TP-60-3 Parts and Svc Manual _rev11-21-06_.pdf

Mount new cables with anchor and cotterpins on bottom panel and bring cable stop end to top of door

CABLE REPLACEMENT PROCEDURE (WITH TENSION ON SPRING)

Securely clamp the track below the panel to be replaced to prevent the door from rising.

Close door from inside. Release spring tension from cables by fully inserting 1/2" diameter x 18" winding

Spring anchor plug and right-hand cable drum mount on curbside, 6-hole spring winding plug and left-

- Torque wheel nut

Close door from inside. Clamp counterbalance shaft with vise grip handle against ceiling to keep cables

Raise bar enough to allow inserting of second winding bar into lower hole and release tension to let

Cables come off front side of cable drums, between door face and header.

Insert the cable stop end into the cable drum slot. Thread the cable into the groove nearest the slot and

Drill out rivets on hinge halves of the panel to be replaced and pry the hinge half loose.

Release spring tension from shaft by fully inserting 1/2" diameter x 18" winding bar into one of the spring

Lift the door panels above the panel to be replaced into the horizontal track and secure with vise grips

Maintaining tension on the cable, slide the cable drum on the counterbalance shaft against the bearing

Loosen set screws on cable drums, releasing cable drum from shaft, remove cable(s) from cable drum(s).

After loosening spring winding plug set screws, use both winding bars to add (lift up) or remove (lower

Vise grip clamps against lower header flange to keep cables tight while winding spring.

After adjusting the spring tension, properly tighten set screws onthe spring winding plug and remove vise

Remove the old panel, line up the new one and drill all of the hinge holes on the bottomof the new panel.

Removecable(s) from door bottom panel by removing anchor and

Clamp counterbalance shaft with vise grip handle against ceiling to keep cables tight. (Fig. 3)

Counterbalance spring winds downward.

Remove cable(s) from door bottom panel by removing anchor and CAUTION:Raising

Insert bolts in the holes, install the hinges over the bolts and tighten the nuts.

Repeat cable mounting procedure for opposite side, making sure drums are against bearings, set screws

Cable anchors are mounted at 4-1/8" from panel edge to centerline.

Lower the door from the horizontals and drill all the holes in top of the panel.

Counterbalance shaft length isopening width minus 1-1/8".

000 miles or Consult axle maintenance for the following:

Determine the number of winds needed for the counterbalance spring by dividing the door opening height

Mount new cables with anchor and cotter pins on bottom panel and or damage to

Run a chalk mark the full length of the counterbalance spring (Fig. 1). Leavevise grips clamped to the

Insert the cable stop end into the cable drum slot. Thread the cable 5 must be done by

Treat the electrical system as you would the chassis. Lubricate sockets, pigtails, battery

Check electrical harness

With the upper door section clamped so it will not fall, tip the paneltoward you to insert the bolts. Install

Maintaining tension on the cable, slide the cable drum on the winding bar in place.

The replacement of the panel is now complete.

Fully insert 1/2" diameter by 18" winding bar into one of the spring winding plug holes. Loosen set screws

Check all fasteners

Inspect for improper ground connections. This is a major cause of lamp failure, especially

Always replace wiring, trailer light cables, and harnesses with an equal or heavier

Repeat cable mounting procedure for opposite side, making suredrums are against bearings,

Check rear bumper and fasteners

Release spring tension by rotating spring windingplug just far enough to allow removal of winding bar

Check Kemlite roof for damage

Inspect the grommets that house the lamps. As they age, they eventually will deteriorate

Lubricate the counterbalance, bearings, rollers, hinges and lock liberally with TODCO Lube. Do not use grease.

Apply the cleaner, working it across the surface in a scrubbing or circular motion. Rinse thoroughly to remove all

Lube or any petroleum-based lubricant on rubber door seals. Please refer to serial number for replacement parts.

INTERMEDIATE AND TOP PANEL REPLACEMENT