Automatic Safety Gear Trigger ASGT

Handbook

KONE ASGT

a18

Table of contents
1 General ...........................................................................................................................................2
2 Safety ..............................................................................................................................................2
3 Maintenance and repair ................................................................................................................3
3.1 Schedule of inspections ..............................................................................................................3
3.2 6 monthly checks.........................................................................................................................3
3.3 Annual inspection and replacement of parts ...............................................................................6
3.4 Assembling of the ASGT device .................................................................................................7
3.5 Annual load test...........................................................................................................................7
4 Installation and use .......................................................................................................................8
4.1 Installation ...................................................................................................................................8
4.2 Test............................................................................................................................................11
4.3 Use of automatic safety gear trigger .........................................................................................13
5 ASGT operational test and verification report......................................................................... 14
6 Spare parts .................................................................................................................................. 16
6.1 Body ..........................................................................................................................................16
6.2 Cable .........................................................................................................................................17
6.3 Other equipment........................................................................................................................18
7 Approvals and version history.................................................................................................. 18

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Automatic Safety Gear Trigger ASGT
Handbook

1 GENERAL

This handbook is for people who are responsible for purchase, issue, use, maintenance, repair or
testing of the Automatic Safety Gear Trigger.
The ASGT is designed for people who use the elevator car or a temporary platform as a man-riding
mobile working platform.
The automatic safety gear trigger is an automatic spring loaded jack which is connected between the
Tirak hook and suspended elevator car / working platform. A steel rope is connected to the safety
gear operating arm and this engages the safety gear:
− automatically when the automatic safety gear trigger is not under tension.
− manually when the latch release has been opened.

2 SAFETY

Do not carry out any repairs yourself.

Repair of the automatic safety gear trigger on site is not allowed.
The automatic safety gear trigger is a safety critical item and must be returned for inspection and
repair by an authorized person:
− if ASGT has operated in a free fall situation.
− if ASGT has sustained accidental damage.
− at 6 month intervals for regular inspection and record updating.
For daily and weekly checks of the automatic safety gear trigger refer to AM-01.03.003.
Ny-lock nuts should be replaced whenever there are signs of wear/looseness.

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Automatic Safety Gear Trigger ASGT
Handbook

3 MAINTENANCE AND REPAIR

3.1 Schedule of inspections

− 6 monthly check
− annual inspection and load test

3.2 6 monthly checks

3.2.1 Gas spring and function check

This is a test to check the condition of the gas springs. The test can be performed either using a
manometer or by hanging load.

0 0

3 1 3 1
>1150 N 115 kg
2 2
115 kg
A8
A7

Gas spring test using manometer Gas spring test by hanging load

The gas springs must not be fully compressed The gas springs must not be fully compressed
before a pulling force more than 1150 N has been by a hanging load of 115 kg.
reached.

Gas springs being fully compressed with less pulling Gas springs being fully compressed by a load
force must be replaced. of 115 kg must be replaced.

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Automatic Safety Gear Trigger ASGT
Handbook

3.2.2 Manual release and latch operation test

Step Action Note

1 Hold the ASGT from the top hole.

Release the latch.

The lower part of the ASGT must fall freely

and the latch must automatically return to
locked position.

A9

2 Still holding the ASGT, lower the device to

a flat surface and let the top part sink down.

The top part of the ASGT should lower to

the latch position. Final latching may
require assistance due to internal friction
especially when new.

A10

3 Loosen the centre bolt nut a little if the

requirements in steps 1 and 2 are not
fulfilled.

DO NOT LUBRICATE THE SLIDING

SURFACES!
A11

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Automatic Safety Gear Trigger ASGT
Handbook

3.2.3 Inspection and replacement of trigger cable parts

Step Action Picture Replacement

1 Check the wire rope Replace the wire rope if
condition. kinks or other damages
occur.

2 Check the wire rope covering Replace the wire rope cover
condition. if the spiral sleeve is
damaged.

3 Check the condition of Replace as required.

shackle and iron grips.

A25

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Automatic Safety Gear Trigger ASGT
Handbook

3.3 Annual inspection and replacement of parts

Inspection includes all 6 monthly checks plus the following load test.
Make a visual check of welded components for cracks and sign of stress.
Step Action Picture Replacement
1 Dismantle the shackle plates Replace the shackle plates
(1). if the round fixing holes
A1 have become oblong.
1
Replace the M16 bolts if
sign of wear.

Replace the Ny-lock nuts if

needed.
2 Check the latch function. The Replace the spring if
spring must return the latch needed.
to locked position from 2
release position. Replace the M16 bolt if sign
of wear.
Dismantle the latch (2).
Replace the Ny-lock nut if
A2 needed.

3 Dismantle the fork (3). 3 Replace the fork if the

round fixing hole has
become oblong or other
visible damages occur, like
cracks in welding etc.

