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GSi 2021 Installation And Operation Manual

U-trough free flow unloading system
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U-Trough Free Flow Unloading
System
Model:
2021
Installation and Operation Manual
PNEG-2343
Version: 1.0
Date: 02-02-21
PNEG-2343

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Summary of Contents for GSi 2021

  • Page 1 U-Trough Free Flow Unloading System Model: 2021 Installation and Operation Manual PNEG-2343 Version: 1.0 Date: 02-02-21 PNEG-2343...
  • Page 2 All information, illustrations, photos and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. PNEG-2343 U-Trough Free Flow Unloading System...

  • Page 3: Table Of Contents

    Table of Contents Contents Chapter 1 Safety ..............................4 Safety Guidelines ..........................4 Cautionary Symbols Definitions ......................5 Safety Cautions ............................. 6 Safety Sign-Off Sheet ........................... 9 Chapter 2 Decals ..............................10 Chapter 3 Machine Components ........................13 U-Trough Unloader ..........................13 Optional Equipment ..........................14 Sweep Components (18'-51') ......................

  • Page 4: Chapter 1 Safety

    1. Safety Safety Guidelines Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is written to help you understand safe operating procedures and problems that can be encountered by the operator and other personnel when using this equipment. Read and save these instructions. As owner or operator, you are responsible for understanding the requirements, hazards, and precautions that exist and to inform others as required.

  • Page 5: Cautionary Symbols Definitions

    1. Safety Cautionary Symbols Definitions Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we use the symbols that are defined below. This symbol indicates an imminently hazardous situation DANGER which, if not avoided, will result in serious injury or death.

  • Page 6: Safety Cautions

    1. Safety Safety Cautions Use Personal Protective Equipment • Use appropriate personal protective equipment: Foot Respiratory Protection Protection Protection Hearing Head Fall Protection Protection Protection Hand Protection • Wear clothing appropriate to the job. • Remove all jewelry. • Tie long hair up and back. ST-0004-1 Follow Safety Instructions •...
  • Page 7 1. Safety Maintain Equipment and Work Area • Understand service procedures before doing work. Keep area clean and dry. • Never service equipment while it is operating. Keep hands, feet and clothing away from moving parts. • Keep your equipment in proper working condition. Replace worn or broken parts immediately.
  • Page 8 1. Safety Use Unload Equipment Properly • Do not operate this equipment alone. Make sure someone nearby is aware of the proper shut down sequence in the event of an emergency. • Do not allow any person intoxicated or under the influence of drugs to operate this equipment.

  • Page 9: Safety Sign-Off Sheet

    1. Safety Safety Sign-Off Sheet Below is a sign-off sheet that can be used to verify that all personnel have read and understood the safety instructions. This sign-off sheet is provided for your convenience and personal record keeping. Date Employee Name Supervisor Name ST-0007 PNEG-2343 U-Trough Free Flow Unloading System...

  • Page 10: Chapter 2 Decals

    2. Decals The types of decals and locations on the equipment are shown below. Good safety requires that you familiarize yourself with the various safety decals, the type of warning and the area or particular function that related to the area, that requires your SAFETY AWARNESS. Sweep Powerhead Powerhead right...
  • Page 11 2. Decals Ref # Decal # Decals Location CAUTION 1. Read and understand Operator’s Manual before starting. 2. Stop motor, shut off power at master power panel and wait for moving parts to stop before servicing, adjusting, 80-00110 Powerhead Left repairing or unplugging.
  • Page 12 2. Decals Ref # Decal # Decals Location DANGER ROTATING FLIGHTING HAZARD KEEP AWAY Sweep and 80-00113 Powerhead Left To prevent serious injury or death from turning motor: 1. Do not enter bin unless power is locked out at master power panel. Stop motor, shut off power at master power panel and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging.

