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Elevator
Installation Manual
for Mechanical Parts

This manual is the property of Hyundai Elevator Co., Ltd. and is loaned subject to
return upon demand. Contents of this publication should not be reproduced in
any form without written permission of Hyundai Elevator Co., Ltd..

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REVISION
NO.

ITEM

Specification

DATE

First Edition

2013.08.24

Edit the format

2013.11.05

Reorganization of the manual

2014.05.30

Manager

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Table of Contents
Safety Information ........................................................................................................................... 9
1. Preparation for Installation ....................................................................................................... 21
Safety Information ..................................................................................................................... 22
1.1 Summary ............................................................................................................................. 25
1.2 Steps for the Installation Work ............................................................................................. 25
1.2.1 Site Inspection ............................................................................................................... 25
1.2.2 Office and Material Warehouse Installation .................................................................... 25
1.2.3 Preparation for Installation Start..................................................................................... 26
1.3 Data for the Installation Work ............................................................................................... 27
1.3.1 Installation Plan ............................................................................................................. 28
1.4 Lope Elevator Installation Process ....................................................................................... 33
1.5 Name of the Elevator Main Parts ......................................................................................... 34
2. Template .................................................................................................................................. 35
Safety Information ..................................................................................................................... 36
2.1 Summary ............................................................................................................................. 37
2.2 Template Material Specification............................................................................................ 37
2.3 How to Install Template ........................................................................................................ 38
2.4 How to Fix the Hatch Template ............................................................................................ 39
2.5 How to Inspect Template Verification and Fixing .................................................................. 40
2.6 Anchor Bolt Work ................................................................................................................. 41
2.6.1 Shape of Wedge Anchor Bolt......................................................................................... 41
2.6.2 How to Install Anchor Bolt .............................................................................................. 41
2.7 Check Sheet for Template.................................................................................................... 43
2.7.1 Passenger E/L Standard Template Dimensions I ........................................................... 43
2.7.2 Passenger E/L Standard Template Dimensions II .......................................................... 45
3. Machine Room ......................................................................................................................... 47
Safety Information ..................................................................................................................... 48
3.1 Summary ............................................................................................................................. 52
3.2 Geared Type Traction Machine ............................................................................................ 52
3.2.1 Structure of Geared Traction Machine ........................................................................... 52
3.2.2 How to Install M/C Foundation ....................................................................................... 53
3.2.3 How to Install Machine Beam ........................................................................................ 53

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3.2.4 How to Install Isolation Pads.......................................................................................... 56


3.2.5 How to Assemble T/M.................................................................................................... 56
3.2.6 How to Measure Sheave Alignment ............................................................................... 57
3.2.7 How to Install Governor ................................................................................................. 57
3.2.8 How to Assemble Governor Cover................................................................................. 58
3.2.9 How to Install Control Panel .......................................................................................... 58
3.3 Gearless Type Traction Machine.......................................................................................... 58
3.3.1 Structure of Gearless Type Traction Machine ................................................................ 59
3.3.2 How to Install Machine Beam ........................................................................................ 60
3.3.3 How to Install the Isolation Pads .................................................................................... 63
3.3.4 How to Install the Machine Bed Support ........................................................................ 64
3.3.5 How to Install the Second Sheave ................................................................................. 65
3.3.6 How to Install the Machine Bed, Machine Bed Support, and Second Sheave Support
Bracket ................................................................................................................................... 65
3.3.7 How to Install Hoist on the Machine Bed ....................................................................... 66
3.3.8 How to Check the Offset Distance of the Main Sheave and the Second Sheave ........... 66
3.3.9 T/M brake (DB1712 (DB250, DB350, DB450), DB2818 (DB450)).................................. 67
3.3.10 How to Adjust T/M Brake (DB1712 (DB250, DB350, DB450), DB2818 (DB450)) ......... 69
3.4 GN Ty Traction Machine <MRL> .......................................................................................... 71
3.4.1 Structure of GN Type Traction Machine ......................................................................... 71
3.4.2 How to Install Machine Beam ........................................................................................ 72
3.4.3 How to Install Prevention Beam and Support Bracket.................................................... 74
3.4.4 How to Install Isolation Pads.......................................................................................... 75
3.4.5 How to Install Traction Machine ..................................................................................... 76
3.4.6 How to Install Governor ................................................................................................. 78
3.4.7 How to Install Isolation Pad and Hitch Plate .................................................................. 81
3.4.8 How to Adjust Hoist brake ............................................................................................. 82
3.5 GY Type Traction Machine <MRL> ...................................................................................... 89
3.5.1 Structure of GY TYPE Traction Machine ........................................................................ 89
3.5.2 How to Install Support Bracket at CWT Rail................................................................... 89
3.5.3 How to Install Isolation Pads and CWT Hitch Plate ........................................................ 90
3.5.4 How to Install Traction Machine ..................................................................................... 91
3.5.5 How to Install Governor ................................................................................................. 95
3.5.6 How to Install Isolation Pads and Hitch Plate ................................................................. 96
3.6 Traction Machine Handle Switch .......................................................................................... 98
3.6.1 Structure of Traction Machine Handle Switch ................................................................ 98
3.6.2 Installation View ............................................................................................................ 99
3.7 Check Sheet for Machine Room ........................................................................................ 101
3.7.1 Machine Foundation .................................................................................................... 101
3.7.2 Traction Machine and Machine Bed............................................................................. 101
3.7.3 Governor ..................................................................................................................... 102
3.7.4 Machine Room Piping ................................................................................................. 102

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3.7.5 Control Panel .............................................................................................................. 102


4. Temporary Car ....................................................................................................................... 103
Safety Information ................................................................................................................... 104
4.1 Summary ........................................................................................................................... 106
4.2 Advanced Work for Assembly Temporary Car .................................................................... 106
4.2.1 How to Install Pit Ladder .............................................................................................. 106
4.2.2 How to Install Buffer Footing (CAR) ............................................................................. 107
4.2.3 How to Install Buffer Footing (CWT) ............................................................................ 107
4.2.4 How to Install 1st Guide Rail (CAR) ............................................................................. 108
4.2.5 How to Install the Buffer .............................................................................................. 108
4.2.6 How to Assemble Safety Device .................................................................................. 109
4.2.7 How to Assemble Car Stile ........................................................................................... 111
4.2.8 Preparation to Install the Bolster <GN Type> ................................................................ 111
4.2.9 How to Assemble Platform........................................................................................... 112
4.2.10 How to Assemble Top Beam ...................................................................................... 114
4.2.11 How to Install Suspension Sheave to the Top Beam <New MRL TYPE> ................... 116
4.2.12 How to Assemble Brace Rod ..................................................................................... 117
4.2.13 How to Install Temporary Guide Shoe........................................................................ 118
4.2.14 How to Install Governor Holding Device .................................................................... 119
4.3 Temporary Car Assembly Process ..................................................................................... 120
4.3.1 Structure of Temporary car .......................................................................................... 120
4.3.2 How to Fix Support Angle ............................................................................................ 120
4.3.3 How to Assemble Column Scaffolding ......................................................................... 121
4.3.4 How to Assemble Support Scaffolding ......................................................................... 121
4.4.5 How to Assemble Horizontal Scaffolding ..................................................................... 122
4.4.6 How to Assemble Reinforcing Scaffolding ................................................................... 122
4.4.7 How to Assemble Safety Guard ................................................................................... 123
4.4.8 How to Install Ceiling and Deck ................................................................................... 123
4.4.9 How to Fix Kick Plate and Equip Extinguisher ............................................................. 124
4.5 Check Sheet for Temporary Car......................................................................................... 125
4.5.1 Buffer and Buffer Footing............................................................................................. 125
4.5.2 Safety Device .............................................................................................................. 126
4.5.3 Car Frame ................................................................................................................... 126
4.5.4 Governor Holding Device ............................................................................................ 126
5. Roping ................................................................................................................................... 127
Safety Information ................................................................................................................... 128
5.1 Summary ........................................................................................................................... 130
5.2 Babbitt type <WBST> ........................................................................................................ 130
5.2.1 How to Fix the Rope and Shackle ............................................................................... 130
5.2.2 How to Make Rope Babbitt .......................................................................................... 131

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5.2.3 How to Assemble the Rope Shackle <WBST> ............................................................ 132


5.2.4 How to Prevent the Entanglement of the Rope <WBST> ............................................. 133
5.2.5 How to Prepare to Deliver Counter Weight into the Hoist Way..................................... 134
5.2.6 How to Hang the CAR Side Rope <WBST> ................................................................ 136
5.3 Wedge Type <WBLX, WBSS> ........................................................................................... 137
5.3.1 Method of WBLXs Wrapping ....................................................................................... 138
5.3.2 WBSS Type ................................................................................................................. 145
5.4 New MRL Type .................................................................................................................. 147
5.4.1 How to Lock the Rope Shackle to the Hoist Side Hitch Plate ....................................... 147
5.4.2 How to Hang the Rope onto the Counterweight Sheave <New MRL> ......................... 147
5.4.3 How to Hang the Rope onto the Hoist <New MRL> ..................................................... 148
6. Guide Rail .............................................................................................................................. 149
Safety Information ................................................................................................................... 150
6.1 Summary ........................................................................................................................... 152
6.2 Structure of Guide Rail ....................................................................................................... 152
6.3 How to Clean Joint Part of Rail .......................................................................................... 152
6.4 Guide Rail Installation Process .......................................................................................... 153
6.4.1 How to Bring the Rail into Hoist Way ........................................................................... 153
6.4.2 How to Connect 1st Rail and Buffer Footing ................................................................. 153
6.4.3 How to Install 1st Rail Bracket ..................................................................................... 154
6.4.4 How to Install Car Rail 2nd Bracket............................................................................... 154
6.4.5 How to Install CWT 2nd Bracket ................................................................................... 155
6.4.6 How to Install CWT 2nd Bracket ................................................................................... 155
6.4.7 How to Adjust the Rails................................................................................................ 156
6.4.8 How to Weld 1st Bracket and 2nd Bracket ................................................................... 157
6.4.9 How to Connect Rail .................................................................................................... 159
6.4.10 How to Measure Rail Straight .................................................................................... 159
6.4.11 How to Install the Top Guide Rail & Rail Bracket ........................................................ 160
7. Entrance ................................................................................................................................ 161
Safety Information ................................................................................................................... 162
7.1 Summary ........................................................................................................................... 163
7.2 Structure of Entrance ......................................................................................................... 163
7.3 Entrance Installation Process ............................................................................................ 164
7.3.1 How to Locate Landing Sill .......................................................................................... 164
7.3.2 How to Install Sill Support (When Masonry) ................................................................. 164
7.3.3 How to Install Landing Sill ........................................................................................... 165
7.3.4 How to Assemble Toe Guard ....................................................................................... 165
7.3.5 How to Measure Jamb Height and Width..................................................................... 166
7.3.6 How to Install the Jamb ............................................................................................... 167

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7.3.7 How to Assemble Jamb & Landing Door Operator....................................................... 169


7.3.8 How to Fix Landing Door Operator (When Masonry) ................................................... 169
7.3.9 How to Fix Landing Door Operator (When Dry Wall) ................................................... 170
7.3.10 How to Assemble Landing Door & Top Cover ............................................................ 170
7.3.11 How to Assemble Triangle Key .................................................................................. 171
7.3.12 How to Adjust Interlock Distance ............................................................................... 171
7.3.13 How to Adjust Door Interlock Center .......................................................................... 172
7.3.14 How to Adjust the Door Interlock Operation ............................................................... 172
8. Car Parts................................................................................................................................ 173
Safety Information ................................................................................................................... 174
8.1 Summary ........................................................................................................................... 175
8.2 Sub Weights ...................................................................................................................... 176
8.2.1 How to Install Sub Weight............................................................................................ 176
8.3 CAR Panels and Ceiling .................................................................................................... 176
8.3.1 How to Install CAR Panels and Celling ........................................................................ 177
8.4 CAR Panels ....................................................................................................................... 179
8.4.1 How to Install CAR Panel ............................................................................................ 179
8.5 How to Install Apron ........................................................................................................... 180
8.6 How to Install Compensation Chain ................................................................................... 180
8.7 How to Install of Whisper Flex............................................................................................ 181
8.8 How to Connect CAR / Counterweight Frame and Whisper Flex Chain ............................. 181
8.9 Sliding Guide Shoe (SGS) ................................................................................................. 182
8.9.1 How to Adjust HGS121K ............................................................................................. 183
8.9.2 How to Adjust HGS122K ............................................................................................. 184
8.9.3 How to Adjust HGS231K ............................................................................................. 185
8.10 Roller Guide Shoe (RGS) ................................................................................................ 186
8.10.1 How to Adjust RGS .................................................................................................... 187
8.10.1 RGS Structure ........................................................................................................... 188
8.10.2 RGS Adjustment Troubleshooting .............................................................................. 190
8.11 Rubber Guide Shoe and Urethane Guide Shoe ............................................................... 191
8.12 How to Assemble Car Header Arm .................................................................................. 192
8.13 How to Assembling Car Header Vertical Rod ................................................................... 192
8.14 How to Assemble Car Header Tie Rod............................................................................. 193
8.15 Car Door Operator <M2CA> ............................................................................................ 194
8.15.1 Structure .................................................................................................................... 194
8.15.2 How to Install M2CA .................................................................................................. 195
8.15.3 How to Adjust M2CA.................................................................................................. 196

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8.15.4 How to Fix the Car Door Operator of M2CA .............................................................. 197
8.16 Car Door Operator < UM2> ............................................................................................. 198
8.16.1 Structure .................................................................................................................... 198
8.16.2 How to Install UM2 .................................................................................................... 198
8.16.3 How to Assemble Safety Edge Cable ........................................................................ 199
8.16.4 How to Install Door Covers ........................................................................................ 199
8.17 CAR Door ........................................................................................................................ 200
8.17.1 How to Adjust CDL Clutch ......................................................................................... 202
8.17.2 How to Install and Adjust General Clutch ................................................................... 202
8.17.3 How to Adjust Gate Switch ........................................................................................ 203
8.17.4 How to Adjust Door Limit Switch ................................................................................ 203
8.18 Safety Edge ..................................................................................................................... 203
8.18.1 How to Install Safety Edge......................................................................................... 204
8.18.2 How to Tie Safety Edge Cable ................................................................................... 204
8.19 How to Install Car Top Board ........................................................................................... 205
8.20 How to Adjust Ribbed V-belt Tension ............................................................................... 205
8.21 How to Adjust Wire Rope Tension .................................................................................... 206

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Elevator
Safety Information

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IMORTANT! READ SAFETY NOTE AND THIS PAGE CAREFULLY


before any work is performed.
1. Overview
Elevator installation accompanies risk caused by heavy materials such as falling because of work in
vertical spaces. Therefore, it is required to put on protective equipments, install safety devices where
there is risk of falling and receive safety training to prevent safety accidents.

2. Personal Protective Requirements


Ensure that personal protective equipment, protective clothing, respiratory devices, protective shields
and barricades, are provied, used and maintained in a sanitary and reliable condition.

2.1 Protective Equipment

Wear protective equipments anytime and anywhere in field.


Safety Helmet (included in Chine Strap)
Safety Belt
Safety Gloves
Safety Shoes

Wear safety belt of full body harness type.

Hand tolls and other object should not be placed in the pockets due to the possibility of snagging on
moving objects or contacting energized equipment

Finger rings, loose jewelry and torn clothing are hazardous and should not be worn

Always were appropriate clothing when welding, grinding or working around an open flame(e.x, Do
not wear oil free clothings)

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2.2 Precaution Guide to Avoid Injury

Prohibit the upper and lower part work at the same time in one hoist way.

Except wiring work, more than two workers ought to work together.

When working with equipment (winch/chain block etc.), workers should Report and Repeat
together. When operating elevator car, report and repeat based on the car. (Ex. Car up, Car down.)

When leaving the work place, power off the device and lock.

Keep clean and neat around working site.

Equip protecting equipments on the dangerous devices.


Earth Leakage
Circuit Breaker

Protective
Cover
Protective
Cover

[Example Parts for Protective Cover]

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3. Checklist before Starting the Work


3.1 Top Work Bench
1) Safety Balustrade

Install with height of 900 1,200 mm.

Install between top balustrade and floor surface.

Firmly fix with clamp.

Use robust material such as single pipe scaffold that can endure 100 kg weight.

2) Working Foothold

The gap between the working footholds should be 30 mm or less.

Firmly fix with locking cables.

3) Others

Install each slope support with 2 pieces (3045).

The distance between the scaffolds at the first level in front of the highest floor gate should be 180
200 mm.

Install eye nut on the wall of the gate (highest floor, highest floor-1 floor).

Do not load beam, traction machine, etc., on the working bench. (Load 250 kg or less including the
workers.)

Install intermediate support if the vertical gap between the horizontal support and the safety
balustrade exceeds 2 m.

Closely install the horizontal support (intermediate support) and safety balustrade to cross each
other.
Refer to MRL Top Work Bench Installation Guideline for other details (HES-B98-071).

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Closely attach to the wall to


cross each other.

[Top Work Bench]

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3.2 Hoist Way Gate


1) Shield the Gate

Fully shield the gate with safety shield plate.

If the gate opening height exceeds 2,300 mm, after installing the safety shield plate, shield top part
opening with rachel net and eye nut

Rachel Net

2300 mm

[Shield the Gate & Rachel Net]

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2) Eye Nut

Install eye nuts (M16) on both side walls of the hoist way gate.

Installation place
-

For life line installation: highest floor, lowest floor +2 floor


Eye Nut

Anchor Bolt
(M16)

(M16)

Life Line Hook


Entrance
Wall
Protective
Pad

[Eye Nut for Life Line Hook]

For safety belt mounting: material delivery floor, highest floor -1 floor(only for MRL model)

[Eye Nut for Safety Belt Hook]

Number of installations: 2 per each floor

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3.3 Temporary CAR Inspection


1) Safety Balustrade Shield the Gate

Install with height of 900 1,200 mm.

Install between top balustrade and floor surface.

Firmly fix with clamp.

