As-21.01.007 - Main - En.-.1 - Kone Rope and Traction Sheave Replacement Instruction For Schindler Smart

KONE Maintenance Instruction for
SCHINDLER Smart MRL
ROPE AND TRACTION SHEAVE REPLACEMENT INSTRUCTION

KONE
©
AS-21.01.007
All
(-) 2010
2010-12-09
rights
Maintenance
KONE
reserved.
Corporation
Instruction for
FOR SCHINDLER SMART MRL TYPE ELEVATORS
This document is intended to be used by people who are familiar with elevator maintenance and
installation and have received proper training on methods and safety as specified by KONE.
© 2010 KONE Corporation AS-21.01.007

All rights reserved. 1 (20) (-) 2010-12-09
Disclosure prohibited
SCHINDLER Smart MRL
Application Notice
This document does not replace or substitute any instructions or manuals provided by the original
manufacturer of the equipment. The user of this document must always ensure that all equipment
specific instructions are taken into consideration when working with the elevator.
AUTHORIZATION NOTICE
This publication is for informational purposes only. All persons participating and using these
instructions must be qualified to perform such work, are required to have received training as
specified by KONE.
Confidentiality Notice
This confidential KONE document is provided to you only for purposes of supporting the maintenance
of equipment under KONE service contract and it may not be used or its contents disclosed for any
other purpose without KONE's prior written permission. Neither this document nor its contents may be
copied or disclosed to third parties for any reason. KONE reserves the right to prosecute any breach of
this obligation.
DISCLAIMER OF WARRANTIES AND LIABILITIES

KONE reserves the right at any time to alter the procedures reflected in this document. No statement
contained in this document is to be construed as a warranty or condition, express or implied, as to any
product, specification or procedure, its merchantability or fitness for any particular purpose or quality,
or as a modification or representation of the terms of any purchase agreement.
This document is intended for the internal use of KONE only. Any outside party using this document or
relying on the accuracy of or disclosing any of the information contained herein assumes all risks
associated therewith. KONE disclaims any liability resulting from or in connection with any outside use
or disclosure of any part of the information in this document. KONE shall not be held liable for any
typographical, factual, or other errors or omissions contained in this document, nor for any outside
party's interpretation or use of the instructions.
Trademark Notices
SCHINDLER and SCHINDLER Smart are registered trademarks of Schindler Elevator Company.
"KONE, MonoSpace, MiniSpace, EcoDisc, TranSys, Alta, KoneXion, KONE ECO3000 and all other
product names are trademarks or registered trademarks of KONE Corporation in various countries."
Copyright Notice
Copyright ©2010 KONE Corporation
All rights reserved. No part of the contents of this document may be copied, reproduced or transmitted
in any form or by any means, or translated into another language or format, in whole or part, without
prior written permission of KONE Corporation.

SCHINDLER Smart MRL
CONTENTS
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Maintenance method safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Before going to the site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Tools to be taken to the topmost floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Tools to be taken to the second topmost floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Tools to be taken to the bottom floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 ROPE AND TRACTION SHEAVE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3 Testing the safety gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Installing the hoisting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.5 Removing the car paneling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.6 Securing the car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.7 Replacing the traction sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.8 Replacing suspension ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.9 Putting the elevator back into service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.10 Finalizing the replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 APPROVALS AND VERSION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SCHINDLER Smart MRL
1 INTRODUCTION
This document describes rope and traction sheave replacement method and actions for SCHINDLER
SMART MRL type elevators.
1.1 Related documents
The following documents are related with maintenance of SCHINDLER SMART type elevators:
• AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and autowalks
• AM-09.13.004 Rope tensioning
• AR-21.01.002 Spare parts manual for Schindler Smart MRL type elevators
• AS-01.01.004 Take Care, End user safety focal points in elevator maintenance
• AS-01.03.101 On-site maintenance safety manual
• AS-21.01.002 Rescue instruction for Schindler Smart MRL type elevators
• ASG-21.07.002 Inspection instruction for safety gear in SCHINDLER SMART MRL type elevators
• ASG-21.01.003 Preventive maintenance instruction for Schindler Smart MRL type elevators
• ASG-21.01.004 Maintenance pocket book for Schindler Smart MRL type elevators
1.2 Abbreviations
MRL Machine Roomless Elevator

RDF Recall Drive Feature
TL Door Telescopic Left Side
TR Door Telescopic Right Side
2 ENVIRONMENTAL ISSUES
Hazardous waste material must be taken care of according to the local requirements and KONE
Environment Strategy.

