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Chapter 2: Introduction

Uncrating and Inspection

What You Should Know

CAUTION

Use proper lifting equipment when lifting or moving the mixer. Failure to do so can
lead to personal injury and equipment damage.

• Transportation and moving should only be performed by trained personnel.

• Improper handling can result in misalignment of the machine main shaft with the cylinder and end

plates.

• Observe local safety practices and procedures.

NOTE:

1. After uncrating your mixer, check for shipping damage and report any damage

immediately to the carrier and to GSI. Please make sure that all parts are accounted
for.

2. If the mixer is not to be installed immediately, make sure to store it in a clean, dry

location that is protected from extreme temperature conditions.

3. Improper motor storage will result in reduced reliability and even motor failure.

18

PNEG-2309

Horizontal Fertilizer Mixer

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Содержание PNEG-2309

Страница 1: ...Horizontal Fertilizer Mixer Installation and User Manual PNEG 2309 Version 1 0 Date 12 03 20 PNEG 2309...

Страница 2: ...tions photos and specifications in this manual are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice 2 PNEG 2309 Hor...

Страница 3: ...le Installation 29 Installing the Torque Arm Gear Reducer 29 Installing the Torque Arm and Turnbuckles 34 Installing the Motor Mounts and Motors 36 Installing the Sheaves and Belts 38 Belt Tension Adj...

Страница 4: ...NOTES 4 PNEG 2309 Horizontal Fertilizer Mixer...

Страница 5: ...ired Unqualified persons must stay out of the work area at all times Alterations must not be made to the equipment Alterations can produce dangerous situations resulting in SERIOUS INJURY or DEATH Thi...

Страница 6: ...mbol indicates an imminently hazardous situation which if not avoided will result in serious injury or death This symbol indicates a potentially hazardous situation which if not avoided can result in...

Страница 7: ...tructions 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 r...

Страница 8: ...ocal codes National Electrical Code for the US Canadian Electric Code or EN60204 along with applicable European Direc tives for Europe Lock out power source before making adjustments cleaning or maint...

Страница 9: ...welding or heating ST 0043 2 Fall Hazard Ladders stairways and platforms are for use by competent and trained personnel only Do not allow children or other unauthorized persons to have access to the...

Страница 10: ...ts or gases Check the atmosphere for harm ful gases or vapors with a suitable gas analyzer and make sure levels are safe before entering Do not smoke or use naked flames Lock out and tag out power sup...

Страница 11: ...eep all guards and covers in place at all times Lock out power source before making adjustments cleaning or maintaining equipment ST 0088 1 Stay Clear of Moving Parts Entanglement in drop gate operati...

Страница 12: ...ls on your equipment are safety indicators which must be carefully read and understood by all personnel involved in the installation operation service and maintenance of the equipment Figure 1 1 Safet...

Страница 13: ...l Warning Rotating Parts B Inside of belt guard covers DC 2469 Decal Danger Missing Guard Rotating Parts C Top of bearing guard covers DC 2525 Decal Warning Rotating Shafts D On the tub to the left an...

Страница 14: ...rts F On top of inspection panels DC 2528 Decal Warning Confined Space Hazard G On top of inspection panels DC 2529 Decal Danger Mixing Paddles To replace a damaged or missing decal contact us to rece...

Страница 15: ...ff sheet that can be used to verify that all personnel have read and understood the safety instructions This sign off sheet is provided for your convenience and personal record keeping Date Employee N...

Страница 16: ...NOTES 16 PNEG 2309 Horizontal Fertilizer Mixer...

Страница 17: ...ely installed in the process 2 Always disconnect and lock out the power before any physical inspection or work is performed 3 If one of the safety decals is damaged or illegible contact GSI immediatel...

Страница 18: ...e main shaft with the cylinder and end plates Observe local safety practices and procedures NOTE 1 After uncrating your mixer check for shipping damage and report any damage immediately to the carrier...

Страница 19: ...mbient temperature and up to 5 000 altitude 2 For 8 Ton Reducer Thermal rating is 89 HP based on 95 F and below ambient temperature and up to 5 000 altitude Belt Drive Table 3 2 Belt drive technical d...

