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GSI Group CE Compliant II Series Assembly Manual

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CE Compliant Series II
Bucket Elevator
Assembly Manual - Original Instructions
PNEG-681CE
Date: 04-29-14
PNEG-681CE

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  • Page 1 CE Compliant Series II Bucket Elevator Assembly Manual - Original Instructions PNEG-681CE Date: 04-29-14 PNEG-681CE...
  • Page 2 Equipment Information Model Number: ______________________________________________ Serial Number: ______________________________________________ RPM: _____________________________________________________ Head Pulley Diameter: ________________________________________ Discharge Height: ____________________________________________ Horsepower: ________________________________________________ GSI Group 1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421 Date Purchased: ___________________________________________ Dealer Name and Phone Number: ________________________________ ________________________________...
  • Page 3 CE Declaration of Incorporation EC MACHINERY DIRECTIVE 2006/42/EC 1004 East Illinois Street, Assumption, IL, 62510, USA +1 217 226 4429 The GSI Group declares that GSI Bucket Elevators Models 15P16/15G16; 20P16/20G16; 25P16/25G16; 30P16/30G16; 30P24/30G24; 40P24/40G24; 50P24/50G24; 56P24/56G24; 50P30/50G30; 60P30/60G30; 70P30/70G30; 50P36/50G36;...
  • Page 4 NOTES PNEG-681CE CE Compliant Series II Bucket Elevator...

  • Page 5: Table Of Contents

    Table of Contents Contents Chapter 1 Introduction ............................6 General Safety Statements ........................6 Receiving Inspection ..........................6 Pre-Installation Notifications ........................6 Chapter 2 Safety ..............................7 Safety Guidelines ..........................7 General Safety Statement ........................8 Safety Instructions ..........................9 Correct Use of the Bucket Elevator ..................... 12 Working at Heights ..........................

  • Page 6: Chapter 1 Introduction

    1. Introduction Thank you for choosing a GSI product. It has been designed to provide excellent performance and service for many years. This manual covers general information about installing the GSI Bucket Elevator. Due to the large variety of equipment features offered, this manual cannot cover every aspect of installation with this manual.

  • Page 7: Chapter 2 Safety

    2. Safety Safety Guidelines This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines.

  • Page 8: General Safety Statement

    2. Safety General Safety Statement Our foremost concern is your safety and the safety of others associated with grain handling equipment. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel. As owner and/or operator, you are responsible to know what requirements, hazards, and precautions exist and inform all personnel associated with the equipment or in the area.

  • Page 9: Safety Instructions

    2. Safety Safety Instructions Our foremost concern is your safety and the safety of others associated with this equipment. We want to keep you as a customer. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel. As owner and/or operator, it is your responsibility to know what requirements, hazards, and precautions exist, and to inform all personnel associated with the equipment or in the area.
  • Page 10 2. Safety Operate Motor Properly In an emergency, shut down the power source. Turn OFF and lock out all power sources before performing any maintenance. Do not operate electric motor equipped units until motors are properly grounded. Disconnect power on electrical driven units before resetting motor overloads.
  • Page 11 2. Safety Prepare for Emergencies Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. Keep Emergency Equipment Quickly Accessible Wear Protective Clothing Wear close-fitting clothing and safety equipment appropriate Eye Protection to the job.

  • Page 12: Correct Use Of The Bucket Elevator

    2. Safety Correct Use of the Bucket Elevator 1. These elevators are designed solely for conveying whole agricultural grain and seeds. Use for any other material is a misuse and could result in serious injury and equipment damage. 2. Never operate the Bucket Elevator without completely enclosing the inlet or outlet, making all moving parts in-accessible to any person.

  • Page 13: Working At Heights

    2. Safety Correct Use of the Bucket Elevator (Continued) 3. Never operate with guards removed or inspection covers open. 4. Never open or work on the moving parts of the Bucket Elevator unless: a. It has been run completely empty of grain. (A loaded elevator might result in unexpected movement of the belt and buckets even when locked out.) b.

  • Page 14: Electrical Safety

    2. Safety Working at Heights (Continued) Figure 2B 5. NEVER attach lifting equipment to ladders or platforms. 6. When working on the equipment, NEVER go outside the safety rails provided. 7. Do not work at heights during high winds, heavy rain, snow, ice or storm. The majority of routine service can be carried out from the service platforms provided.
  • Page 15 2. Safety Electrical Safety (Continued) 4. Emergency stops. a. Wired to stop the equipment motor (and any other associated equipment) immediately when pressed. b. Must remain engaged until manually disengaged. c. The equipment should not be able to re-start immediately the emergency stop is re-set. 5.

