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GSi X Series Installation Manual

Bucket elevator platform and ladder
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30"-36" Bucket Elevator Platform
and Ladder "X" Series
Installation Manual
PNEG-1849
Version: 2.0
Date: 06-20-16
PNEG-1849

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Summary of Contents for GSi X Series

  • Page 1 30"-36" Bucket Elevator Platform and Ladder “X” Series Installation Manual PNEG-1849 Version: 2.0 Date: 06-20-16 PNEG-1849...
  • Page 2 Use of the equipment information page will help you identify the equipment in the case that you need to call your dealer or installer. This information should be filled out and kept on record. Equipment Information Model #:___________________________________________ Serial #:____________________________________ Date Purchased:____________________________________ Dealer/Distributor Name and Phone #:___________________________________________ Material Handling...

  • Page 3: Table Of Contents

    Table of Contents Contents Chapter 1 Introduction ............................5 Chapter 2 Safety ..............................6 Safety Guidelines ..........................6 Cautionary Symbols Definitions ......................7 Safety Cautions ............................. 8 Safety Sign-Off Sheet ......................... 12 Chapter 3 Decal Location ............................ 13 Chapter 4 Overview ............................. 14 Chapter 5 Ladder Assembly ..........................
  • Page 4 Table of Contents Chapter 10 30"-36" Head Platform Post, Rails and Bracing ................79 Attach Head Bearing Support Angle to Lower Head for 30" .............. 79 Attach Head Bearing Support Angle to Lower Head for 36" .............. 79 Attach Handrail Supports to Deck E ....................80 Install Posts ............................

  • Page 5: Chapter 1 Introduction

    1. Introduction Chapter 1: Introduction READ THIS MANUAL carefully to learn how to properly use and install equipment. Failure to do so could result in personal injury or equipment damage. INSPECT the shipment immediately upon arrival. The customer is responsible for ensuring that all quantities are correct.

  • Page 6: Chapter 2 Safety

    2. Safety Chapter 2: 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. Save these safety guidelines for future reference.

  • Page 7: Cautionary Symbols Definitions

    2. 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 8: Safety Cautions

    2. Safety Safety Cautions Use Personal Protective Equipment • Use appropriate personal protective equipment: Foot Respiratory Protection Protection Protection Head Fall Hearing Protection Protection Protection Hand Protection • Wear clothing appropriate to the job. • Remove all jewelry. ST-0004-1 • Tie long hair up and back.
  • Page 9 2. 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 10 2. Safety Toxic Fume and Dust Hazard • Remove paint before welding or heating. • Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. • Do all work outside or in a well-ventilated area. Dispose of paint and solvent properly.
  • Page 11 2. Safety Fall Hazard • Ladders, stairways and platforms are for use by competent and trained personnel only. Do not allow children or other unauthorized persons to have access to the equipment. • Access to the equipment must be restricted by the use of security fencing and lockable gates.

  • Page 12: Safety Sign-Off Sheet

    2. 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-1849 30"-36"...

  • Page 13: Chapter 3 Decal Location

    3. Decal Location Chapter 3: Decal Location DANGER DO NOT EXCEED PLATFORM LOAD LIMIT > 500 lbs Load limit = 500 LBS. (2.25 kN) (2.25 kN) Excessive load will damage platform and cause platform to fall. Injury or death will result. DC-2146 PNEG-1849 30"-36"...

  • Page 14: Chapter 4 Overview

    4. Overview Chapter 4: Overview This section is intended to provide a general, high-level overview of platform assembly for the GSI bucket elevator. Detailed instructions are given in the pages to come. This section should be used for reference only and is intended to provide general guidance about the overall process only.

