Step Chain OFFSET 400mm for KONE ECO3000 and TravelMaster

Escalator Step Chain Installation Instructions

1. Core Safety Precaution
   • Lock and tag out the escalator power supply before all operations, ensure the equipment remains stationary and powered off throughout the entire installation process.
   • Wear certified personal protective equipment (PPE) including safety gloves, goggles, and anti-slip safety shoes.
   • Set up safety barriers around the work area to block unauthorized access.

2. Tools & Materials Preparation

• • Required tools: Wrenches, socket sets, chain cutters, lifting equipment, tension gauges, lubrication tools, and precision measuring tools.
  • Required materials: New escalator step chain (matching the manufacturer’s model specifications), manufacturer-approved chain lubricant, and replacement fasteners (if needed).

3. Step-by-Step Installation

• Step 1: Pre-Installation Inspection
  • Inspect the new step chain for manufacturing defects, deformation, or damage; confirm the chain specifications fully match the escalator model.
  • Inspect drive sprockets, tensioners, and guide rails for wear, damage, or misalignment; replace severely worn components before installation.
• Step 2: Dismantle Obstacles
  • Remove escalator steps, inner/outer cover plates, and apron boards at the working section to fully access the chain assembly.
  • Secure the unused chain section with professional fixtures or steel wires to avoid accidental displacement.
• Step 3: Remove Old Chain (for replacement scenarios)
  • Loosen the chain tensioner to release all tension from the old step chain.
  • Disconnect the old chain from drive sprockets and tension wheels, then lift it out from the escalator truss.
  • Clean the drive system, sprocket teeth, and guide rails thoroughly to remove dust, debris, and residual old lubricant.
• Step 4: Install the New Step Chain
  • Lay the new chain along the guide rails, ensure precise engagement with drive sprockets and tension wheels on both sides of the escalator.
  • Align chain links with sprocket teeth accurately, avoid misalignment or tooth skipping.
  • Connect the chain two ends with the manufacturer-specified connecting links, and secure with snap rings or locking fasteners.
• Step 5: Tension & Alignment Adjustment
  • Adjust the chain tensioner to reach the manufacturer-recommended tension value, and verify with a tension gauge.
  • Check the chain operation on both sides, ensure smooth running on sprockets and guide rails without lateral deviation.
  • Confirm the chain transitions properly at the upper and lower reversing sections.
• Step 6: Lubrication
  • Apply manufacturer-approved chain lubricant evenly to all chain links, rollers, and pins.
  • Wipe off excess lubricant to prevent dust and debris accumulation.
• Step 7: Reassemble Dismantled Components
  • Reinstall escalator steps, cover plates, apron boards, and other removed parts in reverse dismantling order.
  • Adjust step positions to ensure smooth movement and consistent gaps between adjacent steps.

4. Post-Installation Testing

• • First perform a no-load test run, check for abnormal noise, vibration, or chain skipping issues.
  • Conduct a full-load test run per the escalator’s rated load, verify the chain runs smoothly and steps operate synchronously.
  • Recheck chain tension and alignment after test runs, make minor adjustments if necessary.
  • Confirm all safety protection functions work normally before putting the escalator back into formal service.