carport KDR Series Programming manual

HZ1077−E
Assemblingmanual
carportKDR-series

Constructionshallbeimplementedbyprofessionals.Problemsmayoccuriftheproductis
installedbysomeonewithouttheproperknowledge.
Notice Pleasebesuretoreturntheinstructionmanualinitsoriginalpackagetotheowner
afterexplainingproductoperationprocedures,maintenanceandinspectionmethods.
Electricdrill,Drill
Ratchetwrench,Adjustableendwrench
ElectricScrewdriver
Measure,Level,Plumbbob,Cutter,Pillar,Plastichammer
Foundationmaterials（Cement,Aggregate,etc）
Sealant,Caulkgun,pallet
CropperorSaw
Pleasepreparetoolsandmaterialsasneeded
NecessaryToolsandMaterialsForInstallation
PrecautionsDuringConstruction
Thecarportisasimplegarage.Donotchangeorremodelitforstorage,recreationalorresidentialpurposes.
Thisproductisforgeneralareas.Ithasasnowaccumulationstrengthof600N/m2(61.2kg/m2),which
correspondsto20cmofsnowfall.Donotinstallinheavysnowarea.
Donotinstallitintheplacewheresnowslidesdownfromthebuildingroofdirectly.
Wheninstallingitbesidesconcretewall,etc.,leavea10cmorlargergapbetweenthepostandthewalldueto
notclasheachotherduringstrongwind.
Besuretoprovideextrasupportpost(optional)wheninstallingitinstrongwindarea.
Wheninstallingitwithsidepanel,besuretosetupsupportpost.
Wheninstallingitwithsidepanel,recommendingtoinstallingitsfrontframeface
tothebuildingduetoreducethewindeffect.
Positioningthepostssothattheydonotaffectundergroundobjects(water
supply,drainpipes,etc.).
Whenmovingtheposts,pleasefollowthecompanyspecifications.
Followtheinstructionsandbesurethatallthespecifiedscrewsandboltsforassemblyaretightenedsecurely.
Donotuseanythingotherthanthespecifiedpartsoroptionalparts.
Thefoundationshouldcomplywithorexceeddimensionspecifications.
Allowsufficientcuringtimefortheconcrete(4to7days)anddonotplaceheavyobjectsonitorsubjectitto
vibrationsduringthecuringperiod.
Besuretokeepthenotebelowtopreventaluminummaterialscorrode.
⑴ Donotuseseasandforthefoundationsinceitcontainssaltandmaycausecorrosion.
Donotuseacementenhancer,water-reducingagentorcryoprotectant.Theymaycausethepoststocorrode.
⑵ Immediatelywipeoffanymortarorstainsfromthesurfaceofaluminumpartssincetheymaycausecorrosion.
⑶ Donotletaluminumpartscomeincontactwithothermetalssuchascopperoriron.Provideinsulationwith
vinyltape,bypainting,etc,.ifnecessary.Otherwisetheproductmaycorrode.
⑷ Besuretoprovidegravelforthefoundationtoallowdrainage,insertwaterdrainageholes(φ5)atthebaseof
thepostsandfoundation.Failuretodosomayleadtowateraccumulationinsidethepostsanddamagethemif
thewaterfreezesandexpandsinside.
Besuretoputthesealantglueasthefollowing.
⑴ Wipeoffanystainsfromthesealingpart.
⑵ Besuretoapplyasealant,asspecified.
⑶ Afterputtingthesealantglueontheholemadeinitsallwallbody,fullytightenthescrew.
⑷ Sealcompletelydeepenoughandfinishthesurfacewithapallet.
WhentheG.L（Groundline）issteep,besuretokeepthedepthofthepostatthelowestlevel.
Afterconstruction,checktheproductstoseeifthebolts,screws,nuts,etc.loosenoranydangerousplacesexist.
Besuretocheckiftheproducthasscratches,dentsordint.
Besuretoexplainproductoperationprocedures,maintenanceandinspectionmethodstotheowner.
PrecautionsDuringInstallation
enoughspace
spacemorethan10cm
concretewalletc
Thankyouverymuchforchoosingourcompany'sproducts.
Pleasebesuretothoroughlyreadtheseinstructionsforassemblyinorderto
properlyandsmoothlyassembleorattachthisproduct.