A3
4 Dismantle the sled (4). Replace if damaged.
A4

5 Dismantle the gas springs (5) Replace the gas springs

from the bar (6). 5 and ball joints if they did not
pass the gas spring test.

6 Replace the bar if the round

D21
hole (D21) has become
5 oblong or other visible
A5 damages occurs on the
bar, like cracks in welding
etc.

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Automatic Safety Gear Trigger ASGT
Handbook

3.4 Assembling of the ASGT device

The assembling steps are reverse to the dismantling steps

Step Action Note
1 Assemble the ASGT parts in reversed order
from the dismantling.

NOTE!
When installing the latch, tighten the nut
and then loosen it so that you can rotate the
A6
big washer by hand.

3.5 Annual load test

This test is to expose and highlight eventual material weakness.

0 0

3 1 3 1
30 KN 3000 kg
2 2
3000 kg

A20
A19

Load test using manometer Load test by hanging load

Load the ASGT with a pulling force of 30 KN Load the ASGT with a hanging load of 3000 kg

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Automatic Safety Gear Trigger ASGT
Handbook

4 INSTALLATION AND USE

4.1 Installation

Step Action Note

1 Attach the rope to the safety gear lever.
2 Attach the safety gear trigger to the Tirak
lifting hook adapter with the bolts, plates and
washers provided.
3 Attach the hoist hook to the safety gear
trigger.
4 Drive the car up with Tirak so that the Tirak CAUTION!
rope is tensioned and the gas springs are With KONE MicroSpace elevators place
fully compressed. counterweight filler weights to the car sling
platform. Refer to elevator level installation
instruction.
5 Fix the angle bracket to the car sling upright
at the machine side. Fit the rope to the angle
bracket. Keep the rope as vertical as
possible.
6 Carefully route the rope guiding tube to the Ensure that there are no kinks or tight bends.
safety gear trigger. Minimum bend radius allowed is 100 mm.
7 Secure the rope guiding tube to the safety
gear trigger.
8 Tension the rope by pulling it. Secure the
rope to the safety gear trigger using the rope
fixing plate.

WARNING!
The rope should be tight. Ensure that the
safety gear arm has not moved. No slack is
permitted.

1007239-1.wmf
8 Adjust the tension of the rope by loosening
or tightening the nut on the angle bracket.

1010310-1.wmf

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Automatic Safety Gear Trigger ASGT
Handbook

Fixing to Eureca car

1007240-1.wmf

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Automatic Safety Gear Trigger ASGT
Handbook

Fixing to CF sling

B A32.wmf

A) Lever for TranSys elevators

B) Universal lever for underslung type car sling
C) Rope attached to the safety gear lever

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Automatic Safety Gear Trigger ASGT
Handbook

Fixing to KONE MicroSpace car sling

17 mm

A31.wmf

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Automatic Safety Gear Trigger ASGT
Handbook

4.2 Test

WARNING!
It is essential that the rust protection is removed from the rails. Otherwise the safety gear will not
operate correctly. Test the operation of the automatic safety gear trigger and safety gear each day
before commencing installation work from the car top.

Step Action Picture

1 Drive the car approximately 500 mm above the buffer.
2 Open the latch release to engage the safety The safety gear must engage.
gear.

1007241.wmf
3 Drive the car downwards to ensure that the safety gear has engaged fully.
4 Drive the car downwards until the Tirak rope The automatic safety gear trigger must be
is slack. Check that the upper part of the latched.
safety gear trigger lowers onto the lower
part. Ensure that the latch release has
engaged to the pin.

1007243.wmf

1007242.wmf

5 Drive the car upwards. CAUTION! KONE MicroSpace:

When the car sling starts to move upwards,
check that synchronisation bar has returned
to lower position and that safety gears have
disengaged.
6 Check the safety gear marks on the guide The marks should be at the same height and
rails. of the same depth and length.
7 If the marks are not equal the safety gear
must be adjusted.

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Automatic Safety Gear Trigger ASGT
Handbook

4.3 Use of automatic safety gear trigger

Step Action Picture

1 Open the latch release to engage the safety The safety gear must engage.
gear.

1007241.wmf
2 Drive the car downwards to ensure that the
safety gear has engaged.
3 Drive the car downwards until the Tirak rope The automatic safety gear trigger must be
is slack. Check that the upper part of the latched.
safety gear trigger lowers onto the lower
part. Ensure that the latch release has
engaged to the pin.

1007243.wmf
4 Secure the car with the parking chain.
5 Detach the Tirak hoist hook from the safety
gear trigger.
6 Perform the required operation.
7 Re-attach the hoist hook to the safety gear
trigger.