  • Page 15: Chapter 5 Ladder Assembly

    5. Ladder Assembly Chapter 5: Ladder Assembly The ladder sections are to be mounted directly to the trunking sections. Quantities and section lengths may vary depending on overall height of system. If you have a non-standard height system, refer to supported bucket height reference chart below for the correct ladder package for the system.
  • Page 16 5. Ladder Assembly Key: HP = Head Platform RP = Rest Platform 40' Bucket elevator 30' Bucket elevator 20' Bucket elevator (1636XRLAD40) (1636XRLAD30) (1636XRLAD20) (1636XWLAD40) (1636XWLAD30) (1636XWLAD20) Figure 5A PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 17 5. Ladder Assembly Key: HP = Head Platform RP = Rest Platform 60' Bucket elevator 50' Bucket elevator 70' Bucket elevator (1636XRLAD60) (1636XRLAD50) (1636XRLAD70) (1636XWLAD60) (1636XWLAD50) (1636XWLAD70) Figure 5B PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 18 5. Ladder Assembly Key: HP = Head platform RP = Rest platform 80' Bucket elevator 90' Bucket elevator 100' Bucket elevator (1636XRLAD80) (1636XRLAD90) (1636XRLAD100) (1636XWLAD80) (1636XWLAD90) (1636XWLAD100) Figure 5C PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 19 5. Ladder Assembly Key: HP = Head Platform RP = Rest Platform 120' Bucket elevator 110' Bucket elevator 130' Bucket elevator (1636XRLAD120) (1636XRLAD110) (1636XRLAD130) (1636XWLAD120) (1636WRLAD110) (1636XWLAD130) Figure 5D PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 20 5. Ladder Assembly Key: HP = Head Platform RP = Rest Platform 150' Bucket elevator 160' Bucket elevator 140' Bucket elevator (1636XRLAD150) (1636XRLAD160) (1636XRLAD140) (1636XWLAD150) (1636XWLAD160) (1636XWLAD140) Figure 5E PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 21 5. Ladder Assembly Key: HP = Head Platform RP = Rest Platform 180' Bucket elevator 170' Bucket elevator (1636XRLAD180) (1636XRLAD170) (1636XWLAD180) (1636XWLAD170) Figure 5F PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 22 5. Ladder Assembly Key: HP = Head Platform RP = Rest Platform 190' Bucket elevator 200' Bucket elevator (1636XRLAD190) (1636XRLAD200) (1636XWLAD190) (1636XWLAD200) Figure 5G PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 23: Typical Ladder/Cage Setup

    5. Ladder Assembly Typical Ladder/Cage Setup Ref # Part # Description 10FOOTRFWX 10' Ladder Section 10FOOTX 10' Ladder Section LDR-BCKTBHP Safety Cage Bell Hoop - Entrance LDR-3FTCAGE 3' Safety Cage Strap LDR-BCKTHOOP Standard Safety Cage Hoop LDR-10FTCAGE 10' Safety Cage Strap 14FOOTRFWX 14' Ladder Section 14FOOTX...

  • Page 24: Chapter 6 Tie Angles, Ladders And Safety Cages

    6. Tie Angles, Ladders and Safety Cages Chapter 6: Tie Angles, Ladders and Safety Cages Attach Tie Angle to Boot Trunking 1. On the NON LADDER SIDE, attach tie angle to the trunking using 1/2" x 1" bolts. (See Figure 6A and Figure 6B.) a.

  • Page 25: Attach Boot Ladder Support Brackets And Boot Ladder Section

    6. Tie Angles, Ladders and Safety Cages Attach Boot Ladder Support Brackets and Boot Ladder Section NOTE: Refer to ladder layout images, Figure 5A-5G on Pages 16-22. NOTE: Ladders can be mounted to either the up-leg or down-leg end of the elevator depending on the height and head platform hatch location.
  • Page 26 6. Tie Angles, Ladders and Safety Cages b. 30"-36" Up-Leg Bracket: Use 3/8" x 1" hex bolts to attach the ladder support brackets to the boot tie angle using the holes indicated in Figure 6D. Note the outer bracket uses the first set of holes towards the outside.

  • Page 27: Install Boot Ladder Section

    6. Tie Angles, Ladders and Safety Cages Install Boot Ladder Section 1. Trim a 10' ladder section to sit so that the first ladder rung is 12" from the ground. (See Figure 6E.) Figure 6E PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 28 6. Tie Angles, Ladders and Safety Cages 2. Attach trimmed ladder section to the left and right ladder brackets using 1/2" x 1" hex bolts through the bottom most set of holes. 3. Attach the next ladder section to the ladder brackets using 1/2" x 1" hex bolts through the top set of holes.

  • Page 29: Tie Angles To Trunking

    6. Tie Angles, Ladders and Safety Cages Tie Angles to Trunking 1. Tie angles must be mounted to each trunking seam on both the ladder and non-ladder side of the trunking. Use 1/2" x 1" bolts. See Figures 6G-6I on Pages 29 and 30 for the correct location of bolts for each elevator size.
  • Page 30 6. Tie Angles, Ladders and Safety Cages Figure 6H 30" Bucket Elevator Tie Angles to Trunking Bolt Locations Figure 6I 36" Bucket Elevator Tie Angles to Trunking Bolt Locations PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 31: Ladder Support Brackets