Dimension,PositionofPostsandBaseDimension
Dimension,PositionofPost
LengthDimension(W)andPostStandardPosition(postcouldbechangedasthedimensionof← →）
29size
58size
Standardtype Longtype Extra-Longtype
51size
DepthDimension（D） ,HeightDimension（H） 〔Depth20・24・27・30size〕

BaseDimension
ConcreteFloor
morethan morethan
morethan morethan morethan morethan
DepthDirection LengthDirection
DepthDirection LengthDirection
Theprojections
whichprevent
floatingat4rounds
steelrod
SolidGround
lncaseofusingstandardsizeinconcretefloor,pleaseinstallunderbelowcondition
１）Thicknessofconcretefloorismorethan100mm.
２）Steelrodandweldingwirenetarearrangedinconcretefloor.
３）Dimensionofprojectionwhichpreventsfloatingat4roundsismorethan50mm×50mm
４）Distance（A）fromoutsideedgeofbasetoaroundconcretefloorismorethandimensionspecifications.
Notice
Incaseof100KN/m2endurancestrengthofground
height28size
height28size
Incaseof50KN/m2endurancestrengthofground

Post・Beam・MainFrameList
PartsInstructionGuide
Pleasebenotedpost,beam,mainframeandcornerbracketaredifferentaccordingtothesizeofbody.
Besuretousethecorrectmaterialsincaseofconnectingthedifferentsizeofbody.
posttype
section
PartsID
section
PartsID
section
PartsID
beamtype
mainframetype
Ushapedgutter
1part
Ushapedgutter
1part
Ushapedgutter
1part
Ushapedgutter
1part
Ushaped
gutter
3parts
Ushaped
gutter 3parts
Ushapedgutter
1part
Ushaped
gutter
3parts
noUshaped
gutter
beamtype
mainframetype
type
bodysize
DepthD LengthW standardpost
extra-longpost longpost
post
componentparts

PartsContents
Pleaseopenthecaptionedcartonandcheckallcontentsinadvance.
Pleasecheckthepartsdefectiveoranydamage.
Wepackedsomeextrascrewinthepartsbox.（x）numberisnecessaryQ'tyforinstallation.
content
name quantity
PartsID shape
content
name quantity
PartsID shape
postset
（standardpost）
postset
（ longpost）
postset
（extralongpost）
post
instruction
manual
instruction
manual
instruction
manual
post
post
beam
frontframe
sideframe RightLeft
each1pc
end
roofretainer
roofretainer
drilling
screw
smalltruss
screw
smalltruss
screw
mainframe
gutter
roundgutter
beamset
lengthset
lengthset
depthset
roofpanel
cushion
roofrafter

corner
bracket
corner
partsset
roofpanel
polycarbonate
cornercap
tappingscrew
anchorrod
beamcap
frontframe
gutter
attachment
bracket
heatprotection
polycarbonate
polycarbonate
(mat）
roofpanel
set
partsbox partsbox
PartsContents
content
name quantity
PartsID shape
content
name quantity
PartsID shape
gasket
raingutter
cap
elbow
gutter
attachment
frontframe
cornercap
guttercorner
cap
fixbracket
seal
RightLeft
each1pc
RightLeft
each1pc
RightLeft
each2pcs drainelbow
saddle
hexagon
（withwasher,
springwasher）
drilling
screw
glue
cautionlabel
snowlabel
assembling
manual

InstallationProcedure
InstallationofPostandBeam
Connectbetweenpostandbeamwithcornerbracketand
fixwithhexagonboltM8×25
Installasthesidewhichthecaution
labelisattachedcomesinside.
hexagonbolt
（withwasher,springwasher）
（partsbox）
（cornerpartsset）
cornerbracket
anchorrod
（postset）
post
post
beam
beam
beamcap
（partsbox）
cautionlabel
InstallCornerCap
Attachthecornercaponthe
cornerbracket.
cornercap
（partsbox）
（partsbox）
tappingscrew
cornerbracket
InstallationtoBaseHole
①Insertpostintothebaseholeandfix
withsupportstandnottofalldown.
②Checkifitisflatandvertical,andcast
concrete.
supportstand
1

