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PNEG-751-G2
User Manual
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GSI PNEG-751-G2 User Manual

PNEG-751-G2
12" Series II Sweep 131' and 135' Diameter
Owner ’s Manual
PNEG-751-G2
Version: 1.0 Date: 11-22-11
Model Number of My Sweep:
__________________________________
Date Delivered:
__________________________________
Date Installed:
__________________________________
NOTE: The manufacturer reserves the right to improve its product whenever possible and practical to
do so. We reserve the right to change, improve and modify products at any time without obligation to make changes, improvements and modifications on equipment sold previously.
Personnel operating or working around this equipment should read this manual. This manual must be delivered with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment. Any misuse of the equipment may void the warranty.
Table of Contents

Contents

Chapter 1 Introduction ..........................................................................................................................................5
Product Introduction .............................................................................................................................. 5
Chapter 2 Safety .....................................................................................................................................................7
Safety Guidelines .................................................................................................................................. 7
Safety Instructions ..................... ... .... .......................................... ... ... ..................................................... 8
Operator Qualifications ....................................................................................... .... ... ... ... ................... 12
Chapter 3 Safety Decals ......................................................................................................................................13
Chapter 4 General Product Information ............................... ....................... ...................... .................................17
Product Information ............................................................................................................................. 17
General Information ............................................................................................................................ 17
Capacities and Specifications ............................................................................................................. 18
Q-D Bushings - Reverse Mounting ..................................................................................................... 21
Chapter 5 Assembly ............................................................................................................................................23
Back Shield Assembly ......................... ... ... ... .... ... ... ... .... ... .......................................... ... ... ... ................ 23
Flighting Assembly .............................................................................................................................. 24
Hanger Bracket Assembly ...................... ... ... .... ... .......................................... ... ... .... ... ... ... ................... 25
Flange Bearing Assembly ...................... ... ... .... ... ... ... .... ... .......................................... ... ... ... ................ 26
Gear Reducer Assembly ............................................... ... ... .......................................... ... ... ................ 26
Drive Axle Assembly and Bearing Support ......................................................................................... 27
Install Reducer Mounting Plate and Reducer ...................................................................................... 29
Key Alignment ..................................................................................................................................... 30
Install Tractor Drive Motor ................................................................................................................... 31
Guard Assembly .................................................................................................................................. 32
Tractor Wheel Assembly ..................................................................................................................... 34
Weight Placement ............................................... ... ... .......................................... .... ... ... ...................... 35
Channel Extension Kit ............................... ... .... ... ... ... .... ... ... ... .... ... ... ................................................... 36
Motor Jack and Base Assembly .......................................................................................................... 37
Motor Installation ................................................................................................................................. 38
Sheave Installation .............................................................................................................................. 39
Electrical Assembly ............................................................................................................................. 42
Jack Support Assembly ....................................................................................................................... 46
Center Pivot Installation ...................................................................................................................... 48
Control Panel Setup ............................................................................................................................ 51
Calibration ........................................................................................................................................... 56
Operation ............................................................................................................................................ 57
Chapter 6 Start-Up ...............................................................................................................................................58
Perform Pre-Start Checks ......................................... .... .......................................... ... ... ... ................... 58
Start the Auger .................................................................................................................................... 59
Chapter 7 Operation ............................................................................................................................................60
Operating the Sweep Auger ............................................................................. ... .... ... ... ... ... .... . ........... 60
Operating the Sweep Auger Control Panel ......................................................................................... 61
Chapter 8 Shut Down ...........................................................................................................................................62
Normal Shut Down .............................................................................................................................. 62
Emergency Shut Down .................................................... ... ... .... ... ... ... ... .... ... ... ................................... 62
Storage Preparation .................................................. .... .......................................... ... ... ... ..
