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Installation Work Manual _______
SECTION 1: RAIL BRACKET WORK

[Contents]

1 Scope

2 Purpose

3 Work procedure

3.1 Marking of the rail bracket positions and


measurement of heights

3.2 Rail bracket

4 Check list and required tools

1. Scope

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Installation Work Manual _______
This manual applies to the fixing of rail brackets in the hoistway for standard type
elevator

2. Purpose
This manual is to provide a standard work procedure required on how to locate and
attach rail brackets in the hoistway

3. Work Procedure

3.1 Marking of the rail bracket positions and measurement of heights

3.1.1 BOM (Bill of Material) take-off for rail brackets

a) Lowest rail @ may be 4m or 5m length


Bracket pitch is shown on figure 1.1

b) The distance from underside of machine room slab to the top


of rail shall be 300mm 500mm

c) Dimension for bracket shall be 300m 2500mm. In case

this is less than 300mm, top rail pitch shall not be greater than
2800mm

d) Rail pitch, bracket pitch and number of bracket intervals are


specified in the hoistway sectional view of the installation
drawings

e) Data shown in figure 1.1 can be found in the hoistway


sectional drawing. Therefore, compare the total height of the
hoistway with the drawing and determine No. of bracket
intervals

Figure 1.1
Rail bracket pitch

3.1.2 To determine the position of lowest rail bracket

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a) Mark on the pit wall the pit depth from the lowest finished part
of the top floor (figure 1.2)

b) Locate the lowest rail bracket point 1,500mm above the pit
floor

c) Make a water level by pouring water into a transparent vinyl


tube. Mark a line in ink on the wall where rail brackets will be
attached

d) As per figure 1.1, mark other bracket locations upward

Figure 1.2
Determine the lowest rail bracket position

3.1.3 To measure the mounting heights of rail brackets for main rail and to
set anchor bolt locations

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a) At rail bracket mounting location, approach the square rule to both
piano wires and find bracket center line. Mark that line in ink on
the wall

b) Bracket mounting height will be dimension H, the distance


between wall and bracket piano wire less 3mm (see figure 1.3)

c) Based on the rail bracket mounting height (refer to table 4.2 for
application of rail brackets), set anchor locations and mark in ink.

Figure 1.3
Measuring mounting heights
of bracket for main rail

3.1.4 To measure the mounting heights of rail brackets for C.W.T rail and to
set anchor bolt locations

a) Mark the center line (vertical) in ink in a similar manner to main rail

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b) Mounting height of rail bracket will be H, the distance between the
wall and piano wire

c) Set anchor locations and mark in ink (refer to table 4.2)

3.1.5 Fabrication of rail brackets

a) Based on the bracket height H (refer to table 4.2 drawing for rail
brackets), order the fabrication and delivery of brackets utilizing
formats and dimensions of table 2.4

4.2 Rail bracket

4.2.1 Application of rail brackets

Table 2.1 Main Rail Bracket

Rail bracket T Ref. Bracket Anchor Remarks


height (H) Figure Material bolt size
H < 16mm 2.2 Flat steel
H < 28mm 2.3 50 x 9 16
H < 250mm 2.4 Flat steel M12 H > 200 reinforced
50 x 9 by flat steel
H < 400mm 2.5 L Steel
H < 500mm 2.6 50 x 4
500 < H Standard 2.7 Middle beam
< 600 Non Standard 2.8 Reinforced by L steel

Table 2.2 C W T Rail Bracket

Rail bracket T Ref. Bracket Anchor Remarks


height (H) Figure Material bolt size
H < 300mm 2.9 L steel 50 x 6 M12
H < 500mm 2.10 (W< 1100kg) Reinforced by round steel
500 < H Standard 2.11 L steel 65 x 6 Middle beam
< 600 Non Standard 2.12 (W < 1500kg) M16 Reinforced by round steel

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Note: Use M16 anchor bolt for : DP-11, DP-13 and DP-15
Use M12 anchor bolt for : DP-6 and DP-9

Table 2.3 Common Bracket for two main rails

Rail bracket T Ref. Bracket Anchor Remarks


height (H) Figure Material bolt size
H < 100mm 2.13 L steel 50 x 4
Flat steel 60 x 9 Bolting not required for
-------------------------------- ----------- --------------------- M12 welding
H < 300mm 2.14 L steel 50 x 4

4.2.2 Details for rail brackets of different heights

Fig 2.1 Slot hole details Fig 2.2 H < 16

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Fig 2.3 H < 28 Fig 2.4 H < 250

Fig 2.5 H < 400 Fig 2.6 H < 500

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Fig 2.8 H < 100 (middle beam is used) Fig 2.7 H < 700

Fig 2.9 H < 300 Fig 2.10 H < 500

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Fig 2.11 Fig 2.12 H < 600

Fig 2.13 H < 100 Fig 2.14 H < 300

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Fig 2.15 Details for round steel reinforcing section

Requisition for Bracket

Client : _____________ Model : _____________ Liner thickness 3mm

Order date : _____________ Written by: ____________ shall be subtracted from


main dimension

Item No. Hoistway No. Hoistway No. Middle Remarks


Beam
Main CWT Main CWT
left Right Left Right Left Right Left Right

Receipt date : ________________________ Manufacture No.:

Description Drawing No. Qty Remarks

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Figure 3.1 Example of bracket height Figure 3.1 Example of bracket height
dimension for main rail dimension for main rail

4. Check List and required tools

No. Check point Yes No Required tool


1 Are the delivered brackets fabricated in
accordance with the requisition dimensions? - transparent
vinyl hose
- square rule
2 Are bracket locations properly marked at each - convex rule
floor? - 15cm steel rule

3 Are brackets delivered as per the applicable


standard?

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SECTION 2: INSTALLATION WORK OF


ENTRANCE PARTS

[Contents]

1. Scope

2. Purpose

3. Work procedure

3.1 Location of anchor bolt holes

3.2 Attaching and centering of sill and pocket

3.3 Attaching jamb

4. Check list and required tools

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1. Scope
This manual applies to the installation work of entrance parts for standard type
elevator

2. Purpose
This manual defines a standard work procedure required for installing entrance parts
of elevator

3. Work Procedure

3.1 Location of anchor bolt holes

3.1.1 To check levels of finished floor

a) above each floor line of finished floor is marked on the rough


surface of the entrance front wall (figure 1.1)

b) Dimension X of finish floor line will be finished floor level

c) Dimension X is normally 100mm, but may vary from floor to


floor or depending on the specific site. Always verify with the
client

Figure 1.1
Marking line of finished floor

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3.1.2 To ink-mark the location of anchor bolt holes

a) Using a wood gauge, mark the anchor bolt locations in ink on the
wall

b) To make horizontal ink lines, mark the relative positions for pocket
anchor, finished floor and sill anchor on the wood gauge. Mark the
horizontal ink lines the wall (see figure 1.2)

c) Put square rule to the piano wire and mark vertical ink lines on the
wall (see figure 1.3)

Figure 1.2

3.1.3 To drill anchor bolt holes

a) Refer to figure 1.4 for the method of hole drilling

b) Refer to figure 1.4, 1.5 and 1.6 for anchor hole locations

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Figure 1.3

Figure 1.4
Center opening door (CO) RPA hole locations

Note) + indicates the RPA locations


This figure is viewed from the inside of hoistway

Figure 1.4
2 panel side opening door (2S) left opening RPA hole locations

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3.2 Attaching and centering of sill and pocket

3.2.1 Attaching sill brackets

a) Set three (3) sill brackets to anchor bolts. Adjust the brackets to
get a temporary level (figure 2.1)

3.2.2 Attaching sill and centering

a) Attaching sill to the brackets. Move the brackets up and down so


that the upper face of sill be adjusted with finished floor line.
Fasten bracket anchor bolts

b) Put " rule at the center punch of sill edge and adjust the center
punch to piano wire by moving the sill from side to side (see figure
2.2)

c) Move the sill back and forth to let the distance from each piano
wire to the back edge of the sill be 30mm (see figure 2.3)

d) Insert liners into the sill and brackets and to make overall
horizontal level

e) Re-verify @~ when the procedure is completed. Fasten each

bolt securely.

f) Spot weld the rectangular washer of anchor bolts to brackets

g) Set a finishing steel sheet between floor and bracket. Spot weld
the sheet to brackets

3.2.3 Attaching pocket and centering

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a) For a standard type elevator (DP-CO) pocket is delivered as one
unit consisting of hanger, door lock switch and pocket cover
assembled at GSIS

b) Set pocket brackets to anchor bolts, attach the pocket

c) Adjust door rail position to the dimensions of the upper face of the
sill. Fasten anchor bolts

d) Let the distance from the front face of door rail to piano wire
become 81mm

e) Lower a weight from marking line of the pocket. Verify that the
distance to the sill center is less than 2mm (figure 2.8)

Figure 2.8

Figure 2.5

Figure 2.6

Figure 2.7

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3.3 Attaching jamb

3.3.1 Assembling jamb

a) Set right jamb and left jamb to upper jamb (figure 3.1)

b) Check the dimension of entrance width after assembling

c) To protect jambs from damage, carry out the assembly work on


wood plate etc.