  • Page 16: Chapter 3 Safety Decals

    Language Pack and the decal locations given in the user’s manual. >220 kg GSI Group 217-226-4421 GSI Group 217-226-4421 DC-2248 DC-2250 DC-2248 DC-2250 GSI Group 217-226-4421 GSI Group Inc. 217-226-4421 DC-2238 DC-2249 DC-2238 DC-2249 Automatic Machinery Automatické stroje a zařízení Automatikus Machinery автоматични машини...
  • Page 17 3. Safety Decals GSI Group 217-226-4421 DC-2213 GSI Group 217-226-4421 DC-2253 DC-2253 DC-2213 The GSI Group 1004 E. Illinois St. Assumption, IL. 62510 150P48 - 105 Model 105'/32.01m Height to discharge 48"/1219 mm Pulley diameter 56 RPM Pulley speed 720 fpm/3.66 m/s...

  • Page 18: Decal Placement

    3. Safety Decals Decal Placement Head section Inspection trunking Decal numbers A. DC-2248 B. DC-2249 C. DC-2251 D. DC-2250 E. DC-2238 F. DC-2252 G. DC-2213 H. DC-2253 Boot section PNEG-681CE CE Compliant Series II Bucket Elevator...

  • Page 19: Chapter 4 Elevator Parts

    4. Elevator Parts Part Identification Figure 4A Ref # Description Bonnet Pressure Relief Panel (One Each Side) Head Pulley Lower Head Section Inspection Door Up-Leg Trunking Down-Leg Trunking Belt Buckets Tie Angles Inspection Section Inspection Door Boot Section Upside Hopper (Downside Hopper Optional) PNEG-681CE CE Compliant Series II Bucket Elevator...

  • Page 20: Chapter 5 Bucket Elevator Foundation

    5. Bucket Elevator Foundation 1. The Bucket Elevator foundation must be designed by a qualified civil engineer and installed by a qualified contractor. 2. Always consider the additional weight of live loads, dead loads, wind loads and soil bearing loads. 3.

  • Page 21: Chapter 6 Boot Section

    6. Boot Section Boot sections are pre-assembled at the factory. Boot inlet hoppers are typically shipped separately. 1. Before installing boot on foundation, examine boot for damage or loose hardware. Do not attempt to install if parts are damaged. 2. Proper position of boot is critical for successful installation. Boot inlet section can be installed as an up-leg or a down-leg inlet.

  • Page 22: Attaching Boot To Foundation

    6. Boot Section Attaching Boot to Foundation 1. Remove the nuts and inlet blank plates to attach boot inlet hopper. 2. Anchor and level boot. Boot must be level and plumb. There are a variety of ways to accomplish this. GSI recommends that you shim to the perimeter, secure with hold-downs and grout the base.

  • Page 23: Inspection Sections

    6. Boot Section Inspection Sections The inspection section of the GSI Bucket Elevator has been designed for easy installation and maintenance. 1. The removable panels can be installed in any order, to allow for the installation of inspection doors at any preferred locations. NOTE: Typical installations often place the inspection section directly above the boot on the up-leg side as the first trunking section.

  • Page 24: Chapter 7 Trunking

    7. Trunking Standard Trunking Standard trunking sections may be fabricated from painted or galvanized steel. IMPORTANT: Galvanized steel trunking MUST have the riveted (huck bolted) seams located to the inside, facing each other on the up-leg and the down-leg. (See Figure 7B.) NOTE: Trunking sections come complete with appropriate hardware and two (2) tie angles.

  • Page 25: Pressure Relief Trunking

    7. Trunking Pressure Relief Trunking Pressure relief trunking is standard trunking that has been modified to include two (2) panels specifically designed for pressure relief. NOTE: This unit requires special attention to the relief panel. This area must be inspected for damage to the panel, frame and particularly the hardware.

  • Page 26: Trunking Installation

    7. Trunking Trunking Installation Prior to any trunking installation, inspect for damage to equipment. Immediately repair or replace defective item(s). NOTE: Always assemble trunking sections on a level surface. 1. Section together to make double trunking. 2. Attach tie angle to single trunking as shown in Figure 7D.

