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GSi Bucket Elevator II Series Assembly Manual

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Series II Bucket Elevator
Assembly Manual
PNEG-681
Version: 2.2
Date: 12-21-20
PNEG-681

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Summary of Contents for GSi Bucket Elevator II Series

  • Page 1 Series II Bucket Elevator Assembly Manual PNEG-681 Version: 2.2 Date: 12-21-20 PNEG-681...
  • 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: Table Of Contents

    Table of Contents Contents Chapter 1 Introduction ............................4 General Safety Statements ........................4 Receiving Inspection ..........................4 Pre-Installation Notifications ........................4 Chapter 2 Safety ..............................5 Safety Guidelines ..........................5 Cautionary Symbols Definitions ......................6 Safety Cautions ............................. 7 Safety Sign-Off Sheet ......................... 11 Chapter 3 Safety Decals ............................12 Decal Placement ..........................

  • Page 4: 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 5: Chapter 2 Safety

    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 6: 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 7: 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. • Tie long hair up and back. ST-0004-1 Follow Safety Instructions •...
  • Page 8 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 9 2. Safety Stay Clear of Moving Parts • Entanglement in rotating sprocket or moving chain will cause serious injury or death. • Keep all guards and covers in place at all times. • Lock-out power source before making adjustments, cleaning, or maintaining equipment.
  • Page 10 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 11: 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-681 Series II Bucket Elevator...

  • Page 12: Chapter 3 Safety Decals

    Do not operate with Do not operate with guard guard removed. Disconnect removed. and lockout power before Disconnect and lockout servicing. power before servicing. GSI Group Inc. 217-226-4421 DC-1199 GSI Group Inc. 217-226-4421 DC-995 DC-1199 DC-995 DANGER DANGER DANGER...
  • Page 13 3. Safety Decals WARNING DANGER DANGER Moving side plate. Auto equipment can start at any time. Disconnect and lockout before servicing. DC-1248 GSI Group 217-226-4421 DC-1248 High voltage. Will cause serious injury or death. Lockout power before servicing. DC-1224 DC-1224 DANGER DANGER Lift Bonnet Only.

  • Page 14: Decal Placement

    3. Safety Decals Decal Placement Head section Inspection trunking Decal numbers 1. DC-1198 2. DC-1199 3. DC-1377 4. DC-1378 5. DC-995 6. DC-994 7. DC-1248 8. DC-1224 9. DC-1601 Boot section PNEG-681 Series II Bucket Elevator...

  • Page 15: 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-681 Series II Bucket Elevator...

  • Page 16: 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 17: Chapter 6 Boot Section

    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. 3. Set boot in place.

  • Page 18: 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.

  • Page 19: 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 20: 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 21: 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 22: 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 23 Failure of U-Lug Welds can occur from over stress. Lift only Bonnet section with U-Lugs. Death or serious injury can occur. DO NOT Lift Bonnet and Lower Head Sections assembled together. DC-1601 GSI Group 217-226-4421 Figure 8B Head Bonnet PNEG-681 Series II Bucket Elevator...

  • Page 24: Chapter 9 Maintaining Plubmness

    9. Maintaining Plubmness 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 PNEG-681 Series II Bucket Elevator...

  • Page 25: Chapter 10 Belting, Splicing And Buckets

    After connecting the ends of the belt together, a winching device such as a come-a-long may be required. GSI recommends splicing the belt by overlapping the belts or by using the bar splice method. 1. When overlap splicing, draw a 5' minimum of the belt coming up from the bottom of the boot over belt hanging down from head.

  • Page 26: Buckets

    10. Belting, Splicing and Buckets 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. 1. Secure bucket by tightening nut to slightly indent belt back with bolt head. 2.
  • Page 27 10. Belting, Splicing and Buckets 4. Loosen the bolts attaching the channels of the weight frame assembly to the bearing plate assembly before adjusting the bearing screws. 5. After adjustments have been made, re-tighten bolts and snug the bearing plate adjustment screw lock nuts.

  • Page 28: 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 29: Slide Base

    11. Drive Motor and Motor Mount Figure 11B Right Hand Motor Placement Decals 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 30: 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 31: Shaft Mount Reducer

    11. Drive Motor and Motor Mount Shaft Mount Reducer For reducer assembly, See Page 38 of the Torque Arm II reducer installation appendix which has detailed instructions for the reducer bushing mounting, cooling fans and backstops. Once the reducer is assembled: 1.
  • Page 32 11. Drive Motor and Motor Mount Figure 11F Belt Guard Figure 11G Belt Guard Mounted to Brackets PNEG-681 Series II Bucket Elevator...
  • Page 33 11. Drive Motor and Motor Mount Figure 11H Slide Bracket Figure 11I Brackets - Use for Higher HP Motors PNEG-681 Series II Bucket Elevator...
  • Page 34 11. Drive Motor and Motor Mount Figure 11J Brackets - Use for Higher HP Motors PNEG-681 Series II Bucket Elevator...

  • Page 35: 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 1/64" of deflection per, 1" of sheave centers on one side of belt, centered between sheaves.

  • Page 36: 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 37: 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 38: 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-681 Series II Bucket Elevator...

  • Page 39: Chapter 14 Warranty

    12 months from the date of shipment (or, if shipped by vessel, 14 months from the date of arrival at the port of discharge). If, in GSI’s sole judgment, a product is found to have a defect in materials and/or workmanship, GSI will, at its own option and expense, repair or replace the product or refund the purchase price.
  • Page 40 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 © 2017 by The GSI Group, LLC Printed in the USA CN-329206...

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