Western Shelter Systems WS-1935 User manual

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WS/GK-1935
Primary Field Shelter

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TABLE OF CONTENTS CONDITIONAL WARRANTY
Western Shelter Systems warrants all products
against defects in materials or workmanship
for a period of one (1) year from date of
manufacture. Component manufacturers’
warranties may exceed that of Western
Shelter.
No warranty is made or implied regarding the
intended use of the product. Warranty does
not cover damage caused by abuse, misuse,
neglect or improper care by the end user in the
application of the Western Shelter Systems
product.
Western Shelter Systems will repair or replace
any component deemed to be faulty from
manufacture in the most ecient and timely
means available to Western Shelter Systems.
Western Shelter Systems must authorize all
claims prior to any action taken by the end
user.
For immediate attention regarding any
defective product, please phone Customer
Support at 1-800-971-7201, 7am-330pm PST.
Shipping: 815 Conger St. Eugene, OR 97402
PO Box 2729 Eugene, OR 97402 USA
Phone [phone]
Toll Free 1-800-971-7201
Fax [phone]
www.WesternShelter.com
A. Warnings 3
B. Shelter Specifications 4
C. Component List 4
D. Erecting the Shelter 5
1. Unpacking the Shelter 6
2. End Frame Assembly 6
3. Center Frame Assemby 6
4. Roof Assembly 7
5. Raising the Frame 8
6. Floor and Basebars 8
7. Hanging the Doors 9
8. Hanging Shelter Walls 9
9. High Wind Tiedowns 10
10. Finishing the Shelter 11
E. Striking the Shelter 12
1. Removing Wall Panels 12
2. Folding Wall Panels 12
3. Folding Floor Panels 13
4. Lowering the Frame 14
5. Removing Vent Caps 14
6. Folding Roof Panels 14
7. Striking the Frame 16
F. Troubleshooting 17
1. Frame Connections 17
2. Wall Panels 17
3. Roof Panels 17
4. Torn or Worn Vinyl 17
5. Parts will not fit in case 17
G. Tips, Care, and Repair 18
1. Vinyl Panels 18
2. Insulation Panels 18
3. Mainframe and Bars 18
4. Hinges and Pull-Pins 18
5. Cases and Lids 18
6. Vinyl Repair 19
7. Replacement Parts 19

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All flammable materials or other
items that are potential fire
hazards must not be placed on or
adjacent to the Shelter.
Pinch hazard: Always wear gloves
when raising or striking the
shelter. Setup entails working
with rigid metal components
bearing significant weight.
A. WARNINGS
Follow all written and common sense safety procedures when raising, striking, and
occupying this shelter. Failure to do so may result in property damage or personal
injury.

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Frame Specifications
All-aluminum frame constructed of 6063-
T5 and 6061-T6 alloys with clear industrial
anodized support members.
Octagonal frame configuration, pivoting from a
central fixture. Roof trusses and uprights shall
be one assembly.
Eave bars and base bars shall lock and unlock
into the mainframe with integral spring-loaded
buttons, requiring no tools for assembly. Eave
bars and base bars shall have a clear anodized
finish.
Eave bars shall be of an extruded design to
accommodate rigid hook-and-loop fastening
strips for the attachment of roof and sidewalls.
Upright legs shall lock either up or down with a
steel captive locking pin. Legs shall have a flat
foot with provisions for securing to the ground
or floor surface. Legs shall provide a full 6-foot
sidewall.
The frame assembly shall include vented
weather caps.
Doors shall be aluminum framed and fabric
covered.
Cover Specifications
The entire cover shall be of 14-oz vinyl-covered
polyester scrim.
The material shall meet NFPA-701 standards
for fire resistance.
The material shall contain ultra-violet ray and
mildew inhibitors.
Roof panel sections shall be thermo-welded to
insure against leakage.
All fabric security to the frame shall be by the
hook-and-loop fastening process.
B. SHELTER SPECIFICATIONS