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Automatic Safety Gear Trigger ASGT
Handbook

5 ASGT OPERATIONAL TEST AND VERIFICATION REPORT

This document describes the required and performed tests by the manufacturer before delivery. The ASGT
must not be delivered and taken into use, unless it has passed the tests and visual inspection below.

This document must be supplied with each ASGT and must be stored centrally in the respective KONE unit.
Each ASGT has a unique serial number.

This test report concerns Batch with serial numbers:

From To

Tested ASGT
Tool with serial Nr In batch
1 Visual inspection of welds
Description
In accordance with drawings 803136, 803138 and 803139

Passed YES NO
2 Release & engagement Operation
Test procedure
ASGT gas springs fully compressed by loading
Manual release handle is triggered
The ASGT must fully extend instantly without delay

Passed YES NO
3 Re engagement Operation
Test description
When removing the load
The manual release Latch closes by the guided weight of the upper body of the ASGT

Passed YES NO
Below certify that tests and visual inspections above has been performed and found fully satisfactory the above
tool is in accordance with the related manufacturing drawings at the time of manufacturing

Date: d.m.y . . .

Manufacturing Company:

Address:

Tested by sign: Checked By sign:

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Automatic Safety Gear Trigger ASGT
Handbook

This document describes the required and performed tests by the manufacturer before delivery. The ASGT
must not be delivered and taken into use, unless it has passed the tests and visual inspection below.

This document must be supplied with each ASGT and must be stored centrally in the respective KONE unit.
Each ASGT has a unique serial number.

This test report concerns Batch with serial numbers:

From 0001 To 0300

Tested ASGT
Tool with serial Nr In batch 0001
1 Visual inspection of welds
Description
In accordance with drawings 803136, 803138 and 803139

Passed YES NO
2 Release & engagement Operation
Test procedure
ASGT gas springs fully compressed by loading
Manual release handle is triggered
The ASGT must fully extend instantly without delay

Passed YES NO
3 Re engagement Operation
Test description
When removing the load
The manual release Latch closes by the guided weight of the upper body of the ASGT

Passed YES NO
Below certify that tests and visual inspections above has been performed and found fully satisfactory the above
tool is in accordance with the related manufacturing drawings at the time of manufacturing

Date: d.m.y .04 .01 .2003

Manufacturing Company: Meroni F.lli s.r.l

Address: Via A volta 18, 23843 DOLZAGO (LC)

Tested by sign: Checked By sign :

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Automatic Safety Gear Trigger ASGT
Handbook

6 SPARE PARTS

6.1 Body

Note! Parts marked with * can be obtained locally if following specifications.

Spare part Remarks Number
Supplier
*Fixing accessories Meroni Bolt M16x80 DIN931 8.8 1
Bolt M16x65 DIN931 8.8 2
Washer A16 DIN9021 1
Washer A16 DIN125A 4
Nut Ny-lock M16 3
A12 Return spring 1.5x12x40 1

Latch 803143 G01 Meroni Latch 1

Return spring 1.5x12x40 1

A13

Fork 803137 G01 Meroni 1

A14
Bar 803138 G01 Meroni 1

A15

Sled 803139 G01 Meroni 1

A16

Shackle plate Meroni 2

803145 G01

A17

Gas spring set Meroni Gas spring 600 N 2

803140H06, Ball joint cup 4
Supplier Code Ball head 4
16-21 25016 600N Washer A8 DIN6798 2
Stockholms fjäder Nut M8 DIN439 2
No: 9118

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Automatic Safety Gear Trigger ASGT
Handbook

6.2 Cable

Note! Parts marked with * can be obtained locally if following specifications.

Spare part Remarks Number
Supplier
Wire rope Meroni L= 1.0 metre 1
covering
KM 772277G06

A21

Wire rope Meroni Steel D6 mm, 1

772277H06 L= 4 metre

Wire rope Bjornsteel A22 Steel D6 mm, 1

772277H11 L= 7 metre

*Iron Grip Local BG-M6 ¼” 3

package 181743

A23
*Shackle Local 8 mm Type 1
A0,25 DIN82101

A24
Rope fixing plate Bjornsteel 1
803146

1027222.wmf

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Automatic Safety Gear Trigger ASGT
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6.3 Other equipment

These parts should be checked and if damages replaced

Spare part Remarks Number
Supplier
Bracket 803144 Bjornsteel Holder for 1
trigger cable

A26
Lever Bjornsteel Safety gear 1
814960G01 adapter lever
(Universal)

A27
Lever Bjornsteel Safety gear 1
814960G02 adapter lever
(TranSys)

A28

7 APPROVALS AND VERSION HISTORY

Compiled by: Technical Editor / Ville Malmiala
Checked by: KCO Installation Support / Anssi Venho
Approved by: KCO Installation Support / Bob Major

Issue Date Description of Change Ref CR Approved By

- 2005-05-23 First issue Bob Major
A
B

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