Install Manual for Hydroswing®
Hydraulic Single Panel Door System
Hydroswing® Hydraulic Single Panel Door System
Install Manual
• Door header
• Fully engineered ASTM 275 steel pre-hung frame
• Hard/soft line clamps
• Connectors ‘L’ joint
• Fabricated and welded to AWS D1.1 and ISO 9001 standards.
• Premium hose sets
• Wind load up to 200mph
• Soft lines
Clevis pin keeper •
• Upper pin point clevis
• Top Chord
• Upper Pin point
• Cross member
• Spherical bearings
with zirks
• HydroLoc® (zero drop)
• Two way hydraulic cylinder
Fully engineered S275 steel •
pre-hung door frame
• Jamb tube
• Push tube
Upright member •
• Splice plate (Interior)
(easy connect jamb splice)
Attach sheeting here •
(Windows or choice of
cladding/treatments)
Carboline carboguard 890 primer •
• Splice plate
(exterior push tube)
• Splice Plate
• Hard lines/softline optional
• Splice plate bolts
• Spherical bearings
with zirks
Clevis pin keeper •
• Lower pin point
Lower pin
point clevis •
• Remote opener antenna
• Remote control
• Key
Hydroswing® Patented bow truss •
(US D584,831 S)
Jamb •
• Hydroswing® logo
• Cane bolt (optional)
• Frame out (window shown)
Walk door option
• Bottom Chord
• Bottom weather seal
Base plate fixing •
UL certified control box •
Pump and Motor •
Power cables •
1
Copyright Hydroswing® North America Inc. 2100 Palomar Airport Rd, Suite 210, Carlsbad, CA 92011 USA • Phone: +1 800 404 4937 • Web: www.hydroswing.com • E mail: enquiries@hydroswing.com
GENERAL INFORMATION
READ CAREFULLY BEFORE
THE INSTALLATION OF YOUR HYDROSWING® SINGLE PANEL HYDRAULIC DOOR
Pre-Install
Information
Dear Valued Customer Congratulations! You have just purchased the world’s finest Hydraulic door system, the HydroSwing® Door.
Low maintenance, quick cycle time, and sealing flush against the building are just a few of the advantages over other door systems.
Our employees take pride in the quality of the door they build and we stand behind our product.
If you have any questions concerning the installation, maintenance, or purchase of a HydroSwing® Door, please call us at +1 800 404 4937.
The installation of a large door is a considerable job which requires knowledge and preparation. This is why we highly recommend you hire someone
specialized to do the job. A professional door installer will adjust the door perfectly and he generally guarantees his work. In other words, he is ready to
come back and make further adjustments if necessary, within the warranty period.
You can obviously do the installation of your HydroSwing® door yourself as long as:
• you have a good deal of experience with do-it-yourself projects
• you have the right tools
• you will have help in handling the frames and the pieces of hardware
• you read the instructions in this manual BEFORE starting the installation of the door, not after.
The installation instructions which follow are meant to be general guidelines which cannot be considered, under any circumstance, as imperative and
final instructions as to the installation of a Hydroswing® hydraulic door. The manufacturer cannot be held liable in the event of any damage which could
result before while and after installing a Hydroswing® hydraulic door. The illustrations in this guide are as precise as possible, slight differences in detail
may appear.
Your HydroSwing® door is probably the largest door you own. It must be installed properly in order to be safe, secure and trouble free.
If you have any doubts concerning your skills in installing a HydroSwing® door, do not hesitate to contact a professional.
2
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SAFETY INSTRUCTIONS - READ THESE INSTRUCTIONS CAREFULLY!
(Please contact our Customer Service immediately if you have any questions about any information in this manual +1 800 404 4937)
Pre-Install
Information
Note: The terms “danger,” “warning” and “caution” are used to imply a risk. Please pay attention when these terms are used in this manual.
Safety First!
1. Clear in front of the door.
2. Have a certified electrician wire the hydraulic pump, motor, control panel *remote, *DC back-up.
3. When installing the HydroSwing® Door, make sure the door is chained or strapped to the forklift until the door is secured to the building.
4. Do not EVER work on the hydraulic lines while the door is open.
* Package options, not included with all doors.
Warning
THE USER IS RESPONSIBLE FOR THE SAFE OPERATION AND CARE OF THE DOOR. WE STRONGLY RECOMMEND THAT ALL PERSONNEL
WHO OPERATE OR WORK ON THE DOOR READ AND UNDERSTAND THESE INSTRUCTIONS PRIOR TO USE. THE DOOR MAY NOT BE
USED FOR ANY OTHER PURPOSE THAN IT IS INTENDED — TO CLOSE OR MAKE AN OPENING ACCESSIBLE FOR PASSAGE.
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3
Table of Contents
Flush Mount Cont.
32
Standard Pump Remote
56
4
Outside Mount
34
Painting 57
Tool Lists5
Outside Mount Cont.
36
Bottom Seal
58
Parts List (Slice Plate)
6
Cylinder Assembly 38
Weather Seal 59
Parts List (Plumbing)
7
Cylinder Assembly 2015
39
Door and Windows
60
Parts List (Fixing)
8
Securing Cylinders - I
40
Door and Windows
61
Parts List 9
Securing Cylinders - I New
41
Cane Bolts62
Parts (Hose and Seals)
10
Flush Mount Plumbing
42
Sheeting
64
Parts, Control box, P & M
11
Flush Mount Plumbing
43
Sheeting (J-Trim)
65
Pre-Installation (Wood)
12
Grease Zerks 66
Pre-Installation (Steel)
13
Finishing
Top Rubber Flashing
67Operation
Unloading
14
Fitting Flush Mount
44
Unloading Cont.
15
Fitting Outside Mount
45
Appendix
Unloading Cont. Prep.
16
Steel Building
46
A - Hydraulic Diagram
68
Unloading Cont. Prep.
17
Wood Building 46
B - Fitting Weld Schedule
69
Concrete Building
46
C - Upright Weld Schedule 70
Assembly
Concrete Pad
47
D - Low Power Wiring Dia.
