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Table of Contents
THINK SAFETY!
Be aware of all safety precautions and warnings. A little common sense will go a long way.
Before beginning any service or maintenance, the maintenance worker MUST take safety
precautions to protect himself, his co-workers, and the riding public.
The work supervisor will provide general procedures for ensuring safety, but the maintenance
worker must understand the equipment and the necessary steps for safely maintaining it.
• Always lock and tag out the main power disconnect before performing any adjustment,
inspection, lubrication, repair, or service to the equipment.
• Always lock and tag out the auxiliary power disconnects, and the emergency power
disconnects before working near the lighting equipment.
• Always barricade both ends of the escalator before beginning any type of work. Barricades
must be in place whenever landing plates or steps are removed.
• Always keep safety circuits in operation.
• Always ensure that no bystanders are near the escalator while it is being started.
• Never assume a circuit is de-energized. Always use a circuit tester before beginning to
work.
• Electrical troubleshooting may require the testing of live high-voltage circuits. Only
qualified electricians and their helpers must perform this.
• When disconnecting the main drive chain or performing maintenance on the brake(s),
always set the step chain-locking device.
• Always run steps at inspection speed using the remote control device.
• The following should be worn while working on the escalator:
o Safety glasses
o Safety shoes
o Protective clothing
o Gloves
Guide Wheels
Remove these screws
Damaged comb section
to remove comb section
replace with new one
Damaged comb
replace section
Limit Switch
(46.7 [1.84])
6 [0.24]
Notes:
1) Switch should trip when Fh is 350-400lbs applied at either side or Fh is 700-800lbs
applied at the center of the combplate.
2) Switch should trip whe Fv is 130-150lbs applied vertically at the center
edge of the combplate.
3) Verify that each side moves equal distance when force is applied. Adjust
springs as needed.
COMBPLATE
SCREWS
COMBFINGERS
.16
TOP OF STEP
TREAD CLEAT
.16
COMBPLATE
COMBFINGERS
1. Remove the newel interior panels and newel skirt panels. (See paragraph 4.4.2 and 4.5.)
2. Disconnect the wiring from the impact switches and remove the conduit.
3. Remove the two large mounting bolts. See the figure below.
4. Replace the combplate assembly in reverse order. (See paragraph 4.1.1.3. for adjustment of
the impact device.)
Combfinger Segment
Guide Wheel
Combplate Assembly
Mounting Bolt Combplate Assembly
Mounting Screw Mounting Bolt
Combplate Assembly
Mounting Bolt Combplate Assembly
Mounting Bolt
Insert allen-wrench
or "T" wrench here
turn 90°
Support Frame
4.2.1.1 Steps
The following steps are for the maintenance and adjustment of the step.
1. Inspect each step for damage to the riser and tread.
2. Inspect each comb segment for broken fingers, cracks. Replace if needed.
3. Observe the steps for shifting, interference or misalignment.
4. Clean the steps of any debris.
5. Check clearance between the steps and skirt panels.
• The clearance should be 1/8 inch.
• Adjust the skirt panel, if required. (See paragraph 4.5.)
6. Check the clearance between steps is not more than 0.15”.
• If the clearance is more, replace the step chain. (See paragraph 4.3.2.)
Setscrew
Sleeve
(After pin is release move
to center of axle)
4-13 of 132
FUJITEC 1200 ESCALATOR
4.2.2.2 Step Wheel Removal and Replacement
The following instructions will aid the worker in removal and replacement of the step wheel
assembly.
1. Remove the step, following steps 1 through 7 in paragraph 4.2.2.1.
2. Loosen and remove M12 nut and lockwasher
3. Remove wheel and axle assembly.
4. Install new wheel and axle assembly.
5. Apply threadlocker to thread of axle, and replace nut.
CAUTION!
R
BA
ET AR
FS TB
TENSION CARRIAGE SPROCKET OF IN
JO
L
EE
LOOSEN NUT WH
EP CK
EL ST RA
HE "T
STEP CHAIN PW "N
S TE
CK E
RA IC
"T PL R
"A SS BA
RUS S ET ICE
T FF R PL
O BA
SS
INT RUS
JO T
DISCONNECT STEP CHAIN HERE E OF
IC
@ MASTERLINK S PL ION .)
