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VERTICOOL - Curlin, Inc.

1. DOCK DOORS VERTICOOL VERTICAL LEVELER DOCK DOOR d ZZ t 27 User s Manual Installation Operations Maintenance and Parts Listing This manual applies to VertiCool Vertical Leveler Dock Doors manufactured beginning August 2012 DO NOT install operate or service this product unless you have read and understand the safety practices warnings installation and operation instructions contained in this manual Failure to do so could result in death or serious injury 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual TABLE OF CONTENTS LIMITED WARRANTY 1 OWNER S RESPONSIBILITIES 2 TOOLS amp MATERIALS 3 K OCHOA IO E E SAFETY 4 dbi Lio Sasu enn ene eee TS EE SITE PREPARATION 6 a sss ha TRACK ANCHORING APPROVED METHODS 8 EE TRACK INSTALLATION 9 rou dou EE TRACK INSTALLATION 12 zu o p n d ccu is III M 2 MEE p M m i M 7 Ui s ETE PANEL INSTALLATION 26 EE ee 5 xu 28 li T ee EE ee TM Er SPRING SHAFT INSTALLATION 35 EE 98 SE E a EE dl ka os geg a WINDING SPRINGS 41 uuu sc Q EE uu DOOR
2. 1 NI 318VO 1900 0 ON LYVd MOV I8 3lVid TANVd vO000 0 ON IVNOI1dO 3001 13S 39NIH ON 96 31 TANVd ON 06 31 TANVd ON cr 31V ld TANVd ON 8 31 1 TANVd ON 1 31 1 TANVd ON 8L 31V ld TANVd ON P2 31V ld TANVd gt Y ATG MM 31 1 T3NVd i Ai 1 LN3IW3OV Id38 LOAYYOO NOISNAWIG ONIOVdS MOVEL YSEWNN 1718385 H3Q0 dO LV NMONM 38 LSNW NOILISOd TANVd ANY TVIH3S V 3215 H3d AHVA STANVd HOOT 11 8L 00 0 ON Tv3S 4388flH WOLLOS 8 00 0 LYVd Tv3S WOLLOS ML Was WOLLOS 2 Vi SS D xA TGWASSV T3NVd WOLLOG pl xA T8IN3SSV TANVd 3L VIQ3IAH3LENI 94900 06 ON Led TANVd dO L diy ASSY W3TIOs qaXId Page 49 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual PARTS LISTING TKO VertiCool Vertical Leveler Dock Doors H3NIVL38 TWAS 1015 1 HO WAS 4001 3018 IN I1d3H SNIH3QHO N3HM 13qON ANY HLGIM T3NVd NOILISOd T3NVd AJIH3A ALON xx 4
3. TYPE OF ANCHOR USED WILL BE OF SUITABLE LENGTH AND APPROPRIATE FOR TYPE OF SOLID BACKING BEHIND WOOD 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC TKO VertiCool Vertical Leveler Dock Doors DTI DOORS SPRING SHAFT INSTALLATION continuea OPERATOR MTG AREA LH OR RH SEE OPERATOR MANUAL FOR MTG SIZE amp LOCATIONS pee TRACK MOUNTING HEIGHT TMH CENTER LINE OF SHAFT CL DOOR OPENING HEIGHT DOH 15 00084 R5 08 12 VC CENTER SPRING PAD INSTALLATION MIN 3 CENTER BRG ANCHOR PAD MIN 3 MOUNTING AREAS MIN SIZE 2 W X 6 H SPLIT SHAFT SHAFT 1 2 DOOR pi OPENING a WIDTH BRUSH SEAL JAMB WALL TRACK MTG L WIDTH TMW OPENING WDH DOW 12 d d SURFACE COUNTERWEIGHT BRG l4 LH amp RH MOUNTING AREAS MIN SIZE 2 W X 6 H TRACK MOUNTING DEPTH INTO BUILDING WTC DEPTH TMD a DOOR OR 6 DUAL SPRING SINGLE SHAFT 2012 4Front Engineered Solutions Inc Page 33 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual SPRING SHAFT INSTALLATION AWARNNG Failure to assemble the Torsion Springs and Counterbalance System correctly will cause the door to fu
4. WINDING SPRINGS AWARNNG The Spring Assembly which includes the Springs Spring Anchor Brackets Cables Cable Drums and Bearing Brackets is under extreme tension and if handled improperly could result in death or serious injury Spring Assemblies should ONLY be installed adjusted or repaired by a trained door systems technician SECURE DOOR 1 Check stacked panels for level 2 Verify that the cable attachment bracket is installed on the correct panel see Installer Detail Sheet 3 Securely lock door in down position to prevent door from opening while winding springs INSTALL CABLES 1 Position Left Hand red drum to shaft making sure that the drum is tight against the bearing race Tighten drum to the shaft If shaft is solid keyed properly align drum shaft and install shaft key prior to tightening 2 Obtain cable that is attached to the left cable bracket on panel and run it up to the shaft between the wall and the drum On straight vertical doors attach cable to the outside hole of the cable attachment bracket 3 Place cable stops in the notch in the backside of drum and turn the drum shaft until all slack in cable is removed Make sure cable is seated properly in the grooves of the drum Fasten locking pliers to the shaft with the handle braced against the wall to keep cables taut Position Right Hand black drum tight against bearing race 6 Obtain cable that is attached to the right cable bracket on panel a
5. PROBABLE CAUSE REMEDY Door raises hard closes easily Insufficient counterbalance Springs need lubrication Increase spring tension Lubricate springs Door closes hard raises easily Too much counterbalance Decrease spring tension Door jumps from floor Too much counterbalance Decrease spring tension Door lifts unevenly light shows on one side of track Door will not stay open Door operates with too much resistance Door improperly leveled sitting crooked Broken spring Insufficient counterbalance Springs need lubrication Broken spring Tracks are too tight or Grease Residue on tracks Slip drums shaft coupler or use cable leveling assemblies top pickup doors to level door Replace Spring Increase spring tension Lubricate springs Replace Spring Adjust tracks to correct width Wipe residue off seals tracks Lubricate all track running surfaces with a light coat of Silicone Spray DO NOT use oil or grease Page 48 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC TKO VertiCool Vertical Leveler Dock Doors DTI DOORS User s Manual PARTS LISTING Fixed plungers are required on all panels 62810 0 96810 0c 96810 0 YL8L0 0c 2900 0c 900 0 9 900 0 OL TWIYAS NOLLVHDTOIJ3NOO ANY 3TA1S Yad S3IHVA LNIOd 1N3INHOV LLV 318
6. DO NOT tighten completely this will allow for adjustments with installation Slide the left drum red on the left side of shaft with the setscrews facing the coupler Slide the right drum black on the right side of shaft with the setscrews facing the coupler Slide on specified end bearings on to both ends of shaft with correct orientation The bearing race has an outside diameter of 1 1 4 and projects from the flange 1 8 The bearing housing has an outside diameter of 2 and projects from the flange 3 8 The bearing race needs to be facing the cable drums Lift counterbalance assembly onto end bearing plates making sure bearings are positioned inside of the plates with races facing inward Secure shaft and bearing to plate using carriage bolts supplied Slide drums against end bearing races Insert the shaft key for each drum when a solid shaft with a keyway is being used Prior to final tightening center bearing bracket bolts and anchors adjust the shaft to ensure its running straight and level Tighten the set screws as follows Solid Shaft Do not exceed 1 2 turn after coming in contact with the shaft Hollow Shaft Tighten set screws enough to dimple shaft about 1 1 4 turns after set screws first hit shaft Page 38 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors DTI DOORS SPRING SHAFT INSTALLATION continea Failure to assemble the Torsi
7. LRG 7 900 ML 11 38 2 ITEM NO S 2 3 AND 4 ARE INCLUDED IN TKO PART NO 30 00877 20 02009 BRUSH LRG 7 1 50 BLK 10 63 ANTI DRIFT DOWN BRUSH KIT FH 1 10 00334 SCREW SLT HEX HD SP 8 X 1 2 10 00335 SCREW SOC HD CAP 1 4 20X3 4 BLK 10 00005 FLNG 1 4 20 RUBBER RUBBER BUMPER ASSEMBLY RH BRUSH LRG 3 TAPERED EDGE AT THE BOTTOM BRUSH LRG TAPERED EDGE AT 3 H STRT PLASTIC TRACK 4 RETAINER AND INSIDE SURFACE OF TRACK m FRONT EDGE OF VERTICAL UNIV STEEL ARE EER 8 STRAIGHT TRACK FRONT EDGE OF PLASTIC TRACK RIGHT HAND SIDE FH I A T SHOWN RIGHT HAND SIDE STL TRACK SHOWN Page 46 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors 40 DOCK DOORS PLANNED MAINTENANCE AWARNING Before servicing the door read and follow the Safety Practices on pages 4 5 and the operations section of this manual DO NOT attempt to repair or adjust door components unless you are a qualified door technician Springs Cable Brackets Cabl
8. normally the longest one provided to upper track section with 1 4 20 x 3 4 carriage bolts and flange nuts This bracket should be placed 2 to 6 below bearing plate mounting bracket See detail D on page 17 Next level the track then anchor bracket to mounting surface using one of the Recommended Anchoring Methods illustrated above Follow manufacturer s recommendations for anchor installation Verify the track is level before continuing Failure to securely position and anchor door tracks per the TRACK SPACING dimension and tolerance engraved on the door mounted Safety Decal may allow the door to fallout of its tracks which could result in death or serious injury 4 Measure over to the opposite track and position at the track spacing dimension engraved on the Safety Decal located on the panel of the door Mark top track mounting bracket anchor location on wall Secure it using one of the Approved Anchoring Methods illustrated above Note Verify the distance between the mounting surface and the top edge of the track is the same on both sides 5 Fill in the rest of the track mounting brackets both sides every 22 to 26 from top track mounting bracket down See page 17 6 Attach C channel to bearing plate mounting brackets to run from the backside of one bearing bracket to the other Attach C channel to top set of holes on bearing plate mounting bracket with 3 8 16 x 1 carriage bolts flange nuts and flat washers Ve
9. 16 X 1 1 2 HEX BOLT 2X FULL THREAD STATIONARY CONE CENTER SHAFT BEARING SPRING WARNING TAG STATIONARY CONE RIGHT DRUM BLACK VERTICAL SHOWN NOTE FLANGE BEARING STANDARD INCLUDED IN CBAL KIT BEARING RACE TO FACE DRUM MOUNT TO INSIDE FACE OF BEARING PLATE DETAILA SPRING WARNING TAG 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 37 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual SPRING SHAFT INSTALLATION continea Failure to assemble the Torsion Springs and Counterbalance System correctly will cause the door to function improperly and could result in death or serious injury DOUBLE SPRING SPLIT SHAFT ASSEMBLY 1 2 10 T1 12 13 14 15 Layout counter balance parts on floor Slide each 1 2 of the coupler flush to the ends of the both shafts that will be mounted together in the center Install keys into shaft coupler and tighten setscrews and locking nuts Coupler shaft and key MUST BE flush Both ends will be bolted together when installing spring assembly Slide center bearing on to each shaft with the race facing the coupler Slide the left spring red on to left shaft with the stationary spring cone facing the coupler Slide the right spring black on to right shaft with the stationary spring cone facing the coupler Bolt spring stationary cones center bearing and center bearing bracket together