InstallationofGutterandFrontFrame
Putthelabel
Besureto
putthelabel
Screwthefixbracketonthepostand
fixthefrontframe,gutterattachment
bracketonthegutter.
Setthegutteronthefixbracketand
screwthegutteronthepostwiththe
attachment.
Andputthecautionlabelinside
thepost.
Setthegutteronthefixbracket
①InstallationofGutter
（partsbox）
（partsbox）
（partsbox）
（depthset）
（depthset）
（depthset）
（partsbox）
cautionlabel
snowlabel
attachedcautionlabel
drillingscrew
frontframe
gutterattachmentbracket
（partsbox）
frontframe
gutterattachmentbracket
fixbracket
post
post
gutter
gutter
smalltrussscrew
smalltrussscrew
fixbracket

Setthegutteronthefixbracket
②InstallationofFrontFrame
①
②
Screwthefrontframeandthegutterattachmentbracket
onthefrontframe.
Screwthefrontframeonthebeamwithfrontframe
gutterattachmentbracket.
（depthset）
（partsbox）
（partsbox）
（partsbox）
（partsbox）
（partsbox）
frontframe
gutterattachmentbracket
frontframe
gutterattachmentbracket
smalltrussscrew
smalltrussscrew
smalltrussscrew
fixbracket
beam
frontframe
fin
fin
seal
（partsbox）
seal
InstallationofGutterincasePostisMoved
InstallationofFrontFrameincasePostisMoved
①Accordingtothepostposition,puncturetheφ4.5holeonthe
gutterandscrewit.
②Putthesealontheunnecessaryhole.
①Accordingtothepostposition,puncturetheφ4.5holeonthe
frontframeandscrewit.
②Putthesealontheunnecessaryhole.
■FixingDrawing

Attachthefrontframeandgutteronthecap
attachedonthesideframe.
Dosealingworkattheconnectingpart.
step2
step2
sealingpart
sealingpart
Attachthefrontframecornercapandgutter
cornercaponthesideframe.
Whenscrewingthesideframe,besurenottonipthetight
rubberwiththescrewhead.
step1
step1
step1
step3
InstallationofSideFrame
InstallationofRoofPanelCushion
Attachtheroofpanelcushionsonthemark-offlines
oftopsideofallthemainframematerial
Aview
Aview
Attachtheroofpanel
cushionsonthe
higherfinside
Whenattachingthe
roofpanelcushion,
besurenottobe
comeoff
roofpanel
cushion
roofpanelcushion
main
frame
main
frame
mark-offlines
356.6
（endpart）
718
（middlepart） 718
（lengthset）
（partsbox）
（partsbox）
drillingscrew
（partsbox）
（partsbox）
（partsbox）
drillingscrew
tightrubber
drillingscrew
drillingscrew
drillingscrew
frontframecornercap
guttercornercap
gutter
makea3.0
holeonthecap
andscrew
（depthset）
（depthset）
（depthset）
frontframe
sideframe
sideframe
sideframe
guttercornercap

InstallationofMainFrame
Insertthemainframetothesideframe（finofthemainframecameto
gutterside）andscrewonthebeamusingtheguidehole.
Screwthesideframetothemainframe.
frontframe
side
frontframe
side
gutter
side
gutter
side
Whenscrewingthemainframe,besurenottonipthetight
rubberwiththescrewhead.
drillingscrew
drillingscrew
drillingscrew
guidehole
beam
beam
frontframe
mainframe
mainframe
fin
sideframe
gutter post
（depthset）
（depthset）
tightrubber
InstallationofMainFrameincasePostisMoved
SeetheUshapedgutterofthebeamandmaketheφ5.2holeonthemainframeandscrewitonthebody
（pictureA）.
Incaseofinstallingthemainframeotherthanpoststandardposition,putthesealontheunnecessaryhole
（pictureB）.
mainframe
mainframe
Ushapedgutter
Ushapedgutter
seal
（partsbox）