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C. COMPONENT LIST
GK1935, basic configuration:
1. Mainframe end sections (2)
2. Mainframe center section (1)
3. Eave bars with fastening strips (12)
4. Base bars without fastening strips (12)
5. Plastic vent caps (2)
6. Double doors (2)
7. Threshold ramps (2)
8. Vinyl roof panel (1)
9. Insulated roof panel (1) not pictured
10. Vinyl wall panels (4)
11. Vinyl floor panel (1)
12. High wind stake kit with straps (1) not pictured
GK1935, common accessories:
1. Insulated wall panels (4)
2. Fluorescent lights with dimmer sleeves (7)
3. Wiring harness (4)

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D. ERECTING THE GK SHELTER
1. Unpack and inventory shelter components
ØIn a clear staging area, unpack and inventory
the shelter components. Check components
against case labels or the component list in
this manual to ensure you have all required
parts.
ØNote: Component list reflects one GK1935
shelter in its basic configuration. Your shelter
system may include additional fixtures or
accessories.
2. Mainframe end section assembly
ØLocate and prepare your shelter site. Stand
up one mainframe end section at one end of
the shelter site. Loosen the web strap from
around its base.
ØOrient the open slot on the key flange
(without a roof truss) toward the opposite
end of the shelter site.
ØOpen up the mainframe until the trusses are
fully unfolded.
ØThis is best accomplished with three people,
each holding two trusses.
ØDepress the locking button on the underside
of each truss to extend them. The lower
locking button will snap into place when the
trusses have reached their full extension.
ØSecure five eave bars between the roof
trusses, with the black fastening strip facing
out. If the shelter is on
uneven ground, you may
have to adjust the frame
slightly to get a fit.
ØRepeat the above steps
to erect the second end
section, facing the first, at
the opposite end of the shelter site.
3. Mainframe center section assembly
ØAttach eave bars to the two corner blocks on
one of the mainframe end sections.
ØWith three people, move the second end
section to meet the first. Line up the eave
bars with the open corner blocks on the
second section.
ØJoin the two sections.

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ØPosition the main frame center section
between the two end sections.
ØThe center section has six trusses, four
telescoping and two fixed. Orient the center
section so that the two fixed trusses are
pointed toward the end sections.
ØUse the captive locking pins to connect the
center section to the key flanges.
ØPartially extend the four telescoping roof
trusses of the center section. They slip over
the center eave bars and share the same
locking buttons. Adjust the frame slightly if
the buttons do not pop back into place.
ØLift the center section until the locking
buttons on all four telescoping roof trusses
snap into place.
ØTo drop the shelter legs, gently squeeze the
folded legs and roof trusses together to
loosen their captive locking pins. Remove the
pins and gently lower all the shelter legs to
the ground. Do not stand up the shelter at
this point.
4. Roof assembly
ØRemove the insulated roof panel from its bag
and place it on the center ridge line of the
frame.
ØUnfold the panel along the ridge line, toward
the key flange on each mainframe end
section. Position the holes in either end of the
panel over the key flange pipes.
ØIf setting up in windy conditions, unroll the
side of the insulated panel facing into the
wind first.
ØRemove the vinyl roof panel from its bag and
place it on the center ridge line of the frame.
Unfold the roof panel along the ridge line,
toward each of the two key flanges.

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ØDo not secure either of the roof panels to the
eave bars at this point.
ØPosition one of the the vent collars of the roof
panel over each key flange pipe.
ØRemove the protective vinyl squares covering
the vent collars. Return these squares to the
field bag; they will be needed again when the
roof is repacked.
ØMake sure both collars are centered on their
respective key flange pipes.
ØTo install the vent caps, pull on the locking pin,
align the cap with the flange pipe and push
the cap down until it meets the collar. Release
the pin and rotate the vent cap until the pin
snaps into place.
ØUnroll the insulated and vinyl roof panels and
lightly attach the fastening strips around the
eave bars to prevent wind from displacing the
roof.
5. Raising the frame
ØWith three people evenly spaced along one
long side of the shelter frame, gently raise
that side, allowing the legs to fold outward. Be
sure to keep fingers clear of the leg hinges as
they unfold. If setting up in windy conditions,
raise the windward side first.
ØLock the four long-side legs into place using
the captive locking pins. Do not lock the
short-side legs at this time.
ØRaise the other side of the shelter, allowing
the legs to fold down. Lock the four long-side
legs into place.
ØNow extend and lock the short-side legs into
place, using the captive locking pins.
6. The floor and basebars
ØThe floor panel is designed to form a weather-
tight seal with the vinyl walls, protecting the
shelter interior against wind and moisture.
ØUnroll the floor panel down the length of the
shelter.
ØUnfold the floor panel. Ensure that the black
fastening strips of the floor are facing up.
Center the floor around the perimeter within
the shelter frame.