Use robust material such as single pipe scaffold that can endure 100 kg weight.

2) Working Foothold

The gap between the working footholds should be 30 mm or less.

Working foothold should be fixed to CAR stile.

Do not fix on the top beam.

3) Protective Ceiling

Use robust perforated board or plywood (12T or more) for protective ceiling.

4) Measures before the Operation

Furnish fire extinguisher in the temporary CAR.

Install pit buffer and governor rope.

Do not work with single rope.

Install counterweight falling off prevention bracket and process bending.

Check the release of the safety line jumper for E-STOP in the control panel.

Use serial safety device (COM) attached product for installation remote controller.

.
[Remote controller for installation]

Install warning plate in the temporary CAR (load weight, prohibition to get on the protective ceiling)

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[Temporary car]

Work with the approval and attendance of the safety personnel (site supervisor,
etc.)
after minimum safety measures if additional works are required after the stepwise
procedures, such as supplementary works.

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4. Other Safety Measures


4.1Site Office

Work progress board (safety and hygiene policy, safety organization chart, emergency contacts,
process table)

Safety rules for each installation process


If there is no office within the site, post the safety rules for each installation process on the right
side wall of the base floor gate.

Maintain records of the inspection daily record and training record in the safety rule booklet for
each installation process provided from Hyundai Elevator.,Ltd..

Install automatic spread fire extinguisher in the office and warehouse.

Use certified products for electric heater, etc.

4.2 Measures in Lifting and Machine Room


1) Machine Room Lifting Hook

Check machine room lifting hook reclamation status.


Make sure to verify at the site with insulation.

Make sure to use the supplied products for lifting bracket.

Fix at least 4 places with M16 anchor bolts.

2) the lifting gate hole with steel plate immediately after completing the lifting.

Ban the use of the


bracket which is
welded at this point.

[Hook for Lifting]

[Bracket for Lifting]

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3) Motor Winch and Chain Block

Support the motor winch using anchor (M12) at least 4 places at the bottom.

Attach safety cover at the motor winch rotating part to prevent finger jamming.

Use shackle and rotation hook (Swivel) during the lifting work.

Attach release device on the lifting hook.

Check the wire rope status.

[Shackle]

Falling Off of
Thread

[Rotation Hook (Swivel)]

Sticking Out
of the Core
Steel

Dent of
Strand

Falling Off of
Strand

[Prohibited Wire Ropes]

[Hook]

Compression

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4.3 Measures for 1st Level Rail Installation


1)
2)
3)

Use exclusive jig (hook) for rail transportation.


Check water leakage at the pit. (If flooded, enter after completing the draining.)
Use working foothold for 1st level rail installation.

Fix the support for working foothold with anchor bolt (M12) at 2 places or more, and use exclusive
steel material for supporting pins.

Do not use building rebar, etc.

Lay the anchor bolt (M12) for 70 mm or more under the ground.

The gap between the working footholds should be 30 mm or less.

Do not load material on the working foothold. (Load 200 kg or less including the worker.)

Do not allow other workers enter below during the rail lifting work, Danger to
injury !

2000 mm

1500 mm

[Working Foothold for 1st Level Rail Installation]

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Elevator
1. Preparation
for Installation

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Safety Information
IMPORTANT! READ SAFETY NOTE AND THIS PAGE CAREFULLY
before installation.
1) Field Survey before Starting the Work

Wear the specified work clothes and protective gears-safety helmet, safety shoes, and safety belt,
during the field survey and actual measurement.

Install the safety shield plate after checking whether the safety balustrade is installed at the gate of
each floor before starting the work. (Perform full shielding of the gate for preventing drop or flying
object into the hoist way.)
If safety balustrade (shield board) is not installed, perform the following measures.
- Joint supply site: Demand the construction company (client) to install the safety balustrade.
- Direct order site: Install the safety balustrade.

Install the fall prevention net right under the hatch room of the lowest floor. (Remove after
completing the floor door installation.)

Check any risk of flooding or flowing rainwater into the machine room and the hoist way.

Check any building material that may fall into the hoist way loaded in the machine room or gate of
each floor. (If there is any loading, demand to move them to other safe place.)

Check the location of the temporary power distribution box, usable capacity, using voltage, whether
temporary power line is necessary, etc.

Verify the delivery path of the material and equipment, and secure storage place.

Check whether heavy object lifting tower crane, whether hoist for material transportation and worker
boarding can be used.

Check the location and strength of the lifting hook installed in the machine room ceiling.
(If necessary, demand supplementation and reinforcement.)

Hang the safety belt hook to a strong structure without danger of falling altogether in the place with
danger of falling during the measurement work.

2) Starting Installation of the Work, Office and Warehouse

Request the client to notify all workers within the site to inform the starting of the elevator work, and
not to drop objects into the hoist way.

Secure the path to prevent hindrance of access to site office and warehouse, and if necessary,
temporary install lighting at the path.

The person in charge of the site should check whether the protective gears (safety shoes, safety
helmet, safety belt, etc.) are secured fully, and train the workers to always wear the protective gears.
(Check if they are wearing the protective gears.)

The person in charge of the site should study all danger elements within the site in advance, and let
the workers know them. Make sure that all the workers go around the site together, establish
improvement plans for each danger element, and start the work after taking the safety measures.

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Install automatic spread fire extinguisher in the office and warehouse, etc., and use certified
products for heating. (Do not use electric heater without certification.)

The person in charge of the site must carry out the safety training (safety rules, etc. for each
installation process of the corresponding work) such as TBM, etc., before starting the work, and
record safety inspection daily record, safety training daily record, and daily work report.

The following documents should be furnished at the site office.


- Safety and hygiene policy, safety organization chart, emergency contacts, process table
- Safety rules for each installation process

If there is no office within the site, post the safety rules for each installation process on the right side
wall of the base floor gate.

3) Delivery of Equipment and Material

Check problems in the braking device and alarm device of the forklift.

Check the lighting status headlight, turn signals, and back light of the forklift.

Check whether no-entrance within the working boundary mark is installed.

Check whether signs are attached at the right places in the material storage/loading place.

Use the equipments such as forklift for delivery of equipment/material if possible.

Position signaling personnel around the equipment/material delivery work place, and follow the
instructions of the signaling personnel.

Check the ground status near the work place. (Danger of forklift falling down.)

Check whether the material loading and storage status are safety.
(Danger of falling down.)

Do not apply too much force when it is moved by human force.

Do not have danger of hand or foot being caught between the objects during
lifting and putting down the material.
(25kg or less when it is carried by 1 human force.)

Wear protective gloves during the transportation, and be careful for injury
by sharp cut surface or breaking of the rope, etc.

Follow the hoist safety rules when building hoist is used for material transportation.

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4) Lifting Work (hoist, control panel, machine stand, etc.)

Check the communication status of the communication equipments such as two-way radio, etc.

Check whether other personnel are prohibited from entering the work boundary.

Check the status of wire rope, fiber rope, shackle, chain block, and machine room lifting hook.

If winch is used, check the status of fixing on the floor and the status of the pulley installation.

Do not work lifting work in bad weather, and prohibit access of the workers in the path of the lifting
object transportation.

Check the lifting entrance in advance, and remove interfering object or dropping object.

Tie the heavy object with rope hanging wire rope and shackle that can sufficiently endure the weight.
(Do not use binding cable or Manila rope.)

Lift the lifting object for about 100mm, and shake to check the fixed status.

The lifting entrance hole should be shielded with steel plate immediately after the machine room
lifting work.

Place a lock, after the gate is installed to the machine room. (Perform rainwater entrance blocking
measures if the machine room gate or ventilation window is not installed.)

Install safety belt hanging facility in the place with danger of falling, and hang the safety belt hook.

Check whether the lifting object weight exceeds the rated capacity of the chain block.
If machine room ceiling hook is not installed safely, or if the location is not correct, use a separate
lifting bracket by fixing it with anchor bolts (M16) at 4 places or more.

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1.1 Summary
After completing the buildings machine room and hoist way, the person in charge of the installation,
visits the site for consulting before the installation starts. Notify the finally decided installation starting
date to the relevant departments to take care of the problems such as material delivery before
the starting. And start the installation after preparing installation plan, specification, equipment list, and
installation tools, etc.

1.2 Steps for the Installation Work


Understand installation process and prepare all the matters needed, before the main installation work is
performed. And prepare as follows to prevent problems in the installation work.
1.2.1 Site Inspection
Decision on the installation starting date through discussion with building construction company
Check power required for the work
Select the location of the material storage
warehouse

#4

#3

Check the building process plan

#5
#1
#14

#2

#13

Prepare site visit report


#6

Compare and verify the building structure and the


installation plan

#8

<Check list on the building structure>


#1 - machine room heights and size
#2 - existence and size of the lifting equipment
#3 - existence and size of the ventilating opening
#4 - existence and firmness of the lifting hook
#5 - existence of the path to machine room
#6 - existence of the stand for machine
#7 - hatch opening specification and hall button location
#8 - height of the over head
#9 - number of stories and floor height
#10 - pit depth and waterproof and cleaning status
#11 - hoist way total height
#12 - powers required for the work
#13 - rope duct, die plate hole processing status
#14 - machine room wall side processing status
at the location of the machine beam installation
#15 - hoistway size

#7

#9
#11
#12

#15

#10

[Figure 2.1 Building Structure]

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1.2.2 Office and Material Warehouse Installation

Install warehouse also for using as an office, if possible.

Install the gate locking device.

Select a place where there is no fire or flood hazard nearby, and furnish fire extinguisher.

Return the material used for warehouse installation after the completion of the construction for using
again.

1.2.3 Preparation for Installation Start

Store the drawings, specification, material list table, building drawing, etc. required for the
installation for easy viewing by the installation workers.

Make up a tool list required for the installation, and request to the relevant department to prepare
them in advance.

Prepare and distribute the site actual measurement report.

Compare and review the building structure and installation reference drawing.

Write the corresponding matters on the site actual measurement report.

Distribute the report to the relevant departments.

If there is a change, have actions taken for all the changes before the installation.

Record the installation process, and equip this in the office for the installation workers

to confirm the process status at any time.

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1.3 Data for the Installation Work


It states the drawings, descriptions of the terms, contents of the necessary data, and way to mark.
Type

Drawing name
Hoist way cross
sectional diagram

Installation
Plan
(Layout)

Hoist way floor


plan
Hatch construction
diagram
Hatch cross
sectional diagram
Hatch design
diagram
Machine room floor
plan
Design diagram

Electricity
drawing
Mechanical
drawing

Contents
It shows floor height, number of stories, total height, driving
distance, height of the top, pit depth, machine room height,
rail bracket mounting location, number of rails, etc.
It shows hoist way size, CAR size, counter weight size, hatch size,
sill installation location, etc.
It shows hatch concrete opening and hall button location.
It shows hatch SILL mounting status.
It shows JAMB size, hatch height, width, etc.
It shows machine beam size, hoist direction, governor location,
control panel location, rope hole location and size, etc.
It shows the shape and design of inside the CAR, door, JAMB,
ceiling, etc.

Electric wiring
diagram

It shows cable number for wiring of each section.

Circuit drawing

It shows operation circuit and function.

Machine assembly
diagram

It shows the assembled shape of each machine.

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1.3.1 Installation Plan


1) Hoist Way Cross Sectional Diagram
It is the drawing drawn at the cross section of the hoist way and machine room to show each floor height,
number of total stories, hoist way total length, CAR driving distance, pit depth, machine room height, and
rail bracket mounting location, etc.

PP(Pit Depth) : pit depth


Distance from the hoist way floor to the lowest floor
hatch SILL top surface

FH(Floor Height) : floor height


Distance from each floor hatch SILL top surface to
the next higher floor hatch SILL top surface

OH(Over Head) : over head


Distance from the highest floor hatch SILL top
surface to the hoist way ceiling bottom surface

Rail distance : marks the 5M guide rail installation


gap and quantity

Rail bracket gap : gap between each rail bracket


and mounting location

2100

FH

TR(Travel Height) : CARs driving distance


Distance from the lowest floor hatch SILL top surface
to the highest floor hatch SILL top surface

OH

Min 150mm

TR

TH(Total Height) : hoist way total height


Distance from the hoist way floor (pit floor) to the
hoist way ceiling bottom surface

Concrete

PP

HOOK
MH

MH(Machine Room Height) : machine room height


Distance from machine room cinder concrete
finishing line to the lifting hook bottom surface at the
ceiling

TH

Pit ladder
Electrical
Outlet

Waterproofed
Pit floor

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2) Hoist Way Floor Plan


It is the drawing to show relevant dimension of inside hoist way, CAR and counter weight (CWT),
guide rail (Guide Rail) and each machine in the hatch, and to set installation location exactly.

X : hoist way inner width size

Y : hoist way inner length size

A : CAR outer width size

B : CAR outer length size

CA : CAR inner width size

CB : CAR inner length size

CAR BG : distance between CAR rails

CWT BG : distance between counter weight rails

EE : distance from end of CAR sill to the center of CAR rail

JJ : effective hatch width

P : distance from the center of CAR to the center of the counter weight(CWT)

BG : distance between CAR and CWT side rails


MX1
X1
A

VENT

CB

VENT

R1

MY

CA

OP

C.P
Panel Board

Machine room entrance

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3) Hatch Construction Diagram


It is the drawing of the construction part for hatch installation. It shows the construction of rebar
with certain interval for fixing JAMB, width and length of concrete opening, and hall button mounting hole
location.

concrete opening height

concrete opening width

JAMB fixing rebar

hall button mounting

location

4) Hatch Cross Sectional Diagram


It shows the cross section of the hatch bottom part construction to mark the hatch SILL installation and
relevant dimensions.
It is generally classified to two types ;

A drawing for hatch SILL installation using angle, etc., if the building construction did not provide
SILL threshold installation for hatch SILL mounting

A drawing for hatch SILL installation when the building construction provided SILL threshold
for hatch SILL mounting
100
FINISH LINE
FINISH LINE

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5) Hatch Design Diagram


It is a drawing to show the hatch JAMB type for each floor and marking the designs. And it shows
the status of the hatch after the installation.
JP-200
JP- 200
TYPE
TYPE

JP050 TYPE
TYPE
JP-050

JP-100
JP100TYPE
TYPE

Jamb

Jamb

Height

Entrance
Height

Height

Entrance

Height

Entrance
Height

Entrance

Entrance

Width

Entrance

Width

Width

6) Machine Room Floor Plan


It shows the location of each machine in the machine room for the setting of the precise location and
core mounting work.

MX : Machine room inner width size

MY : Machine room inner length size

X : Hoist way inner width size

Y : Hoist way inner length size

A, B : Gap between the left and right machine beam with the hoist sheave at the center

C : Distance from the center of the governor to the center of the hoist sheave

P : Distance from the hoist main sheave end to the deflector sheave end

R : Distance between the ropes of the governor

Q : Distance from the center of the CAR to the governor rope


MX

<Machine Room Parts>


#1 : Machine Beam
#2 : Governor
#3 : Traction Machine& Motor
#4 : Deflector Sheave
#5 : Main Sheave
#6 : Hoist way Duct

2- 200
HOLE

C
A

100
HOLE

1
4

Q
3

Control
Panel

MY

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7) Design Diagram
Generally, it is a special drawing for understanding of the overall shape during the design and installation,
if the inside of the CAR and door, JAMB and electricity designs are special types.
8) Connection Table
It is the drawing marked the cable numbers for connecting each section during the installation work.
9) Circuit Drawing
It is the drawing of the operation circuits and functions classified by each model.
10) Machine Assembly Diagram
It is the drawing showing the all the assembled shapes of each part for a mechanical adjustment work
during the installation work.
11) Parts Table
It is the drawing classified to machine and electrical parts with required quantity and applied drawing
number for each part.
<Major Contents of Each Part Table>

REVISED : brief description of the revision date and revised contents of the parts table

REMARK : separate specification designation or notes

BLOCK : block number of the applied part

PART NAME : part name

PART NO : material number of the applied part

Q'TY : quantity of the part

DRAWING NO : drawing number of the applied part

EDGE : safety edge specification

C. DOOR MTL : CAR door material

JJ H : effective hatch width and height

STOP : total number of stopping floors

LIGHTING : applied ceiling lighting

CONTROL : applied model

WALL MTL : CAR wall material

A B : CAR outer size

CA CB : CAR inner size

EE : distance from CAR SILL end to the center of the CAR

TOTAL HT : entire length of the hoist way

VER HEAD : distance from the highest floor hatch SILL top surface to the hoist way ceiling bottom
surface

PIT DEPTH : distance from the lowest floor hall SILL top surface to the hoist way bottom surface

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1.4 Lope Elevator Installation Process


Block

No.

Description

Preparation for Installation

Scaffolding Installation

Template Installation

Hatch Sill Installation

Jamb & button Box Installation

Hanger Case Installation

Anchor Bolt Works

Center Bracket Installation

Rail Bracket Installation

10

Rail Assembly & Plumbing

11

Elevation of Heavy Materials

12

Machine Beam Installation

13

T/M, C/P, GOV. Installation & Plumbing

14

Shaft & M/C Beam Ducting

15

Hatch Door Installation & Plumbing

16

Hatch Door Opening/Locking Devices Adjustment

17

Car Assembly & Parts Installation

18

CWT Assembly & Rope Hanging

19

T/Cable Hanging & Wiring

20

Shaft & M/C Room Wiring

21

Car Wiring

22

Scaffolding Disassembly

23

Supervisory Panel Installation & Wiring

24

Low Speed Trial Operation & Adjustment

25

Miscellaneous Works

26

High Speed Trial Operation & Adjustment

27

Miscellaneous Works

28

Safety Inspection

29

Transfer Preparation

30

Inspection & Delivery

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1.5 Name of the Elevator Main Parts


()
Governor

Traction Name

Controller

Counterweight guide
rail

Harness
Cable

Counterweight
rail
bracket

Landing
vane

Oiler

Car Door
Operator
Hatch
Door Operator

Main
rope
Car
top operator

Car

Limit switch
cam

Car
Door

Safety
shoe

Safety
device

Hatch

Sill

Car
guide shoe

Travelling
cable

Hall Position
Indicator

Jamb

Hatch
Door

Counterweight
guide shoe

Counterweight

Hall button

switch

Limit
Gov. Tension

Sheave

Car
Buffer

Pit
switch
Counterweight buffer

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Safety Information
IMPORTANT! READ SAFETY NOTE AND THIS PAGE CAREFULLY
before installation.