10. 379100 92810 02 ON HL 6p WO11O8 dOO1 adis 4001 3918 Was 1 LN3IW39V 1d321 1V3S 1018 1 WOLLOS8 N3HM 13GON YOO SV TI3M SV NMON 38 LSAW S38lINQN 1VI43S V 3216 H3d AWHVA S IHNVd HOOQ 11 15 00084 R5 08 12 VC SHOOG AWM xH3NIV L33 1 8 1015 1 INO LLOS 318000 ie SZ810 0Z v 9 qOO1 WAS JIS HR MM doo13adis Was ri AT8IN3SSV TANVd 31VIO3IAS3 LNI A 18N3SSV TANVd s dOOT1319NIS a 18n0Q 86810 02 ONd 0 dOO1 1V3S 3aqlS 26810 02 ONd HE ZF dOO1 1V3S 3415 089L0 02 ONd 9 4001 1V3S 3aqlS V1100 02 ONd HE ZL dHOO1 1V3S 3415 8 00 02 ONd HE 8L HOO1 1V3S 9 00 02 ONd HE vZ dHOO1 1V3S 3aqlS MM 4001 3dis Was 8610 02 ON LYYd 00 8 1018 1 WAS 67810 0 ON LYYd 00 8 1018 1 WAS YANIVLAY 1018 1 TWAS 3916 2012 4Front Engineered Solutions Inc 99610 02 ON 066 1018 1 1736 99610 02 ON 067 1015 1 7736 79610 02 ON LYWd 0698 1015 1 1736 26800 02 ON LYWd 06 LL 1015 1 1736 6800 02 ON LYWd 06 1018 1 1736 72000 02 LYWd 0662 1018 1 1736 00610 02 ON LYWd 06 62 1015 1 TWAS A 66810 02 ON 06 Lr 1015 1 TWAS 18810 0 1 4 06
11. 45 TKO TKO VertiCool Vertical Leveler Dock Doors User s Manual DOCK DOORS AVAI LABLE OPTIONS continued Track Protector VC e Anti Drift Down Brush Kits STL Track and FH I A T TRACK PROTECTOR VC PART NUMBER DESCRIPTION QTY REQD 20 02107 TRACK PROTECTOR 2 20 00794 TRACK WW SPLICE ANGLE DKO 10 00027 BOLT CRG 1 4 20 X 1 10 00026 BOLT CRG 1 4 20 X 3 4 10 00005 NUT FLNG 1 4 20 NOTE PARTS INCLUDED IN KIT TRACK PROTECTOR VC PART NO 30 00880 TRACK PROTECTOR 1 4 20 X 1 CRG BOLT PART NO 20 02107 PART NO 10 00027 12 18 II TRACK PROTECTOR BELOW DOOR WE e HEADER 20 00794 1 4 20 FLNG 10 00005 1 4 20 X 3 4 CRG BOLT PART NO 10 00026 FIELD INSTALLATION INSTRUCTIONS 1 REMOVE EXISTING 1 4 20 X 1 CARRIAGE BOLTS AND FLANGE NUTS AS SHOWN ON DETAIL A 2 ATTACH THE TRACK PROTECTOR BRACKET TO STEEL TRACK AT 12 TO 18 BELOW THE HEADER OR AS NOTED ON THE DRAWING 3 REATTACH THE CARRIAGE BOLTS AND THEN TIGHTEN FLANGE NUTS RIGHT HAND SIDE I 4 REPEAT STEPS 1 THRU 3 FOR THE OPPOSITE SIDE TRACK TRACK SHOWN NOTE ADJUST AS NEEDED BASED ON TRUCK DOOR STYLE PART NUMBER DESCRIPTION 1 ITEM NO S 1 3 5 AND 6 ARE INCLUDED IN TKO PART NO 30 00876 20 02007 RETNR LRG 7 STR ML 11 38 ANTI DRIFT DOWN BRUSH KIT STL TACK 20 02008 RETNR
12. 9 1018 1 TWAS 76800 02 ON LYWd 06 1 1018 1 TWAS 96800 02 ON LYWd 06 7L 1015 1 TWAS 46700 02 ON LYWd 0662 1018 1 WAS E YANIVLAY 1018 1 7738 3016 AT8IN3SSV TANVd dO L Fixed plungers are required panels Page 50 User s Manual TKO VertiCool Vertical Leveler Dock Doors CC DOCK DOORS PARTS LISTING STEEL TRACK ASSEMBLY PARTS STRAIGHT VERTICAL TRACK SHOWN NOTE DIFFERENT TRACK CONFIGURATIONS EXIST WITHIN EACH DOOR MODEL LINE A SERIAL NUMBER AND DOOR MODEL IS REQUIRED WHEN ORDERING TRACK COMPONENTS CONSULT FACTORY FOR SPECIFIC TRACK CONFIGURATION AND PARTS IDENTIFICATION FOR YOUR SPECIFIC COMPONENT NEED STEEL STRT TRACK PART NO S WILL VARY LEFT HAND SIDE le STEEL STRT TRACK dp PART NO S WILL VARY gt RIGHT HAND SIDE es TRACK LINER EXT TW di PART NO S WILL d TRACK WW STRT WITH DOOR HEIGHT dir EXT BRKT MOD Za PART 20 01601 OR TRACK LINER EXT PART NO S WILL VARY WITH DOOR HEIGHT RADIANT BARRIER PART NO 20 01863 LENGTH VARIES WITH DOOR HEIGHT TRACK LINER TW PART NO 20 01815 OR TRACK LINER PART NO 20 01942 RUBBER FOAM VINYL PART NO 20 01862 LENGTH VARIES WITH DOOR HEIGHT STEEL TRACK VC BTM H 20 02033 R
13. ANCHORING REQUIRE THAT THE TRACK SPACING DIMENSION TOLERANCES OF 1 4 NOT TO BE EXCEEDED RECOMMENDED MOUNTING MOUNTING MOUNTING STEEL TRACK TO STEEL TRACK TO STEEL TRACK TO STEEL TRACK TO C 90 HOLLOW FILLED BLOCK OR WOOD BACKED BY STRUCTURAL SOLID CONCRETE A SOLID MATERIAL STEEL CONCRETE BLOCK V 3 8 FLAT WASHER 3 8 16 SINGLE OR DOUBLE EXPANSION SHIELD ANCHOR OR 3 8 SHORT LAG SHIELDS EVERY 18 3 8 FLAT WASHER MINIMUM 3 8 X 1 7 8 SLEEVE TYPE ANCHOR EVERY 18 3 8 FLAT WASHER 3 8 X 3 ANCHOR EVERY 18 3 8 X 1 1 2 SELF TAPPING SCREWS E FLAT TYPE OF ANCHOR USED WILL BE SUITABLE FOR TYPE OF SOLID BACKING BEHIND WOOD Failure to securely position and anchor door tracks per the TRACK SPACING dimension and tolerance engraved on the door mounted Safety Decal may allow the door to fallout of its tracks which could result in death or serious injury Page 20 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors DTI DOORS TRACK NSTALLATIO N continued TILT T2 UPPER TRACK INSTALLATION END BUMPER D e Al 30 3 TYP DETAIL C TOP SAFETY SPREADER BAR CABLE SAFETY SHIELD HEADER SAFETY SPREADER BAR UPPER TRACK SECTIO
14. Double Expansion Shield Anchors are recommended Follow manufacturer s recommendations for installation Failure to securely position and anchor door tracks per the TRACK SPACING dimension and tolerance engraved on the door mounted Safety Decal may allow the tracks to become too wide and allow the door to fall out of its tracks which could result in death or serious injury Shims may be required between the track and wall surface to ensure the TRACK SPACING is maintained and that the tracks are anchored securely NOTE ALL METHODS OF LOWER TRACK UPPER TRACK AND BEARING BRACKET ANCHORING REQUIRE THAT THE TRACK SPACING DIMENSION TOLERANCES OF 1 4 NOT TO BE EXCEEDED RECOMMENDED MOUNTING MOUNTING MOUNTING MOUNTING STEEL TRACK TO STEEL TRACK TO STEEL TRACK TO STEEL TRACK TO C 90 HOLLOW FILLED BLOCK OR WOOD BACKED BY STRUCTURAL SOLID CONCRETE A SOLID MATERIAL STEEL CONCRETE BLOCK i a H 3 8 FLAT 3 8 FLAT WASHER 3 8 FLAT 3 8 FLAT R WASHER WASHER jaw rur 3 8 X 1 1 2 MINIMUM SELF SES ANCHOR Gm SINGLE DOUBLE EVERY 18 EXPANSION SHIELD ANCHOR EVERY 18 ANCHOR OR 3 8 SHORT TYPE OF ANCHOR USED WILL BE SUITABLE FOR TYPE OF SOLID LAG SHIELDS EVERY 18 BACKING BEHIND WOOD Page 8 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Do
15. OPERATION 45 PLANNED MAINTENANCE 46 TROUBLE SHOOTING 47 PARTS LISTING 48 Page II 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors CC DOCK DOORS LIMITED WARRANTY THIS LIMITED WARRANTY IS TKO DOCK DOORS SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK DOOR AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES EXPRESS OR IMPLIED TKO DOCK DOORS warrants that this DOCK DOOR will be free from flaws in material and workmanship under normal use for a period of ONE 1 year from the earlier of 1 60 days after the date of initial shipment by TKO DOCK DOORS or 2 the date of installation of the DOCK DOOR by the original purchaser provided that the owner maintains and operates the DOCK DOOR in accordance with this User s Manual EXTENDED LIMITED WARRANTY In the event that this DOCK DOOR proves deficient in material or workmanship within the applicable limited warranty period TKO DOCK DOORS will at its option 1 Replace the DOCK DOOR or the deficient portion of either without charge to the owner or 2 Alter or repair the DOCK DOOR on site or elsewhere without charge to the owner This limited warranty does not cover any failure caused by improper installation abuse negligence or failure to maintain and adjust the DOCK DOOR properly Parts requiring replacement due to damage resulting from abuse or improper operation are not covered by this warranty TKO DO
16. are required on all panels Page 26 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors SO DOCK DOORS PANEL INSTALLATION ontinueo PANEL STACKING TOP PANEL PICKUP CABLE LEVELING BRACKETS SHOWN FOR EXACT LOCATION OF PICKUP CABLE BRACKETS SEE IDS INSTALLER DETAIL SHEET IN OWNER S PARTS BOOK CABLE ASSEMBLY N OUTSIDE HOLE DETAIL D DETAIL B DETAIL C HINGE PIN LEG OF RUE RING LEG OF RUE RING MUST POINT DOWN DETAIL A TO PREVENT RING FROM TEARING SEALS FEMALE HINGE 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 2f CC DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual PANEL INSTALLATION continued LOCK INSTALLATION Identify quantity of slide lock assemblies to be installed and customer desired location s 2 Position slide lock assembly so that slide lock bar is level and in line with slide lock hole on track when door is fully closed and creating proper seal at bottom 3 Install slide lock assembly to panel plate using 4 TEK screws Slide lock bar MUST extend through the track allowing proper clearance of lock hole when bar is engaged SLIDE LOCK INSTALLATION MALE HINGE FEMALE HINGE FIXED PLUNGER SLIDE LOCK TEK SCREW 14 X 3 4 FRONT EDGE OF SLIDE LOCK HOUSING MUST NOT EXTEND 48 PA
17. door and is legible If the Safety Decal is not present contact the factory to obtain a replacement Safety Decal SAFETY INSTRUCTIONS 2 Model Name Vericon 2277210277772 ILL meo CAN CAUSE SERIOUS INJURY OR DEATH The Warning Placard Part Number 15 00086 illustrated below must be posted by the installer next to the door visible to the users of the door Inspect each door every 30 days to ensure that this placard is still posted near the door and is legible Replace as necessary POST NEAR DOCK DOOR Read and follow all warnings and instructions in the Owner s Manual door mounted Safety Decal and this wall mounted Placard Personnel using the dock doors must be properly trained NEVER use damaged or malfunctioning dock doors Report problems immediately to supervisor Operate door only when it is properly adjusted and free of obstructions Should the door become difficult to operate or completely inoperative immediately report to supervisor DO NOT throw door up violently Using excessive force to open the door may cause the door cables to jump or door panels to disengage from tracks DO NOT close door onto obstructions Obstructions in the opening may stop the door s movement and cause the door cables to jump or door panels to disengage from tracks TRACK SPACING tolerances MUST always be maintained with tracks securely mounted before door is operated Operating door
