Overhead door 780 CD Series User manual

INSTALLATION INSTRUCTIONS
Series 780 CD, 790 CW
USE PROPER LIFTING EQUIPMENT AND
CORRECT LIFTING PROCEDURES TO
AVOID INJURY.
220153-0001
8/14/03
1
© Overhead Door Corporation
!!CAUTION

Keep people clear of opening while
Door is moving.
Do Not allow children to play with
the Door operator.
Do Not operate a Door that jams or
one that has a broken spring.
POTENTIAL HAZARD EFFECT PREVENTION
MOVING DOOR
HIGH SPRING TENSION
WARNING: Can Cause
Serious Injury or Death
WARNING: Can Cause
Serious Injury or Death
Do Not try to remove, repair or adjust
springs or anything to which Door spring
parts are fastened, such as, wood blocks,
steel brackets, cables or other like items.
Repairs and adjustments must be made
by a trained service person using proper
tools and instructions.
Overhead doors are large, heavy objects that move with the help of springs under high tension
and electric motors. Since moving objects, springs under tension, and electric motors can
cause injuries, your safety and the safety of others depend on you reading the information in
this manual. If you have questions or do not understand the information presented, call your
nearest service representative.
In this section and those that follow, the words Danger, Warning and Caution are used to
emphasize important safety information. The word:
DANGER means that severe injury or death will result from failure to follow instructions.
WARNING means that severe injury or death can result from failure to follow instructions.
CAUTION means that property damage or injury can result from failure to follow instructions.
The word NOTE is used to indicate important steps to be followed or important considerations.
SAFETY INFORMATION
IMPORTANT
OVERVIEW OF POTENTIAL HAZARDS
READ THIS MANUAL CAREFULLY AND OBSERVE ALL WARNINGS WHEN INSTALLING,
OPERATING OR MAINTAINING YOUR OVERHEAD DOOR.
CHECK for shipping damage.
CHECK door against packing list to make sure door
is the same as ordered and all parts are included.
CHECK width and height of door opening against
sizes noted with shipment to assure that door will fit.
CHECK to make sure headroom and side clearances
are adequate (Figure 1).
Read these instructions completely before
attempting to install this door.
WARRANTY VOID IF DOOR IS NOT INSTALLED
ACCORDING TO INSTRUCTIONS.
DO NOT CUT OR REMOVE RETAINING BANDS
UNTIL INSTRUCTED TO DO SO.
CHECK WARNING LABELS ON DOOR FOR PROPER
INSTALLATION PROCEDURE.
2

