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INSTALLATION MANUAL

JOURNEY LU/LA

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Summary of Contents for JOURNEY LA

Page 1: ...INSTALLATION MANUAL JOURNEY LU LA ...

Page 2: ...omplish the process Site conditions can often dictate a change in tactics and a modification of the standard procedure This manual presents the most straight forward procedures that will work in the widest range of situations This manual was written with the support of CE staff but more importantly years of feedback from technicians like you We value and require your feedback to help make this man...

Page 3: ...inder Sling Finish T Rail Install Installing the Sheave Roping Sling Bleeding the Cylinder Setting the Pre Stoke Roping Jack Post Cab Floor Platform Adjusting the Side Rollers Adjusting the Safeties and Brakes Testing Safeties Testing and Checking the Travel Attaching Sling Extensions Assemble the Cab Cab Stabilizer Tape Reader Installing Sill Operator and Cab doors Attaching Light Curtains and Ha...

Page 4: ...mpers Electrical multi meter For hard pipe Pipe wrenches Pipe threader cutter Materials Not Supplied Fasteners for rail brackets M3 A for non wood rail wall or through bolting Shim material for base plate and rail brackets the base plate shims should be metal the rail brackets shims should be to local codes and standards Appropriate clamps for the hydraulic hose or pipe used Appropriate clips to a...

Page 5: ...o drawings Pit free of water and debris Permanent power in place Are you prepared with alternate temporary 220V power Engineering plans are the latest version Ensure sleeves conduit for the wiring and hydraulic lines are in place Procedure Using the final approved site drawings confirm the following The pit depth is correct The total travel distance is correct The overhead is correct The shaft wid...

Page 6: ...Consider all site hazards including the following and take all steps required to address them during every stage of the installation o High voltages within pump and controller Proper training and use of lock out procedures o Elevator door openings present fall risk to all Guard all shaft openings at all times o Pinch points within shaft Remove guard or avoid when working around moving equipment o ...

Page 7: ...uded with the elevator and may be required include the following Conduit connectors and cable tray Clamps to attach the hydraulic pipe to the wall Hydraulic pipe and fittings Two 3 inch sleeves for the hoses and cables to pass through into the hoistway Fire rated foam material to seal penetrations through the wall Appropriate thread sealant for the hydraulic connections Mineral spirits and abrasiv...

Page 8: ... Access to the 208 220 575 VAC and 120 VAC disconnects and flash zones o Mechanical room ventilation lighting and access o Accessibility of pump and controller for future service Mount electrical controller and have 208 220 575 VAC emergency power disconnect and 120VAC lighting power connected Attach pump power and valve connections from controller as per pump drawing package If not already connec...

Page 9: ...ficient enough to carry the weight of the people using it Options for mounting the rail brackets Wooden rail walls o Wood lags 5 inch long 3 8th with 3 8th washers Filled block and concrete rail walls o Wedge anchors 5 inch long 3 8th wedge anchors with 3 8th hardware Hollow block walls o We do not recommend hollow block walls o Consult the specifications of your structural engineer Other options ...

Page 10: ...e shaft from top to bottom and begin to install the brackets on the previously marked rail bracket locations Sliders The objective of this section is to install the sliders onto the rail brackets such that the rails are centered between the brackets the correct distance from the rail wall 6 inches correct distance apart 32 and 5 8 inches Although it is possible to only install the left sliders at ...

Page 11: ...tween the left and right sliders is 32 and 5 8 inches Adjust the slider in and out so that the V notch is 6 inches from the rail wall Tighten the slider in place Attach the plumb line so that it hangs freely from the V notch and runs over right inside edge of the slider down to nearly the bottom of the shaft Install the remaining sliders on the right hand side Note you may want to create a jig usi...

Page 12: ...the area where the baseplate will sit is flat and smooth Set the baseplate directly under the bottom rail bracket Check that the baseplate is sitting level side to side and front to back and use metal shims not provided if necessary to make it level Note if shims are needed metal ones are required Do not bolt it in place yet that can be done after the cylinder and 2nd rail is in place ...

