pneg-681 - bucket elevator series 2

PNEG-681

Bucket ElevatorSeries 2

Assembly Manual

PNEG-681Rev: 10-16-06

PNEG-681 Series 2 Bucket Elevator

Assembly

2

Use of the Equipment Information page will help you identify your equipment in thecase that you need to notify the company. For this reason, this information shouldbe filled out and kept on record.

Equipment Information

Model Number: _______________________________

Serial Number: _______________________________

RPM: _______________________________

Head Pulley Dia.: _______________________________

Discharge Height: _______________________________

Horsepower: _______________________________

The GSI Group, Inc.1004 East Illinois StreetP.O. Box 20Assumption, IL 62510USAPhone: 217-226-4421Fax: 800-800-5329

Date Purchased: ________________________________

Dealer Nameand Phone Number: ________________________________

________________________________

________________________________


Assembly

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Table of Contents

Equipment Information ......................................................................................... 2

Safety Guidelines ................................................................................................. 4

Safety Decals ....................................................................................................... 8

Elevator Parts ..................................................................................................... 11

Getting Started ................................................................................................... 12

Assembly ............................................................................................................ 13

Final Checks & Start-Up ..................................................................................... 29

Appendix 1 (Torque Arm) ................................................................................... 30

Appendix 2 (Roller Bearings) .............................................................................. 41

Appendix 3 (Pillow Blocks) ................................................................................. 43

Warranty .................................................................................... Inside Back Cover


Assembly

4

This manual contains information that is important for you, the owner/operator, to know andunderstand. This information relates to protecting personal safety and preventingequipment 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 yourecognize this information, we use the symbols that are defined below.

Please read the manual and pay attention to these sections. Failure to read this manualand it’s safety instructions is a misuse of the equipment and may lead to serious injury or death.

SAFETY GUIDELINES

DANGER indicates an imminently hazardous situationwhich, if not avoided, will result in death or serious injury.

This is the safety alert symbol. It is used to alert youto potential personal injury hazards. Obey allsafety messages that follow this symbol to avoid pos-sible injury or death.

WARNING indicates a potentially hazardous situation which,if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, ifnot avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates apotentially hazardous situation which, if not avoided, mayresult in property damage.

NOTE indicates information about the equipment that youshould pay special attention to.


Assembly

5

FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this manualand on your machine safety signs. Keep signs ingood condition. Replace missing or damagedsafety signs. Be sure new equipment compo-nents and repair parts include the current safetysigns. Replacement safety signs are availablefrom the manufacturer.

Learn how to operate the machine and how touse controls properly. Do not let anyone operatewithout instruction.

Keep your machinery in proper working condi-tion. Unauthorized modifications to the machinemay impair the function and/or safety and affectmachine life.

If you do not understand any part of this manualand need assistance, contact your dealer.

STAY CLEAR OF MOVING BELT

Entanglement in moving belt can cause seriousinjury or death.

Keep all shields and covers in place at all times.

Wear close fitting clothing. Stop and lock outpower source before making adjustments,cleaning, or maintaining equipment.

OPERATE MOTOR PROPERLY

Do not operate electric motor equipped unitsuntil motors are properly grounded.

Disconnect power on electrical driven unitsbefore resetting motor overloads.

Do not repetitively stop and start the drive inorder to free a plugged condition. Jogging thedrive in this type of condition can damage theelevator and/or drive components.


Assembly

6

PRACTICE SAFE MAINTENANCE

Understand service procedures before doingwork. Keep area clean and dry.

Never lubricate, service, or adjust machine whileit is in operation. Keep hands, feet, and clothingfrom rotating belt and idlers.

Keep all parts in good condition and properlyinstalled. Fix damage immediately. Replaceworn or broken parts. Remove any build upgrease, oil, or debris.

REMOVE PAINT BEFORE WELDING ORHEATING

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paintis heated by welding, soldering, or using a torch.

Do all work outside or in a well ventilated area.Dispose of paint and solvent properly.

Remove paint before welding or heating:

• If you sand or grind paint, avoid breathingthe dust. Wear an approved respirator.

• If you use solvent or paint stripper, removestripper with soap and water before welding.Remove solvent or stripper containers andother flammable material from area. Allowfumes to disperse at least 15 minutes beforewelding or heating.


Assembly

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PREPARE FOR EMERGENCIES

Be prepared if fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambu-lance service, hospital, and fire department nearyour telephone.

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipmentappropriate to the job.

Safety glasses should be worn at all times toprotect eyes from debris.

Wear gloves to protect your hands from sharpedges on plastic or steel parts.

A respirator may be needed to help preventbreathing potentially toxic fumes and dust.

Wear hard hat and steel toe boots to helpprotect your head and toes from falling debris.

Eye Protection

Gloves

Steel ToeBoots

Respirator

Hard Hat


Assembly

8

Safety decals should be read, and understood, by allpeople in the grain handling area. Safety decals havebeen affixed to the equipment to warn of danger topersons and of possible equipment damage. Thesedecals must never be removed, tampered with, paintedover or obscured in any way. If labels are damaged orbecome unreadable, replacement labels are availablefrom the manufacturer.

If a decal is damaged or is missing contact:

The GSI Group, Inc.Material Handling1004 East Illinois StreetP.O. Box 20Assumption, IL 62510USAPhone: 217-226-4421Fax: 800-800-5329

A free replacement decal will be sent to you. (Refer toDC number on the decal).

DECALS

Explosion release willcause severe injury ordeath. Avoid area around explosion ventduring operation.

DC-1377

WARNINGSHEAR POINT

DC-995

Keep hands clear of moving parts. Do not operate with guard removed. Disconnect and lockout power before servicing.

SHEAR POINTKeep hands clear of moving parts. Do not operate with guard removed. Disconnect and lockout power before servicing.

DC-994

WARNING

DC-1199

Keep hands clear of moving parts. Do notoperate with guardremoved. Disconnectand lockout powerbefore servicing.

WARNING

DC-1198

Thrown or flyingobjects.Eye protectionrequired.

WARNING

DC-1378

Platform collapse can cause serious injury. Do not exceed 500 lb.maximum load.

DC-1199

1

2

DC-1199

DC-13773

DC-13784

DC-9955

DC-9946


Assembly

9

WARNINGMoving side plate.Auto equipment canstart at any time.Disconnect and lockout before servicing.

DC-1248

Correct

DC-1601

CRUSH HAZARD.Failure of U-Lug Welds can occur from over stress.

Death or serious injury can occur.Lift only Bonnet section with U-Lugs.

DO NOT Lift Bonnet and Lower Head Sections assembled together.

IncorrectLift Bonnet Only.

DC-1224

DC-12487

DC-12248

DC-16019


Assembly

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DECAL PLACEMENT

Head Section

Boot Section

InspectionTrunking

12

12

DECALNUMBERS

1. DC-11982. DC-11993. DC-13774. DC-13785. DC-9956. DC-9947. DC-12488. DC-12249. DC-1601

9

6


Assembly

11

1. Bonnet2. Pressure Relief Panel (one each side)3. Head Pulley4. Lower Head Section5. Inspection Door6. Up Leg Trunking7. Down Leg Trunking

8. Belt9. Buckets10. Tie Angles11. Inspection Section12. Inspection Door13. Boot Section14. Upside Hopper (Downside Hopper optional)

PART IDENTIFICATION


Assembly

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Pre-Installation Preparation

Our Bucket Elevators are designed to be vertically self-supporting when erected but must be supported or guyedagainst wind loads.

The manufacturer is the vendor of the elevator andcertain of its optional accessories only and does notassume responsibility for the installationrecommendations contained within this manual. Theinstallation recommendations contained within thismanual are for consideration only. The user or installermust consult a civil or structural engineer regarding thedesign, construction and supervision of the entireinstallation, including the elevator foundation and theguying cable and/or bracing system.

