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AGI M42 Assembly, Operation And Maintenance Manual

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M42 Bucket Elevators
Assembly, Operation, and Maintenance Manual
This manual applies to:
Bucket elevator capacities: 8000–20,000 BPH (283–708 m
Read this manual before using product. Failure to
follow instructions and safety precautions can
result in serious injury, death, or property
damage. Keep manual for future reference.
3
/h)
Part Number: 10230018 R10
Revised: January 26, 2024
Original Instructions

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  • Page 1 M42 Bucket Elevators Assembly, Operation, and Maintenance Manual This manual applies to: Bucket elevator capacities: 8000–20,000 BPH (283–708 m Read this manual before using product. Failure to Part Number: 10230018 R10 follow instructions and safety precautions can Revised: January 26, 2024...
  • Page 2 New in this Manual The following changes have been made in this revision of the manual: Description Section Part number changes were made. Complete the Work Platform Distributor Platform Updates were made. Back cover Reformatted to standard AGI manual format. All sections...
  • Page 3 This product has been designed and manufactured to meet general engineering standards. Other local regulations may apply and must be followed by the operator. All personnel must be trained in the correct operational and safety procedures for this product. Use the sign-off sheet below to record initial and periodic reviews of this manual with all personnel.
  • Page 4 M42 BUCKET ELEVATORS – 10230018 R10...

  • Page 5: Table Of Contents

    M42 BUCKET ELEVATORS – CONTENTS 1. Introduction ............................8 1.1 Intended Use ..........................8 2. Safety............................... 9 2.1 Safety Alert Symbol and Signal Words..................9 2.2 General Safety Information....................... 9 2.3 Belt and Bucket Safety ......................9 2.4 Torque Arm Safety ........................10 2.5 Explosion Vent Safety......................
  • Page 6 M42 BUCKET ELEVATORS – 6.2.1 Trunking, Platforms, and Ladders General Assembly..........35 6.3 Lifting and Moving........................36 6.4 General Platform Installation Requirements ................37 6.4.1 Platforms Hardware ....................37 6.4.2 Installing Floor Planks....................38 6.5 Installing the Work Platform ....................39 6.5.1 Platform Top View, Basic Dimensions..............
  • Page 7 M42 BUCKET ELEVATORS – 6.16 Installing the Bucket Elevator Belt ..................97 6.16.1 Installing The Belt Into the Elevator ..............97 6.16.2 Splicing The Belt ..................... 99 6.16.3 Belt Splice Methods ..................... 100 6.17 Tensioning and Aligning the Bucket Elevator Belt.............. 104 6.18 Adjusting the Baffle......................

  • Page 8: Introduction

    Keep this manual handy for frequent reference and to review with new personnel. A sign-off form is provided on the inside front cover for your convenience. If any information in this manual is not understood or if you need additional information, please contact AGI or your representative for assistance.

  • Page 9: Safety

    • Follow a health and safety program for your worksite. Contact your local occupational health and safety organization for information. • Contact your local representative or AGI if you need assistance or additional information. • Always follow applicable local codes and regulations.

  • Page 10: Torque Arm Safety

    2. SAFETY M42 BUCKET ELEVATORS – 2.4. Torque Arm Safety Bucket Elevator gear reducers may be equipped with backstops and torque arms / swing base. Never remove the torque arm / swing base when the bucket elevator is loaded. Removal of the torque arm / swing base may cause the reducer to suddenly rotate resulting in serious injury or death.

  • Page 11: Strong Magnetic Fields

    M42 BUCKET ELEVATORS – 2. SAFETY 2.7. Strong Magnetic Fields The bucket elevator could be equipped with strong magnets on the boot inlet. To prevent serious injury or death. • Stay clear! Can be harmful to pacemaker wearers and other medical implants.

  • Page 12: Combustible Dust

    2. SAFETY M42 BUCKET ELEVATORS – 2.9. Combustible Dust The bucket elevator has been designed for safe use in areas where hazards due to combustible dust may potentially occur. Help reduce the risk of a dust explosion by following the preventive measures below.

  • Page 13: Fall Protection System Safety

    • If a fall event should occur, immediately call emergency responders. 2.12. Platform Safety • Check the platform working load. Do not overload. Contact AGI before adding any equipment to a platform. • Close platform access door before and after working on the platform.

  • Page 14: Electric Motor Safety

    2. SAFETY M42 BUCKET ELEVATORS – 2.13.1 Electric Motor Safety Power Source • Electric motors and controls shall be installed and serviced by a qualified electrician and must meet all local codes and standards. • Ensure electrical wiring and cords remain in good condition; replace if necessary.

  • Page 15: Safety Equipment

    M42 BUCKET ELEVATORS – 2. SAFETY 2.15. Safety Equipment The following safety equipment should be kept on site. • Fire Extinguisher • First-Aid Kit Have a properly-stocked first-aid kit Provide a fire extinguisher for use in case available for use should the need arise, of an accident.
  • Page 16 8110-00016 This is NOT an inspection or service panel. DO NOT remove or alter the panel or fasteners in any way. Contact AGI for replacement panel and fasteners. PN 90204034 (placed on (if unit has explosion vents) WARNING AGI M16–M48...
  • Page 17 This is NOT an inspection or service panel. • Shut off and lock out power source before DO NOT remove or alter the panel or inspecting or servicing machine. fasteners in any way. Contact AGI for 90204011 (a) replacement panel and fasteners. 90204010...

