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DMC 176 Owner's Manual

Red giant grain stir-ator
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OWNER'S MANUAL
Red Giant
Grain Stir-Ator
Model 176
PNEG-1358
Date: 9-20-06
PNEG-1358
1004 East Illinois Street •
Assumption, IL 62510 •
Ph:(217) 226-4421

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  • Page 1 OWNER’S MANUAL Red Giant Grain Stir-Ator Model 176 PNEG-1358 Date: 9-20-06 PNEG-1358 1004 East Illinois Street • Assumption, IL 62510 • Ph:(217) 226-4421...

  • Page 3: Table Of Contents

    1004 East Illinois Street • Assumption, IL 62510 • Ph:(217) 226-4421 TABLE OF CONTENTS Safety Guidelines ..................4 Final Inspection Checklist ............... 8 Operator Qualifications ................9 Decals ....................10-12 Installation Procedures .................13 Bin Wall Stresses ...................32 Overall Size and Dimensions ............33-34 Parts, Wiring Diagrams, &...

  • Page 4: Safety Guidelines

    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.
  • Page 5 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 compo- nents and repair parts include the current safety signs.
  • Page 6 PRACTICE SAFE MAINTENANCE Always disconnect and lockout all power sources before servicing equipment. Understand service procedures before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is in operation. Keep hands, feet, and clothing from rotating parts.
  • Page 7 PREPARE FOR EMERGENCIES Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambu- lance service, hospital, and fire department near your telephone. WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment Eye Protection appropriate to the job.

  • Page 8: Final Inspection Checklist

    FINAL INSPECTION CHECK LIST HAVE YOU READ THE OWNER’S MANUAL COMPLETELY - YOURSELF? STUDY IT. Is there at least 7" clearance between the top of the track and the lowest part of the roof or roof braces? Are the track splices correctly installed? Consult the Drawings in the OWNER’S MANUAL? Is the suspension tee properly hung, LEVEL, with the end loops down, with lead-in wire and shut-off chain properly installed? Is the frame of the Stirator about 1"...

  • Page 9: Operator Qualifications

    Operator Qualifications A. The User/Operator must be competent and experienced to operate this equipment. Anyone who works with or around this equipment must have good common sense in order to be qualified. These persons must also know and meet all other qualifications, such as: 1.

  • Page 10: Decals

    THE DECALS SHOWN ON THIS PAGE MUST BE DISPLAYED AS SHOWN. Replacements are available upon request. Write to: DMC, 1004 E. Illinois St., Assumption, IL 62510 (217) 287-2653 PLEASE NOTE: 1. Decals on the page are not actual size. 2. Keep all decals wiped clean at all times.
  • Page 11 THE DECALS SHOWN ON THIS PAGE MUST BE DISPLAYED AS SHOWN. Replacements are available upon request. Write to: DMC, 1004 E. Illinois St., Assumption, IL 62510 (217) 287-2653 PLEASE NOTE: 1. Decals on the page are not actual size. 2. Keep all decals wiped clean at all times.
  • Page 12 THE DECALS SHOWN ON THIS PAGE MUST BE DISPLAYED AS SHOWN. Replacements are available upon request. Write to: DMC, 1004 E. Illinois St., Assumption, IL 62510 (217) 287-2653 PLEASE NOTE: 1. Decals on the page are not actual size. 2. Keep all decals wiped clean at all times.