Chapter 9 Maintenance ........................................................................................................................................63
Maintain the Auger .............................................................................................................................. 63
Lubrication .............................. ............. ............. ............. ............. ............ ............. ................................ 64
PNEG-751-G2 12" Series II Sweep 131' and 135' Diameter 3
................. 62
Table of Contents
Chapter 10 Control Panel Diagrams ...................................................................................................................69
Control Panel Schematic (460/3/60) Pre-June 2010 ......................................................................... 69
Grain Sweep Schematic Post-June 2010 (S2PFA) ........................................................................... 70
Grain Sweep Schematic Post-June 2010 (S2PFB) ........................................................................... 71
Grain Sweep Schematic Post-June 2010 (S2PFC) ........................................................................... 72
Chapter 11 Troubleshooting ...............................................................................................................................73
FAQs ................................................................................................................................................. 74
Chapter 12 Parts List ...........................................................................................................................................81
Main Auger Components .................... ... ... ... .......................................... .... ... ... ... .... ... ... ... ... ............... 82
Flight Components ............................................................................................................................ 84
End Bearing Components ................................................................................................................. 85
Auger Drive Components .................................................................................................................. 86
Drive Assembly .................................................................................................................................. 88
Tractor Chain Guard Parts ................................................................................................................ 90
Motor Mount Jack and Base Assembly (GC09993) .......................................................................... 91
Jack Supports .................................................................................................................................... 92
Control Panel Components (S2PFA) ........... .... ... ... ... .... ... ... ... .... ... ... ... ... .... ........................................ 94
Control Panel Components Post-June 2010 (S2PFA) ................................. ... ... .... ... ... ... ... .... ... ... ... .. 96
Control Panel Components Post-June 2010 (S2PFB) ................................. ... ... .... ... ... ... ... .... ... ... ... .. 98
Control Panel Components Post-June 2010 (S2PFC) ................................................................. ... 100
Weight Extension Kit (GC12311) . .... ... ... ... .......................................... ... .... ... ... ... .... ......................... 102
Chapter 13 Warranty ..........................................................................................................................................103
4 PNEG-751-G2 12" Series II Sweep 131' and 135' Diameter

1. Introduction

Product Introduction
Congratulations. Your selection of the GSI Series II Sweep is a wise investment. It will give you years of dependable service. The main function of the Series II Sweep is to clean out the remaining grain, from the bin, after all gravity unloading has finished. The GSI Series II Sweep is a single pass sweep only. The unit will only operate in a round grain bin equipped with a center sump in the bin floor. NOTE: The bin manufacturer should be contacted for their recommendations on your bin’s structural integrity. The following are sweep criteria recommendations.
Issues Recommendations
A track is required under each of the sweep tires and jack wheels where they travel over the aeration (steel) floor. This is the case for all steel flooring including full floor and flush floor aeration. The track should be a minimum of 10 gauge thick and made from steel. The steel can be galvanized for the jack wheel paths but needs to have a non-slip coating for the drive tire paths. The drive tire track coating must not be course
Flooring.
enough to damage the drive tires. A Chart on Page 17 is included that shows radius dimensions locating the points of contact between the sweep and the bin floor. The dimensions may be used to figure the material quantities of track to support the sweep across the aeration flooring. The track material is not supplied with the sweep and must be supplied by the installer or purchased from GSI. The dimensions are approximate and the assembled sweep should be checked for exact points of contact.
Center sump size.
Number of intermediate sumps.
Routing the power supply to the sweep.
Floor level tolerance.
If installing a sump with collector ring, the opening will be 42" x 42" for 12" sweep size. The sump hopper supplied by GSI was designed with sufficient clearance around
the collector ring housing to allow grain to gravity flow through the hopper and be carried away by the material handling equipment below. 42-3/4" is the maximum opening size to allow rolling clearance for the casters assembled to the head end jack. If made smaller, grain flow may be decreased to an unacceptable level.
**Flow of grain is limited to 15000 BPH when using this sump and collector ring housing assembly. The collector ring housing extends 22-1/2" down from the floor surface and is approximately 14-1/4" x 14-1/4" in size.
Intermediate sump pumps must be installed on a maximum of 10' centers where the sweep will be parked during storage. The first intermediate sump should be placed at a maximum of 10' from the center sumps and the end sump should be no more than 4' from the bin wall.
The extra sumps will help clean out the grain in front of the sweep, reducing the start-up load. Doing this will save labor dollars and hours of work to dig out the sweep and will help the sweep during start-up. The sweep is not designed to start-up when submerged in material. The sweep should be parked behind the intermediate sumps with sumps on the auger side of the sweep.
The only option is to use the hopper sump with collector ring. This allows the power to be transferred through a mechanical device in the center sump and does not twist any cords.
The top edge of the sump hopper and the top edge of the “X” brace support must be level with the floor. The floor must be level within 3/4" plus (or) minus, preferably less. Any high or low points must be gradually sloped. The change in elevation should be no more than 3/4" over 60".
