GSI Group PNEG-1807CE, Installation Manual - Original Instructions

Page 1: ...PNEG 1807CE CE Compliant 16 24 Bucket Elevator Platform and Ladder X Series Installation Manual Original Instructions PNEG 1807CE Date 05 16 14 ...

Page 2: ...ler or installer This information should be filled out and kept on record Equipment Information Model ___________________________________________ Serial ____________________________________ Date Purchased ____________________________________ Dealer Distributor Name and Phone ___________________________________________ Material Handling 1004 E Illinois St Assumption IL 62510 Phone 1 217 226 4421 ...

Page 3: ...atform Cross Channel to Rest Platform Mounting Channels 39 Ladder Support 44 Chapter 8 16 24 Head Platform Assembly 45 Attach Main Support Channels to Lower Head 45 Install Deck A and Toe Board 46 Install Deck A to Main Support Channels 47 Install Deck C and Toe Board 49 Install Deck C to Main Support Channels 50 Install Deck E 51 Install Adapter Bracket for 16 Platforms 53 Install Hatch Filler Pl...

Page 4: ... shortage on the bill of lading to justify their claim to the transport company THIS MANUAL SHOULD BE CONSIDERED a permanent part of your equipment and should be easily accessible when needed This warranty provides you the assurance that the company will back its products when defects appear within the warranty period In some circumstances the company also provides field improvements often without...

Page 5: ...ay attention to these sections Failure to read this manual and its safety instructions is a misuse of the equipment and may lead to serious injury or death DANGER WARNING CAUTION NOTICE 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 situatio...

Page 6: ...e consulted before installations are made 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 an...

Page 7: ... 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 We...

Page 8: ...latform and Ladder X Series 3 Decal Location Chapter 3 Decal Location DO NOT EXCEED PLATFORM LOAD LIMIT DC 2146 Excessive load will damage platform and cause platform to fall Load limit 500 LBS 2 25 kN DANGER 500 lbs 2 25 kN Injury or death will result ...

Page 9: ...nual particular attention is given to the initial orientation of channels and aligning bolt holes Failure to complete these initial steps correctly will significantly impede the assembly and installation of the bucket elevator platforms 4 Decking and Toe Boards Decking is etched with alpha characters to assist with orienting decks and aligning holes for connections Decking connections should be fi...

Page 10: ...de to installation layout The exact assembly may vary due to the unique nature of each bucket elevator Ladder and Platform Layout for European CE Compliance To comply with European Directives for CE marking the maximum rest platform spacing is reduced in accordance with EN ISO14122 4 2004 Please follow the recommended layouts given below See Figures 5A 5G on Pages 10 16 Figure 5A 14 4 26 m Section...

Page 11: ...ction 1636XRLAD60CE 1636XWLAD60CE 1636XRLAD70CE 1636XWLAD70CE 1636XRLAD80CE 1636XWLAD80CE RP RP RP RP RP RP RP RP HP HP HP Key HP Head Platform RP Rest Platform 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 10 3 0 m Section 14 4 26 m Sect...

Page 12: ...ction 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 10 3 0 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 10 3 0 m Section 10 3 0 m Section 10 3 0 m Section 1636XRLAD90CE 1636XWLAD90CE 1636XRLAD100CE 1636XWLAD100CE 1636XRLAD110CE 1636XWLAD110CE RP RP RP RP RP RP RP RP RP RP RP RP Key HP Head Platform RP Rest Platform HP HP H...

Page 13: ...ection 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section RP RP RP R...

Page 14: ...4 4 26 m Section 10 3 0 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 1636XRLAD150CE 1636XWLAD150CE RP RP RP 1636XRLAD160CE 1636XWLAD160CE RP Key HP Head Platform RP Rest Platform RP RP RP 14 4 26 m Section 10 3 0 m Section RP 14 4 26 m Section 10 3 0 m Section RP 14 4 26 m Section 10 3 0 m Section RP 14 4 26 m Section 10 3 0 m Section RP 14 4 26 m Section 10 3 0 m Section 14 4 26 ...

Page 15: ... 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 14 4 26 m Section RP RP RP RP RP RP RP 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Sec...

Page 16: ... 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section RP RP RP RP RP RP RP 1636XRLAD200CE 1636XWLAD200CE 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Section 10 3 0 m Section 14 4 26 m Sectio...

