WB Installation Manual ME ENG 4.0

4.
0 Ver
2015.11.18
WBVF
Installation Manual
for Mechanical Parts
This manual is the property of Hyundai Elevator Co., Ltd. and is loaned subject to
return upon demand. Contents publication shoud not be reproduced in any form
without written permission of Hyundai Elevator Co., Ltd..
Installation Manual for Mechanical Parts WBVF
REVISION
NO. Specification DATE Manager
0 First Edition 2013.08.24
1 Edit the format 2013.11.05
2 Reorganization of the manual 2014.05.30
Reorganization of the manual

3 2015.01.23
(3. Machine Room Part)
3.7 TM Handle Switch part Update

4 2015.06.10
(GX30 Type)
3.3 Gearless-New MR Type Traction

5 2015.10.08
Machine(GX30, GA75, GA100 Model) Part Update
Reorganization of the manual

6 2015.11.18
(New Style Guide)
2
Table of Contents
1. Safety Information .........................................................................................................................8
1.1 Safety Requirements ............................................................................................................8
1.1.1 Protective Equipment .................................................................................................8
1.2 Common Safety Precautions ..............................................................................................10
1.2.1 Precautions ..............................................................................................................10
1.3 Precautions for Each Work Process ...................................................................................13
1.3.1 Site Visit and Survey before Construction ...............................................................13
1.3.2 Construction and the Office / Warehouse Installation ..............................................15
1.3.3 Bringing Equipment and Material .............................................................................18
1.3.4 Lifting .......................................................................................................................19
1.3.5 Template Work .........................................................................................................20
1.3.6 Welding Machine Installation and Welding Work .....................................................21
1.3.7 Machine Room Work (Installing the Traction Machine, Governor, and Control Panel)
22
1.3.8 Installing the Motor Winch ........................................................................................23
1.3.9 Installing the First Rail ..............................................................................................24
1.3.10 Car Frame Assembly .............................................................................................26
1.3.11 Bringing the Counterweight and Rope Work ..........................................................27
1.3.12 Temporary Low-Speed Test Drive .........................................................................28
1.3.13 Rail Installation .......................................................................................................30
1.3.14 Entrance Installation ..............................................................................................31
1.3.15 Car Panel Assembly ..............................................................................................32
1.3.16 Piping and Wiring ...................................................................................................33
1.3.17 Preparations for a High-Speed Test Drive .............................................................33
1.3.18 High-Speed Test Drive ...........................................................................................34
1.3.19 Cleaning and Finishing ..........................................................................................35
2. Standard Installation Process for Rope-Type Elevators .............................................................36
3. Main Components of Elevator .....................................................................................................38
4. Work before Installation ..............................................................................................................39

4.1 Site Visit .............................................................................................................................39
4.2 Office and Warehouse Installation .....................................................................................40
4.3 Preparation of the Floor Plans and References .................................................................41
5. Template .....................................................................................................................................42
5.1 Specifications of Template Material ...................................................................................42
5.2 Cutting the Template Material ............................................................................................42
5.3 Installing the Template on the Upper Entrance ..................................................................43
5.4 Checking and Fixing the Template .....................................................................................44
5.5 Check Sheet .......................................................................................................................45
5.5.1 Standard Template Sizes of Passenger Elevator Ⅰ ................................................46
5.5.2 Standard Template Sizes of Passenger Elevator Ⅱ ................................................48
6. Traction Machine ........................................................................................................................50
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WBVF Installation Manual for Mechanical Parts
6.1 Geared Type Traction Machine ..........................................................................................50

6.1.1 Installing the Machine Beam ....................................................................................50
6.1.2 Installing the Machine Beam Plate ...........................................................................52
6.1.3 Installing the Isolation Pad .......................................................................................54
6.1.4 Assembling the Traction Machine ............................................................................54
6.1.5 Checking the Vertical Alignment of the Sheave .......................................................54
6.1.6 Installing the Governor .............................................................................................55
6.1.7 Assembling the Governor Cover ..............................................................................56
6.1.8 Installing the Control Panel ......................................................................................56
6.2 Gearless-MR Type Traction Machine (GT/GX Model) .......................................................57
6.2.1 Installing the Machine Beam Support ......................................................................58
6.2.3 Installing the Isolation Pad .......................................................................................60
6.2.4 Installing the Machine Bed Support .........................................................................60
6.2.5 Engaging the Secondary Sheave and Secondary Sheave Support Bracket ...........61
6.2.6 Installing the Machine Bed .......................................................................................62
6.2.7 Installing the Traction Machine ................................................................................63
6.3 Gearless-New MR Type Traction Machine (GX30, GA75/100 Model) ...............................66
6.3.1 Installing the Base Beam .........................................................................................67
6.3.3 Installing the Isolation Pad Assembly ......................................................................71
6.3.4 Assembling the Blocking Beam ...............................................................................71
6.3.5 Assembling the Machine Bed and Deflector Sheave ...............................................72
6.3.6 Assembling the Traction Machine ............................................................................73
6.3.8 Assembling the Rope Guard ....................................................................................74
6.3.9 Assembling the Traction Machine Cover .................................................................75
6.3.10 Final Inspection ......................................................................................................76
6.4 Gearless-MRL Type Traction Machine (GN Model) ...........................................................77
6.4.2 Installing the Support Bracket ..................................................................................79
6.4.3 Installing the Traction Machine Isolation Pad ..........................................................80
6.5 Gearless-New MRL Type Traction Machine (GY Model) ...................................................88
6.5.1 Installing Support Bracket on the Counterweight Side .............................................88
6.5.2 Installing the Machine Foundation ...........................................................................90
6.5.3 Installing Isolation Pad .............................................................................................92
6.5.4 Installing the Traction Machine Plate .......................................................................92
6.5.7 Installing Isolation Pad and Hitch Plate ....................................................................99
6.6 Gearless Type Traction Machine Brake .............................................................................99
6.7 Traction Machine Handle Switch ......................................................................................100
6.7.1 Structure of Traction Machine Handle Switch ........................................................100
4
6.7.2 Checking the Installation ........................................................................................102

6.8 Check Sheet .....................................................................................................................103
6.8.1 Machine Beam .......................................................................................................103
6.8.2 Traction Machine and Machine Bed ......................................................................104
6.8.3 Governor ................................................................................................................104
6.8.4 Machine Room Piping ............................................................................................105
6.8.5 Control Panel .........................................................................................................105
7. Temporary Car ..........................................................................................................................106

7.1 Preparations for Assembling Temporary Car ...................................................................106
7.1.1 Installing the Pit Ladder .........................................................................................106
7.1.2 Installing Buffer Footing for Car .............................................................................106
7.1.3 Installing Buffer Footing for Counterweight ............................................................107
7.1.4 Installing the 1st Rail ..............................................................................................107
7.1.5 Installing the Buffer ................................................................................................108
7.1.6 Installing the Safety Device ....................................................................................109
7.1.7 Car Stile Assembly .................................................................................................111
7.1.8 Bolster Assembly (GN Type) .................................................................................112
7.1.9 Platform Assembly .................................................................................................114
7.1.10 Installing the Top Beam (Gearless Type) ............................................................116
7.1.11 Align the bolt holes of the top beam with the bolt holes of the top beam suspension
sheave. Then, tighten them with bolts. .................................................................117
7.1.12 Brace Rod Assembly ...........................................................................................118
7.1.13 Installing the Temporary Guide Shoe ..................................................................119
7.1.14 Installing the Governor Holding Device ................................................................120
7.2 Temporary Car Assembly .................................................................................................124
7.2.1 Installing the Support Angle for Temporary Car .....................................................124
7.2.2 Vertical Pillar Assembly .........................................................................................125
7.2.3 Support Scaffold Assembly ....................................................................................126
7.2.4 Horizontal Reinforcement Pipe Assembly ..............................................................126
7.2.5 Safety Fence Assembly .........................................................................................127
7.2.6 Installing Protective Ceiling and Work Plate ..........................................................127
7.2.7 Installing the Fall Prevention Bumper and Furnishing Fire Extinguisher ...............128
7.3 Check Sheet .....................................................................................................................128
7.3.1 Buffer and Buffer Footing .......................................................................................128
7.3.2 Safety Device .........................................................................................................129
7.3.3 Car Frame ..............................................................................................................130
7.3.4 Governor Holding Device .......................................................................................130
8. Rope Work ................................................................................................................................131

8.1 1:1 Hanging the Main Rope ..............................................................................................131
8.1.1 Winding the Steel Wire around the Rope (Babbitt Type) .......................................131
8.1.2 Filling the Rope Socket with Babbitt ......................................................................132
8.1.3 Connecting the Car and Counterweight with Rope ................................................133
8.1.4 Preventing Rope Twisting ......................................................................................134
8.1.5 Bringing the Counterweight into the Hoistway .......................................................134
8.1.6 Hanging the Rope on the Car Side (Babbitt Type) ................................................136
8.2 2:1 Hanging the Main Rope ..............................................................................................137
5
8.2.1 Engaging the Wedge-Type Rope ...........................................................................137

8.2.2 Wrapping Method ...................................................................................................138
8.3 Hanging the Upper MRL Rope .........................................................................................144
8.3.1 Engaging the Shackle on the MRL Rope ...............................................................144
8.3.2 Bringing the Counterweight into the Hoistway .......................................................145
8.3.3 Hanging the Rope on the Traction Machine Main Sheave ....................................146
8.4 New MRL Type .................................................................................................................147
8.4.1 Installing the Hitch Plate on the Car Hitch and Counterweight Sides ....................147
8.4.2 Rope Work .............................................................................................................148
8.4.3 Installing the Temporary Subweight .......................................................................160
8.4.4 Installing the Subweight Fixing Bracket .................................................................161
9. Guide Rail .................................................................................................................................162

9.1 Cleaning the Rail Joint Part ..............................................................................................162
9.2 Measuring the Rail Bracket ..............................................................................................163
9.3 Bringing the Rail into the Hoistway ...................................................................................163
9.4 Fixing the 1st Guide Rail ..................................................................................................164
9.5 Checking the Rail Bracket Installing Location ..................................................................165
9.6 Installing the 1st Rail Bracket ...........................................................................................165
9.7 Installing the 2nd Rail Bracket (Car/Counterweight side) .................................................167
9.8 Installing the 2nd Rail Bracket (Using Common rail) ........................................................168
9.9 Centering the Rail .............................................................................................................169
9.10 Welding the 1st Bracket and 2nd Bracket ......................................................................170
9.11 Connecting the Rail ........................................................................................................171
9.12 Measuring the Rail Straightness ....................................................................................172
9.13 Installing the Top Rail at the Top Side ...........................................................................173
10. Entrance ..................................................................................................................................174

10.1 Landing Sill .....................................................................................................................174
10.1.1 Determining the Installation Position of Sill Support ............................................174
10.1.2 Installing the Sill Support .....................................................................................175
10.1.3 Installing the Landing Sill .....................................................................................176
10.1.4 Installing the Toe Guard .......................................................................................177
10.2 Jamb ...............................................................................................................................177
10.2.1 Measuring the Jamb Dimensions .........................................................................177
10.2.2 Installing the Jamb ...............................................................................................178
10.3 Landing Door Operator ...................................................................................................184
10.3.1 Installing the Landing Door Operator ...................................................................184
10.4 Landing Door ..................................................................................................................186
10.4.1 Installing the Landing Door ..................................................................................186
10.4.2 Installing the Triangle Key ....................................................................................188
10.4.3 Adjusting the Landing Door Release Roller .........................................................189
10.4.4 Adjusting the Door Interlock Center .....................................................................189
10.4.5 Adjusting the Door Interlock Operation ................................................................190
11. Car ..........................................................................................................................................191

11.1 Installing the Subweight .................................................................................................191
11.2 Installing the Car Panel and Ceiling ...............................................................................192
6
11.3 Centering Car Panel .......................................................................................................194

11.4 Installing the Apron .........................................................................................................196
11.5 Installing Compensation Chain .......................................................................................196
11.6 Installing the Whisper-Flex Chain ...................................................................................197
11.7 Connecting the Car and Counterweight with the Whisper-Flex Chain ...........................198
11.8 Adjusting the Guide Shoe ...............................................................................................198
11.8.1 Sliding Guide Shoe ..............................................................................................198
11.8.2 Roller Guide Shoe ................................................................................................202
11.8.3 Rubber Guide Shoes and Urethane Guide Shoes ...............................................206
11.9 Car Header Arm Assembly .............................................................................................206
11.10 Installing the Vertical Rod .............................................................................................207
11.11 Tie Rod Assembly ........................................................................................................208
11.12 Car Door Operator ........................................................................................................209
11.12.1 M2CA .................................................................................................................210
11.12.2 UM2 ...................................................................................................................214
11.12.3 P1 .......................................................................................................................215
11.13 Safety Edge Cable Wiring ............................................................................................218
11.14 Installing the Door Cover ..............................................................................................219
11.15 Car Door .......................................................................................................................220
11.16 Installing the Clutch ......................................................................................................221
11.16.1 CDL Clutch .........................................................................................................221
11.16.2 General Clutch ...................................................................................................222
11.17 Safety Edge Cable Wiring ............................................................................................224
11.18 Installing the Car Junction Box .....................................................................................225
11.19 Adjusting the Rib V-Belt Tension ..................................................................................225
11.20 Adjusting the Wire Rope Tension .................................................................................226
7
1. Safety Information
Important
Read the Safety Note and Safety Information on this page carefully before starting to work.
Since the installation of an elevator is carried out in vertical space, there is always the danger of objects
or people falling into the space. Be sure to always wear personal protective equipment. In areas where
there is the risk of falling, install the safety equipment before carrying out the work. Also, perform safety
training to prevent safety accidents.
1.1 Safety Requirements
1.1.1 Protective Equipment
• Everyone on the worksite should always wear personal protective equipment regardless of the work-
place or process.
Safety helmet
Safety belt
Protective gloves
Safety shoes
• Use a full-body harness for a safety belt.
• Do not keep any tools including portable tools inside the pockets of your work clothes.
• Do not wear accessories that may conduct electricity.
8 Safety Information
• Install the eye nuts (M16) on both walls of the hoistway entrance.
(1) For mounting the lifeline: Top floor, bottom floor + 2 floors
[Figure 1.1 Eye Nuts for Installing the Lifeline]
(2) For mounting the safety belt: Floor for bringing the materials, top floor - 1 floor (applied only to the
MRL type)
Number of installed eye nuts: 2 for each floor
Safety Information
9
[Figure 1.2 Eye Nuts for Installing the Safety Belt]
1.2 Common Safety Precautions
1.2.1 Precautions
• Everyone on the worksite, regardless of the workplace or process, should always wear designated
work clothes and personal protective equipment (safety helmet, safety shoes, and full-body harness).
(Do not wear sleeveless work clothes.)
• When working inside or near the hoistway, be sure to connect the hook of the full-body harness to
the eye nuts or a solid structure.
• In the following locations, install the eye nuts (M16) on both walls of the hoistway entrance and
connect the hook of the full-body harness to the eye nuts while working.
 For mounting the safety belt: Floor for bringing the materials, top floor - 1 floor (applied only to the
MRL type)
 For mounting the lifeline: Top floor, bottom floor + 2 floors