    6. Tie Angles, Ladders and Safety Cages Ladder Support Brackets 1. Attach ladder support brackets to tie angle using 3/8" x 1" hex bolts (S-7469). Use the holes shown Figure 6J for each size elevator. 2. Mount the upper right and upper left hand ladder support brackets to the top tie angle with 3/8" bolts. 3.
  • Page 32 6. Tie Angles, Ladders and Safety Cages Figure 6K 30"-36" Ladder Bracket Location for Up-Leg Figure 6L 30"-36" Ladder Bracket Location for Down-Leg PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 33: Attach Ladders To Ladder Brackets

    6. Tie Angles, Ladders and Safety Cages Attach Ladders to Ladder Brackets 1. Attach ladder sections to the ladder brackets using 1/2" x 1" hex bolts (S-7935). (See Figure 6M.) Figure 6M PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 34: Safety Cage Installation

    6. Tie Angles, Ladders and Safety Cages Safety Cage Installation Safety cage entrance must be installed to the ladders within 7'-8' from the ground or platform deck. (See Figure 6N.) Figure 6N PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 35: Install Safety Cage

    6. Tie Angles, Ladders and Safety Cages Install Safety Cage Safety cages are 10' sections, with the exception of the 3' entrance section. 1. Locate safety cage hoops (LDR-BCKTBHP) along the ladder rails where the safety cage hoops will be installed. NOTE: The end hoops of a 10' section are spaced 4' from the two (2) middle hoops, which are spaced 2' apart.
  • Page 36 6. Tie Angles, Ladders and Safety Cages 2. Attach safety cage hoops to ladder using 1/2" x 1" bolts and nuts. (See Figure 6P.) Figure 6P PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 37 6. Tie Angles, Ladders and Safety Cages 3. Install the seven (7) 10' safety cage straps along the safety cage hoops using 5/16" x 3/4" bolts and nuts. NOTE: Bolt heads should be to the inside of the hoop. (See Figure 6Q.) Figure 6Q PNEG-1849 30"-36"...

  • Page 38: Chapter 7 Rest Platform

    7. Rest Platform Chapter 7: Rest Platform Rest Platform Tie Angles to Bucket Elevators 1. Install rest platform tie angles to the lower trunking on both the ladder side and non-ladder side of the trunking. Use 1/2" x 1" bolts through the bolt holes indicated for the bucket elevator size being installed.
  • Page 39 7. Rest Platform Figure 7C 30" Rest Platform Tie Angle Bolt Locations - Non-Ladder Side Figure 7D 36" Rest platform tie angle bolt locations - Ladder and non-ladder side have the same bolt hole locations. PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 40: Attach Rest Platform Channel To The Rest Platform Tie Angle

    7. Rest Platform Attach Rest Platform Channel to the Rest Platform Tie Angle 1. Connect rest platform mounting channels to the rest platform tie angles using 1/2" x 1" bolts. Bolt hole locations for 30"-36" bucket elevator will be the same. (See Figure 7E.) Figure 7E Bolt hole locations for 30"-36"...

  • Page 41: Rest Platform Cross Channel To Rest Platform Mounting Channels

    7. Rest Platform Rest Platform Cross Channel to Rest Platform Mounting Channels 1. Place the rest platform cross channels between the rest platform mounting channels and connect those using 3/8" x 3/4" hex bolts. (See Figure 7F.) Figure 7F Rest Platform Cross Channel to Rest Platform Mounting Channels 2.
  • Page 42 7. Rest Platform 3. Install the handrail platform posts to the rest platform mounting channels and rest platform channels using six (6) 5/16" x 3/4" flanged hex bolts for each post, four (4) bolt to the front and two (2) on the side.
  • Page 43 7. Rest Platform 5. Install the front and back intermediate handrails to the platform posts using 5/16" x 3/4" flanged hex bolts. Adjust the rail into position by sliding it out to the correct length. 6. After cutting the two (2) large and two (2) small intermediate handrails, slide them to the correct length and install them to the handrail posts on the short sides of the platform using 5/16"...
  • Page 44 7. Rest Platform 7. Connect the front rest platform handrails and the side rest platform handrails to the handrail platform post using 5/16" x 2" hex bolts. (See Figure 7K.) Figure 7K PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 45 7. Rest Platform 8. Platform braces must be installed from handrail posts to mounting and cross channels using 5/16" x 3/4" flanged hex bolts. Braces should be attached to the outside of the platform post and to the inside of the mounting and cross channels. NOTE: Safety cage bars (LDR-5171BE) are used as platform braces/tie angle braces through out this installation.
  • Page 46 7. Rest Platform 9. Install ladder support brackets to the rest platform cross channel using 3/8" x 3/4" hex bolts. 10. Attach ladders to ladder support brackets using 1/2" x 3/4" hex bolts. (See Figure 7M.) Figure 7M PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 47: Ladder Support

    7. Rest Platform Ladder Support Figure 7N PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 48: Chapter 8 30"-36" Head Platform Right Hand Drive

    8. 30"-36" Head Platform Right Hand Drive Chapter 8: 30"-36" Head Platform Right Hand Drive To facilitate quick and easy assembly, numerous parts are pre-assembled prior to shipping. Considerable time is dedicated at the beginning of this manual to the proper orientation of channels and decks.