The MOST IMPORTANT preparations are retaining alicensed engineer to plan the installation and a qualifiedmillwright or contractor to erect the elevator and theaccompanying equipment and structures.

BUCKET ELEVATOR FOUNDATIONThe bucket elevator foundation must be designed by aqualified civil engineer and installed by a qualifiedcontractor. Consideration should be given to live loads,dead loads, wind loads, and soil bearing loads. Attentionshould also be given to ensure proper moisture run-offon the top of the base.

Introduction

Thank you for your choice of our product, which hasbeen designed to give you excellent performance andservice for many years.

This manual covers general information on the yourBucket Elevator installation. We can not be responsiblefor the installation of this, or any other, bucket elevator.Due to the large variety of equipment features offered,we can not cover every aspect of installation with thismanual. We offer suggested methods for installingbucket elevators. You should rely on your qualifiedcontractor’s experience and techniques.

General Safety Statements

The principal concern of the manufacturer is your safetyand the safety of others associated with grain handlingequipment. We encourage all personnel operating,installing or maintaining this equipment to readthoroughly through this manual before proceeding. It isthe responsibility of the buyer to make this manualavailable to the person or persons involved with thisequipment. Guards and safety labels have been installedprior to leaving the manufacturing plant. These devicesare not to be removed, altered or defaced in any way.Alterations to the equipment may produce a verydangerous situation and may cause serious injury ordeath.

We recommend contacting your local power company,and having a representative survey your installation sothe wiring is compatible with their system, and adequatepower is supplied to your unit.

Use of the Equipment Information page will help youidentify your equipment if you need to contact us. Keepthis information on record.

Receiving Inspection

Carefully inspect the shipment for damage as soon as itis received. Verify that the quantity of parts or packagesactually received corresponds to the quantity shown onthe packing slip. Any discrepancies should be clarifiedimmediately. One or more cartons containing thefasteners required for assembly are included with theshipment. Report any damage or shortage to thedelivering carrier as soon as possible. Themanufacturer’s responsibility for damage to theequipment ends with acceptance by the deliveringcarrier. Refer to the bill of lading. Save all paperworkand documentation furnished with any of the elevatorcomponents.

The elevator has not been designed to support otherequipment such as cleaners, distributors or spouting.

Separate structures must be provided for anyaccessory equipment.

GETTING STARTED


Assembly

13

Boot Section

Prior to boot installation on the foundation, examineentire boot for any damage or loose hardware. Do notattempt to install if parts are damaged.

Boot sections are pre-assembled at the factory, howeverBoot Inlet Hoppers are typically shipped separately.Take time now to identify the up and down side of theboot, as proper positioning is critical. The boot inletsection can be installed either as an up-leg or a down-leginlet. You will note that the up-leg inlet position isapproximately six (6”) inches higher than the down-legside. By removing the nuts and inlet blank plates, theboot inlet hopper can be attached.

Inlet Blank Plate(Standard)

Inlet Hopper(on Upside)

Upside

DownSide

Figure 1: Boot Section

BOOT SECTION

There are a variety of ways to anchor and level the bootsection. It is our recommendation to shim to theperimeter, then secure with hold-downs, and finally groutthe base. Whatever technique is used it is important thatthe boot be level and plumb. Check boot levelness andplumbness periodically throughout the installationprocess to insure proper elevator erection. After boot isset in place, level in all directions prior to anchoring. Useanchor bolts and mounting brackets (not supplied) tosecure boot to foundation.


Assembly

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The inspection section of your Bucket Elevator has beendesigned for ease in installation and maintenance. Theremovable panels are versatile and can be installed inany order. This design allows for the inspection doors tobe installed at various positions determined by theinstaller. Typically, the inspection section is locateddirectly above the boot, on the up-leg side as the firsttrunking section.

Along with the inspection section you will receiveinstallation hardware and two (2) tie-angles. Unitscontaining 42” diameter pulleys and larger, will include across tie on the legs, which will be included. (See Figure2 & 3)

INSPECTION SECTION

This type of installation will vary and will depend onyour configuration and application.

Figure 2: Inspection Section


Assembly

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The standard trunking sections may be fabricated fromeither painted steel or galvanized steel. The galvanizedsteel trunking must have the riveted (Huck Bolted)seams located to the inside facing each other on the upleg and the down leg. (See Figure 4.)

The trunking sections come complete with theappropriate hardware and two (2) tie angles. Unitscontaining 42" diameter or larger pulleys, have a crosstie angle included for additional support.

STANDARD TRUNKING

Figure 3: Painted Trunking

Figure 4: Galvanized Trunking

Cross Ties(Only 42" orlarger dia.pulleys only)

Painted

Tie Angles(Additional setshown fororientation)

Cross Ties


Assembly

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Pressure Relief Trunking is standard trunking that hasbeen modified to include two panels specificallydesigned for pressure relief. These panels will belocated on the short sides of the trunking directlyopposite of each other and centered on ten foot (10’)sections of trunking. Included with the mountinghardware will be two (2) tie-angles. As with othersystems utilizing 42” diameter and larger pulleys, therewill be a cross-tie located on the legs.

PRESSURE RELIEFTRUNKING

This unit requires specialattention to the relief panel.This area must be inspected fordamage to the panel, frame andparticularly the hardware.DO NOT INSTALL TRUNKING IFTHERE IS ANY APPARENTDAMAGE OR DEFECT.

Removal of all shipping boltsin the Pressure Relief Panelsare required before operatingany bucket elevator

Figure 5: Pressure Relief Trunking


Assembly

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Prior to any trunking installation inspect for damage toequipment. Immediately repair or replace defectiveitem(s). It is very important to locate a level surface areain order to correctly assemble the trunking sections.

Section together to make double trunking. Attach tieangle to single trunking as shown. Also if 42" diameter orlarger install cross-tie angle. Multiple sections can beground assembled. Make sure these sections areassembled straight without twist. (We suggests no morethan thirty (30) linear feet at any time). Caulk all matingcompanion angle surfaces to insure water and dustresistance.

It is important to maintain plumb and square trunkingin all directions. Guying and plumbing the trunkingin all directions is recommended after each section isinstalled. It is recommended that these levels bechecked throughout the legging installation process.It is equally important to insure that all connectinghardware is secure.

The Bucket Elevator Lower Head Section is primarilyassembled at the factory. The installation hardware usedto attach the head section to the trunking system isincluded. The drive is shipped separately from the LowerHead Section. It is important to inspect all parts fordamage and to insure that all hardware is secure.

TRUNKING INSTALLATION

The attachment bolt holes in the tie angles areintentionally tight for the ½" dia. Bolts. This is to

aid for more precise plumbing of the trunking.DO NOT drill out attachment hole. If bolts are

hindered going through hole, thread boltsthrough to reduce chances of damaging threads.

LOWER HEAD SECTION

Figure 6: Trunking Joint

Figure 7: Lower Head Section

Pulley

Discharge

Inspection Door


Assembly

18

To ensure proper bucket elevator plumbness, set up twotransits, one in each direction. Refer to the figure belowfor proper tolerance in elevator erection.

PLUMBING

Figure 8: Plumbing Tolerance


Assembly

19

The Bonnet has been designed in two piece constructionto allow the front (Discharge) side to slide forward andclamp in place for maintenance to the belt, buckets,pulley, etc. The rear (up-leg) side bonnet included factoryinstalled pressure relief panels. These panels should becarefully inspected for damage including screws andwashers. Pressure relief vent door should not be alteredin any way except to remove shipping bolts. Motor mountand torque arm will need to be adjusted to fit your drivepackage per supplied detail. Hardware used to attachbonnet section to head section is included.