• When working inside the hoistway, be sure to use a lifeline (Ø16 mm) and an anchorage connector
(Cobra). Remove the lifeline before operating the temporary car. (In the case of the New Yzer model,
however, after completing the rope work, remove the lifeline before working on the entrance.)
• Two people or more should work as a team, except for wiring work.
• Do not work on the upper / lower parts of the hoistway at the same time.
• When leaving the worksite, be sure to turn off all equipment and lock up all power tools, equipment,
elevators, power switches, and control switches. (To prevent unauthorized access)
• Smoking is not allowed except in designated areas.
• When two or more people are working or operating the equipment (winch, chain block, etc.), be sure
to repeat the verbal commands to each other to check the safety status.
• When operating the car, repeat the verbal commands to each other. (e.g., Car up, car down)
• Install the prescribed protective devices for handling dangerous machines or devices. (Do not
dismantle these devices while working.)
• Be sure to turn off the power before repairing or inspecting dangerous machines or devices, including
power tools.
• Be sure to use power tools that are appropriate for the work. (Do not use a grinder to cut the plywood
or rails.)
• Store dangerous materials such as oil and gas in a designated area. Bring only one day’s supply to
the worksite to use.
• Perform the following measures to prevent accidents such as rollover and falling when it rains, snows
or when the worksite freezes.
 Check the hallway (work path) and worksite before starting work.
 Be sure to use a cart for loads of 20 kg or more. (Manually carrying the load is not allowed.)
• Install lighting and protective netting at the worksite and in the hallway. (If it is difficult to install lighting,
use portable lighting fixtures.)
Safety Information
11
[Figure 1.3 Precautions]
[Figure 1.4 Installing the Lifeline]
1.3 Precautions for Each Work Process
1.3.1 Site Visit and Survey before Construction
Warning
• Beware of the danger of falling objects or falling while performing the site visit and survey.
• Beware of falling while installing the shield plate.
• Be sure to wear designated work clothes and personal protective equipment (safety helmet, safety
shoes, full-body harness) when performing the site visit and survey before construction.
• The project manager should check if a safety fence was installed at the entrance of each floor.
Perform the following measures if a safety fence was not installed.
 In the case of third-party construction work
: Request that the construction company (contractor) install the safety fence.
(Hold off on the construction (material delivery) if a safety fence was not installed.)
 In the case of Hyundai construction work
: Install a safety fence at the entrance of each floor during construction.
• In areas where there is a risk of falling during the survey, be sure to connect the hook of the full-body
harness to a solid structure.
Safety Information
13
• During construction, check if a safety fence was installed at the entrance of each floor and then install
a safety shield plate. (Cover every side of the entrance so objects do not fall or fly into the hoistway.)
• The project manager should check if the rebar was removed from the hoistway. If not, ask the
construction company (contractor) to remove the rebar. (Hold off on the construction (material
delivery) if the rebar was not removed from the hoistway.)
• The project manager should check if an outer wall was installed in the steel-framed hoistway. If not,
ask the construction company (contractor) to install an outer wall. (Hold off on the construction (mate-
rial delivery) if the rebar was not removed from the hoistway.)
• When installing the safety shield, use a stable workbench so you don't fall down.
• Check if there is a risk of flooding or flow of rainwater to the machine room or hoistway.
• Check if there is any construction material that is at risk of falling into the hoistway in the machine
room or the entrance of each floor. (When loading and stacking, move them to a safe location.)
• Check the location of the distribution box for a construction power source, its capacity and voltage,
and determine if a construction power line is necessary.
• Check the delivery path for the material and equipment, and secure a storage place for them.
• Check if you can use the tower crane and the hoist for materials and passengers.
• Check the location and strength of the lifting hook installed on the ceiling of the machine room.
(Request reinforcement if necessary.)
[Figure 1.5 Safety Fence]
[Figure 1.6 Safety Shield]
1.3.2 Construction and the Office / Warehouse Installation
Caution
• There is the risk of fire from using unauthorized heaters.
• There is the risk of rollover while moving to the worksite.
• Request that the contractor notify all workers on the worksite so they are aware of the elevator
construction work that is underway and no objects fall into the hoistway.
• Secure a path between the office and warehouse and install lighting along the path if necessary.
• The worksite manager should check if there is enough personal protective equipment (safety shoes,
safety helmet, full-body harness, etc.) for workers and carry out the safety training to ensure that
workers always wear them. (Must check whether all workers are wearing their personal protective
equipment.)
• The worksite manager should identify all worksite risk factors in advance and inform the workers. Be
sure to look around the worksite with all workers and establish the measures for each risk factor
before starting the work.
• Install automatic diffusion fire extinguishers in the office and warehouse, and use iron trash cans.
• Use authorized heaters in the office and warehouse. Storage of flammable materials is prohibited.
• The worksite manager should carry out safety training such as TBM (safety rules for each installation
process) before starting work and record the safety inspection / training in a daily log.
• Keep a first-aid kit in the office.
Safety Information
15
• Be sure to keep the following documents in the office.

 Safety and Health Guidelines, Safety Organization Chart, Emergency Contact, Process Schedule
 Safety Rules for Each Installation Process

(If there is no office at the worksite, keep the Safety Rules for Each Installation Process on the right
wall of the entrance on the main floor.)
[Figure 1.7 Safety Rules for Each Installation Process]

[Figure 1.8 Safety and Health Guidelines, Safety Organization Chart, Emergency Contact, and
Process Schedule]
Safety Information
17
1.3.3 Bringing Equipment and Material
1) Things to check before starting work

• Check if there is any problems with the braking and alarm system of the forklift.
• Check if the headlights, turn signals, and taillights of the forklift turn on properly.
• Check measures to prevent unauthorized people from entering the work zone.
[Figure 1.9 Measures to Prevent Unauthorized Access to the Worksite]
• Check if a sign is attached to the area where materials are loaded and stacked.
• Check the worksite and transportation route (work path).
• Check the weight and center of gravity of the load.
2) Precautions
Caution
• Avoid straining your body when carrying heavy objects. Be careful not to get your hands or feet
caught when lifting or placing objects. (One person should not carry more than 25 kg.)
• While carrying objects, be sure to wear protective gloves. Be careful not hurt yourself or cut
the rope on the sharp edges of an object.
Notice
Check the ground conditions around the worksite. (Danger of forklift rollover.)
• Use a forklift to deliver equipment / materials.
• A signal person should be present at the worksite where equipment / materials are being carried. The
forklift operator should follow the instructions of the signal person.
• Lay down the materials or tie them with rope so they do not roll over.
• Install a safety fence around the area where materials are stacked and stored. (Post the name and
contact number of the person in charge.)
• Comply with the hoist safety rules while carrying materials using a hoist.
1.3.4 Lifting
Caution
• Be careful not to get hurt by falling objects while lifting or carrying a load.
• Be careful not to get caught under the lifting machine. Beware of the risk of a rollover.
• Check the conditions of communication devices such as a radio set.
• Check measures to prevent unauthorized people from entering the work zone.
• Check the conditions of the rope sling, belt sling, shackle, lifting machine, and lifting hook.
• When using the motor winch, make sure that it is fixed to the floor.
[Figure 1.10 Checking the Lifting Machine and Rope]
• Do not carry out lifting work in bad weather. Prevent workers from accessing the load transport path.
• Check the load entrance in advance and remove any objects that may interfere or fall.
• Be sure to fasten the load with a rope sling or belt sling and shackle that can withstand the weight of
the load. (Do not use the tie wire, Manila rope, and rope sling fixed with a U clip.)
• Lift the load up to about 100 mm and shake it to check if it is securely fixed.
• Immediately cover the lifting hole in the machine room with a steel plate after carrying out the lifting
work.
• If an entrance door is installed in the machine room, lock the door.
• In places where there is a risk of falling, be sure to install the facility for fixing the full-body harness
and connect the hook to the facility.
• The rated capacity of the lifting machine should be larger than the weight of the load.
• If the hook installed on the ceiling of the machine room is not stable or its position is not right, fix 4 or
more parts of a separate lifting bracket with anchor bolts (M16) to use it.
Safety Information
19
• Install the supporting rope to the load when lifting it and prevent unauthorized people from
approaching the work zone.
• In the case of the new MRL model, be sure to conduct the hook test on the hoistway to secure safety
before lifting a load.
• In the case of the new MRL model, install a swivel on the hoistway hook and at the end of the rope.
[Figure 1.11 Lifting Hook]
1.3.5 Template Work

• Check if the safety fence and safety shield plate are properly installed on each floor.
• Check the conditions of the power tools that will be used for the work.
• Check if the hoistway pit is clean and if there is any flammable materials in it.
• Check measures to prevent unauthorized people from entering the machine room.
2) Precautions
Warning
• Beware of injuries caused by falling objects or a worker who has fallen.
• Beware of falling when working on a ladder.
Caution
Beware of electric shock due to power tools.
• If there is any object that is at risk of falling around the entrance, hoistway, and machine room, be
sure to remove it completely. Cover the opening with a shield and then carry out the template work.
• Do not carry out the template work on the upper and lower parts at the same time.
• When using a separate work plate while working on the lower template, be sure to secure it firmly.
• Install the ladder in the hoistway pit firmly.
• Firmly cover the lifting hole in the machine room and then carry out the upper template work.
• After completing the template work, be sure to tightly cover the hole in the machine room.
• Install work lights at the top and bottom floors. (150 lux or above)
1.3.6 Welding Machine Installation and Welding Work

• Check the condition of the wire sheath.
• Check the condition of the welding machine holder. (Use the product with the designated insulation
handle.)
• Check the operating condition of the electric shock prevention device.
Safety Information
21
2) Precautions
Caution
Be sure to wear personal protective equipment such as welding gloves and a welding safety mask
during welding. (Beware of electric shock and burns during welding.)
Notice
• Be sure the secondary ground line is in contact with the welding target. If the ground line is
detached from the welding target, remove the ground on the elevator system ground line. (To
prevent damage on the system ground line due to welding current.)
• Make sure that the welding cable is well-organized. In the place that is flooded or has exces-
sive moisture, drain the water and install the cable cleat.
• Be sure to remove flammable substances from the work zone before welding.
• Use the welding machine in a safe place where there is no risk of flooding.
• Be sure to use a power cord, welding wire, and ground wire with enough capacity.
• Use designated lugs and bolts for the wiring ends that a connected to the 1st and 2nd sides of the
welding machine to connect them properly..
• Do not leave the welding machine holder unattended when power is supplied.
• Be sure to furnish a fire extinguisher and prevent sparks from flying during welding. (sparks blocking
device, fire blanket, etc.)
[Figure 1.12 Welding Machine]
1.3.7 Machine Room Work (Installing the Traction Machine, Governor, and Control
Panel)

• Check the conditions of the chain block, lifting machine, and lifting hook on the ceiling of the hoistway.
• Check the conditions of the wire rope and shackle.
• Check the insulation and sheath conditions of the holder on the AC arc welding machine.
2) Precautions
Warning
• Do not work on the upper and lower parts at the same time when working in the machine room.
• Do not hang the traction machine and work underneath it. (Do not lift more than 100 mm from
the floor of the machine room or the machine beam.)
• Beware of falling objects due to problems with the lifting hook or chain block problems.
Caution
• Be careful not to get hurt by the corner of the machine stand while working in the machine
room. (If the stand corner is not chamfered, cover the corner with a plastic or rubber cap.
• Be careful not to get crushed by the traction machine or traction machine beam.
Notice
Prevent unauthorized access to the machine room. (If a fireproof door is not installed, install a
shield plate at the entrance of the machine room.)
• If the hook installed on the ceiling of the machine room is not stable or its position is not right, fix 4 or
more parts of a separate lifting bracket with anchor bolts (M16) to use it. (In the case of large-sized
traction machines, install the lifting beam.)
• The rated capacity of the lifting device should be larger than the weight of the traction machine. For
hanging devices, use rope slings (alloy), belt slings, and shackles. (Do not use the tie wire, Manila
rope, and rope sling fixed with a U clip.)
• Do not leave the worksite while lifting a load such as the traction machine.
• Do not remove the lock of the chain block connected to the traction machine before the traction
machine, traction machine beam, Isolation Pad, and machine beam have been fixed with bolts or
welding.
• Cover the machine room hole tightly.
• Install the governor and check its operating condition.
• Follow the safety rules while welding.
1.3.8 Installing the Motor Winch
Warning
• If there is a risk of being crushed in the hoistway due to the safety device and platform
assembly work, do not use the motor winch.
• Attach the cover to the winch. (Be careful not to catch your fingers.)
• While lifting a load, prevent other people from accessing the area under the load. (Do not stop
the work while lifting the load.)
• There is the risk of falling objects due to the loose winch fixing section and too much load.
Safety Information
23
• Use anchor bolts (M16) to fasten 4 or more parts of the winch.
• Install pulleys at the locations where the rope bends so the load can be supported by the pulleys when
the rope is wound and unwound.
• Use anchor bolts (M16) to fasten 2 or more parts of the bracket on the concrete and hang the pulley
on the bracket directly or using the shackle.
• The rope should not touch objects other than the pulley or get twisted during operation.
• The E-Stop switch should be installed on the control panel of the winch.
• There should be clear communication between the worker and operator while working on the winch.
• The winch operator should frequently check how the rope is wound around the drum.
• If the winch is not used, cut off the power and cover and store it.
• When using the winch for lifting a load, be sure to use the lifting shackle.
[Figure 1.13 Motor Winch]
1.3.9 Installing the First Rail

• Check the conditions of the lifting hook, winch, and pulley.
• Check the E-Stop switch of the wire rope, shackle, and motor winch.
• Check the installation conditions of the protective devices on the power tools.
• Check for the leakage in the pit. (When flooded, drain the water before accessing the pit.)
2) Precautions
Warning
• When carrying the rail or placing the rail on the floor, be careful not to fall down or get your
fingers or feet caught under the rail. (Use the jig for carrying the rail.)
• Place a warning sign and secure a safe moving path so outside workers do not get hurt by the
rail.
• Prevent other people from approaching the area under the rail while lifting it.
• If the rail hanging on the winch rope rotates while lifting it, make sure that the rail has
completely stopped before continuing with the lifting work.
Caution
Beware of electric shock due to power tools.
Notice
• Do not step on the rail. (To prevent rollover and deformation of the rail)
• Do not use the building rebar or climbing hooks.
• Firmly fasten the work plate so it does not move. (Do not load more than 200 kg including the
workers on it.)
• Use anchor bolts (M12) to fasten 2 or more parts of the work plate support and use dedicated
steel material for the support pins.
• When lifting the rail, install 5 m of supporting rope (belt sling) or more and use the dedicated shackle.
• Firmly fasten the work plate so it does not move. (Do not load 200 kg or more including workers.)
• The work plate pipe support should be securely fixed at 2 or more locations (lay the M12 anchor bolt
at a location 70 mm deep or more under the ground) and use the dedicated steel material for the
support pins. (Do not use the building rebar, etc.)
[Figure 1.14 Work Plate for Installing the 1st Rail]
Safety Information
25
1.3.10 Car Frame Assembly

• Check the conditions of the lifting hook, winch, chain block, and pulley in the machine room.
• Check the installation conditions of the protective devices on the power tools.
2) Precautions
Warning
• Prevent other people from approaching the area under the load while lifting it. (Beware of
falling loads.)
• Hang the wire rope for lifting the load on the chain and gradually pull the chain block while you
work. (Be careful not to get caught between the load and the hoistway wall.)
• Beware of falling while working.
Notice
• There is the danger of rollover and being crushed due to the material.
• Beware of electric shock due to power tools.
• Consider the total weight of the car frame when installing the support.
• When assembling the load such as the safety device and platform, use a lifting device with a rated
capacity above the weight of the load.
• Use a fastening device, such as rope sling, bracket, and shackle, with sufficient lifting capacity to work
with the lifting device.
• When hanging a load on a lifting device, use a rope sling or belt sling and shackle to firmly fasten it.
(Do not use the tie wire, Manila rope, and rope sling fixed with a U clip.)
• Do not step on the platform before it has been placed it on the safety device and tightened with
assembly bolts. (To prevent rollover of the platform)
• When transporting the platform from the elevator hall to the hoistway, be sure to use the supporting
rope for lifting. Also, prevent other people from approaching the work zone.
[Figure 1.15 Using the Supporting Rope]
1.3.11 Bringing the Counterweight and Rope Work

