Stannah MIDILIFT XL PLUS Operating manual

MIDILIFT XL PLUS
MAINTENANCE GUIDE

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 2
CONTENTS LIST
1INTRODUCTION .............................................................................................................................................. 4
2SAFETY............................................................................................................................................................ 4
3CLEANING ....................................................................................................................................................... 4
4LIFT ACCESS AND PROCEDURES............................................................................................................... 4
4.1 Cabin Access ............................................................................................................................................. 4
4.2 Cabin operating panel (COP) removed...................................................................................................... 4
4.3 Upper floor landing controls ....................................................................................................................... 4
4.4 Ceiling removed ......................................................................................................................................... 5
4.5 COP and rear wall removed....................................................................................................................... 5
4.6 Overspeed governor tests.......................................................................................................................... 5
4.7 Brake assembly.......................................................................................................................................... 5
4.8 Load weighing device – Rated load setup ................................................................................................. 5
4.9 Load weighing device – Calibration ........................................................................................................... 5
5SERVICING ...................................................................................................................................................... 5
6CUSTOMER COMMUNICATIONS .................................................................................................................. 5
7TOOLING REQUIREMENT.............................................................................................................................. 6
8MAINTENANCE BREAKDOWN...................................................................................................................... 6
8.1 Essential requirement / Visual checks ....................................................................................................... 6
8.2 Phase 1 ...................................................................................................................................................... 6
8.3 Phase 2 ...................................................................................................................................................... 7
8.4 Phase 3 ...................................................................................................................................................... 7
8.5 Phase 4 ...................................................................................................................................................... 7
8.6 5 year check............................................................................................................................................... 7
8.7 Additional checks ....................................................................................................................................... 7
9MAINTENANCE INSTRUCTION – ESSENTIAL MAINTENANCE ................................................................. 9
9.1 Smoothness of ride .................................................................................................................................... 9
9.2 Cabin lighting ............................................................................................................................................. 9
9.3 Floor covering ............................................................................................................................................ 9
9.4 Name plate............................................................................................................................................... 10
9.5 Car fixtures............................................................................................................................................... 10
9.6 Car walls................................................................................................................................................... 10
9.7 Floor levels............................................................................................................................................... 10
9.8 Emergency equipment ............................................................................................................................. 10
9.9 Safety edges ............................................................................................................................................ 11
9.10 Light Curtains ........................................................................................................................................... 11
9.11 Control panels .......................................................................................................................................... 11
9.12 Brake operation........................................................................................................................................ 12
9.13 Door operation ......................................................................................................................................... 12
9.14 Landing door locks and beaks ................................................................................................................. 12
9.15 Indicators (DDU’s and push buttons etc…).............................................................................................. 12
9.16 Visual inspection/light clean ..................................................................................................................... 13
10 MAINTENANCE INSTRUCTION – PHASE 1................................................................................................ 13
10.1 Risk assessment and general lift check................................................................................................... 13
10.2 Car overload............................................................................................................................................. 13
10.3 Manual release......................................................................................................................................... 14
10.4 Rope connections and wear/stretch......................................................................................................... 14
10.5 Earth bonding, insulation and electrical ................................................................................................... 15
11 MAINTENANCE INSTRUCTION – PHASE 2................................................................................................ 15
11.1 Roof top.................................................................................................................................................... 15
11.2 Upper shaft work ...................................................................................................................................... 15
11.3 Drive shaft bearings ................................................................................................................................. 16
11.4 Ultimate limit switch.................................................................................................................................. 16
11.5 Safety gear and overspeed governor....................................................................................................... 17
11.6 Encoder and timing belt ........................................................................................................................... 17
11.7 Guides and fixings.................................................................................................................................... 18
11.8 Trailing cable and chain ........................................................................................................................... 18
11.9 Sling and car fixtures................................................................................................................................ 19
11.10 Gearbox/motor ......................................................................................................................................... 19
12 MAINTENANCE INSTRUCTION – PHASE 3................................................................................................ 19
12.1 Counterweight .......................................................................................................................................... 19

