PNEG-2309 - Horizontal Fertilizer Mixer

Horizontal Fertilizer Mixer

Installation and User Manual

PNEG-2309Version 1.0

Date: 12-03-20

PNEG-2309

All information, illustrations, photos, and specifications in this manual are based on the latestinformation available at the time of publication. The right is reserved to make changes at anytime without notice.

2 PNEG-2309 Horizontal Fertilizer Mixer

ContentsChapter 1 Safety Precautions ....................................................................................................................5

Safety Guidelines ........................................................................................................................5Cautionary Symbol Definitions......................................................................................................6Safety Cautions...........................................................................................................................7Safety Decals ...........................................................................................................................12Safety Sign-off Sheet.................................................................................................................15

Chapter 2 Introduction.............................................................................................................................17Contact Information ...................................................................................................................17General Safety Statements .......................................................................................................17Uncrating and Inspection ...........................................................................................................18

Chapter 3 Mixer Parts and Specifications................................................................................................19Mixer Specifications ..................................................................................................................19Mixer Dimensions......................................................................................................................21Service Parts (4-Ton Mixer) ........................................................................................................22Service Parts (8-Ton Mixer) ........................................................................................................24

Chapter 4 Mixer Assembly.......................................................................................................................27Assembling the Mixer Halves .....................................................................................................27Installing the Center Cover.........................................................................................................28Nozzle Installation .....................................................................................................................29Installing the Torque Arm Gear Reducer......................................................................................29Installing the Torque Arm and Turnbuckles ..................................................................................34Installing the Motor Mounts and Motors.......................................................................................36Installing the Sheaves and Belts .................................................................................................38Belt Tension Adjustment ............................................................................................................41Installing the Bearing Guards .....................................................................................................42Installing the Limit Switches .......................................................................................................43Hazard Monitoring.....................................................................................................................44

Chapter 5 Mixer Installation.....................................................................................................................45Important Pre-Startup Notifications .............................................................................................45Lifting the Horizontal Mixer.........................................................................................................45Wiring Installation......................................................................................................................46

Chapter 6 Operation ................................................................................................................................47Loading the Mixer......................................................................................................................47Loading Sequence ....................................................................................................................47

Chapter 7 Troubleshooting......................................................................................................................49Chapter 8 Maintenance............................................................................................................................55

General ....................................................................................................................................55Bearings...................................................................................................................................56Gear Reducer ..........................................................................................................................56Drive V-Belts.............................................................................................................................56Shafts Seals .............................................................................................................................56Limited Warranty - N.A. Fertilizer Products .............................................................................57

PNEG-2309 Horizontal Fertilizer Mixer 3

NOTES


1 Safety PrecautionsTopics Covered in this Chapter

▪ Safety Guidelines▪ Cautionary Symbol Definitions▪ Safety Cautions▪ Safety Decals▪ Safety Sign-off Sheet

Safety GuidelinesSafety guidelines are general-to-specific safety rules that must be followed at all times. This manual iswritten to help you understand safe operating procedures and problems that can be encountered by theoperator and other personnel when using this equipment. Read and save these instructions.

As owner or operator, you are responsible for understanding the requirements, hazards, and precautionsthat exist and to inform others as required. Unqualified persons must stay out of the work area at alltimes.

Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting inSERIOUS INJURYor DEATH.

This equipment must be installed in accordance with the current installation codes and applicable regula-tions, which must be carefully followed in all cases. Authorities having jurisdiction must be consultedbefore installations are made.

When necessary, you must consider the installation location relative to electrical, fuel and water utilities.

Personnel operating or working around equipment must read this manual. This manual must be deliveredwith equipment to its owner. Failure to read this manual and its safety instructions is a misuse of theequipment.

ST-0001–4


Chapter 1: Safety Precautions

Cautionary Symbol DefinitionsCautionary symbols appear in this manual and on product decals. The symbols alert the user of potentialsafety hazards, prohibited activities and mandatory actions. To help you recognize this information, weuse the symbols that are defined below.

Table 1-1 Description of the different cautionary symbols

Symbol Description

This symbol indicates an imminently hazardous situation which, ifnot avoided, will result in serious injury or death.

This symbol indicates a potentially hazardous situation which, if notavoided, can result in serious injury or death.

This symbol indicates a potentially hazardous situation which, if notavoided, can result in minor or moderate injury.

This symbol is used to address practices not related to personalinjury.

This symbol indicates a general hazard.

This symbol indicates a prohibited activity.

This symbol indicates a mandatory action.

ST-0005–2



Safety CautionsUse Personal Protective Equipment

• Use appropriate personal protective equipment:

EyeProtection

RespiratoryProtection

FootProtection

HearingProtection

HeadProtection

FallProtection

HandProtection

• Wear clothing appropriate to the job.

• Remove all jewelry.

• Tie long hair up and back.ST-0004–1

Follow Safety Instructions

• Carefully read all safety messages in this manual and safetysigns on your machine. Keep signs in good condition.Replace missing or damaged safety signs. Be sure newequipment components and repair parts include the currentsafety signs. Replacement safety signs are available fromthe manufacturer.

• Learn how to operate the machine and how to use controlsproperly. Do not let anyone operate without instruction.

• If you do not understand any part of this manual or needassistance, contact your dealer.

ST-0002–1



Maintain Equipment and Work Area

• Understand service procedures before doing work. Keeparea clean and dry.

• Never service equipment while it is operating. Keep hands,feet, and clothing away from moving parts.

• Keep your equipment in proper working condition. Replaceworn or broken parts immediately.

ST-0003–1

Install and Operate Electrical Equipment Properly

• Electrical controls must be installed by a qualified electricianand must meet the standards set by applicable local codes(National Electrical Code for the US, Canadian ElectricCode, or EN60204 along with applicable European Direc-tives for Europe).

• Lock-out power source before making adjustments, cleaning,or maintaining equipment.

• Make sure all equipment is properly grounded.ST-0027–4

Fall Hazard

• Keep access door closed while on a platform to avoid falls.

• Always use proper personal protective equipment andproper clothing when using equipment. Failure to followsafety precautions can result in severe injury or death.

ST-0042–2

Flying Material Hazard

• Flying material can cause severe eyeinjury or blindness.

• Wear safety glasses around operatingequipment.

ST-0074–1



Toxic Fume and Dust Hazard

• Do all work outside or in a well-ventilated area. Dispose ofpaint and solvent properly.

• Remove paint before welding or heating:

— Avoid potentially toxic fumes and dust. Hazardousfumes can be generated when paint is heated by weld-ing, soldering, or using a torch.

— If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.

— If you use solvent or paint-stripper, remove stripper withsoap and water before welding.

— Remove solvent or stripper containers and other flam-mable material from area. Allow fumes to disperse atleast 15 minutes before welding or heating

ST-0043–2

Fall Hazard

• Ladders, stairways and platforms are for use by competentand trained personnel only. Do not allow children or otherunauthorized persons to have access to the equipment.

• Access to the equipment must be restricted by the use ofsecurity fencing and lockable gates.

• Lower sections of ladders must be fitted with a lockablesafety gate to prevent unauthorized access.

• Make sure that hot surfaces have had adequate time to coolbefore working on or in the equipment.

• Lock out and tag out power supplies and fuel supplies to allequipment.

• Do not attach lifting equipment to ladders or platforms.