• Check the conditions of the lifting hook, winch, chain block, and pulley in the machine room.
• Check the conditions of the wire rope, shackle, and operating switch.
• Check if a fire extinguisher has been furnished.
2) Precautions
Warning
• Be careful not to get your fingers caught on the sheave while working on the rope.
• Beware of falling when bringing the weight and counter case.
Caution
When working with the Babbitt, be sure to wear personal protective equipment such as protective
gloves and protective goggles and furnish a fire extinguisher to prevent a fire.
Notice
• There is the risk of fire due to welding.
• Be sure to hang the rope of the governor on the tension sheave completely so the safety
device can operate in case of an accident.
• When working on the entrance or top of the car, be sure to connect the hook of the full-body harness
to the eye nut or a solid structure.
• When lowering the rope, use a radio set so the ropes do not get twisted with each other.
• After completing the rope work, install the covers on the traction machine and governor.
• Assemble the rope socket on the car-side hitch plate and tighten the double nuts. Then, insert the pin.
Safety Information
27
• Check if the car socket is completely tightened, and gradually loosen the chain on the chain block on
which the counterweight is hanging so the load is applied to the main rope.
• Load the weight on the counter case and tighten the bracket. Then, fasten the weight and counter
case at the same time. (To prevent the weight from falling due to the operation shock or after getting
caught with the object in the hoistway.)
• When bringing the counter case loaded with the weight into the hoistway, beware of falling due to the
weight of the load. (Use a full-body harness and lifting rope.)
• When loading the weight on the counter case at the lowest floor, engage the guide shoe to the 1st
rail to prevent the counter case from falling.
• When moving the weight, make sure that you don't injure yourself and use the motor winch if possible.
(One person should not carry more than 25 kg.)
 MRL model (including the high-rise model)
: Do not put the load (e.g. weight) on the MRL top workbench. (Do not load over 250 kg including
workers.)
 Remodeling
: Use the chain block and automatic bar to firmly fix the car to the top section.
Work at the lowest floor when loading the weight on the counter case. (Do not load the weight on
the counter case at the highest floor.)
1.3.12 Temporary Low-Speed Test Drive

• Temporary Low-Speed Test Drive
• Check the power and the voltage of the lighting.
• Check if the shoe of the traction machine brake touches the drum properly, and if the spring is tight-
ened properly.
2) Precautions
Caution
• Beware of electric shock due to the power supply (380 V).
• Be careful not to get caught by the traction machine.
Notice
Be careful not to get caught by the traction machine.
• Check the sheath of the temporary wiring cable for damage. Then, bury the cable along a safe path
and protect it with a temporary cover to prevent damage.
[Figure 1.16 Insulation]
• Install a lock on the entrance to the machine room to prevent others from entering the room.
• Install a temporary power (380 V) cable so it does not touch the machine room floor.
• Place the automatic / manual switch on the control panel to manual mode and prevent others from
operating it arbitrarily until the car is ready for high-speed operation.
• Check if all safety switches on the control panel, the governor switch, emergency stop switch in the
car, and UP / DOWN buttons operate properly.
• Check if there are any problems when the car frame and counterweight operate at low speeds. (Inter-
ference by a foreign object, assembly status, rope connection status, etc...)
• Repeat the verbal commands to each other while operating the car. (e.g., Car up, car down)
Safety Information
29
• Install the E-STOP and COM (serial safety device) switches on the remote controller for installation.
(Check if the safety line jumper is removed for E-STOP in the control panel.)
[Figure 1.17 Serial Safety Device]
• Before the Test Drive, install a low-speed governor (50 m/min) on the car whose speed is 300 m/min
or more.
• Before the Test Drive, install a low-speed governor (50 m/min) on the car whose speed is 300 m/min
or more.
1.3.13 Rail Installation

• Check the operating conditions of the winch and pulley.
• Check the installation conditions of the lifting hook in the machine room and the protective devices
on the power tools.
• Check the insulation and sheath conditions of the holder on the welding machine.
• Check if the "Do not step on the protective ceiling" sign is attached to the protective ceiling.
• Check if the E-STOP and COM switches on the remote controller function properly.
2) Precautions
Warning
• Never use a lifeline when operating a temporary car. However, in the case of the new MRL
type, be sure to use the lifeline when installing the rail.
• While working, do not go outside of the safety fence or lift the rail abruptly. Also, be careful not
to slip while tightening a bolt.
• While the temporary car is rising, the worker should be careful not to bump into the car at the
point where the temporary car encounters the counterweight. When the car is below the point
where it encounters the counterweight, assemble the guide shoe and ride the rail to safely go
down.
• Do not ride on top of the protective ceiling while working.
• Do not ride on top of the protective ceiling while working.
• While working with the hammer drill, maintain a stable posture. Be careful not to fall down if
the drill gets caught in the rebar and suddenly rotates.
Caution
• Be careful not to get your fingers caught when assembling the joint on the guide rail.
• Be careful not to get your hands caught between the sheave and rope.
• Be sure to wear personal protective equipment (safety helmet, safety belt, and safety shoes) and
connect the safety belt to a solid structure.
• While the temporary car is operating, make sure that the counterweight does not interfere with the
hoistway wall or other objects.
• Install a safety fence and protective ceiling on the workbench located at the top of the car.
• Be sure to install the governor when installing the rail. (Check if it operates properly before beginning
the work.)
• Install an impact buffer in the pit and inject oil in the case of an oil buffer. (Car / Counterweight side)
• Other safety rules follow the safety rules for installing the 1st rail.
• Do not overload the rail and components on the workbench of the temporary car.
• Do not touch the rope while driving the temporary car.
1.3.14 Entrance Installation

• Check if a fire extinguisher has been furnished.
• Check if protective devices are installed on the power tools.
2) Precautions
Warning
• While working with the hammer drill, maintain a stable posture. Be careful not to fall down if
the drill gets caught in the rebar and suddenly rotates.
• Do not work on the upper and lower parts at the same time.
• When working at the entrance, be sure to connect the full-body harness to a solid structure.
• Lay the materials on the floor so they do not fall down in front of the entrance.
• Be careful not to get hurt by the sharp edges of the jamb or door.
• If the landing door is not installed after installing the jamb, reinstall the safety fence and shield plate.
• Check the lock status of the interlock after installing the door.
Safety Information
31
• Do not remove the protective ceiling on the temporary car until the doors are installed on all the floors.
• Do not carry out pre-work such as constructing a jamb at the entrance.
• Follow the safety rules while welding. (Beware of the risk of fire due to the welding work.)
• After installing the landing door, check the position of the temporary car when entering the hoistway.
1.3.15 Car Panel Assembly

• Check the lighting conditions to ensure an efficient work process.
• Check the installation conditions of the ladder and work plate.
2) Precautions
Caution
• When placing the car ceiling on the car wall, be careful not to get your fingers caught. (Beware
of the risk of getting caught between the materials)
• Be careful not to get hurt by the sharp edges of the steel plate on the car wall.
• Remove any foreign objects such as projections, pins from the hoistway wall in advance.
• Firmly fasten the four corners of the car ceiling using a sturdy lifting device. (Do not use wrought iron.
Beware of the danger of falling while working.)
• When you move to another location on the car wall, be sure to connect the full-body harness. (Beware
of the danger of falling.)
• Be sure to work in teams of two people and repeat the verbal commands to each other while working.
(Establish a signal system when working in teams of two people.)
[Figure 1.18 Installation Conditions]
1.3.16 Piping and Wiring

• To prevent electric shock, check if all the switches on the distribution box and control panel are cut
off from the power and grounded properly.
• When working on the wiring around the car or inside the hoistway, be sure to connect the full-body
harness to the car structure. Make sure thTest Driveat the wiring does not interfere with the hoistway
components.
2) Precautions
Warning
When installing the lower switch and working on the wiring, step on the workbench and work in a
stable posture. (Beware of the danger of falling.)
Caution
When using a common wiring tray for the building, be sure to cut off the power to every wiring in
advance. (Beware of electric shock while working on the wiring.)
• Make sure that the opening is blocked while working in the machine room.
• Remove the connector connected to the control panel.
• Make sure that the distribution box is locked after working.
• Be sure to place the Hilti gun against the wall in a stable position when firing it. (Only authorized
personnel are allowed to use the gun.)
1.3.17 Preparations for a High-Speed Test Drive
Warning
• Do not work on the upper and lower parts at the same time. (Beware of falling objects.)
• Beware of falling objects such as weights.
• Beware of the danger of an accident due to improper manipulation of the control panel.
• While operating the car, repeat the verbal commands to each other.
• Check if the machine room, car, pit, and hoistway are suitable for operation.
• Check if the machine room, car, pit, and hoistway are suitable for operation.
• Place the control panel switch to manual mode and attach a "Do not operate" sign.
• Install a safety fence on top of the car and use a full-body harness while working on top of the car.
Safety Information
33
• Install a fixing bracket so the weight does not move after it is loaded.
• Install safety switches (e.g. final limit switches on the upper / lower part) and check the operating
conditions.
• When riding on top of the car, open the landing door and check to see if there is a car.
• After adjusting the door, remove the jumpers on the interlock switch and gate switch and recover the
switch functions.
[Figure 1.19 Preparations for High-Speed Test Drive]
1.3.18 High-Speed Test Drive

• Check if all the safety switches, including the interlock switch on each floor, operate properly.
• Inspect the brake, governor, safety device, terminal slowdown switch on the upper / lower part, and
final limit switch.
• Check if there is any interfering object around the traction machine and governor.
• Check the operating conditions of the interphone or radio set that is used for communicating between
workers in the car and machine room.
2) Precautions
Warning
• Do not perform high-speed test drives while there is a worker on top of the car.
Caution
There is the danger of electric shock while working on the control panel.
Notice
When checking the power control system on the control panel, cut off the main power. If the
inverter is embedded with a condenser (e.g., inverter 900 type), hazardous voltage may still
remain even after the power has been cut off. Therefore, wait for at least 10 minutes and check if
the residual voltage remains before working.
• When riding on top of the car, open the landing door and check to see if there is a car. Then, convert
the automatic switch to manual mode.
• When working on top of the car, be sure to operate the stop switch on the control panel at the top of
the car.
• When working in the pit, open and fix the landing door on the lowest floor, turn on the pit lighting
switch, and then place the pit safety switch to the stop position.
1.3.19 Cleaning and Finishing
Warning
• When working in the pit, open and fix the landing door on the lowest floor and cut off the pit
safety switch to stop car operation. (If you inevitably need to close the landing door on the
lowest floor, be sure to have a worker outside the landing door.)
• When moving out from the pit, do not hang on the bottom of the car or grab the closed landing
door. (There is the danger of falling and being crushed due to the sudden lifting/lowering of
car.)
• When repairing or inspecting the elevator used for construction or removing foreign objects
such as the guide rail from the top of the car, be sure to cut off the automatic operation switch.
If there is the danger of falling, be sure to connect the full-body harness to a solid structure.
(Place a "Do not use while working on the elevator" sign at the elevator hall button on every
floor.)
• In the case of 2 or more cars in parallel,

 Prohibit high-speed operation for one of them and install a partition between the cars.
 Do not work on the upper and lower parts at the same time. (If it is inevitable, align the cars
at the same height.)
 If any one CAR can be driven, do not step on the middle beam or move over to an adjacent
CAR.
Notice
There is the danger of collision with a car or weight by operating the car.
• When cleaning the traction machine and governor in the machine room, be sure to cut off the main
power.
• When cleaning the car and hoistway, do not use an arbitrary jumper on the safety switch.
• Use diesel oi when cleaning the rail. (Do not use thinners.)
• Beware of slipping accidents due to the oil on top of the car or pit.
• When removing the reinforcing tape on the jamb and door, beware of the sharp edges on the steel
plate. When removing the reinforcing tape inside the hoistway, be sure to ride on top of the car and
work in a stable posture.
Safety Information
35
2. Standard Installation Process for Rope-Type Elevators
1-1. Supply construction power and install lighting

1. Construction and warehouse
installation
1-2. Check the machine room and hoistway
2-1. Install safety facilities
2-2. Process template material

2. Template installation
2-3. Install template
2-4. Measure the jamb and bracket
3-1. Lift the load for each structure
3-2. Install the machine beam, machine foundation, and

3. Machine room installation governor
3-3. Center the traction machine, control panel, and

governor
4-1. Install the 1st scaffold and buffer
4-2. Install the 1st guide rail

4. Car assembly
4-3. Assemble the safety device and car frame
4-4. Install the workbench on top of the car
5-1. Lower the rope and shackle on the counterweight

side
5. Rope hanging
5-2. Hang the ropes on the car side and governor side
5-3. Bring the counterweight into the hoistway
6-1. Perform piping on the machine room
6-2. Perform wiring on the machine room

6. Low-speed test run
6-3. Perform low-speed test run
6-4. Check and adjust the brake
7-1. Install the rail bracket
7. Hoistway component installation 7-2. Install the guide rail
7-3. Install the separating beam
8-1. Install the entrance sill
8. Elevator hall component installation 8-2. Install the jamb
8-3. Install the landing door
Standard Installation Process for Rope-Type Elevators

36
9-1. Perform cable wiring on the hoistway
9. Hoistway electric work 9-2. Mount limit switch
9-3. Lower the T-cable and perform wiring
10-1. Mount the guide shoe
10-2. Assemble the car panel
10-3. Mount the car door

10. Car panel and component assembly
10-4. Mount the car components
10-5. Center the car
10-6. Perform wiring around the car
11-1. Mount the landing device
11. High-speed test run 11-2. Check the signal line and measure overall height
11-3. Check the indicators and buttons
12. Inspection and customer delivery
Standard Installation Process for Rope-Type Elevators

37
3. Main Components of Elevator
Main Components of Elevator

38
4. Work before Installation

The construction period is determined based on when the construction for the machine room and
hoistway is completed. Before construction, the installation manager should visit the worksite and consult
with the construction company to finally decide on the construction date. Notify the related departments
of the final construction date so the materials can be delivered for the construction in a timely manner.
Prepare the installation plans, specifications, component list, and installation tools in advance.
4.1 Site Visit

• Decide on the construction date after consulting with the construction company.
• Check the power necessary for the work.
• Check the construction plans.
• Decide the location of the warehouse.
• Write the site visit report.
• Compare the building structure with the installation plans.
39 Work before Installation

<Items to Check on the Building Structure>

#1 Height and size of the machine room
#2 Presence of a lifting hole and its size(if
necessary)
#3 Presence of a ventilation hole and its size
#4 Presence of a lifting hook and its sturdiness
#5 Presence of a path to machine room
#6 Presence of a support on the machine beam
#7 Dimensions of the entrance opening and the
position of the hall button
#8 Height of the top part
#9 Number of floors and the floor rise
#10 Pit depth and cleanliness
#11 Overall height of the hoistway
#12 Power necessary for the work
#13 Conditions of the rope duct and template
hole
#14 Conditions of the machine room wall at the
location of machine beam
#15 Dimensions of the hoistway
[Figure 4.1 Building Structure]
4.2 Office and Warehouse Installation

