catwalks - ksi : ksi · the catwalk area is to provide safe access to perform maintenance and/or...

Catwalks

Catwalk Construction and Operator/Parts Manual

COM-CATWALK-0812 PRINTED IN U.S.A.

Catwalks

2 2

INTRODUCTION ......................................................................................................................................................... 3

SAFETY ............................................................................................................................................................................. 4

ASSEMBLY ...................................................................................................................................................................... 12

INSTALLATION ........................................................................................................................................................... 24

PARTS ............................................................................................................................................................................. 31

BOLT TORQUE SPECIFICATIONS ....................................................................................................................... 41

Table of Contents

Table of Contents

Personnel operating or working around this equipment

should read this manual. This manual must be delivered with

equipment to its owner. Failure to read this manual and its

safety instructions is a misuse of the equipment. Any misuse

of the equipment may void the warranty.

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Introduction

Introduction

Thank you for purchasing your new Catwalk from KSi Conveyors. We are pleased to have you as a customer,

and hope you will enjoy many years of productive service from our products and staff.

Please read and understand this manual before operating the equipment. Pay special attention to the safety in-

formation to protect yourself from harm. If you need information beyond what can be found in the manual,

please give our friendly staff a call at 888 KSI-CONV.

KSi SAFETY

Replace missing guards and shields

FREE OF CHARGE!

KSi Conveyors are built to provide many years of dependable

service to our customers through durable craftsmanship.

One of the most important aspects of KSi engineering is

SAFETY 1st design throughout all product lines. At KSi safety

is NO ACCIDENT!

That is why KSi is implementing its SAFETY 1st program.

Should you ever need guards, shields, safety decals or owner/

operator manuals, simply contact KSi and we will supply you

with them FREE OF CHARGE!

If you need any of the above listed safety items or have safety

questions, please contact KSi:

1 ST

454 N State Route 49

Cissna Park IL 60924

Ph: 815-457-2403

888-574-2668

General Information A. KSi reserves the right to improve its product whenever possible and practical to do so. We reserve

the right to change, improve and modify products at any time without obligation to make changes,

improvements and modifications on equipment previously sold.

B. When receiving merchandise, it is important to check the quantity of parts and their descriptions

with the packing list enclosed with each package. All claims for freight damage or shortage

must be made with the consignee within ten (10) days from the date of the occurrence of freight

damage. The consignee should accept the shipment after noting the damage or loss.

C. KSi does not make any guarantees on self cleanout or the cross contamination of seed of any

kind for their conveyors, Manual cleanout will be required.

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Safety

TIPS FOR SAFE OPERATION OF KSI CONVEYORS

This Safety Alert symbol means

ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

The Safety Alert symbol identifies important safety messages on KSI conveyors and in the manual.

When you see this symbol, be alert to the possibility of personal injury or death. Follow the in-

structions in the safety message.

Why is SAFETY important?

The Three Best Reasons

Accidents Disable and Kill

Accidents Cost $$

Accidents Can be Avoided

SIGNAL WORDS:

DANGER -

WARNING -

CAUTION -

NOTE THE USE OF SIGNAL WORDS DANGER, WARNING

AND CAUTION WITH THE SAFETY MESSAGES. THE APPRO-

PRIATE SIGNAL WORD FOR EACH MESSAGE HAS BEEN SE-

LECTED USING THE FOLLOWING GUIDELINES:

Indicates an imminently hazardous situation that, if not avoided, will

result in death or serious injury. This signal word is to be limited to

the most extreme situations, typically for machine components that,

for functional purposes, cannot be guarded.

Indicates a potentially hazardous situation that, if not avoided, could

result in death or serious injury, and includes hazards that exposed

when guards are removed. It may also be used to alert against unsafe

practices.

Indicates a potentially hazardous situation that, if not avoided, may

result in minor or moderate injury. It may also be used to alert against

unsafe practices.

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Safety

1. General Safety Statements.

A. KSi’s principal concern is your safety and the safety of others associated with grain handling equip-

ment. We want to keep you as a customer. This manual is to help you understand safe installation

procedures and some problems which may be encountered by the operator and other personnel.