  • Page 49: Attach Cross Deck Support Channels To Lower Head

    8. 30"-36" Head Platform Right Hand Drive Attach Cross Deck Support Channels to Lower Head Three (3) cross deck support channels support the platform. Two (2) of the channels are attached to brackets on the lower head section and the third channel is attached to the decking itself but is not attached directly to the lower head.

  • Page 50: For 30" Right Side Drive

    8. 30"-36" Head Platform Right Hand Drive Attach Main Support Channels to Lower Head For 30" Right Side Drive Orient the Channel Place lower head section on solid and level surface. 1. At Discharge End orient the channel so that: a.
  • Page 51 8. 30"-36" Head Platform Right Hand Drive 30" Right Holes etched on channel Holes etched on channel Six (6) bolt holes at this end. Non-drive side (Hatch located on this side.) Lower head here Drive Side Eight (8) bolt holes at this end. Note orientation of channel Figure 8B 30"...

  • Page 52: For 36" Right Side Drive

    8. 30"-36" Head Platform Right Hand Drive For 36" Right Side Drive Orient the Channel Place lower head section on solid and level surface. 1. At the Discharge End orient the channel so that: a. Channel opening is outward, toward the discharge end of the head. b.
  • Page 53 8. 30"-36" Head Platform Right Hand Drive Holes etched on channel 36" Right Holes etched on channel Six (6) bolt holes at this end. Non-drive side (Hatch located on this side.) Lower head here Drive side Eight (8) bolt holes at this end. Note orientation of channel Figure 8D 36"...

  • Page 54: Attach Deck A To Hatch Cover Plate

    8. 30"-36" Head Platform Right Hand Drive Attach Deck A to Hatch Cover Plate NOTE: Only two (2) side of deck plate are attached at this time. 1. Locate pre-assembled Deck A. This plank consists of the two (2) hatch openings and is labeled with holes etched with the letter A.

  • Page 55: Slide/Place Toe Boards On Cross Deck Support Channels

    8. 30"-36" Head Platform Right Hand Drive Slide/Place Toe Boards on Cross Deck Support Channels NOTE: Due to the snug fit, you should slide the toe boards in place before placing and securing Deck A or any subsequent decking. 1. On the non-drive side slide one toe board (HP36STBX) into place. 2.

  • Page 56: Connect Deck A To Cross Deck Support Channels And Toe Board

    8. 30"-36" Head Platform Right Hand Drive Connect Deck A to Cross Deck Support Channels and Toe Board NOTE: Orientation of etched holes on deck and channel is critical to subsequent steps. Connect all bolts only finger tight until deck is completely assembled and then tighten to proper torque. 1.
  • Page 57 8. 30"-36" Head Platform Right Hand Drive Figure 8I PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 58: Connect Deck C To Cross Deck Support Channel And To Toe Board

    8. 30"-36" Head Platform Right Hand Drive Connect Deck C to Cross Deck Support Channel and to Toe Board NOTE: The orientation of the flanges on Deck C is critical to subsequent steps. Tighten bolts only finger tight until deck alignment is complete. 1.
  • Page 59 8. 30"-36" Head Platform Right Hand Drive Figure 8K Underside View of Deck C to Toe Board PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 60: Connect Deck F To Cross Deck Support Channels And Deck C

    8. 30"-36" Head Platform Right Hand Drive Connect Deck F to Cross Deck Support Channels and Deck C IMPORTANT: Connect all bolts only finger tight until deck is completely assembled and then tighten to proper torque. 1. Locate pre-assembled Deck F. This deck consists of two (2) planks. 2.
  • Page 61 8. 30"-36" Head Platform Right Hand Drive 6. Connect Deck F to Deck C using 3/8" x 1" bolts (S-7469) with flange nuts (S-10028). a. Align F Deck hole F2 to C deck hole C6. b. Align F Deck hole F1 to C deck hole C7. (See Figure 8M.) DECK C Figure 8M Deck F to Deck C...