Check the installation status of safety balustrade and safety shield plate on each floor.

Check the status of electronic tools to be used for the work.

Check if there is any flammable object in the hoist way pit and check the cleanness.

If there is an object that may fall near the gate, in the hoist way or machine room, remove it
completely, shield the opening, and perform the die plate work.

Do not perform the die plate work at top and bottom at the same time.

During the die plate work at the bottom, if the depth of the pit is deeper than the specification, firmly
install a separate working foothold.

Firmly install the ladder for access to the pit.

Firmly shield the lifting entrance of the machine room, and perform the die plate work at the top.

After completing the die plate work, firmly block the machine room hole without gap.

Install the working lighting at the highest floor and the lowest floor. (100 lux or higher)

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2.1 Summary
The template installation work is an important work setting the standard for each part installation
according to the installation plan (Layout), and it is classified to the top part template installed
in the machine room and the bottom part template installed in the pit.

2.2 Template Material Specification


Perform the template work using C-beam or balk timber with certain specification as the top plate
template material, and effectively select and use C-beam, channel, angle, etc. as the bottom part
plate material according to the conditions of the site.
1) Top part template material

C-beam : Use standard part with C603010t2.3 or more.

Balk timber : Use specification of 7012 or more.

2) Bottom part template material

C-beam : Use standard part with C603010t2.3 or more.

channel : Use specification of 754075 or more.

Angle : Use specification of L7575t6 or more.

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2.3 How to Install Template


Mark the center point of width and length of each template material (hatch, CAR, CWT).
Based on the above center points, calculate each dimension by the installation plan (Layout) and
temporarily install the template material at the correct location of the machine room floor and pit.
Make the bottom plate on the CAR and counter weight buffer footing with the same method as the
top part plate, and temporarily install it.

Center
#2

#1 CWT
CWT
center line
CWT template
(CWT
) material

BG/2-5

BG/2-5

1mm

line
#1 Car
CARcenter

(Car template
(CAR
)
Material)

BG/2-5

BG/2-5

center line
#1 Entrance

Entrance)
template material
(

JJ/2

JJ/2

[Figure 2.1 Template Diagram for Counter Weight Rear Drop Type]

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2.4 How to Fix the Hatch Template


Drill a 1mm hole in the template, have a piano wire go through the hole and temporarily connect so
that the piano wire can be a straight line inside the hoist way.
Based on the temporary piano wire of the hatch template lowered from the top, from the location
to install each floor hatch SILL, measure the distance of A-A, B-B, C-C in the following figure to
select the most appropriate SILL installation location, and fix and install the hatch template
according to this location.

C'

B'

A'

[Figure 2.2 Entrance Template Location Selecting]


Adjust the top and bottom plate material for the distance between the hatch piano wire and the hoist
way floor to be at least 115mm. (For 2 doors central opening and closing type door)

Entrance Piano Wire


Entrance Floor

Min 115mm

[Figure 2.3 Temporary Piano Wire]

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2.5 How to Inspect Template Verification and Fixing


When the hatch template is fixed, based on this, according to the dimension on the design plan, install
the CAR and counter weight rail templates.
Based on the dimension of the design plan, check the dimension of the template again, and then fix it.
Fix the piano wire connected through the top and bottom part template to be a tight straight line.

B
E

CWT

H'
P
D

CAR
A
G

G'

Entrance

F
C

[Figure 2.4 Template Installation Dimensions]

EE

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2.6 Anchor Bolt Work


2.6.1 Shape of Wedge Anchor Bolt
Anchor bolt consists of body, sleeve, flat washer, spring washer and nut. Below figure shows the shape
of an anchor bolt.
Bolt

Sleeve

Nut

Length

[Figure 2.5 Anchor Bolt]

2.6.2 How to Install Anchor Bolt


Anchor bolt mounting and installing method is as follows.
Insert close bit into hammer drill.

[Figure 2.6 Close Bit]


Mark the hole depth of the location that will be drilled on close bit.
Mark the hole depth according to the anchor bolt size by using colorful vinyl tape.
Put hammer drill vertically on the spot that will be drilled and drill the hole by turning on the hammer
drill switch.
If the verticality is not accurate due to the incorrect installation of rebar during wedge
anchor bolt work, adjust it to maintain accurate verticality to prevent the loosening or
breaking of anchor bolt.

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Drill the hole to the depth suitable for the anchor bolt size according to [Table 2.1 Anchor Bolt
Size].
(Unit : mm)
Classification

Diameter

Total Length

Close Bit Dimension

Hole Depth

M10

D10

75

D10

50 2

M12

D12

100

D12

80 2

M16

D16

125

D16

90 2

[Table 2.1 Anchor Bolt Size]


After drilling the hole, insert anchor bolt into the hole along with bracket by using hammer. Maintain
accurate verticality to prevent the loosening or breaking of anchor bolt.

Bracket
Hammer

[Figure 2.7 Anchor Bolt Insertion]


After inserting anchor bolt, fix it by fastening the nut of anchor bolt tightly.
Expose the screw thread of anchor bolt about 1mm from nut as shown in below figure.
To prevent the loosening of bolt, tighten it by using ratchet or spanner.

More than 10mm


10mm

[Figure 2.8 Anchor Bolt Assembly]

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2.7 Check Sheet for Template


The standard template dimensions for passenger E/L are as follows.
2.7.1 Passenger E/L Standard Template Dimensions I
B
E'
ALG.X=26mm
ASG=19.5mm
CWT
H'
P
D

CAR
A
G

EE

G'

Entrance

F
C

(Unit : mm)
Use

Capacity
(Kg)

15 (1000)

Entrance
Car
Width
Interior

G, G

BG

900

1600
1500

1758

1200 770 1085 1698 1180 900

1000

1800
1500

1958

1200 775 1095 1898 1180 1000 974 621 500 1244.7 2154.0 2180.3

1100

2000
1350

2158

1200 710 1010 2098 1180 1100 1074 621 550 1287.5 2052.0 2080.8

1000

1800
1700

1958

1200 875 1195 1938 1180 1000 974 621 500 1309.3 2329.7 2354.0

1100

2000
1500

2158

1200 785 1085 2138 1180 1100 1074 621 550 1330.3 2179.2 2206.4

1100

2000
1750

2158

1200 905 1215 2138 1180 1100 1074 621 550 1404.5 2397.2 2421.9

1100

2150
1600

2308

1200 840 1130 2288 1180 1100 1149 621 550 1423.3 2265.6 2291.8

24 (1600)

EE

CA x CB

20 (1350)

BG

Template Dimension(Speed 150m/min) ALG.X TYPE

OP

17 (1150)

Passenger
E/L

Car
CWT
Rail
Rail
Width Width

845 621 450 1143.2 2116.5 2142.0

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(Unit : mm)

Use

Car
CWT
Entrance
Car
Rail
Rail
Width
Interior
Capacity
Width Width
(Kg)
CA x
OP
BG
BG EE
CB
15 (1000)

G, G

900

1600
1500

1758

1200 770 1085 1698 1180 900

1000

1800
1500

1958

1200 775 1095 1898 1180 1000 974 614.5 500 1244.7 2157.2 2176.9

1100

2000
1350

2158

1200 710 1010 2098 1180 1100 1074 614.5 550 1287.5 2055.5 2077.1

1000

1800
1700

1958

1200 875 1195 1938 1180 1000 974 614.5 500 1309.3 2332.7 2351.0

1100

2000
1500

2158

1200 785 1085 2138 1180 1100 1074 614.5 550 1330.3 2182.6 2202.9

1100

2000
1750

2158

1200 905 1215 2138 1180 1100 1074 614.5 550 1404.5 2400.2 2418.8

1100

2150
1600

2308

1200 840 1130 2288 1180 1100 1149 614.5 550 1423.3 2268.8 2288.4

17 (1150)

Passenger
E/L

Template Dimension(Speed 150m/min) ASG18.1 TYPE

20 (1350)

24 (1600)

845 614.5 450 1143.2 2119.6 2138.7

(Unit : mm)

Use

Capacity
(Kg)

15 (1000)

Entrance
Car
Width
Interior

Template Dimension(Speed 150m/min) ASG18.1 TYPE

OP

CA x
CB

BG

900

1600
1500

1758

1200 770 1125 1698 1180 900

845

621 450 1143.2 2151.6 2176.7

1000

1800
1500

1958

1200 775 1135 1898 1180 1000 974

621 500 1244.7 2188.8 2214.7

1100

2000
1350

2158

1200 710 1050 2098 1180 1100 1074 621 550 1287.5 2085.6 2114.0

1000

1800
1700

1958

1200 875 1235 1938 1180 1000 974

1100

2000
1500

2158

1200 785 1125 2138 1180 1100 1074 621 550 1330.3 2213.7 2240.4

1100

2000
1750

2158

1200 905 1255 2138 1180 1100 1074 621 550 1404.5 2432.6 2457.0

1100

2150
1600

2308

1200 840 1170 2288 1180 1100 1149 621 550 1423.3 2300.5 2326.3

17 (1150)

Passenger
E/L

Car
CWT
Rail
Rail
Width Width

20 (1350)

24 (1600)

BG

EE

G, G

621 500 1309.3 2365.3 2389.3

[Table 2.2 Passenger E/L Standard Template Dimensions]


If entrance, car interior, rail width and etc. are non-standard, calculate them separately.

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CWT

2.7.2 Passenger E/L Standard Template Dimensions II

H'
D

CAR

G'

Entrance

F
C

EE

ALG.X=291.5
ASG18.1=220.5

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(Unit : mm)
Use

Car CWT
Entrance
Car inside rail
raid
Capacity width
width width
(Kg)
OP
CA x CB
BG
BG
15 (1000)

Template Dimension(ALG.X TYPE)


EE

G, G'

900

1600 1500 1758 1200

770 291.5 1698 1180 900

845 VAR 450 1143.2

1000

1800 1500 1958 1200

775 291.5 1898 1180 1000 974 VAR 500 1244.7

1100

2000 1350 2158 1200

710 291.5 2098 1180 1100 1074 VAR 550 1287.5

1000

1800 1700 1958 1200

875 291.5 1938 1180 1000 974 VAR 500 1309.3

1100

2000 1500 2158 1200

785 291.5 2138 1180 1100 1074 VAR 550 1330.3

1100

2000 1750 2158 1200

905 291.5 2138 1180 1100 1074 VAR 550 1404.5

1100

2150 1600 2308 1200

840 291.5 2288 1180 1100 1149 VAR 550 1423.3

17 (1150)
Passenger
E/L

20 (1350)

24 (1600)

(Unit : mm)
Use

Capacity
(Kg)

Entrance
Car Inside
Width
OP

15 (1000)

CA x CB

Car CWT
Rail Rail
Width Width
BG

BG

Template Dimension(ALG.X TYPE)


EE

845 VAR 450 1143.2

1200

775 220.5 1898 1180 1000 974 VAR 500 1244.7

2000 1350 2158

1200

710 220.5 2098 1180 1100 1074 VAR 550 1287.5

1000

1800 1700 1958

1200

875 220.5 1938 1180 1000 974 VAR 500 1309.3

1100

2000 1500 2158

1200

785 220.5 2138 1180 1100 1074 VAR 550 1330.3

1100

2000 1750 2158

1200

905 220.5 2138 1180 1100 1074 VAR 550 1404.5

1100

2150 1600 2308

1200

840 220.5 2288 1180 1100 1149 VAR 550 1423.3

900

1600 1500 1758

1200

770 220.5 1698 1180 900

1000

1800 1500 1958

1100

G, G'

17 (1150)
Passenger
E/L

20 (1350)

24 (1600)

[Table 2.3 Standard Template Dimensions (unit : mm)]

If entrance, car interior, rail width and etc. are non-standard, calculate them separately.

Left and right CWT rail widths are the same.

VAR is variable

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Elevator
3. Machine Room

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Safety Information
IMPORTANT! READ SAFETY NOTE AND THIS PAGE CAREFULLY
before installation.
1) Welder Installation and Welding Work

Check the sheath status of the cable.


Check the status of the welder holder. (Use the product with the specified insulation handle)
Check the operation status of the electricity protector.
Use the welder in stable condition at a place without the risk of flooding.
Use power cable, welding line, and grounding line with sufficient capacity.
Completely connect the end part of the cable connected to the 1st and 2nd side of the welder using
the specified lug and bolt.
Install a separate exclusive switch for the welder switch.
Make sure to have the 2nd grounding line to touch the welding object. If the
grounding line and the welding object are apart inevitably, remove the grounding of
the hoist system grounding line.
(Prevent the damage of the system grounding line by the welding current.)

Do not leave the welder holder alone while power is supplied.


During the welding work, make sure to wear protective gears such as welding gloves, welding cloth,
etc.
During the work, arrange and use the welding cable, and drain and install cable table at a place with
flooding or moist.
During the welding work, always have the fire extinguisher equipped, and take measures to prevent
spark scattering. (Spark scattering prevention facility, fire prevention bag, etc.)

2) Machine Room Work (hoist, governor, control panel installation)

Check the chain block and machine room lifting hook status.
Check the status of the wire rope and shackle.
Check the insulation status and sheath status at the AC Arch welder holder part.
If the hook in the machine room ceiling is not safely installed or if the location is incorrect, use a
separate lifting bracket fixed with anchor bolts (M16) at 4 or more places.
(For a large size hoist, install lifting beam.)
Use the chain block with the rated capacity of 2 times or more of TM weight, and use rope hanging
wire rope, shackle, etc. for the lifting equipment. (Do not use binding line or Manila rope.)
Do not work under TM, when TM is hung. (Do not lift 100mm or more from the machine room floor
or machine stand.)
Until TM, TM beam, vibration proof rubber, and machine stand are fixed with bolt or welding, do not
remove the binding of the chain block hanging on TM.

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Firmly block the machine room hole without gap.


Install the governor, and check the operation status of the governor.
Follow the welding work safety rules during the welding work.

3) Machine Room Work (MRL model)

Check the chain block and machine room lifting hook status.
Check the status of the wire rope and shackle.
Check the insulation status and sheath status at the AC Arch welder holder part.
Check the pit drain for lower part drive type.
Always wear protective gears (safety helmet, safety belt, and safety shoes), and carry out the work
while the safety belt is locked.
During the machine room work, do not perform the work at top and bottom at the same time.
Do not place hoist and various beams on top of the Top Work Bench.
After completing mechanical part installation, close the left side opening. (Prevent outside rainwater
or foreign object entering.)
If temporary power is used, make sure to fix cable and power cut-off switch on the wall.
Install the work bench by the machine room drawing dimension and considering the die plating and
overhead.
During the work, make sure to lock the safety belt to eye nut or a strong structure that has no risk of
falling altogether.
Firmly fix the scaffold using clamp.
Install the Working Foothold with the gap of 30mm or less, and firmly fix with the binding cable.
During the working basement installation work, mount eye nut on the external wall of the hoist way
and work with the safety belt locked.
Check for the piano wire interference in front of the gate. (150~180mm gap)
Install the slope support with 30 ~ 45. (Install 2 for each)
Install the safety balustrade at 0.9m ~ 1.2m. (Intermediate bar installation)
Install the 2 level Working Foothold with hatch foothold for safe access.
Firmly fix the access ladder with clamp with width 300mm or more, gap with wall 150mm or more.
(The ladder foothold gap should be a structure with uniform gap and preventing slipping.)
If the working bench is removed inevitably for material lifting, etc., make sure to restore it after the
completion of the work.

4) Motor Winch Installation

Do not use the winch for heavy object lifting over the permitted capacity of the winch, such as lifting
of the hoist or the assembled CAR, except for rail and CAR assembly work.
Do not use the motor winch at a place with danger of worker contraction accident inside the hoist
way such as the safety device and platform assembly work, etc.
Fix the winch with anchor bolts (M16) at 4 or more places before the usage.
In the part where the rope direction changes, make sure to install a pulley with sufficient
capacity, and when the rope is winding or released, have the weight be supported by the pulley.

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Fix the pulley by hanging it directly on the bracket fixed on a concrete with anchor bolts (M16) at 2 or
more places or on the shackle.
During the operation, rope should not be in contact with objects other than the pulley or it should not
be entangled.
Make sure to install E-STOP switch in the winch operation panel.
During the winch operation, have certain communication signals between the worker and
the operator.
The winch operator should check the rope winding on the drum all the time, and all the workers
should check the operation status of the pulley.
Attach a cover on the winch to prevent the finger jamming accident, etc.
When the winch is not in use, make sure to cut off the power and store with the cover on it.
When a heavy object is lifted, prohibit the access underneath it. (Do not finish the work as in lifted
state.)
When a lifting work is done with a winch, make sure to use lifting shackle.

5) Scaffold Assembly

Do not use twisted or bent scaffold.


(Use product suitable for Ministry of Employment and Labor Protective Equipment Self Safety
Verification Notice)

Remove foreign object such as cement or binding line attached to scaffold in advance.
Use the clamp that complies with the specification for scaffold assembly clamp.
(Use product suitable for Ministry of Employment and Labor Protective Equipment Self Safety
Verification Notice)

During the scaffold assembly or work inside hoist way, make sure to hook the safety belt to the
already assembled scaffold or other strong structure to prevent falling accident.
When you stand and work on the scaffold for scaffold assembly or other works, make sure to firmly
fix the working foothold and work with stable posture on it.
The height of the scaffold podium should be about 1.5m. If it is higher than that, add the podiums
to maintain the height between the scaffold podiums to be within 1.5m.
For crossways scaffold, when the worker stands on it by leaning on the hoist way wall, prevent the
shaking of the scaffold.
Install the safety net for every 3 stories or within the interval of 8m.