B. As the 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 are in the area.

Safety precautions may be required from the personnel. Avoid any alteration to the catwalk. Such

alterations may produce a very dangerous situation, where serious injury or death may occur.

C. 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.

D. Untrained operators subject themselves and other to serious injury or death. NEVER ALLOW

untrained personnel to enter catwalk area.

E. Keep children and other unqualified personnel out of the working area at all times.

F. The catwalk area is to provide safe access to perform maintenance and/or repairs to the overbin

equipment.

G. Be sure ALL operators are adequately rested and prepared to perform all functions of working from

catwalk platform.

H. Keep hair, loose clothing , and shoestrings away from rotating and moving parts. Never wear

loose fitting clothing when maintaining equipment from the catwalk area.

I. NEVER allow any person intoxicated or under the influence of drugs or alcohol on the catwalk at any

time. This is strictly prohibited.

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Safety

1. General Safety Statements (cont.)

J. Make sure someone is nearby and aware of your presence in event of an accident or emergency.

K. NEVER work alone.

L. ALWAYS think before acting. NEVER act impulsively around the equipment.

M. Make sure ALL equipment is locked in position before operating.

N. Keep hands and feet away from the conveyor intake and other moving parts when working from the

catwalk area.

O. NEVER repair/replace catwalk rails, parts, etc. unless wearing proper fall protection (PPE).

P. Use caution not to hit the catwalk when positioning a conveyor over the over-bin intake.

Q. Use ample lighting after sunset to light the catwalk work area.

R. ALWAYS lockout ALL power to the equipment prior to making any repair and/or maintenance from

the catwalk platform.

S. Keep the area around intake free of obstacles such as electrical cords, blocks, etc. that might trip

workers.

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Safety

BEWARE OF ELECTRICAL HAZARDS

Electricity can kill! Use extreme caution around electrical components.

Have your electric company check the transformer and lead wires to be sure they are

large enough to handle the additional load of the motor.

Electrical wiring should be done by a qualified electrician and all components shall

comply with applicable provisions of National Fire Protection Association Standard

NFPA No. 70, American National Standard Inst. ANSI-C1 or with the requirements

of the authority of having local jurisdiction.

KSi assumes no responsibility for the electrical wiring used with this machine.

KSi will not be liable for failure of the equipment due to poor or improper electrical

power installation.

Wires which are too small deliver insufficient voltage causing the motor to overload or

burn out.

Improper or inadequate wiring can kill or cause fires.

All electrical devices used on this machine shall be arranged to operate in a “fail safe”

manner, that is, if power failure or failure of device occurs, a hazardous condition must

not result . This means, the machine must not restart by itself after a power failure etc.

when power returns.

A pinch point is any place on the equipment which can injure the operator.

2. Pinch Points.

A. Components of this equipment have sharp edges which can scrape and/or cut an operator.

B. Not using proper personal protective equipment (P.P.E. or LOTO) can sever an operator’s limb or

even kill.

3. Shields and Guards.

A. Always keep all shields and guards in place on overbin conveyor when working from catwalk area.

B. Missing shields for guards can be replaced for free by contacting KSi.

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Safety

4. Personal Protective Equipment-

P..P.E.

A. The proper personal protective equipment

should be worn at all time.

B. Always wear safety glasses when in the work

area

C. Proper footwear should be worn during the

installation process, as well as any mainte-

nance functions.

D. It is recommended to wear protective gloves

during the installation process, as well as any

maintenance functions. It is recommended to

wear them also when removing any covers.

E. The use of fall protection is required at all

times during the installation process, as well

as maintenance functions.

F. The operator should never wear jewelry.

G. Loose fitting clothes should not be worn

around moving parts on conveyors or equip-

ment. Any clothing that becomes loosened

should be tucked in tightly

H. Loose or dangling shoe strings should be

tucked in.

