KONE 3000S/3000X MINISPACE TM AND KONE ECODOM 3000/5000 SCAFFOLDLESS INSTALLATION

Installation AM-01.01.084 All (B) 2005 rights 2008-03-03 3000S/X reserved Instruction Corporation MiniSpace KONE 3000S/3000X MINISPACE TM AND KONE ECODOM TM 3000/5000 SCAFFOLDLESS INSTALLATION 1039265.wmf 1 (359) AM-01.01.084

Confidentiality Notice This proprietary and confidential document is provided to you only for purposes of installing and/or maintaining KONE products and it may not be used or its contents disclosed for any other purpose without KONE's prior written permission. Neither this document nor its contents may be copied or disclosed to third parties for any reason. KONE reserves the right to prosecute any breach of this obligation. Authorization Notice This publication is for informational purposes only. All persons participating in the installation and/or maintenance of KONE equipment and using these instructions must be qualified to perform such work, are required to have received equipment specific training as specified by KONE and must have KONE Corporation's authorization to install and maintain KONE equipment. DISCLAIMER OF WARRANTIES AND LIABILITIES KONE reserves the right at any time to alter the product design, specifications and procedures reflected in this document. NO STATEMENT CONTAINED IN THIS DOCUMENT IS TO BE CONSTRUED AS A WARRANTY OR CONDITION, EXPRESS OR IMPLIED, AS TO ANY PRODUCT, SPECIFICATION OR PROCEDURE, ITS MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OR QUALITY, OR AS A MODIFICATION OR REPRESENTATION OF THE TERMS OF ANY PURCHASE AGREEMENT. KONE DISCLAIMS ANY LIABILITY RESULTING FROM OR IN CONNECTION WITH THE USE OR DISCLOSURE OF INFORMATION IN THIS DOCUMENT. KONE HAS NO LIABILITY FOR TYPOGRAPHICAL OR OTHER ERRORS OR OMISSIONS CONTAINED IN THIS DOCUMENT OR ANYONE'S INTERPRETATION OF THE INSTRUCTIONS. THE USER OF THIS DOCUMENT ASSUMES ALL RISKS ASSOCIATED WITH THE USE OR DISCLOSURE OF THIS DOCUMENT. Trademark Notice "KONE, MonoSpace, MiniSpace, EcoDisc, TranSys, Alta, KoneXion, KONE ECO3000 and all other product names are trademarks or registered trademarks of KONE Corporation in various countries." Copyright Notice Copyright. No part of the contents of this document may be copied, reproduced or transmitted in any form or by any means, or translated into another language or format, in whole or part, without prior written permission of KONE Corporation. 2 (359) AM-01.01.084

LIST OF CONTENTS 1 GENERAL.............................................................. 10 1.1 Related documents...................................................11 1.2 Abbreviations....................................................... 13 2 SAFETY................................................................ 17 2.1 General safety precautions............................................ 17 2.2 Installation method safety............................................. 18 2.3 Recommended working postures and ergonomic methods................... 20 2.4 Danger and personal protection signs.................................... 21 2.5 Special precautions to limit injury in the event of a fall....................... 22 3 SITE REQUIREMENTS AND TOOLS......................................... 23 3.1 Site requirements................................................... 23 3.2 Tools............................................................. 25 4 UNLOADING AND DISTRIBUTION........................................... 37 4.1 Off-loading and distributing materials.................................... 37 5 HOIST INSTALLATION..................................................... 39 5.1 Lists of hoist equipment parts.......................................... 39 5.2 Selecting correct Tirak hoist........................................... 45 5.3 Safety checks...................................................... 46 5.4 Hanging the hoist from a beam in the ceiling (option A)...................... 47 5.5 Hanging the hoist from a beam on the floor (option B)....................... 49 5.6 Overspeed governor................................................. 51 5.7 Testing the hoist equipment............................................ 53 6 PLUMBING.............................................................. 56 6.1 Placing the plumbing template (single elevator)............................ 56 6.2 Plumbing (single elevator from finished machine room or temporary deck)...... 60 6.3 Filling in plumbing table............................................... 61 6.4 Plumbing groups of lifts............................................... 63 6.5 Dividing beams..................................................... 65 7 FIRST GUIDE RAILS AND PIT EQUIPMENT................................... 67 7.1 Preparations for guide rails and pit...................................... 68 7.2 Drilling holes to wall for guide rail brackets................................ 71 7.3 Lifting the first guide rails.............................................. 73 7.4 Bracket combinations................................................ 74 7.5 The first two rings of guide rail brackets.................................. 78 7.6 Fixing the first guide rails.............................................. 79 7.7 Guide rail alignment at the guide rail bracket level.......................... 80 7.8 Checking the car guide rail parallelity.................................... 81 7.9 Aligning the first counterweight guide rails................................ 82 7.10 Buffers........................................................... 84 3 (359) AM-01.01.084

7.11 PB73.3 overspeed governor tension weight............................... 85 7.12 OL35 overspeed governor tension weight................................. 86 7.13 OL100 overspeed governor tension weight................................ 86 7.14 Installing counterweight frame on buffer.................................. 88 7.15 Filling counterweight with 40 % of filler weights............................ 90 8 CAR INSTALLATION, EURECA.............................................. 91 8.1 Assembling upright and bottom beam.................................... 91 8.2 Second upright..................................................... 98 8.3 Car safety gear.................................................... 100 8.4 Car floor.......................................................... 101 8.5 Fixing the automatic safety gear trigger rope to the safety gear linkage......... 104 8.6 Car walls......................................................... 105 8.7 Glass walls....................................................... 107 8.8 Top beam..........................................................111 8.9 Balustrade........................................................113 8.10 Car roof...........................................................116 8.11 Kick plates and finalising the balustrade.................................117 9 CAR INSTALLATION, MCD.................................................119 9.1 Preparations for bottom beam installation................................ 120 9.2 How to use guide clamp............................................. 121 9.3 Installing car sling CF10UP........................................... 123 9.4 Installing car sling CFE10............................................ 133 9.5 Installing car floor.................................................. 140 9.6 Positioning car floor................................................. 141 9.7 Wall panels....................................................... 143 9.8 Car roof.......................................................... 143 9.9 Top beam......................................................... 143 9.10 Upper isolations.................................................... 146 9.11 Car front installation................................................ 147 9.12 Balustrade and skirtings............................................. 147 9.13 Lifting pockets and guide rail securing chains............................. 147 10 THIRD RING OF GUIDE RAIL BRACKETS.................................... 148 10.1 Installing bracket on machine side..................................... 148 10.2 Aligning guide rails................................................. 151 11 HOIST ATTACHMENT, EURECA CAR....................................... 152 12 HOIST ATTACHMENT, MCD CAR.......................................... 155 13 GUIDE RAIL INSTALLATION............................................... 157 13.1 Second ring of guide rails............................................ 158 13.2 Installation and use of automatic safety gear trigger........................ 159 13.3 Fixings under the Eureca car......................................... 165 13.4 Fixings under the MCD car........................................... 166 4 (359) AM-01.01.084

