IGD20 Complete Manual

Overhead Geared Elevator Traction Machine
IGD20
Geared Machine
Complete Operation and Service Manual
SUZHOU TORIN DRIVE EQUIPMENT CO., LTD.
Manual No. TDII-003-IGD20 Revision 01 / December 2011

Overhead Geared Elevator Traction Machine
Contents
Limited Liability and Warranty ............................................................................. 1
Safety Precautions ................................................................................................... 1
Product Specific Warnings...................................................................................... 2
Arrival of the Equipment ........................................................................................ 3
Application ............................................................................................................... 3
Machine Overview ................................................................................................... 5
Installation ................................................................................................................ 6
Adjustments ............................................................................................................. 9
Brake Torque Adjustment ......................................................................................................... 9
Brake Stroke Adjustment ........................................................................................................ 11
Brake Synchronous Adjustment ............................................................................................. 12
Maintenance ........................................................................................................... 12
Brake Stroke Check ................................................................................................................ 12
Brake Lining Wear Check ...................................................................................................... 12
Lubricating Check .................................................................................................................. 13
Replacement ........................................................................................................... 14
Encoder Replacement ............................................................................................................. 14
Brake Switch Replacement..................................................................................................... 15
Motor Replacement ................................................................................................................ 16
Brake Replacement................................................................................................................. 17
Brake Lining Replacement ..................................................................................................... 18
Sheave replacement ................................................................................................................ 19
Ring Gear Replacement.......................................................................................................... 21
Bearing Replacement ............................................................................................................. 26
O-Rings and Seal Replacement .............................................................................................. 29
Troubleshooting chart ........................................................................................... 31
Traction Machine Assembly.................................................................................. 32
Brake Assembly...................................................................................................... 34
Mechanical Dimensions ......................................................................................... 36
Manual No. TDII-003-IGD20 Revision 01 / December 2011

IGD20 Complete Operation and Service Manual Revision 01 / December 2011
Limited Liability and Warranty
The manufacturer shall NOT be liable for any loss of profit, indirect, incidental or
consequential damages of any kind including, but not limited to, personal injury, labor cost,
downtime, etc.
The manufacturer warranty shall cover 12 months from the date of installation or 24 months
from the date of shipment whatever comes first. The limited warranty does not apply to normal
wear and tear items or any machines that have been subjected to misuse, misapplication,
improper installation, improper modification/adjustment/repair or inadequate maintenance, etc.
Safety Precautions
Please read this page BEFORE any work is performed on Elevator Equipment.
Important!
The procedures contained in this manual are intended for the use of qualified elevator
personnel. In the interest of your personal safety and the safety of others, do NOT attempt
ANY procedure that you are NOT qualified to perform.
All procedures must be done in accordance with the applicable rules in the latest edition of the
EN81 and any governing local codes.
Terms in This Manual
CAUTION statements identify conditions that could result in

damage to the equipment or other property if improper procedures are followed.
WARNING statements identify conditions that could result in

personal injury if improper procedures are followed.
General Safety
Specific warnings and cautions are found where they apply, and DO NOT appear in this
summary.
Electrical Safety
All wiring must be in accordance to local governing code and standards.
Manual No. TDII-003-IGD20 1 Revision 01 / December 2011

Use the Proper Fuse

To avoid fire hazards, use only a fuse of the correct type, voltage, and current rating as specified
in the parts list for the product.
Electrical Hazards
Electric shocks can cause personal injury or loss of life. Circuit breakers, switches and fuses
may NOT disconnect all power to the equipment. Always refer to the wiring diagrams. Please
verify if the AC supply is grounded or not, high voltage will be present at many points.
Printed Circuit Cards

When printed circuit cards are involved, do NOT remove connections or cards from the
equipment while power is applied. This can damage equipment. Always store and ship printed
circuit cards in separate static bags.
Mainline Disconnect
Unless otherwise suggested, always turn OFF, Lock and Tag out the mainline disconnect to
remove power from the equipment.
Test Equipment Safety

Always refer to manufacturers’ instruction book for proper test equipment operation and
adjustments.
Buzzer type continuity testers can damage electronic components. Connection of devices such
as voltmeters on certain low level analog circuits may degrade electronic system performance.
Always use a voltmeter with a minimum impedance of 1M Ohm/Volt. A digital voltmeter is
recommended.
When Power Is On
Dangerous voltages exist at several points in some products. To avoid personal injury, do NOT
touch exposed electrical connections or components while power is ON.
Product Specific Warnings
The IGD20 Machine MUST be balanced during hoisting. See Hoisting

Method in the Installation section for proper lifting procedures.
Hang the elevator car before removing ANY bolts. Failure to do so may
result in severe injury and equipment damage.