18. header to the top end of panel travel per the installation instructions on pages 17 to 23 If the Safety Spreader Bars are not installed the Tracks may spread if impacted and allow the door to fall Failure to follow these instructions could result in death or serious injury Page 18 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors DTI DOORS TRACK NSTALLATIO continued TILT T1 SAFETY SPREADER BAR INSTALLATION C CHANNEL ASSEMBLY DETAIL E RUBBER BUMPER TOP SAFETY SPREADER BAR Da Mat CABLE Ps N 22 TO 26 FROM D TOP TRACK MTG SHIELD N 7 BRACKET DOWN D E ei D A f 1 A HEADER SAFETY Hf Ml SPREADER BAR IG M esl HI UPPER TRACK H SECTION DOOR HEADER TRACK SPACING 1 4 TRACK SPACING DETAIL A 27 6 12 24 ABOVE K DOOR HEADER S SAFETY SPREADER SAFETY CABLE BAR MTG BRACKET TRACK MOUNTING BRACKET SAFETY CABLE GRIP SPREADER DETAIL D BAR DETAIL B 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 19 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual TRACK l NSTALLATIO N continued TILT T2 UPPER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Production Detail Sheet It illustrates the assembly of the track component parts 2 Attach upper tracks to lo
19. of panel travel per the installation instructions on pages 16 to 25 If the Safety Spreader Bars are not installed properly the Tracks may spread if impacted and allow the door fo fall Failure to follow these instructions could result in death or serious injury Page 12 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors CC DOCK DOORS TRACK NSTALLATIO continued UPPER STEEL TRACK INSTALLATION EI i DOOR HEADER UPPER TRACKS LOWER TRACKS sv T1 T2 VERTICAL SERIES TILT SERIES TRACK SPACING 1 4 TRACK SPACING 1 4 LOWER TRACKS UPPER TRACKS 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 13 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual TRACK NSTALLATIO INI continued STRAIGHT VERTICAL UPPER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Production Detail Sheet It illustrates the assembly of the track component parts 2 Check how track is assembled Upper tracks will have bearing plates mounted to them See job specific track drawing to determine how parts fit together 3 Attach upper tracks to lowers Attach pieces with 1 4 20x3 4 carriage bolts and flange nuts Pieces MUST fit together to give a smooth transition Any sharp edges may cause
20. s MUST BE structurally sound to support weight of Spring s and the torque put on them TKO Dock Doors DOES NOT supply Spring Mounting Pads or Wall Mounting Hardware RECOMMENDED ANCHORS FOR HOLLOW BLOCK WALL TKO recommends the following 3 8 16 Concrete Single or Double Expansion Shield Anchors and 3 8 Flat Washers one per each anchor used in install 3 8 Short Lag Shields and 3 8 Flat Washers per each anchor used in install NOTE Anchors must be those suitable per the manufacturer for use in hollow block wall and installed per the manufacturer s instructions 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 3 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual SAFETY SAFETY SIGNAL WORDS You may find safety signal words such as DANGER WARNING or CAUTION throughout this owner s manual Their use is explained below This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible death or injury DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury NOTICE Notice is use
21. upper tracks See pages 12 through 25 for upper track installation instructions FLOOR TO TRACK BRACKET INSTALLATION NOTES 1 MOUNT FLOOR TO TRACK BRACKETS TO BOTTOM SIDE OF TRACK WITH HARDWARE SUPPLIED 2 CHECK AND MAINTAIN PROPER TRACK SPACING 3 MOUNT BRACKETS TO FLOOR WITH APPROPRIATE HARDWARE FOR FLOOR MATERIAL NOT SUPPLIED INCLUDED IN HARDWARE BAG 30 00574 HRDW FLOOR TO TRACK BRACKET INCLUDED IN KIT PART NO 30 00085 FLOOR TO TRACK BRKT KIT BOLT CRG 1 4 20 X 3 4 10 00026 FLOOR ANCHOR BOLT NOT INCLUDED e NUT FLNG 1 4 20 i 10 00005 FLOOR TO TRACK BRACKET 20 00007 BOTTOM STRT STEEL TRACK RIGHT HAND SIDE SHOWN 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 11 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual TRACK l NSTALLATIO N continued UPPER STEEL TRACK INSTALLATION The location of the INSTALLATION INSTRUCTIONS for the various UPPER TRACK STYLES are listed in the table below TRACK STYLE INSTALLATION INSTRUCTIONS Vertical Upper Track sss Pages 14 through 15 m Pages 16 through 19 ILL EE Pages 20 through 23 Center Spring Pad Installation Pages 24 through 25 All TKO Dock Doors except Straight Verticals SV require Safety Spreader Bar cross bracing and Safety Cable Assemblies to be installed in the area from the header to the top end
22. 2012 4Front Engineered Solutions Inc Page 15 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual TRACK l NSTALLATIO N continued TILT T1 UPPER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Production Detail Sheet It illustrates the assembly of the track component parts 2 Attach upper tracks to lowers Use provided splice angles Attach pieces with 1 4 20 3 4 carriage bolts and flange nuts Pieces MUST fit together to give a smooth transition Any sharp edges may cause plunger damage Track will angle away from wall at approximately a 5 angle Rise 12 Run 1 NOTE ALL METHODS OF LOWER TRACK UPPER TRACK AND BEARING BRACKET ANCHORING REQUIRE THAT THE TRACK SPACING DIMENSION TOLERANCES OF 1 4 NOT TO BE EXCEEDED RECOMMENDED MOUNTING MOUNTING MOUNTING MOUNTING STEEL TRACK TO STEEL TRACK TO STEEL TRACK TO STEEL TRACK TO C 90 HOLLOW FILLED BLOCK OR WOOD BACKED BY STRUCTURAL CONCRETE BLOCK SOLID CONCRETE A SOLID MATERIAL STEEL 1 2 E FLAT 3 8 FLAT WASHER 3 8 FLAT 3 8 FLAT WASHER WASHER aen 3 8 X 1 1 2 MINIMUM ale X 3 SELF 3 8 X 1 7 8 TAPPING en 16 SLEEVE TYPE EE SCREWS SINGLE OR DOUBLE 18 EXPANSION SHIELD ANCHOR EVERY TS ANCHOR OR 3 8 SHORT TYPE OF ANCHOR USED WILL BE SUITABLE FOR TYPE OF SOLID LAG SHIELDS EVERY 18 BACKING BEHIND WOOD 3 Attach top track mounting bracket
23. 4Front Engineered Solutions Inc COUNTERWEIGHT BRG ANCHOR PAD LH amp OR RH MOUNTING AREAS MIN SIZE 2 W X 6 H Page 7 TKO TKO VertiCool Vertical Leveler Dock Doors User s Manual DOCK DOORS TRACK ANCHORING APPROVED METHODS STRUCTURE 1 Anchors MUST BE centered in the slotted holes of the steel tracks to provide the ability to adjust in or out if necessary It is installers responsibility to make final adjustments to tracks to eliminate any light gaps between seals and jambs 2 mounting the track to wood it is not recommended that the tracks be mounted solely to a single 2 x 4 2 x 6 2 x etc wood face jamb Anchor through wood jamb and into structural member using a minimum 3 8 x 3 anchor backed with a 3 8 flat washer Position anchors as listed in item 1 above Fasteners must be appropriate for the material of the structural member 3 If mounting the track to steel position welds or anchors as listed in item 1 above 4 f mounting the track to solid concrete anchor tracks using minimum 3 8 x 1 7 8 concrete sleeve anchor backed with a 3 8 flat washer Position anchors as listed in item 1 above If a wood face jamb exists anchor through wood jamb and into concrete structure Follow manufacturer s recommendations for installation 5 f mounting to hollow block it is important to use 3 8 expansion type anchors specifically designed for this use 3 8 16 Concrete Single or
24. AFETY SPREADER BAR DETAIL D DETAIL B Failure to securely position and anchor door tracks per the TRACK SPACING dimension and tolerance engraved on the door mounted Safety Decal may allow the door to fallout of its tracks which could result in death or serious injury 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 17 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual TRACK NSTALLATIO continued TILT T1 UPPER TRACK INSTALLATION continued 8 Install safety spreader bar assemblies Mount upper and lower safety spreader bar brackets to upper track with 1 4 20 x 3 4 carriage bolts and flange nuts Brackets need to be attached 12 24 above header and 12 to 24 below top of tracks See page 19 Run two 2 safety spreader bars horizontally from brackets and attach to brackets with 5 16 18 x 3 4 carriage bolts and flange nuts Repeat for the other side of the door opening 9 Install two 2 Safety Cables Bolt two safety cable spool ends to the top horizontal safety spreader bar approximately 30 from each end Attach two cable grip devices to the bottom safety spreader bar approximately 30 from each end Feed each cable through the top and bottom cable grip devices and pull tight Trim excess wire All TKO Dock Doors except Straight Verticals SV require Safety Spreader Bar cross bracing and Safety Cable Assemblies to be installed in the area from the
25. CK DOORS DISCLAIMS ANY RESPONSIBILITY OR LIABILITY FOR ANY LOSS OR DAMAGE OF ANY KIND INCLUDING WITHOUT LIMITATION DIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OR LOST PROFITS OR LOST PRODUCTION arising out of or related to the use installation or maintenance of the DOCK DOOR including premature product wear product failure property damage or bodily injury resulting from use of unauthorized replacement parts or modification of the DOCK DOOR TKO DOCK DOORSSs sole obligation with regard to a DOCK DOOR that is claimed to be deficient in material or workmanship shall be as set forth in this Limited Warranty This Limited Warranty will be null and void if the original purchaser does not notify TKO DOCK DOORS s warranty department within ninety 90 days after the product deficiency is discovered THERE ARE NO WARRANTIES EXPRESS OR IMPLIED WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF INCLUDING BUT NOT LIMITED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE ALL OF WHICH TKO DOCK DOORS HEREBY DISCLAIMS For questions regarding this warranty services or parts contact TKO Customer Service at 1 800 575 3366 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 1 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual OWNER S RESPONSIBILITIES THE OWNER S RESPONSIBILITIES INCLUDE THE FOLLOWING The owners should recognize the inherent danger of the interface between the dock