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 3
12.2 Pit buffer ................................................................................................................................................... 20
12.3 Tension Pulley.......................................................................................................................................... 20
12.4 Cabin floor................................................................................................................................................ 21
12.5 Pit clean.................................................................................................................................................... 21
13 MAINTENANCE INSTRUCTION – PHASE 4................................................................................................ 21
13.1 Brake lining .............................................................................................................................................. 21
13.2 Thorough clean ........................................................................................................................................ 22
14 5 YEAR MAINTENANCE CHECKS............................................................................................................... 22
14.1 Gearbox/motor detailed check ................................................................................................................. 22
14.2 Earth bonding, insulation and electrical visual......................................................................................... 22
14.3 Safety gear and overspeed governor (Full safety activation required) .................................................... 23
15 ADDITIONAL CHECKS ................................................................................................................................. 23
15.1 Autodialer ................................................................................................................................................. 23
15.2 Telephone ................................................................................................................................................ 24
15.3 Intercom ................................................................................................................................................... 24
15.4 Power door operator ................................................................................................................................ 24
15.5 Fire alarm shut down................................................................................................................................ 24
15.6 UPS .......................................................................................................................................................... 25
16 APPENDIX A.................................................................................................................................................. 26
16.1 Cabin operating panel (COP) removed.................................................................................................... 26
16.2 Upper floor landing controls ..................................................................................................................... 27
16.3 Ceiling removed - Important note: persons are note permitted to stand on car roof ............................... 28
16.4 COP and rear wall removed..................................................................................................................... 29
17 APPENDIX B.................................................................................................................................................. 30
17.1 Brake lining .............................................................................................................................................. 30
17.2 Overspeed governor activation tests (with remote test control)............................................................... 31
17.3 Overspeed governor activation tests (without remote test control) ......................................................... 32
17.4 Overspeed lift ........................................................................................................................................... 33
17.5 Set the lift to run at 80.0 Hz...................................................................................................................... 34
17.6 Re set the lift to run at 50.0 Hz ................................................................................................................ 34
17.7 Overload controller calibrations ............................................................................................................... 35
17.8 Overload alarm setup............................................................................................................................... 35
17.9 Safety chain switch locations ................................................................................................................... 36

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 4
1 INTRODUCTION
This maintenance guide is to help provide understanding of the correct maintenance schedule.
Your Platform Lift has been manufactured and installed to comply with the Essential Safety Requirements of the
Machinery Directive 2006/42/EC and International Standard EN 81-41 and a correct maintenance schedule will
ensure that the lift will remain at these standards.
This schedule has been designed for use by approved engineers/technicians who have completed the recognised
training course.
2 SAFETY
As stated it is imperative that any work carried out the lift is performed by suitably trained technicians. When
completing any component replacement, ensure that the lift is isolated from the mains electrical supply. This can
be achieved using the mains isolation, usually situated within a 5m radius of the upper floor entrance.
If there is any doubt that a lift cannot be left in safe condition, then the customer and supervisor are to be
consulted, advising that the lift may be removed from service. A report should be included in this procedure
advising on the full remedial work. The ultimate decision of continued use rests with the owner, but should the
owner ignore the advice to switch off, the branch manager should be informed.
3 CLEANING
As part of all maintenance checks to be complete on the lift, there will be a requirement of some level of cleaning.
The following shows area of cleaning required and recommended cleaning procedures.
Paint finishes – These should be cleaned with a damp cloth using an aerosol type of furniture polish.
Stainless steel – This should be cleaned with a soft cloth soaked in light oil (“3 in 1” or “Johnson’s baby oil”) and
then wiped off with a dry lint-free cloth.
Vinyl skin plate or laminate boards – This should be cleaned with a soft cloth using an aerosol type of furniture
polish.
Mirrors or glass – These should be cleaned with a soft cloth and any glass cleaning product.
Platform Flooring – This should be cleaned with a damp cloth and a mild detergent. Ensure that excess water is
squeezed out prior to cleaning.
4 LIFT ACCESS AND PROCEDURES
For the various maintenance checks different levels of lift access will be required. These levels of access are listed
below and can be displayed in more detail later within this document.
4.1 Cabin Access
Cabin access is the process of entering the lift to ride up and down completing simple routine checks.
4.2 Cabin operating panel (COP) removed
Behind the COP lays the load weighing device and the main lift controller. (16.1 Cabin operating panel (COP)
removed, pg 26).
4.3 Upper floor landing controls
There are two areas where these controls may be located either in an external controller or within the upper
landing door. (16.2 Upper floor landing controls, pg 27).

