Home

WELTERWEIGHT - Curlin, Inc.

1. gig FLAT SU FLAT 3 8 FLAT 3 8 FLAT WASHER WASHER WASHER ASHER 3 8 3 8 X 1 1 2 MINIMUM ANCHOR SELF TAPPING OR DOUBLE SLEEVE ANCHOR EVERY 18 i8 FILLET EVERY 18 EXPANSION SHIELD EVERY 18 1 1 2 LONG ANCHOR OR EVERY 18 3 8 X 1 3 4 SHORT TYPE OF ANCHOR USED WILL BE OF LAG SHIELD SUITABLE LENGTH AND APPROPRIATE FOR EVERY 18 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 tracks to become to wide and allow the door to fallout of its tracks which could result in death or serious injury Shims may be required between the track end bearing plates and wall surface to ensure the TRACK SPACING is maintained and that the tracks are anchored securely 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 installation instructions If the Safety Spreader Bars are not installed properly 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 44 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS
2. i EU i BELAT 3 8 FLAT 3 8 FLAT 3 8 FLAT 2 WASHER WASHER WASHER 3 8 X 3 3 8 X 1 1 2 MINIMUM ANCHOR SELF TAPPING 3 8 16 SINGLE 3 8 X 1 7 8 EVERY 18 SCREWS PLUG WELD OR DOUBLE SLEEVE ANCHOR EVERY 18 4 8 FILLET EVERY 18 EXPANSION SHIELD EVERY 18 1 1 2 LONG ANCHOR OR EVERY 18 3 8 X 1 3 4 SHORT TYPE OF ANCHOR USED WILL BE OF LAG SHIELD SUITABLE LENGTH AND APPROPRIATE FOR EVERY 18 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 tracks to become to 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 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 installation instructions If the tracks are not firmly stabilized with the Spreader Bars the Tracks may injury spread and allow the door to fall Failure to follow these instructions could result in death or serious injury Page 46 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW Use
3. Check and properly secure all track anchors Check for signs of abnormal wear or damage Safety Spreader Bar Check Safety Spreader Bar Assemblies for High Lift and Tilt doors are installed and undamaged Backhangs Sway Check for signs of abnormal wear or damage and properly secure Braces all fasteners Check for signs of abnormal wear or damage Verify shafts on Spring Plungers retract inside bearings by pulling on handles NOTE If shaft does not retract replace Plungers Lubricate Spring Plungers by removing cover lubricate shaft bearings and e springs with lightweight oil slide back shaft by pulling on handle while hold ing shaft in retracted position lubricate shaft areas that are normally hidden Poy the bearings 4 0 0 0 Plunger shafts and bearings Hinges Check for signs of abnormal wear or damage e Fasteners Check and properly secure all fasteners e 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 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 71 DOORS TKO WelterWeight Dock Doors User s Manual TROUBLE SHOOTING Before servicing the door read and follow the Safety Practices
4. DOCK DOORS WELTERWEIGHT DOCK DOOR User s Manual Installation Operations Maintenance and Parts Listing This manual applies to WelterWeight Dock Doors manufactured beginning May 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 00015 R10 05 12 WW A DOCK DOORS TKO WelterWeight Dock Doors User s Manual TABLE OF CONTENTS LIMITED WARRANTY 1 OWNER S RESPONSIBILITIES 2 TOOLS amp MATERIALS 3 SAFETY 4 c MAMMA SITE PREPARATION 6 TRACK ANCHORING APPROVED METHODS 10 1225 rue ne TRACK INSTALLATION 12 uda ui He 12 STEEL TRACK INSTALLATION 17 Verica Upper NENNEN 18 ee RM s UM Uu o C P 28 NCC UW TRACK INSTALLATION 32 eo UE 34 Amr m ua cce 36 ILIA MN aD kai 28 PANEL INSTALLATION 48 2 ys oa ete E VE T O E T E 52 LI
5. CMT 52 M E 53 SPRING SHAFT INSTALLATION 56 D 56 EO Nd ETE 56 pou mg ud E 60 Double Spring Split Shaft Assembly 62 Page II 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TABLE OF CONTENTS continued TKO WelterWeight Dock Doors DOORS WINDING SPRINGS 64 ld ROO is isi uo 1o PEE DOOR OPERATION 68 AVAILABLE OPTIONS 69 PLANNED MAINTENANCE 70 TROUBLE SHOOTING 71 PARTS LISTING 72 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page III A DOCK DOORS TKO WelterWeight Dock Doors User s Manual Page iV 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T 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 in
6. NOTE SPRING CONES MOVE OUTWARD WHEN WINDING SPRING WARNING TAG WINDING al BLACK WINDING CONE RIGHT DRUM BLACK VERTICAL SHOWN Page 66 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight 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 BE 1 2 TURN MINIMUM ON DRUM CHALK LINE CENTER BRG BRKT STD 3 6 UNIV SHAFT COUPLER RED LEFT SIDE NOTE SPRING CONES MOVE OUTWARD WHEN WINDING 2 SPRING WARNING TAGS _ 2 BLACK WINDING CONE RIGHT DRUM BLACK VERTICAL SHOWN 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 67 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual DOOR OPERATION Before operating the door read and follow the Safety Practices on pages 4 5 Stand back Moving door can crush you Keep people clear while door is moving Failure to follow these in
7. 3 1 Y L TRACK SPACING TOOL E P DETAIL A AWARNNG FULL HEIGHT IMPACT A TRACK OPTION SHOWN 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 12 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors DTI DOORS TRACK INSTALLATION continued STEEL TRACK NOTE ALL METHODS OF LOWER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK MOUNTING TRACK TO WOOD BACKED MOUNTING TRACK TO STRUCTURAL CONCRETE BLOCK OR SOLID CONCRETE BY A SOLID MATERIAL STEEL i N 3 8 FLAT 3 8 FLAT ELT N 3 8 FLAT WASHER WASHER oo 3 8 X 3 ANCHOR EVERY 18 MINIMUM 3 8 X 1 7 8 3 8 16 SINGLE SLEEVE ANCHOR OR DOUBLE EVERY 18 EXPANSION SHIELD ANCHOR OR 3 8 X 1 3 4 SHORT LAG SHIELD EVERY 18 3 8 FLAT WASHER
8. 3 8 X 1 1 2 MINIMUM pim SELF TAPPING 3 8 X 1 7 8 EVERY AS SCREWS SLEEVE ANCHOR EVERY 18 EVERY 18 TYPE OF ANCHOR USED WILL BE OF SUITABLE LENGTH AND APPROPRIATE FOR TYPE OF SOLID BACKING BEHIND WOOD 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors DTI DOORS SPRING SHAFT INSTALLATION continuea OPERATOR MTG AREA LH OR RH SEE OPERATOR MANUAL FOR MTG SIZE amp LOCATIONS 7 MOUNTING HEIGHT TMH CENTER LINE OF SHAFT CL DOOR OPENING HEIGHT DOH 15 00015 R10 05 12 WW 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 gt OPENING WIDTH HEADER BRUSH SEAL JAMB WALL TRACK MTG L WIDTH TMW MTG OPENING Us WDH DOW 12 0 0 SURFACE COUNTERWEIGHT BRG l4 ANCHOR PAD LH amp OR RH MOUNTING AREAS MIN SIZE 2 W X 6 H TRACK MOUNTING M DEPTH INTO BUILDING WTC DEPTH TMD i DOOR 6 DUAL SPRING SINGLE SHAFT 2012 4Front Engineered Solutions Inc Page 57 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual SPRING SHAFT INSTALLATION Failure to assemble the Torsion
9. SPACING DETAIL B SEE PAGES 22 AND 23 FOR INSTRUCTIONS NOTE TRACK SPACING MUST BE MAINTAINED ON SAFETY SPREADER BAR INSTALLATION THROUGHOUT ENTIRE LENGTH OF TRACK 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 23 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual STEEL TRACK INSTALLATION continuea TILT T2 UPPER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Production Detail Sheet contained in the Owner s Parts Book It illustrates the assembly of the track component parts 2 Attach upper tracks to lowers Bolt 6 cast aluminum transition to lower tracks 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 bearing plate to track Attach bearing plate to bearing spacer bracket at factory established center line C L of shaft with 3 8 16 x 1 carriage bolts and flange nuts spacer bracket is factory attached to straight track 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 Bearing plate MUST BE mounted
10. Measure DOOR OPENING WIDTH DOW The finished DOW MUST match the designed TRACK SPACING dimension as shown on the third panel The door panels will not easily break away and reset properly when impacted or the door panels may fall out of the tracks if the track spacing is not kept within 1 4 of designed track spacing Measure width at floor mid jamb and header to identify and correct any width variations 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 Check jambs with a level to ensure the jambs are square to door opening Correct any jamb condition that will not allow the panels to break out properly 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 If the jambs are not level and straight a portion of the jamb may be exposed in relation to the track restricting the panels from properly knocking out Inspect jamb walls for any obstructions Ensure that nothing will impede the door s outward movement when impacted Any sharp edges MUST BE eliminated to prevent possible seal damage as panels swing into the opening when impacted TKO recommends the easy to install optional 3 6
11. UW TRACK INSTALLATION continued ROOF PITCH UPPER TRACK INSTALLATION continued 6 Install safety spreader bar assemblies Attach safety spreader bar brackets 6 to 12 from the radius 6 to 12 from end of horizontal track and right above the track splice channel at the header Mount brackets to track using 5 16 18 x 3 4 carriage bolts and flange nuts Attach a total of 3 safety spreader bars to the brackets using 5 16 18 x 3 4 carriage bolts and flange nuts DO NOT tighten bolts until backhangs and sway bracing have been installed Repeat for both sides Spreader bars should run from one track side to the other to keep track from separating Center and bolt safety cable spool end to back horizontal spreader bar Attach cable grip device to bottom spreader bar at the header Wrap cable over the middle safety spreader bar and fasten with cable tie Feed cable through the cable grip device and pull tight Trim excess wire 7 Attach back hangs Verify that tracks retain proper spacing Move tracks to necessary width and tie into structure or ceiling with 12 gauge minimum steel angle back hang Sway bracing must also be attached to back hangs to prevent tracks from moving Fasten sway bracing only after tracks are aligned and parallel with panels when door is in UP Position Attachment of back hang material to the surrounding structure must be in compliance with all local and state building codes for the specific location ROOF PITCH UPPER TRACK I
12. 3 8 X 1 1 2 SELF TAPPING SCREWS EVERY 18 TYPE OF ANCHOR USED WILL BE OF SUITABLE LENGTH AND APPROPRIATE FOR TYPE OF SOLID BACKING BEHIND WOOD UW TRACK NOTE ALL METHODS OF LOWER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED MOUNTING TRACK TO C 90 HOLLOW CONCRETE BLOCK MOUNTING TRACK TO FILLED BLOCK M MOUNTING TRACK TO WOOD BACKED IT 3 8 FLAT 3 8 FLAT 3 8 FLAT WASHER WASHER WASHER L MINIMUM 3 8 X 1 7 8 13 8 X3 SLEEVE ANCHOR ANCHOR EVERY 18 EVERY 18 L 3 8 16 SINGLE OR DOUBLE EXPANSION SHIELD ANCHOR OR 3 8 X 1 3 4 SHORT LAG SHIELD EVERY 18 MOUNTING TRACK TO STRUCTURAL OR SOLID CONCRETE BYASOLID MATERIAL STEEL 3 8 FLAT WASHER 3 8 X 1 1 2 SELF TAPPING SCREWS EVERY 18 TYPE OF ANCHOR USED WILL BE OF SUITABLE LENGTH AND APPROPRIATE FOR TYPE OF SOLID BACKING BEHIND WOOD ALTERNATE MOUNTING TRACK TO STRUCTURAL MOUNTING TRACK TO STRUCTURAL STEEL WITH STEEL WITH FILLET WELDS PLUG WELDS PLUG WELD EVERY 18 1 8 FILLET 1 1 2 LONG EVERY 18 NOTICE Alternate Track Mounting Methods will not allow track adjustment if necessary TKO strongly suggests the use of self tapping screws instead of welding
13. 10 00007 FLNG 5 16 18 3 MOUNT BRACKETS TO FLOOR WITH APPROPRIATE HARDWARE FOR FLOOR MATERIAL NOT SUPPLIED 10 00026 CRG 1 4 20 X 3 4 10 00005 NUT FLNG 1 4 20 INCLUDED IN HARDWARE BAG 30 00574 HRDW FLOOR TO TRACK BRACKET FLOOR ANCHOR NOT INCLUDED o 2 lt FULL HEIGHT RH SIDE SHOWN TW TRACK RH SIDE SHOWN BOLT CRG 1 4 20 X 2 3 4 10 00029 EXISTING alk m NUT FLNG 1 4 20 IS 10 00005 STEEL TRACK WITH ExisriNG NUT STEEL TRACK IMPACT A TRACK OPTION LH SIDE SHOWN RH SIDE SHOWN Page 16 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors DOCK DOORS STEEL TRACK INSTALLATION continuea 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 Straight Vertical Upper Track Installation Pages 18 through 19 TitT1UpperTrackInstalltion Pages 20 through 23 Tilt T2 Upper Track Installation Pages 24 through 27 Roof Pitch Upper Track Installation Pages 28 through 29 High Lift Upper Track Installation 00000 Pages 30 through 31 Center Spring Pad Installation Pages 3
