4802-5128 - Fan Bearing Remote Lubrication Kit · 4 4802-5128 Fan Bearing Remote Lubrication Kit 1. Safety Safety Guidelines This manual contains information that is important for

4802-5128

Fan Bearing RemoteLubrication Kit

Installation Manual

4802-5128Version: 2.0

Date: 02-08-16

2 4802-5128 Fan Bearing Remote Lubrication Kit

Table of Contents

4802-5128 Fan Bearing Remote Lubrication Kit 3

ContentsChapter 1 Safety .....................................................................................................................................................4

Safety Guidelines ...................................................................................................................................4Safety Instructions ..................................................................................................................................5

Chapter 2 Installation ............................................................................................................................................7Tools Required .......................................................................................................................................7Installing the Remote Lubrication Kit ......................................................................................................7Additional Applications .........................................................................................................................14

Chapter 3 Packing List ........................................................................................................................................15Fan Bearing Remote Lubrication Kit Packing List ................................................................................15

Chapter 4 Warranty ..............................................................................................................................................17


1. Safety

Safety Guidelines

This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections. 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

CAUTION

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.

This symbol 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, may result in minor or moderate injury.

This symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

This symbol indicates an imminently hazardous situation which, if not avoided, will result in serious injury or death.

1. Safety


Safety Instructions

Our foremost concern is your safety and the safety of others associated with this equipment. We want to keep you as a customer. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel.

As owner and/or operator, it is your responsibility to know what requirements, hazards, and precautions exist, and to inform all personnel associated with the equipment or in the area. Safety precautions may be required from the personnel. Avoid any alterations to the equipment. Such alterations may produce a very dangerous situation where SERIOUS INJURY or DEATH may occur.

This equipment shall be installed in accordance with the current installation codes and applicable regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

Install and Operate Electrical Equipment Properly

Electrical controls should be installed by a qualified electrician and must meet the standards set by the National Electrical Code and all local and state codes.

Disconnect and lock out all power sources before installing wires/cables or servicing equipment.

Electric Shock Hazard

Keep Hands Away from Moving Parts

DO NOT put hand or arm in fan. Rotating parts can crush and dismember.

DO NOT put any kind of tool inside fan to try and clear debris while the fan is running. Damage to the equipment will result.

ALWAYS turn OFF and lock out all power sources before servicing equipment.

Keep all shields and covers in place during operation. Rotating Fan Blade

1. Safety


Prepare for Emergencies

Be prepared if fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Keep Emergency Equipment Quickly Accessible

Wear Protective Clothing

Wear close-fitting clothing and safety equipment appropriate to the job.

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.

Wear a hard hat to help protect your head.

Wear appropriate fall protection equipment when working at elevations greater than six feet (6').

Eye Protection

Gloves

Steel-Toed

Respirator

Hard Hat

Fall Protection


2. Installation

Tools Required

1. Cordless drill

2. 1/2" Drill bit

3. 3/8" Hex bit

4. 7/16" Hex bit

5. 8" Adjustable wrench

6. 17 mm Open end/boxed end wrench

7. Side cutting pliers

Installing the Remote Lubrication Kit

1. Remove the old grease zerk (A) fittings from the bearings. Make sure the holes are clean and clear of debris. (See Figure 2A.)

Figure 2A

Ref # Description

A Grease Zerk

B Bearing Housing

A

B

2. Installation


2. Install the two (2) small black nylon washers onto the threaded ends of both 1/4"-28 adapter fittings (RBI bearings) and install into the bearing housing. IMPORTANT: Make sure the fittings do not bottom out when tightening them into the bearing housings, this will restrict the grease flow. (See Figure 2B.)

NOTE: If the bearings have the larger 1/8" NPT hole size, skip this step. (Dodge bearings)

Figure 2B

3. Install and tighten the two (2) 1/8" NPT jam nuts (E) onto the 90° slip lock plastic fittings (F). Then install them into the bearing housings (B). Make sure both fittings are pointing in the direction you plan to run the nylon tubing to the outside of the fan housing. (See Figure 2C.)

IMPORTANT: Make sure the fittings do not bottom out when tightening them into the bearing housings (B), this will restrict the grease flow.

Figure 2C

Ref # Description

B Bearing Housings

C Nylon Washers

D Adapter Fittings

Ref # Description

B Bearing Housings

E Jam Nut

F 90° Slip Lock Fittings

C

B

DC

D

B

E

F

F

B

2. Installation


4. Cut the black nylon tubing (G) into two (2) equal lengths of 4'. Insert the tubes into the slip lock fittings and tighten. NOTE: Make sure the ends of the tubing are open and round before inserting them into the slip lock fittings. (See Figure 2D.)

