AM-01.01.250 A

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KONE MONOSPACE®, RELEASE 3.0

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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.

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. 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.

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."

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1 GENERAL

The single and flexible man 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 MonoSpace® release 3.0 elevators.

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.

All installation tasks must be controlled and verified during installation by filling in the QD-181.211 which is used as a checklist before:

– commissioning – safety inspection

– handover to maintenance and customer

1.1 Abbreviations

1.1.1 General

Abbreviation Term Definition

FFL finished floor level

CL central line

DBG distance between guide rails

A marking of entrance e.g. A-door/side usually main door, always MAP side B marking of entrance e.g. B-door/side

C marking of entrance e.g. C-door/side opposite main door D marking of entrance e.g. D-door/side

A B1 B2 C2 D2 D1 C1 1078299.wmf

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1.1.2 Elevator shaft and car

NOTE: For more information on following cases, see AM-01.01.256:

- low pit devices

- low headroom, SH  3320 mm

- small car, BB  900 mm or DD  1000 mm

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

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

distance

mm given as a minimum

car

CH car clear height mm

BB car clear width mm

DD car clear depth mm

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Elevator shaft vertical dimensions

Frame doors Front doors

HH CH SH H HF PH HR 1007040.wmf HB HB HB SH HH CH HH PH HF H HA HA 1007041.wmf

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1.1.3 Landing/front and frame door

Elevator shaft horizontal dimensions, front door

LW from clear opening to elevator shaft wall mm

LW1 from clear opening to elevator shaft wall mm

LD side wall depth mm

LR door raw opening width mm front door case LR=WW

HR door raw opening height mm

HA front door lintel height mm

HB front door extension height mm

LL door clear opening width mm

HH door clear opening height mm

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1.1.4 Additional abbreviations

MAP = maintenance access panel SEP = shaft electrification panel

Elevator shaft horizontal dimensions, frame door

FW front wall width mm

FW1 front wall width mm

FD front wall depth mm

LR door raw opening width mm LR=WW-2*FW or WW-(FW+FW1)

HR door raw opening height mm

LL door clear opening width mm

HH door clear opening height mm

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1.2

1.3 Daily installation order guide

1.3.1 Single man schedule

The table below indicates phases of the installation.

Elevator Prerequisites to meet the schedule

Elevator shaft

5 floors, 12 m travel, single side entrances

Complete on time / error free delivery Door type AMDL1 or AMDL2, frame non fire

rated, installation with expander bolts for guide rails and landing doors

Installation site fulfilling the 5 Site Absolutes

Car interior

One handrail and one mirror Fitter has installed 5-8 units prior. Working within allocated working hours.

Day Action

1 Arrival at site, transporting tools, receiving delivery. Installing man riding hoist, installing overspeed governor. Setting the lasers.

Plumbing and establishing plumbing table.

Installing first guide rail brackets and pit ladder, preparing counterweight frame. Installing and aligning first lengths of guide rails and brackets. Installing buffers and counterweight frame.

Installing sling and installing overspeed governor. 2 Installing car and initial loading of the counterweight.

Waste material handling.

Installing automatic safety gear trigger.

Attaching man riding hoist to car and installing third ring of guide rail brackets. Installing car interior.

Installing working light to the car roof.

Installing and aligning guide rails and brackets to intermediate floors. 3 Installing topmost floor lengths of guide rails and brackets.

Transferring the overspeed governor to its final position and setting the rope to final length.

Installing car sill.

Installing machine and rope fixings. Installing landing door sill brackets.

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1.3.2 Flexible man schedule

The table below indicates in which phases of the installation two men are required and when the installation can be undertaking by a single man.

4 Installing landing doors.

Installing car front wall and car door. Installing last landing door.

Installing trunking and elevator shaft lighting. Waste material handling.

5 Installing MAP, SEP and drive panels.

Installing elevator shaft top wiring and brake lever.

Installing travelling cables, elevator shaft wiring and signalization. 6 Installing car wiring and setting positioning system and ramps.

Installing pit wiring. Waste material handling.

Installing car electrification and car operating panel.

7 Placing filler weights inside the car for balancing operations, roping. Closing the brake, re-checking the brake lever operation, safety checks, commissioning and removal of tools.

Balancing and final steps.

Cleaning down the elevator shaft and disposal of waste materials. Safety inspection (assistance with test weights).

Day Action Task split

fitter 1 / 2

1 Arrival at site, transporting tools, receiving delivery. 1 2 Installing the man riding hoist, installing the overspeed governor. 1 2

Setting the plumbing jig. 2

Cleaning guide rails and mounting fish plates. 1

Plumbing and establishing plumbing table. 2

Installing first guide rail brackets and pit ladder, preparing counterweight frame.

1 Installing and aligning first lengths of guide rails and brackets.

Installing buffers and counterweight frame.

1 2

Installing sling and installing overspeed governor for single man working.