  • Page 13: Chapter 3 Machine Components

    3. Machine Components U-Trough Unloader NOTE: 48' bin diameter model shown. Figure 3A Ref # Description Ref # Description Center Gearbox Assembly Bin Plate Center Grate Unloader Flight Sweep (See detailed view on Page 16.) Powerhead Elevator Drive Wheel Assembly Horizontal Powerhead Options Center Floor Flange Hydraulic (Motor Included)

  • Page 14: Optional Equipment

    3. Machine Components Optional Equipment 25° Incline Elbow (For Horizontal Powerhead Only) 1. Uses a wood bushing and universal joint. 2. Shown with electric powerhead. Powerhead not included. Figure 3B U-Trough Extension (For Horizontal Powerhead Only) 1. Sizes from 6" (457 mm) to 120" (3048 mm), 6"...

  • Page 15: Sweep Components (18'-51')

    3. Machine Components Sweep Components (18'-51') Figure 3E Sweep Components (18'-51') Parts List Ref # Description Ref # Description 5/8" x 1" Bolt with 3/16" Hole Sweep End Flight Washer Sweep Backplate 3/16" Drive-In Grease Zerk Sweep Flight (Available in 6", 7-1/4" and 8") M6 x 1.0 Grease Zerk Wood Bushing (Sweep Sizes 27' and Up) Elevator Drive Wheel Assembly...

  • Page 16: Sweep Components (52'-6" - 66')

    3. Machine Components Sweep Components (52'-6" - 66') Figure 3F Sweep Components (52'-6" - 66') Parts List Ref # Description Ref # Description 1/2" x 1-1/2" Bolt Sweep End Flight 1/2" x 3-1/2" Bolt Grade 8 Sweep Backplate 1/2" Flange Nut Grade 5 UNC Sweep Flight (Available in 6", 7-1/4"...

  • Page 17: Chapter 4 Installation

    4. Installation Unloaders Under Aeration Floor 1. Cut 12" (H) x 14" (W) (305 mm x 356 mm) rough opening (52) in the bin wall where the unloader is to exit the bin. (See Figure 4A.) Figure 4A Ref # Description Ref # Description...
  • Page 18 4. Installation 3. Install the bin wall flange as shown in Figure Figure 4C Ref # Description Ref # Description Bin Plate Upper Bin Plate Lower Foam Sealing Strips 4. Secure the bin wall flange with self-tapping screws (33) as shown in Figure Figure 4D Ref #...
  • Page 19 4. Installation 5. Layout the aeration floor and cut the opening around the gates (57). Refer to Page 53 for rough opening dimensions. (See Figure 4E.) Trough axis direction Figure 4E 6. Install the gate seal assemblies (56) on each intermediate gate (57). Secure to trough with the supplied hardware (2 and 17).
  • Page 20 4. Installation 7. Install the intermediate floor flange (59) and secure with self-tapping screws (33) (not provided). (See Figure 4G.) Ref # Description Intermediate Gate Aeration Floor Intermediate Floor Flange Trough axis direction Figure 4G 8. Install the center floor flange (105) (but not the center floor grate yet). (See Figure 4H.) Trough axis direction...

  • Page 21: Unloaders In Concrete Knock-Out

    4. Installation Unloaders in Concrete Knock-Out 1. Center the unloader in the bin foundation. Anchor to the bottom of the knock-out with the concrete anchor bolts (16) (not provided). (See Figure 4I.) Ref # Description Concrete Anchor Bolts Figure 4I 2.

  • Page 22: Sweep Drive

    4. Installation Sweep Drive Center Gearbox Assembly 1. Remove the two 1/2" flange nuts (20) to securing the dust cover (63) and remove the dust cover (63). Keep the flange nuts (20) for Step 7 on Page 25. The dust cover (63) can be discarded. (See Figure 4L.) Ref # Description...
  • Page 23 4. Installation 3. Prepare the gearbox assembly (106) for installation by removing the two shipping brackets (64). Remove four bolts (13) as shown in Figure 4N. The shipping brackets (64) can be discarded. The removed hardware is used in the next step. Ref # Description Bolt with Washers...
  • Page 24 4. Installation 5. Remove the flight strap (66) at the powerhead (41) end of the unloader. This allows the flighting to be moved for the next step. The removed flight strap (66) and hardware can be discarded. (See Figure 4P.) Ref # Description Powerhead...
  • Page 25 4. Installation 7. Install the gearbox access cover (69) and the center floor flange grate (38). Secure them with the two flange nuts (18) removed earlier. Secure the center floor flange grate (38) with self-tapping screws (33) (not provided). (See Figure 4S and Figure 4T.) Figure 4S Figure 4T Ref #...
  • Page 26 4. Installation 8. Install the shifter assembly at the powerhead end of the unloader. Secure the shifter linkage end (72) to the shifter shaft (73) with the 3/8" x 3/4" bolt (6) and washers (26 and 30). Secure the shifter bracket (74) to the lid (75) with the 3/8"...