• Do not go outside of the safety rails provided on elevatedplatforms.

• Do not work at heights during high winds, rain, snow, or icestorms.

ST-0056–1



Confined Space Hazards and Entry Procedures

• Note that the interior of this equipment is considered a con-fined space. Maintenance of this equipment can requireaccess to the confined space.

• Access doors must be shut and locked except when accessis required.

• Doors giving access to dangerous equipment must be safetyinterlocked.

• The following entry procedures must be followed:

— Be aware of all possible hazards present inside the con-fined space and wear personal protective equipment(PPE) as needed.

— Complete a permit to work and follow all permit requiredconfined space entry procedures defined by the sitemanager.

— Make sure that the area has been purged of any hazard-ous products or gases. Check the atmosphere for harm-ful gases or vapors with a suitable gas analyzer andmake sure levels are safe before entering.

— Do not smoke or use naked flames.

— Lock out and tag out power supplies and fuel supplies toall equipment.

— Do not work alone. Work in teams of at least three sothat help is immediately available in the event of anemergency.

— Confirm that all personnel have safely exited the equip-ment and tools have been recovered once work iscomplete.

ST-0055–1

Stay Clear of Hoisted Equipment

• Always use proper lifting or hoisting equipment when assem-bling or disassembling equipment

• Do not walk or stand under hoisted equipment.

• Always use sturdy and stable supports when needed forinstallation. Not following these safety precautions createsthe risk of falling equipment, which can crush personnel andcause serious injury or death.

ST-0047–1



Stay Clear of Rotating Parts

• Do not service equipment while theequipment is in operation.

• Entanglement in rotating shafts, mixingpaddles or exposed belts will cause seri-ous injury or death.

• Keep all guards and covers in place atall times.

• Lock-out power source before makingadjustments, cleaning, or maintainingequipment.

ST-0088–1

Stay Clear of Moving Parts

• Entanglement in drop gate operatingmechanism can cause serious injury.

• Keep all guards and covers in place atall times.

• Lock-out power source before makingadjustments, cleaning, or maintainingequipment.

ST-0089–1



Safety DecalsThe safety decals on your equipment are safety indicators which must be carefully read and understoodby all personnel involved in the installation, operation, service and maintenance of the equipment.

Figure 1-1 Safety decal locations



Ref# Location Decal No. Decal Description

A Outside of belt guardcovers DC-2468 Decal, Warning, Rotating

Parts

B Inside of belt guardcovers DC-2469

Decal, Danger, MissingGuard, Rotating Parts

C Top of bearing guardcovers DC-2525 Decal, Warning, Rotating

Shafts

DOn the tub to the leftand right of bearings DC-2526

Decal, Danger, MissingGuard, Rotating Shafts



Ref# Location Decal No. Decal Description

EOn actuator guard

front panel DC-2527 Decal, Warning, Moving Parts

FOn top of inspection

panels DC-2528Decal, Warning, Confined

Space Hazard

GOn top of inspection

panels DC-2529 Decal, Danger, MixingPaddles

To replace a damaged or missing decal, contact us to receive a free replacement.

GSI Decals

1004 E. Illinois St.Assumption, IL 62510Tel: 1-217-226-4421



Safety Sign-off SheetBelow is a sign-off sheet that can be used to verify that all personnel have read and understood the safetyinstructions. This sign-off sheet is provided for your convenience and personal record keeping.

Date Employee Name Supervisor Name

ST-0007


NOTES


2 IntroductionTopics Covered in this Chapter

▪ Contact Information▪ General Safety Statements▪ Uncrating and Inspection

Contact InformationPlease contact your GSI dealer if you have any questions or contact GSI. Visit our website at www.grain-systems.com. If calling with questions about your product, please have the following information ready:

• Serial Number

• Model Number

• Part Description

• Quantity Required

General Safety Statements1. Precautions have been taken to ensure that machinery is supplied with all necessary safety guards,

covers, and warning labels. However, since this equipment is often part of a larger plant process, itis the responsibility of the customer to ensure that the machinery is safely 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 immediately for a replacement.

4. Under no circumstances should any attempt be made to override the safety equipment that issupplied on this mixer. Micro switches should never be tampered with so that the machine willoperate when the covers and grates are open. If the mixer must be loaded with the cover open,safety grating with a lock out switch must be provided.

5. Under no circumstances should any person attempt to put their hand through the inlets or thedischarge of the machine. If the agitator is in operation, amputation of a limb will occur.

6. This machine should only be operated by trained personnel. Proper training includes reading andunderstanding this manual.


http://www.grainsystems.com

http://www.grainsystems.com

Chapter 2: Introduction

Uncrating and InspectionWhat You Should Know

CAUTION

Use proper lifting equipment when lifting or moving the mixer. Failure to do so canlead 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 endplates.

• Observe local safety practices and procedures.

NOTE:

1. After uncrating your mixer, check for shipping damage and report any damageimmediately to the carrier and to GSI. Please make sure that all parts are accountedfor.

2. If the mixer is not to be installed immediately, make sure to store it in a clean, drylocation that is protected from extreme temperature conditions.

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


3 Mixer Parts and SpecificationsTopics Covered in this Chapter

▪ Mixer Specifications▪ Mixer Dimensions▪ Service Parts (4-Ton Mixer)▪ Service Parts (8-Ton Mixer)

Mixer SpecificationsGear ReducerTable 3-1 Reducer technical data

Mixer Reducer Mechanical Rating(HP)

Adjusted ThermalRating (HP)

Drive Shaft Size(in.)

Actual ServiceFactor

4-Ton TA8407H40 77.35 51 4-7/16 1.93

8-Ton TA10507H40 114.13 89 5-15/16 1.52

NOTE:

1. For 4-Ton Reducer: Thermal rating is 51 HP based on 95°F and below ambienttemperature and up to 5,000' altitude.

2. For 8-Ton Reducer: Thermal rating is 89 HP based on 95°F and below ambienttemperature and up to 5,000' altitude.

Belt DriveTable 3-2 Belt drive technical data

Mixer Speed Ratio Belt Speed(ft./min)

Belt Pull(lbs.)

Static Shaft Load(lbs.) Service Factor Final Shaft Output

(RPM)

4-Ton 1.27 3,207 1,234 1,211 2.06 35

8-Ton 1.67 4,078 1,072 1,078 1.57 26

Table 3-3 Belt drive technical data (Contd.)

Mixer Center Distance(in.)

Facewidth(in.)

Driver PitchDiameter (in.)

Driven PitchDiameter (in.)

Install/Take-up CenterDistance Range (in.)

4-Ton 40.4 3.06 7.00 8.90 39.35 - 41.85

8-Ton 51.1 3.06 8.90 14.90 50.07 - 53.27


Chapter 3: Mixer Parts and Specifications

TensioningTable 3-4 Sonic tension meter data

Mixer Tension Frequency (Hz) Belt Mass Constant (g/m) Span Length (in.) # of Belts

4-Ton 34 - 41 140.0 40.34 4

8-Ton 25 - 31 140.0 50.98 4

Table 3-5 Force deflection method

Mixer Span Length (in.) Belt Deflection Distance (in.) Belt Deflection Force (lbs.)

4-Ton 40.34 0.63 10.3 - 15.0

8-Ton 50.98 0.80 12.6 - 13.5

NOTE: Values shown are for new belts.