Page 17: ...runking 1 On the NON LADDER SIDE attach tie angle to the trunking using 1 2 x 1 bolts See Figure 6A below and Figure 6B on Page 18 a For 16 Boot Tie Angle With lip of tie angle up and outward align tie angle so that it extends beyond the trunking at each end See Figure 6A Figure 6A 16 Boot Tie Angle Ref Part Description A BECT1640FX Type X Tie Angle B S 7935 12 x 1 Bolt Down leg Up leg 16 Boot Tie...

Page 18: ... For 24 Boot Tie Angle With lip of tie angle up and outward align edge of tie angle to edge of trunking at down leg end With this alignment tie angle will extend slightly beyond the edge of trunking at the up leg end as shown in Figure 6B Figure 6B 24 Boot Tie Angle Ref Part Description A BECT1640FX Type X Tie Angle B S 7935 12 x 1 Bolt Down leg Up leg 24 Boot Tie Angle ...

Page 19: ...ing the holes indicated based on bucket elevator size in Figure 6C attach ladder support brackets to boot tie angle using 3 8 x 1 hex bolts Remember to double check if the ladder should start on the up leg side or the down leg side See Figures 6C 6H on Pages 19 24 a 16 Down leg boot bracket Use 3 8 x 1 hex bolts to attach the ladder support brackets to the boot tie angle using the holes indicated ...

Page 20: ... Section Continued b 16 Up leg boot bracket Use 3 8 x 1 hex bolts to attach the ladder support brackets to the boot tie angle using the holes indicated in Figure 6D Note the outer bracket attaches to the tie angle with two 2 empty holes remain on the outside Figure 6D 16 Boot Bracket Up Leg Ref Part Description C S 7469 3 8 x 1 Hex Bolt Down leg Up leg 16 Boot Bracket Up Leg ...

Page 21: ...on Continued c 24 Down leg boot bracket Use 3 8 x 1 hex bolts to attach the ladder support brackets to the boot tie angle using the holes indicated in Figure 6E Note the outer bracket will have two 2 empty holes to the outside of the connection at the tie angle Figure 6E 24 Boot Bracket Down Leg Ref Part Description C S 7469 3 8 x 1 Hex Bolt Down leg Up leg 24 Boot Bracket Down Leg ...

Page 22: ...t Ladder Section Continued d 24 Up leg boot bracket Use 3 8 x 1 hex bolts to attach the ladder support brackets to the boot tie angle using the holes indicated in Figure 6F Note the outer bracket uses the two 2 outer most set of holes on the tie angle Figure 6F 24 Boot Bracket Up Leg Ref Part Description C S 7469 3 8 x 1 Hex Bolt Down leg Up leg 24 Boot Bracket Up Leg ...

Page 23: ...r Platform and Ladder X Series 23 Install Boot Ladder Section 1 Trim a 10 ladder section to sit so that the first ladder rung is 12 from the ground See Figure 6G Figure 6G Ref Description A Cut this section of the ladder so bottom rung of the ladder is 12 from the ground Trim Ladder to Ground ...

Page 24: ... x 1 hex bolts through the bottom most set of holes 3 Attach the next ladder section to the ladder brackets using 1 2 x 1 hex bolts through the top set of holes See Figure 6H Figure 6H 4 Secure the bottom of the ladder to the boot or ground NOTE Bracket for this step is not included Ref Part Description B LAD1648TLH Trunk Support Bracket L H Side C LAD1648TRH Trunk Support Bracket R H Side D S 793...

Page 25: ...each elevator size Tie angle must be installed at every trunking seam NOTE The bottom tie angle will be replaced with a rest platform tie angle GECT1640FCRPX2 where a rest platform is to be installed See Figure 6I Figure 6I Tie Angle Installation Locations Ref Part Description A BECT1640FX 16 24 Type X Trunking Tie Angle A GECT1640FX B S 7935 1 2 x 1 Hex Bolt Tie Angle Installation Locations Down ...

Page 26: ...atform and Ladder X Series Tie Angles to Trunking Continued Figure 6J 16 Bucket Elevator Tie Angles to Trunking Bolt Locations Ref Part Description A BECT1640FX 16 24 Type X Trunking Tie Angle A GECT1640FX C Up Leg Set D Down Leg Set E Install Bolt Here Ladder side Non ladder side 16 Bolt Locations ...

Page 27: ...iant 16 24 Bucket Elevator Platform and Ladder X Series 27 Tie Angles to Trunking Continued Figure 6K 24 Bucket Elevator Tie Angles to Trunking Bolt Locations Ref Description C Up Leg Set D Down Leg Set E Install Bolt Here 24 Bolt Locations Ladder side Non ladder side ...

