NOV Series Manual Part 1 EN (M368-15) PDF

INSTRUCTIONS MANUAL
FOR THE NOV SERIES

PERSENNEL/MATERIAL
INDUSTRIAL ELEVATORS
Part 1
Instruction Manual Number: M368-15

Revision number: 0-03/2015
STROS
Sedlanské strojírny, a.s. Tel.: +420 318 842 404
Strojírenská 791 Fax: +420 318 821 230
264 01 Sedlčany E-mail: info@stros.cz
Czech Republic http://www.stros.cz
CONTENTS
CONTENTS
FOREWORD ............................................................................................................................................................... - 4 -
TERMINOLOGY AND SIGNS ................................................................................................................................. - 7 -
WORK SAFETY ......................................................................................................................................................... - 9 -

USER’S BASIC RESPONSIBILITIES ......................................................................................................................... - 9 -
ELEVATOR DATA .................................................................................................................................................. - 11 -
SAFETY EQUIPMENT .............................................................................................................................................. - 11 -
ADDITIONAL AND RELATED INFORMATION ................................................................................................... - 12 -
Power supply requirements .................................................................................................................................... - 12 -
Bolted joints ........................................................................................................................................................... - 13 -
Elevator foundation ................................................................................................................................................ - 13 -
Protective zone around the elevator ....................................................................................................................... - 14 -
Tie-ins ..................................................................................................................................................................... - 14 -
Reduction of the bearing capacity of the elevator structure by corrosion ............................................................. - 15 -
Safety distances and clearances ............................................................................................................................. - 15 -
Load on landings .................................................................................................................................................... - 16 -
Storage of the elevator and its components ............................................................................................................ - 16 -
ELEVATOR DESCRIPTION ..................................................................................................................................... - 18 -
ELEVATOR CONTROLS .................................................................................................................................................. - 19 -
Signalization ........................................................................................................................................................... - 20 -
ELEVATOR ERECTION AND DISMANTLING ................................................................................................. - 25 -
PROGRAMMING OF LANDINGS ........................................................................................................................ - 25 -
EMERGENCY SITUATIONS, FAILURES ........................................................................................................... - 27 -

POWER BLACKOUT ................................................................................................................................................ - 28 -
SAFETY DEVICE TRIPPING ................................................................................................................................... - 29 -
OVERRIDING THE TOP NORMAL LIMIT ............................................................................................................. - 30 -
OVERRIDING THE BOTTOM NORMAL LIMIT, OVERRIDING THE BOTTOM FINAL LIMIT ....................... - 30 -
INSPECTIONS AND MAINTENANCE ................................................................................................................. - 31 -
PERIODIC INSPECTIONS AND MAINTENANCE OF THE ELEVATOR ............................................................. - 31 -
ELEVATOR LUBRICATION .................................................................................................................................... - 33 -
Rack lubrication ..................................................................................................................................................... - 35 -
CHECK OF RACK AND PINIONS ............................................................................................................................ - 37 -
Tooth clearance adjustment ................................................................................................................................... - 49 -
Rack replacement ................................................................................................................................................... - 50 -
Pinion replacement ................................................................................................................................................ - 51 -
ADJUSTMENT AND REPLACEMENT OF GUIDE ROLLERS .............................................................................. - 53 -
SAFETY HOOKS AND SUPPORTS ......................................................................................................................... - 54 -
INSTALLATION AND ADJUSTMENT OF LIMIT CAMS ...................................................................................... - 60 -
SAFETY DEVICE REPLACEMENT AND MAINTENANCE ................................................................................. - 63 -
WORKING UNDER THE CAR ................................................................................................................................. - 63 -
TESTING ................................................................................................................................................................... - 64 -
TESTS CARRIED OUT BY THE USER .................................................................................................................... - 65 -
Erection Test (Specialized Test) ............................................................................................................................. - 65 -
Verification Test ..................................................................................................................................................... - 65 -
Specialized Inspections .......................................................................................................................................... - 65 -
Check of elevator components ................................................................................................................................ - 66 -
Loadless test ........................................................................................................................................................... - 67 -
Static test ................................................................................................................................................................ - 67 -
Dynamic test ........................................................................................................................................................... - 67 -
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CONTENTS
Single brake test ..................................................................................................................................................... - 68 -
Safety device test .................................................................................................................................................... - 68 -
Emergency lowering test ........................................................................................................................................ - 69 -
Test of the bottom final limit................................................................................................................................... - 69 -
Test of the top final limit......................................................................................................................................... - 69 -
SERVICE ................................................................................................................................................................... - 70 -
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FOREWORD
FOREWORD
This Instructions Manual contains information on the product, specific requirements for safe
erection, operation, maintenance and periodic checks and tests of the NOV series rack and pinion
elevators.
This Part 1 of the Instructions Manual is accompanied by Part 2, which is an inseparable part of the
whole manual and contains information specific to a particular elevator model.
Each person that is to install, operate, maintain or test the elevator must become thoroughly
acquainted with all the parts of the manual that are relevant for their activity, so as to avoid causing
injury to themselves or others, or substantial property damage. It is essential to know especially the
risks that arise from disregard of work safety principles.
The manual therefore contains highlighted sections (in bold print) introduced by the following
symbol:
! WARNING !
This symbol means “CAUTION! YOUR SAFETY AND THE SAFETY OF YOUR CO-
WORKERS IS IN DANGER!”
Activities that may cause damage to the equipment are introduced with the following symbol:
ATTENTION
Additional and complementing information is introduced with the following inscription:
Note:
The requirements contained in this manual are based on customary regulations, knowledge and
equipment standards. In some cases, local regulations governing the equipment may deviate from
instructions contained in this manual. In such cases, the more stringent of the requirements (in
favor of higher work safety) will prevail.
Consult special applications, modifications to the elevator and specially fabricated components
with the supplier or manufacturer of the equipment.
Requirements for qualification of personnel having to do with the elevator (operation,

maintenance, tests) are stipulated in the respective sections of the manual. It is unacceptable for
persons without appropriate (and in some cases documented) qualification to work on the elevator.
The intervals stipulated for periodic maintenance, inspections and tests must not be exceeded. If
these intervals are given in hours of operation as well as time periods, the interval that comes first
will prevail. Activities noted “as needed” will be determined by the elevator user according to the
operating conditions.
The manufacturer cannot foresee all the contingencies that may pose possible risk hazard.
Therefore, the information and warnings contained in this manual are not comprehensive and
exhaustive.
When using a tool, procedure or equipment that is not explicitly recommended, you must verify
yourself whether it is safe for you and others and whether it may damage the equipment or impair
its safety.
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FOREWORD
While the elevator is in use, procure the latest information regarding the equipment and its
operation from the manufacturer or your supplier.
This manual does not contain detailed procedures for the erection and dismantling of the elevator,
neither does it describe the setup of the foundation and tying the mast. Likewise, some other
requirements, common in relocated elevators, are omitted.
Should a need arise to relocate the elevator in the future, these procedures must be determined with
respect to the conditions of the subsequent use.
The elevator manufacturer is not responsible for any damage arising from disrespect to the
requirements specified herein.
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TERMINOLOGY AND SIGNS
Example of an NOV series elevator

Fig. 2.1
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TERMINOLOGY
Instructions manual - this document. The major part of operating documentation, which further
includes supplements to this manual, spare parts catalogue, logbook, unless agreed
otherwise in the purchase contract.
Local regulations - national and local regulations, requirements and authority stipulations
pertaining to the given type of equipment and its operation.
Authorized specialist - a person authorized to perform specialist inspections, erection and
specialist tests in the required extent.
Authorized person – a designated person, properly trained, qualified by their knowledge and
experience, acquainted with applicable codes and regulations, and competent to
perform the required activities.
Operator – a person operating the elevator.
Elevator user - a person responsible for the operation of the elevator.
Operation : in operation/service - situations while the elevator is in use. The elevator may by at
any position, loaded or unloaded, in motion or stationary.
out of operation/service – a situation when an unloaded car is at the base,
disconnected from the mains, and the main disconnect switch in the OFF position and
locked.
Emergency actions - procedures for rescuing personnel from the elevator car with the assistance
of an authorized person.
Emergency lowering - a device that will lower the car to the nearest lower landing in case of
power blackout or malfunction of the elevator other than the safety device tripping.
EMERGENCY STOP (E-stop) - a switch that will stop the elevator and prevent its further
operation
Safety distance – the minimum distance between any moving part of the elevator and any place
accessible by persons.
Hoistway - the space in which the elevator travels.
Nominal capacity/Rated load - the maximum permissible mass of persons and materials.
Foundation slab – a slab made of reinforced concrete, to which the base frame of the elevator is
attached.
Elevator unit - an assembly consisting of a complete base enclosure and a complete elevator
car, including control panels and motors.
Base frame - the lowest located load-bearing structure. Vertical forces and bending moments
from the elevator operation are transferred into the foundation slab via the base frame.
Mast/Tower – a structure that supports and guides the elevator car. The mast consists of mast
sections.
Tie-ins - a system o horizontal supports connecting the mast to the building.
Drive unit – it consists of three motors and the safety device.
Landings – the stories in a building (or another structure) designated for loading and unloading the
elevator car.
Landing equipment (supplied with the elevator) – equipment preventing personnel from entering
the dangerous area of the hoistway. It consists of landing gates.
Landing gate – a single-piece hinged, or center swing door, which is mechanically and electrically
interlocked. It allows access into the elevator car from a landing.
Normal limit switch – a device that stops the elevator at the terminal (top and bottom) landings.
Final limit switch – a device that stops the elevator in the event that it overrides a normal limit
switch.
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Travelling/Trailing cable – a cable connecting the control panel at the base station with the panel
located on the elevator car.
Lifting harness – part of the elevator accessories. A wire rope lifting harness located on the car and
designated for lifting the and manipulating the elevator unit.
Cable trolley – a device that tautens the travelling cable. It is used with greater tower heights.
Inspection controller – a pushbutton controller used during elevator installation and during
inspections.
Drop Test controller – a plug-in pendant controller for testing the safety device.
SIGNS
H (ft, m) …………………………….. mast height
Z (ft, m) ……………………………... lifting height
L (inch, mm) ………………………. distance between the mast center line (y) and the building
(tie-in length)
B (inch, mm) ………………………… horizontal distance between the tying points in the structure
b (ft, m) ……………………………… vertical distance between tie-ins (tie-in spacing)
c (ft, m) ……………………………… top mast overhang
s (inch, mm) …………………………. width
d (inch, mm) ………………………… length
v (inch, mm) …………………………. height
J.N. (lb, kg) ………………………….. rated load of the elevator
P (lb, kN) ……………………………. concrete slab vertical load
p (psi, MPa )…………………………. ground pressure of concrete slab
x ……………………………………… mast center line (normal to facade)
y ………………………………………mast center line (parallel to facade)
(SP) ………………………………….. Special procedure. It is specified either in another part of the
Instructions Manual or in its Appendices.
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WORK SAFETY
WORK SAFETY
USER’S BASIC RESPONSIBILITIES:
- To keep and file the elevator operating documentation. To allow authorized personnel to access
all the information they need to perform their duty. To keep register of authorized persons and
their certificates of training and health condition.
- To make sure that all work related to the installation, operation, maintenance and testing of the
elevator are performed by authorized person, and that it is appropriately and timely
documented.
- To make sure that the daily inspections are performed and documented.
- To stipulate a notification responsibility in the event of failures, including emergency
situations. To determine procedures in case of an emergency.
- To determine a procedure in case of an accident.
- To become familiar with and enforce all the safety requirements contained in this manual and
its supplements, as well as any local regulations and codes governing the installation, operation,
maintenance and tests of personnel-and-material construction elevators.
- To always appoint a foreman (responsible person), if the elevator is be worked on by a group.
! WARNING !
IT IS FORBIDDEN TO :
- use the elevator unless all the required tests and inspections have been performed, or if a
defect threatening the safety of operation has been identified,
- use the elevator for other than the designated purposes,
- use the elevator if its relevant documentation is incomplete,
- allow unauthorized personnel to use the elevator,
- overload the elevator (with the exception of tests) and/or the landings,
- use the elevator if the wind speed exceeds 45 mph (72 km/h),
- leave the elevator loaded after use,
- use the elevator as a passage way (in walkthrough cars),
- allow unauthorized personnel to maintain, repair or modify the elevator,
- transport objects protruding out of the car or placed outside of the car,
- leave the elevator connected to the mains and unsecured against misuse after finishing the
day’s operation,
- allow unauthorized personnel to perform emergency actions.
! WARNING !
It is essential that the personnel operating the elevator and authorized to work on it be
qualified for the given type of work.
These personnel must be: physically fit