  • Page 62: Attach Third Cross Deck Support Channel To Decking

    8. 30"-36" Head Platform Right Hand Drive Attach Third Cross Deck Support Channel to Decking Connect all bolts only finger tight until deck is completely assembled and then tighten to proper torque. 1. Orient channel: Locate the third cross deck support channel (HP36CDSCX) and orient it so the “Y” side faces up and hole Y1 is on the non-drive side of the lower head assembly.
  • Page 63 8. 30"-36" Head Platform Right Hand Drive 5. Connect Deck E to Deck A and Deck C using 3/8" x 3/4" bolts (S-7105) with flange nuts (S-10028). (See Figure 8P.) a. A Deck hole A5 to E deck hole E1. b.

  • Page 64: Chapter 9 30"-36" Head Platform Left Hand Drive

    9. 30"-36" Head Platform Left Hand Drive Chapter 9: 30"-36" Head Platform Left Hand Drive To facilitate quick and easy assembly, numerous parts are pre-assembled prior to shipping. Considerable time is dedicated at the beginning of this manual to the proper orientation of channels and decks.

  • Page 65: Attach Cross Deck Support Channels To Lower Head

    9. 30"-36" Head Platform Left Hand Drive Attach Cross Deck Support Channels to Lower Head Three (3) cross deck support channels support the platform. Two (2) of the channels are attached to brackets on the lower head section and the third channel is attached to the decking itself but is not attached directly to the lower head.

  • Page 66: For 30" Left Side Drive

    9. 30"-36" Head Platform Left Hand Drive For 30" Left Side Drive Orient the Channel 1. At Discharge End orient the channel so that: a. Channel opening is outward, toward the discharge end of the head. b. Holes labeled with “X” face up. c.
  • Page 67 9. 30"-36" Head Platform Left Hand Drive 30" Left Holes etched on channel Holes etched on channel Eight (8) bolt holes at this end. Drive side Lower head here Non-drive side (Hatch located on this side.) Six (6) bolt holes at this end. Note orientation of channel Figure 9B 30"...

  • Page 68: For 36" Left Side Drive

    9. 30"-36" Head Platform Left Hand Drive For 36" Left Side Drive Orient the Channel 1. At Discharge End orient the channel so that: a. Channel opening is outward, toward the discharge end of the head. b. Holes labeled with “Y” face up. c.
  • Page 69 9. 30"-36" Head Platform Left Hand Drive 36" Left Holes etched on channel Holes etched on channel Eight (8) bolt holes at this end. Drive side Lower head here Non-Drive side (Hatch located on this side.) Six (6) bolt holes at this end.

  • Page 70: Attach Deck A To Hatch Cover Plate

    9. 30"-36" Head Platform Left Hand Drive Attach Deck A to Hatch Cover Plate NOTE: Only two (2) side of deck plate are attached at this time. 1. Locate pre-assembled Deck A: This plank consists of the hatch opening, the hatch filler plate and is labeled with holes etched with the letter A.

  • Page 71: Slide/Place Toe Boards On Cross Deck Support Channels

    9. 30"-36" Head Platform Left Hand Drive Slide/Place Toe Boards on Cross Deck Support Channels NOTE: Due to the snug fit, you should slide the toe boards in place before placing and securing Deck A or any subsequent decking. 1. On the non-drive side slide one toe board (HP36STBX) into place. 2.

  • Page 72: Connect Deck A To Cross Deck Support Channels And Toe Board

    9. 30"-36" Head Platform Left Hand Drive Connect Deck A to Cross Deck Support Channels and Toe Board NOTE: Orientation of etched holes on deck and channel is critical to subsequent steps. Tighten bolts only finger tight until all decking is installed. 1.

  • Page 73: Connect Deck C To Cross Deck Support Channel And To Toe Board

    9. 30"-36" Head Platform Left Hand Drive Figure 9I 6. Connect Deck A to Toe Board: Line up holes on toe board with holes on Deck A: a. Deck hole A8 and toe board hole A1. b. Deck hole A12 to toe board hole A5. Connect Deck C to Cross Deck Support Channel and to Toe Board NOTE: The orientation of the flanges on Deck C is critical to subsequent steps.
  • Page 74 9. 30"-36" Head Platform Left Hand Drive DECK A Figure 9J Deck C to Cross Deck Support Channels DECK A Figure 9K Underside View of Deck C to Toe Board 6. Connect Deck C to toe board using 3/8" x 1" bolts (S-7469) with flange nuts (S-10028). a.

