ZIEHL-ABEGG ZAS0 User manual

Amendment of the original operating
instructions
Quick Check of the bolted connection of
the worm wheel of the elevator machines
ZAS0, ZAS1, ZAS2, ZAS3 A-TIA19_04-GB
ZIEHL-ABEGG SE | Heinz-Ziehl-Straße | 74653 Künzelsau | Tel. [phone] | [e-mail] | www.ziehl-abegg.de
A-TIA19_04-GB Article no. 01013454-GB Issue: 1933 Index 006 Created on: 19.07.2019
ZAS0
ZAS1
ZAS2
ZAS3
Quick Check of the bolted connection of the worm wheel
This service manual must be kept
as part of the drive’s inspection
logbook!
Date inspection Inspector’s name / first name
1. Quick Check
2. Quick Check
3. Quick Check

Content
1 General information ........................................................ 3
1.1 Importance of the service manual for quick check of the bolted connections of the worm
wheel .............................................................. 4
1.2 Target group ......................................................... 4
1.3 xclusion of liability ................................................... 4
1.4 Copyright ........................................................... 4
2 Safety instructions ......................................................... 5
2.1 Pictographs ......................................................... 5
2.2 Requirements placed on the personnel / due diligence ........................ 5
2.3 General safety instructions .............................................. 5
3 Quick Check .............................................................. 6
3.1 Operational area ...................................................... 6
3.2 Requirements for the quick check ........................................ 6
3.3 Target of the quick check: .............................................. 6
3.4 General Preliminary Clarification: ......................................... 6
3.5 Specific Preliminary Clarification: ......................................... 7
3.6 Required tools ....................................................... 7
4 Quick Check of the bolted connection of the orm heel ......................... 8
4.1 Removing the name plate / Opening the maintenance hole ..................... 8
4.2 Positioning of the worm wheel ........................................... 9
4.3 Optical appraisal of the fitting bolts ........................................ 9
4.3.1 Identification of the fitting bolts ...................................... 10
4.3.2 Inspection of the length of the fitting bolts .............................. 11
4.4 Visual inspection of the screw locking device ................................ 11
4.4.1 Checking the size of the tooth lock washer ............................. 12
4.4.2 Checking for spring washer ........................................ 13
4.5 Correct execution of the bolted connection ................................. 14
4.6 Inspection of tightening ................................................. 14
4.6.1 Optical appraisal of the nuts ....................................... 15
4.6.2 Inspection of tightening with suitable spanner ............................ 15
4.7 Documentation of the inspection results .................................... 16
5 Enclosure ................................................................ 17
5.1 Drawing for special spanner for ZAS2 with transmission ratio 27:1 and 27:2 and ZAS3
17
5.2 Test protocol 1 ....................................................... 18
5.3 Test protocol 2 ....................................................... 21
5.4 Report to the company ZI HL-AB GG S ................................. 23
Service instructions ZAS0, ZAS1, ZAS2, ZAS3
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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1 General information
Initial Situation:
The gears must be checked for loose fixing bolts or nuts on the bolted connection of the worm wheel.
Additionally there might be gear parts that have to be replaced.
Principle:
If no loose bolts are to be found at the gear, however, it contains parts that have to be exchanged, the
gear is not in order. The parts must be replaced accordingly.
Chart:
Overvie of the quick checks - transition to annual visual inspection as part of the regular
maintenance and inspection
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 General information
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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1.1 Importance of the service manual for quick check of the bolted connections of the
orm heel
ZAS0, ZAS1, ZAS2 and ZAS3 are elevator machines with worm gears.
"
This service manual describes the inspection of the bolted connection of the fitting bolt and nut of
the worm wheel for SWG0-, SWG1-, SWG2- and SWG3-gearboxes for ZAS0-, ZAS1-, ZAS2- and
ZAS3-elevator machines, which is not a replacement for the regular maintenance of the drive,
which has to be carried out regularly.
"
The service manual does not replace the original operating instructions of the elevator machine or
frequency inverter!
"
This service manual for the inspection of the bolted connection of the worm wheel is an amendment
to the original operating instruction:
ZAS0 Article No. 01008051-GB A-TBA11_06-GB
ZAS1 Article No. 01009054-GB A-TBA13_02-GB
ZAS2 Article No. 01008066-GB A-TBA13_03-GB
ZAS3 Article No. 01008067-GB A-TBA13_04-GB
"
A current hardcopy version of the original operating instruction and this service manual must be
available at the drive!
1.2 Target group
The service manual address persons entrusted with maintenance and servicing and who have the
corresponding qualifications and skills for their job.
1.3 Exclusion of liability
ZI HL-AB GG S is not liable for damage due to misuse, incorrect use, improper use or as a
consequence of unauthorized repairs or modifications.
