RESIDENTIAL SECTIONAL INSULATED STEEL DOORS
INSTALLATION
INSTRUCTIONS
CLOPAY CONSUMER SERVICES • 1-800-225-6729
INSTRUCTIONS COMPATIBLE WITH THE FOLLOWING MODELS
Composite Overlay Faux Wood Doors CAN, CRM, GLN, GLM // Composite Overlay Doors CXU, CS, CFF, CGU, CG, CD, SXU, SC, SF // Carriage House Steel
Doors GR2SU, GR2LU, GR1SU, GR1LU, GR2SP, GR2LP, GR1SP, GR1LP, GD2SU, GD2LU, GD1SU, GD1LU, GD2SP, GD2LP, GD1SP, GD1LP, AR2SU, AR2LU, AR1SU,
AR1LU, AR2SP, AR2LP, AR1SP, AR1LP // Insulated Steel Doors 4050, 4051, 4053, 4132, 4138, 4300, 4301, 4302, 4305, 4308, 4309, 4310, HDG, HDGL, HDGF, HDGC,
HDGCC, HDGR, HDGRC, 2050, 2053, 2051, 2132, 2138, 6200, 6203, 6130, 6133, 6202, 6132, 6201, 6131, 6208, 6138, 6205, 6209, 9130, 9131, 9132, 9133, 9134, 9135,
9138, 9139, 9200, 9201, 9202, 9203, 9204, 9205, 9208, 9209, HDPCC1, HDPRC1, HDPCC2, HDPRC2, HDP20, HDPL20, HDPF20, HDPC20, HDPR20, HDP13, HDPL13,
HDPF13, HDPC13, HDPR13, 7200, 7203, 7130, 7133, 7202, 7132, 7201, 7131, 7208, 7138, 7205, 7209, 7139
STEP 1 - BEFORE YOU BEGIN
TABLE OF CONTENTS
■
Verify you have all parts and materials required for installation.
STEP 2 Read Safety Information . . . . . . . . . . . . . . . . . . . . . . . 2
STEP 3 Check Headroom, Backroom, Sideroom . . . . . . . . . . . . 3
STEP 4 Review Complete Door Assembly and Verify Hardware . 4–6
STEP 5 Remove the Existing Door . . . . . . . . . . . . . . . . . . . . . . 7
STEP 6 Prepare the Opening . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEP 7 Prepare the First (Bottom) Section . . . . . . . . . . . . . 9–10
STEP 8 Install Lift Handles . . . . . . . . . . . . . . . . . . . . . . . . 11–13
STEP 9 Install Door Sections . . . . . . . . . . . . . . . . . . . . . . 14–16
• Door Components (See Page 5).
If missing parts or damaged sections, call Clopay Consumer
Services Hotline 1-800-225-6729.
■
Read instructions completely and/or watch installation video.
■
HEADROOM: Verify appropriate amount of headroom to install door
(STEP 3).
■
■
LOW HEADROOM: Special instructions and additional hardware may be
required (STEP 3, Table 3-B).
STEP 10 Reinforce the Top Section for Garage Door Opener
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–18
INSTALLATION TIME: Allow enough time to complete installation.
Garage will be open and unsecured during installation and will not be
able to be used until tracks are installed.
STEP 11 Assemble and Install the Track. . . . . . . . . . . . . . . 19–21
STEP 12 Install Lock (If Included) . . . . . . . . . . . . . . . . . . . . . . . 22
STEP 13 Install Pull Rope (Manually Opened Doors Only) . . . . . 22
STEP 14 Install Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STEP 15 Attach Automatic Garage Door Opener . . . . . . . . . . . 23
GENERAL MAINTENANCE & CARE. . . . . . . . . . . . . . . . . . . . . 25–31
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
• Removing existing door will take approximately 1–3 hours.
• Typical installation time is 9–12 hours.
■
TRACK AND HARDWARE: Express warranties apply only to doors
installed using original, factory-supplied sections, parts and hardware
and in strict adherence with these instructions.
! WARNING
Never reuse old track or hardware when installing a new door as it may
cause installation problems or door to fall which could result in serious
personal injury or property damage.
INSTALLATION VIDEO:
residential-installation-videos
or scan the QR code on the right.
■
AUTOMATIC DOOR OPENER: Installation of a reinforced mounting point
is required to avoid damage (STEP 10). Sold separately.
