Fast Track Installation Process

Fast Track Installation Process
Fast Track Installation Process
Fast Track TIP – Revision 1
Fast Track 1
Utilizing the Contract Machine to move the Car Frame
throughout the Hoistway
Dual Line Wire
Dual Laser
Rail Alignment System
Rail Alignment System
(Straight- Line or Plumb Rails)
(Plumb Rails Only)
Fast Track 2
Utilizing a Cable Climbing Hoist to move the Car Frame
throughout the Hoistway
ThyssenKrupp Elevator
Fast Track Installation Process
Table of Contents
Section 1
– Introduction, Safety, and Job Preparation ............................................ 1
Section 2
– Machine Room Block- Out Installation.................................................. 15
Section 3
– Early Delivery ................................................................................... 27
Fast Track 2 Schedule (with Laser Rail Alignment)......................................................... 31
Section 4
– Laser Rail Alignment System .............................................................. 37
Section 5
– Pit Equipment, Car, and CWT Frame ................................................... 53
Section 6
– Fast Track II (Utilizing Cable Climbing Hoist to Install Rails)..................... 61
Section 7
– Entrances, and Doors........................................................................ 89
Section 8
– Piping, and Wiring Hoistway............................................................... 119
Section 9
– Cab, Door Operator, Adjusting, and Turnover ....................................... 129
Fast Track 1 Schedule (with Line Wire Rail Alignment) .................................................... 167
Section 10 - Line Wire Rail Alignment System......................................................... 173
Section 11 - Pit Equipment, Car, and CWT Frame ................................................... 191
Section 12 - Fast Track 1 (Utilizing Contract Machine to Install Rails)* ........................ 199
*After completion of Section 12, continue with Sections 7, 8 and 9
Appendix
– Specialty Tooling, and Supplier Contact Information .............................. 223
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Fast Track Installation Process
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ThyssenKrupp Elevator
Fast Track Installation Process
Section 1
Introduction, Safety, and
Job Preparation
Getting Started
Section 1 – Introduction, Safety, and Job Preparation
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Fast Track Installation Process
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Section 1 – Introduction, Safety, and Job Preparation
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Fast Track Installation Process
Jobsite Safety
Safety Policy
Presidents Message
At ThyssenKrupp Elevator Company (TKE), we regard our employees as our most valuable asset.
We are committed to protect our employees, the public, property, and the environment from
accidental loss. Providing our employees with a safe and hazard free workplace is our primary
objective.
Safety is the responsibility of each and every employee. All employees must maintain their own
personal commitment to the safety and health program and strive for continuous improvement.
An effective safety culture is the result of an efficient system supported by a people- oriented team
effort.
The safety and health process along with costs, scheduling, quality, and production provide an
important function in the efficient operation of TKE business.
The fundamental objective of preventing accidents is to develop and maintain procedures for
managing all aspects of safety and health. We continue to work towards controlling the lost time
along with the pain and suffering we experience with every accident. The following procedures are
guidelines to follow to put our employees in the safest workplace possible. All employees shall
comply with ThyssenKrupp Elevator Company safety policy and procedures.
By “Setting the Standards in Safety”, we continuously improve our safety program, thereby, exceed
industry standards to become a leader in our industry.
Barry Pletch
President
Section 1 – Introduction, Safety, and Job Preparation
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ThyssenKrupp Elevator
Fast Track Installation Process
Safety
All employees shall have their personal protective equipment on the jobsite at all times. The
following Personal Protective Equipment (PPE) is mandatory on construction jobsites:
• Hard hats are to be worn during all phases of construction.
• Hearing protection must be used when sound levels exceed 85 dB.
Rule of Thumb: If you raise your voice to speak to others at a distance of 5 feet or less – hearing
protection shall be worn.
•
•
Company approved eye protection shall be worn at all times on construction sites, and
whenever work activities are being performed where there is a potential for an eye injury to
occur.
Safety footwear for employees shall either meet the ANSI requirements for footwear or shall
meet the following requirements:
o Leather uppers
o Oil resistant soles
•
Personal Fall Arrest Equipment
o On construction sites, a personal fall arrest system shall be worn at all times when
working in the hoistway(s).
o On construction sites, a personal fall arrest system shall be worn at all times when
working around the hoistway(s) up to the point where the hoistway(s) are fully
enclosed.
o Once an elevator car is placed on automatic operation, the personal fall arrest system
shall only be worn when subjected to a possible fall hazard, and lockout procedures
are used, or removed from automatic operation at the controller, and car movement
is controlled at the car top inspection station.
o The personal fall arrest system shall be connected to a suitable anchor at all times
when there is a fall hazard of 6 feet or more.
•
Lockout/Tagout
o If any employee is working on equipment that may be accidentally energized, then
EACH employee working on the equipment shall have a personal lock on the lockout
device.
o If a piece of equipment is being secured due to repairs and no employees are
working on the equipment, then a company lock can be used.
o Keys and combinations for personal locks cannot be given out to any employee
except the employee assigned the personal lock.
o All personal locks shall be identified with a label that states that the lock is to be used
as a lockout lock.
Section 1 – Introduction, Safety, and Job Preparation
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ThyssenKrupp Elevator
Fast Track Installation Process
•
Ground Fault Circuit Interrupter (GFCI)
o Employees shall use ground fault circuit interrupters (GFCI) on all 120 volt, singlephase, 15 – 20 ampere receptacle outlets when connecting electrical equipment and
tools used in connection with processes of construction, maintenance, and alterations.
o A GFCI device shall be used at the power source.
o If the General Contractor is providing a GFCI circuit, ThyssenKrupp employees may
use the protected circuit instead of using their portable GFCI. However, this circuit
shall be tested to ensure that it is a GFCI circuit prior to each use. Employees should
still use personal GFCI within their work area.
•
ThyssenKrupp Jumper Kit (issued to adjusters and qualified mechanics that have been
trained on the use of jumpers).
On modernization and new construction, many jumpers are used to operate elevators. The
following rules must be strictly followed:
o A Jumper Log shall be established for each controller to ensure that affected
personnel are aware that the safety circuits are NOT functioning.
o The mechanic shall be responsible to ensure that the Jumper Log is completed.
o The Jumper Log shall be kept in a conspicuous spot in the controller and shall NOT be
removed until all jumpers are removed.
o Jumpers should be removed as soon as they are no longer required and duly noted
on the Jumper Log.
•
ThyssenKrupp Elevator Employees’ Safety Handbook
Section 1 – Introduction, Safety, and Job Preparation
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ThyssenKrupp Elevator
Fast Track Installation Process
Pre- Start Requirements
The following items must be completed prior to manning the job:
•
•
•
•
•
•
•
•
•
•
•
•
•
Free standing removable OSHA approved barricades must be provided at all openings.
A properly installed steel beam must be in place with a minimum capacity of 5000#.
There must be safe stairway access to all floors.
The work area must be clear and free of debris – there must be no tripping hazards in the
work area.
A lockable, fused disconnect must be in place. The switch must contain three phase wires
and a ground – four (4) wires. The disconnect must support the proper motor horsepower as
required by the power confirmation letter (form).
A 110 volt, 20 amp power supply with ground fault circuit interrupter must be provided.
The equipment room must be completely dry walled and fire taped.
The equipment room must be clean and dry.
The equipment room must have adequate lighting.
The pit must be clean and dry.
A lockable, fused 110 volt 20 amp disconnect must be provided.
Inserts or weld- plates must be provided at measurements off of layouts, and all walls drywalled and fire- stopped, except where there is an entrance.
A rough opening of 6” larger than the finished opening must be provided
If these items are not complete upon the anticipated start date, immediately notify the
Supervisor/Manager.
Section 1 – Introduction, Safety, and Job Preparation
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ThyssenKrupp Elevator
Fast Track Installation Process
Fast Track 1 Safety Checklist
IMPORTANT!
The following must be verified prior to using the contract machine
to move the carframe
From the Machine Room:
•
•
•
•
•
•
•
•
•
All holes in the floor are covered or the machine room is protected from unauthorized entry.
The machine brake is properly cleaned and adjusted.
All disconnects for three- phase and single- phase power are fused, and lockable.
All machine guards are in place.
The governor is roped and operational along with the over- speed switch.
All hoist ropes are terminated with nuts locked, and cotter pins installed.
All hoist ropes are “hobbled” at their termination points.
The rope gripper is installed, and operational (if applicable).
Correct colored wedges are used, and wedge clips are set at 2”, and 4” from shackle.
From the Hoistway:
•
•
•
•
•
•
•
•
•
The correct amount of filler weights are in the CWT frame.
(CWT frame and weights = total car sling (less contract platform) + 600lbs)
The crosshead platform is securely installed, and includes all handrails/kickboards.
The counterweight frame is not susceptible to obstruction during movement due to hoistway
configuration. If so, skates or skids are attached.
The counterweight rods, or tie- downs are installed, and all weights are secured in the frame.
The car safeties are clean, and adjusted.
The car, and CWT buffers are installed, and filled with the appropriate amount of oil.
The temporary run button is in good condition.
The governor tension frame is installed, and properly positioned to allow for rope stretch.
If any of the above items can not be met, a Risk Assessment Form must be completed and
approved by Regional VP prior to proceeding with the installation.
The above Items have been completed:
Mechanic In Charge
Section 1 – Introduction, Safety, and Job Preparation
Date
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ThyssenKrupp Elevator
Fast Track Installation Process
Company Tools Required
General Tools
Qty.
1
2
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Tool
Qty.
Tool
Safety Line Installation Tool
Safety Lines (Cable)
Safety Bags (PPE)
Wire Rope Grabs
Six Wheel Aluminum Channel Dolly
2- Wheel Hand Truck
Golo or Capstan Hoist
Golo or Capstan Mounting Bracket
3/16” Cable (Golo) or Fiber Rope (Capstan)
Sheave Blocks (Cable)
Pallet Jack
Knaack Storage Boxes
8’ Step Ladder
20’ Extension Ladder
Nut Driver Kit (3/16”- 7/16” and 5mm- 11mm)
Hilti TE- 6C Rotary Hammer Drill
6” Rotating Hammer/Drill Bits (1/4”, 3/8”, 1/2”,
and 5/8”)
DeWalt Cordless Impact Wrench (1/2” Drive)
3/8” Impact Socket (1/2” Drive)
3/4” Impact Socket (1/2” Drive)
15/16” Impact Socket (1/2” Drive)
1 1/8” Impact Socket (1/2” Drive)
DeWalt Chop Saw (100 V)
DeWalt 18 V Reciprocating Saw, and 1/2”
Cordless Drill Kit
DeWalt 4 1/2” Grinder (100 V)
DeWalt 1/2” Cordless Drill (18 V)
DeWalt Cordless Wet/Dry Vacuum (18 V)
DeWalt Assorted Bit Set (100 pc.)
1
1
1
2
2
1 Set
1
1
2
1
1
1
1
1
1
2
1
100’ Minimum Run Button Traveler Cord
Temporary Run Station
Traction Controller Adapter (Pig Tail)
50’ ThyssenKrupp Extension Cords
Halogen Lights with Clamps
Sill and Header Gauges
Fluke Volt/Ohm Meter
Fluke Hard Sided Meter Case
3’ Nylon Slings
Alligator Clips
Ampere Meter
Fluke T- Pack Meter Hanging Kit
Door Torque Gauge
Digital Tachometer (Hand- Held)
Full Face Shield
Pin Clevis
Traveling Cable stripper
1
1
2
1
1
1
1
2
1 Set
2
1
Laser Rail Alignment
4
1
2
2
2
2
PLS3 Lasers
Dual Beam Laser Target
Dual Beam Laser Bracket/Holder
Round Rail Laser Bracket/Holder
Laser Targets (Bulls- Eyes)
Rear Attachment Bracket (if Jumps involved)
Stepper Bits
Drill Bit Set (1/16”- 1/2”)
Vise Grip C- Clamps
Wire Strippers
Sta- Kon Pliers
Rail Lifter (for Omega, “T”, or both)
Counterweight Magnet
Cable Shortening Brackets
CWT Rail Aligning Gauge (for Omega, or “T”)
V- Groove Cable Bracket
Pay- Off Reel
Line Wire Rail Alignment
1
1
2
1
Aluminum Target Board
Dual Line Rail Bug
Dual Line Ratchet Brackets
Rail Aligning Wire Spool
Fast Track 2 (Tirak Hoist) Only
1
1
1
2
Cable Climbing Hoist (1500 lb. or 2400 lb.)
Dual Block- Stop, or 2 Individual Block- Stops
Crosshead Mounting Bracket
Special Wire Rope (Main, and Secondary)
Section 1 – Introduction, Safety, and Job Preparation
1
1
1
Power Box (1500 lb. Only)
100’ Power Cord
Pig Tail
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ThyssenKrupp Elevator
Fast Track Installation Process
Personal Tools Required
Personal Hand Tools
Qty
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Tool
15/16" Wrenches
¾" Wrenches
9/16" Wrenches
½" Wrenches
7/16" Wrenches
3/8" Wrenches
15/16" Socket
¾" Socket
9/16" Socket
7/16" Socket
3/8" Socket
Spinner Wrench/Nut Driver (Set)
Torpedo Level
Straight- Slot Screwdriver (Set)
Phillips- Head Screwdriver (Set)
Allen- Head Wrench (Set) Metric and
Standard
Framing Square
Tri- square
Speed Square
Plumb Bob
C- Grip Pliers
Qty
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
Tool
Tape Measures
Flashlight
4 Ft. Level
Wire Strippers
Straight- Slot Wiring Screwdrivers
Small Flat File
Small Crescent Wrench
Large Crescent Wrench
Channel Lock Pliers (Large)
Channel Lock Pliers (Small)
Needle- Nose Pliers
Two- Pound Hammer
Four- Pound Hammer
Ball Peen Hammer
Hack Saw
Tin Snips
Pry Bar (Large)
Pry Bar (Small)
Chisel (Set)
Punch (Set)
Vise- Grip Pliers
Chalk Box
Refer to the Appendix for a complete description of specialty tooling and supplier contact
information.
Section 1 – Introduction, Safety, and Job Preparation
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ThyssenKrupp Elevator
Fast Track Installation Process
DON'T DO IT
DO NOT LET EMPLOYEES WORK UNSAFELY OR IN AN UNSAFE
LOCATION.
DO NOT PROCEED WITH WORK WITHOUT A CHANGE ORDER.
DO NOT TURN OVER AN ELEVATOR WITHOUT CHECKING WITH
ACCOUNTING.
DO NOT DRILL JACK HOLES WITHOUT A ROCK CLAUSE, PWA, OR
EXECUTED CONTRACT.
DO NOT START A JOB WITHOUT A SCHEDULE OR A PLAN.
DO NOT MAKE PROMISES THAT WE CAN’T KEEP.
DO NOT START A JOB UNTIL THE BUILDING IS READY.
DO NOT LET YOUR EMPLOYEES GUESS WHAT IS HAPPENING.
KEEP THEM INFORMED.
DO NOT FORGET YOUR PAPERWORK.
DO NOT NEGOTIATE UNION ISSUES WITHOUT CONSULTATION.
DO NOT PROCEED WITH EXTENDED OVERTIME (more than 5 days)
WITHOUT WRITTEN AUTHORIZATION.
DO NOT LOAN COMPANY TOOLS OR EQUIPMENT WITHOUT WRITTEN
PERMISSION AND A TEMPORARY ACCEPTANCE FORM SIGNED.
DO NOT FORGET YOUR COMPANY CODE OF ETHICS.
Section 1 – Introduction, Safety, and Job Preparation
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ThyssenKrupp Elevator
Fast Track Installation Process
The superintendent coordinates with the factory, the trucking company, and the General Contractor to
ensure on time material delivery to the jobsite. The superintendent also arranges for forklift
availability. If a forklift does not come with the delivery truck, or is not available at the site, the
superintendent will need to rent one and have it delivered.
Section 1 – Introduction, Safety, and Job Preparation
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ThyssenKrupp Elevator
Fast Track Installation Process
Place the material, in the order you are going to install, as close to the hoistway as possible. Rollable
access is key to the efficient handling of material, as well as, the elimination of strains and sprains.
Inserts
Prior to the crews manning the job, the superintendent makes sure that the job is ready to start (i.e.
hoist beam is in place, pit is clean and dry, barricades are adequate and in place, three- phase power
is available, and that general house keeping is in order).
Section 1 – Introduction, Safety, and Job Preparation
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ThyssenKrupp Elevator
Fast Track Installation Process
Plan your work before you start – practice the five “P’s”
Prior
Planning
Prevents
Poor
Performance!!!
ƒ
Fill out the Project Management Book’s Pre- Start Safety Checklist and the Fast Track
Safety Checklist.
ƒ
Plan to meet the goal! Thoroughly communicate the goal to others (i.e. team members and
the General Contractor).
ƒ
Perform all work in accordance with the guidelines set forth in the Employees’ Safety and
Accident Prevention Program.
Section 1 – Introduction, Safety, and Job Preparation
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Fast Track Installation Process
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Section 1 – Introduction, Safety, and Job Preparation
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ThyssenKrupp Elevator
Fast Track Installation Process
Section 2
Machine Room Block- Out
Installation
NOTE: Shows all Block- Outs needed for Fast
Track 1. If using Laser Rail Alignment
System (Section 5) the Target Line
Block- Outs (triple tube) are not
required.
Section 2 – Machine Room Block- Out Installation
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Fast Track Installation Process
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Section 2 – Machine Room Block- Out Installation
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ThyssenKrupp Elevator
Fast Track Installation Process
Machine Room Slab Block- Out Installation
Properly locating/securing of block- outs prior to pouring of the concrete slab is critical to ensuring a
smooth start to the rail alignment process, and the installation of the machine room equipment.
Ensure the block- outs being used are properly sized. Using larger than required block- outs could
interfere with machine room equipment, and jeopardize the integrity of the structural slab.