• Install the warehouse so it can also be used as an office.
• Install the lock on the entrance.
• Select an area where there is no risk of fire and flooding and furnish a fire extinguisher.
• Materials used for installing the warehouse should be returned after construction so they can be used
for other worksites.
40 Work before Installation

4.3 Preparation of the Floor Plans and References

• Collect the floor plans, specifications, material list, and architecture drawings necessary for installa-
tion and store them in a place that can be easily accessed by the workers.
• List the tools necessary for installation and submit requests to the relevant department.
• Compare the building structure with the reference installation drawing. Then, write down the details
on the site visit report and submit it to the relevant departments. Before the installation, take the
appropriate measures when any changes occur.
• Establish the installation plans according to the conditions at the worksite and the installation tech-
nologies used. Then, submit these plans to the construction company and keep them in the office so
installation workers can figure out the process status as needed.
[Table 4.1 Installation Drawings]
Type Floor plan Description
Hoistway It shows the floor rise, the number of floors, overall height, driving
distance, height of the top part, pit depth, machine room height,
cross-section mounting positions of the rail brackets, and the number of rails.
It shows the dimensions of the hoistway, car size, counterweight

Hoistway floor plan
size, entrance size, and installation location of the sill.
Entrance It shows the concrete opening of the entrance and the location of
construction plan the elevator hall button.
Installation
Entrance floor plan It shows the mounting status of the entrance sill.
plan
Entrance design
It shows the size of jamb, and entrance height and width.
plan
It shows the size of the machine beam, direction of the traction

Machine room
machine, position of the governor, position of the control panel,
floor plan and the position and size of the rope hole.
It shows the shape and design specifications of the inside of the

Design plan
car, door, jamb, and ceiling.
Electric wiring
Electric It shows the line numbers for wiring each section.
diagram
floor plan
Circuit diagram It shows the operating circuits and their functions.
Machine Machine assembly

It shows the assembly of each device.
floor plan diagram
Work before Installation

41
5. Template
Installation of the template is important as its layout determines the specifications for installing each
component. The template is divided into the upper template, which is installed on the floor of the machine
room, and the lower template, which is installed in the pit.
5.1 Specifications of Template Material

For upper template materials, C channels of designated specifications are used. For lower template mate-
rials, C channels, channels, and angles are selected based on the conditions at the worksite.
1) Upper template material

• C channel: Specifications of C60 × 30 × 10 × 2.3 or above.
2) Lower template material

• C channel: Specifications of C60 × 30 × 10 × 2.3 or above.
• Channel: Specifications of E75 × 40 × 7 × 5 or above.
• Angle: Specifications of L75 × 75 × 6 or above.
5.2 Cutting the Template Material

(1) Indicate the horizontal and vertical center lines on the template materials for the entrance, car, and
counterweight.
(2) Check the entrance width (JJ) based on the center lines of the entrance template material.
(3) Make 1 mm piano-line holes at the end positions of the entrance width (JJ).
(4) Check the distance between car rails (CAR BG) based on the center lines of the car rail template
material.
(5) Make 1 mm piano-line holes at the end positions which are determined by subtracting 10 mm from
the distance between car rails (CAR BG).
42 Template
(6) Check the distance between counterweight rails (CWT BG) based on the center lines of the counter-
weight rail template material.
(7) Make a 1 mm piano-line hole at the end positions which are determined by subtracting 10 mm from
the distance between counterweight rails (CWT BG).
5.3 Installing the Template on the Upper Entrance

(1) Make a 1mm hole on the template material and pass the piano wire through the hole so the piano
wire is aligned in a straight line inside the hoistway.
(2) Based on the temporary piano wire of the entrance template, measure the distance between A-A', B-
B', and C-C' as shown in the figure below at the position where the hatch sill for each floor will be
installed. Then, select the most appropriate position for installing the sill and fix the position of the
entrance template based on the sill installation position.
Template
43
(3) Adjust the upper template material so the piano line is located 115 mm away from the inner wall of
the entrance (end part of the entrance floor).
5.4 Checking and Fixing the Template

(1) Once you fix the entrance template, install the templates for the car and counterweight rails based on
the location of the entrance plate so they match the size on the installation plans.
(2) Based on the dimensions on the installation plans, check the size of the template as shown in the
figure below and fix it. (Refer to Check Sheet)
(3) Tie the piano wires that have penetrated the upper and lower template materials and align and fix
them in a straight line.
44 Template
5.5 Check Sheet

The standard template sizes of a passenger elevator are as follows.
Template
45
5.5.1 Standard Template Sizes of Passenger Elevator Ⅰ
[Table 5.1 Standard Template Size Table for a Passenger Elevator (unit: mm)]
(unit: mm)
CWT
Entranc Inside of Car rail
Person( e width the car width rail Template size (speed 150 m/min or below) ALG.X TYPE
Purpose width
kg)
OP CA x CB BG BG EE P A B C D E′ F G, G′ H H′
15 1600 ×
900 1758 1200 770 1085 1698 1180 900 845 621 450 1143.2 2116.5 2142.0
(1000) 1500
1800 ×
1000 1958 1200 775 1095 1898 1180 1000 974 621 500 1244.7 2154.0 2180.3
17 1500
(1150) 2000 ×
1100 2158 1200 710 1010 2098 1180 1100 1074 621 550 1287.5 2052.0 2080.8
1350
For
1800 ×
passeng 1000 1958 1200 875 1195 1938 1180 1000 974 621 500 1309.3 2329.7 2354.0
20 1700
er
(1350) 2000 ×
1100 2158 1200 785 1085 2138 1180 1100 1074 621 550 1330.3 2179.2 2206.4
1500
2000 ×
1100 2158 1200 905 1215 2138 1180 1100 1074 621 550 1404.5 2397.2 2421.9
24 1750
(1600) 2150 ×
1100 2308 1200 840 1130 2288 1180 1100 1149 621 550 1423.3 2265.6 2291.8
1600
46 Template
(unit: mm)
CWT
Purpose width
kg)
15 1600 ×
900 1758 1200 770 1085 1698 1180 900 845 614.5 450 1143.2 2119.6 2138.7
(1000) 1500
1800 ×
1000 1958 1200 775 1095 1898 1180 1000 974 614.5 500 1244.7 2157.2 2176.9
17 1500
(1150) 2000 ×
1100 2158 1200 710 1010 2098 1180 1100 1074 614.5 550 1287.5 2055.5 2077.1
1350
For
1800 ×
passeng 1000 1958 1200 875 1195 1938 1180 1000 974 614.5 500 1309.3 2332.7 2351.0
20 1700
er
(1350) 2000 ×
1100 2158 1200 785 1085 2138 1180 1100 1074 614.5 550 1330.3 2182.6 2202.9
1500
2000 ×
1100 2158 1200 905 1215 2138 1180 1100 1074 614.5 550 1404.5 2400.2 2418.8
24 1750
(1600) 2150 ×
1100 2308 1200 840 1130 2288 1180 1100 1149 614.5 550 1423.3 2268.8 2288.4
1600
(unit: mm)
CWT
Purpose width
kg)
15 1600 ×
900 1758 1200 770 1125 1698 1180 900 845 621 450 1143.2 2151.6 2176.7
(1000) 1500
1800 ×
1000 1958 1200 775 1135 1898 1180 1000 974 621 500 1244.7 2188.8 2214.7
17 1500
(1150) 2000 ×
1100 2158 1200 710 1050 2098 1180 1100 1074 621 550 1287.5 2085.6 2114.0
1350
For
1800 ×
passeng 1000 1958 1200 875 1235 1938 1180 1000 974 621 500 1309.3 2365.3 2389.3
20 1700
er
(1350) 2000 ×
1100 2158 1200 785 1125 2138 1180 1100 1074 621 550 1330.3 2213.7 2240.4
1500
2000 ×
1100 2158 1200 905 1255 2138 1180 1100 1074 621 550 1404.5 2432.6 2457.0
24 1750
(1600) 2150 ×
1100 2308 1200 840 1170 2288 1180 1100 1149 621 550 1423.3 2300.5 2326.3
1600
If the size of the entrance, inside of the car, and rail width do not meet the standards, you need to
calculate them separately.
Template
47
5.5.2 Standard Template Sizes of Passenger Elevator Ⅱ
[Table 5.2 Standard Template Size Table (unit: mm)]

(unit: mm)
Car CWT
Entrance Inside of the
Person rail rail Template size (speed 150 m/min or below) ALG.X TYPE
Purpose width car
(kg) width width
15 (1000) 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 ● ●
17 (1150)
1100 2000 × 1350 2158 1200 710 291.5 2098 1180 1100 1074 VAR 550 1287.5 ● ●
For
1000 1800 × 1700 1958 1200 875 291.5 1938 1180 1000 974 VAR 500 1309.3 ● ●
passenger 20 (1350)
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 ● ●
24 (1600)
1100 2150 × 1600 2308 1200 840 291.5 2288 1180 1100 1149 VAR 550 1423.3 ● ●
48 Template
(unit: mm)
Car CWT
Entrance Inside of the
Person rail rail Template size (speed 150 m/min or below) ALG.X TYPE
Purpose width car
(kg) width width
15 (1000) 900 1600 × 1500 1758 1200 770 220.5 1698 1180 900 845 VAR 450 1143.2 ● ●
1000 1800 × 1500 1958 1200 775 220.5 1898 1180 1000 974 VAR 500 1244.7 ● ●
17 (1150)
1100 2000 × 1350 2158 1200 710 220.5 2098 1180 1100 1074 VAR 550 1287.5 ● ●
For
1000 1800 × 1700 1958 1200 875 220.5 1938 1180 1000 974 VAR 500 1309.3 ● ●
passenger 20 (1350)
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 ● ●
24 (1600)
1100 2150 × 1600 2308 1200 840 220.5 2288 1180 1100 1149 VAR 550 1423.3 ● ●
• If the sizes of the entrance, inside of the car, and rail width do not meet the standards, you
need to calculate them separately.
• The position determined by the counterweight rail width is the same on the left and right sides.
• VAR means a changing value.
Template
49
6. Traction Machine
Install the traction machine, machine foundation, machine beam, governor and Isolation Pad for
absorbing shock in the machine room. Also, install the control panel and the electric piping that connects
the control panel with the traction machine and governor so the elevator can be controlled electrically.
6.1 Geared Type Traction Machine
6.1.1 Installing the Machine Beam
To determine the position of the machine beam, refer to the installation plan (layout) of the machine room
floor to calculate the relevant values and paint the ink line.
50 Traction Machine
[Table 6.1 Distance between X-X' on the Machine Beam Position]
Category TM500 TM600 TM900
X 230 253 203
X' 170 203 203
• Check the anchor size on the wall of the machine beam

If the wall is not destructed as in the "Q" part shown in the figure below, check if 110 mm or more of
the machine beam is suspended on the destructed area as well as on the hanging area (150 mm or
more is recommended).
Traction Machine
51
6.1.2 Installing the Machine Beam Plate
(1) Use anchor bolts to fasten 4 parts of the machine beam plate and insert the liner to level the plate.
(2) Install the machine beam by aligning it at the center of the ink line. Then, check if the machine beam
is level and weld the machine beam plate with the machine beam to fix them.
(3) After checking the leveling and size of the machine beam, connect the machine beam and weld it with
an angle of a designated size to fix it.
• Standards for machine beam installation
[The gap difference should be within 0.5 mm]
52 Traction Machine
[The leveling deviation in horizontal direction should be within 1 mm]
[The allowed mutual gap should be within 1 mm]
• Mortar finishing thickness

After centering the traction machine, apply concrete on the space between the floor and lower part of
the machine beam for at least 100 mm from the machine room floor.
Traction Machine
53
6.1.3 Installing the Isolation Pad
6.1.4 Assembling the Traction Machine
Adjust the leveling of the traction machine and machine beam as shown in the figure. Then, fasten them
with bolts.
6.1.5 Checking the Vertical Alignment of the Sheave
(1) Lower the plumb line from the top of the main sheave to adjust the deviation between the upper and
lower sheave within 1 mm.
(2) Align the centers of the main sheave and deflector sheave in a straight line.
54 Traction Machine
6.1.6 Installing the Governor
(1) Refer to the installation plans(layout) to select the installation location of governor and level the
machine room floor and governor support.
(2) Lower the plumb line to the governor sheave side and slowly rotate the sheave so the deviation
between A and A' points is within 1 mm.
Traction Machine
55
6.1.7 Assembling the Governor Cover
After installing the governor, fasten the cover of the governor with bolts.
6.1.8 Installing the Control Panel
(1) Refer to the installation plans(layout) to select the position of the control panel.
(2) Tighten the anchor bolts on the 4 holes at the bottom of the control panel and insert the liner to level
the control panel.
56 Traction Machine
6.2 Gearless-MR Type Traction Machine (GT/GX Model)
Traction Machine
57
6.2.1 Installing the Machine Beam Support
(1) Refer to the installation plans(layout) to calculate the related values. Then, mark the machine room
floor with an ink line.
(2) Install the beam support based on the ink line. After installing the beam support, use the anchor bolts
to fix the fixing angle so the beam support does not move.
• Mortar finishing thickness

After centering the traction machine, apply concrete on the space between the floor and lower part of
the machine beam for at least 100 mm from the machine room floor.
(1) Mount the machine beam on the beam support and check the beam distance and leveling.
(2) After checking the distance and leveling (refer to Standards for Beam Installation), weld the part
where the machine beam and beam support are in contact.
58 Traction Machine
[The level difference should be within 0.5 mm]
Traction Machine
59
6.2.3 Installing the Isolation Pad
Mount the Isolation Pad on the machine beam and fasten the bolts to install the Isolation Pad.
6.2.4 Installing the Machine Bed Support
Mount the machine bed support on the Isolation Pad and fix it with bolts.
60 Traction Machine
6.2.5 Engaging the Secondary Sheave and Secondary Sheave Support Bracket
Fix the secondary sheave support bracket on the secondary sheave with nuts.
Traction Machine
61
6.2.6 Installing the Machine Bed
(1) Fix the machine bed support on the machine bed with bolts.
(2) Fix the secondary sheave support bracket on the machine bed with bolts.
62 Traction Machine
6.2.7 Installing the Traction Machine
Mount the traction machine on the machine bed, level the traction machine, and tighten it with bolts.
Traction Machine
63
In the case of double wrapping, adjust the offset between the center of the traction machine main sheave
and the center of the secondary sheave to 1 mm or less.
64 Traction Machine
Traction Machine
65
6.3 Gearless-New MR Type Traction Machine (GX30, GA75/100 Model)
66 Traction Machine
6.3.1 Installing the Base Beam
(1) Based on the layout plans and the installed template, place the base beam on the machine room floor.
Traction Machine
67
(2) Fix the base bracket on the machine room floor with anchor bolts and weld the base bracket to the
base beam to fix the beam.
68 Traction Machine
(1) Refer to the layout plans and place the machine beam on the base beam. Then, weld them.
[The level difference should be within 0.5 mm]
Traction Machine
69