Figure 3.1
CO

3.3.2 Attaching jamb onto sill

a) To keep the sill surface from damage, mark entrance center and
entrance width on the upper face in pencil (figure 3.2, figure 3.3)

b) Loosely fit the jamb to sill until jamb is set 7mm above the sill.
Keeping the jamb perpendicular to sill, fasten the fixing bolts

Figure 3.2
DP type E/L (CO)

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Figure 3.3
Attaching jamb for DP type E/L (2S)

3.3.3 Attaching jamb to pocket and centering

a) Loosely set the jamb to pocket

b) Verify that the distance between right (or left) side wire and right
(or left) jamb is 121mm

c) From the jamb top, lower a weight, verify that the deformation from
inclination, torsion or bending is less than 1mm (see figure 3.4)

d) Fasten fixing bolts (see figure 3.4)

e) Re-verify item (b) and (c)

3.3.4 Securing jamb

a) After centering set steel bars between jambs reinforcing part and
building reinforcing bar. Secure the connections by welding. Take
care not to damage jamb surfaces when carrying out welding
(figure 3.6)

b) After welding recheck inclination, torsion or bending of jamb. Re-


verify figure 3.5 is met

c) Put bricks between jamb and building wall. Finish the surface with
mortar

3.3.5 Attaching indicator box

a) Remove indicator box cover

b) Loosely set the box into indicator hall with wooden wedge, etc.
dimensions X, Y shall comply with installation drawing (figure 3.7)

c) Using leveler or plumb bop makes the box position correctly. Set
the indicator box so that it locates 0 ~ 3mm from the finished wall
surface. Caution: thickness of wall finish may be different from
floor to floor

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d) After positioning the indicator box, weld building reinforcing bar to


indicator box (see figure 3.9)

e) Fill the area around mortar box, except piping area, with mortar

f) To prevent mortar from entering indicator box when finishing wall,


provide temporary protection on the indication

Figure 3.10
Assembly drawing of entrance area for standard type elevator (center open)

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Figure 3.11
Assembly drawing of entrance area for standard type elevator (side open)

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4. Check List and required tools

No. Check point Yes No Required tool

1 Is building finished floor correctly verified? - ink pad case


- tape measure
- level
2 Are anchor bolt locations correct? - transparent
vinyl hose
- weight
3 Are attaching and centering of sill correct? (plumb bop)
- welding machine
- square rule
4 Are sill brackets spot welded? - 15cm steel rule
- electric hammer
drill
5 Are attaching and centering of pocket - electric hammer
correct? drill bit
- spanner set
6 Are centering and fixing of jamb correct? - impacting tool
- hammer

7 Is indicator box secured at correct position at


each floor?

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SECTION 3: CENTERING WORK IN THE


MACHINE ROOM

[Contents]

1. Scope

2. Purpose

3. Work procedure

3.1 Centering in the machine room

4. Check list and required tools

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1. Scope
This manual applies to the centering work in the machine room for standard type
elevator

2. Purpose
This manual is to provide a standard work procedure required for centering on the
machine room

3. Work Procedure

3.1 Centering in the machine room

a) Place templates on the machine room opening and hang plumb


bops down to the top templates

b) Adjust and match template @ with the main rail center. Mark the
main rail centerline on the machine room floor in ink

c) Adjust and match template @ with the cage center. Mark the cage
centerline on the machine room floor

d) Use two plumb bops for each template @ or b and mark the line
using the two points

e) based on these main rail and cage centers, install various machine
in the machine room

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Figure 1.2
Details of centering in machine room

4. Check List and required tools

No. Check point Yes No Required tool

1 Are ink-marking lines on the machine room - ink pad case


floor correct? - tape measure 3m
- weight
2 Is the center location of each equipment (plumb bop)
correct?

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SECTION 4: INSTALLATION OF MACHINE


BEAM & ASSEMBLY WORK OF
TRACTION MACHINE

[Contents]

1. Scope

2. Purpose

3. Work procedure

3.1 Installation of machine beam


3.2 Installation of traction machine
3.3 Installation of control panel
3.4 Installation of floor controller
3.5 Governor machine

4. Check list and required tools

1. Scope

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Installation Work Manual _______
This manual applies to the assembly work of machine beam, traction machine,
control panel, floor controller, governor machine in machine room for standard type
elevator

2. Purpose
This manual defines a standard work procedure required for assembly work in the
elevator machine room

3. Work Procedure

3.1 Installation of machine beam

3.1.1 when inserting one end of M/C beam into wall and securing with
mortar

a) verify that ink lines are marked as per the installation drawing

b) is a penetration made on the wall area where M/C beam is


inserted? If not break the wall off to provide a penetration. Take
extreme care when the outer wall surface is waterproof finished

c) place machine beams so that each beam is apart 200mm &


350mm apart from cage center. Each beam end shall rest
approximately 100mm on the wall

d) check relative level of both M/C beams. Fasten anchor bolts


(M12). Fill the wall area with mortar

e) after positioning M/C beam, mark main rail center on the beam

3.1.2 when fixing M/C beam without inserting M/C beam into wall

a) mount the M/C beams on the wall so that each beam end rest
100mm on the wall fasten anchor bolts (figure 1.3)

b) after positioning M/C beam, mark the main rail center on the beam
(punch)

Figure 1.3

3.1.3 tolerance of M/C beam installation

a) lateral level tolerance A of M/C beam shall be less than 1mm

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b) relative installation deviation B of M/C beams shall be less than


1.5mm

c) longitudinal level tolerance C of M/C beam shall be less than 1mm

d) relative level difference D of M/C beams shall be less than 1mm

Figure 1.4

Figure 1.5

Figure 1.6

3.2 Installation of traction machine

3.2.1 setting rubber for anti-vibration

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a) shift main rail center position to the M/C beam upper face. Mark
setting points of rubber for anti-vibration which are located L1, L2
apart from the main rail center (figure 2.2)

Figure 2.1

Figure 2.2

3.2.2 installation of traction machine

for the sake of safety during transportation, traction machine is


delivered as each unit of sub-beam, machine base and traction
machine

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(a) TKM type traction machine

Figure 2.3

(b) Field assembled traction machine

Figure 2.4

3.2.3 setting beam pulley

a) loosely assemble the beam pulley to machine base

b) align beam pulley to sheave (when aligning, insert liner between


machine bases)

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c) make sure error alignment of beam pulley off center line shall be
less than 1.5mm

d) when aligning beam pulley to sheave, obtain center by extending


wire at the side of each pulley

3.3 Installation of control panel

3.3.1 installation of pull box

a) observe installation location of control panel (refer to installation


drawing) and hammer 4 sets of anchor bolts into machine room
floor. Set pull box

b) obtain horizontal level of pull box by inserting lines plate between


pull box and machine room floor. Fasten anchor bolts.

3.3.2 installation of control panel

a) place the control panel on the pull box. Loosely fix 4 sets bolt to
pull box

b) adjust the inclination of control panel within 2mm by inserting liners


between pull box and control panel. Fasten the fixing bolts
securely (see figure 3.2)

3.4 Installation of floor controller

3.4.1 installation of brackets

a) observe the installation location of floor controller (refer to


installation drawing). Hammer 4 sets of anchor bolts into machine
room floor. Set brackets for floor controller (figure 3.2)

b) obtain horizontal level of both brackets by inserting liners between


brackets and floor. Fasten anchor bolts.

