24' Tower Dryer Fan Style Catwalk Assembly Installation Manual PNEG-1875 Date: 05-09-13 PNEG-1875
PNEG-1875 24' Tower Dryer Fan Style Catwalk Assembly
Table of Contents Contents Chapter 1 Introduction .......................................................................................................................................... 4 Chapter 2 Safety ..................................................................................................................................................... 5 Safety Guidelines ..................................................................................................................................
1. Introduction READ THIS MANUAL carefully to learn how to properly use and install equipment. Failure to do so could result in personal injury or equipment damage. INSPECT the shipment immediately upon arrival. The customer is responsible for ensuring that all quantities are correct. The customer should report and note any damage or shortage on the bill of lading to justify their claim to the transport company.
2. Safety Safety Guidelines This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections.
2. Safety Prepare for Emergencies Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. Keep Emergency Equipment Quickly Accessible Wear Protective Clothing Wear close-fitting clothing and safety equipment appropriate to the job. Eye Protection Remove all jewelry. Gloves Tie long hair up and back. Wear safety glasses at all times to protect eyes from debris.
3. Decals Safety decals should be read and understood by all people in and around the dryer area. If the following safety decals are not displayed on your dryer or if they are damaged, contact the GSI for replacement: GSI Decals 1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421 DANGER > 1000 lbs (4.50 kN) DO NOT EXCEED PLATFORM LOAD LIMIT Load limit = 1000 LBS. (4.50 kN) Excessive load will damage platform and cause platform to fall. Injury or death will result.
NOTES 8 PNEG-1875 24' Tower Dryer Fan Style Catwalk Assembly
24' Outside Fan Style Catwalk Assembly Instructions (GT4-1039-24F) PNEG-1875 24' Tower Dryer Fan Style Catwalk Assembly 9
4. 24' Outside Catwalk Installation Instructions Installing Z-Clips (GT1-2036) 1. Bolt Z-clip (GT1-2036) to all vertical channels (GT1-0001). The Z-clip can be installed on each vertical channel as wall sheets are installed using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 4A and Figure 4B.
4. 24' Outside Catwalk Installation Instructions Installing Swing Gate Stop (GT1-2045) 1. Identify the ladder opening vertical channel and install the swing gate stop (GT1-2045) to the vertical channel (GT1-0001) as wall sheets are installed using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 4C and Figure 4D.
4. 24' Outside Catwalk Installation Instructions Installing Catwalk Support Clip (GT1-2040-BS) 1. Install catwalk support clips (GT1-2040-BS) to all vertical channels (GT1-0001). Support clip can be installed on each vertical channel as the wall sheets are installed using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 4E.) 2. The distance between the Z-clip and support clip for 24' outside catwalk is 31-1/2". (See Figure 4F.
4. 24' Outside Catwalk Installation Instructions Installing Inner Toe Board (GT1-2035) and Ladder Opening Toe Board (GT4-1465) 1. Install the inner toe board (GT1-2035) to the Z-clips (GT1-2036). All toe boards should be installed between the Z-clips using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 4G.) 2. At the ladder location, install the ladder opening toe board (GT4-1465) to Z-clips using 3/8"-16 x 1" YDP grade 8 or grade 8.
4. 24' Outside Catwalk Installation Instructions Installing Inner Toe Board (GT1-2035) and Ladder Opening Toe Board (GT4-1465) (Continued) Figure 4H 24' Ladder Opening Toe Board (GT4-1465) 3. Inner toe board is arranged with overlap slots on each side. Install 24' inner toe boards (GT1-2035) to corresponding slots as shown in Figure 4I.
4. 24' Outside Catwalk Installation Instructions Installing Plank (GT1-2033) to Inner Toe Board (GT1-2035) 1. Install planks around the dryer on inner toe board starting from ladder opening toe board (GT4-1465) as shown by arrow in the Figure 4J. 2. Planks (GT1-2033) are installed to bottom two (2) holes of the inner toe board (GT1-2035) using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 4J.
4. 24' Outside Catwalk Installation Instructions Installing Planks (GT1-2033) to Inner Toe Board (GT1-2035) (Continued) 4. Install all the planks (GT1-2033) continuously around the dryer except at the jack pole locations. (See Figure 4L and Figure 4M.
