Trac-Rite 977 User manual

ROLLING CURTAIN DOOR
INSTALLATION, MAINTENANCE
& PARTS MANUAL
314 Wilburn Road, Sun Prairie, WI 53590
Phone: [phone]; Fax: [phone]
Technical Help Line: 888-700-TRAC (8722)
Web Site: www.tracrite.com
E-mail: [email protected]
Read manual thoroughly prior to installing door. Rolling steel doors are large, heavy objects that move with the help
of springs under extreme tension. Since moving objects and springs under tension can cause injuries, your safety
and the safety of others depends on you reading and following the information in this manual. Check your work prior
to operating door.
POTENTIAL HAZARD EFFECT PREVENTION
MOVING DOOR Can Cause Serious Keep people clear of opening while door is moving. Get help
Injury or Death or use support when lifting new door into place.
EXTREME SPRING Can Cause Serious Installation, repairs, and adjustments must be made by a qualied
TENSION Injury or Death door mechanic using proper tools, methods, and instructions.
Before winding torsion spring, make sure door is fully open
and curtain is wrapped on barrel.
WARNING
This Manual MUST Be Left with the Owner.
CAUTION
Use proper lifting equipment and correct lifting
procedures to avoid injury.
DO NOT CUT BANDS which hold door in a roll. You will be
informed when to cut bands within this manual.
No guarantee will be given or responsibility accepted by
Trac-Rite Door, Inc. if door is not installed as instructed.
For proper operation, follow instructions given.
NOTE!
MODEL 977 & 977WL
CAUTION
If door springs are not adjusted properly,
door damage can result. Door should not
slam up or down
#651105
3/21

© 2021 TRAC-RITE DOOR
Door Assembly - Parts Layout
Page 2
WALL
WALL
14. SPRING CLIP
7. BRACKET
STANDARD SPACEGUARD LATCH
OPTIONAL SPACEGUARD CYLINDER LOCK
9. INTERIOR LATCH
(OPTIONAL)
9. INTERIOR LATCH
PULL ROPE HANDLE
(CENTERED ON DOOR)
10. MOUNTING FASTENERS
KEEPER (PART OF 11)
6. BOTTOM ASSEMBLY
8. DOOR GUIDE
OPTIONAL DRAFT STOP
11. DOOR STOP
7. BRACKET
3. SPRINGS
2. DRUMS
1. DEAD AXLE
ASSEMBLY
4. AXLE
5. DOOR CURTAIN
ASSEMBLY
OPTIONAL CURTAIN WINDLOCKS
12. SADDLE W/ TENSIONER
13. AXLE SADDLE
WEAR GUARD

Do not use model 944 and 955 hardware on model
977 doors. It is not structurally adequate. If door
falls, serious injury and/or damage to door can
result.
WARNING
1) Do not install this rolling steel curtain door
unless you read and understand the installation
instructions!
2) DO NOT CUT THE BANDS which hold the door
curtain in a roll! This is performed once the door has
been hung in the opening.
3) DO NOT REMOVE WHITE FELT TAPE on the inside
of the door curtain. It is a door component, NOT
packaging material.
NOTE!
WARNING
Improper installation of anchoring devices or installation into unsound material may result
in premature product wear, product failure, property damage or serious personal injury.
2.2 Door Width Verication: The door curtain width should
measure 3” greater than the framed opening width.
2.3 Framed Opening Verication:
• Proper size dimensionally?
• Opening square? Plumb?
• Is the jamb structurally/dimensionally adequate?
Reference paragraph 3. Jamb Preparation for specics.
• Clearances? (Reference Figure 1)
3. JAMB PREPARATION:
3.1 Are the jambs structurally and/or dimensionally adequate
to accept door brackets and guides? Trac-Rite is not
responsible for the structural integrity of the jamb itself!
3.2 Narrow Jamb Application: Narrow jamb plates are
available, for situations in which the jamb is not wide enough
for bracket mounting. This condition should be made known
at the time of order entry so that you will have the hardware
when you need it. (See Figure 2).
3.3 Trac-Rite does not supply fasteners for attaching the
door brackets and guides to concrete or concrete masonry
jambs. Trac-Rite does supply fasteners for metal and wood
jambs.
• Door bracket to jamb fasteners must be 3/8” in
diameter, and be constructed of ASTM A-307 steel or
greater.
2. INSPECTION:
2.1 Door and Hardware: Upon receiving the door shipment,
immediately inspect the door and hardware for damage.
Verify the product received with the packing list. Damages
and/or shortages should be reported immediately to Trac-
Rite customer service at 800-448-8979 or [email protected].
Please have your bill of lading and packing list to reference
when reporting shortages or damage. Do not install damaged
material without authorization from Trac-Rite.
Prior to beginning door installation, read the instruction manual
in its entirety. Please contact Trac-Rite with any questions
at 888-700-8722. Answering questions up front will greatly
reduce the probability of installation miscues.
1. GENERAL:
The following terms are dened as:
Warning - serious personal injury or death can result from
failure to follow instructions.
Caution - minor injury or property damage can result from
failure to follow instructions.
Note - special attention should be given to the instructions.
©2021 TRAC-RITE DOOR Page 3
Figure 1.

