Rexnord Manual

Rex High Performance
Chain Bucket Elevator

Manual 3520
Table of
Contents
Safety
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Installing, Servicing, Maintaining, or Repairing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Startup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Housecleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Introduction
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Technical Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Supervision of Installation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation Inspection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Inspection Service: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Elevator Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Material Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Policy Statements
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Corrections of Minor Misfits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Installation
Elevator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boot Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Intermediate Casings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Securing Flange Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Lateral Support Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Single Leg Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Double Leg Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Platform, Platform Collars, Grating and Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Lower Head Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Upper Head Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Ladder and Safety Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Hoist Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Take-up Assembly and Take-up Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Head Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Shim Requirement Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Aligning Head and Foot Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Handling Coiled Chain (Shipping Sections) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Rigging and Lifting Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Interference Fits at Chain Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Table of Contents
High Performance Chain Bucket Elevator

Manual 3520
Table of Contents
Chain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Assembling Rex Sealed Joint Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Linkmaster Chain Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Pre-assembling Chain Shipping Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Installing Chain in an Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Installing Chain at the Boot Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Installing Chain at the Head Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Pre-assembling Chain and Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Rigging and Lifting Pre-assembled Chain and Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Installing Pre-assembled Chain and Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Bucket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Buckets Mounted on Two Strands of Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Bucket Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Installing Buckets Using Chain hoists or Equivalent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Installing Stop Blocks on Take-up Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Upper Stop Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Lower Stop Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Installing/Adjusting Rubber Peeler Lip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Backstop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Hollow Shaft Mounted Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Solid Shaft Mounted Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Drive Unit Mounted On Elevator Casing (Chain Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Drive Unit Mounted Separate From Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Belt Driven Reducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Direct Driven Reducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Shaft and Sprocket or Shaft and Sheave Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Drive Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Chain Slack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Drive Chain Enclosure Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Installation of Oil-Tight Chain Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Installation of Non-Freestanding Non-Oil-Tight Chain Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
Installation of Freestanding Non-Oil-Tight Chain Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Installation of Chain Guard Support Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Installation of Motion Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Installation of Boot Flood Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
Installation Checklist I - Pre-Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Elevator Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Operating Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Initial Operation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
Installation Checklist II - Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Required Elevator Installation Follow-up Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Elevator Housing, Platforms and Hoist Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Chain and Bucket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Take-up Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Installation Checklist III - Required Installation Follow-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Normal Operation
Operating Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Table of Contents
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Manual 3520
Table of Contents
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Start-up and Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Boot Flood Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Motion Sensor Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Preventative Maintenance
Preventative Maintenance Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Preventative Maintenance Checklist I - Monthly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Preventative Maintenance Checklist II - Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Chain Elongation Measurements Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Chain Elongation Pin and Bushing Measurements Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Maintenance
Rubber Peeler Lip Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Bucket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Bucket Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Chain Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Monthly Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Annual Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Procedure No. 1 - Measuring Overall Length of X Number of Chain Pitches . . . . . . . . . . . . . . . . . 7-5
Procedure No. 2 - Measuring OD of Chain Pins and ID of Chain Bushings . . . . . . . . . . . . . . . . . . . 7-6
Three Year Chain Analysis (Program) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Chain Wear Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Chain Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Chain Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Installing Replacement Chain in Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Pre-assembled Chain and Bucket Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Head Shaft Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Head Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Head Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Foot Shaft Assembly Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Assembling Components to a Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Segmental Traction Wheels or Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Segmental Traction Wheel or Sprocket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Segmental Traction Wheel or Sprocket Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Segmental Traction Wheel(s) or Sprocket(s) Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Installation of Segmental Rims On Foot Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Installation of Segmental Rims on Head Shaft by Breaking Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Installing Segmental Rims On Head Shaft, Without Breaking/Removing Chain . . . . . . . . . . . . . . . . . . 7-28
Subroutine for Replacing 3 Piece Segmental Rim with a New 3 Piece Segmental Rim . . . . . . . . . 7-29
Mounting a Segmental Rim Body to Head or Foot Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Aligning Bodies Mounted with Locking Assemblies On Double Chain Strand Elevator . . . . . . . . . . . . . 7-31
Procedure to Align Bodies without Segmental Rims Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Aligning Bodies with Segmental Rim Sprockets Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Head Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
NI-HARD Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
NI-HARD Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Take-up Assembly and Take-up Guides Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Take-up Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Table of Contents
iii

Manual 3520
Table of Contents
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Adjusting Stop Blocks on Take-up Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Upper Stop Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Lower Stop Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Backstop Maintenance and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Drive Unit Maintenance and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Drive Chain and Sprockets Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Belt and Sheave Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Motion Sensor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Boot Flood Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Belt Wander Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Housing (Boot, Intermediate Casings, Collars, and Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Boot Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
Intermediate Casings and Collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Lateral Support Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Upper and Lower Head Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Platform, Grating, Handrails, Ladders, Safety Cage, and Hoist Frame . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Long Term Storage

Primary Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Secondary Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Table of Contents
iv

Manual 3520
1
Safety
Introduction
Accidents resulting from the use of conveyors and bulk handling equipment can be
reduced or eliminated by following safe practices in installation, operation, and
maintenance. Only trained and qualified personnel should perform these activities.
Personnel must be trained in recognizing hazards and taking safety precautions. Refer to
ANSI B20.1-1996, American National Safety Standard for Conveyors. Additionally,
personnel must wear hard hats, safety glasses, steel toed shoes, use a safety harness when
appropriate and wear suitable clothing that protects body areas exposed to direct contact.
Rexnord advocates a safety program consisting of the following elements.
Management commitment
Written lockout/tagout procedures
Accident investigation/prevention
Assignment of responsibility
Procedures for startup of equipment
Documented training program
Installing, Servicing, Maintaining, or Repairing Equipment

The following steps are followed when servicing, maintaining, or repairing equipment
where the unexpected startup, energization, or the release of stored energy could cause
injury to employees working on or around the equipment serviced. Refer to OSHA/
MSHA lockout/tagout standards.
1. NOTIFY ALL AFFECTED EMPLOYEES that a lockout/tagout system is going to be
utilized and state the reason why. The authorized employee shall know the type and
magnitude of energy that the machine utilizes and understands the associated hazards.
2. PREPARATION FOR SHUTDOWN. Before turning off the machine or equipment,
the authorized employee shall be familiar with the types of energy involved, the
hazards associated with the energy sources, and the method and means to control the
energy. At this time, all affected employees should be notified of the proposed
shutdown.
3. EQUIPMENT SHUTDOWN. The equipment shall be shut down per established
company standards in accordance with OSHA/ MSHA standards. Shutdown shall be
conducted in the sequence prescribed in the company's written procedure.
4. LOCKOUT DEVICE APPLICATION. The authorized employee shall affix lockout
devices on all energy isolating devices.
5. STORED ENERGY. Every potential hazardous stored or residual energy shall be
relieved, disconnected, restrained, or rendered safe. This is usually accomplished
using blocks, blanks, straps, etc.
6. VERIFICATION OF ISOLATION. Before starting work on the machines or
equipment that have been locked out, the operating controls shall be activated to
verify proper energy isolation. At this time, maintenance, repairs, or service can be
conducted.
Safety
11

Manual 3520
1
Safety
Startup Procedures
When maintenance, repairs, or service is complete, the equipment can be released from
lockout. Lockout devices are removed and energy is restored to the equipment using the
following procedures:
1. THE WORK AREA IS INSPECTED to ensure that all nonessential items have been
removed. Any machine or equipment guarding that was removed MUST be
reinstalled.
2. ALL AFFECTED EMPLOYEES ARE NOTIFIED that the machine or equipment is
to be activated and lockouts are being removed.
3. CHECK WORK AREA, VERIFY IT IS CLEAR OF EMPLOYEES AND TOOLS.
Verify that all operating controls are in the off or neutral position. Authorized
employees can then remove their specific lockouts.
4. THE EMPLOYEE WHO APPLIED EACH lockout device must remove it from the
energy-isolating device.
Safety Inspection
Conduct a minimum of one documented safety inspection per year by someone trained
and authorized by management. This certification should include the following elements:
Date of inspection
Verification of safety training/conformance
Name of person performing the inspection
Verify safety equipment functional
An elevator shall be used to convey only the specified commodities or materials

within the rated capacity and the rated speed. Where special use is not indicated, or
ratings are not available, good industry practice is observed.
Only a trained person is permitted to operate an elevator. Training includes instruction

in operation under normal conditions and emergency situations.
Where safety is dependent upon stopping devices or starting devices or both, they are
kept free of obstructions to permit ready access.
The area around loading and unloading points is kept clear of obstructions that could
endanger personnel.
Personnel working on or near an elevator are instructed as to the location and

operation of pertinent stopping devices.
An elevator is used to transport only loads it is designed to handle safely.
Under no circumstances are the safety characteristics of the elevator to be altered if

such alternations would endanger personnel.
Routine inspections and corrective maintenance measures are conducted to ensure that
all guards and safety devices are installed and function properly.
Elevators are NOT maintained or serviced while in operation.
Operation
Safety
12

Manual 3520
1
Safety
Safety Signs: labels are placed conspicuously in hazardous areas to warn of possible
injury. Contact Rexnord to obtain additional safety labels.
Maintenance
Only qualified and trained personnel perform maintenance and service.
Whenever possible, elevator is emptied of material before maintenance activities.
No maintenance or service is performed when an elevator is in operation.
When an elevator is stopped for maintenance or service, the starting devices, prime
movers, or powered accessories are locked out in accordance with a procedure designed
to protect all persons or groups involved with the elevator against an unexpected restart.
Personnel alerted to the hazards of stored energy, which may exist after the power
source is locked-out.
When an elevator is stopped, allow sufficient time for material/elevator to cool before
direct contact.
Allow sufficient time for dust/fumes to settle before servicing enclosed elevators.
Anytime a guard or safety device is removed, they are reinstalled and function properly
before startup.
Lubrication
Elevators shall not be lubricated while in operation.
Where the drip of lubricants or process liquids on the floor constitutes a hazard, drip
pans, or other means of eliminating the hazard shall be provided.
Adjustment
Elevators shall not be adjusted while in operation.
Housecleaning
Personnel performing these routine activities require awareness training of the hazards
while housecleaning near an operating elevator. These hazards are, among others,
inadvertent contact, entanglement, high temperatures, slipping/falling, toxic dust, fumes
and noise. The precautions described in Operation, page 1-2 must be followed.
Noise
The sound pressure level produced by elevators are known to exceed 70 dBa, at distances
and locations on the elevator where affected personnel are present. Total sound pressure
levels near an elevator depend largely on the material handled, loading and unloading
chute profiles, additional equipment functioning in conjunction with the elevator and the
environment and/or structure wherein elevators operate. As each application varies,
Rexnord recommends that end-users measure the sound pressure level for each elevator
and take appropriate action as required by government regulations.
Safety
13

Manual 3520
2
Introduction
Preface
This manual contains instructions for installation, operation, and maintenance of Rex
High-Performance Bucket Elevators. The reliable operation and long service life of these
elevators depend to a great extent on the care taken during installation and operation, and
the degree of maintenance.
These instructions do not purport to cover all details or variations in equipment nor to
provide for every possible contingency to be met in connection with installation, operation
or maintenance.
Should further information be desired or should particular problems arise which are not
covered sufficiently for the purchasers purpose, the matter should be referred to Rexnord
Industries Incorporated.
Workmanship
This manual is intended only as an aid for the installation, operation and maintenance of
Rexnord Industries Incorporated equipment.
It is further based on the assumption that only qualified workmen will perform the service
work, utilizing good workmanship and practices at all times.
Technical Services
Various technical services are available to you. If you are interested, we can furnish
supervision of erection, erection inspection only, or inspection service. As you can readily
understand, the finest equipment available will not do the job unless it is installed properly.
Supervision of Installation:
Supervision of Installation permits you to furnish your own manpower, tools, payroll,
insurance, etc., with the assurance of a competent man to supervise the work and assure
you of a job properly installed. This type of work is done on a per diem basis as outlined in
our material proposal. If it is to be handled on a contract basis, there would be a time limit
included.
Rexnord highly recommends using this service when installing a new piece of Rex
equipment.
Installation Inspection:
Installation Inspection service allows you to handle complete erection and avail yourself
of our specialist for a final check of erection and initial operation. Payment would be on a
per diem basis as outlined in our material proposal.
Inspection Service:
Inspection Service covers such matters as trouble-shooting and correction of difficulties

after initial or extended operation and inspection for repairs and replacement purposes.
Since many of our customers are availing themselves of these services, our servicemen are
in the field much of the time. Therefore, please allow sufficient time for us to schedule a
man to coincide with your needs.
Introduction
21

Manual 3520
2
Introduction
To place an order for technical services please contact Rexnord Industries

Incorporated, Industrial Chain and Conveyor, 4800 W. Mitchell St., Milwaukee, WI
53214, Attention: Field Service Manager and provide the following information:
Introduction
Rexnord Order Number
Your Order Number
Company Name who purchased equipment
End User Company Name of equipment
Your Name & Title
Type of service required
Date work required
Purchase order number for the Technical Service to be provided
Location and directions to the site.
22

Manual 3520
2
Introduction
Elevator Nomenclature
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
16
18
REX-0001
Figure 2-1:
Typical Rex High-Performance Chain Bucket Elevator

1
2
3
4
5
6
7
8
Introduction
Split upper head section

Segmental rim traction wheel or sprocket with solid steel body
Pillow block roller bearings
Head shaft bearing supports integral with lower head section
Lower head section
Stub discharge spout with adjustable rubber peeler lip
Support collar
Intermediate casing with deep beaded crimps for stiffness
23

Manual 3520
2
Introduction
9 Heavy-duty Rex steel roller-less chain

10 Buckets
11 Intermediate hinged type inspection door (optional)
12 Flanged inlet opening for easy connection to loading chute
13 Boot section
14 Internal gravity take-up
15 Segmental rim traction wheel or sprocket with body
16 Front and rear cleanout and access panels with quick acting latches
17 Double hinged access doors with quick acting latches
18 Flanged bottom with flat base plate for complete bearing on foundation
WARNING
Failure to observe and follow all safety instructions
may result in serious personal injury or property
damage.
Safety
Elevator moving parts operate unguarded by necessity of function, i.e. belts, chain,
pulleys, buckets, etc. create hazards to be avoided. We strongly recommend that
equipment installers, operators and maintenance personnel use a LOCKOUT/TAGOUT
safety procedure whenever installing or servicing equipment, and that all affected
personnel receive training in safety practices, including awareness of hazard areas to be
avoided. In addition, the use of proper tools and methods can prevent accidents that can
result in severe injury to all affected personnel.
A number of safety instructions are listed throughout this manual. They are designated by
a black triangle around a white exclamation point and the word WARNING in bold
letters. These instructions alert affected personnel of hazard areas or unsafe procedures.
Study them carefully and follow them: insist that those working with you do the same,
accidents are often caused by carelessness or negligence. Safety instructions describe
hazards presented by the elevator, but due to the variety of material handled and the means
the material enters and exits the elevator, Rexnord cannot describe all of the hazards
present in an installation. The Rex High-Performance Bucket Elevator must be operated in
accordance with all installation and safety instructions in this manual.
Shipping
Copies of packing lists are attached to the shipment and sent to personnel as specified in
instructions of your purchase order.
It is the responsibility of personnel at the installation site to obtain a copy of this list.
As the material is unloaded, a careful check should be made against the packing list.
Damaged material is to be reported to the carrier company and Rexnord Industries
Incorporated immediately to insure proper substantiation for claims and adjustments.
It is your responsibility to file claims as Rexnord Industries Incorporated has no
authority to allow claims.
Introduction
24

Manual 3520
2
Introduction
Site Preparation
Before the actual installation of the equipment is begun, a thorough inspection of the site
is necessary.
Rexnord Industries Incorporated assumes no responsibility for site preparation.
It is recommended that the site be cleared of all excess material to allow for free and easy
movement by installation personnel and the equipment they are utilizing.
All foundation anchor bolts and other steelwork embedded in concrete must be checked
for cleanliness, accuracy of location, and alignment.
Constant referral to General Arrangement Drawing(s) and Anchor Bolt Layout
Drawing(s), and diligent use of a ruler, surveyors transit, etc., will insure accuracy when
the equipment is erected.
It is understood that, in the event of error in location of embedded steelwork or anchor
bolts, they will be correctly positioned by the party or parties responsible before
installation of the equipment proceeds.
Drawings
The material furnished on this order will be assembled as indicated on Rexnord
Industries Incorporated General Arrangement Drawings.
The drawings were prepared specifically for this equipment.
The drawings are located in the back of this manual under the tab heading "Drawings".
If additional copies are required, contact Rexnord Industries Incorporated, Industrial
Chain and Conveyor, 4800 W. Mitchell St., Milwaukee, WI 53214, with the following
information:
Rexnord Order Number
Your Order Number
Company Name who purchased equipment
End User Company Name of equipment
Material Identification
The materials and components needed to install and operate a piece of equipment are
assigned a series of mark numbers to help identify the parts as they are received and
installed. These mark numbers are indicated on the General Arrangement Drawings which
are a part of this manual, located under the tab labeled "Drawings".
This marking system is intended to provide a cross-reference between the General
Arrangement Drawing(s) [Erection Drawings(s)] and piece parts. For example, the mark
number identification system enables you to take a piece part and establish on which
General Arrangement Drawing it is shown, and also where it is located on the drawing.
Conversely, you can use the mark numbers that are shown on the General Arrangement
Drawings to identify all of the piece parts that are needed for a piece of equipment.
Further identification is shown on each piece and/or sub-assembly as noted below.
Introduction
25

Manual 3520
2
Introduction
1
2
200000 - 05 - 02 Unit - 5
MK 100 - 05 - 10
3
REX-0095
Figure 2-2:
Example 1 of Structural Mark Number Tag

1 General Arrangement Drawing Number - The "200000" is the order
number and the "05-02" is the drawing suffix
2 Rexnord Unit Number - The unit number "Unit - 5" refers to a complete
piece of equipment such as one complete bucket elevator
3 Mark number - Fabrication Drawing Suffix Number "10" (200000 -05 - 02
number with 200000 omitted)
On the General Arrangement Drawing, you will find this piece identified as MK100-05-31
or 735-80200-80. An arrow is drawn to the exact location of the piece or sub-assembly on
the General Arrangement Drawing.
735 - 80200 - 80
REX-0096
Figure 2-3:

1 Fabrication Drawing Number - Numbers such as "325630", "103-595", or
"CA3240" may also used instead of the "735-80200"
Introduction
26

Manual 3520
2
Introduction
2 Mark number - Fabrication Drawing Suffix Number "80"

Where there is a large quantity of identical pieces, such as collars, buckets or bearing
plates, only a representative number of pieces in each bundle will be marked. At least one
marked piece from each bundle should be saved until the last of the bundle has been
erected. Otherwise, the remaining pieces not marked cannot be identified.
When material is shipped direct from our vendors, pieces may be marked similarly to
above examples for easy identification.
Machinery shafting will be stamped on one end with Rex order number, mark number and
shafting assembly drawing number.
1
2
200000 - 04 - 10 MK 200
or
635 - 40057 - 80
3
REX-0097
Figure 2-4:

1 Shafting Assembly Drawing Number - The "200000" is the Rexnordorder
number, the "04" identifies the unit number and the "10" is the drawing
number
2 Mark number - "MK 200"
3 Shafting Assembly Drawing Number - "635-40057"
4 Mark number - "80"
All miscellaneous loose items such as bolts, nuts, washers, etc. are identified as Field
Material in addition to our regular marking. This material will be packaged individually
according to fabrication drawing numbers.
When a number of Field Material packages are required to complete your order, the
packages are collectively shipped in one or more larger containers. These containers will
be identified as Box #1, Box #2, etc., and the contents of each outlined on our packing list.
Any special markings which you requested have been added to our regular method of
identification
READ THIS MANUAL COMPLETELY BEFORE INSTALLING OR OPERATING THIS EQUIPMENT.
Introduction
27

Manual 3520
3
Policy Statements
Installation Procedures
The procedures outlined represent an accepted method for installing bucket elevators. It is
recognized that other procedures may be equally effective and that variations may prove
advisable, depending on conditions and surroundings. However, variations from the
methods described in this manual must be approved by Rexnord prior to installation of
the unit. It is recommended that personnel familiar with elevator installation be used for
installation of equipment.
Tolerances
Rexnord supplied equipment is made to the tolerances and specifications specified on
Rexnord intermediate casing or fabricated weldment drawings, so the work required to
align, shim, plumb, etc. is kept to a minimum during the field installation of the bucket
elevator, thus assuring successful operation.
Rexnord often implements the use of jigs and fixtures to ensure that fabricated items
supplied by Rexnord are held to the drawing tolerances. Rexnord expects/requires that
items fabricated by purchaser or purchasers vendor(s) for Rex equipment also meet these
same tolerances and specifications. If the geometric tolerances and specifications are not
met on items fabricated by purchaser or purchasers vendor(s) for Rex equipment, it is the
responsibility of the customer or contractor installing it to meet final assembled tolerances
as defined in the Rexnord field service manual. Rexnord assumes no additional financial
responsibility for any additional installation time or materials that might be required to
meet assembled elevator tolerance (as defined in Rexnord Service Manual) or is required
to make the equipment operate successfully.
Corrections of Minor Misfits

Standard construction for fabricated steel allows for tolerance in lengths and hole
locations.
Minor misfits are considered a normal part of erection work.
The accumulation of the tolerances in foundations, grades, setting of anchor bolts, etc.
create the necessity to use drift pins, reamers, and gas cutting and welding equipment.
Dimensional tolerance must be compensated for in fit-up.
When new units are tied into existing units, it can be expected that a major amount of fitup is required because, accumulated tolerances are already built into the existing
equipment, making the job of tie-in and alignment a matter of detail fit-up.
Corrections of minor misfits and a reasonable amount of cutting and reaming are
considered a part of installation. Any assembly error which prevents further
assembly by moderate use of drift pins, cutting, or welding is to be reported in
writing to Rexnord Industries Incorporated. Do not proceed without written
approval from Rexnord Industries Incorporated.
Policy Statements
31

Manual 3520
STOP
3
Policy Statements
Failure to comply with all procedures within this manual will relieve
Rexnord of any and all liability in connection with the installation and
operation of the elevator.
READ THIS MANUAL COMPLETELY BEFORE INSTALLING OR OPERATING THIS EQUIPMENT.
Policy Statements
32

Manual 3520
4
Installation
Elevator Assembly
Foundation
The concrete pad or steel supports on which the elevator is to be installed should be
checked before installation of the boot section. There are three vital points to look for
when checking the pad.
1. Elevator centerlines are established properly within work points.
2. The top of the concrete pad is at the proper elevation.
3. Anchor bolts are properly located about elevator centerlines and are at the proper
height.
See Figure 4-1.
1
3
Y
C
2
2
3
1
X
A
"B"
"Z"
6
REX-0002
Figure 4-1:
Locating Elevator Foundation

1
2
3
4
Installation
Typical work points

Elevator centerlines
Anchor bolts
Top of concrete pad
41

Manual 3520
4
Installation
5 Elevator centerlines set to X Y Z dimensions for typical work points

6 Anchor bolts set to A B C as shown on General Arrangement
Drawings
The anchor bolts position and projection must be as shown in the General Arrangement
Drawings located under the tab labeled Drawings. If location of anchor bolts is not
correct, this situation must be remedied at once.
Any sizeable error in locating the anchor bolts would undoubtedly mean additional trouble
later in the installation of the elevator. Tie-in points could be missed, loading and
discharge areas misdirected and even interference from existing structures could be
encountered.
The anchor bolts should be imbedded in the concrete at least several days before installing
the elevator.
Boot Section
The boot section should be placed over the anchor bolts.
STOP
It is imperative and absolutely essential that the boot section be plumb

vertically and level horizontally. If this is not achieved, the balance of the
elevator will not line up, and its operation will be seriously affected.
Shim as required to plumb boot section. Use plumb lines or transit to plumb sides and ends
of boot. When this has been accomplished, and only then, secure the boot by tightening
down the anchor bolts. Care must be exercised here not to disturb the alignment of the
boot section. At this time, the boot section must be grouted into place. See Figure 4-2.
Installation
42

Manual 3520
4
Installation
2
1
REX-0003
Figure 4-2:
Elevator Foundation
1
2
3
4
5
Top of concrete
Grout
Shims
Place 2 nuts on each anchor bolt
Plumb bobs/plumblines Top and bottom of boot section plumb
Two nuts are to be used on all anchor bolts to insure against nuts becoming loose.
Intermediate Casings
The intermediate casings are assembled to the boot section after the boot has been
properly grouted. Install the intermediate casings on the boot in the sequence shown in the
General Arrangement Drawings located under the tab labeled Drawings.
Intermediate casings must be installed on elevator as shown in the General Arrangement
Drawings found under the tab labeled Drawings or inspection doors and lateral support
collars will not be located at the proper elevation, and platform steel will not bolt
together.
Intermediate casings must be installed onto the elevator individually. Rexnord suggests
fabricating a lifting beam which bolts to the casing flanges to handle individual casings.
See Figure 4-3 for a typical design of a lifting beam.
Installation
43

Manual 3520
4
Installation
REX-0004
Figure 4-3:
Typical Lifting Beam For Handling Individual Sections

1 Lifting beam Field fabricated
Be sure that the sealing compound specified in the General Arrangement Drawings is
placed between all sections.
Each intermediate casing must be plumbed to a tolerance of 3 mm (1/8) maximum with
respect to the boot, as it is assembled to the preceding section.
When assembling casings, secure the center bolts only. The center bolt holes are located at
midpoint on the casing flange connection angle. The balance of the bolts should be
inserted and tightened after the section is plumbed and before proceeding with the next
section.
Installation
44

Manual 3520
4
Installation
1
Y
X
X
X
X
3
4
5
REX-0005
Figure 4-4:
Plumbing Elevator Casings

1
2
3
4
5
Record measurements from plumblines to sides and ends of casings.

Bracket to hold plumblines Field fabricated
Casing being installed
Plumblines
Plumb bobs approx. 4 kg (10 lbs.) each
To plumb casings, fabricate brackets as illustrated and drop at least two plumblines as
indicated. Measure from wire to sides and ends of casing at the top flange angle of the
casing. In the boot section take measurements as close to the bottom of the boot as
possible. Mark the places in which measurements were taken in the boot when checking
the plumb of the first casing installed, and use the same spots as a reference for plumbing
all the following casings.
Installation
45

Manual 3520
4
Installation
Securing Flange Bolts.

