitoring device) are connected to the control unit in the form of a safety
chain for the purpose of monitoring. The escalator or autowalk is switched off upon activation
of one of these safety devices.
NOTE! The illustrations in your operating instructions may deviate from the design of your
escalator or autowalk.
NOTE! The side specification (left or right) always refers to an escalator viewed from the
lower end towards the upper end, or an autowalk viewed from the return end towards
the drive end.
um5100002d
3
8
2
4, 6
5
7
13
1
6
7
12
11
um5100002c
9
10
3 SAFETY INSTRUCTIONS FOR ESCALATORS AND AUTOWALKS
Compliance with safety regulations is of the greatest importance with escalators and
autowalks. It is the responsibility of the operator to actively work towards achieving the safe
behaviour of end users, to draw attention to the attached safety notices and to make
provision for regular (quarterly) servicing and inspections. In addition, daily checking of the
escalator or autowalk is required before switching on and off.
3.1 Safe behavior in the vicinity of and on escaIators or autowaIks
Accidents on escalators or autowalks can be avoided by attaching clear safety notices.
Maintain the safety of end users in the vicinity of the unit by making sure that users always
comply with the safety notices and safety rules.
Make sure of the foIIowing:
Do not allow unattended children to play in the vicinity of or on the unit
Do not allow end users with prams or pushchairs, people in wheelchairs, or end users with
walking aids to use the unit. Ask them to use the elevator.
Do not allow end users with bulky or heavy luggage to enter the escalator. Ask them to
use the elevator.
Do not allow anyone to ride on the handrail, or place heavy or bulky objects on the
handrail.
Do not allow anyone to pull on the handrail or pull it out of the handrail guide.
Do not allow anyone to use a downwards travelling unit in an upward direction or an
upwards travelling unit in a downward direction.
Do not allow anyone to run up or down the unit.
Do not allow anyone to press the Emergency Stop button, except in an emergency.
Do not allow end users to use the unit barefooted.
Encourage end users to lift their feet when they enter or leave the unit.
Encourage end users to stand in the middle of the step and not to drag their shoes along
the skirts.
Do not allow end users to sit, kneel, or support themselves with their hands on a step
during operation of the unit. Leaning over the balustrade while the unit is in operation is
not allowed.
Encourage end users to keep their hands, feet, clothing items, and shoelaces away from
the skirts. There is a danger of entrapment.
Encourage end users to promptly step onto and off of the unit when entering and exiting
so that no congestion occurs.
Do not allow heavy or bulky objects to be transported on the unit.
WARNING
Do not lean against the side of the handrail from the outside generally in the area of the
balustrade heads while the unit is in operation, otherwise there is a danger of falling.
It is the responsibility of the operator to make sure of this by way of structural measures
(for example: railings).
4 SAFETY NOTICES (PICTOGRAMS)
Your escalator or autowalk is equipped with safety notices (pictograms). If these safety
notices are missing or if they are damaged, they must be replaced immediately.
Pictograms in accordance with EN 115:1995 and GB 16899-1997
Pictograms in accordance with EN 115-1:2008+A1:2010 and GB 16899-2011
5 FREE AREA FOR END USERS - EN 115
In order that escalator or autowalk users can safely enter and leave the unit, there must be
free (clear) areas for unit exits and entries to handle end user congestion.
For all conversions always take into consideration the dimensions required by EN 115 and
GB 16899 for the end user.
EN 115:1995 and GB 16899-1997 state that:
the width of the free area must at least comply
with the distance between the handrail center
lines (A). The depth must be at least 2500 mm,
measured from the end of the balustrade.
A = Distance between the handrail center lines
The free area may be reduced to 2000 mm, if
the area is increased in width by at least twice
the distance between the handrail center lines
(B).
B = Twice the distance between the handrail
center lines
EN 115-1:2008 + A1:2010 and GB 16899-2011
state that:
The width of the free area must at least comply
with the distance between the outer edges of the
handrails plus 80 mm on each side (A). The
depth must be at least 2500 mm, measured from
the end of the balustrade.
A = Distance between the outer edges of the
handrails plus 80 mm on each side
The free area may be reduced to 2000 mm, if
the area is increased in width by at least twice
the distance between the outer edges of the
handrails plus 80 mm on each side (B).
B = Twice the distance between the outer edges
of the handrails plus 80 mm on each side
C = common crossing area for adjacent units
6 REGULAR INSPECTION AND TESTING
Make sure that regular safety inspections and tests are performed at least once per quarter
and after each repair. It is recommended that all work on the escalator or autowalk be
performed by KONE service personnel only.
The annual safety inspection and testing is usually monitored by a local inspector who is
authorized by the licensing authority.
The inspector responsible for checking the escalator or autowalk components can demand
the performance of additional tests by a skilled KONE erector.
NOTE! For more information on regular inspections and testing consult the latest version of
EN 115 or the local licensing authority.
NOTE! The safety standards required in EN 115 are the minimum requirements. Local
directives can make additional requirements of the regular inspections and tests.
Clarify with the responsible licensing authority which additional inspections and tests
are required in your region.
7 CLEANING
Clean escalator or autowalk parts as described in section 7.1 Stainless steel surfaces, section
7.2 Push-buttons and switches, and section 7.3 Handrail surfaces.
7.1 StainIess steeI surfaces
Clean stainless steel surfaces with mild soap and water. Then use a stainless steel cleaner to
clean and protect the surfaces.
7.2 Push-buttons and switches
Wipe push-buttons and switches with alcohol or water / soap-based cleaning agents.
7.3 HandraiI surfaces
Wipe down the handrails with a cloth moistened with a cleaning agent.
It is recommended that you use a special handrail cleaning agent or mild soap and warm
water. Then wipe the handrail with a dry cloth.
8 CHAIN LUBRICATION BY HAND (STANDARD)
Fill the oil into the cup (1L).
Open the regulating valve and drop oil into chains with proper flux. Ensure that the whole
chain length is lubricated.
This operation is recommended to do by KONE maintenance people.
CAUTION
If plastic parts (for example, made of polycarbonate) are treated with corrosive cleaning
agents (for example, with chlorinated hydrocarbon cleaners), the plastic parts can get
damaged.
Push-buttons and switches made of poly-carbonate plastic dissolve in chlorinated
hydrocarbon cleaners. Therefore use only approved cleaning agents.
CAUTION
To avoid waste, close the oiler valve immediately after lubrication.
9 INFORMATION DISPLAY 501 (OPTIONAL)
The information display indicates in plain text any faults that occur. The information display is
located in the inner deck on the upper left side of the escalator or autowalk. Should the step
band stop unexpectedly, the corresponding text for the fault is displayed.
In this case, try to restart the escalator or autowalk.
If this is not possible, inform KONE Customer Service. Quote the serial number of your unit.
This can be found on the type identification plate which fixed on the handrail front plate.
10 SWITCHING ON (OPERATING MODE VARIANTS)
The operating mode variants available for escalator or autowalk are described below.
10.1 Prior to switching on
In order to assess the operational safety of the escalator or autowalk, the operator must
check the condition of the escalator or autowalk several times daily and before each start-up.
The check consists of a visual and a functional check (for example: emergency stop push-
button, comb segments, and optional equipment such as step demarcation lights)
The visual check determines the presence of any externally recognizable deviations. For
example, the removal of components such as panelling or covers that can affect the safety of
personnel traffic is not allowed.
Check also whether skirts, inner and outer decks, frontplates, or combplates have loose
fastening elements or need cleaning. If necessary, have the fastening elements secured
and components cleaned by KONE customer service department before switching on.
During the functional check the escalator or autowalk must revolve several times. To do so it
must be switched on as described in section 10.2 to section 10.5. Observe the step band and
handrails in the process and make sure the unit runs fault free, particularly with respect to
damaged or missing steps.
After performance of the aforementioned tests the unit can be switched on as described in
section 10.2 to section 10.5.
10.2 Switching on Smart star-deIta (standard)
Each time before switching on the unit,
perform a visual and functional check in
accordance with section 10.1 Prior to
switching on.
1 To switch on, insert the key into the key-
operated switch (1).
The key-operated switch is located at
the lower right and upper left of the
inner side of the handrail entry.
2 Start the unit in the operational direction
you require by turning the key.
Key switch at lower right side: Turn
clockwise to run the unit downwards
and counter-clockwise to run the unit
upwards.
Key switch at upper left side (optional):
Turn clockwise to run the unit upwards
and counter-clockwise to run the unit
downwards.
The unit starts up immediately.
3 After actuation of the key, turn it immediately back to the middle position and pull it out of
the key-operated switch (1).
The direction can only be changed after actuation of stop switch (2).
Simultaneously with unit start-up the operational direction is indicated optically by traffic lights
(optional).
NOTE! After start-up, only allow the public to use the unit after ensuring that the step band
and handrails are running correctly. Observe at least two revolutions of the step
band. In particular, make sure there are no damaged or missing steps.
The transport of bulky or heavy goods is not permissible.