mentally tenacious
sufficiently trained and authorized
The nature and extent of the authorization is determined by local regulations and codes.
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WORK SAFETY
Respect the following warnings:
! WARNING !
Always wear a safety hardhat and safety antiskid shoes when installing, maintaining and
testing the elevator.
Always use fall arrest gear (safety harness) when working in heights or in an unenclosed
space.
! WARNING !
Whenever working on the elevator, secure it against undesirable movement by pressing the
EMERGENCY STOP button and by turning off and locking out the main disconnect switch.
!WARNING !
If the elevator is located in a shaft, it is forbidden to lean out of the car area during
inspections or erection.
! WARNING !
Always secure the car against falling whilst working underneath the car, or maintaining or
servicing the motors or the safety device.
! WARNING !
Study all the other warnings and attentions contained in other parts of this manual. If in
doubt or in need of a clarification, please contact the elevator manufacturer or your
supplier. Discontinue any further work before obtaining appropriate instruction or
information.
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ELEVATOR DATA
ELEVATOR DATA
The dimensions and parameters of the elevator are detailed in Part 2 of the Instruction Manual and
in the General Arrangement Drawing (GAD).
SAFETY EQUIPMENT
Item Function,
Safety device limit switch Safety device tripping in down direction.
Car door switch door closing
door closing/locking
Switch
- landing gate gate closing/locking
- landing gate interlock
Roof hatch switch hatch closing
EMERGENCY STOP
- in car (RM2) stops the elevator and prevents its further operation
- on car roof
- in the pit
- on DROP TEST controller
Normal limit switches Top and bottom limit
Final limit switch Final limit
Emergency Lowering device Emergency lowering to the nearest lower landing
Item Specification Function, function check

Safety device KZ3A overspeed in down direction
Emergency Lowering device

An emergency device that allows for the elevator to be lowered to the nearest lower landing in case
of power blackout or malfunction of the elevator. It is described thereinafter.
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ELEVATOR DATA
ADDITIONAL AND RELATED INFORMATION
Power supply requirements
The main power supply must be appropriately sized, the line physically as short as possible, and in
compliance with local regulations.
For elevators of the NOV series the manufacturer recommends:
FLA [A] Recommended Recommended Approx.

fuses (slow cable size voltage drop
over 100 m
fuses)* mm2/AWG (330 ft)
VFD/DOL**
[VAC]
40 50A 10/#8 26/90
50 60A 10/#8 33/110
60 70A 10/#8 40/130
70 80A 10/#8 46/150
16#6 29/110
80 90A 10/#8 52/173
16/#6 33/125
25/#4 20/70
90 100A 10/#8 59
16/#6 37
25/#4 24
100 125A 16/#6 41
25/#4 26
125 150A 16/#6 51
25/#4 33
35/#2 20
The Full Load Amperage (FLA) is listed in the electrical layout drawing.
*FUSE – High Interrupting Capacity, Current Lifting Classes (z. B, R, J)
** Voltage drop in the supply and travelling cable during starting current, under normal
operating conditions, and when AWG cables are used.
Irrespective of the cable sizes listed above, local regulations and conditions must be adhered
to. When determining the cable size, voltage drops in both the supply and travelling cables
must be taken into account. The voltage drop must not exceed 160 V during starting current,
i.e. voltage on the motor must not drop below 300 VAC during takeoff.
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ELEVATOR DATA
Bolted joints
ATTENTION
During erection and repairs, always make sure that:
 undamaged bolts, nuts and washers of the specified size and strength grade are used,
 bolted joints are tightened to the specified torque,
 bolted joints are sufficiently secured.
Note: Use connecting material of 8.8 strength grade for joints subject to strain. Strength class
specification is usually stamped on the nut or bolt head. If in doubt as to the connecting
material’s compliance, do not use it. Use galvanized or zinc plated connecting material.
Specification of requirements for bolted joints:
Property
Joint Size (strength) Tightening torque (N.m)
class
Mast section to mast section M24 8.8 350
Rack to mast section M16 8.8 200
Guide roller bogey to car frame M20 8.8 300
Guide roller to bogey/car M16 8.8 200
Back-up roller to machinery plate M20 8.8 300
Machinery plate to car M16 8.8 200
Gearbox to machinery plate M16 8.8 200
Safety device to plate M16 8.8 150
! WARNING !
The locking ability of self-locking (nylon) nuts wears down with repeated use. Limit their
repeated use to three times at most. It is forbidden to use nuts with substantially reduced
locking ability.
Recommended tightening torques of other bolted joints:
Size Tightening torque (N.m) Tightening torque of

self-locking nuts (N.m)
M10 25 30
M12 40 45
M16 80 90
Elevator foundation
The elevator foundation consists of a concrete slab made of reinforced concrete with a built-in
foundation frame.
The specific dimensions and configurations are detailed in the General Arrangement Drawing
(GAD).
ATTENTION
A detailed procedure is provided in the NOV Series Installation Manual.
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ELEVATOR DATA
Protective zone around the elevator
ATTENTION
During erection and dismantling and when working above the base station, the area around
the elevator must be fenced (see figure 3.3). The size of the protective zone is determined by
the user based on local regulations and with regard to other circumstances (height of mast,
other protective measures, etc.).
Fencing round a elevator, protective zone

Figure 3.3
ATTENTION
Mark the fenced area clearly with an appropriate number of “Falling Objects” warning
signs.
Tie-ins
The tie-ins are detailed in the GAD and their installation is dealt with in the NOV Series
Installation Manual.
! WARNING !
Always wear a safety harness when working at a height or in areas with fall hazard. Use the
designated tie-off points on either side of the drive unit.
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ELEVATOR DATA
Reduction of the bearing capacity of the elevator structure by corrosion.
! WARNING !
Parts of the elevator structure substantially weakened by corrosion must not be used!
Replace corroded parts! The mast corner pipes must not be thinned by corrosion by more
than 10%.
Safety distances and clearances
In an operating elevator, a safety distance between any moving part of car and any point of access
for persons is at least:
Safe horizontal distance Fixed barrier (wall) height

Ft (mm) Ft (mm)
100 – 150 (4“ – 6“) 2500 (8‘ – 2 3/8“)
min. 350 (1‘-1 ¾“) 2000 (6‘-6 ¾“)
min. 900 (2‘-11 3/8“) 1600 (5‘-3“)
min. 1000 (3‘-3 3/8“) 1200 (3‘-11 ¼“)
ATTENTION
The clearance between the car sill and the landing sill must not exceed 32 mm (1 ¼“).
However, this clearance should not be less than approx. 25 mm (1”). A smaller clearance
could cause car to collide with a landing if other requirements for safe operation are not fully
met (clearances, incorrect adjustment of other elevator components).
Headroom above car

If there is a horizontal obstruction above the elevator (ceiling etc.), there must be a clearance of at
least 1.8 m (5’) between the car roof and the horizontal obstacle when the elevator is on the final
limit. At the same time, there must be a clearance of at least 0.3 m (1’) between the horizontal
obstacle and the elevator components located above the car roof.
A minimum top runby of at least 6” (0.15 m) must be provided when the car is on the final limit
switch.
Clearance under the car

If the car activates the final limit switch during operation, this switch must cut off the electric
power supply before the car makes contact with the buffers.
Note: For the purpose of working under the car, the elevator is supplied with a demountable stop
(a toothy steel block that mounts onto the rack), which is used to prevent the car from moving
downwards. The vertical work space under the car must be at least 1.8 m (5’).
! WARNING !
The setting, maintenance and subsequent inspections of specified clearances are very
important for the safety of the elevator and the persons using it. Disrespecting these
requirements can cause serious bodily injury or damage to the machine.
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ELEVATOR DATA
Load on landings
When loading and unloading the elevator, various fluctuating loads are imparted on the landings by
people and materials. The landing floor and the fixation of the landing gates and the corresponding
structures must be sufficiently strong, safe and in compliance with local regulations.
! WARNING !
The landings must not be overloaded. Work must be organized in such a way that no
material is left and no persons loiter at the landings. Landings are designated only for
loading, unloading and calling the elevator.
Storage of the elevator and its components
For long-term storage, or when the elevator is to be put out of service for a prolonged period
of time, it is especially important to:
 clean all components, mend any damage to the surface finishing, and, depending on the period
of storage, conserve functional surfaces,
 lubricate the machine as per the lubrication schedule, prevent lubricant leakage, especially from
the gearboxes,
 underlay the stored components in a suitable manner, prevent soiling by mud, prevent damage,
 Store parts in such a way that they do not collect water (beware of ice formation in cavities),
 pay special attention to electrical equipment. Treat contacts and moving parts with suitable
chemicals. Prevent water and dirt penetration to plugs and sockets. It is recommended to place
humidity absorbers (silica gels) inside the electrical enclosures,
 lock electrical panels properly,
 inspect, clean, and conserve connecting material and store it indoors,
 disconnect the emergency light battery (by removing the fuse)
 monitor the duration of the outage (storage)
Note: Sheltered storage saves operation costs and extends the life of the machine.
! WARNING !
Always be mindful of the risk of possible pollution of the storage area by lubricant leakage or
washdown. Prevent environmental damage. Observe local regulations.
! WARNING !
When storing an elevator equipped with a variable frequency drive (VFD), or a VFD as a
spare part, it is necessary to power up the VFD at least once a year in order to maintain the
capacitors inside it. If the VFD has been off power for more than a year despite the above
instructions, it is advisable to first connect it to a lower voltage supply, or to a DC supply of
up to 700 V with a low amperage. This will format the capacitors and ensure the equipment’s
longevity. Only then should the VFD be connected to permanent power.
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ELEVATOR DATA
ATTENTION
Check the capacity of the battery periodically. When its voltage drops below 20.4V (the red
and yellow lights on the TE2 power supply are on), immediately charge the battery. If its
voltage drops below 19.2V (only the red light is on), replace the battery. If the elevator is to
be cut off from both the supply lines for a prolonged period of time, disconnect the battery to
protect it from damage by running flat. Disconnect the battery by removing the fuse from the
battery module.
The battery’s fuses are removed prior to shipping. On installing the elevator, the fuses must
be replaced.
Monitoring the periods of long-term storage:
Date of last connection to mains
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ELEVATOR DATA
ELEVATOR DESCRIPTION
Base station
The base station consists of a base enclosure (if applicable) and base frame, to which the mast and
the buffer springs are attached. It contains a hinged, interlocked door. This door can only be opened
when the car is at the base station. The configuration of the base station is evident from Figure 2.2.
Mast
The mast is bolted together of mast sections. The mast sections are fitted with rack and include
connecting bolts and nuts.
Car
The car frame is welded, made of tensile steel beams, with guide rails for vertical rise car doors.
The car is guided along the mast corner tubes by means of guide rollers.
The car walls and doors are of aluminum or stainless steel sheeting.
The car door has a safety-glass vision panel in it, it is statically balanced and interlocked. The door
can only be opened at a landing.
The car contains electrical panels with control elements. The inside of the car contains a safety
device, which will stop the car should the nominal speed in the down direction be exceeded. The
safety device engages its pinion with the rack.
The roof has a hatch with a trapdoor in it. The ladder to access the hatch is located inside the car.
The roof is equipped with safety railing and a lifting harness for lifting and manipulating the car.
The car also contains elements preventing the car from falling out of engagement with the mast in
extreme breakdown situations. The limit switches are on the safety device plate.
Drive unit
The drive unit is located above the car. It consists of a frame, machinery plate and gear motors. The
drive plate further contains back-up rollers (absorbing the pinion reactions) and elements
preventing the pinions from falling out of engagement with the rack.
The drive consists of one to three gearboxes (depending on the size and capacity of the elevator)
with electric brake motors on the input and with drive pinions on the output.
Thermal protection of the motors in provided by thermistors in the motor winding and a
temperature relay wired in the motor power supply circuit.
Emergency lowering
The elevator is equipped with an emergency lowering system for the event of a power blackout or
malfunction. On mounting the hand lever, it is possible to open the motor brakes, whereafter the
car descends at a controlled speed to the nearest lower landing, where it stops automatically. If need
be, this procedure can be repeated, and thus the car can be lowered all the way to the base station.
The emergency lowering cannot be used if the safety device has tripped.
Landing equipment
To prevent access into the dangerous area of the hoistway, the landings are equipped with landing
gates, which can be of various types.
Landing gates are equipped with interlocks, they are mechanically locked and their opening and
closing is electrically monitored. A landing gate can only be opened if the car is at the landing.
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ELEVATOR DATA
Elevator lighting
Inside the car – alongside the normal car light, the elevator is equipped with an emergency light,
which will illumine the car in the event of a power blackout, and will last for at least 4 hours.
At the landings – lighting outside of the elevator car is not part of the elevator delivery.
! WARNING !
The elevator user must provide illumination of all landings and access ways leading to them.
Sufficient lighting of controllers and moving bars is especially important. Insufficient lighting
may cause serious bodily injury.
Small and additional parts