1 2

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2 Installing the car and initial loading of the counterweight. 1 2

Waste material handling. 1

Installing the automatic safety gear trigger. 1

Attaching the man riding hoist to car and installing the third ring of guide rail brackets.

2

Installing the car interior. 1

Installing and aligning guide rails and brackets to intermediate floors.

1

Preparing the car and counterweight guide rail brackets. 2

Preparing machine and landing door brackets 2

3 Installing top most floor lengths of guide rails and brackets. 1 Transferring the overspeed governor to final position and setting the rope to final length.

1

Installing the pulley beam and car sill. 1

Installing the machine and rope fixings. 1

Installing the landing door sill brackets. 1

4 Installing the trunking and elevator shaft lighting 1

Installing the landing doors, not finally adjusted. 1

Installing the car front wall and car door. 1

Installing the last landing door. 1

5 Final adjustment of the landing doors. 1

Installing the MAP, SEP and drive panels. 1

Installing the elevator shaft top wiring and brake lever. 1 Installing the travelling cables, shaft wiring and signalization. 1 6 Installing car wiring and setting positioning system and ramps. 1

Installing the pit wiring. 1

Installing the car electrification and car operating panel. 1 7 Placing filler weights inside the car for balancing operations, roping. 1

Closing of the brake and re-check of the brake lever operation, safety checks, commissioning and removal of tools.

1

Balancing and final steps. 1

Cleaning down the elevator shaft and disposal of waste materials. 1

Safety inspection (assistance with test weights). 1 (2)

Day Action Task split

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1.4 Customer experience

The focus of your work must always be customer satisfaction. To reach and exceed the customers’ expectations, be polite, constructive and co-operative, and communicate clearly. Remember that for customers, you represent KONE, so ensure that you handle or at least communicate all customer requests and feedback to the correct persons.

For more information on how to deliver best-in-class customer experiences through behavior and communication, see the KONE Ambassador program in KONE intranet (search for Ambassador) or contact your supervisor.

1.5 Step numbering in the pictures

1. When reading this instruction, note that the numbers in the pictures refer to the step numbers. 2 3 1

1. Xxxxxxxxxx

2. Xxxxxx

3. Xxxxxxxx

1082830.wmf

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1.6 Explanation for quality requirement table

Quality Requirements:

Required mandatory outcomes upon completion of the chapter.

MAIN hazards identified. Other hazards are described

within each chapter.

!!! CAUTION - issues that affect reliability !!!

This area highlights the negative effects of failing to meet the

quality requirements. SORT STABILIZE SHINE STANDARDIZE SUSTAIN Reminder of 5S standards.

Method tools needed:

Tools from the installation kit. Hand tools needed:

Tools from the tool kit. 5S Installation Progress Report

Progressive reminder to complete this document.

QD-181.211

Progressive reminder to complete this document.

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2 SAFETY

When you are working on your own ensure that: – someone in authority knows where you are – regular checks are made to ensure your safety

If you have any doubts about Single Man Working on your specific job site, discuss them with your supervisor.

Where required, discuss method statements and risk assessments with your supervisor and colleagues before starting work.

Work safely and follow local codes and agreed practices.

Certain components are from their characteristics, weight and size not suitable to be installed by Single Man Working methods. These components are highlighted in the installation chapter section, as an example car glass rear wall.

2.1 General safety

The words WARNING and CAUTION are used to highlight possible hazardous situations to persons or equipment as follows:

2.1.1 Safety instructions

Following safety instructions should be referred to in conjunction with this installation instruction:

– AM-01.03.001 Preventing falls from height when working on elevators, escalators and building doors

– AM-01.03.002 Take 5 - Electrical safety when working on elevators

– AM-01.03.003 Take 2 - Double security safety practice when using hoists for man riding purposes

– AM-01.03.010 Safe working in elevator shaft and machine room areas – Man riding hoist manual

WARNING: This is to warn about serious safety hazards.

CAUTION: This is to warn about damage to equipment which may also involve a safety

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NOTE: Installation work must only be carried out by competent and qualified personnel.

2.1.2 Double security safety practise when using hoists for man riding purposes

Refer to AM-01.03.003 - Take 2 Double security safety practice when using hoists for man riding purposes.

To ensure your and your co-workers personal safety you must always be protected from falling by two independent devices.

It is not permitted to drive or to be on top of the suspended platform without double security: 1. Safety gear

The safety gear must be connected to the overspeed governor and automatic safety gear trigger.

2. Man riding hoist

The man riding hoist must be correctly attached to the car sling using the fittings provided with the hoist.

It is not permitted to disconnect the man riding hoist or remove the hook from the car until it has been double secured:

1. Safety gear

The car must be secured on the safety gear using the automatic safety gear trigger. 2. Chains

The parking chain(s) must secure the car to the agreed anchorage point in the shaft.

2.1.3 Electrical working safety

Familiarise yourself with the safety instruction AM-01.03.002 and follow it at all times. 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:

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.)

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2.1.4 General safety precautions

Safety precautions Note

Follow your national lift codes and other safety related regulations.