I. Long hair should be tied up and/or back.

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Safety

5. Operator Qualifications.

A. The User/Operator must be competent and experienced to work from catwalk platform. Anyone who

works around conveyors must have good common sense in order to be qualified. These persons must also

know and meet all other qualifications, such as:

1. Any person who has not read and/or does not understand all operation and safety procedures

is not qualified to operate any conveyor systems.

2. Certain regulations apply to personnel operating power machinery. Personnel under the age

of 18 years may not operate power machinery, including conveyors. It is your responsibility,

as owner and/or supervisor, to know what these regulations are in your area or situation.

3. Unqualified or incompetent persons are to remain out of the work area.

4. O.S.H.A. (Occupational Safety & Health Administration) regulations state:

“At the time of initial assignment, and at least annually thereafter, the employer shall instruct

every employee in the safe operation and servicing of all equipment with which the employee

is, or will be, involved.” (Federal Occupational Safety & Health Standards for Agriculture.

Subpart D, Section 19287.57 (a) (6).

B. As a requirement of OSHA, it is necessary for the employer to train the employee in the safe operating

and safety procedures for this conveyor. We included this sign-off sheet for your convenience and

personal record keeping. All unqualified persons are to stay out of the work area at all times. It is

recommended that another qualified person who knows the shutdown procedure is in the area in an

event of an emergency. A person who has not read this manual and understands all operating and

safety instructions is not qualified to operate this machine.

Date Employee’s name (printed) Employee’s Signature

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

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Safety

WARNING! Owners and Contractors: Before starting construction of your cat-

walk, 1) READ AND UNDERSTAND THIS MANUAL! 2) Read and understand the

instructions for all equipment, auxiliary equipment, structures, other products, and the

like within or connected to this catwalk system / grain system. 3) View all illustrations

in this manual. 4) Read and understand any applicable OSHA Regulations, Building

Codes, and Electric Codes.

WARNING! Make certain that all persons on catwalks during construction are

properly fastened to safety cables to prevent injury or death due to falling.

WARNING! Installation of accessories or equipment in or on the catwalk that

would over stress the structure in any manner will void the Warranty. If you do not

have specific recommendations from KSi, where additional loading is involved, please

contact KSi before installing any such accessories or equipment.

WARNING! Make certain that all persons within the work area on ladders, lifts,

scaffolds, or the like are secure and not in danger of falling! Also make certain that the

work surfaces are clean and free of clutter.

WARNING! UNDER NO CIRCUMSTANCES SHALL ANY

OTHER BOLT BE SUBSTITUTED FOR THOSE SUPPLIED BY

KSi!

WARNING! Any alterations to catwalks without the authorization of the KSi

Conveyors Inc. engineering department is prohibited!

WARNING! Local codes supersede the instructions provided in this manual and

should be strictly adhered to. Contact the manufacturer if you have questions.

WARNING! Avoid injury or death! Use extreme caution when working from

heights. Use the proper equipment when working from heights. Take the proper pre-

cautions to prevent persons or objects from falling!

Catwalks

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Safety

WARNING! DO NOT substitute parts or hardware for those supplied by KSi.

WARNING! Read and understand all of the instructions in this manual before

starting assembly. Build you catwalks in accordance with the instructions. Failure to

build you catwalk correctly could result in structural damage or failure! Structural

damage or failure of any of these assemblies could result in injury or death of persons.

Call KSi if you have any questions regarding assembly.

WARNING! Be certain to build your catwalk in exact accordance with your cat-

walk layout!

WARNING! Do not use any damaged catwalk components. It may not be safe.

WARNING! If you have any problems with construction or if additional wind

loading will be added to the catwalk, contact the factory immediately!

WARNING! When adding additional equipment not previously accounted for,

considerable wind load or weight may be added to the catwalk. Be certain that your

KSi catwalk is designed and staged for all equipment, and any future additions. If you

are uncertain, contact the factory before installing the catwalk.

WARNING! Pre-position components before field welding. Verify that all in-

stallation requirements are satisfied!

WARNING! IMPORTANT: If any question or difficulty should arise

during the process of the catwalks installation, the contractor or owner

should contact KSi to get an answer or to resolve the problem!