HEAD BONNET SECTION

Bonnet section ‘U’ lugs are forlifting bonnet section aloneonly, DO NOT LIFT BONNETAND LOWER HEAD SECTIONTOGETHER!

Removal of all shipping boltsin the Pressure Relief Panelsare required before operatingany bucket elevator

Figure 9: Head Bonnet

Inspection Door

Pressure Relief Panel

U-Lugs


Assembly

20

Buckets are attached to belting using elevator boltspushed through the belting back side, through theelevator bucket, a flat (fender) washer, a lock washer,and a nut. Secure bucket by tightening nut to slightlyindent belt back with bolt head. Remember to leavebuckets around splice area off, if installing bucketsprior to belt installation. (See diagram)

The belt for your elevator leg has been specificallychosen based on leg height, grain, weight, pulleydiameter, etc. The belt has been pre-punched toaccommodate special buckets with specific spacing.The most important criteria when choosing an installationtechnique is to choose one that is safest for you.Installing the belt can be accomplished several differentways. Prior to installing the belt, the boot pulley shouldbe raised to it’s upper most point to allow for proper belttensioning. On shorter installations, first assembling thebuckets to the belt may be less time consuming.However, the additional weight of the buckets andconnecting hardware make the belt more difficult tohandle.

One of the methods used to install belts is to feed thebelt up through the inspection section, over the headpulley, feeding through the Down-Leg, around the bootpulley, and back up to the splice.

BELTING, BUCKETS, ANDSPLICING

Belting

Splicing

To prevent the belt from rollingover the top, anchor the upperend securely.

Upon connecting the ends of the belt together a winchingdevice such as a Come-a-Long may be required. Therecommended splice technique is achieved by overlappingthe belts or the bar splice. When lap-splicing, draw a 5’minimum of the belt coming up from the bottom of theboot, over belt hanging down from head.

An alternative method, the bar splice (not included) isusually accomplished by turning the ends of the belt outand affixing the manufactured bar splice components per the manufacturer’s recommendations. Lacing and otherspecific types of belt splicing are not recommended.Please consult the factory or your contractor if in question.

Figure 10: Belt Splicing

Buckets

DO NOT OVER TIGHTEN BOLTS!Torque requirements are as follows:

50 inch pounds for 1/4" bolts96 inch pounds for 5/16" bolts, and

180 inch pounds for 3/8" bolts.Overtightening can lead to breakage.

ALWAYS recheck bolts for correct torque afterinitial start up and periodically thereafter.

BeltingGoing UpFrom Boot

Belting GoingDown From Head


Assembly

21

Figure 11: Take-Ups

Remove any slack in belt after splice connection bylowering boot pulley. It is important that the boot pulleyand shaft are checked and maintained to be horizontallylevel.

REMOVING SLACKFROM BELT

Do not over tighten belt, as this will decrease the lifeof the belt.

Lowering the bearing plate to which the belt istracking towards on the boot pulley should cause

the belt to track back towards the center of thepulley. Inversely, raising the bearing plate to

which the belt is tracking away from will achievebelt centering as well.

Manual Screw Take-Ups

Gravity Take-Ups

For manual screw take-ups, turning the take-up screwson each side of the boot controls the boot pulley position.After adjustment, be sure to lock each take-up screw inposition with the locknut provided.

For gravity take-ups, weight provides the tensioningmethod. In some cases no additional weight in the weightbox may be needed because the weight of the belt, cups,weight box assembly and boot pulley assembly mayprovide adequate tensioning in the belt to eliminate

slippage at the head pulley. When adding additionalweight (weight not included), use maximum increments of100 pounds and make sure the weight is equallydistributed from side to side for proper belt tracking. Thebearing plate adjustment screws are used to level theboot pulley after any needed weight is added. Loosen thebolts attaching the channels of the weight frameassembly to the bearing plate assembly before adjustingthe bearing screws. After adjustments have been made,retighten bolts and snug the bearing plate adjustmentscrew locknuts.


Assembly

22

To determine the correct placement of your motor mountassembly, do as follows:

1.) Find the side of the motor mount which has two decalsaffixed. (See Fig 12.) One decal will have “LH” for lefthand and one will have “RH” for right hand.

2.) Place the motor mount such that the decals face awayfrom the pulley towards the end of the head bearingangles.

3.) Find your horsepower, class rating and drive applica-tion side on the decals. Follow the indication line next tothose numbers to where it points down to the bottom ofthe motor mount.

4.) Slide the motor mount in or out while keeping thecorrect decal mark lined up with the outside toe of thehead bearing angle. (See Fig. 13) This will align the holesin the head bearing angles to the proper holes in themotor mount assembly.

5.) Using the proper hardware, bolt the motor mount downto the head bearing angles.

The following assembly instructions are for standarddrives as purchased with your elevator from the com-pany. The standard drive is designed using the DodgeTorque Arm II shaft mount reducer and details on theapplication of this reducer are included in the Torque ArmII Appendix of this manual. If you have purchased aspecial drive or purchased the drive components fromanother source, refer to manuals supplied with the vendorcomponents.

Your drive assembly is designed so that the samecomponents fit in either a left hand or right hand driveapplication. If facing the head side, the reducer isbetween you and the head, and the head discharge is onthe right hand side of you, then you have a right handdrive application. Conversely, if the head discharge is onthe left side of you, then you have a left hand driveapplication. The figures shown below are for a right handapplication.

DRIVE ASSEMBLY

MOTOR MOUNT ASSEMBLY

Figure 12: Motor Mount Plate

Figure 13: Right Hand MotorPlacement Decals

Motor Mount

Right HandDecal

Head BearingAngles

Decal

Toe ofHeadBearingAngle

Motor Mount

Left HandDecal


Assembly

23

Figure 14: Motor Slide Base

Motor Slide Base

Motor

Motor Mount

Slide BasePlace the motor slide base upon top of the motor mount,respectively to the drive application side. The slide basewill fit in only one set of holes. (See Fig 14.) Make surethat the tensioning bolt is positioned so that tightening willpull the motor away from the pulley. Using the properhardware, bolt the slide base to the motor mount.

Place the motor onto the motor slide base and positionthe motor as close as possible toward the pulley. Usingthe proper hardware, bolt into position.

TensioningBolt


Assembly

24

Place the torque arm Tube assembly to the head sectionby sliding the two gussets of the torque arm assemblybetween the head bearing angles, making sure thelocking bolts face away from the head section, attach withthe proper hardware. (See Fig 3) On 16” & 24” Elevators,the torque arm tube will slide in and out freely with themotor’s torque causing a positive lock situation. In 30” &up Elevators, loosen the three locking bolts and place thetorque arm foot mounting tube in the torque arm assem-bly such that the foot mounting bracket is to the side inwhich the reducer will be mounted. Wait until the reduceris set on the shaft to retighten the locking bolts.

For reducer assembly, see page 30 of the Torque Arm IIReducer Installation Appendix. This appendix hasdetailed installation instructions of the reducer bushingmounting along with instructions for options such ascooling fans and backstops. Once the reducer is as-sembled, attach the torque arm turnbuckle assembly tothe reducer, and the torque arm foot to the foot mountingbracket of the torque arm tube using the proper hardware.