General Specifications

4-Ton Mixer 8-Ton Mixer

• Scott 96" x 96" twin shaft mixer with 151 cu. ft.mixing capacity at 75% total capacity.

• End plates and tub are 304 stainless steelconstruction.

• Bearing shelves and gussets are carbon steel.

• Agitator is carbon steel.

• 1/4" end plates and 3/8" tub.

• Interior finish: Standard mill

• Exterior finish: Painted STEEL-IT

• Seals: Double 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:

• Final mixer speed: 35 RPM

• Two 40 HP motors.

• Two Dodge TA8407H40 shaft mount reducers.

• Two belt drives with covers.

• Scott 120" x 120" twin shaft mixer with 294 cu. ft.mixing capacity at 75% total capacity.

• End plates and tub are 304 stainless steelconstruction.

• Bearing shelves and gussets are carbon steel.

• Agitator is carbon steel.

• 1/4" end plates and 3/8" tub.

• Interior finish: Standard mill

• Exterior finish: Painted STEEL-IT

• Seals: Double stuffing box re-packable both ends

• Two 5-15/16" Dodge ISAF drive bearings.

• Two 5-7/16" Dodge ISAF idle bearings.

• Discharge: Two 20" x 115" air-operated drop gates

• Two 8" x 54" intervents.

Motor and Drive:

• Final mixer speed: 26 RPM

• Two 75 HP motors.

• Two Dodge TA10507H40 shaft mount reducers.

• Two belt drives with covers.



Mixer DimensionsNOTE: The dimensions (approximate) shown below are for reference only. Refer to the certified drawingprovided with each mixer for actual dimensions.

Figure 3-1 4-Ton mixer dimensions

Figure 3-2 8-Ton mixer dimensions



Service Parts (4-Ton Mixer)Figure 3-3 4-Ton mixer parts



Table 3-6 4-Ton mixer parts listS.No Part # Description S.No Part # Description

1 See NoteCover Weld-Mixer, 4T, Center, 10 Ga., SS (OrderSpecific) 30 MHC00077 Bushing, 2517 x 2-7/16" T.L.

2 See NotePanel Weld-Mixer, Chemical Injection,”X” Ports, 1/4" SS (Order Specific) 31 MHC00814 Sheave, 4 GR 5V 9.0-2517 T.L.

3 See Note Transition - 4T Mixer to Surge Hopper 10 Ga., SS 32 XD2628 Belt, 5V x 1060

4 See Note Flex Connection - 4T Mixer Surge Hopper 33 FR-3483 Belt Guard Bushing Cover Weld-TA8,12 Ga., SS

5 See Note Clamp Bar - Transition 4T Mixer Surge Hopper,10 Ga., SS 34 FR-3485 Belt Guard Assembly-TA8, 14 Ga., SS

6 FR-1982 Cover Weld-Mixer, 4T, Access, 10 Ga., SS 35 S-7021 Washer, Flat 3/8" 304 SS

7 FR-3019 Inspection Door Weld, 24 x 20, 10 Ga., SS, withDecals 36 S-7104 Bolt, HHCS 3/8"-16 UNC x 1" 304 SS

8 FR-3523 Bearing Guard Left-Mixer, 4T, Drive, with Decal,SS 37 S-7603 Bolt, HHCS 3/8"-16 UNC x 3/4" 304 SS

9 FR-3525 Bearing Guard Right-Mixer, 4T, Drive, with Decal,SS 38 S-8032 Nut, Hex Whiz Serrated Flange 3/8"-16

UNC 304 SS

10 FR-3527 Bearing Guard Bottom-Mixer, 4T, Drive, 14 Ga.,SS 39 S-7072 Washer, Flat 1/2" 304 SS

11 FR-3528 Bearing Guard-Mixer, 4T, Idle, 14 Ga., SS 40 S-7413 Bolt, HHCS 1/2"-13 UNC x 1" 304 SS

12 FR-3529 Bearing Guard Top-Mixer, 4T, Idle, with Decal,SS 41 S-7506 Bolt, HHCS 1/2"-13 UNC x 1-1/2" 304

SS

13 FR-3458 Cylinder Guard Left-Mixer, 4T, Left Panel Weld,14 Ga., SS 42 S-20068 Nut, Hex Whiz Serrated Flange 1/2"-13

UNC 304 SS

14 FR-3460 Cylinder Guard Left-Mixer, 4T, Right Panel,14 Ga., SS 43 S-7084 Washer, Flat 5/8" 304 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 5/8"-11 UNC 304 SS

17 FR-3463 Cylinder Guard Right-Mixer, 4T, Left Panel,14 Ga., SS 46 S-20710 Screw, SMS HWH SLT #12 x 1" SS

18 FR-3464 Cylinder Guard Right-Mixer, 4T, Right PanelWeld, 14 Ga., SS 47 35690 Grommet, 1" I.D. 0.12" Groove

19 FR-3466 Cylinder Guard Right-Mixer, 4T, Top Left Panel,14 Ga., SS 48 534054 Seal, 1/8" Thick x 1" Width Sponge

1 Side Adhesive

20 FR-3467 Cylinder Guard Right-Mixer, 4T, Top Right Panel,14 Ga., SS 49 MHC02434

Bearing, Dodge P4B534-ISAF-407R(Bearing, Drive End)

21 FR-3468 Cylinder Guard-Mixer, 4T, Front Panel with DecalSS 50 MHC02436

Bearing, Sealmaster, MP 63 (Bearing,Idle End)

22 FR-3470 Cylinder Guard Grease Panel-Mixer, 14 Ga., SS 51 CE-00527Bearing, 2-7/16" Bore 4 Bolt FlangeDodge F4BSC207 (Bearing, DropGate)

23 MHC01104 Bushing, Taper, TA8407TB x 4-7/16" 52 MHC02437Bearing, Dodge P2B-BASP-108(Bearing, Drop Gate)

24 MHC01345 Shaft, Reducer, Dodge #TA8407H40 53 MHC02438Bearing, Dodge P2B-BASP-207(Bearing, Drop Gate)

25 MHC01146 Arm, Torque Kit, TA7315/8407RA 54 FR-2714 Cylinder, Air 5 B x 18 STK, NorgrenEA12

26 TA8MM Motor Mount, TA8 NS FR-2715 Repair Kit, Norgren Air Cylinder

27 MTR-0067FMotor FD HE, 50 HP 1775 RPM 230/460V 3 PH60 Hz 326T TEFC NS FR-2716 Seal, Packing, Drive End, 63", Scott

Mixer

28 MHC00054 Bushing, 2517 x 2-1/8" T.L. NS FR-2717 Seal, Packing, Idle End, 57", ScottMixer

29 MHC00979 Sheave, 4 GR 5V 7.1-2517 T.L. NS FR-2720 Drop Gate, Backseal, 20', Scott Mixer

NOTE: This component is order-specific. Refer to the certified drawing provided with the unit for this part number.



