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C250
ROLL -UP DOOR INSTALLATION GUIDE
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SAFETY CONSIDERATIONS
Please watch the DVD that has
been provided prior to installation.
DO NOT CUT BANDS
OR WRAPPING
UNTIL INSTRUCTED.
WARNING
A rolling door is a large heavy
object that moves with the help of
springs under extreme tension and
electric motors. Moving objects
and springs under tension and
electric motors can cause serious
injuries or death. For your safety
and the safety of others, follow
these instructions.
caution
Use proper lifting equipment and
correct lifting procedures to avoid
damage or injury.
potential
hazard
Moving Door
Spring Tension
Electric Shock
effect prevention
CAN CAUSE
SERIOUS
INJURY OR
DEATH
CAN CAUSE
SERIOUS
INJURY OR
DEATH
CAN CAUSE
SERIOUS
INJURY OR
DEATH
DO NOT stand or walk under moving
door. Keep door in full view and free
of obstructions while operating.
DO NOT allow children to operate
the door or door controls.
DO NOT stand or walk under moving
door. Keep door in full view and free
of obstructions while operating.
DO NOT allow children to
operate the door or door controls.
DO NOT stand or walk under moving
door. Keep door in full view and free
of obstructions while operating.
DO NOT allow children to
operate the door or door controls.
important note!
DO NOT cut tape and plastic wrap that holds the door in a roll until you are instructed to do so in step 13B.
Mueller Inc. cannot guarantee or accept responsibility for doors that are not installed as directed.
Please Read and understand all instructions before beginning the installation process.
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c
OPERATION / MEASUREMENTS
OPERATION A B C D E
Push-up 2 1/2” 6 1/4” 6 1/4” 10 1/4” 9 7/8”
C250
Reduced Hand Chain 2 1/2” 6 1/4” 8 1/4” 10 1/4” 9 7/8”
c
C250 MODELS
Opening Vertical Horizontal
Height Headroom Headroom
Thru 8’ 18” 20”
Over 8’ Thru 10’ 19” 21 1/2”
Over 10’ Thru 12’ 20” 22 1/2”
Over 12’ Thru 14’ 21” 23 1/2”
Over 14’ Thru 18’ 22 1/2” 24 1/2”
Over 18’ Thru 20’ 23 1/2” 25 1/2”
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STEP 1: WALL OPENING
DO NOT CUT BANDS OR WRAPPING UNTIL INSTRUCTED.
A Check wall opening width and height and verify these
measurements against size of door to be installed.
B Verify that jambs are plumb.
C Checkoorandheaderforlevel.
D Check for adequate side clearance at jambs and
clearance above and at sides of header. See
Clearance charts for minimum requirements.
E Verifythattheguidemountingsurfaceonthejambisush.
F Make sure all parts required for installation are
with the door; see parts list in hardware box.
G Required tools
a. Tape measure
b. Electric drill, 1/2 inch
c. Drill bits, 3/8 inch
d. 3/8 inch nut setter
e. 1/2 inch drive socket set
f. Adjustable wrench
g. Leveling device; water or laser level recommended
h. Pocket / utility knife
STEP 2: MOUNTING PLATES
A If the door will be installed to steel jambs, mounting
plates for the door mounting plates are required and
may be welded or bolted to the jambs.
B Top of mounting plates should be located approximately
10 inches above the top of the door opening. The inside
edge of mounting plate should be 1 1/2” from the inside
of the door jamb. (Note: direction of arrows
on mounting plates.) This is the most important
step; mounting plates MUST be level to each other;
checking via laser or water level is recommended,
do not go by relationship to door header; door header
may not be level.
Note: Minimum door jamb size of 8” x 3.5” 14 gauge,
grade 55 is required to support Roll Up Doors
1”
10”
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RUD1 Plates are provided with doors greater than 12’ x 12’. Field fabricated support brackets are also acceptable
on doors larger than 12’ x 12’. This reinforces the door jambs and prevents the door from coning or walking.
1
D
U
R
Optional Field Fab RUD1 provided
with door
STEP 3: GUIDES AND MOUNTING BRACKETS TO STEEL JAMB
A Mounting brackets and guides must
be attached using fasteners provided.
