Installation Manual for XX Translation

XXX Translation
Alimak SE-series
Permanent Lifts

This manual is only applicable if the manufacturing number indicated below corresponds to the manufacturing number stamped on the identification
sign of the equipment. Where there is a conflict contact your ALIMAK representative.

YOUR LIFT HAS:

Part No. 9097 716 - 1 08

Manufacturing No.: Year:
2006 - 03 - 01

BACK
 FOREWORD
This product is designed and manufactured to meet strict quality
and safety standards. The manual is intended to provide
instructions to installation personnel in order to safely control
installation and operation of Alimak lifts.

Potential risk for user or equipment is indicated in the following

way in this book:

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in
death or serious injury.

WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.

CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in
minor or moderate injury.

IMPORTANT: Information with these headings

indicates the possibility of damage
to the equipment.

Photographs and drawings are illustrative only and do not necessarily show the
design of the products on the market at any given point in time. The products must
be used in conformity with applicable practice and safety regulations. Specifications
of the products and equipment presented herein are subject to change without notice.
CONTENTS
TECHNICAL DESCRIPTION

A
TECHNICAL DATA & SPECIFICATIONS

B
IMPORTANT SAFETY INSTRUCTIONS

C
OPERATING INSTRUCTIONS

D
SERVICE AND MAINTENANCE

E
ELECTRIC TROUBLESHOOTING

F
FOUNDATION

G
LIFT MAST AND TIES

H
PREPARATION BEFORE INSTALLATION

I
INSTALLATION

K
APPENDIX:
Tightening torque
Location of landing door relative the mast tubes
Optional details for attaching the door front
Lighting in pit

See Technical Description for chapters A, B, G, and H.

See Operator’s Manual for chapters C, D, E and F.

Copyright © Alimak AB 2002.

All rights reserved.
IMPORTANT SAFETY INSTRUCTIONS C0

Safety instructions .......................................... C 1

ALIMAK 34440 - 1/01

Important Safety Instructions
C1
General
Over the years serious accidents have occurred during the erection
and dismantling of rack and pinion lifts and construction hoists.
Common to these accidents has been the ”human factor”, i.e.
non adherence to proper safety procedures and common sense.
This document affects those personnel involved in the erection,
dismantling and servicing of such equipment.

Some examples:
Leaning over the safety railing on the car roof while the lift is
moving upwards can cause you to be struck by a tie or a cable
guide.
Incomplete installation of mast bolts can cause separation of the
mast sections, leading to the fall of the car with subsequent loss c1

of life or serious injuries.

Not following the correct tie-in schedules.
Avoid the risk of accidents by carefully studying these instruc-
tions regularly. Think clearly. Do not rush the work and
always check to make certain that the work is being done
properly. SAFETY FIRST!

Safety instructions
Local safety regulations
– All local regulations shall apply.

Weather conditions – installation outdoors

– Lifts must not be erected or dismantled in wind speeds
exceeding 15 m/sec. (33 mph) or as governed by local
regulations where more stringent.
c2

Preparation
These diagrams are only typical
– The Maintenance Manual and Installation Manual are to be
carefully studied before work begins.
– The site of erection/dismantling must be made secure from
falling objects by barricading or roping off the area.
– No admittance to the lift car during erection or dismantling
by unauthorized personnel.

Safety equipment and protective clothing

– Prescribed safety equipment and clothing such as hard hat,
safety shoes, safety harness, etc. shall be used.
– Loose fitting clothes such as scarves must not be used as
they might become entangled in moving parts.

ALIMAK 34441 - 1/01

C2
c3
Always lock the main ”ON/OFF” switch
with a padlock to prevent unintentional
operation while service/inspection work
is carried out.
c4
The main ”ON/OFF” switch must be in
the ”OFF” position before the panel
door can be opened.
General
– Read all Warning and Instruction Signs.
– Keep the work area clean. Any oil spillage must be removed
immediately to avoid the risk of slipping.
– Never climb on the mast.
– During erection, dismantling or hoistway inspection, the lift
must always be operated from the car roof. When working
from the car roof take precautions to avoid being struck by
mast ties, cable guides, landings, structure openings, etc.
while lift is moving.
– When the control equipment on the car roof is to be left on
temporarily during installation / dismantling or service, the
main switch in the control panel of the lift car must be
switched off and locked in order to ensure no accidental
moving of the car.
– Before carrying out any service work, the ”Normal/
Inspection” switch in the electric cabinet on lift car must be
placed in the ”Inspection” position.
This is very important especially for lifts with ”Auto return”
or similar remote control function.
– Under no circumstances the lift shall be driven if there is a
person inside the base enclosure, on the mast or a tie.
– Complete each item of work before starting a new one or
taking a break. This is especially important when bolting
or unbolting mast sections and ties.
Mast and mast tie
– The maximum tie distance and mast overhang indicated in
the applicable Installation drawing or Manual, must be
adhered to.
– Bolted joints shall always be tightened to the required torque
as prescribed.
– If any structural damage or severe corrosion is seen on such
items as mast sections or mast ties, the lift must be immedia-
tely taken out of service and the extent of the damage be
determined and corrective action taken before the lift is put
into service again.
Electrical power
– Work performed on electrical equipment must be carried out
by competent personnel, trained for such work. The power
supply must be switched off and locked before work is
performed.
ALIMAK 34442 - 1/01
Accessible areas adjacent to hoistway
C3
– Scaffolding, platforms and other accessible areas located closer
than 0.5 m (1 ft. 8 in.) must be provided with 2.5 m (8 ft.)
high enclosures or in accordance with local regulations.

Authorization of lift personnel

– A routine that guarantees continuous product training
(Authorization), that was done during the lift installation,
must be set and maintained by a responsible person. Contact
Alimak or an Alimak representative, if this training is
required.

Illumination
– Adequate lighting (minimum 50 lux) shall be provided to
illuminate the site for the full travelling height of travel of
the lift. (By customer!)

Lightning strike
– The lift shall be earthed (grounded) so that the charge from a
lightning strike is connected to earth.

Working under the lift car

– When working under the lift car, always secure the car
mechanically, by safe means (i.e. a 95 x 95 mm (4 x 4 in.)
wooden plank). The lift’s main disconnect switch must
always be turned off and padlocked.

Spare parts
– Unauthorized spare parts are not to be used. Only ”Alimak
Genuine Spare Parts” are to be installed.

Exchange of safety components

– Detailed inspection and control of these components shall be
done per separate instructions and before the lift is put into
operation.

Inspection after major modifications or accidents

– Inspection and testing should be carried out after major
modifications or after an accident to make certain that the
lift operates properly.

When servicing a lift with both A and B door

– Always check that the lift is driven to a landing level which
allows exiting of the car without interference of the
electric panel door.

ALIMAK 34443 - 1/01

PREPARATIONS BEFORE INSTALLATION I0

General ............................................................ I 1
Permission ....................................................... I 1
Erection place.................................................. I 1
Foundation ...................................................... I 1
Delivery inspection ......................................... I 1
Arrangement of power supply....................... I 2
Client's power supply ...................................... I 2
Power supply from generator set at jobsite I 4
Voltage drop in the power supply ................. I 4

ALIMAK 34430 - 1/02

Preparations before installation
I1
To install your rack and pinion lift as efficiently and safely as
possible and at lowest cost, it is important that the following
preparations be made before the erector is called and the installa-
tion is started.
STOP

Permission
Make sure the chosen site of erection meets the requirements set
out by local authorities for safety and inspection and that their
permission, if necessary, to install the hoist/lift has been obtained. i1

Erection place
Prepare the installation site so that electric power, light, lifting
equipment and tools are available and there is adequate access
for the lift transporter – beware of overhead obstructions.
If possible, prepare for the installation of ties and landing
accessories such as supports, platforms and railing. Suitable
places for attaching the ties are vaults, balconies or other
concrete or steel structures. See applicable Installation drawing.
Remember that these structures must be strong enough to absorb
the reaction forces of the ties and landing door assemblies.
All mast sections should be stored on dry firm ground and as
close to the erection site as possible.

Foundation
Prepare the foundation with parts required for attaching the base
frame of the mast. See chapter ”Foundation” in the manual
Technical Description.
IMPORTANT! Make sure before pouring the foundation
i2
that the measurement between the
foundation frame and the face of the
hoistway corresponds to the ties to be used.

