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Roll-up doors are becoming increasingly common among box trucks. Unlike traditional swing doors, roll-up doors take up almost no space when opened. However, the downside is that these types of doors consist of smaller moving parts. From the panels to the individual rollers, these components must synchronize with each other to ensure smooth operation. If any of these parts fail due to damage, wear, or a factory defect, it will most likely render the entire assembly unable to open, close, or lock properly.

COMMON ROLL-UP PROBLEMS

Box truck roll-up doors are designed for frequent operation in demanding work environments; however, certain parts are more prone to abuse and wear, making them more susceptible to damage. These issues are often categorized alongside typical mechanical failures that fleet operators face daily. These include the following:

Tracks

Modern roll-up doors have tracks guiding the door to ensure proper alignment with the latch and prevent it from swinging. If any part of the track gets dented, bent, or obstructed, the door panels may not roll up or down properly.

Hinges

Hinges also tend to come apart if installed incorrectly or because of a manufacturing defect that was not detected and corrected. This can prevent the door from locking or closing correctly, or damage other parts of the door.

Springs

Roll-up doors also use a set of springs to make the rolling mechanism smoother and more manageable. Exposure to dirt and moisture can cause the springs to become brittle, compromising their function. In severe cases, the spring may crack or break apart entirely.

Rollers

Rollers in roll-up doors are designed to be highly durable, so they don’t wear out as often as the previous parts we’ve mentioned. However, they also tend to get clogged over time by dirt, mud, and debris. If the obstruction is substantial enough, the roller may lose its alignment, become stuck, or completely dislodge from its guide. Rollers also tend to lose their lubrication over time, resulting in squeaking or grinding noises as well as making it harder to pull the door down.

MAINTENANCE TIPS

Broken truck roll-up doors should never be ignored. Aside from being inconvenient, a faulty roll-up door compromises the security of your truck’s cargo and makes it an accident risk. Thankfully, this can be avoided entirely with proper use and regular maintenance of the roll-up doors. Much like ensuring a liftgate remains functional, keeping your rear enclosure in good repair is essential for daily productivity.

Here are some of the ways you can maintain the life of your truck’s roll-up doors.

Conduct regular inspections. Experts recommend inspecting the roll-up door assembly at least once a week. From the outside, inspect the panels for rust or damage, as well as frayed or worn cables or pull straps. The lock and keeper should also pivot freely and securely engage with the latch plate. On the inside, check if the rollers, tracks, and hinges are in the correct position, securely fastened, and have sufficient lubrication. Be sure to inspect the spring assembly inside the header and check for signs of corrosion or misalignment of the cables within the grooves of the cable drum. Consistent checks are one of the most reliable methods for vehicle longevity and safe operation.

Aside from a visual inspection, be sure to check the door’s movement as well. The amount of side shift movement the door makes when opened should be no more than 3/8 inch in total. This can usually be adjusted by adding or removing spacer washers on the rollers at the joint of the first panel, either at the top or bottom. Also, note any points where the door starts to squeal or hits a snag when being rolled up or down. This can indicate corrosion or obstruction on a specific part of the track.

• Schedule a checkup. If you notice anything unusual with your truck’s roll-up door, we strongly recommend having it inspected at the shop. A technician, specifically one specializing in roll-up doors, can provide an in-depth diagnosis to determine if there’s something wrong with the door and make appropriate recommendations. This type of professional oversight is necessary to prevent expensive mechanical bills later on.
• Clean regularly. Be sure to include the roll-up doors in your truck’s regular cleaning schedule. Doing so will prevent a buildup of dust and debris that can prevent the door from moving or closing correctly. Accumulated dirt can also absorb and retain moisture, resulting in unsightly and potentially damaging rust spots on the metal parts of the door assembly. Following rigorous cleaning habits will help protect the finish and the moving parts from premature corrosion.

The best method for cleaning roll-up doors is with a mild detergent and water, along with a soft-bristled brush or a microfiber cloth. Wipe the door surfaces on both sides, the track, and exposed mechanical components. Rinse and allow to dry completely. Do not use a power washer or a high-pressure hose, as this may seep into the internal mechanism and lead to corrosion.

• Lubricate. The rollers, hinges, and other moving parts require regular lubrication to ensure smooth movement, but regular grease doesn’t cut it. Instead, you will need a lubricant that’s specially formulated for use with roll-up doors. This lubricant covers a larger surface area, allowing it to penetrate deeper into the roller mechanism compared to regular lubricant. Several of these products on the market may have additional properties, such as non-drying or increased water resistance.

Roller door lubricant is typically sold in spray cans, making the application process as easy as spraying an even coat of lubricant over the tracks, rollers, and other components. You can also apply the lubricant on a clean cloth and wipe it on the various parts of your roll-up door. Just make sure not to overdo it, as too much lubricant can also attract dust and dirt.

• Avoid using excessive force. Modern roll-up doors contain springs, balancer bars, and other mechanisms to ensure smooth operation with minimal effort. So slamming the door open or shut is not only unnecessary but also puts it under excess strain and potentially damage it in the long run.

If the roll-up door is indeed busted, repair or replacement of affected parts should be done as soon as possible to prevent injury and further damage to the rest of the roll-up door assembly. It’s also highly recommended to use only OE-compliant parts as replacements. While they may be more expensive, components that meet OE standards will ultimately lead to bigger savings for you and your business in the long run.