GSI PNEG-1849 User Manual

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PNEG-1849

30"-36" Bucket Elevator Platform and Ladder “X” Series

Installation Manual

PNEG-1849

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-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

Table of Contents

Chapter 1 Introduction .......................................................................................................................................... 5

Chapter 2 Safety ..................................................................................................................................................... 6

Safety Guidelines .................................................................................................................................. 6

Safety Instructions ..................... ... .... .......................................... ... ... ..................................................... 7

Chapter 3 Decal Location ...................................................................................................................................... 9

Chapter 4 Overview ............................................................................................................................................. 10

Chapter 5 Ladder Assembly ............................................................................................................................... 11

Typical Ladder/Cage Setup ................................................................................................................. 19

Chapter 6 Tie Angles, Ladders and Safety Cages ............................................................................................ 20

Attach Tie Angle to Boot Trunking ................................................ ... ... ... .... ... ... ... .... ... ... ... ... .... ...... ... ... 20

Attach Boot Ladder Support Brackets and Boot Ladder Section ........................................................ 21

Install Boot Ladder Section ................................................................................................................. 23

Tie Angles to Trunking ........... ... ... .... ... ... ... ... .......................................... .... ... ... ... .... ... ......................... 25

Ladder Support Brackets .................................................................................................................... 27

Attach Ladders to Ladder Brackets ............................... ... ... ... .... ... ... .......................................... ...... ... 29

Safety Cage Installation ......... ... ... .... ... .......................................... ... ... ... .... ... ... ... .... ... ... ... .......... ... ... ... 30

Install Safety Cage .............................................................................................................................. 31

Chapter 7 Rest Platform ...................................................................................................................................... 34

Rest Platform Tie Angles to Bucket Elevators .................................................................................... 34

Attach Rest Platform Channel to the Rest Platform Tie Angle ............................ .... ... ... ... ... .... ... ... ... ... 36

Rest Platform Cross Channel to Rest Platform Mounting Channels ................................................... 37

Ladder Support ................................................................................................................................... 43

Chapter 8 30"-36" Head Platform Right Hand Drive ......................................................................................... 44

Cross Deck Support Channels to Lower Head ................................................................................... 45

For 30" Right Side Drive ...................................................................................................................... 46

For 36" Right Side Drive ...................................................................................................................... 48

Attach Deck A to Hatch Cover Plate ................................................................................................... 50

Slide/Place Toe Boards on Cross Deck Support Channels ................................................................ 51

Connect Deck A to Cross Deck Support Channels and Toe Board .................................................... 52

Connect Deck C to Cross Deck Support Channel and to Toe Board .................................................. 54

Connect Deck F to Cross Deck Support Channels and Deck C ............ .......................................... ... 56

Attach Third Cross Deck Support Channel to Decking ........................................................... ............ 58

Attach Deck E to Deck A, Deck C and Cross Deck Support Channel .................... ... ... ... ................... 58

Chapter 9 30"-36" Head Platform Left Hand Drive ............................................................................................ 60

Attach Cross Deck Support Channels to Lower Head ........................................................................ 61

For 30" Left Side Drive ..................................................................................................................... ... 62

For 36" Left Side Drive ..................................................................................................................... ... 64

Attach Deck A to Hatch Cover Plate ................................................................................................... 66

Slide/Place Toe Boards on Cross Deck Support Channels ................................................................ 67

Connect Deck A to Cross Deck Support Channels and Toe Board .................................................... 68

Connect Deck C to Cross Deck Support Channel and to Toe Board .................................................. 69

Connect Deck F to Cross Deck Support Channels and Deck C ............ .......................................... ... 71

Attach Third Cross Deck Support Channel to Decking ........................................................... ............ 73

Attach Deck E to Deck A, Deck C and Cross Deck Support Channel .................... ... ... ... ................... 73

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 3

Table of Contents

Chapter 10 30"-36" Head Platform Post, Rails and Bracing ................................................................ ... ......... 75

Attach Head Bearing Support Angle to Lower Head for 30" .............................................................. 75

Attach Head Bearing Support Angle to Lower Head for 36" .............................................................. 75

Attach Handrail Supports to Deck E .................................................................................................. 76

Install Posts .................................................................................................. ... ... .... ... ........................ 77

Install Head Side Posts ..................................................................................................................... 78

Attach Intermediate Handrails to Posts ............................................................................................. 81

Install Upper Handrails ...................................................................................................................... 83

Install Safety Cage Bar Cross Supports ................ ... .... ... .......................................... ... ... ... .... ... ... ..... 85

Chapter 11 Install Hatch ...................................................................................................................................... 86

Chapter 12 4 x 5 Distributor Platform (Optional) ............................................................................................... 89

Install Clamp Band ...................................... .... ... ... ... .... .......................................... ... ... ... .................. 89

Assemble Supports ........................................................................................................................... 90

Assemble Decking ............................................................................................................................. 92

Install Handrail Posts - Non Entrance Side ........................ ... .... ... ... ... ... .... ... ... ... ............................... 94

Assemble and Install Intermediate Handrails .................................................................................... 96

Install Safety Bar Cross Supports ...................................................................................................... 96

Install Upper Handrails ...................................................................................................................... 97

Safety Gate Package (Optional) ........................................................................................................ 98

Chapter 13 6 x 6 Distributor Platforms ............................................................................................................... 99

Platform Clamps ....................... ... .... ... ... ... .......................................... ... .... ... ..................................... 99

Support Channels and Knee Braces ............................................................................................... 100

Toe Boards ............................ ... .......................................... .......................................... ................... 101

Cross Braces for Knee Braces ........................................................................................................ 102

Platform Decking ................................ .......................................... ... ... ............................................. 104

Platform Post ......................... ... ... .... ... ... ... .......................................... ... .... ...................................... 106

Tie Braces ....................................................................................................................................... 107

Intermediate Handrail ...................................................................................................................... 108

Upper Handrails ............................................................................................................................... 109

Safety Gate Package (If Ordered as Optional) ... ... ... .... ... ... ... .... ... ... .......................................... ... ... 112

Chapter 14 Warranty .......................................................................................................................................... 115

4 PNEG-1849 30"-36" 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-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 5

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

6 PNEG-1849 30"-36" 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-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 7

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

8 PNEG-1849 30"-36" 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-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 9

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 (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 ladder layouts

and charts identifying the support height for ladder packages can be found o n Pages 11 through 19.

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.

10 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

5. Ladder Assembly

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 12-18 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'.

CAUTION

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 11

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

Figure 5A

12 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

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

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 13

Figure 5B

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

Figure 5C

14 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

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

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 15

Figure 5D

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

Figure 5E

16 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

5. Ladder Assembly

170' Bucket elevator

(1636XRLAD170)

(1636XWLAD170)

180' Bucket elevator

(1636XRLAD180)

(1636XWLAD180)

Key: HP = Head Platform

RP = Rest Platform

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 17

Figure 5F

5. Ladder Assembly

Key: HP = Head Platform

RP = Rest Platform

190' Bucket elevator

(1636XRLAD190)

(1636XWLAD190)

200' Bucket elevator

(1636XRLAD200)

(1636XWLAD200)

Figure 5G

18 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

Typical Ladder/Cage Setup

7'-8' to ground or

nearest platform deck

Ref # P art # 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

5. Ladder Assembly

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 19

Figure 5H Typical Ladder/Cage Assembly Layout (30' Shown.)