WARNING! Do not attempt catwalk construction when the weather makes it

unsafe. Especially, when the wind conditions are not favorable!

Catwalks

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Assembly

KSL212 Drive end Group

Stage one

1. Put the following pieces together with 7/16” hex head bolts and nuts.

2. Do not tighten nuts.

Catwalks

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Assembly


Stage two

1. Keep adding the pieces with 7/16” hex head bolts and nuts without tightening

the nuts.

Catwalks

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Assembly


Stage three

1. Mount the stiffeners to the bottom of the deck pieces and loosely install 3/8”

carriage bolts and nuts.

Catwalks

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Assembly


Stage four

1. Install the hand rails and kick plates with 3/8” slotted bolts and nuts.

2. Tighten all the nuts.

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Assembly

KSL212 Tail end Group

Stage one

1. Put the following pieces together with 7/16” hex head bolts and nuts.

2. Do not tighten.

Catwalks

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Assembly


Stage two

1. Keep adding the pieces with 7/16” hex head bolts and nuts without tightening

the nuts.

Catwalks

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Assembly


Stage three

1. Mount the stiffeners to the bottom of the deck pieces and loosely install 3/8”

carriage bolts and nuts.

Catwalks

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Assembly


Stage four

1. Install the hand rails and kick plates with 3/8” slotted bolts and nuts.

2. Tighten all the nuts.

Catwalks

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Assembly

KS0850 8’ SECTION

1. Put bottom rails together with 7/16” hex bolts and nuts.

2. Put deck plates on with 3/8” carriage bolts and nuts.

3. Put handrails on with 3/8” slotted bolts and nuts.

4. Put 2 safety rings on for each bin (item1) with 3/8” hex bolts and nuts.

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Assembly

KS1250 12’ SECTION

1. Put bottom rails together with 7/16” hex bolts and nuts.



4. Put 2 safety rings on for each bin (item1) with 3/8” hex bolts and nuts.

Catwalks

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Assembly

KS112 LADDER SECTION



Catwalks

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Assembly

CATWALK ASSEMBLY

1. Each Conveyor will have a drive end and a tail end assembly.

2. The drive end and the tail end could be on either end of finished catwalk.

3. The diagrams are set up so that the left end is the drive end and the right end is the tail end.

4. If the ends are reversed then build the drive end like the tail end and the tail end like the

drive end.

5. Put together the drive end and then the right amount of 8’ and 12’ sections for the bin site

length and then the tail end.

6. Catwalk is made for the drive end to be the end for the bin landing and entry point.

7. If the tail end is to have the bin landing and entry point, it must be built like the drive end.

48’ SECTION AND CONVEYOR

ITM QTY PART NO.

1 1 CONVEYOR

2 2 8' SECTION

3 2 12" SECTION

4 1 RIGHT LANDING

5 1 LEFT LANDING

5 4

3 2

1

Catwalks

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Installation of Catwalk/Overbin conveyor.

1. Assemble sections, in photos, according to parts diagrams on pages 15 thru 20.

Installation

Catwalks

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Installation of Catwalk/ Overbin conveyor.

1. Set catwalk and overbinup on tower brackets per Picture A.

2. Drill holes and put brackets in to secure the catwalk to the towers once you are sure it is in the right position as

in picture B. Safe application for drilling holes to connect platform to brackets will require the use of fall pro-

tection equipment. Connection to be made from underside of platform and brackets.

Picture A

Picture B

Installation

Catwalks

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Installation of Catwalk

1. Picture of completed conveyor and catwalk.

Installation

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Upper view from catwalk during final installation process.

View of platform access from bin ladder during assembly process.

*Note: Access from bin ladder to catwalk varies by design of each individual

seed site.

Installation

Catwalks

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Assembled catwalk platform and overbin conveyor prior to lifting up on bin

supports. (Yellow lifting brackets were designed and used by KSi Service

Techs)

View of the catwalk / overbin after it has been secured to bin support braces.