Rexnord recommends that site personnel fasten bolts using the Turn of the Nut
tightening technique, as bolt tension and not torque, create the safest connection. Bolts are
installed in all holes of the connection and brought to a snug tight condition; that is when
the mating flanges or plies of the joint are in firm contact. Snug tightening progresses
systematically from the most rigid part of the connection to the free edges until all bolts in
the connection are fully compacted. Following this operation, all bolts are tightened
further another 1/3 turn, progressing again from the most rigid part of the joint to its free
edges.
The flanges on the casing sections are not machined. It is, therefore, possible that small
fabrication inaccuracies, within structural tolerances, may be present. Check each
identical intermediate section as it is placed in position. Check for plumbness after
securing only the four bolts at midpoint of each flange connection angle.
Check each casing as it is placed in position, and if necessary, rotate 180. If inaccuracy is
not compensated for, invert section end-over-end. If necessary, the section as inverted
may be rotated 180.
Casings with doors or openings cannot be inverted. However, it may be possible to rotate
these casings180 to achieve plumbness.
The balance of the bolts should be inserted and tightened after the casing is plumbed and
before proceeding with the next casing.
The installation of all of the remaining casings must follow this procedure.
To secure and hold elevator casings in plumb, install lateral support bracing as lateral
support bracing elevations are reached with the intermediate casings.
Lateral Support Bracing

Elevators are self-supporting but not free standing.
Lateral supports are required for all elevator casings due to their design and basic
construction.
For outdoor installation, lateral bracing must be furnished to support the elevator casing
satisfactorily to a foundation or an adjoining structure. See Figure 4-5. Refer to the
following recommended information regarding suitable bracing.
Installation
46

Manual 3520
4
Installation
4
3
REX-0090
Figure 4-5:
Typical Lateral Bracing

1 Clearance of 2 mm (1/16) required between each side of lateral support
collar and support frame
2 Lateral support collar
3 Casing
4 Support frame
If the elevator is installed indoors, the casings being installed must be supported by the
floor framing or building framework for required lateral support.
It is recommended that lateral supports for elevator bracing, where possible, be horizontal
and constructed so that vertical loadings transmitted to lateral supports are negligible. Guy
wires are not recommended.
Any seismic conditions or unusual wind conditions should be noted in the original
contract specifications so that provision for accommodating such conditions is
incorporated within unit construction.
Single Leg Casing

Unless otherwise indicated in the General Arrangement Drawings located under the tab
labeled Drawings, all single leg elevators are to be laterally braced approximately every
6.1 m (20' 0") of height. The upper lateral support is to be located at the base of the lower
head section or immediately below the head platform knee brace support collar.
It is recommended that slip joint bracing be utilized. The type shown below should be
employed. When in doubt, consult Rexnord Industries Incorporated.
Installation
47

Manual 3520
4
Installation
1
2
REX-0091
Figure 4-6:
Lateral Supports Exterior

1 Lateral support collar - furnished by Rexnord installed in field
2 Support frame - furnished and installed by customer
Lateral support collars, furnished by Rexnord, are field welded to the elevator casings.
Bracing and support frame are not furnished by Rexnord.
1
2
REX-0092
Figure 4-7:
Lateral Supports For Units That Extend Through Floor Openings

1 Lateral support collar - furnished by Rexnord, installed in field
Double Leg Casing

Unless otherwise indicated in the General Arrangement Drawings located under the tab
labeled Drawings, all double leg elevators are to be laterally braced approximately
every 18.3 m (60' 0") of height. If the unit is 18.3 m or less, it must have at least one lateral
support at the lower head section. The upper lateral support is to be located at the base of
the lower head section or immediately below the head platform.
Installation
48

Manual 3520
4
Installation
It is recommended that slip joint bracing be utilized. The type shown below should be
employed.
When in doubt, consult Rexnord Industries Incorporated.
1
2
REX-0093
Figure 4-8:
Double Leg Lateral Supports

1 Lateral support collar - furnished by Rexnord installed in field
Lateral support collars, furnished by Rexnord, are field welded to the elevator casings.
Bracing and support frame are not furnished by Rexnord.
1
2
REX-0094
Figure 4-9:
Bracing For Units That Extend Through Floor Openings

1 Lateral support collar - furnished by Rexnord, installed in field
Platform, Platform Collars, Grating and Handrails

Rex head platforms are supported by the elevator by incorporating the head platform
frame and the platform knee brace support collar as part of the intermediate casings.
The platform frame and support collar must be assembled on the elevator at the proper
elevation as shown in the General Arrangement Drawings located under the tab labeled
Drawings.
Installation
49

Manual 3520
4
Installation
The platform frame and the support collar must be plumb to the boot section using the
same procedure and tolerances used to plumb the intermediate casings.
The platform, grating, and hand railing comes disassembled and must be installed per the
platform grating and handrail drawings included in the drawing packet of this manual.
Lower Head Section

The lower head section can now be assembled to the top intermediate section. This
section, like all others must be plumbed.
Plumb the lower head section to the boot using the same procedure used to plumb the
intermediate casings.
STOP
The maximum out-of-plumb tolerance between the boot section and the
lower head section should not exceed 6 mm (1/4) maximum.
Upper Head Section

The upper head section should be installed after all components have been installed in the
elevator and the head shaft assembly has been leveled and aligned within the elevator.
Before installing the upper head section to the lower head section, check and correctly
orientate the head shaft dust seals. The head shaft dust seals mount to the outside of the
upper head section with the rubber half of the seal pressed against the upper head. In many
cases the head shaft dust seals are rectangular and will fit between the dust seal holding
bars in the upper head section only one way. If the seals are oriented incorrectly the upper
head section must be removed so seals can be rotated.
Bolt split upper head section in place. Use the sealant furnished with the elevator between
all the bolted connections.
Ladder and Safety Cage

The ladder and safety cage should be completely assembled before attaching it to the
elevator proper. It can be attached in one piece or in sections, depending on its length or
facilities available.
Refer to the ladder drawing, which is part of this manual, for complete and detailed
assembly instructions. Start the first cage ring so that the slot in the cage ring fits over the
top of the ladder rung. Subsequent cage rings are also hooked over a ladder rung.
By observing this procedure, no trouble should be encountered with ladder section splices
interfering with the cage ring assembly. A special cage ring spacing dimension is provided
near the top of the ladder. These rings do not necessarily have to fit over the top of the
ladder rungs. Attach the ladder in the location and position indicated in the General
Arrangement Drawings located under the tab labeled Drawings.
When mounting ladder to surrounding steel, mount ladder so that it can move with the
elevator as it expands and contracts.
Installation
4 10

Manual 3520
STOP
4
Installation
Do not apply force to ladder when trying to mount it to surrounding steel,

doing so could force elevator out of alignment and cause operational
problems.
Hoist Frame
The hoist frame comes disassembled and must be installed per the hoist frame drawings
included in the drawing packet of this manual.
The hoist frame is designed to lift the combined load of the chain and empty buckets
only. The take-up must be in the raised position, and raised independently from the chain
and bucket assembly.
Hoist frame capacities vary. See the General Arrangement Drawings located under the tab
labeled Drawings for load values. Capacity ratings are also marked on lifting beams.
CAUTION
Capacity of extended hoist beam is significantly less
than capacity of hoist beam between columns. Refer
to elevator General Arrangement Drawings located
under the tab labeled Drawings for hoist capacities
Take-up Assembly and Take-up Guide Installation

For proper chain tension and elevator operation it is imperative that the take-up assembly
be properly installed within the boot section.
To properly install the take-up assembly, the traction wheel or sprocket must be placed on
the elevator centerline and be centrally located within the boot section. Also there must be
a 3 mm (1/8) clearance between each side of the take-up frame and take-up guides.
Installation
4 11

Manual 3520
4
Installation
2
REX-0006
Figure 4-10:
Take-up Assembly and Guides

1 Take-up assembly
2 Take-up guide assemblies
Installation Note
In some cases the foot shaft assembly is offset from the elevator centerline. Use and refer
to the General Arrangement Drawings specific to the elevator being worked on when
installing the take-up assembly.
Perform the following steps to ensure proper installation of the take-up assembly:
1. Support take-up assembly within boot section from lifting beam with a chain hoist.
See Figure 4-11.
2. Install take-up guides within door frames of boot, making sure take-up frame is placed
properly within guides.
3. Install take-up guide mounting hardware, but do not tighten.
Installation
4 12

Manual 3520
4
Installation
4. Place 3 mm (1/8) thick shims between the take-up frame and take-up guides at top
and bottom ends of the take-up assembly. See Figure 4-12.
Bend 3 mm shims to form a 90 corner. This will keep shims from dropping too far
between the take-up assembly and take-up guides and also aid in removal of shims later.
5. Install C-clamps around take-up frame and take-up guides to hold shims in place. See
Figure 4-11.
6. Shift take-up assembly and guides so the centerline of the traction wheel or sprocket is
centered within the boot section and also lies on the elevator centerline.
Plumblines must be strung within the elevator and used to set the traction wheel or
sprocket to elevators centerline. See Aligning Head and Foot Shaft, page 4-18 for
instructions in placement of plumblines.
7. Plumb take-up guides end to end and side to side using a level. Make sure traction
wheel or sprocket stays positioned on elevator centerline while plumbing take-up
guides.
8. Tighten take-up mounting hardware.
9. Remove C-clamps and shims.
Installation
4 13

Manual 3520
4
Installation
5
4
REX-0007
Figure 4-11:
Cutaway of Boot Positioning/Setting Take-up and Guides

1
2
3
4
5
Installation
Lifting beam
Chain hoist
Lifting ring
Boot section
C-clamps
4 14

Manual 3520
4
Installation
3
3m
)
1/8
m(
REX-0008
Figure 4-12:
Insertion of Shim Between Take-up and Guide

1 Take-up assembly
2 Take-up guide assembly
3 Shim, 3 mm (1/8) thick
Head Shaft Installation

Install the head shaft as oriented in the elevators General Arrangement Drawings located
under the tab labeled Drawings. Mount the headshaft on the lower head, bearing
support, utilizing a shim pack (shim packs supplied by Rexnord) under each head bearing.
One shim pack* consists of the following:
Quantity
2
1
Plate Gage
16 gage
10 gage
Approximate
1.5189 mm
3.4163 mm
Approximate
0.0598"
0.1345"
*Quantity and Gage shown for standard shim pack. Quantity and Gage could vary in
certain circumstances.
To ease head shaft assembly installation, lower and align the fixed bearing to the lower
head first, then slide the floating bearing into alignment, before lowering and mounting it
to the lower head. (The fixed bearing is the bearing closest to the drive input end of the
head shaft. See the head shaft assembly drawing for more information.)
Check backstop or holdback device for proper rotation if included as part of the head shaft
assembly. See the Drive Assembly tab in the manual for specific manufacturers service
instructions.
Installation
4 15

Manual 3520
4
Installation
The mounting bolts on the head shaft bearings are to be double nutted, this will insure
against nuts becoming loose.
To level the head shaft properly, the head shaft must be clean. All debris, burrs, and/or
protective coatings must be removed before leveling shaft.
To get an accurate level reading on the head shaft, the head shaft bearing mounting bolts
must be tight before taking level reading.
The head shaft must be leveled to within 0.25 millimeters per meter (0.003 in per ft.) and
parallel with the foot shaft.
To level head shaft, remove shims from shim packs and/or install more shims as
necessary.
Installation Note
Additional shims required to level head shaft are to be supplied by customer or
contractor. Rexnord does not supply shim material over and above shim packs.
STOP
Use full shims across bearing housing base where shimming is required
not just at bolt holes. If two (2) shims are required to shim across housing
base due to physical limitations of shim materialbutt ends of shims
together. DO NOT OVERLAP ENDS.
Installation Note
When checking the level of the head shaft the use of a level that is graduated to allow the
user to take readings in millimeters per meter or inches per foot is recommended.
Machinists, Mechanics or Precision levels are such levels with the recommended
graduations. Because of limited space around shafting area it is recommended using one
of the levels listed above with an approximate length of 150200 mm (68).
Shim Requirement Example

To figure the shim thickness required to level the head shaft, follow the example below.
Installation
4 16

Manual 3520
4
Installation
1
X
3
2
L
REX-0009
Figure 4-13:
Shim Requirements
1 X Bearing centers in meters or feet
2 Y Shim required to level head shaft
3 L Level measurement in mm/meter or inches/foot
To calculate Y (Shim required to level head shaft) use the appropriate equation below.
X M x L mm/M = Y in millimeters.
or
X ft x L in/ft = Y in inches.
Example:
Bearing centers = 1.5 M.
Level reading = 0.40 mm/1 M (Drive bearing being the high end).
Shim required = 1.5 M x 0.40 mm/M = 0.60 mm thick.
Install 0.60 mm shim under bearing opposite side of drive.
or
Remove a 0.60 mm shim from under drive bearing.
The head shaft should be initially installed square on the lower head section. The
centerline of the traction wheel or sprocket should be equal distance from the side walls of
the lower head. The bearings should be centrally located within the bearing jack bolts.
Installation Note
It may be necessary to readjust the head shaft after checking alignment between head and
foot shaft assemblies. The centerline of the traction wheel and/or sprocketpulley of the
head and foot shaft must be in alignment. Also the head and foot shaft assemblies must be
parallel. See Aligning Head and Foot Shaft, page 4-18.
Installation
4 17

Manual 3520
4
Installation
Aligning Head and Foot Shaft

The head and foot shaft assemblies must be aligned properly. Improperly aligned shafting
will result in operational problems and/or rapid wear of elevator components.
Before aligning the shafting, refer to the General Arrangement Drawing of the elevator
being worked on; in some applications the foot shaft is offset from the elevators
centerline.
The elevator boot section may or may not have had the take-up assembly installed at the
factory, in either case, the alignment of the shafting must be checked.
The head and foot shaft are in proper alignment when the following are true:
STOP
The head and foot shaft are parallel.
The centerline of the traction wheel(s) and/or sprocket(s) of the head and foot shaft are
aligned with each other.
Alignment between the traction wheel(s) and/or sprocket(s) of the head

and foot shaft must not deviate more than 3 mm (1/8). See Figure 4-14.
To check the shafting alignment, drop two plumblines from the head shaft. Position lines
so they are near the ends of the shafts and are out near the edge of the traction wheels and/
or sprockets as shown in Figure 4-14. A minimum of two plumblines must be used to
check alignment.
Head shaft and foot shaft must be level before aligning shafting.
Installation Note
When installing plumblines:
Installation
To clear the take-up counterweight box at the boot end of the elevator, it is necessary
to offset the plumblines away from the head shaft.
To set plumblines correctly, set the lines so that they are at the ends of the foot shaft.
Setting lines near the ends of the head shaft will result in hitting take-up frame in boot
sections with the lines or plumb bobs.
4 18

Manual 3520
4
Installation
A
B
D
E
C = D
-------------+B
2
5
A
C
A
REX-0010
Figure 4-14:
Shaft Alignment
1 A Measurement between plumbline and side of segmented traction
wheel or sprocket
2 B Measurement between plumbline and edge of head shaft
3 C Measurement between plumbline and edge of foot shaft
4 D Head shaft diameter
5 E foot shaft diameter
Installation
4 19

Manual 3520
4
Installation
Handling Coiled Chain (Shipping Sections)

For convenience in shipping and handling, chains are coiled in segments approximately
3 m (10') long. The chain is wired together so that it does not uncoil during shipment. In
most cases, coiled chain segments are stacked on a pallet and shrink wrapped or boxed.
The chain should not be unwrapped until it is ready to be installed in an elevator. Until the
chain is ready to be installed, it should be moved by lifting the pallets with a forklift.
The chain coils when palletized are placed on their side and must be handled properly or
the chain can be twisted/damaged. When handling the individual chain coils from a pallet,
the whole chain coil must be supported as shown in Figure 4-15.
STOP
Never connect a hook into the center or onto the end of a coiled chain in
order to lift it; doing so will place great stress against the chain sidebars
causing the chain to become twisted.
CAUTION
To prevent personal injury, stand clear when hoisting.
REX-0012
Figure 4-15:
Lifting Chain Coils

Coiled chain must be uncoiled before installing it into an elevator.
To uncoil chain, position coil so chain joints are parallel to the ground and roll out the coil
into a straight line. The chain segment is now in a position in which it can be installed in
the elevator or connected to another segment of chain.
Rigging and Lifting Chain

Determine the total weight of the chain segment or assembly prior to lifting so the proper
Installation
4 20

Manual 3520
4
Installation
lifting equipment can be acquired.

Refer to the elevators General Arrangement Drawing to determine the weight of the chain
to be lifted.
Always connect rigging around a chain bushing, close to one end of the chain segment or
assembly to be lifted. See Figure 4-16.
REX-0011
Figure 4-16:
Rigging and Lifting Chain

STOP
Never install rigging through the chain pin holes or around a chain pin or
damage to the components may result.
Always lift chain with the chain joints parallel to the ground as shown in Figure 4-17.
STOP
Installation
Never lift a chain while it is laying on the sidebars or the chain can
become twisted and damaged. See Figure 4-17.
4 21

Manual 3520
4
Installation
REX-0013
Figure 4-17:
Lifting Chain
Interference Fits at Chain Joints

Sidebars of all chain are heat-treated for strength and wear resistance. Bushings and pins
are assembled to sidebars with controlled interference (press) fits. These relatively heavy
interference fits provide a significant improvement in sidebar fatigue strength. As the pin
interference fit increases, the sidebar fatigue strength increases.
This increase in sidebar fatigue strength, as a result of the interference fit, is the reason that
the chain pins or holes in sidebars must not be ground for ease of assembly.
Grinding chain pins or holes in sidebars to ease assembly will reduce the fatigue strength
of the sidebars. This may result in sidebar failures which will cause the entire chain and
bucket assembly to fall into the boot of the elevator.
STOP
Do not heat chain side bars, grind the holes in side bars or grind chain pins
for ease in assembly. Side bar fatigue may result and chain warranty will
be void.
Chain Assembly
Proper chain assembly is crucial in the safe and smooth operation of an elevator.
Pins and rivets are manufactured in a variety of geometric shapes. They can be a straight
cylinder, have multiple stepped diameters, have locking flats or various head shapes.
These variations in geometry will dictate the proper direction and method of assembly and
disassembly. A pin with either a flat on a head end or a larger stepped diameter will not
pass through the smaller cotter-side sidebar hole. Likewise, the round shank of a pin with
Installation
4 22

Manual 3520
4
Installation
locking flats on the cotter end will not pass through the slotted cotter-side sidebar hole.
To ensure that the elevator will operate smoothly and safely perform the following steps
without deviation.
STOP
Chain warranty is void on improperly assembled chain. Elevator components

that fail due to improper chain assembly are also void of warranty.
WARNING
Improperly assembled chain may result in chain
failure. Falling chain can cause personal injury or
death.
1. Make sure the chain attachments of both segments being joined are oriented in the
same direction. Chain segments that are being joined while laying on the ground,
should be positioned so the chain joints are parallel to the ground.
Installation Note
See Assembling Rex Sealed Joint Chain, page 4-24 for additional chain assembly Step a
through Step c that must be performed when assembling sealed joint chain prior to going
to Step 2 below.
2. Slide the block (bushing) link end of one chain segment into the attachment sidebars
end of another segment and align pin holes.
3. Insert the chain pin by hand through the head side attachment sidebar, the bushing and
into the cotter side attachment sidebar.
Installation Note
Pin can be inserted through the chain joint from one side of the chain only. The head side
attachment side bar is stamped with an H, The cotter side attachment side bar is
stamped with a C.
4. Push pin through interference fit of attachment side bars so that the head of the pin is
in contact with the head side attachment sidebar.
Chain segments can be assembled either by pressing the pins into the chain
sidebars or by driving them in with a hammer. Rexnord recommends pressing
the pins into the chain sidebars with a RexLinkmaster Chain Tool, because it
is less likely that the chain will be damaged during assembly.
Larger size Rex chains must be assembled by pressing the pins into the chain;
driving pins with hammers is not an option because hammering on the pins
will not overcome the interference fit between chain pin and side bar.
See Linkmaster Chain Tools, page 4-26 for more information on pressing
pins into chain.
STOP
Installation
Chain/pins damaged during assembly must be replaced with new chain/

pins or chain warranty will be void and chain failure may result.
4 23

Manual 3520
4
Installation
5. Install pin-lock through hole in end of chain pin. Bend the end of the pin-lock so it can
not back out of the chain pin.
6. Check that the newly assembled chain joint flexes freely. If the joint does not flex,
firmly strike the cotter end of the pin with a 35 Kg (6-12 lb) hammer to loosen the
joint.
STOP
Failure to loosen the chain joint will cause erratic chain action and could
result in buckets hitting the casing. The chain must flex freely.
REX-0014
Figure 4-18:
Loosening Tight Chain Joints

1 Tight chain joint
2 Chain joint loosened
Assembling Rex Sealed Joint Chain

Rex Sealed Joint Chain uses a polymeric seal to protect the chain joint and if properly
installed will increase chain life significantly. The seal was designed to prevent abrasive
Installation
4 24

Manual 3520
4
Installation
material from entering and lubricant from leaving the chain joint which in turn, reduces
joint wear and increases the chains life.
Each shipped section of Rex Sealed Joint Chain will have a plastic bag attached to it
containing:
Quantity
Item
Tube of Lubricant
Polymeric Seals
Pin-lock
REX-0089
Figure 4-19:
Sealed Joint Chain Kit

1 Lubricant
2 Seals
3 Pin-lock
The following steps must be performed in addition to, and prior to, Step 2 in the steps
outlined in Chain Assembly, page 4-22 to ensure proper assembly of the sealed joint
chain sections:
a. Using a clean cloth, wipe clean the connecting pin, ID of bushing, and outer area of
the sidebar which the seal will come in contact with including the seal retaining
ring mounted on the end of the bushing.
b. Spread a generous amount of the lubricant from the tube into the bushing ID and
along the surfaces of the sidebars where the seal comes in contact.
c. Use the remaining lubricant to spread over the pin and inside of sidebar holes to
ease field assembly.
STOP
Installation
Extreme care must be taken not to damage seals when sliding block link
between chain attachment sidebars.
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4
Installation
Installation Note
It is often difficult to slide the block link into the attachment sidebars because there is not
enough clearance with the seals in place. If the bushing link is forced into position,
damage can be caused to the seals! To avoid this, it will be necessary to spread the
attachment links about 12 mm (1/32-1/16) to allow easy entry of the bushing link.
STOP
Do not over spread the attachment sidebars as they could bend and/or
cause twist in this section of chain.
Linkmaster Chain Tools

Connecting the chain shipping segments or assemblies is best accomplished with the Rex
Linkmaster chain tool. The Linkmaster chain tool is designed specifically for
assembling and disassembling Rex chains and equivalent Linkbelt chains. The
Linkmaster chain tool presses the chain pins in and out of the sidebars, greatly reducing
the risk of damaging the chain during assembly.
When assembling the chain, use the correct size Linkmaster chain tool for the job.
Rexnord has developed two models of Linkmaster chain tools. The original Linkmaster
tool assembles all the smaller to medium size High-Performance elevator chains, the
LinkmasterII chain tool assembles all the largest High-Performance elevator chains. See
Figure 4-20.
Contact Rexnord if there is any question to which tool best fits your application.
REX-0015
Figure 4-20:
Rex Linkmaster Chain Tool

To accommodate and assemble the many Rex chains used in Rexnord equipment, the
Linkmaster and Linkmaster II chain tools use different size adapter support plates or pin
pushers to support the chains properly within the tool. When setting up the Linkmaster or
Linkmaster II chain tool make sure that the correct adapter support plate or pin pusher is
bolted into the tool.
If the correct adapter support plate or pin pusher is not available or there is a question of
which adapter is correct for your application, please contact Rexnord.
Installation Note
Installation
4 26

Manual 3520
4
Installation
It is very helpful to apply a light coat of oil to the sidebar holes and surface of the pin to
ease assembly prior to using the Linkmaster tool.
Pre-assembling Chain Shipping Sections

To expedite the installation of chain into an elevator it is possible to pre-assemble chain
shipping segments prior to installation.
Pre-assemble the chain just prior to it being required/installed in the elevator. Chain
segments pre-assembled too early can be subjected to many harsh environments which can
damage the chain, causing many operational problems when installed.
STOP
Do not pre-assemble chain shipping segments together until the elevator is

ready to have them installed. Store the chain as specified in the long term
storage section of the manual until it is needed, so it will not be damaged.
Before pre-assembling chain segments, make sure the area in which assembly will take
place is secure, chain is not in heavy equipment pathways, subjected to falling objects,
sitting in water and/or mud if it rains, etc.
When pre-assembling chain follow all the chain instructions given under the headings:
Handling Coiled Chain (Shipping Sections), page 4-20
Rigging and Lifting Chain, page 4-20
Interference Fits at Chain Joints, page 4-22
Chain Assembly, page 4-22
Linkmaster Chain Tools, page 4-26.
When installing chain at the boot section:
Rexnord recommends pre-assembling chain segments into six meter (twenty foot)
assemblies for ease in handling.
Pre-assemble chain in an area close to the boot section so chain is less likely to be
damaged when moving it into the elevator.
When installing chain at the head section:
STOP
Assemble chain segments in an area in which the crane operator can easily view and
pickup the assemblies without dragging them.
Do not make the chain assemblies longer than what the crane can lift clear over the top
of the elevator and any other objects in the cranes swing path.
Make sure all chain joints flex freely. This is especially important on
double strand elevators where the chain attachments on one chain strand
must be in alignment and level with the other strand, so the buckets will
hang straight/level in the elevator.
Installing Chain in an Elevator

Chain can be installed in an elevator in a number of ways. The best way depends on the
Installation
4 27

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4
Installation
location and access of the elevator.

