INSTALLATION USER MANUAL FOR KONE ELEVATORS

KONE Elevators
Installation User Manual

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INSTALLATION USER MANUAL FOR KONE ELEVATORS

© 2019 KONE Corporation

All rights reserved.

Important Notice
This guidelines and instructions document and its contents (the “Instructions”) are for informational purposes only.
The Instructions do not contain all the relevant information regarding the performance of the maintenance for the
equipment in question and the installation or replacement of associated components (the “Work”). Any person
engaging in the Work must follow all instructions related to the respective equipment. Further, such persons must
be qualified and authorized to perform the Work, which includes possessing licenses required by law.

Authorized Use – License

KONE grants the authorized recipient of the Instructions (“Authorized User”), a limited, revocable license to possess and
use the Instructions for the purpose of performing the Work (“License”). Possession or use of the Instructions in a manner
inconsistent with the License granted is strictly prohibited. Under no circumstances is the Authorized User permitted
to copy, disclose, publish, or disseminate the Instructions to anyone, unless prior written consent has been obtained
from KONE. In the event the purpose for which the License is granted ceases, the Authorized User shall either return the
Instructions to KONE or destroy the Instructions. Violation of this paragraph may result in legal or equitable action against
the Authorized User.

Prohibited Possession or Use by Others

Possession, use, copying, disclosure, publication, or dissemination of the Instructions by an individual who or entity
that is not an Authorized User is strictly prohibited (“Prohibited Use”), unless prior written consent is obtained
from KONE. Prohibited Use shall result in legal or equitable action by KONE against violators.

Disclaimer of Liability
The Instructions do not contain all the necessary information for performing the Work and you may not solely rely
on the Instructions to perform the Work. The Authorized User assumes all risk associated with using and relying on
the accuracy of the Instructions. KONE disclaims any and all liability for loss or damage including without limitation,
indirect or consequential loss or damage, resulting from or in connection with the Authorized User’s use of the
Instructions or the Prohibited Use. KONE shall not be held liable for any typographical, factual, or other errors or
omissions contained in the Instructions, nor for any party’s interpretation or use of the Instructions.

No Warranty
The Instructions are provided “As-Is.” No statement contained in the Instructions is to be construed as a warranty
or condition, express or implied, as to any product, specification or procedure, its merchantability or fitness for any
particular purpose or quality, or as a modification or representation of the terms of any purchase or other agreement.
Any reliance the Authorized User places on such information is therefore strictly at the Authorized User’s own risk.
KONE reserves the right at any time to alter the product design, specifications and procedures reflected in the
Instructions without obligation to notify you or any other party beforehand.

Proprietary, Confidential, Intellectual Property

The Instructions are owned by KONE Corporation, its affiliates, and its subsidiaries (“KONE”). The Instructions are
proprietary, confidential, and contain KONE intellectual property and trade secrets. The Instructions are protected by
international and local intellectual property laws, including but not limited to copyright law. Unless otherwise expressly
mentioned, all trademarks and product names in the Instructions are trademarks or registered trademarks of KONE.
Unauthorized possession, use, copying, disclosure, publication, or dissemination of the Instructions infringes upon
KONE’s legal rights and shall result in legal or equitable action by KONE against violators.

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INSTALLATION USER MANUAL FOR KONE ELEVATORS

Contents
1 Introduction 4

2 Safety and environment 4

3 Standard installation tools 6

4 Main components of elevators 7

5 Installation prerequisites 10

6 Installation process 11

7 Installation quality control 12

8 Handover 13

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INSTALLATION USER MANUAL FOR KONE ELEVATORS

1 Introduction
You are the owner of KONE elevator now,
congratulations! And we are sure that our new
equipment will win your complete satisfaction.
Safety and reliability are KONE’s primary concerns
and have always been an emphasis in the design,
manufacturing, installation and maintenance
processes of all KONE elevators. The revolutionary
KONE elevator production along with KONE’s quality
assurance technology, will guarantee you a pioneering,
ecologically friendly elevator with its sustainable
functionality in the years to come.
The purpose of this manual is to provide general
instructions on the installation and usage of your
KONE elevator. It is not a detailed description of the
functions of KONE elevators, although an overview of
its operation is provided. Following the instructions
in this manual ensures you a safe, comfortable and
reliable experience for the elevator users in your
building. It also increases the longevity of your elevator
and thus better retain your investment value.