In case of conflict between the code and this instruction, rely on your code.

The local safety codes and rules must be obeyed at all times.

Refer to your local procedures for the type of entrance protection required.

Follow this instruction. Do not skip any step, otherwise there may be a potentially

dangerous situation which you have not considered.

Warning signs highlight possible hazards. (See page 28.)

ENSURE THAT ELECTRICAL

EQUIPMENT AND CONDUCTORS ARE SAFELY DE-ENERGISED BEFORE WORKING ON THEM.

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.

Do not connect or disconnect any connectors when the power is ON. Personal safety equipment must be available and used as required.

Refer to the list of Personal safety items on page 28.

Use only approved manual handling techniques.

Do not work at different levels within the same / adjacent elevator shaft enclosures. The rust protection must be removed from

the rails. Otherwise, the safety gear will not operate correctly.

Refer to page 59 for specific safety notes.

Prevent falls from height:

1. Identify all possible fall hazards. 2. Remove the fall hazards, if possible.

3. If it is not possible to remove a fall hazard, then reduce the risk of fall using fall prevention methods.

4. If it is not possible to protect against a fall hazard using fall prevention methods, then use fall arrest equipment but only when verified through specific risk assessment. The provision of suitable rescue equipment, instruction and training must be available to ensure the timely rescue in case of a fall.

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CAUTION: Safety harnesses with

lanyards. 

When your safety harness is not secured to a life line or other approved anchorage point, ensure the lanyard does not cause a catching or tripping hazard.

If applicable, safety harnesses must be used in accordance with your national codes.

Always position the car at a safe level relative to landing before accessing or egressing. NEVER WORK UNDER A SUSPENDED

LOAD!

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 hoists for man riding purposes.

Additional safeguards ensure that there is no unwanted movement of the car due to hoist control or other failure.

Take care handling waste materials in accordance with your local regulations.

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2.2

2.3 Installation method safety

Special feature Note

The car is used as the working platform. Do not drive on the car roof until the balustrade is fitted and the safety gear is connected.

The man riding hoist is positioned on the car roof and an additional securing rope is attached to the overspeed governor lifting eye.

The man riding hoist is used to move the car during the initial stages of the

installation.

The man riding hoist and overspeed governor are suspended from lifting eyes in top of the elevator shaft.

The elevator’s own overspeed governor and safety gear are used during installation.

Refer to AM-01.03.003 Take 2.

The automatic safety gear trigger engages the safety gear automatically in the event of hoist rope failure or manually when it is necessary to secure the car.

The parking chain is used to secure the car to a car guide rail bracket whenever the hoist hook is disconnected from the car or when you are working under the car in the pit.

Always keep the chain as tight as possible.

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.

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.

Emergency descent from the car roof. If there is a power failure on site, it is always possible to move the car to a lower landing level using the brake releasing lever. For emergency descent refer to the man riding hoist handbook.

Guide rails are lifted using the car. Guide rails are fitted in the conventional way using the sliding clamp to lift each rail.

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Blocking device

After roping, whenever working on the

traction or suspension elements the blocking device must be used.

WARNING: The blocking device is not

strong enough on its own to support the weight of the car. In situations where the car is not supported by the ropes it must be secured using the parking chain and safety gear.

When moving the car on manual brake release, do not let it overspeed. Check speed indication LEDs on LOP-CB board.

Do not leave the brake open. (Try to limit the motor rotation to 1 second intervals.)

If you are working on your own, ensure that someone in charge knows where you are and that regular checks are made to ensure your safety.

If you have any doubts about single man working on a specific site, discuss with your supervisor.

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2.4 Danger and personal protection signs

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.

Danger signs

Danger Sign Danger Sign Danger Sign

Electric shock Risk of falling Magnetic field

Risk of fire Corrosion

Dermatological risk

Entry prohibited

General hazard warning

Suspended load Pinching hazard

Personal protection signs

Mandatory Sign Mandatory Sign Mandatory Sign

Safety helmet Overall Dust mask

Hearing protection Safety shoes with ankle protection Safety gloves Rubber gloves Fall prevention equipment

Safety goggles Fall prevention

measures Man riding hoist

mandatory inspection

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3 SITE REQUIREMENTS AND TOOLS

THE FIVE SITE ABSOLUTES

1. The elevator shaft is clean and dry before installation work starts.

2. The shaft is constructed according to KONE layout drawings and the shaft openings are sealed for safety.

3. The lifting eyes and the ventilation ducts specified by KONE are in place. 4. 3-phase power supply for elevator and installation hoisting is provided.

5. A 30 m2 storage space is provided on the ground floor close to the shaft and the access ways to the shaft are clear.

3.1 Site requirements

Before installation can start, ensure that the following things have been done: – The site must be 100 % ready.

– Transport routes must be defined and agreed as close as possible to the elevator shaft. – Elevator shaft tolerances must be checked by the supervisor.

– Delivery must be complete and on site.

