Kopron KDR-CR Quick setup guide

RAISED DOCK SHELTER
LOGISTIC SOLUTIONS
ASSEMBLY, USE AND
MAINTENANCE MANUAL
OD. KDR-CR

Assembly, use and maintenance manual 3
INTRODUCTION
UNIT I DESCRIPTIONS
UNIT II IDENTIFICATION AND CONTROL
OF THE MATERIAL
UNIT III VERIFICATION OF THE MASONRY WORK
UNIT IV INSTRUCTIONS
UNIT V ENVIRONMENT POLLUTION
UNIT VI SPARE PARTS
UNIT VII SERVICE / GUARANTEE
GENERAL INDEX
gb
KOPRON
K
OP
R
ON
K
OP
R
ON
K
OP
R
ON
gb
KOPRON
KOPRON
KOPRON
KOPRON

Assembly, use and maintenance manual 4
INTRODUCTION
UNIT I - DE CRIPTION
CHAP. 1
1.1 DE CRIPTION OF RAI ED DOCK HELTER
1.2 IMPROPER U E
1.3 IDENTIFICATION PLATE
CHAP. 2
2.1 DIMEN IONAL DATA
UNIT II - IDENTIFICATION AND CONTROL OF THE MATERIAL
CHAP. 1
1.1 PREAMBLE
1.2 IDENTIFICATION AND CONTROL OF THE MATERIAL
UNIT III - VERIFICATION OF THE MA ONRY WORK
CHAP. 1
1.1 VERIFICATION OF THE MA ONRY WORK
UNIT IV - IN TRUCTION
CHAP. 1- TRAN PORT IN TRUCTION
1.1 GENERAL INDICATION
1.2 HANDLING IN TRUCTION
CHAP. 2 – IN TALLATION
2.1 BEFORE TARTING
2.2 DOCK HELTER A EMBLY
2.2.1 NOTE REGARDING U E OF THE DOWEL
2.3 LI T OF TOOL AND EQUIPMENT
2.4 REMOVING EXCEEDING MATERIAL
2.5 ENVIRONMENT CONDITION
CHAP. 3 - U E
3.1 RI K AND PROTECTION
3.2 FIRE PREVENTION
CHAP. 4 - ANOMALIE , MAINTENANCE AND REPAIR
4 1 PREVENTIVE MAINTENANCE AND PLANNED IN PECTION
4.2 NOTE ON THE EQUIPMENT TO BE U ED
CHAP. 5 - IN TRUCTION ON AFETY
5.1 OTHER RI K
5.2 MAINTENANCE IN TRUCTION
UNIT V - ENVIRONMENT POLLUTION
CHAP. 1 -
1.1 DI PO AL AND DI MANTELLING
UNIT VI - PARE PART
CHAP. 1 –
1.1 PARE PART
UNIT VII – ERVICE/ GARANTEE
CHAP. 1
1.1 PROCEDURE TO REQUE T A I TANCE
1.2 TERM AND CONDITION FOR INTERVENTION UNDER GUARANTEE
All drawings and technical characteristics may be subject to changes at any time,
should this occur we shall provide to update the manual as soon as possible.
Kopron .p.A.
page 5
7
7
8
9
10
10
12
13
13
14
15
16
23
23
23
24
24
25
25
26
27
28
28
29
29
SUMMARY

Assembly, use and maintenance manual 5
This manual is a guide for installers, users and maintenance personnel as well as
being useful for preventing accidents during life cycle of the equipment from instal-
lation to dismantling.
In case instructions are not clear or should particular problems arise and are not men-
tioned herein, please apply to our service department. Do not take personal initiati-
ves for interventions if instructions are not fully understood.
Buyer and personnel involved in installation should read this manual before using the
equipment. We would suggest to keep a copy of this manual handy in a place where
it can be easily consulted.
Assembly and installation must be carried out by qualified personnel adequately
equipped to operate in absolute safety condition. A dedicated chapter on risks will
face the matter in detail.
Preventive maintenance for solving anomalies must be programmed according to
regulations which require only specialized personnel to carry out interventions.
To have another copy of the manual you may contact our service department at the
following address:
.p.A.
via Primo Maggio s.n.
20064 Gorgonzola – Milan - Italy
'02 – 921 52. 1
KOPRON .p.A. have the right to update or improve the manual without affecting the
validity of this version.
Some important points have been highlighted by using symbols explained on next
page.
INTRODUCTION

Assembly, use and maintenance manual 6
SYMBOLS
DANGER – NOTICE
This sign indicates serious danger which must not be underestimated in order not to
risk people’s health and safety.
CAUTION
This sign indicates the requirement to be careful on how to move and act in order
not to risk people’s health and safety and cause economical damages.
IMPORTANT
This sign indicates technical information and important regulations to pay attention
to.
ECOLOGY
Remarks regarding ecology
PROHIBITION
If instructions contained in this manual are not strictly followed and original spare
parts are not used, or in case ordinary maintenance or non authorized interven-
tions are carried out Buyer will take his own responsabilties and guarantee will no
longer be valid.
Kopron .p.A.
INTRODUCTION
!





