Catwalk #4 Manual - Chief Agri/Industrial

Transcription

P/N 9621142 Rev 0
INSTALLATION MANUAL
TYPE 4 CATWALK SYSTEM
“We Engineer Relationships”
CHIEF INDUSTRIES, INC. – AGRI/INDUSTRIAL DIVISION
Installation Manual
 Chief Industries, Inc.
4400 East 39th Street • PO Box 848
Kearney, NE 68847
Phone 800.359.7600
P/N 9621142 Rev 0
Table of Contents
Introduction .............................................................................. 1
Standard Limited Warranty ....................................................... 2
General Safety Statement ........................................................ 5
Work Area Safety Statement........................................................... 5
Auxiliary Equipment Safety ............................................................. 6
Packaging and Color Coding Information ................................. 7
Diagram of Catwalk Components ............................................. 8
Individual Catwalk Components ...................................................... 9
Terminating End Brace ............................................................................. 9
Cross Brace .............................................................................................. 9
Wind Diagonal........................................................................................... 9
Side Truss Section .................................................................................... 9
End Enclosure........................................................................................... 9
Walkway.................................................................................................. 10
Mounting Areas / Weight ........................................................ 10
Before You Begin ................................................................... 11
Unloading: ..................................................................................... 11
Storage of Materials: ..................................................................... 11
Claims for Shortages or Damaged Parts:...................................... 11
Manpower Requirement Estimate: ................................................ 12
Tool and Equipment Requirement Estimate:................................. 12
Tips and Shortcuts: ....................................................................... 12
Bolt Torque ............................................................................ 13
Catwalk Sections.................................................................... 13
Connect Catwalk Sections ..................................................... 19
Catwalk Section Weights .............................................................. 20
Conveyor Mounting ................................................................ 20
Install Catwalk Support System .............................................. 20
Enlarged Drop through Opening............................................. 22
Summary................................................................................ 24
P/N 9621142 Rev 0
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Introduction
Thank you for purchasing a Type 4 Catwalk System. The attached guidelines have
been derived from contractors with years of experience with installations of Type
4 Catwalk Systems. These guidelines present an easy, safe and effective method of
installation, although alternate installation methods may be used.
This proprietary information is loaned with the expressed agreement that the
drawings and information therein contained are the property of Chief Industries,
Inc. and will not be reproduced, copied, or otherwise disposed of, directly or
indirectly, and will not be used in whole or in part to assist in making or to furnish
any information for the making of drawings, prints or other reproduction hereof,
or for the making of additional products or equipment except upon written
permission of Chief Industries, Inc. first obtained and specific as to each case.
The acceptance of this material will be construed as an acceptance of the
foregoing agreement.
The technical data contained herein is the most recent available at the time of
publication and is subject to modification without notice. Chief Industries, Inc.
reserves the right to modify the construction and method of operation of their
products at any time without any obligation on their part to modify any equipment
previously sold and delivered.
Chief Industries, Inc. 800-359-7600
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Standard Limited Warranty
1. What is covered by this standard limited warranty?
If you are the original retail purchaser of Chief Manufactured Catwalk and Tower System,
Chief Industries, Inc. expressly warrants to you that the components manufactured by Chief
Industries, Inc. were, on the date of delivery to you, free from defects in the composition of
material, Chief workmanship, and design.
2. Duration of this standard limited warranty and notice requirements.
This standard limited warranty is applicable under normal use and service to defects which
become evident within a period of one (1) year from the date of delivery of your Chief Catwalk
and Tower System to you and which are reported in writing to Chief Industries, Inc. within
thirty (30) days of discovery of the defect. In any event, Chief’s obligations under this
standard limited warranty shall expire thirteen (13) months from the invoice date.
In order to obtain warranty service, simply contact Chief Industries, Inc. in writing with the
following information:
•
•
•
•
•
•
Your name
Location of the product
Dealer name
Description of problem
Any pertinent information
Date of purchase
No claim will be processes until all of this information has been received in writing by Chief
Industries, Inc. For warranty service, contact:
Chief Industries, Inc.