TORQUE ARM SHAFT MOUNT REDUCER

Figure 16: TorqueArm (30" - 48")

Figure 17: TorqueArm (16" - 24")

Head Bearing Angles

Gusset

Torque Arm Tube

Turnbuckle

Foot

Motor

Nut

GussetHead Bearing Angles

Torque Arm Tube

Motor

ReducerDrive

Locking Bolts


Assembly

25

Attach the drive guard brackets to the motor mountassembly. (See Fig 4) The shorter broken legs of thebrackets will point towards the pulley. Align the guardrear panel of the guard to the brackets. Note, in a righthand drive application as shown in Fig. 4, the flanges ofthe guard rear panel will face away from the head section,but in a left hand application, the flanges will pointtowards the head section. The wider, larger, hole in theguard rear panel is intended to accept the motor outputshaft. The guard rear panel will only attach in oneorientation. Once rear panel is bolted on, attach the driveguard struts to the bearing support of the head sectionand to the rear panel. Using hardware, bolt the two strutstogether. All brackets are designed to be adjustable.

Place sheaves onto the output shaft of the motor and theinput shaft of the reducer. Place belts upon the sheaves.

DRIVE GUARDNote that the reducer may need to be rotated, clock-wise or counterclockwise, in conjunction with slidebase adjustments, to achieve correct center distancefor the drive belts. Move the location of the reducertorque arm turnbuckle to achieve this rotation, asneeded. The belts are designed specifically per applica-tion. Once the drive belts are tensioned, and the reduceris rotated (if necessary), tighten all bolts. For installingthe safety screen around the motor output shaft, approxi-mate the hole location to the screen, and snip clearancehole in screen. (See Fig 5) Attach using proper hard-ware. Attach belt guard cover, latch and bolt.

Figure 18: Belt Guard

MountingBrackets

Side Bracket

Belt GuardCover

LargeSheave

Belt GuardRear Panel

Shaft mount reducers are shipped without lubri-cant! Do not operate the elevator until the gear

reducer has been filled with an approved lubricantas noted in the Torque Arm II Appendix of this

manual. With the reducer in vertical position, fillwith lubricant until oil runs out of oil level plug.

See the Appendix for volume of oil per reducer size.

SmallSheave

(Right Hand Drive Shown.)


Assembly

26

DRIVE GUARD

Figure 19: Belt GuardMounted To Brackets

Rear BeltGuard Panel

Bushing

Sheave

SlideBracket

Bushing

Sheave

Safety Screen(Hole must becut out.)


Assembly

27

DRIVE GUARD

Figure 20: Slide Bracket

SlideBracket


Assembly

28

Belts are designed to fit loose upon installation.Tensioning of belts to an acceptable level isaccomplished through the Motor Mount Adjustable SlideBase. Proper tension is 1/64" of deflection per, 1" ofsheave centers on one side of belt, centered betweensheaves.

DRIVE BELTS

Figure 21: Drive Belt

Too much tension shortens belt life.Check belt tension frequently duringthe first 24-48 hours of operation.


Assembly

29

Final Checks and Start-up

Adjust the throat plate in the head discharge so there isabout 1/4” clearance between it and edge of the bucketson the lap splice.

Start-UpOnce you are sure everything is complete and alladjustments are made and proper lubrication is done, runthe elevator for an initial break-in WITHOUT load forseveral hours. Look and listen for any irregularitiesbefore running any material through the unit. Recheck allmoving parts and adjust as needed. The final tension ofthe belt is done under load.

MaintenanceThe belt will stretch after installation and may needfurther adjustment. Expect some stretching during thefirst few weeks of operation. On manual take-up boots,belt tension should be maintained by turning the boottake up screws slowly and evenly to maintain propertracking. When the screw adjustment is completelyused, the belt will have to be re-spliced. Good belttension is critical for proper traction on the pulley andoptimum performance.Regularly scheduled maintenance will ensure long lifeand safe operation of the unit.

Routine maintenance checks may include general wear,loose nuts and bolts, electrical wiring, contacts, switches,misalignment, guy wire inspection, bearing seals andlubrication and oil content for gearbox.

FINAL CHECKS & START-UP

1. Check clearance at the lap splice.

2. Do a final check of all parts to be sure all hardwareis tight and no foreign objects or tools are left insideelevator.

3. Check all guards, inspection doors, and removableplates to be sure they are in place and secure.

4. Tighten the take-up screws on the boot evenly totighten the belt on the pulley, keeping bottom pulleylevel, and work from side to side in small amountsuntil belt is tight.

5. Rotate by hand or carefully jog drive to check forproper rotation, clearance and operation of entireunit. Make any adjustments necessary. Jogminimum of one complete revolution of belt. If noproblems exist, carefully run elevator while checkingall aspects of operation of the unit.

TrackingTracking of the belt is very important for optimum results.To correct any tracking problems first adjust the bootbearing plates. Adjust the take up screws downward onthe side that the belt is tracking toward. If this does notcorrect the problem or if the belt is tracking properly onthe boot pulley but not the head pulley, furtheradjustments to the head pulley may be required.

The bearing side that the belt is tracking toward mayneed to be shimmed to compensate. After loosening thehead bearing bolts that go thru the head angle, use thejacking screws to raise the bearing. A full shim is placedunder the bearing base, jack screws are backed off andthe bearing mounting bolts are retightened. Use thinshims to make small adjustments until the belt tracksproperly.

Figure 22: Throat Plate


Appendix 1 - Torque Arm

30

3. Mount reducer on driven shaft as follows:

WARNING: To ensure that drive is not unexpectedly started,turn off and lock out or tag power source before proceeding.Remove all external loads from drive before removing orservicing drive or accessories. Failure to observe theseprecautions could result in bodily injury.

For Taper Bushed Reducer: Mount reducer on driven shaftper instruction in Torque-Arm II Bushing Installation section ofthis manual.

4. Install sheave on input shaft as close to reducer as practical.(See Fig. 2)

5. If not using a Dodge Torque-Arm II motor mount, installmotor and V-belt drive so belt will approximately be at rightangles to the centerline between driven and input shaft. (SeeFig. 3) This will permit tightening the V-belt with the torque arm.

6. Install torque arm and adapter plates reusing the reducerbolts. The adapter plates will fit in any position around the inputend reducer.

7. Install torque arm fulcrum on a flat and rigid support so thatthe torque arm will be approximately at right angles to thecenterline through the driven shaft and the torque arm anchorscrew. (See Fig. 4) Make sure that there is sufficient take-up inthe turnbuckle for belt tension adjustment when using V-beltdrive.

1. Use lifting bracket to lift reducer.

2. The running position of the reducer is shown in Figure 1. Thereducer is supplied with 6 plugs. Install the magnetic drain plug inthe hole closest to the bottom of the reducer. Discard the tape thatcovers the vent plug in shipment and install this plug in thetopmost hole. Of the two remaining plugs on the sides of thereducer, the lowest one is the minimum level plug.

The running position of the reducer can vary from the verticalposition shown in Figure 1. In certain sizes of elevator drives, thereducer is swung by shortening or lengthening the turnbuckle. Thisis to obtain the correct center distance for drive belt from themotor. If the reducer is located to a postion of over 20° from thevertical position shown, the oil level plug cannot be used safely tocheck the oil level. Disconnect the turnbuckle torque arm andswing to within 5° of vertical position to check the oil level.

Torque Arm II ReducerInstallation

Figure 1 - Mounting Position

2 - Vent

3 - Level

5 - (Near) Plug6 - (Far) Plug

4 - Plug

1 - Drain



31

CAUTION: Unit is shipped without oil. Add proper amount ofrecommended lubricant before operating. Failure to observethis precaution could result in damage to or destruction of theequipment

8. Fill gear reducer with recommended lubricant. See Table 2.

KEEPCLOSE

KEEPCLOSE

INPUTSHAFT

DRIVENSHAFT

Figure 2 – Reducer and Sheave Installation

RIGHT ANGLE ORMAY VARY 30°

V-BELTDRIVE

V-BELTDRIVE MAYBE LOCATEDTO THERIGHT IFDESIRED

Figure 3 – Angle of V-Drive

TORQUEARM MAYBE LOCATEDTO THERIGHT IFDESIRED

RIGHT ANGLE ORMAY VARY 20° IN

TENSION ORCOMPRESSION

TORQUE-ARMAND BELT

TAKE-UP

Figure 4 – Angle of Torque-Arm

TORQUE-ARM II BUSHINGINSTALLATIONWARNING: To ensure that drive is not unexpectedly started,turn off and lock out or tag power source before proceeding.Remove all external loads from drive before removing orservicing drive or accessories. Failure to observe theseprecautions could result in bodily injury.