Free areas at the unit entry and exit points must be kept clear at all times.
Units must be adequately lit during operation.
DaiIy tests during the switch-on procedure
It is recommended that your representative keeps a record of the daily checks during the
switching-on procedure. These records should be saved for three years. Anything
conspicuous should be reported immediately to a qualified service technician.
CAUTION
Do not start / stop the unit if persons or objects are on the unit, otherwise there is a
danger of falling.
10.3 Switching on Stand-by speed with inverter (optionaI)
Each time before switching on the unit, perform a
visual and functional check in accordance with
section 10.1 Prior to switching on.
1 To switch on, insert the key into the key-operated
switch (1).
The key-operated switch is located at the lower
right and upper left of the inner side of the
handrail entry.
2 Pre-select the operational direction by turning the
key.
Key switch at lower right side: Turn clockwise to
pre-select down running direction and counter-
clockwise to pre-select up running direction.
Key switch at upper left side: Turn clockwise to
pre-select up running direction and counter-
clockwise to pre-select down running direction.
The unit starts immediately when the light barrier is interrupted.
Simultaneously to unit start-up the operational direction is indicated optically by traffic lights
(optional).
Initially the unit runs in stand-by mode (approximately 50% travel speed). If an end user walks
through the light barrier (3) in the area of the bottom or top unit entries, the step band speed
is increased to the full travel speed.
Upon expiration of the normal run-time (travel time plus after-run-time) the step band is
switched automatically back to stand-by mode for energy saving reasons.
NOTE! After start-up, only allow the public to use the unit after ensuring that the step band
and handrails are running correctly. Observe at least two revolutions of the step
band. In particular, make sure there are no damaged or missing steps.
The transport of bulky or heavy goods is not permissible.
Free areas at the unit entry and exit points must be kept clear at all times.
Units must be adequately lit during operation.
DaiIy tests during the switch-on procedure
It is recommended that your representative keeps a record of the daily checks during the
switching-on procedure. These records should be saved for three years. Anything
conspicuous should be reported immediately to a qualified service technician.
CAUTION
danger of falling.
10.4 Switching on Automatic start / stop (optionaI)
Each time before switching on the unit, perform a visual and functional check in accordance
with section 10.1 Prior to switching on.
Starting
1 To switch on, insert the key into the key-operated switch (1).
The key-operated switch is located at the lower right and upper left of the inner side of
the handrail entry.
2 Pre-select the operational direction by turning the key.
Key switch at lower right side: Turn clockwise to pre-select down running direction and
counter-clockwise to pre-select up running direction.
Key switch at upper left side: Turn clockwise to pre-select up running direction and
counter-clockwise to pre-select down running direction.
The unit starts immediately when the light barrier is interrupted.
Simultaneously to unit start-up the operational direction is indicated optically by traffic lights
(optional required by the code).
Setting
The unit in this operating mode is equipped with radar sensors. The radar sensors consist of
two parts: radar heads and radar amplifiers. Both the sensitivity and the sensing distance can
be adjusted on the radar amplifiers. If the adjustment is needed, call the KONE maintenance
personnel. For more information, see section 13 Safety check prior to restarting the escalator
or autowalk.
When the sensing distance is set, a detection area is set up in front of the unit entrance
accordingly. Once an end user walks into the area from any direction, he / she should be
detected by the radar sensors. The control system makes the unit start running.
The step band runs a prescribed length of time and stops until the sensors are detected again
by a passenger walking through the detection area.
Units with the radar sensors are preset to run only in one direction (either up or down). If an
end user tries to enter from the wrong direction, the unit starts to run for a defined time to
prevent the user from using the unit as a stairway.
10.5 Switching on Automatic start and Stand-by (optionaI)
Switching on automatic start and stand-by is a combined feature. In this mode the unit starts
as described in automatic start / stop mode. After expiration of the normal run-time, it
switches to stand-by mode (about half of normal speed). After a pre-determined time of 10
seconds (time is adjustable) during which there is no passenger, the unit comes to a complete
stop. The cycle repeats when the next end user passes the sensor. Traffic lights are standard
with this feature.
For more information on starting and setting, see section 10.4 Switching on Automatic start /
stop (optional).
11 SWITCHING OFF
11.1 OperationaI stop
Press stop button (1) to switch off the unit
(operational stop).
The stop button is located at the lower right
and upper left of the inner side of the
handrail entry.
The unit makes a controlled stop.
11.2 Emergency stop
If, while the unit is in operation an unforeseen
emergency situation occurs, the unit must be
switched off immediately.
Only in this emergency situation should the
stop button (1) be pressed, independently of
whether any persons or objects are on the
unit.
Stop buttons are located on the skirts at the
bottom right and top left of the inner side of the handrail entry.
The unit can be switched on again after a visual check.
CAUTION
danger of falling.
12 SWITCHING OFF THE MAIN POWER SUPPLY
If required, switch off the main power supply of the unit as follows:
1 Go to the main power switch. It is located in the upper maintenance chamber on the
control cabinet of your escalator or autowalk.
2 Turn the main power switch to OFF ("0") to disconnect the main power supply.
3 Lock the switch in the position OFF ("0") with a padlock.
12.1 Recovering the auxiIiary brake
An auxiliary brake is mandatory for vertical rises above 6 m, and optional for vertical rises not
greater than 6 m. When the main power of the unit is switched off, the auxiliary brake will be
activated. After the main power is switched on again and before the unit can operate
normally, firstly recover the auxiliary brake with the following method.
For upward operation:
Directly turn the key switch to let the unit operate upward for around 3 seconds. The auxiliary
brake block is pushed down when you hear a crash sound. After that, the unit enters the
normal operation mode.
For downward operation:
After performing the same operation as above, press the stop button to stop the escalator.
Turn the key switch to let the unit operate downward, and then the unit enters the normal
operation mode.
CAUTION
Always switch off the unit before opening the maintenance chamber, otherwise there is a
personal injury hazard.
CAUTION
Cordon off both unit entries by erecting personnel traffic barriers. Removal of the barrier is
not allowed until the maintenance chamber has been closed, otherwise there is a
personal injury hazard.
CAUTION
Before the auxiliary brake is recovered, the unit can not work if directly turning the key
switch to let the unit operate downward.
13 SAFETY CHECK PRIOR TO RESTARTING THE ESCALATOR OR
AUTOWALK
If the escalator or autowalk is switched off during operation due to a fault (for example: by a
safety device or power failure), have the following points checked before restarting:
NOTE! The procedure described below should be performed only by KONE's service
department or by skilled personnel who have been qualified by the manufacturer of
the unit.
1 Read the fault message on the info display in the PCB control unit.
2 Check the following points on the escalator or autowalk.
whether two or more teeth of a comb segment are damaged or broken
whether there are any foreign bodies in the comb segment or in the step band
whether a safety device has been activated
a damaged step in the step band
an increased gap between two steps
the distance between the steps and the skirts
drive chain and step chain lubrication
whether auxiliary brake looses or recovers (if provided)
check the handrail surface quality and isochronous step speed
faults in the electrical system
whether any switches are loose
whether any cables are loose
whether the coating on the balustrade skirt is worn through
3 Reset the error message on the control unit by pressing the reset button. The reset button
is located on top of the control cabinet.
4 Connect the handheld pendant control.
5 Start the unit in travel direction.
6 Check the input voltage.
7 Check the inspection travel.
If the unit does not start up, read the fault display and proceed in compliance with the
fault code indicated.
8 Remove the handheld pendant control.
9 Restart the unit.
10 Check the running step band for abnormal sounds (for example: at the step inlet) and for
erratic running.
NOTE! Always correct faults of any kind whatsoever before giving clearance for unit use.
CAUTION
Cordon off both escalator entries by erecting personnel traffic barriers. Removal of the
barrier is not allowed until the maintenance chamber has been closed, otherwise there is
a personal injury hazard.
CAUTION
The auxiliary brake must be reset by manual after power failure.
14 VERSION HISTORY
Compiled by: Technical Illustrator / Guo Li Li
Checked by: Escalator PCM Assistant Manager / Shang Rui
Approved by: Escalator Platform Category & PCM Manager / Weber Ralf
Issue Date Description of Change Ref. CR Changed by Approved by
- 2012-07-05 First issue Weber Ralf
15 FEEDBACK
Click one of the star buttons in the PDF version to rate the document and report errors or
suggest improvements. This opens your default e-mail client. Users of printed documents can
send feedback directly to ktd@kone.com.
