Cumberland Tunnel Door Owner's manual

Brand: Cumberland

Model: Tunnel Door

Type: Owner's manual

Part No. 4801-3500 Rev 2/08 Owner’s Manual Installing Tunnel Door

Tunnel Door

Owners Manual

Hired-Hand, Mfg., Inc.

PO Box 140

1733 County Road 68

Bremen, Alabama 35033

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 2 of 16

Table of Contents

Section Description Page

1. Warnings......................................................................................................................................................3

2. Limited Warranty.........................................................................................................................................3

2. General.........................................................................................................................................................4

4. Framing Diagram.........................................................................................................................................4

5. Installation Instructions................................................................................................................................5

5.1 Hanger Board Assembly.......................................................................................................................5

5.2 P-Seal Material .....................................................................................................................................5

5.3 Install Bottom Channel.........................................................................................................................7

5.4 Install Top Channel...............................................................................................................................8

5.5 Install First Door Assembly..................................................................................................................8

5.6 Install End Channel...............................................................................................................................9

5.7 Making H-Channels............................................................................................................................10

5.8 Mount the Next Panel.........................................................................................................................10

5.9 Install a Top 10 Foot Channel.............................................................................................................11

5.10 Install a Bottom 10 Foot Channel.......................................................................................................11

5.11 Assemble Temporary Door Tie-Up....................................................................................................11

5.12 Tighten the two halves of the Channel ...............................................................................................13

5.13 Install Pulley/Bracket Assemblies......................................................................................................13

5.14 Assemble the Cable System................................................................................................................13

5.15 Adjusting Door for Ventilation...........................................................................................................13

5.16 Sealing the Door.................................................................................................................................14

5.17 Caulking the Door...............................................................................................................................14

5.18 Checking the Door Opening Clearance ..............................................................................................14

Please Retain This Manual for Future Reference

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 3 of 16

1. Warnings

WARNING

Disconnect all Electrical Power before installing the Tunnel Door

2. Limited Warranty

All products are warranted to be free from defects in material and workmanship for a

period of one (1) year from the date of purchase if installed and used in strict accordance with the

installation instructions. Liability is limited to the sale price of any products proved to be

defective or, at manufacturer’s option, to the replacement of such products upon their return. No

products are to be returned to the manufacturer, until there is an inspection and/or a return-goods

authorization (RGA) number is issued.

All complaints should be directed first to the authorized distributor who sold the product.

If satisfaction is not obtained or the name of the distributor is not known, write the manufacturer

that appears below, directed to the attention of Customer Service Manager.

This limited warranty is expressly in lieu of any and all representations and warranties

expressed or implied, including any implied warranty of merchantability or fitness for a

particular purpose. The remedy set forth in this limited warranty shall be the exclusive remedy

available to any person. No person has authority to bind the manufacturer to any representation

or warranty other than this limited warranty. The manufacturer shall not be liable for any

consequential damages resulting from the use of our products or caused by any defect, failure or

malfunction of our products. (Some areas do not allow the exclusion or limitation of incidental or

consequential damages, so the above limitation or exclusion may not apply to you).

This warranty gives you specific legal rights and you may also have other rights that vary

from area to area.

Warrantor: Hired-Hand Mfg., Inc.

PO Box 140

1751 County Road 68

Bremen, Alabama 35033

Phone 256-287-7000

IMPORTANT!

Locate packing slip and make sure that all listed parts are enclosed. If not, call your Hired-Hand distributor

immediately. Please read and understand all instructions in this manual before installing Tunnel Door.

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 4 of 16

Figure 1 – Tunnel Door Framing Diagram

NOTE: X is determined by length of tunnel inlet of existing house. The opening is to be 2”

less on each end than the tunnel door length.

