42"-48" Bucket Elevator Platform
and Ladder “X” Series
Installation Manual
PNEG-1842
Date: 03-13-12
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
2PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
Attach Intermediate Handrails to Posts ............................................................................................... 88
Install the Hatch .................................................................................................................................. 89
Attach Knee Braces to Platform and Trunking (48" Only) ................................................................... 92
Chapter 10 6 x 6 Distributor Platforms ............................................................................................................... 94
4PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
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.
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series5
2. Safety
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.
DANGER
WARNING
CAUTION
NOTICE
6PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
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 p arts. 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.
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series7
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
8PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
Chapter 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.
3. Decal Location
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series9
4. Overview
Chapter 4: Overview
This section is intended to provide a general, high-level overview of platform assembly for the 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 (42" or 4") 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 ladder layouts
and charts identifying the support height for ladder packages can be found o n Pages 11 through 20.
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 insta lled. 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 require 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.
10PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
5. Ladder Assembly
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
Part #Supported Bucket Height (Ft.)Part #Supported Bucket Height (Ft.)
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 13-19 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 50' through 230'.
CAUTION
12PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
5. Ladder Assembly
Key: HP = Head Platform
RP = Rest Platform
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series13
Figure 5A
5. Ladder Assembly
Key: HP = Head platform
RP = Rest platform
Figure 5B
14PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
5. Ladder Assembly
Key: HP = Head Platform
RP = Rest Platform
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series15
Figure 5C
5. Ladder Assembly
Key: HP = Head Platform
RP = Rest Platform
Figure 5D
16PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
5. Ladder Assembly
Key: HP = Head Platform
RP = Rest Platform
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series17
Figure 5E
5. Ladder Assembly
Key: HP = Head Platform
RP = Rest Platform
Figure 5F
18PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
5. Ladder Assembly
Key: HP = Head Platform
RP = Rest Platform
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series19
Chapter 6: Tie Angles, Ladders and Safety Cages
Attach Tie Angle to Boot Trunking
1. When installing the tie angles, be sure sides with the notches face out away from the trunk and the
side with the straight edge is installed against the trunking angles. Only one tie angle for the ladder
side and one tie angle for the non-ladder side is used.
a. For 42" Boot Tie Angle: Install the tie angle (GECT4204X or BECT4204X) to both sides of the
trunking attached at the boot using 1/2" x 1" HHCS bolts (S-7935) and 1/2" flange nuts (S-8506).
(See Figure 6A.)
Figure 6A 42" Boot Tie Angle
b. For 48" Boot Tie Angle: Install the tie angle (GECT4804X or BECT4804X) to both sides of the
trunking attached at the boot using 1/2" x 1" HHCS bolts (S-7935) and 1/2" flange nuts (S-8506).
(See Figure 6B.)
Figure 6B 48" Boot Tie Angle
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series21
6. Tie Angles, Ladders and Safety Cages
Attach Boot Ladder Support Brackets to Boot Tie Angle
NOTE: Refer to ladder layout images,Figure 5A-5Gon Pages 13-19.
NOTE: Ladder can be mounted to either the up-leg or the down-leg of the elevator depending on the
height and head platform hatch location. Double check if the ladder should start on the up-leg
or down-leg.
NOTE: Both the up-leg and down-leg ladder bracket locations are shown in this manual. Actual installation
location on either the up-leg or the down-leg will be determined by owner preference.
1. 42" Up-Leg Boot Brackets: Use 3/8" x 1" HHCS bolts (S-7469) and 3/8" flange nuts (S-10028) to
attach the ladder support brackets (LAD1648TRH and LAD1648TLH) to the bottom of the boot tie
angle using holes indicated. (See Figure 6C.)
Figure 6C 42" Up-Leg Boot Bracket
2. 42" Down-Leg Boot Brackets: Use 3/8" x 1" HHCS bolts (S-7469) and 3 /8" flange nuts (S-10028 )
to attach the ladder support brackets (LAD1648TRH and LAD1648TLH) to the bottom of the boot tie
angle using holes indicated. (See Figure 6D.)