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Appendix: B
MAINTENANCE MANUAL
OF ESCALATOR &
AUTOWALK
MAINTENANCE MANUAL
OF ESCALATOR
MBM-2 Manual Add-ons for KONE TravelMaster
110 Escalator
Maintenance Instructions
All rights reserved. 1 (39)
MBM-2 Manual Add-ons for KONE TravelMaster 110 Escalator (EJV R1.2/1.3/1.4/1.4.1) Maintenance Instructions ASG-51.05.001 2006 KONE Corporation All rights reserved (H) 2011-01-28 KONE Corporation EJV 1.5
KONE TRAVELMASTER 110 ESCALATOR
MBM-2 (Modular Based Maintenance)
110 Escalator
TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MBM-2 modular based maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY DEVICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Location of safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step band lock device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BASIC MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product-specific instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STEP MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removing steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Reinstalling steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BRAKE MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Auxiliary brake (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COMB PLATE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DRIVE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GUIDE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HANDRAIL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Handrail drive system overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Handrail guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
110 Escalator
STANDARD TOOLS
Toshiba pulling tool (TE4Z6KZ802P001, for lifting the access cover)
Handle for lifting landing (DEE0075707)
Label - Proactive oil replacement (KM987329G01)
Callipers for motor brake lining check (KM167619)
SAFETY DEVICES
Location of safety devices
110 Escalator
Additional safety switches:
Name Explanation
B 20 Water level switch (for outdoor) (if equipped)
B 36 Missing step monitor, lower (if equipped)
B 37 Missing step monitor, upper (if equipped)
B 50 Handrail speed monitor, left (if equipped)
B 51 Handrail speed monitor, right (if equipped)
S 1 Control current circuit breaker, lower
S 5 Emergency stop switch, lower
S 6 Emergency stop switch, upper
S 60-61 Comb plate impact switch lower left and right
S 62-63 Comb plate impact switch upper left and right
S 65-66 Handrail inlet switch lower left and right
S 67-68 Handrail inlet switch upper left and right
S 70 Step sag switch, lower
S 72 Step sag switch, upper
S 75-76 Broken step-chain switch lower left and right
S 80 Step band lock (upper pit left) (if equipped)
S 100-101 Skirting switch, lower left and right
S 102-103 Skirting switch, upper left and right
S 104-105 Skirting switch, inclined section (if equipped)
S 130 Access cover switch, lower
S 131 Access cover switch, upper
S 145 Broken drive chain switch
EJV EJV Explanation
S 84 S 85 Auxiliary brake lift monitor
S 85 S 85.1 Auxiliary brake lift monitor (the second motor)
S 183 S 83 The first motor brake lift monitor
S 184 S 84 The first motor brake lift monitor
S 181 S 83.1 The second motor brake lift monitor
S 182 S 84.1 The second motor brake lift monitor
S 187 S 81 The first motor brake wearing monitor
S 188 S 82 The first motor brake wearing monitor
S 185 S 81.1 The second motor brake wearing monitor
S 186 S 82.1 The second motor brake wearing monitor
110 Escalator
Step band lock device
The step band lock device must be activated any time you are working in the step band.
For EJV
Step Action Note
1 Place barricades at both ends of the
escalator, remove access cover and
turn main power supply OFF.
2 Take out controller from upper pit using
controller lifting tool.
3 Remove flywheel cover.
4 Remove step guard.
5 Raise handlebar (3) of step band lock
from slot (1).
6 Keep pushing step band lock (4) to
drive wheel disc (5) while running
flywheel manually.
Stop until step band lock is
engaged.
7 Put handlebar into slot (2).
The step band lock switch should be
actuated (10 displayed on main
board).
8 After finishing work, release the step
band lock by moving handlebar (3) from
slot (2) to slot (1).
9 Reinstall the parts in reverse order of
removal. Turn main power supply ON,
reinstall access cover, and remove
barricades.
110 Escalator
For EJV
NOTE! If there is no step band lock device, rated lifting slings and shackles must be used
attaching the slings between the chain sprocket wheels and the lifting eye points on
the truss. The slings must be fitted in such a manner that there is no free movement
of the sprocket wheel.
Step Action Note
escalator, remove access cover and
turn main power supply OFF.
2 Take out controller from upper pit using
controller lifting tool if needed.
3 Lift and push the handle (2) until bolts
(3) and teeth of the sprocket (4) are
engaged. If necessary, release the
main brake manually.
The step band lock switch (1) should
be actuated ("10" displayed on main
board).
4 After finishing work, release the step
band lock.
Release the handle (2) to separate
the bolts (3) from sprockets.
5 Put the controller back in pit, turn main
power supply ON, reinstall access
cover, and remove barricades.
110 Escalator
BASIC MODULE
Lower end
Step Maintenance task Method and standard
1 Check step chain tension. In the lower end pit, check step chain
tension by measuring the compressed
spring length between washers. Spring
length should be 95 mm.
2 Check function of skirt
switches (if equipped).
1 Make sure the main power supply is
OFF.
2 Remove the inner upper and lower
curve decking.
3 Change the blind plug to the hand-held
pendant control. Turn the main power
supply ON.
4 Place a thickness gauge 3.2 mm
between the switch actuator (1) and
the inside surface of the skirt (2) so
that the switch actuates.
NOTE! Do not place a thickness gauge
on the step side of the skirt.
Try to normally run the escalator in
both directions on inspection.
The escalator should not start.
5 Repeat the procedure for the opposite
side of the escalator.
3 Check LED light electric
cabinet (if equipped).
1 Check the LED lighting in lower pit.
2 Open the electric cabinet.
3 Check the fan function.
4 Clean the air filter, replace it if needed.
4 Check the inverter cabinet (if
equipped).
1 Check the fan condition.
2 Turn the main power supply OFF.
3 Open the inverter cabinet.
4 Check and clean the air filter, replace it
if needed.
5 Check the fall protection barrier (if
equipped).
1 Manually check if the fall protection
barrier is fastened securely.
2 Check if the screws are loose.
3 Check the barrier along the inclined
section.

110 Escalator
Upper end
1 Check function of skirt switches. Refer to the method and standard for
function of skirt switches in Basic
Module>Lower end.
2 Check automatic oilers (if
equipped).
Lubricate step chain with the
recommended lubricant.
[lubricate only from upper end
equipment driving down]
If lubrication is not suitable, reset the
parameter of pump, refer to Product-
specific instructions>Automatic oiler.
Lubricate connection area 1 and area 2
on every link
3 Check LED light electric cabinet
(if equipped).
1 Check the LED lighting in upper pit.
2 Open the electric cabinet.
4 Clean the air filter, replace it if
needed.
equipped).
2 Turn the main power supply OFF.
3 Open the inverter cabinet.
4 Check and clean the air filter, replace
it if needed.
5 Lift the controller back in the pit.
6 Check the fall protection barrier (if
equipped).
1 Manually check if the fall protection
2 Check if the screws are loose.
110 Escalator
Product-specific instructions
Automatic oiler
Automatic oiler lubricates drive chains, handrail drive chains and step chains automatically
and regularly.
Maintenance task: Check operation of automatic oilers
Maintenance method and standards:
For EJV
Step Action Note
1 Check the oil level in the oil tank.
Fill with clean oil.
NOTE! Make sure oil is absolutely
clean when filling the
automatic oiler.
2 Turn the switch F62 (24 V AC) OFF
inside the controller, the pump will
start.
The oil should come out from the
nozzles or oil brushes.
The pressure value of oil pump is
displayed on the pressure indicator
(if equipped) and should not be
below 1.0 Mpa.
NOTE! Clean the pump filter and
lubrication port filter yearly.
110 Escalator
3 If the chain is not lubricated properly,
adjust the nozzles or oil brushes.
4 Check every joint for oil leakage.
Tighten the joints, if necessary. Turn
the switch F62 ON.
5 Check and adjust the electrical
parameter setting according to
lubrication quality (just for first
maintenance visit).
If lubrication of chains is not sufficient,
readjust the pulse length parameters.
WARNING! Basic parameters may not
be valid for all escalators.
For more information on the lubrication
parameters, refer to the tables named:
pulse length (lubrication pump on time)
and delay between pulses (lubrication
pump off time).
Pulse length (Lubrication pump on time)
a)
a) The pulse length means one circle time.
Vertical rise
(m)
2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5
Parameter 19
(minute)
00 00 00 00 00 00 00 01 01 01 01 01 01 01 01 01
Parameter 20
(second)
33 38 41 46 49 54 57 2 5 10 13 18 21 26 29 34
Delay between pulses (Lubrication pump off time)
Indoor escalators Outdoor escalators
Parameter 21 (hour) 35 25
Parameter 22 (minute) 00 00
Parameter 23 (second) 00 00
NOTE! Parameters must be checked after first maintenance is completed. If necessary,
adjust parameters slightly according to the actual humidity and temperature.
Step Action Note
110 Escalator
For EJV
Step Action Note
automatic oiler.
2 Check that the chain is lubricated
properly. If needed, adjust the nozzles
or oil brushes.
Tighten the joints if needed.
110 Escalator
4 If needed, set the Ton and Toff on the
time relay in the control cabinet again
according to current status.
For Ton and Toff parameter setting,
refer to the following table.
NOTE! Parameters must be checked
after first maintenance is
completed. If necessary,
adjust parameters slightly
according to the actual
humidity and temperature.