4. 24' Outside Catwalk Installation Instructions Installing Planks (GT1-2033) to Inner Toe Board (GT1-2035) (Continued) 5. Each plank should be overlapped at the edges and bolted with 5/16"-18 x 3/4" YDP grade 8 or grade 8.2 bolts (S-4303) and 5/16"-18 YDP grade 2 nuts (S-3611). (See Figure 4N.) Truss bolt 5/16"-18 x 3/4" YDP grade 8 or grade 8.
4. 24' Outside Catwalk Installation Instructions Installing Plank Support (GT1-2086) 1. Once the planks are installed, install the plank support (GT1-2086) to the last plank (GT1-2033) and toe board (GT4-1465) using 5/16"-18 x 3/4" YPD grade 8 and grade 8.2 bolts (S-4303), 5/16"-18 YPD grade 2 nuts (S-3611) and flange bolts 3/8"-16 x 1" YDP grade 8 or grade 8.2 (S-7927). (See Figure 4O.
4. 24' Outside Catwalk Installation Instructions Installing Knee Support (GT1-2039-BS) 1. Install the knee support (GT1-2039-BS) around the dryer between the catwalk support clips (GT1-2040-BS) and planks (GT1-2033) using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 4P and Figure 4Q.
4. 24' Outside Catwalk Installation Instructions Installing Outer Toe Board (GT1-2034) and Catwalk Vertical Support (GT1-2037-BS) 1. Install all the outer toe boards (GT1-2034) to the planks (GT1-2033). (See Figure 4R.) 2. When installing the outer toe board with planks, install the catwalk vertical support (GT1-2037-BS) simultaneously at proper locations using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 4R.) Figure 4R 3.
4. 24' Outside Catwalk Installation Instructions Installing Handrails (GT1-2038-24O) 1. Install the handrail (GT1-2038-24O) to the catwalk vertical support (GT1-2037-BS) using 5/16"-18 ZN U-bolts (S-10171) and 5/16"-18 YDP grade 2 nuts (S-3611) to tighten the handrail with vertical post. (See Figure 4T.) (See Page 22.
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4. 24' Outside Catwalk Installation Instructions Installing Safety Gate (GT4-1455) 1. Install the swing gate support (GT1-2087) with the plank support (GT1-2086) using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See detail J in Figure 4W.) 2. Install two (2) catwalk handrails (GT1-0920) between the swing gate support (GT1-2087) and the catwalk vertical support (GT1-2037-BS) using 3/8"-16 x 1" YDP grade 8 or grade 8.
4. 24' Outside Catwalk Installation Instructions Installing Safety Gate (GT4-1455) (Continued) 5. Install the ladder safety gate assembly (GT4-1455) to the swing gate support (GT1-2087) using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See detail L in Figure 4X.) 6.
4. 24' Outside Catwalk Installation Instructions Installing Ladder Bracket (GT1-2088) 1. Install the ladder bracket (GT1-2088) to the ladder opening toe board (GT4-1465) using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 4Y.
4. 24' Outside Catwalk Installation Instructions Installing Planks at Jack Pole Locations Once catwalk is lifted above the jack poles, install the planks at jack pole locations from top using 5/16"-18 x 3/4" YPD grade 8 or grade 8.2 bolts (S-4303) and retainer nuts (090-1709-6). (See Figure 4Z.) Figure 4Z 1. Insert the retainer nut (090-1709-6) to the rounded edge of the plank slot and slide it to the proper position as shown in the detail O of Figure 4AA. 2.
4. 24' Outside Catwalk Installation Instructions Installing Planks at Jack Pole Locations (Continued) 3. Install the holding plate (GT1-2144) (pre-assembled with two (2) extruded nuts (S-10175)) to the proper slots in the toe board and hand tight using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolt (S-7927) and 3/8"-16 ZN grade 5 nut (S-968). (See Figure 4AB.) 4. Now adjust the plank to align with the slot and bolt from outside the toe board. (See Figure 4AB.
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24' Inside Fan Style Catwalk Assembly Instructions (GT4-1043-24F) PNEG-1875 24' Tower Dryer Fan Style Catwalk Assembly 29
5. 24' Inside Catwalk Installation Instructions Installing Z-Clips (GT1-2036) 1. Bolt Z-clips (GT1-2036) to all vertical channels (GT1-0001). The Z-clip can be installed on each vertical channel as inner wall sheets are installed using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 5A.
