TK-50 Installation Manual Rev 1.1 - EVO1 PDF

Evolution1 – Installation Manual
Machine Roomless Elevator

Preparation for Elevator Installation
Installation Manual
Version: 1.0
Installation Manual
Warning
Elevator installer should undergo training organized by local bureau of labor and social secutiry and obtain
qualified operation certificate, and this manual is hereby handled by certified professionals. In order to protect you
and others, please don’t try any uncertified operation.
All operations must be in conformity with the latest national codes on electric engineering, safety rules on elevator and
all related local administrative laws and regulations.
ThyssenKrupp Elevator is the proprietary of all drawings and materials of the manual. Hereby, the company has rights
to take them back anytime. Any organization and individual shall not publish, copy and directly or indirectly cite contents
of the manual or not damage interests of the company in any form.
We try our best to ensure high accuracy and timely update of the manual. However, we shall not take any liability for
adverse impacts brought by errors or omissions of the manual. For any problem in the manual, please contact Thys-
senKrupp Elevator (Korea) as soon as possible!
ThyssenKrupp Elevator (Korea)

Installation Manual
Contents
1 General ................................................................................................................................ 1
2 Safety matters need attention .......................................................................................... 1
3 Preparations at construction site ..................................................................................... 2
4 Tools preparation ............................................................................................................... 3
5 Scaffold erection ................................................................................................................ 4
6 Templates ............................................................................................................................ 6
ThyssenKrupp Elevaotr (Korea)

Installation Manual
Preparation for Elevator Installation

1 General
The installation and clients are closely to each other.In order to install smoothly and improve efficiency,
the installers are supposed to have good communication with clients and receive vigorously sustain by
customs.If it is necessary, inform the local quality inspection department before installation.
2 Safety matters need attention

2.1 Inspection before installation
The installation staff should have obtained the operation certificate for works of special types of labor .
Before starting the work,you must carry on the following items of security checking:
a) Safety protective devices (such as scaffold, safety net, safety helmet, safety belt and so on)；
b) Machinery equipments and electrical facilities (such as electric welding machine, hoisting
equipments and so on, especially the safety devices)；
c) Auxiliary tools (such as oxygen, acetylene and so on)；
e) Others.
2.2 Maintenance of working environment

The construction site must keep neat and prevent stallers from trip while working.Simultaneously, pay
attention to fire protection.
2.3 Safety matters need attention in the Hoist-way

When installing, removing or modifying the scaffold, there must be certified lift installation personnel at
the scene. In the process of installation, you should wear suitable protective clothing, safety helmet,
safety belt and so on.And you should avoid carrying on many kinds of work in different floors
simultaneously in the Hoist-way.
2.4 Protection of Hoist-way entrance

At the Hoist-way entrance, you should take measures to prevent dropping. you should set some barriers
or warning board to remind people of dropping danger.
2.5 Fire protection

While using portable cutter, welding apparatus and gas cutting equipment, pay attention to prevent fire.
Place the inflammable or highly explosive cargo to the safety site.
2.6 Management of gas

Dangerous gas like oxygen, acetylene must be managed by specialist. Dangerous gas should be
deposited in Hoist-way ventilating place, and avoid of high temperature or long time insolation.
2.7 Safety prevention

When welding, gas cutting and drilling holes, you must wear the protecting glasses. Before operating the
electric welding machine, you must make sure it does not have any fault and guarantee the security of
operation.
2.8 Test running

The Hoist-way is forbidden to enter. And forbid non-professional personnel to enter the machine
room.before operation, you should confirm that all safety circuit work normally.only when the power is cut
off , the electrical equipment is able to run. In the process, you must put a warning board on the power
switch box to remind people that it is forbidden to access the power switch.
2.9 Safety inspection

Everyday after finishing the work, you should check: whether electrical switchs and gas valves are closed,
whether the fire-protection equipment is in good state and whether there is any unsafe factor. Once
discovering any abnormal situation , you should deal with it immediately.
ThyssenKrupp Elevator (Korea) 1

Installation Manual
2.10 Safety mark instruction
Beware of electric shock Beware of falling thing Beware of falling thing Beware of crash
Wear safety Wear Wear Wear Tie

helmet protecting shoes protecting gloves protecting glasses safety rope
3 Preparations at construction site

3.1 Communication with clients
It is supposed to observe the clients’ related rules and regulations when entering the construction site.
Discuss with clients and scheme installation procedure and project scheduling.
3.2 Verifying Hoist-way
To measure lift Hoist-way is to recheck the dimensions on GAD before the installation.The surveying
mainly contains the plane size in the Hoist-way, the verticality, the holes in the Hoist-way , position of
embeded parts, pit depth, top clearance,the hoisting height and so on. If you discover anything is not
coincidence with GAD dimensions, you should inform the client to revise. Check whether the Hoist-way pit
is seal and waterproof.Confirm whether the power is accordance with the installation requirement.
3.3 Check parts and related data
Representatives of clients, suppliers and construction corps confirm the opening records and signature. If
you discover leakage parts and wrong parts, you should feed back to the supplier in written form
promptly.
3.4 Material storage
Conform the material storage region is safe and the size is appropriate.
3.5 Determine installation plan
Discuss and determine the installation plan with clients. Installation flow refers to figure 3-1.
Figure 3-1 Installation flow chart

Installation Manual
4 Tools preparation
Installation tools mainly contain several kinds as following table 4-1 showing:
Table 4-1 Installation tools
No. Name Standard Quantity
Common Tools
1 Sharp nose plier 160mm 2
2 Diagonal cutting plier 160-200mm 2

3 Cutting plier 160-200mm 2
4 Vise 160-200mm 2
Multipurpose bolt
5 75-200mm 2
turns
6 Cross bolt turns 75-200mm（Suction） 2
7 Character bolt turns 75-200mm (Suction) 2
8 Electrician's knife 4
Double ended solid
9 10×13、17×19、24×30、36×40 2set
wrench
Double ended box
10 10×13、17×19、24×30、36×40 2 set
wrench
11 Socket wrench 1 set
12 Torque wrench 1 set
13 Hammer 5-10kg 10-12
14 Oil gun 1set
15 Oil pot 0.5-0.75kg 2
Aetylene welding and
16 1 set
shearing tool
17 Electric welding tool 1 set
18 Chain block 3ton、5ton 1
19 Rigging eye ring 6
20 Rigging unscrews 6
The steel wire griping
21 1 set
head
Flowing tubing head
22 5T 2
pressure Hoisting jack
Bench work tools
23 Electric impact drills 1
24 Hand butts 1.5-10mm 1
Angular orientation
25 100-150mm 1
grinder
26 Iron hammer 2
square、flat、round、semicircle
27 Steel file 1
thick、medium、thin
28 Carpenter's saw 600mm 1

Installation Manual
Installation tools（Supplyment）
No. Name Standard Quantity
Installation Tools
29 Flashlight 1
30 Test pencil 1
31 Electric iron 40W 1
32 Solder sucker 18g 1
33 Exhausted line pliers 2
34 Avonmeter 1
35 Charge type flare 1
36 Hand lamp 36V（with safety mask） 1
forming block of
37 5M 1
power source
38 Power transformer 220V/36V 2
Measuring tools
39 Angle ruler 250×250mm 2
40 Steel tapeline 5M 2
41 Steel ruler 30cm 2
42 Feeler gauge 0.02-1mm 1
43 Straightedge horizon 500mm 1
44 Vernier caliper 150-300mm 1
Debugging tools and instrument measuring appliance
45 Ohmmeter Million Ohms 1
46 Ampere meter 1
47 Speed meter 1
48 Psophometer 1
49 Thermometer 1
50 Sycnhronoscope 1
51 Spring balance 0-50kg 1
5 Scaffold erection
Determine the scaffold type in terms of car size and counterweight location. No matter what material you
choose, you must conform the stability and carrying capacity of scaffold. You should put isolated pedal on
each layer crossbeam of scaffold and fix both ends of the pedal with crossbeam firmly. The location of
scaffold should be convenient for construction and have no effect on line-putting.

Installation Manual
5.1 Layout dimensions of scaffold in the Hoist-way

Determine layout dimensions of scaffold in the Hoist-way in terms of relative position of counterweight
and car guide rail in the Hoist-way and position of wireway tube. And the scaffold should keep certain
distance with these devices to the plumbing line for construction. When the couterweight is at the back of
car, the top view of scaffold refers to figure 5-1.
100 100
1
2
3
4
100 100
250
Figure 5-1 couterweight at rear
5.2 Vertical layout dimension of scaffold in the Hoist-way

The vertical interval of the scaffold’s cross rod should be in the range of 1700~1800mm generally. The
cross rod at the landing entrance should be erected refferring to the figure 5-2. Add two climbing rods
between adjacent beams at one side of scaffold for climbing convinently. Refer to figure 5-3.
1
Figure 5-2 Vertical layout diagram of 1- Cross rod；2- Erect rod；3-Climbing rod；4- Isolate pedal
scaffold’s cross rod Figure 5-3 scaffold in the Hoist-way
5.3 Requirements of laying isolate pedals on each cross beam of all level scaffolds.
You should lay isolate pedals on each beam of all level scaffolds and make them as a whole. The width
should be wider than 600mm. Both ends of the pedal should extend the cross beams 100~200mm. And
fix the isolate pedals with the cross beam firmly by galvanized iron wire whose diameter should be bigger
than 1.2mm. And the adjacent pedal should be cross layed at right angles.
5.4 Installation of construction lighting.

a) You should use 36V low voltage lighting and take measures to protect overload and short circuit;
b) In the middle of scaffold, install a lighting lamp withshield every 2~2.5m along the whole
Hoist-way. And make sure the lighting lamp is bright enough. At the same time, install hand lamp sockets
at proper position.
c) Make sure metal covers of the movable electric devices are grounding reliably. And you must wear
the rubber insulated gloves when using these devices.

Installation Manual
6 Templates
6.1 Method of making templates
Choose wood for making templates in terms of cross section dimension of Hoist-way. The wood should
be not easy deformation, dry and it can endure certain weight. And the wood must be straight and
smooth, planed all round and right angles each other. The cross section dimension refers to table 6-1.
Table 6-1
Hoisting Height /m Thickness/mm Width/mm Remark
When the hoisting height is over the
Less than 20m 40 80 height showed in the table. you should
increase the relevent thickness and
More than 20m width of the wood, or use metallic
50 90,100 templates.
Less than40m
According to GAD demension of Hoist-way, mark out the center line of car and car door,clear width line of
car door opening and center line of guide rail. All deviation of these lines should not be more than 0.3mm.
Saw up oblique mouths with thin saw at all points for plumbing line. And nail iron nails near to these
mouths to fix plumbing line. Between templates, fix them with steel nails.Refer to figure 6-1
Figure 6-1 Scheme of templates
6.2 Locate templates and plumbing line

Fix 4 brackets(each direction of both sides with two nolts )by expansion anchors in the same level which is
500-600mm below from the top Hoist-way. Put two 100×100(mm) wood beam on the brackets. Adjust all
the beams with level bar, and then fix the beams with wedges. The levelness of the beams should be less
than 5mm. If it is more than 5mm, adjust the pads between beams and brackets. Refer to figure 6-2
(a) (b)
Figure 6-2 Scheme of Fixing wooden beam

Installation Manual
If the Hoist-way panel is structured by brick, drill four 150×150(mm) holes horizontally at the position of
installing brackets. Insert the beams into the holes and adjust them to be horizontal. And fix them with
wedges. Refer to Figure 6-3.
A
500～600
A A A
Figure 6-3 Scheme of fixing wooden beams in the Hoist-way with brick wall structure
Put the templates on the trimmer beam and adjust them to be horizontal. According to the clear width of
car door which the templates put on and GAD, make sure whether the construction is suitable and
determine the location of templates. Refer to figure 6-4
Figure 6-4 Scheme of laying templates on the wooden beams

Saw up a mouth at the mark of the templates and hang adequately heavy hammer by 0.4～0.5mm wire
ropes. Nail a ironnail behind the saw. And release the wire rope through the saw draft. After one end of
the wire rope reaches to the right position, wind the wire rope round the ironnail. Refer to figure 6-5. To
prevent wire rope from jitter, fix a templates similar in the pit at the height of 500~700mm from the pit
floor. After the plumbing line has been static, fix it on the pit templates by U nail. Refer to figure 6-6.
Figure 6-5 Scheme of plumbing line Figure 6-6 Scheme of fixing pit templates

Shaft Equipment Installation
Installation Manual (EVO1)
Version: 1.0
Installation Manual
Warning
All operations must be in conformity with the latest national codes on electric engineering, safety rules on elevator
and all related local administrative laws and regulations.
ThyssenKrupp Elevator is the proprietary of all drawings and materials of the manual. Hereby, the company has
rights to take them back anytime. Any organization and individual shall not publish, copy and directly or indirectly
cite contents of the manual or not damage interests of the company in any form.
We try our best to ensure high accuracy and timely update of the manual. However, we shall not take any liability
for adverse impacts brought by errors or omissions of the manual. For any problem in the manual, please contact
ThyssenKrupp Elevator (Korea) as soon as possible!