Agri / Industrial Division – Customer Service Department
P.O. Box 848
Kearney, NE 68848
3. Chief’s Obligations
By purchasing your Chief Catwalk and Tower System subject to this standard limited warranty,
you and Chief Industries, Inc. expressly agree to an allocation of the risks of product failure
between you and Chief Industries, Inc. This allocation is recognized by both parties and is
reflected in the price of the Chief Catwalk and Tower System.
4. Remedies Available From Chief
If a defect in your Chief Catwalk and Tower System is covered by this standard limited
warranty, Chief Industries, Inc. will supply replacement parts F.O.B. Chief Industries, Inc.,
Kearney, Nebraska. In addition, during the first year of the warranty, Chief Industries, Inc. will
supply the labor necessary to make repairs in your Chief Catwalk and Tower System made
necessary by such defect or faults. Chief Industries, Inc. will request at least two competitive
bids for labor, as shall in the judgment of Chief Industries, Inc. be the most competitive
remedy for the failure covered by this warranty. Of course, Chief Industries, Inc. reserves the
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right to reject all such bids and to obtain additional bids. Upon acceptance of a bid by Chief
Industries, Inc., Chief Industries, Inc. will authorize the necessary repair.
5. Remedies Not Available From Chief
The obligations stated in the preceding paragraph are the sole and exclusive remedies
available from Chief Industries, Inc. in the event of problems with your Chief Catwalk and
Tower System. Chief Industries, Inc. will not be liable for the costs of dismantling defect parts
or installing replacement parts, including labor costs, after the first year, and Chief Industries,
Inc. will not be liable for any special, incidental pr consequential damages based upon breach
of warranty, breach of contract negligence, strict tort, or any other legal theory.
6. What is Not Covered by this Standard Limited Warranty
a)
Chief manufactured product not sold as part of the catwalk and tower
system.
b) Products, components, equipment accessories, or parts manufactured by
someone other than Chief Industries, Inc.
c) Accessories, Temporary grain storage bins, or bins designed for storage of
products other than whole grain storage.
d) Damage or loss during shipment of the Chief Catwalk and Tower Systems.
e) Damage or loss caused by the acts or omissions of the erector or his agents.
f) Damage or loss caused, in whole or in part, by inadequate or improper site
selection, inadequate or improper site preparation, inadequate or improper
foundation, or any other failure to provide a suitable installation or
installation environment for a suitable installation or installation of the Chief
Catwalk and Tower System, or any product, component, equipment,
accessories, parts used in conjunction with the Chief Catwalk and Tower
System.
g) Damage or loss caused, in whole or in part, by the use of the Chief Catwalk
and Tower System for purposes other than those for which it was designed.
h) Damage or loss caused, in whole or in part by unauthorized attachments,
modifications, or alterations of the Chief Catwalk and Tower System.
i) Damage or loss caused, in whole or in part, by improper or inadequate
maintenance, misuse, or abuse of the Chief Catwalk and Tower System.
7. No Other Warranties
a)
Complete and exclusive agreement:
i. This agreement is the complete and exclusive agreement between
you and Chief Industries, Inc. concerning the allocation of the risks
of damage or loss arising from manufactured component failure. It
supersedes all prior agreements, whether written or oral, and all
other communications between you and Chief concerning the
allocation of those risks. No employee of Chief Industries, Inc. or
any other person, including authorized dealers and any other
person authorized to sell a Chief Catwalk and Tower System, has
any authority to make representations, promises, or warranties in
addition to those contained herein.
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b) This standard limited warranty is in lieu of all other warranties, expressed or
implied, including warranties of merchantability and fitness for a particular
purpose.
8. Allocation of Risks
This agreement allocates the risks of damage or loss arising from product failure between
Chief Industries, Inc. and purchaser. This allocation is recognized by both parties and was
reflected in the purchase price of the goods.
As purchaser of a Chief Catwalk and Tower System and this standard limited warranty, I
acknowledge that I have read the foregoing agreement, understand its provisions and agree to
be bound by its terms.
Chief Industries, Inc.
Agri / Industrial Division
P.O. Box 848
Kearney, NE 68848
By:____________________________________________________________
Date:__________________________________________________________
Purchaser’s Signature:____________________________________________
Date Signed:____________________________________________________
Purchaser’s Name:_______________________________________________
Purchaser’s Address:_____________________________________________
Invoice Date:___________________________________________________
Invoice Number:________________________________________________
Dealer:________________________________________________________
Customer:_____________________________________________________
Customer Address:______________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
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General Safety Statement
Your safety and the safety of others is a primary concern to Chief Industries, Inc.