Diameter tolerances are limited by foundation limits and sweep operation as well as
Bin roundness tolerance.
structural issues. For 72' diameter and larger, the overall tolerance would be plus or minus 1-1/4" on the radius, plus or minus 1" on 42'-66' diameter bins and plus or minus 3/4" on 30'-39' bins.
PNEG-751-G2 12" Series II Sweep 131' and 135' Diameter 5
1. Introduction
Issues Recommendations
Bin opening size required for installation.
Vo ltage specification.
Electrical requirements.
The tail section is the largest piece of a standard Series II Sweep. The dimensions for a 12" tail section are 21-1/4" x 51-1/2". If the bin wall is not too thick, this unit should fit through a 21-1/2" x 45" opening.
The Series II Sweep is designed to operate using 460 volt 3 phase 60 cycle power. The voltage must be within plus or minus 4% for proper operation. Volt ages outside of this range may cause excessive power draw or other operating problems. Please contact the factory for applications outside of these parameters.
Electrical controls and wiring should be installed by a qualified electrician. The conductor cables should comply with the National Electric Code and any local codes which may apply.
Disconnect and lock out the power before servicing the equipment, entering the bin or resetting the motor overloads.
The control panel MUST be mounted OUTSIDE the bin near the door. It must be located so the operator has a full view of the equipment and can see that all personnel are clear. It must NEVER be installed inside the bin. The foot switch has to be plugged into the control panel and depressed before the sweep is operational. It has a 10' cord so the sweep can only be monitored from OUTSIDE the bin. The thermal protection cord must also be plugged in before the sweep will operate.

2. Safety

DANGER
WARNING
CAUTION
NOTICE
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Safety Guidelines
This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections. Failure to read this manual and its safety instructions is a misuse of the equipment and may lead to serious injury or death.
PNEG-751-G2 12" Series II Sweep 131' and 135' Diameter 7
2. Safety
Read and Understand Manual
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.
Keep Hands Away from Moving Parts
DO NOT put hand or arm in hopper. Rotating auger can crush and dismember.
DO NOT put any kind of tool inside hopper to try and clear debris while the auger is running. Damage to the equipment will result.
ALWAYS turn off and lock out all power sources before servicing equipment.
Keep all shields and covers in place during operation.
Rotating Auger
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 p roduce 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.
2. Safety
Operate Motor Properly
In an emergency, shut down the power source. Turn OFF and lock out all power sources before performing
any maintenance. Do not operate electric motor equipped units until motors are
properly grounded. Disconnect power on electrical driven units before resetting
motor overloads. Do not repetitively stop and start the drive in order to free a
plugged condition. Jogging the drive in this manner can damage the equipment and/or drive components.
Electric Shock Hazard
Maintain Equipment and Work Area
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 broke n parts. Remove an y built-up grease, oil, and debris.
Keep Emergency Equipment Quickly Accessible
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.
PNEG-751-G2 12" Series II Sweep 131' and 135' Diameter 9
2. Safety
Eye Protection
Gloves
Steel Toe Boots
Respirator
Hard Hat
Fall Protection
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').
Operate Unload Equipment Properly
• Untrained operators subject themselves and others to SERIOUS INJURY or DEATH. NEVER allow untrained personnel to operate this equipment.
• NEVER work alone.
• Keep children and other unqualified personnel out of the working area at ALL times. Refer to the Start-Up section of this manual for diagrams of the work area.
• Make sure ALL equipment is locked in position before operating.
• NEVER start equipment until ALL persons are clear of the work area.
• Keep hands and feet away from the auger intake and other moving parts.
• NEVER attempt to assist machinery operation or to remove trash from equipment while in operation.
• Be sure all operators are adequately rested and prepared to perform all functions of operating this equipment.
• NEVER allow any person intoxicated or under the influence of alcohol or drugs to operate the equipment.
• Make sure someone is nearby who is aware of the proper shut down sequence in the event of an accident or emergency.
• ALWAYS think before acting. NEVER act impulsively around the equipment.
• NEVER allow anyone inside a bin, truck or wagon which is being unloaded by an auger or conveyor. Flowing grain can trap and suffocate in seconds.
• Use ample overhead lighting after sunset to light the work area.
• Keep area around intake free of obstacles such as electrical cords, blocks, etc., that might trip workers.
• NEVER drive, stand or walk under the equipment.
• Use caution not to hit the auger when positioning the load.
• ALWAYS lock out ALL power to the equipment when finished unloading a bin.