Arrival of the Equipment

Receiving
Upon arrival of the machine, make a visual check for any external damage immediately upon
their arrival on site. If any damage incurred in transit is found, make a notice of claim in the
presence of the forwarder. If necessary, do not put these machines into operation.
Hoisting
See Hoisting Method in the Installation section for proper lifting procedures.
Storing
During storage in a warehouse or on the elevator job site, precautions should be taken to protect
the machine from dust, dirt, moisture, and temperature extremes.
Application
Overview
The IGD20 Machine is a geared machine designed for elevators. Its worm and gear
configuration allows speeds up to1.75 m/s(maximum), and an elevator capacity of up to 884
KG with 1:1 roping. The maximum capacity is 1768 KG with 2:1 roping.
The IGD20 machine uses a drum brake with dual brake solenoids. The qualified elevator
personnel can adjust the compression length of the spring to control the brake torque.
Codes and Standards

These machines are designed to comply with National Code. The motors are designed with
insulation class F minimum.
Environmental Specifications
Operating ambient temperature: 0℃to 50℃
Storage temperature: 0℃to 60℃
Humidity: relative humidity of 10% to 95% non-condensing
Altitude: Up to 1000m above sea level without de-rating
Specifications
Induction motors: 380V / 50Hz / 4 poles / 3-phase
Brake coils: 110VDC / 1A
Maximum full load mass: 4,500 KG
Sheave diameter: 530 mm
Up to 5 x 13mm Ropes

Designed for 180 starts per hour at 40% elevator duty cycle and 1:1 roping
Incremental encoder: 1024 pulse per revolution
Estimated weight: 625 KG
Detailed Machine Specifications
IGD20 IGD20 IGD20 IGD20 IGD20 IGD20 IGD20 IGD20

Model Number -51P7- -61P7- -80P5- -80P6- -80P7- -81P0- -81P5- -81P7-
13mm 13mm 13mm 13mm 13mm 13mm 13mm 13mm
Motor （Kw） 9 11 9 9 9 9 12.5 15
Elevator
（Kg） 544 680 884 884 884 884 884 884
Capacity
Elevator
（m/s） 1.75 1.75 0.5 0.63 0.75 1 1.5 1.5
Speed
Pole # 4 4 4 4 4 4 4 4
Gear
47:2 47:2 41:1 41:1 41:1 41:1 53:2 47:2
Ratio
Motor
（VAC） 380 380 380 380 380 380 380 380
Voltage
Current （A） 18.5 23 18.5 18.5 18.5 18.5 25 30
Motor
（RPM） 1483 1483 739 931 1109 1478 1433 1483
speed
Diameter 530 530 530 530 530 530 530 530

Sheave Rope# 4 4 5 5 5 5 5 5
Spec
(mm） Φ 13 13 13 13 13 13 13 13
Pitch 19 19 19 19 19 19 19 19

Machine Overview
The following is a list of major components of the IGD20 Machine. Along with a description of
their functions, there is an overview of some of the critical adjustments and maintenance
information. See Installation and Maintenance in detail.
 Brake Solenoid –It is an independent electrically controlled solenoid that, when, energized
removes pressure applied by the brake shoes to the brake drum.
 Brake Switch – Is installed in the brake system, its function is to give feedback of the
acting of brake to the inverter.
 Brake Arms–The mechanical arms that are used, to press the brake shoes against the brake
drum. Each arm operates independently.
 Brake Spring –The spring’s function is to, supply the necessary force to the brake shoes
when the brake is de-energized. The spring creates friction between the brake shoe and the
brake drum to hold the suspended load. The spring works in compression, and the length
of spring is determined by the force required to hold the load.
 Brake Lining–they are used to provide friction between the brake drum and the brake arm.
 Brake –The electromechanical device that is used to prevent the elevator from moving
when the car is at rest.
 Motor –The part of the hoist motor assembly used to provide the necessary torque and
speed to move the elevator when in operation.
 Brake Drum –The smooth surfaced drum connected to the worm shaft. When the brake is
energized the brake shoes are released from the brake drum..
 Encoder –Is a device that is directly coupled to the armature shaft of the hoist motor. Its
function is to give the motor speed feedback to the elevator inverter drive and controller.
Brake Solenoid
Brake Spring
Brake Spring
Brake Arm
Brake Lining

Brake Manual Release
Motor
Encoder
Brake Drum
Figure1 IGD20 Machine Assembly
Installation
Recommended Hoisting Method
Figure2 IGD20 Machine Recommended Hoisting Method

Motor Connection
Use the job wiring diagrams with the motor configuration information to connect the motor to
the controller.
Inverter drive output reactor: it is strongly recommended that a load reactor be
installed between the inverter and motor to filter out high transient peak voltages that
may damage the motor windings.
Before operating the machine, refer to the appropriate Product

Manual and verify that the drive parameters for the job are set correctly.
Motor Connection
Connect the motor cable (U, V, W, and grounding) to three phase AC reactor then to frequency
inverter output terminal, and check the short-circuiting between the windings and the ground
before connection.
Brake Connection
The power terminal of brake is BK+ (positive pole) and BK-(negative pole).
There are two micro switches installed in the brake, their function is to give feed back on the
action of the brake. Users can connect it according to their control system requests.

Incremental Encoder Connection (Optional Accessory)

These machines may be supplied with Nemicon’s SBH 1024 -2T Incremental Optical Encoder. The
incremental resolution is 1024 pulses per revolution. The field personnel can connect the encoder to
the inverter by following the figure below for proper encoder signals: A and B and +V and GND (+V
and GND is the encoder power supply is 12V).