  • Page 13: Installation Procedures

    RED GIANT INSTALLATION PROCEDURES NOTE PRIOR TO ASSEMBLY AND INSTALLATION CONSULT THE BIN ERECTION MANUAL OR MANUFACTURER FOR ANY SPECIAL UNIT HANGING OR SUPPORT LOCATIONS. STEP 1 All Red Giant Grain Stir-Ators come shipped as follows: (1) Trolley Base Assembly - 4 Auger and 6 Auger Units (1) Trolley Extension Bundle - Red Giant Stir-Ator...
  • Page 14 STEP 3 NOTE THE SEVEN-INCH DISTANCE FROM THE EAVE OF THE BIN TO THE CENTER LINE OF THE HOLES IN THE TRACK. Bins with steeply-pitched roofs may allow the 7" distance to be reduced. Roofs with the low or “flat” profiles may require more clearance.
  • Page 15 CHAIN IDLER SUPPORT BRACKETS Photo 2 STEP 8 Put main frame on saw horses (two pieces), as shown in Photo 2. Then space about 11-1/2 inches apart with angle flanges outward. Be sure chain idler support brackets are on the same end. STEP 9 Place inboard pivot end over main frame as shown in Photo 3.
  • Page 16 STEP 10 Place the outboard pivot end over main frame with track drive rollers’ toward the outside. Secure with two 3/8" x 1" hex- head bolts. Place flat washers on bolt, putting bolt through outboard pivot end and frame, securing with lock-washer and nut on the inside (two on each side) then place two 3/8"...
  • Page 17 STEP 12 FOR SIX AUGER UNITS ONLY: The six- auger trolley comes in two sections; one four-auger section plus an extension. First remove the bolts holding the center gear box on the four-auger section. See Photo 7 or Drawing F on page 44. Then, place two-auger section over four-auger section and replace gear box bolts.
  • Page 18 STEP 13 Place the 3/4" x 14" axle shaft through the trolley body axle bushings. Two axles are used on a four-auger trolley, and three axles are used on all 36' four auger, and all six-auger trolleys. After the axles have been installed, place one 3/4"...
  • Page 19 STEP 15 Next install the hold-down bracket, using four 5/16" x 3/4" hex-head bolts with lock- washers and nuts. Two sets of holes are punched in the bracket. Use the TOP HOLES when installing the hold-down bracket on a SIX-AUGER UNIT and the BOTTOM HOLES are provided for use when installing a FOUR-AUGER UNIT.
  • Page 20 STEP 17 Bolt the drive guide arm on to the center inboard pivot and chain idler support yoke, using three 1/4" x 3/4" carriage bolts with lock-washers and nuts. BE SURE THE GUIDE ARM IS POSITIONED AS IN Photo 12. See Drawing E on page 42.
  • Page 21 STEP 19 Install motor mount, with support plate, using six 5/16" x 3/4" hex-head bolts with lock-washers and nuts. Bolt mount bracket in third hole from the outboard end on trolley side rail. BE SURE MOUNTING PLATE IS ON THE SAME SIDE AS ELECTRICAL CORDS.
  • Page 22 STEP 21 Installation of gearbox drive belts - FOUR AUGER UNIT: Using two set of AX-38 V-belts, install one matched set on each end of top drive assembly. Check to be sure belt alignment is proper. Also, be sure clutch idlers are positioned as shown in Photos 16 and Installation of gearbox drive belts - SIX AUGER UNIT: First, follow the...
  • Page 23 STEP 21 (CONT’D) Using extension-shaft Delrin coupler, connect extension-shaft to top drive-shaft assembly as shown in Photo 20. Secure Delrin coupler with drive-in pin, or with steel pin and clip. Now tighten securely the 5/16" x 3/4" carriage bolts. Complete installation by installing matched pair of AX-38 V-belts.
  • Page 24 STEP 22 Installation of gearbox connecting-shaft shields using two shields for four-auger unit and three shields for six-auger unit. Simply place shield in position as shown in Photo 22. Firmly place notched end of shield between gearbox mounting brackets, and complete installation by hooking spring to the bottom side of the trolley frame.
  • Page 25 STEP 24 Gear Motor Installation: Place nylon flat washer on to track unit drive shaft. See Drawing D on page 40. Then, install the 3/16" x 5/8" woodruff key into the track unit assembly drive shaft, after which you slide one-half of the lovejoy coupler on to the drive shaft and secure.
  • Page 26 STEP 26 Position 5, 7-1/2 or 10 HP motor, mating the motor mount holes to the motor mount plate holes and securing with four 3/8" x 1-1/4" hex-head bolts, flat washers, lock washers and nuts, DO NOT TIGHTEN BOLTS, Place 4" O.D., double B-groove pulley on to motor shaft, using 1/4"...
  • Page 27 STEP 27 Place all belt shields as shown in Photo 28 (FOUR AUGER) - Photo 29 (SIX AUGER) - Photo 30 (OUTER SHIELD - SIX AUGER) -Photo 31 (FOUR & SIX AUGER TRACK DRIVE UNIT SHIELD). If electric motors other than the ones provided by David Manufacturing Co.
  • Page 28 STEP 28 Assemble the two-piece suspension ‘T’, using a 3/8" x 2-1/2" hex-head bolt, and 3/8" hex locknut. See Photo 32 or Drawing B on page 36. STEP 28A Install link from center suspension tee into clevis. Install 1/2" x 2" bolt and securely tighten 1/2"...
  • Page 29 to the shut-off chain so that it will not get caught on the unit. See Photo AA. Use the shut-off support chain(s} to hold the shut-off chain so that there is adequate clearance between the shut-off chain and the Red Giant as it travels underneath. See Photo 22.
  • Page 30 FLIGHTING IS RE-WELDED Photo 35 PROPERLY. CUTTING THE AUGER FROM THE TOP WILL VOID THE WARRANTY. DMC has a One-Season warranty on its down augers up to 22 feet long. DMC offers NO WARRANTY on 24 ft. long down augers. STEP 33 The last step is the installation of the down augers.
  • Page 31 Install the “Danger” decals on the bin. One on the inside of the walk-in door and one on the inside of the manhole door. Place the “DMC - Red Giant” decal on the outside of the walk-in door. PNEG-1358 Red Giant Stir-Ator...