71
E - Wiring Selection Table
72
Pre-Install
Table of Contents
Pre-Install
4
Push Tube Assembly
18
Remove Forklift
48
Non standard Uprights
20
Outside Mount Plumbing
48
Standard Uprights 22
Standard Uprights 50
Information
Jambs 24
Standard Pump 52
Register Product
73
Hydraulics
Hy-Power Pump
53
Product Update Reg.
73
Contact Details
74
Hard Pipe Assembly
26
Wiring
52
Flush Mount
28
Securing Cylinders - II
54
Hard Pipe Assembly
30
Weather Seal 55
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Below is a comprehensive list of tools that you
will need to install your door. While some items
on this list are interchangeable with similar tools,
we strongly recommend that you have all the
items listed present at your install. Having them
present will prevent you from having to stop your
installation to locate specific items.
Standard Hand Tools
• Tin Snips
Wrenches
Safety Equipment
• 1/4” Wrench
• Safety Glasses
• 7/16” Wrench
• Welding Mask
• 1/2” Wrench (two needed)
• 9/16” Wrench
• 5/8” Wrench
• 11/16” Wrench
• 3/4” Wrench (two needed)
• 7/8” Wrench
• Hearing Protection for operations like
grinding
• Work Gloves
• Steel Toe Boots
• Safety Harness
• Anything else specific to your work site
Power Tools
• Electric Impact Driver (corded)
Other
• 3lb (1.3kg) Hammer
• Hammer Drill w/ 1/2” masonry bit
• 2 people to help install
• 12-15” Bessey/C- Clamps/Welder’s Vice
(concrete anchors only)
• Ratchet Straps
• 3/4” Impact Socket
Grips (two needed)
• Needle Nose Pliers
• 2" Coring Bit (cane bolts only)
• Cordless Drill (w/ 5/16” and 7/16” drives)
• 15-20’ Log Chain
• Electric Drill (corded w/bit asst. up to
• 6000lb (2700kg) Telescoping Forklift (Doors
• Standard Pliers
9/16”)
weigh about 4.75 lbs./sq. ft. You may need
• Vice Grip
• 4 1/2” Grinder with Grinding Wheels,
more than one lift for larger doors.)
• Crescent Wrench (at least 1 1/4”)
• 4’ (120cm) Level
• Funnel
• Regular and Phillips Screwdrivers
Pre-Install
Tool List
Cutoff Wheels, and a Wire Wheel
• Extension cords.
Welding Supplies
• Welder/Generator with at least 6600 Watts
• Grease Gun and White Lithium Grease
(220V/30 Amp)
• Chalk Line
• 1/8” 7018 Welding Rods or
• All Terrain Scissor Lift
• Telescopic Ladder
• SAE 10/ISO 32 Weight Hydraulic Oil
• 6 cans red oxide primer
• 1/8” 6011 Welding Rods
• Slag Hammer
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5
Pre-Install
Push Tube
Splice Plate,
Outside
THD/AGD Splice
Plate, Outside
Push Tube
Standard Splice
Splice Plate,
Plate, Left
Inside
THD/AGD Splice
Plate, Inside
6
Standard Splice
Plate, Right
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Needle Flow Control
Tee Fitting
Pre-Install
Valve (Optional)
Hard Pipe
M/F Elbow
Bent Hard Pipe
Pipe Union
M/M Elbow
Restrictor
Adapter
M/M O-ring
Elbow
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7
Concrete
Anchor
Thru Bolt
Pre-Install
NOTE:
Lag Bolt
Cylinder
Pin
Cylinder Pin and Spiral Lock
has been updated to a Clevis
Pin and Clevis Keeperon our
latest doors.
Spiral Lock
Standard
Splice Bolt
Thru Bolt
Washer
Jiffy Clip
Screw
Jamb Bolt
Tek Screw
Pump Mount
Bolt
Grease Zerk
8
Thru Bolt Nut /
Standard Splice Nut
Pump Mount
Washer
Pump Mount
Bolt
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Hard Pipe
Clamp Base
Plate
Pre-Install
(Outside
Mount Only)
Hard Pipe
Clamp
Assembly
Antenna
Mount
Antenna
Jiffy Clip
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Antenna
Cable (Coax)
9
Bottom/Top Seal
Pre-Install
Rubber
Short Hydraulic Hose
Long Hydraulic Hose
10
Weather Seal
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Pre-Install
Standard Pump
MADE IN THE USA
Hydroswing® North America Inc. 2100 Palomar Airport rd, Suite 210, Carlsbad CA 92011 • Tel +1 800-404-4937 •
www.hydroswing.com
Standard Pump
Control Box
Hy-Power
Pump
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11
Pre-Installation
Important Information:
fig. 1
For more information on
mounting the Hydroswing®
Single Panel Hydraulic
Door refer to our Mounting
Protocols in our Download
page! (www.hydroswing.com)
Pre-Install
On new buildings, leave the sheeting
around the rough opening off. It’s
easiest to schedule your installation
before you begin sheeting that side of
your building.
On existing building, loosen the
sheeting enough that it can be pulled
back 6-12" (15-30cm).
The building jamb and header should
be clear and flush for 4” (10cm) around
the rough opening for a flush mount,
7” (17cm) on the top and 5” (12.5cm)
on the sides for an outside mount.
Any gaps along the jamb or header,
fig. 1, must be filled. For example,
many headers are fixed across the
jamb. In that case, material should be
added until the jamb is flush with the
header, fig. 2.
Steel rough openings should have plate
welded across the gaps, fig. 3.
Wooden headers should be 2-ply
and at least 3” (7.5cm) thick. Lateral
X-braces are recommended.
The area directly in front of the rough
opening should be clear and large
enough to accommodate the door and
lifting equipment.
12
fig. 2
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Important Information:
We recommend adding angle
iron under the metal plate for
added strength
Pre-Install
(Positioned under the hinge)
For example download our
mounting protocols.
fig. 3
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13
Unloading
Loosen the straps securing the door to
the flatbed.
