Escalator: Field Method Manual

OTIS Field Method Manual
Repair
506NCE_EN_FM3
Sect.: 12.2
Escalator OTIS 506 NCE Page: Cover
Date: 05 /99
Escalator
Otis 506 NCE
Document History
Revision Description of changes
No Date Department
Cover sheet added.
1 08.02 SW - CSS Document no. G 9171 M 01 deleted.
Copyright 1999, OTIS GmbH Berlin
Pegasus ID No. 506NCE_EN_FM3 added.
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Escalator OTIS 506 NCE Page: 1/ 144
Date: 05 /99
12.2. Repair Pages

List of contents
12.2.0 Safety activities 3- 4
12.2.1 Change of main drive 5-17
12.2.2 Change of main drive chain 18-19
12.2.3 Change of step roller 20-21
12.2.4 Change of step 22
12.2.5 Change of step chain 23-26
12.2.6 Change of step chain roller 27-29
12.2.7 Change of comb 30-31
12.2.8 Change of handrail of linear belt handrail drive system 32-40
12.2.9 Change of handrail of traction wheel drive system 41-49
12.2.10 Change of handrail drive sprocket of linear belt 50-55
handrail drive system
12.2.11 Change of handrail drive sprocket of traction wheel 56-59
drive system
12.2.12 change of handrail pressure roller chain 60-64
of traction wheel drive system
12.2.13 Change of poly-V-belt 65-70
12.2.14 Change of handrail drive unit 71-77
12.2.15 Change of roller (roller bow) of linear belt 78-83
12.2.16 Change of roller (roller bow) of traction wheel 84-89
drive system
12.2.17 Change of safety equipment 90-104

12.2.17.1 Change of main drive chain control contact 90
12.2.17.2 Change of skirt panel safety contact 91-92
12.2.13.3 Change of broken step & chain wheel control 93-94
contact
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12.2. Repair Pages

12.2.17.4 Change of step chain roller monitoring switch 95-96
12.2.17.5 Change of handrail entry device 97-99
12.2.17.6 Change of broken step chain device 100-101
12.2.17.7 Change of comb plate safety device 102-104
12.2.18 Change of lighting 105-111
12.2.18.1 Change of skirt panel lighting 105-107
12.2.18.2 Change of under step lighting 108-109
12.2.18.3 Change of traffic light 110
12.2.18.4 Change of direction indicator 111
12.2.19 Change of balustrade 112-125
12.2.19.1 Change of newel glass panel 112-122
12.2.19.2 Change of straight glass panel 123-124
12.2.19.3 Change of newel plastic profile 125
12.2.20 Change of operation panel (UL/LL) 126-128
12.2.21 change of stop switch in control device (UL / LL) 129-130
12.2.22 change of key switch in control device (UL / LL) 131-132
12.2.23 change of LED in control device (UL) 133-134
12.2.24 Change of tension carriage 135-141
12.2.25 Special tooling 142-144
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12.2.0 SAFETY MEASUREMENTS PREPARATION- AND FINAL WORKS

The Worldwide Jobsite Safety Standards are incorporated into a separate
document. This compilation just explains main features of safety standards
for Escalators and Trav-O-Lators.
1. Preparation work
1. Stop escalator via stopping button on one of the landings.
2. Block the landings.
3. Open landings with tooling GAA 27 BW1.
4. Switch off main switch ( with lock secure)
(for intermittend operation, operate in addition the maintenance switch"S30")
5. Take off the controller.
6. Remove blind plug on the revision plug adapter at the controller resp.
terminal block in the lower landing.
7. Connect revision control.
Remark to 5.:
A lifting device from Otis factory Stadthagen under the tooling WZ 26201 M1
can be obtained.
Controller not lay
2. Final work
1. Remove revision control and plug in blind plug.
2. Lift controller in the landing
(for intermittend operation, operate in addition the maintenance switch "S30").
3. Switch on main switch. (remove lock)
4. Close landing.
5. Take off blocking on landing.
6. Set escalator via key switch in operation.
with operation panel 1.1 2.6

failure indication field operation
stop button key switch
upper landing
without operation panel

key switch
LED
lower landing
stop button
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Continuation
1.2 2.5 1.3 2.4
blocking in the upper and

lower landing
floor plate
lifting device
WZ GAA 27 BW1
no entry for
unauthorized persons
upper landing lower landing

1.4 1.6 1.7 2.1 1.4 2.3
plug adapter with
for lifting device switch 1.6 1.7
GBA 26201 M1 inspection plug adapter
IBU/X7 control switch
SSLL/Q3
revision control
new safety button
controller
inspection plug adapter
terminal block IBL/X6
plug adapter
main switch
MS/Q01
power on power off

tool GAA 27 EA
assistance
for main swich
power off & switch locked
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12.2.1. Change of main drive
1.1 Preparation of safety measurements - see sheet 3, point 1.1 - 1.7.
1.2 Removal of first step.

1.2.1 Remove step guard in the lower landing.
1.2.2 Removal of 8 steps.
1.2.2.1 Lift snap pin by means of step lifting device tooling GO 6815 Y1, move sliding
bush to the axle center (each left and right side), mark step and step axle and
take out step.
1.2.2.2 Turn on main switch, run step band with the revision control by one step and
remove steps 2 - 9 as mentioned under point 1.2.2.1.
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(Continuation) Change of main drive
1.3 Run open step band to upper landing and turn off main switch.
1.4 Measure spring tension on tension carriage and release tension on tension
carriage.
sliding block
pressure spring
1.5 Dismantle balustrade parts.

1.5.1 Dismantle bended inner decking on both sides on the upper landing.
inner decking inner decking
tooling 5385
clamp
tooling WZ 5382 holder
version-
guardian
version-
stainless
steel
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1.5.2 Dismantle complete handrail entry box on both sides on the upper landing.
version-old
bolt connection
on the glass panel
deflector (outside, inside)
fastening nut
M12 / 37 Nm
fastening bolt M10x50

44 Nm with rubber protecting tube
safety
fastening screw switch
handrail entry guard
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version-old
remains unchanged adjusting screw

outside
shim glued
fastening bolt M 10x 50 / 44 Nm

with rubber protecting tube
fastening points
M 12 / 37 Nm
remains unchanged
fastening points skeleton inside

M 8x25 / 22 Nm
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entry device version-new
1
disassembly/assembly
very carefully
deflector outside deflector inside
inner shell
nut/washer M4
do not remove!
moulding inside
do not remove! shell inside
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moulding inside
nut/washer M4 do not remove!
do not remove!
3
clip

nut/washer M10
clip
clip

front plate
link
clip
4
clip
chim
hexagon socket
head cap screw
M6x30 switch
handrail guard front plate

cover insert guard
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5 shell outside
nut/washer M8 hexagon bolt M6x20

not necessary to do not change adjustment!
remove; keep in
position!
hexagon bolt M10x50
washer A 10,5
rubber protecting tube
chim nut/washer M10
chim
nut/washer M12
not necessary to remove;
keep in position!
bar
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6
not necessary to remove;
keep in position!
nut/washer M8
keep in position!
welded bolt M8
for fastening of
outer shell
holder for skirt panel

keep in position!
skeleton
holder for
handrail entry box
connection to
skirt panelling
clip
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1.5.3 Pull off handrail in the lower curve of both sides.
tooling 5365
1.5.4 Pull off handrail from the balustrade on the upper landing on both sides.
1.5.5 Remove glass panels on both sides of upper landing.

1.5.5.1 Loose profil to the straight part of the panel.
1.5.5.2 Loose push- and wedge connections, remove panels.
torque Nm
M6
T-screw
wedge
insert wedges during erection

by means of wood wedge and
plastic hammer
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1.6 Remove step guard in the upper landing.

1.7 Dismantle the complete floorplate, angle profile and supporting beam on the
upper landing.
1.8 Remove drive chain from the machine.
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1.9 Loosen and remove fastening points of the machine and take out the complete
machine.
hold down bolt

with counter nut hold down clamp
welded
adjusting bolt
with counter nut
hold down clamp
nut / washer
hold down bolt
with counter nut
to main drive
welded
adjusting bolt
with counter nut
markings for machine

adjustment
hold down clamp
welded
adjusting bolt
with counter nut
1.10 Open step chain

Attention: Never open chain without chain tension tooling !
1.10.1 Secure step chain in front- and rear run

1.10.2 Remove chain locks on the step chains
1.10.3 Remove step chain from main drive
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1.11 Loose bearing fastening to the truss

1.11.1 Remove pin connections on the bearing fastening to the truss
bearing fastening with

flange on the truss
provided
with pins
bearing fastening
on the flange plate
torque 90 Nm -10
1.11.2 Remove the welding points on the step chain roller track.
1.12 Dismantle the pipes for bearing lubrication.