Installation Manual
Contents
1 Preliminary Traction machine Installation ....................................................................... 1
2. Guide rail Installation ...................................................................................................... 16
3 Machine beam, Governor, Control Cabinet and ARD Device etc Installation ............. 29
4 Buffer Installation ............................................................................................................ 42
5. Cunterweigth case, counterweight block and pit screen Installation........................ 45
6. Main rope Installation ..................................................................................................... 51
7. Compensation chain Installation ................................................................................... 56
8 Electrical equipment of shaft .......................................................................................... 59

Installation Manual
Shaft Equipments
Installation of the shaft equipments shall comply with civil works drawing of the shaft, installation manual of
equipments and related regulations and standards.
1 Preliminary Traction machine Installation
1.1 Attentions
1.2 Tool preparation

Table 1-1 List of Tools Prepared
Name: double-ended spanner Name: ratchet spanner and Name: offset ring spanner
straight connection
Specifications: 10×13, 17×19, Specifications of straight Specifications: 10×13, 17×19,

24×30, 36×40 connection: 10×13, 17×19, 24×30, 36×40
24×30, 36×40
Name: steel tape Name: bow shackle Name: leveling instrument
Specifications: ≥5m Specifications: M－BW3.2 Specifications: 500mm
Name: plumb bob Name: Chain block Name: sling
Specifications: 700g Specifications: rated capacity Specifications: rated capacity

=1t(two) ≥3t

Installation Manual
Table 1-1 List of Tools Prepared (Continued)
Name: PMS215 master Name: DAF210 master

installation tool installation tool
Specifications: one set Specifications: one set
1.3 Installation requirements of traction machine

Installation of traction machine needs a high intensity of labor, so it is necessary to arrange a special person
to give instructions on site and call attention to safety and protection problems all the time. Workers shall
concentrate on installtion and the commander shall give instructions orderly.
1.4 Install scaffold on the top floor of shaft

The conditions of top floor of shaft before installation of traction machine is shown as Figure 1-1.
Figure 1-1 Top Floor of the Shaft

Installation Manual
The conditions of top floor of shaft before installation of traction machine is shown as Figure 1-2.
Figure 1-2 Installation of Traction machine on the Top Floor of the Shaft
In order to install the traction machine, it is required to erect scaffold on the top floor of the shaft. According
to the installation requirements (e.g. Figure 1-1 and Figure 1-2) and the installation steps of traction machine
to be introduced below, erection of scaffold must be in line with safety requirements.
1.5 Installation steps of traction machines
1.5.1 Install speed governor beam
a) Install I-shape steel bars in the shaft:
I-shape steel bars
Figure 1-3 Installation of I-shape Steel Bars

Installation Manual
Regulate the top surface of the two I-shape steel bars at the same level, with the flatness of them
≤0.5/1000.See Figure 1-4 for positions of I-shape steel bars in the shaft. As setting-out work (i.e. jig
template preparation and plumb line arrangement) has not been carried out, it is possible that position and
dimension of the I-shape steel bars can not reach the requirements in Figure 1-4 exactly, and after
installation of the guide rail appropriate adjustment will be done.
Connecting line of the Central line of the

counterweight guide rail counterweight wheel
Central line
of the car
I steel bar I steel bar
This side shall be in parallel

This side shall be in parallel
with embedded steel plate.

with embedded steel plate.
Connecting
line of the car
guide rail
Rated load of
Dimension for PMS215, Dimension for DAF210,
elevator,
mm mm
kg
630 525 510
800 650 635
1000 775 760
1150 875 —
Figure 1-4 Position of I-shape Steel Bars

Installation Manual
b) Install speed governor beam in the shaft:
Speed limiter beam
I shape steel bar
Figure 1-5 Installation of Speed Governor Beam
Regulate the top surface of the speed governor beam at the same level, with the flatness ≤0.5/1000. Weld
the speed governor beam and the I-shape steel bar together. See Figure 1-6 for the position of speed
governor beam. It will be adjusted again after installation of the guide rail. (The speed governor beam weighs
99kg and can be hoisted and shifted without obstruction.)
Central line of
the car
I shape steel bar I shape steel bar
Connecting line of
the car guide rail
Beam of speed limiter
Rated load of Dimension for PMS215, Dimension for DAF210,

elevator, kg mm mm
630 525 510
800 650 635
1000 775 760
1150 875 —
Figure 1-6 Position of Speed Governor Beam

Installation Manual
1.5.2 Installation of traction machine
1.5.2.1 Installation methods for PMS215 traction machine
a) Fit the traction machine beam, gusset plate, washer and bolt assembly in the shaft; each traction
machine beam weighs 60kg and can be hoisted and fitted without obstruction. See Figure 17 and Figure 1-8
for conditions after installation.
Traction
machine beam
Washer
Gusset plate
Bolt assembly
Figure 1-7 Installation of Traction machine Beam, Gusset Plate, Washer and Bolt Assembly
Connecting line of the Connecting line of Central line of the

counter weight guide rail the car guide rail counterweight wheel
Traction
machine beam
Gusset plate
Central line
of the car
Figure 1-8 Position of Traction machine Beam

Installation Manual
If the depth of the shaft is overlarge (e.g. 100mm), it is allowed to take advantages of the gusset plate and
washer at the time of installing traction machine beam so that the gusset plate and washer can stretch out of
the traction machine beam and the integral component can stay on the embedded steel plate of the load
bearing wall solidly. See Figure 1-9.
Traction
machine beam
Gusset plate
Washer
Bolt assembly
Figure 1-9 Installation of Gusset Plate and Washer

b) Install the hanging beam of PMS215 master installation tool on the traction machine beam. See Figure
1-10 and Figure 1-11.
Traction machine
beam
Hanging beam
Figure 1-10 Installation of Hanging Beam
Hanging beam
Traction machine
beam
Figure 1-11 Relative Position of Hanging Beam and Traction machine Beam

Installation Manual
c) Fit the traction machine and the basket of the master installation tool outside the shaft on the top floor.
See Figure 1-12.
T/M
Flat washer 16
Spring
washer 16
Bolt M16×30
Bask
et
Figure 1-12 Installation of Traction machine and Basket
d) Lift the basket with traction machine to the scaffold platform on the top floor (with the hook and chain
block at the top of the shaft).
e) Hang the chain block over the hanging beam. See Figure 1-13.
Hanging
beam
Chain block
Figure 1-13 Chain Block

Installation Manual
f) Lift the basket under the traction machine beam with chain block and align the mounting holes at the
lower end of the traction machine beam side with those at the upper end; connect the traction machine beam
with the traction machine with M16×55 bolts; do not screw the bolts down, keeping the bolts 25mm down the
traction machine body. See Figure 1-14.
Chain block
T/M
Basket
Bolt M16×55
Figure 1-14 Hoist of Traction machine
g) Dismantle the basket column and install it reversely again and hang the hook of the chain block. See
Figure 1-15.
Basket
column Basket
column
Figure 1-15 Reverse Installation of Basket Column

Installation Manual
h) Remove M16×55 bolts at two sides of the traction machine beam and hoist the traction machine in place
with chain block; align the mounting holes at the side of the traction machine beam with those at the side of
the traction machine (from the top hole to the lowest hole); connect the traction machine beam and traction
machine with appropriate fasteners (M16×55 bolts, spring washer 16, flat washer 16); do not screw the bolts
down, keeping the bolts 18mm down the traction machine body. See Figure 1-16.
Bolt M16×55
Spring washer
16
Flat washer
16
Figure 1-16 Placement of Traction machine and Connection with Beam
i) Dismantle the basket, chain block and hanging beam, and loosen the bolts assembly at two ends of the
traction machine beam; and then screw down the bolts at the side of the traction machine; connect the
traction machine beam and the traction machine solidly; by now, preliminary installation of the traction
machine has been finished. See Figure 1-17.
Figure 1-17 Dismantlement of Installation Tools

Installation Manual
1.5.2.2 Installation method of traction machine DAF210

a) The traction machine beam, gusset plate, subplate, bolt assembly are assembled in the shaft; the
weight of a single traction machine beam is 60kg and it can be successfully hoisted and assembled. The
assembly is shown in figure 1-18 and figure 1-19.
Traction machine beam
Sub plate
Gusset
plate
Bolt assembly
Figure 1-18 Installing the traction machine beam, gusset plate, subplate and bolt assembly
Counterweight Centre line of

Car rail wiring
rail wiring counterweight wheel
machine beam
gusset
Central line
of the car
Figure 1-19 Location drawing of the traction machine beam

Installation Manual
If the depth dimensions of shaft is more larger (such as 100 mm), when assembling the traction machine
beam, it is feasible to use the waist hole in the front row of the gusset plate and the subplate, thus, to make
the gusset plate and the subplate to extrude the traction machine beam so as to lay the overall assembly on
the pre-casting steel plate of the bearing wall effectively and firmly, as shown in figure 1-20.
Traction
machine beam
Gusset plate
Sub plate
Bolt
assembly
Figure 1-20 Installation diagram of the gusset plate and sub plate extruding the traction machine beam
b) Install the suspension beam among the installation tools of DAF210 host machine on the traction
machine beam, as shown in figure 1-21 and figure 1-22.
Traction
machine beam
Suspension
Figure 1-21 Installing the suspension beam
Suspension beam
machine beam
Figure 1-22 The relative position of the suspension beam and the traction machine beam

Installation Manual
c) Assemble the hanging basket of the installation tools of the traction machine and host machine in the
outside of the shaft on the top level, as in figure 1-23.
Traction
machine
Flat washer
16
Spring washer
16
Bolt M16×35 Hanging
basket
Figure 1-23 Assembling traction machine and hanging basket
d) The hanging basket with the traction machine in it is lifted and carried to scaffolding platform in the shaft
on the top level (making use of the lifting hook and chain block on the top level of the shaft).
e) Hang the chain block on the suspension beam, as in figure 1-24.
Suspension
beam
Chain block
Figure 1-24 Hanging the chain block

Installation Manual
f) Use a chain block to hoist the hanging basket under the traction machine beam and make the mounting
hole in the bottom end on the side of the traction machine beam to align with that on the most upper end on
the side of the traction machine beam. Use a bolt of M16×55 to connect the traction machine beam to the
traction machine; this moment, the bolt cannot be tightened; the depth of the bolt screwing in the traction
machine is approximately 20mm, as shown in figure 1-25.
Chain block
Traction
machine
Hanging
basket
Bolt M16×55
Figure 1-25 Sling traction machine
g) Dismount the hanging basket; invert it to support from under the bottom of the traction machine and
hang the lifting hook of the chain block on it, as in figure 1-26.
Bolt M16×35
Spring
Hanging washer 16
basket Flat washer Hanging
16 basket
Figure 1-26 Inverting the vertical shaft of the hanging basket

Installation Manual
h) Dismount the M16×55 bolt on the side of the traction machine beam; further hoist the traction machine
in place with the chain block to align the mounting holes on the side of the traction machine beam with the
mounting holes on the side of the traction machine completely (to align from up to down). Use the
corresponding fasteners (bolt M16×55, spring washer 16, flat washer 16) to connect the traction machine
beam with the traction machine; now, the bolt cannot be tightened; the depth of the bolt screwing in the
traction machine is approximately 18mm, as in figure 1-27.
Bolt M16×55
Spring washer
Hanging 16
basket Flat washer 16 Hanging
basket
Figure 1-27 Traction machine in place and its connection to the beam
i) Dismount the hanging basket, chain block, suspension beam; loosen the bolt assembly in both ends of
the traction machine beam; then, tighten the bolt on the side of the traction machine to firmly connect the
traction machine beam to the traction machine. Then, the preliminary installation of the traction machine has
been completed, as shown in figure 1-28.
Figure 1-28 Dismounting the installation tools

Installation Manual
2. Guide rail Installation

2.1 Attentions
2.2 Tools preparation

Table 2-1 Tools preparation table
Name: steel ruler Name: steel tape Name: steel gauge
Specification: 300mm Specification: ≥5m Specification: 13 pieces
Name: angle square Name: knife straight edge Name: spirit level
Specification: 200mm Specification: 300mm Specification: 600mm
Table 2-1 Tools preparation table (continued)
Name: double offset ring spanner Name: chain block Name: sling
Specification: 17×19 Specification: rated elevating Specification: rated elevating

capacity ≥3t capacity ≥3t

Installation Manual
Name: double-ended spanner Name: bow shackle Name: plumb bob
Specification: 13×17 Specification: M-BW3.2 Specification: 700g
Name: electric impact drill Name: air cylinder
Specification: φ13, φ17, φ22 drill Specification: manual
2.3 Construction requirements for installing guide rail

The labor intensity for installing the guide rail is larger; thus it is necessary to preset the specially-asigned
person in charge of the on-scene command and to constantly remind the problem of safety protection.
During the construction, he shall constrate his attention to make commands clearly.
2.4 Installation of rail seat
For installing the rail seat, it is necessary to use the steel expansion bolt for fastening. In accordance with the
installation requirements (as shown in 2-1), first drill holes in the corresponding location in the pit foundation
with the electric impact drill (the diameter of bore of the M12 steel expansion bolt is 16mm; the diameter of
bore of the M16 steel expansion bolt is 20mm); then, place the steel expansion bolt and the taper pin in the
hole; moreover, hammer to taper pin with a hammer and dedicated core rod to make the bottom ends of
both the taper pin and of the steel expansion bolt parallel and level, thus, to expand the periphery of the
bottom of the steel expansion bolt so it can be firmly fixed in the foundation; aim the mounting hole on the
rail seat in the hole of the steel expansion bole; successively put on the flat washer and the spring washer;
screw in the hexagon-headed bolt to firmly fix the rail seat to the foundation.
Figure 2-1 Requirements on Layout of Buffer beam

Installation Manual
2.4.1 Installation of car rail seat:
Figure 2-2 Installation of Buffer beam
Figure 2-3 Photo of Buffer

2.5 Determination of the installation location of rail support
I amplification
Traction
Rail support machine beam
Rail support
II amplification
Rail support
Figure 2-4 Arrangement requirements of rail support

Installation Manual
The installation location of each rail support shall be based on the construction layout drawing of shaft.
Before installation, refer to the angle square for the steel wire of sample support to underline in the shaft wall
one by one. To start from the most under one, determine the elevation of the lowest one; the first support up
from the shaft pit shall be 1,000mm from the pit bottom. The distance from the first support down from the
shaft top to the shaft top shall be 300 to 500mm. The space between two rail supports should be no more
than 2,500mm; each guide rail requires at least to be installed with two rail supports. For the location
arrangement of the rail support, it is necessary to consider that the location of the connection plate of the
guide rail shall not collide with it and shall be staggered up and down.
2.6 Installation of rail support

The guide rail adopts anchor bolt M12×90/50 for fastenning. On the basis of the underlining locations of the
rail support in the shaft, drill hole with the drill of φ18mm in the concrete shaft wall, with the drlling depth no
less than 68mm. When drilling a hole, the reinforcement in the wall are often touched, which generates
stronger counter-force, so when drilling a hole, the stance and posture shall be selected and meanwhile, the
seat belt shall be fastened. The air cylinder will be used to blow off the dust in the hole after drilling (as
shown in figure 2-5).
Figure 2-5 Processing anchor bolt hole

a) Installing car rail support
a.1) Connect the fixed support to the shaft wall:
This surface shall be ensured as level. In

order to ensure level surface of the fixed
Fixed support support, gasket can be used for
adjustment. After that, it is required to
weld at least two points on it with the
support to prevent the gasket from falling
off due to vibration.
Anchor Bolt
Nut
Flat washer
Spring washer
Figure 2-6 Installation of fixed support

Installation Manual
a.2) Connect the rail support to the fixed support:
Rail support
Full Weld
Fixed support
Figure 2-7 Installation of rail support
b) Installing the counterweight rail support
This surface shall be ensured as level. In

order to ensure level surface of the fixed
Fixed support support, gasket can be used for
adjustment. After that, it is required to
weld at least two points on it with the
support to prevent the gasket from falling
off due to vibration.
Anchor Bolt
Nut
Flat washer
Spring washer
Figure 2-8 Installation of fixed support

Installation Manual
b.2) Connect rail support with the fixed support:
Full weld
Full weld
Full weld
Note: when used in the second gear

Full weld (from the pit to the top) rail support,
full welds at the above two figures
shall be changed as the spot welds,
when the counterweight frame work
is loaded, the marking positions are
fastened by the full welds.
Supporting撑脚
lug
Waling
横挡
Nut
Rail support
导轨支架
Spring washer
固定支架
Fixed support
大垫圈
Flat washer
12
Flat washer
Bolt
Figure 2-9 Installation of rail support

Installation Manual
2.7 Installing the guide rail

Instruction: the guide rail of the car top is 4m; the upper end face is plane; there are sunk coaks in the lower
end, as shown in figure 2-10; its installation location in the shaft is shown in figure 2-11; the legnth of the
guide rail on the car top cannot be changed during the field installation. Therefore, before installing the car
guide rail, calculate the length of the guide rail in the bottom of the shaft according to the shaft height and
the situation of the configured guide rail; the installation personnel shall process (saw) the bottom guide rail
according to the length calculated.
A direction
amplification
Figure 2-10 Guide rail on the car top
Traction machine
beam
Counter-
weight rail Car rail Counter-
weight rail
Figure 2-11 The height position of the guide rail on the car top in the shaft
Attentions for installation:
a) The guide rail shall be hoisted with the chain block or the winding engine, which must be reliable and
fixed and can endure the lifting and pulling force of more than 1,000kg.
b) When carrying, stockpiling and hoisting the guide rail, attention to protect it to avoid tortuposity and
damage to the guide rail.
c) Wash the part for putting together the guide rail with the connection plate; fasten the connection plate to
the up end of the guide rail;
d) It is necessary to hoist the guide rail from up to down; the lowermost guide rail shall be mounted on the
rail seat according to the requirements;
e) Fasten the guide rail to the rail support with the compression guide plate, dedicated washer and
fastener;