Delivery inspection
Check the delivery against shipping lists and look for transpor- Transportation
damage?
tation damage. Shortages?
Should there be any damage, report the same to the responsible
transportation insurance company within 7 days from the date
of arrival of the goods.
Other claims should be made to ALIMAK representative within
the same period.
i3

ALIMAK 34431 - 1/02

I2 Arrangement of power supply
Direct On Line (DOL) starting of electric motors results in a very
high starting current. The current must overcome the resistance
in the cables which results in a voltage drop. This voltage drop
occurs not only in the trailing cables, but also in the power
supply cable installed between the jobsite distribution board and
the electric panel ”B” at the base. The total voltage drop is the
sum of the voltage drop in all the cables. The consequence of
the voltage drop is a substantial reduction in the output torque
i4
of the motor.
In order to avoid starting problems it is of the utmost importance
that the main power supply is adequately sized with respect to
the starting current and the voltage drop. The following data
should be noted:
– During starting conditions, in the upward direction with rated
load, the voltage drop must not exceed 15% of the rated
voltage when measured at the motor terminals. In the base
panel, the voltage drop of the incoming power supply
terminals must not exceed 3% of the rated voltage during the
starting conditions.
– Once the rated speed is established during upward travel with
rated load, the voltage drop must not exceed 5% of the rated
voltage when measured at the motor terminals. In the base
panel, the incoming power supply voltage should, in practice,
not drop at all, i.e. not exceed 1 – 2 % drop.
– Except for the above mentioned supply voltage levels
during start and running conditions, the quality of the
main power supply to the lift/hoist must be in accordance
with the requirements of EN 50160:1999.

Client’s power supply

Supply cables to hoists and lifts with DOL or Y/D starting
The 3-phase power supply cable from the jobsite distribution
board to the ”B” panel at the base can be calculated from the
f4 formulas below. The formulas are applicable for the most common
types of lifts and lifts having 1, 2 or 3 motor drive machinery
with DOL-starting at 400V, 50Hz and 460V, 60Hz.
Note: If an earth leakage circuit breaker, ELCB, (ground fault
circuit breaker) is to be used, the trip-out value should be
chosen for equipment protection i.e. 500mA.
Use of 30mA ELCB is not recommended as it continuously
trips due to the motor starting current.
The following table should only be used for guidance.
See actual lift data.

ALIMAK 34432 - 1/02

 I3
No. of Motor power Motor power Power supply Minimum Fuse at *
motors continuous / 25% continuous / 25% cable to Base panel. recommended Cu- 400V 50Hz
intermittent 50 Hz intermittent 60 Hz Conductor area, copper Conductor area 460V 60 Hz

1 4.8 / 7.0 kW 5.7 / 8.5 kW a = L x 0.09 mm2 6 mm2 25 AT

1 7.5 / 8.8 kW 8.6 / 10 kW a = L x 0.17 mm2 10 mm2 35 AT
2 7.5 / 8.8 kW 8.6 / 10 kW a = L x 0.34 mm2 16 mm2 63 AT
1 i11 / 13 kW 12.6 / 15 kW i a = L x 0.25 mm2 10 mm2 35 AT

a = Conductor area mm2, Cu. To be rounded up to standard sizes, i.e. 10, 16, 25, 35 mm2 etc.
L = Length in m of the 3-phase power supply cable from the jobsite distribution board to the Base panel
For conductor sizes in AWG Nos., see conversion table below.
* In order to avoid single phasing should a main fuse blow, we strongly recommend the power supply to be fused
by means of a three-phase circuit breaker.

Supply cables to hoists and lifts with VFC

(Variable Frequency Converter)
The size of the power supply cable must always comply with
Rules and Regulations stipulated by the local Authority for
electrical installations. The Customer's power supply cable must
also be sized to ensure that the voltage drop in the Base panel
does not exceed 3% when starting with full load with the lift mo-
ving in the upward direction.
The size of the power supply cable can be calculated by follo-
wing formula:
a = L x P x 0.0056... ...where
a = Conductor area in mm2 copper
L = Length in m of the power supply cable from distribution
board to the Base panel
P = Drive motor power in kW on the lift
Installed motor power Minimum cable size
kW (S3 = 25% ED) (copper) mm2
3 – 5.5 4
6 – 10 6
11 – 20 10
21 – 30 10
31 – 40 16
41 – 50 25
51 – 75 (35) 50

IMPORTANT! The power supply cable must be sized

according to the drive motor power installed on the hoist/lift.
Minimum size of the supply cable is shown on the table
above. The table refers to supply voltage 400V to 460V,
50/60Hz.
See note re: earth circuit breaker on previous page.

ALIMAK 34433 - 1/02

I4 Power supply from generator set at jobsite
Required generator power
It is recommended that the generator be capable of providing a
starting current of A amperes at rated voltage. If this is not
possible, the guidelines below can be used.
For DOL starting of Alimak lifts having 1 or 2 drive motors we
suggest the following generator sizes:
– 1 motor drive size 112, 7.0 kW (8.5 kW) 65 kVA min.
– 1 motor drive size 132, 8.8 kW (10 kW) 70 kVA min.
– 2 motor drive size 132, 8.8 kW (10 kW) 140 kVA min.
It should be noted that the recommended generator sizes are
large due to the fact that the DOL starting of the motor(s) draws
a large current resulting in a voltage drop which would cause
the contactors to oscillate on and off. A smaller generator might
be used but this can only be established by practical experience
related to a specific make and model of the generator set.
For VFC (Variable Frequency Converter) operated lifts the
generator size in kVA should be approximately 2 x the installed
motor power in kW, (S3 = 25% ED).

Voltage drop in the power supply

Typical symptoms
– The lift will not start with the full rated load.
– The brakes will not lift when starting in the Up-direction.
– The contactors oscillate on and off (”chatter”) when starting
with full load in the Up-direction.
– The contacts of the Up and the main contactors are damaged.

Steps to be taken to overcome a voltage drop problem at the

jobsite
The best method to avoid any voltage drop problem is to make a
proper engineering review of the conditions at the job site
before installing the lift. When installed, the options are limited.
However, should a situation occur where the power supply seems
to be insufficient, it is important to determine whether this
depends on the voltage drop in the power supply or something
else. Use an instrument to measure the incoming power supply
voltage in both the B-panel at the base and the M-panel on/in
the car. Take the readings during starting conditions in the

ALIMAK 34434 - 1/02

 I5
upward direction with rated load in the car. If the voltage drop
exceeds the values given above, one or more of the following
steps can be taken:
1. Increase the conductor size in the power supply cable from
the jobsite distribution board to the B-panel at base.
2. Increase the conductor size in the trailing power cables
between the base panel and the car. Due to mechanical and
performance reasons, the conductors in the trailing cable
should not exceed 16 mm2.
The fixed cable to the junction box at 1/2 lifting height can
be increased in size.
3. Reduce the rated load.
4. Install a step-up transformer xxx/690V in the power supply
in order to increase the voltage.
Note! Motor windings must be adaptable to this higher voltage.
Otherwise the motor must be changed. To give the best possi-
ble advantage, the step-up transformer should preferably be
located close to the jobsite distribution board.
5. Use some sort of soft start equipment.

If you have any questions regarding the power supply cables

or the trailing cables, please contact Alimak for advice.

Conversion table mm2 to AWG

AWG No. mm2 Nearest IEC std.

(American Wire Gauge) mm2

0000 107.2 95 alt. 120

000 85.03 70 alt. 95
00 67.43 70
0 53.48 50
1 42.41 35 alt. 50
2 33.63 35
4 21.15 16 alt. 25
6 13.3 10 alt. 16
8 8.366 6 alt. 10
10 5.261 4 alt. 6
12 3.309 2.5 alt. 4
14 2.081 1.5 alt. 2.5
16 1.309 1.5
18 0.8231 0.75 alt. 1.0

ALIMAK 34439 - 1/02

INSTALLATION K0

General ............................................................ K 1
Principles for assembling a R&P lift ............ K 2
Bottom mast support / Buffers ...................... K 4
Lower limit cams ............................................ K 6
Car ................................................................... K 8
Trailing power cable....................................... K 10
Main power supply ......................................... K 11
Mast / Guide rail ............................................ K 12
Erection and handling of mast sections ........ K 14
Mast ties .......................................................... K 16
Introduction to the principles
of cable installation......................................... K 18
Cable installation instructions....................... K 20
Top buffer........................................................ K 26
Upper limit cams ............................................ K 27
Pit, base enclosure and landings.................... K 28
Final commissioning procedure ...................... K 35

Installation must be carried out by

competent personnel, trained by
ALIMAK for such work.

ALIMAK 34485 - 1/05

Installation
K1
General
During the installation phase the responsible erector must carry
out visual inspection of all components to determine if there is
any transportation damage.
Should damage to safety critical parts occur, the parts must be
replaced – if there are any questions contact ALIMAK’s
representative.