1.13 Remove complete main drive.

1.13.1 Place "A" frame chain fall support/s and mount lifting device with bevel according
to load.
1.13.2 Mount bevel on main drive, take it out and set it on the landing in U-beam
and roll it from the landing to a pallet.
(Secure it against slipping !)
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Transition track
Step roller reversal

track
Shaft
Sprockets for
Sprocket for
step chain
main drive chain
1.14 Installation of dismantled parts in reverse order.
1.15 Function test
1.16 Final works see sheet 3, points 2.1-2.6 .
Tools: Standard maintenance tooling

right-angle grinder, drilling machine, drill bit 11 mm dia.
ruler about 500 mm, 1 ring spanner SW 36 mm, chisel,
1 fork wrench SW 36 mm, hammer 1000 g, handspike 1 m,
ratchet and joints and 2 extensions 250 mm long,
2 step pin lifter, rope, "A" frame chain fall support,
lifting device and bevel for 500 kg load, 2 pieces of U-beams,

1 pallet, tooling for opening and closing the step chain,
handrail-hook, tooling 5385 for taking out the inner decking
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12.2.2 Change of main drive chain
2.1 Preparation of safety measurements see sheet 3, points 1.1 - 1.7.
2.2 Removal of old drive chain.

2.2.1 Switch on main switch.
2.2.2 Run drive chain by means of revision control until chain key is in proper position.
2.2.3 Switch off main switch.
2.2.4 Loose fastening screws on the machine, move machine with handspike until
chain is loose.
2.2.5 Move drive chain control contact (BDC) upwards and arrest it.
switch
span box
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(Continuation) Change of main drive chain

2.3 Installation of new chain.
2.3.1 Connect new chain with the old one by means of chain lock.
2.3.2 Release brake, turn machine by hand and pull in new chain.
2.3.3 Let brake drop in and remove old chain.
2.3.4 Installation of chain lock.
2.3.5 Move machine by means of handspike, adjust chain tension and tighten
fastening screws.
Tension Box
10+10mm
2.3.7 Test function of main drive chain control contact.

2.3.7.1 Turn on main switch.
2.3.7.2 Try to start escalator via the revision control device.
Escalator must not start.
2.3.7.3 Installation and adjustment of main drive chain control contact (BDC) according
to adjustment instruction and start up.
Escalator must start.
2.3.8.5 Switch off main switch.
2.4 Final works see sheet 3, points 2.1 - 2.6.

Tooling: Standard maintenance tooling, handspike
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12.2.3 Change of step roller
3.1 Preparation of safety measurements see page 3,

points 1.1 - 1.7
3.2 Removal of step(s).
3.2.1 Turn on main switch.
3.2.2 Run step band with the revision control from the upper
landing in the necessary position.
3.2.3 Turn off control switch.
3.2.4 Remove step guard.
3.2.5 Remove step (marking of steps and step axles when
dismounting several steps).
3.3 Remove step roller.

3.3.1 Removal of shaft safety device.
3.3.2 Removal of step roller by means of pulling off device.
3.3.3 Cleaning of step roller set.
3.4 Installation of the new step roller.

3.4.1 Install step roller on the shaft by means of tooling
3.4.2 Install safety ring.
3.5 Installation of step(s) in reverse order as mentioned under

3.6 Adjust step(s).
3.7 Turn on control switch.
3.8 Make function test.
3.9 Install step guard.
3.10 Final works see page 3, points 2.1 - 2.6.
Tooling: Standard maintenance tooling,

2 toolings for dismantling step, puller
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(Continuation) Change of step roller
When lifting the snap pin, the

step bushing can move inside
towards the step axle centre.
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12.2.4 Change of step(s)
4.1 Preparation of safety measurements see page 3, points 1.1 - 1.3 and 1.6 - 1.7.
4.2 Removal of step(s).
4.2.1 Run step band with the revision control in the necessary position in the lower landing.
4.2.2 Turn off control switch.
4.2.4 Marking of steps and step axles (when removing several steps).
tool for
dismantling step
When the snap pin is lifted,

the step bushing can be moved
4.3 Installation of step(s) in reverse order as mentioned under point 4.2.

4.4 Adjust step(s) see adjusting instruction.
4.5 Turn on control switch and make function test.
4.6 Install step guard.
4.7 Final works see page 3, points 2.1 and 2.4 - 2.6.

2 tools for dismantling step
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12.2.5 Change of step chain
5.1 Preparation of safety measurements see page 3, points 1.1 - 1.7.

5.2 Preparation work for dismanteling.
5.2.1 Transportation of new step chain in the range of lower landing.
5.2.2.1 Remove first and second inner decking (loose electric connections)
5.2.3 Removal of all steps.
5.2.3.1 Remove first step.
5.2.3.1.1 Lift snap pin by means of step lifting device GO 6815 V1, move step axle
bushing to the axle center (each left and right side), mark step and step axle
and take out the step.
5.2.3.1.2 Turn on main switch, run step band with the revision control by one step and
dismount the remaining steps as mentioned under point 5.2.3.1.1.
5.2.4 Release tension carriage (measure spring tension before).
5.2.4.1 Loose counter nut on the tension springs on both sides.
5.2.4.2 Release springs from tension carriage.
5.2.5 Release handrail drive unit (pressure roller carrier).
5.3 Removal of old step chain in the lower landing.

Attention: Never open chain without chain tension tooling !
5.3.1 Installation of chain tension tooling on both sides via 2 axles.
5.3.2 Fasten and secure chain in fore-run with a rope.
5.3.3 Remove retaining ring and connecting link (link A with pins, link B without pins)
with tooling.
5.3.4 Remove connection link.
5.3.5 Remove step chain parts (10-fold units) in down-direction.
5.3.5.1 Remove chain tension tooling and run chain with handwheel in down-direction.
5.3.5.2 Assemidle step chain units in lower landing.
5.3.5.3 Let down last part on the step axle by means of rope, put it together and place
it on a car.
5.4 Cleaning of rails and inner side of escalator.

5.5 Install new chain.

5.5.1 Roll out first part of step chain (on clean floor or plastic sheet).
5.5.2 Let down rope from the upper landing and fasten rope on the first step axle.
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(Continuation) Change of step chain

5.5.3 Lift step chain and pull in with rope.
5.5.4 Roll out second part and connect with an intermediate part one and two.
5.5.5 Pull in further step chain and mount further parts.
(Pay attention to proper set the sprocket for handrail drive between the
chain links)
5.5.6 Put step chain on the step wheel.
5.5.7 Put handwheel on the machine and turn it upwards by hand until the step chain
is lying 2/3 on the step chain wheel.
5.5.8 Remove rope and turn step chain further.
5.5.9 Place step chain on the step chain wheel in the reverse position.
5.5.10 Install chain tension tooling in good position on both chain ends and pull chain
together.
5.5.11 Install connection links, links and retaining rings.
5.5.12 Remove rope.
5.7 Oil step chain.

5.7.1 Pretension tension carriage to about 50 %.
5.7.2 Turn on main switch and run escalator with the revision control in up-direction.
5.7.3 Apply oil no. 39 by hand.
5.7.4 Turn off main switch.
5.8 Adjust tension carriage.

5.8.1 Tighten nuts for the tension carriage springs and adjust spring tension according
to given dimension.
5.8.2 Look counter nuts.
5.8.3 Adjust broken step chain device according to instruction.
5.8.4 Function test of broken step chain device on both sides.
5.8.4.1 Interrupt and arrest contacts.
5.8.4.3 Try to start escalator with the revision control device.
5.8.4.4 Set back contacts and start again.
5.8.4.5 Turn off main switch.
5.9 Adjust handrail drive.

5.9.1 (see adjusting instruction)
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5.10 Installation of components.

5.10.1 Installation of dismantled components in reverse order of points 5.2.2.
5.11 Testing of distance step to skirt panel.

Distance dimension: 1,5 mm (max. 2,5 mm) per side
5.12 Check proper inlet of steps in the comb (if necessary the steps are to
be adjusted via the shims on the step axle).
Tooling: Standard maintenance tooling

1 Euro-plan, cleaning mass,
cleaning rag, brush, extractor
rope about 30 m, extension cable
step chain tooling for:
step links and step axle
chain tension tooling
Attention: Never open chain without chain tension tooling.
ACCIDENTS CAN HAPPEN !

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Tooling- 9704 CC1 for step chain dismantling
Tooling- 9704 CB1 for step chain assembly
for step links for step axle
pressure screw
pressure screw step axle
pressure piece
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12.2.6. Change of step chain roller

6.2 Turn on main switch.
6.3 Run range of defective roller(s) in the lower landing.
6.4 Turn off main switch.
6.5 Remove step(s).

6.5.2 Lift snap pin by means of step lifting device, move step axle bushing to
the axle center (left and right) and take out step.
6.5.3 Mark steps when taking out more than one.
6.6 Remove defective step chain roller(s).

6.6.1 Install chain tension toolings on both sides via 2 axles.
6.6.2 Remove retaining rings.
6.6.3 Remove links with the link-tooling.
6.6.4 Change of step chain roller(s) (double unit = 2 rollers with links).
6.7 Assembly of dismounted parts.

