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Farm/Commercial
Distributor Cable Control
Installation Manual
PNEG-1375
Date: 05-08-07
PNEG-1375
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Equipment Information
Use of the Equipment Information page will help you identify your equipment in the case that
you need call your dealer or installer. This information should be filled out and kept on record.
Model #: ____________________________
Serial #: _____________________________
RPM: _______________________________
Head Pulley Dia.: _____________________
Discharge Height: _____________________
Horsepower: _________________________
Spout Dia.: __________________________
# of Spouts: __________________________
Date Purchased: _____________________
Dealer Name and Phone #: _____________
___________________________________
___________________________________
___________________________________
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Table of Contents
Contents
Chapter 1 Introduction ...................................................................................................................... 4
Chapter 2 Safety .................................................................................................................................. 5
Safety Guidelines ................................................................................................................ 5
Sign-off Sheet ..................................................................................................................... 8
Chapter 3 Decal Locations ................................................................................................................. 9
Chapter 4 Part Identification ............................................................................................................ 10
Distributor Cable Control Farm/Commercial ..................................................................... 10
Distributor Hardware ......................................................................................................... 10
10" Bucket Elevator ........................................................................................................... 10
16" - 36" Bucket Elevator .................................................................................................. 10
Chapter 5 Installation ...................................................................................................................... 11
Installation of Cable Wheel & Coupler Connector ............................................................. 11
Connector Pulley Assembly .............................................................................................. 12
Cable Guide Location ........................................................................................................ 13
Upper Cable Guide Assembly ........................................................................................... 14
Control Handle Installation ................................................................................................ 16
Lower Cable Wheel Assembly .......................................................................................... 17
Cable Guides .................................................................................................................... 19
Cable Installation ............................................................................................................... 20
Chapter 6 Warranty ........................................................................................................................... 23
PNEG-1375 Farm/Commercial Distributor Cable Control 3
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1. INTRODUCTION
Thank you for choosing this product. It is designed to give excellent performance and service for
many years.
This manual covers general information on the distributor cable control installation. Due to the
wide variety of field conditions we cannot cover every aspect of installation. We offer one method
for installing equipment but, rely on your qualified contractor’s experience and techniques. Some
conditions and surroundings do not allow certain practices during the installation of equipment.
We cannot be responsible for the installation of the distributor and accessories. We encourage
anyone installing or maintaining this equipment to thoroughly read this manual before
proceeding.
The company is the vendor of the distributor and certain of its optional accessories only and does
not assume responsibility for the installation. The installation recommendations contained within
this manual are for consideration only.
READ THIS MANUAL carefully to learn how to properly use and install this equipment. Failure
to do so could result in personal injury or equipment damage.
INSPECT the shipment immediately upon arrival. The Customer is responsible for ensuring that
all quantities are correct. Report any damage or shortages by recording a detailed description
on the Bill of Lading to justify the Customer’s claim from the Transport Firm. Our responsibility
for damage to the equipment ends with acceptance by the delivering carrier. Save all paperwork
and documentation furnished with any of the equipment.
THIS MANUAL SHOULD BE CONSIDERED a permanent part of your equipment and should be
easily accessible when needed.
A WARRANTY is provided as part of the company’s support program for customers who use and
maintain their equipment as described in the manual. The warranty is explained on the Warranty
page located on the inside back cover of this manual.
This warranty provides you the assurance that the company will back its products where defects
appear within the warranty period. Should the equipment be abused or modified to change its
performance beyond the factory specifications, the warranty will become void.
Note: All information, illustrations, 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.
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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 it’s safety instructions is a misuse of the equipment and
may lead to serious injury or death.
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.
F
Y
DANGER
WARNING
CAUTION
CAUTION
NOTE
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage.
NOTE indicates information about the equipment that
you should pay special attention to.
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2. SAFETY
Follow Safety Instructions
Carefully read all safety messages in this manual and
on your machine safety signs. Keep signs in good
condition. Replace missing or damaged safety signs.
Be sure new equipment components and repair parts
include the current safety signs. Replacement safety
signs are available from the manufacturer.
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
instruction. Keep children and other unqualified out of
the working area of ALL times.
Keep your machinery in proper working condition.
Unauthorized modifications to the machine may
impair the function and/or safety and affect machine
life.
If you do not understand any part of this manual and
need assistance, contact your dealer.
Read and Understand Manual
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
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Wear Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.
Safety glasses should be worn at all times
to protect eyes from debris.
2. SAFETY
Eye Protection
Wear gloves to protect your hands from
sharp edges on plastic or steel parts.