With the use of a chalk box, framing square, tape measure, and pencil, the wood form or corrugated
steel “Q” decking should be marked complete. All centerlines are to be chalked post wise, from
wall- to- wall, and all other reference points are to be marked perpendicular using a framing square.
If the job is a duplex, or multiplex, the main rail line should be chalked the complete distance of the
elevator bank at the two tightest points. This will ensure the rails will be in the same plane, keeping
door frames in a straight line in the corridors.
NOTE: Slab reactions as they pertain to ThyssenKrupp equipment, must be approved by the
General Contractor ,or structural engineer prior to setting block- outs.
Using the contract specific layouts, verify the hoistway size post- wise, and front- to- back. If the
machine room, and clear hoistway perimeter locations cannot be clearly determined, the General
Contractor should be contacted for clarification, and the marking reference points. At a minimum,
these references need to include the front- of- clear hoistway, and center- of- clear hoistway
locations.
IMPORTANT!
If there is any questions or concerns with the measurements provided by the
contractor or on the layout, contact your superintendent immediately.
Section 2 – Machine Room Block- Out Installation
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ThyssenKrupp Elevator
Fast Track Installation Process
Refer to the example contract specific layouts on the following pages to obtain the required
measurements for locating of the block- outs.
SAMPLE LAYOUT
For Illustration Purposes only
2
4
5
1
Dimension
Dimension
Dimension
Dimension
Dimension
1
2
3
4
5
–
–
–
–
–
3
Clear Hoistway depth.
Clear Hoistway width.
Front Hoistway to Centerline of Car Rails.
Distance between Guides (DBG).
CWT DBG.
Section 2 – Machine Room Block- Out Installation
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ThyssenKrupp Elevator
Fast Track Installation Process
SAMPLE LAYOUT
For Illustration Purposes only
7
6
Dimension 6 – Governor location from Centerline of Car Rails.
Dimension 7 – Centerline of CWT Rails from Centerline of Car Rails.
Section 2 – Machine Room Block- Out Installation
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ThyssenKrupp Elevator
Fast Track Installation Process
Block- Out Kit Arrangements
Section 2 – Machine Room Block- Out Installation
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ThyssenKrupp Elevator
Fast Track Installation Process
Mark Main and CWT Rail Line
Chalk Main Rail Line
Mark the centerline of the main rails, and
CWT rails, from the front hoistway on both the
left- and- right sides. Refer to dimension 3 on
the sample layout..
Snap a chalk line along these two points (rail
line) for reference.
Mark Center of DBG
Mark Half of DBG
Along the centerline of the main rails, mark
the center of the DBG, and also, the clear
hoistway, if different. Refer to dimension 2 on
the sample layout.
Section 2 – Machine Room Block- Out Installation
Mark the front of each main rail by taking half
of the DBG from the center of the clear
hoistway. Using a square, transfer the DBG
mark to the front and back, about 6” in
length, perpendicular to the centerline of the
main rails. Refer to dimension 4 on the
sample layout.
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ThyssenKrupp Elevator
Fast Track Installation Process
Mark the location of the governor 1 ¾” past
(closer to the wall) the DBG line from the
previous step. Using a square, transfer the
mark towards the back about 12” in length,
perpendicular to the centerline of the main
rails.
Mark the location of the first governor rope
drop (closest to main rail line) on the line from
the previous step. Refer to dimension 6 on
the sample layout.
3 1/4”
Centerline of
Governor 1 3/4”
from front of Rail
Centerline of
Target Lines
Centerline of
Main Rails
Centerline
Front of Main
Rail
Set the triple tube target line block- out. The
centerline of the 2 back tubes (target line
locations) is to be located ¼” from the back
of the rail. For a 5/8” rail, that would be 3 ¼”
from the front of the main rail. For a #3/4 rail,
the distance would be 4 1/8”.
Double Check
After the target line tubes have been set, and
screwed down, double check them by measuring
center- to- center from one of the back parallel
tubes on each side. This measurement should
equal DBG + 6 ½ ” (for 5/8” rail), or DBG + 8 ¼ ”
(for a #3/4 rail).
NOTE: If “Q” decking is being used, the holes
will either need to be pre- cut prior to
setting the block- out or a straight tip
torch will be required after the pour to get
down into the tubes.
Section 2 – Machine Room Block- Out Installation
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ThyssenKrupp Elevator
Fast Track Installation Process
Set the governor block- out along the proper
centerline, using the mark for the first
governor, rope drop to properly space it from
the centerline of the main rails.
NOTE: If “Q” decking is being used, the holes
will either need to be pre- cut prior to
setting the block- out, or a straight tip
torch will be required after the pour to
get down into the tubes.
Locate CWT Rail Line
Measuring off the centerline of the main rails,
locate the centerline of the CWT rails in two
places. Refer to dimension 7 on the sample
layout.
Section 2 – Machine Room Block- Out Installation
After the governor block- out has been set,
and screwed down, double check it to ensure
it is properly spaced. The center- to- center
distance of the target line tube, and the
governor tube should be 1 ½ ” for a 5/8” rail,
or 2 3/8” for a #3/4 rail.
Chalk CWT Rail Line
Snap a chalk line along these two points (CWT
rail line) for reference.
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ThyssenKrupp Elevator
Fast Track Installation Process
CWT Rail Line
Center Line
of DBG
Main Rail Line
Along the centerline of the CWT rails, mark the
center of the CWT DBG. Refer to dimension 5
on the sample layout.
Verify the centerline of the CWT rails is square
with the centerline of the main rails, by using a
framing square, and string between the center
points of each line.
Double Check
Set the 8” x 8” rope drop block- outs at the
center point of the main rail DBG, and the
center point of the CWT rail DBG.
Section 2 – Machine Room Block- Out Installation
After the rope drop block- outs have been set
and screwed down, double check them by
measuring the center- to- center of each blockout. Refer to dimension 7 on the sample
layout.
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ThyssenKrupp Elevator
Fast Track Installation Process
Set Duct
The remaining 8” x 8” block- out is for the
riser/duct. This should be set a minimum of
10” off of the front inside wall of the hoistway.
The block- outs are now set. Cover the tops
with duct tape to keep concrete and other
debris clear.
Additional Requirements for Corrugated Steel “Q” Decking
When block- outs are set on corrugated decking, ensure all spaces/voids are sealed to prevent the
entry of concrete under the block- outs. Also, if the outside footprint of the block- out falls within a
flute, and is left unsupported, a piece of scrap material (example - steel angle) should be used to
span the flute and provide support.
Section 2 – Machine Room Block- Out Installation
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Fast Track Installation Process
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Section 2 – Machine Room Block- Out Installation
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Fast Track Installation Process
Section 3
Early Delivery
NOTE: Early Machine and Controller delivery is
available on all Traction jobs, specify at
the time of ordering.
Section 3 – Early Delivery
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Fast Track Installation Process
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Section 3 – Early Delivery
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Fast Track Installation Process
Important!
When flying in or setting early
equipment, ensure to remove all pallets
from the equipment, and set as close to
final location as possible.
If block- outs were used, ensure to cut
them down flush with the floor to
prevent any interference when
positioning the equipment.
Also, always remember to reweatherproof (cover) all ThyssenKrupp
equipment.
Section 3 – Early Delivery
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ThyssenKrupp Elevator
Fast Track Installation Process
Fly Machine in Place
Re-Weatherproof Machine
Remove all pallets from bottom of controller/machine, and ensure all block- outs in the machine
room are cut down flush with the floor. Hoist the controller, and machine to the machine room, and
set in correct location. Cover the equipment with a TKE waterproof bag, and tie it down.
NOTE: Order machine and controller for early delivery. Fly them from the truck to their location in
the machine room. In the event the crane is not available when they arrive, simply stage in
a location that they will not have to be re- handled when the crane is available. Ensure
equipment is covered to stay dry.
Caution
!
Section 3 – Early Delivery
Ensure to fasten down all equipment that could be blown
off the building.
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ThyssenKrupp Elevator
Fast Track Installation Process
Fast Track 2
Laser Rail Alignment
NOTE: The Line Wire Alignment Method
(Section 10) can be utilized in place of
the Laser Rail Alignment Method
(Section 4) if desired.
Fast Track 2 – Laser Rail Alignment
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Fast Track Installation Process
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Fast Track 2 – Laser Rail Alignment
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ThyssenKrupp Elevator
Fast Track Installation Process
Fast Track 2 Quick Chart
Lasers & Tirak Motor
This process combination is the preferred installation method since it is the safest and most flexible with regards to the general
contractor’s schedule. Note that the times reflected below are total hours and do not include initial prep work (ie material unloading)
Set Pit Channels Correct, Survey Hoistway &
Mount Material Hoist – 4 Hours (Day 1)
1
Day 1
Cwt Pit Channel
Temporary Placement
of Lasers for setting of
machine
Set Machine/Governor, Drop Tirak Hoist Cables
& Install Rigging off Machine – 4 Hours (Day 1)
2
Day 1
Cwt Rope
Drop
Laser Beams from
Lasers on Pit
Channels used to
Locate Machine
Position
Governor
Drops
Car Pit Channel
Car Rope
Drop
Temporary Placement of Lasers for setting
pit channels and surveying hoistway
Hoistway
Riser
Set First Round of Main & Cwt Rails Complete &
Install Car/Cwt Buffers – 8 Hours (Day 1)
Day 1
3
Cwt Rail
Hoist Cwt Frame into Place & Build Car Frame –
16 Hours (Day 2)
Car Frame
Dual Beam
Laser Bracket/
Lasers
Laser Beam
Day 2
4
Main
Rail
Laser Beam
Laser
Bracket/
Laser
Main Rail
Car Buffer
Build Crosshead Work Deck & Install Tirak Hoist
& Mounting Bracket – 4 Hours (Day 3)
5
Tirak
Mounting
Bracket
4x4's
Crosshead
Day 3
6
Day 3
Begin Stacking Rails
Day 3
Hitch
FRONT
Plate
Fast Track 2 – Laser Rail Alignment
Front
Floor
Section
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ThyssenKrupp Elevator
Fast Track Installation Process
Fast Track 2 – Traction Installation Planner (4 Stop)
* Add 4 team hours (1/2 day) for each opening above 4. ** Add 8 team hours (1 Day) for rear opening.
Day
Task
Pre Day
Pre Day
1
Set machine room block- outs.
Early Equipment – hoist machine room equipment into place.
Mobilize to jobsite, and unload truck, and stage material.
Drop safety lines, and clean/attach rails, and fishplates.
Install rigging, and mount hoist.
Set the main, and CWT rail pit channel to the proper DBG in correct location that
matches the lobby landing by using lasers.
Survey hoistway, and anchor pit channels.
Run all duct, and conduit in MR, and set governor (start).
Run all duct, and conduit in MR, and set governor (complete).
Pull, and terminate all machine room wiring.
Set machine perfect with lasers
Drop two Tirak hoist, and safety block cables, and anchor hoist at bottom landing.
Install, and align the first round(s) of main rails, and CWT rails
Install car, and counterweight buffers (fill buffers with oil), and governor tension
frame.
Hoist CWT frame into place with guides, and block- up adding correct temp
weights
Build the car frame (start)
Build the car frame (complete)
Build the work deck on top of the crosshead, including handrails, and overhead
protection, then add Tirak hoist.
Build door frames, and clean/file mains, and CWT fishplates (start).
Build door frames, and clean/file mains, and CWT fishplates (complete).
Stack/align the main, and CWT rails, including fishplates (start)
Stack/align the main, and CWT rails, including fishplates (start)
Finish setting/installing main, and CWT rail brackets (start).
Finish setting/installing main, and CWT rail brackets (complete).
Break down, clean, and lubricate brake and start- up machine, checking rotation. Rope
the elevator complete adding contract platform and remove Tirak hoist and cables (start).
Rope the elevator complete, adding contract platform, and remove Tirak hoist, and cables
(complete).
Install all door frame strut angles, strut channels, sills, and headers.
Distribute assembled, and install all door frames (jambs).
Install all hall fixture boxes.
Run all hoistway duct, and conduit.
2
3
4
5
6
7
8
9
10
Fast Track 2 – Laser Rail Alignment
Team
Hours
(Target)
Team
Hours
(Actual)
2
2
8
2
1
1
1
3
2
4
1
1
3
1
2
2
4
2
2
2
6
3
5
3
5
3
5
5
1
2
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ThyssenKrupp Elevator
Fast Track Installation Process
Fast Track 2 – Traction Installation Planner (4 Stop)
* Add 4 team hours (1/2 day) for each opening above 4. ** Add 8 team hours (1 Day) for rear opening.
Day
11
12
13
14
15
16
17
18
19
Task
Install all hoistway electrical components (i.e., limit switches, pit switches, buffer
switches, LON or CAN boxes, etc.).
Hang, and adjust all hoistway doors (adjust door gibs, install all retainers, and set
all upthrust rollers).
Install and adjust all door closers (spirators or sash weights), and install, and adjust all
door locks.
Pull, and terminate all hoistway wiring, and feed the wire, including TC to the
controller. Cover the hoistway duct.
Install all hoistway fascia, and dust covers.
Add the appropriate amount of fillerweights to the counterweight frame for cab
rd
(2/3 total).
Build the cab.
Install, and adjust the cab doors.
Install LDO door operator.
Install, and adjust cab door clutch, and restrictor devices.
Install Pana 40 devices on cab door(s), or strike column (if applicable).
Install door zone sensor on car top.
Install cab steadiers.
Plumb the cab.
Install all door zone sensors, or vanes in the hoistway.
Wire cab complete (i.e., top of car, and COP).
Install toe- guard.
Static balance the car.
Set- up roller guides, and safeties.
Add test weights to the car, and the proper amount of fillerweights to the
rd
counterweight frame (last 1/3 ).
Tie the fillerweights down inside the counterweight frame.
Set- up counterweight rollerguides.
Install, and wire the hall fixtures.
Wire the controller (traveling cable).
Wire the controller (hoistway wires).
Clean the hoistway, machine room, cab, and car top.
Begin adjusting of car.
Complete adjusting of car.
Perform inspection, and complete the following:
ƒ Fill out all applicable reports, including Field Test and Data Report.
ƒ Get Final Acceptance form signed (if paid to 905).
ƒ Do handover to Service Department.
TOTAL TEAM HOURS
Fast Track 2 – Laser Rail Alignment
Team
Hours
(Target)
Team
Hours
(Actual)
4
4
4
4
3
2
3
2
1
2
1
1
1
1
2
3
1
1
1
3
1
1
1
1
1
3
4
8
8
156
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Fast Track Installation Process
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Fast Track 2 – Laser Rail Alignment
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Fast Track Installation Process
Section 4
Laser Rail Alignment System
NOTE: Process uses Dual Lasers on each Main
Rail for Rail and Machine installation.
Section 4 – Laser Rail Alignment System
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Fast Track Installation Process
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Section 4 – Laser Rail Alignment System
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Fast Track Installation Process
Laser Rail Alignment Overview
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Laser Rail Alignment System
The laser alignment system is an alternative to the traditional line wire system. Like the dual line wire
system, it plumbs and squares rails with a single step. To get the optimal accuracy out of this
process, the following is recommended.
•
Use PLS3 lasers manufactured by Pacific
Laser Systems. They are self leveling and
are highly accurate.
•
Protect the lasers from falling debris or
dropping.
•
Ensure batteries are fresh.
•
Use on units with up to 100 ft of rise.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Working from the pit, prepare to set the main rail pit channel. First, mark the center point of the
buffer attachment plate. Then, set the overall width of the pit channel by taking half of the contract
DBG, plus rail size from the center point of the buffer plate, to each end. Ensure each end is square
and vertically level. After tightening bolts, double check the squareness.
Main Rail Line mark
Position a laser on the pit floor close to the side wall. Referencing the contract layout, locate the
main rail line by measuring from the front hoistway wall to the laser line. Place a mark on each side
of the hoistway.
The measurement should NOT be taken from the pit wall, but instead, from higher up on the
hoistway wall at the level where the entrance frame will be located. Since the pit wall, and the
hoistway wall are not always flush, this will ensure proper clearances.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Rear of Pit
Channel
Main Rail
Line
½ Pit Channel Depth
Using the location of the main rail line, subtract ½ of the pit steel depth from this measurement to
calculate the location for the front edge of the pit steel. Chalk this line.
+
Follow only if Hoistway
matches layout
Place the front edge of the channel on the reference mark from the previous step. Then, center the
channel by measuring from the inside end of the pit channel to the wall, and verifying with the
contract layout.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Anchor the pit channel into place using the plate that comes attached to the channel as a washer.
NOTE: The pit channel can still be adjusted up to 2”, if required, after surveying the hoistway.
Lasers
Once anchored in place, double check that the DBG is set correctly. Also, verify the channel location
by setting the laser on the main rail line of the channel, and measuring from the beam to the
hoistway wall at the level where the entrance frame will be located.
Adjust the pit channel if necessary.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Prepare to set the CWT pit channel using the same steps as the main rail channel. Find the
centerline of the CWT buffer plate, and using the DBG, set, and square each end.
Centerline of Main and
CWT Pit Channels
Locate the CWT pit channel by squaring it to
the main rail pit channel. Verify the distance
between the channels from the layout, and
then, measure from outside- to- inside of the
channels.
Section 4 – Laser Rail Alignment System
Double check location of the CWT pit channel,
front- to- back, by measuring inside- to- outside
on the main, and CWT pit channels. Anchor
into place, and recheck measurements.
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ThyssenKrupp Elevator
Fast Track Installation Process
Stringing Rail Lines in Pit (Bottom) for Duplex/Triplex (If Applicable)
Now that the pit steel is set, if the unit is part of a duplex, or triplex, mark one continuous chalk line
for the front edge of all the pit channels. Set the other channels to these marks, and center as
previously described. This will ensure straight entrances in the corridors.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Survey the hoistway.