3.4.2 installation of floor controller

a) place the floor controller on the brackets fit fixing bolts

b) adjust the inclination of floor controller within 2mm by inserting


liners between floor controller and brackets. Fasten fixing bolts
securely

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3.4.3 installation of F.ctr pulley

a) observe the installation location of floor controller pulley (refer to


installation drawing). Hammer 4 sets of anchor bolts into machine
room floor. Set the floor controller pulley

b) from the pulley top, lower a weight. Adjust the inclination (to each
side and front and rear) within 1mm by inserting liners between
pulley and mounting frames and machine room floor. At the same
time fasten the anchor bolt after check that mounting frames are
horizontal

c) during commissioning of elevator (slow moving), observe how tape


roll over pulley. Slanting to right or left side means in complete
vertical alignment. Readjust and correct inclination

Figure 4.4
Outline drawing for floor controller

3.4.4 relative centering for floor controller and pulley

a) after setting floor controller and pulley, verify the alignment of floor
controllers driving sprocket with pulleys

b) after verifying, fasten each bolt

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Figure 4.5

Table 4.1

F.ctr Speed (m/min) Stroke L(m) H(m) 1(mm) Weight (kg)


L < 40 1250 810 60
Use for DP Not greater than 60
40 < L < 60 1000 1160 80
L < 40 1250 810 95
Use for DP Not less than 90
40 < L < 60 1600 1160 115

3.5 Governor machine (GOV. M/C)

3.5.1 Preparation of work

a) confirm the installation location of Gov. M/C (refer to installation


drawing). Hammer 2 sets of anchor bolts into machine room floor.
Set the Gov. M/C mounting frame

3.5.2 Installation of Gov. M/C

a) set Gov. M/C on Gov. M/C mounting frame and check the
inclination. Fit and fasten the fixing bolts (M12). Inclination shall
be less than 1mm

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Figure 5.1
Outline drawing for D-8RS governor

Front View Side View

1 Governor pulley 2 compression spring


3 shoe frame 4 shoe
5 ratchet 6 balancing spring
7 governor rope 8 governor base
9 trip lever 10 pawl
11 governor switch cam 12 governor switch
13 adjust screw 14 fly weight (pendulum)
15 shoe lever

4. Check List and required tools

No. Check point Yes No Required tool

1 Are the dimensions of resting portion of M/C - chain block


beams proper? - spanner set
- general tools
2 Is horizontal level of each M/C beam proper? - tape measure
- 5cm steel rule
- steel rule
3 Are isolation rubber pads installed properly? - welding machine

4 Is traction machine installed properly?

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5 Is beam pulley assembled properly?

6 Is control panel assembled properly?

SECTION 5: ASSEMBLING HATCH DOOR

[Contents]

1. Scope

2. Purpose

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3. Work procedure

3.1 Assembling hatch door (SM-G)


3.2 setting gripper cam
3.3 assembling hatch door (SM-SB)

4 Check list and required tools

1. Scope
This manual applies to the assembly work of hatch door for elevator

2. Purpose
This manual defines a standard work procedure required for assembling work of
hatch door

3. Work Procedure

3.1 Assembling hatch door (SM-G)

3.1.1 Assembling hatch door

a) Set hatch door to the hanger vertically and adjust the gap between
hatch sill and door to be 5 + 1mm (see figure 1.1, figure 1.2)

b) Adjust the gap between hatch door and jamb to be 4 + 2mm (see
figure 1.3)

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c) Using stopper roller adjusting hole of the hanger, adjust the gap
between rail and stopper roller to be 0.3 0.7mm (to measure the
gap, insert gap gauge between rail and stopper roller)

Figure 1.1

Figure 1.2

3.1.2 Driving rope

a) Check that door mating line coincides with sill center when hatch
door is completely closed

b) Hold the rope and check tension (figure 1.4)

c) When rope tension is not proper, adjust the rope tension by


moving about the adjustable pulleys of driving rope which are
attached at both ends of pocket (Figure 1.5)

3.1.3 Setting LINK and door cover

a) Set link as per figure 1.6

b) Check the position where hatch door close smoothly by itself

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Figure 1.6
Setting hatch door link

3.2 Setting gripper cam

3.2.1 Setting gripper cam

a) Close hatch door and loosely set the cam

b) Insert liner between door and gripper cam and let the distance to
cage sill be 8 + 2mm (see figure 2.1)

c) Check that the gap between hook and guide of door and lock seat
become not less than 2mm (figure 2.2)

d) Set the gripper cam vertically. Measure the distance from door
stopper at upper and lower location and let the difference in
dimension become less than 1mm (figure 2.3)

e) With setting hole of gripper cam, align end edge of door lock seat
with hook base line. Therefore, hook gap G=4+1mm is obtained
(figure 2.4)

f) Let the gap between gripper cam and gripper roller of cage door
become 10+4mm (this work has to be carried out as soon as E/L
slow operation is finished figure 2.5)

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g) Move door lock switch up and down by the use of door lock seat
hole and align the end edge of door lock seat with hook base line.
Therefore, related dimension 9+2mm is obtained (figure 2.5)

h) Check the roller does not touch stopper (figure 2.5)

i) Verify that the opening gap between door seat and hook is 4+1mm
as per figure 2.7

j) Check that the hook does not touch the forcing OFF PIN in the
state of figure 2.7

k) At close position, release the gripper cam positively and verify the
followings: (1) S/W wipe becomes 2-3mm
(2) verify repeatedly the locking of pre-set hook

l) Check that door can be opened positively by the outside opening


key (figure 2.9)

m) Attach inside opening straps

3.3 Assembling hatch door (SM-SB)

3.3.1 Assembling hatch door

a) Set hatch door to the hanger vertically and adjust the gap between
hatch sill and door to be 5+1mm, using liner (figure 3.3)

b) Adjust the gap between hatch door and jamb to be 4 + 2mm (see
figure 3.3)

c) Using stopper roller adjusting hole of the hanger, adjust the gap
between rail and stopper roller to be 0.3-0.7mm (to measure the
gap insert a gap gauge between rail and stopper roller) figure
3.4

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3.3.2 Driving rope

a) Check that door mating line coincides with sill center when hatch
door is completely closed

b) Hold the rope and check the tension (figure 3.5)

c) When rope tension is not proper, adjust the rope tension by the
use of adjusting bolts which are attached at both ends of pocket
(figure 1.5)

Figure 3.5

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Figure 3.6

3.3.3 Door lock device system

a) Check the gap between cage sill and roller is 8+2mm

b) Adjust the door lock base so that the gap between hook and claw
be 3+1mm (figure 3.6)

c) Check that the locking dimension B between roller and coupling


is 14mm and that the gap C between roller and coupling is
10+4mm

d) Using liner, adjust the locking depth between hook and claw to be
9+1mm. Let the locking surface of claw coincides with hook
control line

e) While pushing the moving roller of door lock device with hand in
the direction of door opening check that hook is completely
released from claw before the door moves

f) Move the moving roller and check that the gap between hook and
the end of claw locking surface become 4 ~ 8mm. Let the hook
stroke be 13 + 4 (figure 3.7)

g) While the door is closed, check the door S/W wipe is 2 3mm and
locking gap is 4 ~ 7.5mm when the moving roller is pulled from
fixed roller and then released

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h) Check the door lock device is not loosened when applying 50kg
force at the lower part of the door

i) Check that door is opened positively by the outside opening key

Figure 3.8

4. Check List and required tools

No. Check point Yes No Required tool

1 Do the gaps between hatch door and sill, - spanner 1 set


jamb comply with the requirements? - steel ruler (15cm)
- tape measure
2 Is the tension of driving rope proper? - hammer
- square ruler

3 Are hatch door link and door cover attached


properly?

4 Is gripper cam set in accordance with this


manual?

