GSi 12" II Series User manual

PNEG-681
Series II Bucket Elevator
Assembly Manual
PNEG-681
Date: 04-26-12

2PNEG-681 Series II Bucket Elevator
Use of the equipment information page will help you identify the equipment in the case that you need to notify the
company. For this reason, this information should be filled out and kept on record.
Equipment Information
Model Number: ______________________________________________
Serial Number: ______________________________________________
RPM: _____________________________________________________
Head Pulley Diameter: ________________________________________
Discharge Height: ____________________________________________
Horsepower: ________________________________________________
GSI Group
1004 E. Illinois St.
Assumption, IL. 62510
Phone: [phone]
Date Purchased: ___________________________________________
Dealer Name and Phone Number: ________________________________
________________________________
________________________________

Table of Contents
PNEG-681 Series II Bucket Elevator 3
Contents
Chapter 1 Introduction ..........................................................................................................................................4
General Safety Statements ................................................................................................................... 4
Receiving Inspection ............................................................................................................................. 4
Pre-Installation Notifications .................................................................................................................. 4
Chapter 2 Safety .....................................................................................................................................................5
Safety Guidelines .................................................................................................................................. 5
General Safety Statement ..................................................................................................................... 6
Safety Instructions ................................................................................................................................. 7
Chapter 3 Safety Decals ......................................................................................................................................10
Decal Placement ................................................................................................................................. 12
Chapter 4 Elevator Parts .....................................................................................................................................13
Part Identification ................................................................................................................................ 13
Chapter 5 Bucket Elevator Foundation ..............................................................................................................14
Chapter 6 Boot Section .......................................................................................................................................15
Attaching Boot to Foundation .............................................................................................................. 15
Inspection Sections ............................................................................................................................. 16
Chapter 7 Trunking ..............................................................................................................................................17
Standard Trunking ............................................................................................................................... 17
Pressure Relief Trunking ..................................................................................................................... 18
Trunking Installation ............................................................................................................................ 19
Chapter 8 Lower Head Section ...........................................................................................................................20
Head Bonnet Section .......................................................................................................................... 20
Chapter 9 Maintaining Plubmness .....................................................................................................................22
Chapter 10 Belting, Splicing and Buckets .........................................................................................................23
Belts ................................................................................................................................................... 23
Splicing .............................................................................................................................................. 23
Buckets .............................................................................................................................................. 24
Belt Slack Removal ........................................................................................................................... 24
Chapter 11 Drive Motor and Motor Mount .........................................................................................................26
Drive .................................................................................................................................................. 26
Motor Mount Assembly ...................................................................................................................... 26
Slide Base ......................................................................................................................................... 27
Torque Arm ........................................................................................................................................ 28
Shaft Mount Reducer ......................................................................................................................... 29
Drive Guard ....................................................................................................................................... 29
Drive Belts ......................................................................................................................................... 33
Chapter 12 Final Checks, Tracking, Start-Up and Maintenance ......................................................................34
General Final Checks ........................................................................................................................ 34
Belt Tracking ...................................................................................................................................... 35
Start-Up ............................................................................................................................................. 35
Maintenance ...................................................................................................................................... 35
Chapter 13 Appendix 1 - Reference Information ...............................................................................................36
Chapter 14 Warranty ............................................................................................................................................37