Adjustments
Brake Torque Adjustment
Generally, the brake stroke has been adjusted in the factory and
does not need to be re-adjusted any more. Adjustment of the brake MUST be complete
before anyone is allowed to ride on the platform.
Preparation
1. Verify that any required Compensation Chains or Rope Assemblies have been installed.
2. On construction jobs, verify that hoist way barricades are in place to prevent unauthorized
access.
Required Tools & Materials:

Open end wrench: 18mm
Torque wrench
Loctite 271
Adjust Procedure Steps

1. Remove the elevator from service.
2. Check the length of the compressed spring .The scale should show the measurement data
per the motor power of the machine, otherwise the length must be readjusted.
Motor Power Spring and Washer length Measurement data Compressed Spring
Kw mm mm measurement
9 70.5 63.5-65.5 5-7
11 70.5 63.5-65.5 5-7
12.5 70.5 60.5-62.5 8-10
15 70.5 60.5-62.5 8-10
Measurement data

3. Go to Step 4 only if the length is out of the range. Otherwise the brake torque is good.
4. Loosen the Spring Adjustment Locknut by open end wrench (18mm), then adjust the
spring adjustment washer slowly to ensure the length is in range.
Spring adjustment
washer Spring adjustment
locknut
5. If the length is too long, tighten the washer clockwise to reduce it. If the length is too short,
loosen the washer counter-clockwise to increase the length.
6. Re-measure and reconfirm that the value of length is good.
7. Also measure the brake torque by torque wrench. To do this remove the encoder cover
from the motor shaft, tighten a bolt M12 into the motor shaft, and install the torque wrench
on the bolt to measure the torque, if motor power <=7.5KW,make sure the
torque >=80Nm;if motor power <=11KW,the torque >=120Nm. For information regarding
how to remove the encoder cover, please refer to Encoder Replacement section—Page 14
8. Then apply red Loctite 271 between the bolt and luck nut for anti-vibration purpose.

Brake Stroke Adjustment
Generally, the brake stroke has been adjusted in the factory and
does not need to be re-adjusted any more.

Open End Wrench: 18mm
Feeler gauges
Adjustment Procedure:
If the brake stroke is too small , the brake drum and brake shoe maybe rubbing and causing an
abnormal noise when it runs. Generally, brake stroke has been tested and set at the factory and
there is no need for any readjustment.
1. Loosen the stroke adjustment locknut, verify that the hit cap and the stroke adjustment bolt
just make contact when the brake’s power is on, and screw the stroke adjustment bolt into
the direction of the brake solenoid.
Hit Cap
Stroke adjustment locknut
Stroke adjustment bolt
2. Measure the gap at the bottom of the brake shoe and the drum, as shown in the below
picture, verify it is 0.1-0.5 mm with feeler gauges, and make sure the gap is about uniform
from top to bottom. If the gap of the top is too big, tighten the bolt clockwise to reduce it. If
the gap is too small, loose the bolt counter-clockwise to increase the gap.
Brake drum Feeler gauges
Brake Lining
3. Tighten the Locknut M12 up then apply Loctite 271 between the locknut and the bolt.

Brake Synchronous Adjustment
This step should be performed when the condition of the brake

torque is as per the machines rated requirement.
Open End Wrench: 18mm
Adjustment Procedure:
1. If one brake arm opens slower than the other brake arm, loose the spring adjustment nut
and locknut.
2. If one brake arm opens faster than the other brake arm, tighten the nut.
3. After adjustment, verify the brake torque again to make sure it is according to Brake
torque adjustment requirement of the machine.
Maintenance
Only qualified personnel are allowed to perform any maintenance

work. The person who performs the maintenance work must be very careful as some work
must be performed when the machine is running.
Brake Stroke Check
Please pay attention to the value of brake stroke during the course
of routine maintenance. If the brake stroke is too short, the power of the solenoid can not
push the brake arm to obtain/shorten the big gap, the brake must be disabled. Generally,
the brake stroke has been adjusted in the factory and does not need to be readjusted in the
field.
Suggested check cycle

Every 3 months after install on the first 6 months. Every 1 year thereafter.
Benchmark Criteria
The gap at the bottom of the brake Shoe and the brake drum should be 0.1~0.5mm.

Brake Lining Wear Check
If the brake lining wear is more than 2 mm, the brake will not
function correctly.
Suggested check cycle

Every 1 year
Benchmark Criteria
The brake lining wear must be less than2mm. Use a steel ruler to measure the thickness of the
brake shoe, the thickness must be more than 6mm. Otherwise replace the brake lining or replace
the whole brake assembly.
Brake lining
Lubricating Check
The oil type we recommend is Shell Omala 460 or Kunlun 34# (equal to 460) elevator oil or
other type of synthetic oils which have similar performance.
Change of oil depends on the cleaning and ageing degree. Check the
oil color, smell and cleaning degree and confirm whether oil needs to be changed. If oil
turns black and has foul smell, it should be changed. Use filter paper to check oil when it
is hot (due to the elevator running) and watch the metal corpuscle/debris if any on the
filter paper to confirm whether needs to change the oil.. The oil volume of the IGD20
machine is 8L. The oil level should be at scale mark. If too little, the lubrication will be not
enough for smooth functioning of the machine. If too much, the oil will be leak out. If the
machine is stored for more than 1 year, the oil should be changed before use.
When using mineral oil, the first oil change should be done after the new machine runs 400
hours. When using synthetic oil, it should be done after 700 hours running. After that it should
be done as per the machines running pattern, change mineral oil every 2000—3000 hours (at
most 12—18 months) and synthetic oil every 3000—4000 hours (at most than 24—36 months).

