(DO NOT CUT BANDS OR WRAPPING UNTIL INSTRUCTED)
www.muellerinc.com
877-2-MUELLER Mueller W300
Installation
Guide
Please Watch the
DVD
That has been
Provided Prior to
Installation
POTENTIAL HAZARD EFFECT PREVENTION
DO NOT stand or walk under
WARNING moving door. Keep door in full
CAN CAUSE view and free of obstructions
SERIOUS INJURY while operating.
A rolling door is a large heavy object that OR DEATH
moves with the help of springs under DO NOT allow children to
extreme tension and electric motors. operate the door or door controls.
MOVING DOOR
Moving objects and springs under tension
and electric motors can cause serious DO NOT stand or walk under
injuries or death. For your safety and the moving door. Keep door in full
safety of others, follow these instructions. CAN CAUSE view and free of obstructions
SERIOUS INJURY while operating.
OR DEATH
DO NOT allow children to
operate the door or door controls.
CAUTION SPRING TENSION
Use proper lifting equipment and correct DO NOT stand or walk under
lifting procedures to avoid damage or moving door. Keep door in full
CAN CAUSE view and free of obstructions
injury. SERIOUS INJURY while operating.
OR DEATH
DO NOT allow children to
ELECTRIC SHOCK 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.
OPERATION A B C D E
Electric 3” 6 1/4” 6 1/4” 10 1/4” 9 7/8”
W300 Push-up 3” 4 1/2” 4 1/2” 5 1/4” 2 1/2”
AXLE DUAL
SUPPORT TENSIONER
END END
W300 Models
OPENING VERTICAL HORIZONTAL
HEIGHT HEADROOM HEADROOM
Thru 8’ 18” 20”
Over 8’ Thru 10’ 19” 21 1/2”
Over 10’ Thru 20” 22 1/2”
12’
Over 12’ Thru 21” 23 1/2”
14’
Over 14’ Thru 22 1/2” 24 1/2”
18’
Over 18’ Thru 23 1/2” 25 1/2”
20’
2
(DO NOT CUT BANDS OR WRAPPING UNTIL INSTRUCTED)
Step 1: WALL OPENING
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. Check floor and header for level.
D. Check for adequate side clearance at jambs and clearance above and at sides of header. See Clearance
charts for minimum requirements.
E. Verify that the guide mounting surface on the jamb is flush.
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, ½ inch
c. Drill bits, 3/8 inch
d. 3/8 inch nut setter
e. ½ 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 flush with 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 flange
size of 3.5" 12 gauge, grade 55 is
recommended for windlock doors.
Check with your engineer if in
doubt.
3
SPECIAL NOTE FOR DOORS LARGER THAN 12’X12’
On larger doors, 12 x 12 and up, field fabricated support brackets need to be added to the
Steel Backing Plate to reinforce the door jambs to prevent the Roll Up Door from coning or
walking
D1
RU
Field fabricated support brackets are
required on doors larger that 12'x12' to
reinforce the door jambs and prevent the
Roll Up Door from coning or walking
Step 3: GUIDES AND MOUNTING BRACKETS TO STEEL JAMB
A. Mounting brackets and guides must be attached using fasteners provided.
4
ITEM JAMB FASTENERS DRILL SIZE PROVIDED FASTENERS
BRACKETS Steel 3/8”-1” Hex Bolt &Nut 7/16” Provided
GUIDES Steel 1/4”-14x1-3/4” TEK Screw None 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]
A. Fasten spur gear to drum using the bolts provided; screwing them into the blind nuts installed on door
drum.
B. Position chain hoist assembly on door axle so that the spur gear on the chain hoist assembly is directly
below the spur gear attached to the door drum. The spur gears will be connected with a short drive chain
later. NOTE: Do not tighten set screws until after tension has been added in Step 16.
5
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 over axle and tensioning hub, with arrow pointing toward wall. Release
spring roll pin.
Step 7: NON-TENSION END
A. Slide axle support over axle, with arrow pointing toward wall.
6
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.
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.
B. Position door on brackets with dual tensioner and tension axle support resting safely on top of mounting
bracket flange. If a chain hoist or electric operator is installed; the mounting bracket may need to be
adjusted on the mounting plate to allow enough room for the chain hoist or electric operator.
C. 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.
D. Each end of door should be equal distance from the header and the curtain must be centered in the
opening.
Step 9: TENSIONER END
A. Loosely attach dual tensioner assembly to door mounting bracket flange using the hardware provided.
B. Tighten the red, square headed, 3/8 inch set screw on the tensioner bracket.
7
Step 10: NON-TENSIONER END
A. Loosely attach axle support to door mounting bracket flange using the hardware provided.
B. Tighten the red, square headed, 3/8 inch set screw on the support bracket
Step 11: ELECTRIC DRIVE END (Optional)
A. Install as per instruction 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.
8
B. Once door is properly aligned tighten bolts to mounting bracket flange.
Step 13: SETTING SPRING INITIAL TENSION
(DO NOT CUT BANDS OR WRAPPING UNTIL INSTRUCTED)
A. Rotate door 2 revolutions in a clockwise direction.
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
9
B. While firmly holding the door, at the bottom 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.
Step 14: MAKE SURE THE TOP OF GUIDE IS BENT.
A. Bend over headstop with a Vise-Grip or an adjustable wrench.
10
Step 15: CHECK DOOR OPERATION
A. Lower and raise the door to test door operation.
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 hub and hold the ratchet firmly. Have
someone else loosen 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.
11
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 15A through 15E as necessary.
Step 17: CHAIN HOIST DRIVE END (Optional) [N/A FOR L250 MODEL]
A. Reposition chain hoist assembly on door axle so that the spur gear on the chain hoist assembly is directly
below the spur gear attached to the door drum. The spur gears will be connected with a drive chain.
12
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.
C. Attach the drive chain from spur gear on the chain hoist to spur gear on the door drum
D. 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.
E. Install hand chain keeper.
Hand Chain
Keeper
Can be
attached to
door jamb
or wall girt
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.
13
B. Note: Make sure the larger end of the plug faces the inside of the guide.
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.
14