Page 28: ...h 3 8 bolts 3 Mount the lower right hand and lower left hand ladder support brackets to the bottom tie angle with 3 8 bolts 4 Secure the flanges of the ladder brackets together with 3 8 x 1 hex bolts NOTE You will only use one set of ladder brackets either the up leg set or the down leg set Figure 6L Ladder Support Bracket Parts Ref Part Description A LAD1648TLH1 Bottom Trunk Support Bracket L H S...

Page 29: ...ies 29 Ladder Support Brackets Continued Figure 6M 16 Ladder Bracket Location for Up Leg Figure 6N 16 Ladder Bracket Location for Down Leg Ref Part Description F BECT1640FX 16 Type X Trunking Tie Angle F GECT1640FX G S 7469 3 8 x 1 Bolt H S 968 3 8 Flange Nut 16 Ladder Brackets on Up Leg 16 Ladder Brackets on Down Leg ...

Page 30: ...Series Ladder Support Brackets Continued Figure 6O 24 Ladder Bracket Location for Up Leg Figure 6P 24 Ladder Bracket Location for Down Leg Ref Part Description F BECT1640FX 24 Type X Trunking Tie Angle F GECT1640FX G S 7469 3 8 x 1 Bolt H S 968 3 8 Flange Nut 24 Ladder Brackets on Up Leg 24 Ladder Brackets on Down Leg ...

Page 31: ... to the ladder brackets using 1 2 x 1 hex bolts S 7935 See Figure 6Q Figure 6Q Ref Part Description A LAD1648TLH1 Bottom Trunk Support Bracket L H Side B LAD1648TLH2 Top Trunk Support Bracket L H Side C LAD1648TRH1 Bottom Trunk Support Bracket R H Side D LAD1648TRH2 Top Trunk Support Bracket R H Side E 10FOOTRFX or 10FOOTX 10 Ladder Section F S 7935 1 2 x 1 Hex Bolt G Ladder Section ...

Page 32: ...NEG 1807CE CE Compliant 16 24 Bucket Elevator Platform and Ladder X Series Safety Cage Installation Safety cage entrance must be installed to the ladders within 7 8 from the ground or platform deck See Figure 6R Figure 6R Ref Description A Safety Cage ...

Page 33: ...section 1 Locate safety cage hoops LDR BCKTBHP along the ladder rails where the safety cage hoops will be installed NOTE The end hoops of a 10 section are spaced 4 from the two 2 middle hoops which are spaced 2 apart See Figure 6S for spacing See Figure 6S Figure 6S 10 Safety Cage Section Ref Part Description A LDR 10FTCAGE 10 Safety Cage Strap B LDR 3FTCAGE 3 Safety Cage Strap C 3 Safety Cage Ent...

Page 34: ...levator Platform and Ladder X Series Install Safety Cage Continued 2 Attach safety cage hoops to ladder using 1 2 x 1 bolts and nuts See Figure 6T Figure 6T Ref Part Description D S 7935 1 2 x 1 HHCS Bolt E S 8506 1 2 Flange Nut F 10FOOTRFWX or 10FOOTX 10 Ladder Section G Safety Cage Hoop ...

Page 35: ... hoops using 5 16 x 3 4 bolts and nuts NOTE Bolt heads should be to the inside of the hoop See Figure 6U Figure 6U Ref Part Description A LDR 10FTCAGE 10 Safety Cage Strap B LDR 3FTCAGE 3 Safety Cage Strap H LDR BCKTBHP Safety Cage Hoop Entrance I S 7645 5 16 x 3 4 Bolt J S 10268 5 16 Flange Nut K LDR BCKTHOOP Safety Cage Hoop Standard L Bottom Holes M Top Holes N Leave these hole open for vertica...

Page 36: ...icated for the bucket elevator size being installed See Figure 7A NOTE Bolt hole starting location on left side of tie angle is marked with the bucket size Figure 7A Tie Angle with Etched Numbers Figure 7B 16 Rest Platform Tie Angle Bolt Locations Ladder Side Ref Part Description Ref Part Description A GECT1640FCRPX2 16 24 Rest Platform Tie Angle C S 8506 1 2 Flange Nut B S 7935 1 2 x 1 Bolt D Hol...