26. DER PART NUMBER DESCRIPTION 20 02027 RETAINER ALUM BLADE SEAL 8 2 20 00640 SEAL BLADE EPDM BLK 2 1 2 20 02028 RETAINER ALUM BLADE SEAL 10 2 OP PANEL BLADE SEAL FACTORY INSTALLED ALUM RETAINER A d BLADE SEAL HEADER DOOR PANEL TOP DOOR PANEL DETAIL A OUTSIDE BLADE WEATHER SEAL KIT FOR TOP OF TOP PANEL DETAIL A SIDE VIEW SV T1 APPLICATIONS WALL SECTION TOP CABLE PICKUP is WALL DOOR HEADER TW VC 4 K TOP PANEL BLADE SEAL EXT ADJUSTABLE POSITION BLADE SEAL BLADE SEAL ALUM RETAINER PARTS ARE FACTORY INSTALLED QTY PART NO DESCRIPTION 1 20 02027 RETAINER ALUM BLADE SEAL 8 2 1 30 00891 BLADE SEAL EXT TOP PANEL TW VC 4 RH 1 30 00892 BLADE SEAL EXT TOP PANEL TW VC 4 LH 4 110 00350 WASHER FLAT 3 16 1 0 4 1 1 1 DETAIL A ISOMETRIC VIEW NOTES 1 CYCLE THEN LEVEL DOOR 2 LOOSEN RH AND LH BLADE SEAL EXTENSION SCREWS 3 SLIDE EXTENSIONS OUTWARD TO OBTAIN POSITIVE SEAL TO TRACKS SEE DETAIL A ABOVE 10 00349 SCREW SHT METAL PH 10 X 1 20 00640 BLADE SEAL EPDM BLACK 2 1 2 20 02028 RETAINER ALUM BLADE SEAL 102 30 00300 K LATH 8 3 4 10 PACK 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page
27. ENTER BRG BRKT STD 3 6 UNIV RED LEFT SIDE BLACK RIGHT NOTE SPRING CONES MOVE OUTWARD WHEN WINDING SPRING WARNING TAG WINDING e BLACK WINDING CONE RIGHT DRUM BLACK VERTICAL SHOWN Page 42 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors 20 DOCK DOORS WI NDING SPRINGS continued The Spring Assembly which includes the Springs Spring Anchor Brackets Cables Cable Drums and Bearing Brackets is under extreme tension and if handled improperly could result in death or serious injury Spring assemblies should ONLY be installed adjusted or repaired by a trained door systems technician SPLIT SHAFT SHOWN WITH DUAL SPRING LEFT DRUM RED HIGH LIFT SHOWN 1 4 X 3 SHAFT KEY SOLID KEYED SHAFT ONLY LOCKING PLIERS CRIMPED CABLE STOP NOTE RED WINDING CONE CABLE MUST 1 2 TURN MINIMUM ON DRUM CHALK LINE CENTER BRG BRKT STD 3 6 UNIV SHAFT COUPLER RED LEFT SIDE NOTE SPRING CONES MOVE u OUTWARD WHEN WINDING 2 w SPRING WARNING TAGS Gi NN BLACK WINDING CONE RIGHT DRUM BLACK VERTICAL SHOWN 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 43 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual DOOR OPERATION Before operating the door read and follow the Safety Practices on pages 4 5 Stand back M
28. IGHT HAND SIDE TRACK LINER AND TRACK LINER EXT PARTS VARY IN LENGTH AND WIDTH WITHIN THE VERTICOOL MODEL LINE AND WITH DOOR PANEL THICKNESS 4 INCH OR 2 INCH 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 51 DIKO N56 W24701 Corporate Circle e Sussex Wisconsin 53089 USA Tel 262 246 1300 Fax 262 246 1301 Web www tkodoors com 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC
29. ION CAN CAUSE SERIOUS INJURY_OR DEATH DONOT adjust repair or remove springs or parts to which springs are connected such as steel brackets cables wood blocks red colored fasteners or other parts of counterbalance system Adjustments or repairs must ONLY be made bya trained door systems technician using proper tools and instructions DONOT remove cover or paint over this tag Product user should inspect this tag periodically for legibility and should order a replacement tag from the door manufacturer as needed CRGD 102 Gy al 9 21 RIGHT SIDE SPRING WARNING TAG 2 2012 4Front Engineered Solutions Inc Page 31 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual SPRING SHAFT INSTALLATION Failure to properly secure the Anchor Pad could allow the Springs to violently disengage from the wall and could result in death or serious injury NEVER use nails It is important that the Torsion Spring Assembly is securely mounted to the wall structure CENTER SPRING PAD CENTER BEARING BRACKET INSTALLATION 1 Measure CENTER LINE OF SHAFT C L and verify area for proper spring pad mounting 2 Identify style of spring shaft assembly supplied with door 3 Center anchor pad s MUST BE at least 2 wide by 6 high to properly support center bearing bracket s Single shafts will require a single pad bracket centered in the do
30. N EVERY 22 TO 26 ABOVE DOOR HEADER DOOR HEADER TRACK SPACING TRACK SPACING I 1 4 12 24 ABOVE SAFETY CABLE DOOR HEADER CABLE GRIP TRACK MOUNTING BRACKET SAFETY SPREADER BAR DETAIL B SAFETY SPREADER BAR MOUNTING 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Page 21 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual TRACK l NSTALLATIO N continued TILT T2 UPPER TRACK INSTALLATION continued 6 Install safety spreader bar assemblies Mount upper and lower safety spreader bar brackets to front face of track using 1 4 20 x 3 4 carriage bolts and flange nuts Brackets need to be placed 12 to 24 above door header and 6 to 12 below top of tracks See page 23 Run two 2 safety spreader bars horizontally from brackets using 5 16 18 x 3 4 carriage bolts and flange nuts Repeat for the other side of the door opening 7 Install two 2 Safety Cables Bolt two safety cable spool ends to the top horizontal safety spreader bar approximately 30 from each end Attach two cable grip devices to the bottom safety spreader bar approximately 30 from each end Feed each cable through the top and bottom cable grip devices and pull tight Trim excess wire All TKO Dock Doors except Straight Verticals SV require Safety Spreader Bar cross bracing and Safety Cable Assemblies to be installed in the area fr
31. NEL PLATE BEYOND OUTER EDGE OF PANEL LOCK HOLE FIXED PLUNGER USE BACK AND CENTER HANDLE PLUNGER COVER MOUNTING HOLES LINTEL SEAL INSTALLATION A Top Panel Blade Seal Factory Installed 1 Cycle then level door 2 Loosen RH and LH blade seal extension screws 3 Slide extensions outward to obtain a positive seal to tracks See pg 45 B Header Blade Seal Optional 2 blade on 1 straight retainer included for installation on header Header Installation 1 Measure each individual jamb width at the header then cut retainer and blade to these exact measurements 2 Install blade on to retainer 3 Hold retainer flat side up to header and adjust in towards the panel just enough to create a good seal across panel width NOTICE Forcing the blade too far into panel will result in excessive drag and poor door opeartion 4 Install assembly to header using appropriate fasteners not included at each end then every 15 to 20 Brush Seal Single 2 brush on 1 straight retainer are sent as standard Brush seals may be mounted to header or panel top Choice determined by best sealing result Follow same installation instructions outlined for the Header Blade Seal above Top Panel Installation Measure width of top panel less side seals then cut aluminum retainer to this length Measure track width just above top of door then cut brush to this measurement Install brush on to retainer position so brush ends are
32. PTIONAL WITH PANEL PLATE Na BOTTOM PANEL r FIXED PLUNGERS ONLY FIXED PLUNGER SUPER PANEL OPTIONAL DETAIL C INTERIOR SURFACE BOTTOM LOOP SEAL HANDLE STEP PLATE v4 ROPE ATT MANDATORY NOTE LH CABLE ATT BRACKET 3 PANEL DOOR SHOWN BTM OF BOTTOM PANEL CABLES MAY ATTACH TO HIGHER PANELS IN T2 APPLICATIONS FOR CABLE ATT BRACKET POSITIONS SEE THE INSTALLER DETAIL SHEET IDS 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 25 S DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual PAN EL NSTALLATIO N continued PANEL STACKING OVERVIEW 1 Assembling panels Identify any specific door order specifications including any all panel accessory options before stacking Panels See Panel PDS Production Detail Sheet and Panel Hardware PDS Production Detail Sheet in the Owner s Parts Book Identify the proper cable attachment bracket mounting location Identify the of door panels per door and their stacking sequence Lube plunger rods with Silicone Spray prior to stacking panels With covers off spray plunger rods thoroughly so that contact points of housing rods are covered For top pickup styles SV and T1 install cables to the outside set of holes of the cable leveling brackets See Detail D on pg 29 Fixed plungers
33. RACK l NSTALLATIO N continued AWARNING Failure to securely position and anchor door tracks per the TRACK SPACING dimension and tolerance engraved on the door mounted Safety Decal may allow the door to fallout of its tracks which could result in death or serious injury Shims may be required between the track and wall surface to ensure the TRACK SPACING is maintained and that the tracks are anchored securely Page 10 PANID LOWER TRACK INSTALLATION DOOR OPENING WIDTH WALL DEFORMATION EXAGGERATED FOR CLARITY TRACK SPACING 1 4 JAMB TRACK SPACING 1 4 OUTER TRACK SHIM AS REQUIRED 12 000 TYP _ 9 000 3 000 2012 4Front Engineered Solutions Inc DOOR HEADER ASSURE TIGHT SEAL ON BOTH SIDES OF THE TRACK BETWEEN RUBBER FOAM AND WALL AND FLOOR 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors 40 DOCK DOORS TRACK NSTALLATIO continued FLOOR TO TRACK BRACKET INSTALLATION Mount floor to track brackets to both sides of track with the hardware supplied Check and maintain proper track spacing Mount brackets to floor with appropriate hardware for floor material NOT supplied Proceed to upper track installation Once lower tracks are securely mounted and spaced prepare to install
34. all for additional placards manuals or with questions regarding proper use maintenance and repair of dock doors d N56 W24701 N Corporate Circle Sussex WI 53089 DOCK DOORS phone 262 820 1217 Fax 262 820 1273 P N 15 00086 REV A 10 10 Page 30 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors SO DOCK DOORS PAN EL NSTALLATIO N continued DECALS amp PLACARD INSTALLATION ontinuea The Spring Warning Tag TKO Part Number 15 00005 must be fastened to the center bearing bracket for the counter balance springs as illustrated on the adjacent page Inspect each door every 30 days to ensure that this tag is still fastened to shaft spring assembly and is legible Replace as necessary e HIGH SPRING TENSION CAN CAUSE SERIOUS INJURY OR DEATH DONOT adjust repair or remove springs or parts to which springs are connected such as steel brackets cables wood blocks red colored fasteners or other parts of counterbalance system Adjustments or repairs must ONLY be made bya trained door systems technician using proper tools and instructions DONOT remove cover or paint over this tag Product user should inspect this tag periodically for legibility and should order a replacement tag ftom the door manufacturer as needed 3 last raz L u CRGD 102 SPRING WARNING TAG 15 00084 R5 08 12 VC HIGH SPRING TENS