6. Tie Angles, Ladders and Safety Cages

Chapter 6: Tie Angles, Ladders and Safety Cages Attach Tie Angle to Boot Tr unking

1. On the NON LADDER SIDE, attach tie angle to the trunking using 1/2" x 1" bolts.

and Figure 6B.)

a. For 30" 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 30" Boot Tie Angle

b. For 36" Boot Tie Angle: With lip of tie angle up and outward, align both edges of tie angle to

edges of trunking. Note the tie angle will not extend beyond the trunking. (See Figure 6B.)

Figure 6B 36" Boot Tie Angle

20 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

6. Tie Angles, Ladders and Safety Cages

Attach Boot Ladder Support Brackets and Boot Ladder Section

NOTE: Refer to ladder layout images, Figure 5A-5G on Pages 12-18. 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 manual, however, only one will

actually be installed based on owner preference and layout of the elevator.

Depending on the height and head platform hatch location. Ladder can be mounted to either the up-leg or the down-leg side, refer to ladder layout Figure 5A-5G on Pages 12-18. NOTE: Both up-leg and down-leg

bracket locations are shown, but only one side will be used.

1. Use the holes indicated based on bucket elevator size in Figure 6C and attach ladder support brackets to boot tie angle using 3/8" x 1" hex bolts. Remember to dou ble check if the ladde r sho uld start on the up-leg side or the down-leg side. (See Figure 6C below and Figure 6D on Page 22.)

a. 30"-36" Down-Leg 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 6C. Note the outer bracket uses the first set of holes on the outside.

Figure 6C 30"-36" Boot Bracket Down-Leg

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 21

6. Tie Angles, Ladders and Safety Cages

b. 30"-36" Up-Leg 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 uses the first set of holes towards the outside.

Figure 6D 30"-36" Boot Bracket Up-Leg

22 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

6. Tie Angles, Ladders 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 6E.)

Figure 6E

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 23

6. Tie Angles, Ladders 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 6F.)

Figure 6F

4. Secure the bottom of the ladder to the boot or ground. NOTE: Bracket for this step is not included.

24 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

6. Tie Angles, Ladders and Safety Cages

Tie Angles to Trunking

1. Tie angles must be mounted to each trunking seam on both the ladder and non-ladder side of the trunking. Use 1/2" x 1" bolts. See Figures 6G-6I on Pages 25 and 26 for the correct location of bolts for each elevator size.

Figure 6G Tie Angle Installation Location

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 25

6. Tie Angles, Ladders and Safety Cages

Figure 6H 30" Bucket Elevator Tie Angles to Trunking Bolt Locations

Figure 6I 36" Bucket Elevator Tie Angles to Trunking Bolt Locations

26 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

6. Tie Angles, Ladders and Safety Cages

Ladder Support Brackets

1. Attach ladder support brackets to tie angle using 3/8" x 1" hex bolts (S-7469). Use the holes shown in Figure 6J for each size elevator.

2. Mount the upper right and upper left hand ladder support brackets to the top tie angle with 3/8" bolts.

3. Mount the lower right hand and lower left hand ladder support brackets to the bottom tie angle with 3/8" bolts. (See Figure 6J.)

4. Secure the flanges of the ladder brackets together with 3/8" x 1" hex bolts.

NOTE: You will only use one set of ladder brackets, either the up-leg set or the down-leg set.

Figure 6J Ladder Support Bracket Parts

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 27

6. Tie Angles, Ladders and Safety Cages

Figure 6K 30"-36" Ladder Bracket Location for Up-Leg

Figure 6L 30"-36" Ladder Bracket Location for Down-Leg

28 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

6. Tie Angles, Ladders and Safety Cages

Attach Ladders to Ladder Brackets

1. Attach ladder sections to the ladder brackets using 1/2" x 1" hex bolts (S-7935). (See Figure 6M.)

Figure 6M

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 29

6. Tie Angles, Ladders and Safety Cages

Safety Cage Installation

Safety cage entrance must be installed to the ladders within 7'-8' from the ground or platform deck.

(See Figure 6N.)

Figure 6N

30 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

6. Tie Angles, Ladders and Safety Cages

Install Safety Cage

Safety cages are 10' sections, with the exception of the 3' entrance section.

1. Locate safety cage hoops (LDR-BCKTBHP) along the ladder rails where the safety cage hoops will be installed. NOTE: The end hoops of a 10' section are spaced 4' from the two (2) middle hoops, which are spaced 2' apart. See Figure 6O for spacing. (See Figure 6O.)

Figure 6O 10' Safety Cage Section

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 31

6. Tie Angles, Ladders and Safety Cages

2. Attach safety cage hoops to ladder using 1/2" x 1" bolts and nuts. (See Figure 6P.)

Figure 6P

32 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

6. Tie Angles, Ladders and Safety Cages

3. Install the seven (7) 10' safety cage straps along the safety cage hoops using 5/16" x 3/4" bolts and nuts. NOTE: Bolt heads should be to the inside of the hoop. (See Figure 6Q.)

Figure 6Q

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 33

7. Rest Platform

Chapter 7: Rest Platform Rest Platform Tie Angles to Bucket Elevators

1. Install rest platform tie angles to the lower trunking on both the ladder side and non-ladder side of the trunking. Use 1/2" x 1" bolts through the bolt holes indicated for the bucket elevator size being installed. (See Figure 7A.)

NOTE: Bolt hole starting location on left side of tie angle is marked with the bucket size.

Figure 7A Tie Angle with Etched Numbers

Figure 7B 30" Rest Platform Tie Angle Bolt Locations - Ladder Side

34 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

7. Rest Platform

Figure 7C 30" Rest Platform Tie Angle Bolt Locations - Non-Ladder Side

Figure 7D 36" Rest platform tie angle bolt locatio ns - Ladder and

non-ladder side have the same bolt hole locations.

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 35

7. Rest Platform

Attach Rest Platform Channel to the Rest Platform Tie Angle

1. Connect rest platform mounting channels to the rest platform tie angles using 1/2" x 1" bolts. Bolt hole locations for 30"-36" bucket elevator will be the same. (See Figure 7E.)

Figure 7E Bolt hole locations for 30"-36" rest platform mounting channels to tie angles.

36 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

7. Rest Platform

Rest Platform Cross Channel to Rest Platform Mounting Channels

1. Place the rest platform cross channels between the rest platform mounting channels and connect those using 3/8" x 3/4" hex bolts. (See Figure 7F.)