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ITEM JAMB FASTENERS DRILL SIZE PROVIDED FASTENERS
Steel 3/8” - 1” Hex Bolt & Nut 7 1/16” Provided
BRACKETS Concrete/Filled Block 3/8” - 3/4” Powers Wedge-Bolt Powers 01316 Not Provided
Wood 3/8” - 7x3” Lag Screw Optional Not Provided
Steel 1/4” - 14x1 - 3/4” TEK Screw None Provided
GUIDES Concrete/Filled Block 1/4” x 1 3/4” Powers Wedge-Bolt Powers 01314 Not Provided
Wood 1/4” - 10x1” Lag Screw Optional Not Provided
B The opening edge of guides should be
inset a very small amount (about 1/8
inch), from the door jamb opening on
each side to minimize the potential
of hitting the guides when entering through the door opening. Both
guides must be plumb. Note: If jambs
are installed correctly the outside to
outside measurement of guides should
be approximately 1 inch wider than
the curtain width.
C Once both guides have been correctly
positioned, attach them to the jambs
using the appropriate fastener at each
hole location.
STEP 4: CHAIN HOIST DRIVE (OPTIONAL) (N/A FOR L250 MODEL)
Option A
A Position chain hoist assembly on door axle so that the
chain hoist gear engages the ring gear. NOTE: Do not
tighten set screws until tension has been added in Step 16.
Axle Support
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Wall
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STEP 5: ELECTRIC OPERATOR (OPTIONAL)
A Install as per instruction provided in electric operator kit.
NOTE: Use the DUAL TENSIONER and not the U-BOLT that is in the Operator Kit.
STEP 6: TENSION END RIGHT SIDE OF DOOR
(LOOKING FROM THE INSIDE OUT) IS RECOMMENDED
A Using dual tensioner assembly’s
spring roll pin located in knurled
wheel, rotate upward in the
direction that clears the axle.
B Slide dual tensioner assembly
vover axle and tensioning hub,
with arrow pointing toward wall.
Release spring roll pin.
Tensioning Hub
Axle
Dual Tensioner
Wall
Spring Roll Pin
STEP 7: NON-TENSION END
A Slide axle support over axle,
STEP 7: NON-TENSION END
with arrow pointing toward wall.
Set Screw
Axle Support
Axle
Wall
Set Screws
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STEP 8: LIFT DOOR
DO NOT CUT BANDS OR WRAPPING.
A Orient door with bottom bar located at 7 o’clock
position. The bottom bar should be facing back into
the building.
B Lift door using a forklift that has padded forks in order to prevent damaging or denting the door curtain.
Leave the forklift in position until the door is securely fastened to the mounting brackets.
C Position door on brackets with dual tensioner and tension axle support resting safely on top of mounting
bracketange.Ifachainhoistorelectricoperatorisinstalled;themountingbracketmayneedtobeadjusted
on the mounting plate to allow enough room for the chain hoist or electric operator.
D Door should be positioned as close as possible to the door header and still be able to rotate the door so that
the bottom bar will clear the door header.
E Each end of door should be equal distance from the header and the curtain must be centered in the opening.
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3/8˝ x 3/4˝ Bolt
STEP 9: TENSIONER END
A Loosely attach dual tensioner assembly to door
mountingbracketangeusingthehardwareprovided.
B Tighten the red, square headed, 3/8 inch set screw
on the tensioner bracket.
Dual Tensioner
STEP 10: NON-TENSIONER END
A Loosely attach axle support to door mounting bracket
angeusingthehardwareprovided.
B Tighten the red, square headed, 3/8 inch set screw
on the support bracket.
Door
Header
Axle
Support
Mounting
Bracket
Flange
3/8˝ Washer
Mounting
Plate
Guide
Door
Jamb
Mounting
Plate
Door
Jamb
Door Header
Mounting Bracket
3/8˝ Washer
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STEP 11: ELECTRIC DRIVE END (OPTIONAL)
A Install as per instructions provided in electric operator kit
B If electric operator has a drive chain, do not attach until
door spring tension has been adjusted in step 15
STEP 12: POSITION DOOR
A With door still wrapped and banded. Push door
assembly as close as possible toward header and still
be able to rotate freely. Each end of door should be
equal distance from the header and the curtain must
be centered in the door opening.
B Once door is properly aligned tighten bolts to
mountingbracketange.
Dual Tensioner
Mounting
Plate
Tighten
These Bolts
Door Jamb
Guide
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STEP 13: SETTING SPRING INITIAL TENSION
DO NOT CUT BANDS OR WRAPPING UNTIL INSTRUCTED.
A Rotate door two revolutions, rotating the top of the
door towards the opening.