13.5 Guide rail clamps................................................... 168 13.6 Intermediate guide rails.............................................. 168 13.7 Topmost guide rails................................................. 171 13.8 Checking guide rail installation........................................ 172 13.9 Bottom pulley beam and travelling cable hanger, Eureca car................. 173 13.10 Preparing the machine and the car for transportation....................... 175 13.11 Transporting machine to the topmost floor............................... 177 14 MACHINE ROOM INSTALLATION.......................................... 178 14.1 Transporting machine and control panel to machine room................... 179 14.2 Fixing machine.................................................... 180 14.3 Plumbing machine.................................................. 182 14.4 Fixing rope anchorages.............................................. 183 14.5 Fixing control panel................................................. 184 14.6 Closing machine room holes.......................................... 185 15 BRAKE ADJUSTMENT................................................... 186 15.1 Fixing the brake release cable to the brake release lever.................... 186 15.2 Installing the brake release cable to the machine.......................... 187 15.3 Main construction of the brake........................................ 188 15.4 Checking the stroke of the brake....................................... 188 15.5 Adjusting the stroke of the brake....................................... 189 15.6 Closing the brake.................................................. 191 15.7 Adjusting the manual brake release device............................... 192 15.8 Checking the operation of the manual brake control........................ 193 15.9 Checking after the brake is adjusted.................................... 193 16 LANDING DOOR INSTALLATION........................................... 194 17 CAR SILL AND FRONT WALLS INSTALLATION, EURECA CAR.................. 195 17.1 Car sill........................................................... 195 17.2 Car front walls..................................................... 196 17.3 Completing the car front installation.................................... 199 18 CAR SILL AND FRONT WALLS INSTALLATION, MCD CAR...................... 201 19 CAR DOOR............................................................ 202 20 MACHINE ROOM ELECTRIFICATION V3F16L DRIVE ELEVATORS............... 203 20.1 Installing main switch unit............................................ 205 20.2 Connections at the controller.......................................... 206 20.3 Connections at the main switch........................................ 208 20.4 Routing and connecting the machine cables.............................. 210 20.5 Overspeed governor wiring........................................... 212 20.6 Connecting travelling cable........................................... 212 21 MACHINE ROOM ELECTRIFICATION V3F25S DRIVE ELEVATORS............... 213 21.1 V3F25S control panel............................................... 214 21.2 Installing main switch unit............................................ 215 5 (359) AM-01.01.084

21.3 Connections at the controller.......................................... 216 21.4 Connections at the main switch........................................ 218 21.5 Routing and connecting the machine cables.............................. 220 21.6 Overspeed governor wiring........................................... 223 21.7 Connecting travelling cable........................................... 224 22 ELEVATOR SHAFT ELECTRIFICATION...................................... 225 22.1 Travelling cables................................................... 225 22.2 Support channels and trunkings for group elevators........................ 226 22.3 Trunking and elevator shaft wiring...................................... 227 22.4 (OSS) out of service switch and (OSI) out of service indication at landing....... 232 22.5 (PRL) priority landing call cables....................................... 232 22.6 (FRD) fireman s drive switch cables from landings......................... 233 22.7 Optional devices in the machine room.................................. 233 22.8 Installation in the pit................................................. 234 23 SIGNALLING DEVICES AT LANDINGS (KDS)................................. 236 24 CAR ELECTRIFICATION, EURECA CAR..................................... 237 24.1 Install the magnet switches on top of the car roof.......................... 237 24.2 Installing the car top connection box.................................... 238 24.3 Install the electrification on the car roof.................................. 240 24.4 Connect into the car top connection box................................. 241 24.5 Install the provision for lift announcer................................... 242 24.6 Install the intercom socket on the car roof................................ 242 24.7 Connectors on LCECCB board........................................ 243 24.8 Curtain of light..................................................... 244 24.9 Routing the cables of the curtain of light................................. 247 24.10 Install the ramps and magnets (driving up)............................... 249 24.11 Wiring of door operator and curtain of light (or photo cell)................... 251 24.12 Options.......................................................... 251 25 CAR ELECTRIFICATION, MCD CAR........................................ 252 25.1 Installation under the car............................................. 252 25.2 Car operating panel installation........................................ 254 25.3 Magnet switches, oscillators and final limit switch on the car roof............. 255 25.4 Connections in the car top connection box............................... 258 25.5 Final adjustment of magnets, oscillator vanes and final limit switch ramps....... 259 26 INITIAL COMMISSIONING OF THE MACHINE (WITHOUT ROPES), V3F25S........ 260 26.1 Health and safety at work............................................ 260 26.2 Check list......................................................... 261 26.3 Connecting supply cable(s) from building................................ 261 26.4 Tests and checks when driving the motor for the first time with RDF........... 261 26.5 Motor first drive.................................................... 262 26.6 Tests and checks when driving the motor for the first time on inspection drive.... 263 6 (359) AM-01.01.084

27 ROPING............................................................... 265 27.1 Roping principle.................................................... 265 27.2 Preparations in the machine room..................................... 265 27.3 Attaching the compensation chain under the Eureca car (optional)............ 266 27.4 Routing the ropes under the car....................................... 267 27.5 Positioning car for roping............................................. 268 27.6 Routing the ropes to the counterweight pulley............................ 270 27.7 Roping the counterweight pulley....................................... 271 27.8 Lifting the counterweight frame........................................ 273 27.9 Shortening the ropes................................................ 274 27.10 Attaching the compensation chain to the counterweight..................... 275 27.11 Finalising the roping................................................ 276 27.12 Slack rope switch.................................................. 277 28 CAR INTERIOR INSTALLATION, EURECA CAR............................... 278 28.1 Ceiling........................................................... 278 28.2 Mirror and handrails................................................ 278 28.3 Skirting installation................................................. 282 28.4 Handicap seat and the top beam cover.................................. 283 29 CAR INTERIOR INSTALLATION, MCD CAR................................... 284 30 CHECKING MACHINE BRAKE AND REMOVING HOIST......................... 285 30.1 Checking the machine brakes......................................... 285 30.2 Dismantling the hoist from the car...................................... 285 30.3 Changing the temporary installation time overspeed governor to the final one (OL100 or PB73.3)......................................................... 287 31 BALANCING............................................................ 289 31.1 Balancing the MCD car............................................. 289 31.2 Adding extra weights to MCD car sling.................................. 291 31.3 Balancing car and counterweight...................................... 292 31.4 Counterweight screen............................................... 293 31.5 Finalising the travelling cable installation................................ 294 32 COMMISSIONING, V3F16L................................................ 295 32.1 Health and safety at work............................................ 295 32.2 Commissioning with construction-time power supply....................... 296 32.3 Commissioning.................................................... 296 32.4 Temporary adjustment of the load weighing device........................ 302 32.5 Driving the elevator for the first time.................................... 303 32.6 Adjusting the load weighing device..................................... 304 32.7 Setup............................................................ 306 33 COMMISSIONING OF THE MACHINE AFTER ROPING, V3F25S.................. 307 33.1 Checks before commissioning........................................ 307 33.2 Preparations...................................................... 307 7 (359) AM-01.01.084

33.3 Emergency light battery.............................................. 308 33.4 LON protocol...................................................... 308 33.5 Drive commissioning................................................ 309 33.6 Levelling accuracy setting............................................ 309 33.7 External options.................................................... 309 33.8 Group connections................................................. 310 34 FINAL STEPS OF COMMISSIONING........................................ 312 34.1 Balancing the empty car and counterweight.............................. 312 34.2 Adding filler weights to the counterweight to correspond to 50 % of rated load... 313 35 COMMISSIONING OF THE CAR DOOR...................................... 315 36 SAFETY INSPECTION, V3F16L............................................ 316 36.1 Standards and rules................................................ 316 36.2 Prerequisites...................................................... 316 36.3 Safety........................................................... 316 36.4 Visual check (Annex D1.c and d, Annex D2.a, b and c)..................... 317 36.5 Measuring insulation resistance of the main supply (Annex D2.f).............. 318 36.6 Measuring insulation resistance of the safety chain (Annex D2.f).............. 318 36.7 Short circuit test (Annex D2.f)......................................... 318 36.8 Checking the running clearances...................................... 319 36.9 Checking the car and counterweight balancing............................ 320 36.10 Readjusting GAIN setting of the load weighing device in the middle of the elevator shaft.................................................................. 320 36.11 Speed measurement (Annex D2.e and h3)............................... 321 36.12 Checking levelling accuracy (±5 mm)................................... 322 36.13 Readjusting OFFSET setting of the load weighing device................... 322 36.14 Upper limit switch check (Annex D2.g).................................. 323 36.15 Traction test with empty car (Annex D2.h)............................... 323 36.16 Thermistor test.................................................... 324 36.17 Drive time supervision test........................................... 324 36.18 Lower limit switch check (Annex D2.g).................................. 325 36.19 Motor current measurement (Annex D2.e and h3) (V3F16L)................. 326 36.20 Preparations for combined traction test and braking test with 125 % load (Annex D.d and h)............................................................... 327 36.21 Combined traction test and braking test with 125% load (Annex D.d and h)..... 328 36.22 Preparations for car safety gear test (Annex D2.j)......................... 328 36.23 Car safety gear test (Annex D2.j)...................................... 329 36.24 Re-setting the elevator after car safety gear test.......................... 331 36.25 Readjusting the load weighing device setting............................. 332 36.26 Test of alarm devices (Annex D2.m).................................... 333 36.27 Counterweight safety gear test (Annex D2.k)............................. 333 36.28 One-sided braking test with rated load.................................. 335 36.29 Car overspeed governor test (Annex D2.i and n).......................... 335 8 (359) AM-01.01.084