Service Parts (8-Ton Mixer)Figure 3-4 8-Ton mixer parts



Table 3-7 8-Ton mixer parts listS.No Part # Description S.No Part # Description

1 See NoteCover Weld-Mixer, 8T, Center, 10 Ga., SS (OrderSpecific) 33 MHC00523 Sheave, 4 GR 5V 15.0-3535 T.L.

2 See NotePanel Weld-Mixer, Chemical Injection, “X” Ports,1/4", SS (Order Specific) 34 XD2632 Belt, V 5V x 1400

3 See Note Transition - 8T Mixer to Surge Hopper, Long Side,10 Ga., SS 35 FR-3476 Belt Guard Bracket-TA10, 10 Ga., SS

4 See Note Transition - 8T Mixer to Surge Hopper, ShortSide, 10 Ga., SS 36 FR-3477 Belt Guard Assembly-TA10, 14 Ga., SS

5 See Note Flex Connection - 8T Mixer Surge Hopper 37 S-7021 Washer, Flat 3/8" 304 SS

6 See Note Clamp Bar - Transition 8T Mixer Surge Hopper,10 Ga., 102", SS 38 S-7603 Bolt, HHCS 3/8"-16 UNC x 3/4" 304 SS

7 See Note Clamp Bar, Transition Mixer to Surge Hopper, SS,10 Ga. 39 S-7104 Bolt, HHCS 3/8"-16 UNC x 1" 304 SS

8 FR-2401 Cover Weld-Mixer, 8T, Access, 10 Ga., SS 40 S-7080 Bolt, HHCS 3/8"-16 UNC x 1-1/4" 304SS

9 FR-3019 Inspection Door Weld, 24 x 20, 10 Ga., SS, withDecals 41 S-8032 Nut, Hex Whiz Serrated Flange 3/8"-16

UNC 304 SS10 FR-3515 Bearing Guard Left-Mixer, 8T, Drive, with Decal,

SS 42 S-7072 Washer, Flat 1/2" 304 SS

11 FR-3517 Bearing Guard Right-Mixer, 8T, Drive, with Decal,SS 43 S-7413 Bolt, HHCS 1/2"-13 UNC x 1" 304 SS

12 FR-3519 Bearing Guard Bottom-Mixer, 8T, Drive, 14 Ga.,SS 44 S-7506 Bolt, HHCS 1/2"-13 UNC x 1-1/2" 304

SS13 FR-3520 Bearing Guard-Mixer, 8T, Idle, 14 Ga., SS 45 S-20068 Nut, Hex Whiz Serrated Flange 1/2"-13

UNC 304 SS14 FR-3521 Bearing Guard Top-Mixer, 8T, Idle, with Decal, SS 46 S-7084 Washer, Flat 5/8" 304 SS

15 FR-3446 Cylinder Guard Left-Mixer, 8T, Left Panel Weld,14 Ga., SS 47 S-20223 Bolt, HHCS 5/8"-11 UNC x 2-1/2" 304

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, 14Ga., SS 49 S-20229 Bolt, HHCS 3/4"-10 UNC x 2" 304 SS

18 FR-3450 Cylinder Guard Left-Mixer, 8T, Top Right Panel,14 Ga., SS 50 S-9258 Nut, Hex 3/4"-10 UNC 304 SS

19 FR-3451 Cylinder Guard Right-Mixer, 8T, Left Panel, 14Ga., SS 51 S-20710 Screw, SMS HWH SLT #12 x 1" SS

20 FR-3452 Cylinder Guard Right-Mixer, 8T, Right PanelWeld, 14 Ga., SS 52 35690 Grommet, 1" I.D. 0.12" Groove

21 FR-3454 Cylinder Guard Right-Mixer, 8T, Top Left Panel,14 Ga., SS 53 534054 Seal, 1/8" Thick x 1" Width Sponge

1 Side Adhesive

22 FR-3455 Cylinder Guard Right-Mixer, 8T, Top Right Panel,14 Ga., SS 54 MHC01298

Bearing, Dodge P4B534-ISAF-515R(Bearing, Drive End)

23 FR-3456 Cylinder Guard-Mixer, 8T, Front Panel with Decal,SS 55 MHC02435

Bearing, Dodge P4B532-ISAF-507RE(Bearing, Idle End)

24 FR-3470 Cylinder Guard Grease Panel-Mixer, 14 Ga., SS 56 CE-00527Bearing, 2-7/16" Bore 4 Bolt FlangeDodge F4BSC207 (Bearing, Drop Gate)

25 MHC01327 Bushing, Taper, TA10507H x 5-15/16" 57 MHC02437Bearing, Dodge P2B-BASP-108(Bearing, Drop Gate)

26 MHC01670 Shaft, Reducer, Dodge#TA10507H40 58 MHC02438Bearing, Dodge P2B-BASP-207(Bearing, Drop Gate)

27 MHC01301 Arm, Torque Kit, TA10507RA 59 FR-2713 Cylinder Air 5 B x 20 STK, NorgrenEA12

28 TA10MM Motor Mount, TA10 NS FR-2715 Repair Kit, Norgren Air Cylinder

29 MTR-0071FMotor HE, 75 HP 1780 RPM 230/460V 3 PH60 Hz 365T TEFC NS FR-2716 Seal, Packing, Drive End, 63", Scott

Mixer30 MHC00899 Bushing, 2517 x 2-3/8" T.L. NS FR-2717 Seal, Packing, Idle End, 57", Scott Mixer31 MHC00814 Sheave, 4 GR 5V 9.0-2517 T.L. NS FR-2720 Drop Gate, Backseal, 20', Scott Mixer32 MHC00530 Bushing, 3535 x 2-11/16" T.L.

NOTE: This component is order-specific. Refer to the certified drawing provided with the unit for this part number.


NOTES


4 Mixer AssemblyTopics Covered in this Chapter

▪ Assembling the Mixer Halves▪ Installing the Center Cover▪ Nozzle Installation▪ Installing the Torque Arm Gear Reducer▪ Installing the Torque Arm and Turnbuckles▪ Installing the Motor Mounts and Motors▪ Installing the Sheaves and Belts▪ Belt Tension Adjustment▪ Installing the Bearing Guards▪ Installing the Limit Switches▪ Hazard Monitoring

Assembling the Mixer HalvesAssemble the two mixer halves (71) together by installing bolts (56) to the end plates.

NOTE: The hardware (56 and 57) to assemble the mixer halves (71) is supplied by Scott equipment.

Figure 4-1 Assembling the mixer halves

56 Bolt 71 Mixer half57 Nut


Chapter 4: Mixer Assembly

Installing the Center Cover1. Apply 1/8" x 1" thick sponge sealant (25) along the outside tub (27) edge, if not already installed.

2. Install the center cover (26) to the tub (27) using 3/8" x 1" HHCS bolts (1), 3/8" flat washers (14) and3/8" flange nuts (21).

Figure 4-2 Installing 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 cover21 3/8" flange nut (S-8032) 27 Tub

3. Install the chemical injection plate (28) onto the 3/8" x 1" welded bolts (2) of the center cover (26)and fasten with 3/8" flange nuts (21).

Figure 4-3 Installing the chemical injection plate

2 3/8" x 1" welded bolt (S-20438) 26 Center cover21 3/8" flange nut (S-8032) 28 Chemical injection plate



Nozzle InstallationNozzles (29) are already installed in the chemical injection plate (28), but you must make sure they are allpositioned so the width of the fan angle is parallel to the length of the plate.

NOTE: The maximum pressure is 1,000 PSI.

Table 4-1 Nozzle flow ratesFlow rates (GPM) Pressure (PSI)

14.1 2020 4031.6 100100 1000

Figure 4-4 Chemical injection plate with nozzles installed

28 Chemical injection plate 29 1/2" MNPT nozzle (FR-2421)81 3/4" to 1/2" FNPT reducer (FR-2420)

Installing the Torque Arm Gear ReducerBelow are general instructions, please refer to the DODGE Instructions manual supplied with the reducerfor all Dodge equipment.