1.4 Copyright
This service manual contains information protected by copyright. The service manual may be neither
completely nor partially photocopied, reproduced, translated or put on a data medium without prior
explicit consent from ZI HL-AB GG S . Infringements are liable for damages.
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 General information
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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2 Safety instructions
2.1 Pictographs
Safety instructions are highlighted with warning triangles and are depicted according to the degree of
hazard as follows.
Danger!
General hazardous area. Death or severe injury or significant property damage can occur if the
corresponding precautions are not taken!
Danger!
Danger by dangerous, electric voltage! Death or severe injury can occur if the corresponding
precautions are not taken!
Information
Important additional information and advice for user.
2.2 Requirements placed on the personnel / due diligence
Danger!
"
Installation, connection to the power supply and commissioning may only be performed by qualified
service personnel! The relevant regulations must be observed!
"
Persons entrusted with the planning, installation, commissioning and maintenance and servicing in
connection with the elevator machine must have the corresponding qualifications and skills for
these jobs. Based on their training, knowledge and experience as well as knowledge of the relevant
standards, they must be able to judge the work transferred to them and be able to recognize
possible hazards.
"
In addition, they must be knowledgeable about the safety regulations, U directives, rules for the
prevention of accidents and the corresponding national as well as regional and in-house
regulations. Personnel undergoing training, instruction, or on apprenticeship may only work on the
elevator machine under the supervision of an experienced person. This also applies to personnel in
general training.
"
Comply with the legal minimum age.
2.3 General safety instructions
Danger!
"
The elevator machine has attachment points: integrally cast eyelets or screwed-on eye bolts, eye
plates or steel cable loops. The attachment points are designed exclusively for transporting the
elevator machine including brake and traction sheave. Do not lift other loads such as bolted on
components, ropes lying on top, etc. with the attachment points. Suitable lifting gear must be used.
Danger!
Warning of hand injuries!
"
Risk of injury from reaching into the rope guard.
"
Do not carry out any activities during operation.
"
Only perform maintenance work on the drive when stopped!
"
If the elevator machine is not energised, no electric torque is available. Releasing the brakes can
cause uncontrolled acceleration of the elevator!
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Safety instructions
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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3 Quick Check
3.1 Operational area
This quick check is to be executed three times and is not part of the regular maintenance.
3.2 Requirements for the quick check
The elevator has to be taken out of service and has to be locked for passenger or goods transport.
3.3 Target of the quick check:
✓Assert whether no parts to be exchanged are installed.
✓To identify any loose nuts with an open-end wrench.
✓To ensure that there is no slackening of the nuts by repeating the inspection twice after 6 months
respectively.
3.4 General Preliminary Clarification:
•Has maintenance been regularly executed and documented?
If no:
"
Inform the operator accordingly and execute maintenance according to instructions "Regular
maintenance and inspection of ZAS elevator machines A-TIA19_07 ", if necessary shut down
the installation.
•Are there any other noticeable problems?
If yes:
"
Inform the operator, if necessary shut down the installation.
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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3.5 Specific Preliminary Clarification:
Figure 3-5-01 - Repair label
( xample with serial number "16411657/1")
Figure 3-5-02 - ZAS0 repair lable position Figure 3-5-03 - ZAS1 to ZAS3 repair label postion
•Was a repair label applied or was a repair documented in the drive's inspection logbook (application
of new screw nuts and Loctite
®
according to A-TIA10-06)?
"
If yes:
Don't use a rench!
No further inspection is required. If necessary please ensure that the repair label matches
the documentation.
If the last regular maintenance is 12 months or more, perform maintenance according to
the current instruction in the instructions "Regular maintenance and inspection of ZAS
elevator machines A-TIA19_07".
"
If no:
Continue with the applicable accelerated inspection.
•Did an quick check (or torque check) take place already?
If yes:
"
Verify that this was documented in the logbook.
"
Assert whether parts to be exchanged were examined and cleared.
"
Determine how often the quick check has been carried out and proceed accordingly.
3.6 Required tools
SWG0, SWG1 and SWG2-gearbox respectively ZAS0, ZAS1 and ZAS2-elevator machine:
•Suitable spanner with size of 15 to 19
•Work lamp
•Hand mirror
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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SWG2 gears ith transmission ratio 27:1 and 27:2 and SWG3 gear and
ZAS2 elevator machine ith transmission ratio 27:1 and 27:2 and ZAS3 elevator machine:
•Special spanner* based on a bent combination spanner (see chapter 5.1. for drawing):
ZAS2-elevator machine with transmission ratio 27:1 and 27:2
-SW18 (ZI HL-AB GG S article number 02500825*)
-SW19 (ZI HL-AB GG S article number 02500826*)
ZAS3 elevator machine
- SW21 (ZI HL-AB GG S article number 02500827*)
- SW22 (ZI HL-AB GG S article number 02500828*)
•Work lamp
•Hand mirror
*The special spanner can be requested from ZI HL-AB GG S .