For good results, we recommend using mineral oil the first time. But please note that it is
prohibited to mix mineral oil and synthetic oil. When changing the mineral oil to synthetic oil
please follow the below steps:
1. Take the rope off from the drive sheave when machine stops running and drain the mineral
oil away.
2. According to machine oil volume, pour kerosene into geared box. After running the
machine at high speed for few minutes, drain the kerosene away. Repeat this step 2 or 3
times.
3. Pour the synthetic oil as per requirement.
4. Run the elevator at high speed in upwards and downwards direction for about 10 minutes
(Check if there is smoke through the oil window).
5. Put on the rope and load 25% of rated load on cabin.
6. Run the elevator in upwards and downwards direction for about 10 minutes and check the
gear box to see if it sends up smoke.
When changing the synthetic oil to mineral oil, please follow the same steps as noted above.
Replacement
The maintenance personnel who does the replacement work, must

make sure that the machine is powered off and the elevator is secured and will not move
unexpectedly. Only qualified personnel are allowed to perform the replacement work.
Please refer to the troubleshooting procedure first and make sure

that the component is actually bad before performing this replacement procedure.
Encoder Replacement

Philips head screw driver
Inner hexagon spanner (6mm)
Clean cloth
Straight head screw driver
1．Method to removing the encoder

1. Remove the encoder shield by Philips head screw driver.
2. Remove the encoder cable by straight head screw driver.
3. Remove the broken encoder.

2．Method to assembly
1. Clean the motor shaft with clean colth, then slip the encoder on to the shaft.
2. Tighten the bolt into the motor through the reed, fasten the encoder with bolt
3. Connect the encoder and the transducer with cable, and fix the encoder shield by screw.
Brake Switch Replacement

that the switch is actually bad before performing this replacement procedure.

Brake switch
Philips screw driver
Loctite 290
Multimeter
Straight head screw driver
Open end wrench(7mm)
Feeler gauges:1mm
1. Method to Disassemble
1. Loosen the bolts and the washers in the brake terminal box by the Philips head screw driver,
and remove the terminal box cover.
2. Remove the brake switch cable which is to be replaced from the brake terminal by straight
head screw driver.
3. Loosen the composite slot screw M4x10 by philips head screw driver, then remove the
broken switch.
2. Method to assembly
1. Clean the switch bracket component installing surface, if it is not clean.
2. Install the brake switch and the switch bracket component on the brake surface by
composite slot screw M4x10.

3. Reconnect the new brake switch cable.

4. Verify with multimeter that the brake switch is functioning.
3. Brake switch adjustment

1. Loosen the adjustment bolts by Philips head screw driver and open end wrench(7mm), and
adjust the position of the brake switch on the slot of the switch bracket component.
2. Place a 1mm feeler gauges between the hit cap and the brake switch, and adjust the switch
slowly, when the switch is active (makes the click noise), tighten the ajustment bolts and
locknut, and remove the feeler gauges.
3. Apply Loctite 290 between the screw heads and the switch body.
Motor Replacement

that the motor is actually bad before performing this replacement procedure.

Hoisting equipment
Arm Puller
Clean cloth
Lubricating oil
Torque Wrench
2. Remove the encoder from the motor; refer to the Encoder Replacement on Page 14
3. Remove the power cable from the terminal box.
4. Install a hoist and rigging over the motor, and hoist the motor until pressure is applied to
the rigging.
5. Remove the Bolts (4) M12x45 and washers.

6. Remove the motor away from the traction machine.

7. Place a big enough block on the ground below the motor, and lower the motor on the block.
8. Fix the arm puller on the shaft joint, and remove the shaft joint, put away the keyway
C12/C16 until the assembly of the new motor.
2. Method to Assembly
1. Clean the motor shaft with clean cloth. Put the keyway on the shaft and apply some
lubricating oil.
2. Press the shaft joint into the motor shaft with a hydraulic pressing machine (A special
machine used for inserting the shaft joint into the motor shaft).
3. Apply some lubricating oil on the rubber coupling, hoist the motor and keep it at a flat level,
make the position of the shaft joint’s keyway and the position of the brake drum’s keyway
180-degree from each other.
4. Tighten the bolts (4) M12x45 and washers to 50-70Nm.
5. Turn the motor and measure the run out of the brake drum it should be within 0.5mm.
Brake Replacement

that the brake is actually bad before performing this replacement procedure.

Hex Wrench (6mm)
1. Remove the elevator from the service.
2. Remove the brake cable and the brake switch cable from the brake terminal box.
3. Loosen the adjustment nuts, then loosen the brake fix bolts(4), and remove the broken
brake.
Brake fix bolts

Adjustment Nuts

1. Install the new brake onto the reduction box, and fix it with the bolts and washers, but do
not tighten it completely.
2. Adjust the position of the brake, make the axes of the solenoid, the spring threaded stud and
the stroke adjustment bolt in the same axes, and tighten the bolts, make the position of the
brake relatively fix.
3. For the brake adjustment process please refer to this manual’s on Page 9-12.
Brake Lining Replacement

that the brake lining is actually bad before performing this replacement procedure.If the
brake lining wears more than 2mm, it must be replaced or replace the whole brake arm
assembly.

Hammer
Retainer pliers
2. Remove the spring adjustment nut & washer, the brake spring, and the spring bolt.
3. Remove the set screws and washers, and install the M6 bolt into the end of the brake arm
pivot pin.
4. Remove the brake arm pins by pulling on the bolt installed in step (3) by using the retainer
pliers.
5. Hoist and remove the brake arm, and move it away from the machine.
NOTE: This brake arm is not heavy enough to require rigging and can be removed by a hand.
6. Remove the circlip, then remove the pin with a hammer and a bolt , use the bolt head to
prop the pin, then hammer the bolt’s other side to get the pin out of the hole.
7. Remove the worn out brake lining.
1. Clean the brake arm and new brake lining with clean cloth.
2. Install in pressure spring into the hole of the brake arm, and fix the brake show (with brake
lining) with the pin and the circlip.