NOTE: If your building design does not allow
for door rotation, lower the door curtain into the
guides and follow the instructions in Step16 to set
door tension.
WARNING DOOR IS UNDER
EXTREME TENSION!
DO NOT CUT BANDS
OR WRAPPING UNTIL
INSTRUCTED
B Whilermlyholdingthedoor,atthebottom
bar is recommended, cut the tape and plastic
wrap that holds the door in a coil ~ exercise
extreme caution; door is now under spring
tension and is dangerous.
C Direct the bottom bar down into the entry of
the guides and bring the door curtain all the
way to the ground. Secure the door in the
closed position with the slide locks on
the bottom bar.
D Slide head stop from outside to inside
of each bracket.
E Secure each head stop in the brackets
with the hardware provided.
F Once both head stops are securely installed,
unlock slide locks on the bottom bar and
check door operation.
1 x 3/8˝
Carriage Bolt
Door
Jamb
Guide
Headstop Bar
3/8˝
Lock Nut
3/8˝
Washer
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STEP 14: MAKE SURE THE TOP OF GUIDE IS BENT
ABendtheapatthetopoftheguide
over the headstop with a Vise-Grip or
an adjustable wrench.
STEP 15: CHECK DOOR OPERATION
A Lower and raise the door to test door operation.
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STEP 16: ADJUST SPRING TENSION
DOOR MUST BE IN THE FULLY OPENED POSITION TO ADJUST SPRINGS.
LOSS OF SPRING TENSION WILL CAUSE
DOOR CURTAIN TO DROP RAPIDLY.
A Open door fully with the bottom bar resting against
the head stops.
B At dual tensioner end, place ½ inch ratchet into tensioning
hubandholdtheratchetrmly.Havesomeoneelseloosen
the square, red headed 3/8 inch set screws on the dual
tensioner and support bracket.
C To increase spring tension, pull down on ratchet ¼ turn.
The dual tensioner will automatically grip the axle and help
hold the new tension setting. Have someone else tighten all
square, red headed 3/8 inch set screws in dual tensioner and
axle support bracket at both ends of the door.
LOSS OF SPRING TENSION WILL CAUSE
DOOR CURTAIN TO DROP RAPIDLY.
D To decrease spring tension, momentarily pull down on
ratchet and then lift the spring roll pin on the dual tensioner’s
knurled wheel. Gently let up on the ratchet, allowing the
axle to rotate ¼ turn to reduce the tension. While holding
the new tension, release the dual tensioner’s spring roll pin.
The dual tensioner will now grip the axle and help hold the
new tension setting. Have someone else tighten all square,
red headed 3/8 inch set screws in dual tensioner and axle
support bracket at both ends of the door.
E Verify that all square, red headed 3/8 inch set screws in dual
tensioner and axle support bracket at both ends of door are
tightened prior to checking door operation.
F Repeat steps 16A through 16E as necessary.
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3/8˝ x 3/4˝ Bolt
STEP 17: CHAIN HOIST DRIVE END
(OPTIONAL) (N/A FOR L250 MODEL)
Chain Hoist
Assembly
Axle Support
Set Screws
Side View
Door
Assembly
Chain Hoist
Assembly
Mounting
Plate
3/8˝ Washer
Door
Jamb
Guide
Door
Header
Mounting
Bracket
Gear
Hand
Chain
A Reposition chain hoist assembly on door axle so that the
gear on the chain hoist assembly fully engages the door
ring gear.
B Tighten the two set screws, on the top of the chain hoist,
so that they engage the axle and prevent the chain hoist
from shifting on the axle.
Inside View of
Chain Hoist
Assembly
C Feed hand chain over pocket wheel and through hoist.
Connect ends of hand chain, being careful not to twist
chain. Hand chain may be lengthened or shortened as
necessary.
D Install hand chain keeper.
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STEP 18: REMOVE STRIPABLE FILM
If the door has (on the outside of door) Stripable Film remove now.
STEP 19: GUIDE PLUG INSTALLATION
A Insert the guide plug into the holes located on the
guide as shown. The plugs must be inserted from
the inside of the guide.
B NOTE: Make sure the larger end of the plug faces
the inside of the guide. If installed from the outside,
the curtain will hang on the guide plugs.
STEP 20: DOOR MAINTENANCE
C Springs may need to be periodically adjusted through the life of the
door in accordance with steps 16 A thru F. Maintain instructions
for the life of the door.
D Check all bolts and nuts, to ensure they are tight as needed.
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C250
INSTALLATION GUIDE
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