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GSi PNEG-2309 Installation And User Manual

Horizontal fertilizer mixer
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Horizontal Fertilizer Mixer
Installation and User Manual
PNEG-2309
Version 1.0
Date: 12-03-20
PNEG-2309

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Summary of Contents for GSi PNEG-2309

  • Page 1 Horizontal Fertilizer Mixer Installation and User Manual PNEG-2309 Version 1.0 Date: 12-03-20 PNEG-2309...
  • 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-2309 Horizontal Fertilizer Mixer...

  • Page 3: Table Of Contents

    Wiring Installation........................46 Chapter 6 Operation ..........................47 Loading the Mixer........................47 Loading Sequence ........................47 Chapter 7 Troubleshooting ........................49 Chapter 8 Maintenance..........................55 General ............................55 Bearings...........................56 Gear Reducer ..........................56 Drive V-Belts..........................56 Shafts Seals ..........................56 Limited Warranty - N.A. Fertilizer Products ................57 PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 4 NOTES PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 5: Chapter 1 Safety Precautions

    Personnel operating or working around equipment must read this manual. This manual must be delivered with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment. ST-0001–4 PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 6: Cautionary Symbol Definitions

    This symbol is used to address practices not related to personal injury. This symbol indicates a general hazard. This symbol indicates a prohibited activity. This symbol indicates a mandatory action. ST-0005–2 PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 7: Safety Cautions

    • Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. • If you do not understand any part of this manual or need assistance, contact your dealer. ST-0002–1 PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 8 Failure to follow safety precautions can result in severe injury or death. ST-0042–2 Flying Material Hazard • Flying material can cause severe eye injury or blindness. • Wear safety glasses around operating equipment. ST-0074–1 PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 9 • Do not attach lifting equipment to ladders or platforms. • Do not go outside of the safety rails provided on elevated platforms. • Do not work at heights during high winds, rain, snow, or ice storms. ST-0056–1 PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 10 • Do not walk or stand under hoisted equipment. • Always use sturdy and stable supports when needed for installation. Not following these safety precautions creates the risk of falling equipment, which can crush personnel and cause serious injury or death. ST-0047–1 PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 11 Stay Clear of Moving Parts • Entanglement in drop gate operating mechanism can cause serious injury. • Keep all guards and covers in place at all times. • Lock-out power source before making adjustments, cleaning, or maintaining equipment. ST-0089–1 PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 12: Safety Decals

    Safety Decals The safety decals on your equipment are safety indicators which must be carefully read and understood by all personnel involved in the installation, operation, service and maintenance of the equipment. Figure 1-1 Safety decal locations PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 13 Inside of belt guard DC-2469 Guard, Rotating Parts covers Top of bearing guard Decal, Warning, Rotating DC-2525 Shafts covers On the tub to the left Decal, Danger, Missing DC-2526 and right of bearings Guard, Rotating Shafts PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 14 Space Hazard On top of inspection Decal, Danger, Mixing DC-2529 panels Paddles To replace a damaged or missing decal, contact us to receive a free replacement. GSI Decals 1004 E. Illinois St. Assumption, IL 62510 Tel: 1-217-226-4421 PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 15: 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-2309 Horizontal Fertilizer Mixer...
  • Page 16 NOTES PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 17: Chapter 2 Introduction

    ▪ General Safety Statements ▪ Uncrating and Inspection Contact Information Please contact your GSI dealer if you have any questions or contact GSI. Visit our website at www.grain- systems.com. If calling with questions about your product, please have the following information ready: •...

  • Page 18: Uncrating And Inspection

    NOTE: 1. After uncrating your mixer, check for shipping damage and report any damage immediately to the carrier and to GSI. Please make sure that all parts are accounted for. 2. If the mixer is not to be installed immediately, make sure to store it in a clean, dry location that is protected from extreme temperature conditions.

  • Page 19: Chapter 3 Mixer Parts And Specifications

    Table 3-3 Belt drive technical data (Contd.) Center Distance Facewidth Driver Pitch Driven Pitch Install/Take-up Center Mixer (in.) (in.) Diameter (in.) Diameter (in.) Distance Range (in.) 4-Ton 40.4 3.06 7.00 8.90 39.35 - 41.85 8-Ton 51.1 3.06 8.90 14.90 50.07 - 53.27 PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 20 • Two 40 HP motors. • Two 75 HP motors. • Two Dodge TA8407H40 shaft mount reducers. • Two Dodge TA10507H40 shaft mount reducers. • Two belt drives with covers. • Two belt drives with covers. PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 21: Mixer Dimensions

    Chapter 3: Mixer Parts and Specifications Mixer Dimensions NOTE: The dimensions (approximate) shown below are for reference only. Refer to the certified drawing provided with each mixer for actual dimensions. Figure 3-1 4-Ton mixer dimensions Figure 3-2 8-Ton mixer dimensions PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 22: Service Parts (4-Ton Mixer)