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ØWorking around the
perimeter of the
shelter, gently lift the
frame and pull the
floor panel under it.
Center the shelter legs
on the vinyl welds at
each corner.
ØAttach all base bars to
the lower legs. You may
have to lift or adjust
the frame to find a fit.
Be sure to keep the
floor flat and tight
while installing the
base bars. The frame
will adjust to its true shape as the base bars
are locked into position.
7. Hanging the doors
ØThe GK1935 shelter includes two double
doors, which can be installed on either the
long or short sides of the frame.
ØRemove the door from its protective vinyl bag.
Detach the insulated and vinyl roof panel from
the eave bar where you will install the door.
ØUnfold the door and hook it over the desired
eave bar. The bottom of the door fits over the
base bar. Make sure both top and bottom of
the doorframe are firmly attached.
ØCenter the door frame by aligning the center
of the frame with the “center door” sticker on
the eave bar.
ØOpen the door completely and install the
threshold ramp. It will fit snugly over the
doorframe.
ØReattach the insulated roof panel to the
doorframe. Align the seam in the insulated
roof panel with the center of the doorframe.
ØRepeat for the other door on the opposite
side of the shelter.
8. Hanging shelter walls
ØAttach the insulated roof panel to the eave
bars using the fastening strips. Align the
center seams on the insulation panel with the
center door label on eave bars. The insulation
panel should completely and evenly overlap
the eaves by about ½ inch.
ØDo not attach the vinyl roof at this time. It will
be attached after the walls are installed.

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ØGateKeeper walls are composed of four
sections. Each is labeled “Right of Door” or
“Left of Door,” referring to the position of the
panel when viewed from outside the shelter,
facing the door.
ØIf your shelter includes insulated wall panels,
hang them first. The procedure is identical for
both vinyl and insulated walls.
ØLoosely attach one
end of a wall panel
to the door frame.
Leave some overlap
on the door so the wall
will be easier to align
later. Work around the
shelter, tacking the
wall up loosely. Get the
entire wall tacked up loosely before you begin
to tighten it.
ØStarting at the
door, align the black
fastening strip on
the wall with the
corresponding strip
on the door. In small
sections, pull the wall
panel as tightly as
possible around the
shelter. When complete, repeat this process
with the other three panels.
ØThe wall panels end
in a large fastening
strip. Each pair of
wall sections should
overlap somewhat,
but complete overlap
is not necessary. Pull
the two wall sections
together as tightly as possible. You may have
to go around and retighten the wall panels
to ensure a good fit. The tighter the fit, the
stronger and quieter the shelter.
ØIf you have just
installed your insulated
wall panels, repeat the
above steps for the
vinyl wall panels. If you
just installed the vinyl
wall panels, move on to
the next step.
ØPull the vinyl roof panel
down over the vinyl
wall panels, aligning
the seams in the vinyl
roof panel with the
roof trusses. Start at
the corners, pulling
down firming to get a
good attachment. Then
secure the middle of
each wall section and
work back toward the
corners.
9. High-wind tiedowns
ØThe high-wind tiedowns can now be hooked
onto the shelter legs. Always stake down your
shelter, even if you do not anticipate windy
conditions.
ØDetach just the corner
of the vinyl roof panel
where you will install
the tiedown. It is easy
to misalign the tiedown
hooks, so ensure they

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go all the way over the two eave bars and to
either side of the shelter leg. The hook will fit
snugly without a gap when fitted properly.
ØAttach the tiedown strap to a stake, water
barrel, sandbag, or
other solid object.
Apply light tension
to the strap, lock the
tensioning mechanism,
then pull tight.
ØClip the small attached
hook to the metal D-
ring on the corner of
the vinyl roof panel.
ØSecure the extra length
of strap with small
fastening strip.
10. Finishing the shelter
ØA series of straps are
attached to the bottom
of each wall panel. Working from inside the
shelter, thread these straps under the nearest
base bar and connect. Continue around the
shelter.
ØSecure the double-D ring wall straps by each
door. First buckle the strap, then thread the
strap through the d-rings and pull tight.
ØAttach the fastening strip on either side of
the door to form a seal under the threshold
ramp.
ØOutside the shelter, create a burm in the floor
using the black straps located at each corner
of the floor.
ØAttach the floor to the fastening strips on
base of each wall panel to those on the floor.
It is not necessary to pull the wall and floor
together tightly.

