INSTALLATION & MAINTENANCE
Commercial & Industrial Sectional Doors
Model: ____________________ Serial No. _________________________________________
(Provided on label on interior door surface)
Size: _____________________
Retain This Booklet For Future Reference
This Manual Contains Important Safety Information
________________________
COMMERCIAL HOTLINE • 1-800-526-4301
2
Table of Contents
Introduction and Opening Preparation
Safety Information ..........................................................................................................3-4
Things to Know Before You Begin .....................................................................................5
Removing the Existing Door ..............................................................................................6
Preparing the Opening ......................................................................................................6
Installing the New Door
Preparing and Installing Door Sections .............................................................................8
C-Channel Attachment (Non-Windload Doors Only) .......................................................10
Lock Installation ............................................................................................................... 12
Track Installation .............................................................................................................15
Standard Radius .....................................................................................................17
Roof Pitch ...............................................................................................................23
Low Headroom Rear Mount....................................................................................24
Low Headroom Front Mount ...................................................................................26
Vertical Lift ..............................................................................................................27
High Lift...................................................................................................................28
Spring Installation ............................................................................................................18
Spring Winding ................................................................................................................19
Maintenance/Adjustments/Options
Final Adjustment and Maintenance ................................................................................22
Attaching an Automatic Opener ....................................................................................... 29
Painting and Windows .....................................................................................................30
Quick Turn Bracket ..........................................................................................................31
Pass Door Instructions ....................................................................................................31
Dear Clopay Customer,
Thank you for purchasing a Clopay Garage Door. Your new Clopay
Garage Door was built to meet the highest industry standard and to
provide you with years of dependable performance.
This manual contains important safety, installation and
maintenance instructions. Carefully follow the instructions and
maintenance recommendations. Please keep this manual for future
reference.
If you should require any assistance or additional information, please
call Clopay at 1-800-526-4301.
Thank you again for choosing Clopay!
Sincerely,
Clopay Building Products Company
America’s Favorite Garage Doors
™
3
SAFETY INFORMATION
I M P O R T A N T !
To Protect Yourself From Injury,
Carefully Read The Following Safety
Information And Warnings Before You Install
Or Attempt To Repair Your New Garage Door
• YoucaninstallyournewgaragedooryourselfIF…
1. you have help (weight can vary from 150 lbs. [70 kg] up to 2,000 lbs. [900 kg]);
2. you have the right tools and reasonable mechanical aptitude or
experience; and
3. you follow these instructions very carefully.
In particular, please note that:
• Garagedoorsusespringstobalancethem.Generally,therearetwotypesofspringsused—extension
springs and torsion springs. If your old door uses torsion springs, do not attempt to remove the
door or the springs yourself. Have a qualified door repair service remove them. Attempting to remove a
torsion spring assembly and/or any red-colored fasteners without proper training or tools may result in an
uncontrolled release of spring forces which can cause serious or fatal injury.
• Thebracketsatthebottomcornersofyourgaragedoorareundergreattension.Do not attempt to
loosen any bracket fasteners and/or any red-colored fasteners except when and as directed in detail in
the following instructions. Otherwise, the bracket could spring out with dangerous force.
• Wheninstallingadoorwithtorsionsprings,alwaysusesolidsteelwindingbars.Windingbarsareavail-
able from many professional door installers. The use of screwdrivers or any substitutes for winding
bars will risk severe injury. See page 19 for further safety instructions regarding winding bars.
• Keephandsandngersclearofsectionjoints,track,andotherdoorpartswhenthedoorisopeningand
closing to avoid injury. The lift handle and pull down rope are located for safe operation as well as easy
use.
• Extension spring doors must never be operated without a properly installed spring containment
cable.
• Boltsmustbeinstalledattherearendofhorizontaltracks.Theseacttostoptherollersandkeepthe
door from rolling off the back of the track.
• Only the track and hardware specified and supplied with the door should be used.
• Expresswarrantiesapplyonlytodoorsinstalledusingoriginal,factory-suppliedsections,parts,andhard-
ware installed in strict accordance with these instructions.
4
SAFETY INFORMATION
I M P O R T A N T !
To Protect Yourself From Injury
Carefully Read The Following Safety
Information And Warnings Before You Install
Or Attempt To Repair Your New Garage Door
• Trackinstallationsmustuseswaybracesonthereartrackhangerstopreventsidewaysmovement.If
the tracks are not firmly stabilized they might spread, allowing the door to fall and cause severe injury
and damage.
• Thecentertorsionspringassemblyusesawoodenpad(2"x6"x12"[51mmx152mmx305mm]
minimum) minor steel plates (
1
⁄
4
"thickx10"x12"[6mmx254mmx305mm]minimum)thatmust be
of good quality and firmly attached to the wall. Four
3
⁄
8
"x3"[10mmx76mm]lagscrewsshould
beusedtoattachwoodstructure.ThewoodneedstobemadeofaGrade2orbetterSouthernYellow
Pine (also known as Southern Pine or Yellow Pine.) DO NOT use wood labeled as Spruce-Pine-Fir (or
SPF). Four
3
⁄
8
"[10mm]masonryanchorscanbeusedonconcreteorblockwalls.Ifthewoodsplitsonce
the torsion spring is in place, it should be replaced by a professional installer. Do not try to remove or
repair a torsion spring assembly or any red-colored fasteners once it is wound.
• Springs,cables,andbottomxturesareunderstrongspringtension.Do not attempt to loosen any
fasteners on these components. You could suddenly release spring forces and risk severe injury.
• Ifthegaragedoorand/oranyofthesupportingtrackaredamaged,operatingthedoorcouldbehazard-
ous. Call an authorized representative of the manufacturer or professional door repair service promptly.
• Do not permit children to play beneath or with any garage door or electric operating controls.
• Ifrepairsareeverrequiredtoyourdoor,safetyandtrouble-freeoperationcanbebestassuredbyusing
original replacement parts.
• Onceyouhavecompletedtheinstallationofyournewgaragedoor,pleasebesurethatyourgarage
complies with all applicable ventilation requirements before you enclose any vehicles in the garage.
Goodventilationavoidsreandhealthhazardscausedbyfumesaccumulatingwithinawell-sealed
garage.
• ClopayBuildingProductsCompanydisclaimsallliabilityforanyinstallationwhichisnotincompliance
with applicable state, county, or local building codes.
• Doorsequippedwithautomaticdooroperatorscancauseseriousinjuryordeathifnotproperlyadjusted
and operated. To insure safe operation of these doors:
a) test the sensitivity of the operator’s safety reverse mechanism monthly;
b) remove the pull rope;
c) make sure the door remains unlocked;
d) do not allow children to play with the controls.
e) do NOT install jackshaft openers on doors with standard lift or low headroom track.
5
IMPORTANT!
Before Starting Installation:
Step 1: Check the opening size and verify that
the door is the proper size for the opening. Wood
jambs require the door to be the same size as
the opening with stop moldings nailed to inside of
opening to seal the door. Steel jambs require the
door to be two-inches wider than the opening to
allow a one-inch door overlap on each side. No
stop moldings are required in this application. The
opening must be plumb and square to assure a
good fit.
Step 2: Check all materials with the pick slip found
in the hardware carton. Any report of shortages
must be accompanied by the Clopay contract num-
ber. A copy of the pick slip is kept at the factory.
Report the number of pieces received along with
the number of pieces short. Springing information,
including the number of turns to wind spring, can
be found on the hardware box label.
Step 3: Check for sufficient headroom and side
room. The chart below contains approximate
clearance requirements. Headroom is the distance
between the top of opening to the ceiling or the
lowest obstruction.
Step 4: The hardware package supplied with your
door should include red fasteners for attachment of
the torsion spring center bracket and/or the bottom
roller brackets. These fasteners must be securely
attached as indicated in the installation manual.
Things to Know Before
You Begin
Read the instructions completely before starting
the installation of the door. Becoming familiar with
the components before assembling the door will
reduce the installation time.
Clearance Requirements
Headroom*
,
**
,
*** Sideroom* Backroom
2"[51mm]Track3"[76mm]Track2"[51mm]Track3"[76mm]Track2"[51mm]Track 3"[76mm]Track
12"[305mm]Radius14
1
/
2
"[368mm]N/A4
1
/
2
"[114mm] 5
1
/
2
"[140mm] DoorHt.+23" DoorHt.+25"
15"[381mm]Radius16"[406mm]18"[457mm] 4
1
/
2
"[114mm] 5
1
/
2
"[140mm] DoorHt.+23" DoorHt.+25"
Low Headroom 6
1
/
2
"[165mm]10"[254mm]6"[152mm] 6
1
/
2
"[165mm] DoorHt.+30" DoorHt.+32"
Rear Torsion
Low Headroom10"[254mm]13"[330mm] 6"[152mm] 6
1
/
2
"[165mm] DoorHt.+23" DoorHt.+25"
Front Torsion
HighLiftHighLift+12"HighLift+12" 4
1
/
2
"[114mm] 5
1
/
2
"[140mm] Varies Varies
Vertical Lift Dr.Ht.+12"Dr.Ht.+12" 4
1
/
2
"[114mm] 5
1
/
2
"[140mm]23"[584mm] 25"[635mm]
* Doors over 18' [549 cm] high, over 1,000 lbs. [454 kg] springing weight, high cycle springs, may require additional
headroom and sideroom. Consult distributor for exact requirements.
* Doors with more than one row of springs require additional headroom.
** Chain hoist and electric operators require additional clearance. See instructions provided with operator for exact
amount.
*** Vertical lift doors with straight incline require additional headroom. Contact factory.
In the interest of safety this symbol means
WARNING or CAUTION. Personal injury and/or
property damage may occur unless instruc-
tions are followed carefully.
• Toavoiddamagetothedoor,youmustreinforce
the top section of the door in order to provide a
strengthened mounting point for attachment of
an automatic opener (see page 29).
• Checkheadroomclearancerequirementsinthe
chart below before beginning.
Springs and related hardware are under
EXTREME spring tension and could cause SE-
VERE INJURY OR DEATH if mishandled.
DO NOT ATTEMPT TO REPAIR OR ADJUST the
springs, red fasteners, hardware, or structure
to which they are attached.
[584 mm]
[635 mm]
[584 mm]
[635 mm]
[762 mm]
[813 mm]
[584 mm]
[635 mm]
[305 mm]
[305 mm]
[305 mm]
[305 mm]
6
Tools Needed
• “C”ClampsorLockingPliers
• Hammer
• WindingBars(TorsionOnly)
• Screwdriver
• TapeMeasure
• Level
• Socketwrenchkit
• Pliers
• Drill,and
1
/
4
"[6mm],
3
/
16
"[5mm],&
3
/
8
"[10mm]bits
• Stepladder
• Sawhorsesorothersupportsforplacingsection
on while assembling
Removing the Existing Door
Garagedoorsusespringstobalancethedoor
weight.Generallytherearetwotypesofsprings
used—extensionspringsandtorsionsprings. If
your present door uses torsion springs, have
a qualified door service professional remove
them. Attempting to remove a torsion spring as-
sembly without proper training and tools may result
in an uncontrolled release of spring forces which
can cause serious or fatal injury.