  • Page 27: Sweeps

    4. Installation Sweeps Installing the Elevator Wheel Assembly 1. Install the elevator wheel assembly (40) to the end of the sweep backplate (44) using 3/8" x 1" carriage bolt (11), 3/8" flat washer (28), 3/8" lock washer (31) and 3/8" hex nut (21). (See Figure 4W.) Ref # Description...
  • Page 28 4. Installation Installing the Sweep onto Center Gearbox 1. Install the sweep (39) onto gearbox sweep arm (65) using sweep pin (35) and secure with 3" hair pin (36). (See Figure 4Y.) Figure 4Y Ref # Description Ref # Description Sweep Pin (1) Sweep 3"...
  • Page 29 4. Installation Sweep Braces and Support Wheel Assemblies (54'-66' Only) 1. Mount sweep brace mounting plates (48) to the sweep backplate (44) using 3/8" x 1" bolt (9) and 3/8" flange nut (19). (See Figure 4AA and Figure 4AB.) Figure 4AA Figure 4AB Ref # Description...
  • Page 30 4. Installation 3. Install the braces (49) to the support wheels and brace mounting plates (48). (See Figure 4AE and Figure 4AF.) Figure 4AE Figure 4AF Ref # Description Ref # Description 1/2" x 1-1/2" Bolt (4) Sweep Brace Mounting Plate 1/2"...
  • Page 31 4. Installation Sweep Stop 1. Mount the sweep stop (42) such that it will stop the sweep before it reaches the walk through door. (See Figure 4AG.) 2. Install the bolt containing a through hole (104) at height shown. Feed cable through hole (104) and reconnect to the sweep stop (42).
  • Page 32 4. Installation Sweep Adjustments Sweep adjustments are critical to achieve proper advancement and in turn, maximize sweep performance. 1. To adjust the overall sweep length, remove the four mounting bolts holding the adjuster plate to the sweep backplate. Re-position it to achieve desired length and then re-install hardware. (See Figure 4AJ.) 2.
  • Page 33 4. Installation 5. See Figure 4AN-Figure 4AS for position options. Figure 4AN Note Slot Position (Back View) Figure 4AQ More Aggressive (Front View) Figure 4AO Note Slot Position (Back View) Figure 4AR Neutral (Front View) Figure 4AS Less Aggressive (Front View) Figure 4AP Note Slot Position (Back View) Ref # Description...

  • Page 34: Polyshield Plate Assembly

    4. Installation Polyshield Plate Assembly 1. Install the bearing (80) in the polyshield plate assembly (81) as shown in Figure 4AT. Figure 4AT Ref # Description Ref # Description 1/2" x 1" Carriage Bolt (4) Bearing Flange (2) 1/2" Flange Nut (4) Polyshield Plate Assembly Bearing Insert (1) Bearing with Eccentric Locking Collar...

  • Page 35: Horizontal Powerhead

    4. Installation Horizontal Powerhead Discharge Gate, Motor Plate Preparation 1. Slide the discharge gate assembly (84) onto the powerhead in the orientation as shown in Figure 4AU. 2. Remove the three bolts and nuts (83) shown along one edge of the powerhead (41) in the preparation for installation of the motor plate assembly.
  • Page 36 4. Installation Powerhead Shaft, Motor Plate 1. Ensure the flighting is pushed fully towards gearbox. 2. Install the motor plate assembly (85) on the top of the powerhead (41), secure with three nuts and bolts removed previously. (See Figure 4AV.) 3.
  • Page 37 4. Installation Bearing Eccentric Locking Collar Installation The bearing on the polyshield plate assembly includes an eccentric locking collar. Complete the following steps to lock the bearing onto the powerhead shaft. 1. Ensure the bearing assembly with eccentric locking collar (89) is assembled on the powerhead shaft (91) as shown in Figure 4AX.
  • Page 38 4. Installation Pulley Taper Bore Hub Installation 1. Be sure the tapered cone surfaces of the bushing (47) and inside of pulley (93) are clean and free of grease and oil. 2. Place the bushing (47) in the pulley (93). 3.