• Be aware of pinch points. A pinch point is a narrow area between two surfaces t hat is likely to trap or catch objects and so is a potential safety hazard.
Operate Unload Equipment Safely
2. Safety
PNEG-751-G2 12" Series II Sweep 131' and 135' Diameter 11
2. Safety
Operator Qualifications
A. The User/Operator must be competent and experienced to operate auger equipment. Anyone who
works with or around augers must have good common sense in order to be qu alified. These persons must also know and meet all other qualifications, such as:
i. Any person who has not read and/or does not understand all operation and safety procedures
is not qualified to operate any auger systems.
ii. Certain regulations apply to personnel operating power machinery. Personnel under the age of
18 years may not operate power machinery, including augers. It is your responsibility, as owner
and/or supervisor, to know what these regulations are in your area or situation. iii. Unqualified or incompetent persons are to remain out of the work area. iv. O.S.H.A. (Occupational Safety and Health Administration) regulations state: “At the time of
initial assignment and at least annually thereafter, the employer shall instruct every employee
in the safe operation and servicing of all equipment with which the employee is, or will be
involved”. (Federal Occupational Safety and Health Standards for Agriculture. Subpart D,
Section 1928.57 (a) (6)).
B. As a requirement of O.S.H.A., it is necessary for the employer to train the employee in the safe
operating and safety procedures for this auger. The sign-off sheet is provided for your convenience and personal record keeping. All unqualified persons are to stay out of the work area at all times. It is strongly recommended that another qualified person who knows the shut down procedure is in the area in the event of an emergency.
Date Employee Name Supervisor Name

3. Safety Decals

The images below show the location of the decals and safety signs which should appear on the Series II Sweep. (Refer to Pages 14-16 for decals.)
NOTE: Please remember safety signs provide important safety information for people working near bin
unloading equipment that is in operation. Any safety signs that are worn, missing, illegible or painted over should be replaced immediately.
Obtain FREE replacements by contacting GSI.
3. Safety Decals
SHEAR POINT Moving parts can crush and cut. Keep hands clear of sprocket and chain.
DC-1386
WARNING
ROTATING AUGER!
• DISCONNECT AND LOCKOUT P OWER BEFORE SERVICING, ADJUSTING OR CLEANING.
• KEEP HANDS, FEET, HAIR AND LOOSE CLOTHING AWAY FROM ROTATING AUGER AND MOVING PARTS AT ALL TIMES.
• NEVER REMOVE O R MODIFY GUARDS OR SHIELDS.
FAILURE TO HEED WILL RESULT IN
SERIOUS INJURY OR DEATH!
DC-1416
DANGERDANGER
Decal “A”
Location: Exterior of chain guard Size: 2" x 4-1/2" Part #: DC-1386
Decal “B”
Location: Two (2) per section on front of top flange Size: 4-5/16" x 5-7/16" Part #: DC-1416
Decal “C”
Location: Centered on motor mount Size: 5-1/2" x 7-3/8" Part #: DC-1379
Decal “D”
Location: Corner of motor mount Size: 2-7/8" x 5" Part #: DC-1224
HIGH VOLTAGE.
Will cause serious injury or death.
Lockout power before servicing.
DC-1224
SHEAR POINT
SHEAR POINT
Keep hands clear of moving parts. Do not operate with guard removed. Disconnect
and lockout power before servicing.
DC-995
WARNING
Decal “G”
Location: Corner of motor mount Size: 2-13/16" x 17/16" Part #: DC-889
Decal “F”
Location: Top of belt guard Size: 4-1/2" x 2" Part #: DC-995
Decal “E”
Location: Corner of motor mount Size: 4-1/2" x 2" Part #: DC-994
Decal “H”
Location: Corner of mount plate Size: 4" x 1-3/4" Part #: DC-1382
Decal “I”
Location: One per section centered on back of top flange Size: 9" x 3-3/4" Part #: DC-834
Keep hands clear of moving parts. Do not operate with guard removed. Disconnect and lockout power before servicing.
3. Safety Decals
DC-994
SHEAR POINT Moving parts can crush and cut. Keep hands clear of sprocket and chain.
DC-1382
3. Safety Decals
A. DANGER Sign No. DC-1395 was supplied with your bin unloading equipment. This safety sign
should be applied to the side of the bin near the bin opening, so it will be viewed by people entering into the bin storage building. Do not cover any safety signs or any other signs that are already there.
B. If the safety sign location suggested is not in full view because of equipment modifications, other
equipment in the area or any reason, then locate the safety sign in a more suitable location.