Figure 7F Rest Platform Cross Channel to Rest Platform Mounting Channels

2. Attach rest platform deck to the bottom of the rest platform mounting channels and rest platform cross channels, using 3/8" x 3/4" hex bolts. Bolt heads should be installed against the deck plate.

(See Figure 7G.) NOTE: The deck plate can be mounted on either the right or left sid e, but the flange

must be mounted towards the opening.

Figure 7G Deck Plate

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 37

7. Rest Platform

3. Install the handrail platform posts to the rest platform mounting channels and rest platform channels using six (6) 5/16" x 3/4" flanged hex bolts for each post, four (4) bolt to the front and two (2) on the side. (See Figure 7H.)

Figure 7H

4. Assemble the intermediate handrails by sliding the small handrail into the larger handrail to create a telescoping handrail that can be adjusted to the correct length between the posts. Two (2) of the small intermediate handrails and two (2) of the large intermediate handrails will need to be cut to fit. The starting length of each rail is 36". Cut 18" off the end of each rail so the final length of each rail is 18". (See Figure 7I.)

Figure 7I

38 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

7. Rest Platform

5. Install the front and back intermediate handrails to the platform posts using 5/16" x 3/4" flanged hex bolts. Adjust the rail into position by sliding it out to the correct length.

6. After cutting the two (2) large and two (2) small intermediate handrails, slide them to the correct length and install them to the handrail posts on the short sides of the platform using 5/16" x 3/4" flanged hex bolts. (See Figure 7J.)

Figure 7J

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 39

7. Rest Platform

7. Connect the front rest platform handrails and the side rest platform handrails to the handrail platform post using 5/16" x 2" hex bolts. (See Figure 7K.)

Figure 7K

40 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

7. Rest Platform

8. Platform braces must be installed from handrail posts to mounting and cross channels using 5/16" x 3/4" flanged hex bolts. Braces should be attached to the outside of the platform post and to the inside of the mounting and cross channels. NOTE: Safety cage bars (LDR-5171BE) are used as

platform braces/tie angle braces through out this installation. Bolt heads should be on inside of platforms. (See Figure 7L.)

Figure 7L

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 41

7. Rest Platform

9. Install ladder support brackets to the rest platform cross channel using 3/8" x 3/4" hex bolts.

10. Attach ladders to ladder support brackets using 1/2" x 3/4" hex bolts. (See Figure 7M.)

Figure 7M

42 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

Ladder Support

7. Rest Platform

Figure 7N

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 43

8. 30"-36" Head Platform Right Hand Drive

Chapter 8: 30"-36" Head Platform Right Hand Drive

To facilitate quick and easy assembly, numerous parts are pre-assembled prior to shipping. Considerable time is dedicated at the beginning of this manual to the proper orientation of channels and

decks. This is because the orientation of these elements is essential to the proper construction of the head platform.

1. There are many ways to get the orientation wrong and only one way to get it right.

2. Proper orientation of the channels and decks is essential proper assembly.

3. Proper construction of the head platform can only be completed if the initial orientation of the channels is done correctly.

Therefore, we strongly advise you take time to confirm that the orientation of these early elements is correct before you begin to assemble the decking on to the channels.

To facilitate proper connections, major connecting holes are etched with alpha-numeric codes. One side is labeled X1 through X7, this side is referred to as the “X” side. The opposite side is labeled with Y1 through Y7 and is referred to as the “Y” side.

44 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

8. 30"-36" Head Platform Right Hand Drive

Cross Deck Support Channels to Lower Head

Three (3) cross deck support channels support the platform. Two (2) of the channels are attached to brackets on the lower head section and the third channel is attached to the decking itself but is not attached directly to the lower head. This third channel will be attached after the deck is assembled.

(See Figure 8A.)

Figure 8A 30"-36" Platform Overview

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 45

8. 30"-36" Head Platform Right Hand Drive

Attach Main Support Channels to Lower Head For 30" Right Side Drive

Orient the Channel

Place lower head section on solid and level surface.

1. At Discharge End orient the channel so that:

a. Channel opening is inward, toward the bracket. b. Hole labeled with “Y” face up. c. Holes Y1 is on the non-drive/hatch side of the lower head. d. Hole Y7 is on the drive side of the lower head. e. Cross deck support channel extends farther on the drive side than on hatch side of lower head.

2. At Up-Leg End orient the channel so that:

a. Channel opening outward, toward the up-leg end of the head. b. Holes labeled with “Y” face up. c. Hole Y1 is on the non-drive side of the lower head. d. Hole Y7 is on the drive side of the lower head. e. Cross deck support channel extends farther on the drive side than on hatch side of lower head.

(See Figure 8C on Page 47.)

3. Attach cross deck support channels (HP36DSCX) to the top-most set of holes of the lower head brackets (HSP36130) using 3/8" x 1" bolts and nuts and properly. (See Figure 8C on Page 47.)

*NOTE: The channels MUST be oriented as shown in Figure 8B and Figure 8C on Page 47 in order for

the decking and subsequent assembly to be done correctly.

46 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

8. 30"-36" Head Platform Right Hand Drive

Holes etched on channel

Up-leg end

Drive Side

Eight (8) bolt holes at this end.

Six (6) bolt holes at this end.

Non-drive side

(Hatch located on this side.)

Lower head here

Discharge end

30" Right

Holes etched on channel

Note orientation of channel

Figure 8B 30" Right Side Drive Channel Position

Figure 8C 30" Right Drive - Cross Deck Support Channels to Lower Head Brackets

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 47

8. 30"-36" Head Platform Right Hand Drive

For 36" Right Side Drive

Orient the Channel

Place lower head section on solid and level surface.

1. At the Discharge End orient the channel so that:

a. Channel opening is outward, toward the discharge end of the head. b. Holes labeled with “X” face up. c. Hole X1 is on the non-drive side of the lower head. d. Hole X7 is on the drive side of the lower head. e. Cross deck support channel extends farther on the drive side than on hatch side of lower head.

2. At the Up-Leg End orient the channel so that:

(See Figure 8D on Page 49.)

3. Attach cross deck support channels (HP36DSCX) to the top-most set of holes of the lower head brackets (HSP36130) using 3/8" x 1" bolts and nuts and torque properly.

*NOTE: The channels MUST be oriented as shown in Figure 8D and Figure 8E on Page 49 in order for

the decking and subsequent assembly to be done correctly.

(See Figure 8E on Page 49.)

48 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

8. 30"-36" Head Platform Right Hand Drive

Lower head here

Non-drive side

(Hatch located on this side.)

Drive side

Note orientation of channel

Holes etched on channel

Six (6) bolt holes at this end.

Eight (8) bolt holes at this end.

Discharge end

Up-leg end

36" Right

Figure 8D 36" Right Side Drive Channel Position

Figure 8E

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 49

8. 30"-36" Head Platform Right Hand Drive

Attach Deck A to Hatch Cover Plate

NOTE: Only two (2) side of deck plate are attached at this time.