(2) Use the bolts and nuts to fix the fixing bracket to both ends of the machine beam.
70 Traction Machine
6.3.3 Installing the Isolation Pad Assembly
Considering the size of the installed template and machine bed, decide on the location of the Isolation
Pads and use rail clips to fix them on the machine beam.
6.3.4 Assembling the Blocking Beam
Place the blocking beam on the Isolation Pad and use the bolts to fix them.
Traction Machine
71
6.3.5 Assembling the Machine Bed and Deflector Sheave
(1) Place the deflector sheave between the machine beams and assemble the machine bed with the
blocking beam.
(2) Lift the deflector sheave and engage it to the lower part of the machine bed.
72 Traction Machine
6.3.6 Assembling the Traction Machine
(1) Place the traction machine on the machine bed.
(2) Use the bolts to fix the traction machine and machine bed.
Traction Machine
73
Lower the plumb line from the top of the main sheave to adjust the deviation between the upper and lower
sheave within 1mm.
6.3.8 Assembling the Rope Guard
After completing the rope work, attach the rope guard to the traction machine so the rope does not
escape.
74 Traction Machine
6.3.9 Assembling the Traction Machine Cover
Use the bolts to fix the traction machine cover on the traction machine.
Traction Machine
75
6.3.10 Final Inspection
(1) Refer to the layout plans to check the installation condition of every component.
(2) Check if every component is firmly assembled.
76 Traction Machine
6.4 Gearless-MRL Type Traction Machine (GN Model)
Traction Machine
77
(1) Refer to the figure below and lift the machine beam through the entrance at the top floor.
(2) When mounting the machine beam on the anchor of the building wall, be sure that the anchor size is
the same as shown in the table below.
Type Anchor size
GN 17, 25, 35 120mm
78 Traction Machine
Type Anchor size
GN 50, 60 130mm
(3) Level the machine beam and fix the base brackets to the bottom of the machine beam using anchor
bolts.
(4) Weld the part where the machine beam and machine beam plate are in contact with a welding bead
diameter of 5 mm or more.
6.4.2 Installing the Support Bracket
Check the A and B sizes, which are the distances between the support bracket and machine beam, and
install the support bracket as shown in the figure below.
Traction Machine
79
6.4.3 Installing the Traction Machine Isolation Pad
Install the traction machine Isolation Pad on the machine beam.
80 Traction Machine
(1) Place the traction machine on the Isolation Pad by aligning the bolt holes.
Traction Machine
81
(2) Use the spirit level to level the front / rear / left / right sides of the traction machine.
82 Traction Machine
(3) Mount the rollover prevention beam on the support bracket and lower the plumb lines at both ends to
check the leveling.
• Mounting positions of roll-over prevention beam and support bracket for each type
Traction Machine
83
(4) Tighten the support bracket to the traction machine with bolts.
(5) Insert the Isolation Pad and liner between the support bracket and rollover prevention beam and fix
them with bolts.
(1) Use the same method as installing the machine beam and mount the governor on the anchor of the
wall. Then, use anchor bolts to fix the base bracket.
84 Traction Machine
(2) Weld the corner where the base bracket and hitch beam plate are in contact with a welding bead
diameter of 5 mm or more.
(3) Mount the hitch beam on the hitch beam plate and weld the corner where the hitch beam plate and
hitch beam are in contact with a welding bead diameter of 5 mm or more.
(4) Weld the governor plate on the hitch beam at the position where the governor will be installed with a
welding bead diameter of 5 mm or more.
Traction Machine
85
(5) Mount the governor on the governor plate and tighten the 4 corners of the governor with bolts.
86 Traction Machine
(6) Mount the Isolation Pad and hitch plate on the hitch plate above the hitch beam. Then, tighten them
with bolts.
Traction Machine
87
6.5 Gearless-New MRL Type Traction Machine (GY Model)
6.5.1 Installing Support Bracket on the Counterweight Side
(1) Attach the support bracket on the top-most part of the counterweight rail.
(2) Use bolts (M12X45), plain washers, spring washers, and nuts to fix the support bracket on the coun-
terweight rail.
(3) If necessary, insert a liner between the counterweight rail and the support bracket to level the support
bracket.
88 Traction Machine
Traction Machine
89
6.5.2 Installing the Machine Foundation
(1) Place the machine foundation on the support bracket.
(2) Use bolts (M12X55), plain washers, spring washers, and nuts to fix the machine foundation on the
car rail.
90 Traction Machine
(3) Use bolts (M12X40), plain washers, spring washers, and nuts to fix the machine foundation on the
support bracket.
(4) Insert a liner with a thickness of 12 mm between the support bracket and the connecting part of the
machine foundation. Then, add or remove the liners depending on the rail height difference to adjust
the difference.
Traction Machine
91
6.5.3 Installing Isolation Pad
Mount the Isolation Pad on machine foundation and fix it using bolts (M12X45), plain washers, spring
washers, and nuts.
6.5.4 Installing the Traction Machine Plate
Mount the traction machine plate on the Isolation Pad and fix it using bolts (M16X50), plain washers, and
spring washers.
92 Traction Machine
(1) Place the car so the top of the car is at the floor height of the top floor.
(2) Fix the safety device gib on the rail.
Traction Machine
93
(3) Install the machine foundation on top of the car.
(4) Move the winch wire rope connected to the car top beam to the traction machine and engage it.
94 Traction Machine
(5) Lift the traction machine and place it on the machine foundation at the top of the car.
(6) For lifting, move back the winch wire rope connected to the traction machine to the car top beam and
engage it.
(7) Move the car so the lower part of the traction machine is at the height of the traction machine plate.
Traction Machine
95
(8) Push the traction machine to place it on the traction machine plate.
(9) Use bolts (M16X50) and spring washers to fix the traction machine on the traction machine plate.
(10) Remove the machine foundation that was installed on top of the car.
96 Traction Machine
(1) Use bolts to tighten the governor support bracket on the top part of the car rail at the opposite side of
the car rail where the traction machine is installed.
(2) Fix the governor support bracket to the governor support with bolts.
Traction Machine
97
(3) Fix the governor on the governor support using bolts.
98 Traction Machine
6.5.7 Installing Isolation Pad and Hitch Plate
Mount the Isolation Pad and hitch plate on the governor support bracket as shown in the figure below.
6.6 Gearless Type Traction Machine Brake
Important
Please refer to "Adjustment Manual" for more details about the traction machine brake.
Notice
• Excessive adjustment of the brake stroke may reduce the braking force. Be sure to adjust it
properly.
• Do not inspect the left / right brakes at the same time.
• During inspection, be sure to keep the braking surface of the brake clean.
• During inspection, use the designated tools and do not apply too much force.
• After inspection, check if the brake stroke and switch operate properly.
This brake is used to maintain the braking status after the elevator has stopped and perform braking in
case of an emergency.
Traction Machine
99
[Table 6.2 Brake Applied for Each Traction Machine]
Traction machine Brake Type
GT17, GT25, GT50 DB1712 (DB250)
GT35, GT70 DB1712 (DB350)
GT71, GT100 DB2818 (DB450) Drum Brake
GN17 NED1712 (NED100)
GN25, GN35, GX35 NED1712 (NED600)
GN50, GN60, GX50, GX60,

EC5415 Disk Brake
GX70, GS50, GX 160 C/D
When released from the factory, the brake is installed as the default. When a problem occurs,
however, adjust the brake according to the manual.
6.7 Traction Machine Handle Switch
6.7.1 Structure of Traction Machine Handle Switch
100 Traction Machine

No. No. No. No.
1 Limit switch 4 Round HD Screw M4x25 - 2EA
Hex. HD Screw, S/W,

2 Bracket 5
P/W M6x12 - 4EA
3 Bracket
Warning
Remove the switch bracket and assemble the TM handle assembly.
Notice
Assemble the switch assembly. (Do not assemble the TM handle.)
• Wiring: Normal Open ("A" contact)
• Switch plunger should be pushed by the switch bracket.
Traction Machine
101
6.7.2 Checking the Installation
1) GT17/25/35/100, GB17/25/35
2) GX35
3) GX50

4) GX60
5) GX70/160
6) GX30
6.8 Check Sheet
6.8.1 Machine Beam
The following table summarizes the installation standards and sizes for the machine beam.
[Table 6.3 Centering Standards for the Machine Beam]
Traction Machine
103
(unit: mm)
Standard
No. Measurement Range Remarks
Value
01 Front / Rear leveling of each machine beam Within 1 mm
02 Left / Right leveling of each machine beam Within 0.5 mm
03 Leveling between machine beams Within 0.5 mm
04 Parallelism between machine beams Within 2 mm
05 Wall anchor size of the machine beam support beam 150 or above
06 Mortar finishing on the machine beam support beam 100 or above
6.8.2 Traction Machine and Machine Bed
[Table 6.4 Centering Standards for Traction Machine and Machine Foundation]
(unit: mm)
Standard
Value
Contact between the traction machine and machine There should

01
bed be no gap.
02 Position of the main sheave Within 1 mm
03 Position of the deflector sheave Within 1 mm
04 Verticality of the main sheave Within 1 mm
05 Verticality of the deflector sheave Within 1 mm
06 Center difference between sheaves Within 1 mm
It should
07 Assembly condition of the taper washer maintain the Weld both points
leveling.
6.8.3 Governor
[Table 6.5 Installation Standards for Governor]

(unit: mm)
Standard
Value
01 Verticality of governor sheave Within 1 mm

Standard
Value
It should be
02 Mortar finishing on the governor support filled
completely.
6.8.4 Machine Room Piping
The following summarizes the installation standards for machine room piping.
(1) Install the connection of the flexible pipe for power lines perpendicular to the floor using a connector.
Be careful not to stretch the flexible pipe.
(2) Use independent pipes to install the encoder pipe.
(3) Install the governor pipe at the same height as the governor switch.
[Table 6.6 Installation Standards for Machine Room Piping]

(unit: mm)
Standard
Value
Pitch
01 Connection of the steel pipe
processing
02 Connection of the flexible tube Use connector
6.8.5 Control Panel
The following summarizes the installation standards for the control panel.
(1) When installing the control panel, refer to the installation plans and maintain a horizontal distance of
3000 mm or more from the side of the control panel to the pillar or wall.
[Table 6.7 Installation Standards for the Control Panel]

(unit: mm)
Standard
Value
It should be
01 Fixing of the control panel
firm.
02 Interference of door None
03 Verticality of control panel Within 3 mm
Traction Machine
105
7. Temporary Car
In order to install the guide rail with a non-scaffold method, assemble the car structure such as the safety
device, support frame, car platform, car stile, and top beam, as well as the governor holding device for
attaching the governor. Before installing the car structure, assemble the 1st guide rail, car or counter-
weight buffer, buffer footing, and governor tension sheave first and then install a temporary safety stand
so workers can safely install the guide rail.
7.1 Preparations for Assembling Temporary Car
7.1.1 Installing the Pit Ladder
Install the pit ladder on the hoistway wall before entering the pit. When installing the ladders on both sides
of the entrance, they should be installed at a place higher than the floor of the landing sill by 1100 mm or
more.
7.1.2 Installing Buffer Footing for Car
(1) Check the layout and inspection standards and measure the pit depth to adjust the height of the buffer
footing at the landing sill.
(2) Install the buffer footing on the pit floor so it matches the lower template. Then, use the spirit level to
precisely level the footing in horizontal and vertical directions.
(3) If the buffer footing is not level, insert the liner to adjust the level.
Temporary Car
106
7.1.3 Installing Buffer Footing for Counterweight
(1) Install the buffer footing on the pit floor so it matches the lower template. Then, use the spirit level to
precisely level the footing in horizontal and vertical directions.
(2) If the buffer footing is not level, insert a liner to adjust the level.
7.1.4 Installing the 1st Rail
(1) Mount the 1st rail on the buffer footing and use the rail clip to fix the rail on the buffer footing.
Temporary Car
107
(2) End points of the guide rails facing each other should be different. (凹, 凸)
7.1.5 Installing the Buffer
(1) Fix the buffer blocking on the buffer footing.
(2) Install the buffer on the buffer blocking.
108 Temporary Car

7.1.6 Installing the Safety Device
(1) Use the rail clip to fix the safety support on the car rail at a point that is lower than the elevator hall
floor of the lowest floor by "X".
"X" = Height of the safety device + Height of the car platform
Temporary Car
109
(2) Insert the safety device between the rails to place it on the safety support.
110 Temporary Car

(3) Pull the actuator arm so the gib on the safety device interlocks with the rail. Fasten the rail or rope on
the rail bracket and check the gib status again.
7.1.7 Car Stile Assembly
(1) Align the bolt holes of the car stile with the bolt holes of the safety device and tighten them with bolts.
(2) Insert a liner between the top beam and car stile to fix them.
Temporary Car
111
7.1.8 Bolster Assembly (GN Type)
(1) In the case of the previous MRL type, place the bolster assembly on the buffer footing and then mount
the safety device on it. Then, use the bolts to tighten the bolster assembly to the safety device.
(2) Check if the installation direction of the bolster assembly matches the horizontal direction of the coun-
terweight.
112 Temporary Car

Temporary Car
113
7.1.9 Platform Assembly
(1) Gradually bring the platform into the hoistway and mount it on the safety device attached to the guide
rail.
114 Temporary Car

(2) Adjust the piano wire of the entrance template and the end part of the platform (sill support) at the
entrance so they are 6 mm apart. Measure the leveling at the corner and center of the platform with
the spirit level so the leveling difference is within 1 mm. Insert a liner to adjust the level.
(3) Align the support frame under the platform with the bolt holes of the safety device. Then, use the bolts
to tighten them.
Temporary Car
115
7.1.10 Installing the Top Beam (Gearless Type)
(1) Align the bolt holes of the top beam with the bolt holes of the car stile. Then, tighten them with bolts.
116 Temporary Car

(2) Align the bolt holes of the top beam with the bolt holes of the top beam suspension sheave. Then,
tighten them with bolts.
7.1.11 Align the bolt holes of the top beam with the bolt holes of the top beam suspen-
sion sheave. Then, tighten them with bolts.
(1) Insert the suspension sheave on both sides of the top beam.
Temporary Car
117
(2) Tighten the bolts so the bolt heads are on the inside of the top beam.
(3) Bring the top beam into the hoistway.
(4) Align the bolt holes of the top beam with the bolt holes of the car stile. Then, tighten them with bolts.
7.1.12 Brace Rod Assembly
(1) Insert the upper part of the brace rod into the hole in the car stile. Then, use the nuts to tighten them.
(2) Insert the lower part of the brace rod into the bracket fixing bolt on the bottom of the platform. Then,
use the nuts to tighten them. At this time, tighten the nuts loosely so the tension is not applied to the
brace rod.
It is not recommended to level the platform using the brace rod.
118 Temporary Car

7.1.13 Installing the Temporary Guide Shoe
(1) The temporary guide shoe makes it possible to drive the temporary car with the piano wire installed
and prevents the temporary car from deviating from the guide rail.
(2) It is installed where the top beam and the upper and lower rails of the safety device interlock. After
installing the guide rail, replace it with a general guide shoe. (There are the wood plate types and the
roller types for the temporary guide shoes.)
Temporary Car
119
7.1.14 Installing the Governor Holding Device
(1) Install the governor rope fixing bracket on the top beam and pass the governor rope through the hole.
(2) Connect the thimble to the upper part of the actuator lever pull bar.
120 Temporary Car

(3) Wrap the thimble with the governor rope and fasten it with a wire clip.
(4) Remove the 1st-step work plate.
(5) Raise the car frame with the winch and place the safety device at the height of the entrance on the
lowest floor.
(6) Fix the governor tension sheave fixing bracket to the car rail with the rail clip.
• When the pit depth exceeds 1,200 mm
Temporary Car
121
• When the pit depth is 1,200 mm or less
(7) Wrap the governor tension sheave with the governor rope and place it on the lower part of the safety
device actuator lever pull bar.
(8) Connect the thimble to the lower part of the actuator lever pull bar.
122 Temporary Car