  • Page 75: Connect Deck F To Cross Deck Support Channels And Deck C

    9. 30"-36" Head Platform Left Hand Drive Connect Deck F to Cross Deck Support Channels and Deck C IMPORTANT: Connect all bolts only finger tight until deck is completely assembled and then tighten to proper torque. 1. Locate pre-assembled Deck F. This deck consists of two (2) planks. 2.
  • Page 76 9. 30"-36" Head Platform Left Hand Drive DECK A DECK C Figure 9M Deck F to Deck C 7. Install the head platform hatch deck support (HP1648HDS) under Deck C and Deck F using 3/8" x 3/4" bolt (S-7105) and nut. (See Figure 9N.) NOTE: You may need to remove a bolt from the toe board if one was installed in this location.

  • Page 77: Attach Third Cross Deck Support Channel To Decking

    9. 30"-36" Head Platform Left Hand Drive Attach Third Cross Deck Support Channel to Decking NOTE: Connect all bolts only finger tight until deck is completely assembled and then tighten to proper torque. 1. Locate the third (3 ) cross deck support channel (HP36CDSCX) and orient it so the X side faces up and hole X1 is on the non-drive side of the lower head assembly.
  • Page 78 9. 30"-36" Head Platform Left Hand Drive DECK C Figure 9O After decking is completely assembled, make sure to go back and tighten all bolts and nuts to the proper torque rating. DECK F DECK C DECK A Figure 9P PNEG-1849 30"-36"...

  • Page 79: Chapter 10 30"-36" Head Platform Post, Rails And Bracing

    10. 30"-36" Head Platform Post, Rails and Bracing Chapter 10: 30"-36" Head Platform Post, Rails and Bracing The following assemblies occur the same on all 30"-36" platform installations, regardless of left or right drive orientation. Attach Head Bearing Support Angle to Lower Head for 30" 1.

  • Page 80: Attach Handrail Supports To Deck E

    10. 30"-36" Head Platform Post, Rails and Bracing Attach Handrail Supports to Deck E 1. Attach two (2) HP handrail supports (HP1648HSH) to Deck E using 3/8" x 3/4" bolts and nuts. (See Figure 10C.) NOTE: The supports that attach to Deck A and Deck F attach at the same time as the platform post.

  • Page 81: Install Posts

    10. 30"-36" Head Platform Post, Rails and Bracing Install Posts 1. Attach two (2) “W” posts (HP1648HWP) to the corner of Deck F using 5/16" x 3/4" bolts (S-6606) and nuts. 2. Attach platform post (HP1648HCP) and HP handrail support (HP1648HSH) to the middle of Deck F. Use 5/16"...

  • Page 82: Install Head Side Posts

    10. 30"-36" Head Platform Post, Rails and Bracing Install Head Side Posts For 30" Side Posts 1. Install side post (HP1648HP) to decking. (See Figure 10E.) Figure 10E 2. Install handrail support bracket (HP30XHSPPT) from toe board to side post (HP1648HP) using 5/16"...
  • Page 83 10. 30"-36" Head Platform Post, Rails and Bracing For 36" Side Posts 1. Attach two (2) HP handrail supports (HP1636HS) to lower head using 3/8" x 1-1/4" bolt (S-2071) and nut. (See Figure 10G.) Figure 10G 2. Attach head side post (HP1648HP) to lower head using 5/16" x 3/4" bolts and nuts. (See Figure 10H.) Figure 10H PNEG-1849 30"-36"...
  • Page 84 10. 30"-36" Head Platform Post, Rails and Bracing 3. Attach side post to decking using 5/16" x 3/4" bolts and nuts. (See Figure 10I.) Figure 10I PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 85: Attach Intermediate Handrails To Posts

    10. 30"-36" Head Platform Post, Rails and Bracing Attach Intermediate Handrails to Posts 1. Cut 20" off the tube end of one small intermediate handrail (LDR-4088) and one large intermediate handrail (LDR-4087). (See Figure 10J.) Slide the small rail into the large rail and install between the posts opposite the discharge end and adjust to fit.
  • Page 86 10. 30"-36" Head Platform Post, Rails and Bracing 3. Install the remaining Intermediate handrails around the platform using 5/16" x 3/4" bolts (S-6606) and nuts. (See Figure 10K.) Figure 10K PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 87: Install Upper Handrails

    10. 30"-36" Head Platform Post, Rails and Bracing Install Upper Handrails 1. Attach handrails to the handrail posts using 5/16" x 2" bolts (S-7877) and hex nuts. Use Figure 10L below and Figure 10M on Page 88 for handrail location. Figure 10L Right Hand Drive Rail Locations PNEG-1849 30"-36"...
  • Page 88 10. 30"-36" Head Platform Post, Rails and Bracing Figure 10M Left Hand Drive Rail Locations PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 89: Install Safety Cage Bar Cross Supports

    10. 30"-36" Head Platform Post, Rails and Bracing Install Safety Cage Bar Cross Supports 1. Attach safety cage bar - 24" (LDR-5171BE) from handrail post to decking kick plates using 5/16" x 3/4" bolts and nuts. (See Figure 10N.) Figure 10N PNEG-1849 30"-36"...