SCHINDLER Smart MRL
3 SAFETY
For general safety precautions and personal safety, refer to AS-01.03.101.
3.1 Maintenance method safety
Note the following safety items when working with SHINDLER SMART MRL type elevators:
• Personal safety equipment must be used as required. Wearing hard hats is compulsory.
• The elevator has to be taken out of service always, when maintenance technician is committing
normal maintenance, inspection or repair visit.
• The car must always be held by two different supports if the ropes are slack or removed. A secured
safety gear and a strap between car fixing eyelet and shaft top hook, or between car and rope
fixing on the opposite side of machine are to be used.
• Never use the blocking device as a car support, it is designed to be used as security only if
suspension ropes are in place and tight. If the blocking device is used, two main supports are still
compulsory.
• Use additional fences or guarding, when there is a danger that outsiders enter working zone or
there are parts or tools causing risks of tripping on the landing.
• Use only inspected and approved lifting devices.
• Use correct manual lifting techniques.
• Prevent the reconnection of auxiliary emergency power supplies etc. The cover of the drive module
must be kept closed always when not working with the module, even if the main power has been
switched OFF.
• Two maintenance technicians are needed to perform the rope replacement. If necessary, use a
suitable communication system (for example, cellular phones).
3.2 Before going to the site
Site survey must have been done before starting the work. Rope replacement plan must have been
made and method chosen. Bring the site survey on the site. Check the site conditions have not
changed after doing the site survey. Go through the check list.
Check that the replacement kit is complete, the list is provided with the kit itself. Check case by case, if
you need special tools.

SCHINDLER Smart MRL
4 TOOLS
Following tools are required to complete the maintenance tasks:
4.1 General
Part Number Tool Illustration / Note

Normal hand tool set
Cleaning cloth
Safety barriers
4.2 Tools to be taken to the topmost floor

Chain hoist Minimum capacity 1000 kg
1007087.wmf
Eye bolts ETS Gaston Roze, minimum capacity 1500 kg
42 32 41.2 120
KM278691 Rope cutter
1018279.wmf

SCHINDLER Smart MRL

KM717384 Rope clamp
Rope reeler
KM265173 Three-step ladder
1070210.wmf
Safety harness

SCHINDLER Smart MRL

Extractor box W140 Facom outside puller U32T15-50.
The outside puller is one specific tool of the
extractor box for the machine W140.
KM654068G01 Guide rail clamps 2 pcs.
1011810.wmf
KM266828 Parking chains 2 pcs. Chain for securing.
1007070.wmf
Hoisting chain for Minimum capacity 1000 kg

securing the traction
sheave
4.3 Tools to be taken to the second topmost floor

Protective cover Thick cardboard or plywood
Suction cups 2 pcs.
4.4 Tools to be taken to the bottom floor

Protective cover Thick cardboard or plywood
Pit props of 1.7 m 2 pcs.
1070198.wmf

SCHINDLER Smart MRL

KM993797 Prop blocks 2 pcs.
KM265173 Three-step ladder
1070210.wmf

SCHINDLER Smart MRL
5 ROPE AND TRACTION SHEAVE REPLACEMENT
5.1 Safety measures
Step Action Illustration/Note

1 Place “Under Maintenance” signs at every
landing.
2 Secure the working spaces with barriers at Protect the walls and the floor to avoid
the bottom floor, top most floor and second damage.
topmost floor.
3 Take the elevator out of service. Ensure the car is empty.
5.2 Preparations

1 Check that the replacement traction sheave Traction sheave diameter is 320 mm on a
matches the existing installation. 1000 rpm machinery only.
Traction sheave diameter is 340 mm on a
1500 rpm and 1950 rpm machineries.
2 Check that the rope diameter is correct.
3 Place the support beams and the blocks in
the pit.
4 Protect the floor at bottom landing, topmost
landing and second topmost landing.
5 Take the tools, traction sheave and the
ropes to the topmost floor.
5.3 Testing the safety gear

1 Refer to ASG-21.07.002 Inspection
instruction for safety gear in SCHINDLER
SMART type elevators.
WARNING
Do not continue with the rope and traction sheave replacement operation if the safety gear test
fails.

SCHINDLER Smart MRL
5.4 Installing the hoisting tools
This task requires one maintenance technician wearing a safety harness on the car roof and another
maintenance technician at the topmost landing.

1 Drive the car on RDF to a position below the The ceiling is composed of a single panel.
topmost landing to access the car roof
safely.
2 Check that the inspection drive unit on the Push down the stop button on car roof, the
car roof operates correctly. elevator should not move.
3 Dress up the safety harness, if not done
earlier.
NOTE! Put the life line around the guide rail
fixing.
Attach the life line to the safety
harness.
4 Go to the car roof. Switch the elevator to

inspection mode.
5 Replace the eye bolts (ETS Gaston Roze)
to the elevator shaft ceiling.
Install the hoisting chain to the closest eye
bolt above the traction sheave.
1071948.wmf
6 Drive the car on inspection to the second

topmost floor.