Ton and Toff parameter setting
Vertical rise (m) 2 3 4 5 6 7 8 9 9.5
Ton
White button 660 minutes
Black button 3 3 4 4 5 5 6 6 7
Toff
Indoor
White button 10100 hours
Black button 2
Outdoor
Black button 1
Step Action Note
110 Escalator
STEP MODULE
Removing steps
Escalator steps usually should be removed at the lower escalator pit.
Maintenance task: Remove steps to open the maintenance access in step band
Step Action Note
1 Remove spring pin (2).
Use a hook or a set of pliers to pull
spring pin out of mounting hole.
2 Remove screw (1) and retaining plate
(3).
Use a screw driver to straighten the
end of the retaining plate.
3 Use the hand-held pendant control to
drive the step band.
The left step roller is accessible from
the hole on the turnaround plate.
110 Escalator
4 Slide the connector (4) towards center
of the step.
5 Remove the step.
Take the left step roller first out of
the hole in turnaround plate.
Take the right step roller out of the
step band.
NOTE! Make sure that the washer
stays on step chain pin.
6 Remove other steps using the same
procedure.
NOTE! On the first maintenance visit,
mark all steps using red spray
paint. Mark the first step in its
corner as number one. Then
run the unit in up direction,
mark the next step as number
two, and so on.
Step Action Note
5012864(2006-06)
110 Escalator
Reinstalling steps
The steps can be interchanged as a result of their modular design.
Maintenance task: Check and reinstall steps
Step Action Note
1 Position step in step band.
Position the right side of step in the
step band.
Position the left side of step in the
step band by placing the left step
roller through the hole in the
turnaround plate.
NOTE! Make sure that the step
guidance pin (A) is installed in
step.
2 Slide connector (1) towards chain roller
(2).
NOTE! Make sure that the washer
stays on the step chain pin.
NOTE! Add grease into the connector
if needed.
3 Mount spring pin to the connector.
Use a hammer to insert spring pin
into the mounting hole.
4 Install and fasten screw (3) with new
retaining plate (4).
Tightening torque for screws (3): MA
= 22 Nm
Retaining plate: DEE2191072
110 Escalator
5 Secure screws by bending retaining
plate (4).
6 Install remaining steps using the same
procedure.
7 Check step for alignment.
8 Install step guards.
Step Action Note
110 Escalator
BRAKE MODULE
Adjustment and checking are needed if stopping distance is not correct.
Maintenance task: Check motor brake lining
For EJV
Step Action Note
1 Open upper access cover, switch OFF
power supply, and engage step band
lock (if equipped).
2 Measure the actual length of springs at
both sides of the brake and record it.
3 Loosen fixing nuts (1) for one side, then
remove springs.
4 Turn brake arm (2) until the brake lining
thickness can be measured.
5 Check brake lining (3) thickness.
If the brake lining thickness is less than
3 mm, replace brake arms and lining.
NOTE! If the brake lining is
contaminated, always replace
it.
6 Check that the surface of the brake
should be free from grease and oil.
Clean if needed.
7 Reinstall brake arms in reverse order of
removal and check that brake arms can
move freely.
8 Adjust springs to the measured length
in step 2. Then lock nuts (1).
9 Check the brake lining for another side.
110 Escalator
For EJV (without brake wearing monitor)
For EJV (with brake wearing monitor)
Step Action Note
power supply.
2 Measure the depth D of brake arm from
measurement hole (1) by callipers.
3 If the brake lining thickness is below 3
mm, replace brake arms and lining.
Brake lining thickness = Measured
data D - 29
5 If needed, replace the brake arm
according to the section Replacing
brake arms
Step Action Note
power supply.
2 Visually check that the brake wearing
monitor is fixed tight.
110 Escalator
Maintenance task: Check main brake spring length
Maintenance task: Check clearance between brake arm and brake solenoid piston
Step Action Note
1 Tighten the spring to make the stopping
distance shorter and loosen the spring
to make the distance longer.
Both springs (1) must be equally
adjusted to ensure the spring length L is
the same on both sides.
2 Lock the adjusting nuts.
Step Action Note
1 Push the piston (2) to C direction.
Measure the clearance between brake
arm (1) and brake solenoid piston (2).
It is very important that there is 1.5 mm
clearance between the brake solenoid
piston (2) and brake arm (1).
2 If adjustment is needed, turn screw (3)
to adjust for 1.5 mm clearance between
brake arm and brake solenoid piston.
110 Escalator
Maintenance task: Check brake lift monitor (normal open) (if equipped)
Maintenance task: Check function of safety latch (if equipped)
Step Action Note
1 Check the switch actuator (1).
Actuate manual handle (4) by hand, the
switch actuator (1) must be released
from the bolt (3) of the bracket (2) and
there are no fault codes 68, 70
displayed on main board.
Release manual handle (4), the brake
is closed, the switch actuator (1) must
be actuated by the bolt (3) of the
bracket (2).
2 Adjust the bolt (3) if needed.
3 Release step band lock (if equipped),
switch ON power supply, and reinstall the
access cover.
Step Action Note
1 Switch off the main power.
110 Escalator
2 Take out the splint to remove the bolt
(3).
3 Remove the slider (4).
4 Pull the bar (5) to adjust the distance
between the arm (1) and the ratchet
wheel (2) to 10 mm.
5 Check that the detecting switch (6) is
activated in this position.
6 Check that the arm (1) can access
completely in the ratchet wheel without
pressing the tappet of the switch to its
end position.
7 Check the slider surface, replacement
is needed if severe wear.
8 If necessary, adjust the switch.
9 Reset the bar and reinstall the slider
(4) after adjustment.
Make sure the slider is in place.
Step Action Note
110 Escalator
All rights reserved. 22 (39
Auxiliary brake (if equipped)
Auxiliary brake is located in upper landing. It is activated in case of escalator power off,
escalator overspeed (over 1.4 times the rated speed), step band reverse direction, broken
drive chain.
Brake trigger device (1)
Brake disc (2)
Sprocket for drive chain (3)
Sprocket for step chain (4)
Brake shoe (5)
NOTE! After auxiliary brake is actuated, the escalator can not run downwards any more
because the detent may engage with the clutch. To normally run the escalator
downwards, just power off and power on the escalator, operate it upwards about 10
seconds (so that the detent can be disengaged from the clutch completely and be
back to the former position) and stop it with electricity.
Step Action Note
1 Confirm that no personnel and tools are on the step band.
2 Stop the equipment normally.
3 Switch OFF the main power.
Auxiliary brake should be released, and the auxiliary
brake stopper is stopping brake wheel.
4 Switch ON the main power.
Auxiliary brake should be actuated and removed from
auxiliary brake wheel.
5 Adjust auxiliary brake if needed.
110 Escalator
COMB PLATE MODULE
Maintenance task: Check comb plate impact device if adjustment is needed
Step Action Note
1 Remove the access cover and change
the blind plug to the hand-held pendant
control. Then turn the control current
OFF. Remove end inner decks (left and
right) located above the comb plate.
2 Check the length of the compressed
spring (4).
The initial length of the spring is
601 mm.
If necessary, adjust the nut (5) to set
the spring length.
3 Check the position of comb plate
impact switch.
The gap between the switch
actuator (1) and the trip arm (2)
should not be above 1 mm.
If needed, turn the nut (3) to adjust
the gap.
4 Check the function of the impact
device.
110 Escalator
110 Escalator
DRIVE MODULE
Drive unit
Maintenance task: Check oil level of gearbox
Maintenance task: Check air breather
Maintenance task: Add oil
Step Action Note
1 Check oil level of gearbox by removing
the filler cap of the dipstick (1).
Oil should be between the upper
and lower marks on dipstick.
Step Action Note
1 Check that air breather (2) is clean.
Step Action Note
1 If the oil is under the lower mark, add
the oil at filler cap (3) until the oil is
between the upper and lower marks.
For more information on oil type, oil
volume and so on, refer to the table Oil
specification.
110 Escalator
Maintenance task: Check oil replacement date
Step Action Note
1 According to oil replacement
information stick, confirm oil
replacement date.
Detailed method, see AS-
51.05.002>Minor Repairs>Changing oil.