2 Safety and environment

2.1 General safety precaution 2.2 Electrical safety
• Entry to a construction and modernization The following five steps must be taken in the specified
site is only permitted under the direct order unless there are essential reasons indicating
supervision of a competent and authorized otherwise:
person such as a supervisor.
• Always ensure that you have the necessary 1. Disconnect the power supply completely.
personal protective equipment.
• Always comply with the safety signs. 2. Secure the power supply against re-connection
• Precaution has to be taken for the hazards
that may affect your safety. 3. Verify that installation is de-energized.
• Pay attention to the surrounding area
and the headroom. Never walk under 4. Check requirements for earthing in special
suspending loads. circumstances.
• Always watch the surface where you are
walking for the uneven ground and holes. 5. Provide protection against adjacent live parts.
• Do not attempt anything that may affect
the safety of others.
• Do not expose yourself to unprotected
edges for the free fall, such as unprotected
staircases. Never lean on barriers.
• Do not enter the area where you are not
sure of the safety. Always request the
competent person.
• Stay away from machines or electrical
components that may start unexpectedly.
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2.3 Danger and personal protection signs

When entering into the site, personal safety equipment must be provided and used as required. Meanwhile,
danger signs must be identified correctly.

Danger signs Personal protection signs - mandatory

Electric shock Risk of falling Magnetic field Safety helmet Overall Dust mask

Hearing Safety shoes with Safety gloves

Corrosion protection ankle protection Rubber gloves
Risk of fire dermatological Entry prohibited
risk

Fall prevention Safety goggles Fall prevention

equipment measures

General hazard Suspended load Pinching hazard

warning

Man riding hoist mandatory First aid kit

inspection

The terms WARNING and CAUTION are used to

highlight possible hazardous situations to persons
or equipment as follows:

Warning This is to warn about serious safety

hazards.

Caution This is to warn about damage to

equipment which may also involve a
safety hazard.
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3 Standard installation tools

Piece Tools Figure Piece Tools Figure

1 Screwdrivers 1 Feeler gauges

1 Hexagonal keys 1 Shaped levels

1 Cordless drill
machine

2 Reversible
ratchet
1 Hammer drill

2 Spanners

1 Frame for
1 Hand riveter milled file

1 File

1 Bevel cutter
pliers
1 Carpenters
Narrow nose hammer
pliers

1 Spring-tape rule 4 G-clamp

2 Suction cup
1 Joiners square handles
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4 Main components of elevators

4.1 Machine
The KONE motor is a gearless synchronous machine
driven by a drive with variable frequency. Gearless
machines have only been traditionally used in larger,
more expensive elevators because they run more
smoothly than geared motors. Because of the cost,
gearless motors were not common in low-rise elevators.
But now KONE has also made them available for all low-
rise elevators.

4.2 Control panel

The control panel is the heart of the elevator system. It
uses the data from the signalization system to drive the
elevator to the correct destination. It also gathers
information from the operation of the elevator. The
elevator drive buttons and the car lighting supply
switch are also located in the control panel.

4.3 Overspeed governor

The function of the overspeed governor is to stop the
elevator with the help of brakes and safety gear if the
elevator car exceeds its maximum speed. If the elevator
car starts moving too fast, the governor locks the
governor rope attaching to the safety gear. The safety
gear then stops the elevator car. The governor is a
mechanical device, so it can be functional even during
power failures.

4.4 Safety gear

The safety gear is a mechanical safety device attached
to the elevator car frame. When the elevator car
exceeds its maximum speed and the governor locks the
governor rope, the safety gear firmly grips the guide
rails and stops the elevator car.
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4.5 Buffers
In compliance with safety regulation, spring,
hydraulic or polyurethane buffers (depending on the
elevator speed) are present below the car and the
counterweight. They can prevent either the car or the
counterweight from crashing against the bottom of the
elevator shaft, in case that limit safety switches do not
work properly.

4.6 Elevator car

The purpose of the elevator car is to provide an
enclosure for passengers so that they may be carried
safely from floor to floor. The elevator car is surrounded
by a car frame to strengthen the elevator car.

4.7 Elevator door

Doors are installed on each floor and on the elevator
car to protect users from injuring themselves during the
elevator operation.