The Dodge Torque-Arm II Reducer is designed to fit bothstandard and short length driven shafts. The Standard TaperBushings series is designed where shaft length is not a concern.The Short Shaft Bushing series is to be used where the drivenshaft does not extend through the reducer.

Standard Taper Bushings:

1. One bushing assembly is required to mount the reducer onthe driven shaft. An assembly consists of two tapered bushings,bushing screws and washers, two bushing backup plates andretaining rings, and necessary shaft key or keys. The drivenshaft must extend through the full length of the reducer. If thedriven shaft does not extend through the reducer do not use thestandard tapered bushings; instead use the short shaft bushingsas described in the Short Shaft Bushings section that follows.The minimum shaft length, as measured from the end of theshaft to the outer edge of the bushing flange (see Figure 5), isgiven in Table 1.

2. Install one bushing backup plate on the end of the hub andsecure with the supplied retaining ring. Repeat procedure forother side.

3. Place one bushing, flange end first, onto the driven shaft andposition per dimension “A”, as shown in Table 1. This will allowthe bolts to be threaded into the bushing for future bushing andreducer removal.

4. Insert the output key in the shaft and bushing. For easy ofinstallation, rotate the driven shaft so that the shaft keyseat is atthe top position.

5. Mount the reducer on the driven shaft and align the shaft keywith the reducer hub keyway. Maintain the recommendedminimum distance “A” from the shaft bearing.

6. Insert the screws, with washers installed, in the unthreadedholes in the bushing flange and align with the threaded holes inthe bushing backup plate. If necessary, rotate the bushingbackup plate to align with the bushing screws. Tighten thescrews lightly. If the reducer must be positioned closer thandimension “A”, place the screws with washers installed, in theunthreaded holes in the bushing before positioning reducermaking sure to maintain at least 1/8” between the screw headsand the bearing.

7. Place the second tapered bushing in position on the shaftand align the bushing keyway with the shaft key. Align theunthreaded holes in the bushing with the threaded holes in thebushing backup plate. If necessary, rotate the bushing backupplate to align with the bushing holes. Insert bushing screws, withwashers installed in the unthreaded holes in the bushing.Tighten screws lightly.

8. Alternately and evenly tighten the screws in the bushingnearest the equipment to the recommended torque given inTable 1. Repeat procedure on outer bushing.

Short Shaft Bushings:

1. One bushing assembly is required to mount the reducer onthe driven shaft. An assembly consists of one long taperedbushing, one short tapered bushing, one tapered bushingwedge, bushing screws and washers, two bushing backup



32

plates and retaining rings, and necessary shaft key or keys.The driven shaft does not need to extend through the reducerfor the short shaft bushing to operate properly. The minimumshaft length, as measured from the end of the shaft to the outeredge of the bushing flange (see Figure 5), is given in Table 1.

AMINIMUM SHAFT LENGTH

Figure 5 – Minimum Recommended Dimensions

Table 1 – Minimum Mounting Dimensions and Bolt TorquesMinimum Required Shaft Length

Reducer Size Standard Taper Bushing Short Shaft BushingTA0107L 6.83 4.32TA1107H 6.95 4.43TA2115H 7.80 4.80TA3203H 8.55 5.46TA4207H 8.94 5.66TA5215H 10.33 6.35TA6307H 10.82 6.72TA7315H 11.87 7.62TA8407H 12.82 8.10TA9415H 13.74 8.56TA10507H 15.46 9.67TA12608H 18.32 11.60

Bushing Screw Information and Minimum Clearance for RemovalReducer Size Fastener Size Torque in Ft.-Lbs. A

TA0107L 5/16-18 20 – 17 1.08TA1107H 5/16-18 20 – 17 1.20TA2115H 3/8-16 20 – 17 1.20TA3203H 3/8-16 20 – 17 1.20TA4207H 3/8-16 26 – 23 1.48TA5215H 1/2-13 77 – 67 1.81TA6307H 1/2-13 77 – 67 1.81TA7315H 1/2-13 77 – 67 2.06TA8407H 1/2-13 77 – 67 2.06TA9415H 5/8-11 86 – 75 2.39TA10507H 5/8-11 86 – 75 2.39TA12608H 5/8-11 86 – 75 2.39

2. The long bushing is designed to be installed from the side ofthe reducer opposite the driven equipment as shown in Figure 6.The long bushing when properly installed is designed to capturethe end of the customer shaft that does not extend through thereducer. Normally the reducer would be mounted such that theinput shaft extends from the side of the reducer opposite thedriven equipment however the reducer design allows installationof the reducer to be mounted in the opposite direction.

3. Install the tapered bushing wedge into the hollow bore of thereducer from the same side as the long bushing will be installed.When installing the tapered bushing wedge into the reducer

hub, install the flange end first so that the thin taper is pointingoutwards towards the long bushing as shown in Figure 6. Thewedge is properly installed when it snaps into place in thereducer hub.

Figure 6 – Short Shaft Bushing and Output Hub Assembly

4. Align the tapered bushing wedge keyway with the reducerhub keyway. The keyway in the wedge is slightly wider than thekeyway in the reducer hub allowing for easier installation.

5. Install one bushing backup plate on the end of the hub andsecure with the supplied retaining ring. Repeat procedure forother side.

6. Install the short bushing; flange first, on the driven shaft andposition per dimension “A”, as shown in Table 1. This will allowthe bolts to be threaded into the bushing for future bushing andreducer removal.

7. Insert the output key in the shaft and bushing. For easy ofinstallation, rotate the driven shaft so that the shaft keyseat is atthe top position.

8. Mount the reducer on the driven shaft and align the shaft keywith the reducer hub keyway. Maintain the recommendedminimum distance “A” from the shaft bearing.

9. Insert the screws, with washers installed, in the unthreadedholes in the bushing flange and align with the threaded holes inthe bushing backup plate. If necessary, rotate the bushingbackup plate to align with the bushing screws. Tighten thescrews lightly. If the reducer must be positioned closer thandimension “A”, place the screws with washers installed, in theunthreaded holes in the bushing before positioning reducermaking sure to maintain at least 1/8” between the screw headsand the bearing.

10. Place the long bushing in position on the shaft and align thebushing keyway with the shaft key. Use care to locate the longbushing with the tapered bushing wedge installed earlier. Alignthe unthreaded holes in the bushing with the threaded holes inthe bushing backup plate. If necessary, rotate the bushingbackup plate to align with the bushing holes. Insert bushingscrews, with washers installed in the unthreaded holes in thebushing. Tighten screws lightly.

11. Alternately and evenly tighten the screws in the bushingnearest the equipment to the recommended torque given inTable 1. Repeat procedure on outer bushing.



33

Bushing Removal for Standard Taper or Short ShaftBushings:

1. Remove bushing screws.

2. Place the screws in the threaded holes provided in thebushing flanges. Tighten the screws alternately and evenly untilthe bushings are free on the shaft. For ease of tighteningscrews make sure screw threads and threaded holes in thebushing flanges are clean. If the reducer was positioned closerthan the recommended minimum distance “A” as shown inTable 1, loosen the inboard bushing screws until they are clearof the bushing flange by 1/8”. Locate two (2) wedges at 180degrees between the bushing flange and the bushing backupplate. Drive the wedges alternately and evenly until the bushingis free on the shaft.