2. General

Part Numbers

System System

Length 5 Foot 4 Foot Length 5 Foot 4 Foot

10 ft 6609-4540 6609-4552

70 ft 6609-4546 6609-4558

20 ft 6609-4541 6609-4553

80 ft 6609-4547 6609-4559

30 ft 6609-4542 6609-4554

90 ft 6609-4548 6609-4560

40 ft 6609-4543 6609-4555

100 ft 6609-4549 6609-4561

50 ft 6609-4544 6609-4556

110 ft 6609-4550 6609-4562

60 ft 6609-4545 6609-4557

120 ft 6609-4551 6609-4563

Split Kit - Used when one system is split into two separate systems 6450-5172

Description

These instructions are for a Tunnel Door System installed in a dedicated wall in an agricultural

confinement building. These instructions cover mounting the Tunnel Door over a Tunnel Inlet System.

The Tunnel Door System can be installed to either a steel framed wall or to a wooden framed wall.

Refer to Figure 1 for Framing Dimensions.

4. Framing Diagram

Structure must be sealed above upper stringer.

Structure must be sealed below lower stringer.

Tunnel inlet opening

A 2x4 layered flat

to seal edge

2x6

2x4

B C

Panel

Height

Dimension

48" 56" 47"

60" 67-3/4" 58-3/4"

Length Dimension C Length Dimension C

10 ft 9' 8" 70 ft 69' 8"

20 ft 19' 8" 80 ft 79' 8"

30 ft 29' 8" 90 ft 89' 8"

40 ft 39' 8" 100 ft 99' 8"

50 ft 49' 8" 110 ft 109' 8"

60 ft 59' 8" 120 ft 119' 8"

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 5 of 16

Figure 3 – Hanger Board Assembly

Hanger Board

2" Min.

Inlet

Opening

Hinge Board

Caulk

Frame the system according to the length of the Tunnel

Door and the Framing Diagram in Figure 1. Be sure to install

the 2x4s on both ends of the system layered to the framing to

provide a good seal to the wall. See Figure 2.

5. Installation Instructions

5.1 Hanger Board Assembly

Mount treated 2 x 4 boards (hinge boards) to the bottom of

the inlet opening. The first and last hinge board must extend 2

inches past each end of the rough opening. See Figure 3. Start

the first nail one (1) inch from the end of the first hinge board and

close to the top of the board. Space the rest of the nails at

approximate 6 inch intervals.

Stagger the location of the nails by placing a nail near the

top, then near the bottom, then near the top, and so on. The top of

the 2 x 4’s must be level horizontally to have a good seal. After

mounting the 2 x 4’s, use silicone caulk (not supplied) between

the wall and the boards, and, between each end of the boards to

seal the cracks.

5.2 P-Seal Material

Unroll Bottom P-Seal material the length of the tunnel door

opening and attach end of the seal to one end of the hinge board.

Pull the seal down to the end of the last hinge board. See

Figures 4 and 5. The bulb of the seal is to be flush with the front

side of the hinge board.

NOTE: Seal material can become twisted in processing

for shipment and when unpacked. Be sure to straighten the

Seal material before attaching it to the Hinge Board.

Notch the end to fit around 2 x 4 filler. Use #10 x 1" wood

screws with neoprene washer. Start one (1) inch from the end of

the Bottom P-Seal. Space each screw every 6 inches. Do not

drive the head of the screws through the surface of the seal.

Notch finished end and cut off excess seal after attaching

seal to end of Hinge Board. See Figure 4.

Unroll Side and Top P-Seal material (See Figure 5) the

length of the tunnel door opening plus 12 feet.

NOTE: Seal material can become twisted in processing

for shipment and when unpacked. Be sure to straighten the

Seal material before attaching it around the Frame.

Start with the edge of the bulb flush with the tunnel opening

and the top of the bulb flush with the back of the Bottom P-seal.

The Side/Top seal is to be tightly compressed against the Bottom

seal. Use #10 x 1" wood screws with neoprene washer. Attach

the lip of the Side/Top seal to the side of the tunnel door opening

as close to the Bottom seal as possible. See Figure 7.

Figure 2 – Frame the System

Figure 4 – Bottom P- Seal

1.95"

.90"

.625"

.60

1.25

Figure 5 – Side/Top P-Seal

2x4 Layered

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 6 of 16

NOTE: At each corner cut

slits in the flat portion of the

seal to allow it to bend

around the corner as

shown.