  • Page 39: Incline Powerhead

    4. Installation Incline Powerhead 1. Remove the powerhead (41) from the standard horizontal position by removing the eight bolts around the perimeter of the box flange (94). Remove the discharge gate seal (95). Remove the powerhead shaft (91) from the unloader flighting by removing two 3-1/2" bolts. (See Figure 4AZ.) Ref # Description...
  • Page 40 4. Installation 3. Install the incline elbow assembly on the end of the unloader. Insert the incline shaft (98) into the flight bushing. Secure the incline elbow assembly to the unloader end by installing the eight nuts and bolts remove in Step 1 around the perimeter of the box flange (94).
  • Page 41 4. Installation 5. Bolt the powerhead (41) onto the end of the incline elbow assembly (97) with the eight bolts removed previously. Ensure the discharge gate seal (95) is re-installed during this step. Insert the powerhead shaft (91) into the incline flight bushing and secure it with two 3-1/2" bolts. (See Figure 4BE and Figure 4BF.) Figure 4BE...

  • Page 42: U-Trough Extension Installation

    4. Installation U-Trough Extension Installation 1. Install the U-trough extension using the hardware provided with the extension. 2. Install the supports. Kits available separately. 3. Install the powerhead as shown on Page PNEG-2343 U-Trough Free Flow Unloading System...

  • Page 43: Chapter 5 Power Requirements

    5. Power Requirements Power requirements are dependent on the grain type, condition and moisture level. Power requirements are suggestions and may vary in specific circumstances. Steps can be taken to reduce the power needed to operate the unloader or sweep if the power available to the site is limited. Operating the unloader at a slower speed and reducing the flow of grain into the unloader will reduce power requirements.

  • Page 44: Hydraulic Drive

    5. Power Requirements U-Trough Unloader without Sweep - Horizontal Powerhead Required HP Required HP Bin Diameter Bin Diameter 12.4" Pulley 18.4" Pulley 12.4" Pulley 18.4" Pulley U-Trough Unloader without Sweep - 25° Incline Elbow and Horizontal Powerhead Required HP Required HP Bin Diameter Bin Diameter 12.4"...

  • Page 45: Chapter 6 Operation

    6. Operation Pre-Operation Check List IMPORTANT: Lock out power source prior to performing pre-operation checks. Failure to do so may result in serious injury or death. 1. Before filling the grain bin, check to ensure that all unloader components are functioning properly. 2.

  • Page 46: Unloading

    6. Operation Unloading ALWAYS UNLOAD FROM THE CENTER GATE FIRST. Unloading from the intermediate gates when the bin is still mostly full, causes excessive stress on the grain bin and can cause the grain bin to be damaged or collapse. Figure 6B Center Unloading Figure 6C Off - Center Unloading 1.

  • Page 47: Chapter 7 Service

    7. Service Gearbox Oil Level (Check levels once per season, or every 50 hours of operation.) 1. Fill the top gearbox to the side plug level. 2. Remove the cover and fill bottom gearbox to line on dipstick. 3. Gearboxes are factory filled with full synthetic 75W90 gear oil. Figure 7A Top Gearbox Figure 7B Bottom Gearbox Ref #...