  • Page 18: Features

    3.1. Main Elevator Parts Note The figure below is a representation of a typical AGI bucket elevator. All features may not be an exact visual representation. For clarity the belt guard is not shown. Do not operate the bucket elevator without the guard installed.
  • Page 19 M42 BUCKET ELEVATORS – 3. FEATURES Figure 4. Table 2. Select Head Components Description Item speed reducer belt drive motor mount motor discharge HNGI-0514 10230018 R10...

  • Page 20: Leg Cross Section Profiles

    3. FEATURES M42 BUCKET ELEVATORS – 3.2. Leg Cross Section Profiles Figure 5. 16” x 14” Leg Profile Figure 6. 26” x 14” Leg Profile 14" 14" (356 mm) (356 mm) (DW) Design Width “A” 16" (406 mm) (DW) Design Width “A”...

  • Page 21: Drive Side Identification

    M42 BUCKET ELEVATORS – 3. FEATURES 3.3. Drive Side Identification Figure 9. Typical Left Hand Drive Right Hand Drive (Optional) (Standard) HNGI-0435b 10230018 R10...

  • Page 22: Stacking Drawing

    3. FEATURES M42 BUCKET ELEVATORS – 3.4. Stacking Drawing Stacking Exception: If the leg is in a boot pit, the leg sections may be rearranged so inspection sections are above grade. If 10 gage leg sections are required for this installation, locate them closest to the boot.

  • Page 23: Site Preparation

    M42 BUCKET ELEVATORS – 4. SITE PREPARATION 4. Site Preparation A professional engineer must be familiar with the following sections to ensure that the site and installation are designed and prepared correctly. Incorrect planning and preparation can result in serious injury and equipment failure.

  • Page 24: Foundation And Anchoring

    4. SITE PREPARATION M42 BUCKET ELEVATORS – 4.2. Foundation and Anchoring Important Consult a qualified engineer and obtain adequate foundation, concrete, anchoring, and structure design for this bucket elevator. Have a qualified contractor build the foundation. Note Consult the responsible engineer of the project for specific information.

  • Page 25: Structural Capacity

    • This bucket elevator is not designed to support or brace other equipment. Important All distributors, cleaners, and/or spouting must be approved in writing by AGI when supported or braced from the bucket elevator. Otherwise, the extra attachments must be independently supported or braced.

  • Page 26: Lateral Support Of Bucket Elevator

    4.6. Lateral Support of Bucket Elevator AGI recommends the use of a tower, designed by a structural engineer licensed in the jurisdiction, to laterally support the bucket elevator. However, guy cables may be used to support some bucket elevators with pulley diameters 30"...

  • Page 27: Guy Cables Horizontal And Vertical Loads

    4.6.1 Guy Cables Horizontal and Vertical Loads Important The loads given in the following tables are approximate loads only. Make sure a qualified engineer designs the guy cable support system. Table 3. Guy Cables M42-80, M42-100, and M42-120 Anchor A Anchor B Anchor C...
  • Page 28 4. SITE PREPARATION M42 BUCKET ELEVATORS – Table 5. Guy Cables M48-100 Anchor A Anchor B Anchor C Height Horizontal Horizontal Vertical Horizontal Horizontal Vertical Horizontal Horizontal Vertical Number Number Number Distance X Load LH Load LV Distance Y Load LH...
  • Page 29 M42 BUCKET ELEVATORS – 4. SITE PREPARATION Table 7. Guy Cables M48-200 Anchor A Anchor B Anchor C Height Horizontal Horizontal Vertical Horizontal Horizontal Vertical Horizontal Horizontal Vertical Number Number Number Distance X Load LH Load LV Distance Y Load LH...

  • Page 30: Electrical Requirements, Controls, And Devices

    – Signal devices to warn personnel of imminent start up, especially if started from a remote location. • Bucket elevators are commonly equipped with devices listed below, and these may be required by local fire codes. AGI recommends these safety devices. Interlocking Devices There are various types of electrical devices for interlocking of bucket elevator with other equipment.
  • Page 31 M42 BUCKET ELEVATORS – 4. SITE PREPARATION Plug Sensors A plug (obstruction) inside the bucket elevator can be caused by a number of different problems (excessive feed of product, impediments to exit of product, internal spillage, broken internal components, or foreign objects).

  • Page 32: Pre-Installation

    An approval drawing contains specific information about component placement and locations. • An approval drawing from AGI is provided with some but not all bucket elevators. • Contact AGI if you are uncertain whether or not an approval drawing was made for this bucket elevator. 5.2. Before Unloading the Shipment 1.

  • Page 33: Product Storage

    M42 BUCKET ELEVATORS – 5. PRE-INSTALLATION 5.4. Product Storage If storing components before installation, follow the instructions below to prevent dirt and moisture accumulation, damage, or injury. Damage to components resulting from improper storage is not covered by warranty. 1. Place components on wood blocks 6" to 8" off the ground. Do not place directly on ground.

  • Page 34: Assembly

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6. Assembly 6.1. Installation Safety • Do not take chances with safety. The components can be large, heavy, and hard to handle. Always use the proper tools, rated lifting equipment, and lifting points for the job.