What You Should Know

WARNING

Turn OFF and lock out or tag power source before performing any maintenance orservice.

1. One bushing assembly is required to mount the reducer on the drive shaft. The bushing assemblyconsists of two tapered bushings, bushing screws and washers, two bushing backup plates andretaining rings, and necessary shaft key or keys. The driven shaft must extend through the fulllength of the reducer.

2. Install one bushing backup plate on the end of the hub and secure with the supplied retaining ring.Repeat the procedure for the other side.



3. Place one bushing (30), flange end first, onto the drive shaft (31) and position per dimension “A” asshown in the below table. This will allow the bolts to be threaded into the bushing (30) for futurebushing and reducer removal.

Table 4-2 Minimum shaft length

Mixer Reducer Size Minimum Shaft Length Minimum Distance from the Shaft Bearing “A”

4-Ton TA8407H 12.82" 2.06"

8-Ton TA10507H 15.46" 2.39"

Figure 4-5 Sliding the bushing onto the drive shaft

30 Bushing 31 Drive shaft



4. Insert the output key (32) in the drive shaft (31) and bushing (30). For ease of installation, rotate thedrive shaft (31) so that the shaft keyseat is at the top position.

NOTE: In most cases the keys (32) that are supplied with the bushing kits are NOTsquare keys andthe orientation of the key (32) is important. Install the key (32) so that it fits snugly into thewidth of the keyseat. The keys are marked with a part number and some keys are alsoetched with “THIS SIDE UP” – these markings should be showing on the top of the key whenit is installed in the shaft keyseat.

Figure 4-6 Inserting the key in the drive shaft

30 Bushing 32 Key31 Drive shaft

5. Mount the reducer (33) on the drive shaft (31) and align the shaft key (32) with the reducer (33) hubkeyway. Maintain the recommended minimum distance “A” from the shaft bearing.

Figure 4-7 Mounting the reducer to the drive shaft

31 Drive shaft 33 Reducer32 Key



6. Insert the bolts (11) with washers (20) installed in the unthreaded holes in the bushing (30) flangeand align with the threaded holes in the bushing backup plate (34). If necessary, rotate the bushingbackup plate (34) to align with the bushing bolts (11). Tighten the bolts (11) lightly.

Figure 4-8 Installing the hardware to the bushing behind the reducer

11 Bushing bolt 30 Bushing20 Split lock washer 34 Bushing backup 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 thethreaded holes in the bushing backup plate (34). If necessary, rotate the bushing backup plate (34)to align with the bushing (30) holes. Insert the bolts (11) with washers (20) installed in theunthreaded holes in the bushing (30). Tighten screws lightly.

Figure 4-9 Sliding the second bushing onto the drive shaft

11 Bushing bolt 31 Drive shaft20 Split lock washer 32 Key30 Bushing 34 Bushing backup plate



8. After installing the second bushing, set the position of the reducer drive relative to the outsidesurface of the end wall of the mixer.

Figure 4-10 Setting the reducer position

9. Alternately and evenly tighten the screws in the bushing nearest the equipment to the recommendedtorque given in the Table 4-3, page 33. Repeat the same for the outer bushing.

Table 4-3 Recommended torque for bushing hardware

Mixer Reducer Size Fastener Size Torque (lbs.-ft.)

4-Ton TA8407H 1/2"-13 77-678-Ton TA10507H 5/8"-11 86-75

10.Fill the gear reducer with the recommended lubricant. Refer to Table 4-4, page 33.

CAUTION

Unit is shipped without oil. Add proper amount of recommended lubricantbefore operating. Failure to observe this precaution can result in damage to theequipment. Refer to the DODGE Instructions manual supplied with the reducer

for all Dodge equipment.

Table 4-4 Oil volume for reducer

Mixer Reducer SizeVolume of Oil to Fill Reducer to Oil Level Plug*(1 quart = 32 fluid ounces = 0.94646 liters)

Quart Liter4-Ton TA8407H 11.7 11.18-Ton TA10507H 27.6 26.1

*Oil quantity is approximate. Service with lubricant until oil runs out of oil level hole.

*Below 15 RPM output speed, oil level must be adjusted to reach the highest oil level plug. If there isa change in reducer position, either more or less oil may be required. Consult Mechanical PowerTransmission Support, Greenville, SC.



Installing the Torque Arm and Turnbuckles1. Install the torque arm adapter plates (35) to the gear reducers (33) using the existing 5/8" x 2" hex

bolts (3), 5/8" flat washers (15), 5/8" lock washer (17) and 5/8" hex nut (22).

NOTE: For 4-Ton mixer: Attach the adapter plates (35) to the two holes in the bottom corner of thereducer (33).

2. Install one end of the torque arm assembly (36) between the adapter plates (35) and the other to thetub (27) using 1" hex bolts (4 or 5), 1" lock washer (19) and 1" hex nut (24).

NOTE: Use 1" x 3-1/2" hex bolt (4) to connect the torque arm assembly (36) with the 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 positionedcorrectly.

NOTE: The torque arms (61) are not equally centered in the turnbuckle (62). The bottom torque arm(61) is extended farther into the turnbuckle (62) than the top torque arm (61) to provideclearance between the jam nut and the adapter plates.

Figure 4-11 Installing the torque arm assembly (4-Ton mixer)

3 5/8" x 2" hex bolt 24 1" hex nut (S-240)4 1" x 3-1/2" hex bolt 27 Tub5 1" x 5" hex bolt 33 Reducer15 5/8" flat washer (S-7400) 35 Adapter plate17 5/8" lock washer (S-3208) 36 Torque arm assembly19 1" lock washer 61 Torque arm22 5/8" hex nut (S-7363) 62 Turnbuckle



NOTE: For 8-Ton mixer: Attach the adapter plates (35) to the three holes in the bottom of the reducer(33).

Figure 4-12 Installing 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 washer (S-3208) 36 Torque arm assembly

19 1" lock washer 61 Torque arm

22 5/8" hex nut (S-7363) 62 Turnbuckle



Installing the Motor Mounts and Motors1. Install the left and right angle supports (37 and 38) to the gear reducer (33) using the existing

5/8" x 2" hex bolts (3), 5/8" flat washers (15), 5/8" lock washer (17) and 5/8" hex nut (22).

Figure 4-13 Installing the angle supports to the reducer

3 5/8" x 2" hex bolt 33 Reducer

15 5/8" flat washer (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 installusing 5/8" x 2" HHCS bolts (6), 5/8" flat washers (15), 5/8" lock washer (17) and 5/8" hex nut (22).

Figure 4-14 Installing the base plate to the angle supports

6 5/8" x 2" HHCS bolt (S-20143) 37 Left angle support

15 5/8" flat washer (S-7400) 38 Right angle support

17 5/8" lock washer (S-3208) 39 Base plate

22 5/8" hex nut (S-7363)



3. Install two 1" hex nuts (24) onto a 1" x 9" threaded rod (10), one at approximately 5" and anotherone at 2" from the end of the rod for a starting position. Repeat for the remaining threaded rods (10).