■
DRILLING: Take care not to drill through outside steel skin unless
otherwise instructed.
Français
■
HIGH WIND AREAS: Doors installed in high windload regions (Florida
La version française de ce supplément peut être accédée en ligne à l'adresse suivante:
FR
ES
and other high wind-prone areas) may require additional reinforcement.
Refer to Supplemental Instructions for details if applicable.
■
PAINTING DOOR: If planning to paint door, follow directions in Care &
Maintenance section. Clopay recommends painting door and allowing it
to dry completely before beginning install.
Español
Se puede acceder a la versión en español del presente suplemento en la siguiente dirección:
STEP 3 - CHECK HEADROOM, BACKROOM, SIDEROOM
Headroom Requirement:
Rough Opening = Door Size
■
Headroom is space needed above top of door for door, overhead tracks
and springs. Measure to check that there are no obstructions within that
space (Fig. 3-A).
Backroom = Door
Height Plus 18"
Headroom
Required
■
■
Refer to Table 3-A for standard headroom requirements.
Track radius can be determined by measuring dimension “R”
(Fig. 3-B).
• If “R” equals 11" to 12", it is a 12" radius track.
• If “R” equals 14" to 15", it is a 15" radius track.
Determine which type of spring you have (STEP 4).
Door
Height
■
NOTE: If there is restricted headroom, several low headroom remedies
are available (Table 3-B). Installation of these options differ from
installation of a standard headroom door.
Supplemental instructions are included with hardware of each low
headroom option.
4-1/2" Minimum Sideroom
Fig. 3-A
Rough Opening:
■
Rough opening (minus stop mold) = same size as door (Fig. 3-A)
Backroom Requirement:
■
Measured from back of door into garage, and should be at least
18" more than height of garage door (Fig. 3-A).
R
Sideroom Requirement:
■
Minimum 3-3/4" is needed on each side of door on interior wall surface
Fig. 3-B
to allow for attachment of vertical track assembly.
■
Minimum 4-1/2" is needed on each side of door above opening for
Table 3-A: Standard Headroom Requirement Chart
torsion spring attachment.
Track
Radius
Headroom
Required
NOTE: If you are installing an automatic opener, about 3" of additional
headroom at the center plus additional backroom is needed. Check
door opener instructions.
Spring Type
Extension Spring
12"
10"
12"
12"
14"
Extension Spring
15"
EZ-SET® Torsion Spring or Torsion Spring
EZ-SET® Torsion Spring or Torsion Spring
12"
15"
Table 3-B: Low Headroom Options*
Spring Type
Extension
Low Headroom Option
Reduces Required Headroom to:
How can I get this option?
Order Low Headroom Track
Low Headroom Track
4-1/2"
4-1/2"
Extension
Low Headroom Conversion Kit
(Modifies Standard Track)
Available at most retail stores
Order Quick Turn Bracket Set
Order Low Headroom Track
Available at most retail stores
Extension
Quick Turn Bracket
8" on 12"
Radius Track
EZ-SET® Torsion
EZ-SET® Torsion
Torsion
Low Headroom Track
(Front Mount Spring)
9-1/2"
9-1/2"
9-1/2"
4-1/2"
Low Headroom Conversion Kit
(Modifies Standard Track)
Low Headroom Track
(Front Mount Spring)
Available from and should be installed by
professional installer only
Torsion
Low Headroom Track
(Rear Mount Spring)
Available from and should be installed by
professional installer only
3
STEP 4 - REVIEW COMPLETE DOOR ASSEMBLY AND VERIFY ALL HARDWARE IS PRESENT
FINAL GARAGE DOOR ASSEMBLY
EXTENSION SPRING SYSTEM SHOWN
Rear Track Hanger
(Not Included)
Containment Cable
Extension Spring
Stationary Sheave
Sheave
Door Jamb
Flag Bracket
Section #4
Top Bracket
Top Bracket
Vertical Track
Vertical Track
#3 Hinge
Operator
Label
#3 Hinge
Section #3
#1 Hinge
#1 Hinge
#1 Hinge
General Safety Label
Long Track Bracket
#2 Hinge
#2 Hinge
Section #2
#1 Hinge
#1 Hinge
Serial Number Label
Short Track Bracket
Bottom Bracket
Bottom Bracket
Inside Step Plate
SPRING SYSTEMS
STANDARDTORSIONSPRINGSYSTEM
STANDARD EXTENSION SPRING SYSTEM
Sheave
End Bearing Plates
Center Bearing Plate
Torsion Tube
Stationary
Red Winding
Cone
Cone
Stationary Sheave
Black Winding
Left (Red)
Cable Drum
Cone
Right (Black)
Cable Drum
EZ-SET® EXTENSION SPRING SYSTEM
EZ-SET®TORSION SPRING SYSTEM
Sheave
EZ-SET®
Winding Unit
Left Cable Drum
EZ-SET® Bracket
®
EZ-SET® Winding Unit
EZ-SET Winding Unit
NOTE: The above illustrations represent a composite of many features found on a variety of garage doors. While not representative of any one door, it
provides a handy reference for the location of specific components. Doors with torsion springs may require EITHER one or two springs depending on
the door weight. Consult your spring manual.