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SECTION 6: ASSEMBLING WORK OF


PLATFORM & COUNTER
WEIGHT

[Contents]

1. Scope

2. Purpose

3. Work procedure

3.1 Assembling the platform


3.2 Assembly of counter weight
3.3 Attaching the compensation chain

4 Check list and required tools

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1. Scope
This manual applies to the assembling work of platform and counter weight for
standard type elevator

2. Purpose
This manual defines a standard work procedure required for the assembling work of
platform and counterweight

3. Work Procedure

3.1 Assembling the platform

3.1.1 preparation work for assembling the platform

a) Platform will be assembled at the top floor. Hang a wire rope or


manilla rope over M/C beam and lower it through M/C room
opening. Using chain block, transport PLF, sling and etc into the
hoist

b) Remove the stationary scaffolds of the top floor

c) Install a support beam and check the level. Use 100mm rigid
timber or beam as the support beam and fix it to steel brackets
(figure 1.1, figure 1.2)

Figure 1.1
Installation drawing for support beam

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Figure 1.2
Support bracket (steel)

3.1.2 assembling the platform

a) Carry the sling into hoistway and set it to the main rail as per figure
1.3, ie; position the sling with wedge being underneath the support
beam and temporarily fix to the rail bracket by binding a piece of
wire (figure 1.3)

b) Carry the platform into the hoistway. Take care not to damage the
jamb and platform

c) Place the platform on the support timber or beam and check the
horizontal level

d) Pull the sling upwards and fix it to platform base temporarily (figure
1.4). Insert M6 pin bolt (see figure 1.5)

e) Hang the cross head up and pre-fit to sling. Insert M16 knock bolt

f) Fix the cross head to sling securely with bolts (M16)

g) Attach the mounting base to the sling

h) Attach the pole to platform base and mounting base (figure 1.7)

i) Attach limit S/W cam to platform base and the mounting base

j) Attach the TIE ROD to platform base and mounting base. Turn the
TIE ROD nuts until they contact tie brackets and then fasten them
by turning half more (figure 1.7)

k) Connect the opening rod to opening level by pin. Insert split pin
(figure 1.6)

l) Pull door machine upwards and attach it to the door M/C mounting
frame. Verify that the distance between the center marking line of

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door machine base and sill center punch is less than 1mm (figure
1.8)

m) Attach door rail to the pole. Fix by inserting knock bolts.

3.1.3 attaching tail cord support

a) Attach the support setting brackets and cord support to the


underside of platform so that the tail cord hanging position be as
per figure 1.9

3.1.4 setting the wedge

a) Figure 1.10 depicts the assembly of wedge (used when E/L speed
is not less than 45 m/min). catch gap should be 3+0.5mm

b) Figure 1.11 should the assembly of wedge for main rail 8K (used
when E/L speed is not less than 60 m/min). Wedge gap should be
5mm

c) Figure 1.12 shows the assembly of wedge for main rail 13K and
over (used when E/L speed is not less than 60 m/min)

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Figure 1.11
Assembly drawing of wedge for T-8K

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Figure .12
Assembly drawing of wedger for T-13K and over

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3.2 Assembly of counter weight

3.2.1 carrying C W T frame into the hoistway

a) Remove guide shoes (2EA) of one side (see figure 2.1)

b) Install wooden supports of length 1200 x 100mm on C W T side


buffer beam

c) Wind a wire on HP part of C W T frame and lift the frame with


electric winch or chain block. Then carefully bring it down on the
wood supports, fitting unremoved guide shoes and guide brackets
to rail. Make C W T frame positioned so that compensation chain
setting brackets direct cage side (indicated on frame as cage
side)

d) Check that C W T frame sets positively on the wood support.


Attach the removed guide shoes and guide brackets

3.2.2 loading weights on C W T frame

a) Erect a proper scaffold at the height where loading is done

b) Hold both ends of weight and load it on the frame (figure 2.3)

c) After loading the pre-determined number of weight, secure the


weight using brackets and rail clip in order to prevent loosing of
weights (figure 2.4)

3.3 attaching the compensation chain

3.3.1 requirements for compensation chain (balance chain)

a) Compensation chain is required to reduce unbalance when E/L


stroke becomes longer. The compensation chain is attached when
E/L stroke exceeds 30 meter

3.3.2 attaching the compensation chain

a) Refer to figure 3.1 and 3.2 for the method of attaching the
compensation chain

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b) Bring the remained compensation chain to cage side (figure 3.3)

Figure 3.2

Figure 3.3

Figure 3.4

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4. Check List and required tools

No. Check point Yes No Required tool

1 Is chain block installed securely? - chain block


- spanner 1 set
- level
2 Is platform assembled in accordance with the - hammer
standard procedure?

3 Is tail cord support attached?

4 Is safety gear setted accurately?

5 Is there any dangerous factors in carrying


counter weight into the hoistway?

6 Are the assembly of counter weight and


weights loading carried out as per standard?

7 Is compensation chain attached? (for E/L


whose stroke exceeds 30m)

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SECTION 7: ASSEMBLING WORK OF CAGE

[Contents]

1. Scope

2. Purpose

3. Work procedure

Cage assembly
Horizontal alignment of platform and plumbness of cage
Assembly of cage door and attachment of link
Assembly of cage door and attachment of door link (SM-SB,C)
Attachment of door safety shoe

4. Check list and required tools

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1. Scope
This manual applies to the assembling work of cage for the standard type elevator

2. Purpose
This manual defines a standard work procedure required for assembling the cage

3. Work Procedure

3.1 cage assembly

3.1.1 Type of cage interior

Day light Star light

New star light crown light


Figure 1.1 cage design

3.1.2 Arranging the cage enclosure wall

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a) Cage panels are numbered (1) (2) . (11) sequentially clockwise
when viewed from the outside of the hoist (figure 1.2)

b) Panels numbered (1) (2) (4) (5) (7) (8) (10) (11) are corner
enclosure wall panels and panels numbered (3) (6) (9) are center
enclosure wall panels

c) Corner walls are assembled by fitting (1), (2), (4), (5), (7), (8), (10)
and (11). But pole (1) and 11 are assembled together at the
outside and bring into the hoistway

Figure 1.2
Numbering of wall panels

3.1.3 Assembly of cage enclosure wall

a) Bring the ceiling panel in the platform and lift it up as high as


possible. Then hang it at the cross head (use rope or steel wire)

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b) Assemble corner walls at the outside of the hoistway

c) Bring the assembled corner walls in the platform and fit them to
kick plate temporarily

d) Check that corner walls and kick plate are fitted together properly,
then fix them securely

e) Lower the ceiling panel and fit it to corner walls (figure 1.4)

f) Fit center panels between corner walls

g) After finishing assembly of cage, re-check the inclination of each


part and assembling condition

Figure 1.3

Figure 1.4

3.2 horizontal alignment of platform and plumbness of cage

3.2.1 removing the wood supports for platform and counter weight (see
figure 2.1)

3.2.2 removing the distance piece (figure 2.2)

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Figure 2.1

Figure 2.2

3.2.3 mounting the guide shoe

a) loosen bolt off approx 10mm

b) check X marked dimension are equal at both sides

Figure 2.3
Set dimension of guide shoe

3.2.4 check for horizontal alignment of platform and plumbness of cage

a) check the horizontal alignment of platform in longitudinal and


lateral directions on the cage sill face

b) check the plumbness of cage in four (4) directions by using a


weight (plumb bob) at the cage entrance pole. Slope of cage in
each direction less than 2mm

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c) in case the cage is slant, correct it in the following method (figure


2.4, figure 2.5)

When inclined in (A) direction When inclined in (B) direction

Remove liners of cushion rubber on (a) Remove liners of cushion rubber on (d)
(b) positions positions

Insert liners removed from (a) (d) Insert liners of cushion rubber on (a) (b)
positions positions

Figure 2.4
Adjusting bolts and cushions rubber

Figure 2.5

3.2.5 attaching the fitting rubber

a) after checking the slope of cage, attach the fitting rubber (figure
2.6)

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Figure 2.6

3.3 assembly of cage door and attachment of link

3.3.1 assembly of cage door

a) attach the hanger on the rail and hang the cage door vertically,
then adjust so that the distance between cage sill and door be 5 +
1mm (figure 3.1, figure 3.2)

b) adjust so that the distance between cage door and pole be 6 +


2mm (figure 3.3)

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c) using adjusting hole of stopper roller on hanger, set the gap
between rail and stopper roller to be 0.3-0.7mm (measure by
inserting a gap gauge between rail and stopper roller) figure 3.1

Figure 3.1

Figure 3.2

Figure 3.3

3.3.2 attaching cage door link (SM-G)

a) attach main link and sub link on the door

b) attach main lever and sub lever

c) attach center connecting lever and connecting rod

d) by moving gripper rollers up and down, adjust the dimension


between gripper rollers to be 40 + 1mm

e) close the door completely and check the door center coincides
with the sill center