Wear steel toe boots to help protect your
toes from falling debris.
A respirator may be needed if a hog house
has poor ventilation. Waste fumes can be
toxic.
Remove all jewelry.
Tuck in any loose or dangling shoe strings.
Long hair should be tied up and back.
Gloves
Steel Toe Boots
Respirator
Hard Hat
Wear hard hat to help protect your head.
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2. SAFETY
Sign-off Sheet
Employer/Employee Training Sign-off Sheet
The principal concern of the company is your safety and the safety of others associated with
grain handling equipment. It is the responsibility of the buyer to make this manual available to
the person or persons involved with this equipment.
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 who are in the
area. Failure to read this manual is a misuse of the equipment.
We have included this Sign-off Sheet for you and your staff to use in the training process on
installation and operation of the equipment described in this manual. Read the entire manual,
sign off and date on Chart below.
Date Employees Name (printed) Employee’s Signature
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
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Install safety decals on components as shown below. Always insure that safety decals are in
place and in good condition. If a decal cannot be easily read for any reason or has been painted
over, replace it immediately. Contact your dealer or the manufacturer to order a replacement
decal free of charge.
C
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WARNING
SHEAR POINT
Keep hands clear of
drum and cables.
Disconnect and lockout
power before servicing.
DC-857
DC-857
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4. PART IDENTIFICATION
Note: Cable is not supplied with cable control. 3/16" aircraft cable is recommended.
Distributor Cable Control Farm/Commercial
FC-DCG
Part # Description Qty
1636DCG Trunk Clamp Assy. 16" - 36" PLTFRM 2
B24C Drive Crate, 24" Inside Cube 1
DFB0388 HD Cable Guide Assy.Top 1
FC-DCG-HDW Hardware, Dist.Cable Guide F/C 1
GSB-0006 Spacer, Bottom Guide 1
GSB-0030 Control Handle 1
GSB-0031 Control Handle Brackets 2
GSB-0045 Connector - Pulley Assembly 1
GSB-0049 Cable Wheel Assembly, Bottom 1
FC-DCG-XL
Part # Description Qty
1636DCG Trunk Clamp Assy. 16" - 36" PLTFRM 2
B42C Drive Crate, 42" x 40" x 24"T ID 1
DFB0388 HD Cable Guide Assy.Top 1
DFB0406 XL Cable Wheel Assy, Bottom 1
DFB0407 XL Control Handle Brackets 2
FC-DCG-HDW Hardware, Dist.Cable Guide F/C 1
GSB-0006 Spacer, Bottom Guide 1
GSB-0030 Control Handle 1
GSB-0045 Connector - Pulley Assembly 1
Distributor Hardware
Part # Description Qty
S-8762 Clamp 3/16" Cable 8
S-7521 Bolt 3/8"-16 x 1-1/2" 3
S-968 3/8"-16 Whiz Nut 3
S-1146 Bolt HHCS 5/16-18 x 1 ZN GR2 6
S-3611 Nut Flangewz 5/16" ZN 6
S-3729 Nut Hex 1/2"-13 ZN YDP GR5 20
S-7329 Bolt HHCS 5/16-18 x 2 ZN GR2 1
S-7382 Nut Nylock 5/16-18 ZN GR5 1
S-8268 Bolt HHCS 1/2-13 x 2 ZN GR8 16
10" Bucket Elevator
Part # Description Qty
GSB-10174 Clamp Band 4
16" - 36" Bucket Elevator
Part # Description Qty
DSP16002 Clamp Band 4
DSP16005 Clamp Rod Weldment 2
FC-DCG-HDW
GSB-10DCG
1636 DCG
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Installation of Cable Wheel & Coupler Connector
Once the distributor has been installed the installation of the cable controls can begin. First install
the cable wheel. This cable wheel mounts to the control pipe coming from the bottom of the
distributor using (3) 3/8"-16 x 1-1/2" Bolts (S-7521) and (3) 3/8-16 whiz nuts (S-968).
S
.
Figure 5A
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5. INSTALLATION
Connector Pulley Assembly
The next piece to install is the connector-pulley assembly (GSB-0045). This piece mounts to the
Top Cable Wheel Weldment as shown in Figure 5B. These are fastened together using (2)
5/16" x 1" bolts and whiz nuts, supplied in the hardware package (FC-DCG-HDW).
Figure 5B
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5. INSTALLATION
Cable Guide Location
Next locate the upper cable guide assembly (DFB0388). The location on the trunking is
determined by the height of the cable wheel. The cable must run in-line from the cable wheel to
the sheaves in the cable guide assembly. This location is shown in Figure 5C. For cable
installation see page 18.