WARNING !
Falling object hazard
Barricade the restricted area on the ground
according to local regulations.
Failure to follow this warning can cause death or
personal injury.

Hoist
IMPORTANT! may
Foronly beof used
identification correct bolt
and nut dimensions as well as
by authorized
quantity – please see enclosed
personnel
Spare Parts Manual.
9047 760 - 101

Check space requirements before installation begins

Determine that there is enough space for the lift installation
relative to the lift car dimension and door location.
Review General Layout Drawing (Installation drawing) or the
dimensional figures in the appendix ”Location of landing door
relative the mast tubes” at the end of this manual.

ALIMAK 34486 - 1/05

K2 Principles for assembling an Alimak R&P lift
Accuracy is necessary for the successful assembly of a rack and
pinion driven lift.

Survey of hoistway.
1. Review General Layout Drawing (Installation drawing) to
determine location of lift on the structure.
2. Utilizing plumb bobs made up of a weight and piano wires
drop lines down from the highest point in the hoistway.
Determine the plumbness of the structure in order to ensure
that no part of the structure will intrude into the hoistway
space.

Straight edge Same distance

on both sides

Plumb line Plumb line

Nail or
similar
device

Please note that this has to be checked carefully.

3. Determine from the drawings the required location of the

mast base frame. Adjust the location in accordance with the
hoistway survey.
Keep in mind that it is easier to increase the distance from
the face of the structure than to decrease this distance.

4. Install the base frame, lift mast and lift car in accordance
with instructions at the end of this manual. Maximum
permitted deviation from the plumb line is 2 mm (1/16’’) on
a mast section length = 1.5 m (4’-11 3/8’’).

IMPORTANT !
Do not install landing doors before installation of
the mast and car.

ALIMAK 34487 - 1/01

Checking the vertical alignment of the lift car support frame
K3
using a plumb line and alternatively a plumb laser tool
5. Use a properly weighted plumb line to adjust the support
frame of the lift car vertically relative to the mast in BOTH
directions. In order to achieve this the guide rollers of the
support frame may require adjustment.
The better the accuracy at this phase of the installation, the
less difficult it will be to adjust the landing doors when they
are installed.
Note that the adjustment of the car support frame guide
rollers does not affect the upper machinery plate guide
rollers.

6. When the landing doors are installed it is very important that

they be plumb and parallel to the car doors. This is essential

When possible create a service space at the bottom landing

in order for the interlock to work properly.
Review General Layout Drawing (Installation drawing) to
determine location of landing doors or the appendix

so that the machinery is accessible from the back.

”Location of landing door relative the mast tubes” at the end
of this manual.

IMPORTANT !
During installation of the mast, car frames and landing
doors the use of a plumb bob is preferable to a spirit
level in order to achieve better accuracy.
Landing doors MUST be parallel to the lift car door.

If the guide rollers and safety brackts on the car frame for
some reason needed to be dismantled
Ensure that ALL rollers and safety brackets will be reinstalled
with the correct location and with their previous adjustment
delivered from the factory. Make proper notes – or better use a
camera for pictures.
The guide and counter rollers are correctly adjusted when
delivered from factory. Always mark the proper roller
adjustment with a permanent ink filt pen or mark with a center
punch before disassembling.
The guide rollers are designed with an eccentric shaft to make it
possible to adjust the car relative the mast tubes – and
furthermore allow the rollers to be adjusted with the proper
roller play.
Faulty adjustment means improper function and unnecessary
wearing.
Missing and incorrectly reinstalled safety brackets (delrail-
ment protections) can cause serious accidents.

ALIMAK 34488 - 1/08

K4 Bottom mast support / Buffers
1. Sweep the concrete slab/base clean.
Lift the bottom mast onto the foundation and fasten the bolts.
Refer to General Layout Drawing (Installation drawing) for
details of expansion bolts or other attachments – install the
bottom mast support on the foundation.
Drilled holes and tightening torques shall be in accordance
with the bolt manufacturer's requirements.
Level the mast by inserting solid steel shims below the
bottom mast support. The shims must be located between
the foundation and bottom mast support directly below the
mast tubes.
Check for plumb using a plumb line or a minimum 2 m (6.5
ft) spirit level in two directions.
Maximum permitted deviation is 2 mm (1/16 inch) from the
intended reference axis over the height of the bottom mast
section.
Tighten the bolts and check against reference axis AGAIN.

Typical location
for 1 buffer

M12x20 bolts are used

for assembling support
for base enclosure to the
bottom mast support.

Support for
base enclosure

Bottom section for type A mast

ALIMAK 34495 - 1/04

 K5
2. Install 2 mast sections on the bottom mast support. Bottom section for
type FE mast section
Mast / Guide rail Weight Bolt Tightening
type dimension torque

Type A 55 kg (121 lbs) 2 pcs. 1”UNC 300 Nm (220 lbf.ft)

Type FE 100 kg (220 lbs) 4 pcs. 1”UNC 300 Nm (220 lbf.ft)
Type A50 110 kg (243 lbs) 4 pcs. 1”UNC 300 Nm (220 lbf.ft)

See the Installation drawing for location of first tie.

3. Install buffer springs. The number of buffers are in accor-

dance with the Installation drawing.
4. Slide down the cable trolley frame (if used) onto the mast
tubes. Do not assemble the cable wheel unit at this time.

IMPORTANT:
Shims must only be used
below mast section tubes.

Bottom section for

type A50 mast section

ALIMAK 34496 - 1/04

K6 Lower limit cams
1. Install the lower limit cams as illustrated after 2 mast
sections have been added to the bottom mast support and
any required mast ties have been installed (see Installation
drawing).
Normal pit depth is 1100 mm (3 ft. 7 in.). If pit depth is
decreased, the limit cams must be extended accordingly.
ALC control system
Cam for
automatically
resetting of the
sliding handle Rack
inside car.

Limit switch for

ALC reference cam
or retardation cam
for VFC operated
lift.
* 2020 or Normal lower &
2085 mm upper limit switch
(6’ - 7 1/2’’
or H gr Final limit switch
6’ - 10 ’’) see below H gn

H gf

Bottom landing level

* 2020 mm for cars with payload 700 kg or less. Normally 1100 mm (3’- 7’’)
* 2085 mm fot cars with payload more tan 700 kg.

(mm x 0.03937 = inches) Base pedestal lower edge

Alternative H gr mm H gf mm H gn mm
Reference cam Retardation cam
DOL / ALC VFC / ALC

Payload 700 kg (1540 lbs.) or less

Speed at 0.60 m/s (120 fpm) 2650 (8’- 8 1/4”) 3070 (10’- 0 3/4”) 2265 (7’- 5 1/4”) 2410 (7’- 11” )
Speed at 0.80 m/s (150 fpm) 3290 (10’- 9 1/2”) –“– –“–
Speed at 1.00 m/s (200 fpm) 3510 (11’- 6 1/4”) –“– –“–

Payload more than 700 kg (1540 lbs.)

Speed at 0.40 m/s ( 80 fpm) 2710 (8’- 10 1/4”) 2910 ( 9’- 6 1/2”) 2325 (7’- 7 1/2”) 2470 (8’- 1 1/4”)
Speed at 0.60 m/s (120 fpm) –“– 3130 (10’- 3 1/4”) –“– –“–
Speed at 0.80 m/s (150 fpm) 3350 (11’- 0” ) –“– –“–
Speed at 1.00 m/s (200 fpm) 3570 (11’- 8 1/2”) –“– –“–

ALIMAK 34497 - 1/07

 (nom. 10.5 mm)
X K7
The mast limit cam angles are installed with bolts and flange locknuts
to the mast.
Note: The horizontal distance (X) between a limit switch attached to IMPORTANT !
the car frame, and a cam on the mast may vary with car roller Check before adjustment!
adjustment. Because of this the dimensions shown below are If cams are covered with ice.
preliminary and must be adjusted during final commissioning. Remove ice / snow before
adjustment.
Relay control system
Cam for
automatically
resetting of the
sliding handle Rack
inside car.

Proximity
switch
Intermediate
landings
* 2020 or see below
2085 mm Normal lower &
(6’ - 7 1/2’’ upper limit switch
or
6’ - 10 ’’) Final limit switch
H gn

H gf

Bottom landing level

* 2020 mm for cars with payload 700 kg or less. Normally 1100 mm (3’- 7’’)
* 2085 mm fot cars with payload more tan 700 kg.