These consist especially of the cams of limit switches and door interlocks, potentially other parts (if
supplied).
Electrical equipment
Electrical equipment consists of electrical control panels, all other electrical devices, fixed and
moving wiring (for power supply, elevator controls and safety functions), car light, power supply
for electric equipment and recording of operation.
Most of the devices are concentrated in the three panels and in the control boxes at the landings.
Other electrical equipment (especially limit switches) are located on the base enclosure, the car,
and the landing gates.
Elevator controls
The elevator can be operated in various modes and equipped with various functions:
MODES OF CONTROL:
Selective/Collective Operation
Each landing corresponds with a button in the car (a keypad may be used if the number of landings
is unusually high). Each landing contains a call box with buttons for selecting the desired direction
of travel. The desired landing is selected by pressing the corresponding luminous button in the car.
The car is called to a landing by pressing a button on the call box. The luminous button stays on
until the call has been performed. Calls are answered in the most efficient manner relevant to
direction. If called to a landing, the car will stop at that landing if it is currently moving in the
desired (selected) direction. If it is passing the landing in the opposite direction, it will not stop, and
will only return to the landing when it has answered all the calls in the current direction. The
terminal landings contain call boxes with only one directional button on them. It is possible to enter
multiple calls from both the car and the landings; the system will memorize them and answer them
in the most efficient way. The position of the elevator is indicated on the display in the car, as well
as the displays on the landing call boxes.
If a keypad controller is used, enter a call by pressing the number of the destination floor and
confirming by the # key.
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ELEVATOR DATA
Single Automatic
Each landing corresponds with a button in the car. Each landing contains a call button for calling
the car. A call can only be entered if the elevator is ready for operation, i.e. if the main disconnect
switches are on, the car is standing still, all doors and gates are closed, no E-stop button is activated
and no fault is registered. In-car calls may be entered immediately on fulfilling the conditions for
operation (doors closed). Calls from landings may only be entered when the luminous button has
gone off, i.e. about 5 seconds after fulfilling the conditions for operation (in-car calls take priority).
Two Stop Elevators

The operation is identical to Single Automatic. The landing call boxes contain a button for calling
the elevator and a button for sending it to the other landing. The position of the elevator is indicated
by illumination of one of the buttons.
Inspection mode/manual operation

For inspection purposes, the elevator is equipped with an Inspection mode controller, where the
unit is controlled solely from the car roof by pressing the RUN button and one of the directional
buttons simultaneously. This mode is activated by turning the Inspection switch to the ON position.
This function, as well as the functions described hereafter, are designated for authorized personnel
only. While in Inspection mode, the car doors are locked and the elevator cannot be controlled by
normal operation means (buttons).
! WARNING !
An authorized person is responsible for a safe usage of these functions and for restoring the
elevator to standard operation.
Signalization
Telephone – The car is equipped with a telephone, which is hooked to the local telephone grid, or
directly connected with a permanent duty workplace. The telephone usually has a HELP button, a
 symbol or a keypad. If it has a keypad, the numbers to dial must be posted next to it. A
connection with an authorized person is made by pressing the HELP button, the  symbol or
dialing the appropriate number. The authorized person must be trained in emergency situations
regarding elevator, and it is their responsibility to determine a suitable solution to the situation and,
if need be, rescue passengers from the elevator – see the Emergency Situations section.
The car operating panel contains luminous landing buttons and the following pilot lights:
READY - it indicates that the car is ready to go

FAILURE - it indicates a fault in the controls; an error code will be displayed on the car
display,
DOOR OPENED – it indicates that a car door or landing gate is opened
The use of the following pilot lights depends on optional functions and features:
FIRE RECALL - it indicates that the Fire Recall mode has been activated
GREASE OF RACK - it indicates a low grease level in the reservoir, or that lubrication is in
progress
OVERLOAD - it indicates overloading of the car, or that the overload detection device has
been bypassed
A two-symbol, seven-segment display (hereinafter DS display), or a graphic display of the PLC.
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ELEVATOR DATA
The car has a horn on it for acoustic emergency signals:

Steady tone – when the Emergency Signal button is pressed.
Intermittent wavering tone – door left open.
Landing call boxes

Landing call boxes contain luminous call buttons – a Single Automatic call box has only one
luminous button on it; a Selective/Collective call box has two luminous buttons for selecting the
desired direction of travel. A two-stop elevator call box has two luminous buttons on it, one for
calling the car to the landing and one for sending it to the other landing. The meaning of the
buttons’ illumination is described in the Modes of Control section of the Elevator Controls chapter.
Landing call boxes can be equipped with DS displays as an option.
Displays at landings (optional):

They show the number of the current or the nearest landing in relation to the position of the car.
If the Drop Test mode is active, the displays show Dt.
Display in car:
1) Two-symbol, seven-segment display:
It shows the number of the current or the nearest landing in relation to the position of the car.
If the Drop Test mode is active, the display shows Dt.
2) Graphic display of the PLC:
It shows the direction of travel and the number of the current or the nearest landing in relation
to the position of the car. When the car is motionless, the display shows the load in the car as
percentage of the car’s nominal capacity, if the percentage is higher than 90 %. In the Inspection
mode, the display shows:
Direction of
DROP TEST mode travel
Load in car*
Rack lubrication in progress*
* Optional features
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ELEVATOR DATA
Error Codes
If the systems registers a fault that prevents the car from operating, an error code will come up on
the display and the FAILURE pilot light will come on.
1) Two-symbol, seven-segment display

The three-digit error code is displayed as the E symbol and the first digit of the error code
alternating with the last two digits at 2 second intervals (e.g. E101 is displayed as E1 alternating
with 01).
If a fault is registered, all calls are cancelled.
If a fault is rectified according to this manual, a new call can be entered. Faults must be reported to
the person responsible for the operation of the elevator. If the elevator is outside a landing, report
the emergency situation by means of the emergency signalization or the telephone, and wait for
rescue instructions.
Example: E102 fault – E-Stop
2) Graphic display of the PLC

Error codes, as well as operation statuses, are displayed in the bottom line of the display. Some
errors also switch on the FAILURE pilot light.
If an error preventing the operation of the elevator is registered, the PLC will display its code and
the FAILURE pilot light will come on.
Example: E108 – Emergency lowering
Error code interpretation

E1-xx error: The elevator is inoperable, all calls are cancelled.
E2-xx error: The elevator stops immediately.
E3-xx error: A functional or safety circuit fault. If the unit is in motion, it makes it to the nearest
landing and stops. In some cases, a new call can be entered.
E4-xx error: A functional fault.
E9-xx error: The elevator stops immediately.
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ELEVATOR DATA
Error
Code Description
ERR101 Safety device
ERR102 E-stop
ERR103 Motor temperature
ERR104 Inverter error
ERR105 Phase relay
ERR106 Roof hatch
ERR107 -not used-
ERR108 Emergency lowering
ERR109 Safety relay fault
ERR110 No.1 safety contactor fault
ERR111 No.2 safety contactor fault
ERR112 Speed limit exceeded
ERR113 Encoder error
ERR114 Encoder position error
ERR115 Brake error
ERR116 Brake contactor error
ERR117 Pit E-Stop
ERR119 Door left open for more than 5 minutes – all calls are cancelled
Loss of main power supply and auxiliary circuit supply – not shown on the display. The
ERR120 PLC is supplied from the battery.
ERR121 SQ1 Final limit switch – limit position override
ERR122 Loss of main power supply; auxiliary circuit still powered up
ERR133 Motor temperature – temperature relay
ERR134
ERR135 E-Stop on roof
ERR136 Safety circuit broken for no apparent reason, or brake circuit breaker fault
ERR137 Preventa relay safety circuit broken for no apparent reason
ERR138 Door lock switch open
ERR139 CanOpen error; elevator will only move in Inspection mode
ERR201 Safety device tripping during operation

ERR202 E-stop during operation
ERR203 Motor temperature during operation
ERR204 Inverter error during operation
ERR205 Phase relay during operation
ERR206 Roof hatch during operation
ERR208 Emergency lowering during operation

ERR210 No. 1 safety circuit during operation
ERR211 CJA – car door open during operation
ERR212 CJA – car door unlocked during operation
ERR215 Car door open during operation
ERR216 Car door unlocked during operation
ERR218 Activation of top normal limit switch during operation
ERR219 SQ1 final limit switch contact open during operation
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ELEVATOR DATA
ERR220 CanOpen communication lost during operation (in Normal mode)
*possible error codes depending on the actual number of landings*

ERR241 CJA – landing 1 gate open during operation
ERR259 CJA – top landing gate open during operation
ERR294 CJA – landing 6 gate unlocked during operation

ERR301 Door closed switch error

ERR303 Roof hatch switch error
ERR305 LMI II overload device load sensing pin communication failure – both pins
ERR306 LMI II overload device load sensing pin communication failure – one of the pins
ERR400 Battery status
ERR410 Incorrectly initiated Drop Test mode
ERR420 In car Quido 30h communication error
ERR421 In car Quido 31h and 32h communication error
ERR422 Landings communication error
ERR999 KM1 safety contactor during operation
ERR998 KM2 safety contactor during operation
Accessories
Accessories consist of: - tools for emergency actions and resetting the safety device,
- “Stop” (toothy block mounted on the rack when working under the car or
lifting the elevator unit)
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ELEVATOR ERECTION AND DISMANTLING
ELEVATOR ERECTION AND DISMANTLING
! WARNING !
Only authorized persons trained in the erection of rack and pinion elevators may erect and
dismantle the elevator.
The scope and type of the authorization is determined by local regulations and is issued by
local authorities.
Connecting the elevator to the main power supply and inspecting the power supply may only
be performed by persons with the appropriate authorization.
Erection and dismantling must be performed in a professional manner and all work safety
regulations, as well as technical and safety requirements contained herein must be observed.
Make sure that the installation of this elevator is permitted and complies with local
regulations.
ATTENTION
This Manual does not contain procedures for the erection and dismantling of the elevator.
All necessary information is provided in the GAD, or the NOV Series Installation Manual.
! WARNING !
The elevator must be tested by an authorized specialist after the completion of the
installation. The elevator is tested in the extent of the “Installation test” and “Initial electrical
inspection”. Although local regulations may stipulate otherwise, the extent of testing
described herein must be regarded as the necessary minimum.
ATTENTION
During erection and dismantling, the elevator is controlled from the car roof by means of the
directional pushbuttons on the controller located on the car roof.
PROGRAMMING OF LANDINGS
Note: If a keypad is used, instructions for programming of landings are provided in Part 2 of this
manual.
It is performed after the installation of the elevator. During the programming session, the elevator
must be in the Inspection mode. It is advisable that the programming be performed by two persons,
one controlling the elevator from the roof and the other checking the position of the elevator and
saving it in the PLC memory.
To turn the elevator over to the Programming mode, drive the cage to the base landing (onto the
bottom limit) and hold the F1 button on the PLC keypad for approx. 5 seconds. The PLC screen
will display a prompt for the Programming mode. Press 0 and confirm by Enter. The screen will
display PROGRAMMING and landing numbers. Confirm the position of landing 1 by pressing the
corresponding button on the panel door. The number 1 (0) on the screen will be highlighted to
confirm the position has been saved in the memory. Go to the next upper landing and level the cage
with the landing. Press the corresponding button on the panel door to save the landing’s position in
the memory. The screen will confirm the saving by highlighting the saved number. Repeat this
procedure at all the upper landings. The screen will highlight the landing numbers that have already
been saved. The Programming mode is terminated automatically when the cage goes down to the
base landing and activates the bottom limit. On turning the elevator over to the Normal mode, it is
ready to be controlled by the landing buttons on the cage operation panel.
To correct a landing’s position, use the same procedure, but only at the landing you wish to correct.
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ELEVATOR DATA
ATTENTION
The values of the individual positions are saved in the memory of the PLC. The position of
the bottom limit cam is the reference point (zero value) for calculating the position of the cage
on the mast. Changing the position of the bottom limit cam will change the positions of all the
landings and it will be necessary to correct them.
The top limit cam must be so adjusted so it does not make the top limit switch when the unit
stops at the top landing.
ATTENTION
If a power blackout occurs while the elevator is away from the base landing, it will have to
find itself when the power is back on. On pressing any button, it will go to the base landing
and reset its position by activating the bottom limit switch. It will display the resetting status
on the screen of the PLC. It is then necessary to enter a new landing call.
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EMERGENCY SITUATIONS, FAILURES