  • Page 32: Bin Wall Stresses

    You will find two charts, Chart 1 and Chart 2. 4 - AUGER One is the shipping weights of the Model 176 Red Giant Stir-Ator, and Chart 2 sets 1184# 1225# 1268#...

  • Page 33: Overall Size And Dimensions

    RED GIANT STIR-ATOR OVERALL SIZE AND DIMENSIONS DRAWING A...
  • Page 34 Red Giant Stir-Ator Overall Dimensions BIN DIAMETER 24' 4A 27' 4A 27' 10" 4A 30' 4A 33' 4A 36' 4A 42' 4A 36' 6A 40' 6A 42' 6A 48' 6A DIMENSION A 52 1/2 PART NUMBER DAVID0375 DAVID0376 DAVID0377 DAVID0378 DAVID0390 DAVID0391 DAVID0392 DAVID0375 DAVID0376 DAVlD0377 DAVID0390 DIMENSION B 26 5/8 29 1/2...

  • Page 35: Parts, Wiring Diagrams, & Drawings

    Red Giant Stir-Ator 4 AUGER 6 AUGER Bin Diameter 27' 10" Part Number DAVID0888 DAVID0889 DAVID0889 DAVID0889 DAVID0890 DAVID0890 DAVID0891 DAVID0890 DAVID0891 DAVlD0891 DAVlD0891 Suspension Chain Part Number DAVID0879 DAVID0880 DAVID0881 DAVID0881 DAVID0882 DAVID0883 DAVID0885 DAVID0883 DAVID0885 DAVID0885 DAVID0887 Shut Off Chain 11' 6"...
  • Page 36 4 - 6 Auger Shields and Electrical Switchboxes Model 176 "Red Giant" Stirator Drawing B...
  • Page 37 4 - 6 Auger Shields and Electrical Switchboxes Ref. No. Part No. No. Req'd Description Ref. No. Part No. No. Req'd Description Pow er Sw itch Box - 3 Phase 230V 30 103E0006 104B2052 Gearbox Driv e Belt Shield 4 Auger 104B2061 Gearbox Driv e Belt Shield 6 Auger Power Switch Box...
  • Page 38 4 - 6 Auger Trolley Base Unit Model 176 "Red Giant" Stirator DRAWING C PNEG-1358 Red Giant Stir-Ator...
  • Page 39 4 - 6 Auger Trolley Base Unit Ref. No. Part No. Qty. Description Ref. No. Part No. Qty. Description Pulley - Double Groov e - 1" x 4-1/4" , A 103B0015 16 Ft. Plain Auger PT0645 103B0016 16 Ft. Hardsurfaced Auger Section (24'-33' 4 Auger) 105B0079 18 Ft.
  • Page 40 Outboard Pivot End and Track Section Model 176 "Red Giant" Stirator DRAWING D PNEG-1358 Red Giant Stir-Ator...
  • Page 41 Outboard Pivot End and Track Section Ref. No. Part No. No. Req'd Description Ref. No. Part No. No. Req'd Description 106C074 As Req'd Track - Bin Wall - 16' Length Bushing - Flanged, 1/2" ID x 3/4" PT0886 103C0038 As Req'd Track Connector Plate OD x 1/2"...
  • Page 42 Center Inboard Pivot End Model 176 "Red Giant" Stirator DRAWING E PNEG-1358 Red Giant Stir-Ator...
  • Page 43 Center Inboard Pivot End Ref. No. Part No. No. Req'd Description Ref. No. Part No. No. Req'd Description 103A0003 Cover - Center Junction Box Power Cord -To Motor (Specify Unit and Wire Size) 3 PHASE 103E0012 Insulating Spacer Washer 14' Long Cord for 24' 4 Auger 104A0005 Center Pivot Junction Box with pin 15' Long Cord for 27' 4 Auger...
  • Page 44 6-AUGER TROLLEY EXTENSION DRAWING F PNEG-1358 Red Giant Stir-Ator...
  • Page 45 6-AUGER TROLLEY EXTENSION Ref No. Part No. No. Req'd Description Ref No. Part No. No. Req'd Description 104B2057-36 68-9/16" Drive Shaft Extension 36' 6 Auger 103B0015 16 Ft. Plain Auger 104B2057-40 76-9/16" Drive Shaft Extension 40' 6 Auger 103B0016 16 Ft. Hardsurfaced Auger 104B2057-42 80-9/16"...