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Figure 3.4
Cage door link

Figure 3.5
Reamer bolt assembly

3.3.3 attaching the door safety shoe

a) attach upper level and lower level of door safety shoe on the cage
door

b) with the adjusting bolt, position the shoe to be apart 35 + 2mm


from the center of both door (figure 3.6, figure 3.7)

c) check that safety shoe S/W is off when push shoe 8mm (figure
3.6, figure 3.7)

d) attach door cover (figure 3.7)

e) affix door safety shoe S/W cable (REED cable) onto main lever
and wire to the apparatus box on the cage (figure 3.8)

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Figure 3.6

Figure 3.7

Figure 3.8
Safety shoe S/W cable layout

3.4 assembly of cage door and attachment of door link (SM-SB, C)

3.4.1 attaching method of center opening

a) fit the door to the hanger and align the centers (figure 4.1)

b) adjust the gap between the door and sill to be 5 + 1mm by


inserting a liner between the hanger and door (figure 4.1)

c) adjust the gap between the door and cage pole to be 6 + 2 mm


(figure 4.2)

d) with the door being completely closed, inclination of the door shall
be less than 2mm and the distance between the door center and
sill center punch shall be less than 1mm

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e) gap between stopper roller and rail is normally adjusted to 0.3
0.7 mm at the factory. If not, type set the gap to be 0.3 0.7 mm
using the stopper adjusting hole of the hanger

f) fix the gripper operating cam at pre-determined position

g) fit the door M/C link to chain pulley and hanger plate and adjust it
checking the door open/close stroke (figure 4.4, 4.3)

Figure 4.1

Figure 4.2

Figure 4.3

h) after checking the open/close position of the door, fit the gripper
with the door being closed. By adjust using adjusting cam the
gripper gap to be 115.5 mm (figure 4.4)

i) adjust the gate switch to be ON at the position 10mm prior to the


door close (figure 4.5)

j) attach door safety shoe. Based on the safety shoe cable layout,
fix the lead wires

Figure 4.4

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Figure 4.5

Figure 4.6

3.4.2 attachment of side open door

a) attach the hanger on the rail and hang the cage door on the
hanger. Align the centers

b) adjust the gap between the door and sill to be 5 + 1mm by


inserting a liner between the hanger and the door

c) adjust the gap between surface doors and door and cage pole to
be 6 + 2 mm (figure 4.7)

d) adjust the gap between door and the cushion rubber attached to
cage pole to be less than 1mm when the 1 st door is completely
closed (figure 4.8)

e) using the stopper roller adjusting hole of hanger, set the gap
between rail and roller to be 0.3 0.7 mm

f) attach gripper operating cam (figure 4.9)

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Figure 4.7

Figure 4.8

Figure 4.9

g) attach door M/C link and adjust open/close positions:

1) when door is opened, the distance to cage pole; 15 + 2


2) the distance between the 1st door end and the 2nd door end;
less than 2mm

however, if the door projects out of the entrance side when the
door is completely open, adjust the stopper bolt located at chain
pulley not to let the door project out

h) when the door is closed, the following dimensions should be met:

1) gap between the 2nd door and ceiling frame; 15 + 1


2) overlap between the 1st door and the 2nd door; 16 + 2
3) overlap between the 1st door and cage pole; 16 + 2
4) overlap between the 2nd door and cage pole; 16 + 2

i) attach the safety shoe

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Figure 4.10

Figure 4.11

Figure 4.12

3.5 Attachment of door safety shoe

3.5.1 Attachment of safety shoe

Figure 5.1
Safety shoe cabling layout

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3.5.2 Attachment of cage door switch

Center open type gate S/W on position (side open type gate SW on position)

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4. Check List and required tools

No. Check point Yes No Required tool

1 Are cage enclosure walls assembled in - Driver


correct sequence? - spanner 1 set
- chanin block
2 Are horizontal alignment of platform and
plumbness of cage correct?

3 Are guide shoe and cushion rubber correctly


attached?

4 Are assembly of cage door and attachment of


link carried out correctly?

5 Is attachment of safety shoe correct?

6 Is attachment of cage door S/W carried out


correctly?

SECTION 8: ROPING

[Contents]

1. Scope

2. Purpose

3. Work procedure

Main rope work


Governor rope work

4. Check list and required tools

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1. Scope
This manual applies to the ropping work for the standard type elevator

2. Purpose
This manual defines a standard work procedure required for roping work

3. Work Procedure

3.1 main rope works

3.1.1 Combination and arrangement of thimble rods

a) Combination and arrangement of thimble rods at cage side and


CWT side are done as per figure 1.1

b) In this figure, (S) depicts short thimble rod, (L) long thimble rod

Figure 1.1
Combination and arrangement of thimble rod

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3.1.2 Socketting

a) Untwist rope end with wires (0.5 ) width approx 30 ~ 35

b) Twist and bind the rope so that the position 330mm apart from the
round tip of the rope will touch the wedge end point (figure 1.1)

c) Put the wedge into the bent rope and pull it into the socket. Fix
the rope with clip temporarily (figure 1.2)

d) Taking care to make the bent rope contact point A, pull the rope
until split pin hole of the wedge comes out (pulling force: 50kg)

e) Insert the split pin into wedge hole and widen the end of the pin.
Widen the pin to the angle 60 (figure 1.3)

f) Fix the clip at its right position (fastening torque of bolt; 300 + 50kg
cm (figure 1.4)

g) Combines 2 ropes at each rope end. Bind them at a length of


30mm with wires (0.5 ) or bind wires

X Note: when the direction of attaching rope is decided, set the clip as per figure 1.5
to prevent clip from slipping from the required position

Figure 1.1

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Figure 1.2

Figure 1.3

Figure 1.4

Figure 1.5

3.1.3 Hanging the rope

a) Prepare socketting for one end of the rope in the machine room
(figure 1.6)

b) Lower the socketted end to the cage and connect it to the thimble
rod. Set as per section A

c) Meeting the hole sequence of the hitch plate, lower the rope to
CWT part. Verify that thimble rod spring seat of cage is put into
the hole of hitch plate

d) Set lock nuts of CWT side thimble rod. See section B

e) Lift the thimble rod and mark the rod hole position on the rope.
See section C

f) Cut the rope with rope cutter at the position located H + 20 from
the taped cutting point

g) Prepare socketting for CWT side end and connect to thimble rod

h) Remove the wood and set the spring

Figure 1.6

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3.2 Governor rope works

3.2.1 Attachment of weight pulley for governor

a) Fix the weight pulley bracket to the clip at the main rail in
accordance with the installation drawing

b) Fixing of governor weight pulley is done as per figure 2.1 and 2.2

Figure 2.1
45.60 m/min weight pulley

Figure 2.2
90.105 m/min weight pulley

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3.2.2 Hanging the governor rope

a) Hang a rope over governor pulley in the machine room and lower
both ends of the rope to the pit

b) Remove rope socket and clip from the catch lever and bring them
in the pit

c) Hang one end of the rope on the socket and fasten with clip (figure
2.3)

d) Carry the other end of the rope through weight pulley of the pit and
fasten on the socket with clip (follow the same fastening method
as C)

e) By pulling the rope upwards, lift the socket to the elevation of


catch lever

f) Fit the rope socket to catch lever so that rope ends direct towards
the wall (figure 2.5). Insert the split pin positively

Figure 2.3

Figure 2.4

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Figure 2.5

4. Check List and required tools

No. Check point Yes No Required tool

1 Are the assembling method of main rope and - Pliers


thimble rod acceptable? - spanner 1 set
- tape measure
2 Are socketting works carried out in - ceasing wire
accordance with the standard?

3 Are all preparation works related to roping


correct?

4 Are roping works carried out correctly? (main


& CWT)

5 Is weight pulley for governor attached as per


the standard?