– Installation start date must be agreed with the customer.

– When starting the installation and the wall mounted MAP is delivered, ask the builder to finalise the wall at the location of the MAP. This ensures that the wall mounted MAP can be installed without re-adjustment.

– 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. Refer to AM-01.03.002 Take 5.

– Installation tools must be available on site. – Recommended hand tools must be available. – Personal safety equipment must be available.

– The site inspection should take place minimum one week before the installation is scheduled to start, in accordance to the delivery process milestones “835”.

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Requirement Note

Adequate lighting and 3 -phase power supply must be temporary or permanent positioned for both the elevator and the man riding hoist according to the layout drawing.

Where required, the elevator shaft lighting can be lowered from the top floor and temporarily secured to the entrance protection horizontal stands.

Lifting eyes must be positioned in the top of the elevator shaft according to the layout drawing and marked with the safe working loads.

If the lifting eye is screw type, the lifting eye must be securely fastened to avoid

untightening. Right handed elevator:

1. Lifting eye for man riding hoist

(2000 kg)

2. Lifting eye for machine (1500 kg) 3. Lifting eye for overspeed governor

(1500 kg)

• front side if skewed sling • rear side if parallel sling 4. Lifting eye for KDM drive

(if applicable, 1500 kg) Typical lifting eye construction:

Maximum diameter of hook section 18 mm.

Finished floor marks must be on each landing.

For group elevators setting out reference lines must be marked on the lowest common floor area.

Elevator shaft and pit must be cleaned and pit waterproofed.

The elevator shaft must be watertight. C-inserts (if used) must be correctly positioned and cleaned.

Suitable material storage areas must be agreed with builder, adjacent to the elevator shaft.

Materials should be stored within 20 metres or close range from 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 and so on), must be defined and clear of obstructions.

WW WD 2 1 3 1077488.wmf 4 3 max 65

!

1078300.wmf

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ALL landings must be protected with full height entrance protection according to the local safety codes and regulations.

Fit temporary barriers around the top and bottom landing entrances wherever

temporary protection is removed or landing doors must remain open.

The entrance protection must be

imperforate. See AM-01.05.016, Installing

light entrance protection (LEP).

The bars must be secured so that they cannot be moved unintentionally horizontally or vertically.

Elevator shaft dimensions and tolerances must be in accordance with layout drawings. Suitable provision for disposal of waste

materials must be available.

According to the local requirements. Appropriate fixing points for safety

harnesses must be available.

Requirement Note

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3.2 Tools

MonoSpace® tools Pcs. Tool Pcs. Tool 2 or 3 Support bars Drawing number: 716161

3 support bars are needed if plumbing jig is used.

1 1 1

Automatic safety gear trigger Drawing number: 803140G01 Brake wire rope bracket: Drawing number: 803144G01 Brake wire rope:

Drawing number: 772277G01

1 Rope fixing plate

Drawing number: 803146

1 Telescopic pipe, Bahco AP-5M Drawing number: KM823588H04

1 Parking chain 2 m, 1500 kg Drawing number: 266828

2 Plumbing supports (pit) Drawing number: 716177G01

1 Guide rail lifting clamp for guide rails T70, T82, T89

2 2

Guide rail securing to car roof Drawing number: 773444G01 Guide rail lifting pocket Drawing number: 762396G01 1082712.wmf 1007069.wmf 1027222.wmf 1010242.wmf 1007070.wmf 1007072.wmf 1007079.wmf P17000195.wmf

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1 Counterweight guide rail positioning tool Drawing number: 716175G01

1 Unwinding device

1 Hoist test bracket, max. load 2000 kg Drawing number: 716157G01

1 Counterweight guide rail alignment tool Drawing number: 716180G01 4 Eyebolt RUD RS-M12 Drawing number: 266824 2 Eyebolt RUD RS-M8 Drawing number: 934990 1 1 1 Hoisting chains: Extension chain 1.5 m, 500 kg Drawing number: 266827 Shortenable chain 2 x 1.5 m, 500 kg Drawing number: 266826

Car/door installation chain 2 x 0.5 m, 500 kg Drawing number: 266825 4 Eyebolt RUD RS-M6 Drawing number: 50300433 3 Shackle 12 mm tap, 1500 kg Drawing number: 754257 MonoSpace® tools Pcs. Tool Pcs. Tool 1007076.wmf 1007084.wmf 1007074.wmf 1031357.wmf 1031357.wmf 1007078.wmf 1031357.wmf 1007081.wmf

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1 Rope grip for rope reeler securing, 9 mm Drawing number: 754257

1 Shackle for car roof rope reeler securing, 8 mm tap, 350 kg

1 Plumbing jig (optional, see APPENDIX

E. Plumbing jig)

2 Plumbing weight (optional, if plumbing jig is used)

Drawing number: 50077610G01

Other installation tools

Pcs. Tool Pcs. Tool

1 Guide rail transportation tool Drawing number: KM971149G01

1 or 2

Swivel balustrade

2 sets in case of TTC (1 set = 2 balustrade parts, upper and lower). Drawing number: KM50026878G02 MonoSpace® tools Pcs. Tool Pcs. Tool 1007083.wmf 1007082.wmf 1007071.wmf 1080362.wmf 1060909.wmf 1078014.wmf

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1 Man riding hoist + pulleys, 750 kg / 1000 kg capacity.