37 SAFETY INSPECTION, V3F25S............................................ 337 38 HANDOVER AFTER INSTALLATION........................................ 338 39 APPROVALS AND VERSION HISTORY...................................... 344 APPENDIX A. Fuses and LEDs.................................................. 345 APPENDIX B. Electrification panels, introduction.................................... 351 APPENDIX C. TROUBLE-SHOOTING INSTRUCTION / VERTICAL VIBRATIONS MX10 elevators with V3F18 or V3F25 drive.......................................... 359 9 (359) AM-01.01.084

1 GENERAL The installation method described in this instruction is designed to ensure an efficient, trouble-free installation, whilst maintaining safe working practices. This is a general instruction which can be used for KONE 3000S/3000X MiniSpace and KONE EcoDom 3000/5000 elevators (MX10 machine, V3F16L/V3F25S drive, rated speed 1.0..2.0 m/s, maximum travel height 100 m). Some of the components may differ from those that are described in this instruction. In these cases refer to the delivery documents or component level AM instructions. Follow this instruction. If it is necessary to deviate from the method a carefully designed, risk assessed, method statement must first be obtained from your front line management. To ensure trouble-free and effective installation the following are mandatory. Requirement The site must be 100 % ready. Transport routes on site must be defined and agreed as close as possible to the elevator shaft. Elevator shaft tolerances must be checked by the project engineer. Delivery must be complete and on site. Installation start date must be agreed with the customer. A locking off system for main electric supply isolator, or other system (for example fuse removal, locking and tagging system, etc. when applicable), must be agreed with main contractor before installation commences. Installation tools must be available on site. Recommended hand tools must be available. Personal safety equipment must be available. Lockable machine room door in place. Note See INSTALLATION PREREQUISITES on page 20. Refer to AM-01.03.002 Take 5. Refer to chapter Installation tools. Refer to chapter Hand tools (recommended) 10 (359) AM-01.01.084

1.1 Related documents Safety and product related information is contained in the following documents. It is mandatory to follow the AM safety instructions and safety related information included in the Tirak manual. Component Document Document ID Fall prevention systems Safety instruction AM-01.03.001 Take 5, Electrical safety Safety instruction AM-01.03.002 Using Tirak hoist for man Safety instruction AM-01.03.003 riding purposes - Rescue instruction AS-01.01.030 Tirak X750 hoist Tirak manual - Tirak X1000 hoist Tirak manual - Tirak X2000 hoist Tirak manual - Installation clamp 654068 Installation instruction AM-09.04.006 Safety gear SGB01, Installation instruction AM-07.04.015 SGB02, SGB03 (car) Safety gear SGB08 (car) Installation instruction AM-07.04.024 MX10 machine Brake adjustment AM-04.08.021 Augusta landing door Installation instruction AM-03.12.047 AMDL landing door, Installation instruction AM-03.12.066 design 2 packages AMD car door Installation instruction AM-03.12.067 Drive 1 electrification Electrical installation, commissioning AM-03.35.022 (AMD door) and troubleshooting instruction Drive 1.5 electrification Electrical installation, commissioning AM-03.35.024 (AMD door) and troubleshooting instruction Curtain of light Installation instruction AM-03.17.011 (delivered with the curtain of light) Eureca car cladding panels Installation instruction AM-06.01.007 Counterweight CWF10 Installation instruction AM-08.01.008 cladding panels KONE Polaris destination Installation instruction AM-12.20.010 control system EBD-E, emergency battery Installation instruction AM-13.30.008 drive Kone remote monitoring Installation instruction AM-13.25.007 Shaft vanes Shaft vane diagrams (delivered to the local front line office) - 11 (359) AM-01.01.084

Component Document Document ID Wiring Wiring diagrams - (delivered to the local front line office) Drive V3F25S Parameter table 870043 Drive Commissioning and safety inspection AM-11.65.024 instruction for drive system V3F25S Drive V3F16L drive parameters 784393 Drive V3F16L drive fault codes 804611 LCE LCE fault codes 813138 LCE LCE user interface menu 813131 KDS signalling devices Installation Instruction AM-12.20.007-CHN AM-12.20.008-CHN AM-12.20.009-CHN Product related maintenance instructions and spare parts lists: Component Document Document ID AMD car door and landing Maintenance instruction AS-03.12.036 doors Spare parts, landing door AR-03.12.076 Spare parts, car door AR-03.12.037 EuReCa car 2.0 Maintenance instruction AS-06.06.006 Spare parts manual AR-06.06.003 MX10 machine Rope replacement AS-09.03.003 Spare parts manual AR-04.06.002 LCE electrification Maintenance instruction AS-10.22.006 Spare parts manual AR-10.22.006 V3F16L drive system Maintenance instruction AS-11.65.009 Spare parts manual AR-10.22.008 V3F25S drive system Maintenance instruction AS-11.65.001 Spare parts manual AR-11.65.008 12 (359) AM-01.01.084

1.2 Abbreviations 1.2.1 General C D B A 1007039.wmf Abbreviation Term Unit Definition FFL finished floor level CL central line DBG distance between guide rails A marking of entrance usually main door e.g. A-door/side B marking of entrance e.g. B-door/side C marking of entrance opposite main door e.g. C-door/side D marking of entrance e.g. D-door/side 1.2.2 Elevator shaft and car Abbreviation Term Unit Definition elevator shaft SH headroom height mm the vertical distance between the finished floor at the highest level served and the roof of the elevator shaft PH pit depth mm that part of the elevator shaft located under the lowest landing level served by the elevator WW elevator shaft width mm the horizontal distance between the inner surfaces of the elevator shaft walls measured parallel to the car width 13 (359) AM-01.01.084

Abbreviation Term Unit Definition WD elevator shaft depth mm the horizontal distance between the inner surfaces of the elevator shaft walls measured parallel to the car depth H travel height mm sum of interfloor distances HF floor to floor mm usually given as a minimum distance car CH car clear height mm BB car clear width mm DD car clear depth mm NE toe guard height mm car and landing door sills Elevator shaft vertical dimensions Frame doors Front doors PH PH HR HH HF HF CH HH H SH CH HA HB HH HA HB HB H SH 1018229.wmf 1018231.wmf 14 (359) AM-01.01.084

1.2.3 Landing door Elevator shaft horizontal dimensions 1007042.wmf Topmost floor Abbreviation Term Unit Definition FW front wall width mm FW1 front wall width mm FW2 front wall width mm FD front wall depth mm LR door raw opening mm LR=WW-2*FW or WW-(FW+FW1) width HR door raw opening mm height LL door clear opening mm width HH door clear opening height mm 15 (359) AM-01.01.084

1.2.4 Machine room NOTE! Some of the details on this page may differ from your local solutions. Refer to the layout drawings. MW MH MD FFL 1038381.wmf Abbreviation Term Unit Definition M/R machine room MH machine room height mm clear height under the beam or hook MW machine room width mm MD machine room depth mm 16 (359) AM-01.01.084