4. Place the 1" x 9" threaded rods (10) through the holes in the base plate (39) and secure in placeusing 1" hex nuts (24) on the bottom, so the base plate (39) is between the two nuts (24).

5. Install the mount plate (40) onto 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 plate

6. Align the motor (41) with the correct holes in the motor mount plate (40) and install using5/8" x 2-1/2" HHCS bolts (7), 5/8" flat washers (16) and 5/8" hex nuts (22).

NOTE: Use 1" hex nuts to adjust the height of the motor (41).

Figure 4-16 Installing the motor to the motor mount plate

7 5/8" x 2-1/2" HHCS bolt (S-20223) 40 Motor mount plate

16 5/8" flat washer (S-7084) 41 Motor

22 5/8" hex nut (S-7363)



Installing the Sheaves and BeltsThe belt guard is shipped assembled. You need to remove the front cover from the assembly beforecontinuing with the installation.

1. Assemble the belt guard bushing cover (42) to the belt guard cover assembly (48) using 3/8" x 3/4"HHCS bolts (9), 3/8" flat washers (14) and 3/8" flange nuts (21).

Figure 4-17 Assembling the belt guard bushing cover with the belt guard assembly

9 3/8" x 3/4" HHCS bolt (S-7603) 42 Belt guard bushing cover14 3/8" flat washer (S-7021) 48 Belt guard assembly21 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 1-1/2"HHCS bolts (8), 1/2" flat washers (18) and 1/2" serrated flange nuts (23).

NOTE: For 4-Ton mixer: There will be one belt guard bushing cover (42) for each drive.

Figure 4-18 Installing the belt guard bushing cover to the angle supports (4-Ton mixer)

8 1/2" x 1-1/2" HHCS bolt (S-7506) 37 Left angle support18 1/2" flat washer (S-7072) 38 Right angle support23 1/2" serrated flange nut (S-20068) 42 Belt guard bushing cover



NOTE: For 8-Ton mixer: There will be two belt guard bushing covers (42) for each drive.

Figure 4-19 Installing the belt guard bushing cover to the angle supports (8-Ton mixer)

8 1/2" x 1-1/2" HHCS bolt (S-7506) 37 Left angle support18 1/2" flat washer (S-7072) 38 Right angle support23 1/2" serrated flange nut (S-20068) 42 Belt guard bushing cover

3. Insert the sheave bushings (44) into the sheave (45 or 46) hubs, making sure to align the sheavebushings (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 the keyway in the hubs with the keys (32) and slide the sheave (45 or 46) assemblies withbushing (44) onto the drive shafts (31).

NOTE:Make sure the sheaves (45 or 46) are aligned vertically above each other and tighten theretaining screws (12).

Figure 4-20 Sliding the sheave assemblies onto the drive shafts

12 Retaining screw 44 Sheave bushing31 Drive shaft 45 Driving sheave32 Key 46 Driven sheave



7. Install the belts (47) onto the sheaves (45 and 46).

Figure 4-21 Installing the belts

45 Driving sheave 47 Belts

46 Driven sheave

8. Install 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" HHCS bolt (S-7603) 43 Belt guard front cover

14 3/8" flat washer (S-7021) 48 Belt guard assembly

21 3/8" flange nut (S-8032)



Belt Tension AdjustmentAdjustment of belt tension is achieved by tightening the hex nuts located on the four jack screws of themotor base.

1. Adjust the motor base 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 inposition.

NOTE: Refer to the Mixer Specifications, page 19 for belt drive and belt tensioning details.

Figure 4-23 Adjusting the belt tension

52 Span 54 Belt deflection

53 Force



Installing the Bearing Guards1. Assemble the left and right bearing guards (49 and 72) together at the top using 3/8" x 3/4" HHCS

bolts (9) and 3/8" flange nuts (21).

NOTE: Make sure to align the access hole in the left bearing guard (49) over the grease zerk in thebearing (50).

2. Place the assembled bearing guards (49 and 72) over 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 and 72) using 3/8" x 3/4" HHCSbolts (9) and 3/8" flange nuts (21).

Figure 4-24 Installing the bearing guards

1 3/8" x 1" HHCS bolt (S-7104) 49 Left bearing guard

9 3/8" x 3/4" HHCS bolt (S-7603) 50 Bearing

14 3/8" flat washer (S-7021) 51 Bearing guard bottom plate

21 3/8" flange nut (S-8032) 72 Right bearing guard

27 Tub



Installing the Limit Switches1. If the mixer was supplied with limit switches for positional information on the drop gate air cylinders,

remove the air cylinder guard and install two tie-rod bracket assemblies 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 air cylinder is 3/8" to1/2" from the retracted position.

3. Secure the sensor (73) to the air cylinder (59) using the set screws.

Figure 4-25 Installing the limit switches

59 Air cylinder 73 Sensor



Hazard MonitoringThe bearing guard is fabricated with knockout sections for the installation of hazard monitoringequipment.

1. The bearing guard top (79) contains three knockout sections (75, 76 and 77) as shown below.These knockout sections (75, 76 and 77) are intended for the installation of a bearing temperaturesensor.

NOTE: A 45 degree grease zerk may be required for access through the knockout section (77).

2. The bearing guard (80) contains a knockout section (78), intended for the installation of a shaftspeed sensor.

NOTE: The shaft end is threaded 1/2"-13 to accommodate a threaded shaft speed sensor. However,a magnetic attachment for the speed sensor is recommended for the simplest installation.

Figure 4-26 Bearing guard knockouts for the installation of hazard monitoring equipment

75 Knockout section for bearing temperature sensor 78 Knockout section for shaft speed sensor

76 Knockout section for bearing temperature sensor 79 Bearing guard top

77 Knockout section for bearing temperature sensor 80 Bearing guard


5 Mixer InstallationTopics Covered in this Chapter

▪ Important Pre-Startup Notifications▪ Lifting the Horizontal Mixer▪ Wiring Installation

Important Pre-Startup Notifications1. Make sure the gear speed reducer is filled with the proper weight and amount of oil. (Gear boxes are

shipped without oil from the factory.) The recommended level and types of lubricants are listed inthe factory manual supplied with the reducer. Running the machine without oil will cause seriousdamage to the gearbox that will not be covered under warranty.

2. Make sure the air operated discharge gates compressed air is plumbed to the cylinder correctly andthat you are running sufficient air pressure to the cylinders. A filter and regulator should be includedin the air supply system to provide 90-110 PSI of clean dry air to the cylinders.

3. On some machines, there is a short break in period. During this period the inside of the tub and theagitator will polish and become smooth and decrease the amount of drag or friction on the agitator. Itmay be necessary to run smaller batches until this is accomplished to keep from drawing excessivehorsepower.

4. The mixer should be installed on solid footings. Failure to do so will result in unnecessaryvibration. Vibration will result in extensive bearing wear and create machinery noise.

5. Make sure all hardware is properly tightened and parts are in good working order. Components canbecome loose during shipment. Failure to check components can result in damage to equipment.Please examine the machine closely before start up.

6. Check the rotation of the machine main shafts. An arrow located on the drive end of the machine willindicate which direction the shafts should turn. Wiring diagrams for the motors are given on themotor nameplate.

Lifting the Horizontal MixerBefore You Begin

1. Lifting of equipment must be done using hoists that are designed for the total weight of theequipment.

2. Ensure that the area below the raised equipment is clear of people.

3. Do not lift from the underside or tub area. Lifting on the channel base is acceptable, if done properly.

4. Consider the center of gravity of the equipment when lifting.

NOTE: Refer to the certified drawing provided for approximate total weight of each mixer before lifting.