  • Page 46 RED GIANT WIRING DIAGRAMS DRAWING G Single Phase - 220 Volt Three Phase - 220 Volt Three Phase - 440 Volt PNEG-1358 Red Giant Stir-Ator...
  • Page 47 STIR-GUARD Ref. No. Part No. No. Req'd Description 106E073 Switch Stand -Off 104E2041 Stir Guard Mounting Plate 104E2044 Cover & Transformer Mount 104E2047 Transformer Stand-Off Bracket S-7215 Hex Flange Whiz Lock Nut, 1/4"-20 UNC S-1430 Flat Washer, 1/4" 019-1002-5 Insulating bushing, 1/2" 053-1012-3 Wire Connector 1EL2041...
  • Page 48 RED GIANT 440 VOLT TRANSFORMER HOOK-UP TRANSFORMER 440/220 VOLT (2EL0314=575/220 VOLT) (3EL5174=380/220 VOLT) 220 VOLT WIRE FROM TRANSFORMER WIRE FROM SWIVEL PNEG-1358 Red Giant Stir-Ator...
  • Page 49 DRAWING H DRAWING J PNEG-1358 Red Giant Stir-Ator...
  • Page 50 DRAWING K DRAWING L PNEG-1358 Red Giant Stir-Ator...
  • Page 51 DRAWING M DRAWING N PNEG-1358 Red Giant Stir-Ator...
  • Page 52 104B2133 Curtis #921270 (137) 1988 4th from Bin Wall, 6A. 104B2110* 104B2136** Bottom Fig., Rd. w/ Gussets 104B2133 Von Ruden #40-176 (2000) 2000 4th from Bin Wall, 6A. Bottom Fig., Rounded 104B0050 Von Ruden #35129 1976 2nd, 3rd, 5th, From Bin Wall, 6A.
  • Page 53 GEARBOX #128 (104B2133) 104B2133 #128 GEARB0X ITEM # PART# DESCRIPTION QTY. 104B2121 CASE 104B2123 PINION HOUSING 33677 ENDCAP,OPEN 104B3069 PINION SHAFT 34532 CROSS SHAFT 104B0059 GEAR, STRAIGHT, 21T 104B0058 GEAR, STRAIGHT, 14T 10285 BEARING CUP 10241 BEARING CONE 34119 ENDCAP, CLOSED PT0805 SEAL, LARGE PT0818...
  • Page 54 GEARBOX #129 (104B2134) 104B2134 #129 GEARB0X ITEM # PART# DESCRIPTION OTY. 104B2121 CASE 104B2123 PINION HOUSING 33677 ENDCAP, OPEN 104B3069 PINION SHAFT 34529 CROSS SHAFT 104B0059 GEAR, STRAIGHT, 21T 104B0058 GEAR, STRAIGHT, 14T 10285 BEARING CUP 10241 BEARING CONE 34119 ENDCAP,CLOSED PT0805 SEAL LARGE...
  • Page 55 GEARBOX #137 (104B2132) 104B2132 #137 GEARBOX ITEM # PART# DESCRIPTION QTY. 10482121 CASE 10482123 PINION HOUSING 33677 ENDCAP, OPEN 104B3069 PINION SHAFT 34530 CROSS SHAFT 104B0059 GEAR, STRAIGHT, 21T 104B0058 GEAR, STRAIGHT, 14T 10285 BEARING CUP 10241 BEARING CONE 34119 ENDCAP, CLOSED PT0805 SEAL, LARGE...
  • Page 56 GEARBOX #150 (104B2135) 104B2135 #150 GEARBOX ITEM # PART# DESCRIPTION QTY. 104B2121 CASE 104B2123 PINION HOUSING 33677 ENDCAP,OPEN 104B3069 PINION SHAFT 104B2127 CROSS SHAFT 104B2129 GEAR, STRAIGHT, 21T 104B2128 GEAR, STRAIGHT, 14T 10285 BEARING CUP 10241 BEARING CONE 3FH0572 RETAINING RING 34119 ENDCAP,CLOSED PT0805...
  • Page 57 RED GIANT GEARBOXES IDENTIFICATION NUMBERS - BOX LOCATIONS PULLEY SIZES - AUGER R.P.M. and 42' 4A)
  • Page 58 RED GIANT WIRING DIAGRAMS GEAR MOTOR MODELS E-3077 (502A0036) & E-3076 (502A0023) S02AOO36 DESCRIPTION Ref. No. E-3077 No. Req'd 501A0016 Gear Assembly, 18 & 60 Tooth 501A0017 Gear, 80 Tooth 501A0018 Cover Gasket 502A0001 Base (Low) 502A0008 Cover With Roller Clutch & Bearing 502A0010 Output Shaft, 3/4"...