6.7.1 Installation of link.
6.7.2 Installation of retaining rings.
6.7.3 Remove chain tension tooling.
6.8 Installation of step(s) in reverse order as mentioned under point 6.5.
6.9 Function test.

cleaning rag, step bolt lifting device GO 6815 Y1
Tooling for: step link and step axle
chain tension tooling
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(Continuation) Change of step chain roller

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(Continuation) Change of step chain roller
tooling 9704 CC1 for step chain dismantling
tooling 9704 CB1 for step chain assembly
for step link for step axle
pressure screw
pressure piece pressure screw
step axle
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12.2.7 Change of comb
7.2 Change of comb.

7.2.1 Removal of comb.
7.2.2 Installation of comb.
7.3 Adjustment of combplate (see instruction) if necessary.
7.4 Function test

7.4.1 Turn on main switch.
7.4.2 Test entry of step in the comb.
7.4.3 Turn off main switch.

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(Continuation) Change of comb
M6x16 M6x16
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12.2.8. Change of handrail of linear belt handrail drive system
handrail passenger line
handrail return line
8.2 Removal of interior panels.

8.2.1 Dismantling of complete inner decking.
8.2.1.1 Removal of fastening screws and marking of parts.
8.2.1.2 Taking out of inner decking with tooling 5385 and secure against slipping
with tooling 5382 if the inner decking is provided with an electric connection.
8.2.1.3 Disconnect electric connection on both sides of inner decking and put decking
carefully down.
plastic profile inner decking
tooling WZ 5385
safety slipping device WZ 5382
screw M4
clamp
skirt panel
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(Continuation) Change of handrail
8.2.2 Dismantle inner side of entry box on the upper and lower landing.
8.2.2.1 Dismantle 2 clipped deflectors outside, inside.
8.2.2.2 Loose the visible screw connection on the glass panel and take out the
clipped in inner shell in floor plate direction and afterwards in newel direction.
8.2.2.3 Dismantle handrail entry profile.
8.2.2.4 Remove clipped in safety switch for the handrail entry.
8.2.2.5 Remove fastening bolt on entry box frame and take off skeleton
inside (take care of shim for the glass panel).
deflector outside, inside
bolt connection
to the glass panel
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fastening nuts
M12 / 37 Nm

44 Nm with rubber protecting tube
fastening screws
safety switch
fastening
screws
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outside
shim
fastening bolt M 10x 50 / 44 Nm

fastening points
M 12 / 37 Nm
remains unchanged
fastening points
M 8x25 / 22 Nm skeleton inside
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8.3 Remove 5 steps.

8.3.2 Removal of first step.
8.3.2.1 Lift snap pin by means of step lifting device, GO 6815 Y1, move step axle
bushing to the axle center (each left and right side), mark step and step
axle, take them out and put them aside.
8.3.2.2 Turn on main switch, run step band with the revision control by each one
step and dismount steps 2 - 5, see point 8.3.2.1.
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8.4 Remove skirt panel on the upper and lower landing.

8.4.1 Remove end of skirt panel.
8.4.1.1 Loosen screw connection on the upper and lower part of the fastening plate.
8.4.1.2 Take out and put down skirt panel.
8.4.2 Remove bended skirt panel on the lower landing.

8.4.2.1 Loosen the screw connections on the upper and lower part of fastening plate.
8.4.2.2 Loosen the T-screws on the skirt panel.
8.4.3 Remove straight skirt panel in the area of handrail drive.

8.4.3.1 Loosen the screw connection on the upper and lower fastening plate.
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8.5 Run open step band in the area of handrail drive by means of revision
control and turn off control switch.
8.6 Loose the handrail drive parts.

8.6.1 Loose the pressure roller carrier via adjusting screw (marked height adjust-
ment) until handrail is laying bare.
Pay attention that rollers are secured against falling out.
8.6.2 Mark and remove the handrail guide fastening.
8.6.3 Loosen fastenings on the length compensation device. Move length
compensation device upwards and arrest it.
adjusting screw
red marking
length compensation
.
impact roller set
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8.7 Removal of old handrail.

8.7.1 Loosen and set back the bended return rail on the upper and lower landing.
8.7.2 Pull handrail on the lower bow from the profile in the fore-run and separate
handrail by means of saw.
8.7.3 Pull out handrail to the lower landing, roll it up and secure it against
rolling up.
handrail
tooling
WZ 5365
skirt panel
apply hook tooling

WZ 5367/66
for profile
8.8 Installation of new handrail.

8.8.1 Provide area of skirt panel and part of step band with protection material
(for protecting the new handrail against damages).
8.8.2 Roll out handrail and put it on the guide profile in the fore-run, above,
below and in centre.
8.8.3 Put handrail on the guide profile in return-run, see point 8.8.2.
8.8.4 Remove protection material.
8.8.5 Pull handrail with long hook, tooling 5366 resp. 5367 on the return-run
and with short hook, tooling 5365 on the fore-run.
8.8.6 Push the curved return-line guiderail against the stop at the upper and lower
landing and fasten the rail.
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Repair
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Date: 05 /99
8.8.7 Adjust handrail drive and length compensation device.

8.8.7.1 Put handrail between pressure roller carrier set and poly-V-belt.
8.8.7.2 Install handrail guide.
8.8.7.3 Adjust length compensation device according to instruction.
8.8.7.4 Adjust pressure roller carrier set according to red marking.
8.9 Installation of skirt panels in reverse order of point 8.4.
Pay attention to distance step to skirt panel !
8.10 Make function test and test handrail run.

8.11 Install dismounted steps.
8.11.1 Turn on control switch and run open step band with revision control to
the lower landing in mounting position.
8.11.2 Installation of step in reverse order of point 8.3.
8.12 Installation of interior panels in reverse order of point 8.2.

wrench SW 13, 30 cm long;
Aids: Protection material,

hook for handrail tooling WZ 5365 / 66 / 67
step lifting device GO6815 Y1, tooling WZ 5385
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12.2.9 Change of handrail of traction wheel drive system

NEWEL
LOWER LANDING
PASSENGER LINE
HANDRAIL DRIVE UNIT

NEWEL
LOWER LANDING ANTISTATIC ROLLER
RETURN LINE

9.2.1.1 Removal of fastening screws,control device in upper and lower landing
(see point 12.2.21.12.2.23) and marking of parts.
9.2.1.2 Taking out of inner decking with tooling WZ 5385 and secure against slipping
with tooling WZ 5382 if the inner decking is provided with an electric connection.
carefully down.
inner decking

holder
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(Continuation) Change of handrail of traction wheel drive system
9.2.2 Dismantle inner side of entry box on the upper and lower landing.
9.2.2.1 Dismantle 2 clipped deflectors outside, inside.
9.2.2.2 Loose the visible screw connection on the glass panel and take out the
clipped in inner shell in floor plate direction and afterwards in newel direction.
9.2.2.3 Dismantle handrail entry profile.
9.2.2.4 Remove clipped in safety switch for the handrail entry.
9.2.2.5 Remove fastening bolt on entry box frame and take off skeleton
inside (take care of shim for the glass panel).
1
very carefully
deflector outside / inside
inner shell
nut/washer M4
do not remove!
moulding inside
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nut/washer M4 moulding inside

do not remove! do not remove!
3
clip

nut/washer M10
clip
clip

front plate
link
4 clip
clip
chim
hexagon socket
head cap screw
M6x30 switch
switch
front plate
handrail guard
cover insert guard
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9.3 Remove 5 steps.

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9.4 Remove skirt panel on the upper and lower landing.

9.4.1 Remove end of skirt panel.
9.4.1.1 Loosen screw connection on the upper and lower part of the fastening plate.
9.4.2 Remove bended skirt panel on the lower landing.

9.4.2.1 Loosen the screw connections on the upper and lower part of fastening plate.
9.4.3 Remove straight skirt panel in the area of handrail drive.

9.4.3.1 Loosen the screw connection on the upper and lower fastening plate.
skirt panel
skirt panel
view A
view A
holder
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9.4.4 Run open step band in the area of handrail drive by means of revision
control and turn off control switch.
9.4.5 Removal of drive sprocket (1 tooth in vertical position in the chain link).
9.4.5.1 Remove a part of step roller rail in return-run.
9.4.5.2 Loosen handrail pressure roller chain.
9.4.5.3 Remove fastening screw and spacer (secure spacer between drive sprocket
and support against loss).
9.4.5.4 Lift up drive sprocket and take out drive sprocket.
9.4.5.5 Loosen roller via the screw.
roller
handrail lengh
handrail drive sprocket compensation
roller
handrail
127 ± 1 mm
roller bow
1
7±
12
HANDRAIL PRESSURE
ROLLER CHAIN
9,3 +0,6 mm
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9.5 Removal of old handrail.

9.5.1 Loosen and set back the bended return rail on the upper and lower landing.
9.5.2 Pull handrail on the lower bow from the profile in the fore-run and separate
handrail by means of saw.
9.5.3 Pull out handrail to the lower landing, roll it up and secure it against
rolling up.
handrail
tooling
WZ 5365
skirt panel
apply hook tooling

WZ 5367/66
for profile
9.6 Installation of new handrail.