  • Page 27: Chapter 8 Lower Head Section

    8. Lower Head Section The Bucket Elevator lower head section is primarily assembled at the factory. 1. The installation hardware used to attach the head section to the trunking system is included with the shipment. 2. The drive is shipped separately from the lower head section. 3.
  • Page 28 8. Lower Head Section Head Bonnet Section (Continued) GSI Group 217-226-4421 DC-2253 Figure 8B Head Bonnet Ref # Description U-Lug Inspection Door Pressure Relief Panel PNEG-681CE CE Compliant Series II Bucket Elevator...

  • Page 29: Chapter 9 Maintaining Plumbness

    9. Maintaining Plumbness To ensure proper Bucket Elevator plumbness, set up two (2) transits, one in each direction. Refer to Figure 9A for proper tolerance in elevator erection. Figure 9A Plumbing Tolerance Ref # Description Bucket Elevator to be Plumb Top to Bottom within ±1/2". Trunk Section Casing PNEG-681CE CE Compliant Series II Bucket Elevator...

  • Page 30: Chapter 10 Belting, Splicing And Buckets

    10. Belting, Splicing and Buckets Belts The belt for the elevator leg has been specifically chosen based on leg height, grain, weight, pulley diameter, etc. The belt has been pre-punched to accommodate special buckets with specific spacing. Installing the belt can be accomplished several different ways. GSI recommends the following: 1.

  • Page 31: Buckets

    10. Belting, Splicing and Buckets Splicing (Continued) Figure 10A Belt Splicing Ref # Description Belting Going Down from Head Belting Going Up from Boot 5' Minimum Direction of Belt Travel Buckets Buckets are attached to belting using elevator bolts pushed through the belting back side, through the elevator bucket, a flat (fender) washer, a lock washer and a nut.

  • Page 32: Belt Slack Removal

    10. Belting, Splicing and Buckets Belt Slack Removal Remove any slack in belt after splice connection by lowering boot pulley. It is important that the boot pulley and shaft are checked and maintained to be horizontally level. Manual Screw Take-Ups 1.
  • Page 33 10. Belting, Splicing and Buckets Belt Slack Removal (Continued) Do not over tighten belt, as this will decrease the life of the belt. 48" (26") Boot section shown 48" (60") Boot section shown Figure 10B Take-Ups Ref # Description Manual Take-Up Screw Gravity Take-Up Weight Box Gravity Take-Up Assembly Bearing Plate Screw...

  • Page 34: Chapter 11 Drive Motor And Motor Mount

    11. Drive Motor and Motor Mount Drive The following assembly instructions are for standard drives as purchased with the elevator. The standard drive is designed using the Dodge Torque Arm II shaft mount reducer. Details for this application are included in the Appendix section on Page If you purchased a special drive or drive components from another source, refer to manuals supplied with these materials.
  • Page 35 11. Drive Motor and Motor Mount Motor Mount Assembly (Continued) Figure 11A Motor Mount Plate Ref # Description Motor Mount Left Hand Decal Right Hand Decal Head Bearing Angles Figure 11B Right Hand Motor Placement Decals Ref # Description Toe of Head Bearing Angle Decal PNEG-681CE CE Compliant Series II Bucket Elevator...

  • Page 36: Slide Base

    11. Drive Motor and Motor Mount Slide Base 1. Place the motor slide base upon top of the motor mount, with respect to the drive application side. 2. Place the motor onto the motor slide base and position the motor as close as possible toward the pulley.

  • Page 37: Torque Arm

    11. Drive Motor and Motor Mount Torque Arm 1. Place the torque arm tube assembly on the head section by sliding the two (2) gussets of the torque arm assembly between the head bearing angles. 2. Make sure the locking bolts face away from the head section. 3.

  • Page 38: Shaft Mount Reducer

    11. Drive Motor and Motor Mount Torque Arm (Continued) Figure 11E Torque Arm (16"-24") Ref # Description Motor Gusset Foot Turnbuckle Torque Arm Tube Head Bearing Angles Shaft Mount Reducer For reducer assembly, See Page 49 of the Torque Arm II Reducer Installation Appendix which has detailed instructions for the reducer bushing mounting, cooling fans and backstops.