Base pedestal lower edge

Alternative Intermediate H gf H gn mm
landings mm Relay control
mm system

Payload 700 kg or less

Speed at 0.40 m/s ( 80 fpm) 2576 (8’- 5 1/2”) 2265 (7’- 5 1/4”) 2530 (8’- 3 1/2”)
Speed at 0.60 m/s (120 fpm) –“– –“– –“–
Speed at 0.63 m/s (140 fpm) –“– –“– –“–

Payload more than 700 kg

Speed at 0.40 m/s ( 80 fpm) 2637 (8’- 7 3/4”) 2325 (7’- 7 1/2”) 2590 (8’- 6” )
Speed at 0.60 m/s (120 fpm) –“– –“– –“–

NOTE! These are only preliminary adjustments. To be re-adjusted during final commissioning.

ALIMAK 34498 - 1/07

K8 Car
1. Set the brake release handle inside the car to its ”ON”
position so that the car can slide down the mast.
2. Remove the two lower side rollers and safety brackets.
3. Attach the lifting accessories and lift the car.
Take care not to damage the rollers during lifting, or instal-
ling the car.
If a spreader is not used, be careful not to damage the
Note! electric panel when lifting.
Shackles and slings are
supplied locally by installers.
The crane or fork lift must be rated for at least 2 ton
lifting capacity and a lifting height of at least 6.5 m
(21.5 ft.).
Alimak car lift tool
Part No. 9100692-002
WARNING!
Falling load hazard
Make sure that lifting accessories (rope, chain,
strap etc.) are properly sized for the load to be lif-
ted and that all of the attachment parts are correctly
installed. Do not walk under suspended load!

Can cause severe personal injury or death.

Use shackles, sling and spreader 4. Lift the car so that the two lower rollers are in contact with
for handling the lift unit.
the mast tubes and the two upper car frame rollers are
engaged behind the mast tubes. Lower the car so that all
pinons mesh with the rack. If the car hangs up during this
lowering operation, this is likely to be due to a pinion failing
to mesh correctly with the rack. If this happens, lift the car
slightly, rotate the affected pinion a small amount and lower
Section of gearbox again.
and machinery frame
5. Slide the car down until the car floor is level with the
landing sill [approximately 1300 mm (4.3 ft) above base].
6. Reapply the brake and remove the lifting accessories.
7. Reassemble, adjust and tighten the two lower side rollers.
8. Then remove the yellow bolts that keep the machinery and
Stop car frame locked together during transport.
between Note ! Cylindrical stops with bolts and washers, that come
car and
with the delivery, must ALWAYS be installed between the
machinery
frame car and the machinery frame to prevent pull rods from
being demolished by the gear pinion, if the car slides
against mechanical stop at the bottom landing.
Section of car frame 9. Attach another mast section.

IMPORTANT !
Do not forget to reinstall the two lower side rollers and
safety brackets.

ALIMAK 34499 - 1/08

 IMPORTANT: If a spreader
is not used, take care not to
K9
Raise damage the electric panel
Dismantle the front part when lifting
of the car roof safety
railing before lifting.
Protect this corner from
damage when lifting.

Exception:
Small cars with DOL machi-
nery can be lifted by the lifting lugs Lower side roller
without use of a spreader.
(Weight less than 1000 kg including machinery)

Connect

Use a ratcheted
Lower
tie down for raising
Carefully locate the car.
guide rollers onto
Lift mast tubes.

Protect this
corner from
damage

Protect this
corner from
damage

ALIMAK 34500 - 1/01

K 10 Trailing Cable – temporary connection
Unwind all trailing power cable from the cable drum at base
landing.
IMPORTANT !
The cable must be unwound in order to avoid twisting.
1. Connect the power conductors 1, 2, 3 and the yellow/green
ground conductor of the trailing cable to the main power
terminals, (the ground conductor to the ground rail), inside
the electrical panel inside the car. Check electrical drawings.
Also connect the 230V alt. 120V conductors to the separate
power terminals and the remaining conductors to the control
terminals. Check according to the electrical drawings.

Remark: All additional electrical equipment MUST be

connected and necessary jumpers made in the base panel to
disconnect the landing door circuit according to the
electrical drawing provided before a drop test can be carried
out.

2. Assemble the trailing cable in the cable bracket on the

correct side of the car frame. The cable length between the
cable bracket and electrical panel must be at least 3 m
(approximately 10 ft) to allow for operations later on when
permanently installing the trailing cable.

M10x35

Cable bracket to be
installed on the correct
side of the car frame
according to the
Installation drwg.
M8x30

3. Connect the other end of the trailing cable to the terminals

in the main electrical panel at the base according to the
electrical drawings for the particular installation.
Locate the panel at a suitable temporary place.

ALIMAK 34501 - 1/08

Main Power Supply
K 11
Work performed on electrical equipment must be carried out
by competent personnel, trained for such work. The power
supply must be switched off and locked before work is
performed.

1. Connect the power supply to the terminals in the main

electrical panel at the base according to the electrical dra-
wings for the particular installation.
Also connect the D-panel (= equipment for remote control-
led drop test from the base landing) where applicable.
2. Provide a jumper between the pit switch terminals and
another between the landing door circuit terminals in the
base panel. (Check electrical drawings provided). k 186

These jumpers must be made in order that the lift can be

used during erection before the emergency stop switch in the
pit and the landing door interlocking circuits are installed.
Always make jumper wires of conductors with colour other
than used in the electrical panel to make the disconnection
easier.
3. Turn on the main switch at the base. Open the electrical
panel in the car and turn on the main switch.
When the phase sequence connections are correct, then the
red indicator on the phase failure relay -K10 is
illuminated.

4. Set the NORM / INSP switch in the electric control panel on

the car roof to the ”INSP” position.
Remark: Leave the NORM / INSP switch in the ”NORM”
position if equipment for remote controlled drop test from
the base landing occurs.

WARNING!
Unintentional moving.
Always prepare the lift for car top operation only,
during erection.
Can cause severe personal injury or death.

ALIMAK 34502 - 1/08

K 12 Mast / Guide rail
Installation of ties must be carried out at the same time as the
erection of the mast at their appropriate tie level.
After 2 sections of mast have been erected, proceed with the
installation of the lower limit cams according to previous
instructions.

DANGER !
Crushing hazard.
When lift is moving, always stand inside safety
railing to avoid being crushed by balconies, scaf-
folds or other protruding structures.
h 40
Will cause severe injury or death.

Deviation of mast
Lateral deviation of each mast section in any direction from the
intended reference line must not exceed 2 mm (1/16’’).

Mast expansion/contraction
The expansion/contraction of the mast is: 0.012 mm/m per
degree °C ( or .000008 in./ft. per degree °F).

See further information regarding the mast installation on

page K14.

Mast Installation
ATTENTION !
Perform out an overspeed safety device test as soon as a
mast height of 10 m (approx. 30 ft.) is reached. See
instructions in the Maintenance Manual.

1. For efficient installation, store as many mast sections

as conveniently possible at base area of the lift.
Raise 1 or 2 sections onto the car roof using the erection
crane.
Drive the car to a point near the top of the mast.
Note! Position car at this point to allow mast to be lowered
and bolted to last mast section. Careful selection of this
k 187 point will permit the erection crane to be unhooked and any
IMPORTANT! required tie installed without having to move the car.
Install mast bolt as shown – with bolt- Lift one mast section and grease the guide collar and
head on the underside of mast frame
and the nut on top.
tension pin and assemble to the existing mast.
Before removing the erection crane sling, make sure that
all mast bolts are properly tightened.

ALIMAK 34503 - 1/01

 K 13
2. Install the ties at the indicated tie level. See Installation
drawing.
Continue as above until mast is erected to at least half
the lifting height elevation, making certain that ties are
installed at the required level.

WARNING!
Unintentional moving.
Always depress the red ”Emergency stop”-button
to prevent unintentional moving while work is
carried out on the mast.
Can cause severe personal injury or death.

Plumbness of the mast

Check possible out-of plumbness of the mast with a plumb line, Straight-edge
plumb laser tool, spirit level or a theodolite, when installing the
first tie. If a correction is required, adjust it by means of the
mast tie.
When installing additional ties check verticality with a long
straight-edge rule, using the ground level plan and first tie as
references. Use a plumb laser tool or a theodolite if desired, but
never use a spirit level above the first tie.
h 46
The use of a straight-edge will also indicate if the mast is
twisted.
Try to use the same or as few references as possible for the
entire mast installation. Straight-edge

Straight-edge rules may be fabricated on site. For an example,

they can be a 2” x 4” x 1.5 m (5 ft) long piece of timber and be
attached to the mast with tie wire. The straight-edge must be
properly attached.

IMPORTANT !
Remove straight-edges after the mast has been installed.

Minimum headroom required above top landing level:

Straight-edge
Direct on line started electric motors, DOL:
1 motor drive = 4.0 m (13 ft.)
2 motor drive = 4.1 m (13 1/2 ft.)