Figure 8 – Side and Top Seal

Figure 9 – Install the Foam Seal

P-Seal

Hinge Board

Notch Side/Top

P-Seal

Hinge

Board

Do not drive the head of the screw through the surface of the seal. Stretch the seal tight up the side of the tunnel

opening, keeping the bulb flush with the opening, and apply a screw about 4" from the top of the tunnel opening

through the flat of the seal. See Figure 8.

Finish screwing the rest of that length of the Side/Top seal at about 6" intervals. At the corner cut slits in the

flat portion of the seal to allow it to bend around the corner. Drive a screw through each flap created by the cuts.

See Figure 9.

Stretch the Side/Top seal across the top of the tunnel opening, screwing the flat of the seal about every 6". Do

not let the seal sag. At the opposite corner cut the slits again and continue to screw the seal tightly down the other

side. Be sure to have some extra seal at the end to allow material to be cut off for a flush fit as at the start.

P-Seal

Hinge

Board

Figure 6 – P-Seal Assembly Figure 7 – Side Seal Corner

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 7 of 16

Panel

Bottom

Channel

Panel

Bottom

Channel B

Starter Panel

A B

4' 5'

5' 1'

Figure 12 – Beginning Hinge Assembly

Hinges

24"

12"

5.3 Install Bottom Channel

To start assembling the door:

4 Foot Door Bottom Channel 5 Foot Door Bottom Channel

Cut a 10 foot Channel in half making two 5 foot pieces.

Set one piece aside to be used on the opposite end of the

door assembly. (Not required for 10 foot Door System)

Cut one foot from a 10 foot channel. Save 9 foot

channel to be used on the opposite end of the door

assembly.

NOTE: Inaccurate and imprecise cutting of the

10 foot Channel will result in material shortage and

poor performance of the tunnel door.

Lay a panel on the ground. Slide the cut

Bottom Channel onto the bottom of the panel. Slide

the channel down until flush with the outside end of

the panel. Use #10 x 1" self-tapping hex head

screws to attach channel to panel. Start the first

screw approximately 3/8" from the end of the panel

and centered on the side of the channel. The next

screw should be approximately 3/8" from the

opposite end of the channel and centered on the side

of the channel. See Figure 10.

Next, slide a 10 foot Channel onto the

bottom of the panel. From the end of the 10

foot Channel start the first screw

approximately 3/8" from the end of the

channel and centered on the side of the

channel. The next screw should be centered

on the side of the Bottom Channel 3/8" from

the edge of the Panel. See Figure 11.

Starting at the outside end of the panel

begin assembling the hinges. Place the first

hinge 12" from the start of the panel with the

top bend of the hinge flush with the face of

the panel and the bottom bend flush against

the bottom face of the Bottom Channel.

Attach the hinge to the bottom face of the

channel first with #10 x 1" self-tapping

screws, keeping the bottom face of the hinge

level. Then screw the top bend of the hinge

to the face of the panel with #10 x 1" self-

tapping screws. Attach hinges the rest of the

way down the channel piece approximately

every 24" up to end of panel following the

same procedure. See Figure 12.

Figure 11 – First 10 ft. Bottom Channel

Figure 8 – First Bottom Channel

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 8 of 16

Figure 14 – Top Channel Assembly

Figure 15 – Attach First Door panel Offset

Panel

Top

Channel

Section A-A

P-Seal

Section A-A Top View

Post

Side/Top Seal

Bottom Seal

Door Panel 2"

2 x 4 Framing

NOTE: Always attach the bottom bend of the

hinge to the bottom face of the channel first.

Attaching the hinge to the face of the panel first will

cause the bottom bend to tilt at an angle and the

hinge will not be parallel with the panel surfaces or

the face of the Hinge Board. See Figure 13.

5.4 Install Top Channel

Start to assemble Top Channel:

4 Foot Door Top Channel 5 Foot Door Top Channel

Cut a 10 foot Channel in half making two 5 foot

pieces. Set one piece aside to be used on the

opposite end of the door assembly.

Cut one foot from a 10 foot channel. Save 9 foot channel to

be used on the opposite end of the door assembly.

Slide the shortened Top Channel onto the panel until the

end of the channel is flush with the outside end of the panel.