OF CAT ICAL
IL LO RIT
SPRING TA T C
DE REC R IS
OR BA
(C INT
Step Chain Axel JO
FUJITEC 1200 ESCALATOR
Master link
remove cotterpins
4-17 of 132
4-18 of 132
MAIN DRIVE SPROCKET
R
BA R
ET BA
FS INT
TENSION CARRIAGE SPROCKET OF JO
E EL
LOOSEN NUT WH
L EP CK
E ST RA
HE "T
STEP CHAIN PW "N
E
ST
CK
RA ICE
"T PL R
"A SS BA
US ET E
TR FS R LIC
OF BA S SP
INT
US
JO TR
DISCONNECT STEP CHAIN HERE E OF
LIC N
@ MASTERLINK SP TIO AL.)
L OF OCA ITIC
I L R
SPRING TA T C
DE REC R IS
OR B A
(C INT
Step Chain Axel J O
Master link
remove cotterpins
FUJITEC 1200 ESCALATOR
Figure 4-9 Step Chain removal and replacement for So. San Francisco
("D" Molding)
Skirt Safety Brush WHEN THE NEWEL INTERIOR PANEL CAN NOT
BE FIT TO THE NEWEL MOLDING, ADJUST IT
Mounting Screw BY USING THESE BRACKETS.
Interior Panels
(Typical for Incline)
Molding Rubber
b
IL
FUJITEC 1200 ESCALATOR
CL
4-24 of 132
Skirt Frame Mounting Screw
Skirt Panel
Mounting Screw
Skirt Panel
Skirt Frame
4. Handrail Disinfecting:
• After completion of cleaning, wipe the handrail surface with a cloth soaked in
disinfectant and quickly dry the surface. Then, apply the following finishing
procedures.
5. Handrail Finishing:
• Application of polished liquid: After the handrail surface is completely dry, apply the
recommended polishing liquid “Rubber Shine” to the surface with a cloth. Wipe only
one light coat of “Rubber Shine” over the entire rubber surface.
• Finishing (Polishing): After the polishing liquid is completely dry, polish surface with
a dry cloth until the rubber surface becomes glossy.
6. Handrail Don’ts
• NEVER operate the escalator while cleaning the handrail with water, detergent, rubber
cleaner, cleaning liquids, disinfectant, and polishing liquid.
THESE SUBSTANCES MUST NEVER BE LEFT ON THE HANDRAIL SURFACE.
• NEVER use heat or hot air to dry the handrail surface.
• Since unknown materials might cause swelling or deterioration of the rubber surface,
NEVER use any material other than those specified.
2. Check tension in the handrail by pulling on the spring force gauge. See Figure 4-12 for
illustration.
3. If tension is less than 70 pounds, adjust take-up device and pressure rollers. (See paragraph
4.6.2.3 for take-up adjustments and 4.6.2.5 for pressure roller adjustments.)
PULL
RUN DOWN
SPRING FORCE GAUGE
HANDRAIL
UPPER NEWEL
670.01 [26.38]
Handrail Drive Chain
Idler take-up
Driven Sprocket
S= 1 8
mm[0
.7"]
L = 670mm[26.38”] S = 18mm[0.7”]
L = (L1+L2)/2
Adjustment rod
Lock nut
Stainless Steel Guide Handrail Tension Device
M8 MOUNTING BOLTS
28 [1.10]
STEEL GUIDE
223.5 [8.80]
HANDRAIL
120 [4.72]
DETAIL F
RETURN GUIDE
HANDRAIL
Rollers
Jam-Nut
Adjustment
Nut
CAUTION!
2) JAM INSERT BY DAMAGEING THE THREADS WHICH TOUCH THE PLATE ON THE INSIDE OF THE
TRUSS BY HITTING THEM WITH A HAMMER & SCREWDRIVER ON THE TOP, BOTTOM, LEFT AND
RIGHT SIDES OF THE INSERT.
