GSI PNEG-1807 User Manual
PNEG-1807
16"-24" Bucket Elevator Platform
and Ladder “X” Series
Installation Manual
PNEG-1807
Date: 02-09-12
Use of the equipment information page will help you identify the 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 #:___________________________________________
Serial #:____________________________________
Date Purchased:____________________________________
Dealer/Distributor Name and Phone #:___________________________________________
Material Handling
1004 E. Illinois St.
Assumption, IL. 62510
Phone: 1-217-226-4421
2 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
Table of Contents
Contents
Chapter 1 Introduction .......................................................................................................................................... 4
Chapter 2 Safety ..................................................................................................................................................... 5
Safety Guidelines .................................................................................................................................. 5
Safety Instructions ..................... ... .... .......................................... ... ... ..................................................... 6
Chapter 3 Decal Location ...................................................................................................................................... 8
Chapter 4 Overview ............................................................................................................................................... 9
Chapter 5 Ladder Assembly ............................................................................................................................... 10
Typical Ladder/Cage Setup ................................................................................................................. 18
Chapter 6 Tie Angles, Ladder Brackets and Safety Cages .............................................................................. 19
Attach Tie Angle to Boot Trunking ................................................ ... ... ... .... ... ... ... .... ... ... ... ... .... ...... ... ... 19
Attach Boot Ladder Support Brackets and Boot Ladder Section ........................................................ 20
Install Boot Ladder Section ................................................................................................................. 22
Tie Angles to Trunking ........... ... ... .... ... ... ... ... .......................................... .... ... ... ... .... ... ......................... 24
Ladder Support Brackets .................................................................................................................... 27
Attach Ladders to Ladder Brackets ............................... ... ... ... .... ... ... .......................................... ...... ... 30
Safety Cage Installation ......... ... ... .... ... .......................................... ... ... ... .... ... ... ... .... ... ... ... .......... ... ... ... 31
Install Safety Cage .............................................................................................................................. 32
Chapter 7 Rest Platform ...................................................................................................................................... 35
Rest Platform Tie Angles to Bucket Elevators .................................................................................... 35
Attach Rest Platform Channel to the Rest Platform Tie Angle ............................ .... ... ... ... ... .... ... ... ... ... 38
Rest Platform Cross Channel to Rest Platform Mounting Channels ................................................... 39
Ladder Support ................................................................................................................................... 44
Chapter 8 16"-24" Head Platform Assembly ..................................................................................................... 45
Attach Main Support Channels to Lower Head ................................... ... .... ... ... ... .... ... ... ... ................... 45
Install Deck A and Toe Board ............................................................................................................. 46
Install Deck A to Main Support Channels ............................................................................................ 47
Install Deck C and Toe Board ............................................................................................................. 49
Install Deck C to Main Support Channels ........................................................................................... 50
Install Deck E ...................................................................................................................................... 51
Install Adapter Bracket for 16" Platforms ............................................................................................ 53
Install Hatch Filler Plate ...................................................................................................................... 54
Install Rail Supports to Deck E ......................... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ...................................... 54
Install “W” Posts (“Corner Posts” x 4) ................................................................................................. 55
Install Platform Posts .......................................................................................................................... 56
Install Intermediate Handrails .............................................................................................................. 58
Install Upper Handrails ........................................................................................................................ 60
Install Tie Braces (Safety Cage Bars) ................................................................................................. 61
Chapter 9 Install Hatch ........................................................................................................................................ 62
Chapter 10 4 x 5 Distributor Platform (Optional) .............................................................................................. 65
16"-24" Clamp Band Installation ........................................................................................................ 65
Assemble Supports (16"-24") ............................................................................................................ 69
Assemble Decking and “W” Corner Post .............................. ................................................. ............ 71
Install Handrail Posts - Non Entrance Side ....................................................................................... 73
Install Intermediate Handrails ............................................................................................................ 75
Install Safety Bar Cross Supports ...................................................................................................... 76
Install Top Handrails .......................................................................................................................... 77
Safety Gate Package (Optional) ........................................................................................................ 78
Chapter 11 Warranty ............................................................................................................................................ 79
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 3
1. Introduction
Chapter 1: Introduction
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.