  • Page 35: Trunking, Platforms, And Ladders General Assembly

    11. Check for loose fasteners and check the operation of the elevator without material. 6.2.1 Trunking, Platforms, and Ladders General Assembly Following is one general method. For approval on other assembly methods, contact AGI. Important On installations with explosion vents, install explosion vents every 20′ (6096 mm).

  • Page 36: Lifting And Moving

    6. ASSEMBLY M42 BUCKET ELEVATORS – Figure 11. Lifting Multiple Sections LIFT CORRECT WAY TO LIFT LIFT WRONG WAY TO LIFT 7. Frequently check that the trunking is level and straight during assembly. Important All trunk sections must be plumbed to within 1/8″ (3.2 mm) before installing the next section.

  • Page 37: General Platform Installation Requirements

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.4. General Platform Installation Requirements Important When installing the platforms, fill all mating bolt holes. Figure 12. Make Certain Each Platform is Level in Both Directions and Plumb HNGI-0404 6.4.1 Platforms Hardware Assemble together the bucket elevator standard platforms using the supplied (Grade 5) 1/2″ x 1″ hex bolts with flange nuts and 3/8″...

  • Page 38: Installing Floor Planks

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.4.2 Installing Floor Planks Figure 14. Floor Plank Undersides Assembly 3/8" fl ange nut fl oor plank 90005027 3/8" x 1" hex bolt 90000031 HNGI-0012 Figure 15. Assembling Plank Ends to the Platform Base HNGI-0013 3/8"...

  • Page 39: Installing The Work Platform

    6.5.1 Platform Top View, Basic Dimensions Platform basic top view dimensions for construction planning and layout. Note AGI recommends welding the main support channels to the elevator legs. Important Before installing the work platform read the entire manual section pertaining to this platform.
  • Page 40 6. ASSEMBLY M42 BUCKET ELEVATORS – Figure 16. Work Platform Top View Basic Dimensions: 16″ (406 mm) Leg Design-Width (DW) Work Platform (Right Hand Drive shown) 183-3/4" (4667 mm) 50-3/16" (1274 mm) 112-7/16" (2856 mm) 24" PLATFORM FRONT (610 mm) 38-3/16"...
  • Page 41 M42 BUCKET ELEVATORS – 6. ASSEMBLY Figure 17. Work Platform Top View Basic Dimensions: 20″ (508 mm) Leg Design-Width (DW) Work Platform (Right Hand Drive shown) 183-3/4" (4667 mm) 50-3/16" (1275 mm) 117-3/16" (2977 mm) 28-3/4" PLATFORM FRONT (730 mm) 38-3/16"...
  • Page 42 6. ASSEMBLY M42 BUCKET ELEVATORS – Figure 18. Work Platform Top View Basic Dimensions: 26″ (660 mm) Leg Design-Width (DW) Work Platform (Right Hand Drive shown) 183-3/4" (4667 mm) 50-3/16" (1275 mm) 122-7/16" (3110 mm) 34" PLATFORM (864 mm) FRONT 38-3/16"...

  • Page 43: Raising The Head Onto Supports

    6.5.2 Raising the Head onto Supports Important It is necessary to temporarily support and stabilize the head and platform during platform assembly. AGI recommends using supports that raise the platform at least 18” (460 mm) up off the ground until the head platform is fully assembled.

  • Page 44: Installing The Platform Brackets And Support Channels

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.5.3 Installing the Platform Brackets and Support Channels Instructions for installing platform brackets between the elevator head and platform base channel. Important Before installing the work platform, read and understand the entire Work Platform manual section.
  • Page 45 1. Install mounting brackets to the front and back of the head where the head assembly connects with the legs. Use the supplied 3/8” hex bolts and flange nuts. Figure 21. Mounting Bracket Locations for M48 and M42 Models head...
  • Page 46 6. ASSEMBLY M42 BUCKET ELEVATORS – 2. Make sure the mounting channels are in the correct orientation. Note When installing mounting channels, orientate the mounting channel flanges for each so they face in opposite directions. Use 1/2” hex bolts and flange nuts at all mounting channels/brackets connection holes.

  • Page 47: Mounting The Work Platform Base

    Plumb and level the head assembly. Plumb and level the work platform and then temporarily support it until it is fully assembled to the elevator head and legs. AGI recommends temporarily supporting the top elevator legs, head assembly, and platform throughout work platform assembly.

  • Page 48: Assembling The Work Platform Base

    6.5.5 Assembling the Work Platform Base Important It is necessary to temporarily support and stabilize the head and platform during platform assembly. AGI recommends using at least (4) supports that raise the platform at least 18″ (460 mm) up off the ground until the head platform is fully assembled.

  • Page 49: Assembling The Work Platform Basic Components

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.5.6 Assembling the Work Platform Basic Components Instructions for basic component assembly; shows parts relative to assembly locations. 1. Use the correct supplied hardware at each connection. See the following figure and the previous page.

  • Page 50: Completing The Work Platform Assembly

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.5.7 Completing the Work Platform Assembly Figure 26. Example Completed Platform base middle section 30” (762 mm) LEG (DW) 10323677 26” (660 mm) LEG (DW) 10323675 20” (508 mm) LEG (DW) front and back rail 10323673 30”...

  • Page 51: Installing The Distributor Platform

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.6. Installing the Distributor Platform 6.6.1 Platform Top View With Dimensions M16–M24 platform basic top view dimensions for construction planning and layout. Note The figure on this page shows the platform configuration for a Right Hand platform. Components arrangement is reversed for a Left Hand drive.

