Cambridge Elevating JOURNEY LU User manual

INSTALLATION MANUAL
JOURNEY LU/LA

Introduction
Cambridge Elevating (CE) strives to make a quality product your customers want in their buildings and an
elevator you can install easily and performs beyond expectations for many years.
With those goals in mind, we have produced this manual and other support documents so every technician has
the installation, and technical information required to be fully informed.
As with any multipart assembly, there is always more than one way to accomplish 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 manual as complete and user-friendly as
possible. Please provide your feedback to the Technical Support department via phone, email, or text anytime.
Thank You,
Technical Support Manager
Cambridge Elevating
1-866-209-3421
[e-mail]

Table of Contents
•Tools List and Materials not supplied
•Site Preparation
•Safety Warnings
•Before you Begin
•Controller and Pump
•Rail Bracket and Sliders
•Baseplate
•Jack-post
•T-Rail (right or left)
•Hydraulic Cylinder
•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 Handrail

Tool List
•Measuring tape 25ft or more
•Light
•Pen and notepad
•Chalk line
•Black sharpie
•18 to 20V Battery powered impact wrench
•Hammer drill
•Socket set
•Battery powered drill
•Drill bit set
•Screwdrivers
•Wrenches
•Allen keys
•Bullet level
•4-to-6-foot level
•Plumb bob with line (two)
•Hammer
•Gloves
•Large funnel
•Ladder
•Pliers
•Drywall saw
•Angle grinder or saw to cut ropes
•Shop vacuum
•Dustpan
•Broom
•Metal shims
•Chain fall or electric hoist
•Vise grips (2)
•Rail files
•Thread sealant
•Clean lint free cloths
•Wire cutters
•Wire strippers
•Wire crimpers
•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 attach the ¼ inch plastic line to the wall
•2L plastic jug
•AW32 hydraulic oil
•Cable ties (small and large)
•Tie wrap anchors
•A mild cleaner appropriate for painted and laminated surfaces
•A window cleaning spray (if you have glass in the cab)
•A stainless-steel cleaner for stainless surfaces
•Soft clean cloth or paper towels
•Garbage bags

Site Preparation
Pre-install site check
NOTE: Prior to beginning the installation, a site inspection is recommended to confirm that the site’s hoistway
dimensions match the engineering plans prepared for the project. Often there are several versions of the elevation and
layout drawings made during the order process. The information on these preliminary drawings will likely be incorrect. If
you are not sure if the version you have is the latest, contact your sales engineer. Confirm all measurements and discuss
any deficiencies with the general contractor so they can be resolved before installation begins.
Some key items to look over and measure, include the following:
•Support wall constructed to specifications
•Pit / travels/ landings / rough door openings / overhead all match the drawing dimensions
•Floors are inline with each other and walls are plumb
•Door opening are inline according to 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 width is correct at each landing
•The shaft depth is correct at each landing
•The rail wall construction is per specifications
•The location of the controller and power unit is as per plan
•The 220 single phase or 208 3 phase and 120 disconnects are or will be installed within 3 feet of the right side of
the main controller’s location
•The rough door openings at each landing are inline and the correct size
•Landing openings should be at least 50 inches wide but we recommend leaving the full width of the hoistway
Contact your sales engineer or technical support (1-866-209-3421) at Cambridge Elevating as soon as possible if any of
the measurements or details vary from the final diagrams.

Safety
All installers must read and follow the “Elevator Industry Field Employees’ Safety Handbook” which is
available from the Elevator World Magazine web site
WWW.ELEVATOR-WORLD.COM .
Installing an elevator within a busy construction site can pose significant hazards to the installers and other
construction personnel. This manual will not attempt to list safety procedures during all steps of the installation
since site conditions and other unknown factors would make this impossible. Constant vigilance and
communication are vital to ensure everyone’s safety.
Consider all site hazards including the following and take all steps required to address them during every stage
of the installation:
oHigh voltages within pump and controller
•Proper training and use of lock out procedures
oElevator door openings present fall risk to all
•Guard all shaft openings at all times
oPinch points within shaft
•Remove, guard, or avoid when working around moving equipment
oLifting heavy items
•Lift properly and share the load
oUse of ladders and scaffolding
•Must be properly installed, maintained and used
oWorking with tools
•Use required protection at all times including gloves, safety glasses and hard hats
oSeveral people working together in a confined space and around machinery
•Requires constant communication and co-operation