Remove the pallet from the flatbed.
Pre-Install
Place it where it is easy to access but
won’t interfere with fitting the door
into the rough opening.
Carefully lift the door sections ensuring
the load is spread evenly across the
door.
Place the door in front of the rough
opening with the truss up and away
from the building, fig. 4.
Be sure to leave adequate room to
assemble the door and maneuver the
lifting equipment.
Inventory the pallet using the included
packing list, fig. 5. If the inventory
is incorrect, immediately contact
Hydroswing Customer Service.
Cut the banding straps holding the
door sections together.
Set the two jamb tubes and cylinders
aside.
14
fig. 4
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1-555-563-9682
Email
WayneC@Comchat.org
Address
Email: GarthA@Hydroswing.com
Inside Mount
Steel Header
Steel Jambs
4 Uprights
4” Tube
4 Hole Splice Plates
134 Bruce St.
Aurora, Ill 23314
Ship to
Date: 12 May 10
Salesperson: Garth Algar
Moonie Industries
Paul Moonie
Phone
Pre-Install
Inventory Sheet
Quote: 33112
Client
Contact
134 Bruce St.
Aurora, Ill 23314
1 - 5hp W/R Power Unit
1 - 66/156 Hydraulic Hoses
1 - Push Button Station
2 - Cement Anchors
7 - Jamb Bolts
10 - Grease Zerks
14 - Jiffy Clips
32 - Splice Bolts and Nuts
1 - Cylinder Pin Kit
1 - Hydraulic Kit
13 - Hose Clamp Assemblies
4 - Cylinder Hose Assemblies
1 - Pump Bracket
4 - Pump Bracket Bolts
2 - Rolls Foam Seal
1 - Install Manual
42ft - 12” Top Rubber
Packed by
HYDROswing, INC.
400 East 4th Street North
Cottonwood, MN 56229
Signature
Toll Free: 1 866 60 HYDRO
Local: 1 507 423 6666
Int: + 1 507 423 6666
www.hydroswing.com
Date
HYDROswing, INC.
1632 W. College Drive
Marshall, MN 56258
fig. 5
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15
Unloading Cont.
Lift the top of the door, Side A, and
place it back, away from the building.
Pre-Install
The hinges on Side A should be facing
the ground and the hard pipe assembly
plates on the header (flush mount
only) should be facing up.
fig. 6
On Side B, lift the edge opposite the
truss up and over, gently lowering it to
the ground.
Now the truss on the bottom section
of the door, Side B, should be closest
to the rough opening and facing down.
fig. 6.
The hinges on the header section,
Side A, should be farthest away from
the rough opening.
Remove any wood bracing still attached
to the door.
16
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Pre-Install
Side B
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Side A
17
Push Tube Assembly
Refer to Weld Schedule in page 69/70
Grind 45° bevels around the push
tubes as outlined in the weld schedule
on p. 70.
Pre-Install
Assembly
Carefully bring the two sections
together so the uprights line up.
On one side of the door, lift the push
tubes and bring them together until
they're aligned.
Use a ratchet strap to ensure the
splices are tight when joined, fig. 7.
Place splice plates on both sides of the
push tube and slip the bolts through,
fig. 8.
Snug the bolts while paying close
attention to the splice to insure it stays
aligned, fig. 9.
Repeat on the opposite push tube.
fig. 7
18
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Refer to Weld Schedule in page 69/70
Assembly
Pre-Install
fig. 9
Push tube
Inner
splice
plate
fig. 8
Outer splice plate
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19
Non Standard Uprights
Refer to Weld Schedule in page 69/70
Use the instructions on this page if you
are installing a Non Standard door.
Pre-Install
Assembly
To join the uprights, start at one side
and work to the other.
Bring the uprights together ensuring
that their ends are snug using a ratchet
strap, fig. 10.
Once the splices are aligned, place
splice plates on both sides of the splice,
fig. 11, and align the 4 predrilled holes.
Clamp the whole assembly together
with Bessey clamps, C-clamps, or
welders’ vice-grips.
Drive the included self-tapping steel
(Tek) screws through the 4 pre-drilled
holes in the direction shown in fig. 11
using an impact wrench, then through
the remaining holes in a manifold
pattern.
Ensure the splices do not shift while
you are driving the screws through the
splices
Repeat on the remaining uprights.
fig. 11
20
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Refer to Weld Schedule in page 69/70
Assembly
Pre-Install
fig. 10
Note:
When in doubt contact customer
services.
Hydroswing® North America reserves
the right to change and upgrade
specifications.
fig. 12
www.hydroswing.com
www.hydroswing.com
USA +1 800 404 4937
UK +44 (0) 1772 563112
CANADA +1 647 534 3845
21
Standard Uprights
Refer to Weld Schedule in page 69/70
Use the instructions on this page if you
are installing a Standard door.
Pre-Install
Assembly
To join the uprights, start at one end
and work to the other.
Upright
Lift and align the uprights ensuring that
their ends are snug.
Use a ratchet strap to ensure splices
are tight when joined, fig. 15.
Place splice plates on both sides of the
splice, fig. 14.
Slip the bolts through.
Screw the nuts on the bolts and snug
but don’t completely tighten, fig. 13.
Repeat on the other uprights.
Splice Plates
fig. 14
22
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Refer to Weld Schedule in page 69/70
Assembly
Pre-Install
fig. 15
fig. 13
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23
Jambs
Refer to Weld Schedule in page 69/70
Grind 45° bevels around the doorjambs
as illustrated in weld schedule on p. 70.
Pre-Install
Assembly
Lift the upper doorjamb on Side A up
and brace it with blocks of wood.
Slide the lower jamb onto the upper
jamb, fig. 16.
Ensure the angle plates on the jamb
match up.
Bolt the jambs together and tighten,
fig. 17.
Weld around the jamb according to the
weld schedule on p.70.
Repeat on the opposite jamb.