4PNEG-681 Series II Bucket Elevator
1. Introduction
Thank you for choosing a GSI product. It has been designed to provide excellent performance andservice
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. This manual provides suggested and recommended methods for installing
the product. GSI recommends you retain a qualified contractor to provide on-site expertise.
GSI is not responsible for the installation of this product.
General Safety Statements
1. Our primary concern is your safety and the safety of others associated with the use of this product.
All personnel responsible for installing, operating or maintaining this equipment should read and
understand this manual. It is the responsibility of the owner to make this manual available to the
person or persons involved with this equipment.
2. Guards and safety labels have been installed prior to leaving the manufacturing plant. These should
not to be removed, altered or defaced in any way.
3. Modifications to equipment may cause extremely dangerous situations that could result in damage
to the equipment as well as serious injury or death. Never modify the equipment.
4. GSI recommends that you contact the local power company to have a representative survey the
installation to ensure wiring is compatible with their system and adequate power is supplied to
the unit.
Receiving Inspection
1. Carefully inspect the shipment for damage as soon as it is received and verify that the quantity of
parts or packages actually received corresponds to the quantity shown on the packing slip.
2. Report any discrepancies, shortages or damages to the delivering carrier as soon as possible.
3. The manufacturer’s responsibility for damage to the equipment ends when the carrier accepts the
equipment for delivery. Refer to the bill of lading for more detailed information.
4. Save all paperwork and documentation furnished with any of the elevator components.
Pre-Installation Notifications
1. GSI is the manufacturer and vendor of the elevator and is responsible only for the optional
accessories also manufactured by GSI.
2. This installation manual should be used for reference only.
3. The owner/user/installer of this equipment is responsible for consulting and retaining a civil or
structural engineer regarding the design, construction and supervision of the entire installation,
including the elevator foundation and the guying cable and/or bracing system.
4. GSI Bucket Elevators are designed to be vertically self-supporting when erected but must be
supported or guyed against wind loads.

PNEG-681 Series II Bucket Elevator 5
2. Safety
Safety Guidelines
This manual contains information that is important for you, the owner/operator, to know and understand.
This information relates to protecting personal safety and preventing equipment problems. It is the
responsibility of the owner/operator to inform anyone operating or working in the area of this equipment
of these safety guidelines. To help you recognize this information, we use the symbols that are defined
below. Please read the manual and pay attention to these sections. Failure to read this manual and its
safety instructions is a misuse of the equipment and may lead to serious injury or death.
DANGER
WARNING
CAUTION
NOTICE
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 a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a
hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE is used to address practices not related to
personal injury.
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.

2. Safety
6PNEG-681 Series II Bucket Elevator
General Safety Statement
Our foremost concern is your safety and the safety of others associated with grain handling equipment.
This manual is to help you understand safe operating procedures and some problems that may be
encountered by the operator and other personnel.
Asowner and/oroperator, youare responsibleto knowwhat requirements,hazards,and precautionsexist
and inform all personnel associated with the equipment or in the area. Safety precautions may be required
from the personnel. Avoid any alterations to the equipment, which may produce a very dangerous
situation, where SERIOUS INJURY or DEATH may occur.
You should consider the location of the bin site relative to power line locations or electrical transmission
equipment. Contact your local power company to review your installation plan or for information
concerning required equipment clearance. Clearance of portable equipment that may be taken to the bin
site should also be reviewed and considered. Any electrical control equipment in contact with the bin
should be properly grounded and installed in accordance with National Electric Code provisions and other
local or national codes.
This product is intended for the use of grain storage only. Any other use is a misuse of the product.
Sidewall bundles or sheets must be stored in a safe manner. The safest method of storing sidewall
bundles is laying horizontally with the arch of the sheet upward, like a dome. Sidewall sheets stored on
edge must be secured so that they cannot fall over and cause injury. Use care when handling and moving
sidewall bundles.
Personnel operating or working around equipment should 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.
This product has sharp edges, which may cause serious injury. To avoid injury, handle
sharp edges with caution and always use proper protective clothing and equipment.

2. Safety
PNEG-681 Series II Bucket Elevator 7
Safety Instructions
Our foremost concern is your safety and the safety of others associated with this equipment. We want to
keep you as a customer. This manual is to help you understand safe operating procedures and some
problems that may be encountered by the operator and other personnel.
As owner and/or operator, it is your responsibility to know what requirements, hazards, and precautions
exist, and to inform all personnel associated with the equipment or in the area. Safety precautions may be
required from the personnel. Avoid any alterations to the equipment. Such alterations may produce a very
dangerous situation where SERIOUS INJURY or DEATH may occur.
This equipment shall be installed in accordance with the current installation codes and applicable
regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
Follow Safety Instructions
Carefully read all safety messages in this manual and
safety signs on your machine. Keep signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components 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 condition.
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 or need
assistance, contact your dealer.
Read and Understand Manual
Stay Clear of Moving Belt
Entanglement in moving belt can cause serious
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.