Installation Manual
f) Wash the concavo-convex mortise; use the rail fish plate and the fastener to connect the concavo-convex
mortises of the upper and lower guide rails; it is feasible to screw it to the spring washer till non-complete
compression, and then to tighten up till the guide rail is revised.
Installation steps of guide rail

a) Installing the car rail
a.1) Connection of the guide rail and the rail seat:
Nut
Spring washer
Flat washer
Rail Clip
Bolt
Liner
Figure 2-12 Installing bottom rail
a.2) Connection between guide rail and rail support:
Rail Clip Bolt
Rail Support
Flat washer Liner

Spring washer
Nut
Rail
Figure 2-13 Connection of guide rail and support

Installation Manual
a.3) Connection between guide rails

Rail fish plate
Guide rail
Guide
rail
Bolt M12 Spring Flat washer 12 Bolt M12×50

washer 12
Figure 2-14 Connection between guide rails
b) Installing counterweight rail

b.1) Connection between guide rail and rail seat:
Nut
Spring washer
Flat washer
Rail Clip
Bolt
Liner
Figure 2-15 Installing bottom rail

Installation Manual
b.2) Connection between guide rail and rail support:
Spring
Flat washer 12 Nut M12
washer12
Liner
Bolt M12×50 Rail clip
Nut M12
Rail Support
Spring
washer12
Flat washer12
Counter-weight
Rail frame
Liner Guide Rail
Rail clip
Bolt M12×40
Guide Rail
Figure 2-16 Connecting guide rail to support

Installation Manual
b.3) Connections between guide rails:

Rail fish plate
Guide rail
Guide rail
Bolt M12
Spring
washer 12
Flat washer 12
Bolt M12×35
Rail fish plate

Guide rail
Guide rail
Bolt M12 Spring Flat washer 12 Bolt M12×50

washer 12
Figure 2-17 Connections between guide rails
2.8 Correction of guide rail

The stand or fall of installation of guide rail directly influences the operational aspect of elevator; therefore, in
correcting the guide rail, it is necessary to do it in strict accordance with the specified size and tolerance. Use
the line transect, correction and guide ruler to correct the verticality and depth of parallelism of guide rail
from up to down, the joint between guide rails, the joint between guide rail and rail support and through
dedicated washer to adjust and fasten the compression guide plate. After all guide rails are corrected and
accepted, reexamine them from up to down; the guide rail after correction shall fulfill the following
requirements of size and tolerance.
a) The deviation of the working face of each guide rail (including the side face and top face) and the base line
for installation shall be no more than the following numerial values every 5m: car rail and the counterweight
rail equiped with the catch block are 0.6mm; T-type counterweight rail which is not equiped with the catch
block is 1.0mm. With the base line for installation, inspect each guide rail in array relative to the base line
and the maximum deviation value shall be taken. When inspecting the guide rail after installation of elevator,
it is feasible to continuosly inspect each 5m of plumb line in sections (inspection for 3 times at least); the
relative maximum deviation among the measured values taken shall be no more than 2 times of the
above-mentioned specified values.

Installation Manual
b) The joint of the car rail and the working face of the counterweight rail equiped with catch block shall not
have continuous gaps and the partial gap shall be no more than 0.5mm; the step in the layup of the guide
rail shall be measured with the parallel ruler with the straightness of 0.01/300 or with other tools and it
shall be no more than 0.05mm; if it is more than 0.05mm, equate it; the sleeking length is more than
150mm; the layup gap of the counterweight rail without the catch block shall be no more than 1mm; the step
in the layup of the guide rail shall be no less than 0.15mm; if it is more or less than this number, correct it
too.
c) The distance deviation beween the top faces of two guide rails: the car rail is+2 mm; the counterweight rail
0
is+3 mm.
0
d) The guide shoe shall not get over the guide rail when the elevator moves to the top.
After the corretion of the guide rail, those which use the bolt to fasten the parts shall all make the washer and
part point welded with at least two points. The second (counting from the pit upward) counterweight rail
support of the indirect side counterweight elevator is exceptional, because it is required to dismount it when
installing the counterweight frame; only after the counterweight frame is installed it can be reinstalled and
make point weld for its washer.
2.9 Installation of the oil pan
After the elivator is installed and prior to its normal operation, it is required to fix an oil pan at the lower end
of the guide rail (as shown below). Fix the slot of the oil pan to the guide rail of the elevator, and the width
of the slot shall be fit with that of the guide rail. It must be insured that three faces of the slot are in tightly
contact with those of the guide rail, a knif could be considered to modify the contact area when necessary.
Hold the oil pan with a block. Oil being collected in the oil pan shall be disposed regularly subject to specific
oil conditions.
situation.
Oil collcting box
Oil collecting box
Figure 1-28 Installation of oil pan Figure 1-29 Installation of oil pan
at car guide rail side at counterweight guide rail side

Installation Manual
The guide rail installation is completed as follows:
Figure 2-20 Guide Rail after Completion of Installation

Installation Manual
3 Machine beam, Governor, Control Cabinet and ARD Device etc Installation
3.1 Attentions
3.2 Tool Preparation

Table 3-1 Tool Preparation
Name: Double ended spanner Name: Ratchet spanner and Name: Double offset ring
straight connector spanner
Specification : 10×13、17×19、 Specification of the straight Specification : 10×13、17×19、
24×30、36×40 connector: 10×13、17×19、 24×30、36×40
24×30、36×40
Name: Steel tape Name: Bow shackle Name: Spirit level

Specification : ≥5m Specification : M－BW3.2 Specification : 500mm
Name: Plumb bob Name: Chain block Name: Sling

Specification :700g Specification : Rated load=1t(2) Specification : Rated load≥3t
3.3 Construction Requirements

Physical labor for adjusting of the machine beam is relatively heavy, thus specially-assigned persons,
responsible for directing onsite operations, and reminding safty concerning problerms shall provided in
advance. Attentions shall be focused during construction operations, and directions shall be delivered in a
resonable and organized manner.
Possition adjustment for the machine beam of the elevator shaft at this time shall be based on the
guide rail that has been adjusted.

Installation Manual
3.4 Adjustment and installation for the machine beam of the elevator shaft
3.4.1 Adjustment of the speed governor beam
Figure 1-5 and Figure1-6 illustrate the position adjustment for the beam of the speed governor, which, upon
completion of the traction machine beam
3.4.2.1 Adjusting and installation methods for traction machine PMS215

a) With the help of the lifting hook at the top of the elevator shaft, hoist and translate the beam of the traction
machine by means of the chain block and the sling (See Picture3-1), and the position after adjusting is
shown in figure 3-2.
Lifting hook of the
Sling
shaft
Chain block
Traction machine
beam
Figure 3-1 Hoisting the traction machine beam
Cables of the
Cables of the guide rail of Centerline of the counter-weight guide Centerline of the
the car counterweight wheel rail traction wheel
Centerline of the
traction wheel
Rated load
Centerline of the car
Figure 3-2 Position of the traction machine beam

Installation Manual
b) Install a bracket beneath the traction machine, to support it. See Figure 3-3
图 3-3 安装支架
Traction
machine
Nut M16
Spring washer 16
Bracket
Flat washer 16
Flat washer 16
Bolt M16×55
Figure 3-3 Installation of support

Figure 3-3 Installation of the traction bracket
c) Installation of the traction sheaves guard. As Shown in Figure 3-4.
Junction Traction
Bolt M6×16 plate sheave guard Flat washer 6
Spring washer Spring washer
6 6
Flat washer 6 Bolt M6×16
Figure 3-4 Installation of the traction sheave guard

d) Installation of the counterweight rope hitch plate. See Figure 3-5.
Counterweight rope hitch plate
Nut M16
Spring washer 16
Flat washer 12
Bracket
Flat washer 12
Bolt M12×40
Figure 3-4 Installation of the counterweight rope hitch plate

Installation Manual
e) Installation of damping rubber. See Figure 3-6.
Set screw
Bolt assembly
I. Dismantling the bolt II. Installation of the

assembly set screw
Set screw
Traction
machine beam
III. Lifting the traction machine beam with the set IV. Setting the damping
screw to a height of 60mm. rubber
V. Get the set screw released（But not

dismantled）, to let the traction machine
beam rest on the damping rubber pad.
Figure 3-6 Installation of the damping rubber pad

f) Installation of the bolt assembly. See Figure3-7.
Nut M16, spring washer16, Flat washer 16
Bolt assembly
Figure 3-7 Installation of the bolt assembly

Installation Manual
g) Installation of the settling angle steel. See Figure3-8.
Settling angle steel
Flat washer 16
Spring washer 16
Bolt M16×40
Settling
angle steel
Figure 3-8 Installation of the settling angle steel

Installation Manual
3.4.2.2 Adjustment and installation methods for traction machine DAF210

Adjusting methods for traction machine DAF210 are the same as those of the PMS215, and position of the
traction machine beam is shown in Figure3-9.
Installation methods for other parts on the traction machine beam are the same as those of the PMS215.
Cables of the
Cables of the guide rail of Centerline of the counter-weight Centerline of the
the car counterweight wheel guide rail traction wheel
Centerline of the
traction wheel
Rated load
Centerline of the car
Figure 3-9 Position of the traction machine beam

Installation Manual
3.5 Installation of the speed governor
Before installation, please read the atatched instruction on installation of speed governor.
a) Fix the base of speed governor to the speed governor beam, complying to the discription of the lay out
plan of the elevator shaft of the motor room. See Figure3-10.
Speed limiter beam

Nut M16
Spring washer 16
Square taper washer

16
Flat washer 16
Bolt M16×55
Speed gov. base
Figure 3-10 Installation of the speed governor base

b) Settle the speed governor on its base, with both sides of the pully groove of the speed governor in
correspondance with the preset holes on the base (the side with a sign of “ down side” of the speed
governor shall be facing to the guide rail on the car of the elevator shaft), then adjust the position of the
speed governor by putting a plumb line from the pully groove of the speed governor ( from the side with a
sign of “down side”) till it reaches the center point of the rope head of the drawing bar. See Figure 3-11.
Speed limiter
Nut M10
Spring washer 10 Brake

line
Flat washer 10
Flat washer 10
Bolt M10×30
Figure 3-11 Installation of the speed limiter

Installation Manual
Via adjustment, deviation between the rope sheeve and the plumb shall be no more than 0.5mm. Routing of
the brake line runs along the wall into the control cabinet beside the elevator hoistway door, bending radius
of the brakeline shall be no less than 100mm, and the hand brake control connecting to the brake line shall
be fixed in the control cabinet. As shown in Figure3-12.
Brake line
Hand brake
control
Control cabinet
Figure3-12 Layout of the brake line and position of the hand brake control
c) Put down a plumb line through the center line of the rope head of the drawing bar on the car fame, rightly
facing to the center of the groove on the right side of Figure 3-13, and the plumb line shall be in vertical
coincidence with that of the speed governor, determine the position of the horizontal position of the tensioner,
which shall be 320mm above the pit floor.
Tensioner device shall be installed on the guiderail of the car and its weight part supported with a block. (See
Figure3-13).
Pressure plate
Bolt M12×45
Large washer 12
Spring washer 12
Nut M12
Tension device
Block
Pit floor
Figure 3-13 Installation of the tensioner

Installation Manual
d) Hanging of the governor rope of the speed governor shall be subject to the following requirements: the
uper end hung on the wheel of the speed governor (see Fiture3-14), the lower end fixed on the tensioner
(see Figure3-15), and both endes are connected to rope hitch plate of the safely hoisting assembly on the
car frame (see Figure3-16).
Governor
rope
Figure 3-14 Hanging the governor rope

Governor rope
Rope blocking bar
Notice: Rope blocking bar on the tensioner shall be

dismantled before hanging the governor rope, and
installed after the completion of the installation of the
governor rope, keeping a space of 2mm with the
governor rope. U-bolt Rope cramp Nut M8
Figure 3-15 Installation of the governor rope
Notice:
1. The rope cramp shall be fixed to the active section,
and the U-bolt shall be buckled on the end of the
governor rope.
2. Three sets of rope cramps, at an interval of 6-7 times Safely hoisting
assembly
the diameter of the governor rope, are required for each
joint.
3. Reasonable load shall be considered when
tightening the rope cramps, and the cramp most remote
from the safely hoisting assembly shall in no way be
fastened firstly and separately; the cramp nearest to the
assembly (the first one) shall be as close as possible to Governor rope
the safely hoisting assembly, but it must be fastened in
a proper manner without bringing any damage to the
external wire of the steel rope.
Figure 3-16 Connection at the rope head

Installation Manual
Governor rope of the speed governor shall be tensioned, and any impact with other parts be avoided. In
addition, rope wheel of the speed governor shall be flexible.
Speed governor after completion of the installation is shown in Figure3-17.
Figure 3-17 Installed speed governor

Installation Manual
3.6 Installation of the control cabinet and the ARD devices
Positioning of the the control cabinet shall be based on requirements for the layout plan of the machine room
(see Figure3-18 and Figure3-19). The ARD devices and the ARD battery box ( if provided) shall be installed
beneath the small control cabinet (refer to Figure 3-18 and Figure 3-19), please see the construction layout
drawing of the contract.
Small control cabinet

Large control cabinet
Small control
cabinet
Large control
cabinet
Figure 3-18 Arrange the control cabinet and the ARD devices
Large control
cabinet
ARD Devices
ARD Battery box
Figure 3-19 Installation position of the control cabinet and the ARD devices

Installation Manual
3.7 Installation of the power switch box
3.7.1 lighting power supply of the machine room shall be independent with the power system for the
elevator, and the lighting switch shall be arranged as per the construction layout drawing of the elevator.
3.7.2 Using the expansion bolt, the power switch box shall be fixed to the wall of the top layer of the
elevator shaft, which could be approached conveniently and rapidly.
3.8 Installation of the locking device
a) Fix the latch of the locing device to the uper beam of the car frame (back on the pulling device of the safety
gear). See Figure3-20 and Figure 3-21.
Bolt M16×45
Flat washer 16
Cross beam of
the car frame
Flat washer 16
Spring washer 16
Nut M16
Latch assembly
Figure 3-20 Installation of the latch assembly
Cross beam of the

car frame
Latch assembly
Latch assembly
Figure 3-21 Completion of installation of the latch assembly

Installation Manual
b) Fix the support board of the elevator locking device to the top guide rail. See Figure3-22, Figure3-23.
Top guide rail
Nut M12
Spring washer 12
Flat washer 12
Supporting plate
Flat washer 12
Nut M12×40
Figure 3-22 Installation of the support board
Top guide rail
Supporting
plate
Figure 3-23 Completion of installation of the supporting plate

Locking devices in operation is illustrated in figure3-24.
Supporting plate Upper beam of the

car frame
Latch assembly
Latch assembly
Supporting plate
Figure 3-24 Locking devices in operation

Installation Manual
4 Buffer Installation
4.1 Attentions
4.2 Tools Preparation

Table 4-1 Table of Tools preparation
Name: Steel ruler Name: Steel tape Name: Plumb bob
Specification: 300mm Specification: ≥5m Specification: 700g
Name: Double ended spanner Name: Electric impact drill Name: Air cylinder
Specification: 17×19 Specification: φ13, φ17, φ22 Specification: Manual

drill
4.3 Inspection of the buffer prior to installation

a) whether the plunger of the hydrolic buffer is rusted? Upon any rusting is discovered, crocous paper could
be considered to polish it, then clean it for rust-proof treatment.
b) Is there any deflect in the polyurethane buffer?