Oil specification
Drive Type
Oil
viscosity
Oil Type
Oil
volume
(L)
Oil change interval
1st time
(h)
Regular
(h)
5.5 kW with CG35B gear VG460
Synthetic
oil
9 1800 20000
7.5, 9.2,11 kW with
CRW160B gear
VG460
Synthetic
oil
17.5 1800 20000
15 kW with CRW180B
gear
VG460
Synthetic
oil
23.5 1800 20000
5.5, 7.5 kW with FJ125R
gear
VG460
Synthetic
oil
6 1800 20000
9.2, 11 kW with FJ160R
gear
VG460
Synthetic
oil
12 1800 20000
15 kW with FJ160R gear VG460
Synthetic
oil
12 1800 20000
7.5 kW motor, with CG35
gear
VG460
Synthetic
oil
9 1800 20000
8 kW motor with CRW160
gear
VG460
Synthetic
oil
17.5 1800 20000
15 kW motor with
CRW160 gear
VG460
Synthetic
oil
17.5 1800 20000
5.5, 7.5 kW motor, with
FTJ125A gear (China
only)
VG460
Synthetic
oil
7.5 1800 20000
COMPONENT:
REPLACEMENT INTERVAL: YEARS
REPLACEMENT NEXT REPLACEMENT
Month/Year Month/Year
/20 /20
110 Escalator
8 kW motor with
FTJ160D gear (China
only)
VG460
Synthetic
oil
15.0 1800 20000
11 kW motor with
FTJ160D gear (China
only)
VG460
Synthetic
oil
15.0 1800 20000
15 kW motor with
FTJ160D gear (China
only)
VG460
Synthetic
oil
12.0 1800 20000
5.5, 7.5 kW motor, with
FJ125 gear (China only)
VG 460
Synthetic
oil
6.0 1800 20000
8 kW motor, with FJ160
gear (China only)
VG 460
Synthetic
oil
12.0 1800 20000
gear (China only)
VG 460
Synthetic
oil
12.0 1800 20000
gear (China only)
VG 460
Synthetic
oil
12.0 1800 20000
5.5, 7.5, 9.2 kW with K87
gear
VG220
Synthetic
oil
10.9 1800 20000
11,15 kW with K97 gear VG220
Synthetic
oil
20 1800 20000
11 kW motor with K107
gear
VG220
Synthetic
oil
33.5 1800 20000
15 kW motor with K107
gear
VG220
Synthetic
oil
33.5 1800 20000
NOTE! Synthetic oil is recommended to be used starting from first replacement. Mineral
oil can be replaced with synthetic oil, but synthetic oil can not be replaced with
mineral oil. Different oil types can not be mixed. If the oil is changed to other type,
the gear box must be cleaned.
Oil specification
Drive Type
Oil
viscosity
Oil Type
Oil
volume
(L)
Oil change interval
1st time
(h)
Regular
(h)
110 Escalator
Maintenance task: Check drive unit mounting bolts and drive chain slack
Step Action Note
1 Check drive unit mounting bolts (1).
Check the drive unit mounting bolts
are tight.
2 Remove the flywheel cover, turn the
flywheel down direction, make sure the
upper side of drive chain is slack.
When the tension is on the upper
side of chain, the slack amount (X)
is 10 mm +/-5 mm (25/64 in.+/- 3/16
in.).
3 If drive chain slack adjusting is needed,
loosen the four fixing bolts (1) on motor
base, loosen the nut (2) and turn the
limiting bolt (3) so that the drive chain
can be tightened appropriately.
4 Tighten the fixing bolts (1) and lock the
nut (2).
5 Reinstall the flywheel cover, turn main
power supply ON.
110 Escalator
All rights reserved. 29 (39
For EJV
For EJV
110 Escalator
For EJV
3
2
1
1
110 Escalator
Maintenance task: Check the gap of broken drive chain switch
Step Action Note
1 Turn the main power supply OFF, check
the gap between drive chains (3) and
the detecting bar (1).
The gap should be 25 35 mm.
2 Adjust the switch (2), if necessary.
3 Physically move the detecting bar to
depress the switch. Listen for audible
click of switch.
110 Escalator
GUIDE MODULE
Maintenance task: Make adjustment if missing step detector does not work
Maintenance task: Check tension carriage
WARNING
If equipped missing step/pallet monitor, run the unit with step/pallet opening, please keep
the step/pallet opening on the upside of step/pallet band, otherwise need to reset the fault
code (58 59) on cabinet.
Step Action Note
1 Remove five steps in a row, and move
the step opening to missing step
detector area in inspection mode.
Actuate the stop button on the hand-
held pendant control.
2 Check clearance between proximity
sensor (1) and tapered flat head screw
of trailing wheel (2).
The sensor should be centered and
approximately 5 mm from the
tapered flat head screw of trailing
wheel.
3 If adjustment is needed, loosen nuts (3)
and adjust until the sensor (1) is
centered and the clearance is correct
from the tapered flat head screw of the
trailing wheel (2).
4 Tighten nuts (3). Check the detector is
working correctly.
Step Action Note
1 Check the tension carriage for
movement with a small pry bar.
2 Check that spring tension is correct
after tensioning the step chain.
Spring length is 95 mm (only the
compressed spring)
110 Escalator
Maintenance task: Check the oil groove of handrail drive chain
Step Action Note
1 Run unit in inspection mode in the UP
direction, stop unit by pressing the stop
button on hand-held pendant control
when step opening is in handrail drive
chain area on upper level. Turn main
power supply OFF, and engage the
step band lock (if equipped).
2 Visually check the oil groove of handrail
drive chain, clean the groove if needed.
3 For EJV 1.5, check the oil drain pipe is
unblocked, clean the pipe if needed.
110 Escalator
Maintenance task: Check handrail drive chain tension
Maintenance task: Adjust handrail drive chain tension if needed
Step Action Note
1 Check handrail drive chain tension (A)
in the center between the handrail drive
chain sprockets (1) and main drive
sprocket (2).
Handrail drive chain tension: A = 9
to 15 mm
2 Adjust handrail drive chain tension if
needed.
Step Action Note
1 Find out the slack side of chain.
If unit is running up before it stops,
then the slack side is Up, vice versa.
2 Remove the upper curve inner deck by
loosening fixing bolts.
3 Release the handrail pressure spring
on two sides.
4 Loosen bearing mounting bolts (2) of
handrail drive wheel shaft (four on right
hand and four on left hand).
110 Escalator
5 Loosen lock nut (3), and adjust handrail
drive chain tension with jack bolt (4).
Set handrail drive chain slack from 9
to 15 mm measured at the drive
chain center between drive chain
sprockets (1).
For EJV 1.1/1.2/1.3/1.4/1.4.1, make
sure measurement B on both sides
of escalator are the same.
Otherwise the handrail wheels are
inclined.
For EJV 1.1, make sure
measurement C on both sides of
escalator are the same to ensure
the handrail drive is parallel to chain
drive.
NOTE! To increase the handrail chain
tension, tighten jack bolt (4)
equally for right hand and left
hand sides.
NOTE! To decrease the handrail chain
tension, loosen jack bolt (4) and
pull handrail drive wheel shaft
(5) to set tension dimension.
NOTE! Empty the oil container if
needed.
Step Action Note
110 Escalator
Maintenance task: Lubricate track in case of lube-free step chain (if equipped)
If required, the step chain lip track may be moistened by a spray in the running surface area
(1).
6 Tighten mounting bolt (2) and lock nut
(3).
7 Reinstall the parts in reverse order of
removal, release the step band lock
device.
8 Check the position of the handrail
pressure roller cluster and check
handrail traction on both sides of
escalator in UP and DOWN directions.
Step Action Note
1 Spray application may be required if
noise is generated between step chain
roller (2) and lip track.
NOTE! Use only a high pressure semi-
synthetic grease (Rivolta SKD
3602), based on metal soap
without solid additives for initial
application.
NOTE! All lubrication-free chains are
identified by SF or SFD in the
chain designation.
2 Spray application may be along the
entire length of lip track.
3 Spray application should be done once
before putting the unit into operation.
Step Action Note
110 Escalator
Maintenance task: Lubricate main shaft and handrail drive shaft
Step Action Note
1 Run escalator normally for several
cycles.
2 Move the opening of the step band to
the lubrication position of bearings in
inspection mode. Press down stop
button on hand-held pendant control.
3 Add grease to the grease nozzle (1)
with an oil gun.
4 Run the escalator normally for several
cycles again in inspection mode.
5 Add grease and cycle the escalator two
more times.
Add grease and cycle the escalator
totally for three separate times.
6 Add grease until old grease flows out
from the bearing.
7 Remove old grease from the bearing
surface.
8 Reinstall all removed parts in reverse
order.
110 Escalator
HANDRAIL MODULE
Handrail drive system overview
Handrail (1)
Handrail drive wheel (2)
Handrail drive shaft (3)
Handrail drive chain (4)
Newel (5)
Handrail guide roller (6)
Handrail pressure roller (7)
Handrail tension device (8)
110 Escalator
Handrail guides
Maintenance task: Check handrail tension
Step Action Note
1 With step band stopped, tilt up handrail
in the lower curve balustrade on one
side.
2 Remove handrail from the handrail
guide, and observe handrail tension.
If tension is correct, the handrail
section removed from the handrail
guide must run straight over the
balustrade.
3 Press handrail back onto handrail
guide.
It must be possible to press the
handrail effortlessly back in place
onto the handrail guide.
4 Adjust handrail tension if needed.

5 Reinstall all handrail onto guide, turn
main power ON.