See hoist equipment parts on page 46.

1 Manual chain hoist, capacity 500 kg (Yale compact 500 or equivalent). A = 289 mm

H = 190 mm

1 Overspeed governor extension rope Drawing number: 772277G05

1 set Machine transporting wheels Drawing number: 715802

1 Elastic grip L = 1 m

1 Site trolley

1 Overspeed governor hanger kit including:

– OSG hanger assembly – Pulley bracket assembly – Climbing rope

Drawing number 823588G01

Pcs. Tool Pcs. Tool 1007086.wmf 1033403.wmf 1007090.wmf 1031365.wmf 1078301.wmf 1010244.wmf

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1 Battery tool

Cable (Drawing number: 859326) and 9V battery (supplied locally)

Used with construction-time power supply.

2 Transportation tool (used with transportation wheels and axle) Drawing number: 854900D01

1 Rope clamp

Drawing number: KM839679G01

2 Hilti PMP34 / PMP45 point laser

2 Target plate 1 Carpenters ruler

1 Laser alignment tool

2 Levelling plate

Pcs. Tool Pcs. Tool 1039959-1.wmf 1078366.wmf M8x50 4 x 1060910.wmf 1078890.wmf +1 0 +2 0 +3 0 +1 0 +2 0 +3 0 H I L T I PM P 34 1080768.wmf 1048308.wmf

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1 Work stool Drawing number: 265173 1 Telescopic ramps Drawing number: KM966635 1 Rope socket 6-8 Drawing number: KM971423G01

1 Electrostatic discharge (ESD) kit

Needed to protect the components from damage if any PC boards are replaced. (KM857505)

2 Installation jig

Drawing number: KM756128 Included in AMD door delivery

2 Plate for ramps

Drawing number: KM50077171

Pcs. Tool Pcs. Tool 1073236.wmf 1077935.wmf 1060911.wmf 1072347.wmf 1073260.wmf 1082413.wmf

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3.2.1 Hand tools (recommended)

Tool Tool

Carpenter’s pencil Lockable tool box for the normal hand tools

Tape measure, L 3.0 m Carpenter’s ruler

Multimeter, protected against high voltage Plastic tuning screw driver

Hammer drilling machine, with dust collector Adjustable spanner, L 200 - (250) mm Cordless drilling machine; with adjustable torque

for car and landing doors and car installation. One extra accumulator (battery), bit cassette including Phillips head and flat heads in different sizes, drill bit cassette (sizes 1.5 - 10 mm). Phillips head bit 150 - 200 mm.

Drill bits:

6 mm (light fitting, pit stop switches) 8 mm (trunking)

10 mm (pit ladder, travelling cable wall fixing) 12 mm L (150) (Hilti, for cutting through reinforcing bars)

Tool for concrete inserts Crow bar, L 500- 700 mm

Spanners:

U end and ring end.

Sizes 10, 11, 12, 13, 15, 16, 17, 18, 19 mm. Min. thickness for 16 - 19 mm spanners is 5 mm.

Screwdrivers:

Flat headed 5 mm L 200 mm.

Electrical, isolated 2.5-3 mm head L150-200mm Phillips head: Standard size L 200 mm.

Ratchet 1/2" drive Ratchet 1/4" drive small model

Extension L 200 mm 1/2" Extension 1/4", L 40 - 150 mm

Sockets (deep) 1/2", 13, 15, 16, 17, 18, 19 mm Sockets 1/4" drive, 10, 11, 12, 13 mm Carpenter’s hammer, 6 Oz. rubber handle,

“shock absorbent”

Sledge hammer, 1000 gram Hammer side flat, end drop forged

Vice grip/polie grip: L 150 mm and L 250 mm Magnetic spirit levels, lengths 700 and 1500 mm Engineers squares:

300 x 150 - 200 mm and 750 x 350 mm

Rivet pliers, replaceable head to cover the different rivet sizes

Side cutter, isolated handles (L 170 mm) Long nose pliers, medium model (L 170 mm) File for guide rail joints, normal model Rope cutting pliers, 8 mm

Knife Hacksaw, standard model

Disc cutter, disc > 125 mm 4 pcs plumbing weights, max. 10 kg/each (diameter max. 40 mm, length max. 300 mm) Engineers square, adjustable block width 30 mm

Pulling rope to pull the man riding hoist rope (plastic, 70 m, Ø6...8 mm)

Sheet metal cutters, professional quality for 0.6...1.5 mm steel sheet

Allen keys, set 3 - 12 mm 2 vacuum handles, capacity 40 - 80 kg

2 G-clamps

1010245.wmf 1007097.wmf

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3.2.2 Installation blister pack KM50091308G02

Material in installation blister

Item Reason Pcs.