The following chain installation procedure has two sub-instruction headings below it, to
allow the procedure to be used to install chain at the boot section or the head section.
Rexnord recommends when at all possible to use the sub-instructions Installing Chain at
the Boot Section, page 4-34 where the chain is installed through the boot section of the
elevator and hoisted up. When there is minimal access to the boot section it is possible to
install the chain sections at the head end of the elevator as described in the sub-instructions
Installing Chain at the Head Section, page 4-36.
The chain installation procedure along with the sub-instructions Installing Chain at the
Head Section, page 4-36 were written to also be used to install pre-assembled chain and
bucket assemblies. Instructions that pertain only to installing the chain and bucket
assemblies are placed in parenthesis {} and should be disregarded when installing chain
only.
1. Lift the take-up assembly to its upper end of travel. Use the take-up lifting beam
located inside the top of the boot section to rig from and lift the take-up.
2. Make preparations to support the chain at the top of the elevator. The chain segments/
assemblies can only be installed in one side of the bucket elevator at a time. Therefore
if the chain segments/assemblies are installed in the load side first, preparations must
be made to support the chain installed on the load side of the elevator while the chain
segments/assemblies are being installed in the return side.
Determine the total weight of the chain {& bucket} strand so the proper lifting and rigging
equipment can be acquired. Refer to elevators General Arrangement Drawings to
determine weight of chain strand.
STOP
Never attempt to lift or support a chain assembly with a hoist frame above
the elevator without checking the hoist capacity. Rexnord supplied hoist
frames are engineered to support the entire chain and bucket assembly,
hoist frames supplied by others may not have the required capacity.
When a hoist frame is not available or the capacity of the hoist frame is insufficient to lift
and/or support the complete chain {& bucket} strand, structural beams maybe placed
across the bearing channels of the lower head section to support it. See Figure 4-21.
STOP
It is the responsibility of the customer/contractor assembling the elevator

to determine the structural beam size needed to support the chain and how
to attach/support it on the elevator.
WARNING
At all times use extreme caution when securing the
rigging on chain, falling chain can cause personal
injury or death.
Installation
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Installation
REX-0016
Figure 4-21:
Preparing Elevator For Chain Installation

1 Bearing channels
2 Structural beam
3 Take-up assembly supported from lifting beam with chain-fall
Customers or contractors planning on pre-assembling buckets to the chain prior to chain
installation must read section Pre-assembling Chain and Buckets, page 4-37 before
proceeding. Rexnord recommends installing the chain in the elevator prior to installing
buckets.
Installation
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Manual 3520
4
Installation
3. Follow the additional directions under one of the headings Installing Chain at the
Boot Section, page 4-34 or Installing Chain at the Head Section, page 4-36 before
proceeding on to Step 4.
Make sure all chain joints flex freely. This is especially important on double strand
elevators where the chain attachments on one chain strand must be aligned and leveled
with the other strand, so the buckets will hang straight/level in the elevator. See Chain
Assembly, page 4-22 for more information.
WARNING
On double strand elevators install one chain strand
complete before installing the second strand. No
work time is allowed under rigged chain. Falling chain
can cause personal injury or death.
4. Connect the two strand halves of chain around the head traction wheel or sprocket.
Use a Linkmaster chain tool or equivalent to make the connection. Maintain the
rigging installed earlier on the chain while making the connection. See Figure 4-22.
Installation
4 30

Manual 3520
4
Installation
4
3
REX-0019
Figure 4-22:
Connecting Chain Strands Around Head Wheel

1
2
3
4
Chain strand halves supported by rigging

Take-up assembly supported from lifting beam
Chain strand halves wrapped over head wheel
Linkmaster chain tool used to connect chain strand halves
5. Connect the chain strand halves at the boot section. Hold the chain securely with
rigging before proceeding to connect halves. Use a come-along or a chain fall to draw
the chain ends together. Install the chain pin using a Linkmaster chain tool or
Installation
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Manual 3520
4
Installation
equivalent. See Figure 4-23.
4
REX-0020
Figure 4-23:
Connecting Chain Strands Around Foot Wheel

1
2
3
4
Chain tied off

Take-up assembly supported by lifting beam
Chain strand halves wrapped around foot wheel
Linkmaster chain tool used to connect chain strand halves
6. For double chain strand elevators only. Perform Step 3 through Step 5 to install the
second strand of chain.
7. Lower the take-up onto the chain(s) making sure the traction wheel(s) or sprocket(s)
is/are positioned on the chain(s) properly.
Installation
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Manual 3520
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Installation
8. Check the elevators General Arrangement Drawing for the proper height of the foot
shaft. The center of the foot shaft should be located within the take-up measurement
given on the drawing. The foot shaft should be positioned as close to the upper limit of
the take-up measurement as possible without going above. It may be necessary to
remove a two-pitch section of chain {and a bucket} to achieve the proper foot shaft
setting.
9. Remove all rigging used to support the chain before proceeding onto bucket
installation.
Installation Note
Rexnord may ship extra chain with the elevator, it is the customers/contractors
responsibility to install the correct amount of chain to properly position foot shaft as
indicated in the elevator General Arrangement Drawings.
STOP
Installation
Do not mount buckets to the chain until the chain has been completely
installed and all connections made in the elevator.
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Manual 3520
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Installation
Installing Chain at the Boot Section

5
1
REX-0017
Figure 4-24:
Installing Chain Through Boot Section

1
2
3
4
Chain strand half being pulled into elevator

Take-up assembly supported by lifting beam
Connecting chain sections to chain strand half being pulled into elevator
Supporting chain strand half with rigging while installing opposite side
chain strand half
5 Note: Rig chain to allow chain strand half to be wrapped halfway over
head wheel
To install the chain through the boot section of the elevator, perform the following steps:
a. Drop a line into the far side of the casing starting from the top of the elevator; using
Installation
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Manual 3520
4
Installation
a hoist, crane, air tugger, or other means available. The line will be used to lift the
chain assembly into the elevator. The working rate of the line, must be rated higher
than half of the complete chain strand weight.
b. Two chain segments (shipping lengths) should be connected together just outside
the end door in the boot section. To avoid twisting or bending, no more than six
meters (twenty feet 20') of chain should be connected together outside of the
elevator during installation. Before assembling, be sure to orient the chain segments
properly so the chain attachments are pointing in the proper direction when the
chain is pulled into the elevator. See the General Arrangement Drawings located
under the tab labeled Drawings for proper chain orientation.
c. Connect the line dropped in Step a around a bushing of the chain assembled in
Step b.
d. Pull the chain into the elevator, feeding it around the bottom of the foot sprocket or
traction wheel and upward towards the head end with the attached line. Stop pulling
chain when approximately 1.5 m (5') of it is still outside the elevator casing. Be
sure that the chain is oriented properly, so the buckets can be later attached to the
chain. See the General Arrangement Drawings located under the tab labeled
Drawings for proper orientation.
Do not feed the chain into the elevator on its side. Prevent the possibility of twist by
feeding it in the manner shown in Figure 4-24.
e. Connect two more shipping segments of chain (approximately 6 m (20')) to the end
of the chain still outside the boot section.
f. Pull attached chain into the elevator leaving approximately 1.5 m (5) of chain
outside the elevator.
g. Keep performing Step e and Step f until half the chain is installed in the elevator.
h. Secure this half strand of chain to the hoist frame or the structural beam that was
placed over the bearing supports. (one half of the chain assembly is now in the
elevator.)
Installation Note
Support the first half of chain so that a few links at the top end of the chain assembly are
free. The free links are needed so the chain can be wrapped around the head traction
wheel or sprocket and attached to the other half of the chain easily.
i. Install the second half of chain by repeating Step a through Step h, feeding the
chain upward on the opposite side of the casing.
Installation
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Installation
Installing Chain at the Head Section
6
2
REX-0018
Figure 4-25:
Installing Chain Through Lower Head Section

1 Chain strand half being lowered and supported by crane or hoist
2 Connecting chain sections together with Linkmaster chain tool
3 Supporting chain strand half inside elevator with rigging while connecting
chain sections
4 Take-up assembly supported by lifting beam
5 Supporting chain strand half with rigging while installing opposite side
chain strand half
6 Rig chain to allow chain strand half to be wrapped halfway over head
wheel
Installation
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Manual 3520
4
Installation
To install the chain through the head section of the elevator, perform the following steps:
a. Rig and lift a chain segment/assembly as described and illustrated in Rigging and
Lifting Chain, page 4-20 {Rigging and Lifting Pre-assembled Chain and
Buckets, page 4-39}. {Make sure the rigging is attached to the proper end of the
assembly so that the buckets will be in the correct orientation when the assembly is
placed in the elevator}
b. Lift segment/assembly over the top of the head section and other structures as
required.
STOP
Never install chain segments/assemblies on the carrying and return runs

(by wrapping it over the head traction wheel or sprocket) of the elevator at
the same time or damage to the chain will result.
c. Lower segment/assembly in through the lower head and down the casings. Guide
the segment/assembly while lowering, so it does not hit and damage other
components and/or structures.
d. Tie off and support the chain segment/assembly in the elevator so that the crane can
be disconnected from it. If one half of the chain strand is now completely installed
in one side of the elevator skip to Step l.
Installation Note
Support the chain and bucket assembly so that a few links at the top end of the chain are
free. The free links are needed so the chain can be easily connected to the next assembly
or later wrapped around the head traction wheel or sprocket and attached to the other
half of the chain.
e. Rig and lift another segment/assembly to the head section.
f. Lower the segment/assembly until it can be connected to the preceding segment/
assembly already being supported in the elevator.
g. Connect the two segments/assemblies together making one long assembly using a
Linkmaster chain tool or equivalent.
h. Lift the long assembly with the crane until the rigging installed to the segment/
assembly in Step d or Step j can be removed safely.
i. Lower the long assembly into the elevator.
j. Tie off and support the assembly in the elevator so that the crane can be
disconnected from it.
k. Repeat Step e through Step j until half of the chain strand is installed on one side of
the elevator.
l. Install segments/assemblies on the other side of the elevator by repeating all the
steps above.
Pre-assembling Chain and Buckets

Under no circumstances should buckets be mounted to the chain prior to being installed in
the elevator unless ALL the following criteria are met:
a. Buckets are designed to be attached to a single strand of chain.
b. The chain and bucket assembly can and will be installed at the head end with a
Installation
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Installation
crane.
c. Crane capacity is greater than complete chain and bucket assembly.
d. All chain and bucket assemblies can be put together in an area in which the crane
can reach and pick them up without dragging.
STOP
Buckets designed to be installed on two strands of chain must never be

pre-assembled.
STOP
Dragging pre-assembled chain and bucket assemblies will damage the

components. Always move pre-assembled chain and bucket assemblies
only with a crane and never back flex assemblies while moving them.
STOP
Do not pre-assemble chain and bucket assemblies together until the

elevator is ready to have them installed. Store the chain and buckets as
specified in the long term storage section of the manual until they are
needed.
For detailed information on handling and connecting chain shipping segments see:
Handling Coiled Chain (Shipping Sections), page 4-20
Rigging and Lifting Chain, page 4-20
Interference Fits at Chain Joints, page 4-22
Chain Assembly, page 4-22
Linkmaster Chain Tools, page 4-26.
Buckets assembled to the chain at the site, prior to it being installed in the elevator, must
be assembled accordingly:
1. Always assemble chain and buckets in an area in which the crane operator can easily
view and pickup the assemblies without dragging them.
2. Assemble the chain and buckets with the buckets lip facing down and the chain
placed on top of the buckets as shown in Figure 4-26.
Installation
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Manual 3520
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Installation
REX-0021
Figure 4-26:
Pre-assembling Chain and Bucket Assemblies

Never assemble the chain and buckets with the buckets laying on their side or
with the chain on the ground and the buckets placed on top.
3. Mount bearing plates on the inside of the buckets when they are supplied or called out
on the elevators General Arrangement Drawings.
4. Use the proper sized mounting hardware and tighten to the proper torque value. For
more information on installing buckets see Bucket Installation, page 4-41.
5. To ease assembly of chain segments it may be necessary to leave the end bucket off of
each section. More than one bucket may be left off the very bottom and top assembly
of the return and load strand halves of the elevator to ease assembly around the
traction wheel(s) or sprocket(s) at the top and bottom of the elevator.
6. Do not make the chain and bucket assemblies longer than what the crane can lift clear
over the top of the elevator and any other objects in the cranes swing path.
STOP
Make sure all chain joints flex freely.
Rigging and Lifting Pre-assembled Chain and Buckets

Pre-assembled chain and bucket assemblies must be rigged properly or damage to the
chain and buckets will result.
Determine the total weight of the chain and bucket assembly so the proper lifting and
rigging equipment can be acquired. Refer to elevators General Arrangement Drawings to
determine weight of the chain and bucket assembly.
Installation
4 39

Manual 3520
STOP
4
Installation
Never attempt to lift a chain and bucket assembly unless the crane
capacity is greater than the chain and bucket assemblys total weight.
Always connect rigging around a chain bushing close to one end of the chain and bucket
assembly to be lifted. See Figure 4-27.
REX-0022
Figure 4-27:
Rigging and Lifting Pre-assembled Chain and Bucket Assemblies

STOP
Never install rigging through the chain pin holes, around a chain pin or
around the buckets; or damage to the components will result.
Pre-assembled chain and bucket assemblies must be lifted straight up with a crane. Never
drag an assembly. See Figure 4-27.
Installation
4 40

Manual 3520
STOP
4
Installation
Never back flex a chain and bucket assembly or damage will result.
Installing Pre-assembled Chain and Buckets

1. To install pre-assembled chain and buckets, follow the procedure under the heading
Installing Chain in an Elevator, page 4-27 using the sub instructions for Installing
Chain at the Head Section, page 4-36. The words Chain assembly or assemblies
in the instructions also pertain to a Chain and Bucket assembly or assemblies.
Instructions with parenthesis {} around them pertain to installing pre-assembled chain
and buckets only.
2. Install any buckets removed or left off the chain and bucket assembly to ease the
installation of the chain pin between chain and bucket assemblies.
Bucket Installation
The buckets can be mounted to the chain after chain installation is complete.
Install/orientate buckets on the chain as shown on the elevators General Arrangement
Drawings. Most buckets will mount on the chain with the head of the mounting hardware
inside the bucket. When bearing plates are supplied or are called out on the General
Arrangement Drawings they must be mounted on the inside of the buckets.
STOP
Failure to install bucket bearing plates when shown on the bucket

assembly view in the General Arrangement Drawing will result in bucket
failure and bucket warranty is void.
STOP
Do not use split (lock) washers or nylon lock nuts when mounting buckets.
Bucket mounting hardware must be tightened to the following torque values in Table 4
A, page 4-41. The mounting hardware must be tightened to the proper torque value during
the installation of the buckets and retightened to the proper torque value after the elevator
has completed the initial run.
Chain No.
Bolt Size
1/2
ER 111, ES833, ER857,
SJM857, ER958, SJM 958 M12 x 1.75
RS 856, ER 859, SJM 859,
5/8
ER 864, SJM 864, ER 956,
SJM 956, ER984, SJM
M16 x 2
984, ER1084
Bolt Grade or Torque Value Torque Value

Class
Nm
ft lb
Grade #2
Class 8.8
70 Nm
79 Nm
52 ft lb
58 ft lb
Grade #2
140 Nm
104 ft lb
Class 8.8
191 Nm
141 ft lb
Table 4A: Bucket Bolt Torque Chart

Bucket mounting hardware must be prick punched following the initial run and
Installation
4 41

Manual 3520
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Installation
retightening of the hardware. When prick punching bucket hardware, distort the bolt
threads directly behind the nut with a chisel or punch. Prick punching hardware is
recommended but tack welding nut to bolt to distort the threads is acceptable. See Figure
4-28.
STOP
If tack welding nut to bolt, DO NOT OVER WELD or hardware failure

will result.Welding ground must be connected to bucket, to prevent arcing
through mechanical components.
REX-0056
Figure 4-28:
Prick Punching or Tack Welding Bucket Hardware

1 Nut tack welded to bolt properly
2 Nut over welded to bolt
3 Bolt prick punched properly
4 Bolt improperly prick punched
Buckets mounted to the chain using Huck fasteners are tightened to the proper
requirement when installed using the proper Huck installation equipment. Therefore, no
tightening with a torque wrench is required before or after the initial operation of the
elevator.
Installation
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Manual 3520
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Installation
1
2
REX-0023
Figure 4-29:
AC Bucket Assembly
1 Stiffeners (Optional)
2 Bearing Plate
REX-0025
Figure 4-30:
ACS Bucket Assembly

1 Bearing Plate
2 ACS buckets attach to back side of chain attachment, all other bucket
types attach to the front or other side of the attachment
Installation
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Manual 3520
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Installation
REX-0027
Figure 4-31:
RP Bucket Assembly - single chain strand

1 Bearing Plate
REX-0028
Figure 4-32:
RP Bucket Assembly - double chain strands

1 Bearing Plate
Installation
4 44

Manual 3520
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Installation
REX-0029
Figure 4-33:
Continuous Bucket Assembly - single chain strand
REX-0030
Figure 4-34:
Installation
Continuous Bucket Assembly - double chain strand
4 45

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Installation
REX-0031
Figure 4-35:
Plastic Bucket Assembly
REX-0026
Figure 4-36:
Sugar Cane Bucket Assembly

Buckets can be mounted in any of three areas, at the boot section, at the head section, or
the three door intermediate section if the elevator is so equipped. In general, bucket
installation is easiest at the three door intermediate section.
Installation
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Installation
Buckets Mounted on Two Strands of Chain
Buckets mounted on two strands of chain can not be installed until the two strands of chain
are aligned. To make sure chain strands are in alignment, at least four buckets must be
mounted in the elevator at various places and the level of the buckets checked. All the
chain joints in each chain strand must freely flex or chain alignment will not be possible.
For information on loosening tight chain joints see Chain Assembly, page 4-22.
STOP
The head shaft MUST BE LEVEL before proceeding to check and align
the chain strands. See Head Shaft Installation, page 4-15 for more
information on leveling the headshaft.
To check and align two chain strands within an elevator perform the following procedure:
1. Move at least two buckets to the head end and foot end of the elevator.
2. At the head end, align the chain attachments of the two strands and mount one bucket
to each chain strand.
3. Tighten the hardware used to mount the bucket in Step 2 to the proper torque value.
See Table 4A, page 4-41 for proper torque values. Check the level of the bucket
using a level approximately as wide as the bucket and with the bucket mounting
hardware tightened properly. Loosen bucket mounting hardware and adjust chain until
bucket hangs level with mounting hardware tight.
Installation Note
If Huck fasteners are to be used to mount buckets, temporarily substitute bolts and nuts for
the Huck fasteners while installing buckets in this procedure. Buckets installed during this
procedure may have to be shifted in order to align the chain strands. The bolts and nuts
can be replaced with Huck fasteners after the chain alignment procedure has been
completed and buckets are being installed following one of the procedures below.
4. At the boot section, the chain attachments of the two strands of chain should appear to
be in alignment. If they are not in alignment one chain most likely has a tight chain
joint, which will require freeing before proceeding to the following steps. For
information on freeing tight chain joints see Chain Assembly, page 4-22.
5. If the attachments are aligned in Step 4, install a bucket to the two strands of chain at
the boot section. Tighten the mounting hardware and check to make sure the bucket
hangs level. If the bucket does not hang level on the chains, locate and correct the
problem causing the bucket to be cocked before proceeding on.
6. Rotate the chain assembly through approximately one quarter of its cycle path within
the elevator (the bucket installed at the head should be straight across from the bucket
installed at the boot).
7. Mount a bucket on the two strands of chain at the head section and at the boot section
as was done in steps 25 making sure the buckets hang level within the elevator.
8. Start installing buckets in the elevator as instructed in one of the two methods below.
Bucket Installation Procedures
There are two methods of moving the chain in the elevator during the bucket installation
process. The first method uses the inching drive of the elevator if so equipped to move the
chain. The second method uses chain falls, come-alongs or equivalent to pull the chain
Installation
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Manual 3520
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Installation
around the elevator.

Installing buckets using the inching drive to rotate the chain:
Before the following procedure can be performed the drive assembly must be properly
installed/mounted to the elevator before the buckets can be assembled to the chain. See
Drive Installation, page 4-55 and the manufacturers literature for the drive in this
manual for drive installation instruction.
1. Block the chain.
2. Mount approximately five buckets. Heavier buckets may require a smaller amount of
buckets to be installed at one time. See item 1 Figure 4-37.
3. Tighten the bucket mounting hardware to the proper torque value given in Table 4A,
page 4-41.
4. Unblock chain.
5. Rotate the chain until the first five buckets are positioned 180 degrees from the area
the buckets were installed. See item 2 Figure 4-37.
6. Block the chain.
7. Install approximately ten buckets. See item 3 Figure 4-37.
8. Unblock chain.
9. Rotate the chain approximately 180 degrees so the buckets can be mounted directly
after the first five buckets mounted in Step 2. See item 4 Figure 4-37.
10. Block chain.
11. Install ten bucket after the first five buckets. See item 1 Figure 4-38.
12. Keep rotating the chain 180 degrees, and installing ten buckets until all the buckets are
mounted to the chain. See item 2 Figure 4-38.
Installation Note
The above procedure keeps the carrying (up) side and the return (down) side of the chain
strand(s) out of equilibrium by the weight of 5 buckets maximum. Installing more buckets
at a time before rotating chain increases the unbalanced load between the two chain
strands.
WARNING
Always block chain before entering elevator.
Unbalanced chain strands can start to rotate in
elevator and serious injury or death can result.
Installation
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Manual 3520
1
4
Installation
"A"
"B"
"A"
"A"
"B"
"A"
REX-0032
REX-0033
REX-0034
REX-0035
Figure 4-37
1
2
3
4
Installation
Installing 5 buckets A
Rotating 5 buckets A 180
Installing 10 buckets B
Rotating 10 buckets B 180
4 49

Manual 3520
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Installation
2
"A"
"B"
"C"
"C"
"B"
"A"
REX-0036
REX-0037
Figure 4-38
1 Installing 10 buckets C behind first 5 buckets A installed
2 Rotate latest installed buckets C 180 to install 10 more buckets
Installing Buckets Using Chain hoists or Equivalent
1. Block the chain.

2. Install the buckets at a convenient location.
3. Tighten the bucket mounting hardware to the proper torque value given in the
Table 4A, Bucket Bolt Torque Chart, page 4-41.
4. Unblock chain.
5. Rotate chain using chain fall until more buckets can be installed.
6. Repeat Step 1 through Step 5 until all the buckets are installed.
WARNING
At all times use extreme caution when securing
rigging on chain, chain strands are very unbalanced
using method above, runaway chain and bucket
assembly can cause personal injury or death.
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Installation
Installing Stop Blocks on Take-up Assembly

The stop blocks are installed after the chain and bucket assembly has been installed and
the take-up shaft has been properly located within the take-up range shown on the
elevators General Arrangement Drawing.
Upper Stop Blocks
The upper stop blocks are mounted in the holes provided in the take-up guides above the
take-up. The upper stop blocks are positioned to allow a 625 mm (1/41) gap between
the upper stop block and the top of the take-up.
STOP
Do not force the take-up down to place the stop blocks in a lower hole on
the take-up guide. A minimum gap of 6 mm (1/4) is needed to allow the
take-up to move freely.
Lower Stop Blocks
The lower stop blocks are installed on the take-up guide in a position that stops the take-up
assembly from driving the buckets into the bottom of the boot if the chain is left to
elongate in excess. To determine the proper placement of the lower stop blocks perform
the following steps:
1. Rotate the chain and bucket assembly so that one bucket is located in the lowest
position in the boot when going around the foot shaft wheel.
2. Measure and record the distance from the lowest point of the bucket (usually the
bucket lip) and the bottom of the elevator.
3. Subtract approximately 25 mm (1") from the measurement recorded in Step 2, and
record this figure.
4. Starting from the bottom of the take-up and measuring down the take-up guide, make
a mark on the take-up guide at the figure recorded in Step 3. If the take-up guide is
shorter than the figure recorded in Step 3 go on to Step 5 without making the mark.
5. Install the lower stop blocks in the hole of the take-up guide that is in line with, or is
just above, the mark made on the take-up guide. If the take-up guide was too short to
make a mark on it in Step 4, install the lower stop blocks in the lowest holes in the
take-up guides.
Installation
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4
Installation
"Z"
5
"A"
"B"
B - 25 mm (1") > A
6
7
Figure 4-39:
REX-0038
Adjusting Stop Blocks

1 Upper stop blocks
2 Z Space between upper stop blocks and top of take-up assembly.
Z = 625 mm (1/41). Adjust by moving upper stop block.
3 Take-up assembly
4 Lower stop blocks
5 A Space between bottom of take-up assembly channel and top of
lower stop blocks
6 B Space between bucket and bottom of boot section
7 Space A must be set 25 mm (1") less than space B by adjusting lower
stop blocks
Installing/Adjusting Rubber Peeler Lip

All Rex High-Performance Bucket Elevators have an adjustable peeler lip. The function
Installation
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Installation
of the peeler lip is to direct material that is still inside the buckets after rotating around the
head shaft assembly towards the discharge spout.
1
3
REX-0039
Figure 4-40:
Properly Adjusted Peeler Lip

1 Rubber lip
2 Mounting hardware
3 Sliding access panel
It is very important that the peeler lip be adjusted properly. See Figure 4-40. The rubber
peeler lip should make slight contact with the bucket lip to minimize the amount of
material falling to the boot section.
STOP
Boot flooding can occur if material falling from buckets is excessive.

If the peeler lip is worn out, missing, or deformed it must be changed immediately!
The mounting hardware of the peeler lip can be easily loosened and tightened by opening
the sliding access panels near the bottom of the lower head section.
WARNING
Always lock out all power sources and block chain
before entering elevator to work on peeler lip.
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Installation
Backstop Installation
There are two different backstop styles that are engineered into Rex equipment. The two
backstop styles are:
a. Externally mounted backstop mounted on the equipments head shaft with an
integrated torque arm that is supported from equipments frame or casing. See
Figure 4-41.
b. Backstop integrated as part of the drive assembly; usually mounted in or on the
main reducer.
4
REX-0040
Figure 4-41:
Head Assembly With External Backstop

1
2
3
4
External backstop
Backstop torque arm
Torque arm support bracket or stirrup
Torque arm support
*Guards removed to show coupling arrangement

In most cases only one of the backstop styles will be used on a single piece of equipment.
STOP
It is recommended that all elevators be equipped with a positive stopping

device. This feature will eliminate extensive damage to the equipment by
preventing a backward action of the elevator if a power failure or some
other unforeseen circumstance occurs. Without this feature, material and/
or equipment could be dropped into the boot whenever an unscheduled
stoppage occurs.
The following points should be followed when an externally mounted backstop is used.
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Installation
1. Before mounting, clean mounting area of head shaft thoroughly, removing the rust
inhibitor and any burrs from the shaft and keyway area.
2. Mount backstop as shown in the General Arrangement Drawings located under the tab
labeled Drawings, following the manufacturers installation and lubrication
instructions.
3. Make sure backstop torque arm is mounted as shown in the General Arrangement
Drawings.
The following points should be followed when using an integrated backstop as part of the
drive.
1. Check reducer rotation before mounting.
2. Lubricate backstop per manufacturers instructions.
STOP
Check motor rotation uncoupled or damage to backstop and other

components will result.
Drive Installation
General
Reducer(s) may be filled with a preservative for protection during shipment and storage.
Refer to tagging and manufacturers service manual instructions regarding draining and
flushing procedures.
Couplings, clutches, and internal backstops must be checked and filled with the proper
lubrication. Refer to the Drive Assembly tab in the manual for specific manufacturers
service instructions on proper types of lubrications and fill levels.
Coupling alignment(s) must be field checked whether motor and coupling is installed in
the field or were installed on drive base before being shipped to site. Alignment of drive
assemblies shipped completely assembled can be shifted during shipment.
Drive units with integrated backstops or holdback devices should be checked for correct
rotation before drive unit is installed on equipment. To check rotation, turn the input shaft
on the reducer by hand. This rotation check must be made prior to coupling motor to
reducer. The backstop is an emergency device only and should not be used to prevent
backward actions under normal conditions.
STOP
Motor must be checked for correct rotation before it is coupled to the

reducer.
Hollow Shaft Mounted Drives

The following points should be followed when shaft mounted drives are used.
1. Properly prepare head shaft and reducer hollow shaft as instructed in reducer
manufacturers literature. Make sure each shaft is thoroughly clean and free from
burrs.
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Installation
2. Check and fit key to keyway if one is used.