Figure 2D

5. On the outside of the fan housing, place the metal mounting bracket (H) vertically in the center of the fan housing and horizontally between the outside of the building wall and the square part of the box area of the fan housing. Use the two (2) 3/8" hex head self-drilling screws supplied in the kit to mount the bracket to the fan housing. NOTE: When installing bracket, ensure that the side with the two (2) larger and inset holes will be oriented downward. (See Figure 2E.)

Figure 2E

Ref # Description

G 4' Nylon Tubings

Ref # Description

H Grease Fitting Mounting Bracket

GG

H

2. Installation


6. Measure up 2" from the top edge of the new mounting bracket and drill two (2) 1/2" diameter holes (J). Take the two (2) rubber circular grommets (I) supplied in the kit and insert them through the holes until they lock into place. (See Figure 2F.)

Figure 2F

7. Visually check the inside holes to make sure they are open and round and not distorted. From the inside of fan housing, install the nylon tubes (G) through the two (2) rubber grommets (I) until the excess tubing levels out horizontally close to the centerline of the fan housing. (See Figure 2H.)

Figure 2G Rubber Grommets from Outside of Housing Figure 2H Rubber Grommets from Inside of Housing

Ref # Description

I Rubber Grommet

J 1/2" Hole

IJ

2"

G

I

Ref # Description

G Nylon Tubing

I Rubber Grommets

2. Installation


8. Install the two (2) metal bulkhead fittings (K) with the square side up. Secure with nuts (L) on the bottom side of the bracket and tighten until they will not rotate. (See Figure 2I.)

Figure 2I

9. Install the two (2) straight plastic slip lock fittings (M) into the top of the bulkhead fittings (K) and tighten until snug. (See Figure 2J.)

Figure 2J

Ref # Description

K Bulkhead Fittings

L Bulkhead Nuts

Ref # Description

K Bulkhead Fittings

M Straight Slip Lock Fittings

K

L

K

M

2. Installation


10. Pull the excess nylon tubing (G) down to the two (2) plastic slip lock fittings (M) and note the length of tubing required to make the necessary connections. NOTE: Make sure you do not cut the lengths too short or you could compress the tubing and form a crease or restriction in the tubing. (See Figure 2K.)

Figure 2K

11. Install the two (2) new grease fittings (N) and plastic protective caps (O) into the bottom of the bulkhead fittings (K) and tighten. (See Figure 2L.)

Figure 2L

Ref # Description

G Nylon Tubing

M Straight Slip Lock Fitting

Ref # Description

K Bulkhead Fittings

N Grease Fitting

O Plastic Caps

G

M

K

N

O

K

2. Installation


12. Snap the two (2) plastic caps (O) onto the grease fittings. From inside the fan housing, route the nylon tubing (G) so that it will not interfere or get damaged by any of the rotating assemblies inside the fan units. If necessary, use small zip ties (P) to secure the tubing. (See Figure 2M.)

Figure 2M

NOTE: Once the assembly has been completed, you will need to pre-fill and purge all the air in the remote grease location fittings and tubing with the fan manufacturer’s recommended/specified type of grease. Once the air has been purged, you will only need to add 1-1/2" to 2" pumps from most hand held grease guns for regular bearing maintenance intervals.

IMPORTANT: Any use of pneumatic or high pressure grease guns or using the incorrect type of grease can void the fan manufacturer’s warranties on the components in this kit and the fan bearings.

Ref # Description

G Nylon Tubing

O Plastic Caps

P Zip Ties

When securing tubing, make sure the tubing is not restricted or blocked. Restricting the tubing can block the flow of grease to the bearings. It can also cause leaks or result in damage to the tubing.

O O

P

G

2. Installation


Additional Applications

This kit also contains additional hardware and fittings for multiple level fan applications. Two (2) additional slip lock connectors and wood lag screws are included for applications where you would want to extend the grease port locations and nylon tubing to a wall mount location. (See Figure 2N.)

Figure 2N

Additional nylon tubing would also be required for this and since each application can require a different length of tubing, the installer must measure out the lengths needed and order additional nylon tubing as necessary. The kit comes standard with 8' of nylon tubing included, which should be enough for any fan rated 54" or smaller. Nylon tubing (1044-1200). (See Figure 2O.)