Start the first screw approximately 3/8" from the end of the

panel and centered on the side of the channel. The next

screw to be approximately 3/8" from opposite end of channel

and centered on side of channel. See Figure 14.

5.5 Install First Door Assembly

Lift the first door assembly and rest the bottom channel on the Bottom P-Seal. With hinges flipped

down, place the door assembly flush with the outside of the bulb of the Side/Top seal. See Figure 15.

NOTE: While it is normal for the Bottom P-Seal to deform under the

weight of the door, do not let the Bottom P-Seal roll over. If it is necessary to

slide the door assembly on the Bottom P-Seal do so carefully so it will not tear

or roll.

Figure 13 – Attach Hinge

Hinge

Self Tapping Scre

ttach this surface

first

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 9 of 16

Hinge

Hinge Board

After setting the door assembly on top of the Bottom P-Seal, one person pulls down on the door to compress the

Bottom P-Seal. Another person attaches the bottom plate of hinge to the Hinge Board with (3) #10 x 1" self-tapping

hex head screws. Tighten down the screw head until it comes in contact with the hinge. See Figure 16.

NOTE: Do not put screw through top RH screw hole in hinge plate.

This hole is to close to the top of the Hinge Board. A screw going into this hole can drill into the seal.

NOTE: Do not over tighten hinge screws.

NOTE: Do not attach hinges to Hinge Board beyond the end of the panel being mounted on Hinge

Board.

After mounting the door, no outside light should show and air should not pass between the door and the P-Seal.

5.6 Install End Channel

4 Foot Door End Channel 5 Foot Door End Channel

Cut a 10 foot Channel into two 4 foot pieces to make

two End Channels. Cut a 10 foot channel into two 5 foot pieces to make two

end channels.

Remember to be precise. Cut notches in both ends of

both pieces of channel 1-1/16" from the end, cutting out

the sides down to the inside of the bottom face. One End

Channel will be used on the opposite end of the Tunnel

Door assembly. Save it for later. See Figure 17.

Slide End Channel onto the end of the panel. Attach

the channel with #10 x 1" self-tapping hex head screws. At

the top of the channel start the first screw approximately

3/8" down from the top edge of the End Channel and

centered in the side of the channel. Do the same on the

opposite end of the End Channel approximately 3/8" up

from the bottom.

Figure 15 – End Cap Notch

1 -1/16"

Figure 16 – Hinges Attached to Hinge Board

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 10 of 16

Figure 18 – Male H-Channel

of 0006-5052 Figure 19 – Female H-Channel of

0006-5052 Figure 20 – H-Channel Assembly

0006-5052

H-Channel

Second 10 ft Panel

H-Channel

1 Foot Gap

ure 21

ure 22

5.7 Making H-Channels

4 Foot Door H-Channels 5 Foot Door H-Channels

Cut a 10 foot Male H-Channel section and a 10 foot

Female H-Channel section into 46-3/16" pieces. One set

of H-Channel sections will be used between each panel.

Example: A 60 foot Tunnel Door has six 10 foot wide

panels and will require 5 sets of 46-3/16" H-Channel.

Cut a 10 foot Male H-Channel section and a 10 foot

Female H-Channel section into 57-3/4" pieces. One set

of H-Channel sections will be used between each panel.

Example: A 60 foot Tunnel Door has fifteen 4 foot wide

panels and will require 14 sets of 57-3/4" H-Channel.

To form the H-Channel, take a Male section and a Female section and hand squeeze the two sections together.

Do not force the mating sections to bottom out. To do so will make the H-Channel difficult to assemble to the

panels. Enough room will need to be left to allow the ends of the panels to easily slide into the H-Channel.

5.8 Mount the Next Panel

Slide the next panel into Bottom Channel. Push the panel towards the mounted panel. Do not push the panels

together yet. Leave a one (1) foot gap. Slip the H-Channel over the end of the mounted panel. Pull the H-Channel

up against the Top Channel. Screw in a #10 x 1" self-tapping screw approximately 3/8" down from the top of the H-

Channel and1/2" from the center. Add a screw half way down the H-Channel and 1/2" from the center. Add a

screw approximately 3/8" from the bottom and 1/2" from the center. See Figure 21.