Page 37: ...ie Angles to Bucket Elevators Continued Figure 7C 24 Rest Platform Tie Angle Bolt Locations Ladder Side Ref Part Description A GECT1640FCRPX2 16 24 Rest Platform Tie Angle B S 7935 1 2 x 1 Bolt C S 8506 1 2 Flange Nut E Hole Marked 24 16 Use Side Marked 24 24 Tie Angle Bolt Locations Ladder Side Down leg Up leg ...

Page 38: ...ngles to Bucket Elevators Continued Figure 7D 16 Rest Platform Tie Angle Bolt Locations Non Ladder Side Ref Part Description A GECT1640FCRPX2 16 24 Rest Platform Tie Angle B S 7935 1 2 x 1 Bolt C S 8506 1 2 Flange Nut D Hole Marked 24 16 Use Side Marked 16 16 Tie Angle Bolt Locations Non Ladder Side Down leg Up leg ...

Page 39: ...ngles to Bucket Elevators Continued Figure 7E 24 Rest Platform Tie Angle Bolt Locations Non Ladder Side Ref Part Description A GECT1640FCRPX2 16 24 Rest Platform Tie Angle B S 7935 1 2 x 1 Bolt C S 8506 1 2 Flange Nut E Hole Marked 24 16 Use Side Marked 24 24 Tie Angle Bolt Locations Non Ladder Side Down leg Up leg ...

Page 40: ...ie angles using 1 2 x 1 bolts Bolt hole locations for 16 24 bucket elevator will be the same See Figure 7F Figure 7F Bolt hole locations for 16 24 rest platform mounting channels to tie angles Ref Part Description A GECT1640FCRPX2 16 24 Rest Platform Tie Angle B S 7935 1 2 x 1 Bolt C S 8506 1 2 Flange Nut D RP1636MCX 16 36 Rest Platform Mounting Channel 16 24 Tie Angle Bolt Locations Mounting Chan...

Page 41: ...platform cross channels between the rest platform mounting channels and connect those using 3 8 x 3 4 hex bolts See Figure 7G Figure 7G Rest Platform Cross Channel to Rest Platform Mounting Channels Ref Part Description A RP1636CCX Rest Platform Cross Channel B RP1636MCX Rest Platform Mounting Channel C S 7105 3 8 x 3 4 Hex Bolt D S 968 3 8 Flange Nut Rest Platform Channels ...

Page 42: ...sing 3 8 x 3 4 hex bolts Bolt heads should be installed against the deck plate See Figure 7H NOTE The deck plate can be mounted on either the right or left side but the flange must be mounted towards the opening Figure 7H Deck Plate Ref Part Description A RP1636CCX Rest Platform Cross Channel B RP1636MCX Rest Platform Mounting Channel C S 7105 3 8 x 3 4 Hex Bolt D S 968 3 8 Flange Nut E RP1636FDP ...

Page 43: ...Install the handrail platform posts to the rest platform mounting channels and rest platform channels using six 6 5 16 x 3 4 flanged hex bolts for each post four 4 bolt to the front and two 2 on the side See Figure 7I Figure 7I Ref Part Description G HP1648HCP Handrail Platform Posts H S 6606 5 16 x 3 4 Flange Bolt I S 10268 5 16 Flange Nut Rest Platform Handrail Posts ...

Page 44: ...ping handrail that can be adjusted to the correct length between the posts Two 2 of the small intermediate handrails and two 2 of the large intermediate handrails will need to be cut to fit The starting length of each rail is 36 Cut 18 off the end of each rail so the final length of each rail is 18 See Figure 7J Figure 7J Ref Description J Cut Two 2 Small Intermediate Rails K Cut Two 2 Large Inter...

Page 45: ...y sliding it out to the correct length 6 After cutting the two 2 large and two 2 small intermediate handrails slide them to the correct length and install them to the handrail posts on the short sides of the platform using 5 16 x 3 4 flanged hex bolts See Figure 7K Figure 7K Ref Part Description H S 6606 5 16 x 3 4 Flange Bolt I S 10268 5 16 Flange Nut L LDR 4087 Large Intermediate Handrail M LDR ...

Page 46: ...latform Mounting Channels Continued 7 Connect the front rest platform handrails and the side rest platform handrails to the handrail platform post using 5 16 x 2 hex bolts See Figure 7L Figure 7L Ref Part Description I S 10268 5 16 Flange Nut O RP1648HF 57 1 2 Handrail P RP1648HS 30 1 Handrail Q S 7877 5 16 x 2 Flange Bolt Handrails ...