Chapter 5: Mixer Installation

WARNING

Only use a certified lifting company that is experienced with lifting heavy equipment.

DANGER

Make sure all personnel is clear from the lifting area.

Lift the horizontal mixer using only the lifting points (55) along the tub (27) end plates.

CAUTION

Do not lift from the underside or tub area. Avoid sudden jarring or dropping.Improper handling can result in misalignment of the machine main shaft withthe cylinder and end plates.

Figure 5-1 Lifting points on mixer

27 Tub 55 Lifting points

Wiring Installation1. All wiring must be performed by a qualified electrician. If problems develop with electrical

components supplied by GSI, contact service personnel immediately. Repairs are not to be madewithout written authorization from GSI. Failure to comply with this could void the manufacturer’swarranty. You will be contacted by the component manufacturer with recommended action.

2. When wiring the motors on the machine, determine that proper electrical support components arebeing used which match the Voltage and Amperage rating of the motors. All explosion proof motorsand components should have UL listings on them. The motor manufacturer’s installation andmaintenance manual is included with the mixer. This will list the proper wiring diagrams, voltage,phase and frequency requirements. In addition, this information is available on the motornameplate.

3. Problems can arise due to insufficient voltage and undersized thermal relays. Insist on wiring that isheavy enough such that voltage drop at full load will not exceed 5% of the nameplate voltage.

4. Proper motor rotation is critical. Be sure the motors are wired to rotate in the correct direction.Failure to do so can result in serious damage to the equipment.


6 OperationTopics Covered in this Chapter

▪ Loading the Mixer▪ Loading Sequence

Loading the Mixer1. The amount of material in the mixer is very important. The single most important factor in mixing

efficiency is not overloading the mixer. The level of material in the mixing chamber should notexceed the rated capacity of the mixer. A rule of thumb is for the product to be below the top of theagitator.

2. If possible, fill the mixer with the agitator in operation. Running the machine during loading willincrease the mixing efficiency and decrease the wear on drive components. If operation requiresstarting the mixer under full load, make sure that the drive assembly is adequate to handle theincreased start up load.

Loading Sequence1. The sequence of ingredient addition into the machine is important. Industry experience dictates that

the best results happen when major ingredients are added first, and after a short period of mixing,the minor ingredient are then added.

2. Always add liquids after the dry ingredients have been added to the mixer.

IMPORTANT: Do not add liquids to an empty mixer.

NOTE: If liquid addition is a major part of the mixing process, periodic inspection and cleaning willbe necessary to maintain the sanitation of the mixer.


NOTES


7 TroubleshootingProblem:Mixer Unable to Pull LoadPossible Solutions:

1. Check all wiring for loose connections, low voltage, or undersize wiring.

2. Clean machinery. Build-up on tub and agitator must be scraped loose to re-new mixing efficiencyand reduce power consumption.

3. Mixer is being loaded too full or being loaded with ingredients too heavy for applied horsepower.

4. Amount of liquid being added is too high.

5. Improper lubrication. Check all bearings and make sure they are greased properly according tomanufacturer’s recommendations.

CAUTION

Do not over-grease bearings, seal damage will occur.

6. Check the compression of the packing seals. Over tension will cause excessive friction on the mainshaft.

7. Mixer agitator running too close to mixer tub. Agitator may need to be adjusted with shims under themain 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 tensioned.

Problem: Gear Reducer Excessively NoisyPossible Solutions:

1. Oil level not properly maintained. All gear boxes are shipped without oil. Gear reducers should befilled at the time of installation in accordance with the manufacturer’s recommendations.

2. Drain and refill oil in the gear reducer seasonally.

3. Motor coupling is not properly aligned to input shaft on reducer.

Problem:Mixer Agitator Rubbing TubPossible Solutions:

1. Agitator bearings loose on base. Tighten bearings down to bearing shelf.

2. Steel blocks positioning agitator bearing worked loose, allowing agitator to rub tub sides.

3. Set collars on agitator bearings are loose allowing agitator to thrust against tub ends. Re-alignagitator and tighten set collars.


Chapter 7: Troubleshooting

4. Agitator may have become slightly distorted by:

a. Relaxing of stress developed during fabrication;

b. An overloading condition; or

c. A foreign object becoming lodged between agitator and tub.

5. Re-adjust agitator as required with shims under the agitator bearings.

Problem: Main Shaft Heating UpPossible Solutions:

Bearings are improperly lubricated. Make sure all the bearings and bearing races are free movingwithin housing. Check that the shaft is not turning within the inside bearing race, and that all setscrews are properly tightened. Ensure that lubrication is according to the bearing manufacturer’srecommendation.

Problem: Product is Dusting Through SealsPossible Solutions:

If the stuffing box seals begin to leak, additional oil can be added or the packing may need to beremoved and replaced with new material.

Problem: Drop Gate Leaks or Does not Open or Close ProperlyPossible Solutions:Adjust the drop gate by following the below steps.

DANGER

Even with no air pressure, the drop gate can move which may result in severe injuryor death.

NOTE: Before adjusting the drop gate, lock the gate arm (60) mechanically by using any of the equipmentlisted below.

• Chain

• Come-along-winch

• Cylinder stop

• Other safety device

Figure 7-1 Mechanically locking the gate

59 Air cylinder 60 Air cylinder arm



1. The gate adjustment is an iterative process. Changing one setting will affect the another.

NOTE: The sealing areas of the gate must be clean before starting the adjustments.

2. Over Center:

a. The linkage should go “over center” and against a hard stop to hold the drop gate (70) closedwithout 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" and the fast evacuation of the product is about 3-5seconds.

Figure 7-2 Checking the over center

27 Tub 67 Crank

62 Turnbuckle 68 Pinch seal

65 Hinge shaft 69 Rocker

66 Drop gate shaft 70 Gate



3. Adjusting the Over Center Setting:

a. Loosen the jam nut (58) on the adjusting bolt (64) on the air cylinder arm (60).

b. Adjust the bolt (64) length to get the desired 1/8" to 1/4" over center dimension and tighten thejam nut (58).

c. Exercise the cylinder (59) - Extending the cylinder (59) closes the gate and retracting thecylinder (59) opens the gate.

Figure 7-3 Adjusting 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 should be 1/4". Use a 1/4" key stock or other material as a feeler gauge to check.

NOTE: Typically, there will be no leakage with the gate adjusted to the below shown tolerances.In case of extremely free flowing, light and aerated material an additional gasket or sealmay be installed between the two angle rings.

Figure 7-4 Checking the gap



5. Achieving the gap by adjusting the turnbuckles:

a. Adjust the turnbuckles (62) to achieve the proper gap along the length of the drop gate when thegate is closed. This can be checked by using a piece of key stock as a feeler gauge. A wider gapmay be acceptable for bulky or non-flowing product.

NOTE: If the door shuts hard or not at all, the turnbuckles (62) are extended too far - there is toomuch distance between points A and B. Keep the gate in the closed position, loosen thejam nuts (63) on the turnbuckles (62) and back off the turnbuckles (62) to shorten thecenter distance. This will allow the turnbuckle (62) to straighten to a slightly over centerposition.