35. alled the Tracks may spread if impacted and allow the door to fall Failure to follow these instructions could result in death or serious injury 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 5 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual SITE PREPARATION AWARNNG Before installing the door read and follow the Safety Practices on pages 4 and 5 Failure to follow the Safety Practices could result in death or serious injury DOOR OPENING 1 Measure DOOR OPENING WIDTH DOW The finished DOW MUST match the designed TRACK SPACING dimension as shown on the panel The door panels may fall out of the tracks if the track spacing is not kept to these exact specifications Measure width at floor mid jamb and header to identify and correct any width variations 2 Measure DOOR OPENING HEIGHT DOH Verify finished DOH matches the door height listed on the door spec sheet Stacked door panels are designed for additional panel height above header for proper sealing If the finished DOH exceeds the specified door height more than 3 contact TKO Doors for assistance 3 Check jambs with a level to ensure the jambs are square to door opening Any compromise will affect the door panel s ability to properly seal against the tracks If jamb repair replacement or adjustment is required it is critical that the original door opening dimensions are maintained as listed in the original door specif
36. and transport vehicle The owner should therefore train and instruct operators in the safe use of the TKO Dock Door as well as all dock equipment devices Nameplates cautions instructions and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended Manufacturer s recommended periodic maintenance and inspection procedures in effect at date of shipment shall be followed and written records of the performance of these procedures should be kept Loading dock doors that are structurally damaged or have experienced failure shall be removed from service inspected by the manufacturer s authorized representative and repaired as needed before being placed back in service The owner shall see that all nameplates caution and instruction markings or labels are in place and legible and that the appropriate operating and maintenance manuals are provided to users Modifications or alterations of loading dock doors shall be made ONLY with the written permission of the original manufacturer When industrial trucks are driven on and off transport vehicles during the loading and unloading operation the brakes on the transport vehicle shall be applied and wheel chocks or positive restraints that provide the equivalent protection of wheel chocks engaged DO NOT install operate or service this product unless you have read and understand the safety practices warnings installation and op
37. d to address practices not related to personal injury SAFETY PRACTICES Read and follow these Safety Practices before installing operating or servicing the door Failure to follow the Safety Practices could result in death or serious injury If you do not understand the instructions ask your supervisor to explain them to you or call TKO at 1 800 575 3366 or ask qualified TKO door technician to assist Installation Maintenance and Service 1 ONLY experienced and qualified door technicians should install or repair doors Springs cable brackets cables drums plungers supports and their hardware are under high tension and can cause injuries if not properly handled Use the proper type and capacity ladders lifting equipment and safety straps or harnesses Safe and efficient installation requires a two person crew Observe OSHA requirements for LOCKOUT or TAGOUT when performing work on doors Observe any all overhead hazards such as electrical air process piping or HVAC ducting when working Move any dock leveler to the dock level storage position before using as a platform for ladders lift trucks or other equipment used in the installation of the door Place barricades on the dock floor around the dock door and in the driveway in front of the door while installing maintaining or repairing the dock door If door is operated with any type of motor or automatic system pull rope MUST BE removed and a safety reversing e
38. de drums against end bearing races Insert the shaft key for each drum when a solid shaft with a keyway is being used 13 Prior to final tightening center bearing bracket bolts and anchors adjust the shaft to ensure it is running straight and level 14 Tighten the set screws as follows Solid Shaft Do not exceed 1 2 turn after coming in contact with the shaft Hollow Shaft Tighten set screws enough to dimple shaft about 1 1 4 turns after set screws first hit shaft Page 36 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors CC DOCK DOORS SPRING SHAFT INSTALLATION ntinuea Failure to assemble the Torsion Springs and Counterbalance System correctly will cause the door to function improperly and could result in death or serious injury DOUBLE SPRING WITH SINGLE SHAFT BEARING RACE TO FACE AWAY FROM DRUM MOUNT TO OUTSIDE FACE OF BEARING PLATEN BEARING OPTION FLANGE BEARING STANDARD BEARING RACE TO FACE DRUM MOUNT TO INSIDE FACE OF BEARING PLATE LEFT DRUM RED 1 HIGH CYCLE BEARING HIGH LIFT SHOWN OR 1 4 X 3 SHAFT KEY 1 25 HIGH CYCLE BEARING SOLID KEYED SHAFT ONLY DETAIL B RED WINDING CONE CENTER BRG BRKT STD 3 6 UNIV RED LEFT SIDE 6 MIN CLEARANCE WINDING RIGHT 1 TUBE SHAFT OR SHORT LEG MUST BE DOWN oes KEYED SHAFT SHOWN 1 1 4 SOLID KEYED SHAFT BLACK WINDING CONE 3 8
39. dge MUST BE installed oar N A 00 4 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC TKO VertiCool Vertical Leveler Dock Doors CC DOCK DOORS SAFETY continued SAFETY PRACTICES Operation 1 2 8 Personnel using the dock doors MUST BE properly trained Operate door ONLY when properly adjusted and free of obstructions Should the door become difficult to operate or completely inoperative immediately report to supervisor DO NOT stand or walk under moving door Keep door in full view and free of obstructions while operating DO NOT allow children to operate the door or controls DO NOT throw door up violently Using excessive force to open the door may cause the door cables to jump off the drums or door panels to disengage from tracks DO NOT close door onto obstructions Obstructions in the opening may stop the doors movement and cause the door cables to jump or door panels to disengage from tracks To avoid injury keep hands free of door parts while operating Panels and door parts may create pinch points when in operation NEVER use damaged or malfunctioning dock door All TKO Dock Doors except Straight Verticals SV require Safety Spreader Bar cross bracing and Safety Cable Assemblies to be installed in the area from the header to the top end of panel travel per the installation instructions on pages 16 through 23 If the Spreader Bars are not inst
40. e Spray is applied to entire track system lower upper radius and horizontal tracks where plunger tips and side seals contact 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 41 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual WI NDING SPRINGS continued 16 Remove locking pliers from shaft 17 While securely holding down the door unlock the door and slowly raise the door Cycle door a few times to determine balance Add or subtract tension as necessary to balance door to customer satisfaction 18 When door is closed make sure that there is positive sealing around side and bottom seals Track adjustment and or leveling may be necessary to accomplish this It is the installer s responsibility to make these adjustments before leaving the job site It is the customer s responsibility to maintain this going forward The Spring Assembly which includes the Springs Spring Anchor Brackets Cables Cable Drums and Bearing Brackets is under extreme tension and if handled improperly could result in death or serious injury Spring assemblies should ONLY be installed adjusted or repaired by a trained door systems technician SINGLE SHAFT SHOWN WITH DUAL SPRING LEFT DRUM RED HIGH LIFT SHOWN 1 4 X 3 SHAFT KEY SOLID KEYED SHAFT ONLY LOCKING PLIERS CRIMPED RED WINDING CONE CABLE STOP FLOATING L CABLE MUST BE 1 2 TURN MINIMUM ON DRUM CABLE STOP CHALK LINE C
41. equal distance away from retainer ends Position retainer flat side down so it is even with panel ends then adjust in towards header wall just enough to create a uniform seal across the opening width NOTICE Forcing the blade too far into header wall will result in excessive drag and poor door opeartion 5 Install assembly to top panel using provided fasteners at each end then every 15 to 20 NRO BD Mg Page 28 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC TKO VertiCool Vertical Leveler Dock Doors CC DOCK DOORS PAN EL NSTALLATIO N continued DECALS amp PLACARD INSTALLATION The Safety Decal Part Number 15 00085 and Product Identification Decal are factory installed to the second panel as shown in the illustration below The installer MUST post the Warning Placard next to the door in a viewable location for the operators of the door DECALS amp PLACARD INSTALLATION WARNING PLACARD 15 00086 SAFETY DECAL IDENTIFICATION TRACK SPACING 15 00085 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 29 CC O TKO VertiCool Vertical Leveler Dock Doors User s Manual PAN EL NSTALLATIO continued DECALS amp PLACARD INSTALLATION continuea The Safety Decal contains the Track Spacing Dimension Serial Number and Model Name Inspect each door every 30 days to ensure that this decal is still fastened to the
42. eration instructions contained in this manual Failure to do so could result in death or serious injury Page 2 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors Sg DOCK DOORS TOOLS amp MATERIALS THE FOLLOWING TOOLS amp MATERIALS ARE NECESSARY FOR PROPER INSTALLATION OF ANY TKO DOOR S AND ARE NOT PROVIDED BY TKO Two Spring Winding Bars approximately 24 minimum long for winding springs 1 2 diameter bars for 2 5 8 diameter springs 5 8 diameter bars for 3 3 4 and 6 diameter springs Tools to mount track to wall using any of the recommend track anchoring methods Hammer Drill or Impact Wrench Tools to mount track to wall using any of the alternate track anchoring methods Hammer Drill or Impact Wrench Welder with welding rods Include grinder if door to be removed is welded to jambs Aerial equipment Ladders scaffolding scissors lift or boom lift Hand tools socket wrench set 7 16 1 2 9 16 4 long level bar clamps or C clamps locking pliers vice grips hammer screwdrivers and tape measure contractor grade Lubricants Light Weight Oil for lubing Torsion Counterbalance Springs Steel angle minimum 12 gauge for Backhangs and Sway Braces Size will vary with different applications Anchors Fasteners used to mount tracks center and end bearing plates etc Spring Mounting Pad