Remove the wood blocks and lower the
completed jamb.
fig. 16
24
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Assembly
Pre-Install
fig. 17
Side A
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25
Hard Pipe Assembly
Follow the appropriate steps for your
type of install, either outside or flush
mount.
Door Header Steel
fig. 18
Flush Mount
Pre-Install
Hydraulics
Place pipe clamp halves along the
bottom row of tapped holes on the
header, fig. 18.
Place half a row of pipe clamp halves
on the top row of the header on the
side the pump will be located on.
The hard pipe sections are pre-cut to
appropriate lengths to span the header.
Divide them into six equal sets.
Join 2 sections of hard pipe with a
T-fitting, fig. 20.
Add an elbow to the top section of the
T-fitting. The elbow should face the
side of the door where the pump will
be located.
fig. 19
Screw a section of hard pipe to the
open end of the elbow.
Add more hard pipe and unions to each
end of the assembly by joining them
with pipe unions to span the header.
26
fig. 20
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Door Header Steel
Pre-Install
Hydraulics
Pump Side
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27
Hard Pipe Assembly
Follow the appropriate steps for your
type of install, either outside or flush
mount.
Door Header Steel
fig. 21
Flush Mount
Pre-Install
Hydraulics
Place pipe clamp halves along the
bottom row of tapped holes on the
header, fig. 21.
Place half a row of pipe clamp halves
on the top row of the header on the
side the pump will be located on.
The hard pipe sections are pre-cut to
appropriate lengths to span the header.
Divide them into six equal sets.
Join 2 sections of hard pipe with a
T-fitting, fig. 23.
Add an elbow to the top section of the
T-fitting. The elbow should face the
side of the door where the pump will
be located.
Screw a section of hard pipe to the
open end of the elbow.
fig. 22
Add more hard pipe and unions to each
end of the assembly by joining them
with pipe unions to span the header.
28
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Door Header Steel
Pre-Install
Hydraulics
Pump Side
fig. 23
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29
Hard Pipe Assembly
Follow the appropriate steps for your
type of install, either outside or flush
mount.
Door Header Steel
fig. 24
Flush Mount
Pre-Install
Hydraulics
Place pipe clamp halves along the
bottom row of tapped holes on the
header, fig. 24.
Place half a row of pipe clamp halves
on the top row of the header on the
side the pump will be located on.
fig. 25
The hard pipe sections are pre-cut to
appropriate lengths to span the header.
Divide them into six equal sets.
Join 2 sections of hard pipe with a
T-fitting, fig. 25.
Add an elbow to the top section of the
T-fitting. The elbow should face the
side of the door where the pump will
be located.
Screw a section of hard pipe to the
open end of the elbow.
Add more hard pipe and unions to each
end of the assembly by joining them
with pipe unions to span the header.
30
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Door Header Steel
Pump Side
Pre-Install
Hydraulics
Note:
When is doubt contact customer
services, Hydroswing® North America
reserves the right to change and
upgrade specifications.
www.hydroswing.com
fig. 26
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CANADA +1 647 534 3845
31
Flush Mount Cont.
Lay the completed pipe assembly in the
groove of the pipe clamp halves, fig.27
Pre-Install
Hydraulics
Place 2 pipe clamp halves, one up one
down, on top of each existing clamp
to ready the header for the next pipe
assembly, fig. 28.
Door Header Steel
fig. 27
Assemble another set of pipes,
T-fitting, and elbow.
Lay the second pipe assembly over the
first.
Place the last set of hard pipe clamps
over the second assembly and secure
them with the metal plates and bolts,
fig. 29. Do not completely tighten the
bolts yet.
Add elbows to the ends of the hard
pipe assemblies.
Slide the top pipe assembly 3 or 4” in
the opposite direction of the pump.
Having the hard pipes staggered will
help when attaching the hoses.
Tighten all the hard pipe clamp
assemblies.
fig. 28
32
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Door Header Steel
Pre-Install
Hydraulics
Pump Side
fig. 29
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33
Outside Mount
If you are doing an outside mount
install, assemble your header as
follows.
fig. 30
Pre-Install
Hydraulics
Measure carefully to ensure hard pipe
clamp plates are correctly spaced to
hold the pipe assemblies. Striking
a line across the rough opening is
suggested, fig. 30.
Secure the hard pipe clamp base plates
to the rough opening’s header, spaced
so they clamp the hard pipe sections
near their middle.
Assemble a complete hard pipe clamp
assembly including two lengths of hard
pipe, fig. 31.
Bolt the whole assembly to a base
plate on the lower level adjacent to the
middle of the header. Snug the bolts
but don’t fully tighten them.
Assemble another clamp with hard
pipes and bolt it in place next to the
first.
fig. 31
Join the four lengths of hard pipe with
two pipe unions, fig. 32.
Repeat the last two steps until you
reach the edge of the door.
34
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Pre-Install
Hydraulics
fig. 32
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35
Outside Mount Cont.
Install and join a second line of pipes
above the first on the pump side of the
door.
fig. 33
Pre-Install
Hydraulics
Install and join a third line of pipes on
the lower level on the non-pump side
of the door.
Once all three sets of hard pipes are
loosely in place, join the bottom two
sets in the middle with two tee fittings,
fig. 34.
Add elbows to the tops of the tee
fittings and join those elbows to the
upper layer of hard pipes on the pump
side.
Add elbows to the six open ends of the
hard pipe assemblies, fig. 36.
Slide the top pipe assembly 3-4” in the
opposite direction of the pump.
Having the hard pipes staggered will
help when attaching the hoses.
Tighten all the hard pipe clamp bolts.
36
fig. 34
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Pre-Install
Hydraulics
fig. 36
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37
fig. 37
Cylinder Assembly
Check to see if you have post 2015
cylinder, if so skip this page.
Details in Fig 39a to adjust HydroLoc®
Pre-Install
Hydraulics
Lay a hydraulic cylinder out with the
ports up.
Remove the metal plugs on the hydraulic
cylinder ports.
Screw the adapter then the restrictor
into the top port. Screw the M/M o-ring
elbow into the bottom port with the
opening pointing toward the top of the
cylinder, fig. 37.