Laser
Beam
Approx. 45 degrees
Reference
mark
If the hoistway rough opening doesn’t allow for easy square access to the side wall, utilize a piece of
conduit bent in a “V” shape. Place a reference mark onto the conduit that is equal to the center line
of the main rail location from the front wall (see contract layout). Hold the conduit into hoistway,
ensuring it is square, and the end is properly positioned in the corner.
If needed, adjust the pit channel to accommodate actual hoistway conditions.
NOTE: If major discrepancies are found while surveying the hoistway, contact the General Contractor.
If additional work is required, obtain the appropriate change order.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Set lasers on the center points of each pit
channel, and transfer the marks to the
machine room floor. Place a white piece of
paper over each rope drop hole, and chalk a
line between each transferred light beam.
This mark (centerline of driver), can then be
used as reference with the contract layout to
set the machine. Set driver to location of
laser on CWT pit channel, and move the
deflector sheave to the center of the laser on
the main pit channel.
NOTE: If planning to use Fast Track 2, the cables
for the cable climbing hoist motor can be
secured at this time to a properly rated
attachment point.
NOTE: These steps not
required if flying in
machine and
setting in place
over holes.
NOTE: Add a Softner/Padding
prior to loading.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Mount a material hoist in shear at the bottom landing. The hoist can be used for hoisting rails, car
frame structure, and the CWT frame.
Install, and align the first round of main rail brackets. Reference the layout drawing, and actual
hoistway dimensions to set the correct distance from the back of the rail.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Install, and align the first round of rails. Plumb, with a 4’ level, and ensure they are square (faced) to
one another by using a tram gauge, or piece of conduit. Ensure that each rail is centered within the
pit channel, and shim between the pit channel, and the bottom of the rail, if it is milled. Double check
the DBG at the lowest level before proceeding.
NOTE: Depending on the pit depth, two rounds of rails may have to be stacked, and aligned prior to
building the car frame.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Attach the dual line laser brackets/lasers at the lowest secured level of the rail, and attach the dual
beam laser target just above. Verify that the lasers are hitting the targets. Correct if necessary, and
repeat verification on both sides.
Move the dual beam laser target to the first bracket that was aligned with the level to ensure the
lasers are still hitting the targets. If it is off, adjust the bracket until centered.
Double check the dual beam laser
target at the first bracket, and readjust accordingly.
Section 4 – Laser Rail Alignment System
Using a ladder, install the second round of brackets, and
align using the dual beam laser target. Then, secure in
place.
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ThyssenKrupp Elevator
Fast Track Installation Process
Using a single- beam laser for “T” or Omega rails, install, and align the first two rounds of CWT rail
brackets. Reference the layout drawing, and actual hoistway dimensions to ensure the location is
accurate.
Pit
First Bracket
Install, and align the first round of CWT rails using a laser. Center each rail within the CWT pit
channel, and plumb to the target in the CWT rail bracket. Repeat for other side. Using a tram gauge,
or piece of conduit, ensure the rails are square to one another.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Laser System for Mid- Rise Units
This laser system attaches to the back of the rail which allows the car to pass. This system should be
used on mid- rise units where repositioning of the lasers is needed. Also, should be used when
jumping rails.
Section 4 – Laser Rail Alignment System
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ThyssenKrupp Elevator
Fast Track Installation Process
Section 5
Pipe Equipment, Car, and
CWT Frame
NOTE: Bottom set of Main and Counterweight
Rails must be installed completely prior
to moving forward on Fast Track 1 or
Fast Track 2.
Section 5 – Pipe Equipment, Car, and CWT Frame
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Fast Track Installation Process
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Section 5 – Pipe Equipment, Car, and CWT Frame
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ThyssenKrupp Elevator
Fast Track Installation Process
Setting of Pit Equipment, Building Car Frame, and Work Deck
Fill all CWT buffers with oil prior to installing them
in pit.
Hoist buffers into place.
Install the car, and CWT buffers, and stands, if supplied. Ensure they are plum, level, and centered.
Remove packing material on piston.
Section 5 – Pipe Equipment, Car, and CWT Frame
55
ThyssenKrupp Elevator
Fast Track Installation Process
Hoist the governor tension frame into place, and install to the rail. Block- up the frame off the pit floor
to accommodate rope stretch.
Add
Guides
Move CWT frame to front of hoistway, using a channel dolly, and remove the CWT tie- down rods
from the frame, and store in the corner of the pit. Then, install 2 roller/slide guides on one side (top
and bottom) of the weight frame. Also, install CWT strike, if provided. Hoist weight frame into place.
Section 5 – Pipe Equipment, Car, and CWT Frame
56
ThyssenKrupp Elevator
Fast Track Installation Process
Blocking
Add the top, and bottom roller/slide guides to the opposite side. Adjust all four guides firmly, and
equally.
Block- up the weight frame so the strike point of the frame is 2’ above the strike of the buffer. Ensure
that the CWT strike plate is attached if provided.
Warning
!
DO NOT add weights in frame unless blocking is of steel, or
you have redundant support (cables, slings, etc.).
Remove rigging, and add the CWT weights to the
frame appropriately. TOTAL CWT WEIGHTS AND
FRAME COMPLETE, EQUAL TOTAL CAR SLING
PLUS 600 LBS (FOR 2 EMPLOYEES AND
MATERIAL), MINUS CONTRACT PLATFORM. After
frame is loaded, add the CWT rods to secure the
weights in the frame.
If Fast Track 1 will be used, add the guide cables by
connecting them to the machine bedplate, down
through the CWT side rope holes, through the
weightframe/weights, and terminated to the pit steel
with turnbuckles.
Section 5 – Pipe Equipment, Car, and CWT Frame
57
ThyssenKrupp Elevator
Fast Track Installation Process
Stage the safety plank in front of the hoistway, and then,
add a means to hold the safety plank secure, and level, on
each side of the rail while setting on the compressed
buffer. Hoist the safety plank into place, centering postwise, and front- to- back, ensuring the plank is level. Then,
drive the wedges upward, centering the throats. This can
be done by using a piece of unistrut extending up from the
pit floor, or by prying the releasing carriage upward, and
securing by governor rope, or temporary means.
Add cam to stile, and then, hoist stiles in place. All car- frame bolts must face away from the rail for
added clearance. Using the spud wrench to hold the stile in place with the safety plank, add all the bolts
hand tight. After completing one stile, repeat process on other stile. Then, hoist crosshead in place,
repeating the process for securing stiles the same as the safety plank.
Section 5 – Pipe Equipment, Car, and CWT Frame
58
ThyssenKrupp Elevator
Fast Track Installation Process
Verify from the layout, the distance from the bottom of the crosshead to the top of the safety plank.
Take into account the thickness of the platform to assure the correct height of the cab. Then, add the
roller guides to the crosshead, and set the tension as tight as possible. Using an impact, tighten all
stile bolts. You may then add your brace rods, platform arms, traveling cable hanger, etc.
NOTE: It is recommended to leave the contract platform off until all the main and CWT rails have
been installed complete.
Install the temporary work platform to the crosshead. Build the supporting structure of the crosshead
work platform using 4x4 timbers. A minimum of 4 timbers should be used with additional timbers
being added, if spacing between exceeds 24”. The timbers at each end of the crosshead should be
located just inside of the roller guides. The other timbers should be spaced evenly between them.
Section 5 – Pipe Equipment, Car, and CWT Frame
59
ThyssenKrupp Elevator
Fast Track Installation Process
½”x6" Carriage
Bolt
Square Plate
Washer
Beveled, Flat &
Lock Washer
4x4
½” Hex Nut
Crosshead Channels
Drill 2 holes in each 4x4, approximately ¾” off the edge of each flange of the crosshead channels.
Using a square plate washer, clip each 4x4 to the top flange of the front, and rear crosshead
channel.
Attach ¾” plywood to the top of the 4x4 frame
with wood screws. Ensure a cut out is made
around the rope hitch.
Complete the assembly of the platform by
attaching handrails, and kickboards to all
sides, with the front rails being removable.
Ensure overhead protection is present on the
work platform, or by guarding all entrances,
and machine room floor openings.
NOTE: If needed, conduit braces may be added to increase
stability. Flatten/drill the ends on 4 pieces of conduit,
and attach one end to an existing hole in the stile, and
the other end to the work deck.
Section 5 – Pipe Equipment, Car, and CWT Frame
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ThyssenKrupp Elevator
Fast Track Installation Process
Section 6
Fast Track 2
Utilizing Cable Climbing Hoist
to Install Rails
NOTE: The Cable Climbing Hoist can be
purchased or leased.
Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
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Fast Track Installation Process
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Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
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ThyssenKrupp Elevator
Fast Track Installation Process
Setting Machine Room Equipment and Controller
Set the machine, and governor, referencing the contract layout, and the rail alignment
template (line wire alignment system), or the laser reference marks (laser alignment system).
NOTE: All block- outs for governor, and machine rope drops must be cut down flush with floor prior
to setting equipment to prevent any interference when positioning.
Set the controller, referencing the contract layout, or to satisfy local codes. After controller is set,
notify electrician to pipe, and wire complete.
Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
63
ThyssenKrupp Elevator
Fast Track Installation Process
Governor Roping Procedure
Step 1
Step 2
Governor
14 Gauge Wire
Governor Rope
Spool
Barricade
Top Floor
Top Floor
Cwt Frame
Bottom Floor
Bottom Floor
Cwt Blocking
Governor Tension
Frame (Blocked)
Step 1
Set the governor rope spool up on rollers at the top landing. With one person in the machine room,
drop a piece of 14 gauge wire down through the governor rope hole furthest away from the rail. With
a second person at the top landing, attach the end of the governor rope to the wire. From the
machine room, begin pulling the rope up to the machine room.
Step 2
Once the rope reaches the machine room, feed the end around the governor sheave, and lower it to
the pit. Once the cable has come off of the spool, set the jaws on the governor.
Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
64
ThyssenKrupp Elevator
Fast Track Installation Process
Step 3
Top Floor
Step 4
Top Floor
Governor
crosshead
hitch
Bottom Floor
Bottom Floor
Governor releasing
carriage
Step 3
From the top landing, pull the rope downward, rotating the governor in the opposite direction. Send
the cable down to the pit, until the other end reaches the height of the governor releasing carriage
termination point.
Step 4
From the pit, terminate the rail side of the governor rope to the releasing carriage arm. After
completing, pull down the opposite side of the governor rope taut, and feed the end through the tail
sheave. Terminate the end to the crosshead attachment point.
Governor Roping is now complete.
Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
65
ThyssenKrupp Elevator
Fast Track Installation Process
Terminate one end of the governor rope to the releasing carriage, and then, terminate the tail end.
Remove the blocking from the governor tension frame, and reset the governor in the machine room.
Ensure all electrical wiring for the governor is complete prior to riding the elevator.
Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
66
ThyssenKrupp Elevator
Fast Track Installation Process
Cable Climbing Hoist Motor Installation
Cable
Chokers
Around
Beam
Hoist
Cables
Hoist
Cables
Cable Chokers
Around Driver
Attach two hoist motor cables to a hoisting beam, or other attachment point (like the machine driver)
rated for the proper capacity (see chart below). They should be separated by no more than 2’.
Lower the cables down the hoistway ensuring the length is sufficient to reach the pit.
NOTE: A steel chocker may be used around a beam with all swedged eyes connected by a clevis. No
nylon/rope slings are to be used. Proper padding must be present around top of beam
flange. If using wood to pad the flanges, ensure to first secure it to the beam to keep it from
falling.
NOTE: If using the laser rail alignment system, the installation of the cables may have already been
completed.
Yield Strengths of American Standard Beams*
Strength in KIPS (1000 lbs.)
Span in
Feet
6
7
8
9
10
11
12
8x4
23
32.4
27.8
24.3
21.6
19.4
17.7
16.2
Nominal Depth and Width of Beam/Weight per Foot
7 x 3 1/4
6 x 3 3/8
5x3
18.4
20
15.3
17.25
12.15
14.75
28.8
24.2
21.0
17.5
14.7
12.2
24.7
20.7
18.0
15.0
12.6
10.4
21.6
18.2
15.8
13.2
11.1
9.1
19.2
16.1
14.0
11.7
9.8
8.1
17.3
14.5
12.6
10.5
8.8
7.3
15.7
13.2
11.5
9.6
8.0
6.6
14.4
12.1
10.5
8.8
7.4
6.1
10
9.8
8.4
7.4
6.6
5.9
5.4
4.9
* Load in center of span with bean fixed against horizontal movement.
* Strength of beam should be capable of supporting the motor’s capacity x 5 (safety factor = 5:1).
Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
67
ThyssenKrupp Elevator
Fast Track Installation Process
Temporary power for
Hoist and Welder
Connect
Pig Tail
Provide the pig tail(s) to the General Contractor/electrician for hook- up to the building power source.
The pig tail should be rated for 30 Amps. To protect against an excessive voltage drop, the power
source should be located at the mid- point of the rise, and close to the hoistway. This location will
allow for the shortest amount of power cord, and still provide access to the full hoistway.
Secure Ropes to
Properly Rated
Attachment Point
or around Machine
Driver
Once on the platform, attach it securely to
the crosshead attachment bracket, and
then, feed the secondary hoist cable into
the block- stop.
Top Floor
Main Hoist Rope
Cable Climbing
Hoist
To install the cable climbing hoist motor
onto the crosshead work platform, begin by
positioning it at the lowest landing. Then,
feed the main load rope into the hoist, and
continue to run the motor, letting it “walk”
itself up the cable to the car top platform.
Hoist Mounting
Bracket
IMPORTANT!
Follow the detailed installation process on
the following pages.
Bottom Floor
Secondary Hoist
Rope
Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
68
ThyssenKrupp Elevator
Fast Track Installation Process
Attachment point
for Hoist Stiffup.
Use only Grade 8
Bolts.
Pedestal/Base
attachment point.
Use only Grade 8
Bolts. Also, point of
attachment for
Single Block-Stop.
Threaded rod
used for securing
the Bracket to the
Crosshead.
Attach the hoist mounting bracket to the crosshead. The bracket should be fully assembled (with the threaded
rod backed out), and lowered down between the crosshead channels. Once the base is below the channels, it
should be turned 90° (perpendicular to the channels), and lifted up against the channel flanges. The threaded
rod should then be tightened up against the channel, “sandwiching” the flange between the base, and the
threaded rod. This will hold the bracket in place when there is no load on
the hoist.
If using the 2 single block- stop arrangement, instead of the dual blockstop, attach the separate single block- stop to the pedestal/base
attachment point using the provided bolts.
IMPORTANT!
If using a non- standard attachment bracket, it must be
engineered/certified for at least the capacity of the hoist motor (including
a 5:1 safety factor), and have the capacity clearly marked. For added
safety, the bracket should also be designed to provide redundancy to
failure of a weld, bolt, or steel member.
Dual Pedestal
design. Each
piece capable
of holding
rated load.
Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
Dual angles,
individually
welded to base
with a two bolt
sheer connection
to Pedestal. Each
angle/bolt
capable of
holding rated
load.
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Run Button
Plug
Bypass Plug
Hook up the power cords/power “Y” to pig tail at power source, and to hoist motor at the bottom
landing. If desired, connect a standard TKE temporary run button to allow remote operation. If the
run button is NOT used, ensure the “bypass” plug is connected to provide functionality to the direct
controls.
Reeving of Primary Load Rope with Dual Block- Stop Arrangement
IMPORTANT!
Prior to normal operation, the secondary wire rope must be installed.
It is against TKE policy to use the hoist to move the temporary work
platform with just a single cable. See next page for instructions on
installing secondary rope.
Reeve the primary load rope into the hoist, and run the hoist in the up direction, letting it climb the cable, up
to the work deck on the crosshead. To reeve the hoist, open the block- stop brake by pushing down on the
control lever (e1), until it locks. Push, and hold the release lever (e3) in a vertical position. The brake
release lever (c4) can be used to help hold the block- stop release lever open. With gloved hands, slide the
rope through the release lever hole, and into the block- stop at point (A). Push it through the block- stop,
and into hoist body (B). Press the up button until the wire rope reeves itself automatically, and exits at point
(C).
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Reeving of Primary Load Rope with 2 Single Block- Stop Arrangement
Entrance
Wire Rope
Exit Wire
Rope
Reeve the primary load rope into the hoist, and run the hoist in the up direction, letting it climb the
cable, up to the work deck on the crosshead. To reeve the hoist, open the block- stop brake by
pushing down on the control lever (d1) until it locks. With gloved hands, push the rope through the
block- stop at (A), and into the rope inlet/body at (B). Press the UP button until the wire rope reeves
itself automatically, and exits at point (C).
Attach the hoist to the crosshead bracket using the 2 grade 8 bolts provided. Attach the strain relief
for the power cord to the bracket.
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Reeving of Secondary Safety Rope with Dual Block- Stop Arrangement
Insert the secondary wire rope at point (D), and push it
through the block- stop until it is tensioned. Ensure the
block- stop brake is open, either through tension on the
primary load rope, or manually pushing the release lever to
the vertical position.
IMPORTANT!
Prior to normal operation, the secondary wire rope must be
installed. It is against TKE policy to use the hoist to move the
temporary work platform with just a single cable.
Reeving of Secondary Safety Rope with 2
Single Block- Stop Arrangement
Insert the secondary wire rope at point shown, and push it through the block- stop until it is
tensioned. Ensure the block- stop brake is open by pushing the control lever down until it
locks.
IMPORTANT!
Prior to normal operation, the secondary wire rope must be
installed. It is against TKE policy to use the hoist to move the
temporary work platform with just a single cable.
Secondary
Safety
Rope
The hoist is now ready for operation. Ensure the Daily Safety Checks are reviewed on the
following pages prior to beginning the rail installation.
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Cable Climbing Hoist Reference
Accessories and Safety Checks
The Tirak cable climbing hoist manufactured by Tractel, Inc., is the recommended hoist motor for use
with the Fast Track 2. Below are the specifications for 2 different Tirak models that are available. If
you are using a different type/model hoist, please refer to that hoist’s user manual for specifications.