M10 x 50 bolt Car guide rail fish plates (standard type) are thicker than before. M10 bolt from the CWT guide rail joint is not long enough to permit the method of leaning back the topmost car guide rail at machine installation.

1

– 5 x 70 wood screw – plastic wall plug – 20 mm plastic tube,

35 mm long

CWT screen secured to shaft wall for TAKE 2 method of guiding hoist rope tension weight.

4

CWT edge trim, 50 mm long

Required to be installed to the guide rail clips of the lowest guide rail brackets.

4

M12 x 80 expander fixings

– 2 x fixings to install a tethering anchor bracket

– 2 x fixings for the hoist test – 1 x fixing to hold temporarily

bracket for rail jointing – 1 x fixing to hold temporarily

bracket for ladder securing

WARNING: Use M12 anchor bolts

only in concrete! If other wall material exists, locally source suitable fixings. Consult your local support function. 6 – 8 x 50 coach screw – M8 mudguard washer – plastic plug

Required to temporarily fix pit ladder to the lowest floor sill area.

NOTE: Required due to the safety

codes of various frontlines.

2

M10

M12

35

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4 OFFLOADING AND DISTRIBUTION

Introduce yourself to the person responsible for the site. Familiarise yourself with the site facilities, the local rules, safety requirements and site management procedures.

4.1 Offloading and distributing materials

CAUTION: 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 to protect your hands. – 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 falling.

– Wear goggles and dust masks as necessary. – Use hearing protection as necessary.

– When using the telescopic ramps ensure they are parallel and cannot slip off leading edge.

NOTE: The 150 kg (300 kg / pair) maximum WLL (working load limit) marking of the

telescopic ramps is based on single axle trolley usage. On specific tested method steps, where a twin axle assembly is used (such as machine transport), the load is more evenly distributed across the ramps. In such cases the WLL is increased to 380 kg / pair of ramps. Always follow the designated method description.

WLL 300 kg / pair of ramps WLL 380 kg / pair of ramps

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1. Fix the transportation wheels to machine package while unloading. 2. Use wooden blocks to tilt machine box when removing the wheels.

Offload the material to the destinated storage area. Arrange the materials to ensure easy access to each component in the installation order.

NOTE: Car floor is at the oppposite side of the packing list.

NOTE: A number at top of each crate indicates the installation order.

Place the machine box so that the side with the holes is downwards.

When offloading the machine from the vehicle, put it into vertical position and use a forklift to place machine onto the axle and wheels. Push the machine into the storage area. Remove the axle and wheels and leave the crate in upright position on two pieces of wood.

The female end of the guide rail bundle is marked with tape. Locate the bundle so that the male side faces the elevator shaft. Handle the bundle carefully so as not to damage ends. Put the guide rail bundle on a higher stable working level to achieve a good working height of 1.0 m.

It is important that the tools and materials are positioned according to the installation order to achieve and maintain a controlled installation environment throughout the installation.

Do not open the packages until you are ready to install the equipment. Check against the material documentation that the delivery is complete. Position the tools and materials to correct levels before the installation starts.

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xxxxxxxx (Draft -) 2012-05-24 All rights reserved. Copyright © 2012 KONE Corporation Mono3 -Unloading order Compiled by: Information Product Author / V ille Malmiala Checked by: Global Installation Support / Solution Manager , Global Packing / Konsti V ille Approved by: Global Installation Support / Anssi V enho 1079322.pdf

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Package group Group header Package label Package label text 100 Installation requisites 110 120 Installation requisites Overspeed governor

200 Guide rails and shaft

beams

210 220 230

Guide rails Guide rail fixings Shaft beams 300 Doors 311 312 330 331 Frame / Fronts Door panels Door operator Railing 400 Machine room 410 420 430 Machine Ropes

Shaft electrification panel

500 Shaft and machine

room 510 440 / 540 Shaft equipment Wiring 600 Car 610 Car

700 Car sling and frame 710

720 730 Car sling Counterweight frame Filler weights A Topmost landing – Long tool box – Hand tools

– Man riding hoist top pulley

– Elevator shaft lighting (if applicable) – Overspeed governor and rope – Parking plate

– Rope suspension, counterweight side B Entrance level / Storage area

– Smaller tool box

– Man riding hoist, ASGT – Working stool

– Counterweight guide alignment tools – Guide rails and brackets

– Counterweight, filler weights – Car sling, car

– Machine

– Car door and landing doors – SEP, MAP, drive panel, COP – Elevator shaft electrification – Pit ladder – Ropes – Wiring material 1007099.wmf

A

B

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4.2 Offloading and transporting landing doors

1. Keep the area on the side of the crate with the identification label “OPEN THIS SIDE” unobstructed.

2. Always transport parts of door one at a time.

3. The top tracks will be stored in the shaft mechanics box.

4. Open the narrow side of the card board box marked “Open this side” by cutting the vertical edges of the side. This is to gain access to the door panels.