Note: Cable is not supplied with cable control. The company recommends 3/16" aircraft
cable.
Figure 5C
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5. INSTALLATION
Upper Cable Guide Assembly
Once the location of the upper cable guide assembly is determined it must be fastened to the
trunking. The assembly of the clamp band and upper cable guide assembly (DFB0388) is shown
in the Figure 5D & Figure 5E. The 1/2" x 2" bolts and nuts that fasten the clamp bands to the
upper cable guide assembly are provide in the hardware package (FC-DCG-HDW). These
clamp bands vary depending on what size leg you have. Refer to the Table below to see what
clamp bands should be used.
Note: Use caution when tightening hardware, DO NOT overtighten and collapse trunking.
Figure 5D Trunking Removed for Clarity
Pulley Dia. Clamp Band Qty
10" GSB10174 2
Figure 5E Trunking Removed for Clarity
16", 24", 30" & 36" Pulleys Part # Qty
Clamp Band DSP16002 2
Clamp w/Rod Weldment DSP16005 1
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5. INSTALLATION
Control Handle Installation
Once the upper assembly has been installed, the control handle needs to be assembled to the
lower cable wheel assembly. There are two brackets (GSB-0031) that mount to the bottom of the
lower cable wheel assembly (GSB-0049). These brackets are fastened with 5/16" x 1" bolts and
whiz nuts. The control handle (GSB-0030) is then mounted between the brackets using the
second hole in the control handle and the end hole on the brackets. This is fastened using
5/16" x 2" bolt and lock nut. The hardware required is located in (FC-DCG-HDW). This assembly
is shown in Figure 5F.
Figure 5F
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5. INSTALLATION
Lower Cable Wheel Assembly
Once the control handle has been assembled the lower cable wheel can be installed. The
location of the lower cable wheel assembly (GSB-0049) is decided by where the operator will be
positioned. Once the desired height has been determined for the lower cable wheel, it must be
fastened to the trunking. The assembly of the lower cable wheel and clamp bands are shown in
Figure 5G & Figure 5H. The 1/2" x 2" bolts and nuts to fasten clamp bands to the lower cable
wheel are provided in the hardware package (FC-DCG-HDW). These clamp bands vary
depending on what size leg you have. Refer to Table on Page 14 to see what clamp bands
should be used.
Note: Use caution when tightening hardware, do not overtighten and collapse trunking.
Figure 5G Trunking Removed for Clarity
Figure 5H Trunking Removed for Clarity
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5. INSTALLATION
Cable Guides
To help keep the cable in-line from the upper assembly to lower assembly intermediate cable
guides need to be installed. The quantity of the intermediate cable guides is determined by the
height of the leg. The company recommends that they be installed every 20 feet. These
intermediate cable guides (GSB-0022) are fastened at the trunking joints using the same
hardware as the joint. The Assembly shows how the intermediate cable guides are located on
the trunk joints (See Figure 5I). For cable installation see page 18.
Note: Cable is not supplied with cable control. The company recommends 3/16" aircraft
cable.
Figure 5I
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5. INSTALLATION
Cable Installation
There is more than one way to install the cable for the cable control. We recommend that you
rely on your qualified contractor’s experience and techniques for cable installation. Below is an
example of one method of installation.
You will need two cables:
Cable 1, Spout Position Cable:
This cable is used to turn the spout. It should be long enough to reach from the Upper Control
Wheel to the Lower Control Wheel assembly. This can be determined by the vertical distance
between the two wheels and the horizontal distance from the side of the trunking to the center
of the Upper Control Wheel. (See Figure 5J for formula) Multiply this distance x 2 to account for
the distance up and back down. Add 26' to this distance to account for 2½ wraps around the
Upper and Lower Control Wheels (Approximately 3'-9" per wrap plus an extra 2 wraps allowance
for possible error. 7 wraps total = 26')
Spout Position Cable Length Formula: (A + B x 2) + 26' = Cable
Note: Cable is not supplied with cable control. The company recommends 3/16" aircraft
cable.
1
Length
Figure 5J
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5. INSTALLATION
When installing, mark the center of the cable. Start at the Upper Control Wheel. Feed the cable
into the holes in the side of the control wheel (as shown in Figure 5K) until the center of the cable
is between the two holes in the side. Wrap each end of the cable one full wrap around wheel.
Figure 5K
Run both ends of the cable through the cable guides (See Figure 5L), continue down through the
intermediate cable guides along trunking (See Figure 5M on Page 20), down to the lower cable
wheel. Wrap each end of the cable 1 full wrap and then cable clamp both ends
(See Figure 5N on Page 21).