Capacity
(lbs)
Power1
Running
Amps
Rope
Size2
XE 701P
1500
1- Phase
220V
12
5/16
XE 1020P
2400
3- Phase
220V
9.6
3/8
Rope Specification2
5x19, 4x26, or 5x26, with fiber
core, or 6x19 (min. 17 wires per
strand), galvanized or black,
lubricated, preformed, IPS or
XIPS.
1 - Voltage should be within +/- 10% of the hoist rating. The XE1020P comes standard with a 220 V
motor. A 480 V motor is recommended, since the permanent power for the elevator is likely 480
V.
2 – Rope meeting the hoist manufacturer’s specs, must be used.
Tirak Hoist Key Components
1. Primary Load Rope.
2. Secondary Safety Rope.
3. Dual BS/BSO block- stop* (secondary brake for primary and
secondary rope).
* 2 single BSO block- stops can be used in place of the dual
block- stop.
4. Emergency Stop.
5. Up/Down direct control buttons.
6. Temporary Run Button connection (allows hoist to be controlled by
standard TKE run button instead of the direct control buttons).
7. Emergency Descent Brake Release Lever (used to lift brake for a
controlled descent in the event of power failure).
8. Stirrup Adapter (connection point to crosshead mounting hitch).
9. Power Cord.
10. Brake Release Port (insertion point for the brake release lever (7))
NOTE: The above features are standard for hoists purchased through the
Tractel Purchasing Agreement, or rented through approved TKE
Supplier. Hoists purchased prior to the Agreement, or obtained from
other Suppliers, may not have all the above options.
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Required Accessories
Power “Y”
Power Cord
Connects directly to 1- phase
hoist motor, and power cord.
Includes 18” legs of SO cord,
with 110 V GFCI for power
tools, along with an extra 220
V connection for a welder.
Connects to power “Y” (1phase), or directly to hoist (3phase), and to pig tail.
Includes 100 ft of 10/4 SO
cord,with strain relief grips.
Pig Tail
Connects to power cord,
and wired directly to
building power source.
Includes 3 ft of 10/4 SO
cord.
Not for use with 3- phase
hoist motors
Temp. Run Button
Standard TKE, pluggable
run button, can be
connected to the hoist for
more operational flexibility.
Tirak Mount
Special Wire Rope
5/16” (XE701P), and 3/8”
(XE1020P) wire rope meeting
hoist manufacturer’s
specifications. Each rope, cut to
length with one end brazed for
ease of feeding into hoist, and
second end double swaged, with
thimbled eye for attachment point.
Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
Mounting bracket that
securely attaches to the
crosshead, and hoist
motor. Must be properly
engineered/certified, and
have capacity label.
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Daily Hoist Safety Checks
Only For Hoists with a Dual Block- Stop (BS/BSO)
Prior to running the hoist each day, the following checks should be performed to ensure the proper
operation of the hoist and safety devices. If any issues are found, the hoist should be immediately
removed from service.
Check I:
At the lowest level, push the DOWN button, to get slack in
the primary load rope, which will cause the release lever
(e3) to tilt to one side locking the brake on the secondary
rope. With gloved hands, try to pull the secondary rope
upwards. You should NOT be able to pull out any rope.
Check II:
At the lowest level, push the emergency stop on the side
of the block- stop (e2). Then, push the DOWN button to
get slack in the primary load rope between the hoist
casing, and the block- stop. Now, open the block- stop
brake by pulling down on control lever (e1) until it locks.
Push release lever (e3) to the vertical position, and with
gloved hands, sharply pull the primary load rope upward.
The block- stop brake should close immediately. ((e1)
lever moves to closed position).
Reset the block- stop brake by pushing down on control
lever (e1) until it locks.
Check III:
Lift platform 3’ above lowest landing, and push the
emergency stop on the side of the block- stop (e2).
Attempt to lower the platform by pushing the DOWN
button. Slack in the primary load rope should appear
between the hoist casing, and the block- stop, meaning
the block- stop is supporting the load.
Raise the platform until the hoist supports the load, and
then, reset (e1) to the open position.
Check IV:
During operation regularly check that the centrifugal
weights are rotating through window (e4).
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Daily Hoist Safety Checks
Only For Hoists with 2 Single Block- Stops (BSO)
Prior to running the hoist each day, the following checks should be performed to ensure the proper
operation of the hoist and safety devices. If any issues are found, the hoist should be immediately
removed from service.
Check I:
For block- stop on primary rope: At the lowest level, push the
emergency stop on the side of the block- stop (d2). Then, push
the DOWN button to get slack in the primary load rope between
the hoist casing, and the block- stop. Now, open the block- stop
brake by pulling down on control lever (d1) until it locks.
With gloved hands, sharply pull the primary load rope upward.
The block- stop brake should close immediately. ((d1) lever
moves to closed position). Reset the block- stop brake by
pushing down on control lever (d1) until it locks.
For block- stop on secondary safety rope: With gloved hands,
sharply pull the primary load rope upward. The block- stop brake
should close immediately. Reset the block- stop brake by pushing
down on control lever (d1) until it locks.
Check II:
For block- stop on primary rope: Lift platform 3’ above lowest
landing, and push the emergency stop on the side of the block- stop
(d2). Attempt to lower the platform by pushing the DOWN button.
Slack in the primary load rope should appear between the hoist
casing, and the block- stop, meaning the block- stop is supporting
the load.
Raise the platform until the hoist supports the load, and then, reset (d1) to the open position.
For block- stop on secondary safety rope: Lift platform3’ above lowest landing, and push the
emergency stop on the side of the block- stop (d2). Attempt to lower the platform by pushing the
DOWN button. Slack in the primary load rope should appear above the other block- stop, meaning
the block- stop on the secondary safety rope is supporting the load
Check III:
During operation, regularly check that the centrifugal weights are rotating on each block- stop
through window (e4).
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Daily Hoist Accessory Safety Checks
In addition to the checks on the previous page, the following items should also be visually inspected
daily:
•
Check the temporary crosshead platform
for any signs of damage. Ensure all
handrails are in place, and in safe
condition.
•
Check the hoist mounting bracket for any
signs of damage. Ensure all bolts are tight,
and secure.
•
Check all power cords, and connections to
ensure no damage.
•
Check the wire rope attachment point
ensuring it is properly secure.
•
Check the wire rope condition. If any of the
following are observed, the rope should be
immediately replaced:
o
Broken wires or strands.
o
Excessive corrosion.
o
Heat damage, evident through
discolored wires.
o
Any of the distortions illustrated in the photos to the right.
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Install Main and Counterweight Rails
Line Wire
Laser
Aligning Fishplates
Install, and align car rails. Align the rail brackets as the platform is moved up, and align the
fishplates on the way down. Rails should be aligned, using the dual line target gauge (for line wire
alignment), or dual beam target gauge (for laser alignment).
Always tighten all 8 fishplate bolts on one side to hold the rail plumb post wise. Prior to tightening,
with an impact, hold the rail eye ball plumb, using the laser or line wire for reference. This will allow
you to work off the temporary work deck rather than a ladder.
Caution
Caution
!
The rail brackets must be aligned as they are installed to keep
adequate contact, and pressure between the rails, and roller
guides.
Caution
!
When stacking and aligning rails, DO NOT run the car up and
out of the rails.
Once the main rails are installed, and aligned, remove the rail aligning wire, or lasers.
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IMPORTANT!
CWT rails must follow the main rails at top, and bottom, regardless if they were
plumbed, or straight lined.
If straight lining the CWT rails, either use the appropriate CWT rail aligning templates, or use the line
wire method.
Rail Template Method
Securely attach the CWT rail template to the wood temporary work platform, referencing the contract
layout. Then, using the car frame as a running template, set all CWT brackets, and stack all CWT
rails at the same time. If the lower round of CWT rails is NOT accessible from the work deck, run the
platform to a completed set of rail brackets, and transfer some reference lines from the “set”
brackets to the contract platform. Use these lines to set the lower rails, and brackets.
Line Wire Method
Line
Wire
Drop two line wires from the machine room, and set to the correct measurement at the top, and
bottom. Secure, and tension the wires to the pit channel using turnbuckles. Set/align the brackets
using the line wire, and stack CWT rails.
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If plumbing the CWT rails, use lasers.
Set the laser in the pit, and ensure it correctly hits the target for the first round of CWT brackets that
have already been set. Set the rest of the brackets, and rails, plumbing to the target in the CWT rail
bracket.
NOTE: Main rail brackets, and counterweight brackets may be installed simultaneously for side
counterweight applications using combination (main and counterweight) brackets.
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Car Roping Procedure
Step 1
Cable Shortening
Bracket
Fiber Rope
Cable Climbing
Hoist
Elevator Hoist
Rope
Car Sling with
Crosshead
Platform
Top Floor
Cable Spool on Rollers
Brace Rod
Arm
Bottom Floor
Main Hoist
Rope
Cwt Frame
Cwt Blocking
Secondary Hoist
Rope
Car Buffer
Taping Bedplate for Shortening
Bracket
Place a hoist rope spool on rollers on the temporary
crosshead platform. Shackle the end complete, unless
deflector guard prevents clearance. Position the crosshead
platform/car frame at the top of the hoistway using the cable
climbing hoist.
With one person in the machine room, install a cable
shortening bracket to the machine bedplate, and lower a fiber
rope through CWT side rope hole. Feed the cable off the
spool while the shackled end is pulled up through the CWT
rope hole.
Cable Shortening Bracket
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Step 2
Cable Climbing
Hoist
Top Floor
Rope Gripper
Bottom Floor
Secondary Hoist
Main Hoist
Rope
Cwt Frame
Car Buffer
Cable Shortening Bracket with
First Cable Attached
Take the cable around the driver/deflector, and down through the car rope hole, until the shackle
reaches the proper location in the crosshead hitch. DO NOT terminate in the hitch plate.
NOTE: If a rope gripper is installed, block it open, and feed the cable through it.
Secure the cable in the shortening bracket.
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Step 3
Top Floor
Shackles in
Cwt Rope
Hitch
Rope Termination in CWT Frame
Bottom Floor
Slip
Traction
Using the cable climbing hoist, run the car down until all of
the rope is off of the spool.
Repeat Step 1 and 2 for remaining hoist ropes.
Once all cables are down to the CWT frame, shackle, and
terminate each cable complete to the CWT frame from the
crosshead work platform. Ensure the cables DO NOT get
crossed.
From the machine room, take out the slack of each cable by
pulling it over the driver. This is accomplished by having
one person loosen a cable from the shortening bracket, and
then, having the team together, slip traction over the driver
eliminating the loose cable. Re- secure the cable in the
shortening bracket, and repeat until slack is removed from
each cable.
Section 6 – Fast Track 2 - Utilizing Cable Climbing Hoist to Install Rails
Loosen
Remove Slack from each Rope
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Step 4
Run
Button
Crosshead Termination
Top Floor
Bottom Floor
Shortening Bracket with
One Cable
Using the cable climbing hoist, position the car frame back at the
top of the hoistway. Ensure it is at the proper level to allow the
shackles to reach the hitch plate.
Terminate each shackle complete to the car hitch plate. Remove
the blocking from the CWT frame, then, remove the cables from
the shortening bracket.
Lower the temporary run button down to the crosshead platform
through the hoistway wireway
Remove cable climbing hoist motor, cables, and accessories.
Car Roping is now complete.
Run Button Cable from
Machine Room
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Install Contract Platform and CWT Guard
Install platform, and brace rods at lowest landing. Level the platform, left- to- right, and shim, if
needed. Install all four brace rods, and level from front- to- back.
Then, install the CWT guard, setting it to the proper height. Add the required signage.
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Run all machine room duct, and conduit complete.
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Pull, and terminate all machine room wiring.
Break down, clean, and re- assemble the
machine brakes, and set the brakes, and the
brake spring tension.
Start up the machine. Verify rotation
direction, and speed.
NOTE: Refer to the appropriate machine product manual for complete instructions.
Caution
!
The governor over- speed (potential) switch, and the rope
gripper switch, must be functioning in the safety circuit, prior to
operation.
NOTE: The cleaning, and setting of machine brakes, temporary start- up of the machine, and
adjusting temporary running speed, must be performed by a qualified person.
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Section 7
Entrances and Doors
NOTE: Refer to the TK Entrance Product Manual
for additional installation instructions.
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Section 7 – Entrances and Doors
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Obtain the finished floor height dimension (per floor, per elevator) from the General Contractor.
Record these dimensions in the Project Management Book, and have the Contractor sign the
completed form. DO NOT guess at the finished floor height! “I have a half inch of marble in the
lobby” or “I am getting real thick carpet in the basement” is NOT acceptable; make the General
Contractor sign for clear, specific, and cast- in- stone, sill height dimensions.
Refer to the TK Entrance Product Manual for additional installation instructions and
illustrations.
Remove protection from the car sill.
Section 7 – Entrances and Doors
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Referencing the layout drawing, establish the clear opening (daylight lines) on the car sill. Apply
some masking, or duct tape, and mark the daylight line directly on the tape. DO NOT scribe a line, or
use an indelible marker on the car sill.
Run the platform to each landing, and transfer the two daylight lines to the floor level of each landing.
Section 7 – Entrances and Doors
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Locate the strut angles using the below table, and the figures on the following page. Select the
opening width, and door opening type (single slide, two speed, or center- opening). Place the inside
face of the nearest strut angle to the correct measurement (Figure 2 and 3) from the daylight line.
After the location of the first angle is established, measure from this point over to the face of the
second angle (Table 1).
Door Type
Opening Width
(Inches)
“A” (Inches)
Single- Speed
32
72 7/8
Single- Speed
34
76 7/8
Single- Speed and Center- Opening
36
80 7/8
Single- Speed and Center- Opening
38
84 7/8
Single- Speed and Center- Opening
40
88 7/8
Single- Speed and Center- Opening
42
92 7/8
Center- Opening
44
96 7/8
Center- Opening
46
100 7/8
Center- Opening
48
104 7/8
Center- Opening
50
108 7/8
Center- Opening
52
112 7/8
Center- Opening
54
116 7/8
Center- Opening
56
120 7/8
Center- Opening
58
124 7/8
Center- Opening
60
128 7/8
Two- Speed
46
79 7/16
Two- Speed
48
82 7/16
Two- Speed
50
85 7/16
Two- Speed
52
88 7/16
Two- Speed
54
91 7/16
Two- Speed
56
94 7/16
Two- Speed
58
97 7/16
Two- Speed
60
100 7/16
Table 1
Section 7 – Entrances and Doors
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Section 7 – Entrances and Doors
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From the daylight line closest to the strike, mark the inside face of the first, or “king” strut angles.
For center- opening doors, the inside face of the strut angles can be marked on the car sill, but on
two- speed, and side- slide doors, at least one of the two strut angle lines will fall outside the car sill.
Measure from the inside of the first, or “king” strut angle to locate the second angle.
Repeat this process until all the daylight, and strut angle lines are marked (four lines per opening).
Preferably, the strut angles are turned out to avoid interferences between wall anchors, and sill
supports, but, the angles may be turned in due to tight hoistway conditions.
The short leg of the strut angle has horizontal slots, so, install the anchors in the center of the slot for
maximum left- to- right adjustment. Try to keep the anchors 4” to 6” down from the finished floor
level to avoid interference with the hoistway sill.
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Set the first round (2) of strut angles at the pit floor, and anchor, or weld the strut angle in place,
referencing the strut angle lines in the hoistway. Place the face of the strut angle as close to the line
as possible. DO NOT get sloppy with the strut angle installation. Getting these angles in the right
spot, the first time, will pay great efficiency dividends in the end!
NOTE: Strut angles run continuously, from the pit floor to a point a couple of feet above the top
landing rough opening. Strut angles are typically not run continuously for a single, or a
minimum number of rear openings.
Install the first round (2) of strut angle splices, and stack the next strut angle. Leave a ¼” gap
between strut angle ends to compensate for building compression.
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Anchor, or weld the strut angles to the landing floor, referencing the angle marks in the hoistway. At
a minimum, the strut angles need to be fastened at each landing floor, and to a support above the
top landing rough opening. Depending on floor heights, the strut angles may span two floors before
a splice is needed.
Follow this “stacking” procedure until all the strut angles are stacked up through to the overhead (to
the nearest support above the top landing rough opening).
Wall Angle
For places where the hoistway walls are
imperfect, or ledges exist, additional wall angles
are supplied to keep the strut angles as straight
as possible.
Section 7 – Entrances and Doors
Install both jamb mounting brackets to the sill
assembly.
NOTE: Once the sill is set to the platform
running clearance, there probably will
not be sufficient room to install the
jamb mounting brackets (feet) later.
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Install all the strut channels with the hardware loose in the slotted holes (one bolt near the bottom,
one bolt near the top). The bottom of the strut channels need to be approximately 3” below the
finished floor. Shove the strut channels back, away from the car, as to provide necessary running
clearance. Repeat this process until all the strut channels are set roughly in place.
Install the sill assembly in place, between the two strut channels. Install the four 3/8” carriage bolts.
The nuts are placed inside the sill support channel to provide for maximum clearance.
As an alternative method, the sill assembly can be pre- assembled loosely to the two strut channels,
with the tops of the channels pulled together forming a “tee pee”. The assembled unit is then carried
to the opening, the bolt in the tops of the channels removed, placed in position between the strut
channels, and bolted into place.
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Level the sill (roll), and tighten the four 3/8” carriage bolts, mating the sill assembly to the strut
channels.
Level the hoistway sill to the floor height marks, or dimensions given by the General Contractor.
Tighten the bolts through the bottom of the strut channels to the strut angles. Before proceeding to
the next floor, ensure that there is sufficient clearance between the car sill and the hoistway sill. (This
distance will be set to 1 ¼” after the hoistway header is set complete.)