3. Remove the outside bushing, the reducer, and then theinboard bushing.

LUBRICATIONIMPORTANT: Because reducer is shipped without oil, it isnecessary to add the proper amount of oil before operatingreducer. Use a high-grade petroleum base rust and oxidationinhibited (R&O) gear oil - see tables. Follow instructions onreducer warning tags, and in the installation manual.

Under average industrial operating conditions, the lubricantshould be changed every 2500 hours of operation or every 6months, whichever occurs first. Drain reducer and flush withkerosene, clean magnetic drain plug and refill to proper levelwith new lubricant.

CAUTION: Too much oil will cause overheating and too littlewill result in gear failure. Check oil level regularly. Failure toobserve this precaution could result in bodily injury.

Under extreme operating conditions, such as rapid rise and fallof temperature, dust, dirt, chemical particles, chemical fumes, oroil sump temperatures above 200°F, the oil should be changedevery 1 to 3 months, depending on severity of conditions.

Table 2 – Oil VolumesApproximate Volume of Oil to Fill Reducer to Oil Level Plug � �

Reducer † Position A † Position B † Position C † Position D † Position E † Position FSize ▲Qt L ▲Qt L ▲Qt L ▲Qt L ▲Qt L ▲Qt L

Single 0.7 0.6 0.5 0.5 0.7 0.6 1.4 1.3 1.3 1.2 1.5 1.4TA0107L Double 0.7 0.6 0.5 0.5 0.6 0.6 1.3 1.3 1.2 1.2 1.4 1.3Single 1.3 1.3 0.7 0.7 0.7 0.6 1.7 1.6 1.5 1.4 1.9 1.8TA1107H Double 1.3 1.3 0.7 0.7 0.6 0.6 1.7 1.6 1.5 1.4 1.9 1.8Single 2.1 2.0 1.2 1.2 1.1 1.0 2.7 2.5 2.3 2.2 3.1 2.8TA2115H Double 2.1 2.0 1.1 1.1 1.0 1.0 2.6 2.5 2.4 2.3 3.0 2.9Single 2.8 2.7 1.6 1.6 1.8 1.7 4.1 3.9 3.3 3.1 4.4 4.2TA3203H Double 2.8 2.7 1.5 1.4 1.7 1.6 4.0 3.8 3.4 3.3 4.2 4.0Single 4.4 4.2 2.6 2.5 2.9 2.8 7.4 7.0 6.3 6.0 7.8 7.3TA4207H Double 4.4 4.2 2.5 2.4 2.8 2.6 7.3 6.9 6.4 6.0 7.5 7.1Single 7.4 7.0 4.9 4.7 5.8 5.5 13.2 12.5 11.6 11.0 13.1 12.4TA5215H Double 7.4 7.0 4.7 4.4 5.5 5.2 12.9 12.2 11.4 10.8 12.6 11.9Single 8.8 8.4 5.8 5.5 6.6 6.2 16.1 15.3 13.2 12.5 16.1 15.3TA6307H Double 8.8 8.4 5.5 5.2 6.2 5.9 15.8 15.0 13.9 13.1 15.3 14.5Single 8.4 8.0 11.8 11.1 13.9 13.2 22.5 21.3 22.1 20.9 25.1 23.7TA7315H Double 8.4 8.0 10.8 10.3 13.2 12.5 22.0 20.9 22.4 21.2 23.1 21.8Single N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/ATA8407H Double 7.7 7.3 11.7 11.1 13.7 12.9 25.1 23.8 24.0 22.7 25.8 24.4Single N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/ATA9415H Double 17.0 16.1 16.8 15.9 18.1 17.1 33.2 31.4 33.2 31.4 38.6 36.5Single N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/ATA10507H Double 38.0 36.0 27.6 26.1 25.8 24.4 53.5 50.6 53.8 50.9 56.1 53.0Single N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/ATA12608H Double 53.0 50.2 41.5 39.3 37.1 35.1 70.7 66.9 72.2 68.3 80.4 76.1

� Oil quantity is approximate. Service with lubricant until oil runs out of oil level hole.† Refer to Figure 1 for mounting positions.▲ US measure: 1 quart = 32 fluid ounces = .94646 liters.� Below 15 RPM output speed, oil level must be adjusted to reach the highest oil level plug. If reducer position is to vary from those shown in Figure 1, either more or lessoil may be required. Consult Dodge.



34

Table 3 – Oil RecommendationsISO Grades For Ambient Temperatures of 50˚F to 125˚F �

Torque-Arm II Reducer SizeOutputRPM TA0107L TA1107H TA2115H TA3203H TA4207H TA5215H TA6307H TA7315H TA8407H TA9415H TA10507H TA12608H

301 – 400 320 320 320 220 220 220 220 220 220 220 220 220201 – 300 320 320 320 220 220 220 220 220 220 220 220 220151 – 200 320 320 320 220 220 220 220 220 220 220 220 220126 – 150 320 320 320 220 220 220 220 220 220 220 220 220101 – 125 320 320 320 320 220 220 220 220 220 220 220 22081 – 100 320 320 320 320 320 220 220 220 220 220 220 22041 – 80 320 320 320 320 320 220 220 220 220 220 220 22011 – 40 320 320 320 320 320 320 320 320 320 320 220 2201 – 10 320 320 320 320 320 320 320 320 320 320 320 320

ISO Grades For Ambient Temperatures of 15˚F to 60˚F �Torque-Arm II Reducer SizeOutput

RPM TA0107L TA1107H TA2115H TA3203H TA4207H TA5215H TA6307H TA7315H TA8407H TA9415H TA10507H TA12608H301 – 400 220 220 220 150 150 150 150 150 150 150 150 150201 – 300 220 220 220 150 150 150 150 150 150 150 150 150151 – 200 220 220 220 150 150 150 150 150 150 150 150 150126 – 150 220 220 220 150 150 150 150 150 150 150 150 150101 – 125 220 220 220 220 150 150 150 150 150 150 150 15081 – 100 220 220 220 220 220 150 150 150 150 150 150 15041 – 80 220 220 220 220 220 150 150 150 150 150 150 15011 – 40 220 220 220 220 220 220 220 220 220 220 150 1501 – 10 220 220 220 220 220 220 220 220 220 220 220 220

� Notes:1. Assumes auxiliary cooling where recommended in the catalog.2. Pour point of lubricant selected should be at least 10°F lower than expected minimum ambient starting temperature.3. Extreme pressure (EP) lubricants are not necessary for average operating conditions. When properly selected for specific applications, TORQUE-ARM II backstops aresuitable for use with EP lubricants.4. Special lubricants may be required for food and drug industry applications where contact with the product being manufactured may occur. Consult a lubricationmanufacturer’s representative for his recommendations.5. For reducers operating in ambient temperatures between -22°F (-30°C) and 20°F (–6.6°C) use a synthetic hydrocarbon lubricant, 100 ISO grade or AGMA 3 grade (forexample, Mobil SHC627). Above 125°F (51°C), consult DODGE Gear Application Engineering (864) 288-9050 for lubrication recommendation.6. Mobil SHC630 Series oil is recommended for high ambient temperatures.



35

GUIDELINES FOR TORQUE-ARM IIREDUCER LONG-TERM STORAGEDuring periods of long storage, or when waiting for delivery orinstallation of other equipment, special care should be taken toprotect a gear reducer to have it ready to be in the bestcondition when placed into service.