9.6.1 Provide area of skirt panel and part of step band with protection material
(for protecting the new handrail against damages).
9.6.2 Roll out handrail and put it on the guide profile in the fore-run, above,
below and in centre.
9.6.3 Put handrail on the guide profile in return-run, see point 9.6.2.
9.6.4 Remove protection material.
9.6.5 Pull handrail with long hook, tooling 5366 resp. 5367 on the return-run
and with short hook, tooling 5365 on the fore-run.
9.6.6 Push the curved return-line guiderail against the stop at the upper and lower
landing and fasten the rail.
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9.7 Installation of drive sprocket and step roller rail in return-run in reverse order .
9.8 Assembly of skirt panel in reverse order .
9.9 Installation of steps in reverse order .
9.10 Installation of inner decking in reverse order.
9.11 Function test.
9.12 Final works see page 3, points 2.1 to 2.6.

Aids: protection material,

slipping safety device inner decking, tooling WZ 5382
step lifting device, tooling GO6815 Y1, tooling WZ 5385
torque wrench for 150 Nm
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12.2.10 Change of handrail drive sprocket of linear belt handrail

drive system
handrail passenger line
handrail return line
pressure roller
carrier
drive sprocket
10.2 Dismantling interior panels.

10.2.1 Removal of straight inner decking in the area of handrail drive.
10.2.1.1 Removal of fastening screws.
10.2.1.2 Take out inner decking with tooling 5385 and secure against slipping
with tooling 5382, if the inner decking is provided with a lighting.
10.2.1.3 Loosen electric connection on both sides of inner decking and put inner
decking carefully down.
tooling 5385
tooling 5382
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(Continuation) Change of handrail drive sprocket of linear belt

10.3 Remove 5 steps.
10.3.1 Removal of step guard in the lower landing.
bushing to the axle centre (each left and right side), mark step and step
10.4 Removal of further 5 steps.

10.4.1 Run step band with the revision control (10 steps at 2 straight steps resp.
12 steps at 3 straight steps on the landing).
10.4.2 Removal of 5 steps, see point 10.3.2.
10.5 Removal of straight skirt panel in the area of handrail drive.

10.5.1 Loosen screw connections on the upper and lower part of the fastening plate.
10.5.2 Loosen T-screws on the skirt panel.
10.5.3 Take out and put down skirt panel.
skirt panel
step
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10.6 Run open step band by means of revision control in the area of handrail drive
and turn off control switch.
10.7 Prepare removal of drive sprocket.
10.7.1 Loosen handrail drive parts.
10.7.1.1 Loosen pressure roller carrier via the adjusting screw outside the red marking
(care should be taken that rollers do not fall out of the pressure roller carrier).
adjusting screw for height adjustment

red marking
pressure roller carrier

drive sprocket
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10.7.1.2 Loosen the 4 fastening points on the handrail drive.

10.7.1.3 Loosen toothed belt by pushing up the handrail drive in direction of upper
landing and secure against slipping by means of fastening screw.
adjustment must
remain unchanged
fastening point of handrail drive on the truss
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10.7.2 Removal of drive sprocket (1 tooth in vertical position in the chain link).
10.7.2.1 Remove a part of step roller rail in return-run.
10.7.2.2 Loosen handrail pressure roller chain.
10.7.2.3 Remove fastening screw and spacer (secure spacer between drive sprocket
10.7.2.4 Lift up drive sprocket, take off toothed belt and take out drive sprocket.
toothed belt
spacer
ball bearing
screw (pin) boring

hexagon socket bolt M20x140
torque 150Nm
pulley
ball bearing
drive sprocket
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10.8 Installation of drive sprocket and handrail drive in reverse order of point 9.7.
10.11 Installation of inner decking in reverse order .
10.12 Function test.


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12.2.11 Change of handrail drive sprocket

of traction wheel drive system NEWEL
LOWER LANDING
PASSENGER LINE
HANDRAIL DRIVE UNIT

NEWEL
RETURN LINE

11.2.1.1 Removal of fastening screws .
carefully down.
inner decking
holder
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(Continuation) Change of handrail drive sprocket



skirt panel
skirt panel
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11.5 Run open step band by means of revision control in the area of handrail drive
11.6 Removal of drive sprocket (1 tooth in vertical position in the chain link).
11.6.1 Remove a part of step roller rail in return-run.
11.6.2 Loosen handrail pressure roller chain.
11.6.3 Remove fastening screw and spacer (secure spacer between drive sprocket
11.6.4 Lift up drive sprocket and take out drive sprocket.
drive sprocket
fastening plate
remains
on truss
9,3 +0,6
fastening bolt
torque= 150 Nm
HANDRAIL PRESSURE
127 ± 1 mm
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11.7 Installation of drive sprocket and handrail drive in reverse order .


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12.2.12 Change of handrail pressure roller chain

of traction wheel drive system NEWEL
LOWER LANDING
PASSENGER LINE
HANDRAIL DRIVE UNIT

NEWEL
RETURN LINE
1
7±
12
HANDRAIL PRESSURE ROLLER

CHAIN
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(Continuation) Change of handrail pressure roller chain


12.2.1 Dismantling inner decking.
12.2.1.1 Removal of fastening screws .
carefully down.
inner decking
holder
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Date: 05 /99



skirt panel
skirt panel
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12.6 Disassembly of handrail pressure roller chain.

12.6.1 Loose pressure roller chain via tension spring.
( consider adjusting dimension)
12.6.2 Put down mounting dimension on the fastening points.
12.6.3 Loose inner bolts are guides for position of handrail pressure chain.
12.6.4 Loose both thread bars and take out handrail pressure chain.
Note: These bolts are guides for position of

handrail pressure roller chain
Please pay attension to clearence between
handrail / handrail pressure roller chain
and step chain
thread bars
HANDRAIL PRESSURE
ROLLER CHAIN thread bars
127 ± 1 mm
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12.7 Disassembly the roller(s).

(applies to change of roller(s)

Tooling: standard maintenance tooling
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12.2.13. Change of poly-V-belt
13.1 Preparation of safety measurements, see page 3, points 1.1 - 1.7.

13.2.1 Remove straight inner decking in the area of handrail drive.
13.2.1.1 Remove fastening screws.
13.2.1.2 Take out inner decking with tooling WZ 5385 and secure against slipping with
tooling 5382, if the inner decking is provided with a lighting.
13.2.1.3 Loose electric connection on both sides of inner decking and put inner
inner decking
plastic profile
tooling WZ 5385
tooling WZ 5382
clamp screw M4
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(Continuation) Change of poly-V-belt
13.3 Removal of 5 steps.

133.3.2 Remove first step.
13.3.2.1 Lift snap pin by means of step lifting device GO 6815 Y1, move step axle
bushing to axle center (each left and right side), mark, take out and put
down step.
13.3.2.2 Turn on main switch, run step band with the revision control by each one step
and dismount steps 2 - 5, as mentioned under point 13.3.2.1.
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13.4 Run open step band in the area of handrail drive by means of revision control

13.5.1 Loosen screw connection on the upper and lower part of fastening plate.
13.5.2 Loosen T-screw on the skirt panel.
skirt panel
step
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13.6 Removal of poly-V-belt.

13.6.1 Loosen pressure roller carrier via the adjusting screw outside the red marking.
adjusting screw for height adjustment
red marking

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13.6.2 Loosen poly-V-belt via the pressure spring.

13.6.3 Remove thread bushing, take poly-V-belt from the rollers and pull out between
pressure roller carrier and handrail.
washer distance max. 0,2 mm

in tensioned condition
turn right to release

pressure spring
turn left to tighten

pressure spring

thread bushing
handrail drive
poly-V-belt
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13.7 Installation of poly-V-belt.
13.8 Assembly of skirt panel in reverse order of point 13.5.
13.9 Installation of steps in reverse order of point 13.3.
13.10 Installation of straight inner decking in reverse order of point 13.2.
13.11 Function test

Aids: Slipping safety device inner decking, tooling WZ 5382,

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12.2.14 Change of handrail drive unit

handrail drive
length compensation device
14.1 Preparation of safety measurements, see page 3, points 1.1 - 1.7.
14.2 Remove inner decking and skirt panel.

14.2.1 Remove straight inner decking in the area of handrail drive.
tooling WZ 5382, if the inner decking is provided with a lighting.
11.2.1.3 Loosen electric connections on both sides of inner decking and put
inner decking carefully down.
plastic profile
inner decking
tooling WZ 5385
tooling WZ 5382
screw M4
clamp
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(Continuation) Change of handrail drive unit

14.3.2.1 Lift snap pin by means of step lifting device, GO 6815 Y1, move step axle bushing
to the axle center (each left and right side), mark step and step axle, take them
out and put them away.
and dismount steps 2 - 5, see point 14.3.2.1.
14.4 Remove further 5 steps.