3. Install the brake arm assembly into the reduction box with the brake arm pivot pin, and fix
it with the bolt M6x12 and washers.
4. Install the spring threaded stud, the brake spring, the spring adjustment nut, and the
adjustment washer.
5. About the brake adjustment please refer to this manual’s on Page 9-12.
Sheave replacement

that the sheave is actually bad before performing this replacement procedure

Hoisting equipment
Torque wrench
Dial meter
Open end wrench: 18mm and 38mm
A Spacer/ Pipe
Clean cloth
2. Loosen the Nut M16 in the Stop Lever by the open spanner, and turn the stop lever (rope
gripper) about 90°along the direction of the arrow.
3. Remove the ropes from the drive sheave.

4. Install a 1/2-ton hoist and rigging over the sheave.
5. Hoist the sheave until pressure is applied to the rigging.
6. Remove the three (3) drive sheave retaining bolts by open end wrench (18mm), and
remove the drive sheave retainer.
7. Place the spacer (1 ¾ section 3” pipe or similar material) over the end of the output shaft.
8. Replace the drive sheave retainer: use three (3) of the long drive sheave carrier bolts, and

put these bolts through the outer set of holes that line up with the threaded holes in the
sheave.
9. Equally tighten the three (3) bolts in the drive sheave retainer until tight. Repeat this
process until the sheave is pulled off of the output shaft and the sheave carrier.
NOTE: The output shaft and sheave carrier are tapered. Once the sheave is moved a small
amount, it can be removed by hand
Drive Sheave
Drive Sheave
Drive Sheave Carrier Bolts
Retainer
Drive Sheave
Retaining
BOLTS
Keyway Spacer
Output Shaft
1. Ensure the replacement sheave keyway is also in the same position of the removed sheave.
This will make it easier to line up the drive sheave and the output shaft keyways.
2. Hoist the replacement sheave into place.
3. Replace the drive sheave retainer and align the three (3) inner holes in the out shaft.
4. Insert, thread, and hand tighten the three (3) drive sheave retaining bolts.
5. Tighten the three (3) drive sheave retaining bolts to 50~70Nm.

6. Clean the rope groove of the drive sheave-this will be used as an indicator surface.
7. Attach a dial meter to the machine, over the drive sheave, between the 12 o’clock and the 1
o’clock position. Set the indicator to measure the side of the cleaned rope groove. See
below figure.
Dial meter
Drive Sheave
8. With the dial meter, check for sheave grove run out(it should be≤0.2mm),by rotating the
drive sheave clockwise one (1) complete revolution.
9. Hang the ropes on the drive sheave.
10. Release the safety and the governor.
11. Turn ON the mainline that was disconnected.
12. With the weight now on the drive sheave, run the car down a few landings & then back up.
13. Reinstall the two (2) rope retainers.
Ring Gear Replacement


Pneumatic wrench
Box end wrench (24mm)
Hammer
Dial indicator
Color ink
Hoisting equipment
Clean cloth
1. Method of replacement
1. Remove the sheave; please refer to this manual’s Sheave Replacement Method to

Disassemble on page 19.

2. Loosen the Plug Cock, drain the oil.
Oiling window hoods
Plug Cock
3. Take apart the pin form the top housing and the bottom housing with hammer, and loosen
the bolts from the spindle through cover and the bolts from the bearing gland.
Spindle
Through-Cover
The Bearing Gland
4. Loosen the bolts and washers.
5. Hoist the top housing with hoisting equipment.

6. Place two stands approximately 300mm apart in an area of the machine room with enough
clearance to work the output shaft and ring gear.
7. Hoist the output shaft assembly from the bottom housing, and lower onto 610mm stands.
8. Place some protective material between the ring gear and the stands.
9. With the assembly resting on the stands, remove the output shaft sling, and set the sheave
side of the output shaft pointing down.
Hoisting equipment
10. Remove the nuts, washers and bolts that secure the ring gear to the gear flange.
NOTE: Note the position of the ring gear bolts, washers and nuts. The new material is to be
installed in the same position.
11. Contact the building engineer to turn off the machine room smoke detectors.
12. Check the mating surface of the new gear and the gear flange for any debris that may
hinder a flush fit.
13. With a gloved hand, set the new gear (with the mating side down on the gear flange), and
gently move the new gear until it drops onto the gear flange.
14. Once the gear is sitting flush, align the holes to match the gear flange (drift pins or an
existing bolt can be used for alignment).
15. Allow the gear to cool completely, then adjust the hole from the flange side up. See below
figure.

Adjust the holes from the

flange side up
16. Insert and tighten the bolts, washers, and lock nuts.
NOTE: It may be necessary to use the lock nut to pull the bolt through; turn the lock until the
bolt head is flat on the gear surface. Do not hammer the bolts.
17. Torque the lock nuts to 108 Nm..
18. Hoist the output shaft assembly into the bottom housing.
2. Method to Adjustment
1. Tighten the bottom housing and the bearing gland with the bolts; tighten the bottom
housing and the spindle through-cover with the bolts.
2. Install the magnetic base of the dial meter to the gear case.
3. Pull the drive sheave in one direction, and then zero the dial meter.
4. Push the drive sheave in the opposite direction, and read the amount of gear movement.
NOTE: The displacement for a machine should be 0.12~0.2mm.