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Check the Following tools

Scriber

Hammer Drill

20mm Spanner

Tape Measure

Welding Machine

17mm Spanner

Hammer

Laser Leveling Machine

19mm Spanner

Horizontal Gauge

Pulley

Monkey Spanner

Plumb

Chain Block

Steel Ruler

Screw Driver

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3.1 Summary
Install hoist (Traction Machine), hoist stand (Machine Foundation), machine stand (Machine Beam),
vibration proof rubber to absorb shock, and governor, etc. inside the machine room.
Along with these, install the CP (Control Panel) and the electric wire pipe facility connecting CP (Control
Panel), hoist, and governor, for electric control of the elevator.

3.2 Geared Type Traction Machine


3.2.1 Structure of Geared Traction Machine
Bolt
Plain Washer
Traction Machine

Bolt
Plain Washer
M/C Foundation
Motor
Deflector sheave

Washer, Nut
Bolt
Stopper

Isolation Pad

M/C Beam

Washer

Washer, Nut

Washer, Nut

Clip, Bolt

Space
Beam
Bracket

Anchor Bolt

Welding

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3.2.2 How to Install M/C Foundation


In accordance with the layout, measure the correct value for M/C installation and mark the position of
the M/C Foundation.
( )
(Car Center
Line)

Machine Room
Wall

(Entrance Line)

(CWT Center Line)

( )

(CWT)

(M/C Foundation

Car & CWT

()

Center Line)

Line
Center

X'

(M/C Foundation
()
150

150

Min. 150mm

M/C Foundation
Length

Min. 150mm

Type

TM500

TM600

TM900

230

253

203

X'

170

203

203

<Length of X, X>

Center Line)

<Template
of the M/C Room>

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3.2.3 How to Install Machine Beam


1) How to Check the Machine Beam length placed on the retaining wall.
In the Q part, M/C Beam should be placed more than 150mm on the retaining wall.

M/C Beam should be placed more than 150mm on the retaining wall.

2) How to Install Machine Beam plates.


Fix the machine beam plats at 4 places with anchor bolt, and insert liner for leveling. Install the machine
beam according to the center of the marked ink line, check the level, and fix the machine beam plate and
the machine beam by welding. After checking the level and dimension of the machine beam,
fix the machine beam by welding the connecting angle of certain specification.

300
300

250
250

150
150

Welding

Angle

Anchor Bolt
Beam
Plate

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3) Tolerances for Installation of the Machine Beam

Mutual level : Max 0.5mm

Horizontal angle : Max 0.5mm

Level in length : Max 1mm

Distance between the beams : Max 1mm

4) The depth of Mortal finish


After installation of the T/M, spaces between the Machine room floor and the M/C Foundation should be
finished with concrete more than 100mm.

Mortal
finish

More
than 100mm
100

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3.2.4 How to Install Isolation Pads

Bolt
(M20)

Isolation Pad

M/C
Foundation
Rail Clip

Machine
Foundation

Machine
Room
Floor
Beam Plate

3.2.5 How to Assemble T/M


Lift the T/M on the M/C Foundation and adjust the horizontal & vertical level of the T/M.
After checking the balance of the T/M, fix the T/M with the bolts as below.

M20 * 120 HEX. Bolt


Traction Machine

Plain Washer

Motor
HEX. Nut

Machine Foundation

Taper Washer
Spring Washer

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3.2.6 How to Measure Sheave Alignment


Adjust to make the vertical degree of the main sheave and the secondary sheave is less than 1mm.
Make sure the main sheaves center is aligned with the deflector sheaves center.

Support
Main Sheave

Top of the
Sheave

Sheave

Piano Wire
Machine
Foundation
Bottom of the
Sheave

Deflector
Sheave
Plumb
Plumb

3.2.7 How to Install Governor


By referring to the installation plan (Layout), select the governor installation location, and adjust
so that the machine room floor and the governor support are horizontal. Lay down the pendulum
on the side of the governor sheave, rotate sheave slowly to adjust the dimension difference at A and A
point to be within 1mm.
Governor

A
A
Hex. Bolt
Gov. Support

Spring Washer
Plain Washer

M12 Anchor Bolt

Finish Line

A'

Center Line of Gov. Rope

Sheave

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3.2.8 How to Assemble Governor Cover


After the governor installation, lock the governor cover with bolt.

Governor
Sheave Cover

Wing Bolt
Spring Washer
Plain Washer
Governor

3.2.9 How to Install Control Panel


By referring to the installation plan (Layout), select the control panel location.
Insert the anchor bolts into the 4 holes of the control panel bottom part, and insert liner for leveling.

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3.3 Gearless Type Traction Machine


3.3.1 Structure of Gearless Type Traction Machine

Traction Machine

Machine Bed
Machine Bed
Support

Isolation Pad
Second Sheave
Machine Beam
Machine Beam Support

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3.3.2 How to Install Machine Beam


1) How to Install the Beam Support
By referring to the installation plan (Layout), calculate relevant dimensions, and mark on the machine
room floor with ink line. Based on the marked ink line, install the beam support. After the beam support
installation, fix the fixing angle with anchor bolt to prevent movement of the beam support.

Beam Support

Fixing Angle

2) How to Check the Machine Beam length placed on the Retaining Wall
After installation of the Traction Machine, spaces between the Machine room floor and the Machine
Foundation should be finished with concrete more than 100mm

Mortal finish

More100
than 100mm

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3) How to Machine beam


Place the machine beam on the beam support, and check the beam gap and level. After checking
the distance and the leveling, (Refer to Tolerances for Installation of Machine Beam.) fix it by welding
the part where machine beam meets the beam support.

Machine Beam
Welding

Welding
Welding

Welding

Machine Beam (Hitch)

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4) Tolerances for Installation of Machine Beam

Mutual level : Max 0.5mm

Horizontal angle : Max 0.5mm

Level in length : Max 1mm

Distance between the beams : Max 1mm

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3.3.3 How to Install the Isolation Pads
Put isolation pads on the machine beam and fix the isolation pads screwing bolts.

Machine Beam

Isolation Pad

Machine Beam Support

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3.3.4 How to Install the Machine Bed Support
Put the isolation pads on the Machine bed support and screw the pads.
1
Machine Bed Support

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3.3.5 How to Install the Second Sheave


Lock and fix the second sheave to the second sheave support bracket with nuts.

Second Sheave
Support Bracket

Nut
Spring Washer
Plain Washer
Second
Sheave

3.3.6 How to Install the Machine Bed, Machine Bed Support, and Second Sheave Support Bracket
Lock the machine bed and machine bed support with bolt.
Lock the machine bed and the second sheave support bracket with bolt.
Machine Bed

Bolt

Bed Support

Spring Washer
Plain Washer

Second Sheave
Support Bracket

Plain Washer
Nut

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3.3.7 How to Install Hoist on the Machine Bed


Place the hoist on the machine bed, check the leveling of the hoist, and lock with bolt.
Traction Machine

Bolt
Machine Bed
Plain Washer

Spring Washer
Square Washer
Nut

3.3.8 How to Check the Offset Distance of the Main Sheave and the Second Sheave
For Double Wrapping, check the installation plan and the diameter of the rope to adjust adequate offset
distance of the hoist main sheave and the second sheave.
Main Sheave Center

Main Sheave

Second Sheave

Second Sheave Center

Rope Diameter

Offset (D)

12mm

5mm

16mm

7mm

22mm

10mm

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3.3.9 T/M brake (DB1712 (DB250, DB350, DB450), DB2818 (DB450))

Excessive brake stroke adjustment decreases the stopping power,


so adjust correctly.

During the inspection, do not inspect the left and the right brake
at the same time.

During the inspection, make sure to maintain clean brake stopping surface.

During the inspection, use specified tool and do not apply excessive force.

After completing the inspection, check whether the brake stroke


and the switch operates properly.

Summary
This brake is used to maintain the stopped state after the elevator has stopped and for emergency stop.

Applied brakes for each hoist


Traction Machine

Brake

Type

GT17, GT25, GT50

DB1712 (DB250)

Drum Brake

GT 25, GT70

DB1712 (DB350)

Drum Brake

GT 100

DB2818 (DB450)

Drum Brake

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1) Structure of T/M brake (DB1712 (DB250, DB350, DB450), DB2818 (DB450))

[Figure 3.1 Brake Structure (DB1712, DB2818)]


2) Brake Spring Adjustment Value

Compressed length

When the brake is

When the brake is


Compressed length

fully installed, check the

fully installed, check the


compressed length

compressed length

[Figure 3.3 DB 2818]

[Figure 3.2 DB 1712]

(Unit : mm)

(Unit : mm)
TM TYPE

GT 100

PERSON

Compressed

Free

P13~P17

112

125

P20~P24

107

125

P28

105

125

TM TYPE

GT 25

GT 35

PERSON

Compressed

Free

P6~P9

99

110

P10~P11

96

110

P13~P15

91

110

P17

89

110

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3.3.10 How to Adjust T/M Brake (DB1712 (DB250, DB350, DB450), DB2818 (DB450))
Check the mechanical structure of the entire brake

Check if all operation parts of the brake works work freely.

Check if brake arm (1) locking pin (2) and brake lining (3) locking pin (4) operations are smooth.

Check if there is interference between the spring stud (5) and brake arm (1) penetration hole.

Check if the plunger rod (6) operation is smooth.

Check if brake open check switch (7) is operated by the switch adjustment bolt (13).

Brake spring adjustment (brake torque adjustment)

This work must be performed before the stroke adjustment work.

During the adjustment of the brake spring (8) compression amount, it is important to have equal
compression amounts in both sides.

Compress the spring as the same as the compression amount marked on the sticker (9) attached
to the connector box.

Fully tighten the locking double nut (10).

Brake stroke adjustment (0.15 ~ 0.2mm)

Completely unscrew stroke adjustment bolt (11) to make the stroke 0mm.

For the stroke to become about 1.5mm, adjust the plunger rod (6) stroke with the stroke
adjustment bolt (11).

Lightly tighten the locking nut (12).

After the adjustment, if there is a lining friction sound, gradually increase the stroke by fine
adjustment of the stroke adjustment bolt (11).

To minimize the brake operation noise, adjust the stroke to be the minimum while the lining does
not touch.

Completely tighten the locking nut (12).

Open check switch adjustment

The brake open check switch is operated by the switch adjustment bolt (13) when the brake is
opened.

While the switch adjustment bolt (13) is apart from the switch contact point, gradually tighten and
after the sound of click by touching the contact point, tighten more by about half round, and fully
tighten the nut.

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Check brake lining gap

While manually operating the CAR, use the gap gauge (0.1mm) to check the gap between the
drum and the brake lining (3).

If it operates normally without touching the lining, to minimize the brake operation noise, readjust
and reduce the stroke while it does not touch the lining.

If the gap is not uniform, or if friction sound occurs, adjust the gap of the brake lining (3) top and
bottom parts to be uniform by fine adjustment of the adjustment bolt (14), and completely tighten
the locking nut (15).

After the adjustment, if friction sound still occurs, check the gap by gradually increasing the stroke
by fine adjustment of the stroke adjustment bolt (11). The gap should be less than 0.3mm.

Final verification

When all the adjustment works are completed, check the brake open check switch operation and
switch contact point gap again.

Check the stroke and lining friction sound again, and check if all locking nuts are completely
tightened.

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3.4 GN Ty Traction Machine <MRL>


3.4.1 Structure of GN Type Traction Machine

Support Bracket

Fall Over Prevention


Traction

Beam

Machine
Machine Beam

Hitch Plate

Hitch Beam

Base Bracket

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3.4.2 How to Install Machine Beam


1) Machine Beam Lifting
Top Floor Entrance

Machine Beam
Hole

Bring in the machine beam through the highest floor hatch

Use the chain block to lift the machine beam

Penetrate the machine beam through the machine beam hole

Put the machine beam on the opposite side hole

2) Machine Beam Location Adjustment


When the machine beam is put on the building breast wall, the minimum dimension to be on the building
breast walls are as follows.

Machine Beam
Entrance

120

100

TYPE

Minimum Straddle dimension

GN 17, 25, 35

120mm

GN 50, 60

130mm

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3) Machine Beam Base Bracket Installation


After adjusting horizontal/vertical of the machine beam, fix the base bracket to the machine beam bottom
part with anchor bolt.

Machine Beam

Base Bracket

4) Base Bracket and Machine Beam Plate Welding


Weld the part where the machine beam meets the machine beam plate.
Then weld on the joints more than 5mm width as below.

Machine Beam Plate

Welding
Welding

Base Bracket

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3.4.3 How to Install Prevention Beam and Support Bracket


1) Fall over Prevention Beam Support Bracket Installation
Check the dimension of the gap A and B between the support bracket and the machine beam in the next
chapter, and install the support bracket as in the following figure.
Support Bracket

Plumb

Plumb

GN17/25/35/60

GN50

2) Fall over Prevention Beam and Support Bracket Mounting Location for Each Model

0
25
0

1071

998
900

900

[GN17/25]

[GN35]

[GN50]

[GN60]

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3.4.4 How to Install Isolation Pads
Install the isolation pads on the Machine beam.
Isolation Pad
Machine Beam

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3.4.5 How to Install Traction Machine


1) Traction Machine Assembly
Lift the hoist on the vibration proof rubber, and lay down by matching the bolt holes.
Use the level meter the front, rear, left, and right level of the hoist.

Traction Machine

Bolt
Spring Washer
Plain Washer

2) Fall over Prevention Beam Level Check and Installation


Place the fall over prevention beam on the support bracket, and lower the pendulums from both ends to
check the level.

Fall Over Prevention


Support

Beam
Plumb

Support
Bracket

Bracket
Plumb

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3) Hoist and Support Bracket Assembly


Lock the hoist and the support bracket with bolts.

Support Bracket

Bolt

4) Support Bracket and Fall over Prevention Beam Locking


Insert the vibration proof rubber and liner between the support bracket and the fall over prevention beam
and lock with bolts

Isolation Pad

Liner
Spring Washer
Support Bracket
Plain Washer

Bolt

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3.4.6 How to Install Governor


1) Governor Hitch Beam Structure

Hitch Plate
Governor

Gov. Plate

Hitch Beam Plate


Isolation Pad

Hitch Beam

Hitch Beam Plate


Base Bracket

2) Governor Hitch Beam Base Bracket Installation


Lift with the same method as the machine beam installation, and lay it on the breast wall with the same
dimension, and fix the base bracket with anchor bolt. Weld and fix the edge where the base bracket
meets the hitch beam plate. Then weld on the joints more than 5mm width as below.

Hitch Beam Plate


Welding

Base Bracket

Welding

Base Bracket

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3) Governor Hitch Beam installation


Place the hitch beam on the hitch beam plate, and weld and fix the edge where the hitch beam plate
meets the hitch beam.

Hitch Beam

Welding
Welding

Hitch Beam Plate

4) Governor Plate installation


Weld and fix the governor plate where the governor will be installed on the hitch beam.
Weld on the joints more than 5mm width as below.

Hitch Beam
Gov. Plate

Welding

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5) Governor Installation
Place the governor on the governor plate, and lock the 4 corners of the governor with bolts.

Governor

Bolt
Plain Washer

Plain Washer
Gov. Plate

Spring Washer
Nut

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3.4.7 How to Install Isolation Pad and Hitch Plate


Sequentially place the isolation pad and the hitch plate on the hitch beam, and lock with bolts.

Bolt
Spring Washer
Plain Washer
Hitch Plate

Isolation Pad

Hitch Plate

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3.4.8 How to Adjust Hoist brake


Before materials are released from factory, MRL GN TYPEs brakes are basically
adjusted and set up. But if there are problems with brakes such as noises,
refer to the following instruction.

Excessive brake stroke adjustment decreases the stopping power,


so adjust correctly.

During the inspection, do not inspect the left and the right brake
at the same time.

During the inspection, make sure to maintain clean brake stopping surface.

During the inspection, use specified tool and do not apply excessive force.

After completing the inspection, check whether the brake stroke


and the switches operate properly.

Summary
This brake is used to maintain the stopped state after the elevator has stopped and for emergency stop.

Applied brakes for each hoist


Traction Machine

Brake

Type

GN17

NED1712 (NED100)

Drum Brake

GN25, GN35, GX35

NED1712 (NED600)

Drum Brake

GN50, GN60
GX50, GX60, GX70, GS50

EX5415

Disk Brake

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1) NED1712 (NED100, NED600)

Check mechanical structure of the entire brake


Check if all the operating parts of the brake work freely.
Check if the brake open check switch is operated by the switch adjustment bolt.

Brake Spring Adjustment (brake torque adjustment)


There are 2 torque adjustment bolts (pad binding force adjustment part) for each brake. The pad
binding force changes according to X value in the following figure. At factory ship-out, pad
binding force is adjusted to the maximum value, but if it changes, adjust in the following order.
By looking at the pad binding force line diagram in the following figure, adjust the X values of the
torque adjustment bolt (10) to be the same in the 2 positions, and fix the adjustment bolt (10) by
tightening the locking nut (11).

Adjusting Bolt (10)


Fixing Nut (11)
Pad

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Brake Stroke Adjustment (0.2mm)


Fix the hexagonal part of the round bolt (20) with a spanner, and loosen the hexagonal nut.
Set the dial gauge as in the following figure.

Compulsory-opening Bolt (18)

Washer (19)

Pad (24)
Hex nut (21)

Round Bolt (20)

When the power is applied to the coil, set the 2 dial gauges at the electric open location to be 0.
While you turn power ON OFF, adjust the round bolt (20) to make the indicator value of the 2 dial
gauges to be 0.2mm. (Note: for total stroke, the average of the 2 places, top and bottom, can
become 0.2mm. Ex.) top part: 0.1, bottom part : 0.3 OK)
After completing the adjustment, tighten the hexagonal nut (21) to fix the round bolt (20), and
operate one more time to check if the stroke is 0.2mm.

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Open Check Switch Adjustment


Open check switch operates within the boundary of 0.07 ~ 0.1mm, and it is set at the factory
ship-out, but adjust it if necessary.
- Limit switch is operated by the adjustment bolt (16).
- Limit switch has A contact point, and it is OPEN when it is not operated, and it is
CLOSE when it is operated.
Fix the hexagonal part of the round bolt (20) with spanner, and loosen the hexagonal nut (21).
Prepare and set 2 dial gauges as in the figure.