4
HARDWARE COMPONENTS INCLUDED
NOTE: All doors will receive (1) spring kit and (1) or more springs. Separate spring installation supplemental instructions should be included with door
hardware. This supplement contains a list of all spring related hardware along with instructions on proper spring installation.
Qty Single Qty Double
Qty Single Qty Double
Doors
X' × 7'
Doors
X' × 7'
Doors
X' × 7'
Doors
X'× 7'
Image
Description
Image
Description
Cable Assembly
2
0
2
Track Bracket (longer)
2
2
5
2
2
2
2
2
2
2
2
2
2
Struts*
1 or 3
Track Bracket (shorter)
#1 Hinge
Lift Handle
Pull Rope
2
1
2
1
11
2
#2 Hinge
#14 × 5/8" Hex Head
Sheet Metal Screw
56
90
#3 Hinge
2
1/4" × 3/4" Hex Head
Self-Tapping Screw
0
16
2
10
22
2
#4 Hinge (5-section doors only)
Top Bracket
2
1/4" × 5/8" Track Bolt
2
3/8"-18 × 3/4"
Lg. Carriage Bolt
Bottom Bracket (1) LH + (1) RH
Flag Bracket (1) LH + (1) RH
Horizontal Angle
2
3/8" Washer
2
16
2
2
22
2
2
1/4" Flange Nut
3/8" Hex Nut
2
10 (4-section Doors)
12 (5-section Doors)
10 (4-section Doors)
12 (5-section Doors)
Rollers
Curved Horizontal Track
2
Vertical Track
2
2
2
2
5/16" × 1-5/8" Lag Bolt
Inside Step Plate
ADDITIONAL HARDWARE COMPONENTS INCLUDED
ONLY WITH COMPOSITE OVERLAY FAUX WOOD DOORS & STEEL CARRIAGE HOUSE DOORS
Image
Description
Door Size
Qty.
Image
Description
Door Size
Qty.
Single Car Doors
8'–9'W
Single Car Doors
8'–9'W
2
2
Roll Grip Handle
Vertical Spade Handle
Double Car Doors
16'W
Double Car Doors
16'W
4
6
4
1
Single Car Doors
8'–9'W
Single Car Doors
8'–9'W
Handle Spacers
Backup Plate
Horizontal Spade Handle
Black Head Carriage Bolt
Double Car Doors
16'W
Double Car Doors
16'W
10
1
2
Single Car Doors
8'–9'W
Single Car Doors
8'–9'W
6
Double Car Doors
16'W
Double Car Doors
16'W
2
10
See next page for Additional Materials Needed (Not Included).
5
ADDITIONAL MATERIALS NEEDED (NOT INCLUDED)
* More struts may be required in high windload areas. (While not representative of any one model, the quantities below can be used as a guide.
In some instances, extra screws/bolts are provided in the event of strip-out or loss of parts.)