This manual was written to assist in the safe installation of the Catwalk System.
It is your responsibility as the owner, builder, operator, or supervisor to know
what specific requirements, precautions and hazards exist and to make these
known to all personnel working with equipment or on the jobsite so that they can
take any necessary safety precautions.
All personnel, including the installation crew, must read and understand the
information contained in this manual before starting construction. Chief
Industries, Inc. is not responsible or liable for the misuse of equipment or
operation of personnel or equipment in an unsafe manner.
Chief Industries, Inc. assumes no liability with respect to proper construction and
inspection, assembly, or use of its products established under applicable laws, all
of which is the sole responsibility of the purchaser and those authorized for the
installation.
Follow all local and federal safety laws and regulations. Make certain that all
equipment and personnel conform to any applicable OSHA regulations.
Work Area Safety Statement
To ensure the safety of all individuals in the work area, only authorized and
trained persons shall install, maintain and use the Catwalk System.
Under no circumstances should unauthorized individuals be allowed to trespass or
be present in the work area.
It shall be the duty of all operators to verify that the work area is clean, organized
and kept free of all debris and tools that might cause an accidental tripping or
falling hazard.
Special care should be taken when working from unsafe heights. Common sense
dictates that when conditions such as rain or wind prohibit the safe use of
equipment, the installation be discontinued.
Chief Industries, Inc. strongly recommends that equipment meeting the current
OSHA / ANSI specifications be used, whether the individual operator is required
by law to do so or not. Properly climbing equipment and secured safety belts
should be used at all times when performing operations work, installation or
maintenance.
Field modifications without the authorization of the manufacturer may present
unknown dangers to the operator and must be avoided.
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Auxiliary Equipment Safety
You may decide to purchase and install “auxiliary equipment” made by other
manufacturers. Chief Industries, Inc. has no control over the design and
manufacture of this equipment. In view of this, at a minimum, we suggest you do
the following:
1. Obtain, read and understand the instructions and cautions of the auxiliary
equipment manufacturer. Be certain that all equipment is installed in
agreement with those instructions.
2. Check with Chief Industries, Inc. to make sure that your bin system is
designed to support any additional loads supplied by the auxiliary
equipment.
3. Obtain any applicable safety decals from the manufacturer and make
certain they are displayed in a visible location.
4. Make certain that all electrical equipment is properly installed and
grounded by a qualified electrician.
5. Check availability and operation of electrical lock out and emergency stop
systems.
6. Be certain that all guards and shields are securely in place.
7. Store all operation / maintenance manuals in a safe place for future use.
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Packaging and Color Coding Information
For your convenience in storing part and installation of the Type 4 Catwalk System, all
packages will be color coded, individual items labeled with an appropriate part number,
and packages labeled.
Example Label for Shipments:
Project Number (28599)
Detail List of Quantities and Part Numbers:
Qty
Chief Part Number
20
20
10
9621019
9621010
9621007
Hardware, including bolts, nuts, screws and other small clips/brackets may be divided
into smaller packages for ease of use and identification.
Where applicable component parts will be marked with the following color codes:
8 Gage
9 Gage
10 Gage
11 Gage
12 Gage
13 Gage
14 Gage
16 Gage
Red
Light Green
Black
Pink
Dark Blue
Brown
Yellow
Green
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Diagram of Catwalk Components
To save time and assist as a quick reference guide, the main component parts and the
main assemblies created from these specific components will be shown on the
following pages. Take note of the orientation of these parts in the top level assemblies
to help reduce time and errors during the installation process.