Photocells have been installed on the elevator car to

prevent the doors from closing if someone is entering
or exiting the elevator, or is standing too close to the
doors. The doors are also fitted with a special lock,
which keeps the doors closed and locked if the elevator
car is not on a landing.

4.8 Counterweight
The counterweight is connected to the elevator car by
suspension ropes. Its function is to reduce the strength
necessary to move the car during its operation. The size
of the counterweight depends on the weight of the car,
plus 50% of the possible load / capacity within the car.
The counterweight is made up of a rigid frame with cast
iron or cement weight inside it.
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4.9 Suspension ropes

The elevator ropes are specially made steel ropes. They
are used to support the car and counterweight and
transmit the movement among: traction machine, car
and counterweight. KONE elevators use four or more
ropes depending on the load to carry. Their coefficient
is 12 (and they are capable of holding 12 times the
maximum weight of the elevator). The use of multiple
ropes eliminates the risk of a hazard due to rope
breakage.

4.10 Car and counterweight guides

Car and counterweight guides are rigid steel guides,
guiding the car and counterweight through the elevator
shaft. Guides are attached vertically to the wall on each
side of the elevator shaft by fixing. There is a joint-type
connection between the guides supported by joint
plates.

4.11 Signalization and landing call station

The signalization system and the landing call stations
are the user interface of the elevator. With operating
panels and displays it informs the passengers of the
position of the elevator, allows them to call the elevator
and set the destination floor. KONE Signalization System
transfers these messages to the elevator network.
The elevator network feeds control information to the
control unit, which then drives the elevator according to
user commands.
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5 Installation prerequisites
5.1 Site requirements
The site inspection should be conducted at least one
week before the installation is scheduled to start. The
following items must be ready before starting the
installation.
NOTE: Items 1 to 5 are the 5 top priority standards.
Only if these prerequisites are met, installation can
be safe, fast and without interruption, and conform
to the construction schedule as well.
1. The elevator shaft is clean, dry and painted before
the installation.
2. Proper three-phase and one-phase power supplies
are in place.
3. Storage place is provided on the ground floor close
to the shaft, and access to the shaft are clear.
4. Shaft opening and recesses are constructed as per
KONE layout drawings.
5. Lifting hooks and ventilation ducts are in place.
6. Adequate lighting must be temporarily or
permanently positioned for the elevator according
to the layout drawing.
7. Finished floor marks must be on each landing.
8. The elevator pit must be waterproof.
9. For group elevators setting out grid lines must be
marked on the lowest common floor area.
10. Landings must be protected with coverings
according to the local safety codes and regulations.
11. Suitable life line and fitments must be in position,
attaching to the centre lifting eye.
12. Suitable provision for disposal of waste materials
must be available.
13. Scaffolding (if used) must be correctly constructed
with safety tag / inspection data properly displayed.
5.2 Unloading and distribution
Introduce yourself to the site agent. Familiarize
yourself with the site facilities, the local rules, safety
requirements and site management procedures.
NOTE: For personal safety and preventing any
damage to the components, do the following.
• Keep the working area clear and unobstructed.
• Never go under any suspending load.
• Use correct techniques for manual lifting.
• Wear gloves.
• Always wear a helmet.
• Wear safety harness and fix it to an approved
fixing point while working in areas where there
is risk of injury from a fall.
• Wear goggles and dust masks as necessary.
It is important that the tools and materials are
positioned according to the installation sequences
to achieve and maintain a controlled installation
environment throughout the installation. Suitable
arrangements must be made for the safe transportation
of materials to all floors.
Do not open the packages until you are ready to
install the equipment. When unload and distribute the
material, follow the steps below:
1. Unload the materials.
2. Check that the delivery is complete with the material
documentation. Complete the check form for return
to factory.
3. Complete the site readiness audit form. Return it to
KONE projects engineer.
4. Position the tools and materials to correct order
before the installation commences.
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6 Installation process

No. Installation order Installation item

• Assembling plumb jig
1 Shaft plumbing jig • Hanging plumb lines

2 Guide rail • Installing guide rail brackets

• Installing guide rails
• Aligning guide rails

• Installing landing doors

3 Landing door • Inspecting landing doors

4 Machine room • Installing machine

• Aligning machine
• Installing control panel
• Installing overspeed governor
• Electrification installing