Thread the bent end of the bent hard
pipe onto elbow , fig. 38, do not tighten
the hard pipes yet.
Pre-2015 Cylinders
Note:
When in doubt contact customer
services.
Hydroswing® North America reserves
the right to change and upgrade
specifications.
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UK +44 (0) 1772 563112
CANADA +1 647 534 3845
Secure the hard pipe to the cylinder with
hard pipe clamps assemblies, tighten,
fig. 38.
Add an elbow to the open end of the
hard pipe facing up fig. 39.
Tighten both ends of the hard pipe.
Repeat with the second cylinder.
38
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fig. 38
Post-2015 Cylinders
fig. 39
Cylinders supplied complete
Pre-Install
Hydraulics
HydroLoc Counterbalance Valve "Zero drop system"
HydroLoc Counterbalance Valve "Zero drop system"
HydroLoc® Valve •
13
HydroLoc Counterbalance Valve
Turn screw clockwise to reduce
setting and release load.
Complete adjustment 3 3/4 turns.
10
CBAL VALVE
13
EXTEND
12
RETRACT
12
fig. 39a
www.hydroswing.com
39
Securing Cylinders - I
Pre 2015
fig. 40
Cylinder pins come with a spiral lock
fastener.
Pre-Install
Hydraulics
Slip an end of one of the spiral lock
fasteners into the groove on the cylinder
pin.
Spin the spiral lock until it slips entirely into
the groove.
Fit the upper clevis to upper pinpoint (on
the jamb), with the hard pipe facing up.
Slip the cylinder pin through the clevis and
pinpoint.
Slip an end of the second spiral lock
fastener into the groove on the cylinder
pin.
fig. 32
Spin the spiral lock until it slips entirely into
the groove.
Repeat with the second cylinder.
40
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Securing Cylinders - I
Main plate
Top plate
Post 2015
Upper Pin
Point Clevis
Push the Clevis pin in leaving the ridge
for the Clevis Pin Keeper to be inserted.
Insert the Clevis Pin Keeper and line up
with the two bolt holes, then tighten
the bolts.
Pre-Install
Hydraulics
Line up the spherical bearing in the
hydraulic cylinder with the Upper Pin
point clevis.
Keeper
Clevis pin
Repeat with the second cylinder.
fig. 40a
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41
Flush Mount Plumbing
These steps should only be completed now
if your doing a flush mount (with integrated
header). If you're installing an outside
mount, do not attach the hoses until you
have secured you door.
Pre-Install
Hydraulics
Attach the long length of conjoined hose
to the top 2 hard pipes on the hard pipe
assemblies, these are the pipes that branch
off of the T and elbow in the middle of the
header, closest to the top of the door, fig.
41.
Tie the free end of the long hydraulic
hose loosely to a horizontal member to
keep it out of the way during fitting.
Attach a short section of hose to the 2
cylinder ports.
Follow the hose from the bottom
cylinder port (with the elbow) and attach
the free end to the bottom inside pipe,
fig. 42.
Follow the hose from the top cylinder
port (with the restrictor) and attach the
free end to the bottom outside pipe.
fig. 41
Repeat with the second cylinder.
42
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Add color tape to each end of the
hydraulic lines to make plumbing the
system easier.
Key
-We Have Colored Our Pipes:
(Blue)
-Main Line Extend
(Yellow) -Main Line Retract
(Green) -Cylinder Line Extend
(Orange) -Cylinder Line Retract
Pre-Install
Hydraulics
Tip:
fig. 42
fig. 43
www.hydroswing.com
43
Fitting
Tip:
Carefully slip the forks under the middle
of the header section marked with the
‘lift here’ stickers. (Add blocking to
protect the header.)
Add blocking between the fork lift and
the door header to protect the door.
Finishing
Pre-Install
Chain or strap the uprights to the forklift
until the door is fully secured to the
rough opening.
fig. 44
Flush Mount
fig. 45
fig. 46
Take special care not to damage the hard
pipe assemblies or hoses when lifting
and fitting door.
Lift slowly up and forward until the door
is vertical.
Move the door to within about a foot
(30.5cm) of the rough opening and
lower it until it’s almost on the ground,
fig. 44. Make sure the door is aligned
with the opening.
Have ground workers push the bottom
of the door forward into place then
lower the door until the jambs are in
place on the ground, fig. 45.
Bring the forklift forward slowly and
lower the door until the header is
straight, fig. 46.
Do not release the door. Keep the
forklift in place to support the door.
Ensure the door is flush, level, and in its
final position before fixing the door to
the building.
44
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Outside Mount
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fig. 48
fig. 49
Finishing
Pre-Install
fig. 47
45
Steel Building
If your building is steel, see the Weld
Schematic on p. 70 for details.
Wood Building
Finishing
Pre-Install
Drill 1/4” (6mm) pilot holes for each lag
along the jambs, fig. 50.
fig. 50
Drive lag bolts into each pre-drilled
hole. Ensure the bolts seat well and
do not strip out.
Drill 1/2" (1cm) holes along the header
for thru bolts. Slip bolts through and
secure with nuts and washers.
Concrete Building
Hammer drill 1/2” (1cm) holes for
concrete anchors, fig. 51.
Insert concrete anchors and tighten.
Ensure the anchors grab properly.
Concrete Pad
If you're going to fix the jambs to the
concrete pad, hammer drill 1/2" (1cm)
holes for concrete anchors, fig. 52.
Insert concrete anchors and tighten.
Ensure the anchors grab properly.
46
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Finishing
Pre-Install
fig. 51
fig. 52
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47
Remove Forklift
Once the door is completely secured
to the building, remove the chain and
forklift.
Important Information:
The hydraulic system must be balanced, the lines feed in via the tee and
elbow in the middle of the header making the lines exactly the same length.
Failure to do this will result in the door operating improperly!
Finishing
Pre-Install
Outside Mount Plumbing
If you're installing an outside mount door,
attach the hydraulic hoses now.
