Maintenance and Service Manual - Doco insulated sectional garage
Contents
1. Ms 5 MT 13 Now slide the complete shaft or half shaft from the side bearing bracket Do this on the other side in the same manner 14 Disassemble the torsion springs of the spring break device 25449 on the ground 15 First check the side bearing brackets and the bearings of the spring break device 25449 in accordance with instruction 6 5 16 Slide the new torsion springs over the shaft and fix them in accordance with the installation manual see installation manual industrial sets of fittings 4 10 10 and installation manual spring break devices 25449 17 Slide the complete shaft or half shaft both back into the side bearing bracket and fix to the construction or offset plate again using bolts A or B 18 Fix both shafts together again by means of the coupler where fitted 19 Now Position the cable drum and mount the cable see instructions in the installation manual industrial sets of fittings with torsion springs 4 13 20 Block the shaft with the self grip wrenches UK V1 0 8 www doco international co uk ojolqo Manual 21 Tension the torsion springs in accordance with instructions see installation manual industrial sets of fittings with torsion springs 4 14 22 Remove the self gripping wrenches and test the door see 6 5 6 7 Checking and or replacing spring break devices These can only be checked if the torsion springs are removed Check the play in the bearings in accordan2. Copy this page for every periodic inspection and file it with the User Manual Date Date Installer Client UK V1 0 16 www doco international co uk i INSPECTION REPORT Product model type serial number etc Client address name address and contact LIST OF INSPECTED ITEMS IN ACCORDANCE WITH MAINTENANCE MANUAL ae Installer s Client s Any work done must be recorded in writing Copy this page for every periodic inspection and file it with the User Manual Date Date Installer Client UK V1 0 17 www doco international co uk i INSPECTION REPORT Product model type serial number etc Client address name address and contact LIST OF INSPECTED ITEMS IN ACCORDANCE WITH MAINTENANCE MANUAL ae Installer s Client s Any work done must be recorded in writing Copy this page for every periodic inspection and file it with the User Manual Date Date Installer Client UK V1 0 18 www doco international co uk i INSPECTION REPORT Product model type serial number etc Client address name address and contact LIST OF INSPECTED ITEMS IN ACCORDANCE WITH MAINTENANCE MANUAL ae Installer s Client s Any work done must be recorded in writing Copy this page for every periodic inspection and file it with the User Manual Date _ Date Installer Client UK V1 0 19 www doco internationa
3. Remove the block from the shaft and the vertical tracks and check the balance UK V1 0 7 www doco international co uk oodo INTERNATIONAL Manual Instructions for replacing torsion springs IMPORTANT There is great strain on tensioned springs proceed carefully at all times especially when performing corrective maintenance Use tensioning bars that are well fitting and that have been well maintained 12025 1 Block the shaft and the door blade Secure the door in such a way that it cannot rise Do so for instance by fastening self grip wrenches on the vertical tracks 2 Insert the first tensioning bar in the winding plug 3 Turn the tensioning bar in the appropriate direction 4 Carefully loosen the bolts of the winding plug and take over the spring tension 5 Remove the steel Key 6 Hold the first tensioning bar and place the second bar in the next hole of the winding plug 7 Turn the second tensioning bar in the desired direction 8 Hold the second tensioning bar takes over the tension and remove the first tensioning bar 9 Repeat steps 4 5 6 until the spring has been de tensioned 10 Loosen the cable fixing bolts on the cable drum and remove the cable 11 Loosen the bolts of the coupler if fitted 12 Loosen the bolts B which fix the spring break device to the construction Should the spring break device 25449 be fixed by means of an offset plate 25448 only loosen bolts A see photograph 5
4. ojolqo INTERNATIONAL part of your door Maintenance and Service Manual For industrial sectional overhead doors with torsion springs T V NORD CERT Y c UK ofolqo Manual Contents 1 Symbols and warning signs 3 2 General 3 3 Safety instructions for maintenance and service 3 4 Maintenance in general 3 4 1 Schedules 4 4 2 Inspection and replacement levels 4 4 3 Inspection level 1 4 4 4 Inspection level 2 or replacement level 2 4 5 Inspection items level 2 and or replacement level 2 4 6 Instructions for inspection level 2 and or replacement level 2 5 6 1 Measuring the forces on the safety edge in accordance with EN 12445 EN 12453 5 6 2 Checking and or replacing the lifting cables 6 6 3 Checking and or replacing rollers 6 6 4 Checking and or replacing side and intermediate hinges 6 6 5 Checking and or replacing the side bearing brackets 7 6 6 Checking door balance replacing torsion springs 7 6 7 Checking and or replacing spring break devices 8 6 8 Checking and adjusting the play between door blade and seals 9 6 9 Checking the bottom seal 9 6 10 Checking the side and lintel seals 9 7 The manufacturer maintenance company 9 Annex A Schedule parts to be replaced approx 5 cycles day 10 Annex B Schedule parts to be replaced approx 10 cycles day 11 Annex C Schedule parts to be replaced approx 15 cycles day 12 Annex D Schedule parts to be replaced approx 20 cycles day 13
5. Annex E Schedule parts to be replaced approx 25 cycles day 14 Form Technical data 15 Form Inspection report 16 UK V1 0 2 www doco international co uk ojolqa 1 Symbols and warning signs A A General symbol for DANGER Symbol for ATTENTION Read carefully the text with this symbol Symbol Risk of physical injury Read carefully the text with this symbol 2 General This maintenance manual has been prepared for use by qualified personnel and therefore not by trainees or do it yourselfers In case of doubt about the maintenance or servicing instructions please contact DOCO International To avoid severe personal injury carefully read and observe all indications and warnings in this maintenance manual This manual has been compiled in accordance with EN 12635 however you should check yourself as to whether this standard corresponds with the local national standards 3 Safety instructions for maintenance and service This manual describes the maintenance servicing of industrial sectional overhead doors with torsion springs this may be supplemented by other maintenance manuals for instance the door operator manual if applicable Adding or leaving out parts can affect the working and therefore the safety of the garage door and is therefore strongly prohibited All indications concerning the assembly right or left are always viewed from the assembly location that is from
6. if found replace the cables It is recommended you should change both cables at the same time IMPORTANT Tensioned springs carry a high tension always be very careful and use the right size and well maintained tensioning rods 12025 2 people minimum are required to tension springs Instructions for changing the cables 1 Move the door to the closed position 2 Block the door blade 3 Make a note of the number of turns required to tension the existing springs 4 Release the tension from the springs see instructions in the installation manual industrial doors fitted with torsion springs section 7 step 1 5 Mark the existing cable at the point where the cable passes through the edge of the cable drum see figure right 6 Loosen the cable locking bolts on the cable drum 7 Remove the cable from the cable drum UK V1 0 5 www doco international co uk oodo INTERNATIONAL Manual 8 Remove the safety cap from the cable break device 9 Remove the eye of the cable from the cable break device PEETER 10 Measure from the bottom of the eye to the mark made in 4 psestrough ie end groove of Ay on the old cables 11 Mark a corresponding mark on the new pair of cables 12 Fit the eye of the new cables onto the cable break bottom corner brackets 13 Pass the cable from the cable break device behind the rollers to the cable drum 14 Pass slack cable through cable fixing hole and secure the cable by tightening the p
7. PARTS TO BE REPLACED Level 2 Tn the case of shot blasted springs being used with a standard calculated lifespan of 25 000 cycles UK V1 0 13 www doco international co uk ofotdo INTERNATIONAL Manual ANNEX E Approx 25 cycles a day PARTS TO BE REPLACED Level 2 Tn the case of shot blasted springs being used with a standard calculated lifespan of 25 000 cycles UK V1 0 14 www doco international co uk 1 Technical data Description Industrial sectional door Factory nr Manufacturer Client and town 2 Door blade Dimensions Weight Kg 3 Balance Number of torsion springs 4 Door operator Manufacturer Power kW Operating voltage Built in safety Yr manufactured Panel type Type First use on DOCO International Limited Unit K4 The Metropolitan Centre Field Way Greenford Middlesex UB6 8UN Control voltage Spring break device 25449 electrical switch 25447 Cable break device 25453 electrical switch 25445 Safety edge device FRABA OSE Other Other data Installer UK V1 0 15 www doco international co uk i INSPECTION REPORT Product model type serial number etc Client address name address and contact LIST OF INSPECTED ITEMS IN ACCORDANCE WITH MAINTENANCE MANUAL Description of work done Installer S Client S signature signature Any work done must be recorded in writing
8. the inside to the outside All measures are in millimetres unless otherwise specified Keep this maintenance manual in a safe place Make sure that the power is switched off and remains switched off while electrical work is carried out Some parts contain sharp edges use protective gloves When performing maintenance to the industrial door always wear at least gloves and safety boots During drilling wear safety goggles Make sure that you can always perform your work in a stable environment if necessary use scaffolding Secure the assembly maintenance area with safety tape to keep others at a distance Make sure there is enough light Only use appropriate tools especially when tensioning the torsion springs Subject to technical changes without written notice 4 Maintenance in general In accordance with CE directives all industrial doors must be checked from the first instance they are being used and with servicing intervals as indicated by the supplier Servicing and or maintenance inspection must be recorded in writing Service and or maintenance inspections must be carried out by an installation professional or company UK V1 0 3 www doco international co uk gt gt o o qo 4 1 Schedules This manual includes two schedules A schedule for 1 Inspection schedule 2 Replacement schedule Inspection mainly means that checks have to be performed Ay Replacement means that
9. ce with 6 5 and the way they function see installation manual spring break device 25449 6 8 Checking and adjusting the play between door blade and seals Check whether the play between the door blade and side seals is still correct Play should be just be sufficient as to allow the rollers to rotate freely If a finger guard 25700 has been fitted this can only be checked by readjusting the roller carrier Instructions for readjusting the play of the door blade 1 Loosen the bolts of the roller carrier 2 Use one hand to put pressure onto the door blade and with the other hand adjust the roller with the roller carrier in such a manner that the roller carrier is pushed against the track with a little tension 3 Use one hand to maintain tension on the roller carrier and retighten the roller carrier nuts Do this for all side hinges 6 9 Checking the bottom seal 80045 In accordance with EU standard EN13241 1 the seals around the door blade need to be in perfect condition in order to retain the classification obtained through testing Check the seals for flexibility and sealing characteristics The sealing characteristics can be checked by closing the door blade The bottom seal should be sealed even in the case of slight unevenness 6 10 Checking the side and lintel seals 24740 In accordance with EU standard EN13241 1 the seals around the door blade need to be in perfect condition in order to retain the classification obtai
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11. lain bolt not coloured red 15 Then secure the cable drum including the key onto the shaft Ay by tightening the bolts red 16 Once again Ensure the position of the left and right cable drum is the same and that the cable tension of both cables is equal Ay 17 To tension springs refer to instructions in the installation manual industrial doors fitted with torsion springs section 4 13 6 3 Checking and or replacing rollers Instructions for checking rollers 1 Remove a roller from the side hinge by undoing the two bolts on the roller carrier and sliding the roller out 2 Take the roller into your hand and check whether the roller can be turned without it making a snapping sound This sound indicates a worn ball bearing Replace the roller 3 Also check the axial play of the bearing See photo if there is more than 0 5 mm of play replace the roller Instructions for replacing rollers 1 Remove a roller from the side hinge by undoing the two bolts on the roller carrier and sliding the roller out 2 Insert the new roller into the roller carrier position roller into track and bolt roller holder onto the roller carrier Adjust in accordance with instruction 6 8 6 4 Checking and or replacing the side and intermediate hinges Check the hinges for breaks see photo marking 1 also check the hinge bolt this should not have worked its way out of the hinge see photo marking 2 Instructions for replacing rol
12. lers 1 Dismount the side or intermediate hinge by loosening the self tapping fasteners 2 Mount the new side or intermediate hinge by tightening the self tapping fasteners 3 Torque for side hinge 15 Nm 4 Torque for intermediate hinge 10 Nm UK V1 0 6 www doco international co uk gt gt oodo INTERNATIONAL Manual 6 5 Checking and or replacing the side bearing brackets These can only be checked if the torsion springs are removed Check whether play in the bearing 1s still within acceptable limits 1 Turn the bearing with your finger and listen for a snapping sound This sound indicates a worn ball bearing Replace the bearing plate 2 Check the axial play Use your finger for this This should be no more than 0 5 mm If there is more play replace the bearing plate 6 6 Checking door balance replacing torsion springs Instructions for testing door balance 1 Move the door in closed position 2 Disengage the door operator if applicable 3 Position the door blade in any given position 4 The door blade must remain in this position Should the door blade rise or fall the torsion springs need to be readjusted 5 In the case of a door blade falling the torsion springs need to be tightened Do this by tightening each spring 0 25 turn each time until the door blade is balanced see correcting the spring tension 6 In the case of a door blade rising the torsion springs need to be loo
13. ned through testing Check the seal for flexibility and wear there must not be any holes in the seals 6 11 Checking electronic safety switches for spring and cable safetydevices In accordance with EN 12604 cable and springsafetydevices have to be equiped with electrical switches In case off spring or cable break the motor has to switch off see page 17 for the article numbers 7 The manufacturer DOCO International Limited Unit K4 The Metropolitan Centre Field Way Greenford Middlesex UB6 8UN T 0044 208 8132266 F 0044 208 8132288 E sales doco international co uk UK V1 0 9 www doco international co uk oodo INTERNATIONAL Manual ANNEX A Approx 5 cycles a day PARTS TO BE REPLACED Level 2 In the case of standard springs being used with a standard calculated lifespan of 15 000 cycles UK V1 0 10 www doco international co uk oodo INTERNATIONAL Manual ANNEX B Approx 10 cycles a day PARTS TO BE REPLACED Level 2 In the case of standard springs being used with a standard calculated lifespan of 15 000 cycles UK V1 0 11 www doco international co uk oodo INTERNATIONAL Manual ANNEX C Approx 15 cycles a day PARTS TO BE REPLACED Level 2 Tn the case of standard springs being used with a standard calculated lifespan of 15 000 cycles UK V1 0 12 www doco international co uk oodo INTERNATIONAL Manual ANNEX D Approx 20 cycles a day
14. ollers instructions see 6 3 4 Checking and or replacing the side and intermediate hinges instructions see 6 4 5 Checking and or replacing the side bearing brackets instructions see 6 5 6 Checking the door balance replacing torsion springs instructions see 6 6 7 Checking and or replacing spring break devices instructions see 6 7 S Checking and adjusting the play between door blade and seals instructions see 6 8 9 Checking the bottom seal instructions see 6 9 10 Checking the side and lintel seals instructions see 6 10 11 Checking electronic safety switches for spring and cable safetydevices instructions see 6 11 UK V1 0 4 www doco international co uk A A oodo INTERNATIONAL Manual 6 Instructions for inspection level 2 and or replacement level 2 6 1 Measuring the forces on the closing side in accordance with EN 12445 EN 12453 This check must be performed using a so called peak force meter See photo Check the peak forces as described below See the figure below Forces must be within the established norm A maximum of 400 N within 0 75 sec graph For further information consult the manual for your peak force meter Force 400 N H 50 mm Dynamic force IMPACT Static force CRUSHING max 2500 300 eT E ar a ks J J h Y 7 a a a K 300 H 585 6 2 Checking and or replacing the lifting cables Check the cables for broken strands kinks and visible wear
15. parts MUST be replaced in accordance with a schedule Ay These schedules have been drawn up based on investigation and endurance testing The replacement schedules have been set up in relation to frequency of use 4 2 Inspection and replacement levels Inspection and or maintenance can be divided into two levels Level 1 Maintenance that may be carried out by the end user caretaker himself Level 2 Maintenance that must be carried out by a qualified company and must be recorded in writing 4 3 Inspection level 1 This inspection must be performed once every 10 000 cycles or once a year Hinges and rollers must be given a single drop of oil SAE 20 quality Check the cables for tears or damage Clean the tracks 4 4 Inspection level 2 or Replacement level 2 Inspection level 2 must be performed once a year or at lesser intervals as required by the frequency of operation by a qualified company and must be recorded in writing in accordance with Inspection Report Replacement level 2 must be performed in accordance with the replacement schedule see Annexes A through E by a qualified company and must be recorded in writing in accordance with Inspection Report 5 Inspection items level 2 and or replacement level 2 1 Measuring the closing edge forces in accordance with EN12445 EN12453 instructions see 6 1 2 Checking and or replacing the lifting cables instructions see 6 2 3 Checking and or replacing r
16. sened Do this by loosening each spring 0 25 turn each time until the door blade is balanced see correcting the spring tension Correcting the spring tension Block the shaft and the door blade Secure the door in such a way that it cannot rise Do so for instance by fastening self grip wrenches on the vertical tracks IMPORTANT There is great strain on tensioned springs proceed carefully at all times especially when performing corrective maintenance Use tensioning bars that are well fitting and that have been well maintained 12025 You can correct the tension by stretching or releasing the spring with 1 full turn 4 x 0 25 turns at the most Make sure that both springs are equally corrected 1 Insert the first tensioning bar in the winding plug 2 Turn the tensioning bar in the appropriate direction 3 Carefully loosen the bolts of the winding plug and take over the spring tension 4 Remove the steel key 5 Hold the first tensioning bar and place the second bar in the next hole of the winding plug 6 Turn the second tensioning bar a quarter of a turn in the desired direction 7 Hold the second tensioning bar takes over the tension and remove the first tensioning bar 8 Repeat steps 4 5 6 until the correct tension has been reached 9 Replace the steel key 10 Secure the winding plug on the shaft by turning both bolts of the winding plug with 27 up to max 34 Nm 11 Now remove the last tensioning bar
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