Before You Begin
Review shipment
Check the shipment for any exterior damage and note it to the delivery driver and on the paperwork, before
signing for the shipment please take photos to help with a claim.
Report any damage to Cambridge Elevating that was not noticed when the elevator was delivered, as soon as it
is found, and any missing parts within a week of delivery. The packing list will tell you what is in each box, in
the cab, on each pallet and attached to the sling.
If anything appears to be missing or damaged, please take photos and contact Technical Support as soon as
possible by calling 1-866-209-3421 or emailing [e-mail].
**Failure to do so may result in items not being covered**
*CHECK THAT ALL SITE DIMENSIONS MATCH THE LAYOUT AND ELEVATION
DRAWINGS, IF THEY DO NOT CALL CAMBRIDGE ELEVATING.
oRemove all packaging and unpack the elevator cab
oRemove the T-rails and rail brackets
oRemove the cab
oIdentify the various components and sub systems
oItems not included 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 abrasive pads (for cleaning the T-rails)
•120VAC disconnect for the lighting power
•Appropriate disconnect for pump with extra contact for emergency power
•Appropriate hardware to attach the following to the wall or floor on which they are to be mounted:
- Rail brackets (lag screws or concrete lags or thru bolts)
- Controller
- Pump (concrete lags)
- T-rail base plate (concrete lags)
- Automatic landing door frame (Cambrian model only)
•Hydraulic oil: For all models use 20-25 gallons (80-100 litres) of Grade 32 or 46 hydraulic oil
oClean the protective material from the T-rails using mineral spirits and an abrasive pad
oEnsure that the hoistway and travel cables provided are long enough for the route required
Call Cambridge Elevating at 1-866-209-3421 before starting the installation if you have any questions or
concerns

Controller and Pump Installation
Procedure:
•Mount the main controller as per mechanical room drawings and in accordance with
local electrical codes and ASME 17.1/CSA B44. Items to consider:
oHow the hydraulic lines can be run between the pump and controller
oHow the hoistway and travel cables can be run to the controller
oAccess to the 208/220/575 VAC and 120 VAC disconnects and flash zones
oMechanical room ventilation, lighting and access
oAccessibility 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 connected, connect the remote pendant (to be used for installation only)
provided to the controller
TYPICAL LULA MACHINE ROOM LAYOUT
R

Rail Brackets and Sliders
The objective is to install the rail brackets on the rail wall according to the elevation and plan-
view drawings supplied in the engineering package. There are various methods utilizing
different equipment in order to accomplish this. We will only state the basic objectives here.
Although ladders can be used to install some of the rail brackets, we recommend building a
wooden platform (scaffolding) at each door opening from which you can safely install the rail
brackets and the T-rails. The design of this platform should be to local codes and sufficient
enough to carry the weight of the people using it.
Options for mounting the rail brackets
•Wooden rail walls-
oWood lags: 5-inch-long 3/8th with 3/8th washers
•Filled block and concrete rail walls-
oWedge anchors: 5-inch-long 3/8th wedge anchors with 3/8th hardware
•Hollow block walls-
oWe do not recommend hollow block walls
oConsult the specifications of your structural engineer
Other options
•Through bolting can be used in some cases, consult the building engineer for hardware
specifications
•Unistrut concrete inserts (available from Cambridge Elevating) with strut nuts and bolts
½ inch strut nuts ½-inch -13 x 1-3/4-inch bolts and washers
•For a structural steel hoistway, the rail brackets can be welded or bolted in place Consult
the building engineer for specifications

Mark the rail bracket locations and snap centerline on the rail wall
Considerations:
•The centerline of the rail system is not typically centered on the rail wall. Please check
your final layout diagram to determine your centerline and rail bracket locations
•The procedure below references your final drawings
Procedure:
•Use the final elevation and layout drawing provided
•Mark the height of each rail bracket location from the pit base to top of shaft
•Use your measuring tape and mark the centerline as shown on the layout drawing
•Mark centerline of rail bracket (note: this is often offset in the shaft) at top of rail wall
as per the plan-view drawing and with the aid of a level, snap a vertical chalk line down
the 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 this point, we recommend installing all
the sliders so that everything can be verified before installing the rails
Procedure:
Top left slider
Install the slider hand tight
Adjust the slider left and right so that it overhangs the rail bracket arm by
½ an inch
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

Bottom left slider
Install the slider hand tight
Adjust the slider left and right so that it just touches the plumb line
•If the bottom slider cannot be adjusted to do this or the line
touches the arm of the rail bracket, you will need to re-adjust the
top slider so that this is possible
Adjust the slider in and out so that the V notch is lined up with the plumb
line
Tighten the slider in place
Install the remaining sliders on the left side
Top right slider
Install the slider hand tight
Adjust the slider left and right so that the distance between 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 using wood or steel that will help you make sure
the distance between the sliders is 32 and 5/8 inches
Install the slider hand tight
Adjust the slider left and right so that the distance between 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