By taking special precautions, problems such as seal leakageand reducer failure due to lack of lubrication, improperlubrication quantity, or contamination can be avoided. Thefollowing precautions will protect gear reducers during periods ofextended storage:

Preparation:

1. Drain oil from the unit. Add a vapor phase corrosioninhibiting oil (VCI-105 oil by Daubert Chemical Co.) inaccordance with Table 4.

2. Seal the unit airtight. Replace the vent plug with a standardpipe plug and wire the vent to the unit.

3. Cover all unpainted exterior parts with a waxy rustpreventative compound that will keep oxygen away from thebare metal. (Non-Rust X-110 by Daubert Chemical Co. orequivalent)

4. The instruction manuals and lubrication tags are paper andmust be kept dry. Either remove these documents and storethem inside, or cover the unit with a durable waterproof coverwhich can keep moisture away.

5. Protect reducer from dust, moisture, and other contaminantsby storing the unit in a dry area.

6. In damp environments, the reducer should be packed insidea moisture-proof container or an envelope of polyethylenecontaining a desiccant material. If the reducer is to be storedoutdoors, cover the entire exterior with a rust preventative.

When placing the reducer into service:

1. Fill the unit to the proper oil level using a recommendedlubricant. The VCI oil will not affect the new lubricant.

2. Clean the shaft extensions with petroleum solvents.

3. Assemble the vent plug into the proper hole.

Follow the installation instructions provided in this manual.

Table 4 – Quantities of VCI #105 OilReducer Size Quantity (Ounces / Milliliter)

TA0107L 1 / 30TA1107H 1 / 30TA2115H 1 / 30TA3203H 1 / 30TA4207H 1 / 30TA5215H 2 / 59TA6307H 2 / 59TA7315H 3 / 89TA8407H 3 / 89TA9415H 4 / 118TA10507H 6 / 177TA12608H 8 / 237

VCI #105 and #10 are interchangeable.VCI #105 is more readily available.



36

OIL VISCOSITY EQUIVALENCY CHART

2000

1000

800

600

500

400

300

200

100

80

60

5040

30

20

10

8

6

5

4

3

2

70

60

50

40

30

20

10

8

5

4

9

7

6

1500

1000

680

460

320

220

150

100

68

8A

8

7

6

5

4

3

2

85W

250

140

90

80W

46

32

22

15

10

7

5

175W

3

2

300

200

150

100

8070

60

50

40

35

32

400

500600

800

1000

1500

2000

3000

4000

50006000

800010,000

cSt/40°C 100°C

cSt/ ISOVG

AGMAGRADES

GRADESGEAR OILS

SUS/100°F

SUS/210°F

SAE

KINEMATICVISCOSITIES

SAYBOLTVISCOSITIES

200

300

100

90

80

70

60

55

50

45

40VISCOSITIES CAN BERELATED HORIZONTALLYONLY.VISCOSITIES BASED ON96 VI SINGLE GRADEOILS.ISO ARE SPECIFIED AT40°C.AGMA ARE SPECIFIED AT40°C.SAE 75W, 80W, AND 85WSPECIFIED AT LOWTEMPERATURE. EQUIVALENTVISCOSITIES FOR 100°FAND 200°F ARE SHOWN.SAE 90 TO 250 SPECIFIEDAT 100°C.



37

COOLING FAN INSTALLATIONWARNING: To ensure that drive is not unexpectedly started,turn off and lock out or tag power source before proceeding.Remove all external loads from drive before removing orservicing drive or accessories. Failure to observe theseprecautions could result in bodily injury.

Unpack all components and inspect for shipping damage. Donot use any component that has been damaged or modified.Make sure all components are clean and free of any foreignmaterial prior to assembly. Cooling fan assembly is designed tofit onto the input shaft before placement of sheeves or beltguard assembly.

Installation for TA4207CF and TA5215CF:

1. Referring to Figure 2, install tapered bushing (9) into bore offan blade assembly (2) and loosely install the three set screwsprovided with fan. Snug set screws but do not tighten at thistime.

2. Slide fan assembly onto input shaft and install input shaftkey. Note: Key is supplied with the TAII reducer. Locate fanblade edge distance “A” (Figure 1) from end of shaft per Table1. Make sure fan assembly rotates without interference wheninput shaft is rotated.

3. Alternately tighten the set screws until fan assembly issecurely installed on the input shaft.

4. Recheck fan assembly for proper location and clearance.Loosen set screws and repeat steps 2 and 3 above if notproperly located.

Installation for TA6307CF through TA12608CF:

1. Referring to Figure 2, install fan guard back plate assembly(1) using the four bolts (4) provided. Note that the screen ismounted towards the reducer. Tighten to recommended torquein Table 1.

CAUTION: Fan guard screen has sharp edges. Use cautionwhen installing to avoid lacerations.

2. Slide fan blade assembly (2) onto input shaft and install keyand set screws (5). Note: Key is supplied with the TAII reducer.Position fan blade edge distance “A” (Figure 1) from end of shaftper Table 1. Make sure fan assembly rotates withoutinterference when input shaft is rotated. Tighten the two fanblade set screws (5) securely.

3. Install fan guard cover (3) with four bolts (6), lockwashers (7),and hex nuts (8). Tighten securely.

4. Verify fan blade rotates freely and does not interfere with fanguard back plate (1) or fan guard cover (3). Adjust fan blade ifnecessary.

Table 1 - Dimensions and Bolt TorqueReducer Size Dim.”A” mm Torque (Ft.-Lbs.)

TA4207H 3-3/4 -----TA5215H 4-5/8 -----TA6307H 4-1/4 33 - 30TA7315H 4-3/8 33 - 30TA8407H 5-1/16 33 - 30TA9415H 6-1/4 33 - 30TA10507H 6-7/16 33 - 30TA12608H 6-7/16 33 - 30

Figure 1 - Fan Blade Placement

A

A

TYPICAL FOR REDUCER SIZES 4 AND 5

TYPICAL FOR REDUCER SIZES 6 THRU 12



38

Figure 2 – Parts Identification

TYPICAL COOLING FAN ASSEMBLYFOR REDUCER SIZES 6 THROUGH 12

TYPICAL COOLING FAN ASSEMBLY FOR REDUCER SIZES 4 AND 5

8

7

1

42

3

5

69

2

Table 2 – Cooling Fan Part NumbersDescription Ref.

Number Quantity TA4207 TA5215 TA6307 TA7315 TA8407 TA9415 TA10507 TA12608

Cooling Fan Assembly � ----- 1 904106 905106 906106 907106 907106 909106 910106 912106Fan Guard Plate Assy.� 1 1 ----- ----- 906519 906519 906519 909519 909519 912519Fan Blade� 2 1 904517 905517 906517 907517 907517 909517 910517 910517Fan Guard Cover� 3 1 ----- ----- 906521 906521 906521 909521 909521 909521Mounting Bolt� 4 4 ----- ----- 411294 411294 411294 411294 411294 411294Fan Set Screw� 5 2 ----- ----- 400086 400086 400086 400086 400086 400086Cover Bolt� 6 4 ----- ----- 411390 411390 411390 411390 411390 411390Lockwasher� 7 4 ----- ----- 419010 419010 419010 419010 419010 419010Hex Nut� 8 4 ----- ----- 407085 407085 407085 407085 407085 407085Taper Bushing Assy.�� 9 1 117162 117092 ----- ----- ----- ----- ----- -----

� Assembly includes parts listed below marked �� Set screws are included with taper bushing assembly.



39

BACKSTOPSWARNING: To ensure that drive is not unexpectedly started,turn off and lock out or tag power source before proceeding.Remove all external loads from drive before removing orservicing drive or accessories. Failure to observe theseprecautions could result in bodily injury.