43. erify that the upper track assembly will fit within the given space Refer to the track print for required track depth 6 Check for potential obstructions that may impede the door s normal upward and downward travel such as an electrical box sprinkler head pipe etc If adjustment or modification is necessary please contact TKO DOORS for assistance 7 Check that the floor mounting area is level from right to left side within 1 4 Be prepared to level or shim under one side of track if necessary Contact TKO Doors for assistance at 1 800 575 3366 Page 6 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual SITE PREPARATION continued TKO VertiCool Vertical Leveler Dock Doors DTI DOORS 12 MIN 3 MIN 3 CENTER BRG ANCHOR PAD MOUNTING AREAS MIN SIZE 2 W X 6 OPERATOR SPLIT SHAFT P MTG AREA LH OR RH SEE OPERATOR MANUAL FOR MTG SIZE amp LOCATIONS t 1 2 DOOR OPENING WIDTH TRACK MOUNTING TRACK HEADER SURFACE MOUNTING HEIGHT TMH din rj CENTER i P M DEPTH INTO LINE OF BRUSH SEAL BUILDING SHAFT g M bh WTC CL JAMB WALL 10 TRACK MTG DOOR WIDTH TMW OPENING HEIGHT MTG DEPTH Bn DOOR OPENING Le eua WIDTH DOW 15 00084 R5 08 12 VC DOOR OPENING TRACK MOUNTING SURFACE OR 6 DUAL SPRING SINGLE SHAFT 2012
44. es Drums Plungers Supports and their hardware are under extreme tension and can cause injuries if not properly handled Always follow the maintenance schedule to ensure all components are in good working condition Damaged or worn parts MUST BE replaced immediately for proper and safe operation It is recommended that the door be made inoperative until the damaged or worn parts have been replaced Observe OSHA requirements for LOCKOUT TAGOUT when performing work on the door Disconnect power before performing maintenance or repair of electrical devices Use proper tag or lockout procedures per OSHA regulations MAINTENANCE SCHEDULE INSPECT INTERVALS ITEM PROCEDURE Every Daily Monthly 3 Months Operation Manually operate the door Check for smooth operation and proper balance p If this door has an automatic opener disconnect it before this inspection Inspect all safety warning product labels placards decals tags Replace if Labels Hn damaged missing Drums Couplers Check all set screws and shaft keys and securely tighten Sprockets Level door in opening if necessary Cables Check for signs of abnormal wear fraying or damage Bearings Check for signs of abnormal wear or damage Cable Attachments Check for signs of abnormal wear or damage and properly secure all fasteners Check for signs of abnormal wear or damage Lub
45. gainst the jamb place measuring tool on floor then adjust track until tool ends are touching the inside faces of both tracks see diagram below Fasten track near floor Move track spacing tool to upper portion of track and repeat procedure described in step 5 Verify TRACK SPACING Measure track width starting at 3 from floor and every 3 on up Track MUST BE kept at proper spacing while being centered in opening TRACK SPACING tolerance is 1 4 Track fasteners must be installed at the correct spacing as described in the methods illustrated on pg 8 Solidify attachments to wall Once TRACK SPACING is correct be certain to tighten down all anchors bolts and finish all welds that may have been left incomplete to allow for moving of track Floor to track bracket installation See page11 for complete installation instructions NOTE Track spacing tool is intended lt to be used for all track sections lower upper and radius sections F TRACK SPACING 1 1 4 at TRACK SPACING 2 lt 1 4 d l TT n d d bw DETAIL TRACK SPACING TOOL T 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 9 DTI DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual T
46. ication sheet 4 Check jambs with a level to ensure the jambs are plumb and straight The tracks MUST BE installed level while maintaining the specified track spacing 5 TKO recommends the use of pipe bollards for protection of the door tracks TRACK MOUNTING SURFACE 1 Measure available TRACK MOUNTING HEIGHT TMH Verify that the required TMH will fit in the available space See job specific documents shipped with your order If the required TMH exceeded what is available contact TKO Doors for assistance 2 Check door specification sheet for track mounting style and track print for TRACK MOUNTING WIDTH TMW Verify that the width of the mounting surface on jamb is equal or greater than the mounting width of the track 3 Check TRACK MOUNTING DEPTH TMD for any obstructions such as a bollard or curb that would interfere with mounting the track to the jamb Verify track depth on track print for track dimension If track depth exceeds available space contact TKO Doors for assistance 4 Make sure all track mounting surfaces header beam and center bearing bracket pads are flush in relation to one another The tracks header seal and center bearing bracket are designed to be installed on the same plane Adjusting of end bearing plates may be necessary to keep upper tracks on the same plane as lower tracks All mounting surfaces MUST BE smooth and free of any weld beads or bolt heads etc 5 Check available DEPTH INTO BUILDING WTC and v
47. istance is required 2 Bottom panel The bottom panels have a horizontal dual bulb seal on the top of the panel and a loop seal on the bottom This panel is 48 high 3 Second panel The Second panel has a horizontal dual bulb seal on the top and bottom of the panel except for 8FT high door where this is also the top panel see top panel identification below This panel could be 48 or 36 high depending on door height If a window panel was supplied it is typically placed in the 2nd panel from bottom position Fixed plungers are required on all panels 4 Top panel The top panels have a T Slot seal on the top of the panel and a horizontal dual bulb seal on the bottom This panel could be 12 18 24 30 36 42 or 48 high depending on door height NOTE For top panel pickup cable attachment brackets the cable must be attached to the outer most location on the bracket See illustration on pg 27 PLUNGER DESCRIPTION FIXED ROLLER PLUNGER ASSY RFP 30 00676 PLUNGER COVER Page 24 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors SO DOCK DOORS PAN EL l NSTALLATIO N continued AWARNNG Fixed plungers are required all panels FULL DOOR PANEL ASSEMBLY CABLE ASSEMBLES OUTSIDE HOLE TOP PANEL INTERMEDIATE PANEL 2ND SV T1 CABLE HINGE SET LEVELING ATT BRACKET SLIDE LOCK assy O
48. k mounting brackets 2 per side at equal spacing See pg 15 Attach to track with 1 4 20 x 3 4 carriage bolts and flange nuts Mount track mounting brackets to the wall with one of the Recommended Anchoring Methods illustrated above Follow manufacturer s recommendations for anchor installation 6 Measure over to the opposite track and position it at the track spacing dimension engraved on the Safety Decal located on the 3rd panel of the door Repeat steps 4 and 5 above Follow manufacturer s recommendations for anchor installation Failure to securely position and anchor door tracks per the TRACK SPACING dimension and tolerance engraved on the door mounted Safety Decal may allow the door to fallout of its tracks which could result in death or serious injury Tracks must be mounted straight level and on the same plane as lower tracks Page 14 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors CC DOCK DOORS TRACK NSTALLATIO continued STRAIGHT VERTICAL UPPER TRACK INSTALLATION SV DRUM LEFT RED SPRING SHAFT ASSEMBLY SV DRUM RIGHT BLACK DETAIL CRG BOLT 1 4 20 X vec Ne 1 4 20 FLNG NUT CENTER TWO 2 BRACKETS ON UPPER TRACK SECTION T UPPER TRACK SECTION 1 4 15 00084 R5 08 12 VC
49. low to avoid exceeding the specified torque Solid Shaft Do not exceed 1 2 turn after coming in contact with the shaft Hollow Shaft Tighten set screws enough to dimple shaft about 1 1 4 turns after set screws first hit shaft Make sure all springs are thoroughly oiled around the entire circumference of the spring with LightWeight oil or equivalent Repeat this procedure for other spring On doors with two springs both springs should be wound the same amount of turns If any adjustment to the Upper Tracks has to be made the door MUST BE locked in the closed position If it is required to add or reduce the tension of the Torsion Springs always use Winding Bars and stay clear to the side Be prepared to handle the force of the Springs NEVER adjust the Center Bearing Bracket after the Springs are wound Use caution when opening the door for the first time If the Tracks are incorrectly mounted too wide the door may fall out of the Tracks 13 14 Install SPRING WARNING TAG as shown in the illustrations below RIGHT SIDE SPRING WARNING TAG SPRING WARNING TAG E It is recommended that only Silicone Spray is applied to entire track system lower upper radius and horizontal tracks where plunger tips and side seals contact 15 While securely holding down the door unlock the door and slowly raise the door It is recommended that ONLY Silicon
50. nction improperly and could result in death or serious injury COMPONENT IDENTIFICATION 1 ldentify specific spring shaft and bearing kit required for selected door See the Counter Balance PDS Production Detail Sheet from the Owner s Parts Book 2 Inspect spring shaft components for any missing or damaged items 3 When viewing the door from the inside of the building looking out RED winding cone torsion springs drums are installed on the left side of the door and BLACK winding cone torsion springs and drums are installed on the right side of the door 4 Failure to install the torsion springs correctly will cause the door to function improperly and could result in serious injury If door is to be equipped with a chain hoist or motor operator a solid keyed shaft MUST BE used for shaft assembly SINGLE SPRING SINGLE SHAFT ASSEMBLY 1 Layout counter balance parts on floor 2 ldentify if spring is left hand red or right hand black 3 Slide center bearing s to the center of the shaft with the bearing race facing away from the selected spring 4 Slide the left spring red on to shaft with the stationary spring cone facing the center of shaft and the winding cone to the outer 5 Slide the right spring black on to shaft with the stationary spring cone facing the center of shaft and the winding cone to the outer 6 Bolt spring stationary cone center bearing s and center bearing bracket s together DO NOT tighten comple