Repeat this process until all the hoistway sills are set to the correct height.
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Install the hoistway header in place between the strut channels, and install the four 3/8” carriage
bolts. Raise the header up, as high as the bolt holes will allow, and tighten all four bolts.
Repeat the process, until all the hoistway headers are bolted into place, raised up, and bolts
tightened.
Header/Sill Gauge
Using the header/sill gauge, set each end of the header to 1 3/8” from the car sill. Tighten the 3/8”
carriage bolts complete between the strut channels, and the strut angles, at the tops of the channels,
as close to the header as possible.
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Header/Sill
Gauge
Header/Sill
Gauge
Run the platform down to the landing hoistway sill, and loosen the bottom strut channel bolts. Adjust
each end of the hoistway sill to 1 ¼” from the car sill using the sill gauge. Tighten the 3/8” carriage
bolts between the strut channel, and the strut angle, at, or near the hoistway sill.
NOTE: The sill can’t be adjusted, unless the header bolts are tight, and vice- versa – the header can’t
be adjusted, unless the sill bolts are tight; one end at a time.
Following this same procedure, set all the headers to 1 3/8”, and all the sills to 1 ¼”, in relation to
the car sill. At the top landing, a level (plumbing the strut channels), plumb bob, or a laser, will have
to be used to set the header, after the hoistway sill has been set to the car sill.
Lay the entrance frame components on a piece of cardboard, or carpet, to protect the finish.
Assemble the entrance frame directly in the opening at the landing.
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Assemble the entrance frame face down. Flush the back edge of the head jamb, strike jamb, and the
return jamb (flush the edge that the hoistway door will pass). DO NOT worry about flushing the front,
or the finish side of the entrance frame, because the amount the head jamb overhangs the entrance
jambs is a variable (maybe flush, or 1/8”, or even ¼”).
Flush the outside edges of both jambs, and the head jamb. Tighten all bolts. Use a speed square to
check that the entrance jambs are square with the head jamb.
Bolt the angle to the hoistway side of the head jamb (two- speed only). The angle will start close to
the center of the opening, and will run to the strike jamb. The angle serves as a visual stop for the
fully closed slow door.
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¼
¼” Whiz Bolts
Stand the completed entrance frame, and
“stab” the entrance frame jambs over the
studs in the frame mounting brackets.
Loosely install the four 3/8” whiz nuts.
Insert the four ¼” whiz bolts through the
hoistway header, and into the welded nuts in the
entrance head jamb. Leave these ¼” bolts
loose.
Run the car down to floor level, and line up the two jambs with the daylight line marks on the car sill.
Also, line up the jambs with the “faced” line on the hoistway sill that is running parallel with the sill
groove.
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Square the jambs using a tri- square, and
tighten the four 3/8” whiz nuts in the frame
mounting bracket.
Run the car up to the head jamb. Place a
square, from the two daylight lines on the car
sill, to each entrance jamb. Slide the head
jamb to match the daylight lines.
After the head jamb is set to the daylight lines
on the car sill, tighten the four ¼” bolts
complete.
Repeat this same process until all the entrance
frames are installed, and set complete.
NOTE: At the top landing, the entrance frame
will have to be plumbed with a four- foot level,
a plumb bob, or a laser.
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Fasten the grout plate to the bottom of the sill support channel using the supplied self- drilling
screws. Hold the plate in place, matching the holes between the plate, and the pre- drilled holes in
the sill support channel. Push the flange of the plate up tight to the hoistway wall, and tighten the
screws using a cordless drill motor with a 5/16” driver.
Anchor the grout plates to the hoistway walls by using concrete anchors, or lag bolts, depending on
wall construction type.
Repeat this process until all the grout plates are installed complete.
Fixture Bracket Mounted to
Entrance Frame
Fixture Bracket
Mounted to Entrance
Frame
Install all the fixture boxes using the supplied brackets (two per fixture). The brackets can be used to
mount the fixture boxes off of the entrance frame, the entrance struts, or the hoistway walls.
The fixture boxes must be installed, as soon as the entrance frames are set (prior to hoistway wall
completion). Depending on wall construction, or type, a length of flexible conduit, or a piece of EMT
may be attached to the back of the fixture box, prior to mounting the box. The length of the flex, or
EMT will depend on the distance between the fixture box, and the hoistway trough (duct).
Uncrate the hoistway doors, and load the doors on the platform.
Place the hoistway door on the hoistway sill, and lean the door back up against the hoistway header.
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Remove both upthrust rollers, and “walk” the door rollers up on the door track, one roller at a time.
Vertical Hanger
Bolts
Place a 9/16” wrench under the leading edge of the door panel (¼” running clearance). Snug the ½”
bolt in the leading edge of the door hanger. Lightly tap the top (leading edge) of the door with a
hammer until the bottom of the door just touches the wrench. If the leading edge of the door needs
to come up to achieve the ¼” running clearance, pick the door up past the ¼” and snug the hanger
bolt; then, tap the door down with a hammer until the bottom of the door just touches the wrench.
Remember: You can’t adjust loose bolts! Keep the hanger bolts snug during adjustment.
When the leading edge of the door panel is properly set to ¼”, fully tighten the leading hanger bolt.
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Using a straight edge, like a torpedo level, flush the bottom leading edge of the hoistway door with
the entrance frame. Raise, or lower the trailing edge of the door panel until the leading edge of the
door panel is flush along the entire height of the entrance frame.
Adjust the trailing edge of the door following the same process used for adjusting the leading edge.
Snug the hanger bolt. Raise the door up, or lightly tap the top of the door down. Fully tighten the
hanger bolt when adjustment is complete.
Roll the door to the closed position (side- slide), and check the leading edge of the door to the
entrance strike column.
NOTE: The leading edge of a door panel should strike both strike column bumpers at the same time.
NEVER allow the door panel to hit the bottom bumper first!
Repeat this same process for multiple door panels within a single entrance. The door adjustment
may have to be “tweaked” to achieve proper door gaps on center- opening doors, or to establish the
proper striking orientation for side- sliding doors.
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Re- install the upthrust rollers.
Adjust the upthrust rollers. Roll the eccentric, in a clockwise manner, until the roller contacts the
bottom of the door track. Back the eccentric roller off (counter- clockwise) until there is a small
(.005”) gap between the roller, and the track. The upthrust rollers are adjusted, as tight to the track
as possible, without touching.
Lower the door gib brackets, and the door retainer brackets until there is a 1/8” running clearance
between the bracket, and the sill. Tighten ¼” whiz bolts. The brackets are shipped raised up, to
minimize the risk of damage.
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Gib with
Roller Eccentric
Adjustment
Adjust the hoistway door gibs to achieve a ¼” running clearance. Use the same 9/16” wrench (open
end) as a gauge. Place the wrench between the leading edge of the door, and the entrance frame.
Turn the gib roller eccentric until the door panel just touches the wrench (gauge). Tighten the lock
nut down on the gib adjusting screw.
Repeat this same process for the trailing (back) edge of the door panel.
Check to see that the door rolls freely, and tracks parallel to the sill groove. Re- adjust, or “tweak” as
needed.
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Hanger Retainer
Bracket
1” long Retainer
Mounting Bolts
Install the top door retainer brackets on the door hangers. The ¼” bolts used to mount the retainer
brackets (top) must be 1” long, because the additional length of the bolts (under the integral door
track) serve as a retainer. Raise the retainers up enough to clear the door track by 1/8”, and tighten
the ¼” bolts.
Relate the hoistway doors (if applicable). Flush the leading edge of the door panel to its respective
return column, and tighten the relating cable clamp.
Install the astragals, and sightguards on the leading edges of the door panels (center- opening only).
The sightguards set back 1/8” from the leading edge of the door panel to allow the astragal to
overlap the door panel edge. (What does the astragal arrangement look like for the new door system
– center - opening?)
Reel Closer Bracket
Mounted inside the
Strut Channel
Install the reel closer bracket to the inside of the strut channel (strike side). Put three, or four wraps
on the reel closer (spirator), and attach the closer cable to the bracket using the supplied snap hook
clip. (The spirator tension will be final adjusted later, after the door lock is set.)
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Bolt the pickup roller assembly to the back of the right- hand (center- opening), or the back of the
leading door panel (two- speed or side- slide). Push the roller assembly all the way to the right, and
tighten. (The left- to- right pickup roller final adjustment will be done later, referencing the cab door
clutch assembly.)
Install the connecting rod between the pickup rollers, and the interlock arm.
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Install the interlock contact box.
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Single Interlock Adjustment
1. Remove the cover from the interlock box.
2. Close the doors, and check the interlock hook to ensure that it is centered on the contacts. See
Figure 29.
3. Put slight pressure on the front interlock hook to verify it does NOT contact the back of the box.
Also, put slight pressure on the back of the interlock hook to verify it does NOT contact the front
of the box/frame.
NOTE: It may be necessary to remove one of the two washers on the interlock hinge bolt, or shim the
interlock box.
Caution
!
NEVER remove both washers on the interlock hinge bolt.
4. Adjust the interlock box so there is an equal distance between the interlock hook, and both sides
of the locking tab on the box (about 1/8I or 3.175mm) when the doors are closed. See Figure 30.
5. Adjust the box vertically to obtain 3/32” contact compression. Ensure that the hook touches both
contact leafs at the same time. See Figure 30.
6. Adjust the connecting rod length so the interlock hook has 1/32” (.79mm) clearance with the top
of the locking tab on the box when the hook is resting on its contacts. See Figure 30. The pickup
roller crank should be resting on its stop at this time.
CRITICAL
DIMENSIONS!!!
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7. Actuate roller crank, and insure hook will clear locking tab on the box. See Figure 31.
8. Adjust interlock hook stop, if necessary, to limit hook travel. See Figure 32.
9. While actuating the rollers, and the interlock hook, check that there is 9/32” (7.2mm) hook
engagement before contacts are bridged. See Figure 32.
NOTE: If necessary, adjust the plastic contact housing in the interlock box to obtain the proper angle,
and position of the contacts.
10. Install the box cover, and ensure that the interlock hook clears the box at the top by a minimum of
1/16” when the hook is raised by actuation of the pickup rollers.
After the interlock adjustment is complete, adjust the spirator to close the door(s) when the door(s)
are released, just ½” from the fully closed position. Basically, the door(s) need to close the final ½”
of travel, with the minimum number of wraps on the spirator (reel closer).
Repeat the process until all spirators are fully adjusted.
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Escutcheon
Hole Pilot
Drill the ½” hole for the escutcheon tube (unlocking device). There is a hole in the reinforcing plate,
in the back of the door, that locates the escutcheon tube. Drill through the back of the door (backto- front) using a sharp 3/8” bit. Use a ½” tapered reamer to ream the hole out to ½”, first, from the
front, and then, from the back.
Caution
!
DO NOT drill the hole using a single pass with a ½” bit, and
don’t drill the final ½” pass back- to- front. This may result in
damage to the finished face of the door.
Escutcheon Tube
Install the escutcheon tube into the finished hole, and apply the bronze collar over the tube at the
back of the door. Use a piece of conduit, or an old socket, and lightly tap the socket with a hammer
until the tube is snug – doesn’t turn.
Repeat this same process until all escutcheon tubes (unlocking devices) are installed at every floor.
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Fascia “hooks”
into groove in Sill.
Start at the hoistway sill at the top landing. Install the top fascia plate. The center of the top fascia
plate is the center of the opening. The top fascia plate hooks into the groove of the hoistway sill.
Pin the top fascia plate to the sill support using self- drilling screws.
Fasten the intermediate fascia plate to the top fascia plate using the lanced slots. The number of
intermediate fascia plates is determined by the specific floor- to- floor heights.
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Lanced Slots
Clip the bottom fascia plate to the top of the entrance header. The bottom fascia plate should
overlap the last intermediate fascia plate.
Measure, and cut two angle supports, or stiffeners, that run from the bottom of the sill to 1” above
the top of header. The angles are easily cut with tin snips. Clamp the angles in place, flush with the
edge of the fascia plates.
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Run self- drilling screws through the pilot
holes in the fascia plates into the angle
stiffener.
Install the bottom landing toe- guard. Pin the
toe- guard to the sill support using self- drilling
screws.
Mount the bottom of the toe- guard to the hoistway wall using the supplied threaded rod.
Install all dust covers (if supplied).
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Section 8
Piping and Wiring Hoistway
NOTE: Refer to the appropriate Controller
Product Manual.
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IMPORTANT!
Determine which controller type is present, and use the appropriate
product manual to complete the piping, and wiring of the hoistway.
Install the hoistway riser in the hoistway. The riser should be in the same general location as the hall
fixtures, and the door locks. Typically, the riser is on the strike side of the hoistway. Take time to
thoroughly plan the duct, or conduit run. Consider clearances, both to elevator equipment, as well
as, building items, clear height requirements, minimal distance, and overall accessibility.
When cutting the duct, leave the duct cover in place. Cut the duct with a chop saw. This will save an
extra cutting step later when covering the duct. Remove the cover, and simply attach the cover to
one side, leaving the duct open.
Use a file to remove all sharp edges.
DO NOT stack the duct tight; leave ¼” gaps between joints, to compensate for building compression.
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Run the vertical section of duct the length of the hoistway.
Complete the duct riser run to the machine room/controller.
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Strain Relief
Bar
Once the riser run is complete, place a strain relief bar at the top of the hoistway at some point at, or
near the top landing hoistway header. Install one strain bar at every landing.
Complete the piping run to all the hall fixture boxes (buttons, keyswitches, and hall lanterns (if
supplied).
NOTE: For LON fixtures, ¾” flex, and pipe, are run to allow the harness plugs to pass. It is difficult
for the plugs to pass through ½” conduit.
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Pipe the hoistway door interlocks, and pipe the smoke detectors (depending on local licensing, work
jurisdiction, and code requirements). Know the maximum allowed flexible conduit length per your
local code, DO NOT exceed it. Also, strap all conduit runs in accordance with local codes, and make
it look neat.
Mount the pit run/stop switch adjacent to the pit ladder at 18” above the bottom landing sill.
NOTE: If the pit is deeper than 66”, two pit switches are required. The pit switch is typically mounted
directly to the duct riser, and the wires are pulled via a chase- nipple.
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Pull all wiring down the hoistway per the controller product manual. Then, pull the individual runs out
to the hall fixture boxes, and keyswitches (including the ground wire). Pull the smoke detector wires
(if applicable), (including the ground wire).
Make all terminations, and splices in the duct using the supplied end splices, or butt splices. Pull the
wire to test the integrity of every splice or termination.
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Fire or High
Temperature Wire
Wire the door locks, and the pit switch - wire everything that is physically in the hoistway. The hall
fixtures, and smoke detectors will be wired later, pending wall construction.
It is imperative that every wire is clearly marked, before it leaves the hoistway, and is fed back to the
machine room. If the riser run to the machine room is duct, pull the hoistway wire back to the power
unit at this time. If the run is in conduit (EMT), the traveling cable, and the hoistway wires will have to
be pulled to the power unit simultaneously.
Hang the traveling cable in the hoistway. Then, feed the traveling cable up the hoistway, and back to
the controller.
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Referencing the appropriate controller product manual, set all switches, and vanes. Then, pipe, and
wire switches.
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Cover the duct in the hoistway and in the machine room complete.
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Section 9
Cab, Door Operator,
Adjusting, and Turnover
NOTE: Refer to the appropriate Controller
Product Manual for complete Adjusting
instructions.
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Install the traveling cable hitch, or bracket to the bottom of the platform. The bracket will be in line
with the traveling cable hanger (hoistway), front- to- back. The hanger bracket (car) will be positioned
approximately 40” from the hoistway wall. The rule is 30 times the traveling cable diameter.
Spool off the remaining length of traveling cable, and coil the cable neatly. Run the car down on the
buffer springs. Hold the traveling cable up to the hitch (bottom of the platform), at a point where the
traveling cable loop just clears the pit floor by one inch (1”). Mark this point on the traveling cable.
Run the car up, and feed the second Kellums grip over the car end of the traveling cable, and up to
the mark. Hang the Kellums grip from the traveling cable hitch.
Feed the traveling cable around the bottom of the platform neatly. Pass the end of the cable over the
bolster channels. Strap the traveling cable neatly, and securely to the platform ribs. Leave the cable
long enough to reach seven feet (7’) up inside the COP. Leave the cable coiled up, and tied
temporarily under the platform until the cab is built, and ready to wire.
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Position the platform at the lowest, or bottom landing. Clean off all tools, parts, and other debris
from the platform. Remove run button cords, or extension cords, that may have been tied to the
brace rods, or side stiles. Sweep the platform clean.
Locate the centerline of the platform, which should be the same as the rail DBG centerline. Use a
framing square, and a straight edge to establish the centerline, running front- to- back the entire
length, or depth of the platform.
NOTE: The platform, or cab centerline will NOT be the center of the opening for two- speed, or sideslide door opening arrangements. Refer to the specific layout for the offset dimension
between the opening centerline, and the cab centerline.
Measure back from the car sill, the distance equal to the thickness of the swing return, and make this
mark on the platform at opposite ends of the car sill. Strike a line through these two marks that runs
parallel to the car sill across the entire width of the platform. This line will be used to square the cab
fronts, and returns to the car sill.
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Cab Centerline
Offset Sill Line
Car Sill
Heavily mark the lines in pencil so that the lines are more legible, and NOT easily erased. A chalk
box can be used, but the lines need to be re- traced in pencil.
Uncrate the cab panels, and wax all wood mating surfaces using the supplied wax block. The wax
will help keep the cab from “squeaking” during operation.
Install all the handrails, if the wall panel sections are pre- assembled. The panels are easier to
handle once the handrails are in place.
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Take the back wall panel through the opening, and place the back wall roughly in place on the
platform.