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 5
4.4 Ceiling removed
Behind the ceiling lays the cabin lighting and terminal rail for the light curtains. The ceiling must also be removed to
access all items within the top of the shaft. Important note: Persons are not permitted to stand on the car roof.
(16.3 Ceiling removed pg 28).
4.5 COP and rear wall removed
To access such items as the safety gear, door ramps and encoder the whole rear panel must be removed. (16.4
COP and rear wall removed pg 29).
4.6 Overspeed governor tests
To complete a test on the safety gear and overspeed governor, a safe working procedure has been drawn up.
(17.2 & 17.3 Overspeed governor activation tests, pg 31/31).
4.7 Brake assembly
As part of the brake assembly, the brake lining will need to be checked, either through suspicion of brake wear, or
as part of the annual service checks (17.1 Brake lining, pg 30).
4.8 Load weighing device – Rated load setup
To complete various tests within the maintenance schedule it is sometimes necessary to alter the rated load setup
on the load weighting device (17.8 Overload alarm setup, pg 35).
4.9 Load weighing device – Calibration
If for any reason the load weighing device is not working in the correct manner, it may be necessary to re calibrate
the unit (17.7 Overload controller calibrations, pg 35)
5 SERVICING
There will be 4 annual services consisting of various maintenance checks. Full instructions for all checks can be
found within this document including diagrams where necessary. It has been assumed that all persons carrying out
these checks will have prior servicing knowledge and be comfortable with basic lift maintenance.
The annual schedule is split into two areas. These will be essential checks (checks that must be completed at
every visit) and phased checks (checks completed annually). Phased checks are broken down into four areas.
To ensure that the maintenance visit remains as efficient as possible the 4 phases will consist of the 4 different
areas of lift access. These phases have been clearly marked on the log card for ease of use by the engineer.
In addition to the essential and phase checks, it will be necessary for the engineer to complete additional
supplementary checks. These will become apparent due to added options on the lift and checks that fall out of the
annual category (more the than 1 year per check).
6 CUSTOMER COMMUNICATIONS
It is very important to talk to the customer about the lift, whilst not being an expert in the field, on occasions they
may know about their specific lift better than the engineers. Listen to them and address the points raised or at least
allay their fears in a sensitive way. It is rare that the passengers complain unnecessary; however it is even rarer
that they will describe it to you in engineering terms.
Although the service of the lift is within the responsibility of the service branch and engineer in question, the overall
responsibility of the lift lies with the customer. Thus taking the lift out of service will be the final decision of the
customer. For this reason, where appropriate the engineer will have the responsibility to convince the customer of
the necessity to take the lift out of service.

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 6
7 TOOLING REQUIREMENT
•General fitters tools plus the following more specialised items,
•Feeler gauge
•Torque wrench
•Multi-meter
•Mega meter
•Labelled electrical shorting wires
•XLplus maintenance keys
•Secondary safety brackets (6203018 x 2)
8 MAINTENANCE BREAKDOWN
8.1 Essential requirement / Visual checks
•Smoothness of ride (pg 9)
•Cabin lighting (pg 9)
•Floor covering (pg 9)
•Name plate (pg 10)
•Car fixtures (pg 10)
•Car walls (pg 10)
•Floor levels (pg 10)
•Emergency equipment (pg 10)
•Safety edges (pg 11)
•Light Curtains (pg 11)
•Control panels (pg 11)
•Brake operation (pg 12)
•Door operation (pg 12)
•Landing door locks and beaks (pg 12)
•Indicators, DDU’s and push buttons etc… (pg 12)
•Visual inspection/light clean (pg 13)
8.2 Phase 1
a) Risk assessment (pg 13)
b) Car overload (pg 13)

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 7
c) Manual release (pg 14)
d) Rope Connections and wear/stretch (pg 14)
e) Earth bonding, insulation and electrical visual check (pg 15)
8.3 Phase 2
f) Roof top (pg 15)
g) Upper shaft work (pg 15)
h) Drive shaft bearings (pg 15)
i) Ultimate limit (pg 16)
j) Safety gear and overspeed governor (pg 17)
k) Encoder and timing belt (pg 17)
l) Guide and fixings (pg 18)
m) Trailing cable and chain (pg 18)
n) Sling and car fixtures (pg 19)
o) Gearbox/motor (pg 19)
8.4 Phase 3
p) Counterweight (pg 19)
q) Pit buffer (pg 20)
r) Tension pulley (pg 20)
s) Cabin Floor (pg 21)
t) Pit clean (pg 21)
8.5 Phase 4
u) Brake lining (pg 21)
v) Thorough clean (pg 22)
8.6 5 year check
•Motor and gear box detailed check (pg 22)
•Earth bonding, insulation and electrical visual check (pg 22)
•Overspeed governor and safety gear (pg 23)
8.7 Additional checks
•Autodialer (pg 23)

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 8
•Telephone (pg 24)
•Intercom (pg 24)
•Power door operator (pg 24)
•Fire alarm shut (pg 24)
•UPS (pg 25)