Attach the long hose to the top 2 hard
pipes on the hard pipe assemblies. These
are the pipes that branch off of the tee
and elbow in the middle of the header,
closest to the top of the door, fig. 53.
Start at the cylinder on the non-pump
side of the door.
Attach a short section of hose to the 2
cylinder ports, fig. 54. Follow the hose
from the bottom cylinder port (with
the elbow) and attach the free end to
the bottom, inside pipe.
Follow the hose from the top cylinder
port (with the restrictor) and attach the
free end to the bottom outside pipe.
Repeat with the pump side cylinder,
fig. 54 and fig 55
48
fig. 53
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Tip:
Add color tape to each end of the
hydraulic lines to make plumbing the
system easier.
fig. 55
Key
Finishing
Pre-Install
-We Have Colored Our Pipes:
(Blue)
-Main Line Extend
(Yellow) -Main Line Retract
(Green) -Cylinder Line Extend
(Orange) -Cylinder Line Retract
fig. 54
www.hydroswing.com
49
Standard Uprights
Follow these steps if you are installing a
Standard door.
Clamp the push tube side seals to the
jamb to straighten the push tubes.
Finishing
Pre-Install
Tighten the bolts on the push tube
and weld in accordance with the weld
schedule on p.70.
Once the door is fixed in its final place
the loose upright splices may square
themselves. If they do not, fig. 56, rock
the door until they do.
Check the first upright to make sure
it is square and level. If it is, fig. 56a,
tighten the bolts to fix the upright in its
final position.
Continue checking and tightening the
remaining uprights.
Once all the uprights are tightened,
weld them in accordance with the weld
schedule on p. 78.
fig. 56
Unclamp the side seals.
50
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Finishing
Pre-Install
Note:
When in doubt contact customer
services.
fig. 56a
Hydroswing® North America reserves
the right to change and upgrade
specifications.
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UK +44 (0) 1772 563112
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51
Standard Pump
Weld, bolt, or screw the pump
mounting bracket in place.
Bolt the pump to the mounting
bracket.
Finishing
Pre-Install
Connect the outside hydraulic hose to
the right side of the pump.
Connect the inside hydraulic hose to
the left side of the pump.
Fill the pump reservoir.
Note:
The plumbing can be completed
with hard or soft lines.
Mount the control box next to the
pump.
Hy-Power Pump
Position the box and weld, bolt, or
screw it in place.
Connect the outside hydraulic hose to
the right side of the pump.
Connect the inside hydraulic hose to
the left side of the pump.
Fill the reservoir.
Wiring
Both pump types must be wired by a
certified electrician.
52
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Finishing
Pre-Install
fig. 57
www.hydroswing.com
fig. 58
53
Securing Cylinders - II
Finishing
Pre-Install
Once the pump is plumbed, filled, and
wired, cycle the cylinders several times
to fill the lines with fluid, (Care should
be taken during this process. You want
to make sure not to fully extend the
cylinders as you could damage the
cylinders, the doors and the foundation).
Connect the lower clevises of the
cylinders with the cylinder pins. Cycling
the cylinders or pushing on the door
will help align the holes fig. 59.
Once the cylinders are connected to
the lower pin points and the pins and
spiral locks are in place, the door may
be cycled fully open and closed.
Check the hydraulic reservoir after
cycling the door open and closed. The
reservoir should be ¾ full when the
door is closed.
Pre-2015 Cylinders
Post-2015 Cylinders
Post 2015 Lower Clevis Pin
Line up the spherical bearing
in the hydraulic cylinder with
the Lower Pin point clevis.
Push the Clevis pin in leaving
the ridge for the Clevis Pin
Keeper to be inserted.
Insert the Clevis Pin Keeper
and line up with the two bolt
holes, then tighten the bolts.
Repeat with the second
cylinder.
Weather Seal
Do not apply the weather seal if it is
colder than 40°F (4.5°C).
Open the door all the way.
Apply the weather seal to the top and
sides of the door's angle iron seal,
fig. 62,not the jamb.
Miter the seal in the corners where
it meets rather than butting one strip
against the other fig. 61.
54
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Note:
Weather seal attaches around the
sealing angle on the door not the
jamb, close up in fig. 63
fig. 63
Finishing
Pre-Install
fig. 62
Sealing Angle
Section of door
Sealing Angle
Weather Seal
fig. 61
Miter the Corners
of the weather seal
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55
Standard Pump Remote
The antenna should have a clear view
of the area where you will be using
your remote.
220V Out
Finishing
Pre-Install
Connect the antenna cable to the
antenna socket on the push button
box, fig. 70a.
Ensure that the antenna cable will
reach the antenna mounting location
from the push button box.
fig. 71
L N
Open
T2 T1
L2 L1
60w
Weld, bolt, or screw the antenna
mount into place.
Close
Connect the antenna and antenna
cable to the antenna mount, fig. 71.
fig. 70a
Painting
We strongly recommend that you paint
your door before sheeting. Corrosion
due to unpainted surfaces is not
covered under warranty.
At a minimum, all welds should be
touched up with primer, fig.72.
220V In
Hydroswing doors are primed with an
oil-based primer (PPG ASP-7035). Use
an appropriate oil-based paint fig.73.
Latest doors are shot blasted and
primed in Carboguard 890 Epoxy
Primer
56
Power Unit Solenoid
fig. 70
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Finishing
Pre-Install
fig. 72
Note:
When in doubt contact customer
services.
Hydroswing® North America reserves
the right to change and upgrade
specifications.
www.hydroswing.com
USA +1 800 404 4937
UK +44 (0) 1772 563112
CANADA +1 647 534 3845
fig. 73
www.hydroswing.com
57
Bottom Seal
Open the door to about shoulder level.
Roll out the rubber labeled ‘bottom’.
Finishing
Pre-Install
Layout the predrilled metal strips in
two sets. You may need to trim the
strips to size.
Clamp or hold the predrilled metal strip
to the backside of the bottom member,
fig. 74.