GUIDE ROLLER
HANDRAIL DRIVE SHEAVE
4-37 of 132
FUJITEC 1200 ESCALATOR
(77.5[3.0])
FROM ESC CENTER 680[26.77]
SHIMS (5.5[0.22])
(SHEAVE J)
(CONFIRM DIM. "X")
HANDRAIL PINCH ROLLER
16 [0.63]
FROM ESC. CENTER 803.5[31.63] FROM ESC CENTER 680[26.77]
SEE DETAIL "A"
FROM ESC CENTER 757.5[29.82]
FROM ESC CENTER 801.5[31.55]
FROM ESC CENTER 822[32.36]
BOLT M12X40
FLATWASHER
LOCKWASHER
THREADED INSERT
MEASURE DISTANCE
Pressure Roller
Assembly
Remove 4 bolts
Adjustment rod
Lock nut
CAUTION!
626+1
0 [
24.65+0.02
0.00 ]
501 [19.72]
1 [0.04] 1 [0.04]
Step Wheel
(B-track)
Step Chain Wheel
(A-track)
626+1
+1 [
24.65+0.04
+0.02 ]
Figure 4-23 Track Measurement
M10 Flatheads
4-46 of 132
B-Track
A-Track
B-Track up-thrust
B-Track
A-Track up-thrust
Upper Turn Track
Trun Track
Turn Track
Base
A/B-Track
Turn Track Base
A-Track up-thrust M-Track up-thrust
M-Track
M-Track
N-Track
A-Track
B-Track up-thrust
B-Track
M20 Bolt
A-Track up-thrust
A-Track
B-Track up-thrust
B-Track
FUJITEC 1200 ESCALATOR
Detail B
Lower Turn Track M-Track
N-Track
FUJITEC 1200 ESCALATOR
CAUTION!
Gear Reducer
Motor 30H.P.
Main Drive
Shaft
Gear Reducer
40 HP Motor Oil Drain Plug
GREASE PLUG
REMOVE BEFORE GREASING
9. Add grease slowly until new grease appears in the shaft hole (fan side of motor) and the
outlet plug.
No matter how relatively minor angular misalignments are, they can produce disproportionate
radial misalignments. In this example, they account for approximately 80% of the worst possible
composite misalignment.
Seal
The following are checkpoints and are important to the maintenance of the drive chain.
Lubrication:
• While the chain is driving, check if the lubricating oil moves toward the link plates, and if
the chain or rotating disc is immersed in the lubricating oil when the lubrication pump is
running.
• When the chain is stopped, check for dirt or abrasive particles produced by improper
lubrication.
• When the chain is removed, the connecting link pin and the edge of the side of the bushing
should be checked.
• If there is any damage or a red or reddish brown color can be noticed, lubrication is
improper or insufficient.
Link Plate:
If repeated loads more than the allowable loads are applied to the chain, there is a strong possibility
of fatigue breakage of the link plate.
Fatigue breakage is difficult to anticipate until a crack is produced.
Usually a crack develops at the edge of a hole or at the side of the link plate, as shown below. The
presence of the cracks should be checked carefully.
Roller Link:
Avoid repeated impact loads over the allowable load as fatigue breakage may occur.
Check the roller in the same way as the link plate. If foreign objects interfere with the engagement
of the roller and sprocket, damage will occur to the roller and a crack may develop. Careful
attention should be paid to this.
Replace any chains damaged due to fatigue breakage.
Chain Elongation:
Chain stretch is calculated as the total amount of elongation caused by wear on the pin and
bushing, but not caused by deformation of the link plate.
Remaining chain life can be estimated by measuring chain elongation.
Measure main drive chain elongation.
9 Measure six links as shown below using calipers.
9 Record L1 and L2.
9 Calculate chain elongation, E, using the equations below.
L=(L1+L2)/2
E(%)=((L-S)/S)x100 (S = standard length)
9 If E> 1.5%, replace chain.
1]
0.8
21[
S=
L = 36.43 inches
S = 0.81 inches
Take up slack or loosen by adjusting the main drive idler sprocket if necessary.
For abnormally stretched chain, replace the chain.
Adjustment Nut
"X"
Detail "A"
See Detail "A"
Spring
Rail
Jam Nut
Adjustment
Nut
MB,SB
SSF
CAUTION!
It will be important to barricade the area of the upper truss and lower truss of the escalator. This is
where most of the work will take place.
Along with the standard tools that the maintenance worker will need, a small crane will be required
to lift the machine out of the truss.
1. Remove landing plates from the upper & lower truss area. See paragraph 4.1.
2. Remove all steps. See paragraph 4.2
3. Remove a portion of the step chain that is in the upper truss area. Be sure to tie off the
remaining portion to the truss to prevent it from piling up in the lower truss area. See
paragraph 4.3.2 for step chain removal and replacement.