Installation

Catwalks

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Photo #1

Photo #2

Photo #1 is showing an assembled catwalk

with overbin being lifted up onto seed bins

with added tower supports.

Photo #2 shows the finished assembly

after it has been secured to the tower

Installation

Catwalks

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Catwalks

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1. Refer to the proper layout view for the area of the machine.

2. Find illustration of the part to be ordered.

3. Note the ITEM number in the balloon point to the part.

4. On the parts list, find the ITEM number listed in the table.

5. Find the Quantity, Part Number, and Description associated with the ITEM number for use when placing

your order.

Paint For matching red paint, use Diamond Vogel IB5588, or equivalent paint.

Order supplies from

Abbreviations used in Parts List AS—Assembly

BKT—Bracket

ITM—Item

LH—Left hand side

NO— Number

OPT—Optional component

QTY—Quantity

RH—Right hand side

AR—As required (e.g. ft. of belt)

(part numbers for stainless conveyors are as

shown in illustrations but with XXXXX-8X

designation)

KSi Conveyors, Inc. 454 N State Route. 49

Cissna Park, IL 60924

Phone: 815-457-2403

888-574-2668

How to Order Parts

Parts

Catwalks

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SECTION DRIVE END LANDING

KSL212

Parts

Catwalks

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ITM QTY PART NO.

1 2 KS-300_SIDERAIL

2 1 KS-301-A_MAIN_RAIL

3 1 KS-302_SIDE_RAIL

4 2 KS-303_SHORT_RAIL

5 1 KS-304_MID_RAIL

6 6 KS-305_CORNER_POST

7 5 KS-306_INSIDE_CORNER

8 3 KS-309-A_POST


10 1 KS-311_MAIN_DECK

11 1 KS-312_SIDE_DECK

12 1 KS-313_MAIN_NARROW_DECK

13 1 KS-314_SIDE_NARROW_DECK

14 2 KS-315_SKIN_BRACE

15 2 KS-316_SKIN_NARROW_BRACE

16 1 KS-317-A_LANDING_WALK

17 1 KS-319_WALK_BRACE

18 2 KS-321-A_END_HAND_RAIL

19 2 KS-322-A_SIDE_HANDRAIL

20 1 KS-324_ENTRY_HANDRAIL

21 1 KS-325-A_SHORT_HANDRAIL

22 2 KS-331-A_END_INT_RAIL

23 2 KS-332-A_SIDE_INT_RAIL

24 1 KS-334_ENTRY_INT_RAIL

25 1 KS-335-A__SHORT_INT_RAIL

26 1 KS-341-A_END_KICKBOARD

27 1 KS-342_SIDE_KICKBOARD

28 1 KS-343_WALK_KICKBOARD

29 1 KS-344_ENTRY_KICKBOARD

30 2 KS-352_CON_MOUNT_CHANNEL

31 2 KS-355-A_CROSS_TIE

32 4 KS-356_SIDERAIL_SPLICE

33 2 KS-357_DECK_TIE

34 1 KS-358_KICK_TIE_CORNER

Parts

Catwalks

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SECTION RIGHT TAIL END LANDING

KSL212

Parts

Catwalks

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ITM QTY PART NO.