Open Checking S/W (15)

Adjusting Bolt (16)

Hex. Nut (17)


Round Bolt (20)

Fixed Core (1)


Moving Core (15)
Measurement Point

Moving Core (15)


Fixed Core (1)

Hex. Nut (21)

When the power is applied to the coil, set the dial gauge to 0.
Turn ONOFF in turn, and adjust the average value of the 2 dial gauges to be 0.08.
Loosen the nut (17) of the switch adjustment bolt, turn counterclockwise several times to make
the switch in no-operation state.
Lightly tighten the hexagonal nut (17).
When the power is not applied to the coil (stroke: 0.08mm), while tightening the switch adjustment
bolt (16), tighten the fixing nut (17) at the location where the switch is operated.
When the power is applied to the coil, check if it operates within the stroke (0.07~0.1mm).
After the limit switch adjustment, check if it operates normally at the final normal stroke (0.2mm).

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2) EC5415

Check Mechanical Structure of the Entire Brake.


Check if all the operating parts of the brake work freely.
Check if the brake open check switch is operated.

Brake Spring Adjustment (brake torque adjustment)


There are 2 torque adjustment bolts (pad binding force adjustment part) for each brake.
The pad binding force changes according to X value in the following figure. At factory ship-out,
pad binding force is adjusted to the maximum value, but if it changes, adjust in the following order.
By looking at the pad binding force line diagram in the following figure, adjust the X values of the
torque adjustment bolt to be the same in the 2 positions, and fix the adjustment bolt by tightening
the locking nut.
Locknut
Adjusting Bolt

X (mm)

Brake Stroke Adjustment (0.4 ~0.5mm)


There areMethod AandMethod Bfor the stroke adjustment. For precise adjustment, adjust
withMethod A.
Also, stroke is 0.4mm in this adjustment manual, but if adjustment is impossible by contacting of the pad
on the disk after the adjustment, it can be up to 0.5mm.
As the stroke gets bigger, the noise gets bigger, so adjust the stroke to be the minimum.

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Method A
Based on the fixed core, place the measuring pin of the dial gauge on the rod (12).
Apply power on the coil.
While power is supplied, set the dial gauge to 0 point.
Block the power to the coil, and read the dial gauge value.
By repeating the power supply and block, use the adjustment bolt (11) to adjust the stroke to be
0.4mm.
After the adjustment, use the fixing nut (11) to fix the adjustment bolt.

When you turn the adjustable bolt clockwise, the pad moves toward the disk.

Always adjust the adjustable bolt when the power is applied.

Method B
Apply power on the coil.
Unscrew the fixing nut (11), and tighten the adjustment bolt (10) until the pad touches the disk.
Make the gap (A+B) between the pads to be 0mm. Be careful not to have the pad excessively
touching the disk by the adjustment bolt (10).
Turn the adjustment bolt (10) counterclockwise by 90. At this time, the coil stroke becomes about
0.5mm.

When you turn the adjustable bolt clockwise, the pad moves toward the disk.

Always adjust the adjustable bolt when the power is applied.

While the power is supplied, measure the distance between the coils.
While the power is blocked, measure the distance between the coils. The stroke of the coil is
the difference between when the operating core touches the coil and when they are apart.
By repeating the power supply and block, use the adjustment bolt (10) to adjust the stroke to be
0.4mm.
After the adjustment, use the fixing nut (11) to fix the adjustment bolt.

Adjusting Bolt (10)


Fixing Nut (11)
Pad
Measuring
Distance

A
B

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Brake Pad Gap Adjustment


Supply power to the coil to move the operating core, completely unscrew pad gap adjustment
hexagonal bolt (24) and nut (26).
(The gap on the adjustment holder (2) side becomes the maximum.)
While power is supplied, adjust the gaps (A and B) between each of the left and right side pad and
disk to match using the adjustment bolt (24). The gap of the coil side increases when the
adjustment bolt (24) is tightened, and when the adjustment bolt is unscrewed,
the gap of the adjustment holder (2) side increases.
After the adjustment, fix the left and right side adjustment bolts (24) using the nut (26).
Repeat the power supply and block for 56 times, and check if the gap between the two pads
and the disk are the same.
Stroke : 0.4mm, A B 0.2mm
If you cannot adjust the gap well, carry out again .

Open check switch adjustment


You dont have to adjust the brake open check switch.
Locknut (26)
Adjusting Bolt (24)

Adjusting Bolt (10)


Fixing Nut (11)
Pad
Measuring

Adjusting Holder (2)

Distance

A
B

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3.5 GY Type Traction Machine <MRL>


3.5.1 Structure of GY TYPE Traction Machine

Governor
Gov. Support

Traction Machine

Hitch Plate

Car Rail
T/M Plate
M/C Foundation

Support Bracket

Hitch Plate
CWT Rail
Car Rail

CWT Rail

3.5.2 How to Install Support Bracket at CWT Rail


At the top of the CWT rail, fix the support bracket using bolts.

Support Bracket

Bolt

CWT Rail

Nut
Plain Washer
Spring Washer

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3.5.3 How to Install Isolation Pads and CWT Hitch Plate


Firstly, put isolation pads on the support bracket. Then, put hitch plate on the isolation pads.

Hitch Plate

Isolation
Pad

Support Bracket

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3.5.4 How to Install Traction Machine
1) Installation of Machine Foundation
Put M/C Foundation on the support bracket and fix it screwing bolts.

M/C Foundation
Nut
Spring Washer
Plain Washer

Plain Washer
Bolt

Support Bracket

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2) Assembling car rail and Machine Foundation
Fix the joint of the Machine Foundation and the car rail with bolts.

180 Rotate

Machine Foundation

Car Rail

Nut
Spring Washer
Plain Washer
Bolt

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3) Isolation Pads Installation


Put isolation pads on the M/C foundation and fix them tightening bolts as below.

Isolation Pad

Nut
Spring Washer
Plain Washer

M/C
Foundation

Plain Washer
Bolt

4) T/M Plate Installation


Put the T/M plate on the isolation pads and fix it with bolts.

T/M Plate

Bolt

Spring

Plain Washer

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5) Installation of the Traction Machine


Place the Traction Machine on the T/M plate and screw bolts from the lower side of the plate.

Traction Machine
T/M Plate

Plain Washer
Spring Washer
Bolt

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3.5.5 How to Install Governor


1) Governor Support Bracket Installation
On the other side of the car rail where T/M is installed, fix the Gov. supporting bracket with bolts at the
top of the car rail.

Gov. Support Bracket

Bolt

Nut

Plain Washer

Car Rail

Spring Washer

2) Governor Support Installation


Assemble the support bracket and the Gov. Support with bolts.

Support Bracket

Gov. Support

Support Bracket
Spring Washer

Plain Washer

Bolts joining both Support Bracket and Gov. Support

Nut

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3) Installation of Governor
Place the governor on the Gov. Support and fix with bolts.

Governor
Nut
Spring Washer
Plain Washer

Plain Washer
Gov. Support
Bolt

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3.5.6 How to Install Isolation Pads and Hitch Plate


Put the isolation pads on the Gov. Support bracket and place the hitch plate on the isolation pads.

Hitch Plate
Governor

Isolation
Pad

Gov. Support Bracket

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3.6 Traction Machine Handle Switch


3.6.1 Structure of Traction Machine Handle Switch

4
5

No.

Name

No.

Name

Limit Switch

Round HD Screw M4x25 - 2EA

Bracket

Hex. HD Screw, S/W, P/W M6x12 - 4EA

Bracket

Assemble only Switch ASS'Y (Do not assemble the TM HANDLE)

Wiring : NORMAL OPEN ("A" contact)

Switch Plunger should be pushed by Switch Bracket

Take off only Switch Bracket and then, assemble the TM HANDLE ASSY

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3.6.2 Installation View
1)

GT17/25/35/100, GB17/25/35

2)

GX35

3)

GX50

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GX60

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3.7 Check Sheet for Machine Room


3.7.1 Machine Foundation
The following table shows machine foundation installation standard and measurements.
(Unit : mm)
No.

Measuring Object

Standard

01

Machine Foundation Front and Rear Horizontality

02

Machine Foundation Left and Right Horizontality

0.5

03

Horizontality between Machine Foundations

0.5

04

Parallelization between Machine Foundations

05

Retaining wall of Machine Foundation Support Beam

Over 150

06

Mortar Finishing of Machine Foundation Support Beam

Over 100

Remarks

[Table 3.1 Machine Foundation Installation Standard]

3.7.2 Traction Machine and Machine Bed


(Unit : mm)
No.

Measuring Object

Standard

01

Contact Point between Traction Machine and Machine Bed

No Gap

02

Main Sheave Location

03

Deflector Sheave Location

04

Main Sheave Vertical Degree

0.5

05

Deflector Sheave Vertical Degree

0.5

06

Difference between Centers of Sheaves (5mm)

0.5

07

Tape Washer Assemble Status

Horizontal

Remarks

2 Spot Welding
Places

[Table 3.2 Traction Machine and Machine Bed Installation Standard]

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3.7.3 Governor
(Unit : mm)
No.

Measuring Object

Standard

01

Governor Sheave Vertical Degree

0.5

02

Mortar Finishing of Governor Support

Fill mortar

Remarks

[Table 3.3 Governor Installation Standard]

3.7.4 Machine Room Piping


The following table shows Machine Room piping standard.
Install the connecting part of power cable flexible pipe by using connector vertically from the bottom
without the deflection of the flexible.
Install the encoder pipe by using independent piping.
Make the height of governor pipe equal to the height of governor switch.
(Unit : mm)
No.

Measuring Object

Standard

01

Steel Pipe Connecting Part

Pitch processing

02

Flexible Tube Connecting Part

Use connector

Remarks

[Table 3.4 Machine Room Piping Standard]

3.7.5 Control Panel


The following table shows the control panel installation standard.
Maintain more than 300mm of horizontal distance from the side of control panel to the pillar or the
wall according to the control panel installation layout.
(Unit : mm)
No.

Measuring Object

Standard

01

Control Panel Fixing

Tightly

02

Door Interruption

None

03

Control Panel Vertical Degree

[Table 3.5 Control Panel Installation Standard]

Remarks

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Elevator
4. Temporary Car

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Safety Information
IMPORTANT! READ SAFETY NOTE AND THIS PAGE CAREFULLY
before installation.
1) 1st Level Rail Installation

Check the status of the machine room lifting hook, winch, and pulley.

Check wire rope, shackle and E-STOP switch of the motor winch.

Check the protective device installation status of the electronic tools.


During the transportation of the rail, when you put down the transported rail on the
floor, be careful of falling down, or jamming of the fingers or foot.

Install caution marks to prevent injury of external workers by the delivered rail, and secure safe path.

Do not stand on the delivered rail. (Danger of falling down and prevention of rail deformation)

When you lift the rail, install the supporting rope (sling belt) for 5m or more, and use exclusive
shackle. (Never use a rebar, mountain climbing hook, etc.)

Firmly fix the working foothold to prevent movement. (Do not load 200kg or more including the
worker.)

Fix the foothold support with anchor at 2 or more places, and use exclusive steel material for the
supporting pin. (Do not use building rebar, etc.)

Prohibit the access of other workers below the rail lifting work space.

During the rail lifting, if the rail hung on the winch rope rotates, start the lifting work again after
verifying that the rail has stopped.

2) CAR Frame Assembly

Check the status of the machine room lifting hook, winch, chain block, and pulley.

Check the wire rope, shackle, and E-STOP switch of the motor winch.

Check the electronic tools protective device installation status.

For easy CAR frame assembly, remove the scaffold, and install work bench on the remaining
scaffold.

Install the support board considering the total weight of the CAR frame.

When you assemble heavy objects such as safety device, platform, etc., use the chain block with
lifting capacity of 2 times or more.

Work the chain block using the fixing devices such as rope hanging wire rope, bracket, and shackle,
etc. with sufficient lifting capacity.

When you tie and hang the lifting object to the chain block, firmly tie using the rope hanging wire
rope and shackle. (Do not use binding cable or Manila rope)

Prohibit access of the workers under the heavy object while the heavy object is hung.

Hang the wire hanging wire rope that tied the heavy object on the chain, and work by slowly pulling
the chain block. (Be careful of the jamming between the heavy object and the hoist way wall.)

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Before putting the platform on the safety device and locking the assembly bolt, do not stand and
work on the platform. (Prevent platform overturning.)

3) CAR Top Workbench Installation

Install the safety balustrades on 3 sides with 0.9m ~ 1.2m height. (Intermediate installation)

Install the safety balustrade with strong structure that can endure 100kg or more weight.

To prevent accident by dropping object, install protective ceiling.

The gap between the working footholds should be 30mm or less, and firmly fix both sides using
exclusive products, etc.

Install E-STOP switch in the operation panel for temporary CAR operation.
(Verify the removal of the jumper of the safety line for E-STOP in the control panel.)

To prevent falling down by the object on the workbench, perform thorough arrangement of the
electronic tools and installation material.
Install the work lighting with sufficient brightness, and the power for lighting and
working power should be separately supplied. (Inverter malfunction may be caused
by insufficient capacity of the transformer or fuse in the control panel or by noise.)
Never board on the protective ceiling. (Attach posting of Prohibition of
boarding on the protective ceiling)

Never board on the protective ceiling. (Attach posting of Prohibition of boarding on the protective
ceiling)

To prevent the fall accident of the temporary CAR, use the main unit engineering technology.
(Prohibition of single rope work)

Install the temporary cable not to interfere with the CAR operation. (Check the connecting part
insulation status.)

Furnish fire extinguisher to prevent fire accident.

For other safety rules, follow the Temporary CAR Installation Guideline.

Check the following tools.

Motor Winch

Hammer Drill

17, 19mm Spanner

24mm Spanner

Rail Gauge

Hammer

30mm Ratchet Wrench

Tape Measure

Steel Ruler (150mm)

14, 17mm Spanner

19, 24 mm Spanner

Spirit Level

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4.1 Summary
To install the guide rail with no-scaffold technology, CAR structures such as Safety Device, Support
Frame, CAR Platform, CAR Stile, Top Beam, etc. and governor holding device (Governor Tension
Sheave) to mount the governor should be assembled and mounted. Before installing the CAR
structures, etc., 1-level guide rail, CAR or counter weight buffer, Buffer Footing and Governor Tension
Sheave, etc. should be assembled first, and for the safe installation of the guide rail by the installation
worker, temporary work safety bar should be installed.

4.2 Advanced Work for Assembly Temporary Car


4.2.1 How to Install Pit Ladder
Fix the pit ladder on the pit wall to access to the pit. When the pit ladder is installed beside the entrance,
the ladder should be placed above 1100mm from the floor.
Pit ladder

1100mm

Anchor bolt
[Pit floor]

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4.2.2 How to Install Buffer Footing (CAR)


Referring to the Layout and the Inspection standard, check the depth between landing sill and pit. And
place the buffer footing at proper height. Install the Buffer Footing on the bottom of the pit according to
bottom template level the Buffer Footing by using a spirit level and fix it.

Plumb Line

Spirit Level

Buffer footing

4.2.3 How to Install Buffer Footing (CWT)


Install the Buffer Footing on the bottom pit according to bottom template.
Level the CWT Buffer Footing by using a spirit level and fix it.

Spirit level
Buffer footing
For car

Buffer footing
For CWT

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4.2.4 How to Install 1st Guide Rail (CAR)


Fix the Guide Rail on the Buffer Footing by Rail clip.
Guide rails ends should be different to the opposite rails end. (, )
Instructions of how to install the rail brackets are written in Ch.7 Rail installation.

Guide rail
Rail clip

Buffer footing

4.2.5 How to Install the Buffer


Fix the Buffer blocking on the Buffer footing by bolt.
Fix the Buffer on the Buffer blocking by bolt and nut.
Buffer
Buffer

Buffer footing

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4.2.6 How to Assemble Safety Device


Fix the Safety support at [X] point from the bottom floor level by rail clip.
[X] = Height of Safety Device + Height of Platform
The lowest floor Level
X=Height of Safety Device
X

+ Height of Platform

Rail clip

Safety Support

Put the Safety device on the Safety support and align Safety device precisely.

Safety device

Safety support

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After align the Safety device precisely, pull Actuator arm through rope and make gib could contact
rail surface.

Guide Rail

Safety Device

Gib

Rail Bracket

Rope
Actuator Arm

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4.2.7 How to Assemble Car Stile


After inserting shim liner between Safety Device and stile, fix it.
After inserting shim liner between Top Beam and Car stile, fix it.

Car Stile

Safety Device

4.2.8 Preparation to Install the Bolster <GN Type>


Put the bolster into the bottom of pit before installing the platform.
Make it sure that the direction of the bolster is right comparing with layout drawing.

Safety Device

Bolster ASS'Y

Buffer Footing

Car Stile

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4.2.9 How to Assemble Platform


Move the platform into the hoist way and put the platform on the safety device installed between the
first guide rails.

2
Platform

Car Stile

Safety Device

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Adjust the distance from the hatch template piano wire and the hatch side platform end (SILL
support) to be 6mm. Measure the leveling at the edge of the platform and center part with level
meter, and adjust the difference of the leveling to be within 1mm.Adjust the horizontal adjustment by
inserting the liner.

[EE]
Piano Wire

Spirit Sill
Sill Support

Hall Floor

Platform

Match the platform bottom part support frame and safety device bolt hole, and lock with bolts.

Platform

Platform
Bolt
Safety Device
Safety Device
<From a top view>

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4.2.10 How to Assemble Top Beam


1) Gearless TYPE
Match the platform bottom part support frame and safety device bolt hole, and lock with bolts.
Plain Washer
Top Beam

Nut

Spring Washer
Bolt

Car Stile

2) Gearless TYPE
Match the top beam bolt hole and top beam suspension sheave bolt hole, and tighten with bolts.