INSPECT the shipment immediately upon arrival. The customer is responsible for ensuring that all
quantities are correct. The customer should report and note any damage or shortage on the bill of
lading to justify their claim to the transport company.
THIS MANUAL SHOULD BE CONSIDERED a permanent part of your equipment and should be easily
accessible when needed.
This warranty provides you the assurance that the company will back its products when defects appear
within the warranty period. In some circumstances, the company also provides field improvements, often
without charge to the customer, even if the product is out of warranty. Should the equipment be abused,
or modified to change its performance beyond the factory specifications, the warranty will become void
and field improvements may be denied.
4 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
2. Safety
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.
Chapter 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.
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 5
2. Safety
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
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
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.
6 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
2. Safety
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
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 7
3. Decal Location
DO NOT EXCEED
PLATFORM LOAD LIMIT
DC-2146
Excessive load will damage
platform and cause
platform to fall.
Load limit = 500 LBS. (2.25 kN)
DANGER
> 500 lbs
(2.25 kN)
Injury or death will result.
Chapter 3: Decal Location
8 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
4. Overview
Chapter 4: Overview
This section is intended to provide a general, high-level overview of platform assembly for your GSI bucket
elevator. Detailed instructions are given in the pages to come.
This section should be used for reference only and is intended to provide general guidance about the
overall process only.
1. Support Channels:
Proper orientation of channels is based upon the size of the bucket elevator (16", 24", 30" or 36")
AND the right/left hand position of the drive. This must be installed correctly at the start or nothing
else will install correctly.
2. Ladders and Safety Cages:
Ladder sections mount directly to the trunking sections of the bucket elevator. Typical lad der layouts
and charts identifying the support height for ladder packages can be fou nd on Pages 10 through 18.
3. Tie Angles to Trunking:
• Proper orientation of the tie angles is critical for correct installation.
• Note differences from up-leg and down-leg installations.
Be sure to follow the instructions for the size and drive position.
Throughout this manual, particular attention is given to the initial orientation of channels and aligning
bolt holes. Failure to complete these initial steps correctly will significantly impede the assembly and
installation of the bucket elevator platforms.
4. Decking and Toe Boards:
Decking is etched with alpha characters to assist with orienting decks and aligning holes for
connections. Decking connections should be finger-tight only initially so that adjustments can be
made once all decks and toe boards are in place. Only then should all hardware be fully torqued.
5. Handrail Platform Posts:
The number and location of platform posts varies based upon platform and bucket elevator size.
6. Handrails:
Intermediate handrails (those at near knee level) may need to be field cut to fit. The amount to trim
varies based upon the size of the platform being installed. The smaller rail then fits inside of the larger
rail so that it “telescopes” between the posts. Always follow best practices of “measure twice cut
once” and verify the measurement is for the bucket elevator size. Upper handrails do not req uire any
alterations in the field prior to assembly.
7. Platform Braces:
Throughout this manual, safety cage bars (LDR-517BE) are used as platform braces. These are
required for support and stability. Please attach as described through the manual.
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 9
5. Ladder Assembly
CAUTION
Due to O.H.S.A. standards, it is required that a rest platform be installed every 30'.
Chapter 5: Ladder Assembly
The ladder sections are to be mounted directly to the trunking sections. Quantities and section lengths
may vary depending on overall height of system. If you have a non-standard height system, refer to
supported bucket height reference chart below for the correct ladder package for the system.
Supported Bucket Height Reference Chart
Part # Supported Bucket Height (Ft.) Part # Supported Bucket Height (Ft.)