Preparing the Opening
Step 1: On the inside of the garage your opening
shouldbeframedwithwoodjambs,2"x6"
[51 mm x 152 mm] if possible, or with steel chan-
nel as shown in Figure 1-J. The side jambs should
extend to approximately the same height as the
headroom required. If you have just removed an
old door, the condition of the jambs should be
inspected. If the jamb has deteriorated, it should
be replaced now. The jambs should be plumb and
the header level. If there are any bolts fastening the
jambs to the wall, the heads should be flush so they
don’t interfere with the installation of your new door.
(FIG.1-J)Typicalinstallationforwood,steel
or masonry jamb material is shown in Figure 2-J.
Step 2: Door stop molding for wood jambs should
be temporarily nailed to the edges of the jambs flush
withtheinside.(FIG.3-J)Sincesteeljambsrequire
thedoortobe2"[51mm]widerthantheopening,
no stop molding is required. Stop molding featuring
a built in weather seal is offered as an option.
Fig. 1-J
Fig. 3-J
Fig. 2-J
WOOD JAMB TO WOOD FRAME
WOOD JAMB TO CONCRETE
(Bracket Mount or Continuous Angle)
1"
Over-
lap
1"
Over-
lap
5
/
16
" x 1"
1" Overlap
5
/
16
" x 1
5
/
8
"
Lag Screw
Masonry Anchor
Countersunk
Lag Screw
(Bracket Mount or Continuous Angle)
CONCRETE JAMB
(Reverse Angle)
STEEL JAMB
(Reverse Angle)
Counter-
sunk
Lag
Screw
1
/
4
" x 1
1
/
2
"
(Min.)
1
1
1
1
[51 mm x 152 mm] 2 [95 mm] 3 [203 mm]
3
Self Tapping
Screw
1
2
3
1
4
1
4
5
/
16
" x 1
5
/
8
"
Lag Screw
1 [25 mm] 2 [6 mm x 38 mm] 3 [8 mm x 25 mm] 4 [8 mm x 41 mm]
3
/
4
"
2
7
If your door has a torsion assembly, you must
make sure that the wood or steel anchor pad
is of good quality, free of cracks or splits,
and is firmly attached to the garage wall.
(Fig. 1-J) Failure to securely attach the anchor
pad could allow the springs to violently pull
away from the garage wall, and could result in
severe injury and/or property damage. Under
no circumstances should the anchor pad be
attached with nails.
RefertoFigure1-J&2-Jforthecongurationof
2"x6"[51mmx152mm]woodjambs.
IMPORTANT: The wood anchor pad must be
madeofaGrade2orbetterSouthernYellow
Pine (also known as Southern Pine or Yellow
Pine)2"x6"x12"[51mmx152mmx305
mm] minimum. The Southern Yellow Pine must
be free of splits and cracks. Do not use wood
labeled as spruce-pine-fir (or SPF). Steel
anchor pads should be
1
/
4
"x10"x12"[6mmx
254 mm x 305 mm] minimum, securely fastened
to the structure.
The wood anchor pad must be installed into the
frame of the garage with at least four
3
/
8
"x3"
[10 mm x 76 mm] long lag screws (one at each
corner). The four lag screws must be installed
no closer than 1
1
/
2
"[38mm]fromthesides
andtheendsofthe2"x6"[51mmx152mm].
These lag screws must fasten into the structural
frame of the building, not the drywall or sheet
rock. Wood anchor pad and
3
/
8
"x3"[10mmx
76 mm] lag screws are not supplied.
NOTE: The anchor pad can be off-center to the
widthoftheopeningbyupto10"[254mm]in
either direction.
ASSEMBLED VIEW
(5) #14 x
3
/
4
"
Red-Colored
Self-Drilling
Screws
Roller Carrier
(2" or 3" Track)
Cotter Pin
Bottom Bracket
End Stile
Lift Cable
Fig. 1-S
(4) #14 x
3
/
4
"
Red-Colored
Self-Drilling
Screws
End
Stile
ASSEMBLED VIEW
Bottom
Bracket
Lift
Cable
STANDARD DUTY BOTTOM
BRACKET ASSEMBLY
HEAVY DUTY BOTTOM BRACKET ASSEMBLY
Cable Pin
Red fasteners must be used for attachment of
the bottom roller brackets on commercial doors.
1
1
2
3
1 [6 mm x 19 mm] 2 [51 mm] 3 [76 mm]
For Torsion Springs Only
8
Preparing and Installing Door
Sections
Step 1: Bottom Section. Find bottom section (the
one with bottom weatherseal), then lay it on saw
horses. Find bottom bracket in hardware carton.
Several different types are used depending on
door thickness, door weight, and track size. Find
the type of bottom bracket supplied in one of the
pictures shown in Figure 1-S and fasten bottom
bracket using the red-colored fasteners shown.
(Low headroom doors refer to Figure 8-T, page 2
Fig. 2-S
End Hinge Top of Each Section
Bottom #2 #3 #4 #5
Section Section Section Section Section
2"[51mm]Trackexcept Continue
as listed below #1 #2 #3 #4 in this
manner
2"[51mm]Trackwith
Vertical or High Lift, (4) or #2 #4 #6 #8 N/A
(5) section high doors only
3"[76mm]Trackexcept Continue
as listed below #3 #4 #5 #6 in this
manner
3"[76mm]Trackwith
Vertical or High Lift, (4) or #4 #6 #8 #10 N/A
(5) section high doors only
Roller
14 GA.
Roller
#1 #2 #4 #6#5
SIDE VIEW
HINGES ARE TALLER WITH
INCREASING NUMBER
#3
HINGE ILLUSTRATION &
ROLLER PLACEMENT
#2, 3, 4, Hinge
#1 Hinge
14 GA.
18 GA.
Center Hinge
– All center hinges are #1 hinges (except for full vision sections, and
Full View doors, see page 13).
– Start end hinge sequence at the top of bottom section.
– Double end hinges use the same # hinge as outside end hinges.
– Rollersinendhingeswillusefarthestsleevefromsection.(FIG.2-S)
– To match the taper of the track some numbered end hinges may repeat instead of increasing
sequentially. For example, a 10’ high door with five sections may have the #3 hinge repeat, in
which case the door would be installed with the following hinge pattern (starting from the bot-
tom): #1, #2, #3, #3, #4. Which and how many hinge numbers repeat depends on the door size
and model. Hinges should always be installed so that the numbers are in increasing order start-
ing from the bottom. Repeating hinge numbers should be located consecutive to each other.
Some have flanges which hook under the bot-
tom section and some do not. Install cables,
thenpositionthebracketinplace.(FIG.1-S)
Install hinges on end and center stiles of the
bottom section using #14 x
3
/
4
"[6mmx19mm]
self-drilling screws. See Figure 2-S for sequence
and hinge placement. For Model 901 doors and
doors with Full Vision see page 13. Stack bot-
tom section in opening. Long stem rollers pro-
vided go into bottom brackets. Install vertical
track as described on page 15. Top rollers will
hold section in place.
Preparing and Installing
Door Sections
Step 1: Bottom Section. Find bottom section (the
one with bottom weatherseal), then lay it on saw
horses. Find bottom bracket in hardware carton.
Several different types are used depending on door
thickness, door weight, and track size. Find the type
of bottom bracket supplied in one of the pictures
shown in Figure 1-S and fasten bottom bracket using
the red-colored fasteners shown. (Low headroom
doors refer to Figure 8-T, page 23.)
9
Fig. 3-S
End
Stile
#1 Hinge
INSTALLED
Strut
Use (2) #14 x
3
/
4
" [6 mm x 19 mm] Self-Drill-
ing Screws. No Pilot Hole Required. Install
Any Location On Hinge But Thru Slot.
ATTACHMENT VIEW — EXPLODED
*Some Doors Have One
More Strut Than Sections,
Place Extra Strut Here.
SINGLE-END HINGED DOOR
Double
End Stile
DOUBLE-END HINGED DOOR
Strut
Single End Stile
Center Stile
Top Bracket
Place Roller
Through
Both Hinges
When Installing
Bottom
Bracket
Sheet Metal Screw
Installed. Self-Drilling
Screws Into Strut
Strutting Schedule
NOTE: All doors do not require struts, follow
instructions listed below according to the number of
struts supplied.
• Number of struts will be shown on hardware
box.
• Allstrutsareattachedwith#14x
3
/
4
"[6mmx19mm]
self-drilling screws to center stiles and end stiles.
• Whenonlyonestrutissupplieditistobemounted
onthetopsection.(FIG.3-S)
• Whenanequalnumberofstrutsandsectionsare
supplied, install one on each section as illustrated,
omittingstrutwithasterisk.(FIG.3-S)
• Ifyourdoorcontainslessstrutsthansections,
evenly distribute the struts from bottom to top.
• Doorsinstalledinhighwindloadregions(Florida
and other hurricane prone areas) may require
additional reinforcement beyond what is detailed
in these instructions. Please refer to engineering
drawings for these areas.
• When there is one more strut provided than
the number of sections this strut is to be
mounted on the bottom section over the bot-
tom bracket as shown in illustration.
(FIG. 3-S)
• Topstrutistobemountedwithtopedgeofstrut
1
/
4
"[6mm]downfromtopofdoorandabovetop
bracketasillustrated—exceptonlowheadroom
installations,seepage23.(FIG.3-S)
• Withsectionfacedownonsawhorses,place
strut on top of section (section should be flat).
Fasten strut at each end stile and each hinge
hole location. Attach each end of the strut first,
then attach center.
10
C-Channel Attachment
(Non-Windload Doors Only)
If you have a windload door, refer to instructions or
drawing provided with door.
Insulated Sandwich Doors Only
Before installation of hinges, tear the liner off the
adhesive on the EPS backer plates and apply
vertically across the section at each center hinge
location.(FIG.4-S)
All Doors
While Section is still on sawhorses, place
C-Channel in the middle of section, with open end
facing down. Using the access holes at each end of
the C-Channel, attach (1) #14 x
3
/
4
"[6mmx19mm]
self-drilling screw through the bottom of the
C-Channel and into the Stile or EPS Backer Plate.
All Doors
Attach the C-Channel straps to the channel and
the stile (or EPS backer plate), using (3) #14 x
3
/
4
"
[6 mm x 19 mm] self-drilling screws, at right. One
strap is to go on each end of the channel, and a
strap is to be placed at each center stile location.
ASSEMBLED
Center
Stile
Or EPS
Backer
Plate
Double End Stile
C-Channel
C-Channel
Strap
#14 x
3
/
4
" [6 mmx 19 mm]
Self-Drilling Screw
Fig. 4-S
11
Fig. 1-LAP
Fig. 2-LAP
Outside
Inside
Inside
Outside
Section Seal
Tongue
Area
Groove
Area
Bottom Bracket
Fig. 7-S
Step Plate
(2) #14 x
3
/
4
" [6 mm x 19 mm] Self-
Drilling Screws Thru Lift Handle,
Bottom Bracket And End Stile
Lift Handle Instructions
Step 2:
Locate the step plate on the upper portion of
either bottom bracket and attach with (2) #14 x
3
/
4
"[6mmx19mm]self-drillingscrews.(FIG.7-S)
Mount the rolled grip lift handle in line above the
step plate using (2) #14 x
3
/
4
" [6 mm x 19 mm]
self-drilling screws. Orient the handle vertically on
the end stile.