1. Locate pre-assembled Deck A. This plank consists of the two (2) hatch openings and is labeled with holes etched with the letter A.

2. Orient Deck A so the hatch cover plate is at the up-leg end of the deck.

3. The hatch will be located at the discharge end and will remain open at this time . A hatch door will be attached to Deck A later and should NOT be installed at this time.

NOTE: ONLY connect the hatch filler plate along two (2) of the four (4) sides of the plate.

4. The holes perpendicular to the length of Deck A should remain open at this time as they will serve to connect the hatch cover plate and Deck A to the cross deck support channel.

5. Attach the hatch cover plate to Deck A using (8) eight 3/8" x 1" carriage bolts (S-3585) with flange nuts (S-10028) and torque to 30 ft/lbs. (See Figure 8F.)

Figure 8F Hatch at Up-Leg End

50 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

8. 30"-36" Head Platform Right Hand Drive

Slide/Place Toe Boards on Cross Deck Support Channels

NOTE: Due to the snug fit, you should slide the toe boards in place before placing and securing Deck A

or any subsequent decking.

1. On the non-drive side slide one toe board (HP36STBX) into place.

2. On the drive side slide one toe board (HP36STBX) into place. (See Figure 8G.)

Figure 8G

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 51

8. 30"-36" Head Platform Right Hand Drive

Connect Deck A to Cross Deck Support Channels and Toe Board

NOTE: Orientation of etched holes on deck and ch annel is critical to subse quent steps. Connect all bolts

only finger tight until deck is completely assembled and then tighten to proper torque.

1. Locate pre-assembled Deck A. This plank consists of the hatch opening and the hatch cover plate.

2. Orient Deck A so the hatch opening is at discharge end of lower head and hatch cover plate is at up-leg end.

3. At the Discharge End, use a punch as needed to line up. (See Figure 8H.)

a. For 36" - Deck hole A1 and channel hole X1. b. For 36" - Deck hole A7 to channel hole X2. c. For 30" - Deck hole A1 and channel hole Y1. d. For 30" - Deck hole A7 to channel hole Y2. e. For both 30" and 36" - Deck hole A2 to toe board hole A2. (See Figure 8I on Page 53.)

NOTE: At this time, the head platform hatch deck support (HP36HDS) should be installed UNDER

Deck A. Line this up with hole A12 on the deck flange near hatch opening and install at the same time attaching deck to toe board. (See Figure 8I on Page 53.)

4. At the Up-Leg End for both 30" and 36", use a punch to align:

a. Channel hole Y1 to corner hole of hatch cover plate. b. Deck hole A4 to toe board hole A4. (See Figure 8I on Page 53.)

5. Connect holes as described above, connect all holes between support channel and Deck A.

Figure 8H

52 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

8. 30"-36" Head Platform Right Hand Drive

Figure 8I

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 53

8. 30"-36" Head Platform Right Hand Drive

Connect Deck C to Cross Deck Support Channel and to Toe Board

NOTE: The orientation of the flanges on Deck C is critical to subsequent steps. Tighten bolts only finger

tight until deck alignment is complete.

1. Locate the pre-assembled Deck C. This deck consists of two (2) planks.

2. Orient Deck C with hole C3 at the discharge end of the lower head.

3. Make sure the extended kick plate flange of Deck C is away from the lower head assembly.

(See Figure 8J below and Figure 8K on Page 55.)

4. Align holes. Use a punch as needed to line up the holes:

a. For 36" - Deck hole C3 and channel hole X5 at discharge end. b. For 30" - Deck hole C3 and channel hole Y5 at discharge end.

5. Connect cross deck support channel and Deck C using 3/8" x 1" carriage bolts (S-3585) with flange nuts (S-10028). Connect all holes between channel and deck. (See Figure 8J.)

6. Align and connect Deck C to toe board using 3/8" x 1" bolts (S-7469) with flange nuts (S-10028).

a. Deck hole C1 to toe board hole A4. b. Deck hole C2 to toe board hole A2.

Figure 8J Deck C to Cross Deck Support Channels

54 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

8. 30"-36" Head Platform Right Hand Drive

Figure 8K Underside View of Deck C to Toe Board

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 55

8. 30"-36" Head Platform Right Hand Drive

Connect Deck F to Cross Deck Support Channels and Deck C

IMPORTANT: Connect all bolts only finger tight until deck is completely assembled and then tighten to

proper torque.

1. Locate pre-assembled Deck F. This deck consists of two (2) planks.

2. Orient Deck F with hole F3 at the discharge end of the lower head and F5 at the up-leg end.

(See Figure 8L.)

3. Align holes. Use a punch as needed to line up the holes:

a. For 36" - Deck hole F3 and channel hole X7. b. For 30" - Deck hole F3 and channel hole Y7. c. For 30" and 36" - Deck hole F5 and channel hole Y7.

4. Connect deck to channel using 3/8" x 1" carriage bolts (S-3585) with flange nuts (S-10028).

5. Orient Deck F flange outside of Deck C flange. (See Figure 8N on Page 57.)

Figure 8L Deck F to Cross Deck Support Channel

56 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

8. 30"-36" Head Platform Right Hand Drive

DECK C

6. Connect Deck F to Deck C using 3/8" x 1" bolts (S-7469) with flange nuts (S-10028). a. Align F Deck hole F2 to C deck hole C6. b. Align F Deck hole F1 to C deck hole C7. (See Figure 8M.)

Figure 8M Deck F to Deck C

7. Install the head platform hatch deck support (HP1648HDS) under Deck C and Deck F using

3/8" x 3/4" bolt (S-7105) and nut. (See Figure 8N.) NOTE: You may need to remove a bolt from the

toe board if one was installed in this location.

Figure 8N

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 57

8. 30"-36" Head Platform Right Hand Drive

DECK C

DECK A

DECK C

Attach Third Cross Deck Support Channel to Decking

Connect all bolts only finger tight until deck is completely assembled and then tighten to proper torque.

1. Orient channel: Locate the third cross deck support channel (HP36DSCX) and orient it so the “Y” side faces up and hole Y1 is on the non-drive side of the lower head assembly.

2. Align holes. Use a punch as needed to line up the holes accordingly:

a. At the drive side - channel hole Y7 on the cross deck support channel to deck hole F4.

(See Figure 8L on Page 56.)

b. At the hatch side - channel hole Y1 on the cross deck support channel to Deck A and deck plate

cover. (See Figure 8H on Page 52.)

c. Connect Deck F to support channels using 3/8" x 1" carriage bolts (S-3585) with flange nuts

(S-10028). Connect all holes between channel and deck.

Attach Deck E to Deck A, Deck C and Cross Deck Support Channel

NOTE: Connect all bolts only finger tight until deck is completely assembled and then tighten to

proper torque.

1. Place Deck E between Deck A and Deck C. (See Figure 8O.)

2. Align holes. Use a punch as needed to align deck holes E5 with channel hole Y4. This will align Deck E with holes on each channel.