H
B
A
J
C*
Jamb
10“
Steel
Wood
Concrete/
Masonry
10“
10“
10“
10“
E
Drill
Size
4“
3/8“ exp. anchor
Use ANSI B95.12
carbide tipped
drill bit
3/8“*
3/8“ bolt
3/8“ Lag
4“
4“
4“
4“
D*
Doors
10“
All
All
7/16“
5/16“
Table 1 - Headplate Fasteners
All
10“
10“
10“
10“
F**
Fastener
Specifications
4“
6“
4“
8“
6“
Operation
Operator
Fastener
Push Up
790
790
780
780
Reduced
Chain Drive
Door Type G
8“
10“
8“
12“
10“
Figure 1
*Excess shaft may be cut off of non-drive sides of
doors for additional clearance. It is recommended that
at least 1” of shaft be retained past the headplate to
facilitate spring tension adjustment.
**Dimension “F” applies to Drive End only.
RH shown, LH opposite.
*Drill size for supplied fasteners. For others, refer to
manufacturer’s specified installation method.
790
780
10“
10“
6“6“ 12“
light weight building jambs from twisting.
Bracing may be required to prevent
NOTES
INSTALLATION
5” above top of guide, if headroom allows)
E, H and G (Figure 1).
1. Locate headplates per dimensions F, (or approximately
2. Hold headplates in mounting position. Using a water
3. IF DOOR IS CHAIN DRIVEN:
top hole in headplates.
Fasten headplates to wall using three fasteners. Use
the wall. If this condition exists then use Thru-bolt.
unit (CMU) wall. DO NOT install fastener in a void in
for brick or stone walls or hollow concrete masonry
Mark mounting hole locations on header. See Table 1
for supplied fasteners.Thru-bolts are recommended
level, check to make sure tops of headplates are level.
OPENING WIDTH + G
E
CD
F
FOR REFERENCE
DRIVE END
3
a. Remove hardware from package.
b. Slide 1/2“-13 nut and 3/8” external tooth locking
washer over bolt as shown in Figure 2. (Note:
Sharp edges of locking washer must be in contact
with flange of self clinching nut).
c. Thread self clinching nut onto threads of bolt and
snug until finger tight.
d. Insert assembly into one of the 3 outer mounting
holes on end ring.
e. Use a backup wrench(channel lock, vise grips or
equivalent) to prevent 1/2“ nut from spinning while
torquing bolt to seat self clinching nut.
f. While maintaining pressure to keep assembly
seated against ring, use a 9/16“ ratchet, wrench
or power driver to turn the bolt and secure the self
clinching nut.
g. Tighten bolt until self clinching nut is fully seated.
(Resistance against the back up wrench will be felt
as clinching nut begins to seat).
h. With backup wrench still applied to 1/2“ nut,
reverse torque on bolt to remove.
I. Repeat for 2 remaining holes.
j. Place bearing into recess of bracket. (Figure 2)
k. Bolt sprocket to bracket to capture bearing.
l. Slide bracket assembly over shaft, and align
appropriate legs to self clinching nuts in ring.
m. Bolt to ring as shown.
n. Thread hand chain thru chain guide slots, over
chain wheel and connect ends. NOTE: Make sure
chain is not twisted.
o. Slide chain hoist assembly onto door shaft.
p. Install drive chain to sprocket and hoist assembly.
Align both sprockets and tighten set screw on
hoist.
q. Install chain keeper to wall.
See Page 4 For Ilustration
Over Up To
-7' 8"
7' 9" 9' 4"
9' 5" 11' 0"
11' 1" 12' 8"
12' 9" 14' 3"
14' 4" 16' 0"
Opening Height
Recommended Minimum
20 1/4" 18 1/4"
21" 19"
21 3/4" 20 3/4"
22 3/4" 21 3/4"
23 1/4" 22 1/4"
24 3/4" 23 3/4"
B
Head Room
Over Up To Recommended Minimum Recommended Minimum Recommended Minimum
-7' 8" 10" 8" 9 1/8" Same 18 1/8" Same
7' 9" 9' 4" 10 1/2" 8 1/2" 9 1/8" Same 18 3/8" Same
9' 5" 11' 0" 11" 10" 10 1/4" Same 19 3/4" Same
11' 1" 12' 8" 11 1/2" 10 1/2" 10 1/4" Same 20 1/4" Same
12' 9" 14' 3" 12" 11" 10 1/2" Same 20 1/2" Same
14' 4" 16' 0" 13" 12" 10 1/2" Same 21" Same
Opening Height HJA
Head Plate Height Axle Setting Back Room

See Page 9 For
Bill Of Materials
790 Installation
With Windlocks
780 Installation
No Windlocks
Self Clinching
Nut Installation
Figure 2a-4:1 Hoist
4
88
88
1919
1919
1919
2626
2525
1616
2929
2929
1313
1313
1515
1515
1515
2727
2727
2828
88
2828
88
1515

5
1919
2929
1313
2828
3232
3333
88
3131
1515
See Page 9 For
Bill Of Materials
Figure 2b-8:1 Hoist