Section Seal. If section seal is provided or bought
as an option, it should be installed over the inside
ship lap or inside the groove as indicated in
Figure 1-LAP and Figure 2-LAP.
Step 3:
#2 Section. Attach bottom half of center hinges
to top of section using #14 x
5
/
8
"[6 mm x 16 mm]
hex head sheet metal screws. Attach end hinges.
(FIG.2-S)IfsectionhaslockseeStep4forse-
quence. Stack section. After section is stacked,
rollers in the track will hold section in place. (If
struts are supplied see Figure 3-S for placement.)
12
Fig. 10-S
End Stile
Track
Engaging
Slot
Fig. 9-S
Fig. 8-S
End Stile
Top of Section Top of Section
(3) #14 x
5
/
8
"
[6 mm x 16 mm]
Sheet Metal
Screws
Roller
(4) #14 x
5
/
8
"
[6 mm x 16 mm]
Sheet Metal
Screws
Roller
4" [102 mm]
Track
18"
[457 mm]
To End
Of Panel
Lock Installation
Step 4: The following locking systems are available
for commercial steel doors:
• SideLock(FIG.8-S)
• InsideSlideBolt(FIG.9-S)
1. Attach the side lock assembly to the second sec-
tion. Unless otherwise specified, this stile will be
located18"[457mm]infromtherighthandsideof
the door (inside facing out). Secure the lock cylinder
#2 with the two long machine screws as illustrated.
Attach the handle (1) and inside lock mechanism
(7), using the fasteners provided.
NOTE: 1
3
/
4
"[44mm]thickdoorsshouldusethe
1
3
/
4
"[44mm]panheadmachinescrew(9)provided
in the lock bag to mount the outside handle.
1
3
/
8
"[35mm]thickdoorsshouldusethe
1
1
/
2
"[38mm]panheadmachinescrewprovided.
2. Finally, attach the lock bar (11) using
1
/
4
"-20x1"
[6mmx25mm]hexheadscrewandnut(10&12),
and lock bar guide (14) using #14 x
5
/
8
"
[6 mm x 16 mm] sheet metal screw. When track is
permanently in place, adjust the lock bar guide so
lock bar rests against the top of one of the engaging
slots in the track. Details are shown in Figure 8-S.
3. The inside slide bolt is installed on the end stile of
the second section so the slide bolt rests against
the top of one of the rectangular engaging slots in
the vertical track. Details are shown in Figure 9-S.
Step 5: #3 Section (and up to, but not including, top
section). Attach bottom half of center hinges to top
of section using #14 x
5
/
8
"[6mmx16mm]hexhead
sheet metal screw. Attach end hinges. (See Figure
2-S, page 8, for sequence.) After section is stacked,
rollers in the track will hold section in place. (If struts
are supplied see Figure 3-S, page 9, for placement.)
Step 6: Continue to stack and install remaining sec-
tions in the same manner as described in Step 5 until
all but the top section are properly in place.
Step 7: Top Section. Place top brackets over
pre-punched holes so they are flush with edge of
section. Center of roller carrier will be about
4"[102mm]downfromtopofsection.Usingfour
#14 x
5
/
8
"[6mmx16mm]hexheadsheetmetal
screws per top bracket, attach top brackets to sec-
tion.(FIG.10-S)(Lowheadroomdoors
3
/
4
" [19 mm] refer to Figure 7-T, page 23.)
If struts are supplied see Figure 3-S, page 9, for
placement.
Stack top section after all tracks are installed, but
before springs are wound.
#14 x
5
⁄8" [6 mm x 16 mm]
Sheet Metal Screw
4" [102 mm]
13
Full Vision Cen-
ter Hinge
Fig. 11-S
Full Vision and Steel Door
If your door has been furnished with one or more
full vision sections, please refer to Figure 11-S
for identification of the special hinge parts which
must be used.
End hinges are of the same type and follow the
same sequence as described in the general
instructions (refer to Figure 2-S, page 8). The
standard #14 x
5
/
8
"[6mmx16mm]hexhead
sheet metal screws are used to fasten the end
hinges to the full vision section. See Figure 12-S
if you have a full vision top section.
For attachment of center hinges,
proceed as follows:
Refer to the drawings in Figure 11-S for identifi-
cation of proper center hinges and the positions
in which they are to be installed. Note that the
#14 x
3
/
4
"[6mmx19mm]self-drillingscrewsare
used in the bottom rails and the
1
/
4
"x
3
/
4
"
[6 mm x 19 mm] hex bolts and
1
/
4
"[6mm]hex
nuts are used to attach the center hinge to the
noftheupperrail.(FIG.12-S)Specialattention
must be given to this step of the procedure since
proper placement of hinges
is critical to installation of the door.
Top Roller Bracket Attachment
Full Vision
Intermediate
Bottom Rail
Full Vision
Intermediate
Top Rail with
Built-in Rib
1
/
4
" x
3
/
4
" Hex Bolt &
[6 mm x 19 mm]
1
/
4
" [6 mm] Flange Nut
#14 x
5
/
8
"
[6 mm x 16 mm]
Sheet Metal Screw
Full Vision
Top Rail
Adjustable
Top Bracket
#14 x
3
/
4
"
[6 mm x 19 mm]
Self-Drilling
Screw
Fig. 12-S
1
1
/
4
" x 1
1
/
4
"
[32 mm x 32 mm]
or 2" x 2"
[51 mm x 51 mm]
Aluminum
Angle
If your door has a full vision top section, it is
very important that each top roller bracket be
attached to the reinforcing fins in the top rail and
the end stile. Two #14 x
3
/
4
"[6mmx19mm]self-
drilling screws should fasten the top of each
bracket to the top rail and one screw should
attach the bottom of the roller bracket be to the
end stile.
Remember: the small indentations that run the
length of the top rail and end stile mark where
the reinforcing fins are located.
Full Vision Cen-
ter Hinge
Combination #1
Roller Hinge &
Full Vision Cen-
ter Hinge
14
Refer to Figures 12-S, 13-S and 14-S for re-
inforcement of full vision sections. After full vi-
sion sections are in place, refer to the general
instructions for completion of your installation.
Sometimes, higher than standard wind loading
requires a bridge strut (aluminum angle with
offsetplates).(FIG.14-S)
Fig. 13-S
1
l
-
l
Door Width What Is Needed For
1
/
8
" [3 mm] Thick Glazing
Up to 11'2" None
[340 cm]
11'4" to 12'2" None
[345 cm to 371 cm]
12'3" to 14'2" One 1
1
/
4
" x 1
1
/
4
" x
1
/
8
" angle per section
[373 cm to 432 cm] [32 mm x 32 mm x 3 mm]
14'3" to 15'2" One 1
1
/
4
" x 1
1
/
4
" x
1
/
8
" angle per section
[442 cm to 462 cm] [32 mm x 32 mm x 3 mm]
15'3" to 16'2" One 1
1
/
4
" x 1
1
/
4
" x
1
/
8
" angle per section
[465 cm to 493 cm] [32 mm x 32 mm x 3 mm]
16'3" to 18'2" One 2" x 2" x
1
/
8
" angle per section
[495 cm to 554 cm] [51 mm x 51 mm x 3 mm]
18'3" to 20'2" One 2" x 2" x
1
/
8
" angle per section
[556 cm to 615 cm] [51 mm x 51 mm x 3 mm]
20'3" and Over One Bridge Strut per section
[617 cm]
REINFORCEMENT SCHEDULE
Door Width What Is Needed For
1
/
4
" [6 mm] Thick Glazing
Up to 11'2" None
[340 cm]
11'4" to 12'2" One 1
1
/
4
" x 1
1
/
4
" x
1
/
8
" angle per section
[345 cm to 371 cm] [32 mm x 32 mm x 3 mm]
12'3" to 14'2" One 1
1
/
4
" x 1
1
/
4
" x
1
/
8
" angle per section
[373 cm to 432 cm] [32 mm x 32 mm x 3 mm]
14'3" to 15'2" One 2" x 2" x
1
/
8
" angle per section
[442 cm to 462 cm] [51 mm x 51 mm x 3 mm]
15'3" to 16'2" One 2" x 2" x
1
/
8
" angle per section
[465 cm to 493 cm] [51 mm x 51 mm x 3 mm]
16'3" to 18'2" One Bridge Strut per section
[495 cm to 554 cm]
18'3" to 20'2" One Bridge Strut per section
[556 cm to 615 cm]
20'3" and Over One Bridge Strut per section
[617 cm]
Fig. 14-S
4" x 6" Offset
Plate
Bottom Rail
Full Vision
Inter-mediate
Top Rail with
Built-in Rib
#14 x
3
/
4
"
Self-Drilling
Screw
2" x 2"
Aluminum
Angle
1
/
4
" x
3
/
4
" Hex Bolt &
1
/
4
" Flange Nut
Full Vision Intermediate
1
3
2
4
5
1 [6 mm x 19 mm] 2 [102 mm x 105 mm] 3 [51 mm x 51 mm] 4 [6 mm x 19 mm]
5 [6 mm]
15
Fig. 1-T
BRACKET MOUNT
(2)
1
/
4
" x
5
/
8
"
[6 mm x 16 mm]
Track Bolts
& Flange Nuts
CONTINUOUS ANGLE
Rivet
(2) Each Bracket
1
/
4
" x
5
/
8
"
[6 mm x 16 mm]
Track Bolts &
Flange Nuts
REVERSE ANGLE
Vertical
Track
1
/
4
" x
5
/
8
"
[6 mm x 16 mm]
Track Bolts &
Flange Nuts
Vertical
Track
Commercial Flag
Bracket
Rivet
(2) Each Bracket
Vertical
Track
Bracket
Rivet
(2) Each Bracket
TAPERED REVERSE
ANGLE MOUNT
Vertical
Track
Continuous Angle
Track
Clip
Track
Clip
Reverse Angle
1
/
4
" x
5
/
8
"
[6 mm x 16 mm]
Track Bolts &
Flange Nuts
Tapered
Reverse
Angle
3. Type of mounting - Bracket mounting is used
on lighter doors with wood jambs. Brackets are
loose or riveted into place. Loose brackets are
attached to the track with (1)
1
/
4
"x
5
/
8
"
[6 mm x 16 mm] track bolt and nut per bracket.
Continuous angle and reverse angle track are
shipped with mounting angle attached. Loosen
nuts on track bolts so track will slide on the
angle.(FIG.1-T)
General Information. There are three basic pieces
of information about your tracks that you need to
know to start installation.
1. Track size - Track comes in two sizes:
2"[51mm]and3"[76mm].
2. Type of lift - Each type of lift is different from the
top of the door on up. However, the vertical track
from the floor to the top of the door does not
change between the different lift options.
(FIG.1-T)Therefore,theverticaltrackinstruc-
tions to the top of the door are explained in one
group (Step 1). Then turn to your specific type
of lift for completion of the installation.