Suspension Sheave

Top Beam

Nut
Bolt
Plain Washer
Spring Washer

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3) New MRL TYPE


Match the top beam bolt hole and CAR stile bolt hole, and tighten with bolts.
Spring Washer
Suspension Sheave

Nut

Plain
Top Beam

Washer
Bolt

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4.2.11 How to Install Suspension Sheave to the Top Beam <New MRL TYPE>
Insert suspension sheaves at both sides of the top beam, and lock them so that the bolt heads are
located inside the top beam.
Bolt
Suspension Sheave

Top Beam

Spring Washer
Nut
Plain Washer

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4.2.12 How to Assemble Brace Rod


Insert Brace Rod top part into the CAR stile brace rod mounting hole, and fix with nuts.
After inserting the brace rod bottom part into platform bottom part bracket fixing bolt, and fix with
nuts. At this time, adjust the nut to be loose so that there is no tension in the brace rod.
Car Stile

Nut

Brace Rod

Brace Rod

Fixing Bolt

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4.2.13 How to Install Temporary Guide Shoe


Temporary guide shoe operates the temporary CAR for the guide rail installation while piano wire is
installed, and it prevents the CAR from falling off the guide rail. It is installed at the place where top beam
meets the top and bottom rail of the safety device, and after completing the guide rail installation, it is
replaced with general guide shoe. There are wooden plate type and roller type among temporary guide
shoes.

Piano Wire

Guide
Rail

Temporary
Guide


Top
Beam

[Figure 4.1 Wooden Plate Temporary Guide Shoe]

Shoe

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4.2.14 How to Install Governor Holding Device


Governor holding device is a device installed on the CAR frame to connect the governor and the safety
device, and when it is operated at abnormal speed, it activates the safety device to stop the CAR.
Upper Gov. Rope

1) Fix governor rod hitch to the top beam.

50

2) Assemble eye nut to the top part of the


upper rod, and insert thimble into eye
Penetrate through thimble and roll up

7
8

3) Fix the rolled up top part governor rope with


wire clip, and maintain each gap to be 50mm.

Top
beam

under rod bottom part hole, and lock with

5) Match safety device lever mounting hole and


under rod bottom part hole, and lock with
bolts.

12

4) Match safety device lever mounting hole and

bolts.

13
50

the top part governor rope.

170 86 100

nut.

5
10

11

6
2

6) Fix the nut for upper rod top part spring gap
to be 100mm, and fix the nut for bottom part

7) Fix the nut for upper rod top part spring gap

50

spring gap to be 170mm.

to be 100mm, and fix the nut for bottom part


spring gap to be 170mm.

turn buckle to adjust it so that the upper rod


and under rod are not bent.

50

8) Cut the bottom part governor rope, and use

Lower
Gov. Rope

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4.3 Temporary Car Assembly Process


4.3.1 Structure of Temporary car

Safety Handrail

Protecting Ceiling

Fire Extinguisher
Deck with kick plate
Car Frame

Support
Scaffolding

4.3.2 How to Fix Support Angle


Fix the Support Angle to Car Frame

Car Frame

Supporting
Angle

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4.3.3 How to Assemble Column Scaffolding


Fix the steel pipe scaffolding on the supporting angle.
Fix the column scaffoldings vertically.

Column Scaffolding
(2000mm)

Supporting
Angle

Scaffolding Clamp

4.3.4 How to Assemble Support Scaffolding


Stand the supporting scaffolding on platform and connect it to column scaffolding using joint pipe.

Joint Pipe

Supporting
Scaffolding

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4.4.5 How to Assemble Horizontal Scaffolding
Assemble horizontal scaffolding to column scaffolding.

4.4.6 How to Assemble Reinforcing Scaffolding


Assemble reinforcing scaffolding.

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4.4.7 How to Assemble Safety Guard


Assemble upper Safety Guard and lower one.

Upper Safety Guard


(Scaffolding)

500

600

Lower Safety
Guard
(Scaffolding)

4.4.8 How to Install Ceiling and Deck


Install protecting ceiling with Lay plywood or deck plate which is thicker than 12T on scaffolding.
Protecting Ceiling

Working Deck

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4.4.9 How to Fix Kick Plate and Equip Extinguisher

Install bottom and protective ceiling by using decks or scaffolds.


Arrange tools used to stand up rails not to fall down.
Install remote controller and winch to be U-shape so that they can be used in the car.
Furnish fluorescent lights and fire extinguishers.
Temporary car includes workbenches, safety guards and protective ceiling and is assembled
for the installation of various components in a stable position.

Kick Plate
Fire Extinguisher

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4.5 Check Sheet for Temporary Car


4.5.1 Buffer and Buffer Footing

There should be more than 4 anchor bolts fixing the buffer footing.

Before installing buffer footing, pit should be clearly cleaned.


(Unit : mm)
No

Measuring Object

Standard

01

Gap between the 1st rail bottom and buffer footing front side

80

02

Front and rear horizontal degree of buffer footing

0.5

03

Left and right horizontal degree of buffer footing

04

Gap between car center and buffer footing center

05

Stepped distance between car buffer footing front side and


CWT buffer footing front side

06

Horizontal degree of buffer

0.5

07

Vertical degree of buffer

0.5

08

Stepped distance between buffer front side and CWT buffer


front side

Remarks

[Table 4.1 Buffer and Buffer Footing Installation Standard]

Buffer
Footing
Buffer
Footing

Support

Anchor
Bolt

[Figure 4.2 Buffer Footing Adjustment Standard]

Rail
Clip

Floor
Finishing
Level

80

Guide Rail

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4.5.2 Safety Device


(Unit : mm)
No.

Measuring Object

Standard

01

Measurements from the base floor bottom finishing and the


bottom of safety device

400

02

Front and rear horizontal degree of safety device

0.5

03

Left and right horizontal degree of safety device

04

Stroke of gib

90

05

Gap between guide rail and gib

3.5

Remarks

[Table 4.2 Safety Device Installation Standard]

4.5.3 Car Frame


(Unit : mm)
No.

Measuring Object

Standard

01

Gap between the end of sill block and piano wire

02

Horizontal degree of the bottom of platform

03

Front and rear horizontal degree of top beam

0.5

04

Left and right horizontal degree of top beam

05

Vertical degree of stile

06

Tension to brace rod

No tension

Remarks

[Table 4.3 Car Frame Installation Standard]

4.5.4 Governor Holding Device


(Unit : mm)
No.

Measuring Object

Standard

01

Interval of rope wire clip

50

02

Interval of upper rope wire clip

03

Interval of lower rope wire clip

0.5

04

Rod status

Not bent

[Table 4.4 Governor Holding Device Installation Standard]

Remarks

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Safety Information
IMPORTANT! READ SAFETY NOTE AND THIS PAGE CAREFULLY
before installation.

Check the status of the machine room lifting hook, winch, chain block, and pulley.

Check the wire rope, shackle, and operation switch.

Check whether fire extinguisher is equipped for fire accident prevention.

When you work at the gate or at the top of the CAR, make sure to lock the safety belt to eye nut or to
a strong structure that has no risk of falling altogether.
During the barbette work, to prevent burn, wear protective gears such as safety
gloves, safety goggles, etc., and make sure to furnish fire extinguisher.

When you lower the rope, be careful not to have the rope entangled with each other, using the
two-way radio, etc.

After completing the roping work, install T/M and governor cover.

Assemble the rope socket to the CAR side hitch plate, tighten the double nut, and insert the pin.

After verifying that the CAR socket is completely locked, slowly release the chain of the chain block
that has the counterweight hanging so that the weight can be applied to the main rope.

Also, completely install the governor rope by hanging on the tension sheave so that the safety
device can be activated at the time of accident.

During the roping work, be careful of the jamming fingers in the sheave.

When you move the weight by human force, be careful of the musculoskeletal
disorders, and when you load the weight, be careful of the jamming of the hand
or foot.

After loading the weight on the counter case, lock the bracket, and fix the weight
and counter case with the automatic surface bar. (Prevent the shock during
operation and dropping of weight by hitting an object in the hoist way)
When you deliver the counter case with weight into the hoist way, be careful of the
falling accident by the weight of the material. (Use safety belt and lifting rope)

When you deliver the weight into the counter case from the lowest floor, lock the guide shoe in the
1st level rail to prevent the falling accident of the counter case.

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When you deliver the weight, be careful not to apply too much bodily force, and use motor winch
if possible. (25 kg or less if moved by 1 human force)
MRL model
(including skyscraper type)

Do not load heavy object such as weight on the MRL Top Work
Bench. (Do not load 250Kg including the worker.)

When you fix the CAR to the top part, firmly fix using chain block and
surface bar.
When you load weight in the counter case, work at the lowest floor.
(Do not load weight at the highest floor.)

Replacement Work

Check the following tools.

Torch Lamp

Electric Grinder

Babbitt Container

Tape Measure

15 Monkey Spanner

Bench

Plier

Connecting Cable

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5.1 Summary
It is the work for pulley action of the CAR and counter weight, after completing machine room and
temporary CAR assembly, by connecting the rope to the CAR and counter weight. The connection is
made from the CAR side top part top beam through the machine room hoist sheave to the counter
weight frame top part, and precise length cutting and precise core out is required for the rope.

5.2 Babbitt type <WBST>


5.2.1 How to Fix the Rope and Shackle
Before fixing the rope to the rope shackle, by referring to the dimensions of the 3 places at the end of the
rope in the table, wind with Steel Wire. At this time, there should be no overlapping of the steel wire.
(Unit : mm)
Rope
Diameter

12

14

A
15

20

20

18

15

16

15
100

115

125

140

155

50

[Table 5.1 Value of the Wound Steel Wire]

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5.2.2 How to Make Rope Babbitt


Untie Strand and cut the Manila rope.
Bend the strand so that height is at least 2.5 times of the diameter.
<After Removing Manila ropes>

HRope
Diameter2.5

Rope Socket

Strand

Wire Rope

Insert Strand into Socket.


Fill Babbitt Metal in the socket after melting with fire
3

Babbitt
Metal

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5.2.3 How to Assemble the Rope Shackle <WBST>


Place the counter weight frame at the hall of the highest floor. Lower the rope through the main sheave
and deflector sheave down to the counter weight frame at the highest floor. Lock the rope socket to
the rope shackle, and lock the rope shackle to the counter weight frame.

Main Rope

Rope Shackle

Spring

CWT Frame
Pin

Plain Washer

Nut

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5.2.4 How to Prevent the Entanglement of the Rope <WBST>


Lower the opposite end of the rope connected to the counter weight frame to the temporary CAR located
at the lowest floor. To prevent the rope from falling off the hoist sheave groove, tie it to the sheave using
steel wire. To prevent the entanglement of the rope with the hoist sheave groove and CAR and counter
weight rope entrance hole, tie the lowering rope in the order.

Preventing the
entanglement

Fixing Wire


Main Sheave

Rope

CWT Frame

<The Top Floor>

[Figure 5.1 Fixing the Tm Sheave with Wire]

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5.2.5 How to Prepare to Deliver Counter Weight into the Hoist Way
Machine Room

1) WBST
Connect the chain of the chain block to the
counter weight top part frame.
Before operating the chain block to deliver the
counter weight frame into the hoist way, fix it
with pipe or chain to prevent slipping from
standing. Put adequate amount of sub
weights in the counter weight frame, and to
prevent the weight from falling off, fix them
right on the surface.

Marking Point

Top Floor

H.Sill
Landing Sill

Imaginary


CWT

Marking Point

Base
Floor

Car & H.Sill

Run-by

Length
Buffer

Pit Depth

Landing Sill

2) the others
Connect the chain of the chain block to the counter weight top part frame.
Before operating the chain block to deliver the counter weight frame into the hoist way, fix it with pipe or
chain to prevent slipping from standing. Put adequate amount of sub weights in the counter weight frame,
and to prevent the weight from falling off, fix them right on the surface.
CWT
Frame
CWT

Fixing
Wire

Entrance

[Figure 5.2 Standard of Loaded Sub Weight]

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Type

BG 900

BG 1000

BG 1200

CWT Frame

115Kg

120Kg

170Kg

[Table 5.2 Dead Load of the CWT Frame]

Type

P8

P11

P13

P15

P17

Temp Car.

329Kg

369Kg

434Kg

449Kg

814Kg

[Table 5.3 Dead Load of the Temporary Car]

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5.2.6 How to Hang the CAR Side Rope <WBST>


Adjust the SILL location of the temporary CAR assembled at the pit to match the top part of the hatch
SILL at the lowest floor hall. Cut the rope according to the CAR, and as the same as connecting the rope
to the counter weight frame, fill the bar bit into the rope socket, and lock the shackle. By referring to the
following figure, lock the rope shackle to the CAR top beam hole.
CAR Top Beam
OF TOP BEAM

[Figure 5.3 Hanging Rope between the Top beam and the Main sheave under 15 Passengers]

3 Strands

Left
side 0~30
(0~30)

4 Strands

5 Strands

6 Strands

CWT

Left side31~45
(31~45)

Rear
Drop

Right
side
(31~45)

31~45

0~30
Right
side
(0~30)

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5.3 Wedge Type <WBLX, WBSS>


Put the rope around the wedge and adjust the extra rope to be less than 300mm. Pull the rope to
the cable joint so that the wedge moves into the cable joint and keeps fixed firmly.

Cable Joint

Rope

Extra Rope

Wedge

Match the pin hole of the rope shackle and the pin hole of the eye bolt on the same line and fix
the rope shackle and eye bolt with the pin. Put a split pin into the hole of the pin so that the pin is not
fallen out.

Extra Rope

Eye Bolt

Pin

Split Pin

Fix the rope end with rubber tape and fix the extra rope & the main rope with a rope clip.
Fixing With Rubber Tape

Rope Clip

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5.3.1 Method of WBLXs Wrapping


1) Double Wrapping
The hoist GT 50, 70, 100 Types are the models with Double Wrapping, and lock the rope to the sheave
as in the following figure.

Main Sheave

Rope

Second Sheave

When hanging ropes on the T/M sheave, abrasion would happen on the T/M sheave.
So put metal plates or metal pipes on the sheave to prevent the abrasion and then
fall main ropes.

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Since the ropes are not fully connected with the car & counter weight hitch plate
at this moment, fix the ropes tightly clips so that the ropes dont slip and fall down.

For the additional safety feature, fall down a rope that is as thick as the main rope
through the rope hole in the machine room. And fix the main ropes on the lowered
rope using wire clips. (Fixing Wire clips should be more than two.)

[Figure 5.4 Prevention of Rope Slip with Rope clip]

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2) 2:1 Roping
Locate the counter weight frame at the lowest floor, and locate the top beam at the highest floor.
Calculate the weight of the counter weight to locate adequate amount of weight at the highest floor.
After installing the first level rail, locate the counter weight frame and temporary CAR at the pit as in
the figure.

CWT Frame
Car Stile
Platform

Pit

Use the temporary guide shoe to fix the counter weight frame to the guide rail.
As in the figure, unscrew the fixing bolt at the one side of the counter weight frame suspension
sheave.

Suspension Sheave

CWT Frame

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Lock one side of the rope to the counter weight hitch plate in the machine room, and lower the rope
with U form to the counter weight side rope hole. Be careful not to have entanglement during the
lowering of the rope.

Rope

CWT Hitch

Hang the U form rope to the already loosened counter weight suspension sheave without reversing
the order.

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To prevent the slipping of the counter weight side rope, temporarily fix the rope in the machine room.
Insert the CAR side rope into the machine room main sheave rope hole and lower to the highest
floor. Hang the rope on the top beam sheave at the highest floor, penetrate the end of the rope into
the main sheave side hitch plate rope hole, to bring up to the machine room.

Temp.
Fixing

Top Beam

Mount the top beam jig to prevent the top beam from being skewed and to prevent the rope from
falling off during the lowering of the top beam.

Top Beam Jig

Nut
Spring Washer
Plain Washer
Top Beam
18K Rail Clip
M16X45 Bolt

18

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Use electronic chain or chain block to insert the top beam into the hoist way, and cut according to
the length of the rope.

1115
Upper Frame

815
Spring Washer

Bolt

Nut
Side Frame

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After loading the sub weight into the weight jig, use chain block to hang to the top beam. With
manual operation of the hoist, lower the top beam. When the top beam is lowered to the CAR stile at
the pit, assemble the top beam and the CAR stile with bolts.

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5.3.2 WBSS Type


1) How to Assemble the Rope Shackles
Make sure that two nuts are fastened and split pins are inserted in the bolts.

Spring Seat

Spring

Nut
Plain Washer

Machine Beam

Main Rope

Machine
Room

Marking Point

Marking Point

Top
Floor

H.SillSill
Landing

Base
Floor
Car & H.Sill
Landing
Sill

Run-by

Buffer Length

Pit Depth

2) How to Deliver the Counterweight into the Hoist Way


For precise cutting of the main rope length,
calculate A dimension using the following
formula.
A=pit depth-buffer length-run by-(hoist
way0.01)
Mark the place with A distance from the
counter weight frame butter bottom part,
and remove the pipe or steel wire that were
used for fixing to prevent slipping.
Pull the chain block to slowly deliver the
counter weight frame into the hoist way.
Adjust the counter weight frame height so

Imaginary
that the A mark at the counter weight
CWT
frame buffer bottom part matches the top
part of the hatch SILL at the highest floor of
the hoist way.

Shackle

Pin

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3) How to Hang the Rope to the Hoist Main Sheave


Hang the rope came up through the counter weight frame sheave onto the hoist main sheave.
The rope rolled and going down goes through the temporary CAR bottom part bolster ASS'Y sheave,
and locked to the opposite side governor hitch plate.

Right Position of the ropes

TM Sheave

CWT Sheave

RIGHT"

Bolster Sheave
Entrance

Bolster Sheave
TM Sheave

WRONG
Bolster Sheave
If the order of rope hanging is wrong,
it causes the entanglement of ropes.
ENTRANCE

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5.4 New MRL Type


5.4.1 How to Lock the Rope Shackle to the Hoist Side Hitch Plate
Lock the rope shackle to the hoist side hitch plate, and lower the rope to the counter weight frame
sheave.