(9) Wrap the thimble with the governor rope and fasten it with a wire clip.
Temporary Car
123
7.2 Temporary Car Assembly
7.2.1 Installing the Support Angle for Temporary Car
Fix the support angle for fixing the scaffold on the car frame.
124 Temporary Car

7.2.2 Vertical Pillar Assembly
(1) Fix the steel pipe scaffold on the support angle.
(2) Engage the scaffold clamps to assemble another steel pipe scaffold in the vertical direction.
Temporary Car
125
7.2.3 Support Scaffold Assembly
(1) Connect the support scaffold at both corners on opposite sides of the car entrance to place it on the
platform.
(2) Assemble the scaffold for supporting the protective ceiling and work plate.
7.2.4 Horizontal Reinforcement Pipe Assembly
Assemble the reinforcement pipe for supporting the protective ceiling and work plate.
126 Temporary Car

7.2.5 Safety Fence Assembly
Install the middle safety fence 600 mm above the work plate. Then, install the upper safety fence 500 mm
above the middle safety fence.
7.2.6 Installing Protective Ceiling and Work Plate
Use the plywood (thickness of 12 T or above) or scaffold plate to install the protective ceiling and work
plate.
Temporary Car
127
7.2.7 Installing the Fall Prevention Bumper and Furnishing Fire Extinguisher
(1) Install the fall prevention bumper so the tools used to erect the rail do not fall.
(2) Install the bumper in a way that it forms a U shape with the lower part of the car so you can use the
remote control and winch inside the car.
(3) Furnish the lighting and fire extinguisher.
(4) Install a separate workbench, safety fence, and protective ceiling on top of the temporary car so you
can install the components such as guide rail in a stable posture.
7.3 Check Sheet
7.3.1 Buffer and Buffer Footing
• Fix the lower part of the buffer footing with 4 or more anchor bolts.
128 Temporary Car

• Be sure to clean the lower part of the pit before attaching the buffer footing.
[Table 7.1 Centering Standards for Buffer and Buffer Footing]

(unit: mm)
Standard
Value
Distance between the lower part of the 1st rail and the
01 80
upper part of the buffer footing
02 Front / Rear leveling of the buffer footing Within 0.5 mm
03 Left / Right leveling of the buffer footing Within 1 mm
04 The sizes of the car center and buffer footing center ±2
Gap difference between the car buffer footing and the

05 ±2
upper part of the Counterweight buffer footing
06 Leveling of the buffer Within 1 mm
07 Verticality of the buffer Within 1 mm
Gap difference between the car buffer and the upper

08 ±2
part of the Counterweight buffer
[Figure 7.1 Centering Standards for Buffer Footing]
7.3.2 Safety Device
[Table 7.2 Centering Standards for Safety Device]
Temporary Car
129
(unit: mm)
Standard
Value
01 Front / Rear leveling of the safety device Within 0.5 mm
02 Left / Right leveling of the safety device Within 1 mm
03 Left / Right distance of the gib and rail Within 1 mm
7.3.3 Car Frame
[Table 7.3 Centering Standards for Car Frame]

(unit: mm)
Standard
Value
Distance between the end of the sill block and piano

01 6 mm
wire
02 Leveling of the platform floor Within 2 mm
03 Front / Rear leveling of the top beam Within 0.5 mm
04 Left / Right leveling of the top beam Within 1 mm
05 Verticality of the stile bar Within 1 mm
There should
06 Tension of the brace rod be not
tension.
7.3.4 Governor Holding Device
[Table 7.4 Centering Standards for Governor Holding Device]

(unit: mm)
Standard
Value
01 Wire clip assembly distance 50
02 Upper spring distance ±2
03 Lower spring distance ± 0.5
There should
04 Rod status be no
bending.
130 Temporary Car

8. Rope Work
After completing the machine room and temporary car assembly, connect the rope to the car and coun-
terweight so the car and counterweight carry out the pulley motion. Perform the rope work from the top
beam at the top of the car through the traction machine sheave in the machine room to the top of the coun-
terweight frame. It requires cutting the rope at the correct length as well as correct centering.
8.1 1:1 Hanging the Main Rope
8.1.1 Winding the Steel Wire around the Rope (Babbitt Type)
Before fixing the rope on the rope shackle, refer to the values on the table below and wind the steel wire
around the 3 parts at the end of the rope. At this time, there should be no overlapping between the steel
wires.
C T B S A
[Table 8.1 Values for Steel Wire Winding]

(unit: mm)
Rope diameter 12 14 16 18 20
A 15
B 15 20
C 15
S 100 115 125 140 155
T 50
Rope Work
131
8.1.2 Filling the Rope Socket with Babbitt
(1) After removing the Manila line, pass the rope through the rope socket and loosen the strand to the
position where the steel wire is wound.
(2) Bend each strand as shown in the figure below. The bending length should be 2.5 times the rope
diameter or more.
132 Rope Work

(3) Pull the rope through the small hole on the rope socket to insert the strands inside the socket
completely.
(4) Pour the melted Babbitt onto the rope socket to fix the rope socket and strands.
8.1.3 Connecting the Car and Counterweight with Rope
(1) Place the counterweight frame on the elevator hall at the top floor.
(2) Pass the rope through the main sheave and deflector sheave and lower it to the counterweight frame
at the top floor.
(3) Engage the rope socket with the rope shackle and the rope shackle with the counterweight frame.
Rope Work
133
8.1.4 Preventing Rope Twisting
(1) Lower the opposite end of the rope connected to the counterweight frame to the temporary car
located on the lowest floor.
(2) In order to prevent the rope from deviating from the groove on the traction machine sheave, wrap the
steel wire around the sheave.
(3) Tie the lowered ropes sequentially to the groove of the traction machine sheave and the rope inlet
hole of the car and counterweight to prevent the ropes from becoming tangled.
8.1.5 Bringing the Counterweight into the Hoistway
(1) To cut the main rope at the correct length, use the following formula to calculate the "A".
"A" = Pit depth - buffer length - run-by - (hoistway × 0.01)
134 Rope Work

(2) Mark the position that is at the distance of "A" from the lower part of the counterweight frame buffer.
Then, remove the pipe or steel wire that was used to prevent slipping.
(3) Pull the chain block and gradually bring the counterweight frame into the hoistway.
(4) Adjust the height of the counterweight frame so the "A" part marked on the lower part of the counter-
weight frame buffer matches the upper part of the hatch sill on the top floor.
(5) Connect the hook of the chain block to the upper frame of the counterweight.
(6) Operate the chain block and fix the counterweight frame using the pipe or chain before bringing it into
the hoistway so it does not slip.
(7) Load an appropriate amount of subweight on the counterweight frame and firmly fix it so the weight
does not deviate.
Rope Work
135
[Figure 8.1 Loading Standards for Subweight]

[Table 8.2 Weight of Counterweight Frame]
Category BG 900 BG 1000 BG 1200
Category 115Kg 120Kg 170Kg
[Table 8.3 Temporary Car Weight (Standard Size)]
Category P8 P11 P13 P15 P17
Temporary Car
329Kg 369Kg 434Kg 449Kg 814Kg
Weight
8.1.6 Hanging the Rope on the Car Side (Babbitt Type)
(1) Adjust the position of the temporary car sill attached on the pit so it matches the upper part of the
hatch sill on the lowest elevator hall floor.
(2) Adjust the position of the temporary car sill attached on the pit so it matches the upper part of the
hatch sill on the lowest elevator hall floor.
(3) Refer to the figure below to engage the rope shackle to the top beam hole of the car.
[Figure 8.2 Hanging the Rope on the Top Beam and Main Sheave for 15 Person or Below]
136 Rope Work

8.2 2:1 Hanging the Main Rope
8.2.1 Engaging the Wedge-Type Rope
(1) Wrap the main rope around the wedge and adjust the length of the main rope so the margin on one
end of the rope is 300 mm or less.
(2) Pull the rope towards the inside of the cable joint so the rope does not move.
Rope Work
137
(3) Align the pin hole of the rope shackle with the pin hole of the eye bolt and fix them with a pin.Be sure
to engage the split pin on the pin hole so the pin does not come out.
(4) Wrap the end of the remaining rope with the insulation tape so the rope does not become loose. Then,
fix the remaining rope and main rope with the rope clip.
8.2.2 Wrapping Method
1) Double Wrapping
(1) Traction machine GT 50, 70, and 100 types are applied with double wrapping. Engage the rope on
the sheave as shown in the figure below.
138 Rope Work

Notice
When lowering the rope, partial wear may occur on the sheave if the rope is engaged to the
sheave. So, place the steel plate or pipe on the sheave and lower the rope upon it to prevent
wearing of the sheave.
(2) The rope socket is not completely engaged on the car and counter hitch plate. So firmly fasten the
rope so the rope does not slip and fall due to its own weight.
(3) As a redundant safety measure, lower another rope of the same kind as the main rope through the
rope hole to the machine room beam by approx. 10 m and use wire clips to engage it with the main
rope once more. (Use two or more wire clips.)
2) 2:1 Rope Work

(1) Place the counterweight frame on the lowest floor and place the top beam on the top floor. Calculate
the weight of the counterweight and place an appropriate amount of weight on the top floor. After
Rope Work
139
installing the 1st rail, place the counterweight frame and temporary car in the pit as shown in the figure
below.
(2) Use the temporary guide shoe to fix the counterweight frame to the guide rail.As shown in the figure
below, loosen the fixing bolts on one side of the counterweight frame suspension sheave.
140 Rope Work

(3) In the machine room, connect one end of the rope to the counterweight hitch plate and lower the rope
through the rope hole in the counterweight side by forming a U shape. Make sure that the rope does
not become tangled while it is being lowered.
(4) Engage the U-shaped rope on the counterweight suspension sheave in a way that the rope order is
not mixed up. After engaging all the ropes, reassemble the sheave.
(5) Firmly fasten the rope temporarily in the machine room so the rope on the counterweight side does
not flow down. Insert the car side rope in the rope hole of the main sheave in the machine room to
lower it to the top floor. Engage the rope to the top beam sheave on the top floor and pass the end of
Rope Work
141
the rope through the rope hole of the hitch plate at the main sheave side to raise it to the machine
room.
(6) Attach the top beam jig that prevents the tilting of the top beam and the deviation of the rope while
lowering the top beam.
142 Rope Work

(7) Use an electronic chain or chain block to bring the top beam into the hoistway and cut the rope to an
appropriate length. Attach the rope shackle at the end of the rope and fasten the rope to the hitch
plate. Assemble the weight jig as shown in the figure below and load the weight.
Rope Work
143
(8) After loading the subweight on the weight jig, use the chain block to hang it on the top beam.Manually
operate the traction machine to lower the top beam. Once the top beam is lowered to the car stile in
the pit, engage the top beam on the car stile with bolts.
8.3 Hanging the Upper MRL Rope
8.3.1 Engaging the Shackle on the MRL Rope
Attach the shackle at the end of the rope and connect the rope to the hitch plate on the traction machine
side.
144 Rope Work

8.3.2 Bringing the Counterweight into the Hoistway
(1) In order to cut the main rope at the correct length, use the following formula to calculate the "A".
"A" = Pit depth - buffer length - run-by - (hoistway × 0.01)
(2) Mark the position that is at the distance of "A" from the lower part of the counterweight frame buffer.
Then, remove the pipe or steel wire that was used to prevent the slipping.
(3) Pull the chain block and gradually bring the counterweight frame into the hoistway.
(4) Adjust the height of the counterweight frame so the "A" part marked on the lower part of the counter-
weight frame buffer matches the upper part of the hatch sill on the top floor.
Rope Work
145
8.3.3 Hanging the Rope on the Traction Machine Main Sheave
(1) Hang the rope, which was raised through the counterweight frame sheave, on the traction machine
main sheave.
(2) Pass the rope on the lowering side through the sheave on the lower bolster assembly of the tempo-
rary car and connect it to the hitch plate on the governor side.
146 Rope Work

8.4 New MRL Type
8.4.1 Installing the Hitch Plate on the Car Hitch and Counterweight Sides
Caution
Beware that the hitch plate may become loose and fall before fixing the rope on the hitch plate.
Install the Isolation Pad and hitch plate on the rope hitch at the common bracket side on the car hitch.
Rope Work
147
8.4.2 Rope Work
Caution
• Before carrying out the rope work, be sure to engage the safety device on the rail to fix the car
safely.
• When filling the Babbitt, there is the danger of fire. Be sure to wear safety gear while working.
(1) Place the car on the top floor, considering the run-by length.
Counterweight side Car side
80 ~ 120 mm
Run-by length 150 mm
(maximum 200 mm)
Ex) If the length of the Counterweight frame support is 1,000 mm,

car platform is located 850 mm below the top floor.
148 Rope Work

(2) Wrap one end of the main ropes sequentially on the traction machine sheave and lower them to the
opposite side.
Rope Work
149
(3) Pass the end of the rope that is wrapped on the traction machine sheave through the hitch plate hole
on the car hitch side.
150 Rope Work

• Rope arrangement from the traction machine main sheave to the Counterweight sheave
 When 1 Counterweight frame suspension sheave and 6 main ropes are used ;
Rope Work
151
 When 2 Counterweight frame suspension sheave and 8, 10 or 12 main ropes are used ;
152 Rope Work

(4) Mark the point that is 130 mm away from the end of the rope that has passed through the hitch plate
hole.
(5) Insert the one end of the rope to the rope socket.
Rope Work
153
(6) Unthread the wrapped strands to the marked point.
(7) Bend each of the unthreaded strand in half as shown in the figure below.
(8) Bend the center steel wire on the rope with a wrench. (Do not cut the center steel wire.)
154 Rope Work

(9) Pull the rope to the opposite side of the socket so the bent rope can be completely inserted into the
socket.
(10) Sufficiently melt the Babbitt and pour it into the socket.
(11) Solidify the Babbitt so the rope and rope socket are firmly secured.
If the Babbitt is not heated enough, the socket may not be filled with the Babbitt sufficiently due to
its fast solidification. So, be sure to heat the Babbitt sufficiently.
Rope Work
155
(12) Fix the rope socket on the hitch plate.
(13) Engage the rope on the groove of the counterweight frame suspension sheave.
(14) Install the cover on the counterweight frame suspension sheave.
(15) Lower the counterweight frame suspension sheave to the counterweight frame. (Make sure that the
rope does not deviate from the sheave.)
(16) Get inside the car and lower the car using the winch.
156 Rope Work

(17) Engage the counterweight frame suspension sheave on the counterweight frame.
Rope Work
157
(18) Temporarily fix the rope with the wood plate as shown in the figure below to prevent the rope from-
flowing.
(19) Pass the main rope through the top beam suspension sheave and pull out the rope to the rope hitch
plate on the governor side.
(20) Wrap the main rope around the wedge and adjust the length of the main rope so the margin on
oneend of the rope is 100mm or less.
158 Rope Work

(21) Pull the rope towards the inside of the cable joint so the rope does not move.
(22) Align the pin hole of the rope socket with the pin hole of the eye bolt and fix them with a pin.
(23) Engage the split pin.
(24) Wrap the end of the remaining rope with the band or cable tie so the rope does not become loose.
Then, fix the remaining rope and main rope with the rope clip.
Rope Work
159
(25) Fix the wood plate at a position 40 mm below the rope clip.
8.4.3 Installing the Temporary Subweight
Refer to the table below and place the subweight that corresponds to +10 % - 20 % of the overall weight
of the temporary car on the counterweight frame.
[Table 8.4 Car Frame Weight Table (unit: kg)]
Car frame
Total
(stile bar, top Counterweig Weight of 1
Pers Safety Platfor weight of
beam, Ceiling ht Frame subweight
on Device m temporary
suspension weight sheet
car
sheave)
P8 100 155 129 100 484 109
P9 100 155 137 105 497 109
P10 100 155 145 110 510 145