MATERIALS NEEDED (NOT INCLUDED)
General
Rear Track Hanger Specific
ˆ (1) Can of Clopay® Pro-Lube
ˆ (24) 10d 3" common nails
ˆ Stop molding
ˆ Wood shims
ˆ Wood block
ˆ Rope
ˆ (1) Rear Track Hanger Kit or material to make track hanger
ˆ 1-1/4" × 1-1/4" minimum 13 ga. (3/32") minimum thickness
punched angle
ˆ (10) 3/8" × 1" bolts and nuts
ˆ (6) 5/16" × 1-1/2" lag screws
TOOLS NEEDED (NOT INCLUDED)
ˆ Work gloves
ˆ Level
ˆ Stepladder
ˆ Hacksaw
ˆ Safety goggles
ˆ C-clamps or locking pliers
ˆ Hammer
ˆ Socket wrench set
ˆ Sawhorses (with non-abrasive
carpet or other soft material on
top surface) or other supports
for placing section on while
assembling
ˆ Wood saw
ˆ Angle square
ˆ 7/16" and 9/16"
box wrenches
ˆ Additional tools may be
ˆ Drill, 1/4", 3/16" and
3/8" drill bits, 7/16" and 9/16"
drive bits
required for spring installation
ˆ Flathead screwdriver
ˆ Measuring tape
6
STEP 5 - REMOVE THE EXISTING DOOR
Step 5-1: Remove Existing Door Springs
NOTE: Garage doors use springs to balance door weight. Springs are
one of two types – extension or torsion. Each of these is available in
either a standard or EZ-SET® assembly option.
■
Use illustrations in STEP 4 to determine which springs existing door
has. If existing door's spring type is not found, please consult spring
manufacturer.
! WARNING
Serious injury could result from an uncontrolled release of spring forces
if spring tension has not been released before other work begins.
C-clamp
Fig. 5-A
! WARNING
To avoid pinch and other crushing injuries, keep hands and fingers clear
of section joints, track and other door parts while door is opening and
closing.
NOTE: Some large doors can weigh as much as 500 lbs. and single car
doors as much as 200 lbs. when spring tension is removed.
Standard Torsion Springs:
! WARNING
Fig. 5-B
If present door uses standard torsion springs, DO NOT attempt to remove
door or springs yourself. They should be removed by a qualified door
service professional. Attempting to remove a torsion spring assembly
without proper training and tools may result in an uncontrolled release of
spring forces which can cause serious injury.
EZ-SET® Extension Springs or EZ-SET® Torsion Springs:
! WARNING
To avoid damage or serious injury, use two or more helpers to assist in
lowering door. EZ-SET® torsion springs adjustments or removal should
only be made with door in down position.
Standard Extension Springs:
! WARNING
Extension adjustments or removal should only be made with door in up
position. To avoid damage or serious injury from door falling, use two or
more helpers to assist in lowering door.
■
With door in down position, position drill with 7/16" socket bit over
winding unit.
■
Using reverse (counter-clockwise) direction on drill, remove all tension
from spring. Repeat for each side.
■
Raise door to full open position.
■
After spring tension has been removed, detach lift cables at
both ends.
■
Place C-clamps or locking pliers tightly on both sides of track under door
so door is held securely in place (Fig. 5-A).
■
Disassemble and remove springs and cable completely from door.
■
With door fully open, most spring tension has been removed.
■
Keeping C-clamps in place to keep door from falling, detach cable at both
Step 5-2: Remove Door Sections and Track
ends.
■
After removal of door springs, door can now be disassembled.
■
Disassemble and remove springs and cable completely from door.
■
Starting with top section, remove hardware and unstack sections one at
a time (Fig. 5-B).
NOTE: Wood blocks should be placed underneath door when closing to
prevent fingers from being trapped.
■
After all sections have been removed from opening, detach all remaining
track and hardware from jambs.
■
Remove C-clamps from track and carefully close door.
■
Hangers that attach rear ends of overhead track to ceiling (rear track
hangers) in many cases can be reused on new door. Be sure they are
made of 13 ga. (3/32") or heavier steel and are not loose or unstable.
■
Weight of door will not be apparent when you first begin to close door.
Door will feel progressively heavier as it is lowered until its full weight is
realized about one foot from floor.
! WARNING
To avoid installation and operation problems from using worn, damaged
or incompatible track, use only track specified and supplied with door.
DO NOT attempt to reuse old track.
7
STEP 6 - PREPARE THE OPENING
NOTE: Rough opening (framed opening without stop molding) = door
size
Step 6-1: Framing
■
If old door was removed, inspect jambs for rotted or damaged wood and
2 x 6
replace immediately.
Header Jamb
■
Inside of door opening should be framed with 2" × 6" lumber.
Opening
Height
■
Vertical jamb should extend past opening (Fig. 6-A) to match headroom
required (Table 3-B).