©2021 TRAC-RITE DOOR
Page 4
Figure 2.
OPTIONAL OPERATOR CAN BE INSTALLED ON
EITHER END OF DOOR ASSEMBLY.
NOTE!
DOOR MUST BE HUNG LEVEL TO ENSURE
PROPER TRACKING.
NOTE!
Figure 3.
5.2 REDUCED DRIVE SYSTEM Install the sprocket on the
preferred side of door assembly and secure with 3- 3/8” x 2”
bolts with 9/16” head. If door is equipped with wind locks the
operator sprocket must be o󰀨set the width of the wind locks
using 2 - 3/8” nuts.
5.3 Slide the chain hoist assembly on the axle and align the
sprockets parallel to each other.
5.3.2 Connect the drive chain around both sprockets, using
the masterlink provided. Do not secure the chain hoist
assembly to the axle at this time. See Figure 5.
5.3.3 Feed hand chain through and around pocket wheel.
Close chain making certain there are no twists in the chain.
5.4 Slide the axle saddle onto the axle after the chain hoist
is in place.
5.5 On the opposite side of the reduced-drive chain hoist,
slide the saddle with the tension device on the axle (tensioner).
5. DOOR PRE-ASSEMBLY:
5.1 Position the door in the opening as shown in Figure 4.
Be sure to place the door on protective material to prevent
damage to the curtain.
• Door guide to jamb fasteners must be 1/4” in diameter,
and be constructed of ASTM A-307 steel or greater.
3.4 Pre-drill jambs to accept door brackets; 7/16” diameter
holes for 3/8” nuts and bolts in steel jambs, proper size pilot
hole for 3/8” lag bolt in wood jambs. Hole locations are shown
in Figure 3. Do not pre-drill jambs for door guide installation.
Figure 4.
FOR DRAWING CLARITY
HAND CHAIN NOT SHOWN
41A72 SPROCKET
ROLLER CHAIN
MAIN HOIST BODY
AXLE
AXLE SADDLE
DOOR BRACKET
(2) 3/8 NUT WL ONLY
3/8 X 2" BOLT
Figure 5.
4. BRACKET MOUNTING:
4.1 Mount the Right and Left bracket according to the
spacing in Figure 3. Make sure there is enough spacing for
the reduced-drive chain hoist on the chosen side of the door
assembly. Fasten using the pre-drilled holes and fasteners
described in Section 3.

Note: The saddle position on the door mounting bracket will
change depending on the height of the door. Position the
saddle in the bracket slots according to the following table:
For doors up to 9’11” tall: position
one bolt in the near end of the slot
closest to the door header and
the second bolt in the center slot.
See Figure 6.
For doors between 10’0” and
11’11”: position one bolt in the
far end of the slot closest to the
door header and the second bolt
in the center slot. See Figure 7.
©2021 TRAC-RITE DOOR Page 5
Figure 11.
For doors between 12’0” and
13’11”: position both bolts in
the center slot. See Figure 8.
For doors between 14’0” and
14’11”: position one bolt in the
middle of the center slot and the
second bolt in the near end of
the far slot. See Figure 9.
For doors taller than 15’0”:
position one bolt in the far
end of the center slot and
the second bolt in the third
slot. See Figure 10.
Note: Make sure the saddles
are spaced evenly from the
header.
Do NOT allow door assembly to roll o󰀨 brackets or move
sideways o󰀨 edge of bracket. If door falls, serious injury or
death and/or damage to door can result.
WARNING
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
6.4 Fasten the tensioner and the axle saddle to the bracket
using - 3/8-16 X 1” hex bolts. Tighten red set screws on both
the tensioner and axle saddle. DO NOT tighten the chain
hoist screws!
6. HOIST DOOR INTO OPENING:
6.1 Utilizing whatever method currently available (forklift,
block and tackle, etc.), hoist the door up over the mounted
brackets. Protect the door while lifting by padding the forks
of the forklift.
6.2 Position the door on the brackets so the tensioner and axle
saddle rest safely on the top ange of the bracket. Make sure
arrows on the tensioner and axle saddle are pointing toward
the wall and the red set screws are facing away from the wall.
6.3 Door should be positioned as close as possible to the
header and still be able to rotate and clear the bottom bar.
The door should also be centered in the opening.
DO NOT allow persons to ride on forklift or other
hoisting equipment being used to lift the curtain
assembly into position. Do not permit any persons
to climb on ladders near the curtain assembly while
it is being hoisted. Should the curtain assembly slip,
SERIOUS INJURY or DEATH to persons standing on
ladders or riding on lifting equipment can occur.
WARNING

