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Catwalks

Catwalk Construction and


Operator/Parts Manual

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


Catwalks Table of Contents

Table of Contents

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

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

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

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

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

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

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.

2
Catwalks 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
1 ST
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:
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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Catwalks 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: 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:

DANGER - 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.

WARNING - 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.

CAUTION - 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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Catwalks 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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Catwalks 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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Catwalks Safety

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.

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.

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Catwalks 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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Catwalks 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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Catwalks 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!

10
Catwalks 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! Do not attempt catwalk construction when the weather makes it


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

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!

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Catwalks 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.

12
Catwalks Assembly

KSL212 Drive end Group


Stage two

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

13
Catwalks Assembly

KSL212 Drive end Group


Stage three

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

14
Catwalks Assembly

KSL212 Drive end Group


Stage four

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

15
Catwalks 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.

16
Catwalks Assembly

KSL212 Tail end Group


Stage two

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

17
Catwalks Assembly

KSL212 Tail end Group


Stage three

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

18
Catwalks Assembly

KSL212 Tail end Group


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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Catwalks 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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Catwalks Assembly

KS1250 12’ 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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Catwalks Assembly

KS112 LADDER SECTION

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


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

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Catwalks 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

3 2

5 1
4

ITM QTY PART NO.


1 1 CONVEYOR
2 2 8' SECTION
3 2 12" SECTION
4 1 RIGHT LANDING
5 1 LEFT LANDING

23
Catwalks Installation

Installation of Catwalk/Overbin conveyor.


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

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Catwalks Installation

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

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Catwalks Installation

Installation of Catwalk
1. Picture of completed conveyor and catwalk.

26
Catwalks Installation

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.

27
Catwalks Installation

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.

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Catwalks Installation

Photo #1 is showing an assembled catwalk


with overbin being lifted up onto seed bins
with added tower supports.

Photo #1

Photo #2 shows the finished assembly


after it has been secured to the tower

Photo #2

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Catwalks

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Parts
Catwalks

How to Order Parts

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

KSi Conveyors, Inc.


454 N State Route. 49
Cissna Park, IL 60924
Phone: 815-457-2403
888-574-2668

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)

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Parts
Catwalks

SECTION DRIVE END LANDING


KSL212

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Parts
Catwalks

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
9 4 KS-310_INSIDE_CORNER
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

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Parts
Catwalks

SECTION RIGHT TAIL END LANDING


KSL212

34
Parts
Catwalks

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
7 5 KS-306_INSIDE_CORNER
8 2 KS-309-A_POST
9 4 KS-310_INSIDE_CORNER
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 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
28 1 KS-352_CON_MOUNT_CHANNEL
29 2 KS-355-A_CROSS_TIE
30 1 KS-358_KICK_TIE_CORNER
31 1 KS-359-A_KICK_OFFSET

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Parts
Catwalks

8’ SECTION
KS-0850

36
Parts
Catwalks

ITM QTY PART NO.


1 2 KS-255_ANCHOR_TIE
2 2 KS-307_96_SIDERAIL
3 2 KS-309-A_POST
4 4 KS-310_INSIDE_CORNER
5 2 KS-318_WALK_DECK
6 2 KS-319_WALK_BRACE
7 2 KS-326_8__HANDRAIL
8 2 KS-336_8__INT_RAIL
9 1 KS-352_CON_MOUNT_CHANNEL
10 2 KS-355-A_CROSS_TIE
11 4 KS-356-A_SIDERAIL_SPLICE
12 4 KS-357_DECK_TIE

37
Parts
Catwalks

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
4 6 KS-310_INSIDE_CORNER
5 3 KS-318_WALK_DECK
6 3 KS-319_WALK_BRACE
7 3 KS-326_8__HANDRAIL
8 3 KS-336_8__INT_RAIL
9 2 KS-352_CON_MOUNT_CHANNEL
10 3 KS-355-A_CROSS_TIE
11 4 KS-356-A_SIDERAIL_SPLICE
12 6 KS-357_DECK_TIE

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Parts
Catwalks

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

39
Parts
Catwalks

48’ SECTION WITHOUT


CONVEYOR

40
Catwalks

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.

Grade 8 Grade 5
Diameter
Dry Torque Lub. Torque Dry Torque Lub. Torque
No. Threads
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

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Catwalks

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