DECREASE SPRING TENSION
If door is easy to open but hard to close-
INCREASE SPRING TENSION
If door is easy to close but hard to open-
DOOR SHOULD OPEN AND CLOSE WITH EQUAL EFFORT.
DO NOT LUBRICATE GUIDES.
NOTE
guides smoothly. If necessary, bend radius to adjust.
13. Make sure radius at top of guides leads curtain into
and secure.
guides. Adjust both guides for clearance if necessary
in Figure 6 is maintained along the full length of the
12. Check both guides to insure the clearance shown
guides for proper door operation.
certain the head of the bolt is on the inside of the
11. Install bottom bar stops as shown in Figure 7. Make
curtain to the floor.
10. Lower bottom bar into guide openings and lower
from unwinding and remove retaining bands.
9. Secure bottom bar or hand chain to prevent curtain
6
Figure 3
FULL TURN
NOTE DIRECTION
OF ARROWS ON
SADDLE CLAMPS
3/4 TURN
DIRECTION
CLOSE
1/4 TURN
1/2 TURN
EXAMPLE:
If the number of initial turns is 1 and ½, locate bottom
bar at the ½ turn position (Figure 3). Step 8 will explain
the winding procedure.
5. Position curtain assembly on headplates according to
dimension J-(Figure 1). Curtain must be centered on
door opening.
6. Install saddle clamps at both ends of door shaft as
shown in Figure 4 and securely tighten saddle clamps
to headplates.
7. Position guides to opening as shown in Figure 5.
Clearance between curtain and inside of guides is
shown in Figure 6. Adjust curtain or guides as
necessary to achieve this spacing. Secure guides to
jambs with supplied fasteners. See Table 2.
8. Curtain assembly counterbalance springs must now
be wound for the number of initial turns required to
set spring tension. As explained in Step 4, use the
initial turn setting to wind counterbalance springs.
EXAMPLE:
If initial turn setting is 1 and ½ use the following procedures:
a. Starting at the ½ turn position, rotate curtain assembly
on door shaft 1 and ½ turns in the “CLOSE” direction
(See Figure 3).
b. Bottom bar should stop at the FULL TURN position.
springs, then locate bottom bar accordingly.(NOTE:
Incorrect number of turns will affect door operation. See
directions on sheet 7 for adjusting spring tension.
for the initial turns required to wind counterbalance
clamping the door shaft. See Table 3, Page 9, for
shaft is required to neutralize the spring before
A reference point marked on the curtain ring and door
correctly when placing curtain assembly on headplates.
essential that the curtain bottom bar be positioned
be wound during the installment procedure. It is
4. Curtain assembly counterbalance springs will have to
Jamb
Steel
Concrete/
Masonry
Wood
*Use ANSI B95.12 carbide tipped drill bit and drill sizes for supplied fasteners.
For all others, refer to manufacturer’s supplied installation method.
1/4“ Screw
1/4“ Screw
1/4“ Masonry Screw
(3/16“ Drill Size,
2-1/4” Deep)*
Optional 1/4“ Expansion
Anchor (1/4“ Drill Size)
1/4“ Lag Screw
3/8“ Expansion Anchor
3/8“ Lag Screw
1/2“ Expansion Anchor
1/2“ Lag Screw
Doors Width
780CD
780CD
780CD
Up to 20’
Up to 16’
Up to 16’
Up to 16’
Up to 16’
Up to 16’
Over
16’ to 20’
Over
16’ to 20’
Every hole
Every other hole
Every other hole
Every other hole
Every hole
Every hole
Every hole
Every hole
Table 2 - Guide Fasteners
790CW
790CW
790CW
Fastener Spacing
99
88
66
11
44
66
77
See Page 9 For
Bill Of Materials
Figure 4

7
Figure 6
11
12
1010
Figure 7
Figure 8 See Page 9 For
Bill Of Materials
See Page 9 For
Bill Of Materials
Increase
Tension
Decrease
Tension
55
2020
2121
23
Figure 9
3/8“ to 5/8”3/8“ to 5/8”
1/8"
to
3/8“
1/8"
to
3/8“
Figure 5
1/4"1/4"1/4"1/4"
NOTE: Distances are measured
from the inside of the guide.
decals to guides at eye level.
16. Apply “WARNING” and “DO NOT LUBRICATE”
15. Tie rope to bottom bar.
14. Install slide locks to bottom bar as shown in Figure 9.
if necessary.
e. Check door operation. Readjust spring tension
d. Tighten set screw on chain hoist, if present.
of door shaft.
dd. Tighten saddle clamp bolt nuts at both ends
DO NOT adjust more than ¼ turn at any time.
cc. Adjust spring tension as desired. NOTE:
of the door shaft.
bb. Loosen saddle clamp bolt nuts at both ends
aa. Apply torque to door shaft using a pipe wrench.
following procedure:
c. Adjust spring tension (Figure 8) according to the
b. Loosen set screw on chain hoist, if present.
a. Raise curtain to fully OPEN position.
TO ADJUST SPRING TENSION:
Steel
Masonry Masonry
Wood Wood
Steel
880CD 890CW 890CW
All Sizes
All Sizes
All Sizes
All Sizes
Over 15’
All Sizes
Up to 15’