    Chapter 3: Mixer Parts and Specifications Service Parts (4-Ton Mixer) Figure 3-3 4-Ton mixer parts PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 23 28 MHC00054 Bushing, 2517 x 2-1/8" T.L. FR-2717 Mixer FR-2720 Drop Gate, Backseal, 20', Scott Mixer 29 MHC00979 Sheave, 4 GR 5V 7.1-2517 T.L. NOTE: This component is order-specific. Refer to the certified drawing provided with the unit for this part number. PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 24: Service Parts (8-Ton Mixer)

    Chapter 3: Mixer Parts and Specifications Service Parts (8-Ton Mixer) Figure 3-4 8-Ton mixer parts PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 25 FR-2720 Drop Gate, Backseal, 20', Scott Mixer 31 MHC00814 Sheave, 4 GR 5V 9.0-2517 T.L. 32 MHC00530 Bushing, 3535 x 2-11/16" T.L. NOTE: This component is order-specific. Refer to the certified drawing provided with the unit for this part number. PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 26 NOTES PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 27: Chapter 4 Mixer Assembly

    Assemble the two mixer halves (71) together by installing bolts (56) to the end plates. NOTE: The hardware (56 and 57) to assemble the mixer halves (71) is supplied by Scott equipment. Figure 4-1 Assembling the mixer halves Bolt Mixer half PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 28: Installing The Center Cover

    3. Install the chemical injection plate (28) onto the 3/8" x 1" welded bolts (2) of the center cover (26) and fasten with 3/8" flange nuts (21). Figure 4-3 Installing the chemical injection plate 3/8" x 1" welded bolt (S-20438) Center cover 3/8" flange nut (S-8032) Chemical injection plate PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 29: Nozzle Installation

    The driven shaft must extend through the full length of the reducer. 2. Install one bushing backup plate on the end of the hub and secure with the supplied retaining ring. Repeat the procedure for the other side. PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 30 Table 4-2 Minimum shaft length Minimum Shaft Length Minimum Distance from the Shaft Bearing “A” Mixer Reducer Size 4-Ton TA8407H 12.82" 2.06" 8-Ton TA10507H 15.46" 2.39" Figure 4-5 Sliding the bushing onto the drive shaft Bushing Drive shaft PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 31 5. Mount the reducer (33) on the drive shaft (31) and align the shaft key (32) with the reducer (33) hub keyway. Maintain the recommended minimum distance “A” from the shaft bearing. Figure 4-7 Mounting the reducer to the drive shaft Drive shaft Reducer PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 32 (30) holes. Insert the bolts (11) with washers (20) installed in the unthreaded holes in the bushing (30). Tighten screws lightly. Figure 4-9 Sliding the second bushing onto the drive shaft Bushing bolt Drive shaft Split lock washer Bushing Bushing backup plate PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 33 *Below 15 RPM output speed, oil level must be adjusted to reach the highest oil level plug. If there is a change in reducer position, either more or less oil may be required. Consult Mechanical Power Transmission Support, Greenville, SC. PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 34: Installing The Torque Arm And Turnbuckles

    5/8" x 2" hex bolt 1" x 3-1/2" hex bolt 1" x 5" hex bolt Reducer 5/8" flat washer (S-7400) Adapter plate 5/8" lock washer (S-3208) Torque arm assembly Torque arm 1" lock washer 5/8" hex nut (S-7363) Turnbuckle PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 35 5/8" x 2" hex bolt 1" x 3-1/2" hex bolt 1" x 5" hex bolt Reducer 5/8" flat washer (S-7400) Adapter plate 5/8" lock washer (S-3208) Torque arm assembly Torque arm 1" lock washer 5/8" hex nut (S-7363) Turnbuckle PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 36: Installing The Motor Mounts And Motors

    Figure 4-14 Installing the base plate to the angle supports 5/8" x 2" HHCS bolt (S-20143) Left angle support 5/8" flat washer (S-7400) Right angle support 5/8" lock washer (S-3208) Base plate 5/8" hex nut (S-7363) PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 37 NOTE: Use 1" hex nuts to adjust the height of the motor (41). Figure 4-16 Installing the motor to the motor mount plate 5/8" x 2-1/2" HHCS bolt (S-20223) Motor mount plate 5/8" flat washer (S-7084) Motor 5/8" hex nut (S-7363) PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 38: Installing The Sheaves And Belts

    Figure 4-18 Installing the belt guard bushing cover to the angle supports (4-Ton mixer) 1/2" x 1-1/2" HHCS bolt (S-7506) Left angle support 1/2" flat washer (S-7072) Right angle support 1/2" serrated flange nut (S-20068) Belt guard bushing cover PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 39 NOTE: Make sure the sheaves (45 or 46) are aligned vertically above each other and tighten the retaining screws (12). Figure 4-20 Sliding the sheave assemblies onto the drive shafts Retaining screw Sheave bushing Driving sheave Drive shaft Driven sheave PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 40 (9), 3/8" flat washers (14) and 3/8" flange nuts (21). Figure 4-22 Installing the belt guard assembly 3/8" x 3/4" HHCS bolt (S-7603) Belt guard front cover 3/8" flat washer (S-7021) Belt guard assembly 3/8" flange nut (S-8032) PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 41: Belt Tension Adjustment