  • Page 52: Assembling The Distributor Platform Basic Components

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.6.2 Assembling the Distributor Platform Basic Components Instructions for basic component assembly. Note Use 3/8” x 1 1/4” hex bolts and 3/8” flange nuts (typical). Use 1/2” hex bolts and flange nuts at all structural frame component connections.

  • Page 53: Completing The Distributor Platform Assembly

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.6.3 Completing the Distributor Platform Assembly Important All threaded rods must be tightened so they securely lock the platform into location. Note Use 1/2” flat washers at all platform support channels slotted-hole connections. 1. Position the platform at the pre-planned necessary height for this installation.
  • Page 54 6. ASSEMBLY M42 BUCKET ELEVATORS – 4. Install the leg casing angles and side platform rails to the inside rails. 5. Install the threaded rods between these angles on both sides of each leg. 6. Finish installing all handrails, ladders, and ladder brackets, and all components into correct positions.

  • Page 55: Installing The Rest Platform

    The rest platform is shipped pre-assembled and will appear similar to the platform in the following figure. The walk surface is designed so it may be located on either the right or left side. Figure 31. Rest Platform Top View Basic Dimensions M42 = 54" (1372 mm) M48 = 60" (1524 mm) locations 42"...

  • Page 56: Positioning The Platform Walk Surface At The Necessary End

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.7.2 Positioning the Platform Walk Surface at the Necessary End This section illustrates the reversible walk surface assembly. Figure 32. Position the Walk Surface at the Correct End for Your Platform Installation 3/8" hex bolt 3/8"...

  • Page 57: Assembling The Rest Platform Basic Components

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.7.3 Assembling The Rest Platform Basic Components Instructions for basic component assembly showing parts relative to assembly locations. Important Use the 3/8″ flat washers (A) at slotted holes. 1. See the following explosion drawing. Install bolts loose. Wait to tighten these until the handrails are fully assembled.

  • Page 58: Installing The Rest Platform To The Elevator At Base To Leg Flanges Locations

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.7.4 Installing the Rest Platform to the Elevator at Base to Leg Flanges Locations Note Pre-read the instructions in this manual section before installing the rest platform to the elevator legs. 1. Assemble the side platform angles snugly to the elevator legs and install the threaded rods nearest the elevator legs.
  • Page 59 M42 BUCKET ELEVATORS – 6. ASSEMBLY 2. Remove the elevator legs spacer angle at the platform base level and replace it with the platform base back bottom side. 3. Raise the platform assembly up to the side platform angles and install the side platform angles to the back top handrail.
  • Page 60 6. ASSEMBLY M42 BUCKET ELEVATORS – 4. Use the elevator legs spacer angle existing hardware to install the platform base back bottom side. Figure 36. Installing the Platform Base Back Bottom Side to the Leg Flanges elevator fl ange platform base back bottom side 3/8"...
  • Page 61 M42 BUCKET ELEVATORS – 6. ASSEMBLY 5. Assemble the platform to the elevator legs and securely tighten all platform to elevator legs hardware. Figure 37. Installing the Platform to the Elevator Legs, Installing the Ladders spacer angle ladder section elevator...

  • Page 62: Installing The Rest Platform At An Intermediate Location

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.7.5 Installing the Rest Platform at an Intermediate Location This section offers instructions for installing the rest platform to the elevator at a leg intermediate location. Note Use 3/8″ x 1″ bin bolts, 3/8″ x 20″ threaded rods, and 3/8″ flange nuts in their proper locations to make each of the connections shown in this manual section.
  • Page 63 M42 BUCKET ELEVATORS – 6. ASSEMBLY 4. Stand facing the side of the leg that the rest platform will connect to. 5. Hold a locator angle up against one of the legs. 6. Insert the 3/8″ x 22″ threaded rods into the locator angle.
  • Page 64 6. ASSEMBLY M42 BUCKET ELEVATORS – 8. Bring the previously assembled locator angles and 3/8″ x 22″ threaded rod assemblies to the platform assembly on the ground before it is raised for installation to the elevator legs. 9. View the following 2 figures now.
  • Page 65 M42 BUCKET ELEVATORS – 6. ASSEMBLY Important Maintain crane rigging connection and tension until all threaded rod nuts are adequately tightened. 13. Measure twice and make certain the inner threaded rods are a little less than D1 distance apart and the outer threaded rods are a little greater than E distance apart.
  • Page 66 6. ASSEMBLY M42 BUCKET ELEVATORS – Installing the Platform to the Elevator Legs 1. Assemble the leg connection rails snugly to the elevator legs and install the threaded rods nearest the elevator legs. Figure 41. Assembling the Leg Connection Rail Assemblies to the Elevator Legs...
  • Page 67 M42 BUCKET ELEVATORS – 6. ASSEMBLY 2. Raise the platform assembly up to the side platform angles and install the side platform angles to the back top handrail. 3. Remove the elevator legs spacer angle at the platform base level and replace it with the platform base back bottom side.

  • Page 68: Installing The Boot

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.8. Installing the Boot Note The foundation must be dry and level. 1. Position the boot in the planned, correct location and check the boot for level. Important Critical: Make certain the top flanges are level in all directions.