SCHINDLER Smart MRL
5.5 Removing the car paneling
Some car ceiling and wall panels must be removed to arrange access to the car roof the emergency
trap door. This task requires one maintenance technician inside the elevator car and another on the car
roof.

1 Remove the ceiling panel and place it on the
second topmost landing.
2 Remove the lateral wall panel with suction
cups.
Place the panel on the landing of the second
topmost floor.
3 Drive and position the car on inspection to

work on the traction sheave.
4 Get off the car roof.
5.6 Securing the car
This task consists of supporting the counterweight in the pit and securing the car with parking chains
and safety gear. No work must be done at two different levels in the elevator shaft at the same time.
5.6.1 Supporting the counterweight

1 Push down the pit stop button and enter the
pit.
2 Remove the counterweight screen and
place it on the bottom landing.
3 Place the support blocks and beams under
the counterweight.
4 Exit the pit and release the pit stop button.
5 Return to the topmost landing.

SCHINDLER Smart MRL
5.6.2 Securing the car with safety gear and parking chains

1 Go to the car roof. Ensure no one is working below in the shaft.
2 Install the guide rail clamps. Attach the
parking chains to the car sling, around and
each side of the car.
3 Install a rope clamp on the car side at the
lowest possible level.
4 Attach the chain hoist to the rope clamp.
5 Get off the car roof.
6 Raise the car with the chain hoist until the
ropes are loose.
7 In the maintenance access panel, activate
the Down overspeed governor mechanical
trigger.
8 Lower the car to the safety gear using the

chain hoist.
9 Go to the car roof.
10 Tighten the parking chains.
11 Remove the rope clamp.

SCHINDLER Smart MRL
5.7 Replacing the traction sheave
This task requires one maintenance technician wearing safety harness on the car roof and one
technician at the topmost floor.

1 Switch the earth leakage circuit breaker for
drive (JFIS) OFF.
2 Remove the protection covers from the
traction sheave.
3 Lift off the suspension ropes from the

traction sheave and put them on the
machine bed plate.
4 Attach the chain hoist to the traction sheave.
5 Remove the cotter of the traction sheave.
6 Using the Facom outside puller, remove the
traction sheave and place it on the landing.
7 Remove the outside puller.
8 Clean the surface of the traction sheave and
shaft.
9 Fasten the new traction sheave to the chain Observe the position of the cotter.
hoist. Retain the access to the cotter after lifting
the traction sheave onto the shaft.
10 Coat the shaft with copper paste.
11 Using the outside puller, fit the traction
sheave onto the shaft.
12 Put the cotter into place.
13 Fit the suspension ropes back on the
traction sheave.

SCHINDLER Smart MRL
5.8 Replacing suspension ropes
This task requires one maintenance technician wearing safety harness on the car roof and one
technician in the pit. They must not work in the elevator shaft at the same time!
Step Counterweight Elevator car

1 Remove the rope guide. Remove the rope guide.
NOTE! The pitched rope is changed first.
2 Clamp ropes 1 and 2 together so that rope 1

does not fall when detached.
3 Unhitch rope 1 from the counterweight Unhitch rope 1. Refer to table 1.
frame. Refer to table 2.
4 Connect old rope 1 with the new rope 1.

SCHINDLER Smart MRL
Step Counterweight Elevator car

5 Once the old rope and the new rope are
connected, pull the old rope down to the
bottom landing.
6 Hitch the new rope to the counterweight
frame.
7 Once the new rope is fastened to the
counterweight frame, clamp the new rope 1
to old rope 2.
8 Hitch the new rope 1 to the car.
9 Cut the rope 1 and secure it.
10 Repeat steps 2 through 9 proceeding through ropes until all the ropes are replaced.
11 Install the rope guide and pitch rope 1. Install the rope guide and pitch rope 1.
Table 1: Location of ropes on the car side.

Load 320 kg 450 kg 630 kg
TR doors 6 to 9 5 to 9 5 to 10
TL doors 2 to 5 1 to 5 1 to 6
Table 2: Location of ropes on the counterweight side.

Load 320 kg 450 kg 630 kg
TR doors 8 to 11 7 to 11 7 to 12
TL doors 2 to 5 1 to 5 1 to 6
5.9 Putting the elevator back into service
5.9.1 Getting the car off parking chains and safety gear
Step Action Note/Illustration

1 Check that the ropes lay properly on the
traction sheave.
2 Install the protection covers to the traction
sheave.
3 Attach the rope clamp to the lowest possible
point above the car roof.
4 Attach the chain hoist to the rope clamp.
5 Remove the parking chains and guide rail
clamps.
6 Go to the landing.