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 9
9 MAINTENANCE INSTRUCTION – ESSENTIAL MAINTENANCE
As discussed earlier within this document, any engineer completing the service can be assumed to have had the
relevant training and have a suitable knowledge of lift technology. Where further instruction is required, this will be
contained in this section of the guide.
As part of the maintenance guide a detailed instruction to of the required standard will be given, if for any reason
an area of the lift falls short of this required standard, this part of the guide will also state clearly the corrective
action expected of the engineer.
9.1 Smoothness of ride
•Required standard
Whilst travelling to top floor and back there must be no knocks, scrapes, groans, vibrations etc… There is to be
minimum vibration with no jolts or juddering and a smooth speed change over.
•Required action
The cause of any unusual noise and vibration must be investigated and if not cured immediately, then reported to a
supervisor with details of suggested remedial work. Vibration sources may indicate bearing failure on a high speed
shaft; therefore it is imperative it is investigated.
A poor quality ride may also be down to the quality of guides and this can be solved by dressing the guides.
9.2 Cabin lighting
•Required standard
There must be no sign of damage, lighting equal, retaining clips in place (where used) and diffusers (where used)
free from cracks or damage.
If the lift is not in use, the cabin lights should switch off after approximately 3 minutes.
•Required action
If the required components are to hand and the work to restore lighting is possible, remedial work is to be complete
and supervisor to be informed. If repair work is not possible and the lift is in an unsafe working condition the
customer must be informed of the removal from service until the required corrective work is complete.
9.3 Floor covering
•Required standard
Floor covering to be secure, flat and without distortion and with no tripping hazards.
•Required action
If a tripping hazard cannot be made safe, then consult customer and report to supervisor that the lift may have to
be removed from service, with details of suggested remedial work.
Note: more injuries are caused by tripping than lift component failure.

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 10
9.4 Name plate
•Required standard
Name plate must be securely fixed and clearly show place of manufacture, CE mark, Lift job number and product
name (XL Plus).
Also clearly within the cabin should be the lifts working load. For a standard XL Plus lift, this will be 400kg. If in
doubt of the working load ask.
•Required action
It is legally required to have above details indicated. If this is not in place consult with customer and supervisor
about the possibility of taking the lift out of service.
9.5 Car fixtures
•Required standard
The security of handrails and mirrors should be in good condition with no sharp edges.
•Required action
Make safe any condition likely to cause harm.
9.6 Car walls
•Required standard
All walls should be secure and free from any damage. Pay particular attention to glass panels to check for any
cracks or scratches.
•Required action
If there are any gaps in the car walls or damage to the walls that cannot be repaired immediately, then consult
customer and report to supervisor that the lift may have to be removed from service, with details of suggested
remedial work.
9.7 Floor levels
•Required standard
As part of EN81-41 2009, the lift must stop within ±10mm of floor level.
•Required action
If floor levels are not within the required tolerance, remedial action must be taken. If floor levels cannot be attained,
then an immediate report to supervisor is required, with suggested remedial works. If floor levels required cannot
be achieved due to older or inadequate equipment, make note on report.
To reset the floor levels reference the XLplus wiring diagram usually contained within the upper landing controller.
9.8 Emergency equipment
•Required standard
Alarm must work and be audible to others with lift electrical supply off. Emergency lighting must work when
electrical supply to the lift is isolated. This can be achieved using the lift isolator switch situated within a 5m radius
of the upper floor.

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 11
All stop switches must work correctly. All stop switches are positioned within the safety chain and when operated
will remove all calls and prevent the lift from moving. The four stop switches in question are in the cabin, the pit, the
test control (landing control panel) and the landing control panel itself.
•Required action
It is unsafe to leave a lift with no form of emergency communication. If the alarm device cannot be made to work,
then consult customer and report to supervisor that lift may have to be removed from service, with details of
suggested remedial work.
If any of the stop switches are not operational perform any remedial work necessary. If still not operational inform
the customer and supplier that the lift must be taken out of service.
9.9 Safety edges
•Required standard
A mechanical safety edge is installed on the XL Plus; these are situated at the top and bottom of each door
aperture on the cabin. Activation of all mechanical edges must bring the lift to an immediate stop and drop the lift
call.
•Required action
Safety edge failure requires the lift to be taken out of service immediately and the requirement to report to
customer and supervisor with recommendations for remedial action.
9.10 Light Curtains
•Required standard
The light curtains are situated at the sides of each door aperture on the cabin. Operation of the light curtain must
bring the lift to a controlled stop and remove the lift call. The voice enunciator should inform the user ‘Light ray
activated, please keep clear of the entrances’.
•Required action
Light curtain failure requires the lift to be taken out of service immediately and report to the customer and
supervisor with recommendations for remedial action. If an error is detected within the voice enunciator, inform the
customer and supervisor of any remedial work required and the recommendation of the lift to be taken out of
service.
9.11 Control panels
•Required Standard
There are two areas to be checked, both the control unit behind the COP (4.2 Cabin operating panel (COP)
removed, pg 4) and the controls at the upper floor (4.3 Upper floor landing controls, pg 4). Contactors and relays
when energised should not buzz or be excessively noisy. There must be no indications of excess contact wear,
dust underneath relay or flash markings around contactors. Fuse holders must be intact with no damage. Check
fuse rating and remove any discarded/used components or shorting wires. All PCB connections must be of sound
nature and there must be no visible damage to the board.
•Required action
If a new contactor, PCB or relay is required, record manufacturer, type number, coil voltage, contact arrangement
and inform supervisor immediately. If new fuses required, record rating and physical dimension.
If it is not possible to leave the lift in a safe working order, inform the customer and supervisor and advise the lift
should be taken out of service.