As one person pushes the second panel towards the mounted panel, the other person slips the H-Channel over

the second panel as they come together. Add screws through H-Channel into second panel as before. See Figure 22.

Attach the Bottom Channel to second 10 foot panel with #10 x 1" self-tapping hex head screws as described in

Section 5.3.

Five (5) foot high Tunnel Doors have four (4) foot wide panels. This allows two panels to be slide onto a 10

foot channel. Just add the H-Channel between each panel.

NOTE: Do not mount hinges at this time.

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 11 of 16

Pulley

Figure 25 – Pulley Installation

10 Foot Bottom

Channel

ure 24

Mark Holes

Bracket

Figure 25

–

Bracket Placement

Elevator Bolt

Top of Doo

Figure 25B – End Cap Notch

5.9 Install a Top 10 Foot Channel

At the top of the panel, slide a 10 foot Channel onto the panel until the end of the channel is flush with the end

of the 5 foot Top Channel. Attach the 10 foot Channel with #10 x 1" self-tapping hex head screws. Start the first

screw approximately 3/8" from the end of the channel and centered on the side of the channel. Repeat at the

opposite end of the panel approximately 3/8" from the edge of the panel. See Figure 23.

5.10 Install a Bottom 10 Foot Channel

Pull up slightly on the end of the Door Assembly and slide a second 10 foot Channel onto the bottom of the

Second Panel. Use a short 2 x 4 or any other object with a flat surface to tap the Channel over until it is flush with

the 10 foot Channel that was previously assembled.

NOTE: Do not bend or ding the corners of the Channel. Ensure the Bottom P-Seal does not get torn or rolled.

Attach the Channel to the panel as before. Attach the hinges to the channel as before but with the door mounted

in the opening. This will require a drill that will allow the operator to drill in the screws from underneath the door.

Do not screw the hinges into the Hinge Board until after the next panel is in place. See Figure 24.

5.11 Assemble Temporary Door Tie-Up

At this point the door assembly will become heavy. To support door

while being assembled add nylon rope/bracket assembly.

Take a 7/8” Pulley supplied with the Tunnel Door Assembly. Measure

6” above the Panel. Place a mark ½” from the edge of the post on the side of

the post toward the winch. At the mark, bolt a 7/8" Nylon Swivel Pulley

using a #10 x 1" self-threading screw and a 3/16" Fender Washer. All

pulleys will be on side of post toward the winch. See Figure 25.

If starting Tunnel Door Assembly from the end of the door closest to the

winch, take the first Tunnel Door Bracket and place it flush with the inside

edge of the End Channel. Place the 45° bend turned outward and even with

the top of the panel. Place a mark through the two bottom holes of the

Bracket. Drill 1/4” holes through the panel at the marks. Be careful not to

drill into the seal. See Figure 25A.

Press Elevator Bolts through the holes from the back side of the door

panel until the square shoulder on the bolt goes into the hole and the head is

flush with the back of the panel. See Figure 25B

For all other Bracket installations along the length of the Door, line up

the holes in the Tunnel Door Bracket with the center of the Pulley wheel and

the 45° bend even with the top of the panel, turned outward. Mark the

Bracket mounting hole locations. Drill and insert Elevator Bolts as

previously describe.

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 12 of 16

Thread the long section of Nylon

Rope through the pulley. Loop the

Nylon Rope around the Bracket and

tie it off with a temporary knot.

Loosen the Thumb Nut Assembly.

At the top, push on the Panel with

one hand against the seal and pull

down on the short end of the rope to

take out the slack. Hold the rope

tight while screwing the wing nut

half of the Thumb Nut back down

against the rope. See Figure 27.

The rest of the Temporary Door Tie

Ups should be placed a maximum of

every 30 feet. Mount the 7/8”

pulley on the side of the post

towards the winch. Then mount the

Tunnel Door Bracket as previously

with the holes in line with the center

of the Pulley wheel. Assemble the

rope as previously instructed. See

Figure 28.

Cut 10 foot length of 3/16”

Nylon Rope from the supplied roll.

