GSi PNEG-1204 User manual

Enclosed Belt
Conveyor
Installation and Operation Manual
PNEG-1204
PNEG-1204
DATE: 10-16-06

READ THIS MANUAL carefully to learn how to
properly use and install equipment. Failure to do
so could result in personal injury or equipment
damage. This manual and safety signs on your
equipment may be available in other languages.
(Consult with your dealer to see what is available)
INSPECT the shipment immediately upon arrival.
The Customer is responsible for ensuring that all
quantities are correct. Report any damage or
shortages by recording a detailed description on
the Bill of Lading to justify the Customer’s claim
from the Transport Firm. Our responsibility for
damage to the equipment ends with acceptance
by the delivering carrier. Save all paperwork and
documentation furnished with any of the enclosed
belt conveyor components.
THIS MANUAL SHOULD BE CONSIDERED a
permanent part of your equipment and should be
easily accessible when needed.
Introduction
WARRANTY is provided as part of the company’s
support program for customers who use and
maintain their equipment as described in the
manual. The warranty is explained on the war-
ranty page located on the inside back cover of
this manual.
This warranty provides you the assurance that the
company will back its products where defects
appear within the warranty period. In some cir-
cumstances, the company also provides field
improvements, often without charge to the cus-
tomer, even if the product is out of warranty.
Should the equipment be abused, or modified to
change its performance beyond the factory speci-
fications, the warranty will become void and field
improvements may be denied.
i

Use of the Equipment Information page will help you identify your equipment in the case that you need to
call your dealer or installer. This information should be filled out and kept on record.
Equipment Information
Model Number:__________________________
Serial Number:___________________________
Date Purchased:____________________
Dealer/Distributor Name and Phone Number:
Material Handling
1004 East Illinois Street
Assumption, Illinois 62510 USA
Phone: [phone]
FAX: [phone]
e-mail: [email protected]
ii

Introduction.....................................................................................i
EquipmentInformation ...................................................................ii
SafetyGuidelines ...........................................................................1
Safety ............................................................................................2
SafetyDecal Locations. .................................................................5
Overview ........................................................................................9
IntermediateSectionInstallation .....................................................10
CoverInstallation............................................................................12
LoaderInstallation ..........................................................................13
Motor&TorqueArmII ReducerInstallation ......................................14
Reducer ....................................................................................15
TorqueArm................................................................................16
TorqueArmBracket...................................................................16
MotorMountBrackets ...............................................................17
MotorMountAdjustment Plate ...................................................17
RearGuard ...............................................................................17
Sheavesand Belts ....................................................................18
V-BeltAdjustment ......................................................................18
Front Guard ...............................................................................19
ReducerLubrication ..................................................................19
FindingBelt Center Line.................................................................19
Squaringthe BeltEnd ....................................................................20
CheckBelt Squareness .................................................................20
InstallationofBelt ...........................................................................21
Splicing Belt ...................................................................................22
BeltTension ...................................................................................26
BeltTracking ..................................................................................27
Spouting.........................................................................................30
SpoutingLocation ..........................................................................31
BeltConveyor Loading...................................................................32
MotionSensor Option ....................................................................33
PressurePlug SwitchOption..........................................................34
StartingConveyor...........................................................................35
Care& Maintenance ......................................................................36
Troubleshooting..............................................................................37
TorqueArm IIAppendix...................................................................38
ImperialBearingsAppendix ...........................................................49
Table of Contents
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.
iii

NOTES
iv

1PNEG-1204 Enclosed Belt Conveyors
Safety
Thismanualcontains informationthatis importantforyou,the owner/operator,to knowand
understand.This informationrelates toprotecting personal safety and preventing equipment
problems.It isthe responsibilityof theowner/operator toinform anyoneoperating or workingin
thearea ofthis equipment ofthese safetyguidelines.Tohelpyou recognizethis information,we
usethe symbolsthat aredefined below. Pleaseread themanual andpay attentionto these
sections.Failure toread thismanual and it’ssafety instructionsis amisuse of theequipment and
maylead to seriousinjury ordeath.
SAFETY GUIDELINES
DANGER indicatesanimminently hazardoussituation
which,ifnot avoided,will resultindeath orserious injury.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid
possible injury or death.
WARNING indicates apotentially hazardoussituation
which,ifnot avoided,could resultindeath orserious injury.
CAUTIONindicatesa potentiallyhazardous situationwhich,
ifnot avoided, mayresult inminor ormoderate injury.
CAUTION usedwithout the safetyalert symbolindicates
apotentiallyhazardous situationwhich,if notavoided,
mayresultin propertydamage.
NOTEindicatesinformation aboutthe equipmentthat
youshouldpay specialattentionto.