25
P11 100 155 154 110 519 145
P13 105 166 168 120 559 145
P15 105 166 172 120 563 145
• Car wall : Based on t1.5 (1.6) wall panel (SUS hairline)

• Ceiling : Sub-ceiling + Ceiling plate
Weight of the temporary subweight = Car frame weight X (1.1 - 1.2) - Counterweight frame weight
Ex) When 36 subweights are supplied for a 8 Person 60 m/m car (weight of one subweight: 25 kg),
484 kg X 1.2 - 109 kg = 530 kg = Temporary subweight input
530 kg / 25 kg = 17 sheets → Input 17 subweights
160 Rope Work

8.4.4 Installing the Subweight Fixing Bracket
After supplying the subweight, use the subweight fixing bracket to fix the subweight.
Rope Work
161
9. Guide Rail
Guide rail is installed inside the hoistway according to the installation standards to guide the car operation.
It has direct impact on the vibration of the car and requires precise installation.
9.1 Cleaning the Rail Joint Part

Before connecting the rail and fish plate, use the diesel to clean the end of rail and the fishplate to protect
from any dust before Installation.
Guide Rail
162
9.2 Measuring the Rail Bracket

(1) On the rail bracket installation height, measure the distance A (A') or B (B') to the hoistway wall from
the car rail template piano wire or the entrance template piano wire.
(2) Refer to the worksite layout to measure the rail bracket length.
9.3 Bringing the Rail into the Hoistway

(1) Temporarily assemble the fish plate on the joint part in one side of the guide rail.
(2) Place shackle in one of the holes of the fish plate and bring the rail into the hoistway using the motor
winch.
Guide Rail
163
9.4 Fixing the 1st Guide Rail

(1) Place the cut surface of the 1st rail so it contacts the buffer footing.
(2) Concave and convex parts at the upper end of the 1st rail should be as shown below.
164 Guide Rail

Concave and convex parts at the upper part of the 1st rail
Car rail common bracket side
Car rail car hitch side
9.5 Checking the Rail Bracket Installing Location

(1) Install the 1st rail bracket 2,000 mm above the hoistway pit floor. Then, install the following brackets
every 2,500 mm afterwards.
(2) Place the piano wire at the center of the 1st rail bracket.
9.6 Installing the 1st Rail Bracket

(1) Locate the center of 1st rail bracket on the piano wire and mark anchor holes on the wall of hoist way.
(2) Drill the anchor hole on the marked spot.
Guide Rail
165
(3) Check the levelness of the 1st bracket using the spirit level to and assemble it by using plain washer,
spring washer and nut. (Assemble it loosely for the adjustment of 2nd rail bracket.)
(4) Fix the 2nd bracket and rail using the rail clip and adjust the location where the rail will be fixed.
(5) Insert liners about 2.7mm (1.6t, 0.8t and 0.3t, 1 for each) into the contact point between the 2nd rail
bracket and the guide rail and adjust the gap between the 2nd rail bracket and the guide rail.
[Figure 9.1 2nd Rail Bracket on Car Side Installation]
166 Guide Rail

[Figure 9.2 2nd Rail Bracket on Counterweight Side Installation]
[Figure 9.3 Common Rail Bracket Installation]
(6) After completing the adjustment, fix the contact point of 1st and 2nd rail brackets by using G-clamp.
9.7 Installing the 2nd Rail Bracket (Car/Counterweight side)

(1) Use the rail clip to fix the 2nd rail bracket and guide rail.
(2) Insert a liner between the guide rail and 2nd rail bracket to adjust the gap.
(3) After leveling the 1st bracket, temporarily fix the 2nd rail bracket and 1st bracket.
Guide Rail
167
9.8 Installing the 2nd Rail Bracket (Using Common rail)

(1) Use the rail clip to fix the 2nd rail bracket and guide rail.
(2) Insert a liner between the guide rail and 2nd rail bracket to adjust the gap.
(3) After leveling the 1st bracket, temporarily fix the 2nd rail bracket and 1st bracket.
168 Guide Rail

9.9 Centering the Rail

(1) Check if the rail template piano wire is placed at the rail center and if it is spaced 5 mm from the rail.
(2) Check if the rail centers facing each other are located on a straight line.
(3) Check if the rail distance (BG) matches that of the layout.
Guide Rail
169
9.10 Welding the 1st Bracket and 2nd Bracket

(1) After finishing the rail adjustment, fix the 1st and 2nd rail brackets so they do not move. Then, weld
the contact area with a welding bead diameter of 5 mm or above as shown in the figure below.
170 Guide Rail

9.11 Connecting the Rail

(1) Bring the rail into the hoistway.
(2) Lift the top rail using the winch.
(3) Lift the top rail using the winch.
(4) While lifting the rail, connect the lower rails consecutively.
Guide Rail
171
9.12 Measuring the Rail Straightness

(1) Measure the straightness of the guide rail using the straight edge.
(2) Insert a liner to adjust the difference.
172 Guide Rail

9.13 Installing the Top Rail at the Top Side

(1) When installing the top rail at the top side, cut the guide rail so the distance between the hoistway
ceiling and the end of the top rail is 100 mm or less.
(2) Make sure that the distance between the hoistway ceiling and the rail bracket installed at the top is
300 - 500 mm.
Guide Rail
173
10. Entrance
Components related to the installation of the entrance are called the elevator hall components. Depending
on the door opening method and opening size, installation method for each component is determined. So,
carry out the installation considering the specifications of each component and the characteristics of the
structure.
10.1 Landing Sill
10.1.1 Determining the Installation Position of Sill Support
Based on the floor finishing line, determine the installation position of sill support considering the heights
of sill support and landing sill.
Entrance
174
[Figure 10.1 Inside the Hoistway]
10.1.2 Installing the Sill Support
(1) Use the anchor bolts (M12) to install the sill support on the installation position.
(2) Check the front / rear and left / right leveling of the sill support using the spirit level.
Entrance
175
10.1.3 Installing the Landing Sill
(1) Installing the Landing Sill
(2) Adjust the landing sill so the distance between the end of the landing sill and the entrance piano wire
is 25 ± 1 mm.
(3) Weld the corners where the landing sill and sill support contact each other.
176 Entrance
10.1.4 Installing the Toe Guard
Fix the toe guard on the landing sill.
10.2 Jamb
10.2.1 Measuring the Jamb Dimensions
Check the distance between the entrance piano wire and the outer wall and the interior finishing thickness
to measure the jamb dimensions.
• JH: Jamb • JD: Jamb • JJ: Entrance width • MH: Transom height
height width (if necessary)
• H: Distance from the entrance piano wire to the outer wall
• JD(jamb width) = H(distance from the piano wire to the outer wall) - 25 mm(sill distance)
- 60 mm(landing sill width) + B(wall finishing thickness)
Entrance
177
[Figure 10.2 Distance between the Car Sill and Outer Wall]
10.2.2 Installing the Jamb
(1) Install the pin anchor bolts (M8) on the location where the frame reinforcement pipe on the entrance
jamb side is placed.
• In the case of JP 50 type, the jamb is fixed at the upper / middle parts.
• In the case of JP 100/200 type, the jamb is fixed at the upper / middle /lower parts.
178 Entrance
(2) Use the bolt (M8X25), spring washer, and plain washer to assemble the jamb side frame and top
frame.
(a) JP 100 type

When engaging the jamb fixing bolt, align the landing door side corners of the top frame and side
frame (1) and the wall side corners of the elevator hall entrance (2) and fix them with bolts.
Entrance
179
(b) JP 50 type
When engaging the jamb fixing bolt, align the landing door side corners of the top frame and side
frame (1) and the wall side corners of the elevator hall entrance (2) and fix them with bolts.
180 Entrance
(3) Adjust the jamb fixing bolt on the landing sill to fit the entrance width.
Entrance
181
(4) Place the jamb on the jamb fixing bolt and fix the jamb fixing bolt.
(5) Use the plumb and entrance piano wire to check the verticality of the jamb.
(6) Place the jamb fixing steel rebar between the jamb side frame reinforcement and anchor bolt (M8)
and weld it to fix the jamb.
• In the case of JP 50 type, the jamb is welded at the upper / middle parts.
• In the case of JP 100/200 type, the jamb is welded at the upper / middle / lower parts.
182 Entrance
Entrance
183
10.3 Landing Door Operator
10.3.1 Installing the Landing Door Operator
(1) Use the bolts to fix the hanger case bracket of the jamb and the landing door operator.
(2) Fix the hanger case bracket and fix the hanger case to the bracket.
• In the case of concrete wall,
(1) Use the anchor bolts to fix the hanger case bracket to the hoistway wall.
(2) Use the bolts to fix the hanger case bracket and the landing door operator.
(3) Make sure that the vertical distance from the entrance piano wire to the end of the hanger
case is 32.3 ± 0.5 mm.
(4) Make sure that the vertical distance from the entrance piano wire to the center of the hanger
case track is 68 ± 0.5 mm.
184 Entrance
• In the case of steel frame structure,

(1) Use the bolts to fix the landing door operator and hanger case bracket.
(2) Weld the hanger case bracket to the steel frame structure.
Entrance
185
10.4 Landing Door
10.4.1 Installing the Landing Door
(1) Align the 450J door shoe of the landing door to the sill groove and tilt it towards the inside of the
hoistway to insert the door shoe to the sill groove.
186 Entrance
(2) After inserting the door shoe, erect the door vertically.
Entrance
187
(3) Insert a liner between the landing door and the hanger plate contact area to create a gap of 5 mm
between the door and landing sill. Then, fix them using the bolts.
10.4.2 Installing the Triangle Key
Install the key cylinder, washer, and nut as shown in the figure below.
188 Entrance
10.4.3 Adjusting the Landing Door Release Roller
(1) Adjust the landing door release door so the distance between it and the car sill is 7.5 ± 1.5 mm.
(2) When the release roller is engaged with the clutch on the car side, check if the 10 ± 1.5 mm of the
release roller overlaps.
(3) Check if the distance between the landing door release door and the cluster cam is 6 ± 1.5 mm.
10.4.4 Adjusting the Door Interlock Center
When the landing door is completely closed, make sure that the distance between the center of the fixed
roller and the opening center line is 150 mm.
Entrance
189
10.4.5 Adjusting the Door Interlock Operation
When the landing door is completely closed, adjust the distance between the center of the fixed roller and
the opening center line.
190 Entrance
11. Car
When assembling the temporary car, mount the car components, such as car panel, car ceiling, car door
operator, entrance pillar, and entrance transom, on the installed car frame and mount other electric
components for high-speed test run.Car door operator is an important component for opening and closing
the door, so it must be adjusted precisely and finely. Car panel and ceiling are the components that the
passengers see directly, so they should be carefully installed not to damage the outside look.
11.1 Installing the Subweight

In this task, while assembling the temporary car, you load the required number of subweights on the coun-
terweight frame considering the car weight and rated capacity in addition to the subweights already
loaded. A team of two people should work as a unit and pay attention to the safety during the work.
• Tools used
 17 and 19 mm spanners  17 and 19 mm ratchet wrenches  Hammer
(1) Raise the car to the location where it is possible to load the subweight as the car crosses the coun-
terweight.
(2) Fasten the safety belt of each worker to a stable location.
(3) Use the ratchet wrench and wrench to release the weight fixing clip and fixing bracket.
(4) Secure the safety plate and insert the subweight to the counterweight frame from the lower part of
the counterweight. At this time, work as a team of two people. Also, make sure that the workers are
in a stable posture during the work to prevent falling.
(5) After inserting an appropriate amount of subweight, use the clip to engage the weight fixing bracket
to the counterweight frame. At this time, use the hammer to place the clip against the counterweight
frame.
191 Car
11.2 Installing the Car Panel and Ceiling

• Tools used
 10 and 13 mm spanners or  17 mm spanner  19 and 24mm ratchet

ratchet wrenches wrenches
 Steel ruler (150 mm)  Spirit level  Right angle ruler
 Hammer
[Figure 11.1 Car Wall Assembly]

(1) Car Wall Assembly
(2) Car wall assembly method differs depending on the size of the car inside. The car wall is assembled
in sub-units. It is divided into 8 units for the elevator of P15 or below and into 11 units for that of P17
or above.
(3) Refer to ]and use the M6x20 bolts on the car wall (A) and (B) and the entrance pillar (I) to assemble
the left / right sides at the same time. Then, reinforce the lower part of the car wall and fix it to the slot
hole of the upper kick plate on the car floor.
(4) Use the M6x20 bolts on the car wall (C) and (D) to assemble the left / right sides at the same time.
Then, reinforce the lower part of the car wall and assemble it to the slot hole of the upper kick plate
on the car floor.
(5) Use the M6x20 bolts on the car wall (E) and (F) to assemble the left / right sides at the same time.
Then, reinforce the lower part of the car wall and assemble it to the slot hole of the upper kick plate
on the car floor.
(6) Use the M6x20 bolts on the car wall (G) and (H) and the entrance pillar (J) to assemble the left / right
sides at the same time. Then, reinforce the lower part of the car wall and assemble it to the slot hole
of the upper kick plate on the car floor.
192 Car
(7) Assemble the unassembled (B), (C), (D), (E), (F) and (G) sides in the outside of the car.
(8) Align the car walls on each corner with the ends of the outside and side of the car wall and assemble
them.
(9) When mounting the hand rail on the car wall, temporarily assemble it to the hole in the car wall before
installation to make it easy to carry the car wall.
(10) After assembling the car wall, use the M6x20 bolts to fix the lower holes of the entrance pillar (I) and
(J) to the tabs on the platform. At this time, be sure to align the end of the entrance pillar with the end
of the car sill.
(11) Insert the entrance transom between the left / right entrance pillars and use the M6x20 bolts to
assemble them in the outside of the car. At this time, precisely align the entrance transom with the
entrance pillar.
(12) Place the protective tape on the upper part of the car sill and mark the entrance width and the center
line for the width.
(13) Place the protective tape on the upper part of the car sill and mark the entrance width and the center
line for the width.
(14) Place the lower part of the sill rear against the platform and use the M8x20 bolts to temporarily fix
them.
(15) Use the spirit level to check the leveling of the entrance sill and fix the car sill on the sill block. At this
time, insert a liner between the car sill and sill block to adjust the leveling.
(16) Use the M5x12 crosshead screws to assemble the apron.
(17) Gradually lower the ceiling that is temporarily fixed to the top beam using the rope to place it on the
top of the car wall.
(18) Align the ceiling hole to the slot hole on the reinforcement at the top of the car wall and fix them using
M6x20 bolts.
(19) Maintain the distance between the vibration isolator on the left / right sides of the ceiling and the car
stile as you temporarily assemble them. At this time, maintain the distance between the vibration
isolator and car stile to 10 mm so you can adjust it when centering the cage.
Car
193
11.3 Centering Car Panel
Depending on the accuracy of the car panel centering, vibration and noise may occur while driving
the car. Be sure to follow the centering procedure precisely.
• Tools used
 10 and 13 mm spanners  14 and 17 mm spanners  24 and 30 mm

ratchets
 Straight ruler (150 mm)  Spirit level  Right angle ruler
194 Car
[Figure 11.2 Measuring Verticality of the Car]