Figure 7-5 Adjusting the gap

62 Turnbuckle 63 Jam nut (turnbuckle)

6. Check the over center and gap. Make adjustments if required.



7. Check if the seal (74) is in 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. Thegate will seal if it is adjusted properly.


8 MaintenanceTopics Covered in this Chapter

▪ General▪ Bearings▪ Gear Reducer▪ Drive V-Belts▪ Shafts Seals

GeneralWhat You Should Know

WARNING

Always lock out or tag out the power source before performing any service ormaintenance to the equipment.

1. The internal surfaces of the machine may need to be cleaned regularly depending on thecharacteristics of the product. Before cleaning, DISCONNECT POWER AND LOCK OUT. Removecovers where applicable for easy access. When complete, replace and properly secure covers.

2. Unusual noises coming from the machine should be investigated immediately. GSI IS NOT LIABLEFOR DAMAGE DUE TO NEGLECT ON THE PART OF THE OPERATOR. If you are concernedabout noise that the machine is making, please shut down and call your dealer immediately.

3. Remove accumulated dirt from the motor, reducer housings and bearings.

a. Motors depend upon unobstructed airflow over their housings for effective cooling.

b. Reducer gear cases must also be free of dirt for effective heat radiation. Most reducers have apressure vent to permit escape of vapors, which may build up internally. If dirt blocks a vent,internal pressure can rupture seals. Leaking lubricant will contaminate the product beinghandled by the elevator and reducer failure and subsequent equipment downtime will definitelyresult if the leak is not discovered in time and repairs made. Original equipment manufacturerswill refuse to honor warranties if a motor or reducer fails because dirt accumulation leads tooverheating or lubricant failure.

c. While cleaning the reducer, check the reducer’s lubricant level and condition. If the level is low,find and correct the leak. If the lubricant is dirty or shows signs of overheating, schedule achange of lubricant as soon as possible.

d. Listen carefully for a noisy motor, reducer, or bearings, or a rubbing belt. Any of these soundscan be a forewarning of overheating and fire or explosion. Correct any problem discoveredimmediately.


Chapter 8: Maintenance

Bearings1. All bearings must be inspected and lubricated regularly. Please follow the manufacturer’s

specifications and schedules. Do not over lubricate the bearings since this could damage thebearing seals.

2. Bearings should be checked periodically for excessive heat or wear. Bearings that are damaged willoverheat or have a grinding noise while the machine is in operation. If either occur, stop the machineimmediately. A damaged bearing could seize, causing serious damage to the shaft. Call your localbearing representative or dealer for replacement or service.

3. Periodically check the set screws for proper tension. This will ensure that the shaft is not turningabout the inside race of the bearing.

Gear ReducerGear reducers are shipped without lubricant to comply with ICC Regulations. Be sure to examinethe oil level in the gear reducer prior to start-up. Refer to the manual supplied with the gear reducerfor the recommended level and lubricant type.

Drive V-BeltsThe V-belt drive should be checked at least once a month for proper tension and belt condition.

Shafts Seals• The shaft seals are a stuffing box style seal with a removable cover on it. The box is filled with an

Oakum or Jute packing.

• The packing is then wet down with oil or gear lubricate. If the seal begins to leak, additional oil canbe added or the packing may need to be removed and replaced with new material.


Chapter 9: Warranty

Limited Warranty - N.A. Fertilizer ProductsThe GSI Group, LLC. (“GSI”) warrants products which it manufactures, to be free of defects in materials and workmanshipunder normal usage and conditions for a period of 12 months from the date of commissioning or 18 months from the dateof delivery to the requested location (or, if shipped by vessel, 20 months from the date of arrival at the port of discharge),whichever comes first. If, in GSI’s sole judgment, a product is found to have a defect in materials and/or workmanship,GSI will, at its own option and expense, repair or replace the product or refund the purchase price. This Limited Warrantyis subject to extension and other terms as set forth below.

Warranty Enhancements: The warranty period for the following products is enhanced as shown below and is inlieu of (and not in addition to) the above stated warranty period.

Product Warranty Period

Bins Bin Structural Design 5 Years

BlendingGSI Horizontal Mixer:▪ Main Shaft▪ Support posts and paddle assembly

5 Years10 Years5 Years

MaterialHandling

Bucket Elevators Structural Design 5 Years

Towers Structural Design 5 Years

Catwalks Structural Design 5 Years

Accessories (stairs, ladders and platforms) Structural Design 5 Years

Conditions and Limitations:THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION SET FORTHHEREIN; SPECIFICALLY, GSI DISCLAIMS ANY AND ALL OTHER WARRANTIES OF ANY KIND, EXPRESS ORIMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE OR USE IN CONNECTION WITH: (I) ANY PRODUCT MANUFACTURED OR SOLD BY GSI,OR (II) ANY ADVICE, INSTRUCTION, RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT,REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION, INSTALLATION,LAYOUT, SUITABILITY FOR A PARTICULAR PURPOSE, OR DESIGN OF SUCH PRODUCTS.

The sole and exclusive remedy for any claimant is set forth in this Limited Warranty and shall not exceed the amount paidfor the product purchased. This Warranty only covers the value of the warranted parts and equipment, and does not coverlabor and/or equipment charges for removing or installing defective parts, shipping charges with respect to such parts, anyapplicable sales or other taxes, or any other charges or expenses not specified in this Warranty. GSI shall not be liable forany other direct, indirect, incidental or consequential damages, including, without limitation, loss of anticipated profits orbenefits. Expenses incurred by or on behalf of a claimant without prior written authorization from the GSI warrantydepartment shall not be reimbursed. This warranty is not transferable and applies only to the original end-user. GSI shallhave no obligation or responsibility for any representations or warranties made by or on behalf of any dealer, agent ordistributor. Prior to installation, the end-user bears all responsibility to comply with federal, state and local codes whichapply to the location and installation of the products.

This Limited Warranty extends solely to products sold by GSI and does not cover any parts, components or materials used in conjunction with theproduct, that are not sold by GSI. GSI assumes no responsibility for claims resulting from construction defects, unauthorized modifications,improper maintenance or servicing of equipment, corrosion or other cosmetic issues caused by storage, application or environmental conditions.Modifications to products not specifically delineated in the manual accompanying the product at initial sale will void all warranties. This LimitedWarranty shall not extend to products or parts which have been damaged by negligent use, misuse, alteration, accident or which have beenimproperly/inadequately maintained.

Notice Procedure:In order to make a valid warranty claim, a written notice of the claim must be submitted via e-mail to [email protected] orverbally by calling Customer Service at 402-330-1500. All claims must be made within 15 days of discovery of the warrantable nonconformance.Service Parts:GSI warrants, subject to all other conditions described in this Warranty, Service Parts which it manufactures for a period of 12 months from thedate of purchase unless specified in Enhancements above.(Limited Warranty - N.A. Fertilizer Products Revised 31 May 2019)


This equipment shall be installed in accordance withthe current installation codes and applicable

regulationswhich should be carefully followed in allcases. Authorities having jurisdiction should be

consulted before installations are made.

1004 E. Illinois St.Assumption, IL 62510-0020Phone: 1-217-226-4421Fax: 1-217-226-4420www.gsiag.com

Copyright © 2020 by The GSI Group, LLCPrinted in the USA CN #358755

Documents

PNEG-2309 - Horizontal Fertilizer Mixer