5. If the displacement does not reach the requirement, turn the bearing gland or the spindle
through-cover (the position of twelve (12) holes), repeatedly adjusted to meet the
requirements straight.
6. Spray or paint layout color on three (3) teeth (equally spaced around the sheave), and allow
it to dry completely.
7. Place the car on inspection Operation. Turn on the mainline disconnect.
8. Run the machine in one direction until the color is marking of the worm and the pattern can
be seen.
9. Repeat Step 12, but run the machine in the opposite direction.
10. Survey the gear pattern carefully.
Contact Layout Color Dye

Area
11. Make sure that the contact area account for 30% of the direction of the gear’s width, and
for 55% of the direction of the gear’s height. If the contact area is to left, increase the shims
of the left side cover, or reduce the shims of the right side cover. If the contact area is to
right, reduce the shims of the left side cover, or increase the shims of the right side cover.
Repeatedly adjust to meet the requirements straight.
12. Clean the junction surface of the bottom housing and the top housing with clean cloth, daub
the sealant around the surface of the bottom housing.
Sealant
13. Hoist the top housing onto the bottom housing with the hoisting equipment, then tighten
them with Bolts, Nuts.

14. Tighten the bolts to fasten the spindle through-cover, and tighten the Bolts to fasten the
bearing gland. See below figure.
15. Put the Pin into the case and the case cover, and inject elevator oil into the case, fit on the
oiling window hoods, and tighten it with bolt.
16. Install the sheave; refer to this manual’s Sheave Replacement Method to Assemble on Page
20.
17. Connect the mainline and test the machine.
Bearing Replacement

The bearing replacement work must be done on the ground, so the machine must be lifted
and moved out of hoist way to perform the bearing replacement work.

Hoisting equipment
Bearing heater
Arm puller
3#general purpose lithium lubricating grease

1. Output shaft bearing replacement

1. The step about hoisting the output shaft assembly from the bottom housing can be done by
refer ring this manual’s Ring Gear Replacement --Method of replacement Step 1~8.
2. Withdraw the spindle through-cover assembly.
NOTE: Don’t damage the seal in the output shaft bearing cover assembly.
3. Remove the bearing with the arm puller.
4. Place the new bearing in or on the bearing heater. And heat it to about 80±15 degree C.
5. With a gloved hand, quickly slide the heated bearing fully onto the output shaft.
6. When the bearing has cooled completely, spread grease outside the ring worm on the inside
lane of the bearing.
7. Apply right amount of 3# General purpose lithium lubricating grease on the seal of the
output shaft bearing cover assembly, and install it to the output shaft.
8. Replace the bearing in the bearing gland with the same method, please refer to steps 3~7.
9. Hoist the output shaft assembly into the bottom housing, and adjust the backlash by
referring to this manual’s Ring Gear Replacement part 2—Backlash Adjustment.
2. Worm Gear Bearing Replacement

1. Remove the brake system; refer to this manual’s Brake Replacement Page 17 and Brake
Lining Replacement Method to Disassemble steps 1~6.
2. Remove the motor refer to this manual’s Motor Replacement –Method to Disassemble.
3. Loosen the Plug Cock, drain the oil.
4. Loosen the Bolt and the washer that tighten the worm shaft front cover, with the M18 mm
open end wrench, and remove the worm shaft front cover.
5. Remove the brake drum and put away the keyway.
6. Loosen the Bolts and the washers that tighten the worm shaft through cover with the
M18mm open end wrench, and remove the worm shaft through cover assembly.
7. Loosen the bolts and the washers from the worm shaft back cover assembly, and remove it.
8. Turn the shaft sheave by hand to remove the worm shaft assembly from the bottom
housing.
9. Install an arm puller on the bearing, and remove the bearing. The front bearing and the back
bearing is same and can be removed the same way.

Brake drum Worm shaft through cover Arm Puller
Back bearing
Front bearing
10. Place the new bearings in the heater, and heat bearings to 80±15 degrees c, then quickly
slide the hot bearing fully onto the worm shaft.
NOTE: Do not wear gloves when performing steps11 and 12.
11. Install the bearing cup of the front bearing into the front bearing bore of the bottom housing,
and apply some 3# general purpose lithium lubricating grease on it.
12. Turn the shaft sheave by hand to install the worm shaft assembly into the bottom housing,
and install the bearing cup of the back bearing into the back bearing bore of the bottom
housing with 3# general purpose lithium lubricating grease.
13. Install the worm shaft back cover assembly and some shims into the corresponding hole,
and screw two bolts and washers on the cross, do not tighten it too much.
14. Install the protecting pipe/spacer into the worm shaft motor side, place the seal into the
worm shaft through cover, and smear some 3#general purpose lithium lubricating grease in
it. Place the bearing and washer in the worm shaft motor side, and remove the protecting
pipe/spacer, tighten the worm shaft through-cover with the Bolts and washers.
15. Tighten the worm shaft back cover with the blots and washers.
16. Cover the brake drum into the worm shaft, then install the worm shaft front cover assembly,
tighten it with bolt and washer, and press the brake drum into the position, note the position
of the keyway to install motor conveniently.
17. Measure the travel movement of the brake drum by moving the drum in the forward and
backward direction with dial meter, the radial movement should be no more than
0.1mm,the axial gap should be 0.03~0.08mm. Adjust the quantity of the shims in the cover
of worm shaft on the back side until they meet the standard.
18. Loosen the bolts and washers to remove the worm shaft back cover, install the seal, and
apply some 3#general purpose lithium lubricating grease. Place the assured shims to the
back bearing bore, tighten it with bolts and washers.
19. Loosen the bolt to open the oil windows lid, then fill in about 9L elevator oil.
20. Install the motor; refer to this manual’s Motor replacement—Method of Assembly.
21. Connect the mainline and test the machine.