2. Safety
8PNEG-681 Series II Bucket Elevator
Operate Motor Properly
In an emergency, shut down the power source.
Turn OFF and lock out all power sources before performing
any maintenance.
Do not operate electric motor equipped units until motors are
properly grounded.
Disconnect power on electrical driven units before resetting
motor overloads.
Do not repetitively stop and start the drive in order to free a
plugged condition. Jogging the drive in this manner can damage
the equipment and/or drive components. Electric Shock Hazard
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 away from rotating parts.
Keep all parts in good condition and properly installed. Fix
damage immediately. Replace worn or broken parts. Remove any
built-up grease, oil, and debris. Maintain Equipment
and Work Area
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.
Breathing Hazard

2. Safety
PNEG-681 Series II Bucket Elevator 9
Prepare for Emergencies
Be prepared if fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone. Keep Emergency Equipment
Quickly Accessible
Wear Protective Clothing
Wear close-fitting clothing and safety equipment appropriate
to the job.
Remove all jewelry.
Tie long hair up and back.
Wear safety glasses at all times to protect eyes from debris.
Wear gloves to protect your hands from sharp edges on
plastic or steel parts.
Wear steel-toed boots to help protect your feet from falling
debris. Tuck in any loose or dangling shoestrings.
A respirator may be needed to prevent breathing potentially
toxic fumes and dust.
Wear a hard hat to help protect your head.
Wear appropriate fall protection equipment when working at
elevations greater than six feet (6').
Eye Protection
Gloves
Steel-Toed Boots
Respirator
Hard Hat
Fall Protection

10 PNEG-681 Series II Bucket Elevator
3. Safety Decals
Safety decals should be read and understood by all people in the grain handling area. Safety decals have
been affixed to the equipment to warn of danger to people and of possible equipment damage. These
decals must not be removed, tampered with, painted over or obscured in any way. If labels are damaged
or become unreadable, replacement labels are available from the manufacturer.
If a decal is damaged or is missing, contact:
GSI Decals
1004 E. Illinois St.
Assumption, IL. 62510
Phone: [phone]
A free replacement decal will be sent to you. (Refer to DC number on the decal.)
DC-1199
DC-1199
DC-1198
Explosion release will
cause severe injury or
death. Avoid area
around explosion vent
during operation.
DC-1377
DC-1378
SHEAR POINT
Keep hands clear of moving
parts. Do not operate with
guard removed. Disconnect
and lockout power before
servicing.
DC-995
WARNING
SHEAR POINT
Keep hands clear of moving
parts. Do not operate with
guard removed. Disconnect
and lockout power before
servicing.
DC-994
DC-1198
DC-1377
DC-1378
DC-995
DC-994
1
2
4
3
5
6

3. Safety Decals
PNEG-681 Series II Bucket Elevator 11
WARNING
Moving side plate.
Auto equipment can
start at any time.
Disconnect and lockout
before servicing.
DC-1248
DC-1248
DC-1224
DC-1601
DC-1601
7
8
9

3. Safety Decals
12 PNEG-681 Series II Bucket Elevator
Decal Placement
Head section
Inspection trunking
Boot section
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

PNEG-681 Series II Bucket Elevator 13
4. Elevator Parts
Part Identification
Figure 4A
Ref # Description
1Bonnet
2 Pressure Relief Panel (One Each Side)
3Head Pulley
4 Lower Head Section
5Inspection Door
6 Up-Leg Trunking
7Down-Leg Trunking
8Belt
9Buckets
10 Tie Angles
11 Inspection Section
12 Inspection Door
13 Boot Section
14 Upside Hopper (Downside Hopper Optional)

14 PNEG-681 Series II Bucket Elevator
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. Always provide for proper moisture run-off on the top of the foundation.

PNEG-681 Series II Bucket Elevator 15
6. Boot Section
Boot sections are pre-assembled at the factory. Boot inlet hoppers are typically shipped separately.
1. Before installing boot on foundation, examine boot for damage or loose hardware. Do not attempt to
install if parts are damaged.
2. Proper position of boot is critical for successful installation. Boot inlet section can be installed as an
up-leg or a down-leg inlet.
3. Identify the up and down side of boot. (See Figure 6A.)
NOTE: The up-leg inlet position is approximately six inches (6") higher than the down-leg side.
Figure 6A Boot Section
Attaching Boot to Foundation
1. Remove the nuts and inlet blank plates to attach boot inlet hopper.
2. Anchor and level boot. Boot must be level and plumb. There are avariety of ways to accomplishthis.
GSI recommends that you shim to the perimeter, secure with hold-downs and grout the base.
3. Set boot in place.
4. Level in all directions prior to anchoring.
5. Use anchor bolts and mounting brackets (not supplied) to secure boot to foundation.
6. Check boot levelness and plumbness periodically throughout the installation process to ensure
proper elevator erection.