Baseplate
Considerations:
•The pit floor must be dry and free of debris
Procedure:
•Sweep the area directly beneath the rail wall, where the baseplate will be placed
•Remove any lumps so that 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

Jack-post
NOTE: The below procedure covers projects that are using a 90mm oil lift cylinders
Procedure:
•Confirm the jack-post length is correct as per the final elevation drawing
•Install the jack-post mounting slider hand tight
•Adjust the slider so that the distance from the face of the slider and the wall 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)
•Check that the jack-post is plumb and true using your level, adjust the base plate if
necessary
Jack-post top

T-rail Installation (Right or Left)
NOTE: Generally, we install the rail furthest away from the door to allow you to position sling,
however you can set both bottom rails and chain fall the sling into position
Install the right or left T-rails starting at the bottom and begin working your way up
Procedure:
•Check the job’s elevation drawing to see if the short T-rail is at the top or bottom
•Loosely attach the 1st T-rail to the base plate to the 1st rail bracket
•Level and plumb before tightening the rail clips. 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 (see image below)
•Add 2nd T-rail to the top of the first. Secure 2nd T-rail to splice plate and next rail bracket(s)
NOTE:Check that it is plumb before tightening all bolts
•Repeat with each new T-rail to the top of the hoistway
•The T-rails should be straight, plumb, and free from burs on the inward facing side

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)

Hydraulic Cylinder Installation
NOTE: Installing the cylinder before the sling will make things easier, however the sling might
be in the way when you want to run your hard pipe. Do what is ideal for your situation.
Procedure:
1. Lower cylinder into shaft with piston end up and place bottom end onto the top of the jack-
post
2. Loosely clamp cylinder to cylinder bracket with the provided U bolt
3. Rotate to access cover plate, located at bottom of cylinder
4. Attach line rupture valve with O rings properly seated (see image below)
5. Run your hydraulic lines as 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 the pump. If hose is not
long enough, run to an appropriate drain-container (not provided) within the pit
11. Complete installing hydraulic lines between cylinder and the pump. (Use fittings provided)
NOTE:Refer to hoistway drawings to ensure there is sufficient clearance along the chosen
route.
12. Fill the pump reservoir with 32 or 46 weight type hydraulic oil

Sling
NOTE: The cross piece on the front of the sling and the leg extensions can be removed and
reinstalled after the sling is in place, if necessary, to get the assembly into the hoist-way.
•Warning! The sling is heavy and awkward to move, work safely.
Procedure:
•Pull up on the shackles until they are out as far as they can come and lock them in place
with two sets of vise grips (see image below).This will disengage the safeties (brakes)
and allow the sling 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 engage the right or left hand side of the sling with
the right or left hand side of the T-rail
•Or if you installed both the left/ and right hand side of the rails, lower the sling into the
position using the chain fall
•Do not remove the vise grips yet

Finish T-rail Installation
NOTE: if you installed the complete bottom rail section this section does not apply
Procedure:
•Check the elevation drawing to see if the short T-rail is at the top or the bottom
•Lower the first T-rail down between the rollers and the rail bracket from the top of the sling
•Loosely attach the 1st T-rail at the base plate and the 1st rail bracket then level and plumb
before tightening the rail clips If it’s the short 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-rail to splice plate and next rail bracket(s)
Note: Check that it is plumb before tightening all bolts
•Repeat step 6 with each new T-rail to the top of the hoistway
•The T-rails should be straight, plumb, and free from burs on the inward facing side

The Sheave
Procedure:
•Remove the shipping bracket that holds the plunger rod in place and discard
•Keep the large bolt, set aside
•Reinstall the Allen bolt that was holding the shipping bracket
•Disassemble the thick bottom plate of the sheave (set aside the hardware)
•Mount the sheave plate to the top of the cylinder using the large bolt from earlier 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 sheave assembly is parallel to the rail bracket
•Loosen the bolts holding the top sheave plate. Removing this later will assist in roping
the sheave

Connect the Wire Ropes to the Sling
NOTE: Do not remove the tape on the ends of the cable as it keeps the ends from unraveling
and protects you from the sharp ends of the wires.
Procedure:
•Remove the electrical tape that is holding the wire rope in a coil
•Lay the rope out and avoid kinking the cable
•Removing the sheaves top plate will make running the cables over the sheave easier
•Run the cables up through the lower left of the sheave wheel and down and out the
bottom right 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 top of the shackle (see image below)
•Install one clip 1 1/8th above the first clip (see image below)
•Bind the two shackles together using two heavy zip ties to prevent rotation
•Remove the vise grips installed when installing the sling
•Reinstall the plate on the top of the sheave