Otis 508 XO aluminum balustrade upper guide rail

Escalator Guide Rail Installation Instructions

1. Safety Precaution

• Lockout and tag out escalator power supply before all work
• Wear certified PPE: safety helmet, gloves, goggles, anti-slip shoes
• Set safety barriers to prevent unauthorized access to working area
• Ensure truss structure is stable and load-bearing qualified

2. Tools & Preparation

• Tools: laser level, torque wrench, straightedge, feeler gauge, socket set, lifting tools
• Parts: step guide rail, handrail guide rail, mounting brackets, fishplates, locking bolts
• Pre-check: rail surface for deformation, cracks or rust; verify model specification matches escalator

3. Reference Positioning

• Mark center line and mounting datum line on escalator truss per drawing
• Confirm bracket spacing within manufacturer’s requirement (max 1.5m standard)
• Drill and fix mounting brackets on truss; ensure firm welding or bolt fastening
• Check bracket horizontal level and vertical perpendicularity

4. Step Guide Rail Installation

• Place main and auxiliary guide rails on pre-fixed brackets
• Align rails with datum line, adjust preliminary height and gap
• Connect rail sections with fishplates; keep joint surface smooth without step deviation
• Tighten connection bolts symmetrically with specified torque
• Check rail straightness and lateral deviation via laser level

5. Handrail Guide Rail Installation

• Install handrail rail brackets at designated positions
• Position curved and straight handrail rails on brackets
• Adjust rail radian and height to ensure consistent handrail running track
• Smooth all joint chamfers to avoid handrail abrasion

6. Precision Adjustment

• Adjust left-right spacing of dual-side step rails within allowable tolerance (±2mm)
• Correct vertical flatness; max vertical deviation ≤1mm per meter
• Center step roller wheels on rail surface; keep vertical perpendicularity
• Eliminate rail distortion, jamming point and sharp edges

7. Fixation & Reinforcement

• Retighten all bracket and joint bolts to standard torque value
• Install anti-loosening washers and locking clips for key fasteners
• Reinforce loose welding points on truss brackets

8. Inspection & Commissioning

• Clean rail surface to remove welding slag, dust and debris
• Perform manual trial run of step chain and handrail
• Check for abnormal friction, noise or jamming during movement
• Run no-load test for 10 minutes; recheck deviation and tightness
• Submit for acceptance after all parameters meet specification