2PNEG-1204 Enclosed Belt Conveyors
Safety
FOLLOW SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual
and on your machine safety signs. Keep signs in
good condition. Replace missing or damaged
safety signs. Be sure new equipment compo-
nents and repair parts include the current safety
signs. Replacement safety signs are available
from the manufacturer.
Learn how to operate the machine and how to
use controls properly. Do not let anyone operate
without instruction.
Keep your machinery in proper working condi-
tion. Unauthorized modifications to the machine
may impair the function and/or safety and affect
machine life.
If you do not understand any part of this manual
and need assistance, contact your dealer.
STAY CLEAR OF ROTATING IDLER
Entanglement in rotating idlers can cause seri-
ous injury or death.
Keep all shields and covers in place at all times.
Wear close fitting clothing. Stop and lock out
power source before making adjustments,
cleaning, or maintaining equipment.
OPERATE MOTOR PROPERLY
Do not operate electric motor equipped units
until motors are properly grounded.
Disconnect power on electrical driven units
before resetting motor overloads.
Do not repetitively stop and start the drive in
order to free a plugged condition. Jogging the
drive in this type of condition can damage the
conveyor and/or drive components.

3PNEG-1204 Enclosed Belt Conveyors
Safety
PRACTICE SAFE MAINTENANCE
Understand service procedures before doing
work. Keep area clean and dry.
Never lubricate, service, or adjust machine while
it is in operation. Keep hands, feet, and clothing
from rotating belt and idlers.
Keep all parts in good condition and properly
installed. Fix damage immediately. Replace
worn or broken parts. Remove any build up
grease, oil, or debris.
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
• If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator.
• If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or stripper containers and
other flammable material from area.Allow
fumes to disperse at least 15 minutes before
welding or heating.

4PNEG-1204 Enclosed Belt Conveyors
Safety
PREPARE FOR EMERGENCIES
Be prepared if fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department near
yourtelephone.
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
Safety glasses should be worn at all times to
protect eyes from debris.
Wear gloves to protect your hands from sharp
edges on plastic or steel parts.
A respirator may be needed to help prevent
breathing potentially toxic fumes and dust.
Wear hard hat and steel toe boots to help
protect your head and toes from falling debris.
Eye Protection
Gloves
Steel Toe
Boots
Respirator
Hard Hat

5PNEG-1204 Enclosed Belt Conveyors
Decals
HEAD SECTION DECAL LOCATIONS
Disconnect and lockout power before
adjusting or servicing.
ROTATING BELT AND PULLEY WILL
CUT OR ENTANGLE.
Failure to heed will result in
personal injury or death.
KEEP HANDS CLEAR
1
1
11
11
1
STANDARD HEAD SECTION
SNUB HEAD SECTION
DC-1672

6PNEG-1204 Enclosed Belt Conveyors
Decals
TAIL SECTION DECAL LOCATIONS
1
Disconnect and lockout power before
adjusting or servicing.
ROTATING BELT AND PULLEY WILL
CUT OR ENTANGLE.
Failure to heed will result in
personal injury or death.
KEEP HANDS CLEAR
1
1
1
BELT CONVEYOR TAIL SECTION
2
2
DC-1672 DC-1690
DC-1690
CAUTION
FALLING HAZARD
Secure open shroud with chain.
Open shroud may fall if unrestrained
and cause bodily injury.

7PNEG-1204 Enclosed Belt Conveyors
Decals
2
KEEP HANDS CLEAR
Disconnect and lockout power before
adjusting or servicing.
MOVING BELT CAN CUT OR ENTANGLE.
Failure to heed can result in
personal injury or death.
LOADER SECTION DECAL LOCATIONS
2
2
2
2
2
2
Decal On Right Side In
Same Location as
Decal on Left Side.
Decal On Right Side In
Same Location as
Decal on Left Side.
FIXED SKIRT LOADER
SWING-UP SKIRT LOADER
DC-1671

8PNEG-1204 Enclosed Belt Conveyors
Decals
2
KEEP HANDS CLEAR
Disconnect and lockout power before
adjusting or servicing.
MOVING BELT CAN CUT OR ENTANGLE.
Failure to heed can result in
personal injury or death.
INTERMEDIATE SECTION DECAL LOCATIONS
Disconnect and lockout power before
adjusting or servicing.
ROTATING BELT AND PULLEY WILL
CUT OR ENTANGLE.
Failure to heed will result in
personal injury or death.
KEEP HANDS CLEAR
1
2
12
Decal On Right Side In
Same Location as
Decal on Left Side.
Decals On Right Side
In Same Location as
Decals on Left Side.
INTERMEDIATE INSPECTION SECTION
STANDARD INTERMEDIATE SECTION
DC-1672 DC-1671