Cable 2, Spout Release Cable:
This cable is used to release the index trigger so that the spout can be turned. This cable should
be able to reach from the control handle at the bottom side of the lower control wheel
(See Figure 5M on Page 20), up over the center pulley of the cable guide assembly, under the
connector pulley assembly, and tie off at the index trigger (See Figure 5L). Allow some extra
cable to be able to tie off at both ends.
Figure 5L
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5. INSTALLATION
Spout Position
Cable
Intermediate
Cable Guide
Spout Release
Cable
Lower Control
Wheel
Control Hanlde
Figure 5M
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5. INSTALLATION
Figure 5N
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5. INSTALLATION
Calibrating the Distributor Spout and the Lower Cable Control Wheel
1. Place the discharge spout index trigger to the far right as shown in Figure 5O.
2. Using the Index Number Decal (Decal part number DC-1799), peel off one of the numbers
(numbered 1 through 10) and place on the Spout Decal Plate in front of the Spout Position
Arrow (See Figure 5N on Page 21).
3. Move to the next spout by pulling up on the Control Handle to disengage the Index Trigger
while rotating the Lower Cable Control Wheel counter-clockwise.
4. Repeat Step 2 & 3 until all spouts have been labeled on the Spout Decal Plate.
Figure 5O
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Warranty
THE GSI GROUP, INC. (GSI) WARRANTS ALL PRODUCTS WHICH IT MANUFACTURES TO
BE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND
CONDITIONS FOR A PERIOD OF 12 MONTHS AFTER RETAIL SALE TO THE ORIGINAL
END USER. THE PURCHASER’S SOLE REMEDY AND GSI’S ONLY OBLIGATION SHALL BE
TO REPAIR OR REPLACE, AT GSI’S OPTION AND EXPENSE, PRODUCTS THAT, IN GSI’S
SOLE JUDGMENT, CONTAIN A MATERIAL DEFECT DUE TO MATERIALS OR
WORKMANSHIP. ALL DELIVERY AND SHIPMENT CHARGES TO AND FROM GSI’S
FACTORY WILL BE PURCHASER’S RESPONSIBILITY. EXPENSES INCURRED BY OR ON
BEHALF OF THE PURCHASER WITHOUT PRIOR WRITTEN AUTHORIZATION FROM AN
AUTHORIZED EMPLOYEE OF GSI SHALL BE THE SOLE RESPONSIBILITY OF THE
PURCHASER.
EXCEPT FOR THE LIMITED WARRANTY EXPRESSED ABOVE, 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 (I) 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. PURCHASER’S SOLE AND EXCLUSIVE REMEDY
IS AS SET FORTH IN THE LIMITED WARRANTY EXPRESSED ABOVE, WHICH SHALL NOT
EXCEED THE AMOUNT PAID FOR THE PRODUCT PURCHASED. THIS WARRANTY IS NOT
TRANSFERABLE AND APPLIES ONLY TO THE ORIGINAL PURCHASER. GSI SHALL HAVE
NO OBLIGATION OR RESPONSIBILITY FOR ANY REPRESENTATIONS OR WARRANTIES
MADE BY OR ON BEHALF OF ANY DEALER, AGENT OR DISTRIBUTOR OF GSI.
GSI ASSUMES NO RESPONSIBILITY FOR CLAIMS RESULTING FROM ERECTION
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 NULLIFY THE
PRODUCT WARRANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE.
THE FOREGOING WARRANTY SHALL NOT EXTEND TO PRODUCTS OR PARTS WHICH
HAVE BEEN DAMAGED BY NEGLIGENT USE, MISUSE, ALTERATION OR ACCIDENT. THIS
WARRANTY EXTENDS SOLELY TO ONLY PRODUCTS MANUFACTURED BY GSI. THIS
WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR
IMPLIED. GSI RESERVES THE RIGHT TO MAKE DESIGN OR SPECIFICATION CHANGES
AT ANY TIME.
PRIOR TO INSTALLATION, PURCHASER HAS THE RESPONSIBILITY TO COMPLY WITH
ALL FEDERAL, STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCATION AND
INSTALLATION OF PRODUCTS MANUFACTURED OR SOLD BY GSI.
PHLEGAL: #1832020 v1 (139LG01!.DOC) (revised December 2005)
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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.
Internet: http://www.grainsystems.com
Copyright © 2007 by the GSI Group
Printed in the USA
GSI Group, Inc.
1004 E. Illinois St.
Assumption, IL 62510-0020
Phone: 1-217-226-4421
Fax: 1-217-226-4420
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