14. BLACK WINDING CONE 3 8 16 X 1 1 2 HEX BOLT 2X 2 FULL THREAD STATIONARY CONE CENTER SHAFT BEARING NORIS TES 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 DETAIL A SPRING WARNING TAG 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 61 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual SPRING SHAFT INSTALLATION continuea 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 cen
15. FROM TOP TRACK TOP SAFETY MTG BRACKET DOWN HEADER SAFETY SPREADER BAR TOOL DETAIL B TRACK SPACING DOOR HEADER TRACK SPLICE CHANNEL uy TRACK MTG BRACKET i SAFETY SPREADER BAR BRACKET STRAIGHT TRACK Is TRACK SPLICE CHANNEL CR uM SAFETY SPREADER BAR G ci TRACK DETAIL A SPACING 1 4 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 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 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 39 T DOCK DOORS TKO WelterWeight Dock Doors User s Manual UW TRACK INSTALLATION continued TILT T2 UPPER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Installer Detail Sheet contained in the Owner s Parts Book It illustrates the assembly of the track component parts Stack track on top of one another to create smooth level transition and splice together with track splice plate Bolt plastic track through steel angle track to the track splice channel with flat head Phillips drive 5 16 18 x 3 machine screws Tracks are factory attached to the steel angle with fl
16. MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL STRUCTURAL STRUCTURAL CONCRETE BLOCK SOLID CONCRETE BYASOLID MATERIAL STEEL STEEL WITH STEEL WITH FILLET WELDS PLUG WELDS l d A AN FLAT 2 3 8 FLAT 3 8 FLAT WASHER WASHER WASHER WASHER 3 8 X3 3 8 X 1 1 2 MINIMUM ANCHOR SELF TAPPING 3 8 16 SINGLE 3 8 X 1 7 8 EVERY 18 SCREWS PLUG WELD OR DOUBLE SLEEVE ANCHOR EVERY 18 4 8 FILLET EVERY 18 EXPANSION SHIELD EVERY 18 1 1 2 LONG ANCHOR OR EVERY 18 3 8 X 1 3 4 SHORT TYPE OF ANCHOR USED WILL BE OF LAG SHIELD SUITABLE LENGTH AND APPROPRIATE FOR EVERY 18 TYPE OF SOLID BACKING BEHIND WOOD 4 Mount horizontal track Horizontal tracks are factory attached to the radius Using proper lifting techniques have helper hold up horizontal track assembly while mounting radius to vertical track Secure radius to vertical track with track splice angle Pieces MUST fit together to give a smooth transition Any sharp edges may cause plunger damage or cable failure Attach with 1 4 20 x 3 4 carriage bolts and flange nuts Upper horizontal track MUST BE both plumb and level with lower tracks Shimming behind upper track bearing bracket may be necessary Mount upper track bearing bracket to wall
17. User s Manual TKO WelterWeight Dock Doors T DOCK DOORS PARTS LISTING STEEL TRACK ASSEMBLY PARTS STRAIGHT VERTICAL TRACK SHOWN NOTE MANY 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 STL STRT TRACK PART NO S WILL VARY LEFT HAND SIDE TRANSITION HEN TRACK WW 6 TRN SKO gt STRT TE LH ALUM PART NO 20 00170 STL STRT TRACK PART NO S WILL VARY I RIGHT HAND SIDE STL LOWER TRACK STYLE AND PART NO S TH TRANSITION WILL VARY T TRACK WW 6 TRN SKO STRT LEFT HAND SIDE RH ALUM PART NO 20 00171 IMPACT A TRACK TRACK WW I A T SKO 36 EXT PART 20 01686 STYLE AND PART NO S WILL VARY RIGHT HAND SIDE IMPACT A TRACK TRACK WW I A T SKO 36 EXT PART NO 20 01686 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 75 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual PARTS LISTING UW TRACK ASSEMBLY PARTS STRAIGHT VERTICAL TRACK SHOWN NOTE MANY TRACK CONFIGURATION EXIST WITHIN EACH DOOR MODEL LINE A SERIAL NO
18. minimum of 2 anchors per angle with chosen method illustrated above Follow manufacturer s recommendations for anchor installation 5 Repeat for the opposite side IMPORTANT Measure and place this track at the dimension engraved on the door mounted Safety Decal 6 Secure upper track sections to wall with 3 evenly spaced track mounting brackets 2 per side see pg 31 Attach track mounting brackets to track with 1 4 20 x 3 4 carriage bolts and flange nuts Mount track brackets securely to wall with one of the Recommended Anchoring Methods illustrated 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 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 20 to 31 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 30 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS STEEL TRACK INSTALLATION
19. spacing BEFORE operating door 11 After panels have been engaged back into the tracks carefully cycle the door to its fully open and closed position several times making sure operation is smooth throughout its entire travel cycle 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 20 through 31 or 38 through 49 depending on track style If the 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 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 5 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual SITE PREPARATION 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 For the TKO Knock out Dock Door system to function properly the door opening MUST BE true square plumb and flush Any compromise of the door opening characteristics may affect the function and performance of the door 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 specification sheet
20. 2 anchors with one of the Recommended Anchoring Methods illustrated above Follow manufacturer s recommendations for anchor installation 5 Secure upper track to wall with 3 jamb brackets 2 per side to track with equal spacing See page 35 Attach to track with 1 4 20 x 3 8 carriage bolts and flange nuts Mount jamb brackets securely 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 Page 34 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors DTI DOORS UW TRACK INSTALLATION continued STRAIGHT VERTICAL UPPER TRACK INSTALLATION am aw e 1 2 0 2 S 0 Bm o gt 2 gt 2 gt Dae A i AM al Eu 2 ks TRACK SPLICE CHANNEL DETAIL A STANDARD MOUNT SHOWN STRAIGHT TRACK 1 4 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 to wide and allow the door to fall out of its tracks which co
21. AND DOOR MODEL IS REQUIRED WHEN ORDERING TRACK COMPONENTS CONSULT FACTORY FOR SPECIFIC CONFIGURATION AND PARTS IDENTIFICATION FOR YOUR SPECIFIC COMPONENT NEED UW STRT TRACK S p PART NO S WILL VARY UW UNIVERSAL STEEL PART 5 WILL VARY SHOWN TRANSITION TRACK UW 12 TRN SKO STRT LH UW UNIVERSAL STEEL EXT E PART NO 20 00587 SHOWN PART NO S WILL VARY VERTICAL TRACK L TRANSITION o TRACK UW 12 TRN SKO STRT RH PART NO 20 00586 Ss UW LOWER TRACK PART NO S WILL VARY S N SCREW 5 16 18 X 2 1 2 10 00046 5 16 18 FLNG NUT PART NO 10 00007 3 0 amp 8 8 6 9 9 9 9 9 9 9 BBB 2 LEFT HAND SIDE SHOWN DOOR SERIAL NO OR TRACK SPACING DIMENSION REQUIRED FOR CORRECT REPLACEMENT PART Page 76 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS NOTES 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 77 DIKO N56 W24701 Corporate Circle e Sussex Wisconsin 53089 USA Tel 262 246 1300 e Fax 262 246
22. BEARING PLATE OFFSET BRACKET UW T2 SAFETY SPREADER FACTORY INSTALLED TO TRACK BAR MTG BRACKET TRACK MOUNTING BRACKET DETAIL C SAFETY CABLE TRACK SPLICE CHANNEL SAFETY CABLE GRIP SPREADER BAR DETAIL A 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 tracks to become to 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 bearing plates and wall surface to ensure the TRACK SPACING is maintained and that the tracks are anchored securely 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 43 T DOCK DOORS TKO WelterWeight Dock Doors User s Manual UW TRACK INSTALLATION continued ROOF PITCH UPPER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Production Detail Sheet contained in the Owner s Parts Book It illustrates the assembly of the track component parts 2 Identify upper supports Identify a beam or structure to attach the end of the horizontal tracks You will need to run back hangs from this structure to the ends of the horizontal tracks once they are up DO NOT use safety spreader angle for this purpose 3 Attach upper track to lower Attach pieces with 5 16 18 x 3 machine screws and flange nuts Pieces MUST fit together to give a smooth transition Any sharp edges may cause plunger
23. Dock Doors User s Manual UW TRACK INSTALLATION continued STRAIGHT VERTICAL UPPER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Production Detail Sheet contained in the Owner s Parts Book It illustrates the assembly of the track component parts 2 Check how track is assembled The track will come assembled in one of three ways A Lower tracks with extended steel B Upper tracks with extended steel C Upper and lower tracks have steel and plastic track same length Track splice bracket will hold upper and lower tracks together for any combination below 3 Attach upper tracks to lowers A If tracks have extra length of steel on the uppers or lower tracks bolt protruding portion of either lower or upper plastic track to the extra length of steel angle track on the opposite track assembly track splice will have to be temporarily removed from lower tracks Bolt plastic track through steel track to the track splice with flat head Phillips drive 5 16 18 x 3 machine screws Parts must fit together to create a smooth transition Any sharp edges may cause plunger damage or failure B If tracks have plastic and steel the same length stack track on top of one another to create smooth level transition and splice together with track splice plate Bolt plastic track through steel angle track to the track splice with flat head Phillips drive 5 16 18 x 3 machine screws C Tracks are factory attached to the steel angle with flat
24. If track adjustment or modification is necessary please contact TKO DOORS for assistance Check that the floor mounting area is level from right to left side within 1 4 Be prepared to shim under one side of track if necessary Page 8 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS SITE PREPARATION continuea TRACK MOUNTING SURFACE COUNTERWEIGHT BRG 12 ANCHOR PAD LH amp OR RH 4 7 MOUNTING AREAS MIN 3 MIN SIZE 2 W X 6 H CENTER BRG ANCHOR PAD MOUNTING AREAS MIN SIZE 2 W X 6 H OPERATOR SPLIT SHAFT MTG AREA LH OR RH SEE OPERATOR MANUAL FOR MTG SIZE amp LOCATIONS 1 2 DOOR P OPENING WIDTH TRACK MOUNTING TRACK HEADER L SURFACE MOUNTING HEIGHT pu 4 dii CENTER i3 i M DEPTH INTO LINE OF BRUSH SEAL BUILDING SHAFT M pp CL JAMB WALL I 0 j TRACK MTG BOR 41 7 WIDTH TMW OPENING HEIGHT MTG DOH DEPTH TMD a DOOR OPENING mu WIDTH DOW OR 6 DUAL SPRING SINGLE SHAFT 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 9 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual TRACK ANCHORING APPROVED METHODS STRUCTURE 1 All anchors fasteners shall be 3 8 DIA and placed in the second from the bottom anchor hole of the track a
25. MUST BE MOUNTED TO TOP PANEL AND FIXED PLUNGERS MUST BE MOUNTED TO THE PANEL DIRECTLY BELOW THE TOP PANEL CABLE ASSEMBLIES OUTSIDE HOLE FIXED PLUNGER OUTSIDE HOLE OUTSIDE HOLE D TOP PANEL Ea NS SPRING OR FIXED PLUNGER INTERMEDIATE SV T1 CABLE LEVELING PANEL 4TH ATTACHMENT BRACKETS FIXED PLUNGER SPRING PLUNGER INTERMEDIATE SPRING OR PANEL FIXED PLUNGER SIDE SEAL SPRING PLUNGER WINDOW OPTIONAL INTERMEDIATE TYPICALLY 3RD PANEL PANEL 2ND SPRING PLUNGER EHNGESET BOTTOM PANEL SLIDE LOCK ASSY OPTIONAL SPRING OR LHR WITH PANEL PLATE x t PLUNGER NALS SUPER PANEL OPTIONAL NS INTERIOR SURFACE S BOTTOM LOOP SEAL NOTE HANDLE STEP PLATE 5 PANEL DOOR SHOWN ROPE ATT MANDATORY DETAIL C LH CABLE ATT BRKT BTM OF BOTTOM PANEL FOR HL T2 OR RP CABLE ATT BRKT POSITIONS SEE THE INSTALLER DETAIL SHEET IDS 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 49 DOORS TKO WelterWeight Dock Doors PAN EL NSTALLATIO N continued User s Manual 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