End Enclosure
Side Truss
Cross Brace
Wind Diagonal
Walkway
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Individual Catwalk Components
Terminating End Brace
9621738
9621709
9621739
30” Mounting
45” Mounting
60” Mounting
Cross Brace
Cross Brace
9621734
9621678
9621736
30” Mounting
45” Mounting
60” Mounting
Wind Diagonal
Wind Diagonal
9621740
9621677
9621742
30” Mounting
45” Mounting
60” Mounting
Side Truss Section
9621705
9621701
9621697
9621676
Terminating End Brace
Truss Section
3’-4” Length
6’-8” Length
10’ Length
20’ Length
End Enclosure
End Enclosure
9621728
9621724
9621731
30” Mounting
45” Mounting
60” Mounting
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Walkway
9621037
9621036
9621035
3’-4” Length
6’-8” Length
10’ Length
End Enclosure
Mounting Areas / Weight
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Before You Begin
Read the entire installation manual and study the standard detail
drawings supplied with shipment.
Check the packing list for parts received and make sure you have everything listed
before signing off on the packing list or bill of lading. Chief Industries, Inc. must be
contacted within (7) seven days after delivery if there is a shortage of parts.
Unloading: When unloading the truck, layout various components according to the
number identification and accessibility to the construction site. The following
describes the basic order in which the components will be assembled.
1.
2.
3.
4.
5.
6.
Wind Diagonals
Cross Braces
End Brace
Side Truss
End Enclosure
Walkway
Storage of Materials: All galvanized items should be protected from weather and
moisture condensation to prevent the formation of white rust. Small parts, such
as bolts, nuts, washers, etc., are just as important to an installation as the large
ones. Make certain these are located and checked before disposing of containers
or packing. Ideally, these items should be stored in their shipping containers until
ready for use on the project. They have been packaged to protect against moisture
and each container is identified as to its content. Sheet steel should be stored with
one end low to prevent moisture condensation. Chief Industries, Inc. shall not be
held responsible for materials that are not protected or stored properly after
delivery.
Claims for Shortages or Damaged Parts: All claims for shortages or damaged
parts must be indicated at the time of delivery. An authorized representative of
the contractor must be responsible for checking the material as it is unloaded from
the truck. If material is unloaded at the building site, and the installation is
subcontracted, we recommend that the contractor be informed of his
responsibilities. Signing the packing list is your confirmation of complete
shipment. If delivery is incomplete or damaged you should promptly file a claim
with the delivering carrier. For shortages determined upon receipt of shipment, a
back order will be immediately issued and priority given for earliest possible
delivery. Shortages determined after acceptance of materials will be handled as a
special house order and will be given priority for earliest possible delivery. The
customer will be charged for these materials. If he receives an allowance from
Chief Industries, Inc., his account will be credited. Chief Industries, Inc. liability
in regard to shortages is limited to supplying the missing materials including
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freight charges by a commercial carrier. Claims for lost time or completion
penalties will not be honored.
Manpower Requirement Estimate: Please note that the size of crew will vary
depending upon the size and complexity of the project and familiarity with installation
procedures. When appropriate your crew should consist of the following to ensure the
project is completed in the time frame allowed.
•
•
•
•
1 worker familiar with components and drawings, Ground Level
1 worker to unload and stage parts, Top Level
2 workers installing parts & setting fasteners
1 supervisor
Please note that this is a partial list
of the tools and equipment needed for installation. Individual installations may vary.
Tool and Equipment Requirement Estimate:
•
•
•
•
Electric Hoist, minimum 2 ton
Open end wrenches and sockets
Impact wrenches with sockets
Standard drift pins, 9/16” tapered shank
Tips and Shortcuts: The parts are packaged to reduce cost. For the most efficient
construction of the complete project please consider the following:
1. Unbundle and sort all components into stacks of similar parts.
2. Layout all parts as shown in the exploded views in the manual.
3. Chief Industries, Inc. ships an additional 10% hardware and fasteners. Collect
all dropped fasteners to ensure you have enough to complete the project.
4. Verify that you use the correct components in each catwalk section before
proceeding to the next.
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Bolt Torque
The correct bolts and bolt torque values as specified and provided by Chief Industries,
Inc. must be used throughout the entire assembly of this catwalk system. Failure to
follow these instructions could result in structural damage and/or failure of the catwalk
system.
Catwalk Sections
Before starting make sure you have a copy of the packing list, this will assist you in
identifying the correct part numbers required for your system.
All local, state and federal safety regulations and requirements must be strictly
observed and enforced.
Installation is largely a matter of individual choice and experience. The following
general outline is provided for reference only.