6. Boot Section
16 PNEG-681 Series II Bucket Elevator
Inspection Sections
The inspection section of the GSI Bucket Elevator has been designed for easy installation
and maintenance.
1. The removable panels can be installed in any order, to allow for the installation of inspection doors
at any preferred locations.
NOTE: Typical installations often place the inspection section directly above the boot on the up-leg side
as the first trunking section.
NOTE: Installation will vary and depend on the configuration and application.
NOTE: Along with the inspection section, you will receive installation hardware and two (2) tie angles.
Units containing 42" diameter pulleys and larger, will include a cross tie on the legs, which will be
included. (See Figure 6B below and Figure 7A on Page 17.)
Figure 6B Inspection Section

PNEG-681 Series II Bucket Elevator 17
7. Trunking
Standard Trunking
Standard trunking sections may be fabricated from painted or galvanized steel.
IMPORTANT: GalvanizedsteeltrunkingMUST havetheriveted (huckbolted)seamslocatedto 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. Units
containing 42" diameter or larger pulleys have a cross tie angle included for additional support.
Figure 7A Painted Trunking Figure 7B Galvanized Trunking

7. Trunking
18 PNEG-681 Series II Bucket Elevator
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. DO NOT INSTALL TRUNKING IF THERE IS ANY
APPARENT DAMAGE OR DEFECT.
1. These panels will be located on the short sides of the trunking directly opposite of each other and
centered on ten foot (10') sections of trunking.
2. Two (2) tie angles are included with the mounting hardware.
3. Systems utilizing 42" diameter and larger pulleys require the installation of a cross tie located on
the legs. (See Figure 7C.)
Figure 7C Pressure Relief Trunking
WARNING
Remove all shipping bolts in the pressure relief panels prior to operating any
bucket elevator.

7. Trunking
PNEG-681 Series II Bucket Elevator 19
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. (If 42" diameter or larger install cross
tie angle.)
3. Multiple sections can be ground assembled.
4. Make sure sections are assembled straight, without twist.
5. Caulk all mating companion angle surfaces to ensure water and dust resistance.
NOTE: Do NOT assemble more than thirty (30) linear feet at any time.
NOTE: It is important to maintain plumb and square trunking in all directions.
• Guy and plumb trunking in all directions after installing each section.
• Check levels through legging installation process.
• Check all connecting hardware is secure after each installation.
NOTE: Attachment bolt holes in the tie angles are intentionally tight for the 1/2" diameter bolts. This helps
ensure more precise plumbing of the trunking. Never drill these holes out for easier installation.
Figure 7D Trunking Joint
CAUTION
NEVER drill out attachment holes for easier installation of the 1/2" diameter bolts.
If bolts are hindered going through hole, thread bolts through to reduce chances
of damaging threads.

20 PNEG-681 Series II Bucket Elevator
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. Inspect all parts for damage and to ensure that all hardware is secure prior to proceeding
with installation. (See Figure 8A.)
Head Bonnet Section
Thebonnethas been designedintwo-piece constructiontoallowthefront (discharge) sidetoslide forward
and clamp in place for maintenance to the belt, buckets, pulley, etc.
1. The rear (up-leg) side bonnet includes factory installed pressure relief panels. These panels should
be carefully inspected for damage including screws and washers.
2. Pressure relief vent door should not be altered in any way, except to remove shipping bolts.
3. Motor mount and torque arm must be adjusted to fit the drive package per supplied detail.
4. Hardware used to attach bonnet section to head section is included. (See Figure 8B on Page 21.)
Figure 8A Lower Head Section
WARNING
Use bonnet section ‘U-lugs’ to lift ONLY the bonnet section.
WARNING
NEVER lift or lower the bonnet section together with the lower head section.
WARNING
Remove all shipping bolts in the pressure relief panels prior to operating any
bucket elevator