O-Rings and Seal Replacement

that the component is actually bad before performing this replacement procedure. If the
position where the bearing is installed leaks oil, then the O-Rings and Seal must be
examined and replaced.

3#general purpose lithium lubricating grease
1. Method of replacement (on the Output shaft)

1. If oil leaked on the bearing cover:
a) Loosen the bolts and washers and remove the bearing gland, and then remove the old
O-Ring.
b) Apply some 3#general purpose lithium lubricating grease into the new O-Ring, and
install it onto the bearing gland.
c) Tighten the Bolts and washers.
2. If oil leaked on the main shaft bearing cover:
a) Remove the sheave, refer to this manual’s Sheave Replacement—Method to
Disassemble.
b) Loosen the bolts and washers and remove the spindle through cover, then remove the
old O-Ring.
Seal
Spindle
through cover
O-Ring
c) Remove the bearing cup from the cover, examine the seal and replace it with new one
if it is damaged.
d) Apply some 3#general purpose lithium lubricating grease on the new O-Ring, and
install it onto the spindle through cover.
e) Tighten the bolts and washers.
f) Install the sheave, refer to this manual’s Sheave Replacement—Method to Assembly.

2. Method to Replacement (on the Worm Shaft)

1. If oil leaked on the worm shaft’s back cover:
a) Loosen the bolts and washers, remove the worm shaft back cover, and then remove
the old O-Ring.
b) Apply some 3#general purpose lithium lubricating grease on the new O-Ring, and install
the O-ring on the worm shaft back cover.
c) Tighten the bolts and washers.
2. If oil leaked on the worm shaft through cover:
a) Remove the motor; please refer to this manual’s Bearing Replacement—Worm shaft
bearing replacement steps 1 - 6.
Seal
Worm shaft through

cover O-Ring
b) Examine the seal and replace it with new one if it is damaged.

c) Apply some 3#general purpose lithium lubricating grease on the new O-Ring, and
install the O-Ring on the worm shaft through cover.
d) Install the bearing, please refer to this manual’s Bearing Replacement—Worm shaft
bearing replacement step13~21.

Troubleshooting chart
The proper maintenance of the geared machines requires adequately

trained qualified personnel and proper tools.
Faults Possible causes Possible solutions

Verify the inverter wiring to make sure it is
a. Incorrect inverter wiring
done correctly.
b. Incorrect inverter parameters Verify the inverter parameters.
c. Incorrect encoder wiring Verify the encoder wiring is correct.
Verify if the inverter alignment procedure is
Motor not d. Bad encoder alignment
performed correctly.
working
e. Loose encoder mounting Tighten the encoder mounting screws
f. Bad encoder Replace the encoder.
g. Bad brakes Verify the brake operations
h. Bad motor contactor Replace motor contactor.
a. Verify brake control currents.
a. Brake friction noise
b. Verify brake strokes.
Abnormal b. Bad grounding Verify that earth ground is good.
noise or c. Bad inverter parameters Make sure inverter parameters are correct
vibration
d. Bad encoder feedbacks Check grounding and shielding.
e. Bad bearing Replace the machine or bearing.
a. Bad grounding Make sure that ground is solid.
Electrical
b. Bad humidity level Make sure the humidity is within the specs.
shocks
c. Broken cable insulation Replace the cable.
a. Oil or grease on brake disk Remove the oil and change the brake lining.
b. Incorrect brake stroke Readjust the brake stroke to factory standard
Check the brake lining thickness and readjust
c. Brake lining wear out to much
Brake not the brake stroke or replace the brake
working d. Bad brake coils Replace the brake assembly
e. Incorrect counterweight
Verify counterweight percentage
percentage
f. Noise absorber height is too big Reduce the absorber height
a. Bad wiring Verify brake wiring
Brake switch b. The position of brake switch not
Readjust the brake switch position
Not working installed correctly
c. Bad brake switch Replace the switch
a. Elevator is overloaded Verify elevator loading and duty cycle
Motor is too
hot b. In correct counterweight
Verify counterweight percentage
percentage

Traction Machine Assembly
No. Torin Drive Part No. Description

1 FYJ200.3-1 The housing bottom
2 FYJ200.3-2 The housing cover
3 GB/T879 Pin
4 FYJ200.3-3 Worm wheel cover
5 GB/T5782 Bolt M18X50
6 GB/T93 Washer 18
7 FYJ200.3-16 Plate
9 GB/T5782 Bolt M20X110
10 GB/T93 Washer 20
11 GB/T6170 Nut M20
12 FYJ200.3-4 Worm wheel
13 FYJ200.3-5 Worm wheel flange
14 GB/T93 Washer 12
15 GB/T6171 Nut M20
16 GB/T28 Bolt M12
17 GB/T297 Bearing
18 FYJ200.3-6 Worm wheel through-cover
19 FYJ200.3-7 Key
20 FYJ200.3-8 Key