8
33
11
22
1717
1818
See Page 9 For
Bill Of Materials

9
Table 3
2.75
2.50
15'6" up to 16'5"
14'6" up to 15'5"
2.50
12'6" up to 13'5" 2.50
11'6" up to 12'5" 2.50
13'6" up to 14'5"
2.50
9'6" up to 10'5" 2.50
8'6" up to 9'5" 2.25
10'6" up to 11'5"
2.25
6'6" up to 7'5" 2.25
5'6" up to 6'5" 2.25
7'6" up to 8'5"
2.00
3'6" up to 4'5" 2.00
2'6" up to 3'5" 2.00
4'6" up to 5'5"
STANDARD DOOR HARDWARE
ITEM PART NUMBER PART DESCRIPTION QTY
1202023-0002 BRACKET, HEADPLATE 2
2220154-0002 STOP, BOTTOM BAR, RH 1
3220154-0001 STOP, BOTTOM BAR, LH 1
4202157-0001 SADDLE CLAMP, SHAFT 4
5306973-0002 SLIDEBOLT, 1"w X 11-1/4" L 2
6080302-2832 WSHR, FLAT, PLD, 3/8 X 1 OD 8
7080105-0628 BOLT, HH, NC, 3/8 X 3 1/2" LG 4
8080322-0382 WASHER, LOCK, 3/8 4
9080352-0616 NUT, HEX, PLD, 3/8-16 NC 4
10 086420-0505 BOLT, CARRIAGE, SQ NECK, RND HD 5/16 X 5/8 2
11 080302-2222 WSHR, FLAT, PLD, 5/16 X 11/16 OD 4
12 080352-0518 NUT, HEX, PLD, 5/16-18 NC 2
20 080352-0420 NUT, HEX, PLD, 1/4-20 2
21 061239-0000 SPACER, ROLLED, 1/4 X 1/4 4
23 086420-0406 BOLT, CARRIAGE, SQ NECK, RND HD 1/4 X 3/4 2
24 205938-0001 STEP / LIFT HANDLE 2
4:1 CHAIN HOIST KIT
ITEM PART NUMBER PART DESCRIPTION QTY
8080322-0382 WASHER, LOCK, 3/8 6
13 220132-0001 SPROCKET BRACKET, SHEETDOOR 1
14 080302-2626 WSHR, FLAT, PLD, 3/8 X 3/16 OD 3
15 080105-0606 BOLT, HH, NC, 3/8 X 3/4" LG 6
16 080324-0008 WASHER, LOCK, EXTERNAL TOOTH, TYPE A 1
19 220071-0001 THREADED INSERT, KNURLED, 3/8 X .150 3
25 080352-0813 NUT, HEX, PLD, 1/2-13 1
26 080105-0610 BOLT, HH, NC, 3/8 X 1-1/4" LG 1
27 308307-0001 SPROCKET, #41-40T, 2" BORE 1
28 608414-0001 BRG, BALL, 1-5/16 ID 1
29 080352-0616 NUT, HEX, PLD, 3/8 - 16 3
30 220065-0001 CHAIN HOIST, TYPE JR 1
8:1 CHAIN HOIST KIT
ITEM PART NUMBER PART DESCRIPTION QTY
8080322-0382 WASHER, LOCK, 3/8 6
13 220132-0001 SPROCKET BRACKET, SHEETDOOR 1
14 080302-2626 WSHR, FLAT, PLD, 3/8 X 3/16 OD 3
15 080105-0606 BOLT, HH, NC, 3/8 X 3/4" LG 3
16 080324-0008 WASHER, LOCK, EXTERNAL TOOTH, TYPE A 1
19 220071-0001 THREADED INSERT, KNURLED, 3/8 X .150 3
25 080352-0813 NUT, HEX, PLD, 1/2-13 1
26 080105-0610 BOLT, HH, NC, 3/8 X 1-1/4" LG 1
28 608414-0001 BRG, BALL, 1-5/16 ID 1
29 080352-0616 NUT, HEX, PLD, 3/8 - 16 3
31 080105-0624 BOLT, HH, NC, 3/8 X 3" LG 3
32 220160-0001 SPROCKET, #41-72T, 1.75" SPACERS 1
33 220161-0001 PLATE, SPROCKET BEARING 1
34 220162-0001 CHAIN HOIST, TYPE JR 8:1 1