Page 6 ©2021 TRAC-RITE DOOR
Immediately install keepers and door stops. These
devices will prevent the door from rolling up and out
of the guides.
WARNING
8.3 Attach the two keepers to the bottom interior edge of
the door using the installed 1/4” carriage bolt and whiz nut.
(Figure 16)
8.4 Tighten door stops installed in paragraph 7.2 making
certain track bolts are seated in guides. (Figure 16)
Figure 14.
8.2 Bend the guide tabs out slightly (about 1/4”). Standing
inside the opening looking out, place your hand on top of the
8. PRE-TENSIONING:
9. FINAL GUIDE ADJUSTMENT:
9.1 To keep the door in the guides during operation the
guides need to be set tighter at the bottom versus the rest
of the door. Failure to tighten the bottom guides can result in
the door pushing out of the opening when closing the door.
See Figure 15.
Care must be taken that the door does not spin
around free as this may cause personal injury and/
or damage to the door. DO NOT grab the springs or
unbolt the springs while there is tension on the door
as this may cause personal injury.
CAUTION
Figure 13.
door and push away from you rotating the door nest (Figure
14). Rotate the door nest two complete revolutions. Hanging
on to the door bottom assembly, carefully cut the stretch wrap
and feed the door curtain into the guides, moving the door
stops aside to let the bottom bar move past. Pull the door
bottom assembly down to waist level.
DOOR CURTAIN
ROTATION DIRECTION
TOWARDS WALL
BANDS
(STRETCH WRAP &
CARDBOARD STRIPS)
WALL
DOOR STOP
WHIZ NUTS
CARRIAGE BOLTS
DRILL 3
8" HOLE
7.3 Position the guides against the jambs according to the
clearance shown in Figure 11 (Figure 12 if windlock model).
Loosely fasten the top of each guide to the door jamb.
This will allow slight adjustment of the guides as the door
installation is completed. DO NOT install the remaining
fasteners until such time as the adjustment is true. Level
one guide and loosely install a second fastener in the bottom
hole. If mounting to masonry, install clips provided as shown in
Figure 13. Align the clips with the holes along the length of the
guide and ush with the back of the guide. (Anchors by others).
Figure 12.
7. GUIDE POSITIONING:
7.1 Before the guides can be used mounting holes for the
top stop need to be drilled. Align the hole in the top stop
with top hole in the guide, mark the two holes needed to
secure the top stop on both guides. Drill the 2 marked spots
using a 3/8” drill bit on each guide.
7.2 Install the carriage bolts, door stops and whiz nuts in
each side guide as shown in Figure 14. DO NOT tighten
at this time. Both top stops will need to be in the same
set of holes on each side of the door for proper operation.
Note: If installing exterior handles, the door will block part of
the nished opening when the door is open.
BOTTOM OF
DOOR CURTAIN
WIND LOCK
TAPCON
MASONRY FASTENER
CONCRETE FILLED
BLOCK JAMB
DOOR CURTAIN
DOOR GUIDE
WIND LOCK
38" min. clearance
VIEW A-A
JAMB INTERIOR
DOOR GUIDE
JAMB OPENING
NON-MASONRY
FASTENING HOLES
MASONRY ANCHOR
MASONRY CLIP
TEK SCREWS #12-14 x 3/4”
MAINTAIN 1/8 TO 1/4” GAP (3-6MM)
BETWEEN GUIDE AND WEAR GUARD
DOOR CURTAIN
DOOR GUIDE
BLOCK JAMB