The back wall may have multiple panel sections. Assemble the rear wall sections, and install the rear
wall handrail prior to sliding the back wall into place. Ensure that the tops of the cab panels are flush
across the top. Slide the back wall all the way (left- to- right) against the hoistway wall. This will give
some access to the joint between the back, and the side wall assemblies.
Place the first cab side wall roughly in place. The side wall may consist of multiple panel sections.
Assemble the cab side wall complete, before sliding the wall into place. Ensure that multiple section
side wall panels remain flush across the top.
Install the side wall handrail (if supplied), while the back of the panel is still accessible.
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Bed Rail Clips
Line up the first side wall with the back wall. Raise the side wall enough to start, or engage the bed
rail clips.
The top of the Back Wall
Panel is higher than the
top of the Side Wall Panel.
Snap the side wall down into place locking the two wall panels.
NOTE: The top of the side panel is lower than the top of the back panel. When the canopy is
installed the canopy will be flush with the top of the back panel.
Slide the side cab wall up against the side stile, and push the back wall as far to the opposite
hoistway wall as possible.
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Assemble the second side wall roughly in place. Again, if this side wall is made up of multiple panel
sections, assemble the sections prior to sliding the side wall into place. Ensure that the side panel
sections are flush across the top.
Install the side wall handrail (if supplied), while the back of the panel is still accessible.
Slide the second side wall in place in relation to the back wall. Again, raise the side wall up just high
enough to start, or to engage the bed rail clips, and snap the side wall down into place locking the
two wall panels.
Slide the three assembled cab walls as far back to the rear edge of the platform as possible. Make
as much room to install the cab fronts as possible!
Apply the five mounting blocks to the detector edge. The five blocks are evenly spaced along the
length of the detector. Hold the detector ¾” off of the bottom of the strike column (the thickness of a
roll of Scotch 33 tape). Hold the detector edge back ¼” from the face of the strike column to help
protect the detector.
After the detector edge is mounted install the bondene cover.
Install the Janus detector on to the strike column before the strike column is mounted. The face of
the strike column will be inaccessible after the strike column is mounted.
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Bolt the strike column in place along the side wall edge. Measure the distance from the face of the
strike column back to the face of the side wall. Hold this dimension uniform, top- to- bottom, and
tighten the hardware complete.
Bolt the filler (dummy) panel in place along the opposite side wall edge. Measure the distance from
one edge of the filler panel back to the face of the side wall. Hold this dimension uniform, top- tobottom, and tighten the hardware complete.
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Bolt the swing return, or COP panel in place adjacent to the filler panel. Flush the top, and flush the
sides, and tighten the hardware complete.
Slide the three assembled cab walls (one back panel and two side panels) roughly into place,
referencing the three lines previously marked on the platform.
Daylight Line
(Strike Side)
Daylight Line
(Return Side)
Set the strike column, the swing return panel, and the filler panel in place referencing the line running
parallel to the car sill, and the two daylight lines marked on the car sill (used for setting the entrance
frame jambs).
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Install the small wood block (supplied) in place under the strike column. Pass the long ¼” bolts down
through the strike, through the wood block, and down through the platform. Install the washers, and
nuts, and tighten the hardware complete.
¼” x 2” Bolts
used to Thru-Bolt
the Returns down
through the
Platform
Using the supplied hardware, and the pre- drilled holes in the platform, bolt the strike column, and
the swing return panel down into place complete. The strike column, and the swing COP, are thrubolted down through the platform with 2” long ¼” bolts.
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Install the toe- guard to the front member of the platform using the supplied 3/8” hardware. Tighten
the hardware complete. Remember that the toe- guard centerline lines up with the opening
centerline, so, for two- speed, and side- slide arrangements the toe- guard will be offset the cab
centerline.
Bolt the toe- guard braces to the toe- guard using the supplied 3/8” hardware. The opposite ends of
the toe- guard brace are fastened to the bottom of the platform with self- drilling screws. Use the
toe- guard braces to plumb the toe- guard.
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Line up the cab side walls measuring to the cab centerline, running front- to- back on the platform.
Shift, and align the side walls until all the side walls measure the same distance from the cab
centerline. Using the supplied wood screws, screw the side walls down into place.
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Shift, and align the rear, or back cab wall, measuring to opposite ends of the offset line referencing
the car sill. When all the individual back panels measure the same distance from the offset reference
line, screw the back wall panels down into place using the supplied wood screws.
Place the rear canopy section in place on top of the cab side walls – butted up against the top of the
rear cab wall. The rear canopy section will typically have the fan, and the emergency exit.
Install the ¼” cab bolts down through the canopy section, and into the tops of the side walls. Install
the rear cab bolts (horizontally) through the canopy section, and through the back cab wall (thrubolted). Install the nuts, and lock washers, but DO NOT tighten the hardware until all the canopy
hardware is in place.
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Place the front canopy section in place, on top of the cab side walls – butted up against the rear
canopy section. The front edge of the front canopy section should be flush with the front ends of the
side cab walls.
Install the ¼” cab bolts down through the front canopy section, and into the tops of the cab side
walls. Install the ¼” hardware between the front, and rear canopy sections. DO NOT tighten the
hardware.
Flush the tops of the side cab walls to the edges of the canopy, and then, tighten the hardware
completely. The canopy helps square the top of the cab.
Tighten the rest of the hardware between the front, and rear canopy sections.
Position the car at the second landing so that the top of the cab front return panels are readily
accessible through the opening.
Install the linear operator unit in place on top of the return panels. Install the outside bolts through
the operator unit, and into the tops of the side wall cab panels. Leave these bolts loose until all the
bolts are in place, up from the return panels.
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Install the front cab bolts (horizontally) through the front canopy section, and through the door
operator unit (thru- bolted). Install the nuts, and lock washers but, DO NOT tighten the hardware until
all the hardware is in place.
Install the ¼” bolts up through the inside of the cab returns, and into the threaded holes in the
operator unit. Some of the bolt holes are accessible from inside the cab; others are only accessible
from the car top, or from the landing opening. After all the bolts are started, align the returns with
the operator unit.
Ensure that the distance between the return panels at the top (clear opening), is the same as the
distance measured between the return panels, down at the car sill.
Tighten the all remaining operator unit, and cab front bolts.
Check the cab front returns for plumb in both directions. Plumb the cab by adjusting the brace rods,
and/or by shimming between the platform, and the bolster channels. Plumbing the cab front is
critical, because the cab front returns set the relationship between the door operator clutch assembly,
and the hoistway components (hoistway sills, headers, and most importantly, the pick up rollers).
Cab Steadier
Unistrut
Install the cab steadiers. Bolt the two pieces of unistrut down to the canopy, and tighten the bolts.
Bolt the cab steadiers down to the unistrut using the supplied 3/8” bolts, and unistrut nuts. DO NOT
tighten the 3/8” hardware until the steadiers are set.
Adjust the rubber bumpers on the cab steadiers tight against the side stiles – all three sides. Tighten
the 3/8” hardware between the steadiers, and the unistrut.
The function of the cab steadiers is to “steady” the cab, NOT to plumb the cab. If one steadier is
tight (binding), and the other steadier is hardly touching the side stile, the cab needs to be replumbed.
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Pendant
Studs
Set the cab door roughly in place on the car sill. Install the pendant studs into the top of the cab
door. Tighten the pendant studs down complete.
Locking Nuts and Flat
Washers on Pendant Studs
Install the locking nuts, and the flat washers on the pendant studs.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Remove the upthrust rollers from the cab door hanger, and set the hanger in place over the pendant
studs. Install the flat washers, and the adjusting nuts on the pendant studs. Set the hanger back in
place on the cab door track, and tighten the adjusting nuts on the pendant studs (raising the door)
until the door clears the car sill.
Repeat this same process for the second door (if supplied).
Re- install the upthrust rollers.
Adjust the cab door upthrust rollers. Turn each eccentric to the right (clockwise) until the upthrust
roller just contacts the bottom of the cab door track, and then, back the eccentric off (counterclockwise) until the roller just clears the bottom of the door track. The upthrust roller needs to be as
close as possible (.05”) without actually touching the door track.
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Adjust the leading edge door height by tightening the adjusting nut on the pendant stud, and using a
9/16” open end wrench as a gauge (1/4” running clearance).
Flush the bottom leading edge of the door with the cab return panel. Tighten, or loosen the rear, or
trailing adjusting nut until the door panel leading edge is flush with the cab return, the entire length of
the door.
Using the same 9/16” open end wrench, set the gap (1/4”) between the top of the door, and the door
operator unit. Tighten the locking nuts on the pendant studs.
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Mount, and adjust the cab door gibs using the same 9/16” wrench as a gauge.
Repeat this same process for the second cab door (if supplied). For two- speed arrangements, the
fast door running clearance (1/4”) is set to the back of slow door instead of the running clearance
being set to a stationary return.
Relate the cab doors (if applicable). Flush the cab doors to the cab return, or to opposite cab returns
(depending on door type), and tighten the relating cable clamp.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Install the clutch/restrictor assembly to the cab doors. The clutch assembly is mounted using four (4)
3/8” carriage bolts. Loosen the four nuts on the carriage bolts, and insert the heads of the carriage
bolts into the matching keyhole slots in the cab door. Push the clutch assembly all the way down
(bottomed out in the cab door slots), and center the clutch assembly, left- to- right, in the center of
the mounting slots. Tighten the four 3/8” nuts.
NOTE: The clutch assembly is shipped with three shim washers on each 3/8” carriage bolt. Remove
one washer from each bolt before mounting the clutch assembly; this is generally a good
starting point.
Run the car to where the top of the clutch opening vane is level with the landing hoistway sill. Add, or
remove shims to get the clutch assembly within ¼” to 3/8” of the landing sill – rough adjustment.
Loosen both ¼” lock nuts, and adjust the top ¼” bolt until the clutch opening vane is ¼” from the
hoistway sill. Tightening the bolt moves the vane closer to the hoistway sill – loosening the bolt
moves the vane away from the hoistway sill.
Run the car up until the bottom of the clutch opening vane is level with the landing hoistway sill.
Adjust the bottom ¼” bolt until the clutch opening vane is ¼” from the hoistway sill. Again,
tightening the bolt moves the vane closer to the hoistway sill – loosening the bolt moves the vane
away from the hoistway sill.
It may take a couple of passes to get both ends of the clutch opening vane at ¼” from the hoistway
sill, because adjusting the top of the vane affects the bottom of the vane, and vice- versa. When both
ends of the vane are set to ¼” from the hoistway sill, lock down both ¼” lock nuts.
NOTE: It is important to note that the major portion of the clutch adjustment be done with the
shims/washers. If the ¼” x 20” bolts are tightened too far, the face of the opening vane will
get out of square with the pickup rollers.
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Opening Vane
Adjusting Bolts
(2)
Install the clutch link rod between the actuator cam, and the actuating arm.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Position the actuating arm roller at 12 o’clock, and tighten the set screws on the clutch link rod.
NOTE: The offset portion of the link rod goes down to the actuator cam. The link rod must be rotated
in such a manner as to clear both the door, and the closing clutch vane in the fully retracted
position. Note the two link rod orientations relative to the height of the door opening.
Position the cab door where the actuating roller is NOT on the pickup cam, and adjust the roller
support to where the actuating arm is picked just enough to keep the closing vane even with the
opening vane (both vanes ¼” from the hoistway sill).
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Actuating Roller
contacting the
Clutch Pickup
Cam
The clutch pickup cam controls the operation of the closing vane.
Roller just
contacting
Cam
3” from fully
closed
Position the clutch pickup cam so that the actuating roller contacts the cam, when the cab door is 1
½” from fully closed – 3” between door panels for center- opening arrangements.
Adjust the height of the clutch pickup cam so that the closing vane is fully picked when the cab
door(s) are/is fully closed. The closing vane will move one inch (1”), from being even with the
opening vane, to its fully retracted position (1 ¼” from the hoistway sill, or even with the car sill line).
Caution
!
If the actuator roller contacts the cam too soon, and the closing
vane is picked too soon, the hoistway doors, and the cab doors
could become “un- coupled” before the full closed position is
achieved.
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Attach the short, and long link rods to the ball joints with #10 nuts, and lock washers.
Attach the short, and long link rod assemblies to the crank lever with #10 lock washers, and nuts.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Attach the crank lever assembly to the door link angle using the crank mounting bracket.
Attach the short link rod assembly to the restrictor hook with a #10 nut, and a lock washer.
Attach the long link rod to the clutch. The link rod should be approximately vertical. A slight angle
does NOT affect operation.
With the door partially open, adjust the hook to be approximately horizontal. Link rod nuts DO NOT
have to be tight yet. Move the restrictor vane in- and- out by hand to check for binding.
If there is a door track bolt where the door stop needs to be located, remove it.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Loosen the fasteners, holding the door stop retaining clip on the door stop. Remove the guard on the
door stops for center- opening door.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Close the car door(s) fully.
Move the door stop roller up to its highest position on the door stop.
Attach the door stop to the door track with a 3/8” bolt, and lock washer.
Center the doorstop roller over the hook, and tighten the doorstop to the track. Ensure that there is
adequate clearance between the door stop, and the door hanger(s) when the door(s) are in the fully
closed position.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Adjust the link rods
until the hook has
1/8” engagement.
Open car door so that the hook is just inside the stop. Using the link rods for adjustment, raise the
hook so that you have approximately 1/8” of engagement. Tighten the link rod nuts to secure the
adjustment. (Moving the crank assembly slightly side- to- side on the link angle can add more
adjustment, if necessary.)
With the car door FULLY CLOSED, and the clutch closing vane retracted, lower the doorstop roller
until the restrictor vane is fully retracted. Tighten the doorstop roller.
Re- install the door stop guard (center- opening only).
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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If the restrictor link rods are longer than 24”, install the retainer clamp. Bend the clamp to leave a
clearance between the rod, and the clamp.
Try to open the car door without the restrictor vane being pushed in – the car door should be locked.
Push the restrictor vane in at least ¼” – the car door should be unlocked.
At the second landing, move the hoistway pickup rollers to ¼” from the car sill. Run the car up to
floor level at the second landing, and adjust the pickup rollers to have ¼” between the pickup roller,
and the clutch opening vane. Open the car doors by hand to ensure that the car doors will NOT lock.
When the car door(s) are fully opened, check to see that the hoistway door(s) are fully opened.
Adjust the hoistway pickup rollers to ensure that the hoistway door(s) are flush with the entrance
frame when the car door(s) are fully opened.
Repeat this process at every landing until all the pickup rollers are set to ¼” from the car sill, and
until all rollers are set to ¼” from the clutch opening vane.
NOTE: There should be at least three- quarters (3/4) of the hoistway pickup roller engaged in the
clutch at every landing.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Field cut slot in
bondene cover
allowing the detector
cable to pass.
Fit the five mounting blocks to the detector edge. The five mounting blocks are spaced evenly along
the length of the detector.
Block the detector edge up from the car sill the amount equal to the detector on the strike – usually
set on a roll of Scotch 33 tape (exactly ¾”). The heights of the two detectors need to be within 1/8”.
Hold the detector back ¼” from the leading edge of the cab door to prevent an object from striking
the detector.
Use the supplied TEK screws to fasten the detector edge to the cab door.
Apply the bondene cover to the detector edge. Slot the cover to allow the detector cable to pass.
Route the detector cables back through the door operator header, and into the Janus controller.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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The cab lights, cab fan, and the cab emergency exit contact are pre- wired to a duct mounted to the
car top. Pipe the harness from this duct down into the header.
Flex from the
top of car duct
is piped down
into the door
operator
header
Feed all car top wiring harnesses down through the header, and down into the COP.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Install the cab light bulbs in the cab fixtures, and wire the lights temporarily before wiring in the COP.
Terminate the top of car wiring harnesses in the COP. Some harnesses will simply plug into a PC
board, while other wire will be terminated to a terminal block.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Pull the traveling cable up into the COP. Strip the traveling cable insulation, and remove the fiber
jacket, and hemp. Terminate the traveling cable wires to the terminal block in the COP.
Wire the hall fixtures per the wiring diagram, and mount the fixture faceplates, and Braille plates.
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Ceiling frame
mounting bracket
Install the drop ceiling frame, and the laminate panels.
Park the cab where the top of car, and the inside of the cab are both accessible. Pull out all stop
switches, and turn every keyswitch to the “run”, or “normal” position. Pull out the pit stop switch.
Remove the temporary run cord, and all other power, or welding cords from the hoistway. Ensure
that everything is clear of the car.
Turn the mainline disconnect switch to the “off” position, and lock the handle. Use a voltmeter to
verify that there is no voltage present. Check each leg to ground.
Unplug, and remove the temporary run cord from the controller. Remove all temporary jumpers from
the controller.
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Terminate all the wires coming from the hoistway. Terminate all the traveling cable wires, and tape
up the spare wires. Terminate all wiring “by others” in the access panel in the top of the controller.
The 120 VAC cab lighting circuit, smoke detector circuits (if applicable), emergency power circuits,
telephone, and auxiliary contact wiring from the mainline disconnect (all terminate in the terminal
block found in the access panel). Routine all wiring terminations (factory or field).
Re- apply the power, and perform voltage checks.
Verify that the safety circuit is operational.
IMPORTANT!
Determine which controller type is present, and use the appropriate
product manual to adjust the controller.
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Complete the State Inspection, Turnover, and Final Acceptance. Refer to the Project Management
Book for the proper forms, and procedures.
Final Inspection Report
Turnover Report
Pre- Inspection Checklist
Final Acceptance
Section 9 – Cab, Door Operator, Adjusting, and Turnover
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Fast Track 1
Line Wire Rail Alignment
NOTE: The Laser Rail Alignment Method
(section 4) can be utilized in place of the
Line Wire Rail Alignment Method (section
10) if desired.
Fast Track 1 – Line Wire Rail Alignment
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Fast Track 1 – Line Wire Rail Alignment
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Fast Track 1 Safety Checklist
IMPORTANT!