51. nd run it up to the shaft between the wall and the drum On straight vertical doors attach cable to the outside hole of the cable attachment bracket o B 7 Place cable stops in the notch in the backside of drum and turn the drum until all slack in cable is removed Make sure cable is seated properly in the grooves of the drum 8 Tighten drum to shaft If shaft is solid keyed properly align drum shaft and install shaft key prior to tightening Each cable MUST have the same amount of pre tension 9 If split shaft is supplied securely tighten shaft coupler bolts set screws and locking nuts WIND SPRINGS See parts book Installer IDS sheet for spring turns 1 Clear the area of personnel and keep yourself out of the direct path of the winding bars while winding the torsion springs 2 Use a sturdy ladder or platform to stand on and keep slightly to the side of the winding bars 3 Mark horizontal chalk line across the entire length of spring s This will help indicate the number of turns placed on the torsion spring s 4 Insert the winding bars into the full depth of hole in the winding cone The spring assembly which includes the springs spring anchor brackets cables cable drums and bearing brackets is under extreme tension Spring assemblies should ONLY be installed adjusted or repaired by a trained door systems technician Winding bars MUST fit snugly into the holes in the winding cone NEVER use smaller rods or screwdriver
52. om the header to the top end of panel travel per the installation instructions on pages 17 to 23 If the Safety Spreader Bars are not installed the Tracks may spread if impacted and allow the door to fall Failure to follow these instructions could result in death or serious injury Page 22 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors 40 DOCK DOORS TRACK NSTALLATIO N continued TILT T2 SAFETY SPREADER BAR INSTALLATION END BUMPER SPREADER BAR 30 3 DETAIL TOP SAFETY SPREADER BAR CABLE SAFETY SHIELD HEADER SAFETY SPREADER BAR UPPER TRACK SECTION EVERY 22 TO 26 ABOVE DOOR HEADER DOOR HEADER TRACK SPACING el TRACK SPACING 1 4 12 24 ABOVE SAFETY CABLE DOOR HEADER TRACK MOUNTING BRACKET SAFETY SPREADER BAR DETAIL B SAFETY SPREADER DETAIL A BAR MOUNTING BRACKET 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 23 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual PANEL INSTALLATION AWARNNG DO NOT allow side seals to compress in any way before panels are actually stacked in opening COMPONENT IDENTIFICATION 1 ldentify panels nspect panels for any missing or damaged panels Call TKO doors or local distributor dealer if ass
53. on Springs and Counterbalance System correctly will cause the door to function improperly and could result in death or serious injury DOUBLE SPRING WITH SPLIT SHAFT BEARING RACE TO FACE AWAY FROM DRUM BEARING OPTION MOUNT TO OUTSIDE FACE OF BEARING PLATE FLANGE BEARING STANDARD BEARING RACE TO FACE DRUM MOUNT TO INSIDE FACE OF BEARING PLATE LEFT DRUM RED HIGH LIFT SHOWN 1 4 X 3 SHAFT KEY SOLID KEYED SHAFT ONLY 1 HIGH CYCLE BEARING OR 1 25 HIGH CYCLE BEARING DETAIL B LEFT HAND SPLIT SHAFT RED WINDING CONE RED LEFT e SIDE IN CLEARANCE BEFORE WINDING SHORT LEG MUST BE DOWN STATIONARY CONE ENTER SHAFT BEARI 2X 3 8 LOCK WASHER A 3 8 16 X 1 1 2 HEX BOLT 4 FULL THREAD DETAILA SPRING WARNING TAG 3 8 16 X 2 BOLT PARTIAL THREAD CENTER BRKT STD 3 6 UNIV SHAFT COUPLER CENTER BRKT STD 3 6 UNIV BLACK RIGHT BLACK WINDING CONE SIDE RIGHT HAND SPLIT SHAFT 1 SOLID KEYED SHAFT SHOWN OR 1 1 4 SOLID KEYED SHAFT SPRING WARNING TAG RIGHT DRUM BLACK VERTICAL SHOWN NOTE INCLUDED IN CBAL KIT FLANGE BEARING STANDARD BEARING RACE TO FACE DRUM MOUNT TO INSIDE FACE OF BEARING PLATE 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 39 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual
54. or opening Dual shafts with couplers will require two pads brackets centered in opening and spaced approximately 12 inches apart Single shafts with Dual 6 Springs will also require two 2 pads brackets 4 Center anchor pad s MUST adequately support the center bearing bracket s and torsion spring assembly 5 If center anchor pad is wood pad MUST BE free of cracks and splits in the wood If wood is cracked or split it MUST BE replaced DO NOT use wood of less than grade 2 yellow pine or wood labeled as spruce pine fur SPF Pilot drill all holes to prevent splitting of wood 6 TKO recommends that the Center Bearing Bracket s not be welded This Alternate Anchoring Method will not allow for adjustment if the spring shaft needs leveling See illustration below for Recommended Anchoring Methods MOUNTING BRACKET TO C 90 HOLLOW CONCRETE BLOCK Page 32 mi a norm l 3 8 FLAT WASHER 3 8 16 SINGLE OR DOUBLE EXPANSION SHIELD ANCHOR OR 3 8 X 1 3 4 SHORT LAG SHIELD EVERY 18 RECOMMENDED ANCHORING METHODS MOUNTING BRACKET MOUNTING BRACKET MOUNTING BRACKET TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL OR SOLID CONCRETE BY ASOLID MATERIAL STEEL li NN 3 8 FLAT 3 8 FLAT 3 8 FLAT WASHER WASHER WASHER DEE 3 8 X 1 1 2 MINIMUM We SELF TAPPING 3 8 X 1 7 8 EVERY AG SCREWS SLEEVE ANCHOR EVERY 18 EVERY 18
55. ors CC DOCK DOORS TRACK INSTALLATION LOWER TRACK INSTALLATION 1 2 Locate the TRACK PRINT PDS Production Detail Sheet It illustrates the assembly of the track component parts Inspect track pieces and line up so that they match job specific track drawing that was supplied with door If track drawing is missing TKO Doors customer service representative for assistance Locate the rubber foam in the Parts box Remove the adhesive cover and apply it along the entire length on the back and bottom of the plastic track liner as shown on the illustration below Repeat for the opposite side track and then continue with the lower track installation RUBBER FOAM STEEL TRACK RADIANT BARRIER PLASTIC TRACK LINER a NOTE RIGHT HAND SIDE OF TRACK SHOWN FOAM TAPE Check the floor pad for level Tops of tracks MUST BE level with one another to within 1 4 or door will not operate smoothly Shimming of tracks off the floor may be necessary While holding the lower left hand LH track against the jamb and flush to the opening carefully level it Use one of the approved fastening methods shown on pg 8 Anchors bolts with flat washers should be placed in the middle of the slotted holes of the steel tracks so tracks can be adjusted later if necessary If steel tracks are to be welded in place track MUST BE correctly placed The track spacing tool can now be used to set the right hand RH track While holding the track a
56. oving door can crush you Keep people clear while door is moving Failure to follow these instructions could result in death or serious injury DO NOT operate door if it is not properly adjusted or free of obstructions NEVER operate door until the entire opening and track guides are free of obstructions equipment material and people 3 Keep hands clear of the tracks hinges springs and plungers at all times Lift and lower door with proper ergonomic methods by using supplied pull rope and door handles step plates 5 Raise and lower door slowly and maintain an even door travel speed Keep door in full view NEVER throw door up or pull door down at high speed 6 DO use the loading dock door if it looks broken or DOES NOT seem to work right Tell your supervisor it needs repair right away 7T Chock truck wheels or lock truck in place with a truck restraining device and set brakes before loading or unloading Keep door closed when not in use 9 Move all equipment material and people away from loading dock door and close dock door before allowing the truck to pull out 10 DO NOT use a fork truck or other material handling equipment to raise or lower the loading dock door Page 44 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors CC DOCK DOORS AVAILABLE OPTIONS Blade Weather Seal Kit for Header Top of Top Panel BLADE WEATHER SEAL KIT FOR HEA
57. plunger damage or cable failure NOTE ALL METHODS OF LOWER TRACK UPPER TRACK AND BEARING BRACKET ANCHORING REQUIRE THAT THE TRACK SPACING DIMENSION TOLERANCES OF 1 4 NOT TO BE EXCEEDED RECOMMENDED MOUNTING MOUNTING MOUNTING MOUNTING STEEL TRACK TO STEEL TRACK TO STEEL TRACK TO STEEL TRACK TO C 90 HOLLOW FILLED BLOCK OR WOOD BACKED BY STRUCTURAL SOLID CONCRETE A SOLID MATERIAL STEEL CONCRETE BLOCK K 3 8 FLAT WASHER 3 8 FLAT 3 8 FLAT WASHER WASHER Jae rum 3 8 X 1 1 2 MINIMUM ee SELF UN Mn eme SINGLE OR DOUBLE EVERY 18 EXPANSION SHIELD ANCHOR EVERY 18 ANCHOR OR 3 8 SHORT LAG SHIELDS EVERY 18 NOTICE Before mounting End Bearing Plates to wall level track and also verify upper track is plumb with lower track Shims may be required between the Bearing Plate Mounting Bracket and mounting surface TYPE OF ANCHOR USED WILL BE SUITABLE FOR TYPE OF SOLID BACKING BEHIND WOOD 4 Level left hand track then mount bearing plate mounting bracket to wall minimum of 2 anchors per bracket with one of the Recommended Anchoring Methods illustrated above Follow manufacturer s recommendations for anchor installation NOTE End Bearing Plate mounting bracket is slotted for adjustment to wall Loosen bracket bolts and adjust as necessary to obtain plumb condition with lower track 5 Secure upper track to wall with 4 trac