  • Page 90: Chapter 11 Install Hatch

    11. Install Hatch Chapter 11: Install Hatch 1. Attach hatch hinge (HP1624HH) to the hatch deck door (HP1624HDD). Orient hinge so that it opens the desired direction. (See Figure 11A.) Fasten using 3/8" x 1" carriage bolts hardware. Figure 11A 2.
  • Page 91 11. Install Hatch 4. Slide two (2) magnets (16-0092) onto each MS #6 x 3/4" FHS flat head screw (S-7166). Position the magnet so the screw head is countersunk into the magnet. (See Figure 11C.) 5. Insert screws with magnets through the hatch door and fasten with the #6 flange nut (S-10133). Figure 11C 6.
  • Page 92 11. Install Hatch 7. Assemble pipe clamps (S-10139) to the magnet mount hatch bracket (HP1648LMM). Insert 3/8" x 3/4" carriage bolts through the magnet mount hatch bracket, 1/2" flat washer and pipe clamp. Fasten with 3/8" nut. (See Figure 11E.) 8.

  • Page 93: Chapter 12 4 X 5 Distributor Platform (Optional)

    12. 4 x 5 Distributor Platform (Optional) Chapter 12: 4 x 5 Distributor Platform (Optional) The distributor platform is optional and only used on bucket elevators that have a distributor spout. The platform is used to access the distributor for maintenance and control adjustments. The platform should be located below the distributor head.

  • Page 94: Assemble Supports

    12. 4 x 5 Distributor Platform (Optional) Assemble Supports Support Channel, Cross Support and Knee Brace Assembly 1. Attach brace channels to the sides of the support channels using four (4) 1/2" x 1" bolts and nuts. Angle the knee braces across the bottom sides of the brace channels and attach using four (4) 1/2"...
  • Page 95 12. 4 x 5 Distributor Platform (Optional) Figure 12C Distributor External Platform Support PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 96: Assemble Decking

    12. 4 x 5 Distributor Platform (Optional) Assemble Decking 1. Align A6 and A8 on platform decking weldment with A6 and A8 on the external platform supports. 2. Install platform decking weldment to the platform support channels using twenty four (24) 1/2"...
  • Page 97 12. 4 x 5 Distributor Platform (Optional) Figure 12E Figure 12F Distributor Platform Toe Board PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 98: Install Handrail Posts - Non Entrance Side

    12. 4 x 5 Distributor Platform (Optional) Figure 12G Distributor Platform Corner Post Install Handrail Posts - Non Entrance Side 1. Install the remaining two (2) “W” corner posts to the corners on the non-entrance side of the decking using four (4) 5/16" x 3/4" flange bolts and nuts per post. 2.
  • Page 99 12. 4 x 5 Distributor Platform (Optional) 4. Install distributor handrail support to the side post on the inside, located closest to the trunking through holes 3 and 4 counting from the top of the post. Use two (2) 5/16" x 3/4" flange bolts and nuts to fasten in place.

  • Page 100: Assemble And Install Intermediate Handrails

    12. 4 x 5 Distributor Platform (Optional) Assemble and Install Intermediate Handrails 1. Insert small intermediate handrail into the large intermediate handrails to create telescoping rails. Cut 30" off one small intermediate and one large intermediate rail to fit at entrance. Adjust all rails to the proper length and install to the posts using the 5 hole down from the top.

  • Page 101: Install Upper Handrails

    12. 4 x 5 Distributor Platform (Optional) Install Upper Handrails 1. Attach handrails to the posts using four (4) 5/16" x 3/4" flange bolts and nuts per handrail. (See Figure 12K.) Figure 12K PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 102: Safety Gate Package (Optional)

    12. 4 x 5 Distributor Platform (Optional) Safety Gate Package (Optional) IMPORTANT: Attach the platform gate bracket to the gate before attaching it to the inside platform post using 5/16" hardware. Attach safety gate assembly to intermediate platform door bracket using 5/16" bolt (S-1196), 5/16"...

  • Page 103: Chapter 13 6 X 6 Distributor Platforms

    13. 6 x 6 Distributor Platforms Chapter 13: 6 x 6 Distributor Platforms This assembly is designed to be located at any elevation on trunking that is needed to provide access to other equipment. Determine elevation of platform surface and work from there. Locate all parts required for assembly by using the chart as shown in Figure 13A.

