Automatic lubricator

Maintenance Instruction

REPLACEMENT INSTRUCTION FOR AUTOMATIC LUBRICATOR

Automatic
©
AS-07.08.003
All
(-) 2009
2009-06-08
rightsKONE
reserved.
lubricator
Corporation

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

1063456.wmf

1063499.wmf

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 1 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

CONTENTS

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Main parts of automatic lubricators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 ENVIRONMENTAL ISSUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Maintenance method safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 SITE REQUIREMENTS AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Before going to the site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 REPLACEMENT OF CAR AND COUNTERWEIGHT LUBRICATORS . . . . . . . . . . . . . . . . . 8
5.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Replacing bottom counterweight lubricators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Replacing car lubricators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4 Replacing top counterweight lubricators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.5 First time installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.6 Replacing old cartridge with new one . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.7 Finalizing lubricator replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 APPROVALS AND VERSION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 2 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

1 INTRODUCTION

This instruction describes actions and methods for replacing automatic guide rail lubricators and
upgrading old lubrication system with automatic lubricators.

1.1 Related documents

The following documents are related with maintenance of automatic lubricator:

• AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and autowalks
• AM-07.07.011 Sliding guide shoes
• AR-07.08.003 Guide rail lubricators
• AS-01.01.004 Take care, end user safety focal points in elevator maintenance
• AS-01.01.010 Lubricant recommendation instruction

1.2 Main parts of automatic lubricators

1.2.1 Simatec lubricator (KM960976)

Figure Description
1. Lubricator cartridge 125 ml or 60 ml
2. Lubricator brush
3. Mounting bracket
1 4. Lock washer M6
5. Fixing screw M6x12
9
6. Fixing nut M6 (2 pcs.)
7. Washer M6 (2 pcs.)
8. Flask of oil (50 ml)
10 NOTE! Oil according to AS-01.01.010
8
9. User manual
10. Fixing screw M6x40

2
7 5
4
1065400.wmf
6

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 3 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

1.2.2 SKF lubricator (KM959359)

Figure Description
1. Lubricator cartridge 125 ml or 60 ml
2. Lubricator felt (for 5, 9 and 16 mm guide
rails)
3. Fixing screw M8x14
1 4. Mounting bracket
5. Fixing nut M8 (2 pcs.)
Flask of oil (100 ml)
NOTE! Oil according to AS-01.01.010
User manual

1065401.wmf
5

2 ENVIRONMENTAL ISSUES

Hazardous waste material must be taken care of according to the local requirements and KONE
Environment Strategy.

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 4 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

3 SAFETY

3.1 General safety precautions

Safety precautions Note

Follow your national lift codes and other safety
related regulations.
Follow your local hot work procedures.
The local safety codes and rules must be
obeyed at all times.
Follow the safe working methods.
Follow this instruction. Do not skip any step,
otherwise there may be a potentially dangerous
situation which you have not considered.
In case of conflict between the Code and the
present instructions, rely on your national code.
Refer to your local procedures for the type of
entrance protection required.
Use barriers and warning signs to inform
and protect the building users.
Warning signs highlight possible hazards.

ENSURE THAT ELECTRICAL EQUIPMENT Do not connect or disconnect any connectors

AND CONDUCTORS ARE SAFELY DE- when the power is ON.
ENERGISED BEFORE WORKING ON THEM.
A locking off system for main electric supply
isolator or other system (for example fuse
removal, locking and tagging system, etc. when
applicable) must be agreed with person
responsible for the building electrification.
Personal safety equipment must be available Refer to the list of Personal safety items on the
and used as required. next chapter.
IF RISK OF INJURY FROM A FALL
Adequate fall prevention system must be in
place.
If the safety harness is used incorrectly you
may still sustain severe injury or death
during a fall or uncontrolled movement of
the elevator. For using fall prevention systems refer to AM-
If you have attached the harness to a guide rail 01.03.001.
bracket or other fixed point in the lift well, you
must ensure that there can be no unwanted
movement of the car or counterweight.
Handle and dispose of waste materials in
accordance with the regulations applicable to
your country/state.
Ensure that your work does not cause a hazard In particular keep access ways and fire exits
to others. clear.
Keep the entrance and emergency exits clear. Refer to AS-01.01.004 Take Care End user
Prevent unintentional access to working area safety in elevator maintenance.
with additional fences.