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ØThe GK1935 must be repacked properly
and in a certain order to ensure the shelter
is ready for deployment the next time it is
needed.
ØClean and dry all wall, roof, and floor panels
before folding and bagging them for storage.
If this is not practical in the field, all panels
should be unpacked, cleaned, dried, and
repacked as soon as possible.
1. Remove wall panels
ØWorking around the inside perimeter of
the shelter floor, unsnap the web straps
connecting the walls to the frame and thread
them back under the frame.
ØSeparate the fastening strip connecting the
walls to the floor.
ØWorking around the outside perimeter of the
roof, separate the fastening strip connecting
the roof to the vinyl walls.
ØUnbuckle the corner retaining straps so the
floor panel lays flat.
ØStarting at one of the doors, pull the vinyl
wall panels away from the shelter. Fold them
hand over hand to prevent the panels from
touching the ground. As you remove panels,
place them on the shelter floor for folding.
ØRemove the four vinyl panels and four
insulated panels (if included) and place them
inside the shelter.
ØRemove doors from the frame, fold in half, and
return them to their bags.
2. Fold wall panels
ØAll GK1935 wall panels are the same size and
are folded the same way. Repeat the following
procedure for each of the shelter’s four wall
vinyl panels.
ØWestern Shelter Systems recommends folding
wall panels on the shelter floor.
ØBegin with the wall panel spread flat, with the
exterior facing up.
ØMake sure window and duct panels are
securely fastened.
ØFold up the lower third of the wall panel (with
the floor straps).
ØFold the lower half of the wall panel up over
the top half.
E. STRIKING THE GK SHELTER

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ØStarting at the end opposite from the “right
of door” or “left of door” label, roll up the wall
panel tightly.
ØContinue rolling until the wall section is in one
compact package. Fold the remaining three
vinyl wall panels in the same way, Return
the wall panels to their labeled field bags for
transport and storage.
ØThe insulated wall panels are folded in a
similar way, except you will want to start with
the interior (white) side of insulation facing
upwards. Then fold in thirds starting from
the bottom edge, and roll up identically to the
vinyl walls. Return the insulated wall panels to
their vinyl storage bags.
3. Fold floor panel
ØRemove and set aside all the shelter base
bars.
ØMove the shelter legs o of the floor, so it can
be folded freely.
ØBegin with the floor spread flat.
ØFold both shorter sides of the floor toward
the middle to form a rectangle, as pictured.
ØFold in the two longer sides so they meet in
the middle of the floor.

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ØFold the sides to the middle again.
ØFold the sides to the middle a third time.
ØFold one side over the opposite side.
ØWorking from both ends, fold up the floor
panel in arm-length sections until they meet
in the middle. Fold one end over the other to
finish folding the floor.
ØPlace the folded floor panel in its field bag for
storage and transport.
4. Lowering the frame
ØRemove the captive locking pins from the four
legs at the shorter ends of the shelter.
ØFold the four unlocked legs up and nest them
together against the roof truss. Squeeze the
leg and roof truss together to make it easier
to insert the locking pin. Replace the captive
pin to lock them in place. The ends of the
frame will sag, but the does not damage the
frame.
ØWith four people evenly spaced along a long
side of the shelter frame, remove the captive
locking pins from the four legs on that side.
Gently lower it to the ground. If conditions are
windy, lower the upwind side first.
ØRemove the captive locking pins from the legs
on the other side of the frame, and gently
lower it to the ground.
5. Remove vent caps
ØWorking around the perimeter of the shelter,
separate the insulated roof panel from the
frame. Push the roof panels up the frame so
you can access the vent caps.
ØPull out on the locking pin and lift the vent
caps o their key flanges. Return them to
their cases for transport and storage.
ØTo prevent damage to the roof fabric, replace
the protective vinyl squares on top of the vent
collars.
6. Fold roof panels
ØBoth roof panels are folded the same way.
Repeat the folding procedure for both vinyl
and insulated roof panels.
ØWestern Shelter Systems recommends folding
the roof panels while still on the frame. This
method will be easier, and gentler to the roof
panels than moving them elsewhere.
ØBegin with the panels rolled fully down the
frame.