MAINTENANCE MANUAL
OF AUTO WALK

TransitMaster 165/185
Horizontal Autowalk Maintenance Instructions
MBM-2 Manual Add-ons for KONE TravelMaster 115 Inclined Autowalk and TransitMaster 165/185 Horizontal Autowalk Maintenance Instructions ASG-51.00.001 2011 KONE Corporation All rights reserved (A) 2012-04-16 KONE Corporation RJV 1.3/AJV 1.0
TRANSITMASTER 165/185 HORIZONTAL AUTOWALK
(AJV 1.0)
MBM-2 (Modular Based Maintenance)
TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MBM-2 modular based maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY DEVICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Location of safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pallet band lock device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BASIC MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Return end. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drive end. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product-specific instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
PALLET MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removing pallets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reinstalling pallets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BRAKE MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Auxiliary brake (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DRIVE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
GUIDE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Second handrail drive unit (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HANDRAIL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Handrail drive system overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Handrail guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
RELATED DOCUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
APPROVALS AND VERSION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FEEDBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
GENERAL INFORMATION
MBM-2 modular based maintenance
This document is meant to be used as an additional MBM-2 instruction for the Generic
MBM-2 Manual ASG-51.01.001.
NOTE! For RJV 1.0 to 1.2, refer to Maintenance Instructions for KONE TravelMaster 115
Inclined Autowalk ASG-51.08.001.
STANDARD TOOLS
No need of additional tools.
SAFETY DEVICES
Location of safety devices
same as AS
Pos. Explanation Name
1 Combplate impact switch return end left and right S 60-61
1 Combplate impact switch drive end left and right S 62-63
2 Handrail inlet switch return end left and right S 65-66
2 Handrail inlet switch drive end left and right S 67-68
3 pallet sag switch, return end S 70
3 pallet sag switch, drive end S 72
4 Broken pallet-chain switch return end left and right S 75-76
5 Emergency stop switch, return end S 5
5 Emergency stop switch, drive end S 6
6 Handrail speed monitor, left (if equipped) B 50
6 Handrail speed monitor, right (if equipped) B 51
7 Access cover switch, return end S 130
7 Access cover switch, drive end S 131
8 Pallet band lock (drive end pit left) (if equipped) S 80
9 Broken drive chain switch (if equipped) S 145
10 Auxiliary brake lift monitor (for RJV) S 85
11 Water level switch (for outdoor) (if equipped) B 20
12, 13 Motor brake wearing monitor S 81-82
14 Missing pallet monitor, return end (if equipped) B 36
14 Missing pallet monitor, drive end (if equipped) B 37
15 Skirting switch (if equipped) S 100-103
16 Control current circuit breaker, return end S 1
17 Motor brake lift monitor (if equipped) S 83-84
Pallet band lock device
The pallet band lock device must be activated any time you are working in the pallet band.
Step Action Note
escalator, remove drive end access
cover and turn main power supply OFF.
NOTE! If there is no pallet band lock
device, rated lifting slings and
shackles must be used
attaching the slings between
the chain sprocket wheels and
the lifting eye points on the
truss. The slings must be fitted
in such a manner that there is
no free movement of the
sprocket wheel.
2 Take out controller from drive end pit
using controller lifting tool if needed.
Turn main power supply ON.
3 Lift and push the handle (2) until bolts
(3) and teeth of the sprocket (4) are
engaged. If necessary, release the
main brake manually.
The pallet band lock switch (1)
should be actuated ("10" displayed
on main board).
4 After finishing work, release the pallet
band lock.
Release the handle (2) to separate
the bolts (3) from sprockets.
5 Put the controller back in pit, reinstall
access cover, and remove barricades.
BASIC MODULE
Return end
1 Check pallet chain tension.
For RJV: 95 mm
In the return end pit, check pallet chain
tension by measuring the compressed
spring length between washers.
For AJV:
95 mm (TransitMaster 165)
to be changed
to be changed
2 Check function of skirt switches
(if equipped).
1 Change the blind plug to the
maintenance handset. Actuate the
stop button on the handset.
2 Remove the inner decking near the
second balustrade panel from the
drive and return ends.
3 Place a thickness gauge 3.2 mm
between the switch actuator (1) and
the inside surface of the skirt (2) so
that the switch actuates.
NOTE! Do not place a thickness gauge
on the pallet side of the skirt.
Release the stop button on
handset, try to inspecting run the
autowalk in both directions on
inspection.
The autowalk should not start.
4 Repeat the procedure for the opposite
side of the autowalk.
3 Check LED light electric cabinet (if
equipped).
1 Check the LED lighting in return end
pit.
2 Open the cabinet.
needed.
equipped).
2 Turn off the power.
3 Open the cabinet.
it if needed.
5 Check the fall protection barrier
(if equipped).
Manually check if the fall protection
Check if the screws are loose.
6 Check the function of the combplate
impact device.
Refer to ASG-51.01.001,
Generic MBM-2 Manual.
7 Adjust the combplate impact
device if function test fails.
Remove the access cover and change
the blind plug to the hand held pendant
OFF.
Remove end inner decks (left and
right) located above the combplate.
Check the length of the compressed
spring (4).
65 1 mm.
If necessary, adjust the nut (5) to
set the spring length.
Check the position of combplate impact
switch.
If needed, turn nut (3) to adjust the
gap.
to be added
Drive end
1 Check function of skirt switches
(if equipped).
Refer to the method and standard for
function of skirt switches in Basic
Module> return end.
2 Lubricate the chain manually (for
gravity oiler).
Lubricate the main drive chain and
handrail drive chain.
Fill the oil in the cup if need.
Open the valve under the oil cup,
inspecting run the unit for two
cycles after oil falls down on the
chain.
Lubricate the step chain.
Put the oil nipple to the step chain
in upper pit.
Inspecting run the unit by
maintenance handset and press
the oil to the chain one cycle for
pin 1, one cycle for pin 2.
Lubricate the other side using the
same method.
3 Check automatic oilers.
Lubricate pallet chain with the
recommended lubricant.
[lubricate only from drive end
equipment driving down]
If lubrication is not correct, refer to
Product-specific instructions>Automatic
oiler.
Lubricate connection area 1 on every
link
4 Check LED light electric cabinet (if
equipped).
1 Check the LED lighting in return end
pit.
2 Open the cabinet and check the fan
function.
needed.
equipped).
2 Turn off the power, open the cabinet.
it if needed.
6 Lift the controller back in the pit.
7 Check the fall protection barrier
(if equipped).
Manually check if the fall protection
Check if the screws are loose.
8 Check the function of the combplate
impact device.
Refer to ASG-51.01.001,
Generic MBM-2 Manual.
9 Adjust the combplate impact
device if function test fails.
Remove the access cover and change
the blind plug to the hand held pendant
OFF.
Remove end inner decks (left and
right) located above the
combplate.
Check the length of the compressed
spring (4).
65 1 mm.
If necessary, adjust the nut (5) to
set the spring length.
Check the position of combplate impact
switch.
If needed, turn nut (3) to adjust the
gap.
to be added
Product-specific instructions
Automatic oiler
Automatic oiler lubricates drive chains, handrail drive chains and pallet chains automatically
and regularly.
Maintenance task: Check operation of automatic oilers
Step Action Note
automatic oiler.
2 Check that the chain is lubricated
properly. If needed, adjust the nozzles
or oil brushes.
Tighten the joints if needed.
For AJV
For RJV
4 If needed, set the Ton and Toff on the
time relay in the control cabinet again
according to current status.
For Ton and Toff parameter setting,
refer to the following table.
NOTE! Parameters must be checked
after first maintenance is
completed. If necessary,
adjust parameters slightly
according to the actual
humidity and temperature.
Autowalk length (m) 20 30 40 50 60 70 80 90 100
Ton White button 660 minutes
Toff
Black button 2 3 4 5 6 7 8 9 10
Indoor
Black button 10
Outdoor
Black button 5
Vertical rise (m) 2 3 4 5 6 7 8
Ton White button 660 minutes
Toff
Black button 1 2 3 4 5 6 7
Indoor
Black button 10
Outdoor
Black button 5
Step Action Note
PALLET MODULE
Removing pallets
The pallets can be removed at the drive or return station.
Maintenance task: Remove pallets
WARNING
If the missing pallet monitor is equipped, run the unit with pallet opening, keep the pallet
opening on the upside of pallet band, otherwise reset the fault code(58 59) on cabinet.
WARNING
In general, the pallet band must be locked using the pallet band lock when performing any
work in or on an open pallet band.
Step Action Note
1 Remove access cover and insert the
hand-held pendant control. Release the
screws (1) and remove pallet guards
(2).
2 Run the pallet band using the hand-
held pendant control until screws (4)
are easily reachable in return section.
WARNING!Only run the pallet band
when no persons are inside the open
pallet band or on it!
3 Planish the folded retaining plates (5)
by a flat screw driver.
4 Remove screws (4) with retaining
plates (5), drag the slide connector (6)
towards the center of the pallet.
5 Raise pallet (7) and pull out pallet
retaining forks (8) from the slider blocks
(9) of the succeeding pallet (10).
NOTE! On the first maintenance visit,
mark all pallets using red spray
paint. Mark the first pallet in its
corner as number one. Then
run the unit towards the drive
station, mark the next pallet as
number two, and so on.
6 Lock unsecured slider blocks (11) in
position by inserting a spreader bar
(12).