Emergency situations occurring during the elevator’s operation may be the following:
 a defect that renders the elevator inoperable,
 a prolonged power blackout,
 the safety device tripping,
 hitting the final limit switch (both top and bottom),
 overriding the final limit switch and hitting the buffers (bottom).
All these emergency situations mean that it is impossible to move the car and they call for taking
special actions.
An emergency situation is reported by means of the telephone to the person responsible for the
elevator operation by the persons travelling inside the car. This person ensures further necessary
measures.
! WARNING !
All emergency situations during the elevator operation must be dealt with by a qualified and
authorized person trained in emergency actions. It is forbidden for the persons in the car to
perform any actions attempting at releasing the elevator and continuing its movement.
Basic rules for emergency actions:

1) Check the condition of the elevator – the position of the car to the landing, accessibility of the
car by emergency means. Visually check the hoistway, mast and trailing cable. Make sure the
doors are closed properly and check emergency control elements (switches) to see if any are
tripped.
2) Read error codes.
3) Check the power supply and the landing gate circuit.
4) Enter the car by emergency means. Do so in compliance with all local regulations and work
safety principles.
Note: In an emergency, the car is entered via the roof hatch.
5) Turn the elevator over to Inspection mode and test ride it.
6) If the elevator will not ride in Inspection mode, lower the car to the nearest lower landing by
means of the Emergency Lowering Device and disembark any personnel and materials.
7) If the condition of the elevator does not allow for the use of the Emergency Lowering Device,
rescue any personnel inside the car by alternative, safe means.
8) Identify the fault by:
a) reading the error code on the car display
b) reading the error code on the display of the VFD
c) measuring the safety circuit (if the safety contactor is not made)
d) resetting the control system by turning off the main disconnect switch on the car panel for 30
seconds and then turning it back on.
9) If the above actions fail to make the elevator operable, contact your authorized service
contractor.
10)Report the failure and record it in the elevator logbook.
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Entering the elevator car in an emergency
! WARNING !
Only persons authorized for emergency actions may enter the car in an emergency. Before
entering, the elevator must be disconnected from the main power supply, the main switch
must be turned off and locked. Ensure that the authorized person is transported onto the car
roof in an absolutely safe way.
Note: This Instructions manual cannot detail the exact procedure for entering the car in an
emergency. This procedure is determined by the elevator user based on the situation and
while observing the safety requirements of this Manual and local regulations.
! WARNING !
Should it become necessary to connect the elevator to the main power supply for the sake of
identifying the cause of the failure, it must be done so by a person authorized for this kind of
actions and based on instructions given by the authorized person inside the car. A flawless
communication between these two persons must be ensured, and the performance of
individual actions mutually confirmed. When finished, turn off and lock the main switch!
POWER BLACKOUT
In the event of a prolonged power blackout, an authorized person decides whether the car should be
lowered to the nearest lower landing. The authorized person designates a person inside the car to
perform the action, and supervises the procedure.
Emergency Lowering
Before lowering the car, make sure that the drive unit is undamaged and that there are no
obstructions to the car’s descent with gravity. The Emergency Lowering Device cannot be used
if the safety device has tripped.
! WARNING !
During emergency lowering, follow the instructions of the authorized person and the
instructions on the sign inside the car.
Procedure:
1. Mount the hand lever stowed underneath the cover.
2. Release the motor brakes by pulling the lever; the elevator will start descending.
3. When the car has reached the nearest lower landing, it will stop automatically.
4. Leave the car.
ATTENTION
After initial acceleration, the speed of the car’s descent will settle on 25m/min (~80FPM). The
lever must be pulled all the way, otherwise the emergency lowering does not work and the
motor brakes suffer considerable wear, possibly resulting in their complete destruction!!!
If the authorized person decides so, it is possible, by first releasing the lever and then pulling it
again, to continue the descent to the next lower landing, or ultimately to the base station.
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! WARNING !
During emergency lowering, the car and landing doors must be closed. Check especially
when repeating the procedure after reaching the nearest lower landing.
SAFETY DEVICE TRIPPING

Procedure:
1) Persons are evacuated from the elevator car regardless of why the safety device has tripped.
2) By inspecting the elevator, the authorized person identifies the reason why the safety device has
tripped. They should focus especially +on the brakes, gearboxes, pinions and rack, and the
guide and back-up rollers.
! WARNING !
When evacuating persons from the elevator car, the elevator must be disconnected from the
main power supply, and the main switch turned off and locked.
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ATTENTION
The procedure for resetting the safety device is determined after identifying the cause of its
tripping.
The cause of the safety device tripping must be eliminated before the safety device is reset.
! WARNING !
If the cause of the safety device tripping is not identified and eliminated with absolute
certainty, an authorized specialist must determine further procedure.
OVERRIDING THE TOP NORMAL LIMIT
If the car overrides the top normal limit, an authorized person lowers the car to the nearest landing
by means of the emergency lowering, and ensures that the car is vacated and unloaded.
Procedure:
1) Turn off the main switch and press the EMERGENCY STOP button on the car.
2) The authorized person designates a person in the car to lower the car to the nearest lower
landing with the emergency lowering device, where the car is to be unloaded.
ATTENTION
See Emergency Lowering section above for the procedure.
3) Lower the empty car to the base station by means of the emergency lowering device. Rectify the
fault and test the operability of the elevator.
OVERRIDING THE BOTTOM NORMAL LIMIT, OVERRIDING THE

BOTTOM FINAL LIMIT
In both these cases, an authorized person ensures that the car is unloaded and drives the car shortly
upwards by means of the INSPECTION controller and after demounting the cam of the bottom
final limit. If the final limit switch is a Schneider ZCK type, it is necessary to press the RESET
button inside the RM2 panel after demounting the cam.
Note: It is advisable to make a mark on the cam, so it is later reinstalled correctly (in the correct
position).
! WARNING !
The cause of the overriding must be identified by an authorized person. The operation of the
elevator may only be resumed when the cause is eliminated and the elevator tested
appropriately.
! WARNING !
In dismantling and reinstalling the bottom normal limit cam, always secure the car against
undesirable movement (the main switch, the EMERGENCY STOP button, the Stop block).
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INSPECTIONS AND MAINTENANCE

Elevator inspections and maintenance ensure that the elevator meets all operating and safety
requirements. Maintenance includes checks, cleaning, lubrication and adjustment that are carried out
periodically or if rendered necessary by the conditions and peculiarities of the operation. The
individual tasks vary in the level of qualification they require.
The elevator user must appoint persons authorized to inspect and maintain the elevator, and must
determine the extent of their responsibilities.
The user keeps and archives the documentation concerning the periodic inspections and maintenance
– CHECK LIST – together with other operation documentation (see Manual Part 2, Appendix I).
During inspections, maintenance and tests, the elevator is to be controlled from the car roof by
means of the INSPECTION controller. This controller is activated by turning the
OPERATION/INSPECTION keyed switch on the INSPECTION controller to the INSPECTION-I
position. The pushbuttons on this controller require constant pressure. Elevators with a frequency
drive run at a reduced speed in this mode.
! WARNING !
It is forbidden to lean out of the car roof area when riding in the Inspection mode.
! WARNING !
The Inspection mode can only be used by an authorized person, who has the key to the
INSPECTION switch and who is responsible for keeping the key safe.
! WARNING !
After turning the OPERATION/INSPECTION switch to the OPERATION position, the
elevator may go to the base station on pressing any landing button (in elevators with a
frequency drive, it will do so at a reduced speed).
PERIODIC INSPECTIONS AND MAINTENANCE OF THE ELEVATOR
PERFORMED BY THE OPERATOR
Before startup each day:

- Visually check the ground enclosure (if applicable) and the elevator car for any changes that
could impair safe operation,
- Unlock and turn on the main switch,
- Test-run the car, verify stopping at the bottom and top positions, the function of the
EMERGENCY STOP button in the car, car and enclosure doors and interlocks and the
overall performance of the elevator (noise, vibrations)
During the day:

- Check if the elevator is utilized the right way,
- Check if the elevator is showing any defects threatening the safety of persons and materials.
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PERFORMED BY THE OPERATOR OR A PERSON RESPONSIBLE FOR THE ELEVATOR
Weekly (50 hours) – perform at least the following:

1) Check if the daily inspections are performed and if the elevator is put into operation the right
way at the beginning of each shift.
2) Inspect the elevator, check legibility and completeness of all instructions and directions for use.
3) Verify that the car door interlock is functional above the bottom landing.
4) Verify that the base enclosure door interlock is functional when the car is above the base.
5) Verify the functionality and safety of the landing gates.
6) Verify that the cable holder passes through the cable guides in the correct manner.
7) Verify the integrity and condition of the supply and trailing power cables, as well as the
function of the cable trolley.
PERFORMED BY THE MAINTENANCE CONTRACTOR
Monthly (200 hours) – in addition to the above mentioned:

8) Check the tightening of the bolts of the drive unit plate, the gearboxes and the safety device.
9) Check the tightening of the guide and back-up rollers.
10) Check all the bolted connections of the tower sections, the rack and the tie-ins.
11) Check the fastening of all limit switch cams.
12) Check the fastening of limit switches.
13) Check the stopping at landings.
14) Check the function of top and bottom limit switches.
15) Check the function of the EMERGENCY STOP and STOP buttons.
16) Check the function of the brakes by performing the Single Brake Test. If necessary, clean the
brakes from dust and impurities.
17) Check the rack and pinions for wear.
18) Check the position (alignment) of the pinions and the rack.
19) Lubricate the rack.
20) Lubricate the safety device bearings.
21) Lubricate the pins of the landing gates.
22) Test the ground fault protectors, check the fastening of terminals and conductors, clean the
inside of the electrical panels, check the fastening of the limit switch levers.
23) Check the filters of the electrical enclosure fans. Replace if necessary.
Every 3 months (600 hours) – in addition to the above mentioned:

24) Check the wear and alignment of the car guide rollers; check the clearances of the safety hooks
and dogs on the car and the drive unit.
25) Lubricate the car door wire ropes and their suspensions, lubricate the guide rails of the door
counterweights.
26) Lubricate the hinges of roof hatch door.
27) Check and, if necessary, adjust (re-gap) the motor brakes.
28) Check the function of the emergency lowering in the extent of at least one landing.
Every year (2400 hours) – in addition to the above mentioned:

29) Lubricate the car guide rollers.
30) Lubricate the back-up rollers of the drive unit.
31) Lubricate the car door wire rope pulleys.
32) Maintain and lubricate the ground enclosure door interlocks.
33) Maintain and lubricate the car door interlocks.
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Every 3 years (7200 hours) – in addition to the above mentioned:

34) Replace the oil in the gearboxes (See the ATTENTION in the Lubrication section).
35) Replace the safety device.
! WARNING !
Any changes in the elevator performance (higher amperage draw, higher operating
temperature, increased drive unit vibration or noise) indicate that there might be a serious
fault in the drive unit or other parts. Discontinue operation until an authorized person
identifies and eliminates the fault.
Failure to comply with this requirement may result in serious bodily harm or property
damage.
ATTENTION
The safety device must be tested every 6 months. The test is carried out as part of the
Specialized Inspection (see the Testing section of this Manual).
ELEVATOR LUBRICATION
It is carried out according to the Lubrication Chart and Figure 8.1.
Lubrication Chart
Lubricating Number Lubricant Method
spot of spots
Monthly (200 hours)
1. Rack -Fin Grease OG- -spraying-
-SKF LGEM 2- -automatic-
2. Safety device bushings 1 grease* grease gun
3. Pins of landing gates oil oil can
4. Landing gate flapper grease smearing
Every 3 months (600 hours) – in addition to the above mentioned
5. Car and landing door wire ropes 6 grease smearing
6. Door balance counterweight rails 4 grease smearing
7. Roof hatch door hinges 2 oil oil can
Every year (2400 hours) – in addition to the above mentioned
8. Guide rollers 12 grease grease gun
9. Back-up rollers 2 grease grease gun
10. Door wire rope pulleys 6 grease refill
11. Pins of landing gate interlocks grease refill
12. Pins of car door interlocks grease refill
Every three years (7200 hours) – in addition to the above mentioned
13. Gearboxes Gear oil refill
– see Note
Note: Grease* specification – see Safety device manual.

Grease = universal grease for ball bearings and sliding bearings of class NL GI 2-3
(e.g. Mogul K3).
Oil = lubricating oil class SAE 10-30.
- 33 - M355-14
ATTENTION
The gearboxes are usually filled up by the manufacturer with SYNTHETIC OIL. There are
plates on the gearboxes containing this information. If so, use SYNTHETIC OIL of viscosity
class ISO VG 220 (for example Shell Tivela Oel WB) suitable for operation in temperature
range of –20 to +40°C.
Change SYNTHETIC OIL every three to four years.
Attention! Do not mix mineral and synthetic oils when refilling oil!
The refill volume is 3.7 liters per one SK9042.1 gearbox, or 7.5 liters per one SK9052.1
gearbox. If the gearbox is mounted vertically, the refill volume is 7.5 liters.
Elevator lubrication, Figure 8.1
- 34 - M355-14
Rack lubrication
The rack may be lubricated by an automatic lubricator, or manually with a spray can. If an
automatic lubricator is used, the intervals are preset by the elevator manufacturer. The level of
lubricant in the reservoir must be checked periodically.
For manual lubrication of the rack, the manufacturer recommends lubricants containing Teflon,
which create a dry film on the rack and do not trap impurities. These lubricants come in spray cans
and so their application is very simple and is performed from the car roof while the car is in
motion. The lubricant is to be sprayed on the top surface of the rack teeth, where the pinions come
in contact with the rack.
Recommended procedure:
When the mast is erected, spray the rack with Fin Grease 0G. The 500 ml container is good for
about 70 m of rack. Repeat the procedure after 1or 2 weeks, which should build a sufficient layer of
the lubricant on the rack teeth (note that the rack will appear dry and unlubricated all the same).
The coating must be renewed every 1to 2 months, but this period may be shortened or extended
depending on the frequency of operation, dustiness of the environment, elevator loading rate etc.
Whether the rack is sufficiently lubricated can be checked by palpation. If the teeth do not feel
waxy to the touch, it is time to lubricate the rack. This check should especially be performed in the
beginning of the operation and its results should be used to determine the optimal lubrication
intervals.
Lubricants containing Teflon, apart from their obvious advantage in not trapping impurities, also
show very good lubricating, noise reducing, and water resistant qualities. In comparison with
conventional methods of lubrication, the lubricated surfaces appear dry, but they are not. Also, the
quantity of the spray-applied lubricant is relatively small, and therefore the overall costs are lower
than in traditional lubricants. The most important savings, however, lie in the considerably longer
life of the rack and the pinions.
The manufacturer can supply the above mentioned lubricants or mediate their distribution.
Automatic rack lubricator (optional feature)
Description: The automatic lubricator consists of a grease reservoir with a level monitor switch,
and a motor-driven pump that delivers the lubricant to the lubrication point.
The automatic lubricator is designated to periodically lubricate the rack and will not deliver enough
lubricant during one lubrication session to adequately lubricate a dry rack. After installing the
elevator, or after a long outage, lubricate the rack manually, or repeat the lubrication session a few
times (go up and down a few times in Inspection mode with the lubricator activated manually).
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ELEVATOR DATA
If the lubricant is used up, the user is notified by the GREASE pilot light flashing. The lubricant is
refilled via the nipple (DIN 71412-AM10x1) located on the body of the pump (see Fig. 8.1-b).
1 – grease nipple
2 – pressure relief valve
3 – follower
4 – max. grease level
5 – lubricant
6 – min. grease level
Fig. 8.1-b Lubrication pump
The manufacturer recommends using weather resistant, open gear lubricants such as the SKF
LGEM2 grease. The viscosity of the lubricant must be between 150 – 5,000 mm2/s.
Automatic lubricator location
- 36 - M355-14
ELEVATOR DATA
Lubrication interval setting

The automatic lubricator only activates in the Normal operation mode. The car registers the number
of trips between the individual landings, and after reaching a preset number of trips, the lubricator
activates and lubricates the appropriate stretch or rack. The preset interval is 10 trips, but it can be
changed.
The lubrication interval is changed in the Inspection mode as follows:
Pres the down arrow on the PLC keypad to display the “Greasing setting” menu:
Move the cursor to the numeric value of the “Lubricate every __ Run” line by means of the arrows
. Press the  button to activate the field (indicted by flashing). The value can be changed by
entering the number directly on the keypad, or by means of the arrows . The range is 0 – 99.
Confirm the entered value by pressing  . The setting is then complete and the menu can be
terminated by pressing the ESC button.
Manual activation of lubricator in Inspection mode

It is possible to initiate a single lubrication session manually. It is performed in the “Greasing
setting” menu and the car must not be located in the top terminal position.
Move the cursor to the OFF field in the “Lubricate now” line by means of the arrows . Press
the  button to activate the field (indicted by flashing). Use the arrows  to change the field to
ON and confirm by pressing  . The setting is then complete and the menu can be terminated by
pressing the ESC button.
The lubricator will now be activated for the entire duration of the next upward travel until the top
normal limit is reached. Stopping the car will not terminate the lubricating session; the lubricator
will reactivate on the next upward trip.
A low grease level is indicated by the GREASE pilot light flashing.
CHECK OF RACK AND PINIONS

Procedure:
1) Visually check the integrity of the pinions, shaft run-out, and pinion mounting.
2) Measure the pinion’s teeth wear (Figure 8.2). The “Z” dimension over two teeth must be greater
than 35.8 mm (Z = 37.1 mm in a brand new pinion).
! WARNING !
If the pinions are worn over the limit, discontinue the operation and replace the pinions.
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ELEVATOR DATA
3) Measure the wear of the rack (Figure 8.2).
While inspecting the rack (along the entire length of the mast), measure the wear at several
places. Measure the wear by pushing a 14 mm diameter roll into the gap between the rack teeth.
The “V“ dimension must be at least 58.8 mm.
4) Measure the clearance between the pinion and the rack (Figure 8.2). The “A“ dimension
(clearance) must be between 2.5 and 3 mm.
5) Verify that the pinion (viewed from above) overlaps the rack equally on both sides and that the
back-up roller leans against the rack with its full width (Figure 8.3).
Check of rack and pinions

Figure 8.2
Top view
Figure 8.3
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Setting of hoist cage, drive unit and safety device plate

Note: Applies to drive units equipped with adjusting screws between the drive unit frame and the top of the
machinery plate (replacement for the previously used load sensing screws). In October 2014, this manual
was revised to include the older version using a rubber strip in place of the current adjusting screws
(Revision 1).
MOUNTING CAGE AND DRIVE UNIT ON MAST
1. Before mounting the hoist cage, the cage front rollers should be adjusted to half their
eccentricity, and the side rollers loosened all the way.
2. Adjust the machinery plate and the safety device plate so that the bushings of the
fastening bolts are centered on the holes in the plates. The top of the safety device plate is
pushed against the cage frame with a clearance of 0.1 – 0.2 mm.
3. The machinery plate is propped against the frame via the two adjusting screws at the top.
The guide rollers (front and rear), as well as the back-up rollers on the machinery plate, are
loosened all the way.
4. Mount the cage and the drive unit onto the mast and pin them together (with regular pins
or load sensing pins).
SETTING CAGE ON MAST

5. Adjust the front and rear cage rollers so that the cage structural beams are parallel with
the mast tubes and the side rollers are in the middle of their axial float (ideal state). All the front
and rear rollers are in contact with the mast pipes. In some cases, the front rollers come in
contact with the mast pipes only after the cage is loaded.
Check the setting of the front and rear rollers by measuring the distance between the two mast
pipes and the face of the beam (U 160), see Figure 1a, detail A. Use any straight edge (e.g. an
aluminum profile) and a tape measure. With the U 160 beam, the ideal distance is 3.5 mm at both
the top and bottom of the cage.
Adjust the side rollers so that the beams are parallel and symmetrical with the mast pipes and the
front and rear rollers are in the middle of their axial float (ideal state). Check the symmetry (the X
dimension) by means of gauges (9 – 13 mm), by measuring the gap between the beam and the
mast pipe (right and left, top and bottom).
In a pair of opposite side rollers, at least one of the rollers must be adjusted with a clearance (0.5
– 1 mm).
An example of ideal setting: The top left side roller has 1 mm clearance, while the top right roller
has no clearance (snug on the pipe), the bottom left roller has no clearance, while the bottom
right roller has 1 mm clearance. Alternatively, all the side rollers have 0.5 mm clearance while the
mast pipes and cage beams are parallel and symmetrical, see Figures 1 a, b, c.
A-A ( 1 : 10 )
Fig. 1 a
Seřízení čelních kladek A(1:5)

Front and rear rollers setting
Spodní kladky
Teor. 3,5
A Bottom rollers
Teor. 3,5
Al.pravítko
Straight edge Stožár
Spodní kladky Mast
Nosník klece
Top rollers Cage beam
X Nosník klece X
X=X X
- 39 - Cage beam M355-14
ELEVATOR DATA
Fig. 1 b
Seřízení klece
Cage setting
Stožár
Mast
A A
X X
Výtah
Cage
X X =- 40X- X M355-14
ELEVATOR DATA
Fig. 1 c
Seřízení bočních kladek

Side rollers setting
Teoretický stav
Theoretical state
0,5
0,5
Skutečný stav
Actual state
0 1
Ride up a short way (approx. 0.5 m) and check the setting of the rollers (consistent clearances in
side rollers, front and rear rollers in contact with the mast pipes). Readjust if necessary and
tighten the guide roller fastening bolts to 200 Nm.
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ELEVATOR DATA
ADJUSTING CLEARANCE BETWEEN PINION AND RACK