5. Remove the top wooden support to access to the sills.

6. When extracting the door panels, do not break the two wooden rings around them. Slide the door panels out the opening.

7. When the panels are stored into the car or at the landing, ensure that the guide shoes are facing up in order to not damage them.

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5 INSTALLING MAN RIDING HOIST AND OVERSPEED GOVERNOR

Man riding hoist and accessories

– inspected and certified (inspection period validity to

meet local code)

– ONLY TRAINED PERSONS TO USE THE HOIST!

– lifting hook in shaft tested

Car overspeed governor

– installed to temporary position

– check data label to ensure correct type and tripping

speed

– ensure correct tripping direction

– ensure the rope is on the small pulley

!!! CAUTION - issues that affect reliability !!!

N/A

NOTE:

Check carefully that the OSG rope is correctly on the groove and UNDERNEATH the internal rope guard!

SORT STABILIZE SHINE

STANDARDIZE SUSTAIN Method tools needed:

Man riding hoist test bracket, overspeed governor hanger, telescopic pole, site trolley, man riding hoist + rope + accessories + hoist test plate (fuse plate)

Hand tools needed:

Pencil, tape measure, hammer drill, hammer, 2 x spanner (19 mm), pulling rope

5S Installation Progress Report N/A

QD-181.211 QD 1 completed

1075605.wmf

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5.1 Man riding hoist parts

NOTE: The man riding hoist type described in this instruction is Tirak X750.

Pos. Item Greifzug 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 rope. Minimum rope length = 2 x elevator shaft height.

30158

5 Safety pin no. 2. 6 mm 12056

6 Electric supply extension cable for main power supply, 45 m, 5 x 1.5 mm2

16537 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

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P17000140.wmf 1. 2. 3. 4. 5. 6. 7. 8. 11. 10. 11. 12. 16. 13. 14.1 9. 14.2. 15.

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5.2 Work positioning equipment or restraint system

NOTE: For more information, see AM-01.03.001 Preventing falls from height when

working on elevators, escalators and building doors.

Work positioning or restraint systems are systems of personal protection designed to secure the user in a safe position where it is not possible to fall. The restraint may also be used as an additional measure to prevent fall when working close to or leaning over the basic entrance protection, for example, when installing components at the top of an elevator shaft. The area around the fall hazard must be segregated to prevent risks to others.

KONE methods do not support the use of work positioning or restraint systems as primary fall prevention systems. This system is suitable as additional protection to the primary protection or where there is a limited risk of injury. They are only to be used where no other better solution is possible, subject to site specific risk assessment. (for example, existing elevator with no car top balustrade).

Work positioning system

NOTE: Wall fixings are located with

KM50091308G02 (Blister - Installation hardware). Use these fixings only in concrete! If other wall material exists, consult your local support function to source suitable fixings.

CAUTION: Work positioning or restraint

systems must not be used to arrest a fall.

Typical equipment includes: – Body belt.

NOTE: A full body harness is sometimes

used but is less suitable for low level anchor point.

– Adjustable lanyard (without shock absorber). Keep the lanyard as short as possible and take extreme care that the lanyard cannot be damaged by sharp edges.

– Suitable fixing point. The anchorage point strength requirements vary, but they must be capable of supporting around double the maximum pull force of a person and be in accordance with local regulations.

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5.3 Safety checks

Make the following safety checks.

5.4 Transporting

1. Use site trolley to transport the man riding hoist.

Item Requirement Risk

Lifting equipment and suspension eyes.

Must be load marked, tested and in good condition according to local requirements.

Falling loads.

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).

Must prevent movement of hoist when contacts are open.

Uncontrolled movement of hoist/car.

Safety harnesses and ropes.

Must be inspected and in good condition. When used, they must always be

securely attached to approved fixing points.

Falling.

SMW06.wmf

1060916.wmf

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5.5 Routing the man riding hoist rope and cable

1. Lower the power supply cable from the topmost landing to the pit. Connect to hoist. Check the operation of the hoist safety functions.

2. Drive out the hoist rope and pull it to the top floor using the lifting rope. 1 = rope entry, 2 = rope exit

If the hoist motor does not run, reverse two phases in the plug by rotating the phase changer* in the plug housing

3. Pull the hoist rope to the topmost landing. Allow 8 metres of slack to reach the elevator shaft ceiling. Loop the hoisting rope through the pulley.

WARNING: When there is a risk of falling wear a tethering system when working at

unguarded landing entrances. Always install the hoist from the lowest landing level. For more information, see AM-01.03.001.

P17000199.wmf 2 1 P17000107.wmf

*

1072131.wmf

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5.6 Installing overspeed governor hanger

NOTE: The counterweight overspeed governor (if any) must have higher tripping speed than the car overspeed governor.