Page 13: ...ll is 4 inches and it is parallel to the wall Tighten the bolts holding the slider in place Install the jack post inside the angled pieces on the baseplate Install the squared U bolt around the jack post and through the holes in the slider and attach using the supplied nuts and washers to the rail bracket Place the jack post top onto the jack post making sure it is oriented correctly see below Che...

Page 14: ...lips NOTE make sure the T rail is centered in the bracket slots to allow for adjustment later If the first T rail is a shorty ensure the cut end is down and the tongue or groove end is up If it s a full length T rail ensure the tongue or groove is facing the proper direction by checking the short T rail s uncut end that will be installed at the top Loosely attach splice plate to top of 1st T rail ...

Page 15: ...BEGIN BY INSTALLING THE RIGHT OR LEFT RAIL FIRST PLACE SLING ON RIGHT OR LEFT RAIL THEN INSTALL OTHER RAIL OR INSTALL BOTH THE BOTTOM RAILS AND CHAIN FALL THE SLING INTO POSITION shown above ...

Page 16: ...s per code requirements for your State or Province 6 Rotate line rupture valve towards the rail wall 7 Tighten clamp holding cylinder to bracket 8 Remove shipping bracket from top of cylinder 9 Install plastic drain elbow and drain line 10 If site conditions permit the clear pvc drain line should be run from the cylinder head to the pump Ensure route of hose allows for fluid to run freely back to ...

Page 17: ...ling to slide onto the rails Adjust the main blue eccentric rollers in order to increase the size of the gap for the rail if necessary Inspect the rollers for damage and clean if necessary The off white rollers are pre adjusted at the factory so that the green mark on the shaft is turned so that it is as far away from where the rail will be rail as possible Maneuver sling into elevator pit and eng...

Page 18: ...t T rail ensure the cut end is down and the tongue or groove is facing up If it s a full length T rail ensure the tongue or groove is facing the proper direction by checking the short T rail s uncut end that will be installed at the top Ensure the T rail is plumb before tightening the rail clips Loosely attach splice plate to top of 1st T rail Add 2nd T rail to the top of the first Secure 2nd T ra...

Page 19: ...arlier step Install the sheave between the rails loosening the shoe brackets as necessary Lower the sheave onto the thick bottom sheave plate Reattach the thick bottom sheave plate to the sheave with the hardware you set aside earlier Adjust the sheave shoe brackets so that there is a 1 16 inch gap between the internal face of the rail and the inside of each shoe Adjust the shoes so that the sheav...

Page 20: ...ght then to the shackles on the sling Run the ropes into the shackles and out the bottom making sure not to cross the ropes Place a heart against each rope wrap a loop around it and then route it back up through the same shackle Make sure at least one foot of rope extends past the top of the shackle Pull the rope tight in order to pull the heart into the shackle Install one clip 3 8th above the to...

Page 21: ...and then repeat above As the oil moves into the top of the cylinder the pitch of the sound will increase Continue forcing the air out of the cylinder by running the power unit until a nice stream of oil starts to flow then retighten the bolt Lift the Sling to Floor Level Procedure Remove the vise grips that were holding the brakes off Using the above information lift the sling so that the finished...

Page 22: ...ylinder using the remote pendant station Hold a measuring tape up to measure the distance between the top of the cylinders casing and the bottom of the sheave plate Stop when the distance between the top of the cylinders casing and the bottom of the sheave plate is equal to the pre stroke distance See image below ...

Page 23: ...his will allow you some room to adjust the rope length later by 4 5 inches or 9 inches of travel o Install the cotter pins and bend over the ends Run the ropes into the shackles and out the bottom making sure not to cross the ropes Place a heart against each rope wrap a loop around it and then route it back up through the same shackle Make sure at least one foot of rope extends past the top of the...