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 12
9.12 Brake operation
•Required standard
After running the lift for the first 2-3 journeys it will become apparent the brakes are working correctly. The lift must
start and stop smoothly with out any vibrations or unexpected noises. An indication of correct brake operation will
be indicated by a smooth ride. With the upper landing control access removed the brake operation will be audible
when the motor starts and stops.
•Required Action
If there is any cause for concern regarding the brake then a thorough investigation of the brake must be made
(13.1 Brake lining, pg 21). If on inspection of the lining, an immediate correction cannot be achieved, the customer
and supervisor must be informed of remedial action and for the lift to be taken out of service.
9.13 Door operation
•Required standard
The door operation is to be as smooth and as quiet as possible. There must be no vibration, juddering or rumbling
at any stage of the door cycle. Speed changes in door travel are to be smooth and door closers must be able to
close doors from any stopped position.
•Required action
Adjust doors and door closers as necessary to achieve correct operation. This will include altering the speed
settings to ensure door closes smoothly and with the correct speed. If there is excessive damage to the door or
door closer which are not immediately resolvable make note of required part numbers and inform customer and
supervisor on possible lift shut down.
9.14 Landing door locks and beaks
•Required standard
On the first 2-3 journeys of the lift ensure that on reaching floor level the required door opens easily and there is no
catching or rubbing of the lock. Once the door has closed ensure the lock comes into operation smoothly and
ensure each of the required doors locks correctly. Once outside the lift ensure that no doors are able to be opened
when lift is not at required floor level. This test MUST be complete at every door as this is a severe safety risk.
Ensure that when doors are not closed (i.e. door beaks are not engaged), lift operation is not possible. If the lift is in
motion, the opening of the door (with door release key) should stop the lift.
•Required action
If there is no smooth operation of any lock, examine thoroughly to check there is any remedial work that can be
carried out (application of lubrication and removal or debris). If there is any issue with lift, lock or beak operation
that cannot be resolved immediately, the lift MUST be taken out of service immediately. Record component
manufacture and part number and inform customer and supervisor.
9.15 Indicators (DDU’s and push buttons etc…)
•Required standard
Ensure that all call station and control panel push button halos work correctly. These should light up when a call is
put in and stay lit until floor level is reached or call is removed.
Regarding DDU’s, all LED’s within the dot matrix should be operational. Floor level should also be indicated at the
required floor level and when the lift is operational an arrow should indicate lift direction.

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 13
•Required action
If it is not possible to fix any of the faulty components, then make a note of type and manufacture and inform
supervisor on required remedial work.
9.16 Visual inspection/light clean
•Required standard
It is essential that all areas are visually inspected. This is best done whilst carrying out a light clean. This will also
reduce the burden of the thorough clean (13.2 Thorough clean, pg 22).
•Required action
Any fault observed is to be rectified. Always repair, adjust, lubricate and clean as a first option. If it is not possible
to rectify the fault, inform the customer and supervisor about remedial work and possible lift shut down.
10 MAINTENANCE INSTRUCTION – PHASE 1
10.1 Risk assessment and general lift check
Ensure assessment is still relevant, if hazard has been addressed or new hazard has been identified record as
such on assessment. Record that assessment has been reviewed by dating and signing.
As in some instances, the finishing of the lift build may not tie in exactly with the lift handover date. For this reason
it is essential that a general lift check is complete as these lifts may have been sat for prolonged periods of time in
undesirable conditions.
10.2 Car overload
•Required standard
The first item to check will be to check the load weighing device is set up correctly. Firstly remove the COP (4.2
Cabin operating panel (COP) removed, pg 4) and check the weight shown when the car is empty and when there is
a known weight in the car. The load weighing controller will be positioned on top of the cabin controller.
To test the car overload is functional; the working load must be changed on the load weighing device (4.8 Load
weighing device – Rated load setup, pg 5). Set the alarm to approximately 50kg so that the weight of a nominal lift
engineer should trip the alarm.
Once this value has been set, stand in lift and attempt to travel upwards. Lift should not move and the overload
alarm ‘OL’ should be displayed on the DDU. Voice enunciation unit will repeat ‘Lift overload, would the last
passenger please leave the car’. Step out of the cabin, log a call to the next floor and close lift door. Lift should be
operational and travel to the required floor.
ON COMPLETION OF OVERLOAD TEST, ENGINEER MUST RE-SET ORIGINAL OVERLOAD VALUE!
•Required action
If the load weighing device is not functional or the device is not calibrated correctly, assess if there is any
immediate remedial solution (4.9 Load weighing device – Calibration, pg 5). If not, then record manufacturer and
part number and inform the supervisor and customer of remedial action and that the lift MUST be taken out of
service immediately.