6 Is roping for governor carried out correctly?

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SECTION 9: ELECTRICAL WORK

[Contents]

1. Scope

2. Purpose

3. Work procedure

Explanation on electrical drawings


Attachment of electrical devices in the hoistway
Conduit piping work
Wiring work

4. Check list and required tools

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1. Scope
This manual applies to electrical work for the standard type elevator

2. Purpose
This manual defines a standard work procedure required for electrical work

3. Work Procedure

3.1 Explanation on electrical drawings

3.1.1 Titles of electrical drawings and the contents

No. Title Contents


1 Skele Ton (1) Main control circuit
2 Skele Ton (2) Main control PCB circuit
3 Skele Ton (3) Safety and control circuit
4 Skele Ton (4) Control circuit
5 Skele Ton (5) Control circuit and door M/C circuit
6 Skele Ton (6) Control circuit
7 Skele Ton (7) Signal circuit
8 Skele Ton (8) Cage button and hatch button circuit
9 Skele Ton (9) Lamp circuit
10 CP Terminal Control panel wiring DWG
11 FCTR connection dwg F. ctr wiring DWG
12 OPB connection dwg Operating board wiring DWG
13 Equipment box connection dwg Connection of ON CAGE and internal wiring
drawing
14 Hatch connection dwg Indicator and button connecting drawing
15 MCR connection dwg Motor external wiring drawing and interphone
wiring drawing

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3.1.2 Symbol used in the electrical drawing and equipment

a) Name of equipment as to the destination of electrical wiring

No Symbol Name of equipment


1 V 3 IM, MG, B, Temperature S/W, AC-PG
2 U GRS (GOV-S/W)
3 R F.ctr
4 Y J Box Cage
5 X Indicator, Button Limit S/W (Hoistway)

b) Abbreviation of electrical equipment and devices

No Abbreviation Description No Abbreviation Description


1 3 IM Three phase 15 SCS Safety catch
induction motor S/W
2 Mg-B Magnet brake 16 MHS Manhole S/W
3 AC-PG AC generator 17 PIT PIT S/W
4 GRS Governor S/W 18 GS Gate S/W
5 F.ctr Floor controller 19 DS Hatch door
S/W
6 CP Control panel 20 FH2 Motor
temperature
S/W
7 SP-CT Current trans 21 FLS (U.D) Final limit S/W
8 CT Current trans 22 ULS.DLS Up, down limit
S/W
9 SY-TR Synchronizing 23 SUS,SDS Up, down slow
trans limit S/W
10 M-FAN Motor cooling 24 RS.-3 Posi (reed
fan S/W)
11 SYR Synchronous 25 ES-B24 Touch button
resistance power supply
12 DBR Resistance for 26 IND Indicator
magnet brake
13 OPB Operating 27 CPI Car posi
board indicator
14 FCRS Floor controller 28 TS Tumbler switch
S/W
29 WS Wall socket 34 Shoe Safety shoe
S/W
30 BELL Emergency bell 35 Auto Automatic
operation
31 WD (110) Weighing 36 ATT Manual
device operation
32 CLS Close limit S/W 37 SRART departure
33 OLS Open limit S/W 38 PASS By pass

c) How to read the identification symbol of wire

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Figure 2.1

3.2 Attachment of electrical devices in the hoistway

3.2.1 Types and quantities of devices to be attached in the hoistway

Table 2.1

No. Item Qty Remarks


1 Junction box 1 EA
2 Cord support 2 EA Including the on the underside of
cage
3 Limit switch 6 EA
4 Shelter plate 1 EA/each
floor
5 Ind box Ditto
6 Door switch Delivered being attached on pocket

3.2.2 Attachment of junction box and cord support

a) Attachment a cord support by M12 anchor bolts at the location


whose height is car stroke 2 + 500mm (figure 2.2)

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b) Attachment of the cord support on the underside of cage is done


using the hole already made at the factory

c) Attach junction box 300mm above the card support using M12
anchor bolts

Figure 2.2 (1)

Figure 2.2 (2)

Figure 2.3

3.2.3 Attachment of LIMIT SWITCH

3.2.4 Attachment of RM-POSI

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Figure 2.4
Attachment of RM POSI

Figure 2.5
Adjusting of RM POSI

Figure 2.6

3.3 Conduit piping work

3.3.1 Conduit piping work in the machine room

a) Conduit piping for traction machine governor (3.1)

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Figure 3.1

b) Conduit piping for floor controller joint

Figure 3.2

3.3.2 Ducting work in the hoistway

a) Using duct connector, hang steel duct down from the joint box into
the hoistway. Duct size shall be 70mm width up to 14 th floor and
120mm width for the 15th and 16th floors (figure 3.3)

b) Use flexible tube or steel pipe when connecting to duct and/or ind.
Box (figure 3.4)

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c) Set the duct end to locate 300 500mm below the bottom floor
and apply end cover on it (figure 3.5)

d) Distance between supports for the duct in the hoistway shall not
be greater than 2.0mm and fix the duct using bolt or HILTI (figure
3.6)

e) Use saddle to fix steel pipes or flexible tubes

Figure 3.3

Figure 3.4

Figure 3.5

Figure 3.6

3.3.3 No-duct piping work in the hoistway

a) Fix indicator junction box on the hoistway wall at each floor using
HILTI GUN

b) When a center beam is located, fix indicator junction box on the


rail using bracket

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Figure 3.7

3.4 Wiring work

3.4.1 Wiring work in the machine room

Figure 4.4

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Table 4.1

No. Motor capacity Earth cable 60 m/min


(KW) 220V 380V
1 5.5 5.5 14 8
2 7.5 5.5 14 8
3 11 5.5 22 8
4 15 5.5 30 14
5 18.5 14 30 14

Figure 4.3

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Table 4.2
Capacities for building power source and cable sizes (speed 60 m/min)

200V 400V
class class
Transformer Earth
Load motor FFB capacity (A) of capacity (KVA) Incoming cable cable Starting KVA (1
capa- bldg side of bldg side size (mm) size set)
city (mm)
Nos. of
passenger Kg KW 1 set 2 set 1 set 2 set 1 set 2 set 50hz 60hz
6 450 5.5 75 30 100 50 15 20 14 5.5 30 8 5.5 39 50
8 550 7.5 75 50 100 75 15 30 22 5.5 38 8 5.5 57 67
9 600 7.5 75 50 400 75 15 30 22 5.5 38 8 5.5 54 67
10 680 7.5 75 50 100 75 15 30 22 5.5 38 8 5.5 54 67
11 750 7.5 75 50 100 75 15 30 22 5.5 38 8 5.5 54 67
13 900 11 100 75 100 75 20 50 30 8 50 14 5.5 81 94
15 1,000 11 100 75 150 100 20 50 30 8 50 14 5.5 81 94
17 1,150 11 100 75 150 100 20 50 30 8 50 14 5.5 81 94
20 1,350 15 125 75 200 100 30 50 38 14 80 22 5.5 101 130
24 1,600 15 125 75 200 100 30 50 38 14 80 22 5.5 101 130

3.4.2 Woromg pf floor controller

a) Check MIC is attached when floor controller is moved to site

b) Check that spare cable is also brought

3.4.3 CVV wiring work

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Figure 4.5

Figure 4.7

3.4.4 Tail cord wiring

a) When unwinding tail cord, take care not to twist the cord. Hang
the cord on the scaffolding for 2-3 days to eliminate any twist from
the cord

b) Set the tail cord on tail cord support with clip, then fix securely
after adjusting R of each tail cord

c) Calculate the L dimension and fix the tail cord with clip to the
cord support of cage underside (figure 4.8)

d) Bind the cord tacking the allowance being less than 500mm.
Raise the junction box of the cage and fix by the tail cord support

e) Fix the tail cord (which runs from the underside of cage to OPB) to
the support attached on the cage (figure 4.9)

f) When aligning E/L to bottom floor level at low speed, adjust at the
underside of the cage so that the lowest position of the cord is 300
+ 50 apart from the PIT (figure 4.10)

Figure 4.8

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Figure 4.9

Figure 4.10

4. Check List and required tools

No. Check point Yes No Required tool

1 Are electrical drawings and specifications in - MEGA tester


accord with each other? - Nipper
- Driver
2 Are electrical devices attached in the - Welding machine
hoistway as per the standard? - Impact tool
(including
3 Are cord supports of junction box attached as personal tools)
per the standard?

4 Is attachment of limit S/W and POSI carried


out in accordance with the standard?

5 Is wiring work in the machine room


performed as per the installation drawing
(except no-duct)?

6 Is ducting work in the hoistway done as per


the standard (except no-duct)?

7 Is no-duct work in the hoistway done in


accordance with the standard?

8 Is wiring work in the machine room (including


floor controller) done in accordance with the
standard?

9 Is CVV wiring performed in accordance with


the standard?

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10 Is wiring work of tail cord carried out in
accordance with the standard?