14.4.1 Run step band with the revision control (10 steps at 2 flat steps resp. 12 steps
at 3 flat steps on the landing).
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14.5 Run open step band by means of revision control to the area of handrail drive
and tun off control switch.
14.6 Dismantling of straight skirt panel in the area of handrail drive.
14.6.1 Loosen screw connection on the upper and lower part of the fastening plate.
14.6.2 Loosen the T-screws on the skirt panel.
skirt panel
step
14.7 Remove handrail drive unit.

14.7.1 Mark handrail drive on the length compensation and loosen it.
handrail drive
length compensation
fastening screw
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14.7.2 Lower pressure roller carrier via the adjusting screw (consider marking).
14.7.3 Take rollers out of bearing.
14.7.4 Remove support for handrail guide on the handrail drive unit.
14.7.5 Pull out handrail between the roller rows.
pressure roller carrier lower/adjust

red marking
support for handrail guide

handrail
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14.7.6 Loose 3 bolt fastenings and tighten locking screw (nut must remain on the bolt).
14.7.7 Pull handrail drive in up-direction, tighten locking screw, take off toothed belt
from wheel, unscrew nuts and take out handrail drive.
bolt fastening
nuts
locking screw
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14.8 Installation of new handrail drive.
14.8.1 Put in new handrail drive and put drive on the fastening bolt, unscrew nuts by
some rotations to avoid slipping of handrail drive.
14.8.2 Put on toothed belt and tighten nuts by hand.
14.8.3 Loose locking screws and let down handrail drive in direction of upper landing
(belt tension by dead weight), tighten nuts and carry out thumb test
(10 mm pressure play).
14.8.4 Put in handrail between the roller rows.

14.8.5 Adjust pressure roller carrier set according to instruction.
14.8.6 Installation of support and guide.
14.8.7 Adjust length compensation device according to instruction (attachment).
14.9 Installation of skirt panel in reverse order of point 14.6.
14.10 Installation of steps in reverse order of points 14.3 to 14.4.
14.11 Install inner decking in reverse order of point 14.2.

Aids: Slipping safety device for inner decking, tooling WZ 5382

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Attachm. Adjusting instruction for handrail drive unit
1. Adjustment of toothed belt
- Release of pressure rollers (C).

- Release of handrail guiding profile attachment (F).
- Slightly unscrewing of (A) and (B).
- Shifting of linear handrail drive in lower landing direction to tense the toothed belt.
- One side of the belt has to be deflected roughtly 10 mm by a normal
human hand pressure.
- Fixing of the linear handrail drive position with (A).
- Fixing of the screw positions at the C-profile with (B).
- Attachment of handrail guiding profile (F).
- Tensioning of pressure rollers (C).
2. Adjustment of poly-V-belt
- Tensioning of pressure spring with (D), until it´s no longer possible to move the
distance ring (E).
- Start the escalator into UP-direction for a few minutes (2 Min.).
- Control the adjustment as described before.
- Fixing of adjustment.
3. Adjustment of pressure roller carrier
- Tensioning of pressure spring with (C) until the red marking on the vane is over the top
of the linear handrail drive box.
- Checking the handrail driving force.
- Correction of the pressure spring tension if necessary.
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12.2.15 Change of a roller of roller bow

of linear belt handrail drive system

15.2 Removal of inner decking and skirt panel.
15.2.1 Remove straight inner decking in the area of roller bow.
with tooling WZ 5382, if the inner decking is provided with a lighting.
15.2.1.3 Loosen electric connection on both sides of inner decking and place inner
inner decking
tooling WZ 5385
clamp
tooling WZ 5382
version-
guardian
version-
stainless
steel
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(Continuation) Change of a roller of roller bow of

linear belt handrail drive system

15.3.2.1 Lift snap pin by means of step lifting device, GO 6815 Y1, move step axle bushing
to the axle center (each left and right side), mark step and step axle, take them
out and put them away.
15.3.2.2 Turn on main switch, run step band with the revision control by each one step and
remove steps 2 - 5, see point 12.3.2.1.
15.4 Remove straight skirt panel in the area of roller bow.

skirt panel
step
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(Continuation) Change of a roller of roller bow

15.5 Run open step band in the area of roller bow by means of revision control
15.6 Remove roller on the length compensation device.

15.6.1 Loose fastening points, move length compensation upwards and fasten it.
15.6.2 Remove safety elements and take off roller.
antistatic roller
handrail guide old version
roller
new version
old version
15.7 Installation of roller on the length compensation device.

15.7.1 Clean and lubricate slightly axle.

15.7.2 Install roller and safety elements.
15.7.3 Loosen length compensation and adjust according to instruction.
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15.8 Remove roller on firm bow.
15.8.1 Remove fastening units and take off roller.
15.8.2 Install and fasten new roller.
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15.9 Remove handrail guide roller resp. antistatic roller.
15.9.1 Remove fastening units and take out roller.
Remark: Adjust length compensation according to attached instruction.
antistatic roller
new version
antistatic roller
old version
handrail guide
roller
old version
handrail guide
roller
new version
15.10 Install skirt panel in reverse order of point 15.4.

15.11 Install steps in reverse order of point 15.3.
15.13 Function test


wrench SW 13, 30 cm long
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Attachm. Adjusting instruction for handrail length compensation
= +5mm
length compensation
10 mm
1. All rollers in the roller bow must be in line. The handrail must run straight through
the track system as seen from above.
2. The handrail support roller bows (A) rest on fastening screws (B). The height is adjusted
by adjusting the entire unit with the pressure bolts (C). The handrail has to run straight
into the fixed guidence, respectively, into the handrail drive.
3. Roller bow (D) adjustment:

- Loose hexagon nut (E). Do not Unscrew the Nut of the Guiding bolt (G).
- Run the escalator downwards about 2000 mm. (Handrail raises the roller bow).
- Run the escalator upwards about 2000 mm (Handrail buckles, roller bow lowers).
- Tighten hexagon nuts (E) at this point.
- The handrail must run loosely through the entire system and may not be
pretensioned at any point.
- This adjustment is correct when the play on the handrail at the newel is + 5 mm
on the length of the handrail (F) and the handrail can be pulled off the rollerbow (D)
approx. 10 mm after upward running.
Otherwise adjust the roller bow (D) upwards in 5 mm steps and check the play at
the newel after each adjustment.
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12.2.16 Change of a roller of roller bow

16.2 Removal of inner decking and skirt panel.

15.2.1 Remove straight inner decking in the area of roller bow.
16.2.1.2 Taking out of inner decking with tooling WZ 5385 and secure against
slipping with tooling WZ 5382, if the inner decking is provided with a lighting.
16.2.1.3 Loosen electric connection on both sides of inner decking and place inner
inner decking
tooling WZ 5385
clamp
tooling WZ 5382
version-
guardian
version-
stainless
steel
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16.3.2.1 Lift snap pin by means of step lifting device, GO 6815 Y1,
move step axle bushing to the axle center (each left and right side),
mark step and step axle, take them out and put them away.
and remove steps 2 - 5, see point 16.3.2.1.
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16.4 Remove straight skirt panel in the area of roller bow.

skirt panel
view B
skirt panel
view A view B
view A
holder
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16.5 Run open step band in the area of roller bow by means of revision control
16.6 Remove roller on the length compensation device and roller bow.
16.6.1 Loose fastening points, move length compensation upwards and fasten it.
16.6.2 Remove safety elements and take off roller.
16.7 Installation of roller on the length compensation device.

16.7.1 Clean and lubricate slightly axle.
16.7.2 Install roller and safety elements.
16.7.3 Loosen length compensation and adjust according to instruction.
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16.9 Remove handrail guide roller or antistatic roller.
16.9.1 Remove fastening units and take out roller.
Remark: Adjust length compensation according to attached instruction.
handrail guide roller
antistatic roller
handrail monitoring
device
16.10 Install skirt panel in reverse order of point 16.4.

16.11 Install steps in reverse order of point 16.3.
16.13 Function test

wrench SW 13, 30 cm long

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Attachm. Adjusting instruction for
handrail length compensation
1. Put escalator in operation in down direction.

