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Your TODCO upward-acting door will provide years of service if it is properly maintained. Repairs and adjustments to the spring and counterbalance assembly, cables or panels must be made by a trained service person. Genuine TODCO replacement parts should be used. Please read the Safety and Maintenance Instructions on previous page. You can ensure the smooth operation of your door by regular lubrication as shown below.
Lubricate the counterbalance, bearings, rollers, hinges and lock liberally with TODCO Lube. Do not use grease. (See below.) Wipe dirt from track. Frequency of door maintenance will vary with climate conditions and door cleaning procedures. Doors which are steam cleaned will need lubricating more often. Doors on equipment which is run in areas where road salts are used will require lock lubrication at closer intervals. Note: Do not use TODCO Lube or any petroleum-based lubricant on rubber door seals. Please refer to serial number for replacement parts.
INTERMEDIATE AND TOP PANEL REPLACEMENT
- Securely clamp the track below the panel to be replaced to prevent the door from rising.
- Drill out rivets on hinge halves of the panel to be replaced and pry the hinge half loose.
- Lift the door panels above the panel to be replaced into the horizontal track and secure with vise grips
clamped on horizontal track.
- Remove the old panel, line up the new one and drill all of the hinge holes on the bottom of the new panel.
- Insert bolts in the holes, install the hinges over the bolts and tighten the nuts.
- Lower the door from the horizontals and drill all the holes in top of the panel.
- With the upper door section clamped so it will not fall, tip the panel
toward you to insert the bolts. Install the hinges over the bolts and tighten the nuts.
The replacement of the panel is now complete.
COUNTERBALANCE MOUNTING DETAILS
|WARNING: High-Tension Spring can cause severe injury or death.
Installation, repairs and adjustments must be made by trained service personnel using proper tools and instructions. Use 1/2" diameter by 18" winding bars only. DO NOT USE bent winding bars, screwdrivers, or punches for spring winding. Read all instructions before starting repair. Always maintain firm footing and control of tools.
CABLE REPLACEMENT PROCEDURE (WITH TENSION ON SPRING)
- Close door from inside. Release spring tension from cables by fully inserting 1/2" diameter x 18" winding bar into one of the spring winding plug holes.
- Raise bar enough to allow inserting of second winding bar into lower hole and release tension to let second bar rest against top panel.
- Loosen set screws on cable drums, releasing cable drum from shaft, remove cable(s) from cable drum(s).
Remove cable(s) from door bottom panel by removing anchor and cotter pin.
|CAUTION: Raising door can cause injury or damage to equipment. Steps 4 and 5 must be done by someone on the outside of the door. DO NOT raise door with winding bar in place.
- Mount new cables with anchor and cotter pins on bottom panel and bring cable stop end to top of door between top panel and header.
- Insert the cable stop end into the cable drum slot. Thread the cable into the groove nearest the slot and turn the cable drum toward you until all slack is taken out, making sure the cable is following in its proper groove.
- Maintaining tension on the cable, slide the cable drum on the counterbalance shaft against the bearing and properly tighten both set screws.
- Repeat cable mounting procedure for opposite side, making sure drums are against bearings, set screws are properly tightened and cables have equal tension.
- Release spring tension by rotating spring winding plug just far enough to allow removal of winding bar against top of door.
Note: Rotating the counterbalance assembly too far may cause cables to jump off cable drum.
SPRING RE-ADJUSTMENT PROCEDURE (WITH CABLES MOUNTED)
- Close door from inside. Clamp counterbalance shaft with vise grip handle against ceiling to keep cables tight. (Fig. 3)
- Release spring tension from shaft by fully inserting 1/2" diameter x 18" winding bar into one of the spring winding plug holes. While holding the bar to keep spring from unwinding, carefully loosen winding plug set screws (2).
- After loosening spring winding plug set screws, use both winding bars to add (lift up) or remove (lower down) spring tension.
- After adjusting the spring tension, properly tighten set screws on the spring winding plug and remove vise grip from the counterbalance shaft.
Note: A properly counterbalanced door should, when stopped, remain at any given location.
CABLE MOUNTING AND SPRING WINDING PROCEDURE
- Mount new cables with anchor and cotter pins on bottom panel and bring cable stop
end to top of door between top panel and header.
- Insert the cable stop end into the cable drum slot. Thread the cable into the groove
nearest the slot and turn the cable drum toward you until all slack is taken out, making
sure the cable is following in its proper groove.
- Maintaining tension on the cable, slide the cable drum on the counterbalance shaft against
the bearing and properly tighten both set screws.
- Clamp counterbalance shaft with vise grip handle against ceiling to keep cables tight. (Fig. 3)
- Repeat cable mounting procedure for opposite side, making sure drums are against bearings,
set screws are properly tightened and cables have equal tension.
- Determine the number of winds needed for the counterbalance spring by dividing the door
opening height (in inches) by 10 and adding three turns. Example: 75 inches divided by 10 = 7.5
turns + 3 turns = 10.5 or 10 and one half turns.
- Run a chalk mark the full length of the counterbalance spring (Fig. 1). Leave vise grips clamped to
the shaft to keep tension on the cables.
- Fully insert 1/2" diameter by 18" winding bar into one of the spring winding plug holes. Loosen set
screws on 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. Turns are counted by using the chalk marks which show up as
stripes as the spring is wound (Fig. 3). Properly tighten both set screws on the spring winding plug and
remove the vice grips from the counterbalance shaft.
Note: 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 tightly and a few quarter turns should be released. If the door has a tendency to drop when stopped, a few more quarter turns should be added.
SHALLOW (RECESSED) HEADER COUNTERBALANCE (FIG. 4)
The shallow (recessed) header counterbalance differs from the conventional counterbalance as follows:
- Spring anchor plug and right-hand cable drum mount on curbside, 6-hole spring winding plug and left-hand cable drum mount on roadside.
- Cables come off front side of cable drums, between door face and header.
- Vise grip clamps against lower header flange to keep cables tight while winding spring.
- Counterbalance spring winds downward.
- Cable anchors are mounted at 4-1/8" from panel edge to centerline.
- Counterbalance shaft length is opening width minus 1-1/8".
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1295 E Fairground Rd. - Marion, OH 43302
TODCO doors, sometimes referred to as todco doors or todco roll up doors, or todco truck doors are the best on the market. TODCO makes plywood doors, fiberglass doors, aluminum doors, aluminum clad doors and polycomposite doors for trucks, cargo vans and truck trailers. TODCO ramps, known as todco rollaramps, are available with spring assist to help drivers in and out of their delivery truck doors or trailer truck doors. TODCO products include TODCOLD doors, dryfreight doors, ArmorTech doors, City cargo doors, CityCargo doors, armor plate doors ArmorPlate doors, weather tight doors and WeatherTite doors.
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