Page 47: ...ts Braces should be attached to the outside of the platform post and to the inside of the mounting and cross channels NOTE Safety cage bars LDR 517BE are used as platform braces tie angle braces through out this installation Bolt heads should be on inside of platforms See Figure 7M Figure 7M Ref Part Description A RP1636CCX Rest Platform Cross Channel B RP1636MCX Rest Platform Mounting Channel H S...

Page 48: ...l ladder support brackets to the rest platform cross channel using 3 8 x 3 4 hex bolts 10 Attach ladders to ladder support brackets using 1 2 x 3 4 hex bolts See Figure 7N Figure 7N Ref Part Description A RP1636CCX Rest Platform Cross Channel C S 7105 3 8 x 3 4 Hex Bolt S LAD1648BLH Ladder Support L H Bracket T LAD1648BRH Ladder Support R H Bracket U S 7932 1 2 x 3 4 Hex Bolt ...

Page 49: ...form and Ladder X Series 49 Ladder Support Figure 7O Ref Part Description A 14FOOTRFWX or 14FOOTX 14 Ladder Section B RP1648LS Ladder Support Rest Platform C RP1648HSX 48 HSP Sides 43 605 Outside Handrail D S 10136 U Bolt 1 4 20 x 1 1 2 NOTE Drill holes where necessary ...

Page 50: ...d if the initial orientation of the channels is done correctly Please take time to confirm that the orientation of these early elements is correct before you begin to assemble the decking on to the channels Attach Main Support Channels to Lower Head 1 Place lower head section on solid and level surface 2 At both the Discharge End and Up Leg End orient the channels so that lip channel openings face...

Page 51: ... punch as needed for alignment connect Deck A to the side toe board with 3 8 flange nuts S 10028 and 3 8 x 3 4 flange bolts S 7105 Torque to standard specifications See Figure 8B a Deck hole A1 to toe board hole A1 b Deck hole A2 to toe board hole A2 c Deck hole A3 to toe board hole A3 NOTE Due to snug fit slide side toe board in place before securing Deck A or any subsequent decking Figure 8B Dec...

Page 52: ...8 x 1 carriage bolts S 3585 and 3 8 flange nuts S 10028 connect Deck A to main support channel IMPORTANT Connect every hole See Figure 8C Figure 8C Deck A to Support Channels Ref Part Description A S 3585 3 8 x 1 Carriage Bolt B S 10028 3 8 Flange Nut C HSP16001X Main Support Channel D NOTE 16 will use this row of holes 16 24 Deck A to Support Channels DECK A ...

Page 53: ...o Deck A This piece installs on the underside of Deck A and extends the width of the deck from edge to edge Using 3 8 flange nuts S 10028 and 3 8 x 3 4 flange bolts S 7105 connect the hatch deck support bar to Deck A kick plate and through the holes labeled A2 on Deck A and side toe board Torque to standard specifications See Figure 8D Figure 8D Deck A HP Deck Supports Ref Part Description E HP162...

Page 54: ...eck C to side toe board using 3 8 x 1 carriage bolts S 3585 with flange nuts S 10028 and torque to standard specifications See Figure 8E a Deck hole C1 to toe board hole A3 b Deck hole C2 to toe board hole A4 c Deck hole C3 to toe board hole A1 NOTE Due to snug fit slide side toe board in place before securing Deck C or any subsequent decking Figure 8E 24 Deck C Toe Board Ref Part Description A S ...

Page 55: ...ls on the underside of Deck C and extends the width of the deck from edge to edge a Using 3 8 flange nuts S 10028 and 3 8 x 3 4 flange bolts S 7105 connect the hatch deck support bar to the kick plate attached to Deck C and to the hole labeled A2 on decking nearest the side toe board and lower head Torque to standard specifications See Figure 8G Figure 8F 16 Deck C to Support Channels Figure 8G De...

Page 56: ...l attach to Deck A Deck C both side toe boards and the main support channel 2 Using a punch as needed for alignment connect Deck E to the side toe board using 3 8 x 1 carriage bolts S 3585 with flange nuts S 10028 Torque to standard specifications See Figure 8H a Deck E hole E1 to Deck A hole A5 b Deck E hole E2 to Deck A hole A4 c Deck E hole E3 to Deck C hole C5 d Deck E hole E4 to Deck C hole C...

Page 57: ...T Connect every hole See Figure 8I 4 Align Deck E so the flanges are to the outside of Deck A and Deck C Using 3 8 x 1 bolts S 7105 and 3 8 flange nuts S 10028 connect Deck E to toe boards and flanges of Deck A and Deck C See Figure 8J Figure 8I 24 Deck E to Support Channels Ref Part Description A S 3585 3 8 x 1 Carriage Bolt B S 10028 3 8 Flange Nut C Deck E Flanges Outside Deck A and Deck C DECK...