2. Set escalator out of function.
3. Test handrailplay (F) on the newel bow.
4. Test handrailplay (10+5 mm) on the handrail lenght compensation.
traction wheel drive

system
= 5mm
10+5 mm
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12.2.17 Change of safety equipments
17.1 Change of main drive chain control contact
17.1.1 Preparation of safety measurements see page 3, points 1.1 - 1.7.
17.1.2. Remove the contact

17.1.2.1 Remove fastening screws, take off contact and basic plate.
17.1.2.2. Disconnect connection wires.
17.1.3 Install the contacts

17.1.3.1 Connect wires and new contact.
17.1.3.2 Adjust contact according to instruction.
17.1.4 Function test

17.1.4.1 Test function
17.1.4.1.1 Move drive chain control contact upwards and arrest it.
17.1.4.1.2 Turn on main switch and start escalator via the revision control.
17.1.4.1.3 Set back drive chain control contact and start again.
17.1.4.1.4 Turn off main switch.
17.1.5 Final works see page 3, points 2.1 - 2.6.
adjusting instruction tension box
BDC / S28
(max. 2
mm)
basic plate
24 mm
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17.2 Change of skirt panel safety contact

(RHSSU; LHSSU; RHSSL; LHSSL)
17.2.2 Removal of bended inner decking and skirt panel.

plastic profile inner decking inner decking
tooling WZ 5385
screw M4
clamp
version-
guardian
version-
stainless
steel
skirt panel
skirt panel
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(Continuation) Change of skirt panel safety contact
17.2.3 Remove contact

17.2.3.1 Disconnect contact and connection wires
17.2.4 Connect wires and the new contact.

17.2.4.1 Adjustment of contact according to instruction.
skirt panel safety contact

17.2.5.1 Turn on main switch, interrupt switch and start escalator via the revision control.
17.2.5.2 Set switch back and start again.
17.2.6 Erection of skirt panel and inner decking in reverse order.

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17.3 Change of broken step- & chain wheel control contact (RSSU; RSSL)
17.3.2 Preparation for change

17.3.2.1 Removal of step guard on the tension carriage in the lower landing.
17.3.2.2 Remove of 2 steps by means of step tooling.

17.3.2.2.1 Remove first step.
17.3.2.2.2 Lift snap pin by means of step lifting device, GO 6815 Y1, move step axle
bushing to the axle center (each left and right side), mark step and step axle,
take them out and put them away.
17.3.2.2.3 Turn on main switch, run step band with the revision control by each one step
and remove step 2, see point 17.3.2.2.2.
17.3.2.2.4 Run open step band in the area of contact with the revision control.
17.3.2.2.5 Turn off main switch.
17.3.3 Change of contact

17.3.3.1 Removal of contact and connection wires.
17.3.3.2 Connect wires on the new contact.
17.3.3.3 Install contact.
17.3.3.4 Adjustment according to instruction.

17.3.4.1 Turn axle out of starting position.
17.3.4.2 Turn on main switch and start escalator with the revision control.
17.3.4.3 Turn axle back in starting position and start again.
17.3.4.4 Run open step band to the lower landing.
17.3.4.6 Install steps in reverse order of point 17.3.2.2.
17.3.4.7 Install guard.

Aids: Step lifting device GO6815 Y1
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(Continuation) Change of broken step- & chain wheel control contact

adjusting
instruction
RSSU / S10 RSSL/ S20
3 mm 3 mm 3 mm 3 mm
3 mm 3 mm
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17.4 Change of step chain roller monitoring switch (LHCRMS;RHCRMS)

17.4.2.1 Removal of step guard on the tension carriage in the lower landing.
17.4.2.2 Remove 2 steps by means of step tooling.

17.4.2.2.1 Remove first step.
17.4.2.2.2 Lift snap pin by means of step lifting device, GO 6815 Y1, move step axle
bushing to the axle center (each left and right side), mark step and step axle,
take them out and put them away.
17.4.2.2.3 Remove second step, as described above.
17.4.2.2.3 Run open step band in the area of contact with the revision control.

17.4.3.1 Removal of contact.
17.4.3.2 Disconnect connection wires from contact.
17.4.3.5 Adjustment of contact (according to instruction).

17.4.4.1 Interrupt contact.
17.4.4.2 Turn on main switch and start escalator via the revision control.
17.4.4.3 Set back contact and start again.

13.4.4.4 Run open step band to the lower landing.

13.4.5 Install steps in reverse order of points 17.4.2.1, 17.4.2.2.1 and 17.4.2.2.2.
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(Continuation) Change of step chain roller monitoring switch
adjusting instruction
LHCRMS / S95 RHCRMS / S94
1 mm 1 mm
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17.5 Change of handrail entry device (RHSL; LHSL; RHSU; LHSU)

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(Continuation) Change of handrail entry device

17.5.2 Removal of inner side of entry box.

17.5.2.1 Remove clipped plastic parts on the entry box.
17.5.2.2 Loosen bolt connection on the front side of glass panel.
17.5.2.3 Take out clipped inner shell (pull in direction of floor plate and newel).

17.5.3.1 Disconnect clipped in contact and pull it out laterally.
17.5.3.2 Disconnect connection wires.
17.5.3.3 Connect wires on new contact.
17.5.3.4 Install new contact until tight fitting is reached.
old version
plastic covering
deflector outside
deflector inside
bolt connection
on the glass panel
safety contact
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(Continuation) Change of handrail entry device
moulding
new version
clip
fastening bolt
nut/washer
clip
clip

front
link clip
clip
chim
hexagon
socket
switch
handrail front
cover
17.5.4 Install inner side of entry box in reverse order of point 17.5.2.

17.5.5.2 Press handrail entry guard on entry box.
17.5.5.3 Set escalator via key switch into function.

17.5.5.4 Release handrail entry device and start again.
17.5.5.5 Stop escalator via stopp-button.

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17.6 Change of broken step chain device (LBC; RBC)
17.6.1 Preparation of safety measurements see page 3, points 1.1 - 1.4 and 1.6 - 1.7.

17.6.3.1 Remove contact.
17.6.3.2 Disconnect wires from contact.
17.6.3.5 Adjustment of contact (see instruction).

17.6.4.1 Interrupt and arrest contact.
17.6.4.2 Turn on main switch and start escalator with revision control.
17.6.4.5 Install step guard.
17.6.5 Final works see page 3, points 2.1 and 2.3 - 2.6.

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(Continuation) Change of broken step chain device
identification
old/new
1 mm LBC / S15
RBC / S14
return button
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17.7 Change of comb plate safety device (LCSU; RCSU; LCSL; RCSL)
17.7.2 Remove bended inner decking in the corresponding landing.

17.7.3 Take out inner decking with tooling WZ 5385 and secure it against slipping with
tooling 5382, if provided with lighting.
17.7.4 Disconnect electric connection on both ends of inner decking.

17.7.5.1 Dismantle contact and the connection wires.
17.7.5.4 Adjustment of contact according to instruction.

17.7.6.2 Interrupt contact and start escalator via key switch (upper landing in down
direction, lower landing in up-direction).
17.7.7 Installation of inner decking in reverse order of points 17.7.2 - 17.7.6.
Aids: Tooling 5382, tooling WZ 5385

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(Continuation) Change of comb plate safety device old version

T-screw M8x20
with nut and washer M8
screws M6x10 holder safety switch
holder
toothed
lockwasher
A4,3
washers A4,3
screws M4x35
identification
old / new
0,5 LCSU / S1
RCSU/ S 2
identification
old / new T-screw M8x20
LCSL=S16 with nut and washer M8
RCSL=S17
holder
safety switch
0,5
toothed
lockwasher
A4,3
washers A4,3
screws M4x35
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(Continuation) Change of comb plate safety device new version
new version
vertical and horizontal
new version
vertical
M6x25
0,3 mm
0,3 mm
143 mm
M4x35
M4x35
0,3
0 mm
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12.2.18. Change of Skirt Panel Lighting

18.1 Change of lighting
(Change only at the damaged side)
18.1.1 Preparation of safety measurements see page 3, points 1.1-1.4 and 1.6-1.7 .
18.1.2 Switch off main switch and power supply (light)
18.1.3 Disassemble the inclining (inner deck) profile

- Screw out screws and press inclining out of the keder
- Lay out covering material at the step range of the inclining
- Folding of the inclining and hook the inclining at the tool (hook)
- Loosening of insert connection
old version
light covering inner decking
fluorescent tubes tooling WZ 5385 fluorescent lamp
fluorescent lamp
tube
Trafo step defuser
skirt panel
working sequence
1. Fix clip on tube
1 holder
clip
2. Bring tube with clip

into position
3. Move clip into holder
2 holder
clip
3
holder
clip
Disassembly of lighting
- Disassemble plastic cover
- Move clip 2 aside
- Disconnect and take out fluorescent tube (Attention: Do not break tube)
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(Continuation) Change of Skirt Panel Lighting
assembly new version tapping screw B2,9x20
holder
fluorescent lamp
holder
inner decking
fluorescent lamp
(length per specification)
snap fitting hook
diffuser
diffuser
Note:
two holderg devices
per fluorescent lamp
cut out
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(Continuation) Change of Skirt Panel Lighting
intermittend skirt panel lighting

skirt panel profile
bulb
18.1.4 Assembly of new fluorescent tube in reversal sequence

18.1.5 Assemble inclining
18.1.7 Remove covering material
Tooling: Standard-tooling, tooling WZ 5385

Auxiliary material: Covering material (rags, rubber)
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18.2 Change of under step lighting in the area of lower resp. upper
landing

18.2.2 Turn off power supply (light).

18.2.3.1 Remove step guard on the tension carriage in the lower landing.
18.2.3.2 Remove 2 steps by means of step tooling.
18.2.3.2.1 Removal of first step.
18.2.3.2.1.1 Lift snap pin by means of step lifting device, GO 6815 Y1, move step axle
18.2.3.2.2 Turn on main switch, run step band with the revision control by one step and
step 2 as mentioned under point 18.2.3.2.1.
18.2.3.3 Run open step band in the area of lighting with the revision control.
18.2.3.5 Change of under step lighting

18.2.3.5.1 Loosen protection cover above the fluorescent tube and take out the tube.
(Attention: avoid breakage).
18.2.3.5.2 Installation of fluorescent tube in reverse order.
18.2.3.6 Turn on ligth switch and make function test of lighting.
18.2.3.7 Install steps in reverse order of point 18.2.3.2.
18.2.3.8 Install step guard.
14.2.3.9 Final works see page 3, points 2.1 - 2.6.