(1) Use the spirit level to check the leveling of the car floor.
(2) Loosen the M8x20 bolts.
(3) Lower the plumb line from the car entrance transom to the side of the entrance pillar to measure the
A-A' distance on the figure. Then, check the up / down and front / rear verticality of the car.
(4) After measurement, loosen the M16 jack bolts at the lower part of the platform in the tilted direction
and insert a liner between the Isolation Pad and support frame to adjust the verticality and leveling of
the car panel. At this time, the up / down and front / rear verticality should be ± 1 mm.
(5) Securely tighten the M16 jack bolts and the Isolation Pad bolts of the car panel.
(6) Check the parallelism between the car sill and landing sill.
(7) If adjustment is necessary after measurement, loosen the M20x50 bolts that fix the support frame and
safety device and use a lever to adjust the left / right parallelism of the car sill and landing sill to 25 ±
1 mm.
(8) After the adjustment, securely tighten the M20x50 bolts.
(9) Use the M8x20 bolts to securely fix the vibration isolator in the ceiling. At this time, Isolation Pad
should be free of compression. When too much tension is applied, carry out the centering again.
(10) When the centering of the car panel is complete, assemble the ceiling components (e.g. fluorescent
lamp).
Car
195
11.4 Installing the Apron

(1) Tighten the bolts to the front holes of the platform to install the apron.
(2) Use the bracket to fix the apron to the platform.
11.5 Installing Compensation Chain

(1) Adjust the compensation chain distance between the car and counterweight to 350 - 400 mm.
(2) Adjust the distance between the lower part of the compensation chain and the pit floor to 150 - 200
mm.
196 Car
(3) Adjust the distance between the center of the compensation guide pipe and the pit floor to 450 - 500
mm.
11.6 Installing the Whisper-Flex Chain

Check if the end of the Whisper-Flex chain and the 3 to 4 links of the chain that extends 1000 mm are
exposed as shown in the figure below so you can engage the U-bolt.
1000 mm
[Figure 11.3 Whisper-Flex Chain]
Car
197
11.7 Connecting the Car and Counterweight with the Whisper-Flex Chain
(1) Assemble the bracket to the lower side of the safety device and engage the U-bolt.
(2) Adjust the car so it is placed at the pit and connect the compensation chain to the car side.
(3) While raising the car, connect the compensation chain to the lower part of the counterweight at the
position where the counterweight and car meet each other at the center of the hoistway.
(4) The end of the Whisper-Flex chain should be spaced at least 250 mm from the hoistway floor. The
distance from the compensation chain guide brush to the end of the Whisper-Flex chain should be at
least 750 mm.
11.8 Adjusting the Guide Shoe
11.8.1 Sliding Guide Shoe
Sliding guide shoe glides upon the oil film along the rail to guide the elevator.
[Table 11.1 Applying the Sliding Guide Shoe for Car]
Speed
Load capacity
~ 60 M/MIN 105 M/MIN
8K ~ 13K HGS121K HGS122K
198 Car
Speed
Load capacity
18K ~ 24K HGS230K
Length of the shoe plate is 120 mm for 121K and 122K and 230 mm for 231K.
[Table 11.2 Applying the Sliding Guide Shoe for Counterweight]
Speed
Load capacity
5K ~ 13K U Type -
8K ~ 13K HGS121K -
18~24K HGS231K -
18K~24K - HGS230K
In the U type, 5K is made of natural rubber and 8 - 13 K of urethane.
1) Adjusting HGS121K
(1) Mount the upper and lower sliding guide shoes.
• At this time, place them so the gap between the upper stile and rail is the same in the front / rear
/ left / right sides.
• Mount the lower sliding guide shoe so the front / rear / left / right gaps of the emergency stop
device are the same.
(2) Adjust the adjustment nut on the lower guide shoe so the gap between the shoe support and frame
is 5 mm.
(3) Adjust the gap on the stopper of the lower guide shoe to 1.5 - 2 mm as shown in the figure.
(4) Adjust the upper guide shoe as in the steps (2) and (3).
(5) Install the oiler and manually operate the elevator to check for interference. (Check the door side and
various switch brackets.)
Car
199
• Mount the upper and lower sliding guide shoes.
(2) Adjust the spring on the lower guide shoe so the gap between the shoe support and frame is 1.5 - 2
mm. Compress the free-state spring by 4 - 5 mm to set its length to 37 - 38 mm.
(3) Adjust the gap on the stopper of the lower guide shoe to 1 - 2 mm as shown in the figure.
200 Car
• At this time, place them so the gap between the upper stile and rail is the same in the front / rear
/ left / right sides.
(2) Rotate the adjustment nut of the lower guide shoe by 3 - 4 mm to adjust the gap between the adjust-
ment nut and shoe support frame to 5 - 7 mm.
(3) Adjust the gap on the stopper of the lower guide shoe to 9 - 11 mm as shown in the figure.
Car
201
11.8.2 Roller Guide Shoe
Roller guide shoe (RGS) moves along the rail to guide the elevator and improve the ride comfort and
elevator system efficiency.
[Table 11.3 Applying the Roller Guide Shoe for Car]
Speed
Load capacity
~120M/Min 120~180M/Min
1,800 kg or less RGS125 RGS150C or RGS160
[Table 11.4 Applying the Roller Guide Shoe for Counterweight]
Speed
Load capacity
~105M/Min 120~180M/Min
1,800 kg or less RGS125 RGS150C or RGS160
202 Car
• Installed elevator car should have no twisted part.
• The stile and rail should be in a straight line without twisting.
(1) The roller guide shoe on the upper and lower parts of the car should be vertical to the rail surface.
Adjust it with a liner if necessary. (Use the plumb and end scale to install the roller guide shoe so the
upper and lower surfaces of the roller have the verticality of 0.25 mm or less.)
(2) Completely loosen the stopper on the upper roller guide shoe and loosen the spring to 50 % of the
preset value. (Prepare for the balancing work.)
(3) Loosen the spring and stopper on the lower roller guide shoe to see if the car moves freely.
(4) Push the car in the horizontal direction and hang on the car as you need to know the direction where
the car moves and how much power is needed to place the guide plate of the roller guide shoe at the
center of the guide rail and to place the safety device.
(5) Based on the information obtained in the step (4), attach the plumb on the lower part of the car to
carry out the balancing work. (Complete the balancing work.)
(6) Set the spring and stopper of the lower roller guide shoe to the settings below and check if the
distance between the car sill and hatch sill is appropriate and if the gibs of the safety device maintain
equal distance on the rail. (Complete the settings of the lower roller guide shoe.)
(7) Set the spring and stopper of the upper roller guide shoe to the settings below. (Complete the settings
of the upper roller guide shoe.)
(8) While manually operating the elevator over the entire floors, see if the distance between the hatch
door release roller and the car door clutch is constant and if there is any interference. (Perform final
check before high-speed operation.)
(9) Operate the elevator at high speed to check the ride comfort.
(10) If there is vibration, rotate the roller with appropriate force to check if it rotates well on the rail surface.
If there is a roller that is too tight, check if the gap on the stopper is appropriate and gradually loosen
the spring to check if the roller rotates properly. (Check and adjust if you do not feel satisfied with the
ride comfort.)
170 mm
Ø80
160 mm
RGS 80
Car
203
170 mm
Ø125
160 mm
RGS 125
170 mm
Ø150
160 mm
RGS 150
[Table 11.5 Spring and Stopper Settings]

(unit : mm)
RGS category Spring [SP] setting Outer stopper setting Inner stopper setting
RGS125 33 ± 1 2
RGS150C 38 ± 1 2
204 Car
RGS category Spring [SP] setting Outer stopper setting Inner stopper setting
RGS160 38 ± 1 2
• Front / Rear direction : Adjust it using the eccentric bolt of the roller. Move it up to
5 mm.
RGS80 • BG direction : Adjust it to the position where the RGS frame and car frame are
mounted.
[SP] 1
2 mm
[Figure 11.4 RGS125 ~ RGS300]
Notice
• Spring and stopper settings have a significant impact on the roller lifespan and ride comfort.
• Load applied to the roller: 11 - 22 kgf
• When RGS adjustment is complete, operate the elevator over the entire floors and check if you
can rotate the roller with appropriate force using your hands.
<Troubleshooting for roller guide shoe adjustment>

• In the case of too much RGS vibration ;
(1) Check if damage has occurred on the surface where the roller and rail are in contact and replace
the damaged component if necessary.
(2) Check if you can rotate the roller with appropriate force using your hands.
• If you cannot rotate the roller with appropriate force ;
Check if the spring and stopper settings are appropriate.
• If you cannot rotate the roller with appropriate force even after adjusting the settings ;
After performing car balancing, readjust the spring and stopper settings and see if you can
rotate the roller with appropriate force.
Car
205
• If horizontal vibration is excessive in RGS 340 (when the peak to peak value of EVA data is 8 gal or
above) ;
Tighten the friction damper for adjustment.
11.8.3 Rubber Guide Shoes and Urethane Guide Shoes
Install the counter frame so its front / rear / left / right sides are placed at the center of the rail. If the rail
has gap difference, it may cause vibration and shoe wear. Operate the elevator over the entire floors to
see if there is anything stuck on the rail. If necessary, adjust the rail gap difference.
46 mm
60 mm 18 0.4 mm 112 mm
86 mm
[Figure 11.5 Rubber Guide Shoe (5K)]
10 + (0.3~0.5) mm
16 + (0.3~0.5) mm
110 mm
86 mm 45 mm
[Figure 11.6 Urethane Guide Shoe (8 - 13K)]
11.9 Car Header Arm Assembly

Use the bolts to assemble the car header arm on the car stile.
206 Car
11.10 Installing the Vertical Rod

(1) Fix the shackle on the top beam and car header arm.
(2) Fix the vertical rod on the shackle of the car header arm.
Car
207
11.11 Tie Rod Assembly

Install the tie rod between the car header arm and car door operator in left / right sides and check the
leveling using the spirit level.
208 Car
11.12 Car Door Operator

Car door operator is released as a separate assembly and fixed by the car header arm. It opens or closes
the car door through the operation of the door motor. Depending on the installation status, it has a signif-
icant impact on the door movement. Be sure to precisely measure the relevant values of each component
for installation.
Car
209
11.12.1 M2CA
210 Car
1) M2CA installation
(1) Engage the shank bolt and tab plate on the car door operator fixing bracket of the ceiling panel in the
direction of the arrow to install the car door operator.
(2) Make sure that the slope between the entrance center and the track center is within 1 mm.
Car
211
212 Car
(3) Use the frame fixing bracket and bolts to fix the car door operator.
Car
213
11.12.2 UM2
1) UM2 installation
Engage the bolts to the car header arm to install the car door operator.
214 Car
11.12.3 P1
Car
215
1) P1 installation
(1) Use the carriage bolts and tab plate to install the car door operator on the door operator fixing bracket
at the ceiling panel.
(2) Use the carriage bolts to adjust the car door operator center as shown in the figure.
216 Car
(3) Use the carriage bolts to adjust the verticality and height of the car door operator as shown in the
figure.
Car
217
(4) Align the frame fixing bracket to the bolt holes on the entrance transom bracket and tighten the M6
bolt, nut, spring washer, and plain washer to fix the car door operator.
11.13 Safety Edge Cable Wiring

(1) Safety Edge Cable Wiring
(2) Tie the cable at an appropriate distance using the cable tie. Then, check the operation.
218 Car
11.14 Installing the Door Cover

Install the door covers on the left, middle, and right sides as shown in the figure.
Car
219
11.15 Car Door

• Tools used
 10 mm spanner  13 mm spanner or ratchet wrench  17 mm spanner
 Phillips head screw-  Flat head screwdriver  15' monkey spanner (350
driver mm)
 Spirit level  Steel ruler (150 mm)
Use the bolts to engage the hanger plate to the car door.
220 Car
11.16 Installing the Clutch

• Tools used
 10 mm spanner  10 mm spanner  Spirit level  Spirit level
11.16.1 CDL Clutch
(1) Check if the distance from the center of entrance to outside surface of the fixed cam of clutch is 101.8
mm.
mm.
Car
221
11.16.2 General Clutch
mm.
(2) When the door is closed, check if the distance between the inner side of the fixed cam and that of the
operating cam is 68 ± 0.5 mm.
222 Car
Car
223
11.17 Safety Edge Cable Wiring
Use the cable guide wire, cable clamp, cable tie, and helical band to carry out wiring as shown in the figure
below.
[Figure 11.7 SE600M Whose Wiring Is Completed]
224 Car
11.18 Installing the Car Junction Box

Install the car junction box on the car junction box fixing bracket.
11.19 Adjusting the Rib V-Belt Tension

Rotate the door motor counter-clockwise as shown in the figure to adjust the tension of the rib V-belt.
Car
225
11.20 Adjusting the Wire Rope Tension

Adjust the socket position of the rope end as shown in the figure to adjust the tension of the wire rope.
226 Car
Car
227

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4.

NO. Specification DATE Manager

0 First Edition 2013.08.24

1 Edit the format 2013.11.05

2 Reorganization of the manual 2014.05.30

Reorganization of the manual

3.7 TM Handle Switch part Update

3.3 Gearless-New MR Type Traction

Reorganization of the manual

2. Standard Installation Process for Rope-Type Elevators .............................................................36

3. Main Components of Elevator .....................................................................................................38

4. Work before Installation ..............................................................................................................39

6. Traction Machine ........................................................................................................................50

6.1 Geared Type Traction Machine ..........................................................................................50

6.7.2 Checking the Installation ........................................................................................102

7. Temporary Car ..........................................................................................................................106

8. Rope Work ................................................................................................................................131

8.2.1 Engaging the Wedge-Type Rope ...........................................................................137

9. Guide Rail .................................................................................................................................162

10. Entrance ..................................................................................................................................174

11. Car ..........................................................................................................................................191

11.3 Centering Car Panel .......................................................................................................194

1.1 Safety Requirements

1.1.1 Protective Equipment

• Do not wear accessories that may conduct electricity.

[Figure 1.1 Eye Nuts for Installing the Lifeline]

[Figure 1.2 Eye Nuts for Installing the Safety Belt]

1.2 Common Safety Precautions

 For mounting the lifeline: Top floor, bottom floor + 2 floors

• Smoking is not allowed except in designated areas.

[Figure 1.3 Precautions]

[Figure 1.4 Installing the Lifeline]

1.3 Precautions for Each Work Process

1.3.1 Site Visit and Survey before Construction

• Beware of falling while installing the shield plate.

[Figure 1.5 Safety Fence]

[Figure 1.6 Safety Shield]

1.3.2 Construction and the Office / Warehouse Installation

• There is the risk of rollover while moving to the worksite.

• Keep a first-aid kit in the office.

• Be sure to keep the following documents in the office.

 Safety Rules for Each Installation Process

[Figure 1.7 Safety Rules for Each Installation Process]

1.3.3 Bringing Equipment and Material

1) Things to check before starting work

[Figure 1.9 Measures to Prevent Unauthorized Access to the Worksite]

• Check the worksite and transportation route (work path).

• Check the weight and center of gravity of the load.

• Use a forklift to deliver equipment / materials.

• Check the conditions of communication devices such as a radio set.

[Figure 1.10 Checking the Lifting Machine and Rope]

• If an entrance door is installed in the machine room, lock the door.

[Figure 1.11 Lifting Hook]

1.3.5 Template Work

1) Things to check before starting work

• Beware of falling when working on a ladder.

• Install the ladder in the hoistway pit firmly.

1.3.6 Welding Machine Installation and Welding Work

1) Things to check before starting work

• Check the operating condition of the electric shock prevention device.

[Figure 1.12 Welding Machine]

1) Things to check before starting work

• Check the conditions of the wire rope and shackle.