  • Page 104: Support Channels And Knee Braces

    13. 6 x 6 Distributor Platforms Support Channels and Knee Braces Assemble clamps securely to the trunk, attach the platform support channel (DSP36005) to the upper clamp using 1/2" hardware. Insert rod (DSP36008) through middle hole in the bracket, attached to the platform support channel using 5/8"...

  • Page 105: Toe Boards

    13. 6 x 6 Distributor Platforms Toe Boards With support assembly attached to trunk and hardware tightened, proceed by attaching the notched toe board angle (DSP36002X) and toe board angle (DSP36003X) to the top of the support channel using the 5/16"...

  • Page 106: Cross Braces For Knee Braces

    13. 6 x 6 Distributor Platforms Cross Braces for Knee Braces Attach knee brace diagonals to bottom side of the knee braces, this will add extra stability to the distributor platform. (See Figure 13D below and Figure 13E on Page 107.) See detail I on Page 107 See detail J...
  • Page 107 13. 6 x 6 Distributor Platforms Cross Braces for Knee Braces (Continued) Figure 13E PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 108: Platform Decking

    13. 6 x 6 Distributor Platforms Platform Decking Attach the floor deck panels to the support channels. Then attach end toe boards (DSP36000X) to the platform decking (DSP36004) with the 5/16" hardware provided. Add extra toe board plates, after all pieces have been attached and positioned properly, tighten all hardware.
  • Page 109 13. 6 x 6 Distributor Platforms Platform Decking (Continued) Figure 13G PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 110: Platform Post

    13. 6 x 6 Distributor Platforms Platform Post Figure 13H shows the assembly of three (3) “W” corner posts (HP1648HWP), three (3) platform posts (HP1648HCP) and two (2) safety gate side posts (HP1648HP). This must all be assembled using 5/16" hardware. Figure 13H PNEG-1849 30"-36"...

  • Page 111: Tie Braces

    13. 6 x 6 Distributor Platforms Tie Braces IMPORTANT: For safety purposes, make sure head of bolts are to the inside of platform with nuts on outside at all connections. NOTE: Safety cage bars are used as tie braces in this installation. Between each of the three (3) “W”...

  • Page 112: Intermediate Handrail

    13. 6 x 6 Distributor Platforms Intermediate Handrail IMPORTANT: For safety purposes, make sure head of bolts are to the inside of platform with nuts on outside at all connections. NOTE: The small intermediate handrail (LDR-4088) fits inside of the large intermediate handrail (LDR-4087).

  • Page 113: Upper Handrails

    13. 6 x 6 Distributor Platforms Upper Handrails IMPORTANT: For safety purposes, make sure head of bolts are to the inside of platform with nuts on outside at all connections. (See Figure 13K.) Figure 13K PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 114 13. 6 x 6 Distributor Platforms Upper Handrails (Continued) Attach hatch outside handrail (HP1648HLH) from “W” corner post to platform post and right side handrail (DSP3036H31) from platform post to next “W” corner post using 5/16" bolt (S-7877) and 5/16" flange nut (S-3611).
  • Page 115 13. 6 x 6 Distributor Platforms Upper Handrails (Continued) Attach hatch outside handrail (HP1648HLH) from “W” corner post to platform post and back side handrail (DSP3036H32) from platform post to next safety gate side post (HP1648HP) using 5/16" bolt (S-7877) and 5/16"...

  • Page 116: Safety Gate Package (If Ordered As Optional)

    13. 6 x 6 Distributor Platforms Safety Gate Package (If Ordered as Optional) IMPORTANT: Attach the platform gate bracket to the gate before attaching it to the inside platform post using 5/16" hardware. Attach safety gate assembly to intermediate platform door bracket using 5/16" bolt (S-1196), 5/16" flat washer (S-845) and 5/16"...
  • Page 117 13. 6 x 6 Distributor Platforms Safety Gate Package (If Ordered as Optional) (Continued) Figure 13Q PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...
  • Page 118 NOTES PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series...

  • Page 119: Chapter 14 Warranty

    14 months from arrival at port of discharge, whichever is earlier. The end-user’s sole remedy (and GSI’s only obligation) is to repair or replace, at GSI’s option and expense, products that in GSI’s judgment, contain a material defect in materials or workmanship.
  • Page 120 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 GSI is a worldwide brand of AGCO Corporation. Copyright © 2016 by The GSI Group, LLC Printed in the USA CN-323002...

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