  • Page 48: Chapter 8 Dimensions

    8. Dimensions U-Trough Unloader for Nominal Bin Diameters U-Trough System with Horizontal Powerhead Figure 8A Ref # Description Ref # Description Extent of Floor Flange Center of Bin Bin Wall Center of Discharge Nominal Bin # of Intermediate Center of Bin to Unloader Nominal Bin Diameter...
  • Page 49 8. Dimensions U-Trough Unloader for Nominal Bin Diameters (Continued) U-Trough System with 25° Incline Elbow and Horizontal Powerhead Figure 8B Ref # Description Ref # Description Extent of Floor Flange Center of Bin Bin Wall Center of Discharge Nominal Bin # of Intermediate Center of Bin to Unloader...

  • Page 50: Gate Dimensions

    8. Dimensions Gate Dimensions Figure 8C Ref # Description Ref # Description Center of Bin I (Minimum Bin Radius) Minimum clearance required between the bin wall J (Maximum Bin Radius) and outer gate for the elevator wheel. PNEG-2343 U-Trough Free Flow Unloading System...
  • Page 51 8. Dimensions Center of Bin to Nominal Bin # of Intermediate Distance Intermediate Gate Diameter Gates Between Gates Center to Center Intermediate Gate Inches Inches Inches 39.3 75.38 1915 51.75 1314 45.3 1149 81.38 2067 57.75 1467 57.3 1454 93.38 2372 69.75 1772...

  • Page 52: Bin Sweep Dimensions

    8. Dimensions Bin Sweep Dimensions Figure 8D Bin Diameter Range Allowing 4-1/2" (114 mm) Sweep Length (L) Nominal Bin Clearance Between Sweep and Bin Wall Diameter Minimum Maximum Minimum Maximum Inches Inches 18.0 97.5 2477 106.5 2705 17.1 18.5 19.5 106.5 2705 115.5...

  • Page 53: Installation Dimensions

    8. Dimensions Installation Dimensions Aeration Floor Installation Gate openings must be added to the aeration floor. Consult the table on Page 51 to determine the location of the openings according to the bin size. Then, cut the openings with dimensions as shown to provide clearance for the floor flanges.
  • Page 54 8. Dimensions Figure 8F Unloader Section View Through Gate Ref # Description Self-Tapping Screw Floor Flange Surface Aeration Floor Support Floor Flange Wdith Typical Aeration Floor Height Maximum Unloader Width Figure 8G Overall Unloader Dimensions Under Bin IMPORTANT: It is imperative that the concrete be absolutely level where the unloader is to be positioned. Failure to do so may cause distortion of the U-Trough when the unit is anchored down.
  • Page 55 8. Dimensions Concrete Knock-Out Installation Knock-out in the foundation must be 10" (216 mm) past the center point as shown in Figure 8H. This is important to ensure that the pivot point of the sweep is centered in the bin once the system has been installed.

  • Page 56: Chapter 9 U-Trough And Sweep Selection Guidelines

    9. U-Trough and Sweep Selection Guidelines IMPORTANT: Capacity requirements must be determined prior to ordering any unload/sweep system. Failure to do so may cause the sweep to overfeed the center gate. This could cause the electric motor to cut out and may damage the sweep backplate. Listed on the next two pages are guidelines to assist with proper flight diameter and motor pulley selection.

  • Page 57: Belt Size Selection

    9. U-Trough and Sweep Selection Guidelines Belt Size Selection Springland MFG does not supply belts. Use the following table to select the correct belt for your unloader. U-Trough Belt Sizes Center to Center Distance Horsepower NEMA Frame 12.4" Pulley (1) 18.4"...

  • Page 58: Chapter 10 Troubleshooting

    10. Troubleshooting Q: My slide gates will not open? 1. Check floor flange gate slide clearance. (See Page 53 for details.) 2. In colder temperatures moisture can collect and freeze slide gate to the lid. Q: Why is my unload tube filled with product? 1.

  • Page 59: Chapter 11 Warranty

    12 months from the date of shipment (or, if shipped by vessel, 14 months from the date of arrival at the port of discharge). If, in GSI’s sole judgment, a product is found to have a defect in materials and/or workmanship, GSI will, at its own option and expense, repair or replace the product or refund the purchase price.
  • Page 60 Authorities having jurisdiction should be consulted before installations are made. 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.com Copyright © 2021 by The GSI Group, LLC Printed in the USA CN-362576...

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