The following must be verified prior to using the contract machine
to move the carframe
From the Machine Room:
•
•
•
•
•
•
•
•
•
All holes in the floor are covered or the machine room is protected from unauthorized entry.
The machine brake is properly cleaned and adjusted.
All disconnects for three- phase and single- phase power are fused, and lockable.
All machine guards are in place.
The governor is roped and operational along with the over- speed switch.
All hoist ropes are terminated with nuts locked, and cotter pins installed.
All hoist ropes are “hobbled” at their termination points.
The rope gripper is installed, and operational (if applicable).
Correct colored wedges are used, and wedge clips are set at 2”, and 4” from shackle.
From the Hoistway:
•
•
•
•
•
•
•
•
•
The correct amount of filler weights are in the CWT frame.
(CWT frame and weights = total car sling (less contract platform) + 600lbs)
The crosshead platform is securely installed, and includes all handrails/kickboards.
The counterweight frame is not susceptible to obstruction during movement due to hoistway
configuration. If so, skates or skids are attached.
The counterweight rods, or tie- downs are installed, and all weights are secured in the frame.
The car safeties are clean, and adjusted.
The car, and CWT buffers are installed, and filled with the appropriate amount of oil.
The temporary run button is in good condition.
The governor tension frame is installed, and properly positioned to allow for rope stretch.
If any of the above items can not be met, a Risk Assessment Form must be completed and
approved by Regional VP prior to proceeding with the installation.
The above Items have been completed:
Mechanic In Charge
Fast Track 1 – Line Wire Rail Alignment
Date
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Fast Track 2 – Traction Installation Planner (4 Stop)
* Add 4 team hours (1/2 day) for each opening above 4. ** Add 8 team hours (1 Day) for rear opening.
Day
Task
Pre Day
Pre Day
1
Set machine room block- outs.
Early Equipment – hoist machine room equipment into place.
Mobilize to jobsite, and unload truck, and stage material.
Drop safety lines, and clean/attach rails, and fishplates.
Install rigging, and mount hoist.
Set the main, and CWT rail pit channel to the proper DBG in correct location that
matches the lobby landing by using lasers.
Survey hoistway, and anchor pit channels.
Run all duct, and conduit in MR, and set governor (start).
Run all duct, and conduit in MR, and set governor (complete).
Pull, and terminate all machine room wiring.
Set machine perfect with lasers
Drop two Tirak hoist, and safety block cables, and anchor hoist at bottom landing.
Install, and align the first round(s) of main rails, and CWT rails
Install car, and counterweight buffers (fill buffers with oil), and governor tension
frame.
Hoist CWT frame into place with guides, and block- up adding correct temp
weights
Build the car frame (start)
Build the car frame (complete)
Build the work deck on top of the crosshead, including handrails, and overhead
protection, then add Tirak hoist.
Build door frames, and clean/file mains, and CWT fishplates (start).
Build door frames, and clean/file mains, and CWT fishplates (complete).
Stack/align the main, and CWT rails, including fishplates (start)
Stack/align the main, and CWT rails, including fishplates (start)
Finish setting/installing main, and CWT rail brackets (start).
Finish setting/installing main, and CWT rail brackets (complete).
Break down, clean, and lubricate brake and start- up machine, checking rotation. Rope
the elevator complete adding contract platform and remove Tirak hoist and cables (start).
Rope the elevator complete, adding contract platform, and remove Tirak hoist, and cables
(complete).
Install all door frame strut angles, strut channels, sills, and headers.
Distribute assembled, and install all door frames (jambs).
Install all hall fixture boxes.
Run all hoistway duct, and conduit.
2
3
4
5
6
7
8
9
10
Fast Track 1 – Line Wire Rail Alignment
Team
Hours
(Target)
Team
Hours
(Actual)
2
2
8
2
1
1
1
3
2
4
1
1
3
1
2
2
4
2
2
2
6
3
5
3
5
3
5
5
1
2
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Fast Track 2 – Traction Installation Planner (4 Stop)
* Add 4 team hours (1/2 day) for each opening above 4. ** Add 8 team hours (1 Day) for rear opening.
Day
11
12
13
14
15
16
17
18
19
Task
Install all hoistway electrical components (i.e., limit switches, pit switches, buffer
switches, LON or CAN boxes, etc.).
Hang, and adjust all hoistway doors (adjust door gibs, install all retainers, and set
all upthrust rollers).
Install and adjust all door closers (spirators or sash weights), and install, and adjust all
door locks.
Pull, and terminate all hoistway wiring, and feed the wire, including TC to the
controller. Cover the hoistway duct.
Install all hoistway fascia, and dust covers.
Add the appropriate amount of fillerweights to the counterweight frame for cab
rd
(2/3 total).
Build the cab.
Install, and adjust the cab doors.
Install LDO door operator.
Install, and adjust cab door clutch, and restrictor devices.
Install Pana 40 devices on cab door(s), or strike column (if applicable).
Install door zone sensor on car top.
Install cab steadiers.
Plumb the cab.
Install all door zone sensors, or vanes in the hoistway.
Wire cab complete (i.e., top of car, and COP).
Install toe- guard.
Static balance the car.
Set- up roller guides, and safeties.
Add test weights to the car, and the proper amount of fillerweights to the
rd
counterweight frame (last 1/3 ).
Tie the fillerweights down inside the counterweight frame.
Set- up counterweight rollerguides.
Install, and wire the hall fixtures.
Wire the controller (traveling cable).
Wire the controller (hoistway wires).
Clean the hoistway, machine room, cab, and car top.
Begin adjusting of car.
Complete adjusting of car.
Perform inspection, and complete the following:
ƒ Fill out all applicable reports, including Field Test and Data Report.
ƒ Get Final Acceptance form signed (if paid to 905).
ƒ Do handover to Service Department.
TOTAL TEAM HOURS
Fast Track 1 – Line Wire Rail Alignment
Team
Hours
(Target)
Team
Hours
(Actual)
4
4
4
4
3
2
3
2
1
2
1
1
1
1
2
3
1
1
1
3
1
1
1
1
1
3
4
8
8
156
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Section 10
Line Wire Rail Alignment
System
NOTE: Process uses Dual .029 Wire on each
Main Rail for Rail installation.
Section 10 – Line Wire Rail Alignment System
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Section 10 – Line Wire Rail Alignment System
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Line Wire Alignment Overview
Cwt Rope Drop
Governor Drops
Dual Line Target Template
Strong Bar
Hoistway
Riser
Car Rope Drop
Rail Alignment Wires
Machine Room – Top View
Cwt Pit Channel
Rail Alignment Wires
Ratchet Bracket Attached
to Back of Pit Channel
Car Pit Channel
Pit – Top View
Section 10 – Line Wire Rail Alignment System
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Line Wire Rail Alignment System
Lay the rail line template across the machine room floor block- outs. Ensure the triple tube (line wire)
block- outs have been cut off flush with the machine room floor. Adjust the template to the correct
dimension referencing the sticker affixed to the gauge, and tighten to hold the dimension. Line wire
hole- to- hole distance should be DBG + 6 1/2” (for 5/8” rails) and 8 1/4” (for #3/4 rails).
Using a spool of aligning (piano) wire, tie a small weight to the end that will fit through the 2” x 2”
block- out hole. Feed the aligning wire with weight through the block- out, and drop to the pit floor.
Then, cut the line, and feed the end through the proper hole in the rail line template, terminating the
lines using a washer. Repeat this process for all 4 lines.
Section 10 – Line Wire Rail Alignment System
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Verify Template/Line Wire Location
in Machine Room
Verify to Layout
Side Wall to Back of
Rail plus ¼”
DBG + 6-½” (for 5/8" Rails)
Main Rail Line
7"
7"
Verify to Layout
Front Wall to Rail Line
minus 7"
Front Hoistway Wall
After dropping all 4 lines to the pit, verify the template/line wire location to the contract layout as
shown above. Mark the template location to the floor, and then proceed to the pit.
Mark center
Set length to ½”DBG on each Side, and
Square Ends
Working from the pit, prepare to set the main rail pit channel. First, mark the center point of the
buffer attachment plate. Then, set the overall width of the pit channel by taking half of the contract
DBG, plus rail size from the center point of the buffer plate to each end. Ensure each end is square,
and vertically level. After tightening bolts, double check the squareness.
Section 10 – Line Wire Rail Alignment System
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Rear of Pit
Channel
Main Rail
Line
½ Pit Channel Depth
Using the contract layout, determine the location of the main rails from the front wall. Subtract ½ of
the pit steel depth from this measurement to calculate the location for the front edge of the pit steel.
Chalk this line.
+
Attach the dual line ratchet brackets to each end of the main pit channel, and verify that the bracket
is centered. Then, place the front edge of the channel on the reference mark from the previous step,
and roughly center from side- to- side.
Section 10 – Line Wire Rail Alignment System
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For use if Bracket
attached to Pit Channel
For use if Bracket
attached to Rail
Attach the 4 line wires into the proper holes of the ratchet brackets. Apply adequate tension. Be
careful NOT to over- tighten the ratchets since the line may break.
Section 10 – Line Wire Rail Alignment System
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Verify Template/Line Wire Location
in Machine Room
Verify to Layout
Side Wall to Back of
Rail plus ¼”
DBG + 6-½” (for 5/8" Rails)
Main Rail Line
7"
7"
Verify to Layout
Front Wall to Rail Line
minus 7"
Measurements
should match if
Straight-Lining Rails
Front Hoistway Wall
Set to Layout
Back of Rail to
Wall plus ¼”
Line Wire
Follow only if Hoistway
matches Layout
Pit Channel
Hoistway
Side Wall
Dual Line
Ratchet Bracket
Locate the pit channel properly, from side- to- side, by measuring from the line wire to the hoistway
wall. This measurement should equal the distance from the back of the rail, to the wall, plus ¼”. For
straight- lining of rails, it should also equal the measurement in the machine room of the line wire
hole, in the rail line template, to the wall in the machine room. If plumbing of lines is desired, the pit
channel can be slightly elevated by continuing to ratchet the lines. Once elevated, it will act as a
large plumb bob. After the channel reaches plumb, set/lower it back to the pit floor.
Ensure the pit channel is square by measuring from line- to- line diagonally. Measure both ways to
prevent creating a parallelogram.
Section 10 – Line Wire Rail Alignment System
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Anchor the pit channel into place using the plate that comes attached to the channel as a washer.
NOTE: The pit channel can still be adjusted up to 2” if required, after surveying the hoistway.
Verify Pit Channel/Line Wire Location in
Hoistway
Verify to Layout
Side Wall to Back of
Rail plus ¼”
DBG + 6-½” (for 5/8" Rails)
Ratchet Bracket
Line Wire
Line
Wires
Measure Here
Pit Channel
Bottom
Landing
Verify to Layout
Verify to Layout
Front Wall to Rail Line
minus 7"
Front Wall to Rail Line
minus 7"
Front Hoistway Wall
Pit Channel w/ Dual
Line Ratchet Bracket
Double check the location of the pit channel. The measurements should NOT be taken from the pit
wall, but instead from higher up on the hoistway wall at the level where the entrance frame will be
located. Since the pit wall, and the hoistway wall are NOT always flush, this will ensure proper
clearances and placement of door frames.
Adjust the pit channel if necessary.
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Prepare to set the CWT pit channel using the same steps as the main rail channel. Find the
centerline of the CWT buffer plate, and using the DBG, set, and square each end.
Centerline of Main and
CWT Pit Channels
Locate the CWT pit channel by squaring it to
the main rail pit channel. Verify the distance
between the channels from the layout, and
then, measure from outside- to- inside of the
channels.
Section 10 – Line Wire Rail Alignment System
Double check location of the CWT pit channel,
front- to- back, by measuring inside- to- outside
on the main and CWT pit channels. Anchor into
place, and recheck measurements.
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Stringing Rail Lines in Pit (Bottom) for Duplex/Triplex (If Applicable)
Cwt Pit Channel
Side Wall to
Back of Rail
Divider Beam
Front Wall to Rail
Line minus ½ Pit
Steel Depth
Car Pit Channel
Front Wall to Rail
Line minus ½ Pit
Steel Depth
Car 1
Car 2
Car 3
FRONT
Now that the pit steel is set, if the unit is part of a duplex, or triplex, mark one continuous chalk line
for the front edge of all the pit channels. Set the other channels to these marks, and center as
previously described. This will ensure straight entrances in the corridors.
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Measure from Corner-toCorner to ensure squareness
Return to the machine room, and double check the location, and squareness of the rail line template
by measuring from each line wire hole diagonally.
Stringing Rail Lines in Machine Room (Top) for Duplex/Triplex
(If Applicable)
Rail Line Template
Front Wall to
Rail Line
minus 7"
Set Per Layout
Car 1
Front Wall to
Rail Line
minus 7"
Set Per Layout
Car 2
Car 3
FRONT
Now that the pit steel is set, and the squareness of the rail line template has been verified, if the unit
is part of a duplex, or triplex, mark one continuous chalk line for the front rail line location of the rail
line template. Set the other rail line templates to this mark, and center per the layout. This will
ensure straight entrances in the corridors.
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Survey the hoistway.
Laser
Beam
Approx. 45 degrees
Reference
mark
If the hoistway rough opening doesn’t allow for easy square access to the side wall, utilize a piece of
conduit bent in a “V” shape. Place a reference mark onto the conduit that is equal to the center line
of the main rail location from the front wall (see contract layout). Hold the conduit into hoistway,
ensuring it is square, and the end is properly positioned in the corner.
If needed, adjust the pit channel to accommodate actual hoistway conditions.
NOTE: If major discrepancies are found while surveying the hoistway, contact the General Contractor.
If additional work is required, obtain the appropriate change order.
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Lines Car 2
Center
removed
Lines Car 1
Mark around the perimeter of the ends of the rail line template, in case the template moves during
anchoring. Anchor the ends of the rail line template into place.
NOTE: The center section of the template can be removed if there is any interference with the setting
of the machine.
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Mount a material hoists in shear at the bottom landing. The hoist can be used for hoisting rails, car
frame structure, and the CWT frame.
Install, and align the first round of main rail brackets. Reference the layout drawing, and actual
hoistway dimensions, to set the correct distance from the back of the rail.
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Set the first round of rails in place, and align using the dual line rail bug (bat wing). The rail should
be positioned so that the line wire is even with the back edge of the bat wing, and centered to each
V- notch. DO NOT position the line wire all the way into the V- notch. Ensure the rails are aligned
at the pit channel, and at the first bracket. If bottom end of rail is milled, shim between it, and the pit
channel. Secure in place. Verify the DBG is correct before continuing with the rail installation.
NOTE: Depending on the pit depth, two rounds of rails may have to be stacked, and aligned prior to
building the car frame.
Using a ladder, install the second round of brackets, and align using the dual line rail bug as in the
previous step. Secure in place. Using a tram gauge, or piece of conduit, ensure the rails are square
to one another.
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Install, and align the first round of CWT rail brackets. Reference the layout drawing, and actual
hoistway dimensions to ensure the location is accurate.
Install, and align the first round of CWT rails. Center each rail within the CWT pit channel, and plumb
with a 4’ level. If using T- rails, ensure the rails are square to one another with a tram gauge, or
piece of conduit.
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Section 11
Pipe Equipment, Car, and
CWT Frame
NOTE: Bottom set of Main and Counterweight
Rails must be installed completely prior
to moving forward on Fast Track 1 or
Fast Track 2.
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Setting of Pit Equipment, Building Car Frame and Work Deck
Fill all CWT buffers with oil prior to installing them
in pit.
Hoist buffers into place.
Install the car, and CWT buffers, and stands, if supplied. Ensure they are plum, level, and centered.
Remove packing material on piston.
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Hoist the governor tension frame into place, and install to the rail. Block- up the frame off the pit floor
to accommodate rope stretch.
Add
Guides
Move CWT frame to front of hoistway using a channel dolly, and remove the CWT tie- down rods from
the frame, and store in the corner of the pit. Then, install 2 roller/slide guides on one side (top and
bottom) of the weight frame. Also, install CWT strike, if provided. Hoist weight frame into place.
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Blocking
Add the top, and bottom roller/slide guides to the opposite side. Adjust all four guides firmly, and
equally.
Block- up the weight frame so the strike point of the frame is 2’ above the strike of the buffer. Ensure
that the CWT strike plate is attached, if provided.
Warning
!
DO NOT add weights in frame unless blocking is of steel, or
you have redundant support (cables, slings, etc.).
Remove rigging, and add the CWT weights to the frame
appropriately. TOTAL CWT WEIGHTS, AND FRAME
COMPLETE, EQUAL TOTAL CAR SLING PLUS 600 LBS
(FOR 2 EMPLOYEES, AND MATERIAL) MINUS CONTRACT
PLATFORM. After frame is loaded, add the CWT rods to
secure the weights in the frame.
If Fast Track 1 will be used, add the guide cables by
connecting them to the machine bedplate, down through the
CWT side rope holes, through the weightframe/weights, and
terminated to the pit steel with turnbuckles.
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Stage the safety plank in front of the hoistway, and then
add a means to hold the safety plank secure, and level on
each side of the rail, while setting on the compressed
buffer. Hoist the safety plank into place, centering postwise, and front- to- back, ensuring the plank is level. Then,
drive the wedges upward, centering the throats. This can
be done by using a piece of unistrut extending up from the
pit floor, or by prying the releasing carriage upward, and
securing by governor rope, or temporary means.
Add cam to stile, and then, hoist stiles in place. All car frame bolts must face away from the rail for
added clearance. Using the spud wrench to hold the stile in place with the safety plank, add all the
bolts hand tight. After completing one stile, repeat process on other stile. Then, hoist crosshead in
place, repeating the process for securing stiles the same as the safety plank.
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Verify from the layout, the distance from the bottom of the crosshead to the top of the safety plank.