Figure 6D 42" Down-Leg Boot Bracket
22PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
6. Tie Angles, Ladders and Safety Cages
3. 48" Down-Leg Boot Brackets: Use 3/8" x 1" HHCS bolts (S-7469) and 3/8 " fla nge nu ts (S-10028)
to attach the ladder support brackets (LAD48TRH and LAD48TLH) to the top of the boot tie angle
using holes indicated. (See Figure 6E.)
Figure 6E 48" Down-Leg Boot Bracket
4. 48" Up-Leg Boot Brackets: Use 3/8" x 1" HHCS bolts (S-7469) and 3/8" flange nuts (S-10028) to
attach the ladder support brackets (LAD48TRH and LAD48TLH) to the top of the boot t ie angle using
holes indicated. (See Figure 6F.)
Figure 6F 48" Up-Leg Boot Bracket
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series23
6. Tie Angles, Ladders and Safety Cages
Install Boot Ladder Section
1. Trim a 10' ladder section so the first ladder rung is 12" from the ground when installed to the ladder
bracket. (See Figure 6G.)
Figure 6G Boot Ladder Section
24PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
6. Tie Angles, Ladders and Safety Cages
2. Attach trimmed ladder section to the left and right ladder brackets using 1/2" x 1" HHCS bolts
(S-7935) and flange nuts (S-8506) through the bottom most set of bracket holes. (See Figure 6H
below for 42" and Figure 6I on Page 26 for 48".)
Figure 6H 42" Ladder to Ladder Brackets
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series25
6. Tie Angles, Ladders and Safety Cages
Figure 6I 48" Ladder to Ladder Brackets
3. Attach the next ladder section to the ladder brackets using 1/2" x 1" HHCS bolts (S-7935) and flange
nuts (S-8506) through the top most set of holes.
4. Secure the bottom of the ladder to the boot or ground. NOTE:Bracket for this step is not included.
26PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
6. Tie Angles, Ladders and Safety Cages
Attach Tie Angles to Trunking
NOTE: Tie angles must be installed at every trunking seam on both the ladder and non-ladder sides.
The bottom tie angle will be replaced with a rest platform tie angle (RP42CHNLX for 42" and
RPCHNLX2 for 48") where a rest platform is to be installed.
NOTE: When installing the tie angles, the notched side must face out away from the trunk and the side
with the straight edge must be installed against the trunking angles.
Two (2) tie angles are installed for both the ladder and non-ladder sides.
1. For 42" Tie Angles: Install two (2) tie angles (GECT4204X or BECT4204X) to both sides of the
trunking seam using 1/2" x 1" HHCS bolts (S-7935) and 1/2" flange nuts (S-8506). Installation is the
same for both the ladder and non-ladder sides. (See Figure 6J belowand Figure 6K on Page 28.)
Figure 6J 42" Tie Angle Installation Locations
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series27
6. Tie Angles, Ladders and Safety Cages
Figure 6K 42" Bucket Elevator Tie Angles to Trunking Bolt Locations
28PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
6. Tie Angles, Ladders and Safety Cages
2. For 48" Tie Angles: Install two (2) tie angles (GECT4804X or BECT4804X) to both sides of the
trunking seam using 1/2" x 1" HHCS bolts (S-7935) and 1/2" flange nuts (S-8506). (See Figure 6L
and Figure 6M.)
Figure 6L 48" Tie Angle Installation Locations
Figure 6M 48" Bucket Elevator Tie Angles to Trunking Bolt Locations
PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series29
6. Tie Angles, Ladders and Safety Cages
Attach Ladder Support Brackets to Tie Angles for 42"
1. For 42" Ladder Brackets: Mount the upper left and upper right hand bra ckets (LAD1 648TLH2 and
LAD1648TRH2) to the top tie angles.
2. Mount the lower left and lower right hand brackets (LAD1648TLH1 and LAD1648TRH1) to the bottom
tie angles.
3. Fasten flanges of brackets and brackets to tie angles using 3/8" x 1" HHCS bolts (S-7469) and
3/8" flange nuts (S-968). (See Figure 6N below,Figure 6Oand Figure 6P on Page 31.)
NOTE: You will only use one set of brackets, either the up-leg set or the down-leg set depending on
your ladder location.
Figure 6N 42" Ladder Support Bracket Parts
30PNEG-1842 42"-48" Bucket Elevator Platform and Ladder “X” Series
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