Страница 20: ...le stuffing box re packable both ends Two 4 7 16 Dodge ISAF drive bearings Two 3 15 16 Sealmaster idle bearings Discharge Two 16 x 91 air operated drop gates Two 6 x 42 intervents Motor and Drive Fina...

Страница 21: ...s NOTE The dimensions approximate shown below are for reference only Refer to the certified drawing provided with each mixer for actual dimensions Figure 3 1 4 Ton mixer dimensions Figure 3 2 8 Ton mi...

Страница 22: ...Chapter 3 Mixer Parts and Specifications Service Parts 4 Ton Mixer Figure 3 3 4 Ton mixer parts 22 PNEG 2309 Horizontal Fertilizer Mixer...

Страница 23: ...4 SS 15 FR 3461 Cylinder Guard Left Mixer 4T Top Left Panel 14 Ga SS 44 S 20223 Bolt HHCS 5 8 11 UNC x 2 1 2 304 SS 16 FR 3462 Cylinder Guard Left Mixer 4T Top Right Panel 14 Ga SS 45 S 7363 Nut Hex 5...

Страница 24: ...Chapter 3 Mixer Parts and Specifications Service Parts 8 Ton Mixer Figure 3 4 8 Ton mixer parts 24 PNEG 2309 Horizontal Fertilizer Mixer...

Страница 25: ...SS 16 FR 3448 Cylinder Guard Left Mixer 8T Right Panel 14 Ga SS 48 S 7363 Nut Hex 5 8 11 UNC 304 SS 17 FR 3449 Cylinder Guard Left Mixer 8T Top Left Panel 14 Ga SS 49 S 20229 Bolt HHCS 3 4 10 UNC x 2...

Страница 26: ...NOTES 26 PNEG 2309 Horizontal Fertilizer Mixer...

Страница 27: ...nstalling the Sheaves and Belts Belt Tension Adjustment Installing the Bearing Guards Installing the Limit Switches Hazard Monitoring Assembling the Mixer Halves Assemble the two mixer halves 71 toget...

Страница 28: ...lling the center cover 1 3 8 x 1 HHCS bolt S 7104 25 1 8 x 1 thick sponge sealant 14 3 8 flat washer S 7021 26 Center cover 21 3 8 flange nut S 8032 27 Tub 3 Install the chemical injection plate 28 on...

Страница 29: ...Reducer Below are general instructions please refer to the DODGE Instructions manual supplied with the reducer for all Dodge equipment What You Should Know WARNING Turn OFF and lock out or tag power...

Страница 30: ...e bolts to be threaded into the bushing 30 for future bushing and reducer removal Table 4 2 Minimum shaft length Mixer Reducer Size Minimum Shaft Length Minimum Distance from the Shaft Bearing A 4 Ton...

Страница 31: ...idth of the keyseat The keys are marked with a part number and some keys are also etched with THIS SIDE UP these markings should be showing on the top of the key when it is installed in the shaft keys...

Страница 32: ...up plate 7 Place the second tapered bushing 30 in position onto the drive shaft 31 and align the bushing 30 keyway with the shaft key 32 Align the unthreaded holes in the bushing 30 flange with the th...

Страница 33: ...AUTION Unit is shipped without oil Add proper amount of recommended lubricant before operating Failure to observe this precaution can result in damage to the equipment Refer to the DODGE Instructions...

Страница 34: ...adapter plates 35 and 1 x 5 hex bolt 5 to connect the torque arm assembly 36 with the tub 27 3 Tighten the torque arm 61 by turning the turnbuckle 62 Make sure the reducer is positioned correctly NOT...

Страница 35: ...nstalling the torque arm assembly 8 Ton mixer 3 5 8 x 2 hex bolt 24 1 hex nut S 240 4 1 x 3 1 2 hex bolt 27 Tub 5 1 x 5 hex bolt 33 Reducer 15 5 8 flat washer S 7400 35 Adapter plate 17 5 8 lock washe...

Страница 36: ...S 7400 37 Left angle support 17 5 8 lock washer S 3208 38 Right angle support 22 5 8 hex nut S 7363 2 Align the slots in the base plate 39 with the holes in the angle supports 37 and 38 and install us...

Страница 37: ...the 1 x 9 threaded rods 10 and secure with 1 hex nuts 24 Figure 4 15 Installing the motor mount plate with threaded studs 10 1 x 9 threaded rod BG 0099 39 Base plate 24 1 hex nut S 240 40 Motor mount...