Hitch Plate

<Rope falling>

5.4.2 How to Hang the Rope onto the Counterweight Sheave <New MRL>
Lock the rope onto the counter weight sheave so that the rope lowered from the hitch plate comes up in
between the two sheaves.
Rope Hanging Direction

<CWT Frame Sheave >

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5.4.3 How to Hang the Rope onto the Hoist <New MRL>
Hang the rope as in the figure so that the rope came up through the counter weight frame sheave goes
through the center hole of the support bracket and goes over to the other side through the hoist sheave.

Rope Hanging Direction

Rope Falling

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6. Guide Rail

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Safety Information
IMPORTANT! READ SAFETY NOTE AND THIS PAGE CAREFULLY
before installation.
1) Rail Installation

Check the operation status of the winch and the pulley.

Check the wire rope, shackle, and E-STOP switch of the motor winch.

Check the status of the machine room lifting hook, and installation status of the protective device of
the electronic tools.

Check the insulations status and sheath status of the welder holder part.

Check the attachment status of the posting of Prohibition of boarding on the protective ceiling on
the protective ceiling.

Always wear protective gears (safety helmet, safety belt, and safety shoes), and the safety belt
should be locked to a strong structure. But, if the body goes over the safety balustrade during the
work, install a lifeline and lock the fall prevention bar (low rib; Cobra) and lock the safety belt.

Be careful of slipping when the body goes outside the safety balustrade excessively, instantly lift the
rail, or during the tightening of the bolt.

During the UP driving of the temporary CAR, be careful of hitting the worker where the temporary
CAR meets the counterweight, and when it is driven below the point meeting the counterweight,
assemble the guide shoe and safely go down by the rail.
Be careful of the finger jamming during the assembly of the guide rail joint.

Always check if the counterweight interferes with hoist way wall or other object during the driving of
the temporary CAR.

Do not install safety balustrade or protective ceiling on the CAR top workbench.

Never board and work on the protective ceiling in any case.

Do not work at the top and the bottom at the same time.

Do not over load rail, parts, etc. on the temporary CAR workbench.
During the hammer drill work, work with a stable posture, and if drill suddenly
rotates by being caught in the rebar during the work, be careful of falling.

During the rail installation work, make sure to install the governor. (Check whether it works before
starting the work.)

Install the collision buffer in the pit. (CAR side / CWT side)

Follow the welding work safety rules.

For other safety rules, follow the 1st level rail installation safety rules.

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2) Rail Installation (All-in-one body engineering technique)

Install the motor winch within 1m from the floor, and use 4 or more fixing jigs.

Use mutual signaling two-way radios, and perform strict call and repeat.

Use motor winch with 2 or more of the lifted rail weight, and make sure to use the hook with hook
release device.

To prevent the entangling of the rope or chain during the rail lifting, use rotating hook (swivel).

Use the rail fixing jig that can endure 10 ton or more weight.
(Make sure to discuss with the building construction company in advance to see if the machine room
floor can sufficiently endure the rail weight.)

When you mount the rail lifting rod on the rail fixing jig, use 2 flat washers (3T or more), and
sufficiently consider weight for jig hanging dimension of the load flat washer.

Firmly fix the work foothold to prevent movement. (Do not load 200Kg or more including the worker.)

Fix the foothold support with anchors at 2 or more places, and use exclusive steel material for the
supporting pin. (Do not use building rebar, etc.)

Check the following tolls.

Welding Machine

Hammer Drill

Scriber

17mm Spanner

24mm Spanner

30mm Spanner

G Clamp(4)

or Ratchet Wrench

Hammer

19mm Spanner
or Ratchet Wrench

Tape Measure

Impact Wrench

Motor Winch

Pulley

Rail Gauge

Steel Ruler(150mm)

Straight Edge

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6.1 Summary
Guide rail is a part playing the role of direct guide for CAR operation, it is installed inside the hoist way
according to the installation standard, and it is an installation process that has direct influence on the
vibration of the CAR, so precise installation is required.

6.2 Structure of Guide Rail

6.3 How to Clean Joint Part of Rail


Clean out the end of rail and the fishplate to protect from any dust before Installation.

Guide Rail

Fish Plate

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6.4 Guide Rail Installation Process


6.4.1 How to Bring the Rail into Hoist Way
Fix the fishplate on one end of the rail before bringing rail into hoist way.
Place hook in one of the holes of the fishplate and bring the rail into hoist way.

Winch Wire
Fish Plate

Shackle

6.4.2 How to Connect 1st Rail and Buffer Footing


Place the Guide rail on the Buffer footing.
Fix the Guide rail on the Buffer footing by the rail clip.

Guide Rail
Rail Clip

Buffer Footing

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6.4.3 How to Install 1st Rail Bracket

300~500

Install the lowest 1st rail bracket at 2,000mm [78 3/4] height from the pit floor and the rest each
2,500mm [98 7/16].
Center of 1st rail bracket should be located at the piano wire.

Machine Room

TOP
RAIL

Piano Wire
st

2500 (EACH PITCH)

1 Rail Bracket

Rail Bracket
Position

2000

2500

Anchor Bolt

PIT

6.4.4 How to Install Car Rail 2nd Bracket


Fix the 2nd rail bracket and guide rail by rail clip.
Put the rail liners between the guide rail and 2nd rail bracket to adjust gap.
Fix the 2nd rail bracket and 1st bracket temporarily after leveling the 1st bracket.
1

2
Guide Rail

Spirit Level

1st Rail Bracket


2nd Rail Bracket
Liner

Rail Clip

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6.4.5 How to Install CWT 2nd Bracket


Fix the 2nd rail bracket and guide rail by rail clip.
Put the rail liners between the guide rail and 2nd rail bracket for adjusting gap.
Fix the 2nd rail bracket and 1st bracket temporarily after leveling the 1st bracket.

Common Rail Bracket

Spirit Level

1st Rail Bracket

6.4.6 How to Install CWT 2nd Bracket


Fix the 2nd rail bracket and guide rail by rail clip.
Put the rail liners between the guide rail and 2nd rail bracket for adjusting gap.
Fix the 2nd rail bracket and 1st bracket temporarily after leveling the 1st bracket.

CWT Rail 2nd Bracket

Spirit Level

Rail Clip

Liner
CWT Rail 2nd Bracket

CWT Rail 1st Bracket

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6.4.7 How to Adjust the Rails
Adjust the center of the guide rail with piano wire (Plumb wire).
Adjust rail alignment (Face to Face, rail BG).
Guide Rail

Ruler
Piano Wire
Rail 1st, 2nd Bracket

Rail Gauge
Guide Rail

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6.4.8 How to Weld 1st Bracket and 2nd Bracket


After finishing adjusting rail installation, fix 1st and 2nd brackets.
Then weld on the joints more than 5mm width as below.

Both sides Welding

Rail 1st Bracket


Both sides
Welding
Rail 2nd Bracket

<For CWT>

<For Car>

After finishing adjusting rail installation, fix 1st and 2nd brackets.
Then weld on the joints more than 5mm width as below.

Rail 1st Bracket

Both
Rail 2nd Bracket

Common Rail Bracket

Sides
Welding

[Figure 6.1 For Car & CWT Common Bracket]

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After finishing adjusting rail installation, fix 1st and 2nd brackets.
Then weld on the joints more than 5mm width as below.

Beam Plate

Both Sides

Common Beam

[Figure 6.1 Common Beam & 2nd Rail Bracket]

After finishing adjusting rail installation, fix 1st and 2nd brackets.
Then weld on the joints more than 5mm as below.

Beam Plate

One site of the


upper side
Both sites of
the lower side
Welding

Welding

60-145mm

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6.4.9 How to Connect Rail


Clear out the connection part of the rail and the fish plate.
After connecting two rails fishplate by bolt and nut, tighten it.

Upper Guide Rail

Fish Plate

Bolt
Nut

Lower Guide Rail

6.4.10 How to Measure Rail Straight


After connecting two rails, check the straight of rail by using straightedge.
Adjust tolerance with shim liner.
Max 0.03mm
(Gap)
Upper Rail

Straight Edge

Lower Rail

Max 0.03mm
(Gap)

Max 0.03mm
(Gap)

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6.4.11 How to Install the Top Guide Rail & Rail Bracket
Clearance of between the end of the top guide rail to ceiling of the hoist way should be less than 3 in.
(80mm). Top rail bracket should be installed at 12 in. ~ 20 in. (300mm ~ 500mm) from ceiling of hoist
way.
Hoist way Ceiling

300~500mm
Max 80mm

The end of the


top rail

The Rail Bracket


installed at the top

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Safety Information
IMPORTANT! READ SAFETY NOTE AND THIS PAGE CAREFULLY
before installation.

To prevent fire accident, check whether fire extinguisher is equipped.

Check the insulation status and the sheath status of the welder holder part.

Check the installation status of the protective devices of the electronic tools.

During the work at the gate, make sure to lock the safety belt to a strong structure.

To prevent falling down of the material assembled and stood in front of the gate, have them laid
down on the floor.

Do not work at the top and the bottom at the same time.

Be careful of the injury from JAMB, or door cut edge.

After JAMB installation, if the floor door is not installed, reinstall the safety balustrade and the shield
window.

After the door installation, check the interlock lock status.

Until completing the door installations in all floors, do not remove the protective ceiling of the
temporary CAR.
During the hammer drill work, work with a stable posture, and if the drill suddenly
rotates by being caught in the rebar, be careful of falling.

Follow the welding work safety rules.

After the floor door installation, when you access the hoist way, check the location of the temporary
CAR.

Check the following tools.

Horizontal Gauge

Steel Ruler

Tape Measure

Hammer

17, 19mm Spanner

Laser Leveler

Steel Ruler (150mm)

Hammer Drill

Scriber

Welding Machine

Weight

Screwdriver

Wedge (made in the field)

10, 13mm Spanner

Screwdriver

14, 16mm Spanner

Monkey Spanner
(350mm)

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7.1 Summary
The parts related to the landing installation are called hall parts, and the installation methods for each
part are classified by door opening type and opening size, so perform the installation work considering
the specification of each component and the characteristics of the structure.

7.2 Structure of Entrance

Door Interlock

Landing Door Operator

Landing Door

[Elevator Hall]

Landing Sill

Toe Guard

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7.3 Entrance Installation Process


7.3.1 How to Locate Landing Sill
Landing Sill is installed at the bottom of the entrance, and will be the basic line of the jamb and other
entrance parts and also guides the door shoe under landing door and prevents doors to be separated
from its orbit. Check the level of bottom finishing line and decide installation position of landing sill.

Finished Floor Line

Sill Support Line

[Elevator Hall]

[Figure 7.1 Inside the hoist way]

7.3.2 How to Install Sill Support (When Masonry)


Fix the Landing sill support on the hoist way wall by anchor bolt.
After installing the Landing sill support, weld plain washer of anchor bolt as spot.
Landing Sill Support
Entrance Floor

Site Welding
Spring Washer
Nut
Anchor

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7.3.3 How to Install Landing Sill


Put the landing sill on the landing sill support and adjust the level using spirit level.
Weld the landing sill to the landing sill support firmly.

Landing Sill

Spirit Level

Sill Support

7.3.4 How to Assemble Toe Guard


Fix the Toe guard on the Landing sill
Fix the Toe guard sill inside the hoist way. (Only the lowest floor)

Landing Sill

Toe Guard

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7.3.5 How to Measure Jamb Height and Width

H : Distance between the entrance piano wire and the outside of the wall

JD = H 25mm(Sill Gap) 60mm(Landing Sill width) + B(Interior finishing Wall width)

JD : Jamb Width

MH : Transom height
(If necessary)

JH : Jamb Height

30

JJ : Entrance Width

Finishing the edge

Sill
Gap

JJ

H.SILL

JD

60

H'

JD

25

H.SILL

Car
Sill

JD

JH

MH

B (Interior finishing Wall Width)


B()

Width)
(Wall
A25
A()

Piano
Wire

Landing Sill width


Jamb width

[Figure 7.1 Distance between the Car Sill and the outside of the wall]

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7.3.6 How to Install the Jamb


As Jamb should be designed and manufactured in line with the design of building, the style of Jamb
could be differed. But, the method of installation is basically same.

Top Frame
Top Frame

<JP100 Type diagram>

<JP500 Type diagram>

Fix the assembled Jamb to the landing sill according to the entrance opening.
Jamb Fixing Bolt

Jamb

Landing Sill

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Adjust the Jamb perpendicularity by using plumb.

Plumb

Plumb

Insert six Anchor bolts on each side of entrance.


Fix the Jamb welding the joint of Fixing Steel Rod, anchor bolts and the Jamb side plate.

Jamb
Side Plate

Anchor bolt

Fixing Steel rod


Anchor bolt

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7.3.7 How to Assemble Jamb & Landing Door Operator


Fix the Landing door operator at the hanger case bracket of the Jamb by bolt.

Landing Door Operator


Landing Door Operator

Plain Washer
Bolt
Spring Washer

Anchor bolt

Jamb

Hanger Case Bracket

7.3.8 How to Fix Landing Door Operator (When Masonry)


Fix the Case bracket at the Landing door operator by bolt.
Fix the Landing door operator on the wall by anchor bolt.
Anchor Bolt
Hanger Case
Bracket

Landing Door Operator

Bolt

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7.3.9 How to Fix Landing Door Operator (When Dry Wall)


Fix the Case bracket at the Landing door operator by bolt.
Weld the Case bracket at the entrance steel frame.

Hanger Case Bracket

Steel-framed Structure

Landing
Door
Operator

Site Welding

7.3.10 How to Assemble Landing Door & Top Cover


After fixing the Landing door at the Landing sill, fix the Landing Door & Top Cover on Hanger Plate.
Adjust the bottom gap with liner (0.4t [1/64], 0.8t [1/32], 2.3t [3/32]).
Hanger Plate

Liner

Landing Door
Landing Door

5mm

[Toe Guard]
Landing Sill

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7.3.11 How to Assemble Triangle Key


Put the Triangle key into the hole of Landing Door. Check the operation status at the entrance.

Key Cylinder

Hex Nut
Cam

Nut
Rubber Washer

Hex Nut

7.3.12 How to Adjust Interlock Distance


Adjust distance between the Landing door release and the Car sill.
Adjust distance between the Landing door release and the Clutch of the Car door operator.
Landing Door
Release Roller
61.5mm

Moving Cam
101.5mm
Car Sill
7.51.5mm

Fixed Cam

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7.3.13 How to Adjust Door Interlock Center


Adjust the Fixed Roller center line and entrance center line when fully closed.

150mm
Opening Center Line
Moving Roller

Fixed Roller

The Center Line of the Fixed Roller

7.3.14 How to Adjust the Door Interlock Operation


Check the Keeper and Hook distance when fully closed.

Keeper

31mm

121mm
Hook

[Door Interlock Closing]

[Door Interlock Opening]

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Safety Information
IMPORTANT! READ SAFETY NOTE AND THIS PAGE CAREFULLY
before installation.

For easy work, check sufficient lighting status.

Check the installation status of the ladder and Working Foothold.

Remove foreign objects on the hoist way wall such as projected objects or pin, etc. in advance.

Firmly fix the CAR ceiling with robust lifting equipment at four corners. (Do not use soft steel.)

When you work by moving the location of the CAR wall, make sure to lock the safety belt during the
work.

Make sure to call and repeat during the work, and must work with 2 people in one team. (Establish
the signaling system during the 2 people working.)

When you put down the CAR ceiling on top of the CAR wall, be careful of
the finger jamming.

Be careful of the injury by the cut edge of the CAR wall steel plate.

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8.1 Summary
During the temporary CAR assembly, on the installation completed CAR frame, CAR panel, CAR ceiling,
CAR door operator, hatch column, hatch top plate, CAR components are mounted, and other electric
parts for high speed test operation are mounted. CAR door operator is an important part for door
opening and closing, so it must be adjusted precisely, and CAR panel and ceiling, etc. are the parts
having direct contact with the passengers, so installation requires special caution to prevent damage of
the exterior surfaces.

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8.2 Sub Weights


Load the required sub weight additionally on the existing sub weight loaded on the counter weight frame
when assembling temporary car in consideration of car deal load and rated capacity. 2 workers
compose a team and it is required to pay attention to safety.
Sub weight loading method differs according to the structure of car compensation device. Therefore, it is
required to check the structure of the compensation device.

Tools

17, 19mm Spanner

17, 19mm Ratchet Wrench

Hammer

8.2.1 How to Install Sub Weight


Pull up the car to the location where car crosses counter weight and becomes suitable to load sub
weight.
Fix the safety belt of each worker to safe location.
Disassemble the weight fixing clip and the fixing bracket by using ratchet wrench and spanner.
Fix safety foothold and insert sub weights into the counter weight frame from the bottom of the
counter weight. 2 workers compose a team and work in safe position to prevent falling.
After completing the insertion of proper amount of sub weights, fix the weight fixing bracket to the
counter weight frame by using weight fixing bracket. Make the clip stick to the counter weight frame
by using hammer.

Sub Weight

Counter Weight
Frame

Counter Weight Fixing Bracket

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8.3 CAR Panels and Ceiling

Tools

10, 13mm Spanner


or Ratchet Wrench

17mm Spanner

19, 24mm Ratchet Wrench

Steel Ruler (150mm)

Horizontal Gauge

Square

Hammer

8.3.1 How to Install CAR Panels and Celling


Fix the ceiling temporarily to the top beam by using rope before car wall installation.
Car wall assembly differs according to the car interior size. It is a split structure. 8-split structure is
applied to P15 accommodations, and 11-split structure is applied to P17 accommodations.
As shown in next figure, assemble the left and right of No. and car walls and No. hatch
pillar at the same time by using M620 bolt, and fix
them to the bottom of car wall and the slot hole of upper
kick plate of car bottom.
Assemble the left and right of No. and car walls
at the same time by using M620 bolt, and fix them to
the bottom of car wall and the slot hole of upper kick
plate of car bottom.
Assemble the left and right of No. and car walls
at the same time by using M620 bolt, and fix them to
the bottom of car wall and the slot hole of upper kick
plate of car bottom.
Assemble the left and right of No. and car walls
Car Sill Edge
and No. hatch pillar at the same time by using
M620 bolt, and fix them to the bottom of car wall and
the slot hole of upper kick plate of car bottom.
Assemble the side of unassembled No. and , No.
[Figure 8.1 Car Wall Assembly]
and and No. and at the outside of car and fix
them.
As shown in next figure, match the outfit of car wall and the end of the side, and assemble the car
wall at each corner.
When mounting hand rail on car wall, assemble it temporarily on car wall to fit with the hole of car
wall before installation in order to move car wall easily.
After completing car wall assembly, match it with the tap mounted to the lower hole of No. and
hatch pillar and platform, and assemble and fix it by using M620 bolt.
Insert the upper plate of hatch between the left and right hatch pillars, and assemble it from the
outside of the car by using M6 20 bolts.
Attach protective tape to the upper side of car sill and mark the effective width of hatch and the
center line of effective width.