Track Installation
16
Fig. 4-T
Fig. 2-T
Fig. 3-T
Allow
1
/
2
"
[13 mm]
Between Track
And Door
Allow
1
/
4
" [6 mm]
Between Door
And Track
ASSEMBLY MAY BE ADJUSTED ALONG JAMB
5
/
16
" x 1
5
/
8
"
[8 mm x 41 mm]
Lag Screw
(7) Shown
Note: Track Can Be Adjusted
By Shifting The Track Brack-
ets In The Slots Where The
5
/
16
" x 1
5
/
8
" [8 mm x 41 mm]
Lag Screws Are Installed.
End Stile
Track
Rotate Into Place
Door
Jamb
Roller
Hinge
Block To
Level
Floor
Line
Jamb
Vertical Track
This Measure-
ment Must Be
Equal On Both
Sides
Hold Track
1
/
2
"
[13 mm] Off Floor
Commercial
Vertical Bracket
Step 1: Vertical Track. Center bottom section
in opening on inside of garage. Level section by
blockinguplowside.(FIG.2-T)Leaveblockuntil
door is completed. Install the vertical track on op-
posite side of where block was placed, over the two
rollers of the bottom section with a twisting motion
as in Figure 3-T. Raise track
1
/
2
"[13mm]offthe
floor, Figure 2-T, and screw
5
/
16
"x1
5
/
8
"
[8 mm x 41 mm] lags (wood jambs), or self-drill-
ing screws (steel jambs) through bottom mount-
ingbracket.(FIG.4-T)Adjusttracksidewaysto
allow
1
/
8
"[3mm]endplayinroller—about
1
/
4
"[6
mm]fromedgeoftracktoedgeofdoor.(FIG.2-T)
Plumb vertical track and put at least two lags or
sheet metal screws in the mounting brackets at the
top of the door. Final adjustment will be made after
door is stacked. Measure from the top of the verti-
cal track to the top of the bottom section and set
the opposite track at exact same height repeating
aboveprocedure.(FIG.2-T)Sincethebottomsec-
tion is level, then the vertical tracks must be level.
Make sure bottom rollers do not come out
of the bottom of the track.
Step 2: Stacking. Stack #2 section on top of bot-
tom section and attach end hinges with rollers in
track to hold section in place. Stack the rest of the
sections except the top (the top section must be
installed after all the tracks are up).
Swing up top half of hinges and use #14 x
5
/
8
"
[6 mm x 16 mm] hex head sheet metal screws to
fasten door.
Step 3: Finishing Vertical Track. Set the top of
the vertical tracks so that there is
1
/
4
"[6mm]end
play in the rollers, about
1
/
2
"[13mm]fromedgeof
tracktoedgeofdoor.(FIG.2-T)Finishattaching
vertical track to the wall. If you are mounting on
steel jambs, you will have to wait until you can raise
the door to finish attaching vertical tracks.
NOTE: To complete the rest of the track installa-
tion, refer to the page explaining your specific lift
option:
Standard Radius .................................Page 17
Roof Pitch ...........................................Page 23
Low Headroom Rear Mount ................Page 24
Low Headroom Front Mount ...............Page 26
Vertical Lift ..........................................Page 27
High Lift ...............................................Page 28
17
Fig. 5-T
Horizontal Angle
1
/
2
" [13 mm]
Between
Horizontal Track &
End of Door
Horizontal
Track
Roller
Roller Bracket
Top Door
Section
VIEW A
VIEW B
(3)
5
/
16
" x 1" Bolts
Backhang
(3)
5
/
16
" Nuts
Attach Back-
hang To Track
With
3
/
8
" x 1" Min.
Bolt & Nut
See View A
Top Door Section
Rear Back-
hang
Second Back-
hang Mounted
Halfway Between
Header & Rear
Backhang See
View B
Horizontal
Angle
3
/
8
" x
3
/
4
"
Carriage
Bolt
3
/
8
" Flange
Nut
(2)
1
/
4
" x
5
/
8
"
Track
Bolts
Commercial
Vertical
Bracket
(3)
5
/
16
" x 1
5
/
8
"
Lag Screws
Attach To Ceiling
Joist
(2)
1
/
4
"
Hex Flange
Nuts
Standard Radius
Attach horizontal track to vertical bracket using
1
/
4
"x
5
/
8
"[6mmx16mm]trackboltsandange
nuts. Attach horizontal angle to vertical bracket us-
ing
3
/
8
"x
3
/
4
"[10mmx19mm]carriageboltsand
flange nuts. Rig a temporary rope to support back
of horizontal tracks. They should be level (parallel)
to1"[25mm]higherinthebackwhencompleted.
Install top section now to other sections. Refer to
Figure10-S,page12.(FIG.5-T)
Spring Installation (Page 18)
Install and wind springs as explained. After
springs are installed and wound, release locking
pliers and raise door so that only the two top
sections are in the horizontal tracks. Secure door
in place with locking pliers on track above a roller,
making sure it can’t be raised, and align horizon-
taltracks.Backhangdoors.(FIG.5-T)Any door
over 12' [366 cm] high requires two backhangs
on each horizontal track. See important note at
top of this page for backhang requirements. All
backhang material is supplied by the installer. See
backhang requirements.
Lower door and push track towards jambs until
door is tight against stop or steel jambs and tight-
en track bolts. Adjust top brackets. (Figure 10-S,
page 12) Install inside side slide lock or lock bar
(Figure8-S&9-S,page12)afterspringiswound.
Nail door stop in place if appllicable.
IMPORTANT:
Backhang Requirements
Important Note: All doors over 12' [366 cm]
high require two backhangs evenly spaced on
eachhorizontaltrack.(FIG.5-T)Also,alllow
headroom track doors, all doors 12' [366 cm]
high and under that are over 600 lbs. [272 kg]
orhave1"[25mm]ofsaginhorizontaltrack
when the door is in full open position, will
require two backhangs evenly spaced on each
horizontal track.
Inspection of horizontal track is required after
completion of garage door installation. With
the garage door in the full open position, there
should only be
1
/
4
"[6mm]offreeplayinrollers
and
1
/
2
"[13mm]fromtheedgeofthehorizontal
tracktotheedgeofthedoor.(FIG.5-T)Realign
tracks if neccessary.
1
2
3
4
1
[8 mm x 25 mm] 2 [8 mm] 3 [10 mm x 25 mm]
4 [8 mm x 41 mm]
1
4
3
2
1
[10 mm] 2 [10 mm x 19 mm] 3 [6 mm] 4 [6 mm x 16 mm]
18
Spring Installation
NOTE: All torsion spring doors will be furnished
with a Red Warning Label. These labels must be
on all spring anchor brackets in plain view. These
Warning Labels will be supplied on spring anchor
brackets or in the hardware carton. If sticker is
missing it is the responsibility of the installer to
contact his supplier and have them provide need-
ed warning labels for installation.
Spring anchor bracket mounting location.
Measure from top of door to center of end bear-
ings. Using this measurement, draw a line at the
same height for shaft location and mount spring
anchor bracket accordingly.
Torque Tube Installation
Slide drums on tube and loosen all set screws.
Slide tube into one end bearing plate then back
through the opposite one. Fasten spring anchor
bracket using
5
/
16
" x 1
5
/
8
" [16 mm x 41 mm]
red-colored lags. See warning below. Tube must
bestraightandlevel.(FIG.1-TOR)
NOTE: Pilot drill in wood with
3
/
16
"[5mm]drill.
Spring anchor brackets anchor the springs
to the wall. You must fasten securely with
red-colored fasteners. Never remove spring
anchor bracket when springs are wound.
Always start with the left drum. Slide it against
the end bearing plate and tighten set screws.
Set screws: Tighten set screws enough to
dimple shaft, about 1
1
/
4
turns after set screws
first hit shaft. Make sure set screws are placed
90 degrees apart.
(FIG. 1-TOR) Bring cable up between wall and
roller shafts behind drum and into notch in
edge of drum. Turn drum and shaft until cable
is tight. Make sure cable stop is seated against
drum. Clamp locking pliers on shaft and
against header to hold cable tight. Wind cable
on right drum and tighten set screws. Tension
must be equal on both cables. Cables are now
set. See spring winding directions. (FIG. 1-TOR)
Auxiliary Shaft Supports
Refer to Figure 1-AT for placement of auxiliary
shaft supports if required.
Solid Shaft Installation
Slide springs and drums on shaft and loosen all set
screws. Install half of shaft coupler. Insert key and
tighten set screw.
Set screws: Do not exceed
1
/
2
turn after coming in
contact with shaft. Make sure set screws are placed
90 degrees apart.
(FIG.2-TOR,ViewF)Slideeithershaftintoendbear-
ing and fasten spring anchor bracket using
5
/
16
" x 1
5
/
8
" [8 mm x 41 mm] red-colored lag screws
(wood jambs)
5
/
16
" x 1" [8mm x 25 mm] red-colored
self-tapping screws (steel jambs). Center shaft on
the mark made earlier for proper height. Slide other
shaft into opposite side and align shaft coupler. Clamp
shaft coupler together and fasten spring anchor brack-
ets. Slide both drums against end bearings and insert
1
/
4
"x
1
/
4
"[6mmx6mm]keysandthentightenset
screws.(FIG.2-TOR,ViewE)Removeclampfrom
shaft coupler.
Bring cable up between wall and roller shafts, behind
drum and into notch in edge of drum. Turn drum and
shaft until cable is tight. Make sure cable stop is seated
against drum.
Clamp locking pliers onto shaft and against header to
hold cable tight. Repeat procedure for setting cable
on the opposite side. Tension must be equal on both
cables. Bolt shaft coupler together. Cables are now set.
See spring winding directions following.
Auxiliary bearings must be assembled to the
shaft before drums are put on shaft.
*Used on 20' [610 cm] or wider doors or doors
730 lbs. [331 kg] or greater. To be installed ap-
proximately 3" in from drum.
**Used only on doors over 20' [610 cm] wide with
only two springs. Auxiliary support bearing is to
be installed halfway between spring and drum.
Auxiliary Support**
Extra Spring Anchor Bracket
With Bearing And Retainer
Spring
Anchor
Bracket
Spring
Anchor
Cone
Spring
Winding
Cone
Auxiliary Support*
Extra Spring Anchor
Bracket With Bearing
And Retainer
Left-hand Red
Drum With Red
Set Screws
See “Manual”
End Bear-
ing Plate
Fig. 1-AT
19
Spring Winding
SPRING TENSION IS DANGEROUS.
A sudden release of the springs could result in
severe injury. Proceed with caution, following
these instructions carefully. Before winding
any tension on springs, make sure door is se-
curely locked down with a vise-grip placed on
vertical track above a roller. Always use proper
size winding bars. Never use screwdrivers or
any tool too large or too small. They may break
and cause serious injury. Stand to the side of
winding bars while winding springs.