3. Properly locate reducer on the head shaft.
4. Install the torque arm to support the reducer at the proper angle.
5. Secure the reducer in place using Shrink disc, Tapered Bushing, or other locking
device supplied with drive. See locking device manufacturers instructions for proper
installation method and torque rating for fasteners.
2
3
6
5
8
4
REX-0041
Figure 4-42:
Hollow Shaft, Style R Reducer

1
2
3
4
5
6
7
8
Reducer R type
Coupling (fluid type shown)*
Motor
Torque arm support
Torque arm
Inching drive option
Shrink disk under cover
Bed Plate
*Guard removed to show coupling arrangement
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Installation
3
REX-0042
Figure 4-43:
Hollow Shaft, Style F Reducer

1
2
3
4
5
Motor
Reducer style F
Torque arm support
Torque arm
Belts and sheaves*
*Guard removed to show assembly
Solid Shaft Mounted Drives

The following points should be followed when using a solid shaft direct drive reducer:
1. The head shaft must be level and head and foot shaft alignment complete, before
aligning the reducer. This includes alignment of head and foot shafts and traction
wheels and/or sprockets.
Verify that the head shaft is in its final proper location before aligning the reducer.
Adjusting the head shaft after aligning the reducer will require re-aligning the reducer a
second time.
2. Verify that one half of the drive coupling (low speed) is mounted to the drive end of
the head shaft. If the coupling has not been mounted, position it onto the head shaft
following the coupling manufacturers instructions.
3. Position the reducer as shown on the installation drawings.
4. Adjust the reducer so that the gap between the two drive couplings (low speed) halves
Installation
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Installation
meets the coupling manufacturers specifications.

5. Use the four jackscrews provided with the reducer bed plate and shim under the
reducer as necessary to achieve proper drive coupling (low speed) alignment.
6. Secure the reducer to the bed plate when the proper drive coupling (low speed)
alignment has been achieved.
7. Follow the coupling manufacturers instructions for joining the drive coupling (low
speed) halves together.
8. Install all of the safety guards.
7
REX-0043
Figure 4-44:
Solid Shaft Mounted Drive

1
2
3
4
5
6
7
Low speed coupling*

Reducer Type R
Coupling (fluid type shown)*
Motor
Bed plate
Inching drive assembly Optional
Drive support
Drive Unit Mounted On Elevator Casing (Chain Drive)

The following points should be followed when mounting a drive reducer supported by the
elevator casings.
1. The head shaft must be level and head and foot shaft alignment complete, before
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Installation
aligning the reducer to the head shaft. This includes alignment of head and foot shafts
and traction wheels and/or sprockets.
Verify that the head shaft is in its final proper location before aligning the reducer to the
head shaft. Adjusting the head shaft after aligning the reducer will require re-aligning the
reducer a second time.
2. Reducer output shaft and the head shaft must be level and parallel to one another.
3. Both the driven sprocket mounted on the head shaft and the driver sprocket mounted
on the drive unit must be in line. They must also be located according to the position
and dimension given on the General Arrangement Drawing. See Shaft and Sprocket
or Shaft and Sheave Alignment, page 4-62 for detailed instructions on alignment.
1
2
7
8
REX-0044
Figure 4-45:
Drive Mounted on Elevator Casing (Chain Drive)

1
2
3
4
5
6
7
Installation
Inching drive Optional*

Main reducer
Coupling (elastomer type)*
Motor
Bed plate
Slide base
Chain and sprocket assembly*
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Installation
8 Drive support
Drive Unit Mounted Separate From Elevator

When an order covers standard elevator equipment and the elevator drive is located
independently from the elevator casing, our engineering responsibilities will be defined as
follows:
No engineering or contingent responsibility is assumed for the elevator drive located
independently on customers building steel, building floors, walkways, etc. It is assumed
that, in purchasing an individual elevator(s) with an independent drive support, full
consideration has been given to thermal expansion and the dampening of vibration that
may be detrimental to the drive machinery, elevator machinery, and/or to the structural
supports.
Belt Driven Reducer Installation

The following points should be followed when installing a reducer which is belt driven.
1. Adjust motor so that its output shaft is parallel to the reducers input shaft.
2. Align sheaves using a straight edge. Slide sheaves into the proper position on the
shafts and tighten setscrews. Do not drive sheaves on or off shafts.
3. The driven sheave mounted on the reducer and the driver sheave mounted on the
motor unit must be in line. They must also be located according to the position and
dimensions given on the drive assembly drawing. See Shaft and Sprocket or Shaft
and Sheave Alignment, page 4-62 for detailed instructions on alignment.
4. Adjust shaft centers of the motor and reducer so belts can be installed without force
them over the grooves in the sheaves.
5. Install belts as a set; all belts should be a matched length.
6. Tighten belts by increasing the shaft centers of the motor and reducer until belts are
taut.
7. Rotate belt and sheaves assembly to seat belts and retighten.
8. To set belt tension with a belt tension checker do the following:
a. Measure the center distance between the drive and driven shafts.
b. In general belts should be tightened so that there is 16 mm of deflection for every
meter (1/64 of deflection for every inch) between shaft centers measured in step a.
STOP
Do not overtighten belts or damage to shaft bearing could result.

9. Make sure all guards are installed properly before operating.
10. Check and retighten sheaves after the first 8 hours of operation. Install guards before
operating.
11. Check belt tension at least every 8 hours during the first two days of operation. During
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Installation
the first two days of operation it is normal for belt tension to require readjustment.
Install guards before operating
3
1
REX-0045
Figure 4-46:
Belt Driven Reducer

1
2
3
4
Sheaves*
Belts*
Motor
Reducer
*Guards removed to show belts and sheaves
Direct Driven Reducer Installation

The following points should be followed when installing a reducer which is direct driven.
1. Check and adjust end gap between motor output shaft and reducer input shaft.
2. Check and adjust angular and parallel tolerance to coupling manufacturers
specifications between motor output shaft and reducer input shaft.
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Installation
3. Install coupling to manufacturers specifications, tightening all hardware to the proper

torque values.
4. Install all guarding before operating.
1
2
3
4
Figure 4-47:
REX-0046
Direct Driven Reducer

1
2
3
4
5
6
7
8
Inching drive Optional

Drive chain Inching drive option*
Clutch coupling and sprocket Inching drive option*
High speed coupling (elastomer type shown)*
Motor
Bed plate
Slide base
Main reducer
*Guards removed to show componentry
Shaft and Sprocket or Shaft and Sheave Alignment

Proper alignment of shafts and sprockets/sheaves is necessary for maximum wear life.
Misalignment of shaft and sprockets will cause:
a. Rapid chain and sprocket wear due to rubbing of chain parts against sides of
sprocket teeth.
b. Rapid and excessive friction wear in chain joints from racking and twisting of
chain.
c. Bearing failure.
Misalignment of shaft and sheaves will cause:
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Manual 3520
a.
b.
c.
d.
4
Installation
Rapid belt wear and failure.

Rapid sheave wear.
Bearing failure.
Belts jumping off sheaves.
To assure proper alignment, the following steps are necessary:

1. Carefully level the shafting to the same plane. Use machinists level directly on shafts
to set horizontal alignment. See Figure 4-48.
REX-0047
Figure 4-48:
Level Shafts
1 Level
2. Check that each sprocket or sheave is axially aligned (perpendicular or 90) to its
respective shaft. Axial alignment of the sprocket or sheave can be checked in a
number of ways: rotating shaft and gauging OD of sprockets with fixed point on
straight edge or a dial indicator, or by rotating a square along the shafts axis and
checking the sprocket or sheave sits perpendicular to the square. See Figure 4-49.
Should a sprocket or sheave be out of axial alignment with the shaft correct the
alignment by:
a. For bored-to-size type sprockets or sheaves, loosen and reset hub setscrews.
b. For taper keyed hub, loosen and reset Gib-head tapered key.
c. For taper lock or compression type hubs, loosen and reset hub setscrews in
accordance with manufacturers instructions.
Installation
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Installation
REX-0048
Figure 4-49:
Axial Alignment Between Sprocket and Shaft or Sheave and Shaft

1 Dial indicator
2 Square
3. Adjust the shafts so that they are parallel by either method:
a. Measuring the distance between the shafts in three places (at each end and
somewhere in the middle) adjusting one or both shafts until all three areas
measured are equal distance apart. See Figure 4-50.
b. Placing a straight edge (or wire for long center distances) against the finished
surface of a sprocket or sheave and adjusting shafts so that there is an equal gap (or
no gap) across sprocket or sheave and straight edge or wire. Note: axial alignment
in Step 2 must be checked and/or corrected before using this procedure. Take care
to hold straight edge against finished surface on side of sprocket. See Figure 4-50.
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Installation
REX-0049
Figure 4-50:
Setting Shafts Parallel

1 Tape measure
2 Straight edge
4. Check sprockets or sheaves are on a common centerline using a straight edge or wire.
Check sprockets or sheaves are positioned upon the shafts as in accordance to
dimensions established on engineering drawings. See Figure 4-51. If a sprocket or
sheave must be moved to achieve a common center, make sure it is axially aligned
with shaft as in Step 2.
Installation
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Installation
REX-0050
Figure 4-51:
Setting Sprockets or Sheaves on Common Centerline

1 Straight edge
Drive Chain Installation

Proper installation of power drive chains is particularly important. Perform the following
items to install the drive chain.
1. Move one of the drive shafts towards the other to reduce the shafts center distance
and allow slack in the chain when placed over the sprockets.
2. Before placing chain on the sprockets make sure that the chain is oriented in the
proper direction. Straight sidebar roller chain does not have a preferred direction. All
steel offset sidebar drive chain with rollers should travel with the closed end forward.
See Figure 4-52.
Installation
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Installation
REX-0051
Figure 4-52:
Steel Offset Sidebar Drive Chain Direction of Travel

1 Direction of travel
STOP
Power drive chains must be operated in the proper direction to assure

maximum wear life of both chain and sprockets.
3. Wrap chain around sprockets.
4. Use the sprockets to hold the chain together when connecting the chain strand. The
sprocket teeth act as a wedge to facilitate forcing the links together against the weight
of the chain. The sprocket teeth will help hold the links in position when inserting the
pin. On larger drives it may be necessary to use a come-along to pull the loose ends of
the strands together in order to insert chain pin.
5. Rexnord recommends using a Rex chain tool when connecting chain which utilizes
press-fit pins.
If a hammer is to be used to drive the chain pins through the sidebars, always back-up
the chain strand. The back-up should be as big or bigger than the hammer used to drive
the pin.
6. Install pin-lock in hole of chain pin installed in Step 5, if chain utilizes them.
7. Check and adjust chain slack.
Chain Slack
The correct amount of slack is essential to the proper operation of the chain. Unlike belts,
chain requires no initial tension and should not be tightened around the sprockets.
When chain is too tight, the working parts carry a much heavier load than is necessary and
work much harder without delivering any more power than properly installed chain. This
causes rapid chain wear because of increased pressures in the joints. In addition, this
condition overloads and accelerates wear in the shaft bearings. See Figure 4-53.
Installation
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Installation
1
REX-0052
Figure 4-53:
Insufficient Slack, Binding

1 Insufficient slack in chain
2 Chain binding on sprockets
Too much slack is also harmful. On long centers particularly, too much slack will cause
vibration and chain flexure, reducing the life of the chain. On long centers, it is
recommended that the slack strand be supported or taken up by idler sprockets or strip
guides of hardwood or brass. The strip is simply a continuous support for the chain which
prevents it from sagging too much. See Figure 4-54.
1
REX-0053
Figure 4-54:
Excessive Slack
1 Excessive slack in chain
Properly adjusted chain drives should permit the slack strand to flex three percent (3%) of
the shafts center distance. As the chain wears and elongates, the chain slack should be
readjusted when the slack strand flexes up to five percent (5%) of the shaft center distance.
See Figure 4-55.
Installation
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Installation
B
2
Figure 4-55:
REX-0054
Correct Slack Example

1 Shaft centers = A in millimeters or inches
2 Slack in chain = B in millimeters or inches
Initially set slack to: Shaft centers A x 3% = minimum chain slack B.
Readjust slack when: Shaft centers A x 5% = maximum chain slack B.
Example:
Shaft Centers A = 1.5 m or 1500 mm
1500 mm x 0.03 = 45 mm
1500 mm x 0.05 = 75 mm
Initially adjust slack B to: 45 mm
Readjust slack B to 45 mm when equal to: 75 mm
When chain slack is excessive, adjustment can be made by moving the drive unit on the
slide base. When drive unit is completely extended on the slide base, or if sprocket shafts
are of fixed design, chain slack may be adjusted by removing one or more links.
The drive chain should be mounted with minimum number of chain links.
When a chain tightener is furnished, it should be adjusted periodically to maintain proper
chain slack. Remove chain link(s) when tightener cannot be adjusted further and slack is
still excessive.
Drive Chain Enclosure Installation

Proper installation of any drive chain enclosure is imperative to the safe and proper
operation of the equipment they are to be installed on.
Enclosures that have been improperly installed and/or aligned will damage shafting, allow
lubricants to leak and/or cause serious bodily injury
To insure proper installation of the drive chain enclosures use one of following procedures
that is appropriate for the type of guard supplied:
a. Installation of oil tight chain guard.
b. Installation of non-freestanding non-oil tight chain guard.
c. Installation of free standing non-oil tight chain guard.
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Installation
Installation of Oil-Tight Chain Guard

1. Calculate clearance between shaft and holes in drive chain enclosure. To calculate
clearance, perform the following:
a. Before opening the two halves of drive chain enclosure measure and record shaft
opening diameters in enclosure.
b. Find shaft diameters from either referencing manuals and drawings or by
measuring shafts and recording diameters.
c. Subtract the shaft diameters from the corresponding opening diameters in the drive
chain enclosure. Divide the result by two and record this number. The recorded
number is the gap that should be observed around the whole shaft and enclosure.
2. Open drive chain enclosure and remove contents.
3. Check contents* within enclosure, the following should be observed:
Quantity
Description
2
Neoprene impregnated cork seal 1/4 thick
1 roll
Split line seal rubber gasket 1/4 x 3/8
1 roll
Rubber gasket with adhesive backing 1/8 x 1/2
1
Site gage
1
Filler plug
1
Drain plug
* Contents listed for standard enclosures. Contents may vary in special
circumstances
4. Clean inside of guard, remove any dirt and debris.
5. Install neoprene impregnated cork shaft seal on shafts by twisting seal open as shown
in Figure 4-56. Split in seal should be above shaft.
2
REX-0081
Figure 4-56:
Installing Cork Seals on Shafts

1 Sprockets
2 Shaft seals
3 Chain line
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Installation
6. Raise lower half of casing into position while carefully guiding seals into the seal
channels. The use of blocks and/or chain hoists may be necessary to hold and adjust
lower casing in position. See Figure 4-57 and Figure 4-58.
1
2
Figure 4-57:
REX-0082
Installing Lower Half of Chain Guard

1
2
3
4
5
Installation
Reducer shaft or take-up

Fixed shaft
Lower half of chain guard
Drain plug
Site gauge
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Installation
1
7
2
2
1
12 mm
6
5
REX-0083
Figure 4-58:
Chain Guard Cross Section

1
2
3
4
5
6
7
8
Seal channel
Neoprene impregnated cork seal 6.35 mm (1/4) thick
Gap between casings and shaft
Oil fill level (oil should be 12 mm (1/2) above lowest point on chain)
Site gauge
Lower half of casing
Split line seal
Upper half of casing
7. Adjust lower casing so that there is proper gap (as calculated in Step 1c) between
casing and shaft.
8. Shift casing side to side to center hubs and sprockets within the sides of the casing
enclosure.
9. Install permanent support under lower half of drive chain enclosure. See Installation
of Chain Guard Support Bracing, page 4-74 for detailed instructions.
10. Remove any foreign material or tools from bottom half of drive chain enclosure.
11. Install site gauge in side of lower drive chain enclosure. See Figure 4-57.
12. Install drain plug in bottom of drive chain enclosure. See Figure 4-57.
13. Fill lower casing with oil until lowest point of chain dips in oil approximately 12 mm
(1/2). See Figure 4-58.
14. Mark this oil level on the sight gauge by painting or by lightly scoring a line on it.
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Installation
Mark a second line 6 mm (1/4) below the first line. These lines indicate the high and
low level in which the oil should be maintained.
15. Install split line seal material in groove of parting line if supplied. See Figure 4-58.
16. Lower the top half of casing into place starting with the large end first. Make sure the
shaft seals are started into the seal channels inside the top casing before pushing the
casings together.
In some cases it is easier to assemble the casing by starting at the smaller end.
17. Install bolts in the bolting clips at each end of the casing.
18. Make sure shafting does not make contact with guard at shaft openings. If contact is
observed, re-adjust mounting brackets attached to lower half of guard to obtain proper
clearance.
STOP
Damage to the head shaft and chain guard is imminent when contact
occurs. Premature head shaft failure and guard leakage is likely to result.
19. Finish welding the mounting brackets to the guard and to the equipment housing.
20. Install oil fill plug in top of upper casing.
21. Install gasket material around inspection door opening if guard is so equipped.
Installation of Non-Freestanding Non-Oil-Tight Chain Guard

1. Calculate clearance between shaft and holes in drive chain enclosure. To calculate
clearance, perform the following:
a. Before opening the two halves of drive chain guard, measure and record shaft
opening diameters in enclosure.
b. Find shaft diameters from either referencing manuals and drawings or by
measuring shafts and recording diameters.
c. Subtract the shaft diameters from the corresponding opening diameters in the drive
chain enclosure. Divide the result by two and record this number. The recorded
number is the gap that should be observed around the whole shaft and enclosure.
2. Open drive chain enclosure and remove contents.
3. Clean inside of guard, remove any dirt and debris.
4. Raise lower half of casing into position. The use of blocks and/or chain falls may be
necessary to hold and adjust lower casing in position.
5. Adjust lower casing so that there is proper gap (as calculated in Step 1c above)
between casing and shaft.
6. Shift casing side to side to center hubs and sprockets within the sides of the casing
enclosure.
7. Install permanent support under lower half of drive chain enclosure.
8. Remove any foreign material or tools from bottom half of drive chain enclosure.
9. Lower top half of casing into place starting the large end first. Note: in some cases it is
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easier to assemble casing by starting at the smaller end.

10. Install bolts in the bolting clips at each end of the casing.
observed, re-adjust mounting brackets attached to lower half of guard to obtain proper
clearance.
STOP
occurs. Premature head shaft failure is likely to result.
Installation of Freestanding Non-Oil-Tight Chain Guard

1. Place guard over drive chain and sprockets.
2. Shift guard so shafts are located in center of shaft openings and hubs and sprockets are
centered between sides of guard.
3. Mark floor at center of holes in bolting clip at each end of guard.
4. Remove guard from around drive chain and sprockets.
5. Prepare flooring for anchors at marks made in step Step 3.
6. Place guard around drive chain and sprockets and anchor to flooring.
observed, re-adjust guard by installing a shim between floor and guard mounting
brackets to obtain proper clearance.
STOP
occurs. Premature head shaft failure is likely to result.
Installation of Chain Guard Support Bracing

The chain guard support bracing supplied with a Rex Elevator (utilizing a chain guard) is
custom designed to fit that particular Rex Elevator. Therefore, a custom drawing is
supplied by Rexnord which provides the necessary instructions to install the support
bracing properly. The chain guard instructions can be found on the Chain Guard Support
Assembly drawing, under the tab labeled Drawings, within this Field Service
Manual.
Installation of Motion Sensor

The motion sensor is a device that detects motion of the chain and bucket assembly. The
motion sensor will de-energize (trip) indicating a problem when the chain and bucket
assembly is not traveling in the elevator at the proper rate of speed.
The motion sensor when de-energized or tripped, should perform the following two
functions:
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Installation
1. Warn operations personnel that there is a problem with the elevator that is causing the
chain and bucket assembly to have stopped or is moving slower than normal.
2. Shut down elevator and all equipment up stream feeding the elevator.
STOP
Elevator must be shut down immediately upon receiving a signal from the
motion sensor. Failure in shutting down elevator will result in extreme
chain wear/damage and eventually chain failure.
See elevators General Arrangement Drawings for location or placement of motion
sensing equipment.
For more information on the motion sensing equipment see the manufacturers literature
under the tab labeled Alarm/Switches.
The motion sensing equipment that comes standard with Rex elevators is the Milltronics
MFA-4 motion failure alarm. Other manufacturers motion sensing equipment are used in
Rex elevators only when customer specifications require it.
In most cases the Milltronics motion sensing equipment supplied by Rexnord will
consist of a main amplifier, preamp, and probe. In some cases the preamp may not be
supplied because it is built into the probe.
All Milltronics motion sensing equipment probes are located in the lower head section of
the elevator. The probe is located in the load end of the lower head unless site access or
plant process dictates an alternative placement. The probe should be installed in the lower
head so that there is a 50 mm (2") gap between the end of the probe and the end of the
bucket lip. See Figure 4-59.
Figure 4-59:
REX-0055
Motion Sensor Setting Gap Between Probe and Buckets

1 Probe
2 Preamp
Installation
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Installation
3 Gap between bucket and probe 50 mm (2")

Rexnord recommends that the preamp and main amplifier be mounted somewhere off the
elevator. A preamp mounted to an elevator casing over time has a tendency to develop
cracks in the electronic board.
Installation of Boot Flood Switch

A boot flood switch is a device that is activated when material has risen to a damaging
and/or dangerous level in the elevators boot section. The device when activated should
perform the following functions:
1. Warn operations personnel that there is a build up of material in the boot section.
2. Activate a shut down sequence of all equipment up stream feeding the elevator.
3. Shut elevator off approximately 1015 minutes after boot flood switch is activated.
STOP
Do not wire/program boot flood switch to immediately shut off the

elevator, or equipment down stream being fed by elevator.
See elevators General Arrangement Drawings for location or placement of the boot flood
switch.
For more information on the Boot flood switch see the manufacturers literature under the
tab labeled Alarm/Switches.
The boot flood switch may be called out on the General Arrangement Drawings as a
Bindicator. Rexnord has standardized on Bindicators Model A Bindicator in our
elevators. Other manufacturers boot flood switches are used in Rex elevators, when
customers specifications require it, these switches will be called out with the other
manufacturers name on the General Arrangement Drawings.
Installation
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Installation
Installation Checklist I - Pre-Initial Operation

Customer:
Customer No:
Installation:
Rexnord No:
Location:
Equipment:
Date:
Service No:
Report By:
Pages:
Table 4-B: Pre-Initial Operation Checklist

Item
No.
Checkpoint Description
1.
Foundation
Check concrete elevation.
Check anchor bolts for position and projection.
2.
Boot Section
Place the boot section over the anchor bolts. Make sure the
flanged inlet opening is facing the correct direction.
Level and plumb the boot section. Use a long carpenters level
to check the flanges, and plumb lines on the inside of the boot
section to check the walls for plumb. Place shims under the
bottom flange (of the boot) as required to level and plumb the
boot.
Boot grouted in place.
3.
Intermediate Casings
Install the intermediate casings in the order shown on Rexnord
drawing titled Erection Key.
Make sure that all inspection doors are orientated in the correct
position.
Make sure sealing compound is placed between all of the intermediate sections.
Each intermediate casing must be plumbed to a tolerance of
3 mm (1/8) maximum with respect to the boot section.
4.

