6", 8" & 10" Utility & Horizontal Bin Unloader Assembly & Operation Manual PNEG-1435 Date: 10-08-10
This Manual is valid for the bulk tank and utility auger catalog numbers in the tables below: Auger Length 6'' Utility Auger 8'' Utility Auger 10'' Utility Auger 11' GUF6111A GUF6112B1A GUF8111A - GUF10111A - 16' GUF6161A GUF6162B1A GUF8161A - GUF10161A - 21' GUF6211A GUF6212B1A GUF8211A - GUF10211A - 27' GUF6271A GUF6272B1A GUF8271A - - 31' - - GUF10311A 33' GUF6331A GUF6332B1A GUF8331A - - 41' GUF6411A GUF6412B1A GUF8411A - GUF10411A - 53' - GUF8531A - Auger Length 6'
Table of Contents Contents Chapter 1 Introduction ....................................................................................................................... 5 General Information ............................................................................................................ 5 Receiving Merchandise and Filing Claims .......................................................................... 5 Capacity ..................................................................................
SAFETY st Replace missing guards and shields FREE OF CHARGE! Our equipment is built to provide many years of dependable service to our customers through durable craftsmanship. One of the most important aspects of our engineering is SAFETY 1st design throughout all product lines. Safety is NO ACCIDENT! That is why we are implementing its SAFETY 1st program.
1. INTRODUCTION General Information READ THIS MANUAL carefully to learn how to properly use and install equipment. Failure to do so could result in personal injury or equipment damage. THIS MANUAL SHOULD BE CONSIDERED a permanent part of your equipment and should be easily accessible when needed. WARRANTY is provided as part of the company’s support program for customers who use and maintain their equipment as described in the manual.
2. SAFETY Safety Guidelines This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections.
2. SAFETY Safety Instructions Our principle concern is your safety and the safety of others associated with grain handling equipment. We want to keep you as a customer. This manual is to help you understand safe operating procedures and some problems which 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.
2. SAFETY Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs. 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.
2. SAFETY Prepare for Emergencies Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. Keep Emergency Equipment Quickly Accessible. Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Eye Protection Safety glasses should be worn at all times to protect eyes from debris.
2. SAFETY Operator Qualifications 1. 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 qualified. These persons must also know and meet all other qualifications, such as: a. Any person who has not read and/or does not understand all operation and safety instructions is not qualified to operate any auger systems. b. Certain regulations apply to personnel operating power machinery.
3. SAFETY DECALS The Decal List below has all the safety decals that should be included with your equipment. The following pages show what the decals look like and where they should be located on the equipment. Inspect all decals and replace any that are illegible, worn, or missing. Contact your local dealer or the manufacturer to order replacement decals free of charge. Contact: The GSI Group 1004 E.
3. SAFETY DECALS Check components shown below to insure that the safety decals are in place and in good condition. If a decal cannot be easily read for any reason or has been painted over, replace it immediately. Contact your dealer or the manufacturer to order a replacement Decal free of charge. Contact: The GSI Group 1004 E.
3. SAFETY DECALS Check components shown below to insure that the safety decals are in place and in good condition. If a decal cannot be easily read for any reason or has been painted over, replace it immediately. Contact your dealer or the manufacturer to order a replacement Decal free of charge. DANGER Sign No. DC-1395 was supplied with your bin unloading equipment.
4. ASSEMBLY & INSTALLATION Assembling the Flight Extension Note: If your auger does not include an extension skip ahead to Step 5. 1. Begin by sliding the extension connecting band onto the main auger tube (Figure 4A).
4. ASSEMBLY & INSTALLATION 2. Slide the flight connecting shaft into the main section of flight and bolt together with Grade 8 Hex Bolt and Stover nut. Next slide extension flight onto connecting shaft and bolt together using proper grade 8 bolts and stover nuts (See Chart) and (Figure 4B).
4. ASSEMBLY & INSTALLATION 3. Slide the extension tube over the extension flight, making sure the tube is pressed securely against the main auger tube (Figure 4C).
4. ASSEMBLY & INSTALLATION 4. Slide the extension connecting band over the two sections of tube, making sure the connecting band is centered over the mated surfaces of the tubes. Tighten the connecting band down using the correct Hex Bolts and Nylock nuts (See Chart) and (Figure 4D).
4. ASSEMBLY & INSTALLATION 5. Insert the intake shaft into the flight and connect with proper grade 8 bolt and stover nut (See Chart) and (Figure 4E). Flight Hardware 6" 3/8" x 2" - 16 Grade 8 Hex Bolts 8" 7/16" x 3" - 14 Grade 8 Hex Bolts 10" 1/2" x 3-1/2" - 13 Grade 8 Hex Bolts Flight Nut Intake Shaft Hex Bolt (See Chart) Figure 4E 6. The galvanized tube may need to be cut to expose enough auger flighting, depending on the application. 6" Units require 20".