  • Page 69: Installing The Inlet Hoppers

    Figure 44. Install Inlet Hoppers up leg inlet hopper inlet hopper standard fl ared inlet hopper inlet hopper HNGI-0270 Table 9. M42 Inlet Hoppers Installation Dimensions Model Standard Flared in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)

  • Page 70: Installing The Discharge Hopper

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.10. Installing the Discharge Hopper 1. Remove the hood front and back from the head assembly. 2. Elevate the head enough to install the discharge hopper to the front of the unit. (See the following figure.) 3.

  • Page 71: Installing The Drive

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.11. Installing the Drive Assemble the drive components as shown in this manual section and as indicated in the instructions that accompany the drive components. Important Refer to all other drive information / instructions provided with the order. If this drive assembly is equipped with a backstop, refer to the backstop manufacturer installation instructions to install the backstop.

  • Page 72: Torque Arm Mounting Bracket Positions

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.11.2 Torque Arm Mounting Bracket Positions Determine and orientate the bracket for torque arm correct position per this installation. Figure 46. Torque Arm Mounting Bracket Positions HNGI-0302 6.11.3 Mounting the Reducer to the Head Shaft and Torque Arm 1.
  • Page 73 M42 BUCKET ELEVATORS – 6. ASSEMBLY 4. Connect the torque arm foot mount to the torque arm bracket, and connect the torque arm bracket to the motor mount as shown in the following figure. Figure 48. Install the Torque Arm Bracket Figure 49.

  • Page 74: Installing The Motor

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.11.4 Installing the Motor 1. Position the motor on the motor mount. See the following two figures. Figure 51. Positioning the Motor on the Motor Mount motor mount motor HNGI-0273 2. Securely bolt the motor to the motor mount plate.

  • Page 75: Installing The Belt Guard Back And Sheaves

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.11.5 Installing the Belt Guard Back and Sheaves Figure 53. Installing Reducer Belt Guard Brackets Figure 54. Installing the Motor Belt Guard Bracket 3/8" lock nut at-reducer bracket motor mount 10338059 reducer reducer housing...

  • Page 76: Installing And Tensioning The V-Belts

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.11.6 Installing and Tensioning the V-belts Install the sheaves, belt, and guard cover back according to the following figures and as shown in any other instructions that may come with these components. Figure 56. Installing the Pulleys and Drive Belt...
  • Page 77 M42 BUCKET ELEVATORS – 6. ASSEMBLY Tensioning V-Belts Refer to the belt manufacturer’s instructions. Adjust jack screw jam nuts equally to raise and lower the motor mount top plate and adjust belt tension. General Tensioning Rules • Ideal tension is the lowest tension at which the belt will not slip under peak load conditions.
  • Page 78 6. ASSEMBLY M42 BUCKET ELEVATORS – belt defl ection belt defl ection 1/64" per inch of span force K span HNGI-0354 5. Once the V-belt tension is correct, tighten the tops on the jackscrews to lock the motor base in position.

  • Page 79: Installing The Belt Guard Cover

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.11.7 Installing the Belt Guard Cover Figure 57. Installing the Cover reducer 5/16" pulley lock nut guard cover 10038061 motor pulley 5/16" 5/16" x 1" washer hex bolt HNGI-0280 6.12. Installing Spacer Angles and Ladder Brackets 1.
  • Page 80 6. ASSEMBLY M42 BUCKET ELEVATORS – 5. Install spacer angles on the top of leg flanges at leg section splices as shown in the following figure. 6. Install a ladder bracket to the spacer angle at the ladder location. Position the ladder bracket so the ladder will pass through the platform ladder opening.
  • Page 81 M42 BUCKET ELEVATORS – 6. ASSEMBLY Note When installation is complete, spacer angle and ladder bracket assemblies should appear as shown in the following figures. 7. Check that completed spacer angle and ladder bracket assemblies at intermediate leg flange connections appears as shown in the following figures.

  • Page 82: Installing Ladders And Cages

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.13. Installing Ladders and Cages Before climbing on ladders or using any platforms: • Check that all ladders to legs installation is complete. • Check that all ladders are completely motion-free and immovable after installation is complete! •...

  • Page 83: Installing Ladder Clip And Bolt Assemblies

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.13.2 Installing Ladder Clip and Bolt Assemblies 1. Use ladder clips to connect ladder brackets and ladder clips to cages 2. Follow the instructions on the next page and in the assembly instructions for this equipment for correct ladder bracket spacing.

  • Page 84: Installing Ladders To Ladder Brackets And Legs

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.13.3 Installing Ladders to Ladder Brackets and Legs 1. Use 3/8″ x 1″ hex bolts and 3/8″ serrated flange nuts to assemble the ladder bracket to the spacer angle. 2. Install at least one ladder bracket per every 10′ (3048 mm) of ladder run.

  • Page 85: Installing Cages, General Assembly

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.13.4 Installing Cages, General Assembly Before climbing on ladders or using any platforms: • Check that all ladders to legs installation is complete. • Check that all ladders are completely motion-free and immovable after installation is complete.
  • Page 86 6. ASSEMBLY M42 BUCKET ELEVATORS – Figure 67. Positioning D-Rings and Typical Cages Assembly Typical Ladder Cage Assembly Standard, Double, and Flared D-Rings DOUBLE D-RING 10’ (3048 mm) used to join cage sections together cage STANDARD D-RING FLARED D-RING 10’...