Draw a straight chalk line across spring. This will
indicate the number of turns on spring as you
wind. Springs will get longer when wound. Using
twocoldrolledsteelwindingbarsabout18"
[457 mm] long (not supplied) that fit snugly in the
winding plug holes, wind the springs toward ceil-
ingasshown.(FIG.1-TOR&3-TOR)Low head-
room double track doors: wind springs toward
the floor (down) instead of up. See instructions
onpages23&24.Windspringsthenumberof
turns shown on the hardware box label. Stretch
the springs the width of two coils then tighten
set screws. This is done by putting the two wind-
ing bars on opposite sides of the winding plug and
pulling towards drum.
At this point, springs are fully wound. Springs
should stretch easily. Do not force, as it could
break the winding plug and cause injury.
Set Screws
Torque Tube: Tighten set screws enough to
dimple shaft, about 1
1
/
4
turns after set screws first
hit shaft.
Solid Shaft: Do not exceed
1
/
2
turn after coming in
contact with shaft.
To finish door installation, refer to your specific
type of track. Final spring tension adjustments
should be made after installation is completed. Al-
ways adjust springs with door closed and locked.
20
Fig. 1-TOR
DETAIL “A”
End Bearing Plate
Righthand Cable Drum (Black)
Black Winding Cone -
Wind Counterclockwise As
Shown In Detail “B”
Left Wound Spring
Lefthand
Cable
Drum
(Red)
1" [25 mm]
O.D. Steel
Tube
End Bearing
Plate
Right Wound Spring
Stationary Spring Cone
Spring Anchor
Bracket
Warning Tag
Bearing (insert
into cone)
Stationary Spring Cone
Left
Wound
Spring
1" [25 mm]
O.D. Steel
Tube
Lefthand
Cable Drum
End Bear-
ing Plate
Right Wound Spring
Detail “B”
– Wind As
Shown
Left
Wound
Spring
Black Winding Cone – Wind
Counterclockwise As
Shown In Detail “B”
Righthand Cable Drum
End Bearing Plate
Winding
Bar (See
Warning)
DETAIL “B”
Wind Counterclockwise
(2) Set
Screws
Red
Winding
Cone
TWO SPRINGS
ON STEEL TUBE
ONE SPRING ON STEEL TUBE
LEFT WOUND SPRING SHOWN
WARNING
Always use good quality, snug fitting, constant diameter, solid steel winding bars when winding or adjust-
ing springs. The use of any other object can result in severe injury. When winding the springs, the winding
bar must be inserted into the full depth of the holes in the winding cone. Keep a firm grip on the winding
bars at all times. Use a sturdy ladder and stand to the side of the winding bars.
If your door has a torsion spring assembly, you must make sure that the wood anchor pad is firmly at-
tached to the garage wall. Failure to securely attach the anchor pad could allow the springs to violently
pull away from the garage wall, and could result in severe injury and/or property damage. In no case
should nails be used.
See Detail “A” –
Center Bearing
Support Assembly
21
TWO SPRINGS ON A SOLID SHAFT SHOWN
VIEW “E”
Solid Shaft
Righthand
Black Drum
Solid Shaft Key
Inserted Into
Left & Righthand
Drums
(2) Set
Screws
(2) Set Screws
Spring An-
chor Plug
Coupler
– See View
“F”
Spring Anchor
Bracket
Warning Tag
(2) Set
Screws
End Bearing Plate
Righthand
Black
Drum With
Set Screws
– See View
“E”
Black Wind-
ing Cone
(Wind Coun-
terclock-
wise)
Left
Wound
Spring
Spring Anchor Bracket
Right Wound Spring
Red Winding Cone
(Wind Counterclockwise)
End Bearing
Plate
VIEW “F”
Solid
Shaft
(4) Set
Screws
Coupler
Solid Shaft
Solid Shaft Key
1) Disassemble Coupler Halves
2) Insert Solid Shafts Into Coupler
3) Insert Solid Shaft Key
4) Tighten Set Screws
Fig. 2-TOR
1" [25 mm] O.D. Split
Solid Steel Shaft
Lefthand Red
Drum – See
View “E”
3
/
8
" [10 mm]
Bolt & Nut
(4 places)
1" [25 mm] O.D.
Solid Shaft
Spacer
Heavy Duty Bearing
End Bearing Plate
Cable Drum
HEAVY DUTY
BEARING
MOUNTING
SYSTEM
(Used for special applications)
Step 1: Attach heavy duty bearing to end
bearing plate with (4)
3
/
8
"[10mm]boltand
nut—makingsurethatboltheadistowardcable
drum as shown in diagram.
Step 2: Slide cable drum, then spacer, and then
bearing plate (with attached bearing) onto the
shaft.
22
FOUR SPRINGS ON SOLID STEEL SHAFT
Spring
Anchor
Bracket
Warning Tag
Bearing
Stationary Spring Cone
Left Wound
Spring
Left
Wound
Spring
See Detail “B”
– Center Bearing
Support Assembly
See Detail “A” –
Supplemental
Center Bearing
Support Assembly
1" [25 mm] O.D. Split Solid Steel Shaft
Assemble Typical To Detail “B”
Lefthand Cable Drum – See FIG. 2-TOR View “E”
End Bearing Plate
Black Winding Cone
Wind Counterclockwise
As Shown In Detail "C"
Right Wound Spring
Shaft Coupler – See FIG. 2-TOR View “F”
DETAIL “B”
(2) Set
Screws
DETAIL “C”
Wind
Counterclockwise
Red Winding
Cone
Fig. 3-TOR
Right Wound Spring
Assemble Typical To Detail “B”
Detail “C” – Wind As Shown
Winding Bar
(See Warning
On Page 19)
Assemble
Typical To
Detail “A”
Red Winding
Cone
Wind As
Shown In
Detail “C”
Assemble Typical To
Detail “B” Lefthand
Black Winding Cone
Wind Counterclockwise
As Shown In Detail "C"
Righthand Cable Drum
End Bearing PlateWarning Tag
Spring
Anchor
Bracket
Bearing
Bearing Re-
tainer
DETAIL “A”
Final Adjustment and
Maintenance
Inside Slide Lock will be installed on the #2 sec-
tion on preferred side. Line up the lock rod with the
lockholeinthetrack(FIG.9-S,page12)making
sure that when lock is in the unlocked position it
doesn’t extend past the end stile. Fasten lock to
the end stile using (4) #14 x
5
/
8
"[6mmx16mm]
sheet metal screws. Lubricate all moving parts
(hinges, rollers, bearings, springs, etc.) with light
weight oil. Do so when installed and thereafter
about every six months. High use doors will re-
quire more frequent lubricating.
Every six months inspect your door for the following:
Do not attempt to adjust door components unless
you are a qualified door mechanic.
• Cablesforfraying
• Torsionspringplugsandspringanchors
• Bearingsinendbearingplates
• Rollersandhinges
• Trackalignment
• Backhangangleandswaybraceattachments
• Tightenallscrewsandnutsonbolts
(seats in cone)
23
Fig. 6-T
End Bearing Plate
Horizontal Track
3
/
8
x 1
1
/
4
" [10 mm x 32 mm]
Slotted Truss Head Bolt & Nut.
Use Hole In Horizontal Track
Vertical
Track
ROOF SLOPE INSTRUCTIONS
1) Fasten Horizontal Track To
RearHanger&Commer-
cial Vertical Bracket
2) Bolt The Extension Angle
Between The Horizontal
Track&TheCommercial
Vertical Bracket
(4)
1
/
4
" x
5
/
8
"
[6 mm x 16 mm]
Track Bolts &
Nuts
Extension Angle (Cut If Too Long)
Commer-
cial Vertical
Bracket
Fig. 7-T
INSIDE VIEW — LIFT CABLE NOT SHOWN
Horiz. Track
Low Head Room
Double Track
Vertical Track
Hinge
Roller
(4)
1
/
4
"
[6 mm]
Flange
Nuts
End Stile
Starter
Angle
Commercial Vertical Bracket
LHR Top Bracket
(See View B)
End Bearing Plate
(LHR Front
Mount Torsion Only)
VIEW B
Roller
LHR Top Bracket
(2) #14 x
5
/
8
"
[6 mm x 16 mm]
Sheet Metal
Screw
Fig. 8-T
(2)
1
/
4
" x
5
/
8
"
[6 mm x 16 mm]
Track Bolts
Thru Vertical
Track &
Comm.
Vertical Bracket
(2)
1
/
4
" x
5
/
8
"
[6 mm x 16 mm]
Track Bolts
Thru Horiz.
Track & Comm.
Vertical Bracket
End Stile
(3)
3
/
8
" [10 mm] Carriage Bolts & Nuts
Bottom
Bracket
Lift Cable
Weatherstrip
Second
End Stile
CBB-
95 LHR
Bracket
Weatherstrip
(5) #14 x
3
/
4
"
[6 mm x 19 mm]
Self-Drilling
Screws
Lift Cable
End Stile
Cotter
Pin
Key
3"
[76 mm]
Roller
Location
2"
[51 mm]
Roller
Location
INSIDE OF DOOR
OUTSIDE OF DOOR
Roof Pitch
Horizontal track follows the pitch of the roof line. Track
is assembled similar to standard lift, except that the
horizontal angle is mounted level just above the radius.
(FIG.6-T)Everythingisputtogetherthesameastype
of track ordered. Installation follows standard radius
track procedure.
Low Headroom Double Track (LHR)
LHR can be installed rear torsion (springs at back of
horizontal track) up to a maximum door weight of 800
lbs., [363 kg] after that, it must be installed front torsion
up to 1,200 lbs. [544 kg]. Front torsion is much easier
to install, but it requires more headroom and the door
will hang in the opening unless an electric operator is
used.
The door hardware for LHR is the same as for
standard radius except special outside bottom
brackets are used to allow cable to ride on the outside
of the track and the top bracket is flat with the top roller
beingtheonlyoneridinginthetoptrack.(FIG.7-T)
Install low headroom bottom brackets and cable
usingred-coloredfasteners.(FIG.8-T)
All struts will be applied according to strutting schedule
on page 9, except the top strut will follow instructions
below.
Top Section Strutting Procedure for LHR
With the top section face down on saw horses, place
strut on top of section (section should be flat). Position
topedgeofstrutapproximately1"[25mm]downfrom
top of door. At each center stile, fasten strut to center
stile with (2) #14 x
5
/
8
"[6mmx16mm]self-drilling
screws. The ends of the struts will require fastening in
the same manner as the center stiles after the sec-
tion has been installed and top brackets have been
installed and adjusted.
(If required)
24
Fig. 9-T
This Backhang To Be Mounted Halfway
Between Header & Rear Backhang
& To Top Track Only. (See View A)
Left-Hand Cable Drum
Left Rear Backhang
Optional Mounting
End Bearing Plate
(See View B)
Comm. Flag
Bracket
WIND THIS
DIRECTION
LHR REAR MOUNT TORSION SPRING DOOR — SIDE VIEW
Lift Cable
Carriage
Bolt
Pulley
Saddle
Flange
Nut
Track
4"
Pulley
Bottom Of Backhang May Need To Be Cut At
45° So There Is No Interference With Lift Cable
View A
PULLEY INSTALLATION
Starter Angle
Mid-horizontAl
bAckhAnger
(3)
5
/
16
" Nuts
(3)
5
/
16
" x 1" Bolts
Horizontal Angle
(3)
5
/
16
" x 1
5
/
8
"
Lag Screws Attach
to Ceiling Joist
3
/
8
" x 1"/min.