5 Pit • Installing buffers

• Installing other components in the pit

6 Car sling • Installing car sling

• Installing safety gear
• Installing guide shoes

7 Counterweight • Installing counterweight frame

• Installing tractive rope

8 Roping • Installing overspeed governor rope
• Installing compensation chain

9 Car • Installing car wall

• Installing door operator
• Installing car top connection box
• Installing final limit switch
• Installing load weighing device

• Installing shaft wiring

10 Electrification • Connecting safety circuit
• Installing traveling cable

11 Scaffolding • Dismantling scaffolding

• Elevator inspection drive

12 Inspection drive

• Installing shaft signalization

13 Shaft • Adjusting door system operation

14 Car decoration • Installing car decoration

15 Commissioning • Elevator commissioning

• Safety function testing

16 Elevator safety inspection
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The installation process may vary according to different methods and site facilities.

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7 Installation quality control
Items are needed to be checked at the end of installation by the supervisor and prior to the handover to client.
7.1 Ride quality
• No abnormal vibration in the elevator car.
• No unacceptable lateral movements in the
elevator car (from bad guide joints and so on).
• No unacceptable noise (from guides,
counterweight joints, OSG rope and tension
weight).
7.2 Tidiness
• The component labeling inside the SEP / MAP /
drive module is in place.
• High voltage warning labels are on the drive
module, inside the MAP and on emergency
battery drive unit.
• Main switch (220) lockout function is as
intended.
• All covers and cable bushings are correctly
in place and secured (clamps on all screened
cables are fitted correctly).
• No abnormal noise is coming from the
contactors (buzzing).
• Rope specification labels are attached to the
rope suspensions.
• Overspeed Governor (OSG) resetting stick is
stored in the correct place.
7.3 Finishing
• There are no temporary over-connections.
• The acceptable standard of wiring, cable routes
and connections is in place.
• Deceleration switches, either upwards or
downwards, operate correctly at top and
bottom of the shaft.
• Machine isolation pads are correctly installed
and no metal-to-metal touch between the
machine body and the fixings.
• Counterweight filler weights are installed
correctly with retaining clamps in place.
7.4 Elevator car
• The acceptable standard of wiring, cable routes
and connections is in the car top connection
box.
• The car roof area is clean.
• The acceptable standard of wiring, wire
connections and fixings to door operator and
COP is in place.
• Door sill and top track are clean.
7.5 Elevator shaft
• The acceptable standard of wiring, wire
connections and fixings is in place.
• Light covers are fitted and in proper condition.
• Lubrication: a light film of oil covers the full
length of blade faces.
• Guide rail brackets are clean.
• Lubrication of guide rail: oil cups are filled.
• No unacceptable noise is detected when door
operates.
7.6 Doors
• Door frames alignment and fixings are in place.
• Door hanger rollers run smoothly.
• No unacceptable noise is detected when door
operates.
• Sill and top track of the car door are clean.
• Lock roller clearance to the coupler is correct in
depth and sideways direction at all landings.
• Door hanger rollers run smoothly.
7.7 Pit area
• Pit is clean and clear form external objects.
• Tension weight switch activator is in correct
position (allowing for OSG rope stretch).
• Travelling cable loop is of minimum 150 mm
from the pit bottom when the car is on the
bottom floor. The loop inner diameter is of
minimum 400 mm. The distance between
travelling cable loops is 100 mm. The text side
of the cable is outside of the loop.
• Oil collection cups are in place.
• The acceptable standard of wiring and
connections is in place.
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INSTALLATION USER MANUAL FOR KONE ELEVATORS
8 Handover
8.1 Inspection before handover
Before the handover procedure can take place,
the safety and quality inspection must have been
conducted and passed.
The safety inspection also covers the issues described
in KONE and local regulations, which must be
mandatorily implemented. It is also important to verify
that some of the issues in the handover form have
already been checked during the safety inspection.
8.2 Handover form
In the handover form, there is a list of items that are
assessed in the handover procedure. Local practices
determine whether it is necessary to specifically
examine all the different points on the list. However,
both the installation and maintenance representatives
must unanimously consent that the items listed are in
an acceptable condition. The purpose of the form is
that its subscribers know that the installation meets
the KONE quality standards.
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Installation User Manual for KONE Elevators

Date: 2019-04-11

KM50072117 Revision: B

KONE Corporation

www.kone.com