26. Owner s Parts Book Identify the proper cable bracket mounting location Identify the of door panels per door and their stacking sequence f upper bump lock option is supplied available only with straight vertical track spring plungers must be mounted to top panel and fixed plungers must be mounted to the panel directly below the top panel Lube plunger spring shafts and bearings with Light oil prior to stacking panels With covers off spray plunger shafts thoroughly so that contact points of housing shafts and bearings are covered Fortop pickup styles Install cables to the outside set of holes of the lift brackets Fixed plungers are required on the Fourth and Higher panels when the counterbalance cable attachment is NOT at the top of the door Page 50 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS PANEL INSTALLATION PANEL STACKING SHOWN FOR EXACT LOCATION OF PICKUP CABLE BRACKETS SEE IDS INSTALLER DETAIL SHEET IN D N OWNER S PARTS BOOK Va S TOP PANEL PICKUP CABLE LEVELING BRACKETS CABLE ASSEMBLIES OUTSIDE HOLE DETAIL B LEG OF RUE RING MUST POINT DOWN TO PREVENT RING FROM TEARING SEALS EK Si LEG OF RUE RING HINGE PIN DETAIL C DETAIL A NOTE 4 PANEL DOOR SHOWN 15 00015 R10 05 12 WW 2012 4Front E
27. R10 05 12 WW WITH STEEL TRACK 2012 4Front Engineered Solutions Inc IMPACT A TRACK LOCK NOT INCLUDED N ASSY CW PANEL A SECTION 24 CWITW FULL HEIGHT IMPACT A TRACK OPTIONAL 1 ES 4 FLOOR TO TRACK BRKT 30 00085 Page 69 WelterWeight Dock Doors User s Manual AVAI LABLE OPTIO NS continued Blade Weather Seal Kit for Header Anti Drift Down Brush Kits for STL Track and FH BLADE WEATHER SEAL KIT FOR HEADER ALUM RETAINER BLADE SEAL WALL SECTION DETAIL B DETAIL A INSIDE TOP DOOR HEADER OUTSIDE PANEL BLADE SEAL PART NUMBER DESCRIPTION 20 02027 RETAINER ALUM BLADE SEAL 82 20 02025 SEAL BLADE VINYL BLK 2 ALUM RETAINER 30 00300 HRDW K LATH 8 3 4 10 PACK 20 02028 RETAINER ALUM BLADE SEAL 10 2 DOOR PANEL OUTSIDE ANTI DRIFT DOWN BRUSH KITS FOR STL TRACK AND I A T 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 LRG 7 90D 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 10 00334 SCREW SLT HEX HD SP 8 X 1 2 10 00335 SCREW SOC HD CAP 1 4
28. SHIM AS REQUIRED REVERSE MOUNT JPME FACE JAMB FACE SHIM AS REQUIRE Q WELD BEAD WELD BEAD SHIM ZZA DOOR OPENING WIDTH REVERSE WALL DEFORMATION MOUNT EXAGGERATED FOR CLARITY i DETAIL B TRACK SPACING 1 4 JAMB e TRACK SPACING 1 4 BACK TRACK BACK TRACK OUTER TRACK WELD BEAD WELD BEAD DOOR HEADER 18 00 MEF E 18 00 TYP gt KIEL 6 00 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 15 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual TRACK INSTALLATION 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 upper tracks See pages 17 through 31 or 34 through 49 depending on track style for upper track installation instructions Fe FLOOR TO TRACK BRACKET INSTALLATION PART NO DESCRIPTION NOTES 1 MOUNT FLOOR TO TRACK BRACKETS TO BOTTOM 20 00007 BRKT FLOOR TO TRACK SIDE OF TRACK WITH HARDWARE SUPPLIED 10 00057 SCREW 5 16 18 X 3 2 CHECK AND MAINTAIN PROPER TRACK SPACING
29. SURFACE 1 Measure available TRACK MOUNTING HEIGHT 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 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 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 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 s are designed to be installed on the same plane Adjustment of end bearing plates will 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 Check available DEPTH INTO BUILDING WTC and verify that the upper track assembly will fit within the given space Refer to the track print for required track depth Check for potential obstructions that may impede the door s normal upward and downward travel such as an electrical box sprinkler head pipe etc
30. 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 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
31. continuea HIGH LIFT UPPER TRACK INSTALLATION continued 7 Install end bumper mounting bar Mount end bumper mounting bar assembly above the safety spreader bar assembly at the location you want the door to stop its travel normally just after the bottom panel clears the header Make sure track spacing dimension is correct before tightening bolts Mount rubber bumpers on the spreader bar on each side of the track approximately 3 from the inside of the track face 8 Attach back hangs Verify that tracks retain proper spacing Move tracks to necessary width and tie into structure or ceiling with 12 gauge minimum steel angle back hang Sway bracing MUST be installed on back hang to keep tracks from moving Make sure tracks are running parallel with door panels before securing back hangs and sway bracing Attachment of back hang material to the surrounding structure must be in compliance with all local and state building codes for the specific location 9 Install safety spreader bar assemblies Attach 3 safety spreader bar brackets 6 to 12 above radius 6 to 12 from end of horizontal track and right above the transition piece at the header See the illustration below Mount brackets to track using 1 4 20 x 3 4 carriage bolts and flange nuts Attach a total of 3 safety spreader bars to the brackets using 5 16 18 x 3 4 carriage bolts and flange nuts Safety spreader bars should run from one track side to the other to keep track from separa
32. damage or operational issues Low headroom roof pitch tracks mount transition to radius assembly Shimming may be required to ensure that the upper tracks are in line with the lower tracks 4 Mount horizontal track Horizontal tracks are factory attached to the radius and the bearing plate Using proper lifting techniques have helper hold up horizontal track assembly while mounting radius to vertical track Secure radius to vertical track section with flat head Phillips drive 5 16 18 x 2 1 2 machine screws and flange nuts Level track then mount vertical track section to wall using one of the Recommended Anchoring methods listed below Anchors fasteners should be placed on top of track then filled in every 18 Track MUST BE level and at proper spacing or door will not work correctly Follow manufacturer s recommendations for anchor installation 5 Repeat for the opposite side Measure and verify that the TRACK SPACING dimension engraved on the door mounted Safety Decal is correct before mounting angle to wall NOTE ALL METHODS OF UPPER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED ALTERNATE MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL STRUCTURAL STRUCTURAL CONCRETE BLOCK SOLID CONCRETE BYASOLID MATERIAL STEEL STEEL WITH STEEL WITH FILLET WELDS PLUG WELDS
33. door 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 Thecable 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 technichian 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 RESETTING IMPACTED PANELS 1 In the event of a panel KNOCKOUT or track impact situation
34. drawing to determine how parts fit together 3 Attach upper tracks to lowers Bolt 6 cast aluminum transition to lower tracks 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 plunger damage NOTE ALL METHODS OF UPPER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED ALTERNATE MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL TO STRUCTURAL TO STRUCTURAL CONCRETE BLOCK OR SOLID CONCRETE BYASOLID MATERIAL STEEL STEEL WITH STEEL WITH FILLET WELDS PLUG WELDS 1 Ti T n NN FLAT BEAT 3 8 FLAT 3 8 FLAT WASHER WASHER WASHER WASHER 3 8 X 3 3 8 X 1 1 2 MINIMUM ANCHOR SELF TAPPING 3 8 16 SINGLE 3 8 X 1 7 8 EVERY 18 SCREWS PLUG WELD OR DOUBLE SLEEVE ANCHOR EVERY 18 4 8 FILLET EVERY 18 EXPANSION SHIELD EVERY 18 4 1 2 LONG ANCHOR OR EVERY 18 3 8 X 1 3 4 SHORT OF ANCHOR USED WILL BE OF LAG SHIELD SUITABLE LENGTH AND APPROPRIATE FOR EVERY 18 TYPE OF SOLID BACKING BEHIND WOOD 4 Upper tracks will stand off wall at approximately1 degree angle Loosen bolts on adjustable upper track bearing bracket then slide bracket back
35. head Phillips drive 5 16 18 x 2 1 2 machine screws 3 machine screws are required when bolting through the track splice plated NOTE ALL METHODS OF UPPER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED ALTERNATE MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL STRUCTURAL STRUCTURAL CONCRETE BLOCK SOLID CONCRETE BYASOLID MATERIAL STEEL STEEL WITH STEEL WITH conten et FILLET WELDS PLUG WELDS Ti di n NN FLAT FLAT 3 8 FLAT 3 8 FLAT 1 WASHER WASHER WASHER Me noe MINIMUM ANCHOR SELF TAPPING 3 8 16 SINGLE 3 8 X 1 7 8 EVERY 18 SCREWS PLUG WELD OR DOUBLE SLEEVE ANCHOR EVERY 18 438 FILLET EVERY 18 EXPANSION SHIELD EVERY 18 1 1 2 LONG ANCHOR OR EVERY 18 3 8 X 1 3 4 SHORT TYPE OF ANCHOR USED WILL BE OF LAG SHIELD SUITABLE LENGTH AND APPROPRIATE FOR EVERY 18 TYPE OF SOLID BACKING BEHIND WOOD NOTICE Before mounting End Bearing Plates to wall level track and also verify upper track is plumb with lower track Loosen bolts on adjustable bearing plate bracket then slide bracket back to wall Re tighten bolts 4 Level track then mount end bearing plate to the upper track bearing bracket Mount upper track bearing bracket to wall minimum of
36. headroom roof pitch tracks mount transition to radius assembly Shimming may be required to ensure that the upper tracks are anchored securely and in line with the lower tracks 4 Mount horizontal track Horizontal tracks are factory attached to the radius Using proper lifting techniques have helper hold up horizontal track assembly while mounting radius to vertical track Secure radius to vertical track with flat head Phillips drive 5 16 18 x 2 1 2 machine screws and flange nuts Level track then mount vertical track section to wall using one of the Recommended Anchoring methods listed below Anchors fasteners should be placed on top of track then filled in every 18 Tracks MUST BE level and at proper spacing or door will not work correctly Follow manufacturer s recommendations for anchor installation 5 Repeat for the opposite side Measure and verify that the TRACK SPACING dimension engraved on the door mounted Safety Decal is correct before mounting angle to wall NOTE ALL METHODS OF UPPER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED ALTERNATE MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL STRUCTURAL STRUCTURAL CONCRETE BLOCK SOLID CONCRETE BYASOLID MATERIAL STEEL STEEL WITH STEEL WITH FILLET WELDS PLUG WELDS
37. 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 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
38. or Full Height Impact A Track to protect portion of the steel track from being damaged due to impacts If the optional Impact A Track is not used TKO recommends the use of pipe bollards for protection of the door tracks Contact TKO Doors for assistance at 1 800 575 3366 Page 6 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors DTI DOORS S P RE PARAT continued OPERATOR DOOR OPENING CENTER BRG ANCHOR PAD MOUNTING AREAS MIN SIZE 2 W X 6 H SPLIT SHAFT MIN 3 MIN 3 l MTG AREA LH OR RH SEE OPERATOR MANUAL FOR MTG SIZE amp LOCATIONS MOUNTING HEIGHT TMH CENTER LINE OF SHAFT CL DOOR OPENING HEIGHT DOH gt OPENING 2 1 2 DOOR WIDTH HEADER Kee I BRUSH SEAL Di JAMB WALL WIDTH TMW TRACK MTG DEPTH DOOR OPENING 4 WIDTH DOW COUNTERWEIGHT ANCHOR LH amp OR RH MOUNTING AREAS MIN SIZE 2 W X 6 H 12 TRACK MOUNTING SURFACE ww DEPTH INTO BUILDING WTC C OR 6 DUAL SPRING SINGLE SHAFT 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 7 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual S TE P RE PARAT continued TRACK MOUNTING
39. 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 cable 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 20 to 31 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 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS STEEL TRACK INSTALLATION continuea TILT T1 SAFETY SPREADER BAR INSTALLATION TRACK MOUNTING BRACKET TOP SAFETY SPREADER BAR SAFETY SPREADER BAR CABLE SAFETY SHIELD MOUNTIGN BRACKET 22 TO 26 FROM TOP TRACK MTG BRACKET DOWN HEADER SAFETY SPREADER BAR DOOR HEADER TRACK SPACING CABLE GRIP S 1 4 k TRACK ut