5. 24' Inside Catwalk Installation Instructions Installing Catwalk Support Clip (GT1-2040-BS) 1. Install catwalk support clips (GT1-2040-BS) to vertical channels (GT1-0001). Support clip can be installed on each vertical channel as the inner wall sheets are installed using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 5B.) 2. The distance between the Z-clip and support clip for 24' inside catwalk is 31-1/2". (See Figure 5C.
5. 24' Inside Catwalk Installation Instructions Installing Outer Toe Board (GT1-2062) 1. Install the outer toe board (GT1-2062) to the Z-clips (GT1-2036). All toe boards should be installed between the Z-clips using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 5D.) Figure 5D 2. Outer toe board is arranged with overlap slots on each side. Install 24' outer toe boards (GT1-2062) to corresponding slots as shown in Figure 5E.
5. 24' Inside Catwalk Installation Instructions Installing Planks (GT1-2033) to Outer Toe Board (GT1-2062) 1. Install the planks (GT1-2033) to the outer toe board (GT1-2062) using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 5F.) NOTE: Make sure the planks are aligned to right slots as marked in Figure 5H on Page 34.
5. 24' Inside Catwalk Installation Instructions Installing Planks (GT1-2033) to Outer Toe Board (GT1-2062) (Continued) 2. Install all the planks (GT1-2033) continuously around the dryer. (See Figure 5G.) Figure 5G 3. Outer toe board (GT1-2062) is arranged with many slots to install plank. Install planks to corresponding slots as shown in Figure 5H.
5. 24' Inside Catwalk Installation Instructions Installing Knee Support (GT1-2039-BS) 1. Install the knee support (GT1-2039-BS) around the dryer between the catwalk support clips (GT1-2040-BS) and planks (GT1-2033) using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 5I.
5. 24' Inside Catwalk Installation Instructions Installing Inner Toe Board (GT1-2061) and Catwalk Vertical Support (GT1-2037-BS) 1. Install all the inner toe boards (GT1-2061) to the planks (GT1-2033). (See Figure 5J.) 2. When installing the inner toe board with planks, install the catwalk vertical support (GT1-2037-BS) simultaneously at proper locations using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 5J.) Figure 5J 3.
5. 24' Inside Catwalk Installation Instructions Installing Handrail (GT1-2038-24I) 1. Install the handrail (GT1-2038-24I) to the catwalk vertical support (GT1-2037-BS) using 5/16"-18 ZN U-bolts (S-10171) and 5/16"-18 YDP grade 2 nuts (S-3611) to tighten the handrail with vertical post. (See Figure 5L and Figure 5M.
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24' Offset (GT4-1047-24F) and Roof Hatch (GT4-1051-24F) Fan Style Platform Assembly Instructions PNEG-1875 24' Tower Dryer Fan Style Catwalk Assembly 39
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Z-Clips (GT1-2036) 1. Bolt Z-clips (GT1-2036) to vertical channels (GT1-0001). The Z-clip can be installed on each vertical channel as wall sheets are installed using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 6A, Figure 6B below, Figure 6C and Figure 6D on Page 41.
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6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Swing Gate Stop (GT1-2045) 1. Install swing gate stops (GT1-2045) to the safety gate opening vertical channel and catwalk end vertical channel on offset catwalk as wall sheets are installed using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 grade 5 nuts (S-968). (See Figure 6E and Figure 6F.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Catwalk Support Clip (GT1-2040-BS) 1. Install catwalk support clips (GT1-2040-BS) to vertical channels (GT1-0001). Support clip can be installed on each vertical channel as the wall sheets are installed using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 6G below and Figure 6I on Page 44.) 2.