1 2 KS-300_SIDERAIL

2 1 KS-301-A_MAIN_RAIL

3 1 KS-302_SIDE_RAIL

4 2 KS-303_SHORT_RAIL

5 1 KS-304_MID_RAIL

6 4 KS-305_CORNER_POST


8 2 KS-309-A_POST


10 1 KS-311_MAIN_DECK

11 1 KS-312_SIDE_DECK

12 1 KS-313_MAIN_NARROW_DECK

13 1 KS-314_SIDE_NARROW_DECK

14 2 KS-315_SKIN_BRACE

15 2 KS-316_SKIN_NARROW_BRACE

16 1 KS-317-A_LANDING_WALK


18 2 KS-321-A_END_HAND_RAIL

19 2 KS-322-A_SIDE_HANDRAIL

20 2 KS-325-A_SHORT_HANDRAIL

21 2 KS-331-A_END_INT_RAIL

22 2 KS-332-A_SIDE_INT_RAIL

23 2 KS-335-A__SHORT_INT_RAIL

24 1 KS-341-A_END_KICKBOARD

25 1 KS-342_SIDE_KICKBOARD

26 1 KS-343_WALK_KICKBOARD

27 1 KS-345_SHORT_KICKBOARD



30 1 KS-358_KICK_TIE_CORNER

31 1 KS-359-A_KICK_OFFSET

Parts

Catwalks

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8’ SECTION

KS-0850

Parts

Catwalks

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ITM QTY PART NO.

1 2 KS-255_ANCHOR_TIE

2 2 KS-307_96_SIDERAIL

3 2 KS-309-A_POST


5 2 KS-318_WALK_DECK


7 2 KS-326_8__HANDRAIL

8 2 KS-336_8__INT_RAIL



11 4 KS-356-A_SIDERAIL_SPLICE


Parts

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12’ SECTION

KS-1250

ITM QTY PART NO.

1 3 KS-255_ANCHOR_TIE

2 2 KS-308_144_SIDERAIL

3 3 KS-309-A_POST


5 3 KS-318_WALK_DECK


7 3 KS-326_8__HANDRAIL

8 3 KS-336_8__INT_RAIL



11 4 KS-356-A_SIDERAIL_SPLICE


Parts

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Parts

LADDER SECTION

KSL-112

ITM QTY PART NO.

1 2 64-LB003_LADDER_BRACKET

2 6 10189_PEAK_HANDRAIL

3 3 50121_WALK_POST

4 3 50162_10_INTER_SECTION

5 3 KS-256_MOUNT_FOOT

6 1 SUKUP_LADDER

Catwalks

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48’ SECTION WITHOUT

CONVEYOR

Parts

Catwalks

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Bolt torque specifications

Proper torquing of bolts, cap screws, studs, and nuts is very important when assembling or installing any compo-

nent on a machine. The chart below lists bolt torques for most popular sizes of bolts. The chart also applies to

tightening studs or tightening nuts. Refer to the chart whenever a bolt must be tightened on a machine.

Two columns of figures are shown for each type of bolt, dry and lubricated. The “dry” column would cover bolts

as the come from the package or bolts with no external lubrication applied. The second column covers bolts exter-

nally lubricated with oil, white lead, anti-seize, graphite, etc. This column should also be used to tighten bolts that

are being loctite applied.

Diameter

No. Threads Dry Torque Lub. Torque Dry Torque Lub. Torque

lbf-ft N-m lbf-ft N-m lbf-ft N-m lbf-ft N-m

4-40 12 1 9 1 8 0.9 6 0.6

6-32 23 2 17 1 16 1 12 1

8-32 41 4 31 3 30 3 22 2

10-24 60 6 45 5 43 4 32 3

1/4-20 144 16 108 12 96 10 75 8

lbf-ft N-m lbf-ft N-m lbf-ft N-m lbf-ft N-m

5/16-18 25 33 18 24 17 23 13 17

3/8-16 45 61 35 47 30 40 23 31

7/16-14 70 94 55 74 50 67 35 47

1/2-13 110 149 80 108 75 101 55 74

9/16-12 150 203 110 149 110 149 80 108

5/8-11 220 298 170 230 150 203 110 149

3/4-10 380 515 280 379 260 352 200 271

7/8-9 600 813 460 623 420 583 320 433

1-8 900 1,220 680 922 640 867 480 650

1 1/8-7 1,280 1,735 960 1,301 800 1,084 600 813

1 1/4-7 1,820 2,467 1,360 1,844 1,120 1,518 840 1,139

1 3/8-6 2,380 3,227 1,780 2,413 1,460 1,979 1,100 1,491

1 1/2-6 3,160 4,284 2,360 3,200 1,940 2,630 1,460 1,979

Grade 5 Grade 8

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catwalks - ksi : ksi · the catwalk area is to provide safe access to perform maintenance and/or...

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