SCHINDLER Smart MRL

7 On the maintenance access panel, push the
overspeed governor mechanical trigger to
deactivate the overspeed governor.
8 Raise the car upwards with the chain hoist

to release the safety gear.
10 Remove the chain hoist.
11 Remove the rope clamp.
12 Go to the landing.
5.9.2 Removing the counterweight supports

1 Release the counterweight by removing the
support beams and blocks underneath the
counterweight.
2 Switch the power ON and drive the car on
RDF to the topmost floor.
3 Switch the power OFF.
4 Check the distance between the The distance must be greater than 150 mm.
counterweight buffer and counterweight
frame (car top over travel).
5 Reassemble the counterweight screen.

SCHINDLER Smart MRL
5.9.3 Assembling the car walls and ceilings
This section describes the procedures for assembling the car wall and ceiling. One technician must be
on the car roof wearing security harness, one technician inside the elevator car.

2 Switch the power ON.
3 Drive the car on inspection to the second
topmost floor.
4 Install the lateral side wall panel back into
place using suction pads.
5 Install the ceiling panel.

6 Drive to the topmost floor.
7 Go to the landing and set the elevator to
NORMAL mode.
5.10 Finalizing the replacement

1 Drive the car up and down two or three
times before you check and equalize the
rope tension.
2 Check the ropes for slackness.
3 Clean the elevator shaft and all working Car roof, machine room and landings
areas.
4 Remove the Under maintenance signs from
the landings.
5 Dispose of old ropes and other waste
material according to local regulations and
KONE Environment Strategy.

SCHINDLER Smart MRL
6 APPROVALS AND VERSION HISTORY
Compiled by: Information Product Author Hannu Tormanen

Checked by: Third Party Equipment Competence Center Director Fabien Fargnier
Third Party Equipment Maintenance Specialist Joao Filipe Domingos
Approved by: SEB Maintenance Development Manager Seppo Valliovuo
Translation approved by:
Issue Date Description of Change Ref CR Approved by

- 2010-12-09 First issue S. Valliovuo

SCHINDLER Smart MRL


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As-21.01.007 - Main - En.-.1 - Kone Rope and Traction Sheave Replacement Instruction For Schindler Smart

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KONE Maintenance Instruction for

SCHINDLER Smart MRL

ROPE AND TRACTION SHEAVE REPLACEMENT INSTRUCTION

FOR SCHINDLER SMART MRL TYPE ELEVATORS

© 2010 KONE Corporation AS-21.01.007

DISCLAIMER OF WARRANTIES AND LIABILITIES

© 2010 KONE Corporation AS-21.01.007

© 2010 KONE Corporation AS-21.01.007

1.1 Related documents

MRL Machine Roomless Elevator

© 2010 KONE Corporation AS-21.01.007

For general safety precautions and personal safety, refer to AS-01.03.101.

3.1 Maintenance method safety

3.2 Before going to the site

© 2010 KONE Corporation AS-21.01.007

Following tools are required to complete the maintenance tasks:

Part Number Tool Illustration / Note

4.2 Tools to be taken to the topmost floor

Part Number Tool Illustration / Note

Eye bolts ETS Gaston Roze, minimum capacity 1500 kg

KM278691 Rope cutter

© 2010 KONE Corporation AS-21.01.007

Part Number Tool Illustration / Note

© 2010 KONE Corporation AS-21.01.007

Part Number Tool Illustration / Note

KM266828 Parking chains 2 pcs. Chain for securing.

Hoisting chain for Minimum capacity 1000 kg

4.3 Tools to be taken to the second topmost floor

Part Number Tool Illustration / Note

4.4 Tools to be taken to the bottom floor

Part Number Tool Illustration / Note

© 2010 KONE Corporation AS-21.01.007

Part Number Tool Illustration / Note

KM265173 Three-step ladder

© 2010 KONE Corporation AS-21.01.007

5 ROPE AND TRACTION SHEAVE REPLACEMENT

5.1 Safety measures

Step Action Illustration/Note

Step Action Illustration/Note

5.3 Testing the safety gear

Step Action Illustration/Note

© 2010 KONE Corporation AS-21.01.007

5.4 Installing the hoisting tools

Step Action Illustration/Note

4 Go to the car roof. Switch the elevator to

6 Drive the car on inspection to the second

© 2010 KONE Corporation AS-21.01.007

5.5 Removing the car paneling

Step Action Illustration/Note

3 Drive and position the car on inspection to

5.6 Securing the car

5.6.1 Supporting the counterweight

Step Action Illustration/Note

© 2010 KONE Corporation AS-21.01.007

Step Action Illustration/Note

8 Lower the car to the safety gear using the

© 2010 KONE Corporation AS-21.01.007

5.7 Replacing the traction sheave

Step Action Illustration/Note

3 Lift off the suspension ropes from the

© 2010 KONE Corporation AS-21.01.007

5.8 Replacing suspension ropes

Step Counterweight Elevator car