10
ITEM PART NUMBER PART DESCRIPTION QTY
1 204215-0002 JAMB EXTENSION - IDLE END 1
2 204214-0002 JAMB EXTENSION - DRIVE END 1
3 205981-0005 MOUNTING BRKT., .188 THK, LH 1
4 205981-0006 MOUNTING BRKT., .188 THK, RH 1
22
11
33
44
ADDITIONAL MOUNTING BRACKETS

11
TROUBLE SHOOTING
- Add shim behind top guide attachment to wall.
- Mounting brackets to low:
a. Raise brackets, or
B. Cut track from bottom. (Door will hang in opening).
Assembly MUST BE parallel with header.
e. Repeat procedure for other end of curtain.
d. Retighten saddle clamp bolts.
Figure 1 - Page 3.
setting has been obtained. See dimension “J” -
c. Push curtain assembly toward header until correct
b. Loosen saddle clamp bolts on one end.
a. Adjustment must be made with door fully open.
To adjust mounting position:
over guide leads... - Door assembly is mounted too far from opening.
6. Door operates stiffly or curtain rattles - Guides are too long.
5. Door telescopes or rolls up unevenly... - Mounting brackets are not level, or are too low.
- To straighten door curtain:
a. Adjust mounting brackets to the correct position
(Figure 1).
b. While positively retaining door curtain to prevent
unwinding of spring, remove guides from jambs.
c. Lower curtain to floor, and carefully raise, to square
the curtain back up on the barrel. (Do Not remove
positive hold on curtain until guides are back in
place). Repeat as necessary.
d. Replace guides and bottom bar stops.
- Guides are not plumb.
- Spring tension too high. See Page 7 for tension
Adjustment procedures.
floor evenly... - Mounting brackets are not level.
4. Bottom weatherseal does not contact - Floor is not level.
both sides).
- Mounting brackets too low. Check Figure 1 for
proper location.
guide. Check Figure 6 for required clearance on
- Insufficient clearance between curtain and inside of
- Guides may be damaged.
must be made with door fully closed).
- Guide leads are improperly adjusted. (Adjustment
- Guides are not plumb.
- Door assembly incorrect distance from wall.
- Curtain assembly is not parallel to opening.
3. Door is hard to operate... - Mounting brackets are not level.
2. Door is easy to open, but hard to close... - Excessive spring tension.
1. Door is easy to close, but hard to open... - Insufficient spring tension.
SYMPTOM POSSIBLE CAUSE

12
large flange rivets.
4. Secure header seal to curtain using 1/8“ diameter,
holes for rivets on 12“ centers using a number 29 drill.
3. Hold header seal along attachment point and drill
2. Raise curtain until attachment point is accessible.
header seal on curtain (Figure 10).
1. With door closed, mark attachment point for
OPTIONAL HEADER SEAL
DOOR MOUNTED RUBBER SEAL
TROUBLE SHOOTING
Figure 10

13
HEADER MOUNTED BRUSH SEAL
HEADER MOUNTED RUBBER SEAL