SealingofGutterCornerCap
Dosealingworkattheconnectingsideoftheguttercornercapandmaterial.
sealingpart
9
InstallationofRainGutter
rainguttercapinstallationside
raingutterinstallationside
Screwthegutterattachmentandgasketonthegutteranddosealingwork.
Usetheglueforraingutterparts.
Attachtherainguttercaponthegutteranddosealingwork.（fig.A）
sealing sealing
（fig.B,Cpartdetail）
rainguttercap
atthestandardpostposition
rainguttercap
installationside
raingutter
installationside
10
Thelengthoftheroundgutter（ℓ2）isdifferentaccording
tothepostposition.
Cuttotheproperlengthonsite.
type
type
type
InstallationofRoofRafter
（depthset）
drillingscrew
ForApart,screwusingtheguidehole.
ForBpart,seeUshapedgutterofthe
mainframeandscrewit.
Thisfigure
indicatesthe
frontframe.
roofrafter
roofrafter
roofrafter
frontframe
frontframe
front
frame
mainframe
mainframe
gutter
（gutter）
gutter
Bpartdetail
Apartdetail Apart
Apart
Bpart
Bpart
Bpart
Ushaped
gutter
8

Besuretodosealingworkaroundscrewsin
ordertopreventdangerwhencleaningaswell
asforwaterproof.
Notice
Whenusingthepolycarbonatemat（SI）,attachthe
unevennesssidedown.
Otherwisethepanelcolorischangedbysunlight.
Cpartdetaildrawing
sealing
sealing
rainguttercap
（partsbox）
（partsbox） （partsbox）
（partsbox）
（partsbox）
（partsbox）
（partsbox）
drillingscrew
（partsbox）
drillingscrew
drillingscrew
saddle
gasket
gutterattachment
gutter
elbow
drainelbow
Cpart
roundgutter
※Cuttheroundgutter
accordingly
（lengthset）
fig.B
fig.A
InstallationofPanel
BeforeInstallingPanel
Checkpostinterval,vertical,flat,anddiagonaldimensionofroof
（RegardingM-connecttype,adjustafterconnected）
Besurethatsealingofraingutterpartisfinished.
It'sdifficulttodosealingworkofraingutterpartafterinstallingpanel.
※Incasediagonaldimensionofroofdoesnotcomeout,loosethe
screwwhichfixgutter,mainframeandbeamandadjustthem.
post
postinterval,vertical,flat
post
11

Remark
Afterinstallingpanel,pullinthepanelstothe
frontframesideas③
Wheninstallingpanel,pleasebenoted
asbelow.
Sortthepanelequally
frontframe
frontframe
gutter
Attachthepanel
totheend.
sideframe roofrafter
A−A'cross-section
・Peeloffthecuringsheet.
・Insertthepanelintothefrontframeandtheninto
thegutter.
InstallationofRoofRetainer
（depthset）
（depthset）
Remark
・Ifthescrewofinstallingtheroofretainer
（middlepart）istightentoomuch,thescrew
willrunidle.
（tighteningtorquelessthan15kgf.cm）
・Ifthescrewheadleanswheninstallingtheroof
retainer,itwillcausewaterleakage（waterwill
enterfromthescrewheadclearance）,
Soinstallitnottomakeclearance.
Inserttheendroofretainerintothefrontframe
sideandseetheU-shapedgutteroftheside
frameandfixfromthefrontframeside.
Dosealingworkattheinsertpartofthe
roofretainer（endpart）.
Inserttheroofretainerintothefront
frameandfixfromthefrontframeside.
Insertuntilittouchesthe
roofpanelcushionofthe
frontframe
step1
step1
step2
step2
step3
step3
drillingscrew
drillingscrew
drillingscrew
roofretainer
roofretainer
roofretainer
endroofretainer
endroofretainer
roofretainer
sideframe
（top）
（bottom）
sideframe
smalltrussscrew
（withwasher）
smalltrussscrew
（withwasher）
sealing
Ushaped
gutter
gutter
InstallationDrawing
12