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(Continuation) Change of under step lighting
switch installed on the

assembly plate in the
upper landing
cable
lamp
plug
cable fluorescent tube
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18.3 Change of traffic light


18.3.3 Dismantling of traffic light.
18.3.3.1 Loosen screw connection.
18.3.3.2 Take off upper part.
18.3.3.3 Loosen plug connection
18.3.3.4 Loosen screw connection on lower part and take it off.
18.3.3.5 Pull off plug connection.
direction sign
outer decking
screw M 4x12
screw M 4x25
screw M 4x25
screw M 4x12
plug
18.3.4 Install new part with printed circuit board in reverse order of point 18.3.3.
18.3.5 Turn on power supply (light) and make function test.
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18.4 Change of direction indicator with fluorescent tubes / engraved

18.4.3 Dismantling of direction indicator
18.4.3.1 Open covering
18.4.3.2 Turn locking elements with key by 90 degree on both sides.
18.4.3.3 Remove part in up-direction.
direction indicator
engraved arrangement in landing area on the

outer balustrade decking profile,
right as per standard.
partition line
fluorescent tubes
locking in the holes of the

cover.
18.4.4 Install new part in reverse order of point 14.4.3.
18.4.5 Turn on power supply (light) and make function test.

Aids: Long key

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12.2.19. Change of balustrade
19.1 Change of newel glass panel

19.1.2 Remove bended inner decking.

19.1.2.1 Remove screw connection.
tooling WZ 5382, if electric connection is available.
19.1.2.3 Loosen electric connections and put decking carefully down.
19.1.2.4 Remove plastic profile incl. holder profile.
19.1.3 Remove inner decking in the area of length compensation as mentioned

under point 19.1.2.
tooling WZ 5385
screw M4
clamp
version-
guardian
version-
stainless
steel
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(Continuation) Change of newel glass panel
Removal of plastic profile
plastic profile inside
plastic profile outside
holder
holder
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19.1.4 Release the length compensation
19.1.5 Remove inner side of entry box

19.1.5.1 Remove clipped in plastic covering
19.1.5.2 Remove screw connection in the front side of entry box and glass panel.
19.1.5.3 Take off inner shell of entry box in direction of floor plate and newel.
19.1.5.4 Remove remaining screw connections, entry box and shim.
old version
bolt connection
on the glass panel
plastic covering
(deflector outside, inside)
fastening nuts
bolt connection
on the glass panel
fastening nuts
safety switch
fastening
screws
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shell outside
shim
fastening bolt with

rubber protecting tube
fastening points
remains unchanged
fastening points
skeleton inside
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1
very carefully
inner shell
nut/washer M4
do not remove!
moulding inside
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moulding inside
nut/washer M4 do not remove!
do not remove!
3
clip

nut/washer M10
clip
clip

front plate
link
4 clip
clip
chim
hexagon socket
head cap screw
M6x30 switch
front plate
handrail guard
cover insert guard
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19.1.6 Remove handrail on the passenger line up to about 0,5 m behind the gap to
the straight newel glass panel.
19.1.7 Remove plastic profile on the aluminium profile of newel bow (50 AHA 1)
for the handrail guide up to joint in return-line.
19.1.8 Remove aluminium profile on the passenger line up to about 0,5 m behind the
gap to the straight newel glass panel by means of hard wood and plastic
hammer (remaining aluminium profile remains on the glass panel).
19.1.9 Loosen screw connection on the fishplate on the connection to the handrail
return line (newel bow connection to straight return-line).
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alu-profile bended
alu-profile passenger-line
plastic profile passenger- bended alu
alu-profile bended
alu-profile return-line
plastic profile return-line
handrail
alu-profile bended
fishplate return-run
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19.1.10 Mark position of wedges, loosen wedges and take out carefully glass panel
with the newel bow (clean the area when glass was broken).
torque Nm
M6
screw
wedge
insert wedges during

installation
by means of hard wood and
plastic hammer !
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Holder to keep glass panel in position

(located near each end of glass panel)
shims for height adjustment
alu-profile
holder factory adjusted,

do not change
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19.1.11 Install new glass panel in reverse order of point 19.1.7 to 19.1.11
19.1.12 Install handrail by means of installation hook.
19.1.13 Install inner side of entry box in reverse order of point 19.1.5.
19.1.14 Adjust length compensation according to instruction.
19.1.15 Install inner decking in reverse order of points 19.1.2 to 19.1.3.
Aids: hard wood, hook for handrail, tooling WZ 5365 / 66 / 67,

slipping safety device, tooling WZ 5382
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19.2 Change of straight glass panel in center part

19.2.2 Remove inner decking (see page 112).
19.2.2.1 Remove screw connection.
15.2.2.2 Take out inner decking with tooling WZ 5385 and secure it against slipping with
tooling WZ 5382, if electric connections are available.
19.2.2.3 Loosen electric connections and put down inner decking carefully.
19.2.3 Remove inner decking in the area of length compensation as mentioned

under point 19.2.2.
19.2.4 Release the handrail.

19.2.5 Remove handrail on the passenger line up to about 0,5 m behind
the alu-profile-joint.
19.2.6 Remove plastic handrailguide profile from the aluminium profile.
19.2.7 Remove complete aluminium profile up to passenger line of glass panel
by means of hard wood and plastic hammer, dismountage of spring
(take care that spring does not get lost).
handrail
alu-profile
spring
plastic profile
19.2.8 Take off plastic profile from outer decking.

19.2.9 Mark position of wedges, loose wedges (put fibre boards into glass supporting
profile) and take out glass panel (when breakage occures, has the area
to be cleaned).
19.2.10 Install new glass panel in reverse order of points 19.2.6 to 19.2.9
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(Continuation) Change of straight glass panel in center part
19.2.11 Installation of handrail by means of installation hook.

19.2.12 Adjust handrail according to instruction.
19.2.13 Install inner decking in reverse order of points 19.2.2 to 19.2.3.
Aids: Hard wood, hook for handrail, tooling WZ 5365 / 66 / 67,

safety slipping device, tooling WZ 5382
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19.3 Change of newel plastic profile

19.3.2 Change until joint in return-line
19.3.2.1 Remove bended inner decking (see picture page 81).
19.3.2.1.1 Remove screw connections.
19.3.2.1.2 Take out inner decking and secure against slipping with tooling 5382, if electric
connection is available.
19.3.2.1.3 Loosen electric connection and put inner decking carefully down.
19.3.2.2 Remove inner shell of handrail entry box (see pictures pages 83 and 84).
19.3.2.2.1 Remove clipped in plastic coverings.
19.3.2.2.2 Remove screw connection in front side of entry box frame and glass panel.
19.3.2.2.3 Take off inner shell of entry box in direction floor plate and newel.
19.3.2.2.4 Remove remaining screw connections, entry box frame and shim.
19.3.2.2.5 Pull off handrail in the area of joint on the passenger line to joint return-line.
19.3.2.2.6 Remove plastic halves from the aluminium profile.
partition line on
joint in return-line
19.3.2.2.7 Install new plastic profile by pressing by hand and possible fixing with hard
wood and/or plastic hammer with slight strokes.
19.3.2.3 Pull on handrail by means of hook.
19.3.3.4 Install entry box in reverse order of point 19.3.3.2.
19.3.3.5 Install inner decking in reverse order of point 19.3.3.1.

19.3.3 Turn on main switch and make function test.

Aids: hard wood, hook for handrail tooling WZ 5365 / 66 / 67
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12.2.20 Change of operating panel (UL/LL)

20.2 Turn off power supply (light & secondary).
20.3 Change long operating panel (with skirt panel lighting) in the upper resp.
lower landing.
upper landing
lower landing
20.3.1 Remove long operating panel

20.3.1.1 Remove bended inner decking in the corresponding landing
20.3.1.2 Put down carefully inner decking with lighting side and secure against slipping.
plastic profile inner decking tooling WT 5385
slipping safety device

screw M4 tooling WZ 5382
clamp
skirt panel
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(Continuation) Change of operating panel (UL/LL)
20.3.1.3 Remove 2 screw connections on the housing of operating panel.