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 5 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

3.2 Personal safety

Gloves, safety shoes, helmets, goggles, dust masks, hearing protection and harnesses are provided
for your personal protection. USE THEM AS REQUIRED.

Safety item Figure

Fall prevention equipment. Refer to AM-
01.03.001.
Dust mask, suitable for working with mineral
wool insulation in landing doors
First aid kit
Safety goggles
Safety gloves
Rubber gloves for cleaning rails
Hearing protection
Hard hats
Work clothes / overalls
Safety shoes with ankle protection P15000060.wmf

3.3 Maintenance method safety

Note the following safety items when working with automatic lubricators:
• General KONE safety regulations must be followed during the work. All normal safety measures
required in elevator maintenance must be implemented. Local safety regulations must also be
followed.
• Refer to AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and
autowalks. The Take 5 safety initiative is designed for installation, servicing, maintenance and
modernisation work done on the elevators.
• Site survey must be done before starting maintenance work.
• Personal safety equipment must be used as required.
• Use proper gloves when handling lubricators and lubricants.
• The different lubricants given for the same application do not correspond to each other completely.
Therefore, they are not to be mixed.
• Safety must be ensured with additional fences or guarding, depending on the site conditions.
• Always use the safety harness attached to an approved fixing point when working in the elevator
shaft.
• Door of the maintenance access panel must always kept closed. Even, when the main power is
OFF, or when not working with the panel.
• Prevent the reconnection of auxiliary emergency power supplies etc.
• Be careful when opening fixing screws and nuts to avoid dropping metal items into the pulley
housings. Although the housings are protected with covers and brushes, it is possible that small
particles get caught in the pulley grooves.
•
•

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 6 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

4 SITE REQUIREMENTS AND TOOLS

4.1 Before going to the site

Site survey must have been done before starting the work. Bring the site survey on the site. Check the
site conditions have not changed after doing the site survey.
Adequate lighting must be arranged. Tools and equipment must be available. Check case by case, if
you need special tools, such as counterweight lifting tool. Check that the replacement kit is complete.

4.2 Tools

Part number Tool Illustration/Note

Normal hand tool set
Emergency opening key

1033717.wmf

KM871952 Door blocking tool

KM893993 Swing door blocking tool
Safety barriers

Water resistant pen

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 7 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

5 REPLACEMENT OF CAR AND COUNTERWEIGHT LUBRICATORS

NOTE! If counterweightless elevator perform safety measures and continue on section 5.3.

5.1 Safety measures

The following safety measures must be carried out before the actual work:

Step Action Illustration/Note

1 Take the elevator out of service.
2 Give a car call to top floor.
3 Open the lowest landing door.
4 Check location of the counterweight
lubricators.
5 Push down the pit stop button.
6 Close the landing door.
7 Give a car call to a floor above.
Check that the elevator does not move.
Separate the elevator if in group.
Make sure the car is empty.
Keep the door open by using door blocking
tool.
In rare cases counterweight lubricators are
installed on the bottom of the counterweight
frame. If lubricators are on the top of the
counterweight frame, continue on section
5.4.

5.2 Replacing bottom counterweight lubricators

Step Action Illustration/Note

1 Open the landing door and block the door
open.
2 Go to the pit.
3 Replace the lubricator according to section
5.5 or 5.6.

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 8 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

5.3 Replacing car lubricators

Step Action Illustration/Note

1 Ride in the car to second floor.
2 Step to the landing, give a car call to a floor
below.
3 After 1 - 2 seconds stop the car by opening
the landing door with emergency opening
key.
4 Test that the car roof stop button and Do not go on the car roof, if the car moves.
inspection drive mode prevent car calls
before going to car roof.
5 Push DOWN the car roof stop button.
Replace the lubricators on the top of car
sling according to section 5.5 or 5.6.

5.4 Replacing top counterweight lubricators

Step Action Illustration/Note

1 Ride in the car to floor on the middle of the
shaft.
2 Step to the landing, give a car call to a floor
below.
3 After 1 - 2 seconds stop the car by opening
the landing door with emergency opening
key.
4 Test that the car roof stop button and Do not go on the car roof, if the car moves.
inspection drive mode prevent car calls
before going to car roof.
5 Go to car roof. In this position both the counterweight and
Drive on inspection until the counterweight car lubricators can be reached.
lubricators are at suitable working position.
6 Push DOWN the car roof stop button.
7 Replace the lubricator according to section
5.5 or 5.6.

