Serco R-620-3 & R-620-4 rail shelters are custom built
for each application. Installation procedures are the
same for all R-620-3 & R-620-4 rail shelters regardless of
size. Installation requires two people and a forklift truck
or similar device to lift and position the shelter
components. Lifting equipment to be determined by
installer.
Improper installation of anchoring devices or
installation into aged or unsound concrete or other
faulty or inadequate building wall construction could
result in serious injury or death, as well as premature
product wear, product failure or property damage.
Inadequate lifting equipment or unsafe lifting practices
can cause a load to fall, tip or swing unexpectedly.
Make sure lifting devices are in good condition and have
a rated capacity of at least 500 lbs. at the lifting angle
being used. Never allow anyone to stand on or near the
rail shelter component when it is lifted or placed.
Failure to follow this warning could result in serious
personal injury or death to bystanders if component
unexpectedly falls, tips or swings.
Read and understand this Installation Manual before
proceeding. Safety standards as described in this
manual must be followed at all times. If you have any
questions contact your supervisor or your local Serco
distributor for assistance.
Assembly of components should be performed in such
a way so as to maintain cleanliness of equipment before
final installation. Lifting equipment to be determined by
installer (man lift and forklift or boom lift typical). Wear
safety glasses, gloves, hard hats, safety shoes and all
necessary protective clothing.
INSTALLATION:
1. Determine door centerline and mounting location of
outside of rail shelter sides.
Mark centerline on rail dock.
Determine unit width and mark ½ this dimension on either
side of centerline mark.
2. Determine position of bottom 2 x 4 frame and bottom
of side frames below dock floor.
Mark dock face 12” or
more (as required) below dock floor at centerline location
and side frame mounting locations.
! IMPORTANT !
Mount unit 12” below dock minimum to allow clearance
for bottom crossbar, frame, rope and pulleys.
3. Mount side frames onto wall.
Outside edge of side
frames should be placed on mark from Step 1. Bottom of
side frames should be placed on mark from Step 2
4. Mount top and bottom 2 x 4 frames to wall.
Fit
between side frames with outside edges flush with ends of
side frames.
! IMPORTANT !
Position mounting anchors (not included) so that they
do not interfere with tension spring movement or
retraction rope operation.
5. Assemble fittings onto top crossbar
. Slide tee fittings
onto each end of crossbar. Attach long leg of elbow fittings
onto each end of crossbar with slotted machine screws in
line with holes in pipe. Tighten setscrew.
Note: Top
crossbar is 2” shorter than bottom crossbar.
6. Assemble top crossbar to cover fabric.
Pre-drilled
holes and machine screws in elbow fittings will align with
grommets in top of cover. Attach pulleys through holes in
middle section of cover and pipe.
7. Assemble top crossbar to upper arms
. Insert marked
end of upper arms into track assembly eye end fitting and
tighten setscrew. Relax spring tension as required. Loosen
setscrews on open end of crossbar tee fittings, slide onto
upper arms and re-tighten setscrews.
WARNING
8. Fasten cover to outside of frames.
Attach with
galvanized ring shank nails (provided) spaced approx. 8”
apart. Nail through fabric hem into edge of wood with cover
tight to wall. If 3-sided cover, nail bottom return flap to
bottom of side frame.
9. Assemble fittings onto bottom crossbar.
Slide short
leg of elbow fitting onto ends of bottom crossbar and tighten
setscrew.
10. Assemble bottom crossbar to lower arms.
Relax
spring tension as required. Loosen setscrews on elbow
fittings, place on lower arms and re-tighten setscrews.
11. Attach bottom crossbar to cover fabric.
Machine
screws in elbow fittings and holes in bottom crossbar (4-
sided cover) will align with grommets in cover. Attach
pulleys through pipe (or pipe and cover if 4-sided) into holes
towards the outside of bottom crossbar.
12. Increase spring tension on arm assemblies.
Adjust
tension evenly between springs and eye screws (by
reducing number of chain links) so that shelter extends to its
full projection. Do not over-tension springs.
13. Align top and bottom crossbars.
With shelter at its
full projection loosen setscrews on crossbar side of upper
tee fittings and crossbar end of lower elbow fittings. Rotate
crossbars so that bolts through cover are aligned up and
down. Re-tighten set screws
14. Assemble upper and lower rope retraction systems.
Each rope path starts on the right eye screw and ends on
the left eye screw flowing through single and double pulleys
as shown. Route bottom rope system through O-rings in
bottom of 4-sided cover. Leave approx. a 2’-0” loop of rope
from each system below large rope cleat position. Attach
rope cleat to left side frame at a point approx. 5’-0” above
dock floor (locate to suit application). Check for smooth
operation then retract shelter and store ropes on cleat.
15. Attach cover tie back straps.
One set provided per
side frame. Nail to inside and outside edge of frame.
16. Caulk between outside of frame and wall
. A silicone
caulk (provided by others) is recommended.
SUGGESTED MOUNTING METHODS:
(Mounting anchors not included)
MASONRY BUILDING WALLS:
Try to hit mortar joints. Use 1/2” or 3/8” x 4” expansion
anchors. Use through-bolt fastening if anchors will not hold,
3/8” threaded rod is recommended.
METAL BUILDING WALLS:
Through-bolt fastening required. Use a back-up plate (steel
or wood) to support bolts or anchor through existing building
horizontal and vertical structural members
.
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