40. step away from the door a safe distance 2 Inspect the door system BEEORE resetting panels Plungers of the top panel must be engaged in track Cables must be properly tensioned and seated in the grooves of the cable drums Panels must be sitting level with hardware intact gt Tracks must be square to jamb face and securely mounted If the above conditions are met continue with resetting door see steps 3 6 below If any of these conditions are not met DO NOT use door Stay clear of door and immediately report incident to supervisor and have a trained door systems technician inspect and reset door 3 Clear fork truck and or all product from dock door area 4 Grab manufacturer supplied handle s and pull door panels back into tracks If the spring plunger tips are obstructed at any point of the return travel the plunger rods may be manually retracted while pulling panels back into tracks Depend ing on conditions this operation may require 2 people to safely reset the door NEVER try to open or close door until all panel plungers are reset back into track and door has been inspected NEVER climb under impacted panels to reset door 5 Check panels track hardware and fasteners for any damage looseness misalignment and verify TRACK SPACING BEFORE operating door 6 After panels have been engaged back into the tracks carefully cycle the door to its fully open and closed position several times making sure operation is sm
41. to wall and retighten bolts 5 Level track and then mount upper track bearing bracket to wall minimum of 2 anchors with one of the Recommended Anchoring Methods illustrated above Follow manufacturer s recommendations for anchor installation 6 Secure upper track section to wall with provided track mounting brackets 2 per side with equal spacing See page 19 Attach track mounting brackets to upper track section with 1 4 20 x 3 4 carriage bolts and flange nuts Secure track mounting brackets to the wall with one of the Recommended Anchoring Methods illustrated above Follow manufacturer s recommendations for anchor installation 7 Repeat steps 4 through 6 for opposite side track Make sure this track is adjusted to the same distance away from wall DO NOT level this side Use supplied track spacing tool to set distance You may also 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 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 Page 18 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS STEEL TRACK INSTALLATION contin
42. 10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS STEEL TRACK INSTALLATION continuea TILT T1 UPPER TRACK INSTALLATION RUBBER BUMPER 2 6 Y E 0 6 12 A TRACK MOUNTING Raa BRACKET TOP SAFETY SPREADER BAR SAFETY SPREADER BAR CABLE SAFETY SHIELD MOUNTIGN BRACKET 22 TO 26 FROM TOP TRACK MTG BRACKET DOWN TRACK SPACING TOOL HEADER SAFETY SPREADER BAR UPPER TRACK SECTION DOOR HEADER TRACK SPACING CABLE GRIP lt b d 1 4 TRACK SPACING DETAIL SEE PAGES 22 AND 23 FOR INSTRUCTIONS NOTE TRACK SPACING MUST BE MAINTAINED ON SAFETY SPREADER BAR INSTALLATION THROUGHOUT ENTIRE LENGTH OF TRACK 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 fall out of its tracks which could result in death or serious injury 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 21 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual STEEL TRACK INSTALLATION continuea TILT T1 UPPER TRACK INSTALLATION continued 8 Install safety spreader bar assemblies Mount upper and lower safety spreader bar brackets to straight track with 1 4 20 x 3 4 carriage bolts and flange nuts Brackets need to be attached 6 to 12 above header and 6 to 12 below top of tracks See page 23 Run two 2 safety
43. 1301 e Web www tkodoors com 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12
44. 2 through 33 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 20 to 31 If the Safety Spreader Bars are not installed properly the Tracks may spread if impacted and allow the door to fall Failure to follow these instructions could result in death or serious injury UPPER STEEL TRACK INSTALLATION UPPER TRACKS LOWER TRACKS HEADER T m 12 12 HL3A2P HL ET SERIES Hi SERIES LH 12 12P LH 3 12P LH HR 48 AND UP LH SERIES SERIES HR 24 OR 361 JAMB dus SPACING 1 4 1 4 _ TRACK TRACK SPACING SPACING UPPER TRACKS LOWER TRACKS 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 17 T DOCK DOORS TKO WelterWeight Dock Doors User s Manual STEEL TRACK INSTALLATION continuea 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 6 cast aluminum transition piece mounted to them as well as the bearing plates Size restrictions in shipping may have these separated See job specific track
45. 20X3 4 BLK 10 00005 NUT FLNG 1 4 20 RUBBER BUMPER 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 VERTICAL UNIV STEEL EAM STRAIGHT TRACK FRONT EDGE OF PLASTIC TRACK RIGHT HAND SIDE FH I A T SHOWN RIGHT HAND SIDE STL TRACK SHOWN Page 70 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T 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 Cables 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 immed
46. 5 00015 R10 05 12 WW User s Manual AVAILABLE OPTIONS TKO WelterWeight Dock Doors DOORS Anti Drift Up Lock Kit for Single Knockout Track Knockout Lock Kit Pilfer Proof Cable Lock Kit ANTI DRIFT UP LOCK KIT FOR SINGLE KNOCKOUT TRACK KNOCKOUT LOCK KIT DESCRIPTION 20 00390 KNOCK OUT LOCK PIN 10 00215 KNOCK OUT LOCK PULL RING 10 0 KNOCK OUT LOCK LANYARD ITEM NO PART 1 30 00012 2 10 00005 DESCRIPTION BUMP LOCK SKO STUD NUT FLNG 1 4 20 ITEM NO PART NO 4 FULL HEIGHT IMPACT A TRACK LL HEIGHT IMPACT A TRACK FULL HEIGHT IMPACT A TRACK BUMP LOCK MOUNTING HOLES suue voce FLOOR IMPACT A TRACK OPTION STEEL TRACK STEEL TRACK AVAILABLE ONLY WITH UW SKO TRACK PILFER PROOF CABLE LOCK KIT ITEM NO PART NO DESCRIPTION 30 0 0116 CABLE PILFER PROOF SUGGESTED LOCK MOUNTING FULL HEIGHT 10 00026 CRG 1 4 20X3 4 10 00005 FLNG 1 4 20 10 00029 BOLT CRG 1 4 20X2 3 4 10 00057 SCREW 5 16 18 3 10 00180 NUT FLNG TRILOK NOSR 5 16 18 WW PANEL SECTION 4 LOWER STEEL TRACK ASSEMBLY WW PANEL SECTION me TO TRACK BRKT 30 00085 STANDARD STEEL TRACK 15 00015
47. ABLE SAFETY SHIELD w 30 3 BEARING BRACKET BRACKETS TWO 2 EVENLY gt SPACED PER SIDE FOR DOORS WITH 72 AND ABOVE TRACK LHR V UP STL RH DOOR HEADER TRANSITION HEADROOM E NOTE TRACK SPACING MUST BE MAINTAINED h RACK THROUGHOUT ENTIRE LENGTH TRACK 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 29 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual STEEL TRACK INSTALLATION continuea LIFT UPPER TRACK INSTALLATION Locate the TRACK PRINT PDS Production Detail Sheet contained in the Owner s Parts Book It illustrates the assembly of the track component parts 2 Identify upper supports Identify a beam or structure to attach the end of the horizontal tracks You will need to run back hangs and sway bracing from this structure to the ends of the horizontal tracks once they are up DO NOT use safety spreader bar angle for this purpose 3 Attach upper tracks to lowers Bolt 6 cast aluminum transition to lower tracks 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 Low headroom tracks have transition factory mounted to radius assembly NOTE ALL METHODS OF UPPER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED ALTERNATE
48. ALTERNATE MOUNTING TRACK TO STRUCTURAL STEEL WITH FILLET WELDS MOUNTING TRACK TO STRUCTURAL STEEL WITH PLUG WELDS 27277277277277777777007272 PLUG WELD EVERY 18 1 8 FILLET 1 1 2 LONG EVERY 18 NOTICE Alternate Track Mounting Methods will not allow track adjustment if necessary TKO strongly suggests the use of self tapping screws instead of welding 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 13 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual TRACK INSTALLATION continued LOWER TRACK INSTALLATION STEEL TRACK DOOR OPENING WIDTH WALL DEFORMATION EXAGGERATED FOR CLARITY E TRACK SPACING 1 4 2 TRACK SPACING 1 4 7 OUTER TRACK gt SHIM AS REQUIRED DOOR HEADER 18 00 i N 18 00 ADS Page 14 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors 20 DOCK DOORS TRACK INSTALLATION continued LOWER TRACK INSTALLATION UW TRACK STANDARD MOUNT DOOR OPENING WIDTH WALL DEFORMATION EXAGGERATED FOR CLARITY STANDARD MOUNT TRACK SPACING 1 4 JAMB 5 TRACK SPACING 1 4 OUTER TRACK DETAILA
49. 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 24 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS STEEL TRACK INSTALLATION continuea TILT T2 UPPER TRACK INSTALLATION END BUMPER NOTE TRACK SPACING MUST BE MAINTAINED SPREADER BAR THROUGHOUT ENTIRE LENGTH OF TRACK d ok 2 1 4 30 3 SPACING RUBBER BUMPER DETAIL C SPREADER BAR TOP SAFETY CABLE SAFETY SHIELD TRACK MOUNTING BRACKETS HEADER SAFETY SPREADER BAR DOOR HEADER TRACK SPACING EVERY 22 TO 26 ABOVE DOOR HEADER 6 12 ABOVE DOOR HEADER DETAIL B 7 SPREADER MOUNTING BRACKET 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 25 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual STEEL TRACK INSTALLATION continuea TILT T2 UPPER TRACK INSTALLATION continued 6 Mount end bumper mounting bar with bumpers Attach bumper mounting bar brackets at the top of each side of track factory attached bolts holding the bearing spacer bracket to track may need to be removed to attach bracket on some track height
50. BAR MTG BRACKET BRACKET DETAIL C SAFETY TRACK SPLICE CHANNEL SPREADER BAR DETAIL A 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 tracks to become to wide and allow the door to fall out of its tracks which could result in death or serious injury 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 41 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual UW TRACK INSTALLATION continued TILT T2 UPPER TRACK INSTALLATION continued 6 Repeat steps 2 through 5 above for the opposite track Position the track at the TRACK SPACING dimension engraved on the Serial Number tag that is attached to the third panel of each door 7 Mount the Track Mounting Brackets evenly spaced at 22 to 26 starting right above the track splice channel at the header header See page 43 Verify the TRACK SPACING dimension and properly torque 23 ft lb the fasteners that attach brackets to the track Tighten the track anchors to the proper torque specified by the anchor manufacturer 8 Install Safety Spreader Bar assembly Mount safety spreader bar brackets to straight track with 5 16 18 x 3 4 carriage bolts and flange nuts Brackets need to be attached right above the track splice channel at the header and 12 to 24 below top of tracks See pg 43 Mount two 2 safety spreader bars horizontally from b
51. CK TO C 90 HOLLOW TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL TO STRUCTURAL STRUCTURAL CONCRETE BLOCK ORSOLID CONCRETE BYASOLID MATERIAL STEEL STEEL WITH STEEL WITH FILLET WELDS PLUG WELDS NN es 3 8 FLAT 3 8 FLAT 3 8 FLAT SHE WASHER WASHER WASHER 3 8 X 3 3 8 X 1 1 2 MINIMUM ANCHOR SELF TAPPING OR DOUBLE SLEEVE ANCHOR EVERY 18 4 8 FILLET EVERY 18 EXPANSION SHIELD EVERY 18 1 1 2 LONG ANCHOR OR EVERY 18 3 8 X 1 3 4 SHORT TYPE OF ANCHOR USED WILL BE OF LAG SHIELD SUITABLE LENGTH AND APPROPRIATE FOR EVERY 18 TYPE OF SOLID BACKING BEHIND WOOD Page 40 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS UW TRACK INSTALLATION continued TILT T2 UPPER TRACK INSTALLATION 30 3 TYP RUBBER BUMPER DETAIL D ASSEMBLY Se al 215 x TOP SAFETY SPREADER BAR STRAIGHT TRACK Pd c TRACK SPACING HEADER UPPER TRACK 1 4 SECTION SPREADER BS TRACK MOUNTING BRACKETS EVENLY SPACED 22 TO 26 TRACK SPACING DOOR HEADER TRACK SPLICE CHANNEL BEARING PLATE UW UPPER TRACK BRG BRACKET UW BEARING PLATE OFFSET TRACK BRACKET UW T2 SAFETY SPREADER MOUNTING FACTORY INSTALLED TO TRACK
52. D ALTERNATE MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL TO STRUCTURAL TO STRUCTURAL CONCRETE BLOCK SOLID CONCRETE BYASOLID MATERIAL STEEL STEEL WITH STEEL WITH RENEE FILLET WELDS PLUG WELDS TN A Nae FLAT 98 FLAT 3 8 FLAT 3 8 FLAT WASHER WASHER WASHER WASHER Eus qs MINIMUM ANCHOR SELF TAPPING 3 8 16 SINGLE 3 8 X 1 7 8 EVERY 18 SCREWS PLUG WELD OR DOUBLE SLEEVE ANCHOR EVERY 18 4 8 FILLET EVERY 18 EXPANSION SHIELD EVERY 18 1 1 2 LONG ANCHOR OR EVERY 18 3 8 X 1 3 4 SHORT TYPE OF ANCHOR USED WILL BE OF LAG SHIELD SUITABLE LENGTH AND APPROPRIATE FOR EVERY 18 TYPE OF SOLID BACKING BEHIND WOOD 3 Attach top track mounting bracket 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 end bearing plate See detail D on page 21 Next level the track then anchor track mounting 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 mounte