Lateral support bracing and twin leg casing ties must be
installed around or on the elevator intermediate casing as
shown on the Erection Key drawing, before installing intermediate casings that are at higher elevations.
Do not weld lateral support bracing to elevator.
Installation
Completion
Date
Checked
By
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Installation

Item
No.
5.
Platform, Platform Collars, Grating and Handrails

Install lower platform support collar tie. Check plumb.
Install platform, grating and handrails as shown on drawings in
manual.
6.
Lower Head Section

Install the lower head as shown on Rexnord drawing titled
Erection Key.
Make sure that discharge end is orientated in the correct position.
Make sure sealing compound is placed between joint of lower
head and intermediate section or platform collar.
The lower head must be plumbed to a tolerance of 6 mm (1/4)
maximum with respect to the boot section.
7.
Upper Head Section

Head shaft dust seals are properly orientated.
Sealant is used between bolted flange connections.
8.
Ladder and Safety Cage

Install ladder as shown on Rexnord ladder drawing in manual.
Ladder is securely fastened to elevator.
Ladder has been mounted so that it can move with elevator as it
expands or contracts.
9.
Hoist Frame
Assemble hoist frame as shown on Rexnord hoist frame drawings supplied in the manual. Make sure hoist frame is
mounted to elevator in the proper orientation.
Make sure all hardware is properly tightened.
10.
Take-up Assembly and Take-up Guides

Install take-up centrally within the boot section according to
General Arrangement Drawings.
Make sure take-up moves freely within the take-up guides, and
that the proper clearances have been established.
11.
Head Shaft Installation

Head shaft is centralized within the lower head section.
A shim pack is installed under each bearing.
Head shaft is level within 0.25 mm/m (0.003 in/ft).
12.
Head and Foot Shaft Alignment

Head and Foot shaft are parallel.
Centerline of the traction wheel and or sprocket of the head and
foot shaft are aligned with each other.
Installation
Completion
Date
Checked
By
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Installation

Item
No.
13.
Chain Assembly/Installation
Chain is orientated in the proper direction.
Use Linkmaster chain tool to assemble chain sections
together.
Make sure chain joints flex freely.
Make sure proper amount of chain has been installed in elevator so tail shaft is located in proper position as stated in General Arrangement Drawings.
Make sure all pin-locks are installed in the chain pins.
14.
Bucket Installation
Buckets orientated in the proper direction.
Buckets installed with only the hardware specified on General
Arrangement Drawing.
Bearing plates were installed if called out on General Arrangement Drawings.
Bucket hardware tightened to the proper torque value specified
in the bucket bolt torque chart of this manual.
15.
Install Stop Blocks on Take-up Guides

Upper stop blocks are positioned 625 mm (1/41) from top
of take-up.
Lower stop blocks positioned to stop take-up from driving
buckets into bottom of boot.
Stop block mounting hardware is tight.
16.
Peeler Lip installation

Rubber lip adjusted to make slight contact with bucket lip.
Mounting hardware is tight.
17.
Backstop Installation
Assembled per manufacturers instructions.
Mounted on head shaft properly.
Oriented for the proper rotation.
Torque arm supported as shown on Rexnord drawings.
Lubrication has been installed in all required points.
All guarding is installed.
18.
Drive Installation
All drive components lubricated per manufacturers instructions.
All couplings have been aligned and tightened per manufacturers specifications.
Backstop has been checked for proper rotation.
Motor rotation checked uncoupled.
Installation
Completion
Date
Checked
By
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Installation

Item
No.
19.
Hollow Shaft Mounted Drive

Head shaft and reducer hollow shaft cleaned properly.
Reducer positioned on head shaft properly.
Locking device between reducer and head shaft is tightened as
specified by the manufacturer.
Torque arm installed properly.
20.
Solid Shaft Mounted Drive

Reducer output shaft is aligned with the head shaft to coupling
manufacturers specifications.
Low speed coupling is installed to manufacturers specifications.
21.
Drive Mounted (Supported) on Elevator Casing

Reducer output shaft and head shaft are parallel.
Drive and driven sprockets are in alignment.
Drive chain is installed in the proper direction and has the
proper slack.
22.
Belt Driven Installation

Shafts are parallel.
All drive sheaves are aligned and tightened properly.
Belts are all the same size and tensioned properly.
23.
Direct Driven Installation

End gap between motor and reducer is to drawing specification.
Coupling has been aligned to manufacturers specifications.
Coupling has been mounted and tightened to manufacturers
specifications.
24.
Chain Driven Installation

Shafts are parallel.
Sprockets are aligned and tightened properly.
Drive chain is oriented in the proper direction.
Connecting pin has been installed properly and joint flexes
freely.
Drive chain has been correctly tightened to allow proper slack.
Installation
Completion
Date
Checked
By
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Manual 3520
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Installation

Item
No.
25.
Chain and Belt Guarding

All guard mounting apparatus have been secured or tightened
properly.
All seals have been installed where required.
Guard does not make contact with the shafting, sprockets,
sheaves or other drive components.
Proper lubricant has been installed to the proper level where
applicable.
Guard is free of all dirt and debris.
26.
Motion Sensor
Gap between probe and bucket lip set at approximately 50 mm
(2").
Preamp and amplifier are mounted securely to something other
than the elevator.
All wiring has been performed.
27.
Boot Flood Switch

Boot flood switch mounted/orientated in the proper position.
Switch diaphragm returns back to original position after being
depressed.
All wiring has been performed.
Installation
Completion
Date
Checked
By
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Installation
Elevator Initial Operation

A very important and necessary part of installing a bucket elevator is placing it through a
constantly monitored, eight (8) hour, no load initial operation.
Initial operation as stated above is part of installing an elevator and as such is the
responsibility of the parities installing it to perform.
STOP
Before an elevator can be placed through initial operation, all proceeding

instructions and items in the Table 4-B, Pre-Initial Operation
Checklist, page 4-77 must be completed and checked.
General Safety Precautions

Taking into consideration all of the physical aspects of the installation, any or all of the
following safeguards are required to protect the operators or those working in the
immediate area of the elevator.
1. HOPPER GRATINGS Open hoppers should be provided with protective grating to
prevent contact with moving bucket line by personnel. Material in feed hopper must
not be poked or pushed with any item.
2. GUARDS For protection of operator and other persons in working area, purchaser
should provide guards for all exposed equipment such as drives, gears, shafts,
couplings, etc.
3. ELECTRICAL EQUIPMENT Electrical equipment conforming to the National
Electrical Code or the National Electrical Safety Code, including requirements for
the environment should be considered for the following functions:
a. Overflow Devices: Electrical interlocks to warn personnel and shut off power
whenever discharge of elevator is interrupted.
b. Overload Protection: To shut off power whenever operation of elevator is stopped
as a result of excessive material, foreign objects, excessively large lumps, etc.
c. Zero Speed Protection: Devices such as motion sensors to shut off power in the
event of any incident which might cause elevator to cease operating.
d. Safety Shut Off Switch: With power lock-out provision at elevator drive.
e. Emergency Stop Switches: Readily accessible wherever required and known to
proper personnel.
f. Electrical Interlocking: To shut down feeding conveyor whenever a receiving
elevator stops.
g. Signal Devices: To warn personnel of imminent start up of elevator, especially if
started from a remote location.
4. WARNING LABELS Warning Labels are positioned on the elevator at all
inspection doors, cleanout doors, and access doors. Do not remove or obscure these
labels. When painting the equipment, do not paint directly over the labels. Additional
labels may be obtained by writing to: Rexnord Industries Incorporated, Industrial
Chain and Conveyor, 4800 W. Mitchell St., Milwaukee, WI 53214, Attention:
Engineering Services.
Installation
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Installation
Operating Safety Instructions

All personnel working on and around the elevator must be familiarized with the following
safety instructions before the elevator can be placed in initial operation:
1. Be sure all debris, foreign objects and tools are removed from the elevator and
adjacent areas.
2. All removable plates, doors, covers and guards are properly secured in place before
operating elevator.
WARNING
Guards, doors, and covers must be securely fastened
before operating this equipment.
3. Doors, guards, removable plates and covers must never be opened or removed while
elevator is in operation.
WARNING
Doors should never be opened when unit is in
operation.
4. Elevator must be shut down and electrically locked out before removing any door,
guard, removable plate or cover.
5. Do not place any parts of the body or other objects into an elevator until all moving
parts have stopped, all power has been electrically locked out, and all potential stored
or residual energy has been rendered safe.
WARNING
Do not put hands, head, or other objects into the
openings unless drive unit is locked out.
6. Operation of interlocking controls, overflow or holdback devices, and safety controls
must be checked out by qualified personnel who thoroughly understand the manner of
operation and the function of every item of equipment. Auxiliary equipment feeding
the elevator must be electrically interlocked with elevator to prevent boot flooding
when elevator is not in operation.
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Installation
WARNING
Do not remove or bypass interlocking controls,

overflow, holdback devices, or safety controls.
Should any item be found to malfunction, replace or

repair before elevator is put into service.
Lock out power before removing guards, access doors

and covers.
Remember to replace guards, access doors, and covers

after completing repairs and before restoring power.
Failure to follow these instructions may result in

personal injury or property damage.
Initial Operation Procedure

Perform the following steps to initially operate the elevator.
1. Check that all work in preceding instructions has been completed and all items have
been checked off in Table 4-B, Pre-Initial Operation Checklist, page 4-77.
2. Check that all items have been addressed under General Safety Precautions, page 482.
3. Check that all personnel working on and around the elevator are familiarized with the
Operating Safety Instructions, page 4-83.
4. Complete one revolution of the chain and bucket assembly by jogging the drive to
check for proper assembly and clearances. Correct any deficiencies and jog elevator
again before continuing to next step.
5. Operate the elevator for eight (8) hours under no load. During the eight (8) hour noload period the elevator must be constantly monitored for the following:
a. Loud or unusual noise
Chain and bucket assembly hitting casings, loading legs, peeler lip, etc.
Jingling noise from loose buckets
Chain jumping on traction wheels or sprockets (elevator and/or drive chain)
Head shaft assembly
Drive assembly
Take-up assembly
b. Excess vibration
Head area
Drive unit
Boot area
c. Overheating
Bearings
Drive unit
d. Leakage of lubrication
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Installation
Drive Unit
Chain guard
Backstop
6. Periodically during the eight (8) hour no load operation, stop the elevator and check
for the following:
a. Evidence of contact or scrubbing between inside of chain sidebars and traction
wheels or sprockets.
b. Evidence of chain and bucket assembly contacting:
Loading legs
Steel portion of peeler lip assembly
Casings
7. Test the holdback device during initial operation. While the unit is operating, turn off
the power and check the holding action of the device. It should grab immediately
without allowing the chain and bucket assembly to reverse its direction of travel.
8. None of the above listed in Step 5 through Step 6 should be present if all installation
instructions in this manual were followed. If any problems are found during the initial
operation, shut down the elevator and correct them before completing the full 8 hour
run.
9. While operating the elevator adjust the main amplifier of the Milltronics motion
sensor to the normal operational speed of the elevator. Set the main amplifier so that it
is checking for UNDERSPEED. Adjust only the Start Delay and Pulses Per Minute
potentiometers and the Pulses Per Minute jumper at this time, all other work on the
Milltronics equipment must be performed while the elevator is off and all power is
locked out. The manufacturers instructions can be found under the tab labeled Alarm/
Switches.
WARNING
Installation
Only adjust the Start Delay and Pulses Per Minute

potentiometers and the Pulses Per Minute jumper on
Milltronics equipment while elevator is in operation.
All other work performed on the Milltronics equipment

must be performed while the elevator is stopped and all
power is locked out.
See manufacturers instructions of non-Milltronics

motion sensors on when and how to adjust equipment.
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Installation
Installation Checklist II - Initial Operation

Customer:
Customer No:
Installation:
Rexnord No:
Location:
Equipment:
Date:
Service No:
Report By:
Pages:
Table 4-C: Initial Operation Checklist

Item
No.
1.
All personnel working on and around the elevator are familiarized with all the safety instructions in the elevator manual before
operation.
2.
All debris, foreign objects and tools are removed from the elevator and adjacent areas before operating.
3.
All doors, guards, removable plates and covers are properly

secured in place before operating elevator.
4.
Jog chain and bucket assembly for one complete revolution to

check for proper assembly and clearance.
5.
Operate elevator with No-Load for 8 hours.
6.
During No-load operation check periodically for:

Loud or unusual noise.
Excessive vibration.
Overheating.
Leakage of lubrication.
7.
Periodically stop and lock out elevator during the initial operation
period and check for:
Contact or scrubbing between inside of chain sidebars and traction wheels or sprockets.
Evidence of contact between chain and bucket assembly and
other elevator components.
8.
Test holdback device during initial operation.
9.
Adjust Milltronics main amplifier to normal operational speed of

elevator.
Installation
Completion
Date
Checked
By
4 86

Manual 3520
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Installation
Table 4-C: Initial Operation Checklist

Item
No.
10.
Completion
Date
Checked
By
Shut off and lock out elevator to correct any deficiencies

observed during initial operation inspection, before completing
the rest of the eight (8) hour run.
Installation
4 87

Manual 3520
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Installation
Required Elevator Installation Follow-up Work

A very important and necessary part of installing a bucket elevator is performing the
Assembly Follow-up Work.
Assembly Follow-up Work as stated above is part of installing an elevator and as such is
the responsibility of the parities installing it to perform.
STOP
Before the assembly follow-up work can be performed on an elevator, all

proceeding instructions and items in the Table 4-B, Pre-Initial Operation
Checklist, page 4-77 and Table 4-C, Initial Operation Checklist, page 486 must be completed and checked.
Elevator must be shut off and all power locked out before starting any work on the
elevator.
Correct any deficiencies that were observed during the initial operating period of the
elevator.
Open doors and covers of the elevator and perform a thorough inspection. Inspect the
following areas as instructed below
WARNING
Guards, doors, and covers must be securely fastened
after completing inspections and work before
unlocking power and operating equipment.
Elevator Housing, Platforms and Hoist Frame

1. Inspect for loose or missing hardware throughout the whole elevator.
2. Inspect for holes and damage that may have been caused from interference between
the chain and bucket assembly caused from misalignment, loose bucket etc.
3. Inspect for loose or shifted grating, secure as shown in General Arrangement
Drawings.
Chain and Bucket Assembly

Initially, joints in new chain tend to be stiff and in turn may not hang completely straight.
During the initial operation the chain joints tend to loosen up and cause the chain to hang
straighter thus making the chain to appear to have grown.
1. Check take-up height to dimensions in elevators General Arrangement Drawings. If
take-up assembly is located near or below the lowest dimension on the drawings, it
may be necessary to remove a few pitches of chain and a bucket.
2. Retighten all bucket mounting hardware to the proper torque value. See Table 4A,
Bucket Bolt Torque Chart, page 4-41.
3. Prick punch bucket hardware directly behind the nut with a chisel or prick punch to
distort threads. Prick punching hardware is recommended but tack welding nut to bolt
Installation
4 88

Manual 3520
4
Installation
to distort the threads is acceptable. See Figure 4-28.
STOP

will result. Welding ground must be connected to bucket, to prevent
arcing through mechanical components.
4. Inspect chain and bucket assembly for damage from interference. If damage is found,
isolate the area where interference has taken place and correct the deficiencies.
5. Inspect inside of chain sidebars and outside of traction wheels or sprockets for
evidence of heavy contact or scrubbing between the components. If heavy contact is
observed check shafting alignment as instructed under Aligning Head and Foot
Shaft, page 4-18.
Buckets that were installed using Huck fasteners require no fastener retightening or prick
punching.
Take-up Assembly
1. Visually inspect take-up assembly for movement or shifting of components. If
anything has shifted, properly position shifted component(s) and check shafting
alignment as instructed under Aligning Head and Foot Shaft, page 4-18.
2. Inspect all mounting hardware in the take-up assembly for tightness; this includes stop
blocks, Rex NI-HARD bearings, body, traction wheels or sprockets, and take-up
guides.
3. Check position of upper stop blocks for proper gap between stop blocks and take-up
frame. Properly adjust the stop blocks. See Installing Stop Blocks on Take-up
Assembly, page 4-51.
Head Assembly
1. Visually inspect head shaft assembly for movement or shifting of components. If
anything has shifted, properly position shifted component(s) and check shafting
alignment. See Aligning Head and Foot Shaft, page 4-18.
If head shaft is shifted to align shafting, drive unit must be realigned to the head shaft
unless drive unit utilizes a hollow shaft reducer. Head shaft adjustment may also require
the torque arm to be shifted on drives that utilize the component.
2. Inspect adjustment of rubber peeler lip. Evidence of slight bucket contact should be
observed in the rubber peeler lip if properly adjusted. Replace rubber peeler lip if
damaged due to improper adjustment.
Drive Unit
1. Inspect all drive components for proper lubrication levels and/or leaks.
2. Visually inspect drive for moved or shifted component(s). If any components have
shifted, properly position shifted component(s) and recheck all drive alignments.
Installation
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Manual 3520
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Installation
3. Check tightness of all components utilizing set screws.

4. Inspect inside of drive chain sidebars and outside of drive sprockets for evidence of
heavy contact or scrubbing between the components. If heavy contact is observed
check sprocket and shaft alignment. See Shaft and Sprocket or Shaft and Sheave
Alignment, page 4-62.
5. Inspect belts and sheaves for excessive wear due to misalignment or improper belt
tension. See Shaft and Sprocket or Shaft and Sheave Alignment, page 4-62 and Belt
Driven Reducer Installation, page 4-60.
Operation
After completing all inspections, the necessary work above, and Installation Checklist III
- Required Installation Follow-up, the elevator is ready to be operated with material.
WARNING
Before an elevator can be operated with material, all
operators and personnel working on and around the
elevator must be familiarized with the safety and
operating instructions found in the operation section
of the manual.
Installation
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Manual 3520
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Installation
Installation Checklist III - Required Installation Follow-up

Customer:
Customer No:
Installation:
Rexnord No:
Location:
Equipment:
Date:
Service No:
Report By:
Pages:
Table 4-D: Required Installation Follow-up Checklist

Item
No.
1.
Lock out all power to elevator before starting any work.
2.
Correct any deficiencies that were noted during the initial operation of the elevator.
3.
Housing, platforms and hoist frame:

Inspect for loose or missing hardware.
Inspect for holes or damage.
Inspect for loose or shifted grating.
4.
Chain and Bucket Assembly

Compare take-up height to drawing dimension to see if the
proper amount of chain is installed in the elevator.
Retighten all bucket mounting hardware to the proper torque
value.
Prick punch bucket hardware.
Inspect chain and buckets for damage from interference.
Inspect inside of chain side bars and outside of traction wheels
or sprockets for evidence of heavy contact or scrubbing
between the components.
5.
Take-up Assembly
Inspect for movement or shifting of components.
All mounting hardware is properly tightened.
Proper gap between take-up frame and upper stop blocks.
6.
Head Assembly
Inspect for movement or shifting of components.
Inspect adjustment of rubber peeler lip.
Installation
Completion
Date
Checked
By
4 91

Manual 3520
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Installation
Table 4-D: Required Installation Follow-up Checklist

Item
No.
7.
Completion
Date
Checked
By
Drive Unit
Inspect all components for proper lubrication levels and/or
leaks.
Inspect for moved or shifted components.
Check all set screws for tightness.
Inspect inside of drive chain sidebars and outside of drive
sprockets for evidence of heavy contact or scrubbing between
the components.
Inspect belts and sheaves for excessive wear due to misalignment or improper belt tension.
Installation
4 92

Manual 3520
5
Normal Operation
Operating Criteria
Proper elevator operation starts with the operator(s) knowing the following design criteria
of the elevator:
1. Material elevator is designed to handle including:
a.
b.
c.
d.
Type of material
Maximum and minimum lump size of material
Maximum and minimum density of material
Maximum moisture content of material
2. Bucket volumetric capacity

3. Normal operating capacity
This information can be found in the application specifications box on the elevators
General Arrangement Drawing titled Specification Sheet.
Elevators handle material volumetrically, not by weight. This means that to handle the
normal operating capacity, the elevator must be fed material within its design criteria, and
at a uniform rate.
Successful operation of any elevator is dependent on controlled feed. Material must be fed
into an elevator at a controlled rate, within its rated capacity, or the boot will flood and
the elevator will eventually stall.
Under normal operating conditions, and to obtain the capacity specified, the buckets
should only be filled to the percentage of water level full stated on the General
Arrangement Drawing titled Specification Sheet.
Do not load buckets to the extent that material spills back down into the boot section. The
boot must not be allowed to pile up with spilled material.
Bucket elevators that are surge or batch fed are prone to rapid component wear and will
not handle the rated elevator design capacity.
Changing the material, material size, or material density from the design criteria can cause
the following:
STOP
Less capacity
Elevator Flooding
Rapid component wear, damage or failure
Uneven loading
Rex buckets are designed to travel at a speed and capacity adaptable to the
type of material specified in the design criteria.
Do not make any changes in material, material size, capacity, moisture
content, or speed of travel, without first consulting Rexnord Industries
Incorporated.
Normal Operation
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Manual 3520
5
Normal Operation
Start-up
Before starting any elevator, check for the following:
STOP
All debris, foreign objects and tools are removed from the elevator and adjacent areas.
All guards are in place on chain drives, couplings, and all moving or rotating parts.
All removable plates and inspection doors are properly secured in place.
All safety devices are working properly.
Auxiliary equipment feeding the elevator are electrically interlocked with elevator to
prevent boot flooding when elevator is not in operation.
Elevator buckets are empty.
Elevators should always be STARTED with buckets empty.

Starting under load places undue strain on chain and drive machinery.
WARNING
Guards, access doors, and covers must be securely

fastened before operating this equipment.
Lock out power before removing guards, access doors

and covers.
Remember to replace guards, access doors, and covers

before restoring power.
Do not remove or bypass interlocking controls,

overflow, or holdback devices, or safety controls.
Should any item be found to malfunction, replace or

repair before elevator is put into service.
Doors should never be opened when unit is in

operation.
Do not put hands, head, or other objects into the

openings unless drive unit is electrically locked out.
Failure to follow these instructions may result in

personal injury or property damage
Start-up and Operating Procedure

The operator(s) should become familiar with all aspects of the construction and normal
operating conditions of the equipment. Thereby, immediately recognizing an abnormal
situation or operating condition before serious damage occurs.
Perform the following instructions to startup and operate a bucket elevator:
1. Start equipment being fed by elevator prior to starting elevator.
2. Start bucket elevator and allow elevator to come up to full operating speed before
applying load (material).
3. Start equipment which feeds elevator after elevator is up to full operating speed.
Normal Operation
52

Manual 3520
5
Normal Operation
4. Apply load at a controlled rate within the capacity of the elevator.

5. Respond appropriately to any and all signals and alarms initiating from the elevator.
6. Periodically inspect elevator for the following during operation:
Loud or unusual noise

Excessive vibration
Bearings or drive overheating
Material leakage
7. Keep a record of all operating hours placed on elevator for maintenance purposes.
8. Record/log all problems and/or alarms experienced with the elevator.
9. Should a stoppage occur in the elevator for any reason, see the following: Motion
Sensor Alarm, page 5-4 and Boot Flood Alarm, page 5-3.
Shutdown Procedure
1. Shut off all feed to the elevator.
2. Always allow the elevator to operate until all buckets are empty. This is especially
imperative on elevators that are not furnished with a backstop, since any material left
in the buckets will empty into and flood the boot section.
STOP
Elevators should always be STARTED with buckets empty. Starting under

load places undue strain on chain and drive machinery. Therefore, it is
imperative to allow all buckets TO EMPTY BEFORE STOPPING
elevator.
3. Shutdown power to elevator.
Boot Flood Alarm

The boot flood alarm warns the operator that material has risen to a damaging and/or
dangerous level in the elevators boot section.
Allowing material to build up any higher within the elevator would cause tremendous
strain on the machinery and will eventually cause machinery failure and/or the elevator to
stall.
When the Bindicator or boot flood switch is activated, perform the following procedure
immediately:
1. Shut off all feed to the elevator.
2. Allow elevator to operate for approximately 10-15 minutes without feed to give the
elevator a chance to clean itself out.
3. Shutdown elevator and lock out power sources.
4. Remove boot access doors or back plate using caution in the event material has built
up sufficiently to create a hazard to personnel.
5. Empty excessive material in boot section and buckets.
Normal Operation
53

Manual 3520
5
Normal Operation
6. Inspect elevator and adjacent equipment and chuting for cause of alarm.
7. Correct any and all problems associated with the alarm.
8. Replace all access doors, plates, and guards.
Motion Sensor Alarm

The motion sensor alarm warns the operator that the chain and bucket assembly is not
traveling at the proper rate of speed.
Rapid wear and failure will result from excessive slippage or a complete stoppage of the
chain and bucket assembly.
When the Milltronics or motion sensor switch is activated, perform the following
procedure immediately:
1. The elevator and equipment feeding the elevator must be shutdown immediately.
2. Lockout all power sources to the elevator.
3. Remove boot access doors or back plate using caution in the event material has built
up sufficiently to create a hazard to personnel.
4. Inspect elevator for the cause of the alarm.
5. Correct any and all problems associated with the alarm.
6. Replace all access doors, plates, and guards.
Normal Operation
54

Manual 3520
6
Preventative
Maintenance
Preventative Maintenance Program

A Preventative Maintenance Program should be established as soon as the elevator has
been placed into operation. Your Preventative Maintenance Program should include
regular inspections of the elevator on a periodic basis.
Rexnord has established the following preventative maintenance program to be used as a
basis in establishing your Plant Preventative Maintenance Program. The preventative
maintenance program outlined here by Rexnord is the minimum amount of checks that it
expects of a plant to be performed during the life of the elevator. Particular conditions at
your plant may dictate a more frequent schedule.
The preventative maintenance program outlined by Rexnord has been broken into two
checklists, Table 6A, Monthly Inspection Checklist (approximately 700
Hours), page 6-2 and Table 6-B, Annual Inspection Checklist (approximately 8000
Hours), page 6-5. The two checklists are structured so that they can be photocopied and
used out in the field while inspecting the elevator.
Rexnord recommends that a binder be setup to accommodate the monthly and annual
inspection reports so good maintenance records are available to use in predicting when
components will require replacement and help in the trouble shooting process if a problem
should arise with the elevator.
61

Manual 3520
6
Preventative Maintenance Checklist I - Monthly Inspection

Customer:
Customer No:
Installation:
Rexnord No:
Location:
Equipment:
Date:
Service No:
Report By:
Pages:
Table 6A: Monthly Inspection Checklist (approximately 700 Hours)

Item
No.
1.
Rubber Peeler Lip

Replace rubber peeler lip if not intact or is heavily worn.
Adjust rubber peeler lip so buckets just touch it during operation.
2.
Buckets
Inspect buckets for marks or damage caused by interference.
Replace any missing or loose mounting hardware. Tighten all
replaced hardware to proper torque values.
Repair or replace any damaged and/or worn buckets.
3.
Chain Assembly
Check all sidebars and bushing ODs for uneven or deep wear
patterns.
Check insides of block links for heavy wear patterns from traction wheel or sprocket.
Check for missing pin-locks or cotters.
4.
Segmental Traction Wheels or Sprockets

Inspect for loose or missing mounting hardware.
Inspect for excessive wear on sides.
Inspect traction wheel to see if worn to, or past wear indicator.
Inspect sprockets for hooked, cracked or broken teeth.
5.
Pillow Block Bearings

Check temperature of housing.
Check housing for cracks and damaged seals.
Check for unusual noise.
Check for proper lubrication.
Clean away excessive material built up around bearing/seals.
Bolts are properly secured.
6.
NI-HARD Bearings
Inspect block and sleeve for damage.
Remarks
Date
Repaired
62

Manual 3520
6

Item
No.
7.
Take-up Frame, Take-up Guides and Stop Blocks

Ensure that take-up frame moves freely up and down take-up
guides.
Inspect take-up frame and take-up guides for wear and damage.
Check and adjust position of upper stop blocks.
Check all stop blocks mounting hardware is tight.
8.
Backstop
Backstop has not moved axially on shaft.
Breather plugs are clean.
Backstop is lubricated per manufacturers instructions.
No lubrication leaks present.
Check for unusual noise, vibration or excessive heat.
All guarding is installed and fastened securely.
9.
Drive Unit (including motor)

Drive base torque arm or mounting bolts are all secure.
No unusual noise, vibration or excessive heat coming from any
of the components.
No lubrication leaking from any of the components.
Breather plug is clean and clear.
10.
Drive chain and sprockets

Check drive chain for proper slack.
11.
Drive belt(s) and sheaves

Belt(s) are in good shape and are properly tensioned.
No evidence of misalignment between sheaves.
Sheaves are not damaged or worn.
No oil or grease on belt(s) or sheaves.
12.
Chain and Belting Guarding

properly.
No leaks around seals.
Lubrication is to the proper level were applicable.
Remarks
Date
Repaired
63

Manual 3520
6

Item
No.
13.
Boot Section:
Inspect for material leakage around doors and loading chute.
Inspect for structural damage, holes, corrosion, and interferences.
Inspect any liner plates and or loading legs.
Remove all material that has built up on the bottom and sides.
14.
Platform, Grating, Handrails, Ladder, Safety Cage and Hoist

Frame:
Check all are clean of debris and material.
Check for loose hardware, damage and corrosion.
Remarks
Date
Repaired
64

Manual 3520
6
Preventative Maintenance Checklist II - Annual Inspection

Customer:
Customer No:
Installation:
Rexnord No:
Location:
Equipment:
Date:
Service No:
Report By:
Pages:
Table 6-B: Annual Inspection Checklist (approximately 8000 Hours)

Item
No.
1.
Rubber Peeler Lip

Replace rubber peeler lip if not intact or is heavily worn.
Adjust rubber peeler lip so buckets just touch it during operation.
2.
Buckets
Remove any material built-up on buckets
Inspect buckets for marks or damage caused by interference.
Replace any missing or loose mounting hardware. Tighten all
replaced hardware to proper torque values properly.
Repair or replace any damaged and/or worn buckets.
3.
Chain Assembly
Check all sidebars and bushing ODs for uneven or deep wear
patterns.
Check insides of block links for heavy wear patterns from traction wheel or sprocket.
Check for missing pin-locks or cotters.
Check and record chain wear by performing yearly chain
inspection outlined in maintenance section.
4.