Thread length of rope through the

first hole from the top of the Bracket

with 6 to 12 inches hanging below

the hole. Thread the end of the rope

through the bottom hole in the

Bracket. Lay the 6” to 12” section

of the rope against itself. See

Figures 25C–25E. Slide the slotted

half of the 3/16” Curtain Thumb

over the two sections of rope and

tighten down the wing nut half of

the Thumb Nut against the rope.

See Figure 26.

Figure 25C Figure 25D Figure 25E

Thread Nylon

Rope Into

Top Bracket

Hole

Loop Nylon

Rope Thru

Bottom

Bracket Hole

Pull Nylon

Rope Tight

Thru Bracket

Holes

Figure 26 Figure 27 Figure 28

Repeat Sections 5.7 through 5.11 until the end of the Tunnel Door opening at which time mount the second set

of shortened Top and Bottom Channels, along with the End Channel. The last panel may have to have excess panel

length cut off before the Top, Bottom, and End Channel is assembled.

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 13 of 16

ure 29

Figure 30A

ure 30C

Figure 30B

5.12 Tighten the two halves of the Channel

Loosen the Temporary Door Tie Ups and slowly lower the door as far as possible. While assistants hold door,

use a rubber mallet to tap the back of the H-Channel assemblies to tighten the two halves of the channel together. If

the lower part of the H-Channel cannot be reached with the mallet, the end of a long 2 x 4 can be used.

5.13 Install Pulley/Bracket Assemblies

At every post throughout the entire length of the Tunnel Door Assembly

where temporary door tie ups have not already been added, place 7/8” Pulleys 6”

above the Panel ½” from the side of the post toward the winch and install the

Tunnel Door Brackets using the procedure described in Section 5.11.

5.14 Assemble the Cable System

Assemble the desired cable system, stringing the cable above the

Tunnel Door. Determine how you will attach the Nylon Rope to the

cable.

Untie the Nylon Rope for the temporary tie ups from the

brackets and pull the rope through the pulley with the direction of the

rope going toward the winch. Do the same thing at each post,

progressing back toward the winch. See Figure 29.

5.15 Adjusting Door for Ventilation

Determine how far the Tunnel Door will travel when lowered for ventilation. It is recommended that the

distance be no more than the center-to-center distance between each post. At that approximate distance from the

7/8" Pulley on the wench side, attach the Nylon Rope onto the cable using the method you desire. Do this the entire

length of the Tunnel Door. At the end of the Door nearest the winch, measure the desired travel distance down the

cable, towards the winch, and attach the Nylon Rope onto the cable. If the location of the winch and/or pulley

assemblies will not allow for the last Nylon Rope to be attached at the travel distance beyond the Tunnel Door, a

double back system can be used. See Figures 30A – 30C.

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 14 of 16

Door Height* A

4' 49.5"

5' 61.25"

* Maximum Angle=80°

80°

Door Hei

5.16 Sealing the Door

Now that all the Nylon Rope lengths have been attached to the cable, it is necessary to tighten the ropes to seal

up any leaks around the seal. Starting at the end opposite the wench, loosen the wing nut on the Curtain Thumb Nut

enough to pull the Nylon Rope down. Push with one hand on the top of the door. Pull the Nylon Rope as tight as

possible. A pair of vice gripes clamped to the end of the rope can aid in this. While keeping the rope tight, re-

tighten the Thumb Nut. Repeat this process the entire length of the Tunnel Door. When finished, the P-Seal should

be compressed and no daylight should be showing across the top of the Door. If this is not the case, repeat these

instructions.

5.17 Caulking the Door

To insure that all leaks are sealed, caulk (not supplied) the cracks between the End Channel and the Top and

Bottom Channel at both ends of the Tunnel Door. Caulk between the H-Channel and the Top and Bottom Channel

the length of the Tunnel Door.

5.18 Checking the Door Opening Clearance

The installation is now complete.

Part No. 4801-3500 Rev 2/08 Installing Tunnel Door Page 15 of 16

NOTES

Cumberland Tunnel Door Owner's manual

Cumberland Tunnel Door Owner's manual

Cumberland Tunnel Door Owner's manual

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