Note: Leave all hardware (bolts, nuts, washers) loose until all components have
been added. This will allow you to square the final catwalk assembly and ensure
that tolerances do not accumulate.
Note: Bolt heads are to be installed inside of the catwalk walkway.
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1. Place truss sides upside down with the midrails facing inward. With
the midrails facing inward the side truss diagonal bracing will be in
opposite directions. Verify the correct catwalk type / style by
looking at the weld dots located near the end of the catwalk.
Truss Section
Three Weld Dots
Indicates Type 3
Four Weld Dots
Indicates Type 4
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2. Place cross braces on truss sections. Attachment plates on the cross
braces will match up with attachment plates on the truss sides.
Verify that walkway tabs are located on the desired walkway side.
These connections will require (4) 3/4” x 2” Grade 5 bolts with lock
washer and nut on the cross brace end plate and (2) 1” x 2-3/4”
Grade 8 bolts with lock washer and nut on the cross brace bottom
plate.
Cross Brace
3. Note that standard sections of catwalk will not have a cross brace
bolted to the last attachment plate on each catwalk section.
4. If installing a start or end section of catwalk only please refer to the
following steps:
a. Terminating end members are used at the start or end of a
catwalk run (total length).
b. The start or end sections of catwalk will have a terminating
end member bolted to the last attachment plate on the truss
sections. Use the same hardware for the terminating end
member as used for the cross braces.
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5. Install wind diagonals on the cross / end braces. The attachment
plate on the wind diagonal will match up with the top side of the
attachment plate on the cross / end braces. Wind diagonals are to be
positioned parallel to one another as shown below. If the position of
the wind diagonal interferes with the conveyor, refer to the enlarged
drop through opening section in this manual. These connections will
require (2) 1” x 2-3/4” Grade 8 bolts with lock washer and nut.
Wind Diagonal
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6. Install End enclosure (required on last section of the catwalk run
only). These connections will require (4) 3/4” x 2” Grade 5 bolts
with lock washer and nut.
End Enclosure
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7. Flip the catwalk over so the cross bracing and wind diagonals are on
the bottom side.
8. Install the walkway on the slotted tabs located on the cross braces.
For every section of walkway these connections will require (8) 5/16”
x 1-1/2” Grade 5 carriage bolts with diamond washers and whiz
flange nuts per 10’ section.
Walkway
If field modifications are required, contact Chief Industries, Inc. before
proceeding. If there are fabrication errors, or shortages occur, do not substitute
similar components. Chief will not be responsible for unauthorized modifications
or for damages incurred during shipping, staging or installation.
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Connect Catwalk Sections
To complete the total length of catwalk required you must next bolt the completed
individual sections together.
1. Bolt a cross brace to the truss sides on the end of one section only. Bolt this
cross brace at the designated holes as described previously. These connections
will require (4) 3/4” x 2” Grade 5 and (2) 1” x 2-3/4” Grade 8 bolts with lock
washer and nut.
2. Install one wind diagonal to a cross brace on the end of each section as
described previously. This connection will require (2) 1” x 2-3/4” Grade 8
bolts with lock washer and nut.
3. Bolt the truss sides from each section together. These connections will require
(6) 1” x 3” Grade 8 bolts with lock washer and nut.
4. Repeat these steps to install additional sections as required until the entire
catwalk run is complete.
Note: Leave all hardware (bolts, nuts, washers) loose until all sections have been
added. This will allow you to square the final catwalk assembly and ensure that
tolerances do not accumulate.
5. At this point assembled conveyor sections may be installed on the catwalk.
6. Hoist the catwalk into place using an appropriate capacity crane. The
catwalk must be supported at points equal to half the catwalk length (free
span length.
Note: The number of catwalk sections that can be connected together is
dependent upon the capabilities of the crane lifting the unit into place. When
lifting the combined weight of the catwalk, any conveyor sections attached and
any other loads such as rigging must be considered into the total weight.
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Catwalk Section Weights
The weights of the assembled catwalk sections only are as follows:
Type 3 = 100 lbs/ft
Type 4 = 130 lbs/ft
Conveyor Mounting
The conveyor may be mounted on the ground, before lifting into place or after the
catwalk has been installed.