©2021 TRAC-RITE DOOR Page 7
9.2 Once the guides are adjusted properly and the door runs
smoothly, install the remaining fasteners and rmly tighten
them.
9.3 Attach guide warning label (shown in Figure 17) to the
guide at eye level.
9.4 Attach tension adjustment warning label (shown in Figure
17) either on the door bracket with the tensioner or to wall
at eye level.
Figure 17.
Figure 15.
Figure 16.
KEEPER
14
"
CARRIAGE BOLT & NUT
BOTTOM OF
DOOR CURTAIN
DOOR GUIDE
HAND BENT GUIDE TAB
DOOR STOP
516
"
CARRIAGE BOLT & NUT
DOOR BRACKET
WALL
10. PULL ROPE INSTALLATION:
10.1 Pull rope handle: Tie a knot in one end of the rope.
Slide the plastic handle onto the rope and pull the knot up
into the handle. Pass the other end of the rope through the
hole in the center of the bottom edge of the door and tie
another knot in the end to keep the rope from pulling through.
For windlocked doors, this is a critical adjustment for the
door to operate correctly. Operate the door fully up and
down multiple times and if any binding or scraping noises
are heard, adjust the door guides to eliminate the binding.
Review Fig 11, VA-A for proper windlock clearance.
Door must operate smoothly before a motor operator
is installed.
NOTE!
NOTE!
Components under extreme spring tension can
cause SERIOUS INJURY or DEATH. Adjustments
and repairs must be made by a qualied door
mechanic using proper tools and instructions. DO
NOT attempt to adjust door tension unless the door
is in the “UP” position and “LOCKED” in place.
WARNING
11. TENSION ADJUSTMENT SYSTEM USE:
11.1 With the door guides adjusted correctly and the door
tensioned properly, the door should open and close very
smoothly and not need the use of the chain hoist or other
opener. With the hand chain hoist disconnected and the door
in the upper third of its height, it should slowly raise by itself
but not raise fast enough to slam into the top stops. With
the door fully closed, it should slowly raise by itself but not
raise fast enough to slam into the top stops. With the door
fully closed, it should be able to be opened when lifted from
the middle of the bottom bar assembly.
11.2 If the tension needs to be adjusted, loosen all 3/8-16
square head set screws in the tensioner, axle saddle, and
chain hoist if applicable.
Serious injury may occur if the door tension is not
fully assumed by the pipe wrench before releasing the
tension on the tension device by pushing upward on the
spring pin. Never force the spring pin. The door tension
must be released before pushing on the spring pin.
WARNING
DOOR PANEL WIDTH + 1.50"
DOOR JAMB
LH DOOR GUIDE RH DOOR GUIDE
WL - GUIDE SPACING
DOOR JAMB
LH DOOR GUIDE RH DOOR GUIDE
NON- WL - GUIDE SPACING
DOOR PANEL WIDTH + 0.750"

Page 8 ©2021 TRAC-RITE DOOR
Figure 18.
Never operate door if the 3/8-16 square head set
screws are not fully tightened on the axle saddles.
WARNING
If the door is easy to close, but hard to open,
increase the spring tension. If the door is hard to
close, but easy to open, decrease spring tension.
NOTE!
11.4 To add tension, grasp the end of the axle pipe with pipe
wrench and apply pressure downward. The cam locks will
disengage as pressure is being applied. The tensioner will
automatically grip the axle and hold the new tension.
11.5 Retighten all 3/8-16 square head set screws that
were loosened in 11.2.
11.6 Repeat step 11 as needed.
13. OPTIONAL FIELD INSTALLED DRAFT STOP OR
BRUSH SEAL:
13.1 Place the door in the closed position before installing
the draft stop. Note that with the door down, the curtain may
bow slightly near the top towards the inside; this bowing is
normal. For the draft stop to be e󰀨ective, it should follow the
“bow” in the door curtain so that it stays in contact across the
entire width of the door curtain. Starting at one end, attach
to header every 9 inches with appropriate fasteners. Cut to
length if necessary.
13.2 Place the door in the closed position before installing
the brush seal. Position brush seal so that it just touches the
valley portion of the curtain. See Figure 20. Fasten brush
seals to jamb every 12 inches with appropriate fasteners.
Tensioning should always be done on the side of the
door that the tension device is installed, with a pipe
wrench minimum length of 18”.
NOTE!
11.3 To remove tension, grasp the end of the axle pipe with a
pipe wrench and apply a slight amount of pressure downward
and hold. Disengage the cam lock by pushing back on the
spring pin. Release tension by moving the pipe wrench
backwards (see Figure 18). Release the spring pin and the
cams will engage to hold tension on the door. Repeat as many
times as necessary.
12. OPTIONAL INTERIOR LOCK INSTALLATION:
12.1 Position door at waist level.
12.2 Assemble components as shown in Figure 18, noting
that two (2) high collar lock washers are placed over each
1/4” one-way screw to allow the lockbar to slide freely.
12.3 As the 1/4” screws are being tightened, move the lock-
bar to assure that the high collar lock washers are inside
the slots in the lockbar.
12.4 Mount the lock strike to the bottom of each guide as
shown with two (2) 1/4” carriage bolts and jam nuts through
the pre-punched holes.
INTERIOR LOCK STRIKE
DOOR CURTAIN
ASSEMBLY
LEFT HAND
DOOR GUIDE
CARRIAGE BOLTS
HEX NUTS
NUT
LOCK WASHER
SLIDE BAR
ONE-WAY SCREWS
LOCK COVER
Figure 19.
Figure 20.
DOOR JAMB
BRUSH SEAL
DOOR GUIDE