Assembly, use and maintenance manual 7
CHAPTER 1
DESCRIPTIONS
1.1 DESCRIPTION RAISED DOCK SHELTER
Raised dock shelters model KDR-C/R are particularly suitable for limiting tempera-
ture variation between inside and outside of the building during loading/unloading
operations.
The central bumper of KDR-C/R dock shelters can be adjusted in height in order to
adhere to the truck positioned on the loading bay.
Their use allows energy saving when either heating or airconditioning is functioning
inside the building. This model in particular has a hot-galvanized steel structure car-
rying flexible bumpers which can resist against front impacts of a truck.
The vehicle by leaning and pressing against the bumper creates thermal insulation.
Bumpers are made of polyurethane foam, minimum density 30 kg/m3, and the cover
sheet consists of a PVC fabric, weighing 800 gr/m2.
Side bumpers are equipped with wear an tear resistant inserts welded to the cover.
Dock shelters prevent the building structure to receive the thrust from the truck
impact.
The fabric of the bumpers is in tear resistant,Class 2 self-extinguishing PVC.
1.2 IMPROPER USE
The raised dock shelters have been specifically designed with the aim to create a
division between the outside of a building and the inside, by adhering to the truck
during loading/unloading operations. They cannot have a different application.
In case Buyers need to use them differently they must inform Kopron S.p.A. who in
case of authorization will suggest how to handle the product in the best way.
Improper use, and ignoring the instructions contained in this manual will imply
Buyer to take his own responsabilities and guarantee will no longer be valid.
UNIT I DESCRIPTIONS



Assembly, use and maintenance manual 8
1.3 IDENTIFICATION PLATE
A permanent identification plate is applied on the right flap as shown in the drawing.
The data on identification plate must always be kept clean and legible.
Should it be ruined and become no longer legibile it must be replaced.
In the request you must mention the model, year of manufacturing and serial num-
ber, data which can be easily found in the documents delivered along with the dock
shelter.
UNIT I DESCRIPTIONS


Assembly, use and maintenance manual 9
CHAPTER 2
TECHNICAL DATA
2.1 DIMENSIONAL DATA
KDR-C/R dock shelters have the possibility to adjust the height of the central bum-
per in order to adhere to the truck which is positioned on the loading bay.
The max height the bumper can reach from ground is of 4200 mm.
From this maximum height the dock shelter can lower the central bumper by 800
mm. This manual operation is facilitated when the bumper is balanced by means of
balance weights.
There are no fixed positions for the central bumper which can be positioned at any
height within the 800 mm.
UNIT I ISTRUCTIONS

Assembly, use and maintenance manual 10
CHAPTER 2
IDENTIFICATION AND CONTROL OF THE MATERIAL
1.1 PREAMBLE
Each shipment of dock shelters is made of one or more packages, in case of multi-
ple orders, already placed on pallets. Max size for each package is mm 1.100 x 3.600
x height 1.300. Each package can reach max 800 kgs.
Material contained in the packages is wrapped in plastic sheets.
All packages have a label carrying the order number.
In case of supply and delivery of more than one dock shelter it could happen to have
the coverings all in one package. uts, bolts and elastic strings can also be packed
all together in one package.
To verify the completeness of the supply we suggest to check all the packages.
If packages are to be stored, the warehouse must be sheltered and dry. Packages
must not be placed one on top of the other in order to avoid damages. Take care not
to damage the PVC fabric when cutting the plastic wrappings.
1.2 IDENTIFICATION AND CONTROL OF THE MATERIAL
Transport documents accompanying the delivery of the dock shelter also include a
packing list detailing the number of bolts, drilling screws necessary for assembly plus
dowels to fix the dock to the wall.
Upon receipt the material must go through inspection with the aid of the packing list
to verify completeness. In case of damages or missing items, written claim must be
made within seven days from delivery and sent through registered mail to Kopron
S.p.A. See drawing enclosed to better identify the details listed in the packing list.
IDENTIFICATION AND CONTROL OF THE MATERIAL