CuttingProceduresofDepthDirection
Incaseofcuttingdepthdirection,besuretocutfromthefrontframeside.
Accordingtothecuttinglengthoftheroof,cutandprocesseachmaterialsandpanels.
Benoticedthedirectionofthematerials.
CutRange
X=lessthan300mm（D＝27,30）
X=lessthan400mm（D＝24）
Cuttingthebeams
Cuttingthesideframes
Cuttingtheroofrafters
Cuttingtheroofretainers
Cuttingtheendroofretainers
Cuttingtheroofpanels
frontframe
side
frontframe
side
Roofcuttingdimension100mm
Roofcuttingdimension100mm
Cuttingdimension（mm）
Depth
Cuttingdimension（mm）
Depth
D20isnotavailable
Cuttingdimensionfomula
Depthdimension（D）
Thebelowindicatesthecuttingdimension（XA）incasethattheroofcuttingdimension
（X）is100mm.
Thebelowindicatesthecuttingdimension（XA）incasethattheroofcuttingdimension
（X）is100mm.
Decidethecuttingdimension（XA）bythecuttingdimensionfomula.
Decidethecuttingdimension（XA）bythecuttingdimensionfomula.
11×19cutting
1.BeamProcessing
2.SideFrameProcessing
notavailable
notavailable

frontframe
side
frontframe
side
frontframe
side
Cuttingdimension（mm）
Depth
Thebelowindicatesthecuttingdimension（XA）incasethattheroof
cuttingdimension（X）is100mm.
Decidethecuttingdimension（XA）bythecuttingdimensionfomula.
Cuttingdimension（mm） Depth
Thebelowindicatesthecuttingdimension（XA）incasethattheroof
cuttingdimension（X）is100mm.
Decidethecuttingdimension（XA）bythecuttingdimensionfomula.
Cuttingdimension（mm） Depth
Thebelowindicatesthecuttingdimension（XA）incasethattheroof
cuttingdimension（X）is100mm.
Decidethecuttingdimension（XA）bythecuttingdimensionfomula.
3.RoofRafterProcessing
5.EndRoofRetainerProcessing
φ5.5（U-shapedgutter）
φ4.2（U-shapedgutter）
φ5（U-shapedgutter）
4.RoofRetainerProcessing
Roofcuttingdimension100mm
Roofcuttingdimension100mm
Roofcuttingdimension100mm
notavailable
notavailable
notavailable

Afterprocessinginstallthebodyaccordingtothemanualof 〜 .
Cuttingdimension（mm）
Depth
Thebelowindicatesthecuttingdimension（XA）incasethattheroofcuttingdimension（X）is100mm.
Decidethecuttingdimension（XA）bythecuttingdimensionfomula.
6.RoofPanelCutting
Roofcuttingdimension100mm
notavailable
frontframe
side

CuttingProceduresofLengthDirection
Thepanelspanis718mm.Incaseofcuttinglengthdirection,cuttinglengthoftheroof（Y）inmultiplesof
718mmisrecommended.
Cutthematerialsfromoppositesideoftheroundgutterinstallation.
Movethepostasthesamelengthasthecutting
lengthoftheroof（Y）.
Cuttingofthefrontframes
Cuttingofthegutter
Cuttingofthemainframes
Cuttingofthepanels
1.FrontFrameProcessing
Cutthematerialsasthesamelengthasthecuttinglengthoftheroof（Y）.
φ3（U-shapedgutter）
Lengthdimension（W）
CutRange
Incasethecuttinglengthisless
thanIpanelpitch.
Y=B=lessthan650mm
Incasethecuttinglengthismore
thanIpanelpitch.
Y=718×n＋B
n=numberofpanelpitch
B=16mm〜650mm
Itcan'tbecutfrom465mmto
535mmforinstallinggasket.
※

Cutthematerialsasthesamelengthasthecuttinglengthoftheroof（Y）.
φ3（U-shapedgutter）
φ5（U-shapedgutter）
30（cuttingonside）
2.GutterProcessing
Cutthematerialsasthesamelengthasthecuttinglengthoftheroof（Y）.
CuttinglengthofroofpanelisassameasB.
φ3（U-shapedgutter）
21（cuttingonside）
3.MainFrameProcessing
4.RoofPanelProcessing
Afterprocessinginstallthebodyaccordingtothemanualof 〜 .

N10.02