9PNEG-1204 Enclosed Belt Conveyors
Conveyor Assembly
CONVEYOR ASSEMBLY
OVERVIEW
1. Removeany bandingand cratingmaterial.
Arrangeallthe conveyor componentsinsuch
afashion thatall are easilyaccessible.
2. Locate sturdyitems to serveas blocking(i.e.
woodblocks, saw horses, etc.). Blocking is
usedto supporttheconveyor sectionsabove
theground tohelp inassembly. Locate and
placethe conveyorsectionson theblocking
inorder,startingwith the head sectionand
concludingwiththe tailsection.
3. Aclearance ofat leastthe width of the
conveyoris recommendedon allsides of the
unit. Lessclearance may beacceptable
however, seriousconsideration mustbe
giventomethods ofmaintenance,removal
andreplacementof theconveyor and/orits
parts.
4. Thestandard conveyorisconstructedwith
onedischarge locatedat the driveend. If
tripper discharge sections are to be used,
thelocation(s) mustbe determinedbefore
continuingwiththeconveyorassembly. It
maybe necessaryto position ashorter
intermediate section to serve as a spacer in
orderto accommodatethe placementof the
tripperdischarge(s) whererequired.
5. Alwaysconsult withtheapproval printsfor
exactconveyorlayout.Maintain adequate
clearancefortail extension.
6. Duringinstallationofthe conveyor, string a
chalkline alongthe conveyor sidesto assure
thatthe conveyoris being assembled in a
straightline.Allhardware should beincluded
withyourconveyor.Itisrecommendedthat all
flangesbe caulkedto sealthe conveyorto
keepthe dust inand theweather out.
7. After allsections arecaulked andbolted, the
loader(s)is/are readyto be installed.
Loadersmust beinstalled withthe grain
streammoving inthe same directionand
same speed as the conveyor belt. (See page
30for recommendedspout loading).
8. After locationof theloader(s) (asto spouts,
gates,and valves) hasbeen established,the
loader(s)are boltedto theconveyor.Donot
weldloader(s) tothe conveyor.(Seepage13
forloaderinstallation).
9. Beltmay nowbehand fedthroughthe
conveyor.Make surewhensplicing beltthat
eachcut isclean, squareand straight.
Detailedbelt assemblyinstructions arelisted
onpages 20- 29.These instructionsshould
befollowedclosely and readthoroughly
beforestarting thisstep.
10.Check drivebeltsfor tension.Alsocheckthe
oillevelin thespeedreducer.Reducers are
shippedwithout oil.Refer to page41for
thetypeand quantityofoil. (DONOToverfill
reducer.)

10 PNEG-1204 Enclosed Belt Conveyors
Conveyor Assembly
MAKE SURE TO READ ASSEMBLY
OVERVIEW ON PAGE 9 FIRST.
1. Intermediatesections aresupplied instan-
dardten foot (10') lengths. Depending on
yourapplication andindividual specifications
however, shortersections maybe requiredto
accommodatea desiredoverall length.
2. After makingsure theflanges arealigned,
tightenallhardware on thetroughsection.
(Itis recommended thatthe flangesare
caulkedto insuresealing fromdust and
outsidemoisture.)
3. Duringassembly ofthe intermediatesec-
tions,carefullyinspect eachflangejoint to
ensurethat theinside bottomand sidesur-
facesof theintermediates areflush. Achalk
lineis helpfulduring thisphase ofthe assem-
blytoensure theproper alignmentofthe
intermediatesection surfaces. Themaxi-
mumrun-outinany directionshouldbe
+/-1/4". Make surethe conveyoris levelin
horizontalapplications.
4. Proceed byattaching thehead and tail
assembliesusing thesame alignmentproce-
duresand precautionsnoted inthe preceding
paragraph.
It is critical for straitness of the conveyor
that the sides and bottom flanges are
aligned flush. Also, it is important that the
inside dimensions of the box measure
equidistant from side-to-side both top and
bottom of the intermediate section
(DimensionA= Dimension B). See diagram
below.
End View of Intermediate Section
(Liners not shown for clarity)
INTERMEDIATE SECTION
INSTALLATION
A
B

11PNEG-1204 Enclosed Belt Conveyors
Conveyor Assembly
INTERMEDIATE SECTION
INSTALLATION (CONT.)
1. IntermediateSections bolttogether along the
sideand bottomflanges. Thecovers are
fastenedtothe coverchannels byflatclips
andeasy griphandles.
2. Standardintermediatesections do nothave
adirection inwhich theybolt to other
intermediatesections. Thecover channels
connectintermediate sectionsonboth ends.
3. Twoinspectionintermediate sections are
includedoneach installation. Theyshouldbe
assembledat thehead andtail. The
inspectionholes shouldbe orientedclosest
tothe heador tail.
4. The inspectiondoor endof each
intermediatesection hasadapter angles
withslotted holesfor boltingto heador
tailsections.
5. A specialcover channelis providedwith the
tailas shownatright.
CoverChannel
Cover
EasyGrip
Handles
Tail Section Intermediate
Inspection
Section
Inspection
Door
TailCoverChannel
Adapter
Angle
with
Slotted
Holes
Flat
Clips