6. Before adjusting the motor pinions, relieve them by manually opening the brakes and
lowering the cage on the buffers. The cage must not be loaded. Alternatively, the brake of the
motor whose pinion is being adjusted can be opened manually to take the load off the pinion.
Example (in a three-motor drive unit):
a) top motor – open brake manually, adjust pinion according to section 7 below
middle motor – open brake manually
bottom motor – brake closed
b) top motor – brake closed
middle motor – open brake manually
bottom motor – open brake manually, adjust pinion according to section 7 below
Before you start adjusting the pinions, loosen the bolted connections between the machinery plate
and the drive unit frame.
7. The goal of this adjustment is to use the back-up rollers (see Fig. 3) to set the clearance
between the rack tooth valley and the tip of the pinion tooth to 2.5 – 3 mm (measured with a
gauge). That corresponds with a tooth clearance of 0.4 – 0.5 mm (measured with a feeler gauge)
in new rack and pinion. Under normal operation conditions, this value is usually around 0.5 mm,
see Fig. 2.
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ELEVATOR DATA
8. To move the pinion away from the rack, loosen the back-up roller that is closer to the
pinion and eccentrically adjust it to create such a clearance between the back-up roller and the
back of the rack that will result in a clearance of 2.5 – 3mm between the rack tooth valley and the
pinion tooth tip when the back-up roller is pressed against the rack. When the cage is loaded,
the back-up rollers must be in contact with the rack (impossible to turn by hand), and must
always be re-tightened to 300 Nm after adjustment, see Fig. 3.
Fig. 3
9. After riding approx. 1 – 2 m in the up direction, the pinion will move away from the rack
and the back-up roller will lean against the back of the rack. Check the clearances between the
rack and pinion teeth, and between the back of the rack and the dog on the machinery plate
(max. 3 mm, measured with a feeler gauge), see Fig. 2.
10. To move the pinion into the rack, proceed according to sections 6 and 7 above. With the
machinery plate bolted connections loosened and with the motor relieved (brake released), the
pinion can be moved into the rack by means of the back-up roller, see Fig. 3. On riding the cage
up (approx. 1 – 2 m), check the clearances according to sections 7 through 9 above.
11. The adjusting screws at the top of the drive unit must be in contact with the machinery
plate. These screws are used to correct the position the machinery plate in relation to the drive
unit frame and with regard to the correct setting of the teeth clearances. The older drive unit
version has a rubber strip in place of the adjusting screws; the machinery plate must then prop
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ELEVATOR DATA
against the drive unit frame with its full width. Shifting the machinery plate when adjusting the
tooth clearances changes the side clearances between the machinery plate and the frame. The
minimum side clearance is 1 mm. At the same time, the cage suspension eye lugs should be
centered on the drive unit suspension eye lugs (ideal state), but there must always be a minimum
clearance of 0.2 mm on the sides of the cage suspension eye lug, see Fig. 4.
Fig. 4
Spojení rámu s klecí

Connection of drive unit to cage
Clearance ~ 0,2mm
Vůle ~ 0,2mm
0,2mm
K K
2,5 teor. 2,5 teor.

Stejná mezera na obou
stranách je ideální.
MIN 0,2mm The same clearance on
either side is ideal.
K-K ( 1:5 )
or. 3 te
3 t e or.
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ELEVATOR DATA
12. If the prescribed clearances are adhered to, tighten the bolts along the perimeter of the
machinery plate to 90 Nm, see Fig. 5. If the clearances are not adhered to, follow section 13
below.
Fig. 5
Deska s rámem
Drive unit frame and
machinery plate
Stavěcí šrouby - dotek s deskou pohonu
Adjusting screws - in contact with the
teor. 20mm
drive unit frame.

Dotáhnot na 90Nm.
Spoje s gum.podložkami a pouzdrem.
Tighten to 90 Nm.
Connections with rubber rings and
bushings.
MIN. 1mm
Clearance ~ 0.2 mm
MIN 1mm mezi rámem a deskou

Vůle ~ 0,2mm
Min. 1 mm between the frame

and the machinery plate.
Excenter
Eccentric.
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ELEVATOR DATA
DRIVE UNIT FRAME SETTING
13. Set the drive unit frame so that its eye lugs are symmetrical to the mast pipes (ideal
state), but with a minimum clearance of 0.2 mm on either side of the cage eye lugs. After
adjusting the symmetry and clearances of the drive unit frame, it is necessary to check
the tooth clearances and the position of the machinery plate. Adjusting the drive unit
frame is directly related to adjusting the clearances between the drive unit frame and the
machinery plate, see section 11 and Figure 4 above.
It is therefore possible to adjust the drive unit frame only, independent of the machinery
plate (the tooth clearances are set correctly). The drive pinions are meshed with the rack
(the cage is empty), the bolts connecting the machinery plate to the frame must be
loosened, and there must be a clearance between the mast pipes and the front and rear
guide rollers at the top of the drive unit. Move the drive unit frame by driving a wedge
between the cage eye lug and the drive unit eye lug. Keep checking the clearance
between the inner drive unit eye lug and the mast pipe (the milled face must be at least 3
mm away from the mast pipe with regard to the symmetry of the frame). When the
adjustment is complete, tighten the bolted connections of the machinery plate to 90 Nm.
14. On checking the alignment of the cage and the drive unit frame, measure the lateral
protrusion of the bottom drive pinion past the rack, and set the same protrusion in the top pinion
(the cage must be aligned and the protrusion in both the pinions must be measured/checked in
the same place in the rack). The protrusion is adjusted by means of the pair of guide rollers that is
closer to the pinion (viewed from the tower, they are the ones the right hand side of the drive unit
frame), see Fig. 6. On completing the adjustment, one of the guide rollers must have at least
1mm clearance, see Fig. 7, detail C.
Fig. 6
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ELEVATOR DATA
15. On setting the protrusion, take the measurement between the beam of the drive unit frame
and a straight edge pushed against the mast tubes, see Fig. 7. Set the same measurement
(approx. 43 – 45 mm in a U120 beam) on the left side of the frame, again by means of the guide
rollers. Ideally, the rear rollers should be in contact with the mast pipe and the front rollers should
be adjusted with a clearance of at least 1 mm (or vice versa) and tightened to 200 Nm, see Fig.
7, detail C. On test running the hoist, check the position of the cage and drive unit guide rollers
(the prescribed guide roller and tooth clearances must be adhered to).
Fig. 7
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ELEVATOR DATA
16. Check that the machinery plate bolted connections are tightened to 90 Nm, and the
back-up rollers to 300 Nm. A loose back-up roller increases the clearance between the rack
and the pinion, which results in vibrations and faster wear. Check the tightening of the
bolted connections periodically according to Table 1.
SAFETY DEVICE PLATE SETTING

17. Check the clearance between the top edge of the plate and the cage frame (0.1 – 0.2
mm), see Fig 8, detail A.
Fig. 8
18. Loosen the bolted connections along the perimeter of the plate and adjust the tooth
clearance between the rack and the pinion(s) to 0.2 – 0.4 mm (measured with a feeler gauge). It
should always be possible to turn the pinion(s) slightly by hand (within the tooth clearance). The
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ELEVATOR DATA
safety device plate can be moved sideways by means of the adjusting screw with the disc
springs. The safety device plate should be parallel with the cage frame and the clearance
between the back of the rack and the dogs on the back of the safety device plate must be 2 – 3
mm. When the safety device trips, the safety device plate must be able to move enough to bring
the hooks in contact with the back of the rack.
The safety device plate can be lifted by means of the two eccentrics located at the bottom of the
safety device plate (perform these adjustments after loosening the bolted connections along the
perimeter of the plate and while checking the tooth clearances). After setting the safety device
plate and tightening its bolted connections to 90 Nm, turn the eccentrics to create a clearance
between them and the safety device plate of at least 0.2 mm (measured with a feeler gauge).
19. Set the preload of the disc springs by compressing their volume to 20 mm. They are in a
serial-parallel sequence of //\\ //\\//\\ (12 springs).
20. Perform further operations with the safety device (positioning, connection tightening)
according to the technical documentation for the specific safety device model.
21. Check the setting of the safety device plate and lubricate the safety device pinion(s) (or
the pinions of the safety device countershaft, if applicable) weekly when the unit is in operation.
Priorities:
1. Tooth clearance between pinion and rack (position: machinery plate vs. drive unit
frame, dogs vs. rack)
2. Lubrication of rack and pinions.
3. Tightening of back-up rollers to 300 Nm (prevention of increasing clearance
between rack and pinion)
4. Clearances in the cage guide rollers and the front and rear guide rollers of the drive
unit (prevention of vibrations and wear of the guide rollers and mast pipes).
5. Setting the same protrusion of the drive pinions past the rack (incline of the drive
unit, even wear of the tooth surface).
6. Symmetry of the drive unit frame in relation to the mast.
7. Symmetry of the cage in relation to the mast.
8. Incline of the cage in relation to the mast pipes.
Tooth clearance adjustment

Tooth clearance adjustment is performed by turning the eccentric pin of the back-up roller.
Procedure:
1) Check that all the car front guide rollers are correctly positioned in relation to the mast pipes.
Rectify any shortcomings.
2) Check clearances of the side guide rollers (should be 0.5 mm in each side roller, or 1 mm
between two opposite side rollers). See figure 8.7.
3) Loosen the bolts attaching the back-up rollers to the machinery plate.
4) Turn the back-up rollers to achieve the correct tooth clearance.
5) Tighten the back-up roller bolts to the specified torque.
Note: To make the back-up roller adjustment easier, it is possible to use a C-clamp for pulling the
pinion into the rack (see figure 8.4). Use one C-clamps per pinion.
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ELEVATOR DATA
Pulling the pinion into the rack

Figure 8.4
The same procedure may be used for removing the back-up roller. Remove the fastening bolt and
pull the back-up roller towards the mast.
Rack replacement
Replacement is performed on detached mast sections.
Note: If the rack is to be replaced on assembled mast, a special procedure must be determined.
Procedure:
1) Remove the three fastening bolts and remove the old rack.
Note: If necessary, heat up the joint to loosen the bolt.
2) Clean the rack contact surfaces.
3) Check and clean the threads for the bolts.
4) Mount a new rack.
ATTENTION
The position of a rack on a mast section must be as shown Fig. 8.5a.
The attachment of rack to mast section is shown in Fig. 8.5b. Use items supplied by the
original equipment manufacturer: 1. M16x80 TUFLOCK bolt, 2. NL16 NORD-LOCK
washer, 3. Nut with corrugated collar. Tighten to the specified torque. When replacing the
rack, replace the connecting material as well (items 1 through 3 listed above).
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Position of rack on mast section Rack to mast section connection

Fig. 8.5a Fig. 8.5b
Pinion replacement
It is only possible to replace the pinions when the drive unit or the gearbox is dismantled.
! WARNING !
When dismantling the drive unit, always ensure that the elevator is disconnected from the
main power supply, the main switch is turned off and locked, and the EMERGENCY STOP
buttons are activated.
! WARNING !
When dismantling a gearbox, the car must be supported with suitable beams propped
between the car and the base frame, and the drive pinions must not be under load.
! WARNING !
When lifting a gearbox assembly, always use adequate rigging means and a safe lifting device
with a load capacity of at least 250 kg.
Make sure the gearbox is safely rigged before loosening the bolts attaching the gearbox to
the machinery plate.
! WARNING !
If the elevator is installed in the confined space of a shaft, an authorized person must
determine a safe procedure.
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Pinion removal and installation

The procedure is shown in Figure 8.6. After removing the circlip, pull off the pinion (using a
pinion puller).
Pinion mounting
Figure 8.6
ATTENTION
Replace a worn pinion with an original spare part only. Make sure the shaft, keys and circlip
are flawless.
All working surfaces of the pinion, the shaft, the parallel keys, etc. must be clean and must
receive a thin layer of grease. Do not hammer the pinion on to the shaft, but slide it on with a
screw!
Gearbox re-installation
Reverse the procedure for gearbox removal as described above. Observe work safety rules. Tighten
the bolts to the specified torque.
! WARNING !
When the installation of the gearbox is complete, check the tooth clearance and the
adjustment of the guide rollers. Then follow the section Emergency Situations - Overriding
the Bottom Final Limit.
! WARNING !
After pinion replacement, the Test After Repair must be performed, at least in the extent of
the Static Test, Dynamic Test and the Brake Test.
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ADJUSTMENT AND REPLACEMENT OF GUIDE ROLLERS
ATTENTION
The front guide rollers must distribute the load evenly along the mast pipes (on both sides of
the car). They must not lean against the pipes eccentrically.
The side guide rollers must be so adjusted that the clearance between the roller and the pipe
is approx. 0.5 mm (Figure 8.7).
Side guide roller