C. Be certain the surface is clean, dry and free of dirt and oil. Peel paper backing from decals and stick
into place. The adhesive backing will bond on contact.
NOTE: Please remember, safety signs provide important safety information for people working near bin
unloading equipment that is in operation.
NOTE: If the Safety Sign cannot be easily read for any reason or has been painted over, replace it
immediately. Additional Safety Signs may be obtained free of charge from your dealer, distributor or ordered from the factory.
Order SAFETY SIGN NO. DC-1395

4. General Product Information

This Series II Sweep is a single pass sweep. Consult the manufacturer of the storage tank regarding the requirements or restrictions of the sweeping process. The manufacturer may require a multiple pass sweep.
WARNING
NEVER enter a grain bin unless ALL power driven equipment has been shut down. Disconnect and lock out power before entering the bin or servicing the equipment.
Product Information
CAUTION
A. The Series II Sweep includes the following components.
• Control panel
• Two (2) motors
•Motor covers
• Motor mount
• Auger flighting
• Auger back shield assembly
• Jack supports
B. The unit will operate only in a round grain bin equipped with a center sump in the bin floor.
General Information
A. GSI reserves the right to improve its product whenever possible and practical to do so. We reserve
the right to change, improve and modify products at any time without obligation to make changes, improvements and modifications on equipment sold previously.
B. This new bin sweep auger has been engineered and manufactured to give years of dependable
service. The care and maintenance of this equipment will affect the satisfaction and service obtained. By following the instructions and recommendations, the owner should receive quality service for many years. If additional information or assistance is required, please contact GSI.
C. It is important to check both the quantity of parts and their descriptions with the packing list enclosed
within each package. All claims for freight damage or shortage must be made by the consignee within ten (10) days of the date of the occurrence. The consignee should accept the shipment after noting the damage or loss on the bill of lading.
D. The Chart below shows radius dimensions locating the points of contact between the sweep and the
bin floor. The dimensions may be used to figure material quantities of track to support the sweep across the aeration flooring. The track material is not supplied with the sweep and must be supplied by the installer. The dimensions are approximate and the assembled sweep should be checked for exact points of contact.
Radius Dimensions from Center of Bin
Bin
Diameter
131' 6 92" 236" 380" 468" 537-1/4" 574-1/2" 677" 135' 6 92" 236" 380" 484" 561-1/4" 598-1/2" 701"
# of
Sections
Head Jack
Wheel
2" Wide
Intermediate
Jack Wheel
3" Wide
Intermediate
Jack Wheel
3" Wide
Intermediate
Jack Wheel
3" Wide
Inside Tire
18" Wide
Outside Tire
18" Wide
Extension
Jack Wheel
3" Wide
4. General Product Information
Electrical controls and wiring should be installed by a qualified electrician. The motor disconnect switches and conductor cables should comply wit h the National Electrical Code and any local codes. Locate reset and motor starting stations so the operator can see that all personnel are clear of the equipment.
There should ALWAYS be two (2) people in the work area.
A main power disconnect switch capable of being locked only in the OFF position should be used. It should be locked in the OFF position whenever work is being done on the Series II Sweep.
Capacities and Specifications
WARNING
A. Use the Chart below to determine the horsepower required.
NOTE: Sweep is not designed to start under full load.
12" Series II Sweep
Bin
Diameter
131' 5 N/A 20 N/A 63.84' (19.46 m) 135' 5 N/A 20 N/A 65.84' (20.07 m)
Drive HP
Bushel/MT per Hour Horsepower
Length Pivot to End
5000/125 6000/155 7000/180
NOTE: The horsepower recommendations are for augering reasonably dry grain. High moisture grain
(greater than 15%) will require greater power for maximum capacity.
NOTE: Sweep drive and carrier wheels require plates or track over aeration flooring for travel and supports
not supplied with the sweep unit. Contact the installer or flooring provider for possible sources and details.
B. A magnetic starter should be used to protect the motor when starting and stopping. It should stop the
motor in case of power interruption, conductor fault, low voltage, circuit interruption or motor overload. The motor must be restarted manually. Some motors have built-in thermal overload protection. If this is the type of motor being used, use only those with a manual reset.
C. The motor starting controls must be located outside the bin. They must NEVER be installed on the
Series II auger inside the bin. D. Disconnect and lock out the power before resetting motor overloads. E. Disconnect and lock out the power before entering the bin. F. Disconnect and lock out the power before servicing the equipment. G. Position the reset and motor starting controls so that the operators have full view of the equipment.