Frequency controlled electric motors, VFC:

1 motor drive = 4.1 m (13 1/2ft.)
2 motor drive = 4.5 m (15 ft.)

ALIMAK 34504 - 1/01

K 14 Erection and handling of mast sections / guide rails
Large cars with car width 1040 mm (3 ft. 5 in.) or greater
These cars have enough room for the mast sections / guide rail
to be carried on the roof and can ALWAYS be assembled with
the manual erection crane.

Cars with car width 910 mm (3 ft.) or less

Cars with car width 910 mm (3 ft.) or less,as there is NOT
enough room on the car roof to carry a mast section/ guide rail
for these sizes of cars, the mast section / guide rail should be
attached to the erection crane or be properly fixed to the outside
of the car roof safety railing during transport.
k 73
CAUTION: Both methods indicated above require proper
rigging and attention to any hoistway obstructions.

Erection crane
Alimak’s manual erection crane part no. 9040 578-000 is
available as an option.
The crane's capacity is 150 kg (330 lbs.).
It is supported by a bracket attached to the car frame, part no.
9098 102-000.
For large lifting heights an electric winch is available as an
option.

This picture shows the largest mast
type and the smallest standard car
size (780 x 1040 mm).
WARNING!
Erection crane collapse hazard
When not in use, always secure the erection crane’s
load hook to the car roof safety railing with the
crane jib turned away from the mast / guide rail.
This in order to prevent an accident when the car is
moving during installation and dismantling.
Can cause severe personal injury or death.

ALIMAK 34493 - 1/01

On site cranes
K 15
First choice in assembling the lift system is the use of a crane
with sufficient lifting height.
3 – 5 mast sections (never exceeding the mast's freestanding
capability) can be assembled lying on the ground before being
lifted to the mast top and assembled.
Our recommendation is to attach the load according to the
figure to avoid driving to the mast top in order to disconnect the
load from the crane hook.

Reason for NOT using a spirit level for plumbing the mast.
We do not recommend that a spirit level be used for mast
alignment,as it is very difficult to achieve a 2 mm maximum
deviation from the reference line.
With this system deviations can easily accumulate causing an
out of plumb mast installation.

ALIMAK 34494 - 1/05

 K 16 Tie for type A tube guide rail

Guide rail Weight Mast bolt Tightening

type dimension torque

A 55 kg (121 lbs) 2 pcs. 1”UNC 300 Nm (220 lbf.ft)

modified type A 58 kg (128 lbs) 2 pcs. 1”UNC 300 Nm (220 lbf.ft)

Wall bracket to
be installed with
nut and bolt or
expansion bolt. Modified type A guide rail for installation with
expansion or through bolts

The modified type A guide rail has brackets, with slotted holes.
Spacers on the attachment bolts allow the guide rail to expand and contract
with variations in temperature.

IMPORTANT !
Arrange scaffold, working platform or similar if you cannot
reach to install tie from the car or the structure.

ALIMAK 34505 - 1/04

Tie for type FE & A50 tube mast sections
K 17
Mast tube clamp assembled with
bolt and nut or expansion bolt.

Mast section Weight Mast bolt Tightening

type dimension torque

FE 100 kg (220 lbs) 4 pcs. 1”UNC 300 Nm (220 lbf.ft)

A50 110 kg (243 lbs) 4 pcs. 1”UNC 300 Nm (220 lbf.ft)

Tie for type FE & A50 tube mast sections

Attach mast tube clamp and brace tube clamp

as close as possible as indicated.

Adjustable support legs.

Max. 15° inclination up or down.

Brace

Wall bracket to be installed with

nut and bolt or expansion bolt.

Pivoted mast tube clamp

ALIMAK 34506 - 1/01

K 18 Introduction to the principles of cable installation

Where Hoistway wiring is required to be run in conduit see

Hoistway Conduit & Wiring Drawing.

The mast is erected up to half the final lifting height + 3 m (10

ft) with the trailing cable hanging free.

k 192

The fixed power cable, mid

point junction box, cable
bracket and cable guides are
loaded on the car and taken
up to the mast top.

k 193

k 194

The fixed cable is connected to the mid point junction box and
installed with the cable bracket to the lift mast.

ALIMAK 34507 - 1/01

 K 19

The trailing cable is disconnected from the main electrical panel

in the car and is connected via the mid point junction box to the
fixed power cable.

k 195

The lift is lowered by gravity

in small increments while the
fixed cables are attached to
the cable tray.
The cable guides are also
attached every 3 – 6 m (10 –
20 ft. ) or according to the
k 196 General Layout Drawing (In-
stallation drawing).

The cable trolley wheel is installed onto the trolley frame. The
trailing cable is hung from the cable bracket on the mast, via the
cable trolley and the cable bracket on the car and is connected
to the terminals in the main electrical panel.
The trailing cable length is adjusted. k 197
The fixed cables are connected to the main electrical panel at
the base.

Read on for further instructions.

ALIMAK 34508 - 1/05

K 20 Cable installation instructions

1. Lift the coiled fixed cable onto the car roof.

Arrange the cable so that it can be easily unwound.
If there is no space for the cable on the car roof:
– Pay out the fixed cable over the hand rail of the lift car
(see figure). Temporarily secure the cable to the hand
Mid point rail so that it cannot slide (e.g. use plastic tape).
junction box

Cable bracket
on mast
Pay out the cable in
loop(s) over the car
hand rail to help in
handling the cable
weight.
k 193

Cable bracket
on car
2. Drive the car carefully upwards to the position for the mid
point junction box, taking with you the fixed cable, the mid
point junction box, sufficient cable ties, the cable bracket,
cable trays and cable guides and all necessary attachment
Cable guide hardware.

3. Install the cable bracket and plate for the junction box, at
half the final lifting height + 3 m (10 ft).

4. Connect one end of the fixed cable to the terminals in the

half height junction box according to the wiring diagram.
Cable trolley Install the mid point junction box to the plate.

5. The main power supply must be isolated at the main

electrical panel at the base and locked off in a secure
manner. It may be convenient to have an assistant doing this.

ALIMAK 34509 - 1/06

6. Disconnect the trailing power cable from the main electrical
K 21
panel.
DO NOT LOOSEN the trailing cable from the cable bracket.

7. Reconnect the end of the trailing cable to the mid point

junction box according to the wiring diagram.
Use the cable conductor numbering for identification so that
correct phase sequence is obtained.

8. Place the trailing cable in the cable bracket which is attached

to the mast (see figure).
Wrap the rubber packing around the trailing cable and
securely attach the trailing cable to the cable bracket.

9. Carefully loosen the trailing cable from the cable bracket on

the car and allow the trailing cable to hang freely from the
cable bracket in the mast, so that the trailing cable now
hangs freely down to the ground.
Remove the trailing cable
Note that there is no cable attached or connected to the car from car main el. panel to
at this stage. terminals in the mid point
junction box in mast

ALIMAK 34510 - 1/06

 K 22 10. While lowering by gravity, stage by stage, install the cable
tray and cable guides attaching the fixed power cable to the
cable tray at 0.5 m (1.5 ft.) intervals.

Fixed
power
Use a flat iron bar or a similar
cable
Cable guide tool to release the centrifugal
brake and motor brake for
manual lowering.

Install brakets for the cable tray every 2nd guide rail/mast
k 196
section (approx. 3 m).
Assemble the cable tray from midpoint mast to the last
landing in a second stage.
Allow the car to lower by gravity,
attaching the fixed cable, the
cable tray and cable guides as
lowering progress.

M8x35

Note: Cable trays for the FE and

A-50 masts can be deleted if the
fixed cable is attached to the mast.

ALIMAK 34511 - 1/08

 Attach a cable guide at 6 m (20 ft.) intervals or less if the
K 23
Installation drawing requires this, due to high wind
conditions in service.

xxIMPORTANT !
Do not install the cable guides at the same level if the
cable trolley has both left and right cable wheels.
Do not locate the cable guides so that the plate spring is
kept open by the cable trolley when the car has stopped
at the landing

k 199

M8x35
Location of the cable tray
The location to the right
cannot be used where large
car frames for load more
than 700 kg (1550 lbs.)
occur.

(.31 ± .04 in.)

8 ± 1.0 mm

303.5 ± 1.0 mm
11. Stop at suitable point approximately 2 m (6.5 ft.), above the (11.95 ± .04 in.)
buffers, but not any lower than the lowest landing level.

12. Support the lift car using timber or similar means in order
that work can be done without risk of the car descending.