Place the edge of the rubber between
the strip and the door. The rubber
should extend to the edges of the steel
side seals.
Screw the rubber and the strip to the
door with Tek screws. Add strips as
needed.
Clamp or hold another strip to the
bottom of the bottom member slightly
to the rear of center, fig. 75.
Place the edge of the rubber between
the strip and the door.
Screw the rubber and the strip to the
door with Tek screws. Add strips as
needed.
fig. 74
Lower door to ensure it seals.
58
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Finishing
Pre-Install
fig. 75
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59
Door and Windows
Fit the window/door into the casing
built into the door’s framing.
Secure the window/door with Tek
screws, fig. 76.
Finishing
Pre-Install
Cut one piece of J-trim 2” (5cm) longer
than the top width of the window/
door.
Trim the ends so each end has a 1”
(2.5cm) tab that can be folded down
over the side trim.
Cut two pieces of J-trim 1” (2.5cm)
longer than the height of the window/
door. Trim the bottom ends to form 1”
(2.5cm tabs that can be folded down
and in across the bottom piece of trim.
Cut one piece of J-trim the width of the
bottom of the window/door.
Screw the bottom J-trim to the bottom
fig. 77.
Screw the side trim to the sides with
the tabs pointing down.
Screw the top trim to the top.
Bend the top tabs down over the sides
and the side tabs over the bottom.
60
fig. 76
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Finishing
Pre-Install
fig. 77
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61
Cane Bolts
Do not install cane bolts if it's windy.
Doing so will cause the bolts and bolt
holes to be misaligned.
Finishing
Pre-Install
Fit the cane bolt onto the upright
with the flanges on either side of the
predrilled holes, fig. 78. The cane bolt
should be inside the door.
Slip the bolts through the bolt holes,
add the nuts, and tighten.
Let the cane bolts rest against the
concrete floor.
Trace a circle on the floor around the
base of each bolt, fig. 79.
Lift the cane bolts and let the handle
rest in the retaining groove.
Open the door.
Core drill a 2" (5cm) wide hole deep
enough that the cane bolt has 1"
(2.5cm) of clearance below it when in
the closed position, fig. 80.
fig. 78
Do not use the drill's hammer feature.
If the hole fills with debris, remove it.
Lower the door and ensure the cane
bolt slips in place.
Repeat with the remaining cane bolts.
62
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Finishing
Pre-Install
fig. 79
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fig. 80
63
Finishing
Pre-Install
fig. 82
Sheeting
64
Secure the starter strip along the bottom of the
door with screws every 12” (30.5cm) on center.
Cut the sheet steel to the appropriate height
for the door fig.82.
Secure a section of J-trim vertically along
one side of the door with screws every 12”
(30.5cm) on center.
Fit the sheet against the door and screw to
cross members between ribs or every 12-18”
(30.5-45cm). Do not screw past the last rib.
Do not screw the top of the sheet.
Fit another sheet so the first rib of the second
sheet laps the last rib of the first sheet and
screw it down.
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Finishing
Pre-Install
fig. 83
Continue adding sheets until you reach the last
sheet of the door.
Trim the final sheet to fit and screw it in place
leaving the outside edge loose.
www.hydroswing.com
Slip J-trim, channel facing in, behind the edge
of the final sheet and secure both to the door
screwing through sheet and trim, fig. 83.
Screw through the top of the sheeting and trim
along the top of the door.
Slip another strip of J-trim, channel facing down,
between the sheeting and door along the top.
65
Grease Zerks
To install the zerks on the hinges, slip
them into a small socket.
Fit the bottom edge of the zerk into the
predrilled hole, fig. 84.
Finishing
Pre-Install
Strike the top of the socket squarely
with a hammer.
Pump white lithium grease in until it
oozes out both sides of the hinge.
Repeat with the other hinges.
Top Rubber Flashing
Slip the rubber flashing under the
sheeting above the door, fig. 85.
Add trim between the rubber and the
sheeting if you choose to use trim.
Screw through the sheeting,trim, and
rubber between every rib to secure it
to the building.
fig. 84
Screw through the bottom of the
rubber into every rib in the steel, fig.
86. & fig. 87.
Securing Hoses
To secure the hydraulic hoses, use the
included jiffy clips to run the hoses
away from the door opening and
cylinders.
66
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Flush Mount
fig. 87
Finishing
Pre-Install
fig. 86
Outside Mount
fig. 85
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67
Appendix A - Hydraulic Diagram
Top
Pre-Install
Appendix
Note:
Your door will ship with
either a Hy-power (left)
or Standard Pump
(right), not both.
Bottom
Your door will ship with either a
Hy-power (left) or Standard Pump
(right), not both.
The 12V DC Backup Unit shown at the
bottom is optional.
The hoses for connecting a 12V Backup
Unit should be left connected.
68
12V Backup is an optional extra and is
only connected when needed.
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SMAW
6-18
.25
Weld 1/4" (6mm) single-fillet lap joints 6" (15cm) on 12" (30cm) off
for both jambs.
.25
Pre-Install
Appendix
Appendix B - Fitting Weld Schedule
SMAW
.25
6-18
SMAW
Weld 1/4" (6mm) single-fillet lap joints completely across each stud.
Retouch cooled welds with oil-based primer.
All measurements are in inches (with approx equivalent in mm/cm).
www.hydroswing.com
69
Appendix C - Upright Weld Schedule
SMAW/GMAW
.375
1.5 - 6.0
.375
1.5 - 6.0
.375
SMAW/GMAW
Pre-Install
Appendix
.375
.375
45°
.25
SMAW/GMAW
Jamb Tube
.375
.375
.375
SMAW/GMAW
.375
.25
45°
SMAW/GMAW
.25
.25
45°
.25
SMAW/GMAW
Push Tube Type #1
.375
.375
SMAW/GMAW
Grind a 45° V-shaped bevel, 1/4”
(6mm) wide, all the way around
the jamb. Weld a 3/8” (9.5mm)
wide bead around the jamb.