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ØFold both shorter sides of the roof panel over
the vent collars to form a rectangle.
ØFold both shorter ends up to the vent collars
again.
ØFold one longer side approximately 6 inches
over the centerline of the roof panel, so it
covers the vent collars.
ØFold the same side over itself.
ØFold the same side over itself again.
ØFold the opposite side up, making it flush with
the side you have already folded.
ØFold the same side over itself.
ØFold the same side over itself again.
ØFold the same side over the top, making a
single roll with the vent collars centered on
the bottom.
ØBegin folding both ends toward the center in
arm-length sections.
ØAt the last fold, bring one end of the panel up
over the opposite end to form one complete
package.
ØPlace the folded panel in its field bag for
transport and storage.
ØThe insulated roof panel folds in the same
manner.

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7. Strike the Frame
ØTraveling around the perimeter of the frame,
nest and hold each leg bar up against its roof
truss. While squeezing the leg and roof truss
together, insert the locking pin to lock them
together.
ØA locking button is located on the underside
of each of the four telescoping roof trusses
on the mainframe center section. Depress
these buttons to create slack on the trusses.
ØDetach the four center telescoping trusses
from the eave bars. Compress the trusses.
ØRemove the captive locking pins connecting
the center section to the end sections.
ØGather all of the trusses together, and stand
the center section up. Tighten the strap
around its base to secure the trusses. To help
the frame fit better, you may stagger the
trusses slightly, so they fold up tighter.
ØRemove all eave bars from the mainframe.
Place them in a field bag or case.
ØOn both mainframe end sections, depress
the lower locking button on the underside of
each roof truss. Slide the trusses back toward
the key flange and depress the upper locking
buttons to secure them in place.
ØNest the trusses together and stand each
mainframe end section up. Tighten a securing
strap around the base of each.
ØPlace the mainframe end sections and the
center section in their field bags for transport
and storage.
ØStorage cases and bags vary depending on
your specific setup. Please refer to the printed
labels for each case’s content.

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F. TROUBLESHOOTING
1. A frame connection will not click into place.
ØBe sure the connection point is free of debris.
ØGently lift the frame to allow it to find a
natural resting position. Lifting to relieve
pressure on the connections allows them to
fit more easily.
ØFirmly tap the connection point with your
palm.
ØIf a button lock is not popping up, try flexing
the frame in various directions until it clicks
into place.
ØDo not use liquid-based lubricants on frame
connections, as this will attract more dust and
debris, making the connection less functional
in the future. Compressed air may be used if
necessary to clean connection points.
2. Wall panels will not meet in the center.
ØVinyl stretches to varying degrees depending
on ambient temperature. The centers of
the wall panels may not fully overlap in all
conditions, but it should be possible to overlap
the walls somewhat in all conditions.
ØIf the wall sections are not meeting, re-
stretch the vinyl starting from the doorframe.
Stretch the vinyl in small sections as you work
along the wall.
ØAfter several years, vinyl ages and can harden
and lose its elasticity. Eventually, the vinyl walls
of your shelter may need to be replaced if
they are not stretching enough to complete
the shelter.
3. Roof panel will not fit fully over the frame
ØWhen securing the roof panel, start by
securing opposite corners of the roof panel
first. Be sure the roof collars are centered on
the key flanges.
ØAs vinyl ages it can harden and lose its
elasticity. Eventually, the vinyl walls of your
shelter may need to be replaced if they
are cracking or not stretching enough to
complete the shelter.
4. Torn or worn-out vinyl
ØSee the Vinyl Repair section (page 20) for
information on how to fix minor tears and
holes in your vinyl panels.
5. Shelter components will not fit in their
cases.
ØMoisture or dirt can add volume to the walls,
floor and roof of the shelter. Be sure all
surfaces are as clean as possible under the
conditions.
ØPush as much air as possible out of the walls,
roof, and floor as you are folding them.
ØPack rigid items, such as base bars, in the
bottom of cases, then fit softer items around
them.
ØTry changing the orientation of bulky
components, such as the end frame
assemblies.
ØHave several people put their weight on the
case lid and secure the latches.