©2021 TRAC-RITE DOOR Page 9
15. REPLACEMENT PARTS:
Part No. Description
Locks:
521226 Interior Lock Package
601811 SpaceGuard Latch Package
502705 SpaceGuard Lock
502721 Lock Out Key
Hardware:
650080 Bracket, Universal, RH, LH
502680 42” Rope (8’ - 10’ tall)
508840 72” Rope (10’ - 12’ tall)
508841 90” Rope (over 12’ tall)
671000 Steel Jamb Package
671001 Wood Jamb Package
671002 Concrete Jamb Package
650060 Axle Saddle w/ Tensioner
650070 Axle Saddle
Springs:
650101 RH, 3.375” ID, 0.3125 wire, 49 coils, 15.63”
650111 LH, 3.375” ID, 0.3125 wire, 49 coils, 15.63”
650121 RH, 3.375” ID, 0.3125 wire, 68 coils, 21.56”
650131 LH, 3.375” ID, 0.3125 wire, 68 coils, 21.56”
600961 RH, 3.375” ID, 0.283 wire, 62 coils, 19.50”
Miscellaneous:
502297 Seal-Rite Bulb Seal
521264 Felt Tape, 2”
502065 Guide Runner
502520 Draft Stop
504300 Touch-up Paint, Evergreen
504301 Touch-up Paint, Sunset Orange
504302 Touch-up Paint, Polar Blue
504303 Touch-up Paint, Royal Blue
504305 Touch-up Paint, Desert Tan
504306 Touch-up Paint, Continental Brown
504307 Touch-up Paint, Garnet
504308 Touch-up Paint, Iced White
50430A Touch-up Paint, Cedar Red
504325 Touch-up Paint, Shale
504323 Touch-up Paint, Bright White
504329 Touch-up Paint, Patriot Red
504332 Touch-up Paint, Lime Green
504326 Touch-up Paint, UB Yellow
504290 Touch-up Paint, Light Stone
504331 Touch-up Paint, Ash Gray
Operators:
651050 8:1 Reduced Drive Chain Hoist
625300 MJ1211 Operator
14. MAINTENANCE:
14.1 INSPECTION: Visually inspect the entire door monthly
for general cleanliness and ease of operation.
14.1.1 Inspect the guides and curtain for wear and/or
accidental damage.
14.1.2 Inspect all fasteners and anchor bolts for loose,
damaged, or missing parts.
14.1.3 If door is equipped with a chain hoist mechanism,
inspect it for missing parts.
14.2 CLEANING: No specific cleaning procedures are
required for your Trac-Rite rolling door. Clean as needed
following good housekeeping practices.
14.2.1 Periodically clean any accumulated dirt from guides;
remove any debris from the guide channels at the oor.
14.3 LUBRICATION: Lubricate the following every six months
or more in dusty and/or wet operating environments.
14.3.1 Guides: Open the door. Spray silicone spray, Pledge™,
or Zep 45™ onto the door guide runners and inside the guide.
14.3.2 Lock: Spray the slide lock with silicone spray or
Pledge™ to promote smooth lock operation.
14.3.3 Chain Hoist Parts: Apply a small amount of oil to
roller chain.
Excessive force in operation may cause damage to
the door.
CAUTION