12 PNEG-1204 Enclosed Belt Conveyors
Conveyor Assembly
1. Fastencovers tothebelt conveyorwiththe
3/8"easy griphandles provided.Adequately
tightenthe3/8" handlesso thatthecovers
arein tight contactwith conveyorcross
channels.
2. Whena loaderis ontheconveyor,the cover
sectionmay haveto becut accordinglyto
accommodatethe loader. Forinstallationof
aloader,see LoaderInstallation onpage 13.
3. Conveyorcovers are made to fitover the
entirewidthand halfthelengthof aconveyor
intermediatesection. Standardcoversmea-
sureapproximately 4' 7"in length.When a
loader is ordered, the cover may be mea-
suredand cutto takeup the displacementof
theloader housing. Thisdepends onthe
positionof theloader.
COVER INSTALLATION
Standard Cover Length
EasyGrip
Handles
3/8" Wing
Nuton Tail
Section to
Secure
Cover.
DO NOT Walk on Conveyor Covers!
4' 7"

13PNEG-1204 Enclosed Belt Conveyors
Conveyor Assembly
GSI’s recommendation for loader installation includes
a minimum distance of no less than 6" between the
center of loader inlet and the tail assembly.
LOADER INSTALLATION
6"
Fixed Skirt Loader
Swing-Up Skirt Loader
1. Thefixed skirtloader alwaysattaches atthe
tailend so nocover modifications should be
necessary.The softrubber skirtsareadjust-
ableand canbe set tolightly touchthe con-
veyorbelt.
1. Ifthe loaderdoesn’tline upexactlywith an
intermediatecover,theintermediate covers
willneed tobe cutto fit. If this isnecessary,
properlyposition loader and cut asection
fromthecovers sothey willfitbetween the
coverchannelbolted tonextsection andthe
loaderflange. Weldcover backtogether to
achieverequiredlength. Repaintwelded
areatoprevent rusting.
2. TheUHMW swing-upskirtsshouldnot touch
theconveyorbelt asthey cancause wearto
thebelt. Usethe adjustableset screwsto
locatethe positionof the skirts.
REMOVE PAINT BEFORE
WELDING OR CUTTING
Avoid hazardous fumes that can be generated
when paint is heated by welding or torching.
Do all work outside or in a well ventilated
area. Dispose of paint and solvent properly.
Remove paint before welding or heating:
• If you sand or grind paint, avoid breathing
the dust. Wear an approved respirator.
• If you use solvent or paint stripper,
remove stripper with soap and water
before welding. Remove solvent or strip
per containers and other flammable
material from area.Allow fumes to
disperse at least 15 minutes before
welding or heating.
Fixed Loader
Swing Up Skirt Loader

14 PNEG-1204 Enclosed Belt Conveyors
Motor Assembly
MOTOR AND SHAFT TORQUE ARM II INSTALLATION
Motor
Allow sufficient distance between bushing and
bearing to remove bushing assembly bolts.
Keep as close
as possible
Head Section
Driven
Pulley
Belt
Guard
Belt
Guard
Bracket
V-Belt
Drive
Pulley
Hex Nut
Motor Adjustment Plate
Jackscrew
Motor Mount Base Plate
Head
Section
Intermediate
Inspection
Section
Motor DrivePulley
V-Belt
Hood
TorqueArm
TurnbuckleAssembly Driven Pulley
Reducer
Drive
NOTE:Belt Guards Not
Shown for Clarity.
TorqueArm
Bracket

15PNEG-1204 Enclosed Belt Conveyors
Motor Assembly
MOTOR AND TORQUE ARM II
REDUCER INSTALLATION
1. Toaidin theinstallationof thereducer onto
theshaft,remove anyprotectivecoating film
fromtheshaft.
2. Placekey inthe keywayonthe driveshaft.
3. Attachinside bushingto thereducer drive.
4. Lineup thekeyway onreducerwith keyon
shaftand slidethe reducerdrive onto the
driveshaft.
5. Slideoutside bushingonto shaftand attach
toreducer drive.Once reducer driveis in
place,fullytightenbothbushings.
(See page 38 for more details.)
Reducer
Shaft
Mount
Reducer
Key
Bushing
Conveyor
Drive
Shaft
Shaft
Mount
Reducer
Bushing
Conveyor
Drive Shaft
WARNING
Shear point. Keep hands
clear of moving parts. Do
not operate with guard
removed. Disconnect
and lockout power before
servicing.
DC-995
SHEAR POINT
Keep hands clear of moving
parts. Do not operate with
guard removed. Disconnect
and lockout power before
servicing.
DC-994
DC-994
DC-995
DC-994
DC-995
BELT GUARD
COVER