  • Page 39: Drive Guard

    11. Drive Motor and Motor Mount Drive Guard 1. Attach the drive guard brackets to the motor mount assembly. (See Figures 11F-11J on Pages 40-43.) The shorter, broken legs of the brackets will point towards the pulley. 2. Align the guard rear panel of the guard to the brackets. NOTE, in a right hand drive application (as shown in Figures 11F-11J on Pages 40-43) the flanges of the guard rear panel will face away from...
  • Page 40 11. Drive Motor and Motor Mount Drive Guard (Continued) Figure 11F Belt Guard (Right hand drive shown.) Ref # Description Side Bracket Large Sheave Small Sheave Belt Guard Cover Belt Guard Rear Panel Mounting Brackets PNEG-681CE CE Compliant Series II Bucket Elevator...
  • Page 41 11. Drive Motor and Motor Mount Drive Guard (Continued) Figure 11G Belt Guard Mounted to Brackets Ref # Description Slide Bracket Bushing Sheave Rear Belt Guard Panel Safety Screen (Hole must be cut out.) PNEG-681CE CE Compliant Series II Bucket Elevator...
  • Page 42 11. Drive Motor and Motor Mount Drive Guard (Continued) Figure 11H Slide Bracket Ref # Description Slide Bracket NOTE: Brackets shown will be used for higher “HP” motors. Figure 11I Brackets - Use for Higher HP Motors Ref # Part # Description DG-48T08200 Bracket, 48"...
  • Page 43 11. Drive Motor and Motor Mount Drive Guard (Continued) NOTE: Brackets shown will be used for higher “HP” motors. Figure 11J Brackets - Use for Higher HP Motors Ref # Part # Description DG-48T08200 Bracket, 48" Drive Guard, 200 HP+ DG-48T034 Plate, Middle Bracket 48"/42"...

  • Page 44: Drive Belts

    11. Drive Motor and Motor Mount Drive Belts Drive belts are designed to fit loosely upon installation. Use the motor mount adjustable slide base to properly tension belts to acceptable levels. Proper tension is 0.4 mm (1/64") of deflection per, 25 mm (1") of sheave centers on one side of belt, centered between sheaves.

  • Page 45: Chapter 12 Final Checks, Tracking, Start-Up And Maintenance

    12. Final Checks, Tracking, Start-Up and Maintenance General Final Checks 1. Adjust the throat plate in the head discharge so there is approximately 1/4" clearance between it and edge of the buckets on the lap splice. (See Figure 12A.) Figure 12A Throat Plate 1.

  • Page 46: Belt Tracking

    12. Final Checks, Tracking, Start-Up and Maintenance Belt Tracking Tracking of the belt is very important for optimum results. 1. To correct any tracking problems. • First adjust the boot bearing plates. • Adjust the take-up screws downward on the side that the belt is tracking toward. 2.

  • Page 47: Dealing With Elevator Blockages

    12. Final Checks, Tracking, Start-Up and Maintenance Dealing with Elevator Blockages Elevator blockage is an unlikely event, but can occur if the equipment being fed by the elevator becomes blocked. To resolve this, take the following steps: 1. Stop the elevator and run the down stream equipment to eliminate any down stream blockage. 2.
  • Page 48 12. Final Checks, Tracking, Start-Up and Maintenance Dealing with Elevator Blockages (Continued) 5. At the boot of the elevator, un-bolt and open the clean-out doors. (See Figure 12C.) Figure 12C Ref # Description Clean-Out Door 6. Allow grain to drop by gravity and remove by hand. a.

  • Page 49: Chapter 13 Appendix 1 - Reference Information

    13. Appendix 1 - Reference Information Information regarding the torque arm, roller bearings and pillow blocks can be downloaded from the Baldor website. Go to www.baldor.com/support/product_manuals.asp Enter the required manual number into the search field. See list below. MN1601 - Dodge Torque-Arm II Speed Reducer Installation MN3033 - Dodge S-2000 Spherical Roller Bearings MN3040 - Dodge TAF Pillow Blocks and S-1 Units PNEG-681CE CE Compliant Series II Bucket Elevator...
  • Page 50 NOTES PNEG-681CE CE Compliant Series II Bucket Elevator...

  • Page 51: Chapter 14 Warranty

    GSI Group, LLC Limited Warranty The GSI Group, LLC (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
  • Page 52 Authorities having jurisdiction should be consulted before installations are made. GSI Group 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 © 2014 by GSI Group Printed in the USA CN-312365...

This manual is also suitable for:

15p16/15g1620p16/20g1625p16/25g1630p16/30g1630p24/30g2440p24/40g24 ... Show all

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