Bolt & Nut
Backhang
Carriage Bolts Through
End Bearing Plate &
Track. Holes In Track
Are Drilled At
3
/
8
"
So End Bearing Plate
Can Be Fastened
Level With The Track
Horizontal
Angle
(2)
3
/
8
"
Flange
Nuts
Track
End Bearing Plate
View b
(Cable Drum Not Shown)
(Backhang Not Shown)
(1)
3
/
4
"
Washer
Pulley Saddle
(Doors Over 350 Lbs.)
Horizontal
Angle
Horizontal
Angle
5"
Pulley
Pulley
(See View A)
Carriage
Bolt
Starter Angle
Flange Nut
View A-2
(Doors Up Through 350 lbs.)
View A-1
(Doors Over 350 lbs. up to 800 lbs.)
Low Headroom Top Brackets
All Door Models: Insert rollers in low headroom
top brackets. On each side of door, insert each
roller into the top horizontal track. Slide each low
headroom top bracket down the top section until top
section is tight against wood stop or steel jamb. If a
top strut has been installed the top bracket will have
to be placed between stile and strut. Line each low
headroom top bracket up with the side of the top
section. Using both slots in each low headroom top
bracket as a guide, drill
3
/
16
"[5mm]pilotholesinthecenterofeachslot
leaving room for final adjustment in both directions.
Steel Door Models: Attach each low headroom top
bracket with two #14 x
5
/
8
"[6mmx16mm]sheet
metalscrews.(FIG.7-T,page23)
Rear Mount Torsion Spring Doors
Attach horizontal track to vertical bracket using
1
/
4
"x
5
/
8
"[6mmx16mm]trackboltsandange
nuts. Attach horizontal angle to the vertical angle
using
3
/
8
"x
3
/
4
"[10mmx5mm]carriageboltsand
flange nuts. The end bearing plate will be positioned
and fastened as shown in Figure 9-T. Some drilling
in end bearing plate and horizontal angle may be
required.
Fordoorsunder350pounds[159kg],installthe4"
[102 mm] pulley as illustrated in Figure 9-T, View A-2.
Fordoorsover350pounds[159kg],installthe5"[127
mm] pulley and saddle as illustrated in Figure 9-T, View
A-1. The carriage bolts used must be installed with the
heads toward the inside of the track and the nuts facing
outside as in the illustration. The cable must be routed
through the pulley saddle prior to attaching to drum.
Rear torsion spring doors will require that springs
be placed at rear of track and a center support
hanger(s) be provided that is strong enough to with-
stand the torque of the springs. Rear of horizontal tracks
must be securely fastened in the proper position before
springs are wound or door is lifted. Doors over 12' [366
cm] high will require two backhangs for each horizontal
track. Horizontal tracks should be level and backhung
according to Figure 9-T. (See important note on page
17 for additional backhang requirements.) All backhang
material is supplied by installer due to ceiling height dif-
ferences.
Install springs according to Figure 10-T and wind. See
spring winding on page 18 for more information. Push
track towards jambs until door is tight against stop or
steel jambs and tighten track bolts. Adjust top brackets
(FIG.7-T,page23)byslidingitupordownondoorin
order to position top section correctly.
Install the inside slide lock or lock bars (page 12) after
springs are wound. Nail door stop in place if applicable.
1
1
3
4
5
7
8
6
6
2
0
[127 mm] 1 [159 kg] 2 [159 kg up to 363 kg] 3 [19 mm] 4 [16 mm x 25 mm] 5 [16 mm x 41 mm] 6 [10 mm] 7 [16 mm] 8 [10 mm x 25 mm] 9 [102 mm]
9
0
25
Left Rear Backhang
LHR REAR MOUNT TORSION SPRING DOOR — REAR VIEW
Right Rear Backhang
Center Rear Backhang
Left End
Bearing
Plate
Spring
Anchor
Bracket
Left Wound
Spring
Left
(Black)
Winding
Cone
Right
Wound
Spring
Spring Anchor Cones
(Red) Left Hand
Cable Drum—
See View C below
(Black)
Right Hand
Cable Drum—
See View D below
Right End
Bearing
Plate
(Red)
Right
Winding
Cone
Drum
(Black)
Drum (Red)
LEFT HAND CABLE DRUM EXPLODED VIEW
(Backhang Not Shown)
Fig. 10-T
Track
(2) Red Set Screws
RIGHT HAND CABLE DRUM EXPLODED VIEW
(Backhang Not Shown)
Red Winding Cone
(2) Red Set
Screws
End Bearing
Plate
Lift Cable
Winding Cone
(Black)
Lift
Cable
End Bearing
Plate
(2) Red Set
Screws
Track
CENTER EXPLODED VIEW
Anchor Cone
Center Backhang
Spring
Anchor
Bracket
Spring
(Attach
to Ceiling
Joist)
(3)
5
/
16
" x 1
5
/
8
" [16 mm x 41 mm]
Lag Screws
(5)
5
/
16
" x 1"
[8 mm x 25 mm]
Bolts & Nuts
26
Fig. 12-T
(3) Lag Screws
Through End
Bearing Plate
Attached To
Jamb
Center Line Of
Bearing
Top Of
Starter
Angle
(2)
3
/
8
" Flange Nuts
END BEARING PLATE INSTALLATION
Fig. 11-T
End Bearing
Plate
(2)
3
/
8
" x
3
/
4
"
Carriage Bolt
Through End
Bearing Plate
And Starter
Angle
3
/
8
" Flange Nut
1
1
/
4
"
Minimum
Bearing Plate And Starter Angle
LHR FRONT TORSION SPRING DOORS
Lefthand
Drum-
Red
With Set
Screws
(See
Exploded
View)
CABLE DRUM
— EXPLODED VIEW
(2)
3
/
8
" x
3
/
4
"
Carriage
Bolt
Through
End
Winding Plug
(Black) With
Set Screws
Wind
Down
Spring An-
chor Plate
Spring An-
chor Bracket
Spring
Anchor
Plugs
Winding Plug (Red)
With Set Screws
End Bearing Plate
(See FIG. 11-T)
Righthand Drum
Black With Set
Screws
Back Hang Mate-
rial Supplied By
Installer
Cable
Right Wound
Spring
Left Wound
Spring
Cable
Drill 2 Holes For
3
/
8
" x
3
/
4
"
[10 mm x 19 mm]
Carriage Bolts
End Bearing
Plate
(2) Set Screws
Wind Down
Black
Winding
Cone
Red Left-hand
Cable Drum
(2) Set
Screws
Lift Cable
1
2
3
3
2
1 [32 mm] 2 [10 mm x 19 mm] 3 [10 mm]
LHR Front Mount Torsion Spring Doors
Attach horizontal track to vertical bracket using
1
/
4
"x
5
/
8
"[6mmx16mm]trackboltsandange
nuts. Attach vertical angle to horizontal angle
using
3
/
8
"x
3
/
4
"[10mmx19mm]carriagebolts
and flange nuts. The end bearing plate will be
positioned and fastened as shown in Figure 11-T.
Some drilling in horizontal angle may be required.
(FIG.7-T,page24)
Install springs according to Figure12-T, and wind.
See spring winding on page 19 for more informa-
tion.
Raise door so that only two sections are in the hor-
izontal tracks. Align horizontals so that spacing is
equal from front to back. Backhang door as shown
in Figure 6-T. (See important note on page 17
for additional backhang requirements.) Raise
door all the way and check for proper track align-
ment. Realign horizontal track if required.
Push track (if adjustable) towards jambs until door
is tight against stop or steel jambs and tighten
track bolts. Adjust top brackets by sliding it up or
down on door in order to position top section cor-
rectly.(FIG.7-T)Installtheinsideslidelockorlock
bars (page 12) after springs are wound. Nail door
stop in place if applicable.
Top Section
Of Door
3/8" X 1" [10 mm X 25 mm] min
bolt. Install in lower track.
Note: Truss head bolt recom-
mended for center hanger
27
Vertical Lift Track
Vertical lift tracks are built as one piece or as two
pieces per side, depending on door height. Follow
the vertical track information (Step 1, page 15) for
the lower part of the track, from the floor to the top
of the door.
Starting at the top of the door, plumb one track
and lag or screw it to the wall all the way up.
Measure the width of the tracks at the top of the
door and set the very top of the second vertical
track at the exact same distance. Finish fastening
the center of the vertical track, making sure the
distance between the tracks is equal from the top
of the door on up. Install top section to other
sections. (FIG. 10-S, page 12)
Attach the bearing plates as shown in Figure
13-T. See spring winding information, page 19 for
installing and winding springs.
IMPORTANT: Do not cut cables. It may seem
like the cables are too long, but they are not. Wind
the extra cable onto the drums.
All vertical lift doors must be sway braced as
in Figure 13-T.
Door may fall out of track if the track is
improperly aligned.
Attach spring bumpers as shown in Figure 14-T.
They will keep door from coming out of top of the
track. Position bumpers so that door clears the
opening and drill in place using
5
/
16
"x1"
[8 mm x x25 mm] hex head bolts to fasten.
Door may come out of track if spring bumper
is not installed.
Push lower vertical track towards jambs until door
is tight against stop or steel jambs and tighten
track bolts. Adjust the bottom of the upper verti-
cal track to align with the top of the lower vertical
track and tighten the track bolts.
Adjusttopbrackets.(FIG.10-S,page12)Install
inside slide lock or lock bars after springs are
wound.(FIG.8-S&9-S,page12)Naildoorstop
in place if applicable.
Fig. 13-T
Fig. 14-T
(2)
1
/
4
" [6 mm]
Hex Flange Nuts
Lag Or Screw
To Wall
Angle Sway Brace Outward
From Door Edge
(2)
1
/
4
"
[6 mm]
Bolts
Spring
Bumper
Spring Bumper
(See Exploded
View, Figure 14-T
Below)
Door Jamb
Header
(2)
1
/
4
" x
5
/
8
"
[6 mm x 16 mm]
Track Bolts
3
/
8
" [10 mm]
Hex Flange
Nut
(2)
3
/
8
" x
3
/
4
"
[10 mm x 19 mm]
Carriage Bolts
Through End
Bearing Plate &
Angle
End Bearing Plate
Fasten To Angle &
Jamb
Slotted
Punched
Angle
(2)
1
/
4
"
[6 mm]
Flange Nuts
End Of Vertical
Track
Spring Bumper
Mounting Plate
(2)
5
/
16
"
[8 mm]
Hex Head Bolts
& Hex Flange Nuts
EXPLODED VIEW
28
Fig. 15-T
Fig. 16-T
Backhang
Material
Installed By
Installer
Fig. 17-T
Track
(2)
3
/
8
" x
3
/
4
"
[10 mm x 19 mm]
Carriage Bolts
Through End
Bearing Plate &
Angle
Horizontal
Angle
Lag or Screw
To Wall
Door
Jamb
(2)
1
/
4
" [6 mm]
Hex Flange Nut
(2)
1
/
4
" x
5
/
8
"
[6 mm x 16 mm]
Track Bolt
3
/
8
" [10 mm] Hex Flange Nut
End Bearing Plate Fasten To
Angle & Jamb
3
/
8
" x
3
/
4
"
[10 mm x 19 mm]
Carriage Bolt
(2)
1
/
4
" x
5
/
8
"
[6 mm x 16 mm]
Track Bolts
Header
(2)
1
/
4
" [6 mm]
Hex Flange Nuts
3
/
8
" [10 mm] Hex Flange Nut
(2)
1
/
4
" [6 mm] Nuts
(2) Lock Washers
(2)
5
/
16
" [8 mm]
Hex Bolts and
Flange Nuts
Bumper
Mounting Plate
End of Track
(2)
1
/
4
" [6 mm]
Bolts
Spring Bumper
Spring Bumper
Track
High Lift Track
Some smaller high lift doors will come with verti-
cal tracks in one piece plus the horizontal tracks.