58. ricate with Light Weight Springs Oil remove excess with shop rag Spring Anchors Check for signs of abnormal wear or damage and properly secure all fasteners Shaft Check for signs of abnormal wear or damage Check for proper track spacing and alignment Track Check and properly secure all track anchors Track Check for signs of abnormal wear or damage Check Safety Spreader Bar Assemblies for Tilt Doors are installed and Safety Spreader Bar undamaged Backhangs Sway Check for signs of abnormal wear or damage and properly secure Braces all fasteners Plunger shaftsand Spray Light Weight Oil onto the plunger shaft and bearings on both sides of bearings the housing to lubricate Hinges Check for signs of abnormal wear or damage Fasteners Check and properly secure all fasteners Panels Check for signs of abnormal wear or damage Panels Clean with soap ONLY Call TKO for approved cleaners 4 As Needed Seals Check for signs of abnormal wear or damage Use Light Weight Oil Caution Solvents may damage the panels and void manufacturers warranty 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 47 TKO TKO VertiCool Vertical Leveler Dock Doors DOCK DOORS TROUBLE SHOOTING User s Manual Before servicing the door read and follow the Safety Practices on pages 4 5 and the Door Operation section on page 45 of this manual TROUBLE TROUBLE SHOOTING GUIDE
59. rify that track spacing is still correct and tracks are level 7 Attach hardware to C channel Attach adjustable track mounting brackets to top and bottom of C channel in the center of the assembly with 1 4 20 x 3 4 carriage bolts and flange nuts See detail C page 17 Anchor adjustable track mounting brackets to wall minimum of two 2 anchors and two 2 3 8 flat washers per bracket These prevents C channel from twisting and stabilizes the upper track section See Detail C page 17 Mount center bearing brackets to C channel with 3 8 16 x 1 carriage bolts and flange nuts Location may vary according to quantity and length of springs Page 16 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors DTI DOORS TRACK l NSTALLATIO N continued TILT T1 UPPER TRACK INSTALLATION DETAIL C 2 6 DETAIL E RUBBER BUMPER TOP SAFETY SPREADER BAR y RA ie RR Do 22 TO 26 FROM CABLE SAFETY __ 8 SHIELD mh p TRACK MTG DOWN HEADER SAFETY Hi d SPREADER BAR I d CH ir UPPER TRACK WE SECTION sss P SR OP IS DOOR HEADER SSS We A n nz R TRACK Sub Z TRACK SPACING ze DETAIL A 12 24 DOOR HEADER SAFETY SPREADER BAR MTG BRACKET TRACK MOUNTING BRACKET S
60. s and Counterbalance System correctly will cause the door to function improperly and could result in death or serious injury SINGLE SPRING WITH SINGLE SHAFT RED WINDING CONE BEARING OPTION BEARING RACE TO FACE AWAY FROM DRUM MOUNT TO OUTSIDE FACE OF BEARING PLATE RED LEFT SIDE 1 HIGH CYCLE BEARING 1 25 HIGH CYCLE BEARING 6 MIN CLEARANCE BEFORE WINDING 2 2 FLANGE BEARING STANDARD lt BEARING RACE TO FACE DRUM MOUNT TO INSIDE FACE OF BEARING PLATE LEFT DRUM RED A HIGH LIFT SHOWN 1 4 X 3 SHAFT KEY SPRING WARNING SOLID KEYED SHAFT ONLY CENTER BRG BRKT STD 3 6 UNIV BLACK WINDING CONE 1 TUBE SHAFT FULL THREAD STATIONARY CONE CENTER SHAFT BEARING 1 SOLID KEYED SHAFT SHOWN 3 8 16 FLNG NUT 2X RIGHT DRUM BLACK VERTICAL SHOWN INCLUDED IN CBAL KIT FLANGE BEARING STANDARD BEARING RACE TO FACE DRUM MOUNT TO INSIDE FACE OF BEARING PLATE SPRING WARNING TAG DETAIL A 15 00084 R5 08 12 VC 2012 4Front Engineered Solutions Inc Page 35 0 DOCK DOORS TKO VertiCool Vertical Leveler Dock Doors User s Manual SPRING SHAFT INSTALLATION AWARNNG Failure to assemble the Torsion Springs and Counterbalance System correctly will cause the door to function improperly and could result in death or serious injury DOUBLE SPRING SINGLE SHAFT ASSEMBLY 1 Layout counter balance par
61. s as winding bars Failure to use proper winding bars could result in death or serious injury Page 40 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors CC DOCK DOORS WI NDING SPRINGS continued WI ND SPRINGS continued 5 6 10 11 12 Wind springs in upward direction 1 4 turn and hold the tension Insert the second winding bar fully into the next available hole in the winding cone Take the load on the second winding bar and remove the first winding bar Wind the second winding bar upward 1 4 turn Always wind springs in 1 4 turn increments Four 1 4 turns are required to obtain one full turn The number of turns can be obtained by counting the turns of the chalk line Continue this procedure until the specified number of turns per spring is obtained If tension in the torsion spring DOES NOT increase when adding 1 4 turn the springs may be reversed As the torsion springs are wound the spring will grow longer Allow winding cone to move outward as turns are applied to prevent kinking of spring wire When the last 1 4 turn has been completed insert a second winding bar into the bottom hole of the winding cone and stretch springs outward 1 2 to 1 This will eliminate the possibility of spring coils binding during operation Tighten setscrews on the winding cone with oiled threads to 15 16 ft lbs Follow the recommendations listed be
62. tely this will allow for adjustments with installation T Slide the left drum red on the left side of shaft with the setscrews facing the center of the shaft 8 Slide the right drum black on the right side of shaft with the setscrews facing the center of the shaft 9 Slide on specified end bearings on to both ends of shaft with correct orientation The bearing race has an outside diameter of 1 1 4 and projects from the flange 1 8 The bearing housing has an outside diameter of 2 and projects from the flange 3 8 The bearing race needs to be facing the cable drums 10 Lift counterbalance assembly onto end bearing plates making sure end bearing are positioned inside of plates with races facing inward 11 Secure shaft and bearing to plate using carriage bolts supplied Verify bearing position specified on IDS Installer Detail Sheet in the owner s parts book 12 Slide drums against end bearing races Insert the shaft key for each drum when a solid shaft with a keyway is being used 13 Tighten the set screws as follows Solid Shaft Do not exceed 1 2 turn after coming in contact with the shaft Hollow Shaft Tighten set screws enough to dimple shaft about 1 1 4 turns after set screws first hit shaft Page 34 2012 4Front Engineered Solutions Inc 15 00084 R5 08 12 VC User s Manual TKO VertiCool Vertical Leveler Dock Doors Sg DOCK DOORS SPRING SHAFT INSTALLATION continea Failure to assemble the Torsion Spring
63. ts on floor 2 For6 Springs Slide the two center bearings to the center of the shaft with the bearing races facing each other 3 For2 5 8 or 3 3 4 dia Springs Slide center bearing to the center of the shaft with the bearing race facing away from the selected spring 4 Slide the left spring red on to shaft with the stationary spring cone facing the center of shaft and the winding cone to the outer 5 Slide the right spring black on to shaft with the stationary spring cone facing the center of shaft and the winding cone to the outer 6 Bolt spring stationary cones center bearing and center bearing bracket together DO NOT tighten completely this will allow for adjustments with installation T Slide the left drum red on the left side of shaft with the setscrews facing the center of the shaft 8 Slide the right drum black on the right side of shaft with the setscrews facing the center of the shaft 9 Slide on specified end bearings on to both ends of shaft with correct orientation The bearing race has an outside diameter of 1 1 4 and projects from the flange 1 8 The bearing housing has an outside diameter of 2 and projects from the flange 3 8 The bearing race needs to be facing the cable drums 10 Lift counterbalance assembly onto end bearing plates making sure bearings are positioned inside of the plates with races facing inward 11 Secure shaft and bearing to plate using carriage bolts supplied 12 Sli
64. wers Use provided splice angles Attach pieces with 1 4 20 x 3 4 carriage bolts and flange nuts Pieces MUST fit together to give a smooth transition Any sharp edges may cause plunger damage or cable failure Track will angle away from wall at approximately a 5 angle Rise 12 Run 1 3 Attach end bearing plate to track Attach End Bearing Plate to offset bearing bracket at factory established center line of shaft with 3 8 16 x 1 carriage bolts and flange nuts offset bearing bracket is factory attached to upper track section Level Track then mount End Bearing Plate to the wall minimum of 2 anchors per plate with one of the Recommended Anchoring Methods illustrated below Follow manufacturer s recommendations for anchor installation 4 Repeat for opposite side measuring to verify track spacing is correct before securing end bearing plate End Bearing Plate MUST BE mounted in the same position as opposite side before tightening bolts 5 Attach track mounting brackets Attach long leg of track mounting brackets to upper track section with 1 4 20 x 3 4 carriage bolts and flange nuts Fill in the rest of the track mounting brackets both sides every 22 to 26 above the door header See page 21 Mount brackets to the wall with one of the Recommended Anchoring Methods illustrated below Follow manufacturer s recommendations for anchor installation NOTE ALL METHODS OF LOWER TRACK UPPER TRACK AND BEARING BRACKET
65. with improper TRACK SPACING or mounting could cause panels to disengage from the track which could crush you and result in death or serious injury Refer to Owner s Manual and Safety Decal mounted on door for proper TRACK SPACING and mounting requirements Impacting this door can create a hazardous situation ALWAYS use caution and carefully follow instructions listed on this Placard and the door mounted Safety Decal ALWAYS follow maintenance schedule to ensure all components are in good working condition Damaged or worn parts must be replaced immediately for proper and safe operation It is recommended that the door be made inoperative until the damaged or worn parts have been replaced The cable attachment bracket is under extreme spring tension DO NOT try to adjust or repair Repairs or adjustments must be made by a trained door systems technician using proper tools and instructions The cable attachment bracket can spring out and hit someone which could result in death or serious injury DOOR OPERATION To operate keep door in full view slowly raise door using manufacturer supplied handle s and lower door by slowly pulling on supplied pull down rope NEVER apply force in a manner which would cause the panels to disengage from the track If door has an automatic opener remove pull rope from door and follow instructions supplied with opener Failure to follow these and other provided warnings could result in death or serious injury C

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