2 x 6
Side Jamb
8"
■
Jambs should be plumb and header should be level.
Minimum
Center
Post
■
Be sure bolts fastening jambs to wall are flush.
(With
Two
Opening
Width
Step 6-2: Stop Molding
4-1/2" Minimum
Sideroom
Doors
Side
■
Door stop molding should be temporarily but securely nailed to edges of
jambs and flush with inside framing (Fig. 6-B).
for Torsion Spring
Inside of Garage
Looking Out
By Side)
NOTE: Stop molding with built-in weatherseal is offered.
Fig. 6-A
Stop
Molding
Outside
Inside
Fig. 6-B
8
STEP 7 - PREPARE FIRST (BOTTOM) SECTION
Step 7-1: Locate Bottom Section
■
Find section with aluminum weatherstrip retainer fastened to one edge.
Retainer is on bottom edge of bottom section (Fig. 7-A).
■
■
Cover sawhorses with carpet or cloth as not to scratch section.
Place section on sawhorses face down.
Fig. 7-A
Aluminum Weatherstrip Retainer
Step 7-2: Attach Bottom Brackets
■
By hand, bend to break apart bottom brackets as shown (Fig. 7-B).
Remove connecting tabs.
■
Slide bottom bracket up to fully engage safety tabs into slots on stile
(Fig. 7-C).
■
Using (2) #14 × 5/8" sheet metal screws, attach bottom brackets to
bottom corners of door section.
Fig. 7-B
#14 x 5/8" Sheet Metal Screws
! WARNING
Bottom Section
Slots
Failure to properly engage safety tabs on bottom bracket into slots on
edge of door may cause sections to fall or spring to break free when
spring tension is applied, which can result in severe injury.
!
Engage
Safety
Tabs
Step 7-3: Attach Standard Extension Springs Lift Cables
Bottom
Bracket
Weatherstrip
NOTE: For Standard Extension Springs — lift cables are the longer and
smaller diameter of the two sets of cables. DO NOT use shorter safety
containment cables as lift cable, this can cause improper door function.
For EZ-Set® Extension Springs — DO NOT attach lift cables now, this
will be done when springs are installed.
Safety Tabs
Fig. 7-C
■
Hook looped ends of lift cable over buttons on bottom brackets
(Fig. 7-D).
Fig. 7-D
Step 7-4: Attach Hinges
■
Hinges are stamped with numbers 1, 2 and 3 on the side of the hinge that
attaches to the section. (Number 4 is stamped on 5-section door only.)
#1 Hinge
■
Attach a #1 hinge to each pair of prepunched holes along top edge of
section using (2) #14 × 5/8" sheet metal screws per hinge (Fig. 7-E).
NOTE: Determine if a strut is required on the bottom section of your
door (Table 7-A). Determine whether door thickness is 1-3/8" or
2" and the width of the end stile (Fig. 7-E). To attach strut, overlap
hinges using 1/4" × 3/4" self-tapping screws as shown (Fig. 7-F).
When predrilled holes do not line up with hinge, drill (2) 3/16" pilot
holes through strut, hinge and door at each location (or use impact
wrench with 7/16" socket and self-tapping screws (Fig. 7-F).
#14 x 5/8"
Sheet Metal Screws
End Stile
Width
Bottom
Astragal
Door
Thickness
Fig. 7-E
1/4" x 3/4" Self-
Tapping
Screws
Strut
End Hinge
End Stile
Fig. 7-F
9
STRUT REQUIREMENTS
TABLE 7-A: CLASSIC STEEL DOORS & CONTEMPORARY STEEL DOORS
TABLE 7-C: STEEL CARRIAGE HOUSE DOORS
The table below shows the strut requirements for insulated doors.
The table below shows the strut requirements for Steel Carriage House doors.
Section
Door Thickness
Door Width
Struts Required
Door
Thickness
Door
Width
End Stile
Width
Bottom
3rd* Top
1-3/8"
Up to 14'10"
None
1-3/8"
1-3/8"
1-3/8"
2"
Up to 14'10"
15'–16'
All
2-1/2"
2-1/2"
All
–
–
–
–
–
✓
(1) 2-1/4" Strut
per door (top)
16'2"–18'
Up to 15'
One strut per section
1-3/8"
1-3/8"
2"
15'–16'
16'2"–18'
Up to 15'
15'2"–20'
–
–
–
–
–
(1) 2-1/4" Strut
per section
2"
15'2"–20'
All
✓
*Section with general safety label.