Larger high lift doors will have the vertical track
in two pieces plus the horizontals. Follow the ver-
tical track information (Step 1, page 15) for the
lower part of the track from the floor to the top
of the door. Starting at the bottom of the door,
plumb one vertical track and lag or screw it to
the wall all the way up. Measure the width of the
tracks at the top of the door and set the very top
of the second track at the exact same distance.
Finish fastening the center of the vertical track,
making sure the distance between the tracks
is equal from the top of the door on up. Attach
the horizontal tracks using
1
/
4
"x
5
/
8
"[6mmx16
mm] track bolts and
3
/
8
"x
3
/
4
"[10mmx19mm]
carriage bolts to attach the horizontal angle. Rig
a temporary rope to support back of horizontal
tracks.Theyshouldbelevel(parallel)to1"[25
mm] higher in back. Attach the bearing plates as
shown in Figure 15-T. Install top section to other
sections.(FIG.10-S,page12)Seespringwind-
ing information for installing and winding springs.
IMPORTANT: Do not cut cables. It may seem
like the cables are too long, but they are not. Wind
the extra cable onto the drums.
After the springs have been installed and wound,
raise the door so that only the two top sections are
in the horizontal track. Secure the door in place
with locking pliers on track above a roller making
sure it can’t be raised. Backhang doors as shown
in Figure 17-T. Any door with a horizontal track
11'6"[350cm]longorlongerrequirestwoback-
hangsoneachhorizontaltrack.(FIG.5-T)(See
important note page 17 for additional backhang
requirements.) Attach spring bumpers as shown in
Figure 16-T. They will keep the door from com-
ing out of the back of the tracks. Push the door
against the stop or steel jambs and tighten track
bolts.Adjusttopbrackets.(FIG.10-S,page12)
Install inside slide lock or lock bars after springs
arewound.(FIG.8-S&9-S,page12)Naildoor
stop in place if applicable.
29
Fig. 2-OP
Fig. 1-OP
Fig. 3-OP
Cut Angle Iron
To Fit Behind
C-Channel
VIEW OF VERTICAL
ANGLE IRON
OPENER REINFORCEMENT ASSEMBLY
FOR C-CHANNEL DOORS
C-Channel
Center Stile
Or Backer
Plate
Cut Angle Iron To Fit
Behind C-Channel
Strap
Attaching an Automatic
Opener
To avoid risk of strangulation or personal injury
to children, you must remove the pull down
rope when you install an automatic garage door
operator.
NOTE: Failure to reinforce the door as illustrated
will void Clopay Warranty.
Doors with a stile at center of door:
• Youwillneedthreepiecesof14gauge2"x2"
[51 mm x 51 mm] punched angle iron. Two
pieces should be 8 ft. [244 cm] long and one at
least24"[610mm]long.The24"[610mm]piece
may have to be trimmed to fit your door.
• Removethefastenersfromthetophalfofthe
three top section hinges closest to, or at, the cen-
ter of the door. One 8 ft. [244 cm] piece of angle
iron is to span across these three hinges and
attached using fasteners previously removed.
• Placeremaining8ft.[244cm]pieceacrossthe
top of the section, bridging across the same three
stiles as the bottom angle. Attach with fasteners
similar to ones used with the hinges. One fas-
tener per stile. If your door has a strut at the top
of the section, remove the bottom strut fasteners
and overlap the flange of the strut with the angle
iron to secure the bottom of the strut. Attach
angle using the fasteners removed with the strut
(FIG.1-OP)RefertoFigure3-OPforC-Channel.
• Cutthe24"[610mm]pieceofpunchedangleiron
to span from top horizontal angle to bottom hori-
zontal angle. Place vertical angle directly above
stile in the center of the door. Attach vertical
angle through both the top and bottom horizontal
angles to the stile beneath with fasteners similar
to ones used with the hinges.
Doors without stile at center of door:
• Youwillneedthreepiecesof14gauge2"x2"
[51 mm x 51 mm] punched angle iron. Two
pieces should be 4 ft. [122 cm] long and one at
least24"[610mm]long.The24"[610mm]piece
may have to be trimmed to fit your door.
• Removethefastenersfromthetophalfofthe
two top section bottom hinges closest to the
center of the door. One 4 ft. [122 cm] piece of
angle iron is to span across these two hinges
and is attached using fasteners previously re-
moved.
• Placeremaining4ft.[122cm]pieceacrossthe
top of the section, bridging across the same two
stiles as the bottom angle. Attach with fasten-
ers similar to ones used with the hinges. One
fastener per stile. If your door has a strut at the
30
top of the section, remove the bottom strut
fasteners and overlap the flange of the strut with
the angle iron to secure the bottom of the strut.
Attach angle using the fasteners removed with
thestrut.(FIG.2-OP)
• Cutthe24"[610mm]pieceofpunchedangle
iron to span from top horizontal angle to bottom
horizontal angle. Place vertical angle directly in
the center of the door. Attach vertical angle to
both the top and bottom horizontal angles with
two
3
/
8
"[10mm]nutsandtwo
3
/
8
"[10mm]bolts.
Refer to Figure 3-OP for C-Channel.
Attach the operator arm of garage door opener to
the short vertical angle. The operator arm must be
attached roughly at the same height of the top roll-
ers of the door.
Painting and Windows
PAINTING
Cleaning: Before painting your door, it must be
free of dirt, oils, chalk, waxes and mildew. The pre-
painted surfaces can be cleaned of dirt, oils, chalk
and mildew with a diluted solution of trisodium
phosphate. Trisodium phosphate is available over
the counter at most stores under the name SOIL-
AX
®
, in many laundry detergents without fabric
softener additives, and in some general purpose
cleaners. Check the label for trisodium phosphate
content. The recommended concentration is
1
⁄
3
cup
[79 ml] of powder to 1
1
/
2
to 2 gallons [6 l to 8 l] of
water. After washing the door, always rinse well
with clear water and allow to dry.
If the door has ever been waxed, the wax must
be removed before painting. Doors are not waxed
during the manufacturing process. This can be
accomplished by wiping the door surface with
a rag saturated with Xylene (Xylol), available at
most paint or hardware stores. Wiping should be
done at moderate pressure and Xylene must not
be allowed to sit on the door for an extended time.
Damage to your door’s paint system can occur if
overexposed to this or other solvents.
Caution: Safety instructions on the solvent’s con-
tainer must be followed. After de-waxing the door,
clean with trisodium phosphate, as stated previ-
ously.
NOTE: Sanding could remove rust-inhibiting com-
pounds, therefore, sanding should be done only
to damaged areas where bare metal has been
exposed. Refer to the “Repair” section of these
instructions.
Repair: Should your door’s paint finish become
damaged, exposing the bare metal, it will become
necessary to repair this area to prevent rust from
forming. The damaged area should be lightly
sanded with a medium to fine sandpaper making
sure to remove all visible red and white rust. Wipe
this area with a dry, clean rag. Coat the sanded
area with a high quality, rust inhibiting, zinc
enriched primer. This type of primer can be found
at most paint or hardware stores, and should be
labeled for covering bare and galvanized steel.
Once the primer is applied, wait the time specified
on the primer’s instructions before you finish paint-
ing your door.
Paint: Your steel garage door can be painted with
a high-quality flat latex exterior grade paint. Since
all paints are not created equal, the following test
needs to be performed: paint should be applied on
a small area of the door (following the instructions
on the paint container), allowed to dry, and evalu-
ated prior to painting the entire door. Paint defects
to look for are blistering and peeling. An additional
test is to apply a strip of masking tape over the
painted area and peel back, checking to see that
the paint ad heres to the door and not to the tape.
After satisfactorily testing a paint, follow the direc-
tions on the container and apply to the door. Be
sure to allow adequate drying time should you
wish to apply a second coat.
With the exception of rubber gasket windows,
windowframes&insertscanbepaintedwitha
high quality latex paint. The plastic should first be
lightly sanded to remove any surface gloss.
NOTE: Do not apply paint when door surface
temperature is different from manufacturer's sug-
gested temperature range for application.
WINDOWS WITH SCREW-DOWN
FRAMES
To avoid injury, use extreme caution in
handling glass window pane. When the frame
is removed, the exposed steel edge of the door
may be sharp. Avoid contact with the steel
edges.
C21-R01-0405
Clopay® Pro-Series® Limited Warranty
Steel Door Limited Warranty Information
We will repair or replace (at our option) any garage door section or hardware that is defective in material or workmanship pursuant to the
terms of this limited warranty. This warranty extends to and benefits only the original purchaser of the garage door. This warranty does not
apply to commercial, industrial or any other non-residential installation.
We will provide, at no cost to you, sections/section components, hardware, springs/spring components or windows to repair or replace
defective sections, hardware, springs/spring components or windows. All labor costs associated with the removal and reinstallation of any
repaired section/section components, hardware or spring/spring components, and the installation of replacement sections/section
components, hardware, spring/spring components, or windows will be your responsibility. We reserve the right to inspect and/or verify any
claimed defect.
The applicable limited warranty periods are as follows:
Model # Paint System
Hardware/
Springs Sections Window
Limited Lifetime 3 yrs. 5 yrs. 10 yrs.
Terms and limitations of the limited warranty are further detailed below:
Paint System Limited Warranty
Clopay warrants the sections of the Models listed above against rust through due to the paint finish cracking, checking or peeling (losing
adhesion) as follows: (a) in residential single family installations for the years designated above from the date of delivery to the original
purchaser; (b) in all other residential installations (including installations on facilities owned in common by condominium associations or similar
organizations), for ten (10) years from date of delivery to the original purchaser, pursuant to the terms of this limited warranty.
Hardware/Spring & Spring Component/Sections/Section Components Limited Warranty
We will repair or replace (at our option) any garage door hardware, section/section components, spring and/or spring component that is
defective in material or workmanship for the term defined in the chart above, pursuant to the terms of this limited warranty. In addition, we will
repair or replace (at our option) any garage door section/section component that is defective in material or workmanship.
Decorative Windows – 10 Year Limited Warranty
Designer windows, snap-in inserts, clear acrylic windows and window frames are warranted for ten (10) years from date of purchase against
manufacturing defects and excessive discoloration. This warranty does not cover any damage or loss caused by harmful chemical action,
abrasive cleansers, or breakdowns due to climate extremes or environmental conditions. No warranty is available for single pane glass.