Inspect for loose or missing mounting hardware.
Inspect for excessive wear on sides.
Inspect traction wheel to see if worn to, or past wear indicator.
Remarks
Date
Repaired
65

Manual 3520
6

Item
No.
5.
Pillow Block Bearings

Check temperature of housing.
Check housing for cracks and damaged seals.
Check for unusual noise.
Check for proper lubrication.
Clean away excessive material built up around bearing/seals.
Bolts are properly secured.
6.
NI-HARD bearings
Measure wall thickness at top of bearing block; Thickness
3 mm (1/4) or less replace complete bearing.
Inspect block and sleeve for damage.
7.
Head Shaft and Body (ies)

Check body(ies) is/are positioned properly on shaft - No movement axially.
Check that all set screws, locking devices, keys, and hardware
securing body(ies), driven sprocket, backstop, etc. are in
good condition, properly seated and tight.
8.
Foot Shaft and Body(ies)

Check body(ies) is/are positioned properly on shaft - No movement axially.
Check that all set screws, locking devices, keys, and hardware
securing body(ies) are in good condition, properly seated and
tight.
9.
Take-up Frame, Take-up Guides and Stop Blocks

Ensure that take-up frame moves freely up and down take-up
guides.
Inspect take-up frame and take-up guides for wear and damage.
Check and adjust position of upper stop blocks.
Check all stop blocks mounting hardware is tight.
10.
Backstop
Check torque arm is supported properly - all bolts holding
bracket or stirrup holding end of torque arm are secure.
Backstop has not moved axially on shaft.
Breather plugs are clean.
Backstop is lubricated per manufacturers instructions.
No lubrication leaks present.
Check for unusual noise, vibration or excessive heat.
Remarks
Date
Repaired
66

Manual 3520
6

Item
No.
11.
Drive Unit (including motor)

Drive base torque arm and mounting bolts are all secured.
No unusual noise, vibration or excessive heat coming from any
of the components.
No lubrication leaking from any of the components.
Breather plug is clean and clear.
12.
Drive chain and sprockets

Check chain and sprockets for evidence of misalignment.
Check drive chain for proper slack.
Check chain for missing pin-locks or cotters.
13.
Drive belt(s) and sheaves

Belt(s) are in good shape and are properly tensioned.
No evidence of misalignment between sheaves.
Sheaves are not damaged or worn.
No oil or grease on belt(s) or sheaves.
No interference between guard and sheaves or belts.
14.
Chain and Belt Guarding

properly.
No leaks around seals.
Lubrication is to the proper level were applicable.
15.
Motion Sensor
Motion probe in good condition - not been damaged.
Gap between probe and bucket lip set at approximately 50 mm
(2").
Preamp and amplifier are mounted securely.
Wiring is in good shape.
Motion sensor is adjusted properly to operating speed of equipment.
All interlocks work properly when the switch is activated.
Remarks
Date
Repaired
67

Manual 3520
6

Item
No.
16.
Boot Flood Switch

Boot flood switch mounted securely.
Diaphragm is in good shape.
Switch diaphragm returns back to original position after being
depressed - switch moves freely.
Wiring is in good shape.
Interlocks work properly when the switch is activated.
17.
Foundation:
Check grout, concrete, and/or steel, supporting base of elevator
is in good condition.
Check nuts on anchor bolts for tightness.
Check area around foundation is clean of debris and material.
18.
Boot Section:
Inspect for material leakage around doors and loading chute.
Inspect for structural damage, holes, corrosion, and interferences.
Inspect any liner plates and or loading legs.
Remove all material that has built up on the bottom and sides.
19.
Intermediate Casings and Collars:

Inspect for material leakage around all casing flanges, inspection doors and panels.
Inspect for structural damage, holes, and corrosion.
Remove all material that has built up on the sides.
20.

Inspect lateral support for cracked welds and loose or missing
hardware.
Inspect bracing for proper gap around casings for expansion.
Make sure gap between bracing and casing is free of debris and
material.
21.
Upper and Lower Head Sections:

Inspect for material leakage around doors flanges, discharge
chute, and shaft seals.
Inspect for structural damage, holes, and corrosion.
22.
Platform, Grating, Handrails, Ladder, Safety Cage and Hoist

Frame:
Check all are clean of debris and material.
Check for loose hardware, damage and corrosion.
Remarks
Date
Repaired
68

Manual 3520
6
Chain Elongation Measurements Worksheet

Equipment:
Location:
Customer No:
Rexnord No:
Report By:
Date:
Chain No.:
Chain Type:
Date Installed:
Hours in Operation:
Refer to Table 7A, Chain Elongation Measurements, page 7-6

to fill out the following:
Number of pitches (X) to measure across:
Length of (X) number of new chain pitches:
Maximum wear length of (X) number of chain pitches:
Measure chain length in three separate areas of each chain strand! Record measurements
below.
1st Chain strand measurements
*2nd Chain Strand measurements
1st
2nd
3rd
*This column is not required for single
strand elevators
Table 6-C: Actual Chain Measurements
If chain measurements equal or exceeds maximum wear length of (X) number of chain
pitches, measure the chain pins and bushings as follows.
Maintenance Note
When chain elongation measurement is at maximum, plan replacement schedule.
Measuring chain pins and bushings will help in determining the time frame for
replacement.
69

Manual 3520
6
Chain Elongation Pin and Bushing Measurements Worksheet

Equipment:
Location:
Customer No:
Rexnord No:
Report By:
Date:
B
C
Block Link
Trailing End
Leading End
Direction Of
Travel
20
Measure Leading Pin Diameter - (PD1)

PD1a
PD1a
PD1b
PD1b
Measure Trailing Pin Diameter - (PD2)
PD1c
PD1c
PD2a
PD2a
PD2b
PD2b
PD2c
PD2c
Refer to Table 7-B, page 7-7 in the Maintenance section to fill out the following:
New Pin Diameter
Maximum Pin Diameter Wear
6 10

Manual 3520
Measure Leading Bushing Inside diameter(BID1)
6
Measure Trailing Bushing Inside diameter(BID2)
BID1a
BID2a
BID2b
BID2b
BID1a
BID1b
BID2a
BID2b
Refer to Table 7-B, Maximum Wear Measurements Of Pin OD & Bushing ID, page 7-7 to fill out the
following:
New Bushing ID
Maximum Bushing ID Wear
Measure Leading Bushing outside diameter(BOD1)
Measure Trailing Bushing outside diameter(BOD2)
BOD1a
BOD2a
BOD1b
BOD1a
BOD1b
BOD2b
BOD2a
BOD2b
Refer to Table 7-C, Maximum Wear Of Bushing OD, page 7-8 to fill out the following:
New Bushing OD
Maximum Bushing OD Wear
6 11

Manual 3520
7
Maintenance
Rubber Peeler Lip Adjustment

The adjustable rubber peeler lip in Rex elevators is an expendable item and must be
inspected at least once a month.
The rubber lip is designed with slotted mounting holes so it can be adjusted as the rubber
wears around the bucket area. The rubber lip requires replacement if it is ripped or all of
the travel in the slotted holes has been used. For replacement, use #50-60 Durometer live
rubber.
For replacement or adjustment instructions see Installing/Adjusting Rubber Peeler Lip,
page 4-52.
Bucket Inspection
Buckets, due to the function they perform must be periodically inspected.
Buckets observed to be worn or damaged must be repaired or replaced.
Accelerated wear and/or damage to the buckets is caused in a number of ways, some
examples are:
Improper material (type, size, temperature, moisture content) fed into elevator.
Elevator is fed too much material or is back legging, forcing buckets to dig material
from boot.
Foreign objects introduced into the elevator (tramp iron, tools, etc.).
Improper operation of elevator.
Interference with other parts/components of the elevator.
Corrosive materials.
Buckets can be inspected in any of three areas of the elevator, at the boot section; at the
head section; or the three door intermediate section if the elevator is so equipped. In
general, bucket inspection is easiest at the three door intermediate section.
The following work should be performed when inspecting buckets:
1. Remove any material build-up from buckets.
2. Replace any loose or missing bucket mounting hardware. Tighten hardware to the
proper torque value found in Table 4A, Bucket Bolt Torque Chart, page 4-41.
3. Inspect buckets for signs of interference with other elevator components. Inspect,
isolate, and repair problem causing interference.
4. Repair or replace any missing, damaged, cracked, or worn buckets.
An elevator bucket is constantly being loaded (stressed) and unloaded (unstressed), or
stress cycled. Over many years of operation the buckets will start to fatigue and crack. The
following illustration depicts the most likely areas in which a bucket will crack.
Maintenance
71

Manual 3520
7
Maintenance
REX-0057
Figure 7-1:
Bucket Fatigue Cracks Example

Replace any buckets that are cracked as shown above. If a large portion of the elevators
buckets are cracked, arrange to replace all buckets within the elevator at the earliest
convenience.
STOP
Buckets routinely required to dig material from the boot section due to
improper operation of the elevator, are prone to premature bucket cracking
similar to the diagram above. Rexnord will not warranty buckets that have
failed due to improper operation of the elevator.
Bucket Removal and Replacement

The following instructions are to be used to remove buckets from a chain assembly or
when replacing a few damaged or worn buckets. See Bucket Installation, page 4-41
when installing buckets into an elevator that has been re-chained.
Buckets can be removed and/or replaced in any of three areas of the elevator, at the boot
section; at the head section; or the three door intermediate section if the elevator is so
equipped. In general, bucket installation is easiest at the three door intermediate section.
Maintenance
72

Manual 3520
7
Maintenance
WARNING
Always block chain before entering elevator.
Unbalanced chain strands can star t to rotate
in elevator and serious injur y or death can
result.
1. Remove buckets by cutting the mounting hardware holding the buckets to the chain. A
torch or chisel may be used to cut hardware. When cutting with a torch do not gouge
chain or buckets.
STOP
When removing bucket mounting hardware with a torch do not induce heat
into chain and/or gouge chain or buckets.
STOP
Never save mounting hardware for reuse. Always install new mounting
hardware to mount buckets in an elevator. The use of old hardware to
mount buckets will result in failure and damage to elevator. Old hardware
is fatigued due to operation, and can not be properly tightened due to prick
punching of threads.
2. Install buckets in the elevator noting proper orientation. Always use new mounting
hardware to mount bucket to chain.
3. Tighten bucket to the proper torque value listed in Table 4A, Bucket Bolt Torque
Chart, page 4-41.
4. Mark the back of replacement buckets so that they can be retightened and prick
punched after 8 hours of operation.
Keep chain strands balanced, always remove and replace a worn or damaged bucket
before moving on to the next.
Chain Assembly Inspection

Rex elevator chains are applied in an elevator at loads below their fatigue limit to assure
that breakage is not a factor during their normal wear life. However, the following will
accelerate wear or cause the chain to fail before the normal wear life can be achieved:
Excessive traction wheel slippage due to overload or jamming of foreign material.
Misalignment of elevator.
Boot flooding.
Grinding or heating of chain pins or sidebar holes to ease assembly.
Improper chain assembly.
Installing new chain on worn/used traction wheels or sprockets.
An elevator chain failure can be very costly to repair due to downtime, expense, damage,
and chain replacement therefore, every effort should be made to regularly inspect and
maintain the chain.
Maintenance
73

Manual 3520
7
Maintenance
There are several types of inspections that should be made throughout the chains service
life.
Monthly visual inspections
Annual visual inspection and non-destructive inspections
Three year thorough analysis of a two pitch sample of the chain
Monthly Chain Inspection

Visually inspect the elevator chain at least once a month for the following:
1. Check chain pins for missing cotters. Replace any cotters that are missing.
2. Check inside block links for unequal wear from traction wheel or sprocket. Heavy
wear on the inside of the side block is usually an indication of misalignment.
3. Check the outside diameter of all bushings for uneven or deep wear patterns and for
small areas of chain that appear to have had the bushings ground or plastic flow of
surface material (appears melted). Uneven or deep wear occurs when the wear life
of a sprocket has been exceeded or worn traction wheels and sprockets have been used
on new chain. If only a small section of chain bushings appear to be ground or
melted, the chain and bucket assembly was stalled and the traction wheel was left to
spin on one section of chain.
4. Visually inspect clearance between each set of inner and outer sidebars. Excessive
clearance suggests pin fracture. Remove pins where excessive clearance indicates pin
fracture. If more than two fractured pins are found, replace the entire chain at earliest
convenience.
5. Correct/repair any and all problems observed during the inspection before placing
elevator back into operation.
Annual Chain Inspection

Chain elongation (stretch) is the result of wear between the chain pins and bushings as
they articulate over traction wheels and/or sprockets. Rexnord case hardens the outside of
the chain pins and all surfaces of the chain bushings to combat this wear and to maximize
the life of the chain. When the hardened case of the pins and/or bushings has been worn
through, the wear rate drastically accelerates and chain failure will shortly follow.
Due to the case hardening of the pins and bushings, wear is consistent and chain life is
predictable. Chain life is predicted by measuring chain elongation and recording the
measurements with the number of hours the chain has been in operation, and comparing it
with tabulated data found within this manual.
By measuring and recording chain elongation and total operational time and comparing it
with tabulated data within this manual, chain life can be predicted allowing chain to be
replaced before failure occurs.
Chain wear should be measured and recorded at least once a year. More frequent wear
measurements maybe required/beneficial in determining the proper time to replace the
chain as it gets closer to the end of its wear life.
1. Perform Monthly Chain Inspection, page 7-4.
Maintenance
74

Manual 3520
7
Maintenance
2. Check chain parts for fatigue.

a. Pins: Hammer test all pins for soundness. Replace all fractured pins. If more than
two fractured pins are found, replace the entire chain at earliest convenience.
b. Sidebars: Visually inspect all sidebars at pin and bushing holes for cracks. Remove
links which have cracked sidebars and replace. However; if more than three links
have cracking at pin and/or bushing holes, schedule immediate replacement of
chain.
c. Attachments: Visually inspect the bend line of all attachments. Replace any
attachments with cracks.
3. Measure chain wear by performing the following Procedures.
Procedure No. 1 - Measuring Overall Length of X Number of Chain Pitches
1. Accurately measure and record a length of chain (number of pitches shown in
Table 7-B, page 7-7) as shown in Figure 7-2. Take at least three measurements in
different areas of the chain assembly; record each value.
2. Compare measured values with corresponding chain figures given in Table 7A,
page 7-6.
3. If chain has elongated more than maximum wear value in Table 7A, page 7-6,
proceed to Procedure No. 2 - Measuring OD of Chain Pins and ID of Chain
Bushings, page 7-6.
To accurately measure chain, always start and finish tape measure on same end of pin,
cotter end to cotter end as shown in Figure 7-2 or from head end to head end (not shown).
Make sure when measuring from cotter end that the end of the tape is on the chain pin and
not caught on the pin-lock or cotter.
REX-0058
Figure 7-2:
Maintenance
Measuring Chain Elongation
75

Manual 3520
1
2
3
4
7
Maintenance
One pitch of chain

Length of chain between set number of chain pitches
Cotter end of chain pin
Head end of chain pin
Length
Chain Number Number of Pitches

ER-111
ES-833
ER-856
SJM or ER-857
SJM or ER-859
SJM or ER-864
SJM or ER-956
SJM or ER-958
ER-979
SJM or ER-984
ER-1084
16
12
12
12
12
12
12
12
12
12
12
Unworn
Maximum Wear
mm
inches
mm
inches
1934.46
1828.80
1828.80
1828.80
1828.80
2133.60
1828.80
1828.80
1828.80
2133.60
2133.60
76.16
72.00
72.00
72.00
72.00
84.00
72.00
72.00
72.00
84.00
84.00
1992.50
1874.52
1874.52
1874.52
1874.52
2180.54
1874.52
1874.52
1874.52
2180.54
2180.54
78.44
73.80
73.80
73.80
73.80
85.85
73.80
73.80
73.80
85.85
85.85
Table 7A: Chain Elongation Measurements

Procedure No. 2 - Measuring OD of Chain Pins and ID of Chain Bushings
1. Randomly remove 4 to 5 pins from chain assembly.
2. Measure and record the pins outside diameter (OD) and bushings inside diameter
(ID) Measure pins and bushings at heaviest wear areas. See Figure 7-3, Figure 7-4
and Chain Wear Analysis, page 7-9
3. Compare measured values with the corresponding dimensions listed in Table 7-B,
page 7-7.
As stated earlier, the wear rate of the pins and bushings drastically accelerates when they
are worn through the hardened case. The following limits recorded in Table 7-B, page 77 reflects the maximum wear allowable in the pins and/or bushings before chain requires
replacement.
Maintenance
76

Manual 3520
7
Maintenance
Pin OD
Chain Number
Unworn
mm
ER-111
ES-833
ER-856
SJM or ER-857
SJM or ER-859
SJM or ER-864
SJM or ER-956
SJM or ER-958
ER-979
SJM or ER-984
ER1084
19.05
19.05
25.40
25.40
31.75
31.75
25.40
28.27
34.92
34.92
41.27
inches
Bushing ID
Maximum
Wear
mm
0.750 16.51
0.750 16.51
1.000 21.91
1.000 21.91
1.250 27.81
1.250 27.81
1.000 21.91
1.113 24.89
1.375 30.86
1.375 30.86
1.625 35.941
Unworn
inches
mm
0.650
0.650
0.865
0.865
1.095
1.095
0.865
0.980
1.215
1.215
1.415
19.56
19.56
26.04
26.04
32.26
32.26
26.04
29.16
35.48
35.48
41.91
inches
Maximum
Wear
mm
inches
0.770 21.21
0.770 21.21
1.025 28.22
1.025 28.22
1.275 35.56
1.275 35.56
1.025 28.22
1.150 31.39
1.400 38.74
1.400 38.74
1.650 45.085
0.835
0.835
1.111
1.111
1.400
1.400
1.111
1.236
1.525
1.525
1.775
Table 7-B: Maximum Wear Measurements Of Pin OD & Bushing ID

Each judgement should be based upon projected wear to predict replacement of the entire
chain before wear exceeds the values given above. More frequent inspections may be
required if wear is approaching the limits listed in Table 7-B, page 7-7.
STOP
If wear of pins and bushings meet or exceed the levels shown in Table 7B, page 7-7, chain should be replaced during the next shutdown, assuming
the shutdown will take place within three months after the measurements
were taken.
Bushing Outside diameter (OD) should be inspected for signs of rapid wear due to
sprocket scrubbing or traction wheel slippage. Measure the Bushing OD and compare the
measurement with the dimensions listed in Table 7-C, page 7-8.
Maintenance
77

Manual 3520
7
Maintenance
Bushing OD
Chain Number
ER-111
ES-833
ER-856
SJM or ER-857
SJM or ER-859
SJM or ER-864
SJM or ER-956
SJM or ER-958
ER-979
SJM or ER-984
ER1084
Unworn
Maximum
Wear
mm
inches
mm
inches
36.576
36.576
44.450
44.450
60.325
60.325
44.450
50.800
63.500
63.500
72.390
1.440
1.440
1.750
1.750
2.375
2.375
1.750
2.000
2.500
2.500
2.850
34.036
34.036
41.148
41.148
55.499
55.499
41.148
47.498
58.674
58.674
67.564
1.340
1.340
1.620
1.620
2.185
2.185
1.620
1.870
2.310
2.310
2.660
Table 7-C: Maximum Wear Of Bushing OD

If OD wear exceeds values given Table 7-C, page 7-8, exposure of the pin may be
imminent requiring immediate replacement of chain.
STOP
Operation of elevator with exposed chain pins will result in chain failure.
Three Year Chain Analysis (Program) Inspection

After any new elevator chain has operated for approximately three years, a representative
sample of the worn chain should be removed from the elevator and submitted to Rexnord
for analysis.
Rexnord will perform destructive and nondestructive tests to the chain sample to analyze
its wear, heat treatment and chain construction.
A technical report will be made and sent to customer by Rexnord with recommendations
that advises when the chain should be replaced and/or if corrective action is required to
improve chain and/or elevator performance.
A good time to get a representative chain sample from an elevator is when the following
two conditions exist:
The chain has been in operation for at least three years.
The take-up assembly requires adjustment within the boot section due to chain
elongation.
When the two conditions above are met the chain links removed from the elevator to
adjust the take-ups height can be sent into Rexnord for analysis, eliminating the need for
replacement links.
To have Rexnord analyze a chain sample perform the following:
1. Remove a two pitch representative sample of chain from the elevator by non
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Maintenance
destructive means. Set aside the chain sample and the two chain pins removed from
chain assembly to remove the two pitch sample.
STOP
Do not remove chain sample from elevator by cutting chain with a torch.
Damage will occur to chain assembly left in the elevator and to the chain
sample. Due to inaccurate results, Rexnord will not perform an analysis
on chain that appears to have been removed from elevator improperly.
2. Install new (replacement) links in chain assembly to replace worn sample if needed
and/or connect carrying and return strands of chain.
3. Contact Rexnord Industrial Chain & Conveyor for a return material authorization
number (RMA) and shipping instructions for chain sample.
4. Ship the two pitch chain sample and the two chain pins set aside in Step 1, along with
chain history and total hours in operation.
5. Perform any corrective work on elevator as advised in Rexnord chain analysis report
sent back to customer.
Chain Wear Analysis

The following chain analysis information is provided to help maintenance personnel
identify normal and abnormal chain wear.
A few of the more common problems observed in elevators are illustrated, for more
information on chain analysis contact Rexnord.
Chain Pins
Normal chain pin wear occurs during articulation of the chain around the traction wheel. A
chain pin handling a dry abrasive material will normally wear similar to Figure 7-3.
REX-0084
Figure 7-3:
Pins With Normal Pin Wear

When taking wear measurements of Outside Diameter of pin for the annual chain
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Maintenance
inspection, always measure the pin at the chain joint bearing surface, rotating tool until the
maximum wear area is read.
Dry cavitation is erosion of the chain joint bearing surfaces similar to Figure 7-4.
3
1
2
REX-0085
Figure 7-4:
Pins Worn by Dry Cavitation

1 Leading pin
2 Trailing pins
3 Areas heavily worn by dry cavitation
Dry cavitation greatly decreases the life of the chain. Dry cavitation is not normal chain
wear, but is often observed in elevator chains that are operated regularly with a flooded
boot, in powdery abrasive material.
The dry cavitation cycle starts when the boot is flooded with material and the conveyed
material enters the chain joint (between the chain bushing and pin). When the chain moves
up the carrying side of the elevator, the working force in the chain joint increases, which
compresses and forces flow of the material out of the joint. Extremely high wear occurs
when the material is forced out of the chain joint. As chain joints wear more material can
penetrate the joint in the relaxed state in the boot which accelerates the process.
To eliminate dry cavitation from occurring in an elevator the chain must not be operated
through the material being conveyed (eliminate boot flooding). Operation and
maintenance personnel must work together to isolate the reason(s) why the boot section is
flooding with material and correct the problem(s).
If dry cavitation can not be eliminated because of a design or operation problem that cant
be changed, contact Rexnord Industrial Chain & Conveyor for other options.
Chain Bushings
Normal wear of the inside diameter of the chain bushing occurs during articulation of the
chain around the traction wheel. A chain handing a dry abrasive material will normally
wear the inside diameter of the bushing similar to Figure 7-5.
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Manual 3520
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Maintenance
20
REX-0059a
Figure 7-5:
Normal Bushing Wear, Inside Diameter

The inside diameter of the bushing does not wear along the chain pitch line but rather
below it at about 20 depending on the traction wheel or sprocket diameter.
Keep in mind, when measuring inside diameter of bushing as directed in the annual chain
inspection, to rotate measuring tool approximately 20 from the chain pitch line to get an
accurate wear reading.
1
2
REX-0086
Figure 7-6:
Bushing IDs Worn by Dry Cavitation

1 Leading bushing
Maintenance
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Manual 3520
7
Maintenance
2 Trailing bushing
3 Heavy wear in bushing ID due to dry cavitation
Normal bushing wear on the outside diameter (OD) occurs due to the interaction with the
traction wheels and/or sprockets.
The leading bushing of a block link always wears more/faster than the trailing bushing.
The leading bushing wears more because, it contacts the traction wheel or sprocket first,
rotating against it as the chain goes from a straight line to an arc.
1
3
REX-0060
Figure 7-7:
Block Link
1 Leading bushing
2 Trailing bushing
3 Direction of chain travel
Bushing wear on the outside diameter does not effect chain elongation. It also does not
effect chain strength unless the bushing is worn through the hard face surface and traction
wheel or sprocket is allowed to make contact with the chain pin.
REX-0087
Figure 7-8:
Bushing ODs With Normal Wear From Traction Wheel

1 Leading bushing
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Manual 3520
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Maintenance
2 Trailing bushing
REX-0088
Figure 7-9:
Bushing ODs With Normal Wear From Sprocket

1 Leading bushing
2 Trailing bushing
STOP
Operation of elevator with exposed chain pins will result in chain failure.
If pins are exposed schedule immediate replacement of chain.
Installing Replacement Chain in Elevator

Replacement chain can be installed in an elevator in a number of ways. The best way
depends on the location and access to the elevator.
Rexnord recommends when at all possible, replacement chain be installed through the
boot section of the elevator and pulled through the elevator with the old chain strand, on
double chain strand elevators in which each bucket is connected to two chain strands the
buckets must be removed before the procedure can be followed. In many cases it is easier
to remove the buckets from the old chain on single chain strand elevators also. The
procedure below covers how to pull new chain into the elevator with the old chain and
bucket assembly.
If the old chain and bucket assembly has been removed from the elevator prior to
installing the replacement chain follow the procedure Installing Chain in an Elevator,
page 4-27.
When there is minimal access to the boot section it is possible to install the replacement
chain at the head end of the elevator, but the old chain and bucket assembly will need to be
removed prior to installing the new chain.
Installation Note
For instructions on installing chain sections at the head end of the elevator follow the
directions found in the Installation chapter of the manual for the following topics:
Maintenance
Pre-assembling Chain and Buckets, page 4-37
Rigging and Lifting Pre-assembled Chain and Buckets, page 4-39

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Maintenance
Installing Pre-assembled Chain and Buckets, page 4-41
Before starting to install elevator chain, the take-up should be positioned at its upper end
of travel to provide for maximum adjustment. To accomplish this, tie off the take-up to the
lifting beam assembled in the top of the boot section. See Figure 4-11: Cutaway of
Boot Positioning/Setting Take-up and Guides, page 4-14.
Customers or contractors planning on pre assembling buckets to chain prior to chain
installation must read Pre-assembling Chain and Buckets, page 4-37 before proceeding.
Rexnord recommends that chain be installed in the elevator first before installing buckets.
To install replacement chain in an elevator, perform the following steps:
1. Secure the old chain and bucket assembly in the elevator so that it can not rotate in the
elevator.
2. At the boot section, use a Linkmaster chain tool to remove a chain pin and separate
the return and carrying runs of the chain. Do not separate the chain with the use of a
torch. A good chain end is needed so the new chain can be attached later.
3. Two replacement chain sections (shipping lengths) should be connected together just
outside the end door under the loading chute in the boot section. To avoid twisting or
bending, no more than six meters (twenty feet) of chain should be connected together
outside of the elevator during installation. Be sure to orient the chain sections in the
proper direction before assembling.
STOP
Make sure all chain joints flex freely. This is especially important on
double strand elevators were the chain attachments on one chain strand
must be aligned and level with the other strand, so the buckets will hang
straight/level in the elevator. See Chain Assembly, page 4-22 for more
information.
4. Connect the two replacement chain sections assembled in Step 3 to the carrying run
end of the old chain and bucket assembly at the boot section. Use a Linkmaster chain
tool to install the chain pin. Make sure that the new replacement chain is oriented the
same as the old chain.
5. Connect a line between what ever is to be used to pull the old chain and bucket
assembly out of the elevator and to the return end of the old chain. Pull the old chain
and bucket assembly out of the elevator while pulling new chain into the elevator.
Remove the rigging used to secure the old chain and bucket assembly in Step 1 before
pulling chain and bucket assembly. The old chain and bucket assembly pulled from
the elevator can be cut off outside the elevator and the line reattached to the remaining
chain and bucket assembly in the elevator if space is at a premium.
6. Pull the new replacement chain into the elevator until approximately 1.5 meters (5 ft.)
of it is still outside the elevator casing. Be sure that the chain is oriented properly. See
the General Arrangement Drawings located under the tab labeled Drawings for
proper orientation.
STOP
Maintenance
Do not feed the chain into the elevator on its side. Prevent the possibility
of twist by feeding it in the manner shown in Figure 4-17: Lifting Chain,
page 4-22.
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Maintenance
7. Connect two more shipping sections of replacement chain approximately 6 meters (20
ft) to the end of the replacement chain still outside the boot section.
8. Pull attached replacement chain into the elevator by pulling old chain and bucket
assembly out, leaving approximately 1.5 meters (5ft) of replacement chain outside the
elevator.
9. Keep performing Step 7 and Step 8 until all of the new replacement chain is installed
in the elevator.
WARNING
On double chain strand elevators install one chain
strand complete before installing the second strand;
so no work time is spent under rigged chain. Falling
chain can cause personal injury or death.
10. Connect the chain strand halves at the boot section. Hold the chain securely with
rigging before proceeding to connect halves. Use a come-along or a chain fall to draw
the chain ends together. Install the chain pin using a Linkmaster chain tool or
equivalent. See Chain Assembly, page 4-22 and Linkmaster Chain Tools, page 426 for more information.
11. Lower the take-up onto the chain making sure the traction wheel(s) or sprocket(s) is/
are positioned on the chain properly.
12. Check the elevators General Arrangement Drawing for proper height of the foot
shaft. The center of the foot shaft should be located within the take-up measurement
given on the drawing. The foot shaft should be positioned as close to the upper limit of
the take-up measurement as possible without going above. It may be necessary to
remove a two-pitch section of chain to achieve the proper foot shaft setting.
13. Remove all rigging used to support the chain before proceeding onto bucket
installation.
Installation Note
Rexnord may ship extra chain with the elevator, it is the contractors responsibility to
install the correct amount of chain to properly position foot shaft as indicated in the
General Arrangement Drawings located under the tab labeled Drawings.
STOP
Do not mount buckets to the chain until the chain has been completely
installed and all connections made in the elevator.
Pre-assembled Chain and Bucket Assemblies

Rexnord provides the option of having the buckets mounted to the chain when purchasing
replacement chain and buckets. The buckets can be mounted to the chain with either nuts
and bolts or Huck fasteners.
This option is available for elevators with buckets mounted on a single strand of chain
only!
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Maintenance
STOP
Do not order buckets pre fastened to the chain unless the chain and bucket
assemblies will be installed at the head end of the elevator with a crane.
STOP
Buckets designed to be installed on two strands of chain must never be

pre-assembled to chain.
STOP
Removal of the old chain and bucket assembly from elevator must be
completed before the new pre-assembled chain can be installed. The old
chain and bucket strand can not be used to drag in new pre-assembled
chain and bucket assemblies at the boot as provided instruction suggests
when installing new chain section (without buckets connected).
STOP
Dragging pre-assembled chain and buckets will damage the components.