SECTION 10: RAILING WORK

[Contents]

1. Scope

2. Purpose

3. Work procedure

Making anchor bolt holes and installing anchor bolts


Buffer die
Centering of rail brackets
Centering of rail

4. Check list and required tools

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1. Scope
This manual applies to the railing work in the hoistway for the standard type elevator

2. Purpose
This manual is to provide a standard work procedure required for railing work in
installing elevator in the hoistway

3. Work Procedure

3.1 Making anchor bolt holes and installing anchor bolts

3.1.1 Required tools

a) Electric hammer (figure 1.1)

Figure 1.1
Electric driven
hammer (HILTI 72)

b) Drill bit (figure 1.2, table 1.1)

Figure 1.2

c) Anchor bolt starking tool

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Table 1.1

Used anchor bolt Diameter D Total length L Hole depth Mark


M 12 RPA 18.0mm 150mm 65mm MMCB 18.0
M 16 RPA 22.2mm 200mm 75mm MMCD 22.0

3.1.2 Configuration of anchor bolts

a) Use RPA anchor bolts supplied by GSIS

Figure 1.3

Table 1.2

Anchor bolt Total length a Thread b c d e


M 12 RPA 100 mm 50 mm 65 mm 50 mm 17.5
M 16 RPA 125 mm 60 mm 75 mm 60 mm 21.6

3.1.3 Making anchor holes

a) Do the job on the safe scaffolding

b) Hold the electric hammer with both hands and rest it on the waist
(do not pose in unsuitable manner). Apply perpendicular to the
wall (figure 1.4)

c) Drill to the depth marked by red line (hole depth L) and pull the
electric hammer horizontally

Figure 1.4

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Figure 2.1 (A)

3.2 Buffer die

3.2.1 Buffer beam work

a) Assembly buffer beam with M12 bolts in accordance with RG


dimensions (CWT buffer beam has been assembled as one unit)
see figure 2.1

Figure 3.2

3.2.2 Centering of CWT rail bracket

a) Make sure that piano wire does not touch scaffolding

b) Set the bracket onto the anchor belt position

c) Measure the distances between piano wire and the bracket. Make
them equal (figure 3.4)

d) Set the square rule at the punch point of rail bracket. Carry out
centering of height (figure 3.5, figure 3.6)

Figure 3.3

Figure 3.4

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Figure 3.5

Figure 3.6

e) Place on a plane D mm pit depth below from the finished level of


the lowest floor (see Table 2.1)

f) Lower a weight from the bottom template and position the buffer
beam. Align horizontal level

g) Fix the buffer beam by filling mortar in the middle and around the
beam. Do not apply mortar into the rail oil pot

h) Set the spring buffer and fix with band

3.3 Centering of rail brackets

3.3.1 Centering of main rail bracket

a) Make sure that piano wires do not touch scaffolding (one for CWT
is made as one unit) see figure 2.1

b) set the bracket on to the anchor bolt position

c) let the rail bracket to be perpendicular to two (2) piano wires using
square rule (insert liners) figure 3.1

d) measure the height with scale and adjust (figure 3.2, 3.3)

3.4 Centering of rail

3.4.1 Assembly of rail

a) use cleaning oil to clean the end rugged sections of each rail and
clean the part of rail face that will contact fish plate

b) cut top and bottom templates out to enable the erection of rails
(see figure 4.1)

c) bring all the rails in the hoistway. Keep tongue sections up while
handling rails. Lay plywood on the pit floor to protect the rails

d) using fish plates, lift the nails up with electric winch

e) match the sections and join the rails with fish plate (see figure 4.2)

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f) secure to the brackets with rail clips

g) top rail shall be cut to actual dimension and assembled

3.4.2 Re-verifying the rail centering

a) dimensions of top and bottom templates shall be correct

b) piano wires shall not be touched by the scaffolding

3.4.3 To measure the bending of rail

a) prior to measuring, clean the measuring point of rail with cleaning


oil

b) starting with the lowest point, carry out centering at each rail
bracket position

c) set the square rule horizontally to the rail side and measure X and
Y (figure 4.3)

d) insert liner between rail and rail bracket to obtain allowable X


dimension

3.4.4 To measure rail gauge (RG)

a) prior to measuring, clean the measuring points of rail with


cleaning oil

3.4.5 Alignment of apposite rails

a) use a long rail gauge whose scale stick edge will be approx 3 mm
apart from piano wire B (see figure 4.5)

b) adjust the rail gauge and set a scale mark to piano wire B. let that
point be the center

c) fit the rail gauge to the rail being measured and move it back and
forth. Read the range of scale against piano wire B

d) determine the center of rocking motion and read the tolerance a


(figure 4.6)

e) if tolerance a is greater than the allowable value, insert the liner


between rail and rail bracket

f) fasten the clip bolts and verify X, Y dimensions. Record the


dimensions

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Figure 4.5

Figure 4.6

Table 4.1 Allowable alignment tolerance value

Tolerance Main rail C W T rail

a 6 mm 12mm

3.4.6 Rail warping

a) measurement for rail warping is carried out where a large warping


can be found during bending check of rails or E/L shakes severely
during commissioning

b) measurement is done at the rail joints with 1M stretch or gap


gauge (figure 4.7)

Figure 4.7

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3.4.7 Mismatch of rail joints

a) rail joint shall be free from mismatch (stepped joint) along rail face.
The mismatch, if any, shall be within the tolerance of table 4.3

b) measurement of the mismatch is done with scale marked


inspection jig. Also put 150mm scale on the joint and insert gap
gauge to measure the same

c) in case mismatch is greater than the allowable limit, do filing to


match (figure 4.9, table 4.4)

Table 4.4 Allowable alignment tolerance value

Filing length Cage rail C W T rail


(A mm) Not less than 150 Not less than 100

Figure 4.8

Figure 4.9

4. Check List and required tools

No. Check point Yes No Required tool

1 Are anchor holes drilled correctly? - Electric Hammer


- Electric Hammer
2 Is centering for rail bracket correct? drill bit
- Weight
3 Are rails assembled/erected properly? - Square Rule
- 15cm rule
4 Are rail joints made correctly? - Electric Driven winch
- Rail gauge
5 Is there any rail warping? - General tool

6 Are buffer dies installed properly?

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SECTION 11: PERSONAL PROTECTION


EQUIPMENT SAFETY
FACILITIES & REQUIRED
TOOLS

[Contents]

1. Scope

2. Purpose

3. Work procedure

Personal protection equipment


Safety facilities
Site appliances and required tools

4. Check list and required tools

1. Scope
This manual applies to the provision of safety facilities in the hoistway and personal
protection equipment in carrying out installation of the elevator

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2. Purpose
This manual is to ensure the safety of each personal and to improve job efficiencies
by providing a standard work procedure required for wearing protection equipment
and arranging safety facilities in the elevator hoistway

3. Work Procedure

3.1 Personal protection equipment


Wear protection equipment as shown on Figure 1.1

Figure 1.1
Wearing personal
protection equipment

3.2 Safety facilities


Safety facilities to be provided in the elevator hoistway are as per figure 1.2

Figure 1.2
Safety facilities

3.3 Site appliances and required tools


Appliances and tools to be prepared at the site prior to job start shall be as
per table 1.1

Table 1.1 List of required appliances and tools

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No. Category Description Specification Quantity Remarks

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1 Tool Box 1 set
2 PREPARATION Temporary electric 2.0 MM X 2 45 meter
wires set
3 & Socket 10 EA
4 Incandescent Bulb 220V / 100W 15 EA
5 Knife Switch
6 Lamp Protection Cover Metallic 10 EA
HOISTING
7 Welding Machine 1 set
- Electric shock Korean 1 set
protector Standard
- Power supply cable 14MM x 2 set 30meter
- Welding machine 22MM
cable and holder 45m, 1EA
- welding machine 22MM 10meter
earth cord
8 Electric Winch Small size 1 set
- Rope for winch 8 50meter
- Power supply cable 3C 30meter
9 Pulley 100 2 set
10 Bracket for attaching 1 set
pulley
11 Wire 12 x 4m 4 set
12 Shackle 12 4 EA
13 Manilla Rope 16 x 40m 1 set
14 Plumb Bop for piano 5kg 7 EA
CENTERING wire
15 Plumb Bop 300g 2 EA
16 Water level 1 = 600mm 1 EA
17 Steel rule 1 meter 1 EA
18 Square ruler 150 x 100mm 1EA
19 Tape measure 3m 1EA Personal
tool
20 15cm ruler 150mm 1EA Ditto
21 Inkpad case 250mm 1EA