2 SAFETY 2.1 General safety precautions Safety precautions Follow your national lift codes and other safety related regulations. Note In case of conflict between the Code and the present commissioning instructions, rely on your Code. Refer to your local procedures for the type of entrance protection required. Warning signs highlight possible hazards. (See page 21.) The local safety codes and rules must be obeyed at all times! Follow the method described in this instruction. Follow this instruction. Do not skip any step, otherwise there may be a potentially dangerous situation which you have not considered. ENSURE THAT ELECTRICAL EQUIPMENT AND CONDUCTORS ARE SAFELY DE-ENERGISED BEFORE WORKING ON THEM. Refer to AM-01.03.002 "Take 5 Electrical Safety When Working on Elevators". The following 5 steps must be taken in the specified order unless there are essential reasons for doing otherwise. Take 5 steps to ensure electrical safety: 1. Disconnect the power supply completely. 2. Secure it against re-connection. 3. Verify that the installation is de-energised. 4. Check requirements for earthing in special circumstances. (This operation may only be carried out by qualified personnel in co-operation with the person responsible for the building electrification who must ensure that the technique can be safely employed in this situation.) 5. Provide protection against adjacent live parts. A locking off system for main electric supply isolator or other system (for example fuse removal, locking and tagging system, etc.) must be agreed with main contractor before installation commences. 17 (359) AM-01.01.084

Safety precautions Do not connect or disconnect any connectors when the power is ON. Note Personal safety equipment must be available and used as required. The rust protection must be removed from the rails. Otherwise, the safety gear will not operate correctly. NEVER WORK UNDER A SUSPENDED LOAD OR AT DIFFERENT LEVELS AT THE SAME ELEVATOR SHAFT! Ensure that the lifting equipment is correctly rated for the task and in good condition. Always use the hoist in accordance with your local regulations! Refer to AM-01.03.003 Take 2 - safe working when using Tirak hoists for man riding purposes. Take care handling the waste in accordance with the local regulations. Refer to the list of Personal safety items on page 19. Refer to specific safety notes. Additional safeguards ensure that there is no unwanted movement of the car due to hoist control or other failure. 2.2 Installation method safety Special feature The car is used as the working platform. The installation hoist is positioned on the car roof and an additional securing rope is attached to the machinery lifting eye. The installation hoist is suspended from lifting eye in top of the elevator shaft. The elevator s own overspeed governor and safety gear are used during installation. The automatic safety gear trigger is used to engage the safety gear when required. Note Do not drive on the car roof until the balustrade is fitted and the safety gear is connected. The installation hoist is used to move the car during the initial stages of the installation. Refer to AM-01.03.003 Take 2. 18 (359) AM-01.01.084

Special feature The parking chain is used to secure the car to a car guide rail bracket whenever the hoist hook is disconnected from the car. Note When working from the car roof you must always park the car using both the parking chain and the safety gear before disconnecting the hoist hook. Emergency descent from the car roof. Guide rails are lifted using the car. When moving the car on manual brake release, do not let it overspeed. (The maximum recommended speed is 0.6 m/s.) Do not leave the brake open. (Try to limit the motor rotation to 1 second intervals.) P17000182.wmf At certain times the hoist hook is removed from the car whilst it is still used as a working platform. During these operations the safety gear must be engaged and the parking chain must be used. If there is a power failure on site, it is always possible to move the car to a lower landing level using the brake release lever. For emergency descent refer to the Tirak handbook. Guide rails are fitted in the conventional way using the sliding clamp to lift each rail. The topmost guide rails are lifted using the guide rail clamp. 19 (359) AM-01.01.084

2.3 Recommended working postures and ergonomic methods These recommended working postures and ergonomic methods has been identified to contribute a better workplace and your well-being. Working height Adjust height of working to enable your hands to be within the vertical area of chest and belt buckle. Working distance Adjust working distance to enable the object to be within length of forearms. Lifting Focus on the lift, even if the lifted object is light! 1. Go close to the lifted object 2. Use your legs 3. Keep your back untwisted and straight 4. Keep both feet on the same lane Loading of transport cart Slide the component onto the KONE transport cart instead of lifting it. Carrying 1. Keep the lifted object as close to the body as possible 2. Keep your back untwisted and straight Moving heavy objects without a handle If the object doesn't contain a handle, push/ slide the object instead of pulling. NOTE! If work is being carried out by kneeling, with bent back/legs or with hands elevated above chest or object is further than length of forearms, ensure to limit time of exposure and alternate the working postures. Make sure that the working area is unobstructed and not hindering you. 20 (359) AM-01.01.084

2.4 Danger and personal protection signs Danger signs Danger Sign Danger Sign Danger Sign Electric shock Risk of falling Magnetic field Risk of fire General hazard warning Corrosion Dermatological risk Suspended load Entry prohibited Squeezing hazard Safety gloves, overall, safety shoes with ankle protection, safety helmet, safety goggles, dust mask, hearing protection and safety harness are provided for your personal protection. USE THEM AS REQUIRED. Personal protection signs Mandatory Sign Mandatory Sign Mandatory Sign Safety helmet Overall Dust mask Hearing protection Fall prevention equipment Safety shoes with ankle protection Safety goggles Safety gloves Rubber gloves First aid kit Tirak mandatory inspection The words WARNING and CAUTION are used to highlight possible hazardous situations to persons or equipment as follows: WARNING CAUTION This is to warn about serious safety hazards. This is to warn about damage to equipment which may also involve a safety hazard. 21 (359) AM-01.01.084

2.5 Special precautions to limit injury in the event of a fall WARNING If the safety harness and its associated equipment are not used correctly you may still sustain severe injury or death during a fall. Requirements Always use the harness attached to an approved fixing point whenever there is a risk of injury from a fall. Refer to AM-01.03.001. It is recommended that you attach the harness to a fixing point at least 2.0 m above the working height. Where this is not possible keep the lanyard AS SHORT AS POSSIBLE to minimize your free fall. (Be aware of the effect of rope and harness stretch when estimating the likely drop area and consider the risks from possibly dangerous striking points such as guide rail brackets.) If you are likely to fall down the side of the car or scaffolding platform level you must try to minimize the free fall distance to 300 mm or less. If you have attached the harness to a guide rail bracket or other fixed point in the elevator shaft you must ensure that there cannot be any unwanted movement of the elevator car. When your safety harness is not secured to a life line or other approved fixing point, ensure that the lanyard does not cause a catching or tripping hazard. Do not share life lines. a1184b4.wmf 22 (359) AM-01.01.084

3 SITE REQUIREMENTS AND TOOLS 3.1 Site requirements The site inspection should take place at least one week before the installation is scheduled to start. NOTE! Whenever possible the machine and control panel should be lifted into the machine room before the roof is erected. If that is not possible, lift machine and control panel up in the elevator shaft and place on the topmost landing before any other work commences. The following things must be ready before starting the installation: Requirement Adequate lighting and 3 -phase power supply must be temporary or permanent positioned for both the lift and the installation hoist according to the layout drawing. Lifting eye or lifting beam must be positioned in the machine room ceiling according to the layout drawing and marked with the safe working load. NOTE!Beams under the machine are not always required. Refer to the layout drawings. Note Where required, the elevator shaft lighting can be lowered from the top floor and temporarily secured to the plumbing jig supports. A a1184a1.wmf 1039114.wmf Finished floor marks must be on each landing. Elevator shaft and pit must be cleaned and pit waterproofed. The elevator shaft must be watertight. 23 (359) AM-01.01.084