1636XRLAD20 0-29 1636XWLAD20 0-29
1636XRLAD30 30-39
1636XRLAD40 40-49 1636XWLAD40 40-49
1636XRLAD50 50-59
1636XRLAD60 60-69 1636XWLAD60 60-69
1636XRLAD70 70-79
1636XRLAD80 80-89 1636XWLAD80 80-89
1636XRLAD90 90-99
1636XRLAD100 100-109 1636XWLAD100 100-109
1636XRLAD110 110-119
1636XRLAD120 120-129 1636XWLAD120 120-129
1636XRLAD130 130-139
1636XRLAD140 140-149 1636XWLAD140 140-149
1636XRLAD150 150-159
1636XRLAD160 160-169 1636XWLAD160 160-169
1636XRLAD170 170-179
1636XRLAD180 180-189 1636XWLAD180 180-189
1636XWLAD30 30-39
1636XWLAD50 50-59
1636XWLAD70 70-79
1636XWLAD90 90-99
1636XWLAD110 110-119
1636XWLAD130 130-139
1636XWLAD150 150-159
1636XWLAD170 170-179
1636XRLAD190 190-199
1636XRLAD200 200-209 1636XWLAD200 200-209
1636XWLAD190 190-199
NOTE: Ladders are of a modular design for ease of modification in the field. These illustrations are only
to be used as a “general” guide to installation layout. The exact assembly may vary due to the
unique nature of each bucket elevator.
See Figures 5A-5G on Pages 11-17 to help determine if the ladders should be started on the up-leg or
down-leg of the elevator and also aid in the ladder order and rest platform locations for bucket elevators
with heights from 20' through 180'.
10 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
5. Ladder Assembly
20' Bucket elevator
(1636XRLAD20)
(1636XWLAD20)
30' Bucket elevator
(1636XRLAD30)
(1636XWLAD30)
40' Bucket elevator
(1636XRLAD40)
(1636XWLAD40)
Key: HP = Head Platform
RP = Rest Platform
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 11
Figure 5A
5. Ladder Assembly
50' Bucket elevator
(1636XRLAD50)
(1636XWLAD50)
60' Bucket elevator
(1636XRLAD60)
(1636XWLAD60)
70' Bucket elevator
(1636XRLAD70)
(1636XWLAD70)
Key: HP = Head Platform
RP = Rest Platform
Figure 5B
12 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
5. Ladder Assembly
80' Bucket elevator
(1636XRLAD80)
(1636XWLAD80)
90' Bucket elevator
(1636XRLAD90)
(1636XWLAD90)
100' Bucket elevator
(1636XRLAD100)
(1636XWLAD100)
Key: HP = Head Platform
RP = Rest Platform
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 13
Figure 5C
5. Ladder Assembly
110' Bucket elevator
(1636XRLAD110)
(1636WRLAD110)
120' Bucket elevator
(1636XRLAD120)
(1636XWLAD120)
130' Bucket elevator
(1636XRLAD130)
(1636XWLAD130)
Key: HP = Head Platform
RP = Rest Platform
Figure 5D
14 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
5. Ladder Assembly
140' Bucket elevator
(1636XRLAD140)
(1636XWLAD140)
150' Bucket elevator
(1636XRLAD150)
(1636XWLAD150)
160' Bucket elevator
(1636XRLAD160)
(1636XWLAD160)
Key: HP = Head Platform
RP = Rest Platform
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 15
Figure 5E
5. Ladder Assembly
170' Bucket elevator
(1636XRLAD170)
(1636XWLAD170)
180' Bucket elevator
(1636XRLAD180)
(1636XWLAD180)
Key: HP = Head Platform
RP = Rest Platform
Figure 5F
16 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
5. Ladder Assembly
Key: HP = Head Platform
RP = Rest Platform
190' Bucket elevator
(1636XRLAD190)
(1636XWLAD190)
200' Bucket elevator
(1636XRLAD200)
(1636XWLAD200)
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 17
Figure 5G
5. Ladder Assembly
7
3
4
4
5
6
1
2
1
7'-8' to ground or
nearest platform deck
Ref # Part # Description
1 10FOOTRFWX 10' Ladder Section
1 10FOOTX 10' Ladder Section
2 LDR-BCKTBHP Safety Cage Bell Hoop - Entrance
3 LDR-3FTCAGE 3' Safety Cage Strap
4 LDR-BCKTHOOP Standard Safety Cage Hoop
5 LDR-10FTCAGE 10' Safety Cage Strap
6 14FOOTRFWX 14' Ladder Section
6 14FOOTX 14' Ladder Section
7 RP1636X Rest Platform
Typical Ladder/Cage Setup
18 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
Figure 5H Typical Ladder/Cage Assembly Layout (30' Shown.)