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 14
10.3 Manual release
•Required standard
It is essential that the manual release for the lift is in sound condition. The manual release procedure should be
both displayed clearly within the upper floor controller and in the customers user guide. Follow these instructions
ensuring that the system works smoothly and that power is removed from the lift.
•Required action
If the release system is not working correctly and any immediate remedial work cannot be complete, inform the
customer and supervisor on future work required and that the lift should be taken out of service.
10.4 Rope connections and wear/stretch
•Required standard
All rope connections must be checked, counterweight, sling and overspeed governor. These connections MUST be
of quality nature and secured with a double nut and split pin. Also check rope grips are tight, with the saddle
section sitting against the working side of the rope.
Any springs used must have no damage present and be even in compression. Check there is no twisting present in
ropes and that any steel work supporting a rope connection must be clear of damage or stress.
Determination when the ropes should have to be discarded must be either,
- According to DIN 15 020, 6 broken wires within a length of 6 x d (36mm overspeed governor and
30mm suspension ropes)
- As specified by supplier, with a reduction of 6% (0.36mm overspeed governor and 0.3mm suspension
ropes)
Rope plate should be clearly visible at the rope connection point on the sling pick up beam (Figure 1 - Rope data
plate).
Figure 1 - Rope data plate
Finally, check for rope stretch. The ultimate limit switch should operate before the counterweight comes into
contact with the pit buffer.
•Required action
If there are any nuts, rope grips or split pins absent replace if possible and make note on log card. Clear any light
corrosion on terminations. If any spring, eyebolts etc… are damaged make note of manufacture and part number
and inform supervisor and customer on required remedial work.
If any ropes are not to the required standard, terminals are pulling through steel work or connections have
excessive corrosion the customer and supervisor must be informed that the lift will need to be taken out of service
immediately.

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 15
If counterweight comes into contact with pit buffer before the ultimate limit switch operates, it is possible to remove
the counterweight packers situated at the bottom of the counterweight. If all packers are removed and problem still
occurs, inform customer and supervisor that lift should be taken out of service and suspension ropes should be
replaced.
10.5 Earth bonding, insulation and electrical
•Required standard
Ensure that all earth bonds are present and that any terminations are secure.
•Required action
If a lift fails to be sufficiently earthed, this will result in a substantial risk to the user. If immediate earth bonding
cannot be achieved then the lift must be taken out of service and the customer and supervisor is to be informed on
the future remedial work.
11 MAINTENANCE INSTRUCTION – PHASE 2
11.1 Roof top
•Required standard
Important note: Persons are not permitted to stand on the car roof. On access of the ceiling (4.4 Ceiling
removed, pg 5), check all light fittings and check any loose electrical terminations or signs of overheating. The
engineer must be able to access roof top and replace roof top with ease and ceiling must be secure once returned
to normal operating position.
•Required action
If any terminals are loose, re tighten and assess the cause. If there is any damage to any component, record
manufacturer and part number and inform supervisor and customer of any remedial work required. If there is any
issue with ceiling access, carry out any remedial work required and inform supervisor and customer if any further
remedial work is required.
11.2 Upper shaft work
•Required standard
Important note: Persons are not permitted to stand on the car roof. On access of the upper shaft work (4.4
Ceiling removed, pg 5), firstly check the traction sheave to ensure there is no indication of cracking and the keyway
has no signs of any movement. Ropes must be sitting at the same depth within grooves and there must be no
signs of fleeting or riffling.
Check all fixings, guides, sheave guard, overspeed governor and horizontal member. Look for any unexpected
debris. Ensure ropes pass through bedplate without clashing with any of the metal work.
•Required action
If there is any damage, looseness in keyway or excessive groove wear, inform supervisor and customer
immediately and advise on required remedial work. Assess whether to advise customer on possible lift shut down.
Re-tighten any loose fixings and if there is any unexpected debris found around bedplate, investigate both. If there
is any clash with ropes and metal work, carry out any immediate remedial work. If not resolvable, inform supervisor
and customer on further remedial work required.