53. ELDS PLUG WELDS PLUG WELD EVERY 18 1 8 FILLET 1 1 2 LONG EVERY 18 NOTICE Alternate Track Mounting Methods will not allow track adjustment if necessary TKO strongly suggests the use of self tapping screws instead of welding NOTE ALL METHODS OF LOWER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED MOUNTING TRACK TO C 90 HOLLOW MOUNTING TRACK TO FILLED BLOCK CONCRETE BLOCK TS MOUNTING TRACK TO WOOD BACKED OR SOLID CONCRETE BYASOLID MATERIAL STEEL IT 3 8 FLAT 3 8 FLAT 3 8 FLAT WASHER WASHER 5l WASHER MINIMUM 3 8 X 1 7 8 3 8 x 3 SLEEVE ANCHOR ANCHOR EVERY 18 EVERY 18 L 3 8 16 SINGLE OR DOUBLE EXPANSION SHIELD ANCHOR OR 3 8 X 1 3 4 SHORT LAG SHIELD EVERY 18 TYPE OF ANCHOR USED WILL BE OF SUITABLE LENGTH AND APPROPRIATE FOR TYPE OF SOLID BACKING BEHIND WOOD MOUNTING TRACK TO STRUCTURAL 3 8 FLAT WASHER 3 8 X 1 1 2 SELF TAPPING SCREWS EVERY 18 ALTERNATE MOUNTING TRACK MOUNTING TRACK TO STRUCTURAL STEEL WITH FILLET WELDS TO STRUCTURAL STEEL WITH PLUG WELDS PLUG WELD EVERY 18 1 8 FILLET 1 1 2 LONG EVERY 18 NOTICE Alternate Track Mounting Methods will not allow track adjustment if necessary TKO strongly sugges
54. H LIFT UPPER TRACK INSTALLATION CABLE TIE CABLE OVER TOP NOT THROUGH HOLE IN ANGLE Oy RADIUS SAFETY SPREADER BAR HEADER SAFETY SPREADER BAR HORIZONTAL TRACK SECTION D VERTICAL BACK SAFETY 55 TRACK SECTION SPREADER BAR TRACK SPACING M lt lt TRACK SPLICE J CHANNEL RUBBER BUMPER ASSEMBLY 6 DOOR HEADER STANDARD MOUNT REVERSE MOUNT STRAIGHT TRACK _ STRAIGHT TRACK 1 IG m L 14 L id TRACK SPACING TRACK SPACING DETAIL B 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 47 A DOCK DOORS TKO WelterWeight 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 assistance 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 n most cases this panel is 24 high 3 Second and Third panels The Second and Third panels have a horizontal dual bulb seal on the top and bottom of the panel This panel could be 18 or 24 high depending on door height Smaller panels are always installed above l
55. 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 the 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 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 blade to this measurement Install blade on to retainer position so blade ends are 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 Fasten assembly to panel top using supplied screws at each end then every 15 to 20 after PWN Fe B Brush Seal Single 2 brush on 1 straight retainer are sent as standard 1 Brush seals may be mounted to header or panel top Choice determined by best sealing result 2 Follow same installation instructions outlined for the Blade Seals above Page 52 2012 4Front Engineered So
56. IG ONIOVdS YO YAENINN TvlH3S HOOG 61900 00 ON LHYd dl9 70000 06 ON L4Vd IWNOILdO X901 20400 06 MOGNIM 0S00 0 ON LYVd WWYSHL MM 10900 0 ON LYVd MOGNIM QHVGNVAIS MM MM SMOCNIM LAS 39NIH 62900 06 ON LYVd cL 31V ld TANVd 72900 06 8L 31V ld TANVd 92900 0 ON LHVd 31 1 TANVd MM T3NVd y RN 01 SI WIYAS NOLLVHOOIJNOO ANY lHSI3H 71 15 Yad S3IHVA LNIOd LINAWHOVLLVY HLON313 18VO ALON NI Q3OV Id3H A I8 A3SSV d 18VO 81 00 0c LYVd 1V3S 388 1H INO LLOS MM Was WOLLOd H3QOHO AWIL LY NMON 38 LSNW NOLLISOd TANVd 3dOSd H38 IDN IVINH3S V 3215 H3d AYVA STANVd HOOQ A T8IN3SSV TANVd INOLLOS A T8IN3SSV TANVd 31 VIQG3INH3LENI 00 06 MOVd MM A T8IN3SSV TANVd R IHVHO MM 33S 4 A T8IN3SSV TANVd IHVHO MM 33S Page 73 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual DOORS TKO WelterWeight Dock Doors PARTS LISTING Fixed plungers are requi
57. ION INSTRUCTIONS Straight Vertical Upper Track Installation Pages 34 to 35 Tilt T4 Upper Track Installation 00000 Pages 36 to 39 Tilt T2 Upper Track Installation Pages 40 to 43 Roof Pitch Upper Track Installation Pages 44 to 45 High LiftUpperTrackInstalaion Pages 46047 Page 32 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS UW TRACK INSTALLATION continued 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 32 to 47 If the Safety Spreader Bars are not installed properly the Tracks may spread if impacted and allow the door to fall Failure to follow these instructions could result in death or serious injury UPPER TRACKS DOOR LOWER TRACKS HEADER SV VERTICAL SERIES HL12 2P 2 HL HL SERIES LH12 2P LH3 12P LH HR 48 AND UP LH SERIES HR 24 AND 36 IG c 5 TRACK SPACING TRACK SPACING TOLERANCE TOLERANCE i IS 25 IS 25 SKO TRACK STRAIGHT TRACK 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 33 T DOCK DOORS TKO WelterWeight
58. NSTALLATION TRACK SPACING RUBBER BUMPERS VERTICAL TRACK 30 3 lt 4 SECTION DETAIL B CABLE SAFETY SHIELD 4 gt SPACING TOOL DOOR HEADER CABLE OVER TOP tt TRACK SPLICE NOT THROUGH E CABLE TIE TRACK SPACING CHANNEL HOLE IN ANGLE WR STANDARD TRACK MOUNT REVERSE TRACK MOUNT IG 2 L 114 w 14 DETAIL TRACK SPACING TRACK SPACING STRAIGHT TRACK STRAIGHT TRACK 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 45 T DOCK DOORS TKO WelterWeight Dock Doors User s Manual UW TRACK INSTALLATION continued HIGH LIFT UPPER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Production Detail Sheet contained in the Owner s Parts Book It illustrates the assembly of the track component parts 2 Identify upper supports Identify a beam or structure to attach the end of the horizontal tracks You will need to run back hangs from this structure to the ends of the horizontal tracks once they are up DO NOT use safety spreader angle for this purpose 3 Attach upper track to lower Attach pieces with flat head Phillips drive 5 16 18 x 2 1 2 machine screws Pieces MUST fit together to give a smooth transition Any sharp edges may cause plunger damage and or operational issues Low
59. ON 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 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 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 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 59 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual SPRING SHAFT INSTALLATION continuea 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
60. PER ASSEMBLY gt P EVERY 22 TO 26 FROM TOP TRACK TOP SAFETY MTG BRACKET DOWN HEADER SAFETY SPREADER BAR TRACK SPACING TOOL DETAIL B TRACK SPACING TRACK SPLICE CHANNEL SAFETY SPREADER BAR BRACKET STRAIGHT TRACK TRACK SPLICE CHANNEL SAFETY SPREADER BAR D TRACK DETAIL A SPACING 1 4 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 to 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 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 37 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual UW TRACK INSTALLATION continued TILT T1 UPPER TRACK INSTALLATION continued 8 Attach hardware to C channel Attach adjustable angle brackets to top and bottom of C channel in the center of the assembly with 3 8 16 x 1 carriage bolts and flange nuts and anchor onto wall These keep tracks from swaying side to side Mount center spring support to C channel with 3 8 16 x 1 carriage bolts and flange nuts Location may vary according to quantity and length of springs 9 Install Safety Spreader Bar assembly Mount sp
61. SHAFT ASSEMBLY 1 Layout counter balance parts 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
62. Springs and Counterbalance System correctly will cause the door to function 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 bear
63. al WINDING SPRINGS 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
64. amage lesenes mesinant ant vorty TRACK SPACING gaged tack to the anu c door to ts opan and cased poston s tor more Failure to follow these and other provided warnings could result In death or serious Injury CAN CAUSE SEROUS OR DEA The Warning Placard Part Number 15 00011 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 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 oper ated Operating
65. arger panels f a window panel was supplied it is typically placed in the 3rd panel from bottom position 4 Fourth and Higher panels The Fourth and Higher panels have a horizontal dual bulb seal on the top and bottom of the panel This panel could be 18 or 24 high depending on door height Fixed plungers are required on the Fourth and Higher panels when the counterbalance cable attachment is NOT at the top of the door 5 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 or 24 high depending on door height NOTE For top panel pickup cable brackets the cable must be attached to the outer most location on the bracket See illustration on pg 49 PLUNGER DESCRIPTION OPTIONAL COVER FOR SPRING PLUNGER IN WINDLOAD PACKAGE SPRING PLUNGER ASSY RRP 30 00792 PLUNGER ASSY PLUNGER ASSY FIXED ROLLER PLUNGER ASSY RRPG2 SPR LHR LH RRPG2 SPR LHR RH RFP 30 00676 30 00707 30 00706 Page 48 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual PAN EL NSTALLATIO N continued WelterWeight Dock Doors Fixed plungers required on the Fourth and Higher panels when the counterbalance cable attachment is NOT at the top of the door FULL DOOR PANEL ASSEMBLY IF UPPER BUMP LOCK OPTION IS SUPPLIED AVAILABLE ONLY ON STRAIGHT VERTICAL SPRING PLUNGERS
66. at head Phillips drive 5 16 18 x 2 1 2 machine screws 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 Assemble the Bearing Plate to the Bearing Plate Mounting Bracket as illustrated below ITEM QTY PART NUMBER DESCRIPTION 1 2 20 00840 BRG PLT AF UW HL T2 2 12 10 00035 BOLT CRG 3 8 16X1 3 12 10 00006 NUT FLNG 3 8 16 4 2 20 01603 UPPER TRACK BRG BRACKET b Attach the Bearing Plate Assembly 1 shown above to the Bearing Plate Offset Bracket 2 Do not apply full torque to the fasteners at this time The bracket may need to be adjusted to ensure proper track alignment The tracks need to be equally spaced from the wall surface and must maintain the correct TRACK SPACING dimension engraved on the door mounted Safety Decal Level track then anchor the Bearing Plate Assembly minimum of 3 anchors to the building structure using one of the Recommended Anchoring Methods illustrated below Tighten bolts on bearing plate and mounting bracket Follow manufacturer s recommendations for anchor installation NOTE ALL METHODS OF UPPER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED ALTERNATE MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRA
67. bracing from this structure to the ends of the horizontal tracks once they are up DO NOT use safety spreader angle for this purpose 3 Attach upper tracks to lowers Bolt 6 cast aluminum transition to lower tracks 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 Low headroom tracks have transition factory mounted to radius assembly NOTE ALL METHODS OF UPPER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED ALTERNATE MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL STRUCTURAL STRUCTURAL CONCRETE BLOCK OR SOLID CONCRETE BYASOLID MATERIAL STEEL STEEL WITH STEEL WITH 7 EE FILLET WELDS PLUG WELDS Ti T E n N FLAT dicli 3 8 FLAT 3 8 FLAT WASHER WASHER WASHER WASHER ae MINIMUM ANCHOR SELF TAPPING 3 8 16 SINGLE 3 8 X 1 7 8 EVERY 18 SCREWS PLUG WELD OR DOUBLE SLEEVE ANCHOR EVERY 18 4 8 FILLET EVERY 18 EXPANSION SHIELD EVERY 18 1 1 2 LONG ANCHOR OR EVERY 18 3 8 X 1 3 4 SHORT TYPE OF ANCHOR USED WILL BE OF LAG SHIELD SUITABLE LENGTH AND APPROPRIATE FOR EVERY 18 TYPE OF SOLID BACKING BEHIND WOOD 4 Mount ho
68. ck floor around the dock door and in the driveway front of the door while installing maintaining or repairing the dock door If door is operated with any type of motor or automatic system TKO highly recommends the use of a UL325 compliant entrapment protection device such as monitored safety edge or monitored photoeye Follow all local and state codes regarding attachment of back hang to structural components of the building 00 4 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS SAFETY continued SAFETY PRACTICES Operation 1 Personnel using the dock doors MUST BE properly trained 2 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 4 DO NOT allow children to operate the door or controls 5 DO NOT throw door up violently Using excessive force to open or close the door may cause the door cables to jump or door panels to disengage from tracks 6 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 7 To avoid injury keep hands free of door parts while operating Panels a