  • Page 87: Correct Ladder Placement At The Platform Location

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.13.5 Correct Ladder Placement at the Platform Location Important OSHA 1910.23(d)(4) states “The side rails of through or sidestep ladders extend 42 inches (1.1 m) above the top of the access level or landing platform served by the ladder.”...

  • Page 88: Example Ladders And Platforms Installed To Leg Sections

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.13.6 Example Ladders and Platforms Installed to Leg Sections Figure 69. Example Installation work platform Customer’s Discretion distributor platform rest platform 20' (6096 mm) maximum with no cage 30' (9144 mm) maximum with cage...

  • Page 89: Stacking The Elevator

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.14. Stacking the Elevator Read this entire manual section before hoisting any bucket elevator sections. Important On installations with explosion vents, install explosion vents every 20′ (6096 mm). 6.14.1 Preparing Stackable Leg Sections for Lifting Do not attempt elevator construction when the weather makes it unsafe.

  • Page 90: Installing Guy Wire Brackets

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.14.2 Installing Guy Wire Brackets Important Guy wire brackets differ according to bucket elevator model. The guy wire brackets that come with this installation may differ from the guy wire brackets shown in these instructions. See all instructions in this manual pertaining to installing guy wires.

  • Page 91: Lifting And Installing Stackable Leg Sections

    M42 BUCKET ELEVATORS – 6. ASSEMBLY Figure 71. Guy Wire Bracket Orientation Top View section section HNGI-0505 6.14.3 Lifting And Installing Stackable Leg Sections 1. If the elevator came with a stacking drawing, follow the stacking drawing. 2. Connect legs to legs as shown below.
  • Page 92 6. ASSEMBLY M42 BUCKET ELEVATORS – Note Completed leg section connections should appear as shown in the following figure. (Guy wire brackets differ according to bucket elevator model. The guy wire brackets being assembled may differ from those shown in the following figure. ) Figure 73.
  • Page 93 M42 BUCKET ELEVATORS – 6. ASSEMBLY 6. Stack one section on another until the complete basic elevator assembly is one unit. See the approximate weights table and the following example stacking illustration. Table 11. Approximate Hoisting Weights Figure 74. Stacking Elevator Sections...

  • Page 94: Setting Elevator Legs

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.14.4 Setting Elevator Legs Important If the boot is in a pit, laterally (horizontally) brace the leg near ground level (work floor) to obtain maximum head clearance on the first set of cables above the ground level.

  • Page 95: Installing The Buckets

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.15. Installing the Buckets 1. Insert the bucket bolts through the back side of the belt. Refer to the approval drawing for specific hardware sizes. 2. Slide the bucket over the bolts and secure with nuts.
  • Page 96 6. ASSEMBLY M42 BUCKET ELEVATORS – Figure 78. Bucket Hardware Torque Pattern TIGHTEN FROM LEFT TO RIGHT TIGHTEN FROM RIGHT TO LEFT TIGHTEN FROM LEFT TO RIGHT Table 12. Maximum Recommended Torque for Elevator Bolts Bolt Size Torque Diameter in-lb...

  • Page 97: Installing The Bucket Elevator Belt

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.16. Installing the Bucket Elevator Belt 6.16.1 Installing The Belt Into the Elevator 1. Raise the boot pulley to its highest take-up position. Figure 79. Adjusting the Belt Take-Up down-leg up-leg adjust the take-up...
  • Page 98 6. ASSEMBLY M42 BUCKET ELEVATORS – Figure 80. Installing the Belt HNGI-0440 ROPE rope feed in belt PULLEY pulley 10230018 R10...

  • Page 99: Splicing The Belt

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.16.2 Splicing The Belt 1. Lock out the bucket elevator. Failure to lock out power can cause severe injury. 2. Prepare the belt ends when required. Cut the belt ends squarely and ensure they are clean and free of debris.

  • Page 100: Belt Splice Methods

    6.16.3 Belt Splice Methods Make certain the final belt splice is made square with the belt to insure a straight running belt. AGI recommends the following splicing methods: Method 1: Butt Lap Splice (Standard) For 30″ (762 mm) pulley and smaller Figure 81.
  • Page 101 M42 BUCKET ELEVATORS – 6. ASSEMBLY Method 2: Dura-Splice Clamps (Optional if ordered) Figure 82. Example Completed Installation HNGI-0465 1. Make certain belt ends are square. 2. Use a crayon or chalk. Draw a line on the belt 2″ (51 mm) in from the belt end. This is the bolt center-line.
  • Page 102 6. ASSEMBLY M42 BUCKET ELEVATORS – 3. Mark the location of the bolt holes on the center-line all the way across the width of the belt. Use the outer clamp bar as a template. Note For maximum splice strength – use as many Dura-Splice sets as possible across the full belt width, making certain the Dura-Splice units are positioned no closer than 1/4”...
  • Page 103 M42 BUCKET ELEVATORS – 6. ASSEMBLY 7. After 15 minutes, re-tighten all bolts again to 75 ft-lb. Important Following the above tightening instructions is important to insure maximum splice strength. Note After all splice clamp sets are installed and all bolts are properly torqued, the Dura-Splice is complete.