3. Connect Deck E to cross deck support channels using 3/8" x 1" carriage bolts (S-3585) with flange nuts (S-10028). Connect all holes between channels and deck.

4. Connect the Deck E kick plate flanges to toe boards and flanges of Deck A and Deck C using 3/8" x 3/4" bolts (S-7105) and 3/8" nuts (S-10028). (See Figure 8O.)

Figure 8O

58 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

8. 30"-36" Head Platform Right Hand Drive

WARNING

After decking is completely assembled, make sure to go back and tighten all bolts and nuts to the proper torque rating.

DECK C

DECK A

5. Connect Deck E to Deck A and Deck C using 3/8" x 3/4" bolts (S-7105) with flange nuts (S-10028).

(See Figure 8P.)

a. A Deck hole A5 to E deck hole E1. b. A Deck hole A6 to E deck hole E2. c. C Deck hole C5 to E deck hole E3. d. C Deck hole C4 to E deck hole E4.

Figure 8P

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 59

9. 30"-36" Head Platform Left Hand Drive

Chapter 9: 30"-36" Head Platform Left Hand Drive

To facilitate quick and easy assembly, numerous parts are pre-assembled prior to shipping. Considerable time is dedicated at the beginning of this manual to the proper orientation of channels and

decks. This is because the orientation of these elements is essential to the proper construction of the head platform.

1. There are many ways to get the orientation wrong and only one way to get it right.

2. Proper orientation of the channels and decks is essential proper assembly.

3. Proper construction of the head platform can only be completed if the initial orientation of the channels is done correctly.

Therefore, we strongly advise you take time to confirm that the orientation of these early elements is correct before you begin to assemble the decking on to the channels.

To facilitate proper connections, major connecting holes are etched with alpha-numeric codes.

• One side is labeled X1 through X7, this side is referred to as the “X” side.

• The opposite side is labeled with Y1 through Y7 and is referred to as the “Y” side.

60 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

9. 30"-36" Head Platform Left Hand Drive

Attach Cross Deck Support Channels to Lower Head

(See Figure 9A.)

Figure 9A Left Platform Overview

NOTE: The difference between left and righ t. The only difference is the channel orientation as they attach

to the lower head brackets. This makes you swap Deck A with the positions of Deck C and Deck F.

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 61

9. 30"-36" Head Platform Left Hand Drive

For 30" Left Side Drive

Orient the Channel

1. At Discharge End orient the channel so that:

2. At Up-Leg End orient the channel so that:

a. Channel opening outward, toward the up-leg end of the head. b. Holes labeled with “X” face up. c. Hole X1 is on the non-drive side of the lower head. d. Hole X7 is on the drive side of the lower head. e. Cross deck support channel extends farther on the drive side than on hatch side of lower head.

(See Figure 9B on Page 63.)

3. Attach cross deck support channels (HP36DSCX) to the top-most set of holes of the lower head brackets (HSP36130) using 3/8" x 1" bolts and nuts. (See Figure 9C on Page 63.)

*NOTE: The channels MUST be oriented as shown in Figure 9B and Figure 9C on Page 63 in order for

the decking and subsequent assembly to be done correctly.

62 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

9. 30"-36" Head Platform Left Hand Drive

Six (6) bolt holes at this end.

Eight (8) bolt holes at this end.

Lower head here

Discharge end

Up-leg end

Non-drive side

(Hatch located on this side.)

Drive side

Note orientation of channel

Holes etched on channel

30" Left

Figure 9C 30" Left Drive - Cross Deck Support Channels to Lower Head Brackets

Figure 9B 30" Left Side Drive Channel Position

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 63

9. 30"-36" Head Platform Left Hand Drive

For 36" Left Side Drive

Orient the Channel

1. At Discharge End orient the channel so that:

a. Channel opening is outward, toward the discharge end of the head. b. Holes labeled with “Y” face up. c. Hole Y1 is on the non-drive side of the lower head. d. Hole Y7 is on the drive side of the lower head. e. Cross deck support channel extends farther on the drive side than on hatch side of lower head.

2. At Up-Leg End orient the channel so that:

(See Figure 9D on Page 65.)

3. Attach cross deck support channels (HP36DSCX) to the top most set of holes of the lower head brackets (HSP36130) using 3/8" x 1" bolts and nuts. (See Figure 9E on Page 65.)

*NOTE: The channels MUST be oriented as shown in Figure 9D and Figure 9E on Page 65 in order for

the decking and subsequent assembly to be done correctly.

64 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

9. 30"-36" Head Platform Left Hand Drive

Holes etched on channel

Lower head here

Up-leg end

Non-Drive side

(Hatch located on this side.)

Six (6) bolt holes at this end.

Eight (8) bolt holes at this end.

Drive side

Discharge end

36" Left

Holes etched on channel

Note orientation of channel

Figure 9D 36" Left Side Drive Channel Position

Figure 9E

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 65

9. 30"-36" Head Platform Left Hand Drive

Attach Deck A to Hatch Cover Plate

NOTE: Only two (2) side of deck plate are attached at this time.

1. Locate pre-assembled Deck A: This plank consists of the hatch opening, the hatch filler plate and is labeled with holes etched with the letter A.

2. Orient Deck A: The hatch cover plate is at the up-leg end of the deck. The hatch will be located at the discharge end and will remain open at this time. A hatch door will be attached to Deck A later and should NOT be installed at this time

3. Attach the hatch cover plate to Deck A: Use eight (8) 3/8" x 1" carriage bolts (S-3585) with flange nuts (S-10028). (See Figure 9F.)

NOTE: ONLY connect the hatch filler plate along two (2) of the four (4) sides of the plate. The ho les

perpendicular to the length of Deck A should remain open at this time as they will serve to connect the hatch cover plate and deck A to the cross deck support channel.

Figure 9F Hatch at Up-Leg End

66 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

9. 30"-36" Head Platform Left Hand Drive

Slide/Place Toe Boards on Cross Deck Support Channels

NOTE: Due to the snug fit, you should slide the toe boards in place before placing and securing Deck A

or any subsequent decking.

1. On the non-drive side slide one toe board (HP36STBX) into place.

2. On the drive side slide one toe board (HP36STBX) into place. (See Figure 9G.)

Figure 9G

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 67

9. 30"-36" Head Platform Left Hand Drive

Connect Deck A to Cross Deck Support Channels and Toe Board

NOTE: Orientation of etched holes on deck and channel is critical to subsequent steps. Tighten bolts o nly

finger tight until all decking is installed.

1. Locate pre-assembled Deck A. This plank consists of the hatch opening and the hatch cover plate.

2. Orient deck a so that hatch opening is at discharge end of lower head and hatch cover plate is at the up-leg end.

3. On the Discharge End, use a punch as needed to line up. (See Figure 9H.)

a. For 36" - Deck hole A9 and channel hole Y2. b. For 30" - Deck hole A9 to channel hole X2.