Requirement For group elevators setting out grid lines must be marked on the lowest common floor area. C-inserts (if used) must be correctly positioned and cleaned. Suitable material storage areas must be agreed with builder, adjacent to the elevator shaft. Suitable storage area must be provided for installation tools. Clear, unobstructed access routes to at least one entrance, at or next to the ground floor, for long or bulky items, (guide rails, car components, doors etc.), must be defined and clear of obstructions. Landings must be protected with coverings according to the local safety codes and regulations. Note Manual transportation of material should be done within 20 metres or close range from the elevator shaft. Fit temporary barriers wherever temporary protection is removed or landing doors have to remain open. It is recommended that entrance protection is imperforate. 1100 530 100 a1196d5.wmf Elevator shaft dimensions and tolerances must be in accordance with layout drawings. Suitable provision for disposal of waste materials must be available. Appropriate fixing points for safety harnesses must be available. According to the local requirements. 24 (359) AM-01.01.084

3.2 Tools 3.2.1 Installation tools MonoSpace tool box 1007065-1.wmf 25 (359) AM-01.01.084

MonoSpace tool box O 40 mm 1010241.wmf 26 (359) AM-01.01.084

Extension 1 installation tool box 1018253.wmf 27 (359) AM-01.01.084

Extension 2 installation tool box 1018261.wmf 28 (359) AM-01.01.084

MonoSpace tools Pcs. Tool Figure 1 1 1 Automatic safety gear trigger Drawing number: 803140G01 Brake wire rope bracket Drawing number: 803144G01 Brake wire rope Drawing number: 772277G01 1007069.wmf 1 Rope fixing plate Drawing number: 803146 1 Parking chain 2 m, 1500 kg 1027222.wmf 1007070.wmf 2 Plumbing supports (pit) Drawing number: 716177G01 1 Counterweight guide rail alignment tool Drawing number: 716180G01 1007072.wmf 1 Counterweight guide rail positioning tool Drawing number: 716175G01 1007074.wmf 4 1 Eyebolts for car 4 x M12 (male) Eyeloop for car 1 x M10 (female) + M10 T-bolt Drawing number: 266824 1007075.wmf 1007077.wmf 29 (359) AM-01.01.084

MonoSpace tools Pcs. Tool Figure Hoisting chains: 1 Extension chain 1.5 m, 500 kg Drawing number: 266827 1 Shortenable chain 2 x 1.5 m, 500 kg Drawing number: 266826 1 Car/door installation chain 2 x 0.5 m, 500 kg Drawing number: 266825 1 Guide rail lifting clamp for guide rails T82-T89 Drawing number: 716165G01 1007078.wmf 2 Shackle 13 mm tap, 1500 kg Drawing number: 754257H02 1007079.wmf 1 Shackle for car roof rope reeler securing, 8 mm tap, 500 kg Drawing number: 754257H03 1 Rope grip for rope reeler securing, 9 mm or 14 mm For correct type see drawing number: 754257H01 1 Hoist test bracket Maximum load 2000 kg Drawing number: 716157G01 1007081.wmf 1007082.wmf 1007083.wmf 1007084.wmf 30 (359) AM-01.01.084

Extension tools Pcs. Tool Figure 1 Extension for counterweight guide rail alignment tool Drawing number: 763082G01 P17000183.wmf 1 Hoist test bracket Maximum load 4000 kg Drawing number: 762395G01 2 Guide rail clamps Drawing number: 654068 1011800.wmf 1011810.wmf 1 Rope cutter 1018279.wmf 2 Plumbing supports (pit) Drawing number: 716177G01 1007072.wmf 31 (359) AM-01.01.084

Extension tools Pcs. Tool Figure 2 Rope grips 1 Car parking chain 2 m, 2500 kg P17000192.wmf 1 Hoist testing chain 2 m, 4000 kg 1 Tirak hoist suspension beam Length = WD, elevator shaft depth 1007070.wmf 1011819.wmf For use of suspension beam see layout drawings. 2 2 Guide rail securing to car roof Drawing number: 773444G01 Guide rail lifting pocket Drawing number: 762396G01 1039259.wmf 2 Shackle Maximum load: 1000 kg Size: D=10, d=11, a=16, C=36 Order number of Bjornsteel: G4161-1T P17000195.wmf 1011817.wmf 32 (359) AM-01.01.084

Other installation tools Pcs. Tool Figure 1 Installation hoist, Tirak X series 750 kg capacity + pulleys. (Optional) See hoist equipment parts on page 39. 1 Installation hoist, Tirak X series 1000 kg capacity + pulleys. (Optional) 1007086.wmf See hoist equipment parts on page 41. 1018293.wmf 1 Installation hoist, Tirak X series 2000 kg capacity + pulleys. (Optional) See hoist equipment parts on page 43. 1011796.wmf 1 Manual chain hoist, capacity 500 kg. Height from hanging hook to lifting hook maximum 270 mm (when the lifting hook is fully raised). Lifting and manoeuvring chain length 5.0 metres. 1 Material hoist Supplied locally For lowering suspension rope from machine room in high travels. 4 G clamp 1007087.wmf 1007097.wmf 33 (359) AM-01.01.084

Other installation tools Pcs. Tool Figure 1 Site trolley Drawing number: 834454 Work stool 1007088.wmf 1 set MX10 machine transporting wheels Drawing number: 715802 1007089.wmf 2 Steel pit prop 80x80x6 mm, supplied locally. 2000 mm 1007090.wmf 1 Battery tool Cable (Drawing number: 859326) and 9V battery (supplied locally) Used with construction-time power supply. 1029362.wmf 1039959-1.wmf 4 Guide blade aligner clamp Type AMF-6800 Supplier: Björnsteel, Finland 1011798.wmf 34 (359) AM-01.01.084

Other installation tools Pcs. Tool Figure 1 Guide rail lifting clamp Drawing number: 733160G01 (maximum load 500 kg) for rails T82-T127 Drawing number: 736196G01 (maximum load 500 kg) for rails T127-T140 1011809.wmf 3.2.2 Tools delivered with the elevator Pieces Tool Figure 1 Car guide blade aligner Drawing number: 803400G01 1 Counterweight guide blade aligner Drawing number: 803400G02 1011821.wmf 1 or more Plumbing templates (In case of through-type car additional templates are provided) Drawing number: 803134 * 1011822.wmf *) Additional template for throughtype elevator a1184a2.wmf 35 (359) AM-01.01.084

3.2.3 Installation time equipment Pcs. Tool Figure 1 Temporary overspeed governor OL100 or PB73.3 for installation time OL100 use (used if elevator rated speed is 1.75 m/s). Tripping speed 0.98 m/s. PB73.3 Use OL35 as an installation time overspeed governor by using smaller groove *). *) OL35 1043109.wmf 3.2.4 Hand tools Refer to KOS-000029 KONE hand tool sets for installation and maintenance purpose. 36 (359) AM-01.01.084

4 UNLOADING AND DISTRIBUTION Introduce yourself to the site agent. Familiarise yourself with the site facilities, the local rules, safety requirements and site management procedures. NOTE! For personal safety and to prevent any damage to the components. Keep the working areas clear and unobstructed. Never go under any suspended load. Use correct manual lifting techniques. Wear gloves. Always wear a helmet. Wear safety harness and fix it to an approved fixing point while working in areas where there is risk of injury from a fall. Wear goggles and dust masks as necessary. Use hearing protection as necessary. 4.1 Off-loading and distributing materials 1 Off-load the material. 2 Check that the delivery is complete with the material documentation. Complete the check form for return to factory. Do not open the packages until you are ready to install the equipment. 3 Complete the site readiness audit form. Return it to KONE projects engineer. 4 Position the tools and materials to correct levels according to the following list before the installation commences. It is important that the tools and materials are positioned according to the installation sequences to achieve and maintain a controlled installation environment throughout the installation. Suitable arrangements must be made for the safe transportation of materials to all floors. 37 (359) AM-01.01.084