Take into account the thickness of the platform to assure the correct height of the cab. Then, add the
roller guides to the crosshead, and set the tension as tight as possible. Using an impact, tighten all
stile bolts. You may then add your brace rods, platform arms, traveling cable hanger, etc.
NOTE: It is recommended to leave the contract platform off until all the main and CWT rails have
been installed complete.
Install the temporary work platform to the crosshead. Build the supporting structure of the crosshead
work platform using 4x4 timbers. A minimum of 4 timbers should be used with additional timbers
being added, if spacing between exceeds 24”. The timbers at each end of the crosshead should be
located just inside of the roller guides. The other timbers should be spaced evenly between them.
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½”x6" Carriage
Bolt
Square Plate
Washer
Beveled, Flat &
Lock Washer
4x4
½” Hex Nut
Crosshead Channels
Drill 2 holes in each 4x4, approximately ¾” off the edge of each flange of the crosshead channels.
Using a square plate washer, clip each 4x4 to the top flange of the front, and rear crosshead
channel.
Attach ¾” plywood to the top of the 4x4 frame
with wood screws. Ensure a cut out is made
around the rope hitch.
Complete the assembly of the platform by
attaching handrails, and kickboards to all
sides, with the front rails being removable.
Ensure overhead protection is present on the
work platform, or by guarding all entrances,
and machine room floor openings.
NOTE: If needed, conduit braces may be added to increase stability.
Flatten/drill the ends on 4 pieces of conduit, and attach one
end to an existing hole in the stile, and the other end to the
work deck.
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Section 12
Fast Track 1
Utilizing Contract Machine to
Install Rails
NOTE: Set, and Wire Machine Room
Equipment, and Rope Car, and
Counterweight.
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Setting Machine Room Equipment and Controller
Set the machine, and governor referencing the contract layout, and the rail alignment
template (line wire alignment system), or the laser reference marks (laser alignment system).
NOTE: All block- outs for governor, and machine rope drops must be cut down flush with floor prior
to setting equipment to prevent any interference when positioning.
Set the controller referencing the contract layout, or to satisfy local codes. After controller is set,
notify electrician to pipe, and wire complete.
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Run all machine room duct, and conduit complete.
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Pull, and terminate all machine room wiring.
Break down, clean, and re- assemble the
machine brakes, and set the brakes, and the
brake spring tension.
Start up the machine. Verify rotation
direction, and speed.
NOTE: Refer to the appropriate machine product manual for complete instructions.
Caution
!
The governor over- speed (potential) switch, and the rope
gripper switch must be functioning in the safety circuit, prior to
operation.
NOTE: The cleaning, and setting of machine brakes, temporary start- up of the machine, and
adjusting temporary running speed must be performed by a qualified person.
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Governor Roping Procedure
Step 1
Step 2
Governor
14 Gauge Wire
Governor Rope
Spool
Barricade
Top Floor
Top Floor
Cwt Frame
Bottom Floor
Bottom Floor
Cwt Blocking
Governor Tension
Frame (Blocked)
Step 1
Set the governor rope spool up on rollers at the top landing. With one person in the machine room,
drop a piece of 14 gauge wire down through the governor rope hole furthest away from the rail. With
a second person at the top landing, attach the end of the governor rope to the wire. From the
machine room, begin pulling the rope up to the machine room.
Step 2
Once the rope reaches the machine room, feed the end around the governor sheave, and lower it to
the pit. Once the cable has come off of the spool, set the jaws on the governor.
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Step 3
Top Floor
Step 4
Top Floor
Governor
crosshead
hitch
Bottom Floor
Bottom Floor
Governor releasing
carriage
Step 3
From the top landing, pull the rope downward, rotating the governor in the opposite direction. Send
the cable down to the pit until the other end reaches the height of the governor releasing carriage
termination point.
Step 4
From the pit, terminate the rail side of the governor rope to the releasing carriage arm. After
completing, pull down the opposite side of the governor rope taut, and feed the end through the tail
sheave. Terminate the end to the crosshead attachment point.
Governor Roping is now complete.
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Terminate one end of the governor rope to the releasing carriage, and then, terminate the tail end.
Remove the blocking from the governor tension frame, and reset the governor in the machine room.
Ensure all electrical wiring for the governor is complete prior to riding the elevator.
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Car Roping Procedure
Step 1
Cable
Shortening
Bracket
Fiber Rope
Rope Spool on rollers
Hoist Rope
Spool
Barricade
Top Floor
Car Sling with
Crosshead
Platform
Install V-Groove tool ASAP to
assist in Cable control
Cwt Frame
Bottom Floor
CWT Blocking
Car Buffer
Set the hoist rope spools up on rollers at the top
landing behind the barricade, and shackle the end
of each rope complete, unless deflector guard
prevents clearance. With one person in the
machine room, install a cable shortening bracket to
the CWT side of the machine bedplate, and lower a
fiber rope through the car side rope hole. With
another person at the top landing, feed the rope off
the spool while the shackled end is pulled up
through the car rope hole.
Taping Bedplate for Shortening Bracket
NOTE: Hoist rope is to be fed from the bottom of the
spool to ensure the spool will roll away from the hoistway
in the event it comes off the rollers.
Cable Shortening Bracket
Cable Shortening Bracket
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Step 2
Secure
each Rope
Secure each Rope
Top Floor
Bottom Floor
Take the cable around the driver/deflector, and down
through the CWT rope hole until the shackle reaches the
CWT hitch plate. If a rope gripper is installed, block it
open, and feed the ropes through it. Then, secure the
rope in the shortening bracket, and repeat for next spool
of rope.
Ropes being fed up through Car
Side Rope Drop and down to CWT
Frame
Ropes Attached to Cable
Shortening Bracket
Rope Gripper
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Step 2 – Continuation
Step 2
All Ropes
Secured
Top Floor
Terminate
Ropes
Rope termination in CWT Frame
Bottom Floor
Slip
Traction
With a third person on the crosshead work deck, terminate
each shackle complete to the counterweight frame ensuring
the cables DO NOT get crossed.
From the machine room, take out the slack of each cable by
pulling it over the driver. This is accomplished by having
one person loosen a cable from the shortening block, and
then having the team together slip traction over the driver
eliminating the loose cable. Re- secure the rope in the
shortening bracket, and repeat until slack is removed from
each rope.
Loosen
Remove Slack from each Rope
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Step 3
Temp. Cable
Support
Cables
Secured
Ropes secure in Bracket
Top Floor
Bottom Floor
Remove Blocking from CWT
Remove
Blocking
Ensure the hoist ropes are secured in the cable shortening bracket,
and then, remove the CWT blocking from the pit.
Temporarily secure the ropes to the driver by tightening down the
bolts on the V- groove cable bracket at the lowest arch of contact on
the car side.
Caution
!
The purpose of the V groove cable bracket on
the driver is to keep ropes securely down in the
V grooves causing traction, and also preventing
cable distortion.
Remove Blocking from CWT
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Step 4
Temp. Cable
Support
Tag Line
Nylon Sling
Rope
Shortening
Bracket
500lb Weight
Cart
Top Floor
Cable Shortening Bracket
Tie Back
Bottom Floor
Weights Secure
Weight Cart attached to Shortening Bracket
From the top landing, secure the opposite end of each rope to another shortening bracket hand tight.
Position a 500lb weight cart on the back side of the barricade, and temporarily secure it to the
barricade, or other secure means of support. Choke 2 short nylon slings to the handle of the cart,
shackling the other ends to the cable shortening bracket. Then, slide the shortening bracket up the
ropes eliminating the slack in the slings, and tighten all the U- bolts on the bracket.
NOTE: Ensure the individual performing the above process is either tied off, or behind the barricade.
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Step 4 – Continuation
Step 4
Temp. Cable
Support
1 Cable
Left
Secured
Tag Line
Nylon Sling
Rope
Shortening
Bracket
1 Rope left secured in Shortening Bracket
500lb Weight
Cart
Top Floor
Remove
Tie Back
Bottom Floor
Weight Cart at edge of Hoistway
Remove all the U- bolts from the cable shortening bracket
in the machine room, except for the one in the center to
prevent the ropes from being damaged by the rope
guard.
Position a person at the top floor with a tag line to the
weight cart. The tag line should be “basketed” around
the weight cart, and NOT tied to it. Ensure the individual
is tied off at this point, or is working from behind the
barricade.
Tag Line basketed around Cart
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Step 5
Remove
Last Rope
Top Floor
Verify V-Groove Bracket is
secure on Driver
Bottom Floor
Cwt Buffer
From the machine room, verify that the V- groove cable
bracket is secure to the driver, and is forcing the ropes
into the V- groove of the sheave. Remove the last Ubolt from the cable shortening bracket. Then, start to
loosen the bolts on the V- groove cable bracket evenly
on each rope side letting the ropes slip traction. Once
the weight cart fully drifts into the hoistway, traction will
be restored, and movement will stop.
Caution
!
Remove last Rope from Shortening
Bracket
The purpose of the V groove cable bracket on the driver is to
keep ropes securely down in the V grooves causing traction,
and also preventing cable distortion.
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Step 5 – Continuation
Step 5
“Pork Chop” tied back to Machine
Top Floor
Bottom Floor
Sling attachment point
Cwt Buffer
Add a wire rope grip “pork chop” to the center hoist cable on
the CWT side, and secure it to the machine structure. This will
limit the movement of the CWT, to the up direction, only. From
the machine room, run the driver in the car down direction 12’.
NOTE: A rope gripper, if installed, may be used in place of the
“Pork Chop”.
“Pork Chop” attached to Cable
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Step 6
Run
Button
B
Cwt strike
point
Run Button Cable from Machine Room
Top Floor
Bottom Floor
A
A = distance from top of platform to bottom floor level
B = distance A + Rope Stretch
Note: If car and cwt buffers are not the same height,
reduce “B” by the difference
Run Button at Top Floor
Mark the correct placement for the CWT frame (B) by transferring a mark on to the hoistway wall that
is equivalent to the distance from the contract platform to the bottom landing (A), “plus” rope stretch,
“minus” any difference in the car, and CWT buffers.
Lower the temporary run button down to the top floor through the hoistway wireway. Then, run the
driver in the car down direction hoisting the CWT frame strike point to the reference mark, and
lowering the weight cart.
NOTE: During the lowering process, one person must be positioned at the first, or second landing
(depending on carframe location) to ensure the weight cart passes by the crosshead platform.
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Step 6 – Continuation
Step 6
Run
Button
Ensure “Pork Chop” attached to Cable
B
Cwt strike
point
Top Floor
Bottom Floor
A
With the weight frame at the correct height, go back to the machine room, and ensure the rope grab
(or rope gripper, if using) is secure.
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Step 7
Temp. Cable
Support
Top Floor
Run
Button
Shackles in Car
Rope Hitch
(All but 1)
Crosshead termination
Bottom Floor
Shortening Bracket with one Cable
Prior to getting in hoistway, ensure the cables are secured from moving in the up direction
From the bottom landing, remove all but one of the hoist cables from the shortening bracket, one by
one, shackling, and terminating them complete in the hitch plate of the crosshead.
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Step 7 – Continuation
Step 7
Temp. Cable
Support
Rope Guards installed
Top Floor
Run
Button
Shackles in Car
Rope Hitch
(All but 1)
Bottom Floor
Run Button at bottom floor
After completing shackle termination, remove all cable restraints
Return to the machine room, and remove the V- groove cable bracket, and the wire rope grip. Install
rope guards complete, and lower temporary run button to the bottom floor.
Depending on the position of the weight cart, run the car in the up or down direction drifting the
weight cart on to the bottom landing floor. Remove the last cable from the shortening bracket, and
shackle/terminate it into the hitch plate.
Car Roping is now complete.
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Install Main and Counterweight Rails
Line Wire
Laser
Aligning Fishplates
Install, and align car rails. Align the rail brackets, as the platform is moved up, and align the
fishplates on the way down. Rails should be aligned, using the dual line target gauge (for line wire
alignment), or dual beam target gauge (for laser alignment).
Always tighten all 8 fishplate bolts on one side to hold the rail plumb post wise. Prior to tightening
with an impact, hold the rail eye ball plumb using the laser or line wire for reference. This will allow
you to work off the temporary work deck rather than a ladder.
Caution
Caution
!
The rail brackets must be aligned as they are installed to keep
adequate contact, and pressure between the rails, and roller
guides.
Caution
!
Caution
!
When stacking and aligning rails, DO NOT run the car up, and
out of the rails.
The installation of the main rails should stop prior to reaching the halfway
point. Before continuing, the CWT rails should be stacked to this same
point. This will eliminate the need to have the car frame pass the unguided CWT frame multiple times, improving safety.
Once the main rails are installed and aligned, remove the rail aligning wire, or lasers.
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IMPORTANT!
CWT rails must follow the Main rails at top and bottom, regardless if they were
plumbed or straight lined.
If straight lining the CWT rails, either use the appropriate CWT rail aligning templates, or use the line
wire method.
Rail Template Method
Securely attach the CWT rail template to the wood temporary work platform, referencing the contract
layout. Then, using the car frame as a running template, set all CWT brackets, and stack all CWT
rails at the same time. If the lower round of CWT rails is NOT accessible from the work deck, run the
platform to a completed set of rail brackets, and transfer some reference lines from the “set”
brackets to the contract platform. Use these lines to set the lower rails, and brackets.
Line Wire Method
Line
Wire
Drop two line wires from the machine room, and set to the correct measurement at the top, and
bottom. Secure, and tension the wires to the pit channel using turnbuckles. Set/align the brackets
using the line wire, and stack CWT rails.
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If plumbing the CWT rails, use lasers.
Set the laser in the pit, and ensure it correctly hits the target for the first round of CWT brackets that
have already been set. Set the rest of the brackets, and rails, plumbing to the target in the CWT rail
bracket.
NOTE: Main rail brackets, and counterweight brackets may be installed simultaneously for side
counterweight applications using combination (main and counterweight) brackets.
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Install Contract Platform and CWT Guard
Install platform, and brace rods at lowest landing. Level the platform, left- to- right, and shim, if
needed. Install all four brace rods, and level from front- to- back.
Then, install the CWT guard, setting it to the proper height. Add the required signage.
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Appendix
Specialty Tooling, and Supplier Contact
Information
Appendix
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Date Shipped
The Vertical Solutions Company
Date Returned
Cable Climbing Hoist and Accessory Order Form
Customer Data / Billing Information
Order Date -
Purchase Order # -
Requester -
Billing Address -
Office Phone Cell Phone Fax Office Code -
Shipping Information
Date Needed -
Ship to Address -
Approx. Return Date Contact Name Preferred Freight Carrier Account Number -
Equipment / Materials Ordering
Qty
Rental
Purchase
□
□
$12/Day - 701P
$14/Day - 1020P
Call for
a quote
□
$1.00/Ft - 5/16”
$1.75/Ft - 3/8”
+ $50.00 for Slings
& Shackles
□
$229.00
□
$3.50/Day
Complete
Accessory
Package
(Includes all listed
items needed to
operate the hoist.
Add’l power cords
are available at
$1.00/Day.)
Hoist Components
Cable Climbing Hoist Motor
□
$220.00
□
$65.00
□
□
Tirak XE701P - 1500lb (220V 1-Phase)
Tirak XE1020P - 2400lb (240V 3-Phase)
Hoist Cable
□ 5/16” - 701P
□ 3/8” - 1020P
Length ________________ Ft. **2 required per hoist
Power ‘Y’ ** For Use With 220V - 1 Phase Only **
Interface between power cord & hoist motor. Comes with a 110V GFCI outlet for power tools
and an extra 220V connection for a welder.
Power Cord - 100 Ft. □ 1-Phase 220V □ 3-Phase 240V
10/4 SO Cord with 30amp plugs. Connects to Power ‘Y’ on 1-phase hoist or directly to hoist
on 3-phase. Be aware of voltage drop when using multiple cords.
Pig Tail
□ 1-Phase 220V □ 3-Phase 240V
Interface between power cord and building power source. 30 amp plug.
Universal Tirak Mount
□
$420.00
For hoist attachment to crosshead or contract platform.
Tirak Storage Box
□
$125.00
Durable painted wooden box with screw-down lid
Pluggable Temporary Run Button Assembly
□
$196.00
Run button station to control the Tirak hoist from a more convenient location, also compatible
with our temporary traveler to control the elevator machine.
Temporary Traveler
□
$189.00
□
CALL
QuickConnectionfromtheTemporaryRunButtonAssemblytotheelevatormachine-70’standard-customlengthsavailable.
Temporary Work Platform □ False Car □ Crosshead
Contract specific wood platform with handrail (supply layout drawing).
Important information:
•
Please order hoists as early in your process as possible - lead times can be 6-8 weeks.
•
Rental charges start the day the material is shipped and stop the day the material is received back.
•
Customers are responsible for any loss or damages not consistent with normal use.
Send Completed Order to: The Vertical Solutions Company
Phone: 877-655-8164 / Fax: 517-655-8167
E-Mail: sales@verticalsolutions.net
Appendix
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ThyssenKrupp Elevator
Fast Track Installation Process
Appendix
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ThyssenKrupp Elevator
Fast Track Installation Process
Appendix
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ThyssenKrupp Elevator
Fast Track Installation Process
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ThyssenKrupp Elevator
Fast Track Installation Process
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ThyssenKrupp Elevator
Fast Track Installation Process
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ThyssenKrupp Elevator
Fast Track Installation Process
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ThyssenKrupp Elevator
Fast Track Installation Process
Appendix
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ThyssenKrupp Elevator
Fast Track Installation Process
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ThyssenKrupp Elevator
Fast Track Installation Process
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Appendix
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All rights reserved. The text of this publication, or any part thereof, may not be reproduced or transmitted in any form by
any means without written consent of ThssenKrupp Elevator.
ThyssenKrupp Elevator Corporation
621 S. Royal Lane, Suite 500
Coppell, TX 75019
Copyright 2005
Printed in the United States of America
Appendix
236
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