7 Remove other four pallets in inspection
mode.
Step Action Note
Reinstalling pallets
The pallets can be interchanged as a result of the modular design.
Maintenance task: Check and reinstall pallets
Step Action Note
1 Check the removed pallets for the
following.
Warp
Cracks
Loose or damaged rollers
Loose or damaged pallet
demarcation strips
Loose hardware
2 Check slider blocks for wear or
damage.
3 Make sure the pallet band is clear of
personnel and equipment.
WARNING! Serious injury or death can
occur from rotating equipment.
Make sure unit is clear of all
personnel and equipment
before attempting to start the
unit.
4 Start the unit and run the pallet band
using the hand-held pendant control
until pallet connection screws (4) are
easily accessible for pallet installation.
5 Remove spreader bars (12).
6 Slide pallet forks (8) onto slider blocks
(9) of the next pallet (10).
NOTE! Make sure installation position
of the slider block is correct.
The slider block is properly
installed with the slider block
protrusion (13) which is
located towards the pallet
chain (14) and facing the base
of the forks (15).
NOTE! Add grease inside the slider
blocks and around slider
connectors if needed. (Grease
type: DEE1547522)
7 Slide pallet connector (6) towards the
center of the pallet.
8 Install screws (4) and retaining plates
(5), and tighten screws.
Tighten screws (4) to M
A
22 Nm
[18.75 lbf-ft].
9 Secure screws by bending retaining
plates (5).
10 Install remaining pallets in the same
manner.
11 Check pallets for alignment.
12 Reinstall pallet guard.
Step Action Note
5016770(2007-11)
9
13
14
15
BRAKE MODULE
Maintenance task: Check clearance between brake arm and brake solenoid piston
Maintenance task: Check brake lift monitor (normal open) (if equipped)
Step Action Note
1 Change the blind plug to the
maintenance handset. Actuate the stop
button on the handset.
2 Push the piston (2) to C direction.
Measure the clearance between brake
arm (1) and brake solenoid piston (2).
It is very important that there is 1.5 mm
clearance between the brake solenoid
piston (2) and brake arm (1).
3 If adjustment is needed, turn screws (3)
to adjust for 1.5 mm clearance between
screws and brake solenoid piston.
Step Action Note
1 Check the switch actuator (1).
Actuate manual handle (4) by hand, the
switch actuator (1) must be released
from the bolt (3) of the bracket (2) and
the fault codes 68, 70 must be
displayed on main board.
Release manual handle (4), the brake
is closed, the switch actuator (1) must
be actuated by the bolt (3) of the
bracket (2). Push the reset button on
cabinet, fault code must be
disappeared.
Maintenance task: Check motor brake lining
Without brake wearing monitor
2 Adjust the bolt (3) if needed.
Step Action Note
1 Measure the depth D of brake arm from
measurement hole (1) by callipers.
2 If the brake lining thickness is below 3
mm, replace brake arms and lining.
Brake lining thickness = Measured
data D - 29
4 If needed, replace the brake arm. Refer to the section Replacing brake
arms of AS-51.00.001.
Step Action Note
With brake wearing monitor
Maintenance task: Check main brake spring length
NOTE! Adjustment and checking are needed if stopping distance is not correct.
Step Action Note
1 Visually check that the brake wearing
monitor is fixed tight.
Step Action Note
1 Tighten the spring to make the stopping
distance shorter and loosen the spring
to make the distance longer.
Both springs (1) must be equally
adjusted to ensure the spring length L is
the same on both sides.
2 Lock the adjusting nuts.
Auxiliary brake (if equipped)
NOTE! Auxiliary brake is only available for RJV.
Auxiliary brake is activated in case of autowalk power off, autowalk overspeed (over 1.4 times
the rated speed), pallet band reverse direction, broken drive chain.
Maintenance task: Check the auxiliary brake trigger device
Maintenance task: Test auxiliary brake function (once a year if no third party inspection)
Step Action Note
1 Drag the auxiliary brake shaft manually.
It must move freely and can reset
automatically.
Switch contacts with the switch
pusher curve part.
The switch pusher and switch must
be fixed tightly.
Step Action Note
1 Place the barricades at both ends,
confirm that no personnel and tools are
on the step band.
NOTE! After auxiliary brake is actuated,
the autowalk can not run
downwards anymore because
that the detent may engage with
the clutch. To normally run the
autowalk downwards, just
power off and power on the
autowalk, operate it upwards
about 10 seconds (so that the
detent can be disengaged from
the clutch completely and be
back to the former position) and
stop it with electricity.
2 Open the access cover, switch off main
power, lift and take out the cabinet.
3 Tie one end of a string on the main
brake holder, put the other end of the
string outside of the pit.
4 Step out of the pit. Switch on the main
power, normally run the unit in down
direction. Drag the string to keep the
main brake open until the unit stops.
Switch off the main power.
Auxiliary brake must be actuated in
3 seconds and stop the unit.
5 Loosen the main brake, remove the
string from brake holder.
6 Put the cabinet back into the pit,
reinstall the access cover and
barricades at both ends, return the unit
to service.
DRIVE MODULE
Change the blind plug to the maintenance handset. Actuate the stop button on the handset.
Maintenance task: Check oil level of gearbox
Maintenance task: Check air breather
Maintenance task: Add oil
Maintenance task: Check oil replacement date
Step Action Note
1 Check oil level of gearbox by removing
the filler cap of the dipstick (1).
Oil should be between the upper
and lower marks on dipstick.
Step Action Note
1 Check that air breather (2) is clean.
Step Action Note
1 If the oil is under the lower mark, add
the oil at filler cap (3) until the oil is
between the upper and lower marks.
For more information on oil type, oil
volume and so on, refer to the table Oil
specification.
Step Action Note
1 According to oil replacement
information stick, confirm oil
replacement date.
Detailed method, see AS-51.00.001>
Minor Repairs>Changing oil.
NOTE! For drive type, you can find it
on body of motor and
gearbox.
COMPONENT:
REPLACEMENT INTERVAL: YEARS
REPLACEMENT NEXT REPLACEMENT
Month/Year Month/Year
/20 /20
Oil specification
Drive type
Oil
viscosity
Oil type
Oil volume
(L)
Oil change interval
1st time (h) Regular (h)
5.5, 7.5kW motor, with
FTJ125A gear
VG460 Synthetic oil 7.5 3600 20000
7.5,9.2, 11kW motor, with
FTJ160D gear
VG460 Synthetic oil 15 3600 20000
5.5kW motor, with
CG35B gear
7.5kW motor, with
CG35B gear (Right side)
7.5kW motor, with
CG35A gear (Left side)
7.5, 9.2, 11kW motor,
with CRW160B gear
(Right side)
7.5, 9.2, 11kW motor,
with CRW160A gear
(Left side)
5.5, 7.5, 9.2, 11kW
motor, with CG26-112
gear
5.5, 7.5, 9.2kW motor,
with K87 gear
7.5, 9.2, 11kW motor,
with K97 gear
11kW motor, with
FTJ160 gear
5.5 kW,7.5kW with
FJ125
7.5, 9.2kW,11 kW with
FJ160
NOTE! Synthetic oil is recommended to be used starting from first replacement. Mineral oil can be
replaced with synthetic oil, but synthetic oil can not be replaced with mineral oil. Different oil types
can not be mixed. If the oil is changed to other type, the gear box must be cleaned.
Maintenance task: Check drive unit mounting bolts and drive chain slack
Step Action Note
1 Check drive unit mounting bolts (1).
The drive unit mounting bolts are
tightened.
2 Remove the flywheel cover, turn the
flywheel in return end direction, make
sure the upper side of drive chain is
slack.
When the tension is on the upper
side of chain, the slack amount (X)
is 10 mm +/-5 mm (25/64 in.+/- 3/16
in.).
3 If drive chain slack adjusting is needed,
loosen the four fixing bolts (1) on motor
base, loosen the nut (2) and turn the
limiting bolt (3) so that the drive chain
can be tightened appropriately.
4 Tighten the fixing bolts (1) and lock the
nut (2).
5 Reinstall the flywheel cover.
Maintenance task: Check the gap of broken drive chain switch
Step Action Note
1 Turn the flywheel in drive end direction
manually. Confirm the slack of chain is
in lower side. Check the gap between
drive chains (3) and the detecting bar
(1).
The gap must be 25 35 mm.
2 Adjust the switch (2), if necessary.
3 Physically move the detecting bar to
depress the switch. The fault code 12
must display on control board. (For 501
upgrade version, fault code is 14.)
4 Remove the maintenance handset,
insert blind plug.
GUIDE MODULE
Maintenance task: Make adjustment if missing pallet detector does not work
Maintenance task: Check tension carriage
WARNING
If missing pallet monitor is equipped, the unit must be run with pallet opening on the
upside of pallet band. Otherwise the fault code (58 59) on cabinet must be reset.
Step Action Note
1 Remove five pallets in a row, and move
the pallet opening to missing pallet
detector area in inspection mode.