A Machine room Control panel Overspeed governor and rope Car and counterweight rope anchorages Installation beams (if applicable) A B Topmost landing Elevator shaft lighting (if applicable) Tirak hoist diverter pulley MonoSpace tool boxes Extension 1 tool box B C Entrance / Storage area MX machine Alignment tools Guide rails, brackets and fish plates Counterweight and filler weights Landing doors to each landing Elevator shaft electrification Compensation chain (if applicable) Tirak hoist Car sling Car Car door and door operator Car operating panel Installation clamps Ropes Extension 2 tool box Working stool Automatic safety gear trigger Parking chain (Extension 1 tool box) Guide rail lifting clamp (MonoSpace tool box) C 1039115.wmf 38 (359) AM-01.01.084

5 HOIST INSTALLATION 5.1 Lists of hoist equipment parts 5.1.1 Tirak X750 Pos. Item Greifzug s component no. 1 Diverter pulley including the safety rope 33009 2 Electric hoist 3 Tension weight 57497 4 Manual rope reeler for maximum 60 m 30158 rope 5 Safety pin no. 2. 6 mm 12056 6 Electric supply extension cable for main 16537 power supply, 45 m, 5 x 1.5 mm 2 7 Pendant controller 8 Extension cable for the pendant control 9 Car adapter for the hoist 53877 10 Car adapter for the hook 53887 11 Adapter axle 72415 12 Split pin 6.3 x 40 63496 13 Diverter pulley Ø160 mm 53997 14.1 Safety pin 5 x 32 mm for diverting pulley 63656 14.2 Safety pin no. 2. 6 mm 12056 15 Tension weight pulley Ø130 mm 20205 16 Tension spring (guide for rope from bottom of Tirak) 8363 Suspension Minimum Tirak rope length 2:1 2 x elevator shaft height 39 (359) AM-01.01.084

Tirak X750 with adapters for elevator installation (2:1 suspension) 1. 7. 2. 6. 8. 5. 16. 12. 3. 4. 10. 11. 9. P17000140-1.wmf 40 (359) AM-01.01.084

5.1.2 Tirak X1000 Pos. Item 1 Diverter pulley, 2:1 pulley with swivel hook, MC2.0 W code 2 Electric hoist Tirak X1033 P, Speed: 9/18 m/min (50 Hz), 35/70 ft/min (60 Hz) *) Fixing bore Ø18 and shackle 2 t 3 Tension weight, 11 kg 4 Manual rope reeler for max. 100 m rope 5 Hoist anchorage kit 6 Electric supply extension cable for main power supply 7 Pendant controller 8 Extension cable for the pendant controller 9 Safety rope for diverter pulley, 3 m, with hook Suspension Minimum Tirak rope length 2:1 2 x elevator shaft height 41 (359) AM-01.01.084

Tirak X1000 with adapters for elevator installation (2:1 suspension) 6 2000kg ø150 309 ø10 9 7 1 1000kg 7 315 60 8 67 2 297 49.5 40..... 585. 370 195 * 292 11 185 5 4 3 1018312-2.wmf 42 (359) AM-01.01.084

5.1.3 Tirak X2000 P Pos. Item 1 2:1 diverter pulley with swivel hook (approx. 6 kg/13.5 lb) 2 Electric hoist (approx. 150 kg/330 lb) Speed: 6/12 m/min (50 Hz) or 23/45 ft/min (60 Hz) *) Fixing bore Ø30 for shackle 8.5 t **) 4 x spacers to position the hoist and hook anchorage in sling 3 Tension weight (approx. 22.5 kg/50 lb) 4 Manual rope reeler with wire rope, Ø14 mm (e.g. 60 m wire rope, approx. 55 kg/120 lb) 5 Hoist anchorage kit 6 Electric supply extension cable for main power supply 7 Pendant controller 8 Extension cable for the pendant controller 9 Safety rope for diverter pulley, 3 m, with hook Suspension Minimum Tirak rope length 2:1 2 x elevator shaft height 43 (359) AM-01.01.084

Tirak X2000 P with adapters for elevator installation (2:1 suspension) 4000 kg 8 6 132 1 14 9 483.5 7 400 2 * 216 132 1154 5 4000 kg 195 21.5 2000 kg 2000 kg 4 3 ** 50 mm 1018318-2.wmf 44 (359) AM-01.01.084

5.2 Selecting correct Tirak hoist Verify that you have the correct hoisting application prior to installation. If in doubt about the required hoist capacity and load to be hoisted contact you supervisor or local engineering support function. You must never start installation unless all correct hoisting equipment are available. 1 Calculate the required Tirak hoist capacity in the following situations: Machine transportation using the car (G1): G1 = Fmax + FT + MX - Q - n x door Roping (G2): G2 = Fmax + FT + ropes - Q Guide rail installation (G3): G3 = Fmax + FT + car guide rails + counterweight guide rails - Q - n x door G1, G2, G3 = load to be lifted with Tirak hoist (kg) Fmax = mass to be gripped (kg), refer to the KONE intranet (EDMS), Component Order Tool (COT), safety gear label or Elevator Supply Unit. FT = weight of two fitters and tools (kg) = 250 kg MX = weight of machine and package (kg): MX10 = 370 kg Q = rated load of the elevator (kg), refer to the layout drawing n = number of car doors ( ) door = weight of a car door (kg) = 130 kg ropes = weight of hoist ropes (kg), see the following table car guide rails = weight of 10 m of car guide rails: T125 = 180 kg; T89 = 123 kg counterweight guide rails = weight of 10 m of counterweight guide rails: T82 = 86 kg; HT60 = 32 kg 2 Select the Tirak hoist type and suspension according to the biggest load (G1, G2 or G3). See the hoist capacity in the table on page 46. If the machine transportation to the topmost floor is done using the site crane, select the Tirak hoist type and suspension according to the bigger load (G2 or G3). 45 (359) AM-01.01.084

Travel (m) Weight of hoist ropes (kg) 10 50 20 79 30 107 40 136 50 165 60 194 70 223 80 252 90 281 100 310 Hoist type Suspension Hoist capacity (kg) Tirak X750 2:1 1500 Tirak X1000 2:1 2000 Tirak X2000 2:1 4000 5.3 Safety checks Make the following safety checks. Item Requirement Risk Lifting equipment and Must be load marked, tested Falling loads. suspension eyes. and in good condition according to local requirements. Hoist and lifting equipment. Must be tested according to local requirements. Plugs and cables. Must be in good condition. Electric shock. Emergency stop button and limit switches (if applicable). Safety harnesses and ropes. Must prevent movement of hoist when contacts are open. Must be inspected and in good condition. When used, they must always be securely attached to approved fixing points. Uncontrolled movement of hoist/car. Falling. 46 (359) AM-01.01.084

5.4 Hanging the hoist from a beam in the ceiling (option A) 1 Transport Tirak rope, reel and pulley to top floor. 2 From the machine-room drop a lifting rope to the top floor. 3 Attach one end of a 5000 kg lifting chain to the pulley hook. 4 Attach the other end of the lifting chain to the lifting rope. 5 Place Tirak rope around the pulley. 6 Pull the pulley to the machine-room and secure it to a 4000 kg lifting beam. Protect the edges of the hole against falling objects. 7 One fitter lowers the rope from the top floor to the pit by feeding the rope by hand, while another fitter fixes the rope hook to the Tirak suspension bar. 8 Temporarily fix the Tirak rope to prevent it from running through the pulley. 9 Uncoil rest of the Tirak rope from reeler and feed down to pit. 10 Feed rope tail through Tirak. NOTE! Take care that the rope does not gather too much momentum. 47 (359) AM-01.01.084

5 6 4 1 7 2 8 3 a1184a3.wmf 1. Suspension beam for lifting eyes 2. Plumbing template 3. Lowest landing 4. Chain, rated for 4000 kg load 5. Lifting trolley, supplied locally 6. Beam clamp, supplied locally 7. Chain, rated for 4000 kg load and timber packing 8. Suspension beam and safety rope of the pulley Refer to your local engineering support function for exact method of suspending hoists. 48 (359) AM-01.01.084