  • Page 104: Tensioning And Aligning The Bucket Elevator Belt

    6. ASSEMBLY M42 BUCKET ELEVATORS – 6.17. Tensioning and Aligning the Bucket Elevator Belt Note A greater belt tension is required when using plastic cups rather than steel. 1. Lock out power to the bucket elevator. Failure to lock out power can cause severe injury.

  • Page 105: Adjusting The Baffle

    M42 BUCKET ELEVATORS – 6. ASSEMBLY 6.18. Adjusting the Baffle Note The discharge baffle is located in the head discharge section. It deflects material from the buckets to minimize material-return down the leg (also known as “back-legging”). Note Buckets mounted on lapped belt splices will run closer to the baffle.

  • Page 106: Operation

    7. OPERATION M42 BUCKET ELEVATORS – 7. Operation For optimal operation, follow these safety precautions, checklists, and instructions. 7.1. Operation Safety • Keep away from rotating and moving parts, including the elevator buckets, drive components, shafts, and bearings. • Keep away from explosion vents during operation.

  • Page 107: Pre-Start Inspection Checklist

    M42 BUCKET ELEVATORS – 7. OPERATION 7.3. Pre-Start Inspection Checklist Important Before starting the bucket elevator for the first time, check and verify the following: • Safety decals are in place and are readable. • Check and record both the head and boot pulley lagging thicknesses. Keep the record of these in a safe place to access for future reference.

  • Page 108: Start-Up And Break-In

    2. Start the motor fully and listen carefully for any abnormal noise or operations. See Section 9. – Troubleshooting on page 114 or contact AGI if any problems occur. 3. Check for proper head and boot pulley belt centering and alignment.. To correct a misaligned belt, refer to Section 8. – Maintenance on page 110.

  • Page 109: Emergency Shutdown

    Always work with a second person when clearing a plugged bucket elevator. Never risk material entrapment. Do not open the cover. AGI recommends using a vacuum truck or other equipment. If needing assistance, contact AGI.

  • Page 110: Maintenance

    • After maintenance is complete, replace all guards, service doors, and/or covers. • Use only genuine AGI replacement parts or equivalent. Use of unauthorized parts will void warranty. If in doubt, contact AGI or your local dealer.

  • Page 111: Routine Maintenance

    M42 BUCKET ELEVATORS – 8. MAINTENANCE 8.3. Routine Maintenance Follow these periodic maintenance instructions to improve bucket elevator efficiency and safe operation. Shut off and lock out all equipment before performing any maintenance. Prevent explosion hazards. Regularly remove any dust on or near bearings, reducers, or gearboxes.
  • Page 112 8. MAINTENANCE M42 BUCKET ELEVATORS – Important Installations, applications, equipment life-spans, and environments differ. Adjust the bucket elevator maintenance schedule as necessary to keep the bucket elevator in safe operating condition.. Keep good records of the hours the bucket elevator has been operated and the maintenance performed.
  • Page 113 M42 BUCKET ELEVATORS – 8. MAINTENANCE Every 6 Months: Check the safety decals Check all safety decals are in place and are readable. Check more frequently, as needed in high dust, full sun, and other adverse environments. Tighten all bucket bolts Tighten bucket bolts until they seat into the belt.

  • Page 114: Troubleshooting

    9. TROUBLESHOOTING M42 BUCKET ELEVATORS – 9. Troubleshooting Find causes and solutions to common problems that can be encountered. Shut down and lock out all power sources before diagnosing any of the causes or attempting any of the solutions below.
  • Page 115 Belt loose. Tighten take-up screws or re-splice the belt as required. Air locked. Check if ventilation at the boot or bucket venting is necessary. Consult an AGI representative. Check the air vents and remove any buildup. Check the dust collection system.
  • Page 116 9. TROUBLESHOOTING M42 BUCKET ELEVATORS – Trouble Problem Cause / Solution Low capacity. Head shaft speed is too slow. Check pulley speed. Low capacity. Head shaft speed is too slow. Check the drawing for the correct drive ratio, consult AGI representative.
  • Page 117 M42 BUCKET ELEVATORS – 9. TROUBLESHOOTING Trouble Problem Cause / Solution Bearing gets hot or Material getting into the Add or upgrade seal to keep material out bearing failure. bearing. of bearing. Bearing has been over- Consult bearing manual’s maintenance lubricated or under- schedule and greasing intervals.
  • Page 118 9. TROUBLESHOOTING M42 BUCKET ELEVATORS – Trouble Problem Cause / Solution Belt not tracking in the Boot pulley improperly Adjust take-up screws on the boot to level center of the boot adjusted. the pulley and align belt in center of pulley.
  • Page 119 M42 BUCKET ELEVATORS – 9. TROUBLESHOOTING Trouble Problem Cause / Solution Excessive belt slippage Head pulley lagging worn or Replace with factory recommended or burning. loose. lagging. Excessive belt slippage Belt has stretched. Adjust belt tension with boot pulley. or burning.
  • Page 120 9. TROUBLESHOOTING M42 BUCKET ELEVATORS – Trouble Problem Cause / Solution Damaged buckets. Belt loose. Tighten take-up screws or re-splice belt as required. Casing bowed and catching. Re-plumb as required. Obstruction in the elevator. Repair or remove. Buckets too large for casing.
  • Page 121 M42 BUCKET ELEVATORS – 9. TROUBLESHOOTING Trouble Problem Cause / Solution Excessive Vibration or Foreign matter in boot. Lockout power and remove obstruction. Noise Flooded boot pit. Check sump pump. Excessively tight belt. Reduce tension on belt. Excessively loose belt.
  • Page 122 9. TROUBLESHOOTING M42 BUCKET ELEVATORS – Drive Assembly Trouble Problem Cause / Solution Drive making noise. Slipping drive belt. Tighten belts, see Drive Belt Tension in Maintenance. Hot shaft, sheave, or bearing. Overheated components indicate a failed bearing requiring repair.
  • Page 123 M42 BUCKET ELEVATORS – 9. TROUBLESHOOTING Trouble Problem Cause / Solution Reducer overheating Low or overfilled gear Not filled according to manufacturer’s lubricant. instructions / refill. Wrong grade or weight of See manufacturer’s instructions and lubricant. replace. Reducer overloaded. Wrong size reducer / obtain proper size.