4 Quick Check of the bolted connection of the orm heel
Danger!
"
Tools may only be inserted into the open gearbox (by removing gearbox cover) if the elevator is
switched off by the main switch, the installation is protected against restart and the operating brake
is closed.
"
It has to be taken care that no limbs, clothing or other objects can get into the maintenance hole
except the tool.
"
While working in the gearbox, ensure that the operating brake is closed properly and that the
manual hand release is not activated.
"
During positioning, the worm wheel moves. At this state it is only allowed to visually locate the
position of the nut from outside with a minimum distance of 30 cm with a sufficient bright work lamp.
4.1 Removing the name plate / Opening the maintenance hole
Figure 4-1-01 Figure 4-1-02
1. Loosen both hexagon head screws M6 (1).
2. Remove the name plate (2) with the sealing on the top of the gearbox.
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check of the bolted connection of the worm wheel
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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4.2 Positioning of the orm heel
Target position of the bolts for inspection
Figure 4-2-01
1. ach nut (3) which has to be inspected should preferably be located in the center of the
maintenance hole.
2. If this is not the case, then bring the nuts into position, one by one for the inspection, in according
to chapter 4.6 – inspection of tightening.
3. It is recommended to mark the traction sheave with a coloured marking to avoid that the
inspection of any nut is missing.
4. The positioning of the worm wheel should be done by using the inspection control. It is an
advantage if the inspection speed is temporarily reduced.
5. As an option, the empty elevator car can be sent to the lowest floor, by a light and controlled
activation of the manual hand release, the worm wheel can be brought to the required position as
well.
4.3 Optical appraisal of the fitting bolts
The objective of the visual inspection is, to determine whether the existing fitting bolts possess without
doubt the correct strength category and length. The screw heads of the fitting bolt and the nuts can be
appraised optically with a suitable work lamp and a hand mirror.
The visual inspection of the fitting bolts must be executed once and does not need repeating.
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check of the bolted connection of the worm wheel
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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4.3.1 Identification of the fitting bolts
According to chapter 10.3.3.1 of the DIN N ISO 898-1, hexagon bolts have to be labeled with the
manufacturer`s symbol and the symbol of the strength class.
Figure 4-3-1-01
‘a‘ manufacturer’s symbol
‘b‘ symbol of the strength class
In all SWG-gearboxes, the fitting bolts used must be of the strength class 8.8 and must be produced in
according to DIN 609.
Fitting bolt according to the norm!
Figure 4-3-1-02
Fitting bolt not according to the norm!
Figure 4-3-1-04
Figure 4-3-1-03 Figure 4-3-1-05
Danger!
"
If the identifing mark of the strength category 8.8 cannot be seen, for example if the screw heads
look as if they were ground down (see figure 4-3-1-04 and figure 4-3-1-05), the elevator has to be
shut down in order to avoid an uncontrolled movement of the elevator car!
"
If an identification of the fitting bolts is not possible please contact ZIEHL-ABEGG SE (see
chapter 5.4 for contact information).
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check of the bolted connection of the worm wheel
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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4.3.2 Inspection of the length of the fitting bolts
All fitting bolts must be long enough that their threads extend beyond the nut. All threads of the nuts
must be used.
Fitting bolt in the correct length!
Figure 4-3-2-01
Fitting bolt too short!
Figure 4-3-2-02
Danger!
"
If not all threads of all 6 nuts are used (see figure 4-3-2-02), the elevator has to be shut down in
order to avoid an uncontrolled movement of the elevator car!
"
If not all threads of a nut are used please contact ZIEHL-ABEGG SE (see chapter 5.4 for
contact information).
4.4 Visual inspection of the scre locking device
The aim of the visual inspection is, to determine beyond doubt whether the available screw locking
device is the correct size and locking type. With a suitable work light and hand mirror, you can visually
inspect the washers and nuts.
The visual inspection of the scre locking device must be executed once and does not need
repeating.
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check of the bolted connection of the worm wheel
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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4.4.1 Checking the size of the tooth lock asher
Tooth lock washer in the correct size!
Figure 4-4-1-01
Tooth lock washer too big!
Figure 4-4-1-02
Danger!
"
If one of the tooth lock washers is too big (see figure 4-4-1-02), the elevator has to be shut down in
order to avoid an uncontrolled movement of the elevator car!
"
If any of the toothed locking ashers is too big please contact ZIEHL-ABEGG SE (see
chapter 5.4 for contact information).