5.5 Hanging the hoist from a beam on the floor (option B) 1039227.wmf 1 Transport Tirak rope, reel and pulley to top floor. 2 From the machine-room drop a lifting rope to the top floor. 3 Lower the power supply cable (from the hole, that is for the main power supply) to the bottom landing. Allow an extra 3 metres of power supply cable at the bottom landing to reach the car roof later in the installation sequence. 49 (359) AM-01.01.084

4 Connect the power supply to the hoist and check the operation of the hoist Be careful when unwinding the rope from the rope reeler. safety functions. 5 Attach one end of a 5000 kg lifting sling to the pulley hook. 6 Attach the other end of the lifting sling to the lifting rope. 7 Place Tirak rope around the pulley. 8 Pull the pulley to the machine-room Protect the edges of the hole against falling objects. 9 Put a U-beam through the lifting sling. Protect the sling from sharp corners with wood. Secure the beam to the floor. When the floor is not load-bearing, fix the U-beam to the support beams. 10 Clip the securing hook over the lifting eye in the machine room. 11 One fitter lowers the rope from the top floor to the pit by feeding the rope by hand, while another fitter fixes the rope hook to the Tirak suspension bar. 1039228.wmf NOTE! Take care that the rope does not gather too much momentum. 12 At the topmost landing, temporarily fix the Tirak rope to prevent it from running through the pulley. 13 Uncoil rest of the Tirak rope from reeler and feed down to pit. 14 Feed rope tail through Tirak. If the hoist motor does not run, reverse two phases in the plug by rotating the phase changer in the plug housing. P17000107.wmf 50 (359) AM-01.01.084

5.6 Overspeed governor WARNING If rated speed of the elevator is 1.75 m/s use temporary overspeed governor for installation time use. Tripping speed 0.98 m/s. OL100 PB73.3 1043110.wmf WARNING If the overspeed governor type is OL35 always use the smaller groove *) during the installation. *) OL35 1043111.wmf 51 (359) AM-01.01.084

1 Place and fix the overspeed governor in position on the machine room floor or onto the beams. Position I-beams to machine room floor, if required. Refer to the layout drawing. PB73 1038644.wmf 1040050.wmf OL100 OL35 2 Ensure that the tripping direction is correct from arrow on governor. 1043095.wmf 52 (359) AM-01.01.084

3 Lower one end of the overspeed governor rope down the pit. 4 Lower the other end of the overspeed governor rope down the pit and secure the rope ends. 5.7 Testing the hoist equipment If the lifting eye or suspension element for the Tirak diverter pulley has not been tested and certified, perform and record the test. The test ensures that the hoist equipment will take the maximum load hoisted during the installation. WARNING No one is allowed to be in the lift well during this test. 53 (359) AM-01.01.084

1 Install the hoist test bracket on the lift well wall on the guide rail side in the height of 1-1.4 metres from the pit floor. *) Tirak X750 or Tirak X1000: M12 bolts or Halfen screws **) Tirak X2000: Expander bolts HSA-F M16x140, 4 pcs * ** 1-1.4 m 1050137.wmf 2 Attach the dynamometer / test plate (breaking strength 2000 kg or 4000 kg, supplied locally) to the hoist test bracket. 3 Shorten the parking chain to 300 mm. 4 Connect the car parking chain (capacity 1500 kg) to the dynamometer / test plate. In case of Tirak X1000 or Tirak X2000 use the hoist testing chain (capacity 4000 kg). 5 Step out of the pit. 6 Drive the hoist slowly upwards until the hoist ropes are under tension. Take up the tension smoothly. Any sudden loadings may damage the equipment. 1009536.wmf 54 (359) AM-01.01.084

7 Run continuously until the load limit of the Tirak hoist is reached or the test plate breaks. Motor power supply is automatically The hoist can now be used for material transportation. Do NOT use the hoist for man riding until: disconnected. Drive the hoist The hoist and hook are correctly downwards to reset it. secured to the car sling (See section 9 Attaching hoist to car sling on page 155). The overspeed governor is connected to the safety gear. The ASGT is fitted and operating 1010613.wmf correctly. 55 (359) AM-01.01.084

6 PLUMBING 6.1 Placing the plumbing template (single elevator) 1 Open template. 2 Place the templates upside down on the floor. Rivet plates from the under side of the template. 4x 3 Position the template to its approximate position. DBG 1011829.wmf 60 A C/L 4 Check the template dimensions in the layout drawing. LL 1011830.wmf 56 (359) AM-01.01.084

5 Through-type car (if applicable): Assemble and place the second template in position. Fix the templates together using screws. Check the template dimensions in the layout drawing. 1 2 1028956.wmf 1. Plumb line holes for landing doors 2. Alignment holes for A-side and C-side templates 57 (359) AM-01.01.084

6.1.1 Lowering the plumb lines 1 Lower all the plumb lines using the outside holes Ø1.5 mm. Use light weights. 2 For long travel or windy conditions stabilize the weights using water buckets. 1011831.wmf 3 Tie the plumb wire back using the securing holes. 1 1 2 2 1011832.wmf 1. Plumb wire for car guide rail 2. Plumb wires for door 58 (359) AM-01.01.084

For dimensions A and B refer to the layout drawings. 1 1 A B DIM A B mm 1. Plumb wires for car guide rail 2. Plumb wires for door 2 2 a1184a4.wmf 59 (359) AM-01.01.084

6.2 Plumbing (single elevator from finished machine room or temporary deck) 6.2.1 Plumbline checking 1 Measure the lift well at each floor. 2 When it has been established that all sill entrances are correct. Secure the template to the floor. Use expander nails for concrete (delivered with the template when fixing to concrete) and wood screws for the wooden floors. 3 Locate and position the counterweight template. Measure from the car plumblines (refer to layout drawing). Secure the template to the floor. 4 Secure the plumb lines to the support brackets in the pit. Check the distance between the plumb lines (A + DBG + A): Guide rail T82 - A is 40 mm. Guide rail T89 - A is 40 mm. Guide rail T125 - A is 50 mm. Guide rail T127 - A is 60 mm. Guide rail T140 - A is 70 mm. A+DBG+A LL 1011834.wmf 60 (359) AM-01.01.084

6.3 Filling in plumbing table Step Action 1 Control the elevator shaft dimensions to ensure that the lift is installed in its optimum position. 2 Refer to the layout drawing and fill the nominal dimensions in the table. Fill in the other rows according to the measurements. 3 Keep the recorded measurements with other lift documentation. Elevator number: Measured by: Date: NOTE! *) Do not forget to measure the C-side and offset of the car and landing door centre lines. C4 C5 C * C6 C3 C1 = C2 SH = D B H D B PH WW A1 A3 A4 A2 WD A5 A A6 1007141.wmf 61 (359) AM-01.01.084

Pos. SH H PH WW WD Measured (mm) Nominal dim. Level 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A1 A2 A3 A4 A5 A6 B D C1 C2 C3 C4 C5 C6 62 (359) AM-01.01.084

6.4 Plumbing groups of lifts 1 Ensure that all the front plumb lines of the elevators are in line. C L C L C L 1007143.wmf 2 Construct a line at right angles to the elevator shaft centre-lines as close as possible to the front walls of the elevator shafts. Work from a reliable reference point, (for example the building grid lines). C L 1007144.wmf 3 Measure out from each centre-line and mark the door clear opening width of each opening on the reference line. C L C L C L LL 1007145.wmf 63 (359) AM-01.01.084

4 Measure from each plumb line to the respective mark on the grid line. If all the measurements are equal the plumb lines are in line and aligned to the building grid. 1007146.wmf = = = = = = 5 Make your plumbing charts for each elevator as before. 6 For elevator shafts on opposite sides of a common lobby, check the plumb line alignment of the adjacent elevators as before. Then measure across the lobby between the plumb lines. (Distance D). If it is necessary to move the template in one elevator shaft all the templates must be moved exactly the same amount. The centre-line must come in the middle of the plumb lines and measurements D must be equal. C L C L C L = = D D 1007147.wmf = = 64 (359) AM-01.01.084