1. Determine the mounting locations
2. Span angle iron (not supplied) across the cross bracing and weld at all
contact points
3. Lift and position the conveyor into place
4. Weld or bolt the conveyor to the mounting angle. Mounting locations on
the conveyor must rest on the angle iron. Do not drill into or cut the
cross members when mounting the conveyor.
Note: If your catwalk structure interferes with the conveyor discharge see the
enlarged drop thru opening in this manual. Do not cut any part of the catwalk to
fit the conveyor or conveyor drive unit.
Install Catwalk Support System
Tower Top
Load Beams
Catwalk Support Beams
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After the support tower structure has been assembled and secured in place the
catwalk can be installed. The support tower structure is designed to support a top
load such as a conveyor or catwalk and this load must be supported by a top load
beam bolted/welded to the top of the support tower structure. The catwalk
support beams/tower top load beams can be field fabricated by millwright or
purchased separately from Chief. (Note: Catwalk support beam recommended
size is W6x20 if field fabricated. Contact customer service for tower top load
beam recommended size if field fabricated.)
1. Lift the assembled catwalk into place using rigging with appropriate support
2.
3.
4.
5.
6.
for the catwalk as specified previously.
Locate the catwalk as desired over the tower support system.
Install catwalk support beams to catwalk cross braces.
a. Catwalk support beams must span two cross braces.
b. Catwalk support beams must contact the cross braces only and
cannot be supported by or be welded to the wind diagonal bracing.
c. Catwalk support beams must be fully welded at all contact points
with 1/4” fillet weld.
Install the tower top load beams across the tower posts as shown.
a. Tower top load beams must span 2 tower posts.
Install the catwalk support beams to the tower top load beams.
a. Catwalk support beams cannot be welded directly to the tower
horizontal bracing or be supported by any part of the tower.
Catwalk support beams must contact the tower top load beams
only.
b. Catwalk support beams must be fully welded at all contact points
with 1/4” fillet weld.
Repeat the above steps till all catwalk sections are installed to the appropriate
support structures.
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Enlarged Drop through Opening
Cut Cross
Brace
Reverse Wind Diagonal
If additional clearance is required for your conveyor drop through, the following
process is recommended. Note that only one (1) enlarged drop through opening
can be used in any given section and must not be applied at a section connection
location.
1. At the desired location remove two wind diagonals.
2. Cut cross member in this location, removing the center section of the tube
3.
4.
5.
6.
between the attachment plates. Note: Do not remove the cross member
attachment plates.
Reinstall cross braces on each side of the opening.
Reverse one wind diagonal (as shown) to form a V shaped opening.
Re- Torque bolts as required.
Reinforce both side truss sections over the opening (un-braced length) with a
continuous beam welded to the lower stringer tube.
a. The length of this tube shall extend to the next cross brace beyond
the opening at each end of the opening.
b. This splice beam shall be constructed of a minimum of a 2” x 2” x
1/4” steel angle for a center drop through opening and a minimum
of a W 6 x 15 for a end drop through opening.
c. Support beams must be fully welded at all contact points with 1/4”
fillet weld.
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7. If an end drop through opening is desired the splice beam described above can
also be used as the catwalk support / spreader beam. Note that a splice angle
may not be used as a catwalk support / spreader beam.
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Summary
While we do not intend to suggest that the preceding assembly instructions are the
only way to install Catwalk Systems, experienced contractors indicate that we have
described the quickest, safest, and most cost-effective method.
Separate assembly instructions and installation information is provided when
required for accessory items.
Unless stated in the quotation, Chief Industries Inc. is not responsible for the
design of any equipment locations, external interference, required loadings, and/or
additional attachments that may be placed upon Catwalk System products.
Common sense safety precautions should always be observed. Chief Industries
Inc. will accept no liability arising from the misuse of equipment. Always Work
Safely!
Should you have any questions concerning assembly instructions, parts or
drawings, please feel free to contact us at any of the following.
 Chief Industries, Inc.
4400 East 39th Street • PO Box 848
Kearney, NE 68847
Phone 800.359.7600
For more information about Chief Industries, Inc. and additional products or services visit our website
www.agri.chiefind.com
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Catwalk #4 Manual - Chief Agri/Industrial

Transcription

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