1. Remove backstop shaft cover and gasket, shown in Figure 7.These parts will not be reused. This cover is directly oppositethe extended end of the input shaft.

2. Clean the face of the gearbox to remove any gasket materialor contamination from the cover mounting surface. It isimportant that contamination not get into the gearbox or thebackstop during the backstop installation/servicing process.

3. Face reducer looking at the side from which the cover wasremoved. Determine carefully the desired direction of freerotation. It is important that the direction be correctlydetermined because to reverse the direction after the backstopis installed, it is necessary to remove the backstop, turn it end-for-end and then reinstall it.

4. Match the arrow on the backstop inner race to the directionof free rotation for the desired shaft. Note that reversing thebackstop end-for end changes the direction of the arrow. Theshaft will rotate in the same direction as the arrow on thebackstop.

5. If the backstop kit has a spacer ring included, install it ontothe shaft first, adjacent to the bearing inner ring.

6. Install the backstop inner race and sprag cage assemblyonto the shaft. DO NOT remove the cage from the inner race orthe shipping strap from the sprag set at this time. Insert the keyinto the inner race and mating shaft keyway. These partsshould slip onto the shaft easily, a light coating of oil may assist

in assembly. Do not use a hammer to force the installation,damage can occur to the shaft and/or the backstop. Slide therace against the spacer or the shaft shoulder and install theretaining ring into the groove in the shaft. Only use the suppliedkey, as it is specifically designed for each backstop.

7. Apply a thin coating of RTV silicone onto the gearbox matingsurface for the outer race (same as the cover area). It isimportant to apply the sealant around the fastener holes toprevent leakage. Do not allow excessive amounts of silicone toenter the gearbox or to be applied to other parts.

8. Install the outer race by gently rotating it opposite the shaftrotation while pressing lightly inwards. Do not force the outerrace into position as backstop damage may occur. Once theouter race is well piloted onto the sprag set, remove theshipping strap from the sprag set by cutting it, being careful notto let the outer race back off the sprags. The outer race shouldslide easily into position with a slight turning motion. A lightcoating of oil on the race inner diameter may ease installation.

9. Align the fastener holes in the outer race with the matingholes in the gearbox. Use the supplied grade 5 fasteners andlock washers only. Torque the fasteners in an alternatingpattern per Table 5.

Table 5 – Backstop Fastener Torque ValuesReducer Size Fastener Size Torque in Ft.-Lbs.

TA0107L 1/4-20 8 – 7TA1107H 1/4-20 8 – 7TA2115H 1/4-20 8 – 7TA3203H 1/4-20 8 – 7TA4207H 1/4-20 8 – 7TA5215H 5/16-18 17 – 15TA6307H 5/16-18 17 – 15TA7315H 3/8-16 30 – 27TA8407H 5/16-18 17 – 15TA9415H 3/8-16 30 – 27TA10507H 3/8-16 30 – 27TA12608H 3/8-16 30 – 27



40

ARROW ON HUB OF INSTALLEDBACKSTOP MUST MATCHDIRECTION OF DESIRED

SHAFT ROTATION

BACKSTOP SHAFTCOVER GASKET

BACKSTOPSHAFT COVER

SPACER (IF APPLICABLE)

OUTER RACE

INNER RACE

RETAININGRING

BACKSTOPFASTENERS

BACKSTOPKEY

REDUCER WITHBACKSTOP INSTALLED

REDUCER WITHOUTBACKSTOP INSTALLED

Figure 7 – Backstop Assembly


Appendix 2 - Roller Bearings

41


Appendix 2 - Roller Bearings

42


Appendix 3 - Pillow Blocks

43



44



45


NOTES

46

The GSI Group, Inc. Warranty

THE GSI GROUP, INC. (“GSI”) WARRANTS ALL PRODUCTS WHICH IT MANUFACTURES TOBE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE ANDCONDITIONS FOR A PERIOD OF 12 MONTHS AFTER RETAIL SALE TO THE ORIGINAL ENDUSER. THE PURCHASER’S SOLE REMEDY AND GSI’S ONLY OBLIGATION SHALL BE TOREPAIR OR REPLACE, AT GSI’S OPTION AND EXPENSE, PRODUCTS THAT, IN GSI’S SOLEJUDGMENT, CONTAIN A MATERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP.ALL DELIVERY AND SHIPMENT CHARGES TO AND FROM GSI’S FACTORY WILL BEPURCHASER’S RESPONSIBILITY. EXPENSES INCURRED BY OR ON BEHALF OF THEPURCHASER WITHOUT PRIOR WRITTEN AUTHORIZATION FROM AN AUTHORIZEDEMPLOYEE OF GSI SHALL BE THE SOLE RESPONSIBILITY OF THE PURCHASER.

EXCEPT FOR THE LIMITED WARRANTY EXPRESSED ABOVE, GSI MAKES NO FURTHERWARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION,WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USEIN CONNECTION WITH (I) PRODUCT MANUFACTURED OR SOLD BY GSI OR (ii) ANYADVICE, INSTRUCTION, RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT,REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THECONFIGURATION, INSTALLATION, LAYOUT, SUITABILITY FOR A PARTICULAR PURPOSE,OR DESIGN OF SUCH PRODUCTS.

GSI SHALL NOT BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL ORCONSEQUENTIAL DAMAGES, INCLUDING, WITHOUT LIMITATION, LOSS OF ANTICIPATEDPROFITS OR BENEFITS. PURCHASER’S SOLE AND EXCLUSIVE REMEDY IS AS SET FORTHIN THE LIMITED WARRANTY EXPRESSED ABOVE, WHICH SHALL NOT EXCEED THEAMOUNT PAID FOR THE PRODUCT PURCHASED. THIS WARRANTY IS NOTTRANSFERABLE AND APPLIES ONLY TO THE ORIGINAL PURCHASER. GSI SHALL HAVENO OBLIGATION OR RESPONSIBILITY FOR ANY REPRESENTATIONS OR WARRANTIESMADE BY OR ON BEHALF OF ANY DEALER, AGENT OR DISTRIBUTOR OF GSI.

GSI ASSUMES NO RESPONSIBILITY FOR CLAIMS RESULTING FROM ERECTION DEFECTSOR UNAUTHORIZED MODIFICATIONS TO PRODUCTS WHICH IT MANUFACTURED.MODIFICATIONS TO PRODUCTS NOT SPECIFICALLY DELINEATED IN THE MANUALACCOMPANYING THE EQUIPMENT AT INITIAL SALE WILL NULLIFY THE PRODUCTWARRANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE.

THE FOREGOING WARRANTY SHALL NOT EXTEND TO PRODUCTS OR PARTS WHICHHAVE BEEN DAMAGED BY NEGLIGENT USE, MISUSE, ALTERATION OR ACCIDENT. THISWARRANTY EXTENDS SOLELY TO ONLY PRODUCTS MANUFACTURED BY GSI. THISWARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS ORIMPLIED. GSI RESERVES THE RIGHT TO MAKE DESIGN OR SPECIFICATION CHANGES ATANY TIME.

PRIOR TO INSTALLATION, PURCHASER HAS THE RESPONSIBILITY TO COMPLY WITH ALLFEDERAL, STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCATION ANDINSTALLATION OF PRODUCTS MANUFACTURED OR SOLD BY GSI.

PHLEGAL: #1832020 v1 (139LG01!.DOC) (revised December 2005)

This Equipment shall be installed in accordancewith the current installation codes and applicableregulations which should be carefully followed in

all cases. Authorities having jurisdiction should beconsulted before installation occurs.

1004 East Illinois StreetAssumption, IL 62510217-226-4421 Phone800-800-5329 FAX

pneg-681 - bucket elevator series 2

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