Always move pre-assembled chain and bucket assemblies with a crane and
always install them at the head end.
Pre-assembled chain and bucket assemblies from Rexnord are crated flat with the bucket
lips down as shown in Figure 4-26: Pre-assembling Chain and Bucket Assemblies,
page 4-39. Each crate will contain one or more assemblies. The assemblies will be
stacked on top of each other, separated with a sub floor to allow each assembly to lie flat.
For ease of transporting and to safe guard against damage, keep assemblies crated until
they are ready to be installed. Unopened crates can be easily moved around the job site
with a forklift.
Before opening crated assemblies:
Move crates in an area where the crane operator can easily view and pick up assemblies
without dragging them.
Make sure crate is oriented properly so bucket lips are facing down as shown in
Figure 4-26: Pre-assembling Chain and Bucket Assemblies, page 4-39.
For instructions on installing pre-assembled chain and buckets see Rigging and Lifting
Pre-assembled Chain and Buckets, page 4-39 and Installing Pre-assembled Chain and
Buckets, page 4-41.
Head Shaft Assembly Removal and Replacement

Head Shaft Removal
To remove the head shaft perform the following:
1. Remove the upper head section.
2. Remove approximately 8 to 10 buckets from the chain around the head wheel so chain
can be easily supported and disconnected.
3. Remove the upper stop blocks and lift the take-up assembly to its upper end of travel.
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Manual 3520
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Maintenance
Use the take-up lifting beam located inside the top of the boot section to rig from and
lift the take-up.
4. Install structural beams across the bearing channels of the lower head section to
support the chain. See Figure 4-21: Preparing Elevator For Chain Installation,
page 4-29.
STOP
It is up to the customer/contractor to determine the structural beam size

needed to support the chain and how to attach/support it on the elevator.
See Elevators General Arrangement Drawings for the weight of the chain and buckets
5. Support the chain strand(s) from the beams installed in Step 4 on the chains return
and carrying runs using come-alongs and/or chain hoists so chain strand(s) can be
disconnected.
6. At the head section, use a Linkmaster chain tool to remove a chain pin (from each
chain strand) and separate the return and carrying runs of the chain. Wrap loose ends
of chain over beam supporting chain so they are out of the way and can be easily
wrapped around segmental rim later. Do not separate the chain with the use of a torch.
7. Disconnect drive from shaft. Remove or disconnect direct connected or shaft mounted
drive from the shaft following the manufacturers instructions or on chain driven
units, remove the upper half of the chain guard and separate the drive chain by
removing a chain pin.
8. Disconnect the external backstop from the elevator if equipped.
9. Loosen and remove the bearing mounting bolts.
10. Place slings around head shaft and lift out of elevator. Save any shims that were under
bearing blocks. Keep the shims from each side separated.
See Elevators General Arrangement Drawings for the weight of the head shaft assembly.
Head Shaft Replacement

To install the head shaft perform the following:
1. Lift/place head shaft assembly on lower head.
2. Follow the instructions given under Head Shaft Installation, page 4-15 and Aligning
Head and Foot Shaft, page 4-18.
3. Wrap loose ends of chain strand(s) back over the traction wheel or sprocket making
sure chain is properly seated on the rim.
4. Reconnect the return and carrying runs of the chain strand(s) by using a Linkmaster
chain tool to install the chain pin(s). See Chain Assembly, page 4-22 for information
on installing chain pins into chain sections.
5. Release the tension from the equipment used to support the chain and remove it from
the head section of the elevator.
6. Reinstall the upper head section. See Upper Head Section, page 4-10.
Maintenance
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Manual 3520
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Maintenance
Foot Shaft Assembly Removal and Replacement

In most cases the foot shaft is only removed from an elevator when the NI-HARD
bearings are replaced. To remove or replace the foot shaft follow the procedure given in
NI-HARD Bearing Replacement, page 7-37.
Assembling Components to a Shaft

When assembling components onto a shaft, always locate the components by measuring/
referencing one end of the shaft only (on a head shaft locate all components from the drive
end). See Figure 7-10.
STOP
Always reference one end of a shaft only to locate all shaft assembly
components to the shaft. Locating components on a shaft using both ends
of the shaft or by measuring from one mounted component to another will
result in improperly positioned components and operational problems.
5
W
(REF)
X
Y
Z
2
REX-0061
Figure 7-10:
Head Shaft Assembly

1 Set and locate all components by measuring from this end of shaft
2 Centerline of driven sprocket
3 Centerline of bearing
4 Centerline of sprocket or traction wheel
5 Reference dimension Do not use to locate components
In most cases it is easier to install the component that is located furthest from the end of
the shaft being measured from first, then installing the next furthest component, and the
next, until all the components are mounted.
Components which make up a shaft assembly can be mounted to a shaft in a number of
ways. Make sure to install the components onto the shaft properly, using the
manufacturers instructions.
Maintenance
7 18

Manual 3520
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Maintenance
a. Locking assemblies or Taper bushing should be installed per the manufacturers

instructions.
b. Gib head tapered keys used to mount components to shafts must be properly fitted
by experienced personnel. Do not drive a Gib head tapered key without first
properly fitting it.
c. Straight keys should be checked for fit by experienced personnel before being
installed. Any set screws or other hardware used to hold a key must be tightened to
the proper torque values specified by the manufacturer of the component.
STOP
Never weld on shaft. Welding components to a shaft or repairing a shaft

by welding will result in shaft failure.

Rex segmental traction wheels and/or sprockets are supplied on Rex elevators for ease in
maintenance. In general the working face (area which makes contact with the chain) of a
traction wheel or sprocket will wear out and require its replacement, but the hub should
never wear or require replacement. Because of this, a complete Rex traction wheel or
sprocket consists of two main components, a segmented traction wheel rim or segmented
sprocket rim (working face) and a body (hub).
The traction wheel or sprocket rim is split into three or more sections which can be easily
mounted or unmounted from the body. By splitting the traction wheel or sprocket into two
components, a traction wheel or sprocket can be replaced without the need to remove the
bearings and disturb the shafting alignment.
The body consists of the hub and a machined area in which to fasten the segmental traction
wheel or sprocket. The body is available with either a solid or split hub. Generally, since
the hub will never have to be replaced, solid hubs are used on new installations, while the
split hub is more convenient for replacement installations. For most situations, Rexnord
recommends using bodies with solid hubs over split hubs.
Segmental rim traction wheels and sprockets are initially fastened with Huck fasteners.
The Huck fasteners are tightened with a special hydraulic tool that eliminates initial run-in
and retightening operations required of other fasteners used to hold the segmental rims to
the body.
The bodies are held in place on a shaft in a number of ways, locking assemblies, Gib head
tapered keys or straight keys with set screws. In general, new installations will have bodies
that are held to the shaft with a locking assembly.
Maintenance
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Manual 3520
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Maintenance
REX-0062
REX-0063
Figure 7-11:
Segmental Rim Sprocket and Traction Wheel
REX-0064
Figure 7-12:
Split Hub
REX-0065
Figure 7-13:
Solid Hub With Locking Assembly
REX-0066
Figure 7-14:
Maintenance
Solid Hub With Tapered Keyway

7 20

Manual 3520
STOP
7
Maintenance
A traction wheel(s) or sprocket(s) located on the head shaft must be

changed every time a new chain is installed in the elevator or accelerated
wear will result in both the chain and the traction wheel(s) or sprocket(s),
decreasing the service life.
Rexnord recommends a traction wheel(s) or sprocket(s) located on the foot shaft be
replaced at the least, every other time the chain is replaced.
STOP
DO NOT LUBRICATE A TRACTION WHEEL.
Segmental Traction Wheel or Sprocket Inspection

Inspect Traction wheels and sprockets on a monthly basis.
The working face of a Rex traction wheel is hardened to extended the service life of the
component. See Figure 7-15. The hardened surface of the traction wheel is approximately
3 mm (1/8) deep. When the hardened surface is worn off, the traction wheel must be
replaced or rapid wear and failure will be eminent.
1
REX-0067
Figure 7-15:
Traction Wheel Cross Section

1 Working surface Very hard 3 mm (1/8) thick
2 Hard material
3 Bevel Wear indicator
Maintenance
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Manual 3520
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Maintenance
4 Un-heat treated zone material

The working face of a sprocket like a traction wheel is hardened to extended the service
life of the component. See Figure 7-16. The hardened surface of the sprocket is
approximately 3 mm (1/8) deep. When the hardened surface is worn off, the sprocket
must be replaced or rapid wear and failure will be eminent.
When a sprocket starts to show a worn hooked tooth pocket, the hardened surface has
been depleted and the sprocket must be replaced.
REX-0068
Figure 7-16:
Sprocket
1 Working face Very hard 3mm (1/8) thick
2 Hard material
3 Un-heat treated zone material
4 Sprocket tooth
5 Sprocket pocket
When inspecting traction wheels and/or sprockets check for the following:
Excessive wear on the side of traction wheel or sprocket; indicating in many cases
misalignment.
Loose or missing segmental mounting hardware.
Evidence of body wobbling on the shaft.
Loose bolts in locking assembly or loose set screws.
Items specific to Traction wheels (Replace traction wheel rim if any of the following
are found):
a. Rim working face is worn close or past indicator on the side of the traction wheel.
b. Flat spots on working face of rim.
c. Evidence of spalling on rim face.
d. Big chunks broken out of rim face. Note: Small chips missing at the end of
segments is normal; traction wheel does not require replacement.
Items specific to Sprockets (Replace sprocket if any of the following are found):
a. Tooth wear indicated by hooking in the pockets.
b. Broken or cracked teeth.
Maintenance
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Manual 3520
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Maintenance
Segmental Traction Wheel or Sprocket Replacement Kit

Replacement segmental rim traction wheels or sprockets are sold/supplied as a kit. The kit
includes the segmental rim and the Grade 5 fasteners (bolts, nuts, and washers) used to
mount them onto the body. See Figure 7-17 or Figure 7-18.
REX-0070
Figure 7-17:
Segmental Sprocket Replacement Kit Shown With Standard

Fastener Package
1 Segmental sprocket rim
2 Hardware kit Bolts, washers, nuts
1
REX-0071
Figure 7-18:
Segmental Traction Wheel Replacement Kit Shown With Optional

Huck Fasteners
1 Segmental traction wheel rim
2 Optional Huck fastener kit Huck bolts, collars
Maintenance
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Manual 3520
7
Maintenance
Upon customer request, Rexnord will substitute and supply Huck fasteners for the bolts
and nuts.
Huck fasteners are used initially to fasten a segmental rim to a body from Rexnord.
Maintenance Notes
Always keep the segments, of a segmental rim traction wheel or sprocket kit tied together,
so segments from one rim are not mixed with another. Segmental rims are cut into
segments randomly, however segments of one rim may be very close in size (length) to
another rim and therefore not easily rematched.
To provide for ease in replacement of a segmental rim, one rim segment is always
fabricated to be a little longer than the others. Using a three segment rim as an example,
two of the segments will be very close in length, but the third will be longer. By providing
this arrangement, the longer section of the old sprocket can be removed and replaced with
one of the shorter segments from the new rim avoiding any wedging and binding of the
segments. The longer segment of the new rim will always be installed last.
Segmental Traction Wheel(s) or Sprocket(s) Kit Installation

A segmental rim traction wheel or sprocket must be replaced in its entirety. New segments
of a segmental rim must not be installed among used segments or segments from another
new rim.
Because the size (outside diameter) of segmental rims varies slightly, the rim segments
must be installed in a specific order. To ensure segments are installed properly the
segments of a rim are match marked and one segment drilled with a pilot hole. See Figure
7-19.
1
A A
REX-0072
Figure 7-19:
Matchmark Sequence
1 Segmental splits
2 Matchmarks On one side only
3 Pilot hole
Maintenance
7 24

Manual 3520
STOP
7
Maintenance
New segmental rim assemblies must be installed as a unit, in its entirety.

Each rim segment will be lettered for identification purposes.
The traction wheels or sprockets on a dual strand elevator shaft must be replaced in pairs.
Failure to replace both segmental rims located on one shaft will result in uneven chain
loads, excessive chain and segmental rim wear, and chain failure.
When installing new traction wheel or sprocket rims on a dual strand elevator shaft, the
matchmark/trademark side of each rim must face the same shaft end and the pilot hole in
each rim must be directly across from each other. Also the bolt or huck fasteners used to
mount the rim to the body must be oriented so the head is against the body flange. See
Figure 7-20.
2
2
1
REX-0077
Figure 7-20:
Orienting Matchmarks and Trademark to Same End of Shaft

1 Trademark and matchmark side of split rims facing same end of shaft
2 Segmental rim
3 Body flange
4 Huck bolt
5 Huck collar
Both Rex bodies and the segmental rims have a pilot hole. Rexnord initially assembles
the rims and bodies with the pilot holes aligned. Upon replacement of the segmental rims
(following proper replacement procedures) the pilot hole between the rim and the body
may not be aligned, but on dual chain strand elevators the pilot holes in the segmental rims
must be aligned with one another.
STOP
It is imperative that the pilot holes in segmental rims on dual chain strand
elevators are properly aligned as well as having the trademark/matchmark
letters face the same shaft end.
Before installing replacement segmental rim traction wheel(s) or sprocket(s), it is
imperative that the mating (machined) surfaces of the rim flange and the body be free of
all foreign materials. The mating surfaces must be cleaned of all materials like grease, oil,
Maintenance
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Manual 3520
7
Maintenance
paint, rust preventative coatings, and metallic burrs to insure a good mating of the contact
surfaces prior to installation of the fasteners.
Maintenance Note
If Huck fasteners are used to hold replacement segmental rims to bodies: Substitute bolts
and nuts for Huck fasteners while installing replacement segmental rims. After all the
segments of the replacement rim are in place and spaced evenly around the body, replace
the bolts with the Huck fasteners.
The fasteners required for each set of rims must be either Grade 5 or ASTM Grade 325
heat treated fasteners.
Bolt Diameter
Torque Value
Inches
Nm
ft lb.
5/8
3/4
1
244
433
962
180
320
710
Table 7-D: Segmental Traction Wheel or Sprocket Mounting Bolt Torque Table
STOP
It is imperative that the torque value of the segmental rim bolts, as

indicated above, be achieved after the new rims are installed (use grade 5
bolts or ASTM grade 325 only).
Installation of Segmental Rims On Foot Shaft

1. Open doors on the sides of the boot section.
2. Remove the upper stop blocks and lift the take-up assembly to its upper end of travel.
Use the take-up lifting beam located inside the top of the boot section to rig from and
lift the take-up.
3. Cut fasteners holding old rim(s) to body(ies). Cut fasteners from the rim side of the
joint so body is not damaged.
4. Bolt the new rim segment with a pilot hole to the body, making sure the pilot hole in
the rim and the body are aligned. Snug the mounting bolts at this time.
STOP
It is critical that the pilot hole in the segmental rims of a dual chain strand
elevator are aligned with one another.
5. Bolt the remainder of the new rim segments to the body, making sure the matchmarks
are oriented properly. On dual chain strand elevators make sure the matchmarks of
both segmental rims are oriented so they can be seen from one end of the shaft. See
Figure 7-20.
6. Adjust the segments on the body so that the gap between the segments is even.
7. Tighten the bolts to the proper torque value listed in Table 7-D, page 7-26 or replace
bolts and nuts with Huck fasteners at this time.
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8. Lower the take-up onto the chain making sure it engages the chain properly.
9. Remove all equipment used to support the take-up.
10. Reinstall the upper stop blocks into the take-up guides. See Installing Stop Blocks on
Take-up Assembly, page 4-51 for installation and setting instructions.
11. Retighten the segmental rim mounting bolts to the proper torque value in Table 7-D,
page 7-26 after operating the elevator with or without material for 100 hours. After
retightening the bolts, prick punch or tack weld the bolt directly beneath the nut. Omit
this step if Huck fasteners were used to mount the segmental rims.
STOP

will result.
Installation of Segmental Rims on Head Shaft by Breaking Chain

1. Perform Step 1 through Step 6 under Head Shaft Removal, page 7-16
2. Cut fasteners holding old rim(s) to body(ies). Cut fasteners from the rim side of the
joint so body is not damaged.
3. Bolt the new rim segment with a pilot hole to the body, making sure the pilot hole in
the rim and the body are aligned. Snug the mounting bolts at this time.
STOP
elevator are aligned.
4. Bolt the remainder of the new rim segments to the body, making sure the matchmarks
are oriented properly. On dual chain strand elevators make sure the matchmarks of
both segmental rims are oriented so they can be seen from one end of the shaft. See
Figure 7-20: Orienting Matchmarks and Trademark to Same End of Shaft, page 725.
5. Adjust the segments on the body so that the gap between the segments is even.
7. Wrap loose ends of chain strand(s) back over the traction wheel or sprocket making
sure chain is properly seated on the rim.
8. Reconnect the return and carrying runs of the chain strand(s) by use of a Linkmaster
chain tool to install the chain pin(s). See Chain Assembly, page 4-22 for information
on installing chain pins into chain sections.
9. Release the tension from the equipment used to support the chain and remove it from
the head section of the elevator.
10. Lower take-up and reinstall stop blocks.
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Maintenance
STOP

will result.
Installing Segmental Rims On Head Shaft, Without Breaking/Removing Chain

The following procedure can only be used to replace segmental rims on elevators that have
inching drives or where there is no inching drive, the input shaft of the reducer can be
rotated by hand.
STOP
Never perform the following procedure using the main drive motor or
damage to the elevator will result.
There are four subroutines under this procedure. Each subroutine is written for replacing
rims with a certain number of segments. The proper subroutine to follow depends on the
number of segments in the new rim and the number of segments in the old rim. Count the
number of segments, and plug the subroutine that matches the number of segments each
rim incorporates into the procedure below.
The following procedure is to be used with all the subroutines found below it:
1. Remove the upper head section.
2. Rotate the elevator with the inching drive or by rotating the input shaft of the main
reducer by hand so the rim segment stated for removal in the subroutine step being
followed is located under the head shaft and is not engaged with the chain.
3. Remove the first old segment(s) listed in the subroutine by cutting the fasteners
holding old rim(s) to body(ies). Cut the fasteners from the old segment(s) and the old
segments in proceeding step, from the rim side of the joint so the body is not damaged.
4. Bolt the new rim segment(s) specified in the subroutine in the area(s) where the old
segment(s) was/were removed. Initially bolt the new rim segments to the body, do not
use Huck fasteners. Snug the mounting bolts at this time. On dual chain strand
elevators make sure the matchmark markings are the same (example AB, AB) and the
matchmarks face the same end of the shaft on the new segment installed on each body
Also make sure the corresponding ends, teeth and/or pilot holes of each segment are
aligned with the other.
STOP
elevator are aligned with one another.
5. Perform steps 24 of this procedure for each step in the subroutine being followed
(until all the segments of the new rim(s) are installed).
6. Check/adjust the segments on the body(ies) so that the gap between the segments is
even.
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STOP

will result.
Subroutine for Replacing 3 Piece Segmental Rim with a New 3 Piece Segmental Rim
REX-0072a
Figure 7-21
1. Remove old segment BC and replace it with new segment CA.
2. Remove old segment CA and replace it with new segment AB.
3. Remove old segment AB and replace it with new segment BC.
REX-0072a
REX-0073
Figure 7-22
1. Remove old segment BC and replace it with new segment CD. Segment CD is much
smaller than the old segment, so install segment CD so there are 2 empty holes on one
end of the segment and 3 empty holes on the other end.
2. Remove old segment CA and replace it with new segment DA. Butt the D ends of
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Manual 3520
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Maintenance
new segments CD and DA together.