NOTE: Doors installed in high windload regions (Florida and other high
wind-prone areas) may require additional reinforcement. Refer to
Supplemental Windload Instructions.
None
(1) 2-1/4" Strut
per door (top)
2"
TABLE 7-B: COMPOSITE OVERLAY FAUX WOOD DOORS &
COMPOSITE OVERLAY DOORS
The table below shows the strut requirements for composite doors.
STRUT REQUIREMENT
Door
Width
Composite
Wood Full
Vision
Up to 2" Thick
2" Thick
Up to 9'0"
None
None
None
(1) 2-1/4" Strut (1) 2-1/4" Strut (1) 2-1/4" Strut
per door (top) per door (top) per door (top)
9'2" to 12'2"
12'4" to 16'2"
16'4" to 18'2"
18'4" to 20'0"
(1) 2-1/4" Strut (1) 2-1/4" Strut (1) 2-1/4" Strut
per section
per section
per section
(1) 3" Strut
per section
(1) 2-1/4" Strut (1) 2-1/4" Strut
per section
per section
(1) 3" Strut
per section
(1) 3" Strut
per section
N/A
NOTE: Window Lite section on double car doors may be packaged with
two struts attached. Remove strut from bottom of window section and
place on top of section #3.
10
STEP 8 - INSTALL LIFT HANDLES
STEP 8A: FOR INSULATED GARAGE DOORS
NOTE: For Composite Doors proceed to STEP 8B. For Steel Carriage
House Doors, proceed to STEP 8C.
2ND SECTION
CUT HERE FOR
1-3/8" DOORS
Step 8A-1: Lift Handle Preparation
■
For 2" thick doors, no modifications are necessary.
LIFT
HANDLE
STEMS
■
For 1-3/8" thick doors, cut stems on lift handle along ridge line using a
hacksaw (Fig. 8A-A).
Step 8A-2: Bottom (First) Section
Fig. 8A-A
■
From front side door section, drill (2) 1/2" holes through section according
(BOTTOM OF LIFT HANDLE)
to Bottom Section Hole Pattern (Fig. 8A-B). Use T-square to ensure vertical
alignment.
LIFT
NOTE: If door has an outside keyed lock, hole pattern should be drilled
on bottom section directly below lock. If door does not have an outside
keyed lock, hole pattern should be drilled directly below hinge closest
to horizontal center of door.
HANDLE
INSIDE
STEP
PLATE
LIFT
HANDLE
■
Install lift handle and inside step plate using (2) #14 × 5/8" sheet metal
screws (Fig. 8A-B).
BOTTOM SECTION
IMPORTANT: Use wrench or socket to drive screws. Do not over-
tighten. DO NOT use an electric drill or driver.
Step 8A-3: Second (Lock) Section
INSIDE STEP
PLATE
To be installed at completion of STEP 9A-4. Not required for door with
outside keyed lock.
■
#14 x 5/8"
SHEET METAL
SCREW
From front side door section, drill (2) 1/2" holes through section according
to Second Section Hole Pattern (Fig. 8A-C). Use T-square to ensure they
are vertically in line.
NOTE: Hole pattern should be drilled directly above hinge closest to
horizontal center of door.
Fig. 8A-B
2" DOOR SHOWN
■
Install lift handle and inside step plate using (2) #14 × 5/8"
sheet metal screws (Fig. 8A-B).
! CAUTION
DO NOT use these prestamped hinge holes for lift handle placement.
Measure per the drilling pattern below. DO NOT use this template for
carriage style or overlay doors.
Painting Lift Handles
• Plastic lift handles can be painted using good quality spray-on or
brushed-on enamel paint.
Lift Handle Hole Drilling Pattern
Outside View
Measure to Hinge Holes
on Opposite Side
1/2" Dia.
2nd Section
3/4"
3/4"
Center Line of
2nd Section
OR
2-3/4" Offset of
Bottom Edge
of Door
Bottom Section
Measure to Hinge Holes
on Opposite Side
Fig. 8A-C
11
STEP 8 - INSTALL LIFT HANDLES
STEP 8B: FOR COMPOSITE DOORS
Step 8B-1:
ꢀ-ꢁ/ꢂ" ꢃꢄomposite ꢅverlay ꢆoorsꢇ
ꢀ-ꢁ/ꢈ" ꢃꢄomposite ꢅverlay Fauꢉ Wood ꢆoorsꢇ
■
Center horizontal handle on outside of bottom door section 2" from
bottom of section. Using handle as a template, mark the holes to be
drilled (Fig. 8B-A).