Figure 8.7
To adjust a guide roller, loosen the fastening bolt and turn the eccentric pin.
Guide roller replacement

Replace a guide roller when it is worn, when it cannot be correctly adjusted, or when it is faulty
(e.g. bad bearing).
ATTENTION
Assess the wear of a guide roller by measuring the D diameter as shown in Figure 8.7. In a
new roller, this dimension is 2 31/32” (75 mm). In a worn roller, it must not be less than 2
25/32” (71 mm).
ATTENTION
Incorrectly adjusted guide rollers may result in serious (irreparable) damage to the mast
sections!
- 53 - M355-14
SAFETY HOOKS AND SUPPORTS
Elevator car – viewed from the mast side

Figure 8.10
- 54 - M355-14
Clearances in safety hooks and supports

Figure 8.11
ATTENTION
As the rollers, pinions and rack wear down, and as the adjustment of the guide rollers alters,
the clearances between the safety hooks and dogs (on the car) and the rack and mast pipes
will alter as well. Check if these clearances are at least 2 mm at all times (see Figure 8.10 and
8.11).
MAINTENANCE AND ADJUSTMENT OF THE BRAKE ELECTRIC

MOTORS AND GEARBOXES
Note: The brake electric motors are equipped with a disc brake, the brake effect of which is
generated by the pressure of the springs (Figure 8.12).
! WARNING !
A faultless function of the brakes is a basic prerequisite for the elevator safety. Therefore, it
is necessary that all maintenance and repair of the brakes are performed by qualified and
authorized personnel.
After each time the brakes are adjusted or dismantled, verify their correct function by testing
them and test running the car.
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ELEVATOR DATA
Electric motor brake

Fig. 8.12
932 B-end shield 990 friction plate

936 complete brake 991 adjusting nut
937 manual release lever 992 dust protection ring
938 brake hub 993 brake lining
939 fan 994 armature
940 fan cover 995 pressure spring
946 fastening screw 998 washer/sealing
971 O-ring 999 V-ring
Brake inspection and adjustment
Note: The brake is accessible upon removing the brake and fan cover. Check the brake per
Figure 8.12. Compared with the standard product, the brakes used in this elevator are
improved in that they have stainless friction plates.
Inspection procedure
1) Lower an empty car at a slow speed and in a controlled manner onto a firm support.
! WARNING !
The procedure is similar to that used for dismantling the drive unit (gearbox). The elevator
car must be supported with suitable beams.
2) Remove the brake and fan cover.

3) Check the air gap at several points along the brake perimeter using a feeler gauge.
- 56 - M355-14
Note: The table below lists the air gap dimensions, minimum brake disc thicknesses and new
brake disc thicknesses. Adjust the air gap (x) if approaches the maximum value.
Brake type x a (minimum) a (new disc)

BRE 60 0.3 - 1mm 11.5mm 14.5 mm
BRE 80 0.4 – 1.1mm 8mm 11.5 mm
BRE100 (DBR120) 0.4 – 1.1mm 12.5mm 16 mm
BRE 150 0.5 – 1.1mm 14.5mm 18 mm
BRE 250 0.5 - 1.2mm 16.5mm 20 mm
4) Check the brake disc thickness.
Note: Replace the brake disc when the it approaches the minimum value. The brake disc may only
be replaced after dismantling the brake.
Recommendation: Order the first replacement of the brake disc from NORD company
and take it as an opportunity to train your personnel.
5) Mount the cover back on.

6) Ride the car shortly upwards, following the special procedure described under Emergency
Situations.
7) Remove the supports that supported the car during the adjustment, and replace any previously
removed parts.
! WARNING !
Always perform the Single Brake Test after adjusting the air gap and. When dismantling and
replacing the brake lining, test the brakes with the prescribed test load in the car in addition
to the above test.
Maintenance of electric motors

Besides the prescribed lubrication and maintenance of the brakes, it is necessary to keep the motors
clean – especially the surfaces of the cooling ribs. This is especially important in summer and if the
ambient temperature is high.
ATTENTION
After 10 year of operation at the latest, have the gearboxes and the brake motors inspected
and overhauled by the manufacturer. The overhaul will include lubrication of bearings and
replacement of any worn parts.
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ELEVATOR DATA
CAR AND LANDING DOOR INTERLOCK MAINTENANCE AND
LUBRICATION
Interlock maintenance
Procedure:
1) Clean (wash) the functional parts.
2) Check that the functional parts are not damaged (worn excessively).
3) Lubricate the pins in sliding bearings (indicated with arrows in Figure 8.13).
ATTENTION
If the interlock is partially disassembled during maintenance, make sure to put it back
together correctly. Replace damaged circlips. All the parts must move freely and their
function may not be impeded in any way.
On completing maintenance work, check the function of the interlock and the clearances
between the interlock roller and the cam interacting with it (~ 1 mm).
1 mm
1 mm
1 mm
Landing gate interlock Car door interlock

Fig. 8.13
Base station and landing gate interlock adjustment
Procedure (Fig. 8.15):

1) Ride the car to the landing so that the interlock roller (1) is lined up with the cam on the car
(2).
2) With the landing gate closed, loosen the bolts (3), adjust the gap between the interlock
roller (1) and the cam (2) to about 1 mm, and tighten the bolt.
3) Adjust the lever (4) of the limit switches (5) so that the limit switches open when the gate
flapper moves (6).
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ELEVATOR DATA
Adjustment check
The correct function of the interlock is checked as follows:
- Car at landing
The interlock must enable the gate to open. When the gate (7) opens, the flapper (6) turns,
the roller (1) rides up the cam (2) and the finger of the lever (8) passes the stop (9). Both the
switches (5) must open.
- Car away from landing
When the gate opens and the flapper (6) turns, the finger of the lever (8) must bump against
the stop (9) and thus prevent the door from opening. The limit switches will stay closed.
5
3 2 5
4 1
1 mm 4
6
9
8
7
Interlock DUS 1
Fig. 8.15
1 mm
Car door interlock adjustment

Procedure: If the door is closed, the lever of locking device has to be in contact with the stop. The
position of the cam has to be adjusted so that there is 1 mm clearance between the
cam and the roller.
Adjustment check is similar to the procedure described above. The door must open and the limit
switches must open if the car is at a landing. If the car is away from a landing, the
door must not open and the limit switches must stay closed.
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INSTALLATION AND ADJUSTMENT OF LIMIT CAMS
! WARNING !
The correct function of the elevator car stopping at the top and at the bottom positions is an
important part of the overall elevator safety system. This corresponds with doubling the
function (normal and final limit). Poor attachment, adjustment or function of the limit switches
or their cams is absolutely unacceptable. The normal limits are important for the operation of
the elevator in the Inspection mode.
Requirements for adjustment.

Stopping at the base station (bottom):
Stopping on the normal limit in the Inspection mode:
An empty car must stop level with the base landing. In DOL elevators, an empty car must stop 3/4”
(20 mm) above the base landing sill.
Final limit
Having overridden the normal limit, the car must stop on the final limit. Power must be removed from
the motors before the car hits the buffers.
Stopping at the top landing:
Normal limit in the Inspection mode:
The car must stop at the top landing so that its floor sill is about ½” (10 mm) above the landing sill. In
DOL elevators, the car must stop level with the landing.
Final limit
Having overridden the normal limit, the car must stop on the final limit. Power must be removed from
the motors before the car overrides the mast.
! WARNING !
When the car activates the top final limit, the requirements for safety distances and clearances
specified in this manual must all be complied with in full.
The positions and dimensions of the limit cams (curves) are shown in Figure 4.13.
ATTENTION
Make sure that the limit switch roller comes in contact with the middle section of the cam, and
that the cam is mounted parallel with the vertical axis of the mast.
The setting of the cam must ensure that the limit switch contact opens sufficiently and that the
limit switch lever has room for overriding.
ATTENTION
The correct position of the bottom normal limit cam is vital for an accurate leveling at all the
other landings, because the position of the other landings is calculated based on the position of
this cam. Should the position of the cam be incorrect, the elevator may level inaccurately at the
upper landings. It is essential that the elevator activates the bottom normal limit in normal
operation.
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Position of limit cams in the mast – Schmersal limit switches

Fig. 4.13
ATTENTION
It is important to identify the type of the limit switches (located on the safety device plate)
and determine the position of the limit cams accordingly (see Fig. 4.13 and 4.14). The limit
switches are either Schmersal or Schneider.
Furthermore, the limit cams are longer in elevators equipped with a variable frequency drive
(600 mm/2’) and shorter in elevators with Direct-On-Line motor control (350 mm/1’-2”).
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Position of limit cams in the mast – Schneider limit switches

Fig. 4.14
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SAFETY DEVICE REPLACEMENT AND MAINTENANCE
ATTENTION
You will find the instructions and procedures in the manual for the specific safety device
model, which is part of the elevator documentation.
Study these instructions thoroughly!
WORKING UNDER THE CAR
! WARNING !
It is only allowed to work under the car if the car is secured against spontaneous movement
and fall. Mount the Stop block on the rack to secure the car. The minimum vertical clearance
under the car (its lowest point) is 6’ (1.8 m).
Never enter the space under an unsupported car!
A safe procedure for the installation of the Stop block must be determined by an authorized
person with respect to the confined space of the shaft.
ATTENTION
Do not forget to remove the Stop block when done working under the car!
Installation of the Stop block on the rack

Figure 8.14
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TESTING
TESTING
Before tests commence:

1) the elevator documentation must be handy,
2) provide conditions for the tests,
3) the elevator must be fit for the tests.
Note: The conditions for the tests include e.g. test loads, the mass of which has been verified,
handling equipment, auxiliary personnel.
! WARNING !
When performing tests, it is forbidden to enter the car, the car roof and the hoistway (space
where the car travels), unless entering these areas is directly related to performing the tests
and retrieving their results.
ATTENTION
1) The test load must be distributed evenly across the car floor area and secured against
displacement.
2) Tests should not be performed too often, as they impose heavy strain on the elevator.
3) All safety requirements specified in this Instructions manual, as well as all relevant local
regulations require compliance.
4) The extent of tests may be specified by local regulations. However, the minimum
requirements set out in this Instructions manual must be adhered to.
Test loads
Type of test Test load

in % of nominal capacity
Static test of elevator car 150%
Single brake test Empty car.
Dynamic test including safety device and brake
110% (125%)
tests
Functional test 100%
Buffer test * 100%*
Erection boom test (dynamic) 110%
Note :
1. The buffer test is only performed by the manufacturer.
2. The erection boom test is performed according to the documentation for the specific model.
- 64 - M355-14
TESTING
TESTS CARRIED OUT BY THE USER

Besides the tests and checks already mentioned, the elevator is to be tested:
 after completion of erection - Erection Test (SP) and Verification Test.
 once a year - Specialized Test (SP),
 after repairs (at least within the extent of the performed repair).
These tests must always be performed by an authorized specialist.
Erection Test (Specialized Test)