WARNING
H. Make sure electric motors are grounded.
WARNING
4. General Product Information
Grade 5 Bolts
Grade 5 bolts are designated by three (3) slash marks on the head.
Grade 8 Bolts Grade 8 bolts are designated by six (6) slash marks even l y spaced on the he ad of th e bo lt.
Grade 8.2 Bolts Grade 8.2 bolts are designated by six (6) slash marks on the head in a sunrise pattern.
Under no condition shall any other fasteners be substituted for those supplied by the manufacturer.
Torque Values to be used when Tightening the Bolts on the Series II Sweep
It takes more force to tighten a 3/4"-10 bolt than to tighten a 1/2"-13 bolt because of its larger diameter. It also takes more force to tighten a grade 8 bolt than it does to tighten a g rade 5 bolt because of the greater material strength. A bolt that is waxed or otherwise lubricated requires much less force to tighten. If the same amount of force is used with a lubricated bolt as with a non-lubricated bolt, the lubricated bolt often will break.
A suggested initial tightening torque is listed in the Chart below.
Size
1/4"-20 8 ft. lbs. 75 in. lbs. 12 ft. lbs. 9 ft. lbs.
1/4"-28 10 ft. lbs. 86 in. lbs. 14 ft. lbs. 10 ft. lbs. 5/16"-18 17 ft. lbs. 13 ft. lbs. 25 ft. lbs. 18 ft. lbs. 5/16"-24 19 ft. lbs. 14 ft. lbs. 25 ft. lbs. 20 ft. lbs.
3/8"-16 30 ft. lbs. 23 ft. lbs. 45 ft. lbs. 35 ft. lbs.
3/8"-24 35 ft. lbs. 25 ft. lbs. 50 ft. lbs. 35 ft. lbs.
1/2"-13 75 ft. lbs. 55 ft. lbs. 110 ft. lbs. 80 ft. lbs.
1/2"-20 90 ft. lbs. 65 ft. lbs. 120 ft. lbs. 90 ft. lbs.
5/8"-11 150 ft. lbs. 110 ft. lbs. 220 ft. lbs. 170 ft. lbs.
5/8"-18 180 ft. lbs. 130 ft. lbs. 240 ft. lbs. 180 ft. lbs.
3/4"-10 260 ft. lbs. 200 ft. lbs. 380 ft. lbs. 280 ft. lbs.
3/4"-16 300 ft. lbs. 220 ft. lbs. 420 ft. lbs. 320 ft. lbs.
7/8"-9 320 ft. lbs. 320 ft. lbs. 600 ft. lbs. 460 ft. lbs.
1"-8 640 ft. lbs. 480 ft. lbs. 900 ft. lbs. 680 ft. lbs. 1-1/8" - 7 800 ft. lbs. 600 ft. lbs. 1280 ft. lbs. 960 ft. lbs. 1-1/4" - 7 1120 ft. lbs. 840 ft. lbs. 1820 ft. lbs. 1360 ft. lbs. 1-3/8" - 6 1460 ft. lbs. 1100 ft. lbs. 2380 ft. lbs. 1780 ft. lbs. 1-1/2" - 6 1910 ft. lbs. 1460 ft. lbs. 3160 ft. lbs. 2360 ft. lbs.
Grade #5 Assembly Torque Grade #8 Assembly Torque
Dry Lubricated Dry Lubricated
CAUTION
4. General Product Information
Insert set screws to install
Insert set screw to remove
Wedging forces in the bushing saw slot, such as that exerted by a narrow edged regular screw driver, may damage or break the bushing. This damage would not be covered under the GSI warranty.
Do not lubricate the bushing taper , bushing bore, hub taper or the shaft. Doing so could result in breakage of the product.
Do not use worn hex key wrenches. Doing so may result in a loose assembly or may damage the screws.
CAUTION
Taper-Lock Bushings
Figure 4A Number 1008 to 3030 Bushing
CAUTION
To Install
1. Clean shaft, bore and outside of bushing and hub bore of all oil, paint and dirt. File away burrs.
2. Insert bushing in hub. Match the hole pattern, not threaded holes (each complete hole will be threaded on one side only).
3. Lightly oil set screws and thread into the half-threaded holes indicated as in Figure 4A.
4. Position the assembly onto the shaft allowing for the small axial movement which will occur during the tightening procedure.