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Put car sill on sill block, and match the center of car and the center of car sill, and match the car sill
effective width marking point with left and right effective widths of hatch.
Stick the rear of car sill to the platform, and fix it by using M8 20 bolts.
Check the horizontal status of hatch sill by using horizontal gauge, and fix car sill to sill block.
Insert liner between car sill and sill block and adjust horizontality.
16 Assemble apron by using M512 cross head screw.
17 Put down the ceiling temporarily fixed to top beam by rope slowly on upper side of car wall.
18 Fit the hole of the ceiling to the slot hole mounted to the upper side of car wall, and fix it by using M6
20 bolts.
19 Maintain the gap between the dustproof device on the left and right of ceiling and the car stile, and
assemble it temporarily. Adjust the gap between the dustproof device and the car stile to be about
10mm.

Car Ceiling
Car Ceiling

Car Panel

Car Panel (Rear)

Car Panel (Side)


Car Panel
Car Panel (Side)

Car Panel

Entrance Column

Car Panel (Side)

Car Platform

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8.4 CAR Panels


Check the horizontal degree of the car platform using the spirit level. Measure the A
and A length falling down the plumb and check the perpendicularity of the entrance
column. Inserting liners, adjust the horizontality and the perpendicularity of the car
panels to be 1mm.

Tools

10, 13mm Spanner

14, 17mm Spanner

19, 24mm Ratchet Wrench

Steel Ruler (150mm)

Horizontal Gauge

Square

8.4.1 How to Install CAR Panel

Entrance
Entrance

Transom
Check the horizontality of car bottom by
Width
Ceiling
using horizontal gauge.
Loosen M820 bolts of car stile and
temporarily fixed dustproof device.
Put down the weight from upper plate of
car hatch to the side of hatch pillar, and
measure A-A' in next figure, and check
the verticality of top/bottom and
Front Wall
front/rear.
Loosen M16 Jack bolt on the bottom of
Entrance
the inclined platform, and insert liner
Column
between dustproof rubber and support
frame, and adjust the horizontality and
verticality of car panel. Adjust the
top/bottom and front/rear verticality to
1mm.
Fix M16 Jack bolt and dustproof rubber
bolt of car panel completely.
Check the parallel of car sill and hatch sill.
[Figure 8.2 Car Verticality Measurement]
If adjustment is required after measurement,
loosen M2050 bolts that fixes support frame and safety device and adjust the left/right parallel of
car sill and hatch sill to 251mm by using lever.
After completing adjustment, fix M2050 bolts completely.
Fix the dustproof device on the ceiling completely by using M8 20 bolts. Dustproof device must be
in natural state without compression. If it receives too much tension, install it again.
After completing the installation of car panel, assemble the ceiling components (such as fluorescent
lamp).

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8.5 How to Install Apron


Fix the apron at the front of the platform by round-headed bolts.
Fix the Bracket between the apron and the platform.

Car Sill

Platform

Apron
Bracket
Apron

8.6 How to Install Compensation Chain


The gap between the compensation chain at each end of car and CWT should be 350~400mm. The gap
between the lowest point of compensation chain and the pit floor should be 150~200mm. The gap
between the middle of the compensation chain guide pipe and the pit floor should be 450~500mm.

CWT Rail
CAR

Compensation
Chain Guide

C
W

Compensation
Chain
350-400mm

450-500mm

Pit Floor
150 - 200mm

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8.7 How to Install of Whisper Flex

1000

To be able to mount U bolt, check if the end of the whisper flex, part that came in about 1000mm inside,
and 3 and 4 chains are exposed as follows.

[Figure 8.3 Whisper Flex Chain]

8.8 How to Connect CAR / Counterweight Frame and Whisper Flex Chain

Safety Device

Channel
U-BOLT
U-BOLT

U-BOLT

S-HOOK
S-HOOK

U-BOLT

Whisper
Flex Chain

(CAR SIDE)
SIDE)
(CAR
MIN 250

(CWT SIDE)
(CWT
SIDE)

Compensation
Chain

Guide Brush
MIN 750
750
MIN.

Assemble bracket at the bottom of the safety


device and lock U-bolt. Place the CAR at the pit,
and connect the compensation chain to the
bottom of the safety device using U-bolt. Drive
the CAR UP, and connect the compensation
chain to the bottom of the counterweight at the
location where counterweight and CAR meets in
the center of the hoist way. After locking the
whisper flex chain to the CAR and the
counterweight, the gap between the end of the
chain and the hoist way floor should be at least
250mm, and the maximum distance between the
compensation guide brush to the end of the
hanging chain should be at least 750mm.

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8.9 Sliding Guide Shoe (SGS)


Sliding Guide Shoes prevent dislocation of the car moving along the guide rails.

For Car

Speed
Rail K
8K ~ 13K

~600M/Min

105M/Min

HGS121K

HGS122K

18K ~ 24K

HGS230K

The length of SHOE PLATE is 230mm for 121K, 122K.

For Counter
Weight

Speed

~105M/Min

120M/Min

5K ~ 13K

U TYPE

8K ~ 13K

HGS121K

18~24K

HGS231K

18K~24K

HGS230K

Rail K

U Types materials are natural rubber for 5K and Urethane for 8~13k.
[Table 8.1 Slide Guide Shoe Application]

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8.9.1 How to Adjust HGS121K


Install upper and lower sliding guide shoes.

Make sure that the upper and lower gaps between rails and guide shoes are equal.

Gaps between the safety device and lower guide shoes should be same.
The gap between the lower guide shoes and shoe supports should be less than 5mm, otherwise
adjust adjusting nuts.
Adjust the gap between the lower guide shoes and the stopper to be 1.5~2mm.
Adjust the upper guide shoes like the lower guide shoes in ,

110

Install oilers and check if there is any interference moving the car. (Door parts, Switches and
Brackets)

Stopper Rubber

Gap : 1.5~2mm

Adjusting Nut

150

120

Setting Gap : 5mm

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8.9.2 How to Adjust HGS122K


Install upper and lower sliding guide shoes.

Make sure that the upper and lower gaps between rails and guide shoes are equal.

Gaps between the safety device and lower guide shoes should be same.
The gap between the lower guide shoes and shoe supports should be 1.5 ~ 2mm, otherwise adjust
spring. The spring length should be 4~5mm when it is free and 37~38mm when it is compressed.
Adjust the gap between the lower guide shoes and the stopper to be 1~2mm.

140

Adjust same as and in 9.8

186

Gap : 1.5~2mm
1.5~2

Free load : 60mm

150

120

Spring Setting : 5mm

1.5~2

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8.9.3 How to Adjust HGS231K

191

Install upper and lower sliding guide shoes.


Make sure that the upper and lower gaps between rails and guide shoes are equal.
Gaps between the safety device and lower guide shoes should be same.
Adjust the gap between the adjusting nut and the frame of the shoe support to be 5~7mm turning
the adjusting nut 3~4mm.
Adjust the upper guide shoes like the lower guide shoes in 2), 3)
Install oilers and check if there is any interference moving the car. (Door parts, Switches and
Brackets)

249

Gap : 9~11mm
Gap : 9~11mm

Gap : 5~7mm

260

230

Adjusting
Nut

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8.10 Roller Guide Shoe (RGS)


The Roller Guide Shoe is the elevator guiding device that moves on the rail and improves the comfort of
the CAR and elevator system efficiency.
Roller Guide Shoe Application Table

For Car

Speed
Rail K
Under 1800kg

For Counter
Weight

Speed
Rail K
Under 1800kg

~120M/Min

120~180M/Min

RGS125

RGS150C or RGS160

~105M/Min

120~180M/Min

RGS125

RGS150C or RGS160

[Table 8.2 Roller Guide Shoe Application]

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8.10.1 How to Adjust RGS


The elevator CAR should be installed without twist.
During the installation, install it for STILE to be lined up with the rail, and there should be no twist.
Install the roller guide shoe at the CAR top part and bottom part to be vertical to the rail surface, and
if necessary adjust with liner. (Use the weight pendulum and cloth piece to install the roller guide
shoe to have the verticality with the top and bottom surface of the roller guide shoe to be within
0.25mm.)
Fully unscrew the top part RGS stopper, and unscrew the spring to 50% of the specified setting
value. (Balance work preparation)
Unscrew the bottom part RGS stopper and spring to check if the CAR moves freely.
Locate the RGS guide plate to be at the center of the guide rail, and since you need to check which
direction the CAR moves to and how much force is required for the safety device to be located, so
push the CAR horizontally and try to hang on the CAR.
Based on the founding from the above , attach balance weight on the CAR for balancing work.
(Balance work completed)
Adjust the bottom part RGS spring and stopper to the following setting value, and check if CAR SILL
and hatch SILL gap is appropriate, and if the gib of the safety device maintains uniform distance on
the rail. (bottom part RGS setting completed)
Adjust top part RGS spring and stopper to the following setting value. (top part RGS setting
completed)
By driving the elevator manually throughout all the floors, check if hatch door release roller and CAR
door clutch gap is uniform, or if there is any other interference. (Final verification before high speed
operation)
Drive the elevator at high speed to check the comfort, and if it is not satisfactory, check again if the
roller rotates well on the rail surface when it is rotated with adequate force, and if there is a tight
roller, check if the gap with stopper is adequate, and by slowly unscrewing the spring, check if the
roller rotates adequately. (Re check points and adjustments when the comfort is not satisfactory)

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8.10.1 RGS Structure

RGS 80

RGS 125

RGS 150

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RGS Type

Spring[SP] Setting (mm)

Outer Spring Setting (mm)

RGS125

331

RGS150C

381

RGS160

381

RGS80

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Inner Stopper Setting (mm)

Front/back direction: adjust with rollers eccentricity bolt, move maximum of 5mm.

BG direction: adjust with RGS frame and CAR frame mounting location.
[Table 8.3 Spring and Stopper setting value]

[Figure 8.4 RGS125 ~ RGS300]

The spring and stopper setting value has big influence on the rollers lifespan
and the comfort.

The weight on the roller is 11 ~ 22 kgf.

When the RGS adjustment is completed, after driving through all the floors,
check if the roller is rotated with adequate force when it is rotated by hand.

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8.10.2 RGS Adjustment Troubleshooting


1)

2)

If there is a severe RGS vibration :


Check if there is damage on the surface where roller touches the rail, and replace if necessary.
Check if the roller is rotated with adequate force when it is rotated by hand.

If it does not rotate with adequate force


: Check if spring and stopper settings are appropriate

If RGS does not rotate with adequate force after setting value adjustment, and big force is
applied to the roller
: After CAR balancing work, readjust the spring and stopper setting values,
and check if the roller is rotated with adequate force.

If there is a severe vibration in the RGS340 crossway direction (peak to peak of EVA data is
8gal or more) :
Adjust by tightening the friction damper.

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8.11 Rubber Guide Shoe and Urethane Guide Shoe


Install so that the front/back/left/right of the counter frame is placed at the center with respect to the rail.
If there is a level difference between the rails, it caused vibration and shoe abrasion, so check if there is
a rail difference hitch by driving inside the CAR for all floors, and if necessary, adjusts the rail level
difference or perform grinding.

[Figure 8.5 Rubber Guide Shoe (5K)]

[Figure 8.6 Urethane Guide Shoe (8~13K)]

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8.12 How to Assemble Car Header Arm


Fix the Car header arm on Car stile by bolt.

Car Stile
Car Header Arm

90 Rotation

Car Header Arm

Car Stile

8.13 How to Assembling Car Header Vertical Rod


After fixing the Hook on the Top beam, fix the upper Vertical rod shackle.
Fix the lower Vertical rod shackle at hook of the Car header arm.

Car Sill Line


Vertical Rod

Top Beam

151mm

Car Header Arm

Car Stile

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8.14 How to Assemble Car Header Tie Rod


Fix one side of the Tie rod on the Car header arm and the other side of the Tie rod at frame of Car door
operator.

<Looking from the top>

Car Header Arm

Car Door Operator

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8.15 Car Door Operator <M2CA>


8.15.1 Structure

Door Motor

Car Door Operator Fixing Bracket


Car Junction Box Fixing Bracket

Drive Pulley
Frame Fixing Bracket

Clutch (CDL)

Frame ASS'Y

Car Sill

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8.15.2 How to Install M2CA


Car door operator is released as an assembled product. It is fixed by car header arm and door is opened
/ closed by rotation of door motor. Door motion is influenced by installation status. Therefore, it is
required to apply the related dimensions of each component accurately.

Tools

Weight

10, 13mm Spanner

Steel Ruler (150mm)

Horizontal Gauge

17, 19mm Spanner


or Ratchet Wrench

24mm Spanner

Lock the near angle bolt and tap plate to the ceiling plate CAR door operator fixing bracket in the arrow
direction to install the CAR door operator.
Carriage Bolt
Tab Plate

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8.15.3 How to Adjust M2CA


Adjust it so that the slope between the center of the hatch and the center of the Track is 1mm.

Track Center

Entrance Center

1mm

Entrance Piano Wire

The gap between the


entrance piano wire and
The gap between the

the door track should be

edge of the car sill and

37mm.

the door track should be


28mm.

37
28

The gap between the car sill


upper side and the hanger
plate lower side should be HH
+ 1891mm.

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8.15.4 How to Fix the Car Door Operator of M2CA
Fix the car door operator screwing bolts on the frame fixing bracket.

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8.16 Car Door Operator < UM2>


8.16.1 Structure

Ribbed V-Belt
Locking Device

Drive Pulley
Motor
Pulley

Timing Belt

Track

Hanger Plate
Gate Switch

Cable Guide Chain


Clutch

8.16.2 How to Install UM2


Install the car door operator on the car header arm tightening bolts.

Car Header Arm

Bolt Tightening

Car Stile
Car Door Operator

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8.16.3 How to Assemble Safety Edge Cable


Wire Safety Edge Cable with Cable Guide Chain & Cable Tie.
Fix the Cable at regular intervals with Cable Ties. And Check the Operation.

Hanger Plate

Car Door Operator

Safety Edge

Cable Guide Chain

8.16.4 How to Install Door Covers


Install the left, right and middle door covers as below.

Right Cover
Mid Cover
Left Cover

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8.17 CAR Door

Tools

13mm Spanner
or Ratchet Wrench

17mm Spanner

Screwdriver

Screwdriver

15 Monkey Spanner(350mm)

Horizontal Gauge

Straight Ruler (150mm)

10mm Spanner

Assemble the car door and the car door operator by using bolts.

The gap between the

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0.50.2

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eccentric roller and the


bottom of the door track
The gap between the car door

should be 0.50.2mm.

and the entrance column


should be 4 or 6mm.

+1

5-2

The gap between the car door


and the car sill should be 5mm.

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8.17.1 How to Adjust CDL Clutch

Tools

10mm Spanner

13mm Spanner

Horizontal Gauge

Steel Ruler (150mm)

The gap between the entrance center and the fixed cam of the clutch should be 101.8mm.
When the doors are closed, the gap between the keeper and the locking device should be 22~24mm.
Entrance Center Line

Pick-up
Cam

Hanger Plate
22~24mm

101.8mm

Moving Cam

Fixed Cam
CDL Clutch

8.17.2 How to Install and Adjust General Clutch


The gap between the entrance center and the fixed cam of the clutch should be 101.8mm.
When the doors are closed, the gap between the fixed cam and the moving cam should be 680.5mm.

Entrance Center Line

680.5mm

Roller
ROLLER

LINK
Link

Hanger Plate
101.8mm

Fixed Cam

Pick-up
PICKUP
CAM
Moving
Cam

Cam

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8.17.3 How to Adjust Gate Switch


Before the CAR door is completely closed, adjust so that the contact point of the gate switch to be
touched when the gap between the doors becomes 10~12mm.

STROKE 5~6mm

8.17.4 How to Adjust Door Limit Switch


When the CAR door is completely opened/closed, adjust so that the switch is activated
when it approaches at least the half of the OLS (Open Limit Switch) and CLS (Close Limit Switch) body
radial pattern.

Close Limit Switch


Open Limit Switch

Sensor Bracket
Sensor Bracket

<When the Doors are fully opened>

<When the Doors are fully closed>

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8.18 Safety Edge


8.18.1 How to Install Safety Edge

Mechanical
Safety Edge

Multibeam

[SE 400M]

[SE 500M]

[SE 600M]

8.18.2 How to Tie Safety Edge Cable


Wire the Cable Guide Wire using Cable Clamp, Cable Tie and Helical Band as below.

Tapping Screw

[Figure8. 7 Fully installed SE600M Type]

[Figure8. 8 Fully installed SE600M Type]

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8.19 How to Install Car Top Board


Install the car top board on the fixing bracket.

Car Junction Box


M8 Bolt

Car Junction Box Fixing Bracket

8.20 How to Adjust Ribbed V-belt Tension


Adjust the Ribbed V-belt tension turning the door motor counterclockwise.

The direction of the tension adjustment

Door Motor

Ribbed
V -belt

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8.21 How to Adjust Wire Rope Tension


Adjust the wire rope tension shifting the Rope end sockets location.

Rope End

The direction of tension


adjustment
Wire Rope