3. Remove old segment AB and replace it with new segments AB and BC, keeping the
matchmarks of the new segments in sequence.
REX-0072a
REX-0074
Figure 7-23
1. Remove old segment BC and replace it with new segments FA and AB, butting A
ends together.
2. Remove old segment CA and replace it with new segment BC and CD. Butt the C
ends of new segments BC and CD together.
3. Remove old segment AB and replace it with new segments DE and EF, keeping the
matchmarks of the new segments in sequence.
REX-0074
Figure 7-24
1. Remove old segment FA and AB and install new segment FA centrally in the open
space.
2. Remove old segment BC and replace it with new segment AB.
3. Remove old segment CD and replace it with new segment BC.
4. Remove old segment DE and replace it with new segment CD.
5. Remove old segment EF and replace it with new segments DE and EF.
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Mounting a Segmental Rim Body to Head or Foot Shaft

Bodies are held in place on a shaft in a number of ways, locking assemblies, gib head taper
keys or straight keys with a set screws. In general, new installations will have bodies that
are held to the shaft with a locking assembly.
Procedure to install a body onto a shaft.
1. Refer to the shaft assembly drawing before installing a body onto a shaft.
2. Slide the body onto the shaft. Orient the body onto shaft as shown on the shaft
assembly drawing.
Maintenance Note
It may be easier to correctly position the body on the shaft with the segmental rim mounted
to the body, since the locating dimensions on the drawing refer to the center of the
segmental rim.
3. Properly position body onto shaft by measuring from the end of the shaft to center of
segmental rim.
4. Lock body onto shaft by what ever means it was designed or supplied with.
a. Locking assemblies should be installed per the manufacturers instructions.
b. Gib head tapered keys used to mount bodies to shafts must be properly fitted by
experienced personnel. Do not drive a gib head tapered key without first properly
fitting it.
c. Straight keys should be checked for fit by experienced personnel before being
installed. After a straight key is installed in a body tighten the set screws to the
proper torque value listed in Table 7-E, page 7-31.
Setscrew Size
5/8
3/4
Torque Value
Nm
ft lb.
130
180
95
133
Table 7-E: Hub Setscrew Torque Table
Aligning Bodies Mounted with Locking Assemblies On Double Chain Strand

Elevator
On double chain strand elevators only, the bodies must be aligned on the shaft. The bodies
used with segmental sprockets require alignment so the sprocket teeth are synchronized
(timed) to provide equal pull on both strands of chain. The bodies used with segmental
traction wheels also require alignment so a segmental traction wheel set can be aligned
properly. Segmental traction wheels are fabricated in matched sets to control run out and
roundness, if the sets are not aligned properly disproportionate tensions and
uncontrollable tracking of the chain strands will result.
Although two procedures to align the bodies are provided below, Rexnord recommends
that the first procedure (without segment rims mounted) be used. The first procedure must
be used for bodies that will have segmental traction wheels attached.
To align bodies on a shaft, the following equipment is required.
a. Level with an accuracy of 0.1 mm/M or 0.005 in/ft.
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Maintenance
Maintenance Note
When checking the level of the shaft and the round stock, the use of a level that is
graduated to allow the user to take readings in millimeters per meter, or inches per
foot, is recommended. Machinists, Mechanics or Precision levels are such levels with
the recommended graduations. Because of limited space around shafting area it is
recommended using one of the levels listed above with an approximate length of 150
200 mm (6"8).
b. Cold finished machined round stock with a length that is a little longer than the
sprocket gauge width. Diameter of round stock:
Aligning bodies without segmental rims attached, 5/8, 3/4, or 1" diameter
depending on mounting hole size in body. (Rim mounting bolt holes are
always in inch dimensions)
Aligning bodies with segmental rims attached, approximately 50 mm (2")
diameter.
c. Miscellaneous mechanics tools.
Procedure to Align Bodies without Segmental Rims Installed

1. The bodies and locking assemblies should be oriented, mounted and positioned
properly on the shaft as shown on the elevators Shaft Assembly Drawing. Once the
bodies are positioned properly on the shaft, lock one of the bodies to the shaft
following the locking assembly manufacturers installation instructions. The other
body should be left loose.
2. The bearings should be properly positioned and mounted securely on the shaft
according to the manufacturers instructions.
3. Level head shaft within 0.8000 mm/M (0.010 in/ft).
4. Rotate loose body so that the pilot hole in that body lines up with the pilot hole in the
fixed body.
5. Insert the round stock through the corresponding rim mounting holes of both bodies.
6. Place the mechanics level on the round stock and check for level. Check level with
round stock installed in different mounting holes along the bodies.
7. Adjust and tighten down the locking assembly of the loose body so a level reading is
obtained through any of the mounting holes between the two bodies.
8. Install Segmental rims. See Segmental Traction Wheel(s) or Sprocket(s) Kit
Installation, page 7-24. For installation procedure follow steps 710 and 15 of
procedure Installation of Segmental Rims on Head Shaft by Breaking Chain,
page 7-27.
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Maintenance
2
4
REX-0075
Figure 7-25:
Aligning Segmental Rim Bodies on Shaft

1
2
3
4
Round stock
Level
Segmental rim body
Pilot hole
Aligning Bodies with Segmental Rim Sprockets Installed

STOP
This procedure can be used with segmental sprockets only. Never align
bodies with segmental traction wheels attached to the bodies
If the segmental rims are bolted onto the bodies Rexnord recommends removing the rims
from the bodies and align the bodies using the procedure outlined above (Procedure to
Align Bodies without Segmental Rims Installed).
1. The bodies and locking assemblies should be oriented, mounted and positioned
properly on the shaft as shown on the elevators shaft assembly drawing. Once the
bodies are positioned properly on the shaft, lock one of the bodies to the shaft
following the locking assembly manufacturers installation instructions. The other
body should be left loose.
2. The bearings should be properly positioned, and mounted securely on the shaft
according to the manufacturers instructions.
3. Level head shaft within 0.8333 mm/M ( 0.010 in/ft).
4. Check that the pilot hole in each rim is aligned with the pilot hole in the body to which
it is mounted. If the pilot holes are in alignment perform Step a, if the pilot holes are
not aligned perform Step b.
a. Rotate the loose body so that the pilot hole in that body and rim line up with the
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Maintenance
pilot hole in the fixed body and rim. Go to Step 5.

b. Rotate the loose body so that the pilot hole in the segmental rim lines up with the
pilot hole in the rim mounted to the fixed body. Go to Step 5.
5. Place the round stock into the horizontal sprocket tooth pockets of both corresponding
segments, tight against the working face radius.
6. Place the mechanics level on the round stock and check for level. Record level.
7. Perform steps Step 5 and Step 6 in other tooth pockets around the sprockets, adjusting
the loose body so that the best overall level readings can be obtained around the
sprockets.
8. Tighten down the locking assembly of the loose body in the position that gave the best
overall level reading results.
3
2
1
REX-0076
Figure 7-26:
Head Shaft Assembly With Rims, Bar, and Level Between Bodies
1 Round stock
2 Level
3 Pilot hole
Head Shaft Bearings

The bearings at the head shaft should be regularly inspected and lubricated, according to
the bearing manufacturers instructions. See Bearings tab in Field Service Manual for
manufacturers instructions.
To ensure bearings are not impregnated with foreign materials, keep the area around the
bearings clean and lubricated. Also keep auxiliary seals lubricated if so equipped.
Regularly Inspect bearings for:
Cracked housing.
Temperature.
Damaged seals.
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Maintenance
Excessive material build-up around bearing/seals.

Unusual noise.
Lubrication condition.
Bearing temperature should be monitored and recorded by plant maintenance personnel
from the first startup of the elevator. Temperature readings should be kept and compared
over the life of the bearing. When noticeable increases in bearing temperature exists the
elevator should be shut down and the bearings inspected.
Maintenance Note
After lubrication or relubrication of bearings a slight temperature increase maybe noticed
for one to two day.
STOP
Never weld on the bearings or housing, or use them as a grounding point

when welding, or bearings may be destroyed.
NI-HARD Bearing Inspection

The Rex NI-HARD bearings are used to support and allow rotation of the take-up shaft
within the take-up frame. The NI-HARD bearings are a very low maintenance item,
requiring no lubrication, but should be inspected at least once a year for wear.
STOP
NI-HARD bearings require no lubrication! It is normal for a NI-HARD

bearing to squeak during operation.
A Rex NI-HARD bearing consists of a block and sleeve. The bearing block is bolted to
the take-up frame with the opening in the block towards the bottom. The bearing sleeve is
held locked to the foot shaft geometrically with a D shaped blind hole.
Figure 7-27 shows a NI-HARD bearing block and sleeve in an unworn condition. The
NI-HARD bearing block in the illustration is oriented as it should appear within the
elevator.
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Maintenance
REX-0078
Figure 7-27:
Unworn NI-HARD Bearing Block and Sleeve

Wear occurs between the sleeve and block after many hours of operation. The outside
diameter of the sleeve will get smaller and the top flange area of the block will get thinner
as shown in Figure 7-28.
3 mm (1/8)
REX-0079
Figure 7-28:
Worn NI-HARD Bearing Block and Sleeve

To inspect the bearing for wear/replacement, measure the top flange area of the block. The
sleeve and block must be replaced when the material left at the top flange area of the block
is 3 mm (1/8) or less.
STOP
Maintenance
Do not allow the sleeve to wear through the top flange of the block, doing
so can cause the elevator to jam.
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Manual 3520
STOP
7
Maintenance
Always replace the block and sleeve as a set.
NI-HARD Bearing Replacement

To replace the NI-HARD bearings, perform the following procedure.
1. Remove take-up assembly as outlined under Take-up Assembly Removal and
Installation, page 7-38.
2. Support the take-up frame and foot shaft assembly so the bearing blocks can be
unbolted.
3. Unbolt the bearing blocks from the take-up frame and slide NI-HARD bearings and
foot shaft assembly out of take-up frame.
4. Remove NI-HARD bearing blocks and sleeves from foot shaft.
5. Install new NI-HARD bearing blocks and sleeves on foot shaft
6. Slide NI-HARD bearings and foot shaft assembly into the take-up frame. Making
sure the bearing block is oriented properly before installing in frame. See Figure 727.
7. Bolt the bearing blocks to the take-up frame.
8. Replace take-up assembly as outlined in Take-up Assembly Removal and
Installation, page 7-38. For detailed instructions on installing and adjusting the takeup assembly see Take-up Assembly and Take-up Guide Installation, page 4-11.
Take-up Assembly and Take-up Guides Inspection

Inspect the take-up and take-up guides monthly for the following.
1. The take-up moves freely up and down between the guides.
If the take-up assembly does not move freely up and down the take-up guides, check for the
following below and perform the necessary work needed to correct the problem:
a. Excessive material buildup between take-up assembly and guides.
Remove excessive material from between take-up and guides.
b. Improper spacing between take-up assembly and guides.
To properly position the take-up assembly and guides see Take-up Assembly and
Take-up Guide Installation, page 4-11.
c. Chain is mistracking on a sprocket or has jumped off the traction wheel or sprocket.
Position chain properly on traction wheel or sprocket.
Check chain for bent or damaged links and replace any that are found.
Check and adjust the position of the upper stop blocks.
2. Wear, corrosion, and bent or broken components.
The take-up and take-up guides wear at the points they make contact with one another. See
Figure 7-29. The wear can easily be observed from the side doors in the boot. When the
flange areas of the take-up and/or guides are excessively worn (worn thin) it is time to
Maintenance
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Manual 3520
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Maintenance
replace the take-up, take-up guides or both.

Damaged or broken components of the take-up or take-up guide must be repaired or
replaced before placing the elevator back into service.
REX-0080
Figure 7-29:
Checking Wear Areas of Take-up Assembly

1 Wear points of take-up assembly
2 Illustration of take-up frame wearing thin
3. All stop block mounting hardware is tight and the upper stop blocks are properly
positioned.
See Adjusting Stop Blocks on Take-up Assembly, page 7-39 for instructions on properly
setting the stop blocks.
Take-up Assembly Removal and Installation

Removal
1. Support the take-up assembly from the lifting beam in the boot section with a chain
hoist. See Figure 4-11: Cutaway of Boot Positioning/Setting Take-up and
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Manual 3520
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Maintenance
Guides, page 4-14

2. Mark the position of one of the take-up guides within the door frame of the boot
section.
3. Unbolt and remove the take-up guide marked in step 2 from the door of the boot
section.
4. Remove take-up assembly from the boot section of the elevator.
Installation
To install the take-up, perform steps 1-4 in the removal section above in reverse order. For
detailed installation instructions and adjustments of the take-up and guides, see Take-up
Assembly and Take-up Guide Installation, page 4-11.
Adjusting Stop Blocks on Take-up Assembly

The stop blocks should be checked for mounting hardware tightness and proper clearance
between stop blocks and take-up monthly. Elevators operating in very harsh conditions
may require more frequent checks.
Upper Stop Blocks
During normal operation the chain will elongate over time due to wear, which in turn will
lower the take-up in the boot.
Periodically adjust the upper stop blocks to sustain the proper gap of 625 mm (1/41)
between the take-up and stop blocks.
STOP
Excessive gap between upper stop blocks and take-up will allow chain to
disengage from traction wheel or sprocket. Damage to chain and bucket
assembly, take-up and take-up guides will result as chain and bucket
assembly swings wildly within elevator boot.
Lower Stop Blocks

The lower stop blocks once installed properly on the take-up guides do not require
adjustment, however the stop block mounting hardware should be checked for tightness
when the upper stop blocks are being checked or adjusted for proper clearance.
STOP
Take-up assembly must never be allowed to set on lower stop blocks when
in operation. If take-up assembly is close to lower stop blocks, chain links
must be removed from elevator.
Backstop Maintenance and Removal

Maintenance
The backstop should be maintained as stated in the manufacturers literature, which can be
found under the drive assembly tab in the Rexnord Service Manual.
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Manual 3520
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Maintenance
In addition to the manufacturers recommendations, backstops should be visually checked

during the elevators monthly inspection for the following:
Backstop is securely and properly mounted on head shaft or drive reducer.
Loose or missing hardware.
All guarding is in place and secure.
Proper lubrication.
Build up of material on or around the backstop.
Proper clearance around torque arm support brackets.
Removal
To remove the backstop from an elevator perform the following steps
1. Empty all elevator buckets.
2. Tie off chain and bucket assembly so it is secure and all the pressure is relieved on
backstop.
3. Remove backstop as instructed in the manufacturers instructions.
WARNING
Never proceeded in removing backstop without
clearing all personnel from elevator area (except
personnel removing backstop) and securing chain
and bucket assembly or serious injury or death can
result.
Drive Unit Maintenance and Removal

Maintenance
The drive unit should be maintained as stated in the manufacturers literature, which can
be found under the Drive Assembly tab in the Rexnord Service Manual.
In addition to the manufacturers recommendations, drive unit should be visually checked
during the elevators monthly inspection for the following:
All the components are lubricated properly.
No lubricant is leaking from any of the components.
All component fasteners are secured and all safety guards are in place.
Breather plug(s) in reducer(s) are not clogged.
No unusual noise or vibrations coming from any of the components.
None of the components are excessively hot.
STOP
Maintenance
Never weld on the drive, or use the drive unit as a grounding point when
welding, or bearings and/or gearing may be destroyed.
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Manual 3520
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Maintenance
Removal
To remove the drive unit from an elevator perform the following steps
1. Empty all elevator buckets.
2. Tie off chain and bucket assembly so it is secure and all the pressure is relieved on
drive unit.
3. Remove drive unit as instructed in the manufacturers instructions.
WARNING
Never proceed in removing drive unit with integrated
backstop without clearing all personnel from elevator
area (except personnel removing drive unit) and
securing chain and bucket assembly or serious injury
or death can result.
Drive Chain and Sprockets Maintenance

The drive chain should be inspected during the elevators monthly inspection. Check the
drive chain for:
a. Check chain sidebars and sprocket sides for evidence of misalignment.
b. Check chain for missing pin-locks or cotters.
c. Check sprockets for hooked or broken teeth.
d. Proper lubrication.
Belt and Sheave Maintenance

The belt(s) and sheaves should be checked monthly for the following and any deficiencies
corrected before operating equipment:
a. Damaged guard or interference between guard and the sheaves or belt
b. Any worn bearings, leaky seals or bent shafts in area which could effect belt and
sheaves performance.
c. Damaged or worn belt(s).
d. Damaged or worn sheaves.
e. Oil or grease on sheaves and belt(s).
f. Belt(s) are properly tensioned.
Motion Sensor Maintenance

The motion sensor switch should be checked during the annual inspection for:
a. motion sensor probe is in good condition and positioned properly.
b. Wiring to the motion sensor switch is all connected and in good condition.
c. Check motion sensor is adjusted properly to operating speed.
d. Check all interlocks work properly when the motion sensor switch is activated.
Maintenance
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Manual 3520
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Maintenance
Boot Flood Switch Maintenance

The boot flood switch should be checked during the annual inspection for:
a. Diaphragm is in good condition.
b. No binding occurs when diaphragm is pushed in or left to return.
c. Wiring to switch is in good shape.
d. Check all interlocks work properly when switch is activated.
Belt Wander Switch Maintenance

The wander switch should be checked during the annual inspection for:
a. Roller or plunger pad in good shape and roller rolls freely.
b. Wiring to switch is in good shape.
c. Check all interlocks are working properly when switch is activated.
Foundation
The area around the foundation must be kept clean of debris and material. A dirty
foundation area is a safety hazard to personnel and equipment.
STOP
Materials left to pile on foundations can lead to the erosion, and/or corrosion of the
foundation and anchor bolts.
Care must be taken not to damage foundation when using power

equipment and machinery to clean around foundation.
The concrete pad or steel supports on which the elevator is installed should be
checked periodically for erosion, chipping, cracking, and/or corrosion. If the
foundation is observed to be in poor shape, the foundation must be repaired or
replaced.
If the foundation must be repaired or replaced, steps must be taken to support the
elevator and hold it in alignment, while the foundation is being worked on.
Do not operate elevator while working on the foundation.
The anchor bolts position and projection must be as shown in the General
Arrangement Drawings located under the tab labeled Drawings. If location of
anchor bolts is not correct, this situation must be remedied at once.
The housing, shafting, and drive alignment must be checked and corrected before
placing elevator back into service.
The anchor bolts should be imbedded in the concrete at least several days before
restarting the elevator.
Periodically check anchor bolt nuts for tightness. Two nuts should always be placed
on each anchor bolt.
Housing (Boot, Intermediate Casings, Collars, and Head)

Rex bucket elevators are self-supporting but not free standing. This means that the
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Manual 3520
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Maintenance
elevator requires lateral supporting to keep it in an align vertical position, but all of the
load (elevator components and material weight) is supported through the elevator casings
and transferred into the foundation.
Periodically the housing must be checked for structural damage (holes, heavy wear, heavy
corrosion and evidence of interference), if any of these are observed the structural
integrity of the elevator may be compromised and the elevator could collapse.
STOP
If any of the structural components are observed to be in need of repair or

replacement, the elevator should be removed from the production circuit
immediately and Rexnord consulted.
When inspecting the elevator pay particular attention to:
STOP
Boot Section, page 7-43
Intermediate Casings and Collars, page 7-44
Platform, Grating, Handrails, Ladders, Safety Cage, and Hoist Frame, page 7-45
Upper and Lower Head Sections, page 7-44
Do not cut holes in any of housings unless instructed in writing by

Rexnord. Cutting holes in the housing can weaken the elevators structure
and cause it to fail.
Boot Section
STOP
Maintenance
Periodically clean out and inspect the boot section for material leakage and wear.
Remove built up material from the sides of the boot section and also clean out any
material lying in the bottom.
Material left in the bottom of the boot section will eventually draw
moisture or settle, getting very hard. This material, if left in the bottom of
the boot section, will prematurely wear and damage the chain and bucket
assembly.
Inspect all seals around all doors, removable panels and flanges for signs of leakage.
Repair any latches, hinges or seals that are worn or missing.
Inspect boot section for wear, damage and corrosion. Pay special attention to the
corner angles. If the boot section and especially the corner angles are observed to be in
poor shape, immediately remove the elevator from operation and consult Rexnord on
how to repair or replace.
Inspect liner plates, replace any liner plates that are worn, damaged or missing. Check
that all liners are securely fastened in place, repair any that are loose.
If equipped, inspect loading legs for interference with chain and bucket assembly,
wear, damage and corrosion.
If evidence of interference is observed between loading legs and chain and bucket
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Manual 3520
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Maintenance
assembly check for the following:

Damaged chain and bucket assembly.
Improperly positioned take-up guides.
Bent or worn take-up frame and take-up guides.
Worn take-up bearings.
Worn sprockets.
Intermediate Casings and Collars
Periodically clean and inspect the intermediate casings for structural damage, holes,
corrosion and evidence of interference.
Pay particular attention for damage to the corners, crimped beads and flange angles. If
any of the preceding are damaged remove the elevator from production and consult
Rexnord
Inspect casing flanges for signs of material leakage. If leakage is observed, inspect the
casing for the following and repair problematic items:
No sealing compound used between flanges.
Flange bolts are loose.
Structural damage to casing flange angles. Consult Rexnord if observed.
Securing the flange bolts. Rexnord recommends that site personnel fasten bolts using the
Turn of the Nut tightening technique, as bolt tension and not torque, create the safest
connection. Bolts are installed in all holes of the connection and brought to a snug tight
condition; that is when the mating flanges or plies of the joint are in firm contact. Snug
tightening progresses systematically from the most rigid part of the connection to the free
edges until all bolts in the connection are fully compacted. Following this operation, all
bolts are tightened further another 1/3 turn, progressing again from the most rigid part of
the joint to its free edges.
Clean and inspect all lateral support bracing.
Make sure there is a gap between the lateral support bracing and the elevator and that
the gap is free of debris and material allowing the elevator to expand.
Inspect all welds and hardware holding the lateral support together. Make sure all
welds are not cracked and all the hardware is not loose or missing. Repair any cracked
welds and loose or missing hardware.
If lateral support bracing is found to have cracked welds, or loose or missing

hardware, casing alignment should be checked. See Intermediate Casings, page 4-3
and Aligning Head and Foot Shaft, page 4-18 for alignment instructions.
Upper and Lower Head Sections
Maintenance
Periodically clean and inspect the head sections for material leakage and wear.
7 44

Manual 3520
7
Maintenance
Remove built up material from the sides and discharge areas of the head section and
also clean out any material lying in the bottom on elevators with pant leg casings.
Inspect all seals around all doors, removable panels and flanges for signs of leakage.
Repair any latches, hinges or seals that are worn or missing.
Inspect the head section for wear, damage and corrosion. Pay special attention to the
corner angles. If the head section and especially the corner angles are observed to be
in poor shape, immediately remove the elevator from operation and consult Rexnord
on how to repair or replace.
Inspect liner plates, replace any liner plates that are worn, damaged or missing. Check
that all liners are securely fastened in place, repair any that are observed loose.
Platform, Grating, Handrails, Ladders, Safety Cage, and Hoist Frame
Maintenance
Periodically clean and inspect any and all platforms, grating, handrails, ladders, safety
cages and hoist frames.
Inspect platform for loose, missing or damaged grating, hardware, and structural steel.
Rope off any problematic areas following proper safety procedures and repair and/or
replace grating immediately.
Inspect handrails for loose hardware or cracked welds holding the handrails together.
Also inspect for any damage and/or heavy corrosion which would make the railing
unsafe. Rope off any problematic areas of handrail following proper safety procedures
and repair or replace immediately.
7 45

Manual 3520
8
Long Term Storage
Primary Recommendations
The primary recommendation is that the entire bucket elevator material should be stored in
a dry, heated and humidity controlled building. Preferably, where the temperature is
controlled between 1040C (50120F) and the maximum relative humidity is below
60%. All material is to be blocked off the floor.
After placing material in building, the following procedures should be adhered to:
1. Initially all machined surfaces should be inspected and given a liberal coat of film
forming type rust inhibitor compound or wax-type protective coating as and where
needed to prevent rusting. Once per month thereafter machined surfaces are to be
reinspected and protective coating should be reapplied as needed.
2. On a monthly basis, the headshaft bearings are to be rotated manually to spread
lubricant over the bearing surfaces and to prevent possible brinelling. Time alone
causes a certain deterioration in the grease. Therefore it is recommended to replenish
or replace the grease before placing headshaft bearings into initial operation and/or
after one year in storage.
3. Most new reducer units are furnished with a rust preventative oil that will protect parts
against rust for a period of twelve months when stored in a dry building after shipment
from the factory. See the reducer manufacturers instructions to verify that the reducer
has been prepared for storage. If reducer has not been preparedly for storage or the
unit will be stored or inactive beyond the above period, follow the manufacturers
instructions to prepare the reducer for long term storage.
If there are no manufacturers instructions on how to prepare the reducer for long term
storage prepare reducer as follows: The reducer unit is to be completely sealed. All
gauges, oil drain plugs, and filler plugs are to tightly snugged up in place. Air vents
are to be sealed with pressure sensitive tape or the opening in the unit closed with a
plastic plug. Grease bearings and seals. Apply pressure sensitive tape around the
dipstick; around the shafts; and against the seal housing of the labyrinth seals. Spray
all internal parts with a rust preventative oil that is soluble in lubricating oil or add
Motorstor vapor phase rust inhibitor. On a monthly basis, inspect the reducer unit,
manually rotate shafts, and spray or add rust inhibitor if necessary.
Before operating, the reducer must be filled to the proper level with a fresh oil meeting
the specifications of the unit. See manufacturers instructions contained in the
Rexnord Field Service Manual.
4. Holdback units or Backstops are shipped without lubricant but do contain one ounce
of Motorstor vapor phase rust inhibitor which will protect internal parts against rust
for a period up to six months.
If the backstop is to be stored or inactive for more than six months, add the
recommended amount of lubricant indicated in the manufacturers instructions
contained in the Rexnord Field Service Manual and add one ounce of Motorstor
every additional six month period.
Indoor dry storage is recommended. If outdoor storage is necessary, cover the
backstop with tarpaulin or suitable covering.
Before placing backstop in operation drain lubricant mixture and replace breather and
Long Term Storage
81

Manual 3520
8
Long Term Storage
oil sight gauge, if removed. Flush backstop and refill with clean, fresh lubricant.
5. Motor shafts are to be rotated manually every month. Add grease to the bearing cavity
every six months allowing some of the existing grease to be purged. At time of
removal from storage or after one year in storage, completely replace the existing
grease in the bearing cavity with new fresh grease.
6. All chain parts must be given a liberal coat of slush oil when first placed into storage
and then on a periodic basis to prevent rusting in the chain joints.
7. All boxed material should be opened and inspected for proof of shipment and then
resealed. Boxed material can be stacked if storage space is at a premium.
8. All painted structural material should be inspected for rust or corrosion and retouched
if required.
Secondary Recommendations
If indoor storage for the entire bucket elevator is impractical, then the material can be
stored as follows:
This procedure can also be used for short term storage.
1. The following material must be stored inside, per instructions given in primary
recommendations above: field box material; all chain; motors; reducer units; and
buckets (if customer prefers not to paint them)
2. The following material can be stored outside on a well drained surface, preferably
paved or crushed stone, and all items must be blocked off the ground:
a. Intermediate Casings: The insides of casings are to be given a coat of paint both on
inside and outside of entire casings. The casings are to be stored in an upright
position (on flanged end).
b. Head Sections and Boot Sections: Follow paint instructions as given in Step 2a
above. All machined surfaces should be given a liberal coat of film forming type
rust inhibitor compound or wax-type protective coating as needed to prevent
rusting. Follow primary recommendations instructions contained in Step 2 for the
head shaft bearings and Step 4 for hold back unit. Both head section and boot
section are to be stored in a upright position. Do not stack.
c. Buckets: All buckets should be prime painted and then rebanded on same shipping
pallets. Pallets can be stacked two high if space is a problem.
d. Platforms: Grating, handrailing, chain guards. This material is shipped banded,
crated or in some cases in loose pieces. This material can be stored in its present
condition as long as material is blocked off the ground.
e. Periodically inspect all of the material for rust or corrosion and maintain as
required.
If the storage recommendations outlined in Primary Recommendations, page 8-1
and Secondary Recommendations, page 8-2 are followed, we are confident that the
integrity of the bucket elevator material will be maintained.
Long Term Storage
82

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Rex High Performance

Chain Bucket Elevator

High Performance Chain Bucket Elevator

Chain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

High Performance Chain Bucket Elevator

High Performance Chain Bucket Elevator

Long Term Storage

Rex High Performance

Installing, Servicing, Maintaining, or Repairing Equipment

High Performance Chain Bucket Elevator

Verification of safety training/conformance

Name of person performing the inspection

Verify safety equipment functional

An elevator shall be used to convey only the specified commodities or materials

Only a trained person is permitted to operate an elevator. Training includes instruction

Personnel working on or near an elevator are instructed as to the location and

An elevator is used to transport only loads it is designed to handle safely.

Under no circumstances are the safety characteristics of the elevator to be altered if

Elevators are NOT maintained or serviced while in operation.

High Performance Chain Bucket Elevator

Rex High Performance

Inspection Service covers such matters as trouble-shooting and correction of difficulties

High Performance Chain Bucket Elevator

To place an order for technical services please contact Rexnord Industries

Rexnord Order Number

Your Order Number

Company Name who purchased equipment

End User Company Name of equipment

Your Name & Title

Type of service required

Date work required

Purchase order number for the Technical Service to be provided

Location and directions to the site.

High Performance Chain Bucket Elevator

Typical Rex High-Performance Chain Bucket Elevator

Split upper head section

High Performance Chain Bucket Elevator

9 Heavy-duty Rex steel roller-less chain

High Performance Chain Bucket Elevator

Rexnord Order Number

Your Order Number

Company Name who purchased equipment

End User Company Name of equipment

High Performance Chain Bucket Elevator

Example 1 of Structural Mark Number Tag

Example 2 of Structural Mark Number Tag

High Performance Chain Bucket Elevator

2 Mark number - Fabrication Drawing Suffix Number "80"

Example 1 of Structural Mark Number Tag

READ THIS MANUAL COMPLETELY BEFORE INSTALLING OR OPERATING THIS EQUIPMENT.

Rex High Performance

Corrections of Minor Misfits

High Performance Chain Bucket Elevator

READ THIS MANUAL COMPLETELY BEFORE INSTALLING OR OPERATING THIS EQUIPMENT.

Rex High Performance

Locating Elevator Foundation

Typical work points

High Performance Chain Bucket Elevator

5 Elevator centerlines set to X Y Z dimensions for typical work points