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6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Inner Toe Board (GT1-2035) 1. Install the inner toe board (GT1-2035) to the Z-clips (GT1-2036). (See Figure 6K.) 2. All the toe boards should be installed between the Z-clips using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 6K.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Inner Toe Board (GT1-2035) (Continued) 3. Inner toe board is arranged with overlap slots on each side. Install 24' offset and roof hatch inner toe boards (GT1-2035) to corresponding slots as shown in Figure 6L.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Plank (GT1-2033) to Inner Toe Board (GT1-2035) 1. Install planks (GT1-2033) to bottom two (2) holes of the inner toe board (GT1-2035) using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 6M.) NOTE: Make sure the planks are aligned to right slots as marked in Figure 6N on Page 48.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Plank (GT1-2033) to Inner Toe Board (GT1-2035) (Continued) 2. Inner toe board (GT1-2035) is arranged with many slots to install plank. Install offset and roof hatch planks to corresponding slots as shown in Figure 6N. Figure 6N 24' Inner Toe Board (GT1-2035) 3. Install all the planks (GT1-2033) continuously around the dryer except at the jack pole locations. (See Figure 6O.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Plank (GT1-2033) to Inner Toe Board (GT1-2035) (Continued) Figure 6P 4. Each plank should be overlapped at the edges and bolted with 5/16"-18 x 3/4" YPD grade 8 or grade 8.2 bolts (S-4303) and 5/16"-18 x 3/4" YPD grade 2 nuts (S-3611). (See Figure 6Q.) Truss bolt 5/16"-18 x 3/4" YDP grade 8 or grade 8.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Plank Support (GT1-2086) 1. Once the planks are installed, install the plank support (GT1-2086) at the catwalk closing end using 5/16"-18 x 3/4" YPD grade 8 or grade 8.2 bolts (S-4303) and 5/16"-18 YDP grade 2 nuts (S-3611). (See Figure 6R.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Knee Support (GT1-2039-BS) 1. Install the knee support (GT1-2039-BS) around the dryer between the catwalk support clips (GT1-2040-BS) and the planks (GT1-2033) using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 6S.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Outer Toe Board (GT1-2034) and Catwalk Vertical Support (GT1-2037-BS) 1. Install all the outer toe boards (GT1-2034) to the planks (GT1-2033). (See Figure 6T.) 2. When installing the outer toe board with planks, install the catwalk vertical support (GT1-2037-BS) simultaneously at proper locations using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). (See Figure 6T.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Long Handrails (GT1-2038-24O) 1. Install the long handrail (GT1-2038-24O) to the catwalk vertical support (GT1-2037-BS) using 5/16"-18 ZN U-bolts (S-10171) and 5/16"-18 YDP grade 2 nuts (S-3611) to tighten the handrail with vertical post. (See Figure 6U.) 2. Use the self-tapping screws SDS #10-16 x 3/4" HWH ZN grade 2 (S-7466) at all handrail pipe joints. (See Figure 6U.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Long Handrails (GT1-2038) (Continued) 3. Install the platform end handrail (GT1-2044) to the catwalk vertical support (GT1-2037-BS) and the platform end plate (GT1-2045). (See Figure 6V below and Figure 6W on Page 55.
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6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Safety Gate (GT4-1455) with Plank Support (GT1-2086) 1. Install the swing gate support (GT1-2087) with the plank support (GT1-2086). 2. Install two (2) catwalk handrails (GT1-0920) between the swing gate support (GT1-2087) and catwalk vertical support (GT1-2037-BS). (See Figure 6X.
6. 24' Offset and Roof Hatch Platform Installation Instructions Installing Safety Gate with Plank Support (Continued) 3. Install the ladder safety gate assembly (GT4-1455) to the swing gate support (GT1-2087) using 3/8"-16 x 1" YDP grade 8 or grade 8.2 bolts (S-7927) and 3/8"-16 ZN grade 5 nuts (S-968). The distance between the plank and handrail is 42". (See Figure 6Y below and Figure 6Z on Page 58.
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7. Parts List 1. 24' Outside Fan Style Catwalk (GT4-1039-24F) - (See Pages 60-63.) 2. 24' Inside Fan Style Catwalk (GT4-1043-24F) - (See Pages 64-67.) 3. 24' Offset Fan Style Platform (GT4-1047-24F) - (See Pages 68-71.) 4. 24' Roof Hatch Fan Style Platform (GT4-1051-24F) - (See Pages 72-75.
7. Parts List 24' Outside Fan Style Catwalk (GT4-1039-24F) NOTE: Use retainer nuts (090-1709-6) at jack pole positions for plank overlap.
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7. Parts List 24' Offset Fan Style Platform (GT4-1047-24F) NOTE: Use retainer nuts (090-1709-6) at jack pole positions for plank overlap.
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7. Parts List 24' Roof Hatch Fan Style Platform (GT4-1051-24F) NOTES: Use retainer nuts (090-1709-6) at jack pole positions for plank overlap.
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NOTES 76 PNEG-1875 24' Tower Dryer Fan Style Catwalk Assembly
8. Warranty GSI Group, LLC Limited Warranty The GSI Group, LLC (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
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. GSI Group 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.