Page 58: ...sembly 58 PNEG 1807CE CE Compliant 16 24 Bucket Elevator Platform and Ladder X Series Install Deck E Continued Figure 8J 24 Deck E Ref Part Description B S 10028 3 8 Flange Nut D S 7105 3 8 x 1 Bolt DECK C DECK A Deck E DECK E ...

Page 59: ...et to cross deck support channel at the up leg end of the platform between Deck A and side toe board and between Deck C and side toe boards See Figure 8K 2 Attach deck adapter bracket HP1624AB to Deck A Deck C and toe boards using four 4 3 8 x 1 bolts S 7105 and nuts See Figure 8L Figure 8K Deck Adapter Bracket to Channel Figure 8L Deck Adapter Bracket to Decks Ref Part Description A S 3585 3 8 x ...

Page 60: ... Hatch Filler Plate 1 Using 3 8 x 1 carriage bolts S 3585 and 3 8 flange nuts S 10028 install the hatch filler plate HP1624HDF over the un used opening See Figure 8M Figure 8M Deck Plate Ref Part Description A HP1624HDF Hatch Deck Filler Plate B S 3585 3 8 x 1 Carriage Bolt C S 10028 3 8 Flange Nut Hatch Filler Plate ...

Page 61: ...ts to Deck E 1 Attach two 2 head platform rail supports HP1648HSH to Deck E as shown using 3 8 x 1 bolts S 7105 and 3 8 flange nuts S 10028 See Figure 8N Figure 8N 24 Deck E Rail Support Brackets Ref Part Description A HP1648HSH Head Platform Rail Support B S 7105 3 8 x 1 Bolt C S 10028 3 8 Flange Nut Deck E Rail Support Brackets ...

Page 62: ...m edges of W corner posts HP1648HWP with bottom edge of platform decking 2 Attach each W corner post to decking using 5 16 x 3 4 flange bolts S 6606 and 5 16 flange nuts S 10268 Torque to standard specifications See Figure 8O Figure 8O Ref Part Description A HP1648HWP Head Distributor W Corner Post B S 6606 5 16 x 3 4 Flange Bolt C S 10268 5 16 Flange Nut W Corner Posts ...

Page 63: ...ntersects with Decks A and C Use 5 16 hex flange nuts S 10268 and 5 16 x 3 4 flange bolts connect the platform posts to the decking NOTE Rail support braces should be between the posts 2 At the discharge end align platform posts as described and attach one platform posts HP1648HCP to the edge of Deck C and Deck A nearest the lower head See Figure 8P Figure 8P Middle End Posts Ref Part Description ...

Page 64: ...ck C install platform post HP1648HCP as shown and connect to the decking through a rail support HP1648HSH Use 5 16 hex flange nuts S 10268 and 5 16 x 3 4 flange bolts to connect the rail supports and platform posts to the decking See Figure 8Q Figure 8Q Deck A Post Bracket Ref Part Description A HP1648HCP Platform Post D HP1648HSH Head Platform Handrail Support Platform Post ...

Page 65: ...ate handrail It is critical that large and small rails be properly identified in advance Rails are cut to size and cutting the wrong rail or to the wrong length will prevent proper installation See Figure 8R Figure 8R Intermediate Handrails Ref Part Description A LDR 4088 Small Intermediate Handrail B S 6606 5 16 x 3 4 Flange Bolt C S 10268 5 16 Hex Flange Nut D LDR 4087 Large Intermediate Handrai...

Page 66: ... using nuts S 10268 and bolts S 6066 d Torque to standard specifications Figure 8S 21 Telescoping Handrail 3 Trim two 2 large and two 2 small rails by 4 each so remaining length of each rail both small and large is 32 See Figure 8T a Install these rails across the up leg and down leg sides of the platform as shown b Insert one small rail inside of one large rail telescope the joined rails from the...

Page 67: ...16 x 2 bolts S 7877 Torque to standard specifications See Figure 8U 2 Attach four 4 hatch handrails HP1648HHS one on each side of the middle drive at each end of the platform Handrails will fit without adjustment Connect using 5 16 nut S 10268 and 5 16 x 2 bolts S 7877 Torque to standard specifications 3 Two 2 59 183 far hatch handrails HP1624HFH and two 2 54 65 handrails HP1624HNH opposite each o...