WE WILL NOT PAY FOR ANY DAMAGES, INCLUDING INCIDENTAL OR CONSEQUENTIAL DAMAGES, CAUSED BY OR RESULTING
FROM DEFECTIVE GARAGE DOOR SECTIONS OR HARDWARE. Some states do not allow the exclusion of incidental or consequential
damages, so the above limitation may not apply to you.
Our warranty shall not extend to or cover deterioration due to damage or rust to the garage door caused by fire, an act of God, other accident
or casualty, vandalism, radiation, harmful fumes or foreign substances in the atmosphere, or occurring as a result of any physical damage or
the failure of paint that is not applied per the manufacturer's specifications after the garage door left our factory, or failure to follow all
installation and maintenance instructions. Nor shall our warranty extend to or cover any damages due to normal wear and tear, or claims with
respect to any products that in any way or degree have been altered, processed, misused or improperly handled or installed.
WE MAKE NO OTHER WARRANTIES, REPRESENTATIONS, OR COVENANTS, EXPRESS OR IMPLIED, WITH RESPECT TO THIS
PRODUCT, INCLUDING BUT NOT LIMITED TO WARRANTIES, REPRESENTATIONS OR COVENANTS AS TO WORKMANSHIP,
DESIGN, CAPACITY, QUALITY, CONDITION, MERCHANTABILITY, OR FITNESS FOR ANY PURPOSE OF THE PRODUCT, EXCEPT FOR
ANY “IMPLIED WARRANTY” AS THAT TERM IS DEFINED IN THE MAGNUSON-MOSS WARRANTY-FEDERAL TRADE COMMISSION
IMPROVEMENT ACT, SUCH IMPLIED WARRANTIES TO BE LIMITED IN DURATION TO A PERIOD OF ONE YEAR FROM THE DATE OF
PURCHASE.
This warranty gives you specific legal rights, and you may also have other rights that vary from state to state.
© Clopay Building Products Company, Inc.
Painting your Door
Paint: Your steel garage door can be painted with a high quality,
100% acrylic latex (flat, satin, or semi-gloss) exterior grade paint.
oil-based
Cleaning: Before painting your door, it must be free of dirt, oils,
chalk, waxes and mildew. The prepainted surfaces can be
cleaned of dirt, oils, chalk and mildew with a diluted solution of
trisodium phosphate. Trisodium phosphate is available over the
counter at most stores under the name SOILAX®, in many
laundry detergents without fabric softener additives, and in some
general purpose cleaners. Check the label for trisodium
phosphate content. The recommended concentration is 1/3 cup
of powder to 1–1/2 to 2 gallons of water. After washing the door,
always rinse well with clear water and allow to dry.
If the door has ever been waxed, the wax must be removed
before painting. Doors are not waxed during the manufacturing
process. The wax can be removed by wiping door surface with a
rag saturated with Xylene (Xylol), available at most paint or
hardware stores. Wiping should be done at moderate pressure
and Xylene must not be allowed to sit on the door for an
extended time. Damage to your door’s paint system can occur if
overexposed to this or other solvents.
Caution: Safety instructions on the solvent’s container must be
followed. After de-waxing the door, clean with trisodium
phosphate, as stated previously.
NOTE: Sanding could remove rust-inhibiting compounds,
therefore, sanding should be done only to damaged areas where
bare metal has been exposed. Refer to the “Paint Repair”
section of these instructions.
Paint Repair: Should your door’s paint finish become damaged,
exposing the bare metal, it will become necessary to repair this
area to prevent rust from forming. The damaged area should be
lightly sanded with a medium to fine sandpaper making sure to
remove all visible red and white rust. Wipe this area with a dry,
clean rag. Coat the sanded area with a high quality, rust
inhibiting, zinc enriched primer. This type of primer can be found
at most paint or hardware stores, and should be labeled for
covering bare and galvanized steel. Once the primer is applied,
wait the time specified on the primer’s instructions before you
finish painting your door.
Paint: Your steel garage door can be painted with a high quality,
100% acrylic latex (flat, satin, or semigloss) exterior grade paint.
Since all paints are not created equal, the following test needs to
be performed: paint should be applied on a small area of the
door (following the instructions on the paint container), allowed to
dry, and evaluated prior to painting the entire door. Paint defects
to look for are blistering and peeling. An additional test is to
apply a strip of masking tape over the painted area and peel
back, checking to see that the paint adheres to the door and not
to the tape.
After satisfactorily testing a paint, follow the directions on the
container and apply to the door. Be sure to allow adequate
drying time should you wish to apply a second coat.
Window frames & inserts can be painted with a high quality,
100% acrylic latex. The plastic should first be lightly sanded to
remove any surface gloss.
NOTE: Do not apply paint when door surface temperature is
different from manufacturer’s suggested temperature range for
application.
Snap-In Grille Removal And Replacement:
NOTE: DO NOT REMOVE SCREWS from the window frame.
Decorative grilles are designed to snap-in and out of the window
frame.
Some doors with windows have a decorative grille attached in
front of the window. The grille can be removed for cleaning or
painting purposes.
1) Remove the tabs on the vertical legs of the grille (two on
short panel windows, six on long panel windows) from the
notches in the front window frame.
2) The grille can be firmly pulled out of the window.
3) Replacing the grille is the reversal of the process described
for removal. The two or six longer tabs on the vertical legs of
the grille must be placed in the notches under the lip of the
front window frame. The two shorter tabs on the horizontal
leg of the grille must be placed under the lip of the front
window frame.
Glass Replacement
To avoid injury, use extreme caution in handling glass window
pane. When the frame is removed, the exposed steel edge of the
door may be sharp. Avoid contact with the steel edges.
Glass Replacement: If your door is equipped with windows and
the glass should need replacement, follow the steps below:
1) With someone holding the outside frame, remove the screws
from the inside window frame.
2) Pull the inside frame out of the door.
3) Carefully remove the broken or old glass.
4) Insert the new glass. The glass should be 17-5/8” x 14-1/16”
(short panel windows) or 40-1/8” x 14-1/16” (long panel
windows). See illustration below for glass dimensions of
single or double arched windows. (FIG. Glass-1)
5) With someone holding the outside frame, reinsert the screws
into the inside frame, trapping the glass.
FIG. Glass-1
NOTE: Do not use oil-based paint. Using oil-based paint will
void the warranty on your door.
Dou
b
le Arch
Glass Dimensions
Single Arch
Glass Dimensions
:$51,1*


Painting preparation: Clean surface first with a diluted
solution of Trisodium Phosphate. The recommended
concentration is 1/3 cup of powder to 1-1/2 to 2 gallons of
water. A cleaning pad (3M Synthetic steel wool GRAY not
green) should be used saturated with this cleaning solution.
Rub with even pressure to lightly scuff the surface while ap-
plying the cleaning solution over all surfaces to be painted.
A final wipe and rinse with clean water and sponge should
be done to remove any loose material. Change water often
to ensure clean rinse and allow to dry. Pre test your paint
on a small area (see paragraph Paint below). If the paint
shows signs of poor adherence, (tape test below) there may
be a problem with the paint or the surface preparation. DO
NOT PROCEED! A new paint or further preparation of the
surface is called for.
Alternate cleaning compounds: Areas of the country that
do not carry Trisodium Phosphate can use a biodegradable
cleaner with the cleaning pad above. Follow above
directions to rinse completely and pre test paint.
Painting: Your steel garage door can be painted with a
high quality 100% acrylic latex (flat, satin, or semigloss)
exterior grade paint. Before painting the door it must be free
of dirt, oil, caulk, waxes and mildew.
Do not use any type of oil based paint or Alkyd modified
acrylic latex paint. These paints will void the warranty of
your door.
If your garage door does not conform to this warranty, notify us in writing at the following address promptly after discovery of the defect.
A Griffon Company, Inc. 2007
Clopay Building Products, Attn: Consumer Services Dept., 1400 West Market Street, Troy, Ohio 45373. Additional copies of our installation
GD4L, G4L, GD4LV, G4LV, GD4S,
G4S, GD4SV, G4SV
3 yrs. 5 yrs. 10 yrs.
C21-R05-1107
GD5S, G5S, GD5SV, G5SV
15 yrs.
and maintenance instructions may be obtained by calling 1-800-225-6729.
31
Fig. 1-LHR
Fig. 1-PD
DEEP RIBBED STEEL PASS DOOR
(Pass Door Shown Is Left Hand Door Swinging Out)
Gear Hinge
(This Side)
#1 Hinge
See
Fig. 4-PD
See Fig. 5-PD
#1 Hinge
Fig. 2-PD
DOUBLE SKINNED INSULATED PASS DOOR
(Pass Door Shown Is Left Hand Door Swinging Out)
Gear Hinge
(This Side)
See Fig. 4-PD
See Fig. 5-PD
Glass Replacement: If your door is equipped with
windows and the glass should need replacement,
follow the steps below:
1) With someone holding the outside frame,
remove the ten screws from the inside window
frame.
2) Pull the inside frame out of the door.
3) Carefully remove the broken or old glass.
4) Insert the new (replacement) glass.
5) With someone holding the outside frame,
reinsert the screws into the inside frame,
trapping the glass.
Quick Turn Bracket
(Reducesheadroomrequirementby2"[51mm].
Quick turn bracket cannot be used in conjunction
with any other low headroom option.) This is used
in place of the existing top roller brackets.
1. Place two rollers in the tubes as shown. On
some doors it will be necessary to try various
roller positions to achieve the proper hinge
location on the door. (FIG. 1-LHR)
2. Position the rollers and the bracket in the door
track. Allow the hinged end of the bracket
to come against the door. Apply sufficient pres-
sure to be sure that the top of the door
is closed tightly against the header.
3. Attach to the top of the door in the same
manner as the original top roller bracket.
4. It may be necessary to relocate holes.
Pass Door Installation
NOTE: Proper alignment of the pass door frame
is critical for smooth operation of the pass door.
After stacking the bottom section, measure the
pass door frame opening at the top and bottom of
the frame (Figure 3-PD). If this measurement is
not exactly the same, the bottom section will need
to be shimmed or clamped so that the frame is
aligned.
See Figure 1-PD (Deep Ribbed Steel Doors) or
Figure 2-PD (Double Skinned Insulated Doors)
for diagram of pass door showing hinge and
closer locations. The strut schedule for pass
doors follows the strut schedule on page 9,
minus 2 struts.
32
©2012 Clopay Corporation P/N 0130006 06/12 COMM-STEEL
Fig. 3-PD
Fig. 4-PD
Inner Pass
Door Frame
Fig. 5-PD
Frame Opening
(Top)
Frame Opening
(Bottom)
Night Latch
Striker Plate
Outer Pass Door Frame
Shim Here To Level
NOTE: Swinging portion of Pass Door on bottom
section may need to be shimmed up during instal-
lation of upper sections to prevent gapping.
(FIG.5-PD)
NOTE: To better ensure proper alignment of
the frame from section to section, install the
center hinges on the gear hinge side of the
aluminum pass door frame first and work out-
wards installing hinges.
Install Lock according to Figure 4-PD.
Install closer according to the closer instructions
provided.