69. d Safety Decal may allow the door to fall out of the tracks which could result in death or serious injury 4 Use the track spacing tool to set the opposite track You may also measure over to the opposite track and position at the track spacing dimension engraved on the Safety Decal located on the 3rd 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 track mounting brackets both sides every 22 to 26 above the door header See page 21 6 Attach C channel to upper track bearing brackets to run from the backside of one bearing bracket to the other Attach C channel to top set of holes on bearing bracket with 3 8 16 x 1 carriage bolts flange nuts and flat washers Verify that track spacing is still correct and tracks are level 7 Attach hardware to C channel Attach adjustable angle 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 and anchor onto wall These prevents C channel from twisting and stabilizes the upper track See Detail C page 21 Mount center spring support 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 20 2012 4Front Engineered Solutions Inc 15 00015 R
70. dicates a potentially hazardous situation which if not avoided could result in minor or moderate injury NOTICE Caution used without the safety alert symbol indicates a potentially hazardous situation which if not avoided could result in property damage SAFETY PRACTICES _AWARNING 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 the do
71. e beyond the manufacturer s control replacement labor or implied cycle life of counter balance system cables spring assemblies drums shaft cones and bearings or center bearing brackets TKO DOCK 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 ORLOST 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 DOORS s 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 TO A 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 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 1 A DOCK DOORS TKO WelterWeight Dock Doors
72. ed 2 Deere ena zn u CRGD 102 SPRING WARNING TAG 15 00015 R10 05 12 WW 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 from the door manufacturer as needed CRGD 102 Gy al 7 9 21 RIGHT SIDE SPRING WARNING TAG A 2012 4Front Engineered Solutions Inc Page 55 A DOCK DOORS TKO WelterWeight 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 b
73. 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 operation instructions contained in this manual Failure to do so could result in death or serious injury Page 2 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T 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 Plunger Spring Shafts and Bearings Torsion Counterbalance Springs Dry Silicone Spray f
74. erticals 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 20 to 31 If the 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 28 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS STEEL TRACK INSTALLATION continuea ROOF PITCH UPPER TRACK INSTALLATION continued 7 Install end bumper mounting bar Mount end bumper mounting bar assembly above the safety spreader bar assembly at the location you want the door to stop its travel normally just after the bottom panel clears the header Make sure track spacing dimension is correct before tightening bolts Mount rubber bumpers on the bumper mounting bar on each side of the track approximately 3 from the inside of the track face See Detail A on the illustration below 8 Attach back hangs Verify that tracks retain proper spacing Move tracks to necessary width and tie into structure or ceiling with 12 gauge minimum steel angle back hang Sway bracing MUST be installed on back hang to keep tracks from moving Make sure tracks are running parallel with door panels before securing back hangs and sway bracing Attachment of back hang material to the surrounding
75. iately 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 or 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 Manually operate the door Check for smooth operation and proper balance Operation If this door has an automatic opener disconnect it before this inspection Inspect all safety warning product labels placards decals tags Replace if Labels e damaged or missing See pgs 53 55 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 e Bearings Check for signs of abnormal wear or damage Cable Attachments Check for signs of abnormal wear or damage and properly secure 4 all fasteners 2 Check for signs of abnormal wear or damage Lubricate with lightweight Springs remove excess with shop rag Spring Anchors Check for signs of abnormal wear or damage and properly secure 4 all fasteners Shaft Check for signs of abnormal wear or damage Check for proper track spacing and alignment
76. ied 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 11 Make sure all springs are thoroughly oiled around the entire circumference of the spring with LightWeight oil or food grade equivalent 12 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 Install SPRING WARNING TAG as shown in the illustrations below SPRING WARNING TAG SPRING WARNING TAG 14 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 Silicone Spray is applied to entire track system lower
77. in the same position as opposite side before tightening bolts 5 Attach vertical track angle mounting brackets Attach long leg of track mounting brackets to straight track with 1 4 20 x 3 4 carriage bolts and flange nuts Fill in track mounting brackets both sides every 22 to 26 above the door header See page 25 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 UPPER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED ALTERNATE MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL STRUCTURAL STRUCTURAL CONCRETE BLOCK OR SOLID CONCRETE BYASOLID MATERIAL STEEL STEEL WITH STEEL WITH m FILLET WELDS PLUG WELDS k NN 3 8 FLAT 3 8 FLAT 3 8 FLAT WASHER ical WASHER WASHER 3 8 X3 3 8 X 1 1 2 MINIMUM ANCHOR SELF TAPPING 3 8 16 SINGLE 3 8 X 1 7 8 EVERY 18 SCREWS PLUG WELD OR DOUBLE SLEEVE ANCHOR EVERY 18 4 8 FILLET EVERY 18 EXPANSION SHIELD EVERY 18 1 1 2 LONG ANCHOR OR EVERY 18 3 8 X 1 3 4 SHORT TYPE OF ANCHOR USED WILL BE OF LAG SHIELD SUITABLE LENGTH AND APPROPRIATE FOR EVERY 18 TYPE OF SOLID
78. ing s and center bearing bracket s 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 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 58 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors 20 DOCK DOORS SPRING SHAFT INSTALLATI
79. ks per the TRACK SPACING dimension and tolerance engraved on the door mounted Safety Decal may allow the tracks to spread and allow the door to fall out of its tracks which could result in death or serious injury Page 10 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors DTI DOORS TRACK ANCHORING APPROVED METHODS STEEL TRACK NOTE ALL METHODS OF LOWER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK MOUNTING TRACK TO WOOD BACKED CONCRETE BLOCK SOLID CONCRETE BY A SOLID MATERIAL STEEL E p N a RES x 4 3 8 FLAT 3 8 FLAT 1 WASHER WASHER 3 8 X 3 ANCHOR EVERY 18 MINIMUM 3 8 X 1 7 8 3 8 16 SINGLE SLEEVE ANCHOR OR DOUBLE EVER le EXPANSION SHIELD ANCHOR OR 3 8 X 1 3 4 SHORT LAG SHIELD EVERY 18 TYPE OF ANCHOR USED WILL BE OF SUITABLE LENGTH AND APPROPRIATE FOR TYPE OF SOLID BACKING BEHIND WOOD MOUNTING TRACK TO STRUCTURAL n 3 8 FLAT WASHER 3 8 X 1 1 2 SELF TAPPING SCREWS EVERY 18 UW TRACK ALTERNATE MOUNTING TRACK MOUNTING TRACK TO STRUCTURAL TO STRUCTURAL STEEL WITH STEEL WITH FILLET W
80. lutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS PAN EL NSTALLATIO N continued DECALS amp PLACARD INSTALLATION The Safety Decal Part Number 15 00053 and Product Identification Decal are factory installed to the third panel on the right side 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 00011 SAFETY DECAL TRACK SPACING 15 00053 PRODUCT IDENTIFICATION 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 53 KO TKO WelterWeight Dock Doors User s Manual DOCK DOORS PANEL INSTALLATION DECALS amp PLACARD INSTALLATION continued 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 door and is legible If the Safety Decal is not present contact the factory to obtain a replacement Safety Decal 5 DOCK DOORS this Safety Dacal and mounted N56 724709 Corporate RESETTING IMPACTED PANELS Phone 282 46 1300 NOCKOUT stance immediate apa rs cal 800 5753386 to MOVING DOOR CAN RESULT SERIOUS INJURY OR Ya ean ean nde long contin DEATH DO NOT CLOSE DOOR vers r any d
81. nd door parts may create pinch points when in operation 8 NEVER use damaged or malfunctioning dock door Resetting Impacted Panels In the event of a panel KNOCK OUT or track impact situation step away from the door a safe distance T Inspect the door system BEFORE resetting panels Plungers on the top panel MUST BE engaged in track Cables MUST BE properly tensioned and seated in the grooves of the cable drums Panels MUST BE sitting level with hardware intact Tracks MUST BE square to jamb face and securely mounted If the above conditions are met continue with resetting door see steps 3 6 below If any of these conditions are not met DO NOT use door Stay clear of door and immediately report incident to supervisor and have a trained door systems technician inspect and reset door 8 Clear fork truck and or all products from dock door area 9 Grab manufacturer supplied handle s and pull door panels back into tracks If the spring plunger tips are obstructed at any point of the return travel the plunger rods may be manually retracted while pulling panels back into tracks Depending on conditions this operation may require 2 people to safely reset the door NEVER try to open or close door until all panel plungers are reset back into track and door has been inspected NEVER climb under impacted panels to reset door 10 Check panels track hardware and fasteners for any damage looseness misalignment and verify track
82. nd then at 18 inch intervals or every 3rd hole Please refer to the Guide on pg 11 for specific applications and instructions NOTICE Welding of tracks is listed as Alternate Anchoring Method however this method will not allow for any track width adjustments For this reason TKO recommends the use of self tapping screws to fasten tracks to metal surfaces instead 2 Anchors fasteners MUST BE centered in the slotted track holes to provide the ability to adjust in or out if necessary an extended bit is recommended 3 If 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 fasten through wood jamb and into structural member using a minimum 3 8 x 3 anchor backed with a 3 8 flat washer Fasteners must be appropriate for the material of the structural member 4 mounting the track to steel position welds or anchors as listed in item 1 above 5 f mounting the track to solid concrete anchor tracks using a minimum 3 8 x 1 7 8 concrete sleeve anchor backed with a 3 8 flat washer If a wood face jamb exists anchor through wood jamb and into concrete structure Follow manufacturer s recommendations for installation 6 If mounting to hollow block it is important to use 3 8 expansion type anchors specifically designed for this use Follow manufacturer s recommendations for installation Failure to securely position and anchor door trac
83. ngineered Solutions Inc Page 51 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual PANEL INSTALLATION continued SLIDE LOCK INSTALLATION 1 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 Spacer blocks are included for any non top pickup doors Spacer blocks are installed between the slide lock housing and panel plate Slide lock bar MUST extend through the track allowing proper clearance of lock hole when bar is engaged Slide lock housing should not extend beyond retainer edge on panel SLIDE LOCK INSTALLATION FEMALE HINGE SPRING A PLUNGER SPRING PLUNGER D COVER FRONT EDGE OF SLIDE LOCK PANEL HOUSING MUST EXTEND PLATE BEYOND OUTER EDGE OF PANEL LOCK HOLE SLIDE LOCK MALE HINGE ASSEMBLY 75 A w s Su X USE BACK AND CENTER dn SLIDE LOCK SPACER BLOCK MOUNTING HOLES iN SCREW 14X3 4 SLIDELOCK SPACER BLOCK OPTIONAL SCREW 14X1 1 2 WHEN SLIDE LOCK SPACER BLOCK IS REQUIRED IN HL LHR T2 APPLICATIONS LINTEL SEAL INSTALLATION A Blade Seal 2 blade on 1 straight retainer 2 sets included for installation on both header and top panel
84. on pages 4 5 and the Door Operation section on page 71 of this manual TROUBLE SHOOTING GUIDE TROUBLE 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 improperly leveled sitting crooked Slip drums shaft coupler or use cable leveling assemblies top pickup doors to level door Door will not stay open Broken spring Insufficient counterbalance Replace Spring Increase spring tension Door operates with too much resistance Springs need lubrication Broken spring Tracks are too tight or Grease Residue on tracks Lubricate springs Replace Spring Adjust tracks to correct width Wipe residue off seals Lubricate all track running surfaces with a light coat of Silicone Spray DO NOT use oil or grease Page 72 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW TKO WelterWeight Dock Doors User s Manual PARTS LISTING Fixed plungers are required on the Fourth and Higher panels when the counterbalance cable attachment is NOT at the top of the door LN3WaOVv Idas 1244400 GAYINOAY SI NOISNAW
85. ooth throughout its entire travel cycle Failure to follow these and other provided warnings could result in death or serious injury Call for additional placards manuals or with questions regarding proper use y K maintenance and repair of dock doors N56 W24701 N Corporate Circle Sussex WI 53089 DOCK DOORS Phone 262 820 1217 Fax 262 820 1273 P N 15 00011 REV G 07 09 Page 54 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors EY DOCK DOORS PANEL INSTALLATION continuea DECALS amp PLACARD INSTALLATION 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 need
86. or lubing tracks and side seals 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 s MUST BE structurally sound to support weight of Spring s and the torque put on them TKO Dock Doors DOES NOT supply Backhang Material Spring Mounting Pads or Wall Mounting Hardware RECOMMENDED ANCHORS FOR HOLLOW BLOCK WALL TKO recommends the following e 3 8 16 Concrete Single or Double Expansion Shield Anchors 3 8 Short Lag Shields e NOTE Anchors must be those suitable per the manufacturer for use in hollow block wall and installed per the manufacturer s instructions 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 3 A DOCK DOORS TKO WelterWeight 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 In
87. panel of each door Adjust this track to be the same distance off the wall as the opposite side while maintaining the correct TRACK SPACING dimension 6 Mount the remaining Track Mounting Brackets every 22 to 26 from top track mounting bracket down See page 37 Verify the TRACK SPACING dimension and properly torque 23 ft lb the fasteners that attach brackets to the track Tighten the track anchors to the proper torque specified by the anchor manufacturer 7 Attach C channel to upper track bearing brackets to run from the backside of one bearing bracket to the other Attach C channel to top set of holes on bearing plate with 3 8 16 x 1 carriage bolts flange nuts and flat washers Verify that track spacing is still correct and tracks are level 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 to 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 Tracks must be mounted straight level and on the same plane as lower tracks Page 36 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS UW TRACK INSTALLATION continued TILT T1 UPPER TRACK INSTALLATION 30 3 TYP UPPER TRACK BEARING BRACKET DETAIL C RUBBER BUM
88. panels Plungers of the top panel MUST BE engaged in track Cables MUST BE properly tensioned and seated in the grooves of the cable drums Panels MUST BE sitting level with hardware intact Tracks MUST BE square to jamb face and securely mounted If the above conditions are met continue with resetting door see steps 3 6 below If any of these conditions are not met DO NOT use door Stay clear of door and immediately report incident to supervisor and have a trained door systems technician inspect and reset door 3 Clear fork truck and or all products from dock door area 4 Grab manufacturer supplied handle s and pull door panels back into tracks If the spring plunger tips are obstructed at any point of the return travel the plunger rods may be manually retracted while pulling panels back into tracks Depending on conditions this operation may require 2 people to safely reset the door NEVER try to open or close door until all panel plungers are reset back into track and door has been inspected NEVER climb under impacted panels to reset door 5 Check panels track hardware and fasteners for any damage looseness misalignment and verify track spacing BEFORE operating door 6 After panels have been engaged back into the tracks carefully cycle the door to its fully open and closed position several times making sure operation is smooth throughout its entire travel cycle Page 68 2012 4Front Engineered Solutions Inc 1
89. plate using carriage bolts supplied 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 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 e 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 60 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors DOCK DOORS SPRING SHAFT INSTALLATION 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 PLATE 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 CLEARANCE BEFORE WINDING 2 RIGHT 1 TUBE SHAFT OR SHORT LEG MUST BE DOWN oes KEYED SHAFT SHOWN 1 1 4 SOLID KEYED SHAFT
90. r s Manual TKO WelterWeight Dock Doors T DOCK DOORS UW TRACK INSTALLATION continued HIGH LIFT UPPER TRACK INSTALLATION continued 6 Install spreader bar assembly Attach spreader bar brackets 6 to 12 before radius 6 to 12 from end of horizontal track and right above the track splice channel at the header Mount brackets to track using 5 16 18 x 3 4 carriage bolts and flange nuts Attach a total of 3 spreader bars to the brackets using 5 16 18 x 3 4 carriage bolts and flange nuts DO NOT tighten bolts until backhangs and sway bracing have been installed Repeat for both sides Spreader bars should run from one track side to the other to keep track from separating Center and bolt safety cable spool end to back horizontal spreader bar Attach cable grip device to bottom spreader bar at the header Wrap cable over the middle spreader bar and fasten with cable tie Feed cable through the cable grip device and pull tight Trim excess wire Attach back hangs Verify that tracks retain proper spacing Move tracks to necessary width and tie into structure or ceiling with 12 gauge minimum steel angle back hang Sway bracing must be also attached to back hangs to prevent tracks from moving Fasten sway bracing only after tracks are aligned and parallel with panels when door is in UP position Attachment of back hang material to the surrounding structure must be in compliance with all local and state building codes for the specific location HIG
91. rackets and attach to brackets with 5 16 18 x 3 4 carriage bolts and flange nuts Repeat for both sides 9 Install two 2 Safety Cables Bolt two 2 safety cable spool end to the top horizontal safety spreader bar approximately 30 from each end Attach two 2 cable grip devices to bottom safety spreader bar approximately 30 from each end Feed cable through the cable grip device 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 header to the top end of panel travel per the installation instructions If the Safety Spreader Bars are not installed properly 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 42 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS UW TRACK INSTALLATION continued TILT T2 UPPER TRACK INSTALLATION 30 3 RUBBER BUMPER DETAIL D AssEMBLY STRAIGHT TRACK SPREADER BAR TRACK SPACING rc 1 4 HEADER SAFETY SPREADER UPPER TRACK SECTION S TRACK MOUNTING BRACKETS EVENLY SPACED AT 22 TO 26 TRACK SPACING DOOR HEADER TRACK SPLICE CHANNEL BEARING PLATE UW UPPER TRACK BRG BRACKET UW
92. reader bar brackets to straight track with 5 16 18 x 3 4 carriage bolts and flange nuts Brackets need to be attached right above the track splice channel at the header and 12 to 24 below the top of tracks See page 39 Mount two 2 spreader bars horizontally from brackets and attach to brackets with 5 16 18 x 3 4 carriage bolts and flange nuts Repeat for both sides 10 Install two 2 Safety Cables Bolt two 2 safety cable spool ends to the top horizontal safety spreader bar approximately 30 from each end Attach two 2 cable grip devices to bottom safety spreader bar approximately 30 from each end Feed cable through the 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 header to the top end of panel travel per the installation instructions If the Safety Spreader Bars are not installed properly 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 38 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS UW TRACK INSTALLATION continued TILT T1 UPPER TRACK INSTALLATION 30 3 TYP UPPER TRACK BEARING BRACKET DETAIL C RUBBER BUMPER ASSEMBLY gt EVERY 22 TO 26
93. red on the Fourth and Higher panels when the counterbalance cable attachment is NOT at the top of the door 21200 02 ON LYWd 52 INOLLOS 4001 Was Adis MM dOO1 adis Was SHOOG MM SLYVd LN3IN3OV Id38 WAS 1018 1 INOLLOS8 9NINH3OQHO LSNW TACOW YOO H38IADN TVIH3S V 3218 AHVA STANVd HOOQ 97700 06 ON LuVd v 4 01 IWAS 3015 MM dOO1 4015 WAS TANVd 31VIQ3IAH3 LNI 77200 04 ON LuVd Zh 4001 WAS ACIS 92200 02 ON LuVd uv E 8l 4001 WAS ACIS 94400 02 LuVd Yc 4001 WAS 3015 MM dOO1 Was TANVd ALVIGSAWYSLNI ra nm SN TANVd dOL 3NIVL33 TWAS 1015 1 HO 1V3S dOO ACIS LN3W3OV 1d34 ONIHIOHO N3HM T3GON T3NVd NOILISOd T3NVd AJIH3A 3 LON xSJ3NIVIL3H TWAS 1015 1 WNOLLOS8 TANVd WOLLOS 1910 0 LYWd 662 LOTS L TWAS YANIVLAY LOTS L 1V3S JAIS TANVd ALVIGAWYSLNI 6800 0 ON LYVd 6 LL 1018 1 TWAS 6800 02 LYVd 64 1018 1 TWAS MM 21910 02 ON LYVd 662 1018 1 TWAS WNIV L3H LOTS L 1V3S JAIS 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 74
94. red to wall 4 Level this track then anchor the Top Track Mounting Bracket to the building structure using one of the Recommended Anchoring Methods illustrated below Then tighten bolts at track Follow manufacturer s recommendations for anchor installation NOTE ALL METHODS OF UPPER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDED ALTERNATE MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK MOUNTING TRACK TO C 90 HOLLOW TO FILLED BLOCK TO WOOD BACKED TO STRUCTURAL STRUCTURAL STRUCTURAL CONCRETE BLOCK SOLID CONCRETE BYASOLID MATERIAL STEEL STEEL WITH STEEL WITH x FILLET WELDS PLUG WELDS ll 4 2 1 AU FLAT 3 8 FLAT 3 8 FLAT WASHER WASHER WASHER WASHER 3 8 X 3 3 8 X 1 1 2 MINIMUM ANCHOR SELF TAPPING 3 8 16 SINGLE 3 8 X 1 7 8 EVERY 18 SCREWS PLUG WELD OR DOUBLE SLEEVE ANCHOR EVERY 18 4 8 FILLET EVERY 18 EXPANSION SHIELD EVERY 18 1 1 2 LONG ANCHOR OR EVERY 18 3 8 X 1 3 4 SHORT TYPE OF ANCHOR USED WILL BE OF LAG SHIELD SUITABLE LENGTH AND APPROPRIATE FOR EVERY 18 TYPE OF SOLID BACKING BEHIND WOOD 5 Repeat steps 2 through 4 above except for leveling for the opposite side Position the track at the TRACK SPACING dimension engraved on the Serial Number tag that is attached to the third
95. rizontal track Horizontal tracks are factory attached to the radius Using proper lifting techniques have helper hold up horizontal track assembly while mounting radius to vertical track Secure radius to vertical tracks with track splice angle Pieces MUST fit together to give a smooth transition Any sharp edges may cause plunger damage or cable failure Attach with 1 4 20 x 3 4 carriage bolts and flange nuts Upper track MUST BE plumb and level with lower track Shimming behind upper track bearing bracket may be necessary Mount upper track bearing bracket to wall minimum of 2 anchors per angle with chosen method Follow manufacturer s recommendations for anchor installation 5 Repeat for the opposite side IMPORTANT Measure and place this track at the dimension engraved on the door mounted Safety Decal 6 Secure upper track sections to wall with 3 evenly spaced track mounting brackets 2 per side see pg 29 Attach track mounting brackets to track with 1 4 20 x 3 4 carriage bolts and flange nuts Mount track brackets securely to wall with one of the Recommended Anchoring Methods illustrated 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 fall out of its tracks which could result in death or serious injury All TKO Dock Doors except Straight V
96. s Mount bracket to track using 1 4 20 x 3 4 carriage bolts and flange nuts Attach bumper mounting bar to the brackets using 5 16 18 x 3 4 carriage bolts and flange nuts Repeat for both sides Mount rubber bumpers on the bumper mounting bar on each side of the track approximately 3 from the inside of the track face 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 right above the transition piece at the header header and 6 to 12 below top of tracks See page 27 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 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 cable 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 20 to 31 If the Safety Spreader Bars are not installed the Tracks may spread if impacted and allow the door to fall Fail
97. screwdrivers as winding bars Failure to use proper winding bars could result in death or serious injury Page 64 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors T DOCK DOORS WI NDING SPRINGS continued WIND SPRINGS continued 5 Wind springs in an upward direction 1 4 turn and hold the tension 6 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 7T 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 8 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 9 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 reduce the possibility of spring coils binding during operation 10 Tighten setscrews on the winding cone with oiled threads to 15 16 ft lbs Follow the recommendations listed below to avoid exceeding the specif
98. stallation 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 TKO DOCK DOORS warrants its WelterWeight Panels will remain operational after resetting from impact under normal use service and maintenance for ONE 1 year excluding any window portion thereof from date of shipment Does not cover punctures cracks or slices in panel s Optional Super Panel TWO 2 year performance limited warranty from date of shipment EXTENDED LIMITED WARRANTY TKO DOCK DOORS warrants its optional Impact A Track for FIVE 5 years from date of purchase This is a performance warranty and for the UHMW portion only Cuts gouges and abrasions are not considered warrantable conditions 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 This limited warranty does not include normal wear modifications and damag
99. structions could result in death or serious injury NEVER try to open or close door until all Panel Plungers are reset back into Track and door has been inspected NEVER climb under impacted Panels to reset door 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 7 Chock truck wheels or lock truck in place with a truck restraining device and set brakes before loading unloading 8 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 RESETTING IMPACTED PANELS 1 In the event of a panel KNOCK OUT or track impact situation step away from the door a safe distance 2 Inspect the door system BEFORE resetting
100. structure must be in compliance with all local and state building codes for the specific location 9 Install safety spreader bar assemblies Attach 3 safety spreader bar brackets 6 to 12 above radius 6 to 12 from end of horizontal track and right above the transition piece at the header See the illustration below Mount brackets to track using 1 4 20 x 3 4 carriage bolts and flange nuts Attach a total of 3 spreader bars to the brackets using 5 16 18 x 3 4 carriage bolts and flange nuts Safety spreader bars should run from one track side to the other to keep track from separating if impacted 10 Install two 2 Safety Cables Bolt two safety cable spool ends to the top horizontal safety spreader bar 30 from each end Attach two cable grip devices to the bottom safety spreader bar aligned with cable grip devices installed on top safety Spreader bar Wrap each cable over the middle safety spreader bar and fasten with cable tie See Detail B on the illustration below Feed each cable through the top and bottom cable grip devices and pull tight Trim excess wire ROOF PITCH UPPER TRACK INSTALLATION END BUMPER MOUNTING BAR CABLE OVER TOP B NOT THROUGH HOLE IN ANGLE F ES _ 6 12 000000 CABLE TIE TRACK SPACING BUMPER 2 MOUNTING BAR DETAIL A A RUBBER ASRS BUMPER Sum SE SAFETY SPREADER BAR RUBBER BUMPERS 555 MS CUT TO TRACK SPACING C
101. ter bearing bracket together 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 e 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 62 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors DOORS SPRING SHAFT INSTALLATION Fail
102. ting if impacted 10 Install two 2 Safety Cables Bolt two safety cable spool ends to the top horizontal safety spreader bar 30 from each end Attach two cable grip devices to the bottom safety spreader bar aligned with cable grip devices installed on top safety Spreader bar Wrap each cable over the middle safety spreader bar and fasten with cable tie Feed each cable through the top and bottom cable grip devices and pull tight Trim excess wire HIGH LIFT UPPER TRACK INSTALLATION DETAIL CABLE OVER TOP NOT THROUGH HOLE IN ANGLE DOOR DETAIL A HEADER Pn PLUG LHR E RADIUS SEA TRANSITION VERTICAL E TRACK NOTE USE IN LHR 24 APPLICATIONS N 6 12 TO CLOSE THE LIGHT GAP BETWEEN D TRANSITION AND THE WALL SAFETY SPREADER BAR CUT TO TRACK SPACING DIMENSION UPPER TRACK BEARING BRACKET TRACK MOUNTING BRACKETS TWO 2 EVENLY SPACED PER SIDE FOR DOORS WITH 72 AND ABOVE HEADROOM b NOTE TRACK SPACING MUST BE MAINTAINED END BUMPER TRACK SPACING THROUGHOUT ENTIRE LENGTH OF TRACK MOUNTING BAR 1 4 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 31 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual UW TRACK INSTALLATION UPPER UW TRACK INSTALLATION The location of the INSTALLATION INSTRUCTIONS for the various UPPER TRACK STYLES are listed in the table below TRACK STYLE INSTALLAT
103. track against the jamb place measuring tool prefered or measuring tape on floor then adjust track until tool ends are touching the inside faces of both tracks see diagram below Both tracks must be centered in the opening and spaced an equal distance away from or into the jambs Fasten track near floor Move track spacing tool to upper portion of track and repeat procedure described in step 5 Verify TRACK SPACING Track MUST BE kept at proper spacing with both tracks centered in the opening Remaining fasteners may now be installed at the correct spacing as described on pg 14 and pg 15 and in the methods illustrated on pg 13 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 9 Install floor to track brackets See page16 for complete installation instructions 10 Panel stacking may be done at this time if door opening needs to be closed up See installation instructions pgs 33 through 37 NOTE Track spacing tool is intended to be used for all track sections lower upper radius sections Sg x SL CE DOOR HEADER M EL nw E V LOWER TRACK
104. ts the use of self tapping screws instead of welding 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 11 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual TRACK INSTALLATION LOWER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Production Detail Sheet It illustrates the assembly of the track component parts 2 Measure finished jamb opening width The actual jamb width must match with the panel width inscriped on the door Call TKO if door width does not match the opening width 3 Inspect track pieces and line up so that they match job specific track drawing that was supplied with door If track drawing is missing call a TKO Doors customer service representative for assistance 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 4 While holding the lower left hand LH track against the jamb and flush to the opening carefully level it Use approved fastening method pg 13 on bottom and top holes in track Anchors bolts should be placed in the middle of the sloted holes so tracks can be adjusted later if necessary If track is to be welded in place lightly tack the bottom and top only Do not fill fasteners welds until you are certain the correct track spacing has been maintained 5 The track spacing tool can now be used to set the right hand RH track While holding the
105. uea STRAIGHT VERTICAL UPPER TRACK INSTALLATION SV DRUM LEFT RED SPRING SHAFT ASSY SV DRUM RIGHT BLACK amp sf BEARING PLATE MOUNTING BRACKET S ir gt DETAIL UPPER TRACK SECTION i CENTER TWO 2 BRACKETS PER SIDE TOOL ON UPPER TRACK iSi SECTION bs i Hi gt 7 j 1 b TRACK SPACING 1 47 LI DETAIL A 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 19 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual STEEL TRACK INSTALLATION continuea 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 Bolt 6 cast aluminum transition to lower tracks 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 plunger damage Track will angle away from wall at approximately a 5 angle Rise 12 Run 1 NOTE ALL METHODS OF UPPER TRACK ANCHORING REQUIRE THE TRACK SPACING TOLERANCES OF 1 4 ARE NOT EXCEEDED RECOMMENDE
106. uld result in death or serious injury Upper tracks must run straight level and plumb with lower tracks TRACK SPACING UPPER TRACK SECTION NOTE USE THIS SET OF HOLES 6 BEARING POSITION TO MOUNT THE BEARING ASSY TO THE BEARING PLATE CENTER 2 TWO TRACK MOUNTING BRACKETS PER SIDE ON UPPER TRACK SECTIONS 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc SPRING SHAFT ASSY T DOCK DOORS TKO WelterWeight Dock Doors User s Manual UW TRACK INSTALLATION continued TILT T1 UPPER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Installer Detail Sheet contained in the Owner s Parts Book It illustrates the assembly of the track component parts 2 Stack track on top of one another to create smooth level transition and splice together with track splice channel Bolt plastic track through steel angle track to the track splice with flat head Phillips drive 5 16 18 x 3 machine screws Tracks are factory attached to the steel angle with flat head Phillips drive 5 16 18 x 2 1 2 machine screws 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 the Top Track Mounting Bracket within 12 from the highest point of the track Leave track bolts loose until bracket is ancho
107. upper radius and horizontal tracks where plunger tips and side seals contact 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 65 A DOCK DOORS TKO WelterWeight Dock Doors User s Manual WINDING 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 CABLE MUST BE 1 2 TURN MINIMUM ON DRUM CABLE STOP CHALK LINE CENTER BRG BRKT STD 3 6 UNIV RED LEFT SIDE BLACK RIGHT
108. ure 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 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 DETAIL SPRING WARNING TAG 3 8 16 X 2 BOLT PARTIAL THREAD CENTER BRG BRKT STD 3 6 UNIV SHAFT COUPLER CENTER BRG 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 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 63 A DOCK DOORS TKO WelterWeight Dock Doors User s Manu
109. ure to follow these instructions could result in death or serious injury Page 26 2012 4Front Engineered Solutions Inc 15 00015 R10 05 12 WW User s Manual TKO WelterWeight Dock Doors STEEL TRACK INSTALLATION TILT T2 SAFETY SPREADER BAR INSTALLATION END BUMPER NOTE TRACK SPACING MUST BE MAINTAINED SPREADER BAR THROUGHOUT ENTIRE LENGTH OF TRACK QA 1 4 TRACK 30 3 SPACING 6 12 RUBBER BUMPER DETAIL C TOP SAFETY SPREADER BAR CABLE SAFETY SHIELD IE TRACK MOUNTING BRACKETS HEADER SAFETY v SPREADER BAR IR S UPPER TRACK SECTION A ETT DOOR HEADER EMEN lt TRACK SPACING p EVERY 22 TO 26 ABOVE DOOR HEADER 6 12 ABOVE DOOR HEADER DETAIL B 7 SAFETY SPREADER MOUNTING BRACKET 15 00015 R10 05 12 WW 2012 4Front Engineered Solutions Inc Page 27 T DOCK DOORS TKO WelterWeight Dock Doors User s Manual STEEL TRACK INSTALLATION continuea ROOF PITCH UPPER TRACK INSTALLATION 1 Locate the TRACK PRINT PDS Production Detail Sheet contained in the Owner s Parts Book It illustrates the assembly of the track component parts 2 Identify upper supports Identify a beam or structure to attach the end of the horizontal tracks You will need to run back hangs and sway
110. y 6 high to properly support center bearing bracket s Single shafts will require a single pad bracket centered in the door 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 56 dut I 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 A SOLID MATERIAL STEEL li NN 3 8 FLAT 3 8 FLAT 3 8 FLAT WASHER WASHER WASHER

WELTERWEIGHT - Curlin, Inc.

Contents

Download Pdf Manuals

Related Search

Related Contents