21 FYJ200.3-9 Main shaft
22 Oil seal
23 GB/T1235 O ring
24 FYJ200.3-10 Oil seal
25 FYJ180-26 Paper washer
26 FYJ200.3-11 Worm cover
27 QB-3-1 Plug Cock
28 QB-3-2 Paper
29 FYJ200.3-12 Paper washer
30 GB/T1235 O ring
31 FYJ200.3-13 Worm through-cover
32 GB/T5783 Bolt M12X40
33 FYJ200.3-14 Worm
34 FYJ200.3-15 Key
35 Oil seal
36 GB/T91 pin

Brake Assembly

1 FYJ200.1-1 Brake arm
2 FYJ200.1-2 Brake lining
4 YJ200.2-3 Brake spring
5 FYJU200.2-8 Spring cover
6 GB/T6171 Nut M12
7 FYJ180.3-2 Bolt
8 FYJ180.3-3 Limited bolt
9 FYJ180.3-9 Hit cap
10 J2.2J-12 Sping
11 J2.2J-10 Copper shaft
12 FYJ180.3-4 Brake box
13 J2.2J-16 Release plate
14 J2.2J-18 Plate
16 J2.2J-17 O ring
17 FYJ180.3-5 Paper washer
18 J2.2J-15 Coil box
19 FYJ180.3-7 Circle plate
20 FYJ180.3-6 Coil box
21 J2.2J-20 Release spanner
22 GB/T68 Bolt M3
23 Junction
24 GB/T68 Bolt M3
25 Junction box
26 Release circle
27 GB/T6170 Nut M10
28 GB/T97.1 Washer 10

29 GB/T93 Washer 10
30 GB/T5782 Bolt M10X110
31 YJ240B.2.1-21 Switch bracket
32 Bolt M4X10
33 Microswitch
34 Bolt M3X15
35 FYJ180.3-8 Nut M3
36 FYJ180.3-8 Plate
37 GB/T6173 Nut M12
38 GB/T869 Rivet

Mechanical Dimensions

Suzhou Torin Drive Equipment Co., LTD

Address：Changshu New &HighTechIndustrial Park, CEDZ, Jiangsu, China
Post No.：215500
Tel：+86-512-52840537/52841532/52841536/52840539
Fax：+86-512-52841915/52845918
E-mail：Sales@ torindrive.com /Hotline@ torindrive.com
Website：http//www.torindrive.cn
Torin Drive International
Mumbai, India
Phone: (022)-28828419
Fax: (022)-28804825
E-mail: india@torindriveintl.com

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Overhead Geared Elevator Traction Machine

SUZHOU TORIN DRIVE EQUIPMENT CO., LTD.

Manual No. TDII-003-IGD20 Revision 01 / December 2011

Safety Precautions ................................................................................................... 1

Product Specific Warnings...................................................................................... 2

Arrival of the Equipment ........................................................................................ 3

Machine Overview ................................................................................................... 5

Troubleshooting chart ........................................................................................... 31

Traction Machine Assembly.................................................................................. 32

Mechanical Dimensions ......................................................................................... 36

Manual No. TDII-003-IGD20 Revision 01 / December 2011

Limited Liability and Warranty

Terms in This Manual

CAUTION statements identify conditions that could result in

WARNING statements identify conditions that could result in

All wiring must be in accordance to local governing code and standards.

Manual No. TDII-003-IGD20 1 Revision 01 / December 2011

Use the Proper Fuse

Printed Circuit Cards

Test Equipment Safety

Product Specific Warnings

The IGD20 Machine MUST be balanced during hoisting. See Hoisting

Manual No. TDII-003-IGD20 2 Revision 01 / December 2011

Arrival of the Equipment

Codes and Standards

Manual No. TDII-003-IGD20 3 Revision 01 / December 2011

Detailed Machine Specifications

IGD20 IGD20 IGD20 IGD20 IGD20 IGD20 IGD20 IGD20

Motor （Kw） 9 11 9 9 9 9 12.5 15

Current （A） 18.5 23 18.5 18.5 18.5 18.5 25 30

Diameter 530 530 530 530 530 530 530 530

Manual No. TDII-003-IGD20 4 Revision 01 / December 2011

Manual No. TDII-003-IGD20 5 Revision 01 / December 2011

Brake Manual Release

Figure2 IGD20 Machine Recommended Hoisting Method

Manual No. TDII-003-IGD20 6 Revision 01 / December 2011

Before operating the machine, refer to the appropriate Product

Manual No. TDII-003-IGD20 7 Revision 01 / December 2011

Incremental Encoder Connection (Optional Accessory)

Manual No. TDII-003-IGD20 8 Revision 01 / December 2011

Required Tools & Materials:

Adjust Procedure Steps

Manual No. TDII-003-IGD20 9 Revision 01 / December 2011

Manual No. TDII-003-IGD20 10 Revision 01 / December 2011

Brake Stroke Adjustment

Required Tools & Materials:

Stroke adjustment locknut

Stroke adjustment bolt

Brake drum Feeler gauges

Manual No. TDII-003-IGD20 11 Revision 01 / December 2011

Brake Synchronous Adjustment

This step should be performed when the condition of the brake

Only qualified personnel are allowed to perform any maintenance

Brake Stroke Check

Suggested check cycle

Manual No. TDII-003-IGD20 12 Revision 01 / December 2011

Brake Lining Wear Check

Suggested check cycle

Manual No. TDII-003-IGD20 13 Revision 01 / December 2011

The maintenance personnel who does the replacement work, must

Please refer to the troubleshooting procedure first and make sure

Required Tools & Materials:

1．Method to removing the encoder

Manual No. TDII-003-IGD20 14 Revision 01 / December 2011