DANGER!
Brake malfunction hazard
Cut off the outermost piece if
Never work under the car without putting support there is a risk that the trailing
under it. cable can blow behind it and
be caught. Apply tectyl or paint
Will cause severe bodily injury or death. on the machined surface to
prevent corrosion.

ALIMAK 34512 - 1/08

K 24 If the trolley has not yet been assembled on the mast tubes:
– Remove the two adjustable guide rollers on one side of the
cable trolley and place the trolley on the mast/guide rail
(.0 below the car.
1. 55
4 in – Reinstall the guide rollers, but only tighten the attachment
m .)
m
bolts by hand.
– Adjust the cable trolley so that the cable wheel is parallel to
the mast/guide rail and that a play of 1.4 mm (.055 in.) is
obtained between roller and mast tube/guide rail flange at
one side of the cable trolley, when corresponding rollers on
the other side of the trolley are in close contact.
Adjustment is made by turning the eccentric shafts of the
rollers until the correct play is obtained whereupon the
attachment bolts are tightened.

13. Install the cable trolley wheel unit on the same side of the
cable trolley frame as the cable bracket on the car. Check
that the cable trolley runs correctly on the mast. A weight
shall be used if the cable trolley only has 1 cable wheel and
4 pcs.
M8x25

2 pcs.
M8x60

Wheel hub with smaller dia.

side must always be turned
towards the cable trolley.

14. Disconnect the trailing power cable in the main electrical

panel at the base.
Pull the cable end through the trolley as illustrated in the
figure and further up to the cable bracket on the car.
Make sure that the cable is not twisted and is free running.

ALIMAK 34513 - 1/08

15. Take the trailing cable to the main electrical panel on the car
K 25
roof and connect it to the terminals where the other end of
the same cable was previously connected.
Note: Remove the jumper between the door circuit terminals To cable
bracket on
in the main panel on the car. car frame

16. Take up the slack of the trailing cable. Carefully slide the car
down the mast until the car floor is level with the lowest
landing.

17. Tension the trailing cable without lifting the trolley from its
position resting on the buffer bracket.
Then pull the trailing cable further so that the cable trolley
touches below the car. Lower the trailing cable to half the
distance just lifted and secure the cable in the cable bracket
on the car.
IMPORTANT !xx
It is most important that the above adjustments are
carefully followed in order that the cable trolley be
exactly midway between the car and the buffers when
the car is at the bottom landing.

18. Coil up the excess trailing cable and fasten it with tape onto
the hand rail of the car roof.

19. Connect the fixed cable to the terminals in the main

electrical panel at the base level. Ensure that the fixed
cable or cables are properly located to avoid damage from
the moving parts of the lift.
Note: Install a temporary jumper wire between the terminals k 197

for the landing door circuit inside the main base panel to
bypass the landing door interlocks, as doors are not installed
at this stage.

20. The main power supply can now be reconnected by

unlocking the isolator at the main electrical panel at the
base. Carefully test run to the mid point junction box level,
checking that the trailing cable and the cable trolley run
freely.
DO NOT LEAN OVER THE HANDRAILS WHEN
DOING THIS CHECK.

21. Proceed with the erection of the mast, mast ties, cable guides
until the final lifting height has been reached.
Don’t forget to attach covers on the corner tubes of the last
mast section before it is lifted into position.

ALIMAK 34514 - 1/01

K 26 M20x200
M16x50
Top buffer assembly
Demand according to EN regulations
– not required according to ASME 17.1
Install top buffer assembly on mast tubes in mast top according
to the following figure.
Distance between buffer / buffer landing on car and buffer in
mast top must be minimum 150 mm (6 in.) or larger, when the
car has stopped at the top terminal landing.

Emergency lowering device

Resetting cams on each landing will automatically cause the
manual lowering handle to reset and stop the car level with the
next lower landing, i.e. the brake(s) are activated.
It is NOT possible to lower the car if the car is stopped at a
landing. The system only works when due to a power failure,
the car is stopped in-between landings.

Remark: Exception to the above may only be permitted with

the customer’s approval and only after a risk assessment is
performed and documented.
Emergency lowering to a designated emergency exit landing or
to a bottom landing can be accomplished.
This can be desirable if as an example the car is stopped in-
between landings and there is a risk of toxic gas built-up in the
hoistway.
Another example is a tall chimney with intermediate landings
and ladders available for exiting the structure, where it is
determined that it is safer to stay in the car and emergency
lowering than climbing down the ladder(s).

IMPORTANT: Sliding through intermediate landings with the

door actuator in extended position means that all landing door
Reset cam on mast at units must be correctly installed and located within stated
each landing level tolerances. If not, door locks and stationary equipment at the
landings will be damaged.

ALIMAK 34515 - 1/07

 Upper limit cams
K 27
Install the normal and final limit cams on an upper mast section.
Type A mast is shown. For type FE and A50 mast the same
dimensions apply.

Rack

Note:
Minimum
distance to
mast end
acc. to table
Limit switch for
below Htm
retardation cam
* 2020 or applicable for Normal upper &
2085 mm VFC operated lower limit switch
(6’ - 7 1/2’’ or lifts.
6’ - 10 ’’) Final limit switch
H tn

H tr H tf

Top landing level

* 2020 mm for cars with payload 700 kg or less.
* 2085 mm for cars with payload more tan 700 kg. (mm x 0.03937 = inches)

Alternative H tr H tf H tm mm H tn mm
mm mm With top Without Relay control ALC control
top buffer top buffer system system

Payload 700 kg (1540 lbs.) or less

Speed at 0.60 m/s (120 fpm) 1825 (5’- 11 3/4”) 2460 3660 3440 2400 2485
(8’- 0 3/4”) (12’- 0”) (11’- 3 1/2”) (7’- 10 1/2”) (8’- 1 3/4”)
Speed at 0.63 m/s (140 fpm) –“– –“– –“– –“– –“–
Speed at 0.80 m/s (150 fpm) 1605 (5’- 3 1/4”) –“– –“– –“– –“–
Speed at 1.00 m/s (200 fpm) 1385 (4’- 6 1/2”) –“– –“– –“– –“–

Payload more than 700 kg (1540 lbs.)

Speed at 0.40 m/s ( 8 fpm) 2105 (6’- 10 3/4”)2520 3720 3500 2460 2545
(8’- 3 1/4”) (12’- 2 1/2”) (11’- 5 3/4”) (8’- 0 3/4”) (8’- 4 1/4”)
Speed at 0.60 m/s (120 fpm) 1885 (6’- 2 1/4”) –“– –“– –“– –“– –“–
Speed at 0.80 m/s (150 fpm) 1665 (5’- 5 1/2”) –“– –“– –“– –“–
Speed at 1.00 m/s (200 fpm) 1445 (4’- 9” ) –“– –“– –“– –“–

NOTE! These are only preliminary adjustments. To be re-adjusted after final commissioning.

ALIMAK 34516 - 1/07

K 28 Pit enclosure, base enclosure and landing enclosures
Refer to the General Layout Drawing (Installation drawing) and
the Spare Parts Manual for more detailed information concerning
door location, size and composition of wall panels and all
attachment parts.

To facilitate installation, the various subassemblies should be

assembled on the ground and then raised into position.

Pit enclosure
1. Identify and place the pit enclosure components according to
the following figure.
The Installation drawing will state the number of extruded
aluminium profiles per wall and their relative positions.
IMPORTANT!
Be careful not to damage the
surface treatment.
Edge profile

Filler element
To be
drilled
on site on
assembly

B
Support feet

A C RIGHT CORNER

LEFT CORNER
This figure is typical of a pit enclosure.
For specific details see General Layout
Drawing (Installation drawing)

2. Identify the corresponding edge profiles for each wall.

The edge profile for side C is precut to length when
delivered. Edge profiles for sides A and B are to be cut to
lengths at site, on assembly.
Allocate the necessary number of self-tapped screws, 4 self-
tapped screws per wall section required.

ALIMAK 34517 - 1/01

 K 29
3. Always start and stop the combination of wall profiles with
one (...or two) 130 mm wide predrilled single or double
flanged wall panel(s).
Corner profiles connecting the walls are assembled with
self-tapped screws 4 pcs. per each corner.

Method for assembling wall panels

Grease on the threads when assembling

Predrilled double flange or single flange wall panel.

4. Assemble all the wall profiles, edge and corner profiles for
each wall according to the figures above and the General
Layout Drawing (Installation drawing).
Always check diagonal measurement in two directions to Interlock
keep the wall sections square.
Maximum allowable deviation relative to pit diagonal
measurment is ±10 mm (1/2 in.)

5. Cut the length of the top and bottom edge profiles to suit the
structure.
Locate the foundation pit according to the General Layout
Drawing (Installation drawing).