  • Page 124: Appendix

    10. APPENDIX M42 BUCKET ELEVATORS – 10. Appendix 10.1. Bucket Elevator Dimensions Figure 93. Bucket Elevator Dimensions Denotes optional 1/4" expanded metal urethane lined areas Right Hand shown HNGI-0507 10230018 R10...
  • Page 125 M42 BUCKET ELEVATORS – 10. APPENDIX Table 13. M42 Dimensions M42-100 M42-120 M42-150 Dimension Label in (mm) in (mm) in (mm) A Leg Design Width (DW) 16 (406) 16 (406) 20 (508) 20-1/4 (514) 20-1/4 (514) 24-1/2 (622) 14 (356)

  • Page 126: Model Specifications

    10. APPENDIX M42 BUCKET ELEVATORS – 10.2. Model Specifications Table 14. M42 Elevator Model Specifications Min: Head Head Cup Size Capacity, Shaft Shell Head in (mm), Welded Spouting Bushels in (mm), gauge / Pulley [Cup Style] / Legging Required Belt Type Bearings...

  • Page 127: Parts Identification

    M42 BUCKET ELEVATORS – 10. APPENDIX 10.3. Parts Identification 10.3.1 Inspection Section Parts Identification HNGI-0522 Table 15. 16″ x 14″ x 10′ (406 mm 356 mm x 3048 mm) Inspection Section, 10323250 Item Quantity Description Part Number 10323248 14″ x 16″ channel flange weldment...
  • Page 128 10. APPENDIX M42 BUCKET ELEVATORS – Table 16. 20″ x 14″ x 10′ (508 mm 356 mm x 3048 mm) Inspection Section, 10323293 Item Quantity Part Number Description 10323292 14″ x 20″ channel flange weldment cover 2, 6, 8 10336649...
  • Page 129 M42 BUCKET ELEVATORS – 10. APPENDIX Table 19. 38″ x 14″ x 10′ (965 mm 356 mm x 3048 mm) Inspection Section, 10323345 Item Quantity Part Number Description 10323343 14″ x 30″ channel flange weldment cover 2, 6, 8 10336728...

  • Page 130: Explosion Vent Parts Identification

    10. APPENDIX M42 BUCKET ELEVATORS – 10.3.2 Explosion Vent Parts Identification Important In the event explosion doors open during pressure release, the replacement of the following shaded parts and explosion vent door panel are required. Note Explosion vents are not applicable and are not used in every installation.

  • Page 131: Spouting Accessories Types And Dimensions

    M42 BUCKET ELEVATORS – 10. APPENDIX 10.4. Spouting Accessories Types and Dimensions Note Contact the factory for dimensional information on spouting accessories 14” (356 mm) and larger. Square and Round Flanges Figure 95. 14″ (354 mm) Flange 5-3/16" (132 mm) 5-1/4"...
  • Page 132 10. APPENDIX M42 BUCKET ELEVATORS – Figure 97. 18″ (457 mm) Flange 6-1/2" (165 mm) 6-5/8" (168 mm) 20-1/8" (511 mm) 6-1/2" (165 mm) HNGI-0510 Figure 98. 20″ (508 mm) Flange 7-1/8" (181 mm) 7-1/4" (184 mm) 22-1/8" (562 mm) 7-1/8"...

  • Page 133: Bolt Torque Values

    Check tightness periodically, using these tables as a guide. Replace the hardware with the same strength bolt, contact AGI if you are unsure. Important Do not substitute any other bolts/fasteners for those supplied by AGI. Table 20. Recommended Bolt Torque Recommended Torque (ft-lb)

  • Page 134: Warranty

    11. WARRANTY M42 BUCKET ELEVATORS – 11. Warranty AGI (the Company) makes the following warranty to the initial retail purchaser of its products (the Customer). Materials and Workmanship The Company warrants products manufactured by it to be free from defects in materials and workmanship in normal use and service for a period of one (1) year after date of delivery to the Customer.
  • Page 135 M42 BUCKET ELEVATORS – 11. WARRANTY 10230018 R10...
  • Page 136 AGI is a leading provider of equipment solutions for agriculture bulk commodities including seed, fertilizer, grain, and feed systems with a growing platform in providing equipment and solutions for food processing facilities. AGI has manufacturing facilities in Canada, the United States, the United Kingdom, Brazil, South Africa, India and Italy and distributes its products globally.

This manual is also suitable for:

M42-80M42-100M42-120M42-150M48-100

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