Installation Manual
4.4 Installation and positioning of the buffer

a) Install the base of the buffer by utilizing the steel expanding nut (see Figure4-1). Diameter of the borehole
of steel expanding nut M12 is 16mm, and that of steel expanding nut M16 is 20mm (When installing the oil
buffer, mounting hole of the steel expanding nut shall be punched with the spotting drill of the drilling
template). Mounting face shall be kept level and perpendicular to the buffer that mounted to it. Base of the
buffer shall be securely connected with the concrete convex platemm of the pit floor.
a.1) Energy storage buffer EN2
Bolt M16×30
Spring washer 16
Flat washer16
Buffer EN2
Steel expanding nutM16
.
a.2) Oil buffer
2 1
3
Rated speed of
Seria1 No.1 Seria1 No.2 Seria1 No.3 Seria1 No.4 Seria1 No.5
the elevator m/s
Spring washer Flat washer Steel expanding nut
2 Buffer YH4/270 Bolt M12×45
12 12 M12
1.75 Buffer YH8/206 Bolt M12×35
12 12 M12
1.5 Buffer YH1A/175 Bolt M12×35
12 12 M12
Figure 4-1Installation of the buffer
b) The buffer shall be installed below the car frame striking plate and the counter frame striking plate,
corresponding to the center of the striking plate.
c) The car frame and counterweight are in corespondance with the mounted buffer seperately.
d) Detailed information on the adjustment methods for the buffer is described in the buffer instruction.

Installation Manual
4.5 Technical requirements on installation of the buffer
a) When the car is at the same level with the end stops, distance between top face of the buffer, and the
striking plate of the car and the counterweight device are as follows: Energy storage buffer(EN2)—200 010
10
mm, Hydraulic buffer— 150 0 mm。
b) Deviation between the buffer center, and center of the striking plate of the car and the counterweight
deviceshall be no more than 20mm.
c) When verticality of the plunger of the hydraulic buffer is no more than 0.5% (after installation of the buffer,
two plumb lines perpendicular to each other from any positions of the front, rear, right or left shall be set to
measure the verticality, see Figure4-2), the filling amount is proper. Security electric switch preventing the
elevator from normal running shall be provided for application in cases that the buffer is not in its normal
position after action.
Figure 4-2 Measurement of the verticality

d) When the elevator is using two compensation lines, for fear of interferance between the two compensation
lines, safety switch device of the hydraulic buffer under the counterweight shall be placed at the middle point
of those two lines.
The buffer, after completion of installation, is shown below:
Figure 4-3 Buffer is completely installed

Installation Manual
5. Cunterweigth case, counterweight block and pit screen Installation

5.1 Attentions

Table 5-1 Table of tool preparation
Name: double-ended spanner Name: steel tape Name: plumb bob
Size：17×19 Size：≥5m Size：700g
Name: bow shackle Name: chain block Name: sling
Size：M-BW3.2 Size：rated lifting weight≥3t Size：rated lifting weight≥3t
5.3 Procedure for installation of Counterweight case

a) Before installation, correct positions of scaffolds interfering the installation. For the indirect side
counterweight elevator, the second tranche (counting from the pit to up) of counterweight guide rail support
shall be dismantled, and the guide rail support shall be immediately mounted, adjusted and fixed after the
Counterweight case is put in.

Installation Manual
b) Consider relevant dimensions for operation and preliminarily determine the distance from the
Counterweight case striking plate and to the top of the buffer when the top floor of the car meets the landing
floor based on heights of counterweight buffer and Counterweight case as shaft as the height of the shaft’s
top floor so as to fabricate a support frame with a height equal to the distance from the striking plate of the
Counterweight case to the bottom surface of the pit or use a padding block (see the following figure 5-1); the
support frame or the padding block shall bear the weight of 1000kg.
Support frame
Figure 5-1 Placement of support frame
c) Place the Counterweight case on the upper part
Counterweight case
Figure 5-2 Placement of Counterweight case
d) Install the safety limit plate at the upper part
Safety limit plate
Flat washer 12
Bolt M12×50
Nut M12
Spring washer 12
Flat washer 12
Figure 5-3 Installation of safety limit plate

Installation Manual
e) Installation of safety limit plate and guide shoe at thelower part

Adjust the adjusting shim to make sure the interval btween the guide shoe liner and the top surface of the
guide rail at one side is 0.5-1.5mm when the guide shoe liner contacts the top surface of the guide rail at the
other side. The interval between the safety limit plate and the guide rail shall be uniform.
Guide shoe
Bolt M12×50
Spring washer
12
Adjusting shim Flat washer 12
Safety limit plate
Figure 5-4 Installation of safety limit plate and guide shoe
f) Install the upper guide shoe.

Adjust the adjusting shim to make sure the interval btween the guide shoe liner and the top surface of the
guide rail at one side is 0.5-1.5mm when the guide shoe liner contacts the top surface of the guide rail at the
other side.
Adjusting Guide shoe

shim
Bolt M12×50
Nut M12
Spring washer
12 Flat washer 12
Figure 5-5 Installation of guide shoe

Installation Manual
g) Install the oil box of the upper guide shoe.

Self-tapping screw Screw M6×25
Oil box
Figure 5-6 Installation of oil box

After counterweight guide shoes are installed and adjusted, front or rear working faces of these two guide
shoes at the upper (or lower) part shall contact with the counterweight guide rail. A certain interval shall be
also remained between the guide shoe liner and the guide rail.
h) Add counterweight block into the Counterweight case.
Installation of counterweight block is the segment in which accidents is most likely to occur; thus, installation
personnel are required to shaft cooperate with each other. The first batch of counterweight blocks are
generally installed after the hanging of main ropes is accomplished (At this time, the support frame at
bottom of the Counterweight case shall be dismantled.); add counterweight blocks in the Counterweight
case with a quantity corresponding to installed basic components of the car; generally, it is appropriate that
the counterweight device is about150kg heavier than the car. For safety, counterweight blocks shall be
pressed by counterweight block pressing plates. Dismantle these counterweight block pressing plates after
the car is assembled; continuously add counterweight blocks based on 40%-50% balance coefficient and
then fix these blocks with counterweight block pressing plates.
Counterweight block Bolt M12×50

pressing plate
Nut M12
Flat washer 12
Bolt M12×50 Spring

washer 12
Flat washer 12
Base
plate
Counterweight
block
Figure 5-7 Installation of counterweight block pressing plate

Installation Manual
The finished installation of counterweight frame and counterweight block is as shown in the following figure:
Figure 5-8 Completion of counterweight installation
5.4 Installation of pit screen

Install the pit screen after the scaffold is dismantled.
The distance from the bottom of the pit screen to the pit floor under the bottom of the pit screen is 300mm;
rubber is installed at the lower end of the pit screen (see the following figure).
Counterweight
guide rail support
Rubber
Figure 5-9 Requirements for installation height of pit screen

Installation Manual
Procedure for installing the pit screen:

a) Fix the support on the counterweight protective net.
Counterweight
guard grid
Bolt M12×40
Flat washer 12
Spring washer
12
Nut M12
Support
Figure 5-10 Installation of support
b) Fix the counterweight protetive net on the guide rail.

Guide rail
Counterweight
guard grid
Bolt M12×40
Pressed guide
plate
Flat washer 12
Spring washer
12
Nut M12
Figure 5-11 Installation of protective net

Installation Manual
6. Main rope Installation
6.1 Attentions

Name: Double-ended spanner Name: steel tape Name: Plumb bob
Size：17×19 Size：5m Size：700g
6.3 Requirements for installation of main rope

a) Safety requirements for installation of main rope:
Gloves shall be used during installation of main ropes to prevent fingers from being hurted by warped steel
wire during laying of main ropes.
b) Requirements for storage
Works of rain, damp and rust prevention shall be carried out for main ropes stored at construction site. It is
not appropriate to directly lay main ropes on the ground and they shall be isolated from acidic and alkaline
substances; no heavy object or equipment shall be placed on them and it shall be prevented that main ropes
are sticked with sand.
c) Construction requirements:
1) Untie main ropes with a correct method (such as the method in figure 6-1). The incorrect method would
cause the knotitng and hidden injuries of main rope.
a) b) c)
a) Correct method of untying b) Correct method of untying c) Incorrect method of untying
Figure 6-1 Method for untying main ropes
2) Do not drag over the main rope from a sand heap to prevent sand from getting into rope gaps of the main
rope. Prevent the main rope from rubbing with cement ground, equipment and shaft scaffold so as to avoid
damages of rope surface wich would cause the decrease of its service life.

Installation Manual
3) The installation of main rope shall include the working procedure of “vortically laying”. Overhang the main
rope in the shaft and conduct the vortically laying with the aid of self-gravity to improve the operating quality.
Firstly “vortically lay” a half of the main rope when the traction ratio of the elevator is 2:1, and then
“vortically lay” the other half of the main rope; each time of conduction shall not be less than 12 hours.
4) Cut off the excessive part after each main rope is installed. After completion of construction, scrub main
ropes with machine oil or special cleaning agent and inspect whether the main rope is abnormal and whether
there is rubbing and collision during operation.
6.4 Fabrication of self-tightening wedge-type rope socket
a) During determination of length of main rope, note that the inflexion length after the rope bypasses the
wedge shall be reserved. The inflexion length shall be 40-50 times as long as the diameter of the main rope.
b) Penetrate the main rope in the rope sleeve and then penetrate the rope sleeve after making the main rope
bypass the wedge and inflect the rope so as to tighten the main rope and compress it tightly with wedge
blocks.
c) After each main rope is inflexed, tightly clamp it together with the main rope at the entrance by using a
rope clamp.
d) Wrap each broken end of the main rope with the rubber tape to prevent it from causing personnel injuries.
e) Procedures for instllation of self-tightening wedge-type rope socket are as follows:
Rope circle Wedge block Main rope
Main rope clip—Nut
Main rope clip—pressing plate
Cotter pin
Main rope clip—U Clip
Figure 6-2 Fabrication of self-tighting wedge-type rope socket

Note: Main rope clamp—pressing plate shall be placed at the load-carrying side of the main rope,
main rope clamp—U-form bolt shall be set at the no-load carrying side of the main rope (namely, at
the side of the short rope).

Installation Manual
6.5 Hanging method of main rope and installation of rope head

a) The hanging method of main rope for the elevator (that is, hang each main rope in the rope race on each
corresponding wheel) is as shown in the following figure:
Indirect side
counterweight rope
socket plate
Traction
sheave
Main rope
Car side rope socket

plate
Car diversion
sheave
Counterweight
diversion sheave
Figure 6-3 Method for hanging of main rope (3D diagram)

Installation Manual
Magnification
Counterweight Counterweight side I
diversion sheave rope socket plate
Main rope No. Main rope No.

4 5
2 3
Ⅰ
Ⅱ
Main rope No.

1

Traction 6 7
sheave
Magnification
II Main rope No.
Main rope No. 1
3 Main rope No.
Car diversion
sheave Main rope No. 2
7 Main rope No.
Main rope No. 4
5 Main rope No.
6
Car side rope

socket plate
Magnification
III
Main rope No.

7
Main rope No.
5 Main rope No.
2
Main rope No.

1
Main rope No.
3 Main rope No.
Main rope No. 6
4
Figure 6-4 Hanging method of main rope (Vertical view)

Installation Manual
Both figures 6-3 and the 6-4 show hanging methods of 7 main ropes. Hanging methods of 6 main
ropes could be obtained by removing the “Main rope 1” in figures, and hanging methods of 5 main
ropes could be obtained by removing “Main rope 5” and “Main rope 6” in figures.
b) Installation of rope head is as shown in the following figure:

Nut
Spring seat
Spring seat Cotter pin
Spring seat
Rope socket
plate
Rope socket
plate
Rope socket
assembly
Figure 6-5 Installation of the rope head to the rope hitch plate
6.6 Tension adjustment of main rope

a) Firstly tring together rope heads with thick iron wire or main rope with a small diameter to avoid the
random revolving of rope heads and to make preparation for adjusting the tension of the main rope.
b)。When the car is at the 2/3 position of the shaft, use a spring scale of 50-100N (≈5～10kg) on the car to
measure the tension of each tractive rope at the counterweight side by a equivalent drawing distance and
adopt the average value of these tensions. Then compare the average value with the difference between
tensions of these ropes. After that, adjust the tension by controlling the rope head rod nut at the car side.
c) During adjustment of tension, control the tension of the rope having the maximum tension deviation to be
equal to or less than 5%.
d) The method of revolving the main rope shall be not used to adjust the tension of the main rope.
e) If the adjustment exceeds the threads range of the rod, it shall be considered to cut off the excessive main
rope. All nuts shall be tightly screwed up after the adjustment is finished.
f) Let the elevator conduct 5-10 times of full-journey operation and then inspect again the tension of the main
rope. Carry out the fine adjustment if the deviation is greater than 5%.

Installation Manual
6.7 Installation of wood clamp

Install the wood clamp under the main rope head at the car side. The distance between the upper end of the
wood clamp and the lower end surface of the speed governor beam is 100mm. It is as shown in the following
figure:
Flat washer 10
Spring washer 10
Nut M10
Nut M10
Spring washer 10
Flat washer 10
Screw M10×200
Wood clamp
Figure 6-6 Installation of wood clamp
7. Compensation chain Installation

7.1 Attentions

Name: double-ended spanner Name: steel tape Name: steel ruler
Size：13×16 Size：≥5m Size：300mm

Installation Manual
7.3 Installation of compensation chain
Car frame
Counterwei
ght
Compensation
chain
Guiding of
compensation chain
Magnification Magnification
I II
steel wire rope U-form bolts

Steel wire rope clamp S-form hook
Figure 7-1 Installation of compensation chain

When installing the balance compensation chain for plastic elevator based on the elevator configuration, one
end of the compensation chain shall be set on the U-form bolt and fixed on the connecting plate at the lower
end of the Counterweight case. The other end of the compensation chain is fixed on the downbeam of the car
with the same method. Meanwhile, install a U-form bolt on the downbeam and set the U-form bolt and the
chain at the front part of the compensation chain respectively on the S-form hook (see figure 7-1).
During installation, the spiral and twine during the coiling course of the compensation chain shall be removed.
The method is as follows (that is, hanging and release): When one end of the compensation is hanged on the
bottom of the car, drive the elevator to the top floor and measure the length required for the compensation
chain; then cut off the chain and roll up and wrap the chain that falls on the ground; hang the wrapped chain
for 24 hours with a distance greater than 1m from the ground; hang the other end after the twine is removed.
After several days of operation of the elevator, recheck whether the compensation chain has spiral or twine
during operation. If the spiral or twine still exists, repeat the operation mentioned above.
The centerline of the guide device and the hanging point shall be on the same vertical line so as to avoid
unexpected failures due to the increase of frication between the balance compensation chain and the guide
device.

Installation Manual
The distance from the lowest point of the compensation chain to the projected shaft pit surface is
100-200mm. After completion of installation, it is suggested to inspect changes in the distace every 20 days
in the initial course of operation and carry out the appropriate adjustment to avoid the collision with the
ground.
This part has been disposed to be transparent.
Figure 7-2 Balance compensation chain of counterweight and plastic elevators
Figure 7-3 underbeam of car support and balance compensation chain of plastic elevator
Figure 7-4 Guide device and balance compensation chain of plastic elevator

Installation Manual
8 Electrical equipment of shaft
8.1 Attentions

Name: double-ended spanner Name: steel tape Name: plumb bob
Size：7×8、10×13、17×19 Size：≥5m Size：700g
Name: steel ruler
Size：300mm
8.3 Construction of shaft slot

Slot shall be laid to be flat and straight, tidy and firm and shall be provided with good earthing. The layout of
slot shall be considered based on the trend of shaft support and speed governor rope, distribution of safety
loop line and outband signal line and conditions of machine room. Incoming and outgoing cable slot shall be
provided with anti-cutting protection.
8.4 Installation of shaft cable
Tie up the safety loop cable and signal cable of the elevator on the hanging point in the slot by using the vinyl
tape (there is a hanging point from space to space). Lay these cables along the line slot until these cables
get out from the floor of the machine room and connect them with the line slot of the machine room; then
insert these cables into the control cabinet.
8.5 Installation of traveling cable
Hang one end of the traveling cable on the rack for specially used by cable at the bottom of the car; the
upper part near the center shall be hanged on the rack at the position that is 1/2 of the shaft + 1.5m. The
other end of the cable shall be inserted into the control cabinet (see figure 11-1).
The traveling cable will move along with the lifting or fall of the car. During installation, the traveling cable
shall be ensured not to collide with or interfere the shaft support, speed reducing switch, flapper bracket at
the landing floor, main rope, speed govenor rope, Counterweight case, pit buffer and other components, or
safety accidents of equipments would likely occur.
Determine the hanging point based on the curvature radius of the cable (The minimum curvature radius of
the cable is 245mm). The hanging of cable shall be carried out prior to its installation to eliminate the stress,
and wave-form distortion and knotting could be avoided after installation; otherwise, the abnormal sway
would occur during operation and the service life of the cable would be influenced.

Installation Manual
The installation procedure is as follows:
top track
control cabinet (in
support
shaft)
upper
car track
cable
hanger
control cabinet
(outer)
trailing
cable
car track
car track
middle
cable
lifting depth
support
car frame
plank
car platform
pit depth
cable support
Figure 8-1 elevation view of mounting traveling cable

Installation Manual
a) Install the upper cable hanger into the guide rail.
Nut M12
Upper cable hanger
Spring washer 12
Big washer 12 Pressing guide plate
Bolt M12×40
Car rail
Figure 8-3 Installation of upper cable hanger

b) Hang the traveling cable on the upper cable hanger.
Pressing plate
Nut M6
Spring washer 6
Flat washer 6
Protective pad Screw M6×35
Traveling cable
Figure 8-4 Hanging of traveling cable

c) Install the middle-end cable support on the guide rail.
Nut M12
spring washer 12
large washer 12
trailing cable guide plate

middle cable
support bolt M12×40
Figure 8-5 Installation of cable support at the middle part

Installation Manual
d) Install the cable pressing plate at the middle part.
Traveling cable
Protective pad
Pressing
Flat washer 10
Nut M12
Bolt M10×40
Spring washer 12
Flat washer 10
Figure 8-6 Installation of cable pressing plate at middle part
e) Install the car cable support on the lower beam of the car frame.
Lower beam
Nut M12
of car frame
Spring washer 12
Flat washer 12
Bolt M12×35
Car cable support
These two parts have been

disposed to be transparent.
Figure 8-7 Installation of car cable support

Installation Manual
f) Hang the traveling cable on the car cable support.
Traveling
cable Pressing plate
assembly
These two parts have been

disposed to be transparent.
Figure 8-8 Hanging of traving cable at the bottom of the car

Installation Manual
Upper cable hanger
Traveling cable
Middle-end cable
support
Under beam of
car support
Car cable support
Figure 8-9 Finished installation of traveling cable

Installation Manual
8.5 Installation of Limit Switch Component and Final Limit Cam
UP
ONLY
Figure 8-10a Dimensions of limit switch (up direction)
DOWN
Figure 8-10b Dimensions of limit switch (down direction)

Installation Manual
TYPE SPEED
Table 8-1 Dimension of limit switch
Limit switch
Upright Final limit cam
Fig. 8-11 Cross Section Sketch of the Installation of Limit Switch and Final Limit Cam
a) The limit switches and the final limit cam should not be deformable but securely welded. The line on the
impact switch surface should coincide with the running direction of the elevator with a deviation not more
than 2mm.
b) Tangent lines of fender wheels of many limit switch should linearly coincide with the running direction of
the elevator with a deviation not more than 1/1000 of the length of the tangent line.
c) Mounting position of limit switches: When taking the relative displacement of car sill and landing sills as a
reference, that is when the distance between the car sill and bottom level landing sill and that between the
car sill and the upper level landing sill are 150mm respectively, the final limit cam is required to run into the
limit switches to beake them to cut off power supply.

Installation Manual
d) Installation steps of the final limit cam is as the following figure 8-12.
Final limit cam Bolt M12×40
Bracket of final Flat washer 12

limit cam
Flat washer 12
Spring washer
12
Nut M12
Nut M12
Spring washer
Installed to the car frame
Spring washer upright column
Bracket of final
12
limit cam
Flat washer 12
Final limit cam
Bolt M12×40 Car frame upright

column
Fig. 8-12 Installation of Final Limit Cam

e) Installation Steps of Limit Switches is as the following figure 8-13.
Limit switches screw M5×20
Nut M6
Spring washer 5
Spring
washer 6
Flat washer 5
Flat
washer 6
Installation of upper limit
Bracket switch
Switch
bracket
Flat washer 6
Bolt M6×25
Installed to guide rail
Installation of bottom limit switch
Upper limit
switch
Guide rail
Limit switches screw M5×20
Spring washer 5
Flat washer 5 Nut M12

Installed to guide rail
Spring washer
12
Square washer
Pressing guide
plate
Bolt M12×40
Lower limit
switch
Fig. 8-13 Installation of Limited Switches

Installation Manual
8.6 Installation of Landing switch and Landing vanes

8.6.1 Installation of Landing switch
a) The Lainding switch support is mounted on the car ceiling.

Car ceiling
轿厢顶
螺Bolt M6×30
栓
M6×30
轿顶支架
Car ceiling support
平垫圈 6
Flat washer 6
弹Spring
垫
6 washer 6
Nut螺M6 母
M6
Figure 6-14 Installation of Landing switch support
b) The Landing switch switch is installed on the car ceiling
Figure 8-15 Installation of Landing switch

Installation Manual
8.6.2 Installation of Landing vanes

a) The blade support of each floor should be installed into the guide rail.
Nut M12
Spring
washer 12
Bolt M6×16
Square
washer 12
Blade bracket
Pressing
guide plate
Car guide
Bolt M12×40
Fig. 8-16 Installation of Blade Support
Landing Sill
Figure 8-17 Layout and adjustment of Landing vanes in shaft

Cage frame and Cage Installation
Installation Manual
Version: 1.0
Installation Manual
Warning

Installation Manual
Contents
1 Attentions ................................................................................................................................................... 1
2 Tools preparation....................................................................................................................................... 1
3 Installation of scaffold .............................................................................................................................. 3
4 Hanging hand chain block ........................................................................................................................ 3
5 Installation of cage frame ........................................................................................................................ 4
6 Installation of safety gear ....................................................................................................................... 11
7 Installation of cage guide shoes ............................................................................................................ 14
8 Installation of balance weight at platform ............................................................................................ 15
9 Vulnerable parts....................................................................................................................................... 16
ThyssenKrupp Elevator (Korea)I

Installation Manual
Cage frame and Cage Installation
1 Attentions
2 Tools preparation
Figure 2-1 Tools Preparation
Name：double-ended wrench Name：ladder Name：offset ring wrench
Standard：7×8、10×13、17×19 Standard：7×8、10×13、17×19
Standard：2m
24×30、36×40 24×30、36×40
Name：steel tape Name：steel rule Name：track level bar
Standard：≥5m Standard：150mm Standard：500mm

Installation Manual
Figure 2-1(supplement)
Name：Plumb bob Name：hand chain block Name：suspension band
Standard：700g Standard：hoisting weight≥3t Standard：hoisting weight≥3t
Name：screwdriver Name：electric impact drill Name：angle square
Standard：parallel head、crosshead Standard：13 Standard：315×200
Name：hexagona wrench
Standard：4、8

Installation Manual
3 Installation of scaffold
Suggestions of scaffold installation are as follows:
3.1 Remove scaffold

Generally, you install cage frame and cage at the top floor.So before installation, you should remove the
scaffolds above the top floor, and drill two square holes(250×250mm) on the wall opposited to the
landing door of the top floor. Their depth extends the center of the wall 20mm and is not less than 75
mm,and their width should be similar to the width of landing door.
3.2 installation of scaffold
Take two square wood beams whose sections are not smaller than 200×200 mm（high quality wood,
each one can bear 2t at least）or two steel beam with the same intensity. Insert one end of them in the
holes on the wall and lay the other end on the landing door entrance floor. And adjust the two square
beams to be parallel and regulate their surfaces to be level. And then fix them. Refer to figure 3-1.
Wall thickness
Wall thickness/2+20
1
1－ wood beam 2－shaft 3－landing door entrance

Figure 3-1
4 Hanging hand chain block

At the center line of the cage,hang a hand chain block loading 3000kg through machine room floor to
supporting beam by round steel slings whose diameter is bigger than Φ50mm or steel tube slings whose
diameter is bigger than Φ75×5mm. Refer to figure 4-1
Machine room
Landing Door
Figure 4-1

Installation Manual
5 Installation of cage frame

Generally, cage devices are composed of cage frame and cage. The basic structure of elevator cage of
different spacifacations are the same. As a result of the different application, the figure and part structure
of the cage has some difference.
5.1 Installation of cage frame

The cage frame of this series elevator are mainly composed of cross head, upright, plank, stay and
car-sheave, are main load carrying structural elements. Refer to figure 5-1
Car sheave
Cross Head
Up light
Stay
Platform
Counterweight at rear elevator Counterweight at side elevator
Figure 5-1
a) Place the plank on the 200×200 mm square wood beams(steel beams). Pay attention to its
position.Refer to figure 5-2.
1－wood beam 2－plank 3－landing door entrance
Figure 5-2

Installation Manual
b) Install upright at both sides. Connect the jointing sheet on upright with plank. Adjust verticality of
upright to be not more than 1.5mm at every directions. Refer to figure 5-3
A M16×45 16
A B 16 16
C 16 16
D M16 16
B C D Connection
Figure 5-3
c) Hoist cross head to proper height, then put it down slowly. Embed it into the upright and connect
them by bolts. And adjust horizontality of cross head. Deviation of two sides in guide rail direction is not
more than 2 mm, and deviation in posterior direction(width of cross head)is not more than 1 mm. Refer to
figure 5-4.
C B A
V V V
A M16×45 12
B 16 12
C 16 12
Figure 5-4
d) Install the car sheave on the cross head, and adjust the verticality of crosshead sheave to be not
over 1mm. Refer to Figure 5-5.
A 5×45 4
Damping pad 4
B
C Pad 4
A C
V D M24 8
V
B D
V V
Figure 5-5 Installation of car sheave

Installation Manual
e) Installation of car sheave for the load 1200kgs above.

1) Install the bracket of car sheave on the cross head. Refer to Figure 5-6.
Cage sheave support
Crosshead
Damping pad
Ⓒ
Ⓑ
Ⓐ
Figure 5-6 Installation of bracket for car sheave
2) Assembling the car sheave in car sheave bracket. Refer to Figure 5-7.
Conduit Cage sheave
Shaft
Cage sheave support

Crosshead
Figure 5-7 Assembling the car sheave in bracket

Installation Manual
3) Fixing the shaft of car sheave by support. Refer to Figure 5-8
Fixed plate
Figure 5-8 Fixing the shaft of car sheave

4) Install the protecting bracket and cover on car sheave bracket. Refer to Figure 5-9, 5-10
Protecting bracket
Figure 5-9 Installation of the protecting backet
Protecting cover
Figure 5-10 Installation of the protecting cover

Installation Manual
f) Connect the stay with upright and plank. Insert the lower end of stay into the steel pipe of plank
and then fix the upper end with upright by fastener. Adjust the horizontality of the whole cage frame by
adjusting the nuts at the lower end of the stay. And adjust the horizontality deviation of plank to be not
more than 2/1000. After adjustment and confirmation, fasten all fasteners. Refer to figure 5-11 and
figure 5-12
A
B
A A M16×45 4
B 16 4
A M16 8 16 4
C
D M16 4
Figure 5-11 Figure 5-12
5.2 Installation of cage

Cage is mainly composed of car platform, car panel, car ceiling and car top handrail.
Ceiling
Cage panel
Floor
Figure 5-13

Installation Manual
a) fix the cage platform on the plank and adjust the horizonality deviation of plank is not more than
2/1000. Attention: Ⓐ(M12×70 bolt) plays a role of protecting weighing rubber in the process of
installation. So it is necessary to twist four Ⓐ to be level with weighing rubber. And then fix the cage
platform and plank by Ⓑ～Ⓔ fasteners. At last, adjust four Ⓐ to be lower than weighing rubber
20mm. Refer to figure 5-14.
A M12×70 4
B M10×30 8
C 10 8
A 10
D 8
E M10 8
Weighing rubber B C D E
Figure 5-14
b) Installation of sustainer at bottom on the platform

Upright
Platform
A M10×30 8
10
A
B 10 8
B
C 10 8
C
D D M10 8
Figure 5-15
c) Install COP of cage and cage panel. Connect the connecting bracket on COP with columns at both sides
as a whole by Ⓐ～Ⓓ. Then connect them with cage platform and related cage panel. After cage connec-
tion, unscrew Ⓔ by hexagona wrench of 4 first. Then insert hexagona wrench of 8 into the semicircle
hole at the end of COP and lift the COP. And take it out in the cage direction. After qualified adjustment,
load the COP into the connecting bracket. Refer to figure 5-10. Attention: In the process of disassembling,
installing and adjusting COP, it is suggested to enwrap its upper end and prevent scratch of cage panel.

Installation Manual
Column
Connecting bracket
Column
Column
D
B
COP
1. Connect the connecting bracket with Column Composite outline figure of COP
2. Connect COP assemblage with floor and car panel 3. Unscrew Ⓔ
Column
Insert hexagon
wrench as 8
Detail figure of part Ⅰ
A Square neck bolt 12
B 6 12
Part Ⅰ 12
C 6
D M6 12
E M4×16 6
4. Take out COP
Figure 5-16

Installation Manual
d) Installation of car ceiling
e) After completing car ceiling installation, install elements of car ceiling such as junction box,
ventilation fan, sustainer and landing switch. All these elements should be layed smooth vertically and
horizontally. And their vertical deviation is not more than 1mm
Figure 5-17
f) Install the cage top handrail. It is mainly composed of handrails at the left, right and posterior side.
Refer to figure 5-18. In the process of installation, install the left and right side handrails at first. Then,
connect the posterior side handrail with the right and left handrails. At last, install the reinforcement plate.
Refer to figure 5-19
Figure 5-18 Figure 5-19
6 Installation of safety gear

After cage frame has been spliced, install the safety gear.
6.1 Composition of safety gear

safety gear is mainly composed of shift mechanism,linkage mechanism and safety block. The operation
instruction of safety gear refers to manufacturer specification.
6.2 Installation of safety gear

6.2.1 Attentions:
a) Observe the total tolerance quality, rated speed and width of guide rail face indicated on the
nameplate strictly
b) A marked by red paint and nuts at B on the special screw pipe must not be dispatched arbitrarily.
Refer to figure 6-1

Installation Manual
B
Figure 6-1
c) Forbid to use the safety gear as guide shoe in the process of installation.
6.2.2 Installation and adjustment of safety gear

In order to make safety gear protect the down motion from overspeed effectively and prevent the safety
gear from misoperation, you should observe the following steps when installing and adjusting at the
construction site.
a) First insert the safety gear into the guide rail. And then rotate the lower end of lifting rod of
operating mechanism into the special screw pipe M8 of lifting device at the top of safety gear. And the
rotary depth is about 15mm. Then fasten it by M8 nut to avoid the lifting rod loosening in the process of
running. Refer to figure 6-2
A M8 4
Platform
A
Lift rod
Figure 6-2
b) Install the safety gear in the place under the upright. It is not necessary to fasten the bolts and
nuts. Adjust the position of safety gear to make the two wedges of safety gear consistent with the gaps of
guide rail. After adjustment, fasten the bolts and nuts. Refer to figure 6-3
D
C A M12×50 8
B 12 8
B
C 12 8
A
D M12 8
Figure 6-3

Installation Manual
c) Connect the lifting rod with linkage device and make the gaps of two wedges of safety gear with
both sides of guide rail are 3.5±1.5mm separately. Refer to figure 6-4
` Cross Head
A M8 4
Gov. Link
A
Lift Rod
Figure 6-4 Connecting Governor Link

d) Fasten the lifting rod
e) check the position of trigger of limit switch. Make sure the limit switch work reliably while the shift
mechanism of safety gear is working and the limit switch can reset while the shift mechanism of safety
gear is resetting. Refer to figure 6-5
Cross head
Trigger of limit
switch
Figure 6-5
Governor Limit switch Limit switch
f) Fix the overspeed governor wire rope by 3 U-Clips. The distance between each other is 48mm.
Refer to figure 6-6.
48
48
Figure 6-6 Fix U-Clip
g) After installation, lift the lift-rod vertically and make the safety jaw can be lifted up to clamp the
guide rails successfully.

Installation Manual
7 Installation of cage guide shoes
Cage guide shoes guides the cage to run on the guide rails reposefully.There are four cage guide shoes.
Two of them are installed on the beams. And the other two are installed under the safety gear.
After the cage frame has been installed, begin to install the guide shoes. Connect the upper and lower
guide shoes with cross head and safety gear seperately but do not fasten them. After installing and
adjusting the cage frame and cage, regulate bolts to make the both working faces of guide shoes be
consistent with the gap of guide rails. And the gap of one side of guide shoe with guide rail is not more
than 1mm. And then adjust the adjusting bolt at back of guide shoe to make the maximal compressed
value of damping rubber at the back of guide shoe be 0.8mm(It means that,adjust bolts to make the
damping rubber at back to contact with conical part first, and then rotate the bolts half a circle). At last,
fasten the guide shoes. Refer to figure 7-1.
Figure 7-1 Installation of Cage Guide shoe

Installation Manual
Figure 7-2 Completion of cage frame installation
8 Installation of balance weight at platform

If the balance weitht is included in elevator installation, it should be progress after installed cage panel,
plateform, safety device and guide shoe. (The cage panel, safety device and guide shoe have been made
into a transparent parts below drawings as figure 8-1 and 8-2.)
a) Remove the buffer plate in plank to unbolt, refer to figure 8-1
b) The balance weight should be hung on plank at both end.
c) It is fixed by the fixing bracket after “b)”, refer to figure 8-2.
d) Return to install the buffer plate in plank.
Note: If the space is enough to install the balance weight, to omit the progressing as a) and d).

Installation Manual
Plank
Buffer plate
Figure 8-1 Removing buffer plate
Balance weight
Pressing Clip
Figure 8-2 Install fixing bracket for balance weight
9 Vulnerable parts
Table 9-1 List of vulnerable parts
NO. Name Standard
1 Guide shoe DX1 sliding guide shoe

2 bearing 6213-2Z

Traction Machine PMS 215 Installation
Installation Manual (EVO1)
Version: 1.0
Installation Manual
Warning
All operations must be in conformity with the latest national codes on electric engineering, safety rules on elevator
and all related local administrative laws and regulations.
ThyssenKrupp Elevator is the proprietary of all drawings and materials of the manual. Hereby, the company has
rights to take them back anytime. Any organization and individual shall not publish, copy and directly or indirectly
cite contents of the manual or not damage interests of the company in any form.
We try our best to ensure high accuracy and timely update of the manual. However, we shall not take any liability
for adverse impacts brought by errors or omissions of the manual. For any problem in the manual, please contact
ThyssenKrupp Elevator (Korea) as soon as possible!

Installation Manual
Contents
1 General ..................................................................................................................................... 1
2 Product Structure and Work Principle .................................................................................. 2
3 Traction Machine Work Condition.......................................................................................... 2
4 Checking of Traction machine before using ......................................................................... 3
5 The installation of traction machine ..................................................................................... 3
6 Running of Traction Machine ................................................................................................. 6
7 The adjustment of the brake force ........................................................................................ 7
8 The decelerating device of upward over-speed protecting device .................................... 7
9 Maintenance of traction machine.......................................................................................... 8
Appendix A Familiar malfunction and corresponding dispose of traction machine ............... 9

Installation Manual
PMS215 Installation and Maintenance

1 General
Firstly, thank you for using our PMS215 gearless traction machine, in order to make the
user to know much about our product, before using this product, please read this manual
carefully. When you find some problem when using our product, and these problems can’t
be solved by this manual, please contact our service and technical personnel, our
professionals will be happy to serve you.
1.1 Mark explanation

In this manual, the following marks are used for warning and important information symbol,
please pay much attention:
If don’t adopt some protecting measures, would lead personnel

casualty and equipments broken.
If don’t adopt some protecting measures, may lead personnel

injured and equipments broken.
Note, please operate according to the instruction, or may lead

Breakage and danger.
1.2 Safety attentions

Note: the correlative personnel to install, debug, operate and maintain the
PMS215 traction machine should have professional training, only the persons
that know much about the gearless PMS traction machine and have related
aptitude can undertake corresponding work.
The operating personnel should strictly allow the related provisions in the
GB7588-2003, the users out of mainland should obey the related
requirements in standard and correlative provisions of the using region and
country.
The operating personnel should be responsible for the safety requirements of
the PMS traction machine, no matter it is the first time installation, inspection
or it is the henceforth maintenance, if some injury happened or the product
was broken owing to the incorrect operating of the working staff or the
operating behavior doesn’t accord with some related provisions, our company
wouldn’t take on the responsibilities.

Installation Manual
2 Product Structure and Work Principle

The PMS215 gearless traction machine produced by ThyssenKrupp Elevator (Shanghai)
Co. Ltd, is mainly constituted by PMS Motor, Traction sheave and Brake system. We adopt
the high-performance permanent magnet material and special motor structure designing
in the PMS Motor, making it have the merit of low velocity and big torsion. The sheave is
installed on the end of the motor shaft; the arrester is dual circuit disc brake. The work
principle of traction machine is the motor power is transferred to sheave torsion, and the
car is running through the fraction force between the sheave and tight wire. When the
arrester brake the shaft, the elevator stop running and the car held still.
Every performance index of the PMS gearless traction machine accord with the regulations
of the 《GB7588-2003》and《GB/T13435-92》,every traction machine is strictly inspected
before leaving factory, the torsion, brake force, insulation voltage, vibration, noise are
inspected, assuring the product quality and performance accord with the regulation of the
standard.
3 Traction Machine Work Condition

a) Altitude: less than 1000m.
b) The ambient temperature: 0~40℃.
c) Average Relative Humidity per month should not be over 90%.
d) The area around motor should be free from any combustible gases and corrosive vapors.
e) The diameter of the traction tight wire≤1/40 of the sheave diameter, lubricant and other
sundries can’t be smeared on the face of the tight wire.
f) The angle of traction between the car side tight wire and counterweight side tight wire
should accord with related standard regulation; user should check the traction condition
when designing the installation structure of the traction machine(the 2:1 suspension mode
is usually used).
g) The power supply of the traction machine must be provided by special synchronous motor
transducer, and the traction machine worked in the mode of close loop. Using the industrial
frequency power to supply the traction is forbidden, avoiding burn the traction machine.
Figure 3-1 Name Plate Data

Installation Manual
4 Checking of Traction machine before using

a) Check the integrality of the traction machine packaging before opening the packaging box;
see that whether there is breakage and humidity.
b) Check the data on the nameplate, see that if the type of the traction machine accord with
the using requirements.
c) Check that if there is breakage on the structure parts, if the fixing parts have the problem
of becoming flexible or desquamate.
d) Check the insulated resistance of the motor winding and solenoid winding, the
numerical value of the insulated resistance shouldn’t be lower than 0.5 megohm, or they
should be dried.
5 The installation of traction machine

5.1 Installation attentions
The installation of traction machine should be strictly according to the

installation drawings, assuring the dragging conditions meet with the standard
requirement.
The traction machine must be wholly suspended and installed, disassembled

installation is forbidden.
The installation plane of the traction machine should be horizontal, and

relevant decreasing vibration measures are needed.

Installation Manual
5.2 Installation dimension

The installation dimension and sketch map of PMS215 please see the Figure 5-1, Figure
5-2and Table 1, Table 2.
Figure 5-1 the Installation Dimension and Sketch Map of the PMS215
Table 1
Type A(mm) B(mm)
PMS215.02HL-20-2.8 770 159

PMS215.02HL-20-4.4 770 159
PMS215.02HL-20-5.6 780 172
PMS215.02HL-20-8.4 780 172
PMS215.02HL-20-8.9 780 172
PMS215.02HL-20-9.8 780 172
PMS215.02HL-20-11.2 780 172
PMS215.02HL-20-6.8 780 172
PMS215.02HL-20-10.2 780 172
PMS215.02HL-20-10.8 780 172
PMS215.02HL-20-11.9 780 172
PMS215.02HL-20-13.6 780 172
PMS215.02HL-20-7.5 780 172
PMS215.02HL-20-11.3 780 172
PMS215.02HL-20-12.0 780 172
PMS215.02HL-20-13.2 780 172
PMS215.02HL-20-15.1 780 172

Installation Manual
Figure 5-2 the Installation Dimension and Sketch Map of the PMS215
Table 2
Type A(mm) B(mm)
PMS215.02HL-20-2.8 723 101.1

PMS215.02HL-20-4.4 723 101.1
PMS215.02HL-20-5.6 723 101.1
PMS215.02HL-20-8.4 723 101.1
PMS215.02HL-20-8.9 723 101.1
PMS215.02HL-20-9.8 723 101.1
PMS215.02HL-20-11.2 723 101.1
PMS215.02HL-20-6.8 730 108.1
PMS215.02HL-20-10.2 730 108.1
PMS215.02HL-20-10.8 730 108.1
PMS215.02HL-20-11.9 730 108.1
PMS215.02HL-20-13.6 730 108.1
PMS215.02HL-20-7.5 730 108.1
PMS215.02HL-20-11.3 730 108.1
PMS215.02HL-20-12.0 730 108.1
PMS215.02HL-20-13.2 730 108.1
PMS215.02HL-20-15.1 730 108.1
Remark:
1) The brake traction machine in Table 1 used is RSO series round brake, the brake traction
machine in Table 2 used is RSR series square brake.

Installation Manual
6 Running of Traction Machine

6.1 Earth
The traction machine should be well earthed, there is earth device at the bottom-right of
the terminal box, and the foundation bolt of the traction machine can be use for earth if
necessary.
6.2 The connection of the main loop

The traction machine power is supplied by transducer; the three outlets of the traction
machine were connected with the three fan-outs of the transducer, see the figure 6-1.The
diameter of connecting wire should be reasonably chosen according to the rated current
(see the Introduction of the transducer).The connecting terminal should be used in the
connection to assure the reliability. ひ is a thermistor buried in the traction machine,3
thermistors are in series, used for the temperature monitor. The connection of thermistor
please sees the figure 6-1.
Figure 6-1 the connection drawing of PMS215main loop
6.3 The specification of the traction machine overload protection

a) The overload protection pattern: using the thermistor to control the temperature, when the
value of resistance reaches some value, cut off the outer power-supplying loop.
b) Enactment pattern:
The controlling temperature of the thermistor is 120℃.
The range of the cooling value of resistance is: 0-600Ω.
When the temperature of the thermistor reaches 120℃, the value of resistance will
increase sharply and be more than 1.7 kΩ, the signal will cut off the power supplying
loop through outer control.

Installation Manual
6.4 The connection of the brake

The brake was composed of two unattached solenoids and windings respectively control
the two unattached disk brake and linings. The two windings of the solenoids were in-
parallel, the rated voltage of single solenoid winding is DC104V, and the connection please
sees the figure 6-2.
Figure 6-2 the connection of brake
6.5 The inspection of the brake

Check the reliability of the parts connection in brake, see if the manual release device is
flexible; when assuring that there is no error, put through the power supply of the brake,
and see if the brake can run normally, if the brake can’t act when the power was supplied,
the power should be cut off immediately, and check the circuit of the brake, correct the
errors. If there is no problem on the circuit, the reason may be that the travel of the
adjusting bolt is too big; please re-adjust the travel o f the adjusting bolt.
7 The adjustment of the brake force

The brake moment of the traction machine have been adjusted well when it leaves factory,
generally speaking there is no need to re-adjust.
Check if the brake force meets the requirement through the static load test when the traction
machine was installed.
The adjustment of the brake force should be done by the professionals, or may
lead casualty or equipment broken.
8 The decelerating device of upward over-speed protecting device

The regulations in item 9.10 of《GB7588-2003》is “the upward overspeed protecting
device of the car which accords with the following requirements should be installed in
the tractive lift. ”, and the regulations in item 9.10.1 is “this device includes
speed-monitoring device and decelerating device, it can detect the overspeed of the car,
the lower limit is 115% of the rated speed, the upper limit is the speed regulated in item
9.9.3, and the device can make the car stopping, or make the car speed decelerating to
the speed of the design scope of the counterweight buffer.”
In the PMS215 series traction machine, the brake is used as the decelerating device,
because it accords with the regulation of item 9.10.4 and has pass the type test of the
whole lift.

Installation Manual
9 Maintenance of traction machine

a) Keep the surface of the traction machine clean;
b) Keep regular supervision; check the agility of the brake, the abrasion of the lining, the
abrasion of the traction sheave, the working condition of the bearings, replace the abrasion
and broken parts.
c) The damageable parts list is as following:
No. Name
1 Lining
2 Traction Sheave
Attentions
The assembly and disassembly of the traction machine should be done by the
professional person .if assembly and disassembly of the traction machine is needed,
please contact our company or the agent, assemble and disassemble the traction
machine optionally may lead traction machine broken and person injured.
The working temperature of the traction machine winding can’t exceed 120℃. The
temperature can be monitored through the thermistor and proper temperature
monitor.
The traction machine generates electricity if it passively rotates, the handsets of the
traction machine will generate high voltage, and some measures should be taken to
avoid people to get an electric shock or lead outer equipments broken.
There should be no oil pollution or other impurities, avoid leading the brake
force decreasing.

Installation Manual
Appendix A Familiar malfunction and corresponding dispose of traction machine
a) The malfunction that the brake don’t unclose

1) There is no power supply in the EM winding or the voltage is incorrect. Please note
the connection of the brake cable and the voltage.
2) The EM winding is broken (disconnection), using the multi-meter to measure it.
b) The sound of unclosing the brake is too big
The clearance between the lining and its interfaces is not proper, if the brake
clearance is too big, the sound would be bigger.
c) The brake force is inadequate when unclosing the brake
1) The spring force is inadequate，re-adjust and checkout.
2) There is oil and some other sundries, make the friction decreasing. Please note to
clean the sundries.
d) The EM winding is overheated
The voltage of the winding is too high; check the voltage of the winding, the max.
value can’t exceed 1.07 times of the rated voltage.
e) The motor is overheated
1) Check if the transducer current is obviously bigger than the rated current of the
motor.
2) Check if the ambient temperature is overheated.
f) The motor current is too high, obviously higher than the rated current
1) The encoder position is incorrect. Re-fix the encoder and make the encoder
self-study (run by the transducer drivers).
2) The motor is overloaded. Lookup the reasons that make the motor overloaded.
g) The motor wobble abnormally, free-run or have too much noise
There are some problems in the control system.
h) The traction sheave abrades abnormally
1) The traction sheave doesn’t mate with the tight wire.
2) The design of the dragging conditions is unreasonable; the angle of traction isn’t
enough.
3) The tensile force of every tight wire isn’t equal.
i) There is slight vibration on the traction machine
The mechanical frame of the traction machine doesn’t level up or the stiffness isn’t
enough.

Entrance & Door Installation
Installation Manual
Version: 1.0
Installation Manual
Warning

Installation Manual
Contents
1 Attentions ............................................................................................................................ 1
2 Tools preparation ............................................................................................................... 1
3 Safety Point ......................................................................................................................... 3
4 Landing Sill Installation ..................................................................................................... 3
5 Jamb Installation ................................................................................................................ 5
6 Button Box Installation ...................................................................................................... 7
7 Header Case Installation ................................................................................................... 8
8 Landing DOOR Installation ................................................................................................ 8
9 Toe Guard Installation ........................................................................................................ 9
10 Assembly of Car Header Case Installation ..................................................................... 10
Appendix [The detailed DWG of Landing Header Case]...................................................... 12

Installation Manual
Entrance & Door Installation
1 Attentions
2 Tools preparation
Figure 2-1 Tools Preparation
Name：double-ended wrench Name：ladder Name：offset ring wrench
Standard：7×8、10×13、17×19 Standard：7×8、10×13、17×19
Standard：2m
24×30、36×40 24×30、36×40
Name：steel tape Name：steel rule Name：track level bar
Standard：≥5m Standard：150mm Standard：500mm

Installation Manual
Figure 2-1(supplement)
Name：Plumb bob Name：hand chain block Name：suspension band
Standard：700g Standard：hoisting weight≥3t Standard：hoisting weight≥3t
Name：screwdriver Name：electric impact drill Name：angle square
Standard：parallel head、crosshead Standard：12 Standard：315×200
Name：hexagona wrench
Standard：4、8

Installation Manual
3 Safety Point
This is to install machine parts relating the elevator in and around entrance; Landing sill, jamb, entrance,
and opening device. These work should be done precisely and firmly to prevent noise, damage, and ac-
cidents.
The floor for the elevator installment and the structure wall are related with the construction of the build-
ing. It is difficult to revise or change any part after the completion of construction. Careful and deep con-
sideration should be taken into before making any decision on elevator LCD, hall lantern and other op-
tions before their installation.
3-1 Danger
 Since there is no guard, passengers could fall into the elevator passage.
 Fall into the elevator passage.
 A frame or other parts could fall down.
 The stainless steel frame has sharp edges.
 Pay attention when using a hammer drill.
3-2 Precaution
 Install a rail and a screen in front of the elevator passage.
 When the door is open for a maintenance work, there should be a staff to prevent people
from approaching.
 Attach a danger sign.
 The height and strength of the rail should be high and strong enough to prevent people’s
access.
 Put on gloves when working with the door frame, which could have sharp edges.
 Keep the regulations and manual of the work in mind. Follow the instructions.
 Check if there is an emergency gate around the working place.
 When the construction team is working in the elevator passage, the E/L team should watch
their working. Do not let the construction team alone work in the passage.
Figure 2-1 safety rail and screen at the entrance
4 Landing Sill Installation

Installed on the bottom of each floor, it guides the door opening and prevents the car from running
off the track.
Table 3-1 Landing sill length measurement
Landing sill length measurement

Without a back angle OPENING x 2 - 60(mm)
With a back angle OPENING x 2 + 100(mm)

Installation Manual
4.1 Landing Sill Installation

a) To decide the height of the entrance floor, ask advice from the construction manager.
b) Keep the construction finishing line and the floor finishing line in parallel using a water
parallel gauge and an inking line.
c) Check the piano line at the entrance.(LANDING SILL and CAR SILL distance:±30mm)
d) Mark an opening line on the back of LANDING SILL as seen in the Figure
Center line of landing sill
Entrance width
Figure 3-1 Center line of landing sill and entrance width
e) Measure the sizes of the piano line and the floor finishing line.
f) Mark the anchor volt point precisely on the retaining wall at the hall side.
g) Make a hole in the marked point with a hammer drill.
h) After placing the anchor bolt, connect with the first bracket (weld the anchor bolt with
the first bracket)
i) Connect the first bracket to the second bracket.
j) Step of inspection
A. Adjust the first bracket bolt to have 30 mm distance from the end of the sill
using the entrance piano line as a standard line.
B. Unite the opening line marked on the Landing sill and the entrance piano line.
C. Unite the floor finishing line and the second bracket bolt.
D. Adjust the Landing sill to be horizontally level in all directions (front, back, right, a
nd left) using a level gauge
E. Fix the bolts firmly.
Table 3-2 Tolerance of Installation
LANDING SILL tolerance JAMB tolerance

Right and left 30 ± 1.0 Center ± 0.5
Right and left
± 1.0 Right and left slope ± 0.5
equilibrium
Front and back Front and back
± 0.5 ± 0.5
equilibrium slope
Center line
Sill Sill Width
Spot welding
Figure 3-2 Landing sill profile and tolerance

Installation Manual
Landing sill
Landing sill
Bracket
Toe guard
Figure 3-3 Landing sill, Sill bracket and Toe guard
4.2 Landing sill blocking board installation

It is to cover the space between the Landing sill and the revetment of its bottom.
The cover prevents mortar or others from falling down through the gap and causing the elevator malfunc-
tion or accidents.
(1) The board should cover the whole area of the entrance.
(2) Do spot welding with the Landing sill plate.
Wide Jamb Standard Jamb

Figure 3-4 Landing sill blocking board installation
5 Jamb Installation
5.1 Jamb Installation
It is installed at the elevator entrance. There are two types in the Jamb; wide and standard.
(1) Check the condition of the piano line before starting the jamb installation work.
(2) Check if the upper board and the side board meet at right angles to each other after asse
mbling the Jamb
(3) Start the anchor work to fix the Jamb frame. Three at each side (see the Figure 5-2)
(4) Lay the jamb frame 5 mm across the Landing sill and fix temporarily to the bracket with b
olts.
(5) Check if there is a twisted or distorted part in the Jamb frame and fasten the bolts.
(6) Drive a wedge into the gap between the Jamb frame and the wall.
(7) Check the vertical line using a weight.
(8) Fix the supporter and the anchor bolts by welding.
(9) The Jamb frame should not be damaged when welding.
(10) Fill in the gap of the back surface of the jamb frame at the both sides of the entrance.

Installation Manual
Landing sill
Note: The position can be changed according to the size of the jamb frame
Figure 4-1 Anchor bolt point for fixing the jamb frame and welding
Figure 4-2 fix the wide JAMB anchor bolt by welding (bottom, middle, and top)
Figure 4-3 fixing the wide JAMB anchor bolt by welding
Landing
sill
Jamb Bracket
Figure 4-4 Jamb installation (Landing sill Connection) and Slope measurement

Installation Manual
5.2 Jamb frame filling board installation (option)

It is a blocking board which fills in the gap between the Jamb frame and the revetment, and is installed to
prevent mortar or others from falling down through the gap and causing the elevator malfunction or acci-
dents.
If the gap in the upper part of the jamb frame is big, the board should be installed in the upper part of
the frame.
1) The filling board should be marked on its right and left sides to draw cables in and out,
and large enough to cover the whole area hole from the top to the bottom of the opening
hole.
2) Insert the filling board to the support beam of the Jamb frame and press the opposite side
to the wall. (Figure 5-8)
3) Fix 3-5 spots with nails firmly.

Filling board Nail
Wide Jamb Standard Jamb
Figure 4-5 Filling board installation
6 Button Box Installation

1) Identify the place for the button box in the L/P plan.
(The distance from the bottom level to the center of the box - standard: 1200mm, for the disabled:
1000mm)
2) Install 2 anchor bolts for fixing the button box on the revetment.
3) Install the button box 3-4 mm deep from the front wall finishing surface.
4) Fasten the button box on the anchor bolt using the support pole and weld.
5) Check if it is at right angles.(slope tolerance : ± 1mm)
Figure 5-1 Button Box

Installation Manual
7 Header Case Installation

1) Assemble the header case from the top of the jamb frame, mark on the back angle hole,
and fix it with the anchor bolts temporarily.
2) The Head case height tolerance is ±0.1 mm.
3) Adjust the center of the head case with the center of the piano line at the entrance.
4) Adjust the center of the Landing sill with the center of the guide rail. [±0.5 mm]
5) Fasten the bolts firmly after completing inspection.
Figure 6-1 Head Case installation

8 Landing Door Installation
1) Remove the tapes on the door guide shoe of the Landing sill and clean
2) Check the dimensions and distances in the Landing sill and the jamb frame.
3) Dissemble the bolts connecting the header case on the top of the Landing door.
4) Insert the Landing door guide shoe to the groove of the Landing sill. Connect them using t
he bolts in 3) temporarily.
5) Adjust to keep 5 mm distance between the bottom of the Landing sill and the Landing doo
r, using the liner and the bolts in 4).
6) Adjust to keep 5 mm distance between the Jamb frame back surface and the door front.
7) When opening and closing the door, check if there is any projection from the inside wall.
8) When the DOOR is closed, adjust the balance of the left and right surface. Repeat 5) and
6).
9) The DOOR INTERLOCK of the header case should be kept locked.(DOOR CLOSE)
(See the operation manual for INTERLOCK operation)
Door connecting
part
Figure 7-1 Landing door installation

Installation Manual
Back angle
Bracket
Hall Header
Closing weight
Case Assembly
Interlock
Hall Door
Figure 7-2 Completion of Landing door installation
9 Toe Guard Installation

The toe guard is a protective board to prevent passengers from jamming or falling down, when the
elevator stops in an emergency.
1) Let the head cover bolt loose
2) Insert the toe guard into the head cover bolt and fix temporarily.
3) After Uniting the Landing sill and the toe guard holes and fix them with bolts
4) Match to the center line and fasten the bolts firmly.
5) The bottom of the toe guard should be curved backward for safety
Toe
Guard
Figure 8-1 Toe Guard Installation
Landing sill
Toe guard
Landing sill
Bracket
Figure 8-2 Completion of Toe Guard Installation

Installation Manual
10 Assembly of Car Header Case Installation

Car entrance gate open/close device is that rotation of Door machine decrease and operate belt, it is
able to open/close the Car entrance gate.
Location of Door machine is upper side of car door.
The half length of total length of opening size is acceleration and the half length of total length of opening
size is deceleration, during open/close the door, there must not noise.
Due to high frequency of maintained work for Door machine, maintained work must easy and conveni-
ence.
If power failure when door close, to rescue passengers inside of cabin, door must open by manual at out-
side of cabin.
Figure 9-1 Car Header case
(1) Car Door Assembly

1) Temporarily assemble ceiling bracket and door machine bracket.
2) Drop plumb from center line of door machine to car sill center line and make sure tolera
nce is less than ±1.0㎜.
3) Measure distance from each end side of entrance to car sill upper end side and make s
ure tolerance is less than 1.0㎜.
(2) Car entrance assembly

Car door must assemble with Door machine and it is movable parts so it must insert and fix strongly
to car sill.
In order to protect noise during high speed operation, install or painting noisy protection material
and be careful damage of car door surface during transportation and installation.
(3) Car entrance assembly method

1) Assemble Car door guide shoe.
2) Assemble Car door hanger to hanger plate.
3) Car door tolerance of vertical and horizontal must be ±1㎜.
4) When car door close, the center line tolerance of car door and car sill must be ±1㎜.
5) The gap between Car door and jamb must be 5±1㎜.
6) The gap between car sill upper side surface and car door bottom edge side must be 5±
1㎜.

Installation Manual
Door Machine
Assembly
Car Header
Assembly
Light curtain Car Door
Car Door Guide shoe
Figure 9-2 Car entrance gate OP/CL device adjustment
Landing Vane Door Motor
Gate switch
Figure 9-3 Car entrance gate assembly

Installation Manual
Appendix [The detailed DWG of Landing Header Case]

Cable Installation
Installation Manual(EVO1)
Version: 1.0
Installation Manual
Warning
qualified operation certificate, and this manual is hereby handled by certified professionals. In order to
protect you and others, please don’t try any uncertified operation.
All operations must be in conformity with the latest national codes on electric engineering, safety rules on
elevator and all related local administrative laws and regulations.
ThyssenKrupp Elevator is the proprietary of all drawings and materials of the manual. Hereby, the company
has rights to take them back anytime. Any organization and individual shall not publish, copy and directly or
indirectly cite contents of the manual or not damage interests of the company in any form.
We try our best to ensure high accuracy and timely update of the manual. However, we shall not take any
liability for adverse impacts brought by errors or omissions of the manual. For any problem in the manual,
please contact ThyssenKrupp Elevator (Korea) as soon as possible!

Installation Manual
Contents
1 Introduction ..................................................................................................................................1
2 Cable lay-out ................................................................................................................................2
3 Hoist-way cable Installation .......................................................................................................6
4 Travelling cable Installation ........................................................................................................9
5 Cage cable Installation............................................................................................................. 12
6 Detection of Cable Installation ................................................................................................ 15

Installation Manual
Cable Installation
1 Introduction
1.1 Attentions
Table 1-1 Table of Tools Preparation
Name: Steel rule Name: Steel tape Name: Plumb bob

Specification: 300mm Specification: ≥5m Specification: 700g
Name: Diagonal-cutting pliers Name: Electric impact drill Name: Air cylinder
Specification: φ6 drill bit,
Specification: 125mm Specification: Manual
φ10 drill bit
Name: Screw driver Name: Hammer Name: Multi-meter

Specification: Flat tip, cross
Specification: Specification:
head

Installation Manual
2 Cable lay-out
Cables between pulleys are laid in open, and use cable wire mount to cling them to hoistway wall for
fixation, see layout in Figure 2-1.
Governor
Lamp Machine driving
W01
W07 W102
Inverter cabinet
W03
Hoistway power terminal W01.3

junction box
W00.1
W00B W00
Control cabinet
W80.1、W80.2
W07.3
MC2-CPIK*
W07.1/W07.2
Trailing cable
Hoistway cable
Figure 2-1 Drawing of Cable Layout between Pulleys
While wiring W00, W00.1 and W01, the parallel distance with other cables (especially MC2-CPIK*
cable, W07.1, W07.2, W80.1 and W01.3 cable) should be as far as possible, if it intersects other
cables, vertical wiring must be performed in the intersection as shown in Figure 2-1.

Installation Manual
2.1 Cable installation for control cabinet end

Cables are connected in control cabinet by four means:
a) Directly connect cables to terminal blocks, Directly connect power cable to inverter terminal, and then
layout wire along the left side of bed plate of control panel, and use cable clamp to fix it, see Figure 2-2;
Cable clamp
Figure 2-2 Power Cable Fixation by Cable Clamp
b) Connect cables to IOC board in the form of Weidmuller and Phoenix plug-in, and then lay in the wiring
channel on the right side of control panel, see Figure 2-3.
Figure 2-3 Weidmuller and Phoenix Plug-in Connection

c) Connect cables to internal wire of control panel with AMP plug-in, and then place connecting plug-in in the
base of control panel and cover the bed plate, see Figure 2-4.
Figure 2-4 AMP Plug-in Connection

Installation Manual
Besides, for all cables with ground wire and shielding layer, ground wire and shielding layer must be reliably
grounded, see Figure 2-5:
Ground copper bars
Figure 2-5 Cable Grounding Connection
d) Directly connect 15-core D-type plug-in to inverter X917, see Figure 2-6, and lock the plug-in.
15-core
D-type plug-in
Figure 2-6 D-type Plug-in Connection
2.2 Cable installation for machine motor end
While wiring for band-type brake detection switch, firstly unscrew the set screw of the switch, open the lid,
and connect it to normally open contact through cable, cover the lid, lock cable, and then fix the switch. See
Figure 2-7.
Fixed screw of microswitch Normally open contact

Installation Manual
Cable locking screw
Figure 2-7 Brake switch on Motor
Motor power cable, brake coil cable and thermistor cable are respectively connected to the wire terminal of
motor junction box, yellow and green ground wires of power cable must be reliably connected to ground
screw. While power cable gets into motor junction box, shielding layer must be stuck at the wall of motor
junction box with straight joint, and maintain good grounding, see Figure 2-8.
Shielding layer fixation
Ground wire fixation
Figure 2-8 Cable Connection in Motor Junction Box
2.3 Cable installation for governor end

Governor switch cable is directly connected to normally closed contact of governor switch, and ground wire is
connected to ground screw.
Figure 2-9 Cable Connection in Gov. Switch
2.4 Encoder cable layout

Encoder cable directly gets into control panel without passing through wiring channel in machine room, and
is connected to inverter with 15-core D-type plug-in.

Installation Manual
3 Hoist-way cable Installation

Hoist-way cable is laid openly, use cable wire mount to cling it to Hoist-way wall for fixation; in each layer,
one Hoist-way junction box separates landing branch cable from Hoist-way main cable; landing branch cable
also must be fixed with cable wire mount, see Figure 3-1.
Door switch
Final Limit switch
LOP
Hoist-way Cable
LIOP
Fireman switch
or Parking switch
Pit switch
Figure 3-1 Hoist-way Cable
While fixing, firstly use electric drill to drill hole in appropriate position, boring depth should not be less than
40mm, and then use air cylinder to blow the dust off the hole, see Figure 3-2.
Figure 3-2 Processing of Anchor hole

Installation Manual
☞ Note: To use the wedge anchor bolt,

make the anchor hole is the same
I as size of anchor bolt.
3.1 Cable installation for LOP, LIOP board end

For LOP, LIOP board cable installation, if the board is metallic, yellow and green core of cable must be reliably
connected to ground screw; if the board is as in Figure 3-5, yellow and green core does not need grounding,
but cable ground terminal must undergo insulating treatment with insulating tape.
Plastic casing
Insulating treatment
with insulating tape
Figure 3-5 LOP and LIOP
3.2 Hoist-way door lock branch cable installation

Hoist-way door lock consists of master lock and secondary lock, which have been connected in series before
delivery, so branch cable cores of Hoist-way door lock are separately connected to the other two contacts of
master and secondary locks, yellow and green cores are connected to nearby ground screw, reliable
grounding, see Figure 3-6:
Branch cable cores of Connecting wire between master
Grounding
hoistway door lock and secondary locks
Figure 3-6 Contactor of Car door

Installation Manual
Figure 3-6 Contactor of Landing door
3.3 Hoist-way Safety and Limit switch cable installation
Cables are reliably connected to limit switch, anti-rope breaking switch and normally closed contact of buffer
switch, and yellow and green cable cores must be reliably connected to screw in metal support of switch to
serve as protective grounding. See Figure 3-7:
Fixing cable with Limit switch cable

nylon cable tie grounding
Limit switch
Fixing cable with Buffer switch

Buffer switch PVC pipe nylon cable tie cable grounding
Figure 3-7 Safety and Limit Switch

Installation Manual
3.4 Pit cable installation
Install one pit service chamber on pit Hoist-way wall, pit service chamber is equipped with terminal blocks,
so all cables getting into service chamber are connected to terminals according to the marks of cable marker,
and yellow and green cores must be reliably connected to ground screw in the board, and then arranged with
nylon cable ties. See Figure 3-8:
Figure 3-8 Pit Switch

After going out pit service chamber, all safety switch cables in pit are laid horizontally and openly along
Hoist-way wall to be near to Hoist-way wall that is the closest to the switch, and then are vertically laid into pit
ground and then to safety switch, fixed with cable wire mount and nylon cable tie on the way. While installing,
based on the construction conditions, if the pit is easily penetrated by water, consider to lay all safety switch
cables in PVC pipe.
4 Travelling cable Installation
After getting into Hoist-way, travelling cables are hung in upper cable bracket component at the top of
Hoist-way; the other end is hung up in dedicated rack of cable at the bottom of car, the upper middle end is
hung up in +1.5m Hoist-way rack lying in 1/2 of Hoist-way, see Figure 4-1. For installation steps of travelling
cable, see Figure 4-2.
U pper cable bracket comp onent
B ed plat e i n m achine room
Car guide
Spl int
T raili ng cabl e
Overall hei ght of hoi st way
Pl ank
M iddl e cable bracket comp onent
T railin g cable
Lif t ing height / 2+150 0
Cable cl eat com ponent

Pi t depth
Figure 4-1 Cable Layout

Installation Manual
A B C D E
A M12 Four
B 12 Four
C 12 Four
D Four
Pressing clip
guide plate
E M12×45 Four
A M6 Two
B 6 Two
C 6 Two
D Two
M6×40
`
D C B A
D E A M12 Two
B 12 Two
C 12 Two
D Pressing clip Two
E M12×45 Two
A B C

Installation Manual
A M6 Two
D
B 6 Two
C 6 Two
D
M6×40 Two
A B C
A M6 Six
A B 6 Six
B
C 6 Six
C
D
M6×40 Six
Figure 4-2 Installation steps of travelling cable

Installation Manual
a) Travelling cables will move with the lifting of car, while installing, it is required to make it not collide with
and interfere with Hoist-way bracket, deceleration switch, leveling blade bracket, tractive steel wire rope,
speed limit steel wire rope, counterweight housing, pit buffer and other components, otherwise equipment
safety accident will easily happen.
b) The minimum curvature radius of cable is about 300mm, and determine hanging point according to cable
curvature radius.
c) Before installing travelling cable, perform the suspension for relieving stress in advance, then after the
installation, the phenomenon that waved twist and knot happens to cable will be avoid, otherwise while
operating, there will be abnormal shaking, and service life of cable will also be influenced.
5 Cage cable Installation

Car (car roof, platform and operation panel) cable is also laid openly, and connected in service chamber of
car roof by two means:
a) Cable is connected to terminal block, see Figure 5-1, Light-curtain cable, photo-cell switch cable and
power cable of elevator emergency communication alarm system.
Service
轿顶检修箱 chamber in Note: Light-curtain cable must be reliably connected
car roof 注：光幕电缆线必须可靠连接于固定接线端子内！
into fixed wiring terminal
Blue wire
X13
蓝色线
Red wire
48 Yellow
红色线黄色线wire
Orange wire +24 F Orange
橙色线wire
0 VF
White
白色线 wire 白色线
White wire
TX Wire connector
压线帽 RX
轿顶检修箱
Service chamber in Note: Photo cell switch cable must be reliably connected
注：平层开关电缆线必须可靠连接于固定接线端子内！
car roof into fixed wiring terminal
X13
棕色线
Brown wire
2
Blue 蓝色线
wire
3
Black wire
黑色线
5
平层感应器
Photo cell switch
Figure 5-1 Light curtain and Photo cell

Installation Manual
b) Cable is connected with AMP plug-in, and is fixed with nylon cable tie as shown in Figure 5-2, see involved
cable in Table 5-1. Yellow and green cores of all cables with ground wire must be reliably connected to
ground copper bars in car roof service chamber, and the devices are reliably connected to ground screw.
Figure 5-2 Car duct
Line 3
Line 2
Line 1
Figure 5-3 Position of Landing sensor
c) When sensor components are installed in positions ③ and ④ of Figure 5-3, after cables W45B, W45F,
W43 (leveling switch cable) and W77 going out car roof service chamber, they directly go to the back of
beam from the bottom of car frame beam, wiring along car frame to electric devices and fixing with nylon
cable tie on the way.
When induction components are installed in positions ① and ② of Figure 5-2, in the face of car roof service
chamber, all car cables (except that the installation of W77 is not changed) fall from left side of car frame to
car roof, and then layout wire along internal wall of car roof, fixing with nylon cable tie on the way.

Installation Manual
d) Principle of cable wiring: layout along beam and car frame in car roof according to actual situations, try to
layout cables in the position not access to maintenance personnel, and use tie to firmly fix it as shown in
Figure 5-4.
Landing
switch cable
Car lighting cable
Car Duct
Door operator cable
Cross head Door operator
Cable
Figure 5-4 Layout Cable in ceiling
5.1 Safety link cable installation
Cable is reliably connected to normally closed contact of safety gear switch, and yellow and green cores of
cable must be reliably grounded. See Figure 5-5:
Safety gear Cable
switch grounding
Figure 5-5 Safety Link Switch

Installation Manual
5.2 Platform cable installation

Platform interphone cable, load measuring device power cable and communication cable are laid along
external wall of car to platform device, and fix them with nylon cable tie on the way.
5.3 Operation panel cable installation

The section in operation panel of operation panel cable has been installed and tested before delivery, it is
only necessary to connect exposed operation panel cable with car roof service chamber or load measuring
device. For specific cables.
6 Detection of Cable Installation

After finishing cable installation, use multi-meter to detect relative items, and electrifying is allowed after
confirmation.
6.1 Ground wire detection

After finishing cable installation, resistance to ground of all grounding points mentioned in the above must be
less than 4Ω.
6.2 Power detection

Control panel is unpowered, detect that resistance between L1, L2 and L3 phase in inlet terminal block X0 of
main power in control panel is ∞, resistance between phase and neutral wire terminal N is ∞; and resistance
between 1L1 and 1LN in inlet terminal block X2 of lighting power is ∞. Electrify control panel, detect that
phase voltage is 380VAC±7%, and line voltage is 220VAC±7%.
6.3 Safety and door lock loop detection

Make sure that normally closed contacts of all safety switches (buffer switch, anti-rope breaking switch, limit
switch, governor switch, safety gear switch, dead-stop switch, car door lock switch, Hoist-way door lock
switch, etc.) are closed, separately detect that resistance between 104, 111, 120, 133 and 137 terminals of
terminal block X2 in control panel is zero, and resistance with neutral wire terminal N is ∞.
6.4 Hoist-way DC24V power detection

Detect that resistance between terminals +24V and 0V of X1 terminal block in control panel is ∞.

TK-50 Installation Manual Rev 1.1 - EVO1 PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

TK-50 Installation Manual Rev 1.1 - EVO1 PDF

Hochgeladen von

Copyright:

Verfügbare Formate

Evolution1 – Installation Manual

Machine Roomless Elevator

ThyssenKrupp Elevator (Korea)

2 Safety matters need attention .......................................................................................... 1

3 Preparations at construction site ..................................................................................... 2

4 Tools preparation ............................................................................................................... 3

5 Scaffold erection ................................................................................................................ 4

ThyssenKrupp Elevaotr (Korea)

Preparation for Elevator Installation

2 Safety matters need attention

2.2 Maintenance of working environment

2.3 Safety matters need attention in the Hoist-way

2.4 Protection of Hoist-way entrance

2.5 Fire protection

2.6 Management of gas

2.7 Safety prevention

2.8 Test running

2.9 Safety inspection

ThyssenKrupp Elevator (Korea) 1

Wear safety Wear Wear Wear Tie

3 Preparations at construction site

Figure 3-1 Installation flow chart

ThyssenKrupp Elevator (Korea) 2

2 Diagonal cutting plier 160-200mm 2

28 Carpenter's saw 600mm 1

ThyssenKrupp Elevator (Korea) 3

ThyssenKrupp Elevator (Korea) 4

5.1 Layout dimensions of scaffold in the Hoist-way

5.2 Vertical layout dimension of scaffold in the Hoist-way

5.4 Installation of construction lighting.

ThyssenKrupp Elevator (Korea) 5

Figure 6-1 Scheme of templates

6.2 Locate templates and plumbing line

ThyssenKrupp Elevator (Korea) 6

Figure 6-4 Scheme of laying templates on the wooden beams

ThyssenKrupp Elevator (Korea) 7

ThyssenKrupp Elevator (Korea)

1 Preliminary Traction machine Installation ....................................................................... 1

2. Guide rail Installation ...................................................................................................... 16

4 Buffer Installation ............................................................................................................ 42

5. Cunterweigth case, counterweight block and pit screen Installation........................ 45

6. Main rope Installation ..................................................................................................... 51

7. Compensation chain Installation ................................................................................... 56

8 Electrical equipment of shaft .......................................................................................... 59

ThyssenKrupp Elevator (Korea)

1.2 Tool preparation

Specifications: 10×13, 17×19, Specifications of straight Specifications: 10×13, 17×19,

Name: steel tape Name: bow shackle Name: leveling instrument

Specifications: ≥5m Specifications: M－BW3.2 Specifications: 500mm

Name: plumb bob Name: Chain block Name: sling

Specifications: 700g Specifications: rated capacity Specifications: rated capacity

ThyssenKrupp Elevator (Korea) 1

Table 1-1 List of Tools Prepared (Continued)

Name: PMS215 master Name: DAF210 master

Specifications: one set Specifications: one set

1.3 Installation requirements of traction machine

1.4 Install scaffold on the top floor of shaft

Figure 1-1 Top Floor of the Shaft

ThyssenKrupp Elevator (Korea) 2

I-shape steel bars

Figure 1-3 Installation of I-shape Steel Bars

ThyssenKrupp Elevator (Korea) 3

Connecting line of the Central line of the