6.5 Dividing beams WARNING Always work with two cars at the same level to ensure work safety and sharing of the work tasks. 1 Measure and mark out the beam centre line and height on the front and rear walls of the elevator shaft. Refer to the WARNING!Use safety harness. layout drawing. 2 Install the wall brackets, (drilled holes and expanding bolts or C-inserts and T- bolts). *) Use shim plates if necessary. 3 Check that the brackets are vertically and horizontally level and in line and level with each other. 4 Remove the upper bolts from the wall brackets. P04000185.wmf 5 Lift the beam into position using the Tirak hoist and soft sling (canvas or nylon). Daily check the condition of the sling and discard it if it is defective. P04000186.wmf 65 (359) AM-01.01.084

6 Check for level and alignment. Measure back from the plumb lines and from the edges of the cars (when working on the car roof). 1028589.wmf 66 (359) AM-01.01.084

7 FIRST GUIDE RAILS AND PIT EQUIPMENT 1029422.wmf 67 (359) AM-01.01.084

7.1 Preparations for guide rails and pit WARNING Do not work beneath suspended loads. Wear harness whenever there is risk of injury from a fall. Ensure that there are no tripping hazards. 1 Clean the guide rails and fish plates. Check that the guide rails are straight. 1009623.wmf 1250 1250 700-900 1010405.wmf WARNING!The rust protection must be removed from the rails. Otherwise the safety gear will not operate correctly. The working method necessitates repeated engagement of the safety gear and even safety gears designed for oiled guide rails will not function under these conditions unless the guides are clean. CAUTION!The guide rails and fish plates must be cleaned thoroughly using the cleaning fluid delivered on site for that purpose. Do not use other non-approved cleaning fluids. WARNING!Work in a well ventilated area and follow the instructions delivered with the cleaner. 68 (359) AM-01.01.084

2 Dress the guide rail joints. 1016904.wmf 3 Check that the guide rails are straight horizontally and vertically and that they are not twisted. 4 Install the fish plates to the guide rails. Tighten the bolts hand tight. 1011864.wmf 5 Clamp the alignment tool to a car guide rail. Adjust the DBG and check that the tool is parallel to the guide. Refer to the layout drawing. 1038862.wmf 1029426.wmf 6 Set the counterweight guide rail positioning tool to correct length. 1009625.wmf P17000201.wmf 69 (359) AM-01.01.084

7 Install clamps to the guide rail blade aligners. Add shim plates for different guide rail sizes: T140-1B = 2 shim plates T140-2B = 4 shim plates T140-3B = 4 shim plates Remove rubber cover from guide blade aligner clamp. 1030000.wmf 70 (359) AM-01.01.084

7.2 Drilling holes to wall for guide rail brackets 1 Place the first 2 rings of guide rail brackets on the pit floor. 2 Transfer the plumb wire position to the wall using a square. 3 Mark out the height of the plumbing support and guide rail brackets. Extend the marks (including the mark for the rear counterweight bracket) along the wall using spirit level. Measure from plumb wire to both side wall and front wall. This measurement is used later to reposition the plumb wires. 1029433.wmf 4 Use the square mark and transfer it to the drilling positions. 5 Drill the holes for the brackets. Refer to the Table of drilling dimensions. 1029434.wmf 71 (359) AM-01.01.084

Table of drilling dimensions Dimension X Dimension A Dimension B 720 mm 618 mm with extension 270 mm 440 mm with extension 77 mm 162 mm with extension X A B X 1600 mm 550 mm X 60 mm 80 mm 110 mm A B 1035683.wmf Bracket data: - drilling depth 75 mm - hole diameter 19 mm Assemble unpainted surfaces against each other to increase friction After guide rail alignment paint the unpainted surfaces a1184a5.wmf 72 (359) AM-01.01.084

7.3 Lifting the first guide rails 1 Tie the draw wire to the sliding clamp to help pulling it back down the guide rail when the hoist is lowered. NOTE! Clamp type depends on guide rail size. 2 Prepare to lift the guides in to the pit using the sliding clamp, fish plates up. 1007158.wmf 3 If there is insufficient space in the pit to place all the guide rails at the side and rear of the car, start with the first 2 runs of guide rails only. 1029436.wmf The rest of the guide rails can be positioned in the pit later when the car has been moved up the elevator shaft. Refer to the layout drawing. 73 (359) AM-01.01.084

7.4 Bracket combinations Combination guide rail brackets 205...370 1038971.wmf 230...390 a1184l.wmf 74 (359) AM-01.01.084

Counterweight guide rail brackets 1038972.wmf 115...300 a1184m.wmf 75 (359) AM-01.01.084

Car guide rail brackets (single side) 80...110 50...80 1029442.wmf 245 165 125 85 1029443.wmf 76 (359) AM-01.01.084

Car guide rail brackets (single side) 80...170 145...375 a1184k.wmf 77 (359) AM-01.01.084

7.5 The first two rings of guide rail brackets 1 Fix the guide rail brackets to the wall. If Ensure that the combination side needed fit shim plates. brackets are level in both planes. 1057179.wmf 78 (359) AM-01.01.084

7.6 Fixing the first guide rails 1 Lift the car guide rail. If oil cups are delivered, install them now. If clip on plastic trays and bottles are delivered, they will be fitted later. Refer to the delivery documents. a1184a7.wmf 2 Position and fix the car guide rails to the brackets. 79 (359) AM-01.01.084

7.7 Guide rail alignment at the guide rail bracket level A 60 a1184a9.wmf 1 Clamp the car guide rail aligner between the guide rails at each bracket level. Ensure that there is no gap between guide rail and clamping bolt. Ensure that the aligner is level. 2 Align the guide rails according to the plumb lines. Verify the distance between guide rails (DBG) with the car guide rail aligner. 80 (359) AM-01.01.084

7.8 Checking the car guide rail parallelity 1 Place the rail aligner against the guide rail blade. 2 Check the parallelity by referring to the alignment tool surface using 300 mm square. 3 Adjust the parallelity. 4 Tighten the bracket bolts. 5 Check the parallelity from opposite side. 6 Tighten the bolts. The guide rail is aligned when: The plumb wires align with the notches of the alignment tools. DBG is correct. (Tolerance is ±0.5 mm) The guide rails are parallel with rail aligner. 1011883.wmf 81 (359) AM-01.01.084

7.9 Aligning the first counterweight guide rails 1 Fix and tighten the first counterweight guide rail to the combination bracket. 2 Fix the rear counterweight guide rail to the bracket using the clips. 3 Clamp the alignment tool in the middle of the two counterweight guide rails (at the same height with the bracket). 4 Align the counterweight guide rails with the alignment tool and the diagonal positioning stick. 1029472.wmf Hold one side of the diagonal positioning stick against the rail and move the other end against the other rail up and down. The other end should just touch the rail face. 5 Tighten the rear counterweight guide rail bracket. 6 Check DBG at bottom using alignment tool. 1029473.wmf 82 (359) AM-01.01.084

7 Repeat the alignment at the second guide rail fixing. 1029474-1.wmf 8 Re-check the alignment at the first guide rail fixing position. Re-align if necessary. 83 (359) AM-01.01.084

7.10 Buffers NOTE! Polyurethane buffers are used when the elevator rated speed is 1.0 m/s. Oil buffers are used when the elevator rated speed is more than 1.0 m/s. 1 Lift the buffers into the pit using the Refer to the layout drawing. hoist. 2 Install the buffers: Mark the centre line of DBG. Position the base. Fit the buffer. Check level and shim if necessary. CAUTION! Check the oil level using dipstick or oil level indicator. Add oil if necessary. Use oil resistant gloves and avoid contact with skin. Make sure not to exceed the maximum oil level indicated on the dipstick or oil level indicator. 1007174.wmf 1043068.wmf 1054rrr.wmf 84 (359) AM-01.01.084