  • Page 59: Operations

    OPERATIONS DRYING IN GRAIN DEPTHS OF OVER 18 FEET IS NOT ADVISED The recommendations below are for drying bins without wall-liners. If wall liners are used, higher temperatures can be used without worry of bin wall moisture. Consequently, a faster fill rate also can be used. 20% - 26% moisture grain from the field is the most profitable harvest-drying range.

  • Page 60: Drying Recommendations

    DRYING RECOMMENDATIONS To get uniform drying of grain in a bin, a uniform flow of air through the grain is required. Some of the factors affecting this air flow are: 1. Grain Cleanliness 2. Grain Depth 3. Grain Moisture The amount of fines and trash in the grain is best controlled by use of a grain cleaner before the grain is put in the bin.
  • Page 61 Disconnect all power to unit before using a pipe wrench (or other means of leverage) on the augers. If the Red Giant is stopped in a full bin of grain, caution must be used when restarting to prevent damage to the machine and/or the grain bin. Before starting the Red Giant Stir-Ator, hook the belt idlers into the neutral position.

  • Page 62: Stir-Guard Operation

    STIR-GUARD OPERATION The Stir-Guard is designed to protect your grain by shutting off the Stir-Ator if the unit is not advancing around the bin normally. As the gearmotor drives the unit around the bin, a microswitch actuator (which rides on the lower notched swivel block) sends a pulse to the solid state timer each time the roller advances one notch.

  • Page 63: Maintenance & Adjustment

    MAINTENANCE AND ADJUSTMENTS Red Giant Stir-A tor The Red Giant Grain Stir-Ator has been designed so that a minimum of maintenance and adjustment will be needed; however, as with any piece of machinery, some adjustments and periodic maintenance could become a necessity.
  • Page 64 MAINTENANCE and ADJUSTMENTS (cont’d) 8. Mercury Switch: The mercury switch controls the trail-back of the auger direction of travel around the bin. This mercury switch is set at the factory for normal trail-back, and should stop the movement of the machine when the bottom of the augers are from 12 to 20 inches back of a vertical line from the auger shaft bearing to the floor.

  • Page 65: Troubleshooting

    RED GIANT TROUBLE SHOOTING ELECTRICAL PROBLEMS: Electrical problems need not be a catastrophe if the process of elimination is used in finding the difficulty. A. Trip to the "OFF" position, the Stir-Ator switch box under the bin roof and check incoming electricity to the switch box.
  • Page 66 RED GIANT TROUBLE SHOOTING A. Fusetrons burned out. B. Loose wires. C. Severe misalignment of gear motor versus drive shaft of track unit which creates a tremendous bind in the gear motor. This can ruin the gear motor. (Place shims under gear motor until/proper alignment is achieved.) D.
  • Page 67 RED GIANT TROUBLE SHOOTING TRACK UNIT: A. Drive chain too loose. (Tighten.) B. Excessive drag of track unit on wall track. C. Teeth in front drive wheel worn excessively, causing slippage. D. Poorly constructed track splice can give undue track drive problems, catching or derailing the unit.

  • Page 68: Storage & Installation Data

    AUGER STUCK IN THE GRAIN: A. Latch all spring-loaded tighteners and then slowly engage one belt idler at a time until all augers are started. B. If the above does not work, block up the Red Giant Stir-Ator and turn each auger with a pipe wrench until free.

  • Page 69: Warranty

    The GSI Group, Inc. 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.
  • Page 70 Red Giant Grain Stir-Ator Model 176 DMC markets across the U.S. and around the world. For more information, contact the DMC Distribution Center closest to you. Illiana Distribution Center Clear Lake Distribution Center 1004 E. Illinois St. 5205 4th Ave South...

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