Step 8B-2:
■
Drill two 1/4" holes straight through the door at the marks.
■
From outside, enlarge the two 1/4" holes using a 3/8" drill, being careful
not to drill through the inside skin of the door.
■
Remove excess foam from the 3/8" holes.
Step 8B-3:
ꢀ-ꢁ/ꢂ"
■
Fig. 8B-A
Insert 3/8" diameter spacer(s) into each hole from the outside of the door.
IMPORTANT: Failure to install spacers may result in damage to the
door.
1/4" - 20 x 2-1/4"
Hex Head Bolt
Step 8B-4:
■
Attach the black handle (outside) and the steel roll grip handle (inside) to
the door using two 1/4" black painted hex head bolts, and two 1/4" hex
nuts (Fig. 8B-B).
Inside Handle
Outside Handle
1/4" Hex Flange Nut
Step 8B-5:
■
Position two vertical handles on the second section. Using handles as a
template, mark holes to be drilled. The lower hole on each vertical handle
must lie between 20" and 30" vertically from the holes on the bottom
handle and be centered 5-1/2" horizontally from each other.
Spacer
Fig. 8B-B
■
Be sure holes on both vertical handles line exactly with holes on the
bottom horizontal handle. No hole may be closer than 2" to the top or
bottom of the section (Fig. 8B-C).
ꢀutside Handle
Step 8B-6:
ꢁ/ꢂ"- ꢅꢆ ꢃ ꢅ -ꢁ/ꢂ"
Heꢃ Head ꢇolt
■
Drill four 1/4" holes straight through the door at the marks.
ꢁ/ꢂ" Heꢃ Flange ꢄut
■
From the outside, enlarge the four 1/4" holes using a 3/8" drill, being
careful not to drill through the inside skin of the door.
■
Remove any excess foam from the 3/8" holes.
Step 8B-7:
■
Insert 3/8" diameter spacer(s) into each hole from the outside of the door.
Spacer
IMPORTANT: Failure to install spacers may result in damage to the
door.
ꢈnside
Handle
Fig. 8B-C
Step 8B-8:
■
Attach each vertical handle (outside) and one steel horizontal roll grip
handle (inside) to the door using (2)1/4" black painted hex head bolts, and
(2) 1/4" hex nuts.
■
Use hex head bolts and hex nuts to fasten the vertical handles to the door
through the remaining holes.
■
Inside handle may be matched with either set of holes so long as it is no
closer than 4" to the top or bottom of the section (Fig. 8B-C).
12
STEP 8 - INSTALL LIFT HANDLES
STEP 8C: FOR STEEL CARRIAGE HOUSE GARAGE DOORS
■
The top carriage bolt should also go through the top hole of the roll grip
Step 8C-1:
handle.
■
Use supplemental templates provided in handle bag to determine handle
■
Attach bottom of roll grip handle with a #14 × 5/8" sheet metal screw
into the backer plate (Fig. 8C-B).
configuration for your door size.
Step 8C-2:
Step 8C-9:
■
Find the center of the distance between embosses on the front of the
■
Repeat STEP 8C-6 through 8B-8 for second handle set (if applicable).
section.
■
Use template included with handle to line up the center lines and the
bottom section.
■
Drill two 1/2" holes where indicated through the front skin of the section
and insulation, but STOP BEFORE drilling through the back skin.
Step 8C-3:
1
■
Flip section over and drill two 5/16" holes through the back skin.
Step 8C-4:
8
■
Slide the black head 1/4" carriage bolt through horizontal spade handle,
5
handle spacer, front of the section, back of the section and roll grip
handle.
4
1
3
■
Secure with 1/4" flange nuts. (Fig. 8C-A or Fig. 8C-B)
7
■
Repeat Steps 8C-2 through 8C-4 for second bottom handle
(if applicable).
4
6
■
Second section (to be installed at completion of STEP 9A-4.
(Not required on doors with outside keyed lock.)
2
Step 8C-5:
