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Roll-Up Door
Installation Instructions
Installation Sheet #INS-97005
STEP 1
Check the door parts to make sure you have received all needed
items. Note any shortages or damages on delivery receipt as Fleet
Engineers cannot be responsible for parts lost or damaged in
shipment.
Figure 1
1. Hardware box - fasteners, rollers, cables, hinges, top fixtures.
2. Counterbalance spring assembly with drums, shaft & bracket(s).
3. Pair of horizontal tracks.
4. Pair of vertical track assemblies.
5. Header seal and retainer or head seal on top panel.
6. Two door halves.
7. Side seals - optional on 3/4 door.
IMPORTANT!
BEFORE PROCEEDING WITH THE INSTALLATION READ
EACH STEP AND SEE SAFETY NOTICE INSTRUCTIONS.
Figure 1
STEP 2:
Headroom
Clearance -
Measure headroom
to be sure there is
sufficient clearance to
accept the counterbalance and to allow the
door to clear under the
roof bows (Figure 2A).
Use the chart in Figure
2B to determine the
required headroom for
your particular installation. Keep in mind that
whatever you add must
be flush with the inside
of the side post.
Note: Figure 2A shows
the counter-balance
against roof skin.
Figure 2A
A B C D E
3/4” Doors 7” 5” 18” 2-1/2” 1-1/2”
Figure 2B
STEP 3: Sideroom Clearance
The minimum sideroom clearance is 2-1/2” on each side from the
post (opening) to the wall. Figure 3.
In the event it is necessary to add on the corner post, keep the
added piece flush with the inside of the header.
Installation Sheet # INS-97005 • Rev A 2/98 • Rev B 6/08
Figure 3
STEP 4: Measuring Door Opening
Because each Fleet Engineers door is custom made, it is necessary to check the opening measurement. These measurements
must be finished opening width and height. “Finished” means
there must be the header and side room clearance mentioned in
previous steps to insure proper installation.
Opening height is from the header to the sill, Figure 2A. Opening
width is from post to post, Figure 3. On older units, measurements should be taken in at least three different places for opening width and height. Cutting back of the floor on older units may
be necessary to permit the door to sit on the sill, below the floor.
See “D” dimension and chart in Figure 2B.
STEP 5: Vertical Track Installation
Position vertical tracks on corner posts as shown in Figure 3 and
clamp in place. Notch in mounting angle should line up with the
bottom of header (Figure 2A). If necessary, the bottom of the
vertical track assemblies may be cut off to permit the notch to line
up with the underside of the header. Keep both tracks the same
length.
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CAUTION!
The vertical track assembly may be raised a maximum of 1/2”
off the sill. Keep both vertical tracks the same length and same
distance off sill.
Mount the vertical track mounting angle flush with the inside edge
of the rear corner posts all the way up and down, Figure 3.
It is critical that the vertical track is installed square. Check the
opening measurements at several points between the vertical
tracks, then measure diagonally. If your measurements are equal,
the door track is square.
The vertical track is to be welded through the plug weld holes to
the post on 12” to 15” centerline. The upper brackets (counterbalance) must be properly secured, welded or bolted, to the header,
Figure 5.
STEP 6: Horizontal Track Installation -
It is important to maintain the same distance between the horizontal and vertical tracks. If wider than the vertical tracks, shim
horizontal track accordingly.
Fasten horizontal tracks securely to provide adequate support for
the door and weld the full length of the couplers at the track joints.
CAUTION!
STEP 7: Counterbalance Installation
If door is equipped with a pre-wound counterbalance, special
precautions must be exercised when handling this assembly. The
spring on this type counterbalance is factory pre-wound and is
under tension.
DO NOT loosen any of the spring set screws until final installation
of the pre-wound counterbalance detailed in Step 9.
Remove the bearing assembly from the road side vertical track.
Slide this bearing onto the right hand cable drum end of the counterbalance shaft. Insert the left end of the counterbalance shaft
into the bearing assembly of the curb side vertical track. Remount
bearing to road side vertical track assembly.
Position and align the spring anchor bracket on the inside of the
header; be sure the shaft is not rubbing on the spring anchor casting. Allow a minimum of 5” for spring growth, Figure 5. FIRMLY
SECURE SPRING ANCHOR BRACKET TO WITHSTAND THE
STRONG TORQUE OF THE SPRING.
An additional counterbalance support bracket is required on 102”
wide units.
STEP 8: Door Installation
Assemble the door half sections together with the bolts, rivets
and/or hinge pins provided, Figure 4. Attach cable assembly to
cable anchor bracket, secure with anchor & cotter pin.
Assemble the slide part of the adjustable top fixture to the premounted base with washer and bolt. Next, insert the roller shafts
into the end hinges, top and bottom fixtures.
IMPORTANT!
ONE TO FOUR SPACER WASHERS SHOULD BE PLACED ON
THE LEFT AND RIGHT SIDES OF THE FIRST SECTION JOINT UP
FROM THE BOTTOM, AND THE FIRST SECTION JOINT DOWN
FROM THE TOP OF THE DOOR. THESE WASHERS WILL HELP
HOLD THE DOOR SQUARE WITH THE TRACK.
Before rolling the door into the tracks, bring the cable ends to the
top of the door and tape to the inside of top panel, Figure 4.
If the unit has no other door, place two small blocks of the same
size under each corner of the door so a light may be placed in the
unit. The blocks will keep the door even while you wind the cables
and counterbalance spring.
Insert door and carefully lower door, supporting door weight onto
wood blocks on sill. Install track stop bolt in end of horizontal
track.
With the door closed, bring the road side cable up between the
drum and the header.
Figure 4
Hook the cable end in the slot in the outer groove of the right
cable drum. Starting in first groove, wind the cable on the drum
winding drum towards you, make sure it properly tracks in each
groove of the cable drum.
Take up the cable slack until snug; push the drum against the
bearing and properly tighten both set screws. Now, clamp the
counterbalance shaft with vice grips, (handle of grips against the
ceiling) to hold the cable taut. (Figure 5)
Repeat the procedure with the curb side cable and drum.
IMPORTANT!
1. CABLE DRUMS MUST BE TIGHT AGAINST BEARINGS.
2. CABLE IS PROPERLY TRACKING IN CABLE DRUM GROOVES.
3. CABLES MUST HAVE EQUAL TENSION.
4. SET SCREWS MUST BE TIGHT.
STEP 9: Spring Winding
To determine the amount of winds on the counterbalance spring,
divide 10 into the door opening height in inches and add 3 turns.
Example: 75 divided by 10 = 7.5 turns + 3 turns = 10.5 or 10 and
one-half turns
Run a chalk mark, (Figure 5) the full length of the counterbalance
spring. Leave the vice grip clamped to the shaft to keep tension
on the cables.
Place a 1/2” dia. x 18 winding bar in the hole in the spring winding plug. Wind the spring by lifting up the bar. While holding the
first bar, place a second bar in the next hole and lift in the same
manner after removing the first bar. Repeat this until the correct
number of complete turns are obtained by counting the chalk
marks which show up as stripes as the spring is wound.
Properly tighten both set screws on the spring winding plug and
remove the vice grips from the counterbalance shaft.
IMPORTANT!
USE 1/2” DIA. x 18” WINDING BARS ONLY. DO NOT USE
SCREWDRIVERS OR TAPERED PUNCHES FOR WINDING.
A properly counterbalanced door should, when stopped, remain at
any given location. If the door leaves the floor by itself, the spring
is wound too tight and a few quarter-turns should be released.
If the door has any tendency to drop when stopped, a few more
quarter-turns should be added.
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PRE-WOUND COUNTERBALANCE: If door
is equipped with a
pre-wound counterbalance, disregard
above instructions and
release spring tension
as follows:
CAUTION!
Make sure cables are
attached to door and
cable drums, that
cables are properly
tensioned, and cable
drums are properly secured to shaft as noted
in Step 8.
Clamp vice grips
above roller to track,
clamping door in down
position.
Loosen and remove
the two (2) set screws
found in the spring
anchor plug, Figure
5. This plug is found
on the right hand end,
(inside looking outside)
of the spring. Spring
tension has now been
transferred to the
cables. Remove vice grips and check door operation.
Figure 5
WARNING!
HIGH TENSION SPRING CAN CAUSE SEVERE
INJURY OR DEATH!
REPAIRS & ADJUSTMENTS MUST BE MADE
BY TRAINED SERVICE PERSONNEL.
STEP 10: Top Fixture
Standing inside the unit with the door closed against the sill
(remove blocks, light cords, etc.), adjust the top fixture slides until
the top panel is in the same plane as the rest of the door sections
and tighten bolts.
STEP 11: Lock Catch Installation
Cut hole in sill for lock catch box, Figure 3. Position catch box on
hole, locate the catch box mark directly below the lock backplate
mark and weld catch box to sill. (Center rivet in lock backplate
should line up with lock catch pin.)
STEP 12: Header Seal Installation
Cut the header seal to length to fit in between the vertical mounting angles and install onto top panel with rubber facing outward.
Drill 1/8” dia. holes and secure with drive rivets or bolts.
STEP 13: Side Seal Installation
With the door raised, insert the optional seal in retaining lip the full
length of the angle, Figure 6.
Insert seal at bottom lance & install drive rivet in lower hole.
Stretch seal 1, insert in top lance and install drive rivet in upper
hole. Snap seal into all remaining lances. Trim off excess seal.
(Drive rivets not provided)
STEP 14: Maintenance & Lubrication -
Lubricate the C/B spring, tracks, bearings, rollers, and hinges
liberally with “WD” Lubricant, Fig.7 (designated by O). Do not use
grease.
NOTE: DOOR MAINTENANCE AND LUBRICATION FREQUENTLY
WILL VARY WITH USE OF THE DOOR, CLIMATE CONDITIONS
AND CLEANING PROCEDURES.
Figure 6
Figure 7
Page 4
maximum security lock
door installation
tolerances
door opening measurements
NOTE: Measure opening width & height at
two different locations for comparison
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Wall-to-Wall standard references
Headroom clearance
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