NOTE: At this time, the head platform hatch deck support (HP36HDS) should be installed UNDER

Deck A. Line this up with hole A4 on the deck flange near hatch opening and install at the same time attaching deck to toe board. (See Figure 9I on Page 69.)

4. On the Up-Leg End for both 36" and 30", use a punch to align channel hole X1 to corner hole of hatch cover plate.

5. After aligning the holes as described above, connect all holes between support channel and Deck A using 3/8" x 1" carriage bolts (S-3585) with flange nuts (S-10028).

Figure 9H

68 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

9. 30"-36" Head Platform Left Hand Drive

Figure 9I

6. Connect Deck A to Toe Board: Line up holes on toe board with holes on Deck A: a. Deck hole A8 and toe board hole A1. b. Deck hole A12 to toe board hole A5.

Connect Deck C to Cross Deck Support Channel and to Toe Board

NOTE: The orientation of the flanges on Deck C is critical to subsequent steps. Tighten bolts only finger

tight until deck alignment is complete.

1. Locate the pre-assembled Deck C. This deck consists of two (2) planks.

2. Orient Deck C with hole C10 at the discharge end of the lower head.

3. Make sure the extended kick plate flange of Deck C is away from the lower head assembly.

(See Figure 9J and Figure 9K on Page 70.)

4. On the Discharge End, use a punch as needed to line up holes: a. For 36" - Deck hole C10 and channel hole Y6. b. For 30" - Deck hole C10 to channel hole X6.

NOTE: The only difference between the 30" and 36" is the channel on the discharge end would be

flipped so the opening of channel is the same as the other two (2) channels for 30".

5. Connect cross deck support channel and deck C using 3/8" x 1" carriage bolts (S-3585) with flange

nuts (S-10028). Connect all holes between channel and deck.

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 69

9. 30"-36" Head Platform Left Hand Drive

DECK A

Figure 9J Deck C to Cross Deck Support Channels

Figure 9K Underside View of Deck C to Toe Board

6. Connect Deck C to toe board using 3/8" x 1" bolts (S-7469) with flange nuts (S-10028). a. Deck hole C11 to toe board hole A1. b. Deck hole C8 to toe board hole A2.

70 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

9. 30"-36" Head Platform Left Hand Drive

DECK A

DECK C

Connect Deck F to Cross Deck Support Channels and Deck C

IMPORTANT: Connect all bolts only finger tight until deck is completely assembled and then tighten to

proper torque.

1. Locate pre-assembled Deck F. This deck consists of two (2) planks.

2. Orient Deck F with hole F7 at the discharge end of the lower head and F6 at the up-leg end.

(See Figure 9L.)

3. Align holes. Use a punch as needed to line up the holes: a. Deck hole F6 and channel hole X7. b. Deck hole F7 and channel hole Y7.

4. Connect deck to channel using 3/8" x 1" carriage bolts (S-3585) with flange nuts (S-10028).

5. Orient Deck F flange outside of Deck C flange. (See Figure 9M on Page 72.)

6. Align and connect Deck F to Deck C using 3/8" x 1" bolts (S-7469) with flange nuts (S-10028). a. F Deck hole F2 to C deck hole C6. b. F Deck hole F1 to C deck hole C7. (See Figure 9L.)

Figure 9L Deck F to Cross Deck Support Channel

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 71

9. 30"-36" Head Platform Left Hand Drive

DECK C

DECK A

Figure 9M Deck F to Deck C

7. Install the head platform hatch deck support (HP1648HDS) under Deck C and Deck F using 3/8" x 3/4" bolt (S-7105) and nut. (See Figure 9N.) NOTE: You may need to remove a bolt from

the toe board if one was installed in this location.

Figure 9N

72 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

9. 30"-36" Head Platform Left Hand Drive

Attach Third Cross Deck Support Channel to Decking

NOTE: Connect all bolts only finger tight until deck is completely assembled and then tighten to

proper torque.

1. Locate the third (3 and hole X1 is on the non-drive side of the lower head assembly.

2. Align holes. Use a punch as needed to align holes accordingly:

a. At the drive side - Channel hole X7 on the cross deck support channel to Deck F hole F6.

(See Figure 9L on Page 71.)

b. At the hatch s ide - Channel hole X2 on the cross deck support chan nel to Deck A hole A10 and

deck plate cover. (See Figure 9H on Page 68.)

c. Connect Deck F to support channels using 3/8" x 1" carriage bolts (S-3585) with flange nuts

(S-10028). Connect all holes between channel and deck.

) cross deck support channel (HP36DSCX) and orient it so the X side faces up

Attach Deck E to Deck A, Deck C and Cross Deck Support Channel

NOTE: Connect all bolts only finger tight until deck is completely assembled and then tighten to

proper torque.

1. Position Deck E between Deck A and Deck C. Note that Deck E will be connected to two (2) channels. (See Figure 9P on Page 74.)

2. Align holes. Use a punch as needed to align deck holes E5 with channel hole X3. This will align Deck E with holes on each channel. (See Figure 9O on Page 74.)

3. Connect Deck E to cross deck support channels using 3/8" x 1" carriage bolts (S-3585) with flange nuts (S-10028). Connect all holes between channels and deck.

4. Connect the Deck E kick plate flanges to toe boards and flanges of Deck A and Deck C using 3/8" x 3/4" bolts (S-7105) and 3/8" nuts (S-10028). (See Figure 9P on Page 74.)

5. Align and connect Deck E to Deck A and Deck C using 3/8" x 1" bolts (S-7469) with flange nuts (S-10028). (See Figure 9P on Page 74.)

a. C Deck hole C12 to E deck hole E1. b. C Deck hole C9 to E deck hole E2. c. A Deck hole A13 to E deck hole E3. d. A Deck hole A11 to E deck hole E4.

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 73

9. 30"-36" Head Platform Left Hand Drive

DECK C

WARNING

After decking is completely assembled, make sure to go back and tighten all bolts and nuts to the proper torque rating.

DECK F

DECK C

DECK A

Figure 9O

Figure 9P

74 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

10. 30"-36" Head Platform Post, Rails and Bracing

Chapter 10: 30"-36" Head Platform Post, Rails and Bracing

The following assemblies occur the same on all 30"-36" platform installations, regardless of left or right drive orientation.

Attach Head Bearing Support Angle to Lower Head for 30"

1. Connect two (2) HP head bearing support brackets (HP30HBE) as shown to the lower head using 3/8" x 1" bolts (S-7469) and nuts.

2. Attach two (2) head bearing angle supports (HP30HBS) to the head bearing support brackets and cross deck support channels with 3/8" x 1" bolts (S-7469) and nuts. (See Figure 10A.)

Figure 10A 30" Bearing Support Clips and Angles

Attach Head Bearing Support Angle to Lower Head for 36"

1. Place two (2) head bearing angle supports (HP36HBS) as shown in Figure 10B.

2. Connect to lower head and cross deck support channel with 3/8" x 1" bolts (S-7469) and nuts.

Figure 10B 36" Bearing Support Angle

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 75

10. 30"-36" Head Platform Post, Rails and Bracing

DECK E

Attach Handrail Supports to Deck E

1. Attach two (2) HP handrail supports (HP1648HSH) to Deck E using 3/8" x 3/4" bolts and nuts.

(See Figure 10C.) NOTE: The supports that attach to Deck A and Deck F attach at the same time

as the platform post.