4. Remove A-Track, A-Track up-thrust, B-Track, B-Track up-thrust and turn around. For
information on removal and replacement see paragraph 4.8.
5. Remove the interior panels, skirt panels, D-molding and Safety Strip for the upper truss
area. See paragraph 4.4 for further instruction.
6. Remove handrail from around upper newel section.
This can be accomplished by first reducing the tension on the handrail.
9 To do this the interior panel over the handrail tension device will need to be
removed. This will expose the tensioning device.
9 With a wrench, raise the idler wheels from the handrail to release the tension. After
the tension is released the handrail can be “peeled” off of the handrail guide around
the upper newel.
7. Disconnect wiring from emergency stop switch, operating panel, and indicator lights.
Be sure to remove conduit from the switch boxes. The newel will be removed to ensure
clearance to remove the machine.
Warning
1. Remove upper and lower landing plates to gain access to the upper and lower trusses. For
floorplate removal see paragraph 4.1.
2. Remove all of the steps see paragraph 4.2. Because the step chain will be broken and tied
off it is important to reduce the weight.
3. Remove the interior panels, skirt panels, D-molding and Safety Strip. See paragraph 4.4
and 4.5 for directions.
4. Remove the portion of the handrail that goes around the upper newel. See paragraph 4.7 for
directions.
5. Disconnect wiring from the emergency stop switch, operating panel, and indicator lights.
Be sure to remove conduit from the switch boxes, the newel will be removed to ensure
clearance for the removal of the main drive.
6. Remove the upper newel. Disconnect the upper A-molding from the newel molding and the
newel sheave. Remove the newel mounting bolts and then remove the newel.
7. Remove the combplate/floorplate, disconnect the comb impact switch wires and remove the
conduit. Remove the combplate mounting bolts and lift the combplate from the truss.
8. Remove lubrication tubing from main drive-chain area and lubricator spray nozzles from
the step chain area. Be sure that all tubing is clear of main drive shaft.
9. Remove chain guard. The guard that is over the step chains needs to be removed.
9 There are two mounting bolts at the top of the guard that are attached to the upper cord
angle and two on the front side of the guard attached to an angle.
9 Loosen all four mounting bolts, with one hand holding the guard remove the bolts,
bottom first then top. Once the bolts have been removed lift the guard out of the truss.
10. Remove the step chain from the upper truss area. Be sure to tie-off the step chain and
remove about 6 units to clear the step chain drive sprockets.
11. Remove the A-track up-thrust and A-track together, B-track and B-track upthrust and turn
around track. See paragraph 4.7 Track removal replacement instructions.
12. Disconnect the main drive chain.
9 Adjust the Drive Chain Idler to allow slack in the drive chain. Locate the master link
and break the chain.
9 Be aware that once the main drive chain is broken the pawl brake will drop into place.
CAUTION!
ADJUSTING RING
FRICTION PLATE
HUB
BRAKE OPERATION
LEADS
SPRING PLUNGER
OUTER PLATE
0.6 [0.024]
0.33[0.013]
COMPRESSION SPRING OUTER 0.43[.017]
ADJUSTING RING
SETSCREW
ADJUSTING RING
SETSCREW
TRIP PLATE
SSF
MB & SB
4-85 of 132
FUJITEC 1200 ESCALATOR
4.10.3 Machine Brake Removal and Replacement
The following instructions will guide the worker in the removal and replacement of the Machine
Brake.
1. Remove the upper landing plates to gain access to the upper truss area. See paragraph 4.1
for instructions.
2. Attach the maintenance pendant to the service box in the upper truss.
3. Remove six to eight steps to gain access to the machine brake. Position the opening over
the machine area exposing the machine brake. (See paragraph 4.2 for instructions.)
4. Engage the pawl brake at this time. Open the Lever Lock Box and with one hand hold the
pawl in position and with the other depress the lever. This will clear the locking area and
allow the lock lever to swivel out of the way releasing the pawl brake. Do not let the pawl
drop, place it into position.
5. Remove the digital sensing head and disc from the machine brake. This is to avoid any
unwanted damage when removing the brake.
6. Disconnect the manual release cable and remove threaded rod. Be sure to put threaded rod
in a secure place.