Actuate the stop button on the hand-
held pendant control.
2 Check clearance between proximity
sensor (1) and the fork (2) of pallet.
The sensor should be centered and
approximately 5 mm from the
tapered flat head screw of trailing
wheel.
3 If adjustment is needed, loosen nuts (3)
and adjust until the sensor (1) is
centered and the clearance is correct
from the fork (2) of pallet.
4 Tighten nuts (3). Check the detector is
working correctly.
Step Action Note
1 Check the tension carriage for
movement with a small pry bar.
2 Check that spring tension is correct
after tensioning the pallet chain.
Spring length must be:
RJV: 95 mm
AJV: 95 mm (TransitMaster 165)
Maintenance task: Check the oil groove of handrail drive chain
Maintenance task: Check handrail drive chain tension
Maintenance task: Adjust handrail drive chain tension if needed.
Step Action Note
1 Run unit in inspection mode in the drive
end direction, actuate the stop button
on maintenance handset when pallet
opening is in handrail drive chain area
on upper level. Turn main power supply
OFF, and engage the pallet band lock
(if equipped).
2 Visually check the oil groove of handrail
drive chain, clean the groove if needed.
3 Check the oil drain pipe is unblocked,
clean the pipe if needed.
4 Check the lubrication brush is at the
right position.
Step Action Note
1 Check handrail drive chain tension (A)
in the center between the handrail drive
chain sprocket (1) and main drive
sprocket (2).
Handrail drive chain tension: A = 11
to 20 mm
2 Adjust handrail drive chain tension if
needed.
Step Action Note
1 Confirm the slack side of chain.
If unit runs towards drive end before
it stops, then the slack side is
towards drive end.
2 Loosen bearing mounting bolt (3) of
handrail drive wheel shaft.
NOTE! To increase the handrail
tension, tighten jack bolt (5)
equally for right hand and left
hand sides.
NOTE! To decrease the handrail
tension, loosen jack bolt (5) and
pull handrail drive wheel shaft
to set tension dimension.
NOTE! Empty the oil container if
needed.
For AJV
3 Loosen lock nut (4), and adjust handrail
drive chain tension with jack bolt (5).
Set handrail drive chain slack to be
standard measured at the drive
chain center between the handrail
drive chain sprocket (1) and main
drive sprocket (2).
Make sure measurement (distance
between axles) on both sides of
autowalk are the same. Otherwise
the handrail wheels are inclined.
4 Tighten mounting bolt (3) and lock nut
(4).
5 Reinstall all of the parts in reverse order
of removal. Release the step band lock
device.
6 Check the position of the handrail.
The handrail drive wheel must be in
the center of the handrail.
For RJV
Step Action Note
Maintenance task: Check the thickness of handrail drive wheel rubber (main handrail drive
wheel and second handrail drive wheel)
Maintenance task: Check the handrail track spring length
Maintenance task: Lubricate track in case of lube-free pallet chain (if equipped)
If required, the pallet chain lip track may be moistened by a spray in the running surface area
(1).
Step Action Note
1 Move the pallet opening to related
handrail drive wheel position.
2 Actuate the stop button on handset,
turn main power OFF, engage the step
band lock device.
3 Check the thickness of handrail drive
wheel rubber on both sides.
NOTE! The thickness should not be
less than 3 mm.
Step Action Note
1 Check the handrail track spring length
on both sides. It should be 93 mm.
Tension it if needed.
2 Release the step band lock, turn main
power ON.
Maintenance task: Grease the bearings of following shafts:
Main shaft (drive end)
Handrail drive shaft (drive end)
Second handrail drive shaft (return end, if equipped) (only for AJV)
Return wheel shaft (return end, if equipped) (only for AJV)
Step Action Note
1 Spray application may be required if
noise is generated between pallet chain
roller (2) and lip track.
NOTE! Use only a high pressure semi-
synthetic grease (Rivolta SKD
3602), based on metal soap
without solid additives for initial
application.
NOTE! All lubrication-free chains are
identified by SF or LF in the
chain designation.
2 Spray application may be along the
entire length of lip track.
3 Spray application should be done once
before putting the unit into operation.
Step Action Note
1 Move the opening of the pallet band to
the lubrication position of bearings in
inspection mode. Actuate the stop
button on the maintenance handset.
2 Add grease to the grease nozzle (1)
with a grease gun.
3 Run the autowalk normally for several
cycles again in inspection mode.
4 Add grease and cycle the autowalk
twice more.
5 Add grease until old grease flows out
from the bearing.
6 Remove old grease from the bearing
surface.
7 Reinstall all of the parts in reverse order
of removal.
to be added
Grease nozzle for main shaft and handrail drive shaft (AJV)
Grease nozzle for main shaft and handrail drive shaft (RJV)
to be added
1
1
Grease nozzle for the second handrail drive shaft
Grease nozzle for return wheel shaft
to be changed
Second handrail drive unit (if equipped)
This device is usually installed in return end.
Maintenance task: Check running noise
Maintenance task: Visually check the seals for leakage
Maintenance task: Check oil level
Step Action Note
1 Remove the pallet opening to second
handrail drive area in inspection mode.
2 Inching run the unit, visually check
vibration and noise of the driver.
3 If the operation is not quiet, investigate
the cause of noise and correct it.
4 If noise cannot be corrected, contact
your supervisor with all details.
Step Action Note
1 Move the pallet opening to second
handrail drive station, turn the control
current OFF in the return end pit,
actuate the emergency stop on
maintenance handset. Actuate the
pallet band lock device in drive end.
2 Visually check the bottom surface of
driver, report to your supervisor for any
oil leaks.
If no leakage, oil level check is not
needed.
Step Action Note
1 Open the oil level plug by M6 allen key,
and check the oil level is close to the
hole.
2 If oil is lack, add oil.
Refer to AS-51.00.001>Minor
repairs>Changing the second handrail
drive oil (if equipped).
HANDRAIL MODULE
Handrail drive system overview
Handrail (1)
Handrail drive wheel (2)
Handrail drive shaft (3)
Handrail drive chain (4)
Newel (5)
Handrail guide roller (6)
Handrail pressure roller (7)
Handrail tension device (8)
Second handrail drive (if equipped for AJV) (9)
to be added, AJV + second handrail drive
Handrail guides
Maintenance task: Check handrail tension
Step Action Note
1 Remove one piece of inner decking in
middle position on both sides.
NOTE! Remove the inner decking from
the fourth balustrade panel
relative to end.
2 Run the unit towards drive end for
several seconds, actuate emergency
stop on the hand-held pendant control.
3 Select one section of truss bar (1) and
press the handrail in middle position.
With around 50 N force, slack is
about 10 20 mm.
4 Tension the handrail in return end pit if
needed.
5 Run the unit in inspection mode
towards return direction for several
seconds, check whether the handrail
peels off from the newel.
6 Tension the handrail again according to
step 2 to step 3 if needed.
7 Reinstall the inner decking and release
the unit for service.
to be added
RELATED DOCUMENTS
The following documents are related with maintenance of KONE TravelMaster 115 (RJV)
and TransitMaster 165/185 (AJV):
AS-51.00.001 MBM-2 Manual Add-ons for KONE TravelMaster 115 and
TransitMaster 165/185 Autowalk Maintenance Instruction
AS-51.05.004, Control System: 501-B upgrade for EJV R1.5 / E40 R1.1 / AJV1.0 / RJV1.3
Diagnostic Guide
AM-51.08.001 KONE TravelMaster 115 and TransitMaster 165/185 Autowalk
Installation Instruction
AR-51.07.002 KONE TransitMaster 165/185 Horizontal Autowalk spare parts
AR-51.08.002 KONE TransitMaster 115 Inclined Autowalk spare parts
5214110D21, EMB_501 upgrade parameter setting for 0.4 m/s with VACON Inverter
1372012D21, VACON inverter adjustment for handrail drive
APPROVALS AND VERSION HISTORY
Compiled by: PIA Technical Writer / Ma Yun Hui
Checked by: CRD Escalator Maintenance Specialist / Ye Zu Ling
Escalator Platform Category & PCM Manager / Weber Ralf
Approved by: SEB Maintenance Development Manager / Seppo Valliovuo
Issue Date Description of change Ref CR Approved by
- 2011-03-14 Document creation. Seppo Valliovuo
A 2012-04-16 Automatic oil Toff parameter setting
changed; checking the gap of broken
drive chain switch added; oil
specificaion changed; handrail guides
checking added. The content for
checking auxiliary brake trigger device
changed. The content of complate
module moved to basic module. The
method for checking thickness of
handrail drive wheel rubber and
handrail track spring length added.
Seppo Valliovuo
FEEDBACK
Click one of the star buttons in the PDF version to rate the document and report errors or
suggest improvements. This opens your default e-mail client. Users of printed documents can
send feedback directly to ktd@kone.com.
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Appendix:C
WIRING DIAGRAM

Escalator 702456

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MASTER INDEX

VOLUME 01: CIVIL ELEMENTS

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