Page 68: ...h of the four 4 W corner posts HP1648HWP attach two 2 tie braces safety cage bar LDR 5171BE from the lower half of the post to the deck kick plate using 5 16 nuts S 10268 and 5 16 x 3 4 flange bolts S 6606 See Figure 8V NOTE Tie braces may be oriented on the inside or outside of the decking kick plates based upon installer preference Figure 8V Safety Cage Cross Brace NOTE See Page 69 for hatch doo...

Page 69: ...Hatch 1 Attach hatch hinge HP1624HH to the hatch deck door HP1624HDD Orient hinge so that it opens the desired direction See Figure 9A Fasten using 3 8 x 1 carriage bolts hardware Figure 9A Ref Part Description A HP1624HDD Hatch Deck Door B HP1624HH Hatch Hinge C S 3585 3 8 x 1 Carriage Bolt D S 10028 3 8 Hex Nut ...

Page 70: ...upport HP1624HS to the bottom of the hatch door using 3 8 x 1 carriage bolts and nuts See Figure 9B 3 Fasten peak cap handle PR 331 to the bottom of the hatch door using 3 8 x 1 carriage bolts and nuts Figure 9B Ref Part Description A HP1624HDD Hatch Deck Door C S 3585 3 8 x 1 Carriage Bolt D S 10028 3 8 Hex Nut E RP 331 Peak Cap Handle ...

Page 71: ... the hatch door and fasten with the 6 flange nut S 10133 Figure 9C 6 Align holes on the hatch hinge with holes along the deck opening closest to the kick plates Install the hatch door to the decking using 3 8 x 3 4 bolts S 7105 and nuts See Figure 9D Figure 9D Hatch Deck Door Magnets Ref Part Description Ref Part Description A HP1624HDD Hatch Deck Door G S 2010 Nylock Nut 10 24 ZN Grade 2 F HP1648...

Page 72: ...t 1 2 flat washer and pipe clamp Fasten with 3 8 nut See Figure 9E 8 Attach pipe clamp around intermediate handrail and fasten loosely with bolts Open hatch plate and slide clamp along handrail until it lines up with the magnets on the hatch plate Tighten clamp to rail Figure 9E Ref Part Description J HP1648LMM Magnet Mount Hatch Bracket K S 10139 Pipe Clamp 1 O D 3 8 Holes with Screw L 3 8 Nut M ...

Page 73: ...n both of the 16 24 long clamp clips and fasten all three 3 together using four 4 1 2 x 1 bolts and nuts This will create the clamp strut assembly 3 Assemble the clamp band weldment clamp channel and clamp strut assembly at one time around the trunking Place clamp rod weldment assembly around the trunking leg and line up holes on 16 24 long clips and clamp channel with the outside set of holes on ...

Page 74: ...d of the long clamp clips and the remaining clamp strut Fasten all five 5 parts together using four 4 1 2 x 1 bolt and nuts Tighten finger tight This will make up the brace channel assembly 3 Assemble the clamp rod weldment clamp channel and brace channel assembly at same time around the trunking Place clamp rod weldment assembly around the trunking leg and line up holes on 16 24 long clips and cl...

Page 75: ... Assemble the 16 24 long clamp assembly clamp channel and clamp rod assembly at same time around the trunking Place clamp rod weldment assembly around the trunking leg and line up holes on 16 24 long clips and clamp channel with the outside set of holes on the clamp rod weldment Fasten all three 3 together using six 6 1 2 x 1 bolts and nuts See Figure 10C Figure 10C Ref Part Description A GSB30210...

Page 76: ... 4 1 2 x 1 bolts and nuts Attach remaining clamp strut to the end of the 16 24 clamp clip Tighten only finger tight See Figure 10D 3 Assemble the clamp rod weldment clamp channel and brace channel assembly at same time around the trunking Place clamp rod weldment assembly around the trunking leg and line up holes on 16 24 long clips and clamp channel with the outside set of holes on the clamp rod ...

Page 77: ...our 4 1 2 x 1 bolts and nuts See Figure 10E 3 Assemble the external platform support DSP1648EPS to the end of the three 3 cross supports using six 6 1 2 x 1 bolts and nuts See Figure 10F on Page 78 NOTE For 24 installation the lower knee brace will use the second hole on the brace and the second hole up from the bottom on the brace channel See Figure 10G on Page 78 Figure 10E Distributor Platform ...