5. Alternately torque set screws to recommended torque setting listed in the Chart below.
6. To increase the gripping force, hammer the face of the bushing using a drift or sleeve. (Do not hit the bushing directly with the hammer.)
7. Re-torque the screws after hammering.
8. Re-check the screw torques after the initial run-in and periodically thereafter. Repeat Steps 5, 6 and 7 if loose.
Recommended Installation Wrench Torque
Bushing # lbs.-in Bushing # lbs.-in
1008, 1108 55 3535 1000
1210, 1215, 1310 175 4040 1700
1610, 1615 175 4545 2450
2012 280 5050 3100
2517, 2525 430
3020, 3030 800
6050, 7060, 8065 7820
To Remove
1. Remove all screws.
4. General Product Information
2. Insert screws in hole or holes indicated on the screw(s).
Figure 4A on Page 20
Q-D Bushings - Reverse Mounting
. Loosen the bushing by tightening
Figure 4B
Figure 4C Overhead View of Q-D Bushing
To Install
1. Clean shaft, bore of bushing, outside of bushing and hub bore of all oil, paint and dirt. File away burrs.
2. Reverse mounting: Place the bushing in hub and insert the cap screws through the drilled holes in the bushing flange. Tighten the cap screws, finger tight into threaded holes in the hub.
3. With the key on the shaft, slide the loosely assembled unit onto the shaft so that the cap screw heads are on the outside. Place the unit in the desired position on the shaft.
4. Tighten the cap screws alternately and evenly to the wrench torque specified in the
NOTE: When tightened, there will be a gap of 1/8" to 1/4" between the bushing flange and the hub.
Should this gap be less, either undersize shafting or the wrong bushing shaft size was used.
5. Tighten the set screw (if supplied) over the key to the torque value listed in the Chart on Page 22.
Chart on Page 22
.
4. General Product Information
Do not lubricate the bushing taper , bushing bore, hub taper or the shaft. Doing so could result in breakage of the product.
Excessive screw torque may cause damage to either the bushing and/or the sheave. Uneven pressure on the jack screws may also damage the bushing flange making removal difficult without damage to the bushing and/or sheave.
Do not use worn hex keys and/or wrenches. Doing so may result in a loose assembly or may damage the screws.
CAUTION
Recommended Installation Wrench Torque
Bushing
H 1/4"-20 x 7/8" 90 N/A N/A
JA #10-24 x 1" 60 N/A N/A
SH 1/4"-20 x 1-3/8" 108 1/4"-20 87
SDS 1/4"-20 x 1-3/8" 108 1/4"-20 87
SD 1/4"-20 x 1-7/8" 108 1/4"-20 87 SK 5/16"-18 x 2" 180 1/4"-20 87 SF 3/8"-16 x 2" 360 3/8"-16 290
E 1/2"-13 x 2-3/4" 720 3/8"-16 290 F 9/16"-12 x 3-5/8" 900 3/8"-16 290
J 5/8"-11 x 4-1/2" 1620 1/2"-13 620
Cap Screw Key Seat Set Screw
Size lbs.-in Size lbs.-in
M 3/4"-10 x 6-3/4" 2700 1/2"-13 620
To Remove
1. Remove all cap screws.
2. Insert the cap screws into the threaded jack hole or holes.
3. Tighten all the jack screws alternately and evenly beginning with the screw farthest from the bushing saw slot. Tighten until the bushing grip is released. Slide the unit off the shaft.

5. Assembly

The section sizes are total length given in inches. The head section has 8" subtracted from the shield length due to the pivot pipe location. The 12" tail section has 5-1/2" added to the shield length due to the end shaft length.
The bolts MUST be installed as shown in Figure 5A.
Back Shield Assembly
A. The sweep has been broken down into four (4) different section types: the head, intermediate, tail
and extension sections.
NOTE: Use the Chart below to determine the identification and the order of assembly of the individual
sweep sections.
12" Series II Sweep Sections
Bin Diameter
131' 6 136" 144" 144" 60" 144" 137-1/2" 63.84' 135' 6 136" 144" 144" 84" 144" 137-1/2" 65.84'
CAUTION
# of
Sections
Head Intermediate Intermediate Intermediate Tail Extension Pivot to End
B. Use eight (8) 5/8"-11 x 1-3/4" grade 8 hex bolts, lock washers and hex nuts at each
section connection.