No. Category Description Specification Quantity Remarks


22 Electric hammer 1 set
23 GENERAL Electric hammer drill bit M12,M16 2EA
24 Impacting tool Ditto 2EA
25 Chisel for concrete M16 x 300M 2EA
26 Chisel (steel) 25 x 22 x 250 1EA
27 Smiths hammer Both side 1EA
usable
28 Hacksaw 250 300MM 1EA

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29 Steel saw for hacksaw 10EA


30 Nail puller 360mm 1EA
31 File Korean 1 set Personal
standard tool
32 Manual chain block 1.5 ton 2 set
33 HILTI gun Korean 1 set
USE
standard
34 Pliers 250mm 1EA
35 Plate sheares 210mm 1EA
36 Double-end spanner Korean 1 set Personal
standard tool
37 Electric drill Ditto 1 set
38 Crimping tool 14 38MM 1 EA
39 PIPING Crimping tool 1.25 5.5MM 1 EA Personal
tool
40 & Pliers 175mm 1 EA Ditto
41 Nipper 125mm 1 EA Ditto
42 WIRING Driver + 170mm 1 EA Ditto
43 Pipe wrench 350mm 1 EA
44 Rail gauge T-8K, T-13K 1 EA
45 Bracket for plumbing 1 set
OTHERS bar
46 Plumbing bar panel 1 set
47 Plumbing material 1 set
48 Piano wire 0.5 1 roll
49 Transparent vinyl hose 10 5m
50 Ceasing wire 1 roll
51 Bind cord 1 roll

4. Check List and required tools

No. Check point Yes No Required tool

1 Do working personnel wear protection - Spanner 1 set


equipment properly? - Hammer
- Driver
2 Are lamps properly protected by protection - Personal tool
covers? 1 set

3 Is the hoistway opening of the machine room


covered?

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4 Is barricade properly provided at each
opening of the hoistway?

5 Is electric shock protector provided in the


welding machine?

6 Are safety foothold binded securely?

7 Are safety nets provided as per the


applicable standards?

8 Are scaffoldings erected securely?

9 Are lighting cables in the hoistway adequate


for their intended use?

10 Are hooks in the machine room installed


securely?

SECTION 12: SCAFFOLDING ASSEMBLY &


DISMANTLING WORK

[Contents]

1. Scope

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2. Purpose

3. Work procedure

Erection of stationary scaffolds


Dismantling the stationary scaffolds
Installation of safety equipment

4. Check list and required tools

1. Scope
This manual applies to steel pipe assembling work in the hoistway for the installation
of the elevator

2. Purpose
This manual is to provide a standard work procedure required for erecting stationary
scaffolds

3. Work Procedure

3.1 Erection of stationary scaffolds


Stationary scaffolds shall be erected in accordance with the following and as
per figure 1.1

3.1.1 Base plates are placed at the bottom section as per of figure 1.1

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3.1.2 height of each section, ie; distance between horizontal members shall
be as per of figure 1.1, 1 metre for the first section from hoistway pit
and 1.5 metre for other sections

3.1.3 when connecting steel pipes, use the joint as per of figure 1.1

3.1.4 use the clamps as per () of figure 1.1 when placing horizontal
members on vertical posts

3.1.5 in case the scaffold exceeds 30 meter in height, reinforce the lower
portion of vertical post (below 31 meter from the top) by fixing two (2)
pipes together as per (f) of figure 1.1

3.1.6 steel pipe for anti-vibration shall be secured at four points every two
sections (3m) by joint, clamp or wire as per (g) of figure 1.1

3.2 Dismantling the stationary scaffolds

3.2.1 Dismantling shall be carried out when mechanical assembly of the


elevator has been completed

3.2.2 Dismantling is to be done in the reverse order to the assembly

3.3 Installation of safety equipment


Installation of safety foothold and safety nets shall be done in accordance with the
rules for personal protection equipment, safety facilities and required tools

Figure 1.1
Assembly of scaffolds

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4. Check List and required tools

No. Check point Yes No Required tool

1 Are scaffolding pipes free from damage, - Spanner set


bend or corrosion? - Hammer

2 Are base plates proper for use?

3 Are all joint securely connected?

4 Are all clips completely tightened?

5 Are distances between horizontal pipes


properly maintained (1.5m)?

6 Are anti-vibration provisions made


adequately?

7 Are all clamps completely tightened?

8 Are horizontal and vertical scaffolds straight


and plumb?

SECTION 13: PARTS DELIVERY &


PLACEMENT

[Contents]

1. Scope

2. Purpose

3. Definition of terms

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4. Work procedure

Information on the delivered parts


Part delivery
Placement work

5. Check list and required tools

1. Scope
This manual applies to the delivery and placement work of the parts and components
for standard type elevators

2. Purpose
This manual is to provide a standard work procedure required for delivery and
placement work of the parts and components

3. Definition of terms

3.1 Parts delivery


Examination and storaging of the delivered parts (from the factory) at the
erection site against the accompanying invoice

3.2 Parts placement


Transportation and placement of each part of the elevator to the specified
location as per table 1.1

4. Work procedure

4.1 Information on the delivered parts

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4.1.1. Classification of parts
(1) An elevator consists of 5 parts as shown on table 1.1

Table 1.1 Classification of parts for standard type elevator

Part No. Part Name Related components


0 HW (hoistway) Components in the hoistway
2 ENT (entrance) Components in the entrance
4 CAR Components in the car
6 MC (M/C) Components in TR M/C
8 CTL (control) Components for control equipment

(2) Components will be delivered in two parts, ie; first delivery


and second delivery

(3) Each component shall be in accordance with the enclosed


packing list

4.1.2. Parts delivery schedule


(1) Dates of first and second delivery are set according to the
erection schedule and such schedule shall be informed to the
Shipping Department by the erection supervisor

(2) Any change in erection schedule at the site shall be


immediately notified to the Shipping Department

4.2 Parts delivery

4.2.1 Site erection supervisor shall discuss with the client and arrange
transportation route and storage area

4.2.2 Receiving of delivered parts and confirmation


When receiving the delivered parts, check the appearance and
quantity of packing against the invoice. Confirm the receipt by signing
on the invoice, on set being returned to the driver and another set
being filled. In case any deficiency is found, return such defect part or
component with a comment on the invoice describing the set
deficiency. This shall be also informed to the Shipping Department

Figure 2.1

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4.2.3 Inspections of parts open each packing and compare the contents
with the packing list attached on the packing box. In case shortage or
damage is found, inform immediately to the Shipping Department of
such deficiency (figure 2.2)

4.2.4 Disposal of packing boxes


Used packing boxes shall be disposed properly

4.2.5 Storage of parts or components


Parts or component shall be properly stored to prevent any damage or
loss. When storing outdoor, place wooden block cover them with
plastic sheet to protect from snow or rain (figure 2.3)

4.3 Placement work

4.3.1 Qualification
Placement of elevator parts (exceeding 1 ton in weight) shall be done
by the qualified personnel only

4.3.2 Location to where parts are transported

Location Part Remarks


M/C M/C beam, pull box, M/C base assembly M/C
Machine room accessory, TR M/C assembly, Gov M/C
CTL F.ctr, F.ctr assembly, control panel, F.ctr pulley
CAR Rope (main rope, Gov rope)
Top Floor CAR Ceiling assembly, side board assembly, cage
door assembly, cage accessory
Each Floor Jamb assembly, entrance accessory, H-door &
others
Storage Area Others not specified above

Note: storage area shall be arranged before hand through discussion with
the client

4.3.3 Installation of winch and snatch block

(1) Installation of snatch block

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Prior to installing snatch block, verify that the machine room
hook is fixed securely and that snatch block and rope are free
from damage and or wear install snatch block (figure 3.1)

Figure 3.1
Installation of hook and snatch block

Figure 3.6
How to tie rope for horizontally
moving of traction machine

Figure 3.7
How to carry traction machine
in the hoistway

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4. Check List and required tools

No. Check point Yes No Required tool

1 Does the winch function properly? - Winch set


- Rope
2 Verify that ropes are free from damage - Snatch block
- General tools
3 Do the snatch blocks operate properly? - Personal tools

4 Are the hooks rigid?

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