7. Disconnect the brake temperature device. The connection is in the pull-box, which is
located over the brake wear device. Be sure that the connector is removed from the pull box
before removing the brake.
8. Loosen the setscrew that holds the torque-adjusting ring and remove the ring.
9. Three socket head screws mount the brake to the mounting plate. Remove these screws and
carefully slide the brake from the shaft.
10. To replace the machine brake follow the directions in reverse order.
11. Before tightening the setscrews on the torque ring, set the air gap to the proper opening.
(See Figure 4-46 Machine Brake Removal and Repair illustration for Millbrae and San
Bruno.) (See Figure 4-47 Machine Brake removal and repair for SSF illustration for South
San Francisco.)
Brake Temp.
lead disconnet
to remove Manual Brake Release
Disconnect cable before
removing brake
Pulser Disk
remove disk
Power leads
Holes for
Brake Disks
4-87 of 132
Manual brake release Brake Temp. leads
disconnect before removing be sure to disconnect
brake
4-88 of 132
before removing brake
Pawl Brake
STEP CHAIN
STEP CHAIN
Oilers
TIMER f PUMP
PUMP UNIT
BOLT M6X20
COVER
LOCK WASHER
BRACKET
Newel Molding
4-98 of 132
IN
E
IN
TE
R
R
UP
T R
M (M ED
O U
TO IS C
R ) ER
BR
AK
E
M BR
O AK
TO
R E
O LI
N
VE IN
R- G
TE W
M EA
6B 4B
JU
N
C
TI
O
N
4A BO
FUJITEC 1200 ESCALATOR
X
5B
M
IS
AL
M IG 7 6A ST STE
IS EP P
SI NE
BR N D U LE ST
O G ST SK PT VE EP
KE ST IR H L
N EP EP
T R ( LE
ST (M SW US SL VE
(M LS T 3) L SK
EP SS IT (S (S IR ST M
C 3) C L1 T IS R
2) H U3
) ) SW
EP E
HA (S U SI
NG MO
IN IT PT
(B
KB C H
TE
1) H R ST
SC (S U EP SE M
ST N
1) KT (M S IS M
1) (S AL
U SS OR IG (P AIN
1) 1) BO NE AW D
X D L RIV
ST BR E
EP AK C
(M E) HA
IN
LS SW
1)
IT
CH
(M
D
C
)
FUJITEC 1200 ESCALATOR
4.13.1 Broken Drive Chain Device Testing and Adjustment
See the pawl brake system for testing and adjustments of the broken drive chain device.
LIMIT SWITCH
SPRING
MOUNTING SCREWS
KICKER
4-104 of 132
Skirt Switch Upper
3 [0.12]
Switch
DETAIL Y
SEE DETAIL-A
BOTTOM OF AXLE
BOTTOM OF RISER
ROLLER ACTUATOR
Mounting Screws
M4 Panhead
2 [0
.08]
BOTTOM OF RISER
ROLLER ACTUATOR
NOTE:
1. THE CENTER OF THE ROLLER ACTUATOR MOUNTED ON THE SWITCH SHOULD BE LOCATED
AT THE POINT SPECIFIED WITH DIMENSIONS FROM S.P. POINT.
2. SWITCH SHOULD TRIP AT 25° WHEN RISER OR STEP AXLE DROPS 5 [.20] FROM LEVEL.
3. INSTALL CONDUIT & FITTINGS PER JOB SPEC. WIRE PER JOB WIRING DIAGRAM.
"TREAD"
"RISER"
STEP
40 [1
.57]
ACK R
"B" T
80 [3.1
3]
21 [0.8
5]
4]
6 [0.2
.53]
115 [4
6 [0.2
4]
Mounting screws
UPPER "B" TRACK
LOWER "B" TRACK
Mounting Bracket
Proximity Switch
BOLT "A"
155 [6.10]
M8 Bolt & Nut
BOLT "B"
Limit Switch
M5 Pan-head
screw and nut
"A" SCREWS
SCREWS
COMPRESSION SPRING
RUBBER GUARD
MOUNTING SCREWS AND NUTS
BRACKET
HANDRAIL ENTRY SWITCH
Disconnect 60A 3Ø
Inverter
Figure 4-65 Controller Panel Layout San Bruno and So. San Francisco
Lubricant Schedule