Figure 10C

76 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

10. 30"-36" Head Platform Post, Rails and Bracing

Install Posts

1. Attach two (2) “W” posts (HP1648HWP) to the corner of Deck F using 5/16" x 3/4" bolts (S-6606) and nuts.

2. Attach platform post (HP1648HCP) and HP handrail support (HP1648HSH) to the middle of Deck F. Use 5/16" x 3/4" bolts (S-6606) to attach post to deck. Use 5/16" x 3/4" bolts (S-6606) to attach support bracket, post and deck together. (See Figure 10D.)

3. Attach platform posts to Deck A and Deck C as shown in Figure 10D. Use four (4) 5/16" x 3/4" bolts (S-6606) and nuts for each post.

Figure 10D

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 77

10. 30"-36" Head Platform Post, Rails and Bracing

Install Head Side Posts

For 30" Side Posts

1. Install side post (HP1648HP) to decking. (See Figure 10E.)

Figure 10E

2. Install handrail support bracket (HP30XHSPPT) from toe board to side post (HP1648HP) using 5/16" x 3/4" bolts and nuts. (See Figure 10F.)

Figure 10F

78 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

10. 30"-36" Head Platform Post, Rails and Bracing

For 36" Side Posts

1. Attach two (2) HP handrail supports (HP1636HS) to lower head using 3/8" x 1-1/4" bolt (S-2071) and nut. (See Figure 10G.)

Figure 10G

2. Attach head side post (HP1648HP) to lower head using 5/16" x 3/4" bolts and nuts. (See Figure 10H.)

Figure 10H

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 79

10. 30"-36" Head Platform Post, Rails and Bracing

3. Attach side post to decking using 5/16" x 3/4" bolts and nuts. (See Figure 10I.)

Figure 10I

80 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

10. 30"-36" Head Platform Post, Rails and Bracing

Attach Intermediate Handrails to Posts

1. Cut 20" off the tube end of one small intermediate handrail (LDR-4088) and one large intermediate handrail (LDR-4087). (See Figure 10J.) Slide the small rail into the large rail and install between the posts opposite the discharge end and adjust to fit. Fasten using 5/16" x 3/4 " bolts (S-6606) and nuts.

2. Cut 12" off the end of two (2) small intermediate handrail (LDR-4088) and two (2) large intermediate handrail (LDR-4087). (See Figure 10J.) Slide the small rails into the large rails and install one set at the discharge end of Deck A. Install the second set opposite the discharge end of Deck A. Fasten using 5/16" x 3/4" bolts (S-6606) and nuts.

Figure 10J

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 81

10. 30"-36" Head Platform Post, Rails and Bracing

3. Install the remaining Intermediate handrails around the platform using 5/16" x 3/4" bolts (S-6606) and nuts. (See Figure 10K.)

Figure 10K

82 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

10. 30"-36" Head Platform Post, Rails and Bracing

Install Upper Handrails

1. Attach handrails to the handrail posts using 5/16" x 2" bolts (S-7877) and hex nuts. Use Figure 10L

below Figure 10M.) for handrail location.

Figure 10L Right Hand Drive Rail Locations

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 83

10. 30"-36" Head Platform Post, Rails and Bracing

Figure 10M Left Hand Drive Rail Locations

84 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

10. 30"-36" Head Platform Post, Rails and Bracing

Install Safety Cage Bar Cross Supports

1. Attach safety cage bar - 24" (LDR-5171BE) from handrail post to decking kick plates using 5/16" x 3/4" bolts and nuts. (See Figure 10N.)

Figure 10N

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 85

11. Install Hatch

Chapter 11: Install Hatch

1. Attach hatch hinge (HP1624HH) to the hatch deck door (HP1624HDD). Orient hinge so that it opens the desired direction. (See Figure 11A.) Fasten using 3/8" x 1" carriage bolts hardware.

Figure 11A

2. Install hatch support (HP1624HS) to the bottom of the hatch door using 3/8" x 1" carriage bolts and nuts. (See Figure 11B.)

3. Fasten peak cap handle (PR-331) to the bottom of the hatch door using 3/8" x 1" carriage bolts and nuts.

Figure 11B

86 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

11. Install Hatch

4. Slide two (2) magnets (16-0092) onto each MS #6 x 3/4" FHS flat head screw (S-7166). Position the magnet so the screw head is countersunk into the magnet. (See Figure 11C.)

5. Insert screws with magnets through the hatch door and fasten with the #6 flange nut (S-10133).

Figure 11C

6. Align holes on the hatch hinge with holes along the deck opening closest to the kick plates. Install the hatch door to the decking using 3/8" x 3/4" bolts (S-7105) and nuts. (See Figure 11D.)

Figure 11D

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 87

11. Install Hatch

7. Assemble pipe clamps (S-10139) to the magnet mount hatch bracket (HP1648LMM). Insert 3/8" x 3/4" carriage bolts through the magnet mount hatch bracket, 1/2" flat washer and pipe clamp. Fasten with 3/8" nut. (See Figure 11E.)

8. Attach pipe clamp around intermediate handrail and fasten loosely with bolts. Open hatch plate and slide clamp along handrail until it lines up with the magnets on the hatch plate. Tighte n clamp to rail.

Figure 11E

88 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

12. 4 x 5 Distributor Platform (Optional)

Chapter 12: 4 x 5 Distributor Platform (Optional)

The distributor platform is optional and only used on bucket elevators that have a distributor spout. The platform is used to access the distributor for maintenance and control adjustments. The platform should be located below the distributor head. NOTE: That the clamp installation to the trunking is different for

16", 24" and the 30"-36" but the rest of the assembly is the same.

Install Clamp Band

30"-36" Top Clamp Band to Trunking

NOTE: 30 "-36" Top and bottom clamps assemble the same. One attaches to the support channel and one

attaches to the brace channels.

1. Slide rods of clamp rod weldment into outside set of holes of clamp bands for both the top and bottom assemblies. Fasten together using four (4) 1/2" hex flange nuts per each clamp.

2. Assemble the top and bottom clamp band weldments, clamp channel and clamp clips at same time around the trunking. Place clamp rod weldment assembly around the trunking leg and line up holes on clamp channel and clamp clips with the inside set of holes on the clamp bands. Fasten all together using six (6) 1/2" x 1" bolts and nuts. (See Figure 12A.)

3. Line up the holes located at the end of the distributor support channels and brace channels with the holes on the clamp clips. Fasten together using four (4) 1/2" x 1" bolts and nuts.