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 16
11.3 Drive shaft bearings
•Required standard
Important note: Persons are not permitted to stand on the car roof. Access to the upper shaft work is gained
by removing the cabin (4.4 Ceiling removed, pg 5)
The main drive shaft support bearings (2 off), located on the bedplate at the top of the shaft, need to be checked
for re-lubrication. The bearings are considered to be lubricated for life, but due to differing operating conditions
(temperature, vibration, loads etc) they need to be checked to ensure the moving elements of the bearing are
lubricated. Firstly, check for excessive noise and vibration while running the lift (remove the motor access panel,
located in the upper landing controller, for a clearer examination of the noise). Also, assess the bearings for
general wear/degradation and check for excessive grease seeping out around the bearing seals (a small amount is
acceptable and will not require attention).
Note: Do not attempt to tighten the bearing collar fixings. Attempts to tighten the fixings could result in
deformation of the collar. If it is suspected that the shaft has moved in the bearings, first check that the
fixings securing the bearing housings to the bedplate are secure. Following this, technical assistance
should be sought due to the specific procedure required to refit the bearings to the shaft.
•Required action
If it is determined that the bearings need relubricating, isolate the power to the lift and gain access to the upper
shaftwork (4.4 Ceiling removed, pg 5). Using a grease gun and SKF LGWA 2, LGMT 2, LGMT 3 or equivalent
grade grease, slowly press in the lubricant into the bearing via the grease nipple located on top of each housing. A
flexible extension hose may be required to access the grease nipples (dependant on headroom). Stop pressing the
grease into the bearing as soon as fresh grease starts escaping out of the seal. Avoid excess pressure as this can
damage the seals.
If the remedial work cannot be completed, or the bearings need replacing, inform the customer and supervisor that
the lift will need to be taken out of service immediately and advise on the work required.
11.4 Ultimate limit switch
•Required standard
The ultimate limit is located on the lift sling. Call the lift up to upper landing using upper landing call station and on
arrival of lift remove COP and rear walls (4.5 COP and rear wall removed, pg 5).
Using the push-pull switch located on the din rail assembly within the upper control unit, switch the lift to slow
speed by pushing the switch in. Use the test control (4.3 Upper floor landing controls, pg 4) to operate the lift
upwards at slow speed. Lift should stop before clashing with bedplate at approximately 50mm above floor level.
When the lift has come to a halt, use the test controls to operate the lift downwards, the lift should not move as the
ultimate limit switch will be engaged.
To move the lift downwards, link out G2A to G3 on the controller. Once the ultimate limit pin has moved away from
the ultimate limit ramp, reset switch ‘A’ and remove link from G2A to G3 (Figure 2 - Ultimate limit switch).
•Required action
If lift comes to a halt before the ultimate limit stops the lift, look the following areas.
- If the counterweight is coming to rest on the buffer before the switch activate, check rope stretch (10.4
Rope connections and wear/stretch, pg 14).
- If the sling clashes with the bedplate before the switch activates. Check the position of the ultimate limit
ramp.
- If the switch pin is activating but not cutting power to the motor, check wiring and carry out any
immediate remedial work.

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 17
2.0
If the ultimate limit switch is still not functional record manufacturer and part number and inform customer and
supervisor on further remedial work and recommend on lift shut down.
It is of up most importance to remove this link once check is complete!
Figure 2 - Ultimate limit switch
11.5 Safety gear and overspeed governor
•Required standard
Before activating the safety gear, verify that they are set up correctly on the guides and there is a gap of 2.0mm
between the safety gear and the back of the guides (Figure 3 - Safety gear setup).
At full speed, activation of the overspeed governor (4.6 Overspeed governor tests, pg 5) must cut power to the
motor and safety chain at G2. Full safety gear activation does not need to be complete in the annual check. This
can be complete in the 5 year check.
Once engaged, enter the lift and check behind the rear wall (4.5 COP and rear wall removed, pg 5) to see that the
safety gear on each side has began to engage. These should not be fully engaged at this stage as the motor will
have cut movement of the lift before full engagement.
.
•Required action
If for any reason the safety gear has not engaged, investigate possible cause. This may be due to a linkage error at
any point between the overspeed activation to the safety gears themselves. If only one of the safety gears are
engaged, ensure that these are set up correctly (Figure 3 - Safety gear setup). Whilst the safety gear activation
plate ‘A’ is lined up in the middle of the access slot, the safety gear roller ‘B’ should be set up in the centre of each
of the safety gears.
Figure 3 - Safety gear setup
11.6 Encoder and timing belt
•Required standard
A
A
B

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 18
The general function of the encoder and timing belt will have been assessed in the checking of the floor level. If
floor levelling is correct, check all fixings are secure and belt is running smoothly within pulleys.
Ensure that timing belt brackets are fixed securely and the encoder cable is clear from moving parts and free from
damage.
•Required action
Tighten any loose fixings and carry out any immediate repair work. If there is any excessive damage to any
component record manufacturer and part number and inform customer and supervisor on further remedial work.
11.7 Guides and fixings
•Required standard
With COP and rear wall removed (4.5 COP and rear wall removed, pg 5), travel the whole length of the shaft
checking all counterweight and car guide fixings are secure. Check for any excessive damage to guides and that
all joints are of quality nature.
With the rear wall removed check the thickness of the slider inserts connecting the sling to the guides (Figure 4 -
Car slider inserts). The correct thickness should be 9.7mm. The minimum thickness of this insert should be 6.7mm
(a reduction of 3.0mm).
9,7
Figure 4 - Car slider inserts
•Required action
Tighten any loose fixings and replace where necessary. Investigate cause for missing fixings or excessive wear
and make note. If there is any excessive damage to any guide, inform customer and supervisor on remedial work
and possibility that lift will need to be taken out of service.
Dress guides where necessary.
If for any reason the slider inserts are below the minimum 6.7mm then new inserts must be ordered and replaced
when possible. Inform the customer and supervisor on the possibility of taking the lift out of service when looking at
lift cabin clearances.
11.8 Trailing cable and chain
•Required standard