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check of the bolted connection of the worm wheel
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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4.4.2 Checking for spring asher
xample 1
Figure 4-4-2-01
xample 2
Figure 4-4-2-02
Danger!
"
If one of the nuts is secured with a spring washer (see figure 4-4-2-01 and 4-4-2-02), the elevator
has to be shut down in order to avoid an uncontrolled movement of the elevator car!
"
If any of the nuts is secured ith a spring asher please contact ZIEHL-ABEGG SE (see
chapter 5.4 for contact information).
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check of the bolted connection of the worm wheel
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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4.5 Correct execution of the bolted connection
Serrated locking nut
and fitting bolt in the correct length!
Correct size of lockwasher
and correct length of fitting bolt!
Figure 4-5-01 Figure 4-5-03
Serrated locking nuts
Figure 4-5-02
4.6 Inspection of tightening
"
The elevator must be switched off by the main switch and protected against restart.
"
Do not activate the manual hand release!
Inspection goal:
Identification of loose nuts.
Inspection goal:
Determine if the bolt and nut are fitted correctly.
The inspection of the nut must be carried out three times after invervals of six months
respectively.
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check of the bolted connection of the worm wheel
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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4.6.1 Optical appraisal of the nuts
Danger!
"
If a loose nut is determined by visual inspection, the elevator has to be shut down in order to avoid
an uncontrolled movement of the elevator car!
"
If a loose nut is determined by visual inspection please contact ZIEHL-ABEGG SE (see
chapter 5.4. for contact information).
4.6.2 Inspection of tightening ith suitable spanner
Direction of the rotation of spanner for inspection of tightening the nuts
Figure 4-6-2-01
1. Apply the suitable tool (4) onto the nut (3) of the bolted connection.
2. Turn clockwise with moderate force according to the following table 4-6-2, without any jerk.
3. On the side of the fitting bolt no spanner is applied for counterholding.
Overvie gearboxes – thread sizes – test forces
Gear Thread Inspection tor-
que
approx.
Lever length
approx.
Force
approx.
Force
approx.
Nm mm N kg
SWG0M102020010010
SWG1M123522015015
SWG2M123522015015
SWG3M145518030030
Table 4-6-2
Evaluation of the tightening of the nut
"
If it is possible to turn a nut on the fitting bolt, or the whole connection of the nut and the fitting bolt,
the bolted connection has to be considered as inadequately.
"
If just one of 6 connections is considered as inadequately, the elevator machine has to be taken out
of order immediately and permanently. The elevator has to be secured against restart.
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check of the bolted connection of the worm wheel
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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Danger!
"
If it is possible to turn a nut on the fitting bolt or the whole connection of the nut and fitting bolt the
elevator has to be shut down in order to avoid an uncontrolled movement of the elevator car!
"
If it is possible to turn a nut on the fitting bolt or the hole connection of the nut and the
fitting bolt, please contact ZIEHL-ABEGG SE (see chapter 5.4. for contact information).
"
After the evaluation of the tightening of the nut, the next nut has to be brought into position
according to “chapter 4.2”.
"
The inspection of the bolt connection of the worm wheel of the gearbox, is completed when all 6
nuts of the worm wheel have been inspected according to the described method above.
4.7 Documentation of the inspection results
Figure 4-8-01
"
Please document the quick check in the attached test protocol (see chapter 5.2 and 5.3).
"
The test protocol 1 (see “Chapter 5.2”) have to remain in document A-TIA19_04.
"
It is recommended the test protocol 2 (see “Chapter 5.3”) should be attached on the gearbox and
clearly visible.
"
It is imperative to inform ZIEHL-ABEGG SE about the quick check (see chapter 5.4.)!
"
Every quick check must be documented in the inspection logbook!
"
If the installation has been inspected please record the findings in test protocol 1 and test
protocol 2!
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 Quick Check of the bolted connection of the worm wheel
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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5Enclosure
5.1 Dra ing for special spanner for ZAS2 ith transmission ratio 27:1 and 27:2 and ZAS3
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 nclosure
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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5.2 Test protocol 1
To remain in the document A-TIA19_04.
Please send a copy of test protocol 1 to ZIEHL-ABEGG SE!
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 nclosure
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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Service instructions ZAS0, ZAS1, ZAS2, ZAS3 nclosure
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
19/24

Please do nload the instructions for "Regular maintenance and inspection of ZAS elevator
machines A-TIA19_07" here:
https:// .ziehl-abegg.com/de/de/do nloads/
Service instructions ZAS0, ZAS1, ZAS2, ZAS3 nclosure
A-TIA19_04-GB 1933 Index 006 Part.-No. 01013454-GB
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