Figure 2O


3. Packing List

Fan Bearing Remote Lubrication Kit Packing List

Part # Description Qty

1021-1100 Fitting 1/8" NPT F to 1/4" x 28 M Reducer 2

1021-1101 Fitting Plastic GRS Dust Cap 2

1021-1102 Fitting Plastic SLPLK 1/4" x 1/4" Tube Union 2

1021-1103 Fitting Plastic SLPLK 1/4" x 1/8" NPT Male 2

1021-1104 Fitting Plastic SLPLK 1/4" x 1/8" NPT Male 90° 2

1021-1105 Fitting Bulkhead Connection 1/4"-28 F to 1/8" NPT F 2

1021-1699 Fitting Grease Straight 1/4"-28 2

1001-0500 Nut 1/8" NPT Bulkhead Hex Z 4

0404-11844 FAB GS GRS Re-Location Bracket 1

4802-5128 Fan Bearing Lubrication Kit Instructions 1

1063-5005 Grommet Push-In 1/4" I.D., 3/4" O.D., 1/8" Thick 2

1044-1200 Nylon Tubing 1/4" O.D. Black 400 PSI 8'

1004-1393 Lag Screw 1/4" x 2" Hex Z 2

1004-0050 Screw, SM #14" x 1" Hex W SL Tek Z 2

1003-1508 Nylon Washer Black 1/2" x 1/4" x 1/8" 2


NOTES


4. Warranty

GSI Group, LLC Limited WarrantyThe GSI Group, LLC (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier. The end-user’s sole remedy (and GSI’s only obligation) is to repair or replace, at GSI’s option and expense, products that in GSI’s judgment, contain a material defect in materials or workmanship. Expenses incurred by or on behalf of the end-user without prior written authorization from the GSI Warranty Group shall be the sole responsibility of the end-user.

Warranty Extensions:The Limited Warranty period is extended for the following products:

GSI further warrants that the portable and tower dryer frame and basket, excluding all auger and auger drive components, shall be free from defects in materials for a period of time beginning on the twelfth (12th) month from the date of purchase and continuing until the sixtieth (60th) month from the date of purchase (extended warranty period). During the extended warranty period, GSI will replace the frame or basket components that prove to be defective under normal conditions of use without charge, excluding the labor, transportation, and/or shipping costs incurred in the performance of this extended warranty.

Conditions and Limitations:THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION SET FORTH ABOVE. SPECIFICALLY, GSI MAKES NO FURTHER WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH: (I) 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.

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 no obligation or responsibility for any representations or warranties made by or on behalf of any dealer, agent or distributor.

GSI assumes no responsibility for claims resulting from construction defects or unauthorized modifications to products which it manufactured. Modifications to products not specifically delineated in the manual accompanying the equipment at initial sale will void the Limited Warranty.

This Limited Warranty shall not extend to products or parts which have been damaged by negligent use, misuse, alteration, accident or which have been improperly/inadequately maintained. This Limited Warranty extends solely to products manufactured by GSI.

Prior to installation, the end-user has the responsibility to comply with federal, state and local codes which apply to the location and installation of products manufactured or sold by GSI.

Product Warranty Period

AP Fans and Flooring

Performer Series Direct Drive Fan Motor 3 Years * Warranty prorated from list price:

0 to 3 years - no cost to end-user

3 to 5 years - end-user pays 25%



** Warranty prorated from list price:

0 to 3 years - no cost to end-user


† Motors, burner components and moving parts not included. Portable dryer screens included. Tower dryer screens not included.

All Fiberglass Housings Lifetime

All Fiberglass Propellers Lifetime

AP and Cumberland Flex-Flo/Pan Feeding System Motors 2 Years

Cumberland Feeding/Watering Systems

Feeder System Pan Assemblies 5 Years **

Feed Tubes (1-3/4" and 2.00") 10 Years *

Centerless Augers 10 Years *

Watering Nipples 10 Years *

Grain Systems Grain Bin Structural Design 5 Years

Grain SystemsFarm FansZimmerman

Portable and Tower Dryers 2 Years

Portable and Tower Dryer Frames and Internal Infrastructure †

5 Years

9101239_1_CR_rev8.DOC (revised January 2014)

Copyright © 2016 by The GSI Group, LLCPrinted in the USA

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

regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be

consulted before installations are made.

1004 E. Illinois St. Assumption, IL 62510-0020

Phone: 1-217-226-4421 Fax: 1-217-226-4420

www.gsiag.com

CN-318514

Cumberland is a part of GSI, a worldwide brand of AGCO Corporation.

Documents

4802-5128 - Fan Bearing Remote Lubrication Kit · 4 4802-5128 Fan Bearing Remote Lubrication Kit 1. Safety Safety Guidelines This manual contains information that is important for