6. Tie Angles, Ladder Brackets and Safety Cages
Chapter 6: Tie Angles, Ladder Brackets and Safety Cages
Attach Tie Angle to Boot Trunking
1. On the NON-LADDER SIDE, attach tie angle to the trunking using 1/2" x 1" bolts.
Figure 6B.)
and
a. For 16" Boot Tie Angle: With lip of tie angle up and outward, align tie angle so that it extends
beyond the trunking at each end. (See Figure 6A.)
(See Figure 6A
Figure 6A 16" Boot Tie Angle
b. For 24" Boot Tie Angle: With lip of tie angle up and outward, align edge of tie angle to edge
of trunking at down-leg end. With this alignment, tie angle will exten d slightly beyond the edge of
trunking at the up-leg end, as shown in Figure 6B.
Figure 6B 24" Boot Tie Angle
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 19
6. Tie Angles, Ladder Brackets and Safety Cages
Attach Boot Ladder Support Brackets and Boot Ladder Section
NOTE: Refer to ladder layout images, Figure 5A-5G on Pages 11-17.
NOTE: Ladders can be mounted to either the up-leg or down-leg end of the elevator depending on the
height and head platform hatch location.
NOTE: Both up-leg and down-leg bracket locations are shown in this manua l. Actual inst alla tion location
on either the up-leg or down-leg will be determined by owner preference.
1. Using the holes indicated based on bucket elevator size in Figure 6C, attach ladder support brackets
to boot tie angle using 3/8" x 1" hex bolts. Remember to double check if the ladder should start on
the up-leg side or the down-leg side. (See Figures 6C-6H on Pages 20-23.)
a. 16" Down-leg boot bracket: Use 3/8" x 1" h ex bolts to attach the ladder support brackets to the
boot tie angle using the holes indicated in Figure 6C. Note the outer bracket uses the outer most
holes of the tie angle and the inner bracket will have two (2) empty holes beside it on the tie angle.
Figure 6C 16" Boot Bracket Down-Leg
b. 16" Up-leg boot bracket: Use 3/8" x 1" hex bolts to attach the ladder support brackets to the
boot tie angle using the holes indicated in Figure 6D. Note the outer bracket attaches to the tie
angle with two (2) empty holes remain on the outside.
Figure 6D 16" Boot Bracket Up-Leg
20 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
6. Tie Angles, Ladder Brackets and Safety Cages
c. 24" Down-leg boot bracket: Use 3/8" x 1" h ex bolts to attach the ladder support brackets to the
boot tie angle using the holes indicated in Figure 6E. Note the outer bracket will have two (2)
empty holes to the outside of the connection at the tie angle.
Figure 6E 24" Boot Bracket Down-Leg
d. 24" Up-leg boot bracket: Use 3/8" x 1" hex bolts to attach the ladder support brackets to the
boot tie angle using the holes indicated in Figure 6F. Note the outer bracket uses the two (2) outer
most set of holes on the tie angle.
Figure 6F 24" Boot Bracket Up-Leg
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 21
6. Tie Angles, Ladder Brackets and Safety Cages
Install Boot Ladder Section
1. Trim a 10' ladder section to sit so that the first ladder rung is 12" from the ground. (See Figure 6G.)
Figure 6G
22 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
6. Tie Angles, Ladder Brackets and Safety Cages
2. Attach trimmed ladder section to the left and right ladder brackets using 1/2" x 1" hex bolts through
the bottom most set of holes.
3. Attach the next ladder section to the ladder brackets using 1/2" x 1" hex bolts through the top set of
holes. (See Figure 6H.)
Figure 6H
4. Secure the bottom of the ladder to the boot or ground. NOTE: Bracket for this step is not included.
PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series 23
6. Tie Angles, Ladder Brackets and Safety Cages
Tie Angles to Trunking
1. On the LADDER SIDE, use 1/2" x 1" bolts. See Figures 6I-6K on Pages 24-26 fo r the correct location
of bolts for each elevator size.
Figure 6I Tie Angle Installation Locations
24 PNEG-1807 16"-24" Bucket Elevator Platform and Ladder “X” Series
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