Supplies:
SMAW/GMAW
.25
SMAW/GMAW
.25
45°
Push Tube Type #2
.375
.375
.375
SMAW/GMAW
Weld a 1/4” (6mm) bead across the
seam.
45°
.25
SMAW/GMAW
.25
45°
Grind a 45° V-shaped bevel, 1/4”
(6mm) wide, all the way around the
tubes. Weld a 3/8” (9.5mm) wide
bead around the tubes.
1/8” 7018 welding rod,
1/8” 6011 welding rod, or
L-56 wire.
SMAW/GMAW
45°
.25
45°
.25
.25
45°
.375
45°
.25
.375
1.5-6.0
.375
1.5-6.0
Standard Upright
45°
.25
SMAW/GMAW
.25
45°
Grind a 45° V-shaped bevel, 1/4”
(6mm) wide, across both the short
sides of both tubes. Weld a 3/8”
(9.5mm) bead across the short sides
after the splice is on.
SMAW/GMAW
.375
.375
1.5 - 6.0
.375
1.5 - 6.0
.375
.375
Weld a 3/8” (9.5mm) bead across
the seam.
SMAW/GMAW
.375
1.5-6.0
.375
1.5-6.0
Stitch 3/8” (9.5mm) wide beads 1
1/2” (38mm) long every 6”
(152mm) on center.
Stitch 3/8” (9.5mm) wide beads 1 1/2”
(38mm) long every 6” (152mm) on
center.
.25
SMAW/GMAW
Weld a 1/4” (6mm) bead across the
seam.
NOTES:
In all cases Splice Plate Welds are symmetrical on both sides of door.
All Splice Plate Welds are to be completed at time of installation.
Jamb and Push Tubes should be straight and square and welds should be completed before
installation of door.
Prequalified Weld Joints
AISC/AWS exempt from tests and qualifications most common welded
joints used in steel construction. Work on prequalified welded joints must
be in accordance with the most current Structural Welding Code.
Uprights should be straight and square and welds should be completed after door is installed.
70
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Pre-Install
Appendix
Appendix D - Low Power Wiring Diagram
Note:
When in doubt contact customer
services.
Hydroswing® North America reserves
the right to change and upgrade
specifications.
www.hydroswing.com
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UK +44 (0) 1772 563112
CANADA +1 647 534 3845
www.hydroswing.com
71
Wire Selection
Appendix E - Wiring Selection Table
Select the appropriate wire gauge for
you install from the chart based on the
your pump type and distance from the
transformer.
Pre-Install
Appendix
If the specifications for your install fall
between two gauges use the heavier
(lower number) of the two.
Using an improper wire gauge could
cause various problems including fire.
Single-Phase Motors 230 Volts
Hp
Conductor Sizes (AWG) for Various Motor
to Transformer Distances
Transformer
KVA
100 ft
150 ft
200 ft
300 ft
500 ft
(30.4m) (45.7m) (60.9m) (91.4m) (152.4m)
2
3
10
8
8
6
4
5
7.5
6
4
4
2
0
Three-Phase Motors 230 & 460 Volts
Hp
72
Motor
Volts
Transformer
KVA
Conductor Sizes (AWG) for Various Motor
to Transformer Distances
100 ft
150 ft
200 ft
300 ft
500 ft
(30.4m) (45.7m) (60.9m) (91.4m) (152.4m)
2
230
3
12
12
12
10
8
2
460
3
12
12
12
12
12
5
230
7.5
10
8
8
6
4
5
460
7.5
12
12
12
10
8
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GENERAL INFORMATION & NOTES
Pre-Install
Information
Appendix
REMEMBER TO REGISTER YOUR HYDROSWING® SINGLE PANEL HYDRAULIC DOOR WHICH WILL ACTIVATE YOUR
WARRANTY AND WE WILL ENSURE ANY PRODUCT UPDATE INFORMATION IS SENT TO YOU.
Please contact Hydroswing® North America for Registration Instructions:
www.hydroswing.com
USA +1 800 404 4937
UK +44 (0) 1772 563112
CANADA +1 647 534 3845
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73
Options available:
• CCTV camera to monitor outside of the
door prior to opening
Options & Contact Details
PRODUCT Certification:
• Audible warning alarm to operate while
the door is in motion
• ISO 9001 Certification and Inspections
Pre-Install
Appendix
Information
• Visual (flashing light) warning signal to
operate while the door is in motion
• Motion detectors on the sides of door
to stop door if activated by personnel or
a vehicle
• AWS D1.1 (American Welding Society)
• Hand pump for manual operation
• CE European Safety certification
• Cane bolts to lock the door to the floor
on the inside
• Personnel door within the main door
• UL Certified Controls and Pumps
• Vision panels Contact Details
Contact Us:
74
USA
(Region 1):
UK, EU, Africa, Russia, Middle East
(Region 2):
CANADA
(Region 3):
AUSTRALIA
(Region 4):
Hydroswing® North America Inc.
2100 Palomar Airport rd
Suite 210, Carlsbad CA 92011
UNITED STATES
Hydroswing® North America Inc.
The Hangar, Pinfold, Harbour
Lane, Salwick, Preston
UNITED KINGDOM
Phone: +1 800 404 4937
International: +1 760 438 4267
Phone: +44 (0) 1772 563112
Fax: +44 (0) 1772 556449
Hydroswing® Canada Limited
34 Eglinton Avenue West
Suite 126, Toronto
ONTARIO
M4R 1A1
CANADA
Phone: +1 647 534 3845
Leda Security Products Pty Ltd.
8/185 Briens Rd Northmead
NSW 2152
PO BOX 128 Wentworthville
NSW 2145
AUSTRALIA
Phone: + 61 2 8413 3410
Fax: + 61 2 8677 7119
Web: www.hydroswing.com
Email: enquires@hydroswing.com
www.hydroswing.co.uk
Email: enquires@hydroswing.com
www.hydroswing.ca
Email: enquires@hydroswing.com
www.ledasecurity.com.au
Email: enquires@hydroswing.com
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