Assembly, use and maintenance manual 11
LIST OF COMPONENTS
IDENTIFICATION AND CONTROL OF THE MATERIAL
Top bumper
Left bumper
Right bumper
Metal rope Ø 4 mm
Balance weight
Eyebolt
Winch
ylon flat profiles
Angle steel 50x50x2
PVC sheet cover
Winch support
Clamp screws for metal rope
Metal rope thimble Ø 4 mm
1
2
3
4
5
6
7
9
11
13
12
10
8
9
10
11
13
3
4
2
5
6
7
8
12
1

CHAPTER 1
VERIFICATION OF THE MASONRY WORK
1.1 VERIFICATION OF THE MASONRY WORK
Before starting assembly you must check if the size of the door space is compatible
with the dock shelter.
Make sure that the external width and height of framework doesn’t prevent the fit-
ting of the door. Length and height of the dock are indicated in the drawing.
Make sure that bolts do not interfere with the electric cables, gas tubes, water pipe-
lines. Eventually you may use specific devices for detecting hidden cables.
Contact with a electric lines can cause fire or electric shocks.
Damaged gas tubes create high risk of explosion. Perforated water pipelines can
cause either damages to the material and/or electric shocks.
Verify with a technician of the Buyer that the carrying structure is suitable to bear the
weight of the dock shelter and the stress caused during working.
This verification must be carried out by a specialist. For any further problem you may
apply to the following Service Dpt in Kopron S.p.A. referring to the data contained in
the transport documents: '[phone] .1
UNIT III VERIFICATION OF THE MASONRY WORK
Assembly, use and maintenance manual 12

!

Assembly, use and maintenance manual 13
CHAPTER 1
INSTRUCTIONS REGARDING TRANSPORT
1.1 GENERAL INDICATIONS
The handling of the material, must be assigned to personnel trained to operate for-
klifts or other machinery used for lifting material
Safety measures must be undertaken to guarantee the stability of the machine and
of the material.
Should the forklift operator be unable to control the way during handling of goods
another person he must go before him and help.
ecessary conditions for lifting material is the perfect balancing of the goods.
The machinery used must be suitable to the volumes and weights to handle. During
operations you must keep an adequate speed and avoid swinging.
Do not leave for any reason the forklift with the material in lifted position. In case of
interruption of manoeuvres always lower the goods.
1.2 HANDLING INSTRUCTIONS
Each shipment of dock shelters is made of one or more packages in case of multi-
ple orders, already placed on pallets. Max size for each package is mm 1.100 x 3.600
x height 1.300. Each package can reach max 800 kgs.
Material contained in the packages is wrapped in plastic sheets.
The transport and handling of material must be by means of a forklift. Forks must
work as shown in the drawing.
o cranes must be used, bridle slings around the package would cause damages to
its contents.
Packages must not be placed one on top of the other in order to avoid damages.
If packages are to be stored, the warehouse must be sheltered and dry.
Take care not to damage the material when cutting the plastic wrappings.
UNIT IV INSTRUCTIONS


!

CHAPTER 2
INSTALLATION ASSEMBLY
2.1 BEFORE STARTING
Along with the delivery of material you may have, upon request, an envelope with
drawings and technical data regarding the supply, which in addition to the instruc-
tions contained in this manual are an aid for an easy, correct and safe assembly of
the dock shelters.
The envelope can also contain information regarding the positioning of the dock shel-
ter and other details on the technical/commercial agreement between Buyer and
Kopron S.p.A.
Therefore, do not start assembly before having read the contents of the envelope.
In case of doubts please apply to the Service Dpt in Kopron S.p.A. at the following
numbers, referring to the order number visible on the packages: '[phone] .1
Assembly must be carried out according to local regulations in force and by specia-
lized and skilled personnel.
Specialized personnel, in charge of the assembly, must be informed in advance about
the work to be done, the risks they may face in order to provide necessary tools and
take the measures for safety.
Assembly must not be carried out in strong windy days. A scaffold must be positio-
ned near the wall where the dock shelter is going to be assembled. Before beginning
work
mark off the working area by means of a white/red ribbon usually used in building
yards, and position warning signs which prohibit the passage of vehicles.
UNIT IV INSTRUCTIONS
Assembly, use and maintenance manual 14
!

Assembly, use and maintenance manual 15
2.2 ASSEMBLY OF THE DOCK SHELTER
Fixing points with dowels Hilti HSA M10 x 120
Divide the dimension which exceeds between the internal width of the dock shelter
and the width of the door in equal parts.
Position the bumpers taking care of their alignment which must be perfect and of spi-
rit levelling, then fix them.
Bumpers must be perfectly in parallel, this can be checked by measuring diagonals
which must be the same.
Please note that the bumper supports are in galvanized steel sheet, any operation
which could scratch off the protective coating, such as welding and grinding which
aret the most common, must be avoided. Protective coating is important to prevent
corrosion.
In doweling the bumpers make sure the holes do not interfere with electric wires, gas
tubes and water pipelines. Eventually you may use specific devices for detecting hid-
den cables.
Contact with electric wires can cause fire or electric shocks.
Damaged gas tubes create high risk of explosion. Perforated water pipelines can
cause either damages to the material and/or electric shocks.
UNIT IV INSTRUCTIONS
!