Extent of the Erection (Specialized) Test:
 check of completeness of operating documentation,
 check of conformity with all relevant regulations and documentation,
 check of elevator components – see the Checked Parts section (SP),
 Loadless Test (SP),
 Static Test (SP),
 Dynamic Test (SP).
ATTENTION
Before the Erection (Specialized) Test, inspection of the electrical equipment must be
performed by an authorized specialist. A record of this inspection must be made out and
enclosed with the elevator documentation.
Verification Test
After installation, every new elevator must be tested (and if need be registered) according to local
regulations and tested in the extent of the Erection Test. This test is usually performed by an
inspector with a technical and work safety supervision authority, who also determines its scope.
Note: The extent of the Verification Test usually corresponds with the extent of the Erection Test.
Specialized Inspections
The safety of the elevator operation must be verified regularly by Specialized Inspections. They are
performed every three months by an authorized specialist.
ATTENTION
A drop test of the safety device must be performed every other Specialized Inspection (i.e.
every 6 months). The 6-month interval must not be exceeded.
Extent of Specialized Inspection:

 check of completeness of operating documentation and fulfillment of authorized persons’
duties,
 check of the elevator components – see the Checked Parts section (SP),
 test of the safety device (carried out every 6 months) (SP),
 Loadless Test (SP).
- 65 - M355-14
TESTING
ATTENTION
A record of the Erection and Specialized Tests must be made out every time. The report must
contain a conclusion as to the eligibility of the elevator for operation (see Appendix IV).
A record of the Specialized Inspection must be made out every time. The report must contain
a conclusion as to the eligibility of the elevator for operation (see Appendix III).
Likewise, a repair and the subsequent test must always be recorded. The user keeps and
archives all documentation relating to tests and Specialized Inspections (reports and records)
together with other elevator operating documentation.
Check of elevator components
Checked Parts
Base station
 base frame (shims, fastening of the first mast section, grounding),
 buffers (position of springs, fastening),
 cable trolley (fastening, function),
 limit switch cams of (position, fastening),
 doors (integrity, rigidity, opening, interlock function),
 electrical panels (completeness, door closing, main switch, controllers, signs and plates, main
power supply),
 EMERGENCY STOP button.
Car
 car frame (geometric shape, welded joints),
 floor, ceiling and walls (integrity), covers,
 guide rollers, safety hooks and dogs (roller adjustment and wear, clearances, integrity),
 car roof (railing, hatch door and switch),
 car door (suspension, balance, interlock function, wire ropes),
 fastening of the drive unit,
 electrical panels (completeness, door closing, switches, controllers, marking),
 controllers (integrity, marking),
 limit switches (integrity, fastening),
 proximity switch (completeness, adjustment),
 electrical wiring (position, integrity),
 lighting and signaling (function),
 accessories for emergency actions, ladder (for accessing the car roof),
 marking (signs and plates).
Drive unit
 gearboxes and pinions (condition of pinion teeth and tooth clearances, fastening, oil leakage),
 electric brake motors (cleanness, brake movability – manual release, fastening and protection
against fall, Bowden cables of the emergency lowering device),
 back-up rollers (in relation to the pinions, adjustment and wear).
 safety device (signs and plates, condition, date it was last tested and date it was last refurbished),
- 66 - M355-14
TESTING
Mast, tie-ins, landing equipment
 mast sections (integrity, wear and rack bolts tightening),
 mast section joints (integrity, tightening, bolts and nuts),
 mast (straightness, uprightness, twist),
 tie-ins (attachment of the tie-ins to the mast and to the wall, joints of the tie-in elements, safety
clearances),
 landing gates (rigidity, integrity, interlock function, interconnecting cables),
 landings (load capacity, sill clearances, related enclosures),
 limit cams of limit switches (position, fastening, car stopping, safety distances),
 limit cams of the Emergency Lowering device (position, fastening),
 cams of door interlocks (fastening, position),
Other:
 other warning signs, instructions and plates,
 storage and condition of accessories (including keys to switches and locks)
 lighting at landings.
Loadless test
It is performed by riding the elevator in both directions along the entire hoistway, so as to assess
the ride qualities and individual functions.
Verify especially the following:
 brake efficiency by testing each brake individually (Single Brake Test - SP),
 noise, vibrations and heating of the drive motors; starting and stopping,
 function of the normal and final limit switches (SP), all EMERGENCY STOP buttons, function
of landing controllers, function the hatch switch,
 precision of leveling at landings, function of the landing gate interlocks,
 safety distances, clearances and runbys.
If faults are discovered during this test, they must be rectified before the elevator is put back in
operation (or before other test may continue).
Static test
It is performed with the corresponding test load evenly distributed across the car floor. The test
duration is 10 minutes. The car must stand still, approx. 150 mm above the buffers.
Check especially the following:
 the car has not moved - crept (static brake efficiency),
 the car construction has not been permanently deformed (rigidity of the construction),
 the drive unit has not suffered damage (strength of pinions and gears),
 the car floor has not suffered damage (strength of the floor).
If faults are discovered during this test, they must be rectified before other test may continue.
Dynamic test
It is performed with the corresponding test load evenly distributed across the car floor.
Check especially the following:
 function of the safety device (Drop Test - SP),
 function of the brakes (make the car stop repeatedly, it must stop with sufficient accuracy),
 running properties (all functions of the elevator, including the normal limit switches), the
EMERGENCY STOP buttons, function of doors, gates and their interlocks.
 EMERGENCY LOWERING device function (described in the Emergency Situations section)
 FIRE RECALL function (described in Elevator Description: Elevator Controls section)
 ACCESS UP function (described in Elevator Description: Elevator Controls section)
- 67 - M355-14
TESTING
Single brake test
The test is performed by an authorized person from the car roof (without any other load).
Procedure:
1) Switch the OPERATION/INSPECTION switch to the INSPECTION-ON position
and ride the car up to a height of approx. 15’ (5 m) by means of the directional pushbuttons.
2) Release one of the brakes by pulling the manual brake release lever.
3) Ride down shortly release the button. The one brake must stop the car. Test the other brake the
same way.
4) Switch the OPERATION/INSPECTION switch back to the INSPECTION-OFF position.
Safety device test

! WARNING !
The correct function of the brakes and braking efficiency must be verified before the safety
device test. Do not allow other persons to be near the elevator unit.
The safety device test must be performed by an authorized person. The car is loaded with the
specified test load evenly distributed across the car floor.
Procedure:
1) Study the documentation of the safety device.
2) Ride the car to landing No. 2.
3) Turn the INSPECTION switch to the INSPECTION-ON position.
4) Turn the TEST switch to the TEST-ON position.
5) Plug in the DROP TEST controller.
6) Step out into the landing (leave the car).
7) Simultaneously press the TEST and DOWN buttons on the DROP TEST controller and hold
them until the car accelerates, the safety device trips and the car comes to a full stop.
ATTENTION
If the safety device fails to trip by the time the car is approx. 7’ (2 m) above the bottom
position, release the test buttons. The car will be stopped by the motor brakes.
In such a case, the reason why the safety device did not trip must be identified.
The reason may be that - the tripping speed was not reached,
- the safety device is not functional.
8) Ride the car up till it is level with the landing by means of the UP button on the DROP TEST
controller.
9) Unplug the DROP TEST controller and switch the TEST selector switch back to the OFF
position.
10) Secure the elevator against accidental movement by pressing the EMERGENCY STOP button.
11) Reset the safety device according to the safety device documentation (SP).
12) Turn the OPERATION/INSPECTION switch to the INSPECTION-OFF position.
! WARNING !
Before resetting the safety device, check that the following parts are in a flawless condition:
- gearbox assemblies,
- guide and back-up rollers,
- pinions,
- Check if the safety device switch is activated and prevents the elevator from going down .
- 68 - M355-14
TESTING
Emergency lowering test:
Procedure:
1. Ride the car to a landing.
2. Turn off the main switch on the panel inside the car (recommended).
3. Mount the emergency lowering hand lever.
4. Descend to the nearest lower landing (base station) by pulling the hand lever all the way.
5. Remove and stow the hand lever.
6. Put a seal on the cover.
ATTENTION
If the descent speed does not settle at about half the nominal speed shortly after pulling the
lever, interrupt the test and check the connection of the emergency circuit, that is the
connection of the resistors, capacitors and all 3 phases of the motors.
This test is to verify the function of the emergency lowering device, the operability of the Bowden
cables and the precision of stopping at a landing.
Test of the bottom final limit
Procedure:
1) Lower the car to just above the buffers by manually releasing the motor brakes.
2) Push the directional buttons in the car to verify that the car will not move in either direction.
3) Put the elevator back in operable condition according to the procedure describe above in the
Emergency Situations, Malfunctions section.
Test of the top final limit

! WARNING !
This test is performed from the car roof by means of the controllers activated in the
INSPECTION mode. The car must be empty!
Procedure:
1) Turn the INSPECTION switch to the INSPECTION-ON position.
2) Ride up and dismantle the cam of the top normal limit (not the final limit!). Activate the
EMERGENCY STOP button in doing so.
3) Check if the cam of the final limit switch is installed correctly. Check that the final limit
switch is installed correctly.
4) Run the car onto the final limit switch by means of the UP button. The car must stop.
! WARNING !
If in danger, release the directional button and, if need be, hit the EMERGENCY STOP
button.
5) Push the directional buttons to verify that the car will not move in either direction.
6) Immobilize the elevator by pressing the EMERGENCY STOP button.
7) Drive the car approx. 7’ (2 m) down by manually releasing the motor brakes.
8) Replace the cam of the top normal limit.
9) Check the function of the top normal limit.
10) Ride the car down to the base station and turn the INSPECTION switch to the INSPECTION-
OFF position.
11) Check the function of both the top and bottom normal limits.
- 69 - M355-14
SERVICE
SERVICE
Specialized service and technical information is provided by your supplier:
McDonough Elevators Inc. Tel.: 800-736-0882

8411 Villa Drive www.mcdelevators.com
Houston, TX 77061, USA
and by the manufacturer:
STROS – Sedlcanske strojirny, a.s. Tel.: 011-420-318-842-404

Strojirenska 791 Fax: 011-420-318-821-230
264 01 Sedlcany E-mail: info@stros.cz
Czech Republic http://www.stros.cz
Specialized service of gearboxes and brake electric motors is provided by representatives of the
drive manufacturer:
Getriebebau NORD
Schlickt + Küchenmeister GmbH & Co.
D-22934 Bargteheide / Hamburg PO Box 1262
Representative in ………………………………….
Tel.:
Fax:
E-mail:
http://www.
- 70 - M355-14

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INSTRUCTIONS MANUAL

FOR THE NOV SERIES

Instruction Manual Number: M368-15

TERMINOLOGY AND SIGNS ................................................................................................................................. - 7 -

WORK SAFETY ......................................................................................................................................................... - 9 -

PROGRAMMING OF LANDINGS ........................................................................................................................ - 25 -

EMERGENCY SITUATIONS, FAILURES ........................................................................................................... - 27 -

Requirements for qualification of personnel having to do with the elevator (operation,

Example of an NOV series elevator

TERMINOLOGY AND SIGNS

These personnel must be: physically fit

Respect the following warnings:

Item Specification Function, function check

Emergency Lowering device

ADDITIONAL AND RELATED INFORMATION

Power supply requirements

For elevators of the NOV series the manufacturer recommends:

FLA [A] Recommended Recommended Approx.

Specification of requirements for bolted joints:

Recommended tightening torques of other bolted joints:

Size Tightening torque (N.m) Tightening torque of

Protective zone around the elevator

Fencing round a elevator, protective zone

Reduction of the bearing capacity of the elevator structure by corrosion.

Safety distances and clearances

Safe horizontal distance Fixed barrier (wall) height

Headroom above car

Clearance under the car

Storage of the elevator and its components

Monitoring the periods of long-term storage:

Date of last connection to mains

Small and additional parts

Two Stop Elevators

Inspection mode/manual operation

READY - it indicates that the car is ready to go

The car has a horn on it for acoustic emergency signals:

Landing call boxes

Displays at landings (optional):

Rack lubrication in progress*

1) Two-symbol, seven-segment display

Example: E102 fault – E-Stop

2) Graphic display of the PLC

Example: E108 – Emergency lowering

Error code interpretation

ERR201 Safety device tripping during operation

ERR208 Emergency lowering during operation

*possible error codes depending on the actual number of landings*

ERR259 CJA – top landing gate open during operation

ERR294 CJA – landing 6 gate unlocked during operation

ERR301 Door closed switch error

EMERGENCY SITUATIONS, FAILURES

Basic rules for emergency actions:

Note: In an emergency, the car is entered via the roof hatch.

Entering the elevator car in an emergency

SAFETY DEVICE TRIPPING

OVERRIDING THE TOP NORMAL LIMIT

OVERRIDING THE BOTTOM NORMAL LIMIT, OVERRIDING THE

INSPECTIONS AND MAINTENANCE

possible error codes depending on the actual number of landings