6. Level the complete foundation pit using the support feet.

7. Trim and install filler elements, to close the wall against

the structure. Drill 9 mm (3/8 inch) diameter holes and Hand rail
bolt with 2 bolts per side.

8. The pit ladder is located beneath the door panel in the

base enclosure. The hand rail to the right above.
See the General Layout Drawing (Installation drawing).

ALIMAK 34518 - 1/05

K 30 Base enclosure
The method and order of assembling the base enclosure is
similar to that for the pit enclosure. However – always start with
the landing door front.

NOTE!
See General Layout Drawing (Installation
drawing). regarding actual door location
and specification of the complete base Wall bracket
enclosure
Perforated
sheet angle rod

Maximum allowable
deviation relative to Base enclosure
pit / enclosure
diagonal measurment
is ±10 mm (1/2 in.)

Pit enclosure

Use the spanner grip Support feet

on the door blade's lower for levelling
hinge pins to adjust the pit enclosure
door vertically.

1. Start by dismantling and reinstalling the landing door front’s

sillplate in its required position.
Locate the landing door front according to the General
Layout Drawing (Installation drawing).
Level, adjust and install the door front in respect to the
center of the mast tube and the car dimensions according to
the General Layout Drawing (Installation drawing) or the
appendix ”Location of landing doors relative the mast tubes”
at the end of this manual.
ALIMAK 34519 - 1/05
 K 31
Car door interlock

Landing door interlock

Car door a

780 mm bi-folding door 28 mm (1.10 in.)

780 & 1040 mm slide door 27 mm (1.06 in.)
1300 & 1560 mm slide door 25 mm (0.98 in.) Distance between interlock roller
on car and interlock cam on the
Car landing shall be 15 ± 5 mm
Distance between sills (.59 ± .2 in.), with both doors
closed.
= a + 5 ( 0.008 in.)
– 0 (5.71 in.) 145 mm

Landing door front

2. Assemble the complete base enclosure in the same manner

as the pit enclosure.

3. Install the emergency stop switch for the pit with its casing
using the predrilled holes to the left or right of the door
front, below the landing push-button box.

4. Attach the main electrical panel at the base in a suitable

place, close to the door on the base enclosure.

ALIMAK 34520 - 1/03

K 32 5. Check that the landing door is parallel to the car door,
which means that the distance between car and landing door
must be equal at all 4 corners.
Also check that the method for emergency opening the
landing door works.

6. Install staircase and platform for bottom landing – if required.

Start with 2 columns attached to the door front. Then next 2
columns. Temporarily attach handrails. Complete the plat-
form and staircase.
Bolt dia./thread
and length
M12x70

M12x30

M12x60
M12x30

7. Connect the landing control cable to the main electrical

panel at the base and each landing unit in accordance with
the electrical drawings.

ALIMAK 34521 - 1/01

8. Before leaving the base level, do the wiring. Remove tempo-
K 33
rary jumper between the pit switch terminals. Also remove
temporary jumper for the landing door circuit in the base
panel and reinstall it at level currently erected i.e. move the
jumper as you go, level by level.

WARNING !
Unintentional moving.
The door interlock must always be connected
immediately when a landing door is installed
(exception: see remark on the next page).
If the jumper wire of the lower landings is not
removed, the lift can be started with the landing
door open.
Can cause severe personal injury or death.

ALIMAK 34522 - 1/01

K 34 Landing enclosure
11. Install next landing in the same way as the base enclosure.
Note that the landing door panel must be mounted
properly before the landing is brought into service.

Remark: If the lift is erected to its final lifting height at

one time and the erection area is barricaded, the installation
of the landings can be carried out from above i.e. starting
with the top landing to avoid having to transport the landing,
panels through the completed landings below.

xx IMPORTANT !
Never run a car passed a landing with the landing door
open.

12. Install remaining landings according to instructions above.

When all landings have been installed, the jumper wire for
the stop circuit/door interlock must be on the top landing.
This by-pass is not to be removed.

20 mm (3/4 in.) Car length 1040 mm (3’ 5’’) landing enclosure

Ensure that the distance between enclosure wall and cable
trolley is minimum 20 mm ( 3/4 in.).
If not – move the wall section outwards to achieve this.

Car size
780 x 1040 mm

DANGER !
Crushing hazard.
All work on the car roof must be carried out with
the utmost caution as there is a risk of being crushed
when driving through floor openings, landings etc.
Will cause severe injury or death.

h 40

ALIMAK 34523 - 1/01

Final commissioning procedure
K 35
1. Remove all the erection equipment from the car.
2. Check the upper limit cams for correct setting. Readjust if
necessary.
3. Carry out the service according to the service and
maintenance schedule (see Maintenance Manual) with the
exception of para 2, 7, 31, 32, 33, 39, 50, and 53.
4. Turn the switch ”NORM / INSP” of the car main electrical
panel to position ”NORMAL”.
5. Make a trial run, pushing the ”CALL” buttons at every
landing. Also make the following tests from each landing:
a) Try to run the lift with the ”CALL” buttons leaving the
landing door open (car door closed).
The lift must not move.
6. Make a trial run with the car, pushing the ”FLOOR” buttons
in the car.
Also check the car interlock systems as follows:
a) Try to run the lift up and down, leaving the car door
open (landing door closed). If there is more than one
door, test each door separately.
b) Try to run the lift up and down, leaving the trapdoor
open (car and landing doors closed).
c) Try to run the lift up and down keeping the ”EMER-
GENCY STOP”-switch in the pit, pressed, with all doors
closed. Reset the button after the test.
d) Check any other interlock equipment in the same way.
e) Turn the switch ”NORM / INSP” on the main electrical
panel on the car roof to ”Inspection” and test according
to 5a) from the car roof.
f) Try to run the lift up and down keeping the ”EMER-
GENCY STOP”-switch on the car roof pressed in.
Reset the switch after the test.
The lift must not move when testing according to a, b,
c, d, e and f above.
g) Reset the switch to ”NORMAL”.
7. Instruct the operator(s) regarding safety regulations, opera-
ting instructions and service and maintenance.
THE LIFT IS NOW READY FOR INSPECTION !

See separate manual for detailed ALC programming instruc-

tions.
Refer to Instruction;
No. 9081447-101 (ALC control system) or
No. 9081448-101 (Relay control system) ...
... regarding Electrical Insulation tests.
ALIMAK 34524 - 1/08
 Appendix 1
Tightening torque
Recommendations according to the chart on the following page
apply in general except for:

ALIMAK Mast bolt, dim. 1” UNC galv.

– Torque : 300 Nm (220 lbf . ft)
– Spanner size : 1 1/2”

ALIMAK Scaffold clamp Ø 76 mm galv.

– Torque : 150 Nm (110 lbf . ft)
– Spanner size : 28 mm 50

ALIMAK Scaffold clamp Ø 76 mm galv.

– Torque : 220 Nm (163 lbf . ft)
– Spanner size : 24 or 27 mm
100

Recommended torques
The chart applies to galvanized bolts and nuts of strength class
8.8 – dry surface.

Dimension Spanner size Galvanized steel (Stainless steel* A4 80)

Torque Torque
Nm lbf . ft Nm lbf . ft
M6 10 mm 10 7 3.5 2.5
M8 13 mm 24 18 8 6
M 10 17 mm 47 35 16 12
M 12 19 mm 81 60 28 20.5
M 14 22 mm 128 95 44 32.5
M 16 24 mm 198 146 67.5 50
M 20 30 mm 386 285 132 97.5
M 24 36 mm 668 493 228.5 168.5

1/4” UNC 7/16” 11 8 4 3

3/8” UNC 9/16” 39 29 13.5 10
1/2” UNC 3/4” 94 69 32 24
5/8” UNC 15/16” 186 137 64 47
3/4” UNC 1 1/8” 327 241 112 82.5
1” UNC 1 1/2” 783 577 268 198
1 1/4” UNC 1 7/8” 1549 1142 530 391
* Tightening torque for stainless steel material quality A2 70 is 25% less.

ALIMAK 34480 - 1/08A

 Appendix 2

Location of landing doors relative to the mast tubes

Door location A, B or both
L1 L1
L3 L3

W2 W2

W3 W1 A B W1 W3

Note: Dimensions W2 and L3 to be reduced by 38 mm (half tube dia.),

if measured from tube outer surface instead of tube center.