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G. TIPS, CARE, AND REPAIR
ØWestern Shelter Systems provides protective
bags for shipping and storage. Do not drag
these bags on the ground.
ØReplacing the components in the proper
bags or aluminum cases ensures all parts
are accounted for and ready for the next
deployment.
ØCleaning and drying of your shelter system
will extend the life of the shelter and eliminate
health issues associated with particulate
buildup. Maintenance is best performed when
the shelter is being taken down. If the shelter
must be packed when wet and/or dusty, It is
VERY important that the shelter is cleaned
and dried as soon as possible.
ØUtilize the following steps to ensure that
proper care and maintenance has been
performed.
1. Vinyl Panels (roof, walls, and floor)
qClean and fold on a clean surface, such as the
shelter floor. Sweep o loose debris. Remove
debris from hook and loop fasteners using a
rigid brush.
qClean with a mild solution such as Simple
Green™, Tilex™, or 10% bleach water solution.
qDo not saturate the fabric, especially the
hook and loop fastener, which tends to retain
water even after prolonged drying times.
qDry thoroughly using towels, leaf blowers or
sunlight.
2 Insulation Panels (roof & walls)
qClean and fold on a clean surface, such as the
shelter floor. Sweep o loose debris. Remove
debris from hook and loop fasteners using a
rigid brush.
qClean with a mild solution such as Simple
Green™, Tilex™, or 10% bleach water solution.
qDo not saturate the fabric, especially the
hook and loop fastener, which tends to retain
water even after prolonged drying times.
qDo not spray cleaner directly on fabric as it
could soak into the air bubbles on the fabric,
leading to mold and mildew. Spray cleaner on
shop towels and wipe to clean.
qNever pressure wash the insulation panels.
qDry thoroughly using towels, leaf blowers or
sunlight.
ØNote: Stains can occur on the white insulation
fabric. These stains, once cleaned, are purely
cosmetic and do not indicate product failure
or health risks.
3. Main Frame, Eave & Base Bars
qBrush o loose debris. Clean dirt and debris
out of the ends of the bars and legs. Wipe
down with a mild solution such as Simple
Green™, Tilex™ or a 10% bleach water
solution.
qDry thoroughly using towels, leaf blowers or
sunlight.
4. Hinge Points & Pull Pins
qKeep moving parts free of debris and dust.
Disassemble and clean if binding occurs.
qDo not use liquid lubricant on moving parts,
as this will cause fouling.

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5. Product Cases & Lids
qBrush o loose debris. Wipe down with a mild
solution such as Simple Green™, Tilex™ or a
10% bleach water solution.
qDry thoroughly using towels, leaf blowers or
sunlight, making sure to remove and dry any
padding material installed in the bottom of
the case.
qClean dirt and debris out.
6. Vinyl Repair
ØAll units come standard with a vinyl repair kit.
Each kit contains a can of vinyl cement and a
supply of patching material.
qTo repair a damaged area, thoroughly clean
with soap and water.
qAllow to dry completely.
qCut out a piece of vinyl fabric slightly larger
than the damaged area.
qOnce completely dry, apply a liberal amount
of vinyl cement to both the repair area and
the patch.
qAllow the cement to become dry to the touch
and place the patch over the damaged area.
Press the patch firmly to ensure complete
contact.
7. Replacement Parts and Accessories
ØWestern Shelter Systems oers a full line of
replacement parts, as well as a wide range
of optional accessories for all GateKeeper
shelters. To view accessories, visit www.
westernshelter.com

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Shipping: 815 Conger St. Eugene, OR 97402
PO Box 2729 Eugene, OR 97402 USA
Phone [phone] • Toll Free 1-800-971-7201
Fax [phone] • www.WesternShelter.com