CAUTION
Figure 5A
5. Assembly
Flighting Assembly
A. Lay out the flight sections in order of assembly starting with the head flight working towards the
tail flight.
B. Using the connecting stubs, bolt the flight sections together with hex bolts and lock nuts. Make sure
the flight ends are in time with each other.
Figure 5B
C. Slide the end stub through the bearing plate on the tail section and into the tail flight securing it with
hex bolts and lock nuts.
Figure 5C
5. Assembly
Hanger Bracket Assembly
A. Bolt the nylon bearings and hanger brackets to the connecting stubs using hex bolts, lock washers
and hex nuts as shown in Figure 5D.
Figure 5D
B. Bolt the hanger brackets to the back shields using two (2) 5/8"-11 x 2" hex bolts, two (2) square
washers, two (2) lock washers and two (2) hex nuts as shown in Figure 5E.
Figure 5E
5. Assembly
Flange Bearing Assembly
A. Slide the flange bearing onto the end stub and bolt it to the end pla te using hex bolts, lock washers
and hex nuts as shown in Figure 5F.
NOTE: Do not tighten the set screws on the bearing at this time. This can be done after t he gear reducer
is installed.
Figure 5F
Gear Reducer Assembly
A. Slide the output shaft of the reducer through the end plate of the head section and into the end of the
head flight. Secure the reducer output shaft to the head flight with hex bolts and lock nuts.
(See Figure 5G on Page 27.)
B. Bolt the reducer to the end plate of the head section using hex bolts, flat washers and lock washers,
supplied with the reducer. (See Figure 5G on Page 27.)
NOTE: The input shaft of the reducer MUST be to the top of the reducer. Refer to Owner’s manual
supplied with the reducer for proper vent plug, fill plug and drain plug locations.
Figure 5G
The gear reducer is NOT filled with oil from the factory. For gear reducer specifications and oil fill recommendations, refer to lubrication section o n Page 64 of this manual.
5. Assembly
NOTICE
Drive Axle Assembly and Bearing Support
A. Loosen set screws on bearings. B. Replace standard grease zerks with 90° grease zerks on both bearings. Make sure the 90° grease
zerk is turned as shown in Figure 5H, so the zerks are accessible from the center of the tractor drive stand.
Figure 5H
C. Slide the axle assembly between the legs of the tractor drive stand as shown in Figure 5I. D. Rotate the pillow block bearings until the bases are facing up. (See Figure 5I.)
Figure 5I
5. Assembly
E. Bolt the bearing support brackets to the legs of the tractor drive stand using 1/2" x 1-3/4" bolts,
1/2" lock washers, 1/2" bevel washers and 1/2" hex nuts. (See Figure 5J.)
Figure 5J
F. Attach pillow block bearings to the bearing support brackets using 5/8" x 2-1/2" bolts, 5/8" lock and
flat washers and 5/8" hex nuts. (See Figure 5K.)
Figure 5K
G. Tighten set screws on pillow block bearings. H. Tighten all hardware.
5. Assembly
CAUTION
The gear reducer is NOT filled with oil from the factory. For gear reducer specifications and oil fill recommendations, refer to Owner’s manual supplied with the reducer or the lubrication information in the lubrication section on
Page 64 of this manual.
The tractor drive gear reducer has a drain plug in the bottom of the housing. Make sure the drain plug is flush or slightly under the surface of the mounting face. If it is not, the plug will not allow the reducer to set flat on the mounting plate and could cause the motor to seize.
THIS TYPE OF DAMAGE IS NOT COVERED BY THE WARRANTY.
Install Reducer Mounting Plate and Reducer
A. Attach the C-face reducer to the mounting plate using four (4) 5/8"-11 x 1-1/4" hex bolts and
lock washers. (See Figure 5L.)
B. Fasten the reducer mounting plate to the tail section plate using four (4) 5/8"-11 x 6" all-thread rods
and sixteen (16) hex nuts. Adjust the mounting plate as close as possible to the tail section plate.
Figure 5L
CAUTION
5. Assembly
CAUTION
All keys should be parallel to the drive shaft. If the key is not straight (parallel) the gearbox quill sleeve will crack.
THIS TYPE OF DAMAGE IS NOT COVERED BY WARRANTY.
Key Alignment
A. Place key in keyway on drive shaft. B. Make sure key is flat (parallel to drive shaft) in keyway as in Figure 5M_1 and Figure 5M_2. NOT
like Figure 5M_3.
Figure 5M
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