1. Route the pulling rope through the hanger. Tighten the lower hook to maintain in correct position. *) Make a loop at the rope end to enable pulling the rope back to the landing. 2. Lift the hanger to the lifting eye.

WARNING: Check the correct orientation for the overspeed governor. The rope guard

must face the shaft wall.

~4

m

~4

m

*

1079201.wmf

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3. Pass the rope over the small groove of the OSG. Check the tripping direction.

4. Secure rope ends together and lower to the pit. Check that ropes do not get entangled. 5. Pull the overspeed governor to hanger. The rope guard must face the wall.

6. Remove the pulling rope. It is needed for car floor installation.

5.7 Fixing the man riding hoist rope

1. Attach the securing rope of the hoist diverting pulley to machine lifting eye. Use telescopic pole and adaptor bracket. Strengthen adaptor bracket:

1 = M6 flange nuts from car bolt delivery, 2 = M6 x 40 bolt, provided locally.

2. Fit hoist rope over the diverting pulley. Attach the pulley to the hoist suspension eye.

1078306.wmf

1

2

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5.8 Lowering the man riding hoist hook to the pit

1. Drive out the hoist rope and lower the hook to the pit. 2. Clip the hoist hook over the suspension bar on the hoist.

3. Fit the car parking chain (capacity 1500 kg) to the underside of the hoist and drive the hoist into the elevator shaft

5.9 Pit ladder

1. When using the ladder, ensure the suitable angle between the ladder and the pit floor. 2. Secure the pit ladder for installation time use according to method A or B. Install the CWT

guide rail bracket while entrance protection is fitted.

3. Fix the pit ladder wall fixing bracket to the machine side wall.

4. Fix the securing strap is to the wall to prevent unwanted removal of the ladder.

P17000146.wmf 1009514.wmf 1078313.wmf PH PH_/3 1 m A B

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5.10 Testing the hoist equipment

If the lifting eye or suspension element for the man riding hoist 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.

1. Install the hoist test bracket on the side wall of the elevator shaft.

NOTE: Fixings* are located with KM50091308G02 (Blister - Installation hardware). Use

these fixings only in concrete! If other wall material exists, locally source suitable fixings 2. CAUTION: If "double" adapter is used, use direct line pulling to prevent hoist damage. 3. Attach the dynamometer or test plate (breaking strength 1500 kg or 2000 kg, supplied

locally) between the hoist and the hoist test bracket. Shorten the parking chain to 300 mm.

NOTE: Select the chain capacity according to the hoist capacity.

4. Drive the hoist slowly upwards until the hoist ropes are almost under tension. Take up the tension smoothly. Sudden loadings may damage the equipment.

5. Run continuously until the load limit of the hoist is reached or the test plate breaks. Motor power supply is automatically disconnected. Drive the hoist downwards to reset it.

6. Write your name and test date on the test plate and store it. Fix it to the tested lifting point after guide rail installation.

WARNING: No one is allowed to be in the elevator shaft during this test.



WARNING: The hoist can be used for material transportation after test. Do not use the

hoist for man riding.

1010613.wmf

1082349.wmf 2

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6 PLUMBING

– plumbing table is completed

– dimensions in the pit are similar to those in layout

drawings

– lasers are positioned on the pit floor according to the

plumbing table

– laser tools are calibrated, clean and batteries checked

!!! CAUTION - issues that affect reliability !!! SORT

STABILIZE SHINE

STANDARDIZE SUSTAIN Method tools needed: Pit ladder, lasers Hand tools needed:

Tape measure, pencil, spirit level 5S Installation Progress Report N/A

QD-181.211 QD 2 completed

1075617.wmf

AM-01.01.250 A

KONE MONOSPACE®, RELEASE 3.0

TABLE OF CONTENTS

1

GENERAL

1.1

Abbreviations

1.2

Related and supplementary documents

1.3

Daily installation order guide

1.4

Customer experience

1.5

Step numbering in the pictures

1. Xxxxxxxxxx

2. Xxxxxx

3. Xxxxxxxx

1.6

Explanation for quality requirement table

2

SAFETY

2.1

General safety

2.2

Recommended working postures and ergonomic methods

2.3

Installation method safety

2.4

Danger and personal protection signs

3

SITE REQUIREMENTS AND TOOLS

3.1

Site requirements

!

3.2

Tools

M10

M12

4

OFFLOADING AND DISTRIBUTION

4.1

Offloading and distributing materials

A

B

4.2

Offloading and transporting landing doors

5

INSTALLING MAN RIDING HOIST AND OVERSPEED GOVERNOR

5.1

Man riding hoist parts

5.2

Work positioning equipment or restraint system

5.3

Safety checks

5.4

Transporting

5.5

Routing the man riding hoist rope and cable

*

5.6

Installing overspeed governor hanger

~4

m

~4

m

*

5.7

Fixing the man riding hoist rope

1

2

5.8

Lowering the man riding hoist hook to the pit

5.9

Pit ladder

5.10

Testing the hoist equipment

6

PLUMBING