KONE EcoMod Escalator

Repair Instructions

3 MAJOR MAINTENANCE TASKS AND REPAIRS

3.1 Replace handrails

Complete the following to replace handrails.

3.1.1 Prepare to remove handrails

Step Action Note

1. Measure the existing handrail and
compare the length to the new one.
• The length, along with the width
and style should be compared to
the new one to make sure that
they are the same.
2. Place safety barricades at both ends of
the escalator.
3. Remove both access covers, and turn
power OFF.
3. Remove all inner decks located above
handrail being replaced.
4. Remove the inner frontplate and brush
guard assemblies at both ends of the
escalator.
5. Turn power ON.
6. Relieve handrail tension by loosening
lock nuts (1) located in lower end pit.
NOTE!Do not remove spring pressure
from adjustment rods in upper end pit
at this time. The handrail must have
traction to be driven off the handrail
drive wheel in the following
procedures for removing the
handrail.

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KONE EcoMod Escalator
Repair Instructions

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KONE EcoMod Escalator
Repair Instructions

3.1.2 Remove handrail

Step Action Note

1. Remove the handrail from the handrail
guides along the incline.
2. Cut completely through handrail (2) with
a hacksaw, at the upper end newel, just
before the newel rollers assemblies (3).
3. Remove the long section of the handrail
(section of handrail below the cut) off of
the handrail guides along the incline,
and position handrail on the floor at the
lower end.
NOTE!The handrail drive spring
pressure should be left on at this
time, to develop enough traction to
complete removal of the handrail.
4. Run the unit on inspection, in small
increments, in the up direction, to
remove the handrail from the handrail
drive wheel (4).
• Check frequently that handrail
does not bind or damage other
components during the removal
procedure.

5. After the handrail is completely clear of

the handrail drive wheel, remove the
handrail at the lower end, by pulling on
it, in a forward direction.
• As you remove the handrail from
the escalator, coil and tie the
handrail in a neat bundle, to be
disposed of later. It may be
necessary to make additional cuts
and bundles, to a long handrail.
One bundle may be too heavy
and large to handle easily.

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KONE EcoMod Escalator
Repair Instructions

Cutting handrail for removal

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KONE EcoMod Escalator
Repair Instructions

3.1.3 Replace handrail

After the handrail is removed, run the steps in the up direction, and position the step band
openings above one another, to allow clear access to the drive wheel. Turn main power
supply OFF, and engage step band lock.

Step Action Note

1. Remove handrail drive spring pressure,
by loosening the adjusting rod nuts (5)
on both adjustment rods with a pair of
17 mm wrenches (spanners), and
relieving all the spring pressure.
• The spring pressure adjustment
rods are located in the upper pit
area.

2. Place the new handrail at the upper end

of the escalator, and unpack it.
3. Unroll the handrail and inspect it for any
defects.
4. Pull the handrail loop down the steps,
slowly, taking care not to damage the
surface of the rubber.
5. Position handrail around upper end
newel so handrail is supported by the
newel.
NOTE!It is important in the following
procedure to remove only one
bracket at a time.
6. Place the handrail on top of the uphill
cluster roller assembly, and remove the
first bracket. Feed the handrail around
the bracket, and replace the bracket.
NOTE!Make sure bracket is replaced in
the same position it was removed.
7. Loop the handrail around the handrail
drive wheel. Make sure handrail is not
caught on any other parts.

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KONE EcoMod Escalator
Repair Instructions

Step Action Note

8. In a similar manner, remove any
additional brackets one at a time,
position the handrail around the
brackets, and replace the brackets one
at a time.
• The brackets are used to align the
upper step track mounting plate,
and should be removed and
replaced one at a time to keep all
track dimensions accurate.
9. Loosen or remove each incline return
handrail guide roller (6).

Loosen or remove each incline return

handrail guide roller
10. Remove handrail tension assembly.
11. Position the handrail completely along
the return side of the incline and at the
handrail tension assembly position.
12. Reinstall (or tighten) all the return
handrail guide rollers (6) along the
incline. Reinstall the lower end handrail
tension assembly.
NOTE!Make sure that the handrail is
straight and free of all obstructions.
13. Position, but do not install handrail on
the upper end newel roller assembly.
14. Install handrail on the handrail guides
down the incline, to a point just before
the lower curve.
15. Install the handrail over the lower end
newel roller assembly, and install it in
the same manner at the upper end
newel roller assembly.
16 Check to make sure that the handrail is
straight and free, around all the lower
end devices.

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KONE EcoMod Escalator
Repair Instructions

Step Action Note

17. Install the final section of the handrail on
the lower curve handrail guides.

3.1.4 Adjust handrail and complete handrail replacement

Step Action Note

1. Make a thorough inspection of the entire
handrail, to make sure there is not any
binding, pinching or obstructions before
completing adjustments.
2. Adjust the handrail tension assembly at
the lower end to remove any slack from
the handrail.
• The handrail should be free to
move smoothly, without excessive
friction.
3. Adjust handrail drive wheel pressure in
the upper end pits at jam nuts (5).
• Upper spring length should be 47
mm [1-7/8 in.], and lower spring
length should be 40 mm [1-9/16
in.].

4. After all adjustments and inspections

are made, run the escalator in both
directions.
• Check for any misalignment,
making sure that noise and
binding are not present. After a
reasonable amount of running,
without any problems or
excessive heat buildup, the final
assembly can be completed.
5. Complete replacement in reverse order
in reverse order of removal, and return
escalator to service.

7-002068 (2009-11)

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