Page 78: ...10G 24 Distributor Platform Knee Brace Ref Part Description Ref Part Description B DSP1648CS Distributor Platform Cross Support F S 8506 1 2 Hex Flange Nut E S 7935 1 2 x 1 Bolt G DSP1648EPS Distributor External Platform Support Distributor External Platform Support NOTE Right hand shown Distributor Platform Knee Brace Ref Part Description C GSB30147 Brace Channel D GSB30148 Knee Brace E S 7935 1 ...

Page 79: ...e of end toe board along the bottom of decking Connect end toe board to decking using 1 2 x 1 bolts and nuts See Figure 10I on Page 80 5 Install the corner W post at the same time as the toe board filler plate Attach toe board filler plate to the decking toe boards located across from the entrance Attach the flat end first using two 2 5 16 x 3 4 flange bolts and nuts Then line up the holes of the ...

Page 80: ...ure 10I Figure 10J 16 Distributor Platform Toe Board Ref Part Description Ref Part Description E DSP1648DEX 18 Decking G S 7935 1 2 x 1 Bolt F GSB36256 Toe Board Short Side H S 8506 1 2 Hex Flange Nut Ref Part Description G S 7935 1 2 x 1 Bolt H S 8506 1 2 Hex Flange Nut I GSB30136X End Toe Board NOTE Right hand shown Distributor Deck Toe Board NOTE Right hand shown ...

Page 81: ... X Series 81 Assemble Decking and W Corner Post Continued Figure 10K Distributor Platform Corner Post Ref Part Description J HP1648HWP Head Distributor W Post K GSB30142X Toe Board Filler Plate L S 6606 5 16 x 3 4 Flange Bolt M S 10268 5 16 Hex Flange Nut Distributor Deck Corner Post NOTE Right hand shown ...

Page 82: ... nuts 3 Attach side posts HP1648HP to the decking at the entrance to the platform using two 2 5 16 x 3 4 flange bolts and nuts per post See Figure 10L 4 Install distributor handrail support to the side post on the inside located closest to the trunking through holes 3 and 4 counting from the top of the post Use two 2 5 16 x 3 4 flange bolts and nuts to fasten in place See Figure 10L Figure 10L Ref...

Page 83: ...mediate rail to fit at entrance Adjust all rails to the proper length and install to the posts using the 5th hole down from the top Fasten in place using two 2 5 16 x 3 4 flange bolts and nuts per each telescoping tube See Figure 10M Figure 10M Ref Part Description Ref Part Description A LDR 4087 Large Intermediate Handrail D S 10268 5 16 Flange Nut B LDR 4088 Small Intermediate Handrail E Cut Sma...

Page 84: ... cage bars LDR 5171BE are used as tie braces in this installation 1 Install safety bar cross supports from the decking toe board to the rail posts using two 2 5 16 x 3 4 flange bolts and nuts per each cross bar support See Figure 10N Figure 10N Ref Part Description A LDR 5171BE Braces B S 6606 5 16 x 3 4 Flange Bolt C S 10268 5 16 Flange Nut NOTE Right hand shown ...

Page 85: ...rails to the posts using four 4 5 16 x 3 4 flange bolts and nuts per handrail See Figure 10O Figure 10O Ref Part Description Ref Part Description A HP1648HDH 64 126 Handrail E DSP1648HNT 43 2 Handrail B S 7877 5 16 x 2 Bolt F DSP1648HSSG 10 5 Handrail C S 10268 5 16 Flange Nut G HP1624HFH 59 479 Handrail D DSP1648HIP 45 2 Handrail NOTE Right hand shown ...

Page 86: ...orm post using 5 16 hardware Attach safety gate assembly to intermediate platform door bracket using 5 16 bolt S 1196 5 16 flat washer S 845 and 5 16 flange nut S 10268 Attach intermediate platform door bracket to two 2 safety gate side posts HP1648HP using 5 16 bolt S 1196 5 16 flat washer S 845 and 5 16 flange nut S 10268 See Figure 10P Figure 10P Ref Part Description A S 1196 5 16 Bolt B S 845 ...

Page 87: ...ESIGN OF SUCH PRODUCTS GSI shall not be liable for any direct indirect incidental or consequential damages including without limitation loss of anticipated profits or benefits The sole and exclusive remedy is set forth in the Limited Warranty which shall not exceed the amount paid for the product purchased This warranty is not transferable and applies only to the original end user GSI shall have n...

Page 88: ...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 com Copyright 2014 by GSI Group Printed in the USA CN 312209 GSI is a worldwide brand of AGCO Corporation ...