Page 24: ... mark the centerline of the rough landing door opening and confirm the door can be properly positioned within the opening and mark the exact location on the floor of the opening If the actual width of the shaft is not as per plans or your door locations are not located where they should be note the issues for now Set the floor in the best possible position for now We will need to know any issues w...

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Page 26: ...uring the inside edge of the blue rollers are flush with the inside face of the rails You may have to adjust side rollers Tighten the four side rollers until they touch the rail but can still be easily turned by hand a Adjust the nuts to bring the rollers in towards the rails b Tighten the outer nuts to hold the rollers in position NOTE Do not use the side rollers to force the rails apart and incr...

Page 27: ......

Page 28: ...een the back of the block and the rail shim provided in the white envelope Tighten the bolts that hold the block in position making sure the block remains parallel to the rail The result should be that the rail is centered between the knurled roller and the back of the brake block This will prevent the rail from rubbing on the block and the roller from catching on a splice ...

Page 29: ... floor Place blocking under the sling that is around 12 inches high such that it will hold up the sling Lower the sling using the remote onto the blocking until the ropes go slack Inspect the paddle that the ropes attach to it should have lowered down onto the slack rope switch and activated it The knurled rollers should be making contact with the rails and have a little more room to move If the b...

Page 30: ...floor plus or minus a inch This is your over travel You will need to account for the flooring to be used in the cab and at the landing o If the cab floor is 3 to 6 inches above the landing floor a Move the cab to the bottom landing b Adjust the nuts on both of the jack post shackles down 1 2 the extra distance This will lengthen the ropes and solve the issue Example The over travel is 5 inches 5 3...

Page 31: ...ing extension There are 4 green stickers on the sling and on the extensions that need to line up when installed Remove the 2 9 16 inch bolts on each side where the extensions are installed line up the green stickers and secure the extension in place with the 2 bolts you removed and add 2 more bolts from the bag Repeat for the other side ...

Page 32: ...a return wall or a return wall with a header attached set in place in the opening and bolt it in place through the floor and to the adjoining wall at the bottom Move the cab if necessary in order to access the ceiling and inside the cab at the same time Bring the ceiling into the shaft and set it on the walls Bolt the ceiling to each wall hand tight with 4 bolts provided Cab with two openings acro...

Page 33: ...ab at the same time Bring the ceiling into the shaft and set it on the walls post Bolt the ceiling to each wall post hand tight with bolts provided Install the remaining bolts between walls 3 inches below and 17 inches below the ceiling hand tight For every type of cab Check that the cab is plumb on each side shift the cab and hold it true Tighten all the bolts Check the cab is still true and each...

Page 34: ... to the diagrams below using inch x 1 1 4 inch hex head bolts attached to strut nuts in the unistrut on the cab roof Line edge of cab bracket up with edge of cab wall with inch slot centered with rod Adjust as required to ensure the cab walls are square and plumb Tighten assembly ...

Page 35: ...arefully unwind the tape Slide the tape through the head unit Send the rest of the tape down to the pit Mount the bottom mounting bracket to the bottom rail bracket Cut the tape so it s a few inches longer Loosely clamp the tape to the bracket pull up on the bracket to get tension Tighten the bolts to secure the tape in place fold up tape and release mounting bracket Follow the instruction in the ...

Page 36: ...nt of the cab Place the operator on the top of your cab and slide over tight to the closing side it should line up with the ceilings edge and the ceiling face Cab Door Panels NOTE The fast door installs towards the closing side in the front track towards landing of the sill plate and the slow door towards the opening side in the back track towards cab of the sill plate Install the slow door first ...

Page 37: ...Adjusting the door with door tool Shim if required Installing the gibs ...

Page 38: ...stance between the mounting holes on the handrail this will be called measurement Y o The distance from the wall to the first mounting hole will be X Y divided by 2 this will be called measurement Z o At the mounting height measure from the left wall over measurement Z and mark the location of the left mounting hole o At the mounting height measure from the right wall over measurement Z and mark t...

Page 39: ...Hand Rail Mounting ...

Page 40: ...Overview of Hoistway Part Location ...

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