Assembly, use and maintenance manual 16
Jamb doweling
The drill insert must be of Ø
10 mm and at least 110 mm
long.
You must check the hole is
clean before positioning the
dowel.
The dowel must be positioned
in the hole in order to leave
the head thread out 2 o 3
mm.
Dowel the pulley supports strictly according to dimensions in the enclosed drawing.
Position the supports in the wall perfectly levelled in the two transverse longitudinal
axes.
.
UNIT IV INSTRUCTIONS

Assembly, use and maintenance manual 17
Doweling of the pulley supports
The drill insert must be of Ø 10 mm and at least 110 mm long.
You must check the hole is clean before positioning the dowel.
The dowel must be positioned in the hole in order to leave the head thread out 2 o 3
mm.
Fix at the back of the central bumper the system for anchoring the door closing fabric
UNIT IV INSTRUCTIONS
Closing fabric
ylon flat wires
Electric screwer
n. 10 tapping screws Ø 4,8 x 13 mm
Central bumper
1
2
3
4
5
3
4
2
5
1

Assembly, use and maintenance manual 18
Assemble the central bumper in between the two side
bumpers with the apposite guides.
Cut the two pieces of the metal rope measuring 2,5 m.
Connect one end of the rope, with a thimble and clamp
screw, to the eyebolt which supports the bumper, connect
the other end of the rope to the balance weight.
To connect the balance weight do not use thimbles, it is
enough to make a ring at the end of the rope with a clamp
screw.
Carry out connection on both sides of the bumper and
position the ropes in the pulley races .
UNIT IV INSTRUCTIONS
Central bumper
Male eyebolt
Thimble for metal rope Ø 4 mm
Side bumper
Pulley
Pulley support
Metal rope Ø 4 mm
Clamp screws
Screw M10x55 with self-locking nut
Balance weight
1
2
3
4
5
6
7
9
10
8
1
2
3
4
5
7
8
9
10
6

Assembly, use and maintenance manual 19
Fix the other side of the closing fabric to the head of the door by following the dra-
wing. First fix the fabric to the angle steel by means of the nylon flat wires and rivets.
Then dowel the angle steel to the head of the door.
UNIT IV INSTRUCTIONS
Closing fabric
n. 5 hammer-in anchor plugs Ø 6 x 50
Metal sheet 50 x 50x 2
Door head
ylon flat wires
n. 20 rivets Ø 3.2 x 10
1
2
3
4
5
6
Angle steel doweling of the loading bay
door.
Diameter of the drill insert must be of
Ø 6 mm and the depth must not be less
than 60 mm.
The hole must be clean before inserting
the dowel.
The hammer-in anchor plugs Ø 6 x 50
positioned at equal distance must be at
least 5.
1
2
3
4
3
5
6
1
6

Assembly, use and maintenance manual 20
Seal the angle steel border with sylicone.
Carry out balancing of the central bumper by moving from the holes the lifting eye-
bolts.
UNIT IV INSTRUCTIONS
Central bumper
Adjustable holes for balancing
Metal rope Ø 4 mm
Lifting eyebolts
Bumper sliding guides
1
2
3
4
5
2
1
5
4
3

Assembly, use and maintenance manual 21
2.2.1 NOTE ON THE USE OF DOWELS
UNIT IV INSTRUCTIONS
anchoring length 120 mm
Certifications ETA, Fire (IBMB and Warrington)
Basic material concrete block (solid, intact)
Environment conditions Inside dry
Type of anchoring Mechanical
Functioning principle Torque controlled expansion
Type of fixing Through-fastening, Pre-setting
Material Straight-carbon steel
Material coating Galvanized min. 5µm
Identific. length mark G
Minimum penetration depth 50 mm
-empty brick
Max diam. passing hole 12 mm
Insert diameter 10 mm
couple requested 30 m
Key size 17 mm
Total length 120 mm
Diam. thread (M) M10
Protection from corrosion Zinc plated to min. 5µm
ASSEMBLY
Drill a hole with insert Ø 10, hole depth 110 mm
Before inserting the dowel make sure the hole is perfectly clean.
Dowel HILTI - type HSA M 10 x 120. Article: 00255842