Car width W Landing door W1 W2 Reduced W2 W3

opening width W 0 mm mm mm minimum

780 mm (2’ - 6 3/4’’) 690 mm (27.16’’) 1040 (40.94’’) 160 ( 6.30’’) 122 (4.80’’) 1040 + 80 (40.94’’+ 3.15’’)
910 mm (3’) Left – ’’ – – ’’ – – ’’ – – ’’ – – ’’ –
910 mm (3’) Right – ’’ – – ’’ – 290 (11.42’’) 252 (9.92’’) – ’’ –
1040 mm (3’ - 5’’) 950 mm (37.40’’) 1300 (51.18’’) 160 ( 6.30’’) 122 (4.80’’) 1300 + 80 (51.18’’+ 3.15’’)
1300 mm (4’ - 3’’) 1270 mm ( 50’’) 1690 (66.53’’) 95 (3.74’’) 57 (2.24’’) 1690 + 80 (66.53’’+ 3.15’’)
1560 mm (5’ - 1 3/8’’) 1530 mm (60.24’’) 1950 (76.77’’) – ’’ – – ’’ – 1950 + 80 (76.77’’+ 3.15’’)

Car length L1 L3 Reduced L 3

L mm mm mm

1040 (3’ - 5’’) car length +370 mm (14.57’’) 380 (14.96’’) 342 (13.46’’)
1170 (3’ - 10’’) – ’’ – 445 (17.52’’) 407 (16.02’’)
1300 (4’ - 3’’) – ’’ – 510 (20.08’’) 472 (18.58’’)
1430 (4’ - 8 1/4’’) – ’’ – 575 (22.64’’) 537 (21.14’’)
1560 (5’ - 1 3/8’’) – ’’ – 640 (25.20’’) 602 (23.70’’)
1690 (5’ - 6 1/2’’) car length +370 mm [or *388 ] (14.57’’[or *15.27’’] ) 705 [or *723] (27.75’’[or *28.64’’] ) 667 (26.26’’)
1950 (6’ - 4 3/4’’) – ’’ – 835 [or *853] (32.87’’[or *33.58’’] ) 797 (31.38’’)
2080 (6’ - 10’’) – ’’ – 900 [or *918] (35.43’’[or *36.14’’] ) 862 (33.94’’)
2210 (7’ - 3’’) – ’’ – 965 [or *983] (37.99’’[or *38.70’’] ) 927 (36.50’’)
2470 (8’ - 1 1/4’’) – ’’ – 1095 [or *1113] (43.11’’[or *43.82’’] ) 1057 (41.61’’)
2600 (8’ - 6 3/8’’) – ’’ – 1160 [or *1178] (45.67’’[or *46.38’’] ) 1122 (44.17’’)
2990 (9’ - 9 3/4’’) – ’’ – 1355 [or *1373] (53.35’’[or *54.05’’] ) 1317 (51.85’’)

* Figures shown in brackets are valid for car width 1690 mm or larger with car door width 1690 or 1950 mm.

ALIMAK 34489 - 1/01

 Appendix 2 continue

Door location C , C and A or C and B

L1
L1
L3
L3

W2
W2
C C

W1 W1
W3 W3

Car width W W2 Reduced W2 Note: Dimensions W2 and L3 to be reduced

minimum mm by 38 mm (half tube dia.), if measured from
tube outer surface instead of tube center.
780 mm (2’ - 6 3/4’’) 1255 mm (49.41’’) 1217 mm (47.91’’)
910 mm (3’) 1385 mm (54.53’’) 1347 mm (53.03’’)
1040 mm (3’ - 5’’) 1515 mm (59.64’’) 1477 mm (58.15’’)
1300 mm (4’ - 3’’) 1838 mm (72.36’’) 1800 mm (70.87’’)
1560 mm (5’ - 1 3/8’’) 2098 mm (82.60’’) 2060 mm (81.10’’)

Car length Landing door W1 L1 L3 Reduced L 3 W3

L mm opening width minimum
W 0 mm mm mm mm mm mm

1040 (3’ - 5’’) 690 (27.16’’) 1040 (40.94’’) 1410 (55.51’’) 325 (12.79’’) 287 (11.30’’) 1040 + 80 (40.94’’+ 3.15’’)
1040 (3’ - 5’’) 950 (37.40’’) 1300 (51.18’’) 1410 (55.51’’) 325 (12.79’’) 287 (11.30’’) 1300 + 80 (51.18’’+ 3.15’’)
1170 (3’ - 10’’) – ’’ – – ’’ – 1540 (60.63’’) 390 (15.35’’) 352 (13.86’’) – ’’ –
1300 (4’ - 3’’) – ’’ – – ’’ – 1670 (65.75’’) 455 (17.91’’) 417 (16.42’’) – ’’ –
1430 (4’ - 8 1/4’’) – ’’ – – ’’ – 1800 (70.87’’) 520 (20.47’’) 482 (18.98’’) – ’’ –
1560 (5’ - 1 3/8’’) – ’’ – – ’’ – 1930 (75.98’’) 585 (23.03’’) 547 (21.53’’) – ’’ –

1690 (5’ - 6 1/2’’) 1270 (50’’) 1690 (66.53’’) 2190 (86.22’’) 715 (28.15’’) 677 (26.65’’) 1690 + 80 (66.53’’+ 3.15’’)
1950 (6’ - 4 3/4’’) – ’’ – – ’’ – 2450 (96.46’’) 845 (33.27’’) 807 (31.77’’) – ’’ –

1690 (5’ - 6 1/2’’) 1530 (60.24’’) 1950 (76.77’’) 2190 (86.22’’) 715 (28.15’’) 677 (26.65’’) 1950 + 80 (76.77’’+ 3.15’’)
1950 (6’ - 4 3/4’’) – ’’ – – ’’ – 2450 (96.46’’) 845 (33.27’’) 807 (31.77’’) – ’’ –
2080 (6’ - 10’’) – ’’ – – ’’ – 2580 (101.57’’) 910 (35.83’’) 872 (34.33’’) – ’’ –
2210 (7’ - 3’’) – ’’ – – ’’ – 2710 (106.69’’) 975 (38.38’’) 937 (36.89’’) – ’’ –
2470 (8’ - 1 1/4’’) – ’’ – – ’’ – 2970 (116.93’’) 1105 (43.50’’) 1067 (42.01’’) – ’’ –
2600 (8’ - 6 3/8’’) – ’’ – – ’’ – 3100 (122.05’’) 1170 (46.06’’) 1132 (44.57’’) – ’’ –
2990 (9’ - 9 3/4’’) – ’’ – – ’’ – 3490 (137.40’’) 1365 (53.74’’) 1327 (52.24’’) – ’’ –

ALIMAK 34490 - 1/01

 Appendix 3

Optional details for attaching landing door front...

... to concrete or steel

Attachment angle
Part. no. 9095 464-102

Expansion bolt or
hexagonal bolt with
washer and nut.
These parts are not
included in delivery Landing door panel outer surface
from factory with holes for attachment.

(1’- 7 3/4’’)
500
Door width A

780 – 1040 mm 50 mm

612.5
(2’)
20

(2’- 6 3/4’’ – 3’- 5’’) (2’’)

1300 – 1560 mm 68 mm
(4’- 3 1/4’’ – 5’- 1 3/8’’) (2 3/4’’) ’’)
(1/4
9
dia.

(1’’
) 25
A 2039 (6’- 8 1/4’’)

1255 (4’- 1 1/2’’)

2505 (8’- 2 1/2’’)

W0
(2
3/4’
612.5

’) 7
(2’)

0
W1
– 14
0 (5
1/2’
W1 ’)
(1 1/4’’) 30

Values for W 0 and W 1 are indicated on previous page

Filler elements to finish the installation of the door panel are

NOT a part of the standard lift delivery and must be furnished
by others.

ALIMAK 34491 - 1/06

 Appendix 3 continue

Optional support beneath the landing door front

Concrete or
NOTE! This option is not a part of the Alimak standard steel structure
delivery.

Door panel to be placed, levelled and bolted onto the steel

brackets.
Slotted holes allow the door panel to be adjusted horizontally.

Use 3 pcs per landing door panels 780 (2’- 6 3/4’’) and 1040
mm (3’- 5’’), and 5 pcs per landing door panels 1300 (4’- 3’’)
and 1560 mm (5’- 1 3/8’’).

Bracket part no.

9097459-102

Expansion bolt or hexagonal

bolt with washer and nut.
Welding also possible.
Method for locating landing doors These parts are not included
Use a plywood board or similar on top of the car railing for in delivery from factory
measuring and location of the landing door on the landing.
It is also possible to fabricate an angle from 3 pcs. of wood
fastened together.

Markings according to former tables for each car size and

various door locations.

L3

W2

Mark Mark

Plywood board or similar with

proper 90° angles.

Landing door front

Mark

ALIMAK 34492 - 1/05