    2. When the V-belt tension is correct, tighten the top nut on the jack screws to lock the motor base in position. NOTE: Refer to the Mixer Specifications, page 19 for belt drive and belt tensioning details. Figure 4-23 Adjusting the belt tension Span Belt deflection Force PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 42: Installing The Bearing Guards

    Figure 4-24 Installing the bearing guards 3/8" x 1" HHCS bolt (S-7104) Left bearing guard 3/8" x 3/4" HHCS bolt (S-7603) Bearing 3/8" flat washer (S-7021) Bearing guard bottom plate 3/8" flange nut (S-8032) Right bearing guard PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 43: Installing The Limit Switches

    1/2" from the extended position and the other sensor is triggered when the air cylinder is 3/8" to 1/2" from the retracted position. 3. Secure the sensor (73) to the air cylinder (59) using the set screws. Figure 4-25 Installing the limit switches Air cylinder Sensor PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 44: Hazard Monitoring

    Figure 4-26 Bearing guard knockouts for the installation of hazard monitoring equipment Knockout section for bearing temperature sensor Knockout section for shaft speed sensor Knockout section for bearing temperature sensor Bearing guard top Knockout section for bearing temperature sensor Bearing guard PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 45: Chapter 5 Mixer Installation

    3. Do not lift from the underside or tub area. Lifting on the channel base is acceptable, if done properly. 4. Consider the center of gravity of the equipment when lifting. NOTE: Refer to the certified drawing provided for approximate total weight of each mixer before lifting. PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 46: Wiring Installation

    1. All wiring must be performed by a qualified electrician. If problems develop with electrical components supplied by GSI, contact service personnel immediately. Repairs are not to be made without written authorization from GSI. Failure to comply with this could void the manufacturer’s warranty.

  • Page 47: Chapter 6 Operation

    2. Always add liquids after the dry ingredients have been added to the mixer. IMPORTANT: Do not add liquids to an empty mixer. NOTE: If liquid addition is a major part of the mixing process, periodic inspection and cleaning will be necessary to maintain the sanitation of the mixer. PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 48 NOTES PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 49: Chapter 7 Troubleshooting

    1. Agitator bearings loose on base. Tighten bearings down to bearing shelf. 2. Steel blocks positioning agitator bearing worked loose, allowing agitator to rub tub sides. 3. Set collars on agitator bearings are loose allowing agitator to thrust against tub ends. Re-align agitator and tighten set collars. PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 50 NOTE: Before adjusting the drop gate, lock the gate arm (60) mechanically by using any of the equipment listed below. • Chain • Come-along-winch • Cylinder stop • Other safety device Figure 7-1 Mechanically locking the gate Air cylinder Air cylinder arm PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 51 The gap between the angle irons is 1/4" and the fast evacuation of the product is about 3-5 seconds. Figure 7-2 Checking the over center Crank Turnbuckle Pinch seal Hinge shaft Rocker Drop gate shaft Gate PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 52 NOTE: Typically, there will be no leakage with the gate adjusted to the below shown tolerances. In case of extremely free flowing, light and aerated material an additional gasket or seal may be installed between the two angle rings. Figure 7-4 Checking the gap PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 53 This will allow the turnbuckle (62) to straighten to a slightly over center position. Figure 7-5 Adjusting the gap Jam nut (turnbuckle) Turnbuckle 6. Check the over center and gap. Make adjustments if required. PNEG-2309 Horizontal Fertilizer Mixer...
  • Page 54 7. Check if the seal (74) is in good condition with the gate open. Figure 7-6 Checking the seal condition Seal NEVER use caulk, silicone or sealing material anywhere in the gate mechanism. The gate will seal if it is adjusted properly. CAUTION PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 55: Chapter 8 Maintenance

    When complete, replace and properly secure covers. 2. Unusual noises coming from the machine should be investigated immediately. GSI IS NOT LIABLE FOR DAMAGE DUE TO NEGLECT ON THE PART OF THE OPERATOR. If you are concerned about noise that the machine is making, please shut down and call your dealer immediately.

  • Page 56: Bearings

    • The packing is then wet down with oil or gear lubricate. If the seal begins to leak, additional oil can be added or the packing may need to be removed and replaced with new material. PNEG-2309 Horizontal Fertilizer Mixer...

  • Page 57: Limited Warranty - N.a. Fertilizer Products

    This Limited Warranty extends solely to products sold by GSI and does not cover any parts, components or materials used in conjunction with the product, that are not sold by GSI. GSI assumes no responsibility for claims resulting from construction defects, unauthorized modifications, improper maintenance or servicing of equipment, corrosion or other cosmetic issues caused by storage, application or environmental conditions.
  • Page 58 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 © 2020 by The GSI Group, LLC Printed in the USA CN #358755...

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