Figure 12A

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 89

12. 4 x 5 Distributor Platform (Optional)

Assemble Supports

Support Channel, Cross Support and Knee Brace Assembly

1. Attach brace channels to the sides of the support channels using four (4) 1/2" x 1" bolts and nuts. Angle the knee braces across the bottom sides of the brace channels and attach using four (4) 1/2" x 1" bolts and nuts.

2. Assemble the cross supports to the bottom side of the support channels using the end and middle sets of holes on the support channels using four (4) 1/2" x 1" bolts and nuts. (See Figure 12B.)

3. Assemble the external platform support (DSP1648EPS) to the end of the three (3) cross supports using six (6) 1/2" x 1" bolts and nuts. (See Figure 12C on Page 91.)

Figure 12B Distributor Platform Cross Support

90 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

12. 4 x 5 Distributor Platform (Optional)

Figure 12C Distributor External Platform Support

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 91

12. 4 x 5 Distributor Platform (Optional)

Assemble Decking

1. Align A6 and A8 on platform decking weldment with A6 and A8 on the external platform supports.

2. Install platform decking weldment to the platform support channels using twenty four (24) 1/2" x 1" bolt and nuts. (See Figure 12D.)

3. Attach the flange of the toe board short side to the bottom of the 18" decking using two (2) 1/2" x 1" bolt and nuts. Then attach 18" decking to the external platform support using one 1/2" x 1" bolt and nut. (See Figure 12F on Page 93.)

4. Align flange of end toe board along the bottom of decking. Connect end toe board to decking using 1/2" x 1" bolts and nuts. (See Figure 12G on Page 94.)

5. Install the corner “W” post at the same time as the toe board filler plate. Attach toe board filler plate to the decking toe boards located across from the entrance. Attach the flat end first using two (2) 5/16" x 3/4" flange bolts and nuts. Then line up the holes of the toe board filler plate with the decking toe board, while also aligning the holes of the “W” post on the corner. Fasten all three (3) together with four (4) 5/16" x 3/4" flange bolts and nuts. (See Figure 12G on Page 94.)

Figure 12D

92 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

12. 4 x 5 Distributor Platform (Optional)

Figure 12E

Figure 12F Distributor Platform Toe Board

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 93

12. 4 x 5 Distributor Platform (Optional)

Figure 12G Distributor Platform Corner Post

Install Handrail Posts - Non Entrance Side

1. Install the remaining two (2) “W” corner posts to the corners on the non-entrance side of th e decking using four (4) 5/16" x 3/4" flange bolts and nuts per post.

2. Install platform post (HP1648HCP) to the inside corner of the decking near the entrance to the platform using four (4) 5/16" x 3/4" flange bolts and nuts.

3. Attach side posts (HP1648HP) to the decking at the entrance to the platform using two (2) 5/16" x 3/4" flange bolts and nuts per post.

94 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

12. 4 x 5 Distributor Platform (Optional)

4. Install distributor handrail support to the side post on the inside, located closest to the trunking through holes 3 and 4 counting from the top of the post. Use two (2) 5/16" x 3/4 " flange bolts and nuts to fasten in place. (See Figure 12H.)

Figure 12H

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 95

12. 4 x 5 Distributor Platform (Optional)

Assemble and Install Intermediate Handrails

1. Insert small intermediate handrail into the large intermediate handrails to create telescoping rails. Cut 30" off one small intermediate and one large intermediate rail to fit at entrance. Adjust all rails to the proper length and install to the posts using the 5 two (2) 5/16" x 3/4" flange bolts and nuts per each telescoping tube. (See Figure 12I.)

hole down from the top. Fasten in place using

Figure 12I

Install Safety Bar Cross Supports

NOTE: Safety cage bars (LDR-5171BE) are used as tie braces in this installation.

1. Install safety bar cross supports from the decking toe board to the rail posts using two (2) 5/16" x 3/4" flange bolts and nuts per each cross bar support. (See Figure 12J.)

Figure 12J

96 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

12. 4 x 5 Distributor Platform (Optional)

Install Upper Handrails

1. Attach handrails to the posts using four (4) 5/16" x 3/4" flange bolts and nuts per handrail.

(See Figure 12K.)

Figure 12K

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 97

12. 4 x 5 Distributor Platform (Optional)

Safety Gate Package (Optional)

IMPORTANT: Attach the platform gate bracket to the gate before attaching it to the inside platform post

using 5/16" hardware.

Attach safety gate assembly to intermediate platform door bracket using 5/16" bolt (S-1196), 5/16" flat washer (S-845) and 5/16" flange nut (S-3611).

Attach intermediate platform door bracket to two (2) safety gate side posts (HP1648HP) using 5/16" bolt (S-1196), 5/16" flat washer (S-845) and 5/16" flange nut (S-3611). (See Figure 12L.)

Figure 12L

98 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

13. 6 x 6 Distributor Platforms

Chapter 13: 6 x 6 Distributor Platforms

This assembly is designed to be located at any elevation on trunking that is needed to provide access to other equipment. Determine elevation of platform surface and work from there. Locate all parts required for assembly by using the chart as shown in Figure 13A.

Platform Clamps

Locate all clamp halves (DSP36007), clamp brackets (DSP36016), threaded rods (DSP36008) and hardware to assemble clamps onto the trunking.

Measure the distance between the clamps to assure proper location for support channels and knee brace attachment. See clamp detail in Figure 13A for hardware orientation.

Attach one clamp half to the end of each platform support channel using 5/8" hardware in the top and bottom holes of the bracket.

Insert rod through the middle hole in the brackets attached to the platform support channel. Fasten using 5/8" nut, 5/8" lock washer and two (2) flat washers.

Place brackets with support channels attached around trunking and fasten in place with clamp bracket using 1/2" hardware.

Adjust the position of the inside nuts of the rod assembly to allow the clamps to be tightened onto the trunking.

NOTE: Tighten clamps onto trunking, do not overtighten and collapse the trunking. Position inside nuts

back to the clamp and tighten.

Figure 13A

PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series 99

13. 6 x 6 Distributor Platforms

Support Channels and Knee Braces

Assemble clamps securely to the trunk, attach the platform support channel (DSP36005) to the upper clamp using 1/2" hardware.

Insert rod (DSP36008) through middle hole in the bracket, attached to the p latform support channel using 5/8" hex nut (S-4110), 5/8" lock washer (S-3208) and two (2) 5/18" flat washers (S-858). The knee braces will attach in the upper set of holes on side of support channels using 1/2" hardware. (See Figure 13B.)

Figure 13B

100 PNEG-1849 30"-36" Bucket Elevator Platform and Ladder “X” Series

GSI PNEG-1849 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

1. Introduction

2. Safety

3. Decal Location

4. Overview

5. Ladder Assembly

6. Tie Angles, Ladders and Safety Cages

7. Rest Platform

8. 30"-36" Head Platform Right Hand Drive

9. 30"-36" Head Platform Left Hand Drive

10. 30"-36" Head Platform Post, Rails and Bracing

11. Install Hatch

12. 4 x 5 Distributor Platform (Optional)

13. 6 x 6 Distributor Platforms