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 9 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

5.5 First time installation

Step Action Illustration/Note

1 Remove the old lubricators.
2 Put the automatic lubricators in place of the Make sure that the automatic lubricators fit in
old lubricators. place of the old ones (depth, fixing etc.).
3 Select the correct felt size according to SKF only. Simatec is suitable to guide rails
guide rail width. Pour approximately 20 ml of widths of 5 - 16 mm.
oil in the cup and put the felt piece in it to
absorb the oil.
Install the felt pieces.
4 Write the installation/replacement date on
the unit with water resistant pen.
5 Pour oil from the flask into the threaded hole
of the lubricator brush/felt.
Fill it with oil (approximately 8 ml). This will
soak up the felt inside the housing.
6 Wet also the bristles of the brush with oil.

1063452.wmf

7 Simatec only:
Cut the fitting on the non-return valve plug
of the cartridge. A small hole should appear
on the plug
Do not remove the plug, as it prevents
uncontrollable oil effluence.

1065407.wmf

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 10 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

Step Action Illustration/Note

8 Insert the fixing screw(s) into the lubricator
base.
Screw the lubricator cartridge onto the
lubricator base.

1063454.wmf

9 Activate the dispenser on the cartridge and

adjust it to the required dispensing times.
Coin or screw driver (SKF), 3 mm allen key
(Simatec).

Recommended times:
• For dry and clean surroundings: 6 to
12 months
• For dry and wet surroundings: 3 to 6
months

1063455.wmf

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 11 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

Step Action Illustration/Note

10 Fix the activated lubrication system.

1063523.wmf 1063524.wmf

Simatec SKF
11 Ensure that the brushes are centred around
the guide rails of the elevator and that they
are adjusted evenly.
12 Return back, if other lubricators must be
replaced.

5.6 Replacing old cartridge with new one

Step Action Illustration/Note

1 Remove the lubricator from car sling or
counterweight frame.
2 Check the unit or felt for wear and damage.
Replace, if needed.
3 Remove the old cartridge.
4 Write the installation/replacement date on
the unit with water-resistant pen.

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 12 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

Step Action Illustration/Note

5 Simatec only:
Cut the fitting on the non-return valve plug
of the cartridge. A small hole should appear
on the plug
Do not remove the plug, as it prevents
uncontrollable oil effluence.

1065407.wmf

6 Insert the fixing screw(s) into the lubricator

base at first.
Screw the lubricator cartridge onto the
lubricator base.

1063454.wmf

7 Activate the dispenser on the cartridge and

adjust it to the required dispensing times.
Coin or screw driver (SKF), 3 mm allen key
(Simatec).

Recommended times:
• For dry and clean surroundings: 6 to
12 months
• For dry and wet surroundings: 3 to 6
months

1063455.wmf

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 13 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

Step Action Illustration/Note

8 Simatec:
Ensure that the brushes are centred around
the guide rails of the elevator and that they =
are adjusted evenly.
=
SKF:
Choose the felt according to the guide rail
width. Squeeze the felt from the sides and
push into the lubricator body.

1065408.wmf

9 Return to beginning, if other lubricators

must be replaced.

5.7 Finalizing lubricator replacement

Step Action Illustration/Note

1 Drive the car all the way up and down the
elevator shaft, check that there is a light film
of oil over the full length of the blade faces.

1065409.wmf

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 14 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

Step Action Illustration/Note

2 Dispose waste material.
Clean the site.
3 Leave the car roof.
Close the landing door.
4 Return the elevator to service.

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 15 (16) (-) 2009-06-08
Disclosure prohibited
Automatic lubricator
Maintenance Instruction

6 APPROVALS AND VERSION HISTORY

Compiled by: Information Product Author Janne Kaskimies

Checked by: SEB Maintenance Specialist Jukka Lindberg
Product Change Manager Seppo Häyrinen
Approved by: SEB Maintenance Development Manager Seppo Valliovuo
Translation approved by:

Issue Date Description of Change Ref CR Approved by

- 2009-06-08 First issue S. Valliovuo

© 2009 KONE Corporation AS-07.08.003

All rights reserved. 16 (16) (-) 2009-06-08
Disclosure prohibited