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 19
Chains and cable must have no twisting or kinks and all anchorage points must be secure. There must be no
surface wear, cracks or splits on any point of the cable and they must run clear of all fixed parts of the lift
installation. Access to the cables can be made through the rear wall of the cabin (4.5 COP and rear wall removed,
pg 5)
•Trailing cable and chain – Required action
If new cables or chains are required make note of type and length and inform customer and supervisor on remedial
work.
11.9 Sling and car fixtures
•Required standard
With COP and rear wall removed (4.5 COP and rear wall removed, pg 5), check all fixings are in place and secure.
Ensure all contact washers are in places and locking nuts are in place at the bottom of the cabin uprights. Check
for damage or excessive wear to sling.
•Required action
Tighten any loose fixings, replace where necessary and investigate cause for missing fixings. If it is not possible to
replace missing fixings or there is any excessive damage to the sling, inform customer and supervisor on remedial
work and possibility that lift will need to be taken out of service.
11.10 Gearbox/motor
•Required standard
Important note: persons are note permitted to stand on car roof. Gearbox/motor can be accessed through
manual release access panel (4.3 Upper floor landing controls, pg 4) and through cabin ceiling (4.4 Ceiling
removed, pg 5). Check torque arm is secure and general appearance of unit is good. Check for oil leaks in and
around gearbox/motor. Check for any unexpected noises or vibrations on gear unit, motor and surrounding areas.
Check to see if fan is working quietly and is drawing air over the motor. Look for any discolouration and any
extreme temperatures, indicating over heating.
•Required action
The cause of any overheating / vibrations must be investigated, inform customer and supervisor on any remedial
work. If oil levels are low, investigate cause. If problem cannot be fixed inform customer and supervisor on any
remedial work and if the lift will need to be taken out of service. If oil leak fixed, top up oil with Synthetic oil type
Telium VCF 320 or equivalent.
12 MAINTENANCE INSTRUCTION – PHASE 3
12.1 Counterweight
•Required standard
Before entering the pit, ensure the pit stop is activated. On completion of test ensure pit stop is de-activated.
All fixings on the counterweight and guard should be secure and present. Both should be clear from damage. Only
a quick examination of the rope connections is required as the full maintenance check will be complete at a
different phase (10.4 Rope connections and wear/stretch, pg 14).
Whilst in the pit check the counterweight sliders (Figure 5 - Counterweight slider). The original thickness of the
slider should be 4.00 and this should not be less than 2.0mm.

Midilift XLplus
Maintenance Guide
Jan 2014 Issue 4 20
4,0
Figure 5 - Counterweight slider
•Required action
Tighten any loose fixings and replace where necessary. Investigate cause for missing fixings and make note. If the
guard has signs of any marks, investigate the cause, this may be due to the sling clashing with the guard or the
guard clashing with the counterweight. If unsolvable inform customer and supervisor on remedial work and
possibility that lift will need to be taken out of service.
12.2 Pit buffer
•Required standard
The buffers must be checked for excess damage and loose fixings. Before entering the pit, ensure the pit stop is
activated. On completion of test ensure pit stop is de-activated.
•Required action
Tighten any loose bolts and take manufacturer and part number if there is excess damage to buffer. Inform
supervisor and customer on further remedial work required.
12.3 Tension Pulley
•Required standard
Take lift to top floor and return to ground floor leaving the car at top floor. Enter the pit using the door release key
and activate the pit stop.
Check tension pulley for any debris and loose fixings. Also check tension pulley sits within tension indicator (Figure
6 - Tension pulley setup). Activate switch, de-activate pit stop and return to cabin. Access control panel (4.2 Cabin
operating panel (COP) removed, pg 4) and check safety chain, chain should be lit to G1 only and feed from G1A to
G1B will be lost. Return to ground floor and de-activate tension pulley switch.
•Required action
Tighten any loose bolts and investigate any cause of debris. Investigate any cause for lost tension within governor
rope and complete any immediate remedial work available. If tension cannot be reached within rope lift MUST be
taken out of service and the customer and supervisor must be informed of future remedial work.
If tension pulley switch needs replacing, record manufacturer
and part number and inform customer and supervisor on remedial
necessary. Lift MUST be taken out of service.
between
0 & 5.0mm
F
T
T
A
'
OSG ro
p
e