20.3.1.4 Loosen protection cover from the housing. (Snap out connection).
(Attention: Pull cable connection out of housing)
20.3.1.5 Loosen plug and pull operating panel with cable ends to the front out of
inner decking.
housing protection cover cable

snap connection
cable connection
snap connection
holes for screw

connection
20.3.2 Install new operating panel in reverse order of points 16.3.1.

Attention:
data adjustment from old to new operating panel has to be done
according to instruction "operating panel 506 NCE"
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(Continuation) Change of operating panel (UL/LL)
20.4 Change short operating panel (without skirt panel lighting) on the upper or
lower landing.
upper landing
lower landing
20.4.1 Remove short operating panel

20.4.1.1 Remove bended inner decking in the corresponding landing,
see point 20.3.1).
20.4.1.2 Put down carefully inner decking with the front sight and secure against slipping.
20.4.1.3 Remove fastening nuts from the threaded bolt.
20.4.1.4 Loosen plug of cables and pull out operating panel with cable ends to the back.
(Attention: Cover must not be removed).
20.4.2 Install new operating panel in reverse order of point 16.4.1.

Attention:
data adjustment from old to new operating panel has to be done
according to instruction "operating panel 506 NCE"
20.5 Turn on power supply (light & secondary).

20.6 Turn on main switch and make function test.
(OTIS must appear on the display)
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12.2.21 Replacement of stop switch in control device,

upper landing and lower landing
Control Device upper landing

with skirt panel lighting without skirt panel lighting
stop button
lower landing
stop button
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(Continuation) Replacement of stop switch in control device,


21.2. Disassembly the inclination, landing.
21.3 Unscrew the fastening washers.
21.4 Open the switch (take off the decking plate).
21.5 Check the current in the wires.
21.6 Replace the stop switch.
21.7 Install the stop switch in the inclination.
21.8 Assembly the inlination.
stop button
stop button
washer / nut M6
rear side
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12.2.22 Replacement of key switch in control device,


key switch
lower landing
key switch
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506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99
(Continuation) Replacement of key switch in control device,


22.3 Unscrew the fastening washers.
22.4 Disassembly the cap.
22.5 Disassembly the holder.
22.6 loosen the unlocking device.
22.7 Unscrew the switch.
22.8 Replace the switch.
22.9 Adjust the switch in the inclination.
22.10 Loosen the screw connection of switch, apply the cover and fasten the switch.
22.11 Assembly the inclination.
key switch
washer / nut M6 washer / nut M6

holder fr cap screw M4
rear side
washer / nut M8
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key switch
Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99
12.2.23 Replacement of LED in control device, upper landing

LED
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506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99
(Continuation) Replacement of LED in control device, upper landing

23.2 Turn off power supply (light & secondary).
23.4 Disassembly the cable.
23.5 Loosen the screw nut.
23.6 Take out the LED.
23.7 Replace the LED.
23.8 Assemble the other way round.
LED
washer
hex.nut M8
LED
pins
with cable
rear side
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Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99
12.2.24 Change of tension carriage

24.2. Remove 10 steps.
24.2.2.1 Lift snap pin with step lifting device GO 6815 Y1, move step axle bushing to
axle center (each left and right side),
mark step and step axle and take out step.
and remove steps 2-10, as mentioned under point 1.2.2.1
24.3 Run open step band to the lower landing for removal of the tension carriage and
turn off main switch.
24.4 Measure spring tension on the tension carriage and release tension carriage.
sliding block
pressure spring
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Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99
(Continuation) Change of tension carriage
24.5 Remove balustrade parts

24.5.1 Remove bended inner decking on both sides on lower landing.
24.5.2 Remove complete entry box of both sides on the lower landing.
tooling WZ 5385
screw M4
clamp
version-
guardian
version-
stainless
steel
plastic covering
(deflector outside, inside)
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Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99

fastening nuts
bolt connection
on the glass panel bolt connection
on the glass panel
fastening screws
safety switch
fastening
screws

shell outside
shims
fastening bolt with rubber protecting tube
fastening points
remains unchanged
skeleton inner side
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Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99

1
very carefully
inner shell
nut/washer M4
do not remove!
moulding inside
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Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99

nut/washer M4 moulding inside
do not remove! do not remove!
3
clip

nut/washer M10
clip
clip

front plate
link
4 clip
clip
chim
hexagon socket
head cap screw
M6x30 switch
switch
front plate
handrail guard
cover insert guard
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Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99
24.5.3 Pull off handrail on one side.

24.5.4 Pull off handrail from the balustrade on the lower landing on one side.
24.5.5 Remove glass panels on one side of lower landing.

24.5.5.1 Loosen profile to straight part of glass panel.
24.5.5.2 Loosen connections, take out glass panel.
24.6 Remove complete floor plate and angle profile on the lower landing.
24.7 Remove safety bow on the tension carriage.
24.8 Opening of step chain

Attention: never open chain without chain tension tooling !
24.8.1 Secure step chain in passenger- and return line.
24.8.2 Remove chain locks on the step chains.
17.8.3 Remove step chain from the tension carriage.
24.9 Disconnect broken step chain devices LBC and RBC.

24.10 Remove upper angles on the left and right side of the tension
carriage guide.
safety bow upper fastening angle
sliding block
fastening points
pressure spring
company private
Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99
24.11 Remove complete tension carriage.

24.11.1 Installation of "A" frame chain fall support/s and mount lifting device with
bevel according to load.
24.11.2 Fasten bevel on the U-profile of the tension carriage, take out and put it on a
pallet.
(secure against slipping !)
24.12 Installation of dismounted parts in reverse order.
24.13 Function test

right-angle grinder, drilling machine, drill bit 11 mm dia.
ruler about 500 mm, chisel,
hammer 1000 g, handspike 1 m
ratchet and joints and 2 extensions 250 mm long,
2 step pin lifter, rope, "A" frame chain fall support,
lifting device and bevel for 500 kg load,
tooling for opening and closing the step chain,
handrail-hook,
tooling WZ 5385 (for taking out the inner decking)
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Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99
12.2.25 Special Tooling
Tooling No. Description Symbol
Tooling WZ 5363 Clamp for testing the friction in the

handrail system.
Tooling WZ 5365 Hook for handrail assembly,

passenger line.
Tooling WZ 5366 Hook for handrail assembly, return line (long hook, part 1)
and WZ 5367 Hook for handrail assembly, return line (long hook, part 2)
part 1
part 2
Tooling WZ 5382 Hook for inner decking with lighting

(to keep in position during maintenance)
Tooling WZ 5384 Tool for lubrication of step axle bushing
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Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99
(Continuation) Special Tooling
Tooling WZ 5385 Tool to clip out diffuser at inner

decking
Tooling WZ 5386 Tool to clip out the outer decking
Tooling Metric feeler gauge to measure gaps

GO 27 BK 1 between comb/step or step/step
Tooling Floorplate lifting device

GAA 27 BW 1
Tooling Plattform to walk on step axles

GAA 27 EZ
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Repair
506NCE_EN_FM3
Sect.: 12.2
Date: 05 /99
(Continuation) Special Tooling

Tooling Step pin lifter

GO 6815 Y1
Tooling 9704 CB1 Step chain assembly device
Tooling 9704 CC1 Step chain disassembly device
Tooling Controller lifting device

GBA 26201 M1
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Escalator: Field Method Manual

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OTIS Field Method Manual

Otis 506 NCE

Pegasus ID No. 506NCE_EN_FM3 added.

12.2. Repair Pages

12.2.17 Change of safety equipment 90-104

12.2. Repair Pages

12.2.0 SAFETY MEASUREMENTS PREPARATION- AND FINAL WORKS

with operation panel 1.1 2.6

stop button key switch

without operation panel

1.2 2.5 1.3 2.4

blocking in the upper and

upper landing lower landing

new safety button

power on power off

12.2.1. Change of main drive

1.1 Preparation of safety measurements - see sheet 3, point 1.1 - 1.7.

1.2 Removal of first step.

(Continuation) Change of main drive

1.5 Dismantle balustrade parts.

inner decking inner decking

(Continuation) Change of main drive

deflector (outside, inside)

fastening bolt M10x50

handrail entry guard

(Continuation) Change of main drive

remains unchanged adjusting screw

fastening bolt M 10x 50 / 44 Nm

fastening points skeleton inside

(Continuation) Change of main drive

entry device version-new

deflector outside deflector inside

(Continuation) Change of main drive

entry device version-new

fastening bolt M10x50

fastening bolt M8x25

handrail guard front plate

(Continuation) Change of main drive

entry device version-new

nut/washer M8 hexagon bolt M6x20

(Continuation) Change of main drive

entry device version-new

holder for skirt panel

(Continuation) Change of main drive

1.5.3 Pull off handrail in the lower curve of both sides.

1.5.5 Remove glass panels on both sides of upper landing.

insert wedges during erection

(Continuation) Change of main drive

1.6 Remove step guard in the upper landing.

(Continuation) Change of main drive

hold down bolt

markings for machine

1.10 Open step chain

1.10.1 Secure step chain in front- and rear run

(Continuation) Change of main drive