4. ASSEMBLY & INSTALLATION Install the Truss Support Note: For Bulk Tank Augers Only. 1. Begin by placing the Truss Support on the top side of the Auger Tube. Position the Truss Support Half Band below the Truss Support and align the holes. Attach together using appropriate hex bolt and Nylock nut. Do not tighten the nuts down until the proper distance has been determined for the desired angle (See Chart) and (Figure 4F).
4. ASSEMBLY & INSTALLATION Installing the Intake Guard Note: For Utility Augers Only. 1. Slide the Intake guard onto the Auger Tube aligning the intake shaft with the bronze bushing (Figure 4G). Auger Tube Intake Guard Flight Bronze Bushing Figure 4G 2. With the Intake Shaft inserted in the bushing make sure to leave approximately 1/2" of clearance between the end of the Flight and the face of the bushing (Figure 4H).
4. ASSEMBLY & INSTALLATION 3. Attach the Intake Guard to the Tube using the proper hex bolts and Nylock nuts through the half bands that are welded to the Intake Guard (See Chart) and (Figure 4I). Intake Guard Bolts 6" 5/16'' -18 x 1-3/4'' GR5 Hex Bolt 8" 5/16'' -18 x 1-3/4'' GR5 Hex Bolt 10" 3/8'' -16 x 1-1/2'' GR5 Hex Bolt Intake Guard Half Band Bolts(See Chart) Figure 4I 4.
4. ASSEMBLY & INSTALLATION Installing Drive Shaft 1. Insert the Drive Shaft into the opposite end of flight with keyway facing outward. Align the holes in the shaft and secure with Grade 8 bolts and stover nuts (See Chart) and (Figure 4K).
4. ASSEMBLY & INSTALLATION Mounting Bearing to Bearing Plate 1. Align bolt holes on Bearing Flange with bolt holes on Bearing Plate. 2. Secure Bearing to Bearing plate using appropriate bolts, lock washers, and nuts (See Chart) and (Figure 4L).
4. ASSEMBLY & INSTALLATION Installing Bearing Plate onto Tube 1. Align Bearing with Drive Shaft and slip Shaft through bearing. 2. Rotate Plate until bolt holes in tube flange and plate align. Secure with appropriate bolts, and Serrated Flange Nuts (See Chart). Bearing Plate Bolts 6" & 8" 5/16" x 1" - 18 Hex Bolts 10'' 3/8" x1" - 1/14'' - 16 Hex Bolts 10" 3/8" x 1" - 16 Hex Bolts 3. Only Secure With UPPER and LOWER four(4) bolts (Figure 4M).
4. ASSEMBLY & INSTALLATION Installing the Motor Mount Adjuster 1. Place Motor Mount Adjuster between the Back Plate and Head Plate on the Discharge Tube. 2. Insert Pivot Rod through the Tube plates and Motor Mount Adjuster. Secure in place with two (2) 3/16" x 2" cotter pins (See Figure 4N).
4. ASSEMBLY & INSTALLATION Installing the Motor Mount Plate 1. Secure one (1) of the motor mount adjustment nuts and one (1) the motor mount adjustment washers approximately 3/4 of the way down the motor mount adjuster’s threaded shaft. 2. Once the nut and washer is secure, slip the Motor Mount Plate over the adjuster and align the pivot holes with the pivot tube (See Figure 4O).
4. ASSEMBLY & INSTALLATION Installing the Belt Guard Brackets 1. Align the holes on the Bearing Plate with the slots on the Belt Guard Mounting Brackets. 2. Secure the Brackets with proper bolts, flat washers, and Serrated Flange Nuts (See Chart) and (Figure 4Q). Serrated Flange Nuts Bearing Plate Flat Washer Belt Guard Mounting Bracket [(See Chart) for Bolt Sizes] Figure 4Q Note: DO NOT tighten the bolts completely.
4. ASSEMBLY & INSTALLATION Installing the Lock Collar 1. Slide the Lock Collar over the Drive Shaft, positioning it against the bearing. Do not tighten the lock collar at this time as it will be tightened later in the assembly (See Figure 4R). Lock Collar Drive Shaft Figure 4R Installing the Pulley 1. Place and position the key into the keyway located on the Drive Shaft. 2. Place the pulley onto the Drive Shaft with the setscrew side of the pulley facing away from the Bearing Plate.
4. ASSEMBLY & INSTALLATION 3. Once the pulley is appropriately positioned, tighten the Setscrew with a hex head wrench to secure it to the drive shaft (See Figure 4S). Key Set Screw Drive Shaft Bearing Plate Flight Pulley Figure 4S Tightening the Lock Collar 1. Using a punch and hammer, drive the lock collar clockwise (the same direction as the shaft rotation). Once the lock collar is set in place, use a hex head wrench to tighten the lock collar by tightening the Setscrew.
4. ASSEMBLY & INSTALLATION Installing the Motor (Not Provided) 1. Attach the Motor to the Motor Mount Plate using appropriate bolts, lock washers, and hex nuts (See Chart). 2. Install pulley onto motor shaft making sure that it is aligned with the flight pulley. It may be necessary to move spacers to gain shaft alignment (See Figure 4T).
4. ASSEMBLY & INSTALLATION Installing the Belt Guard 1. With the belts properly tensioned remove the bottom Belt Guard cover and slip Belt Guard down over motor shaft. 2. Bolt the Belt Guard to the Belt Guard Mounting Brackets, the brackets should still be loose at this time. 3. Align the motor shaft and the Flight Drive Shaft in the Belt Guard’s slot, making sure that the Belt Guard DOES NOT contact either pulley, and tighten down the Belt Guard Mounting Brackets to the Bearing Plate (See Figure 4U).
5. ELECTRIC DRIVE MOTORS Horsepower Information for Electric Motors 1. Horsepower recommendations are for augering reasonably dry grain at different angles. Grain with 15% moisture and above may require more horsepower if maximum capacity is to be maintained. Use a 2.5" to 3.0" motor pulley for a recommended auger speed of 550 to 650 R.P.M. Motor pulley not furnished. Excessive wear will result if auger speed is in excess of 700 R.P.M. and auger load up will occur if auger speed is less than 500 R.P.M.
5. ELECTRIC DRIVE MOTORS Power Source 1. Use electric motors that operate at 1750 R.P.M 2. Electric motors and controls should be installed by a qualified electrician and must meet the standards set by the National Electrical Code and all local and state codes. 3. A magnetic starter should be used to protect your motor when starting and stopping. It should stop the motor in case of power interruption, conductor fault, low voltage, circuit interruption, or motor overload.
6. STARTUP Start-Up and Break-In WARNING ALWAYS keep ALL guards and shields in place, until all the power is disconnected and locked out. 1. Make sure ALL belts are tensioned properly. 2. Make sure ALL shields are in place and that the belt(s) and pulley(s) are able to move freely. 3. Double check the assembly instructions to see that all parts have been assembled properly. 4. During operation of equipment, one person should be in a position to monitor the entire operation.
6. STARTUP CAUTION NEVER operate augers empty for any length of time as excessive wear will result. 8. Do not stop or start augers under load, especially before the flight and tube become well polished, as this may cause the auger to “lockup”. CAUTION Excessive wear will result if auger is run at speeds in excess of what is recommended. 9. Do not run auger at to slow speed, this will load up or over load the auger.
7. OPERATION Operate the Auger Note: The auger capacity can fluctuate greatly under varying conditions. Moisture content, different commodities, amount of foreign matter and speeds all play a part in the performance of the auger. Twenty-five percent(25%) moisture may cut capacity by as much as (40%) under some conditions. 1. Make certain there are at least two (2) people in the work area to monitor operations at all times. 2. Visually inspect the auger periodically during operation.
8. MAINTENANCE Maintain the Auger DANGER ALWAYS shutdown and disconnect the power supply before adjusting, servicing or cleaning the equipment. 1. Use caution when repairing or replacing equipment parts. 2. Make sure ALL decals are legible and tightly attached to the auger. If necessary, replace them FREE OF CHARGE by contacting your dealer or the manufacturer. 3. Ensure that ALL electric motors, etc., are operating at the proper speed 4. Maintain proper adjustments on the belt(s) 5.
9. SHUTDOWN Normal Shutdown 1. Make certain unloading tubes are empty before stopping the unit. 2. Disconnect and lockout the power source before leaving the work area. Emergency Shutdown 1. Know how to shutdown the auger in case of an emergency. 2. Disconnect and lockout the power source. 3. Close bin well control gates. 4. Clear out as much grain from the auger and hopper as you can. CAUTION Never restart when under a full load. Starting unit under load may result in damage to the machine.
10. PARTS LIST 1. 6" Utility & Bulk Auger Parts 2. 8" Utility & Bulk Auger Parts 3.
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11. TROUBLESHOOTING Problem 1. The Auger is vibrating. 2. Capacity is too low. 3. The Auger plugs. Possible Cause Corrective Action 1. Damage can occur to the auger flighting, causing noise. Damage usually is caused from foreign material being run through the auger. 1. It may be necessary to remove the flighting for inspection. 2. Drive belt may be overtightened, putting head stub and flight in a bind. 2. Loosen the drive belts. 1. There may not be enough grain reaching the auger. 1.
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Limited Warranty The GSI Group, LLC. (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
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. GSI Group 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.