Страница 38: ...S 7603 42 Belt guard bushing cover 14 3 8 flat washer S 7021 48 Belt guard assembly 21 3 8 flange nut S 8032 2 Install the belt guard bushing covers 42 to the angle supports 37 and 38 using 1 2 x 1 1...

Страница 39: ...to align the sheave bushings 44 with the notches in the hubs 4 Insert the screws 12 into the sheaves 45 or 46 that are opposite each other 5 Place keys 32 into keyways on the drive shafts 31 6 Align...

Страница 40: ...nstall the belt guard front cover 43 to the belt guard assembly 48 using 3 8 x 3 4 HHCS bolts 9 3 8 flat washers 14 and 3 8 flange nuts 21 Figure 4 22 Installing the belt guard assembly 9 3 8 x 3 4 HH...

Страница 41: ...ase equally at all four jack screws to maintain the shaft alignment 2 When the V belt tension is correct tighten the top nut on the jack screws to lock the motor base in position NOTE Refer to the Mix...

Страница 42: ...the bearing 50 and fasten to the tub 27 using 3 8 x 1 HHCS bolts 1 3 8 flat washers 14 and 3 8 flange nuts 21 in the middle slot 3 Install the bearing guard bottom plate 51 to the bearing guards 49 a...

Страница 43: ...es on each cylinder 2 Adjust the position of the bracket assemblies so one sensor is triggered when the air cylinder is 3 8 to 1 2 from the extended position and the other sensor is triggered when the...

Страница 44: ...ing guard 80 contains a knockout section 78 intended for the installation of a shaft speed sensor NOTE The shaft end is threaded 1 2 13 to accommodate a threaded shaft speed sensor However a magnetic...

Страница 45: ...ller batches until this is accomplished to keep from drawing excessive horsepower 4 The mixer should be installed on solid footings Failure to do so will result in unnecessary vibration Vibration will...

Страница 46: ...s could void the manufacturer s warranty You will be contacted by the component manufacturer with recommended action 2 When wiring the motors on the machine determine that proper electrical support co...

Страница 47: ...e the wear on drive components If operation requires starting the mixer under full load make sure that the drive assembly is adequate to handle the increased start up load Loading Sequence 1 The seque...

Страница 48: ...NOTES 48 PNEG 2309 Horizontal Fertilizer Mixer...

Страница 49: ...need to be adjusted with shims under the main bearings 8 Mixer agitator running too fast Refer to Mixer Specifications page 19 for proper shaft speed 9 Belt drive slippage Belts must be properly tensi...

Страница 50: ...ication is according to the bearing manufacturer s recommendation Problem Product is Dusting Through Seals Possible Solutions If the stuffing box seals begin to leak additional oil can be added or the...

Страница 51: ...go over center and against a hard stop to hold the drop gate 70 closed without the assistance of the air cylinder b The over center travel is about 1 8 to 1 4 c The gap between the angle irons is 1 4...

Страница 52: ...djusting the over center 58 Jam nut air cylinder arm 60 Air cylinder arm 59 Air cylinder 64 Adjusting bolt 4 Gap a Mechanically lock the gate as mentioned above before adjusting the gap b The gap shou...

Страница 53: ...If the door shuts hard or not at all the turnbuckles 62 are extended too far there is too much distance between points A and B Keep the gate in the closed position loosen the jam nuts 63 on the turnb...

Страница 54: ...n good condition with the gate open Figure 7 6 Checking the seal condition 74 Seal CAUTION NEVER use caulk silicone or sealing material anywhere in the gate mechanism The gate will seal if it is adjus...

Страница 55: ...sings for effective cooling b Reducer gear cases must also be free of dirt for effective heat radiation Most reducers have a pressure vent to permit escape of vapors which may build up internally If d...

Страница 56: ...r proper tension This will ensure that the shaft is not turning about the inside race of the bearing Gear Reducer Gear reducers are shipped without lubricant to comply with ICC Regulations Be sure to...

Страница 57: ...and does not cover labor and or equipment charges for removing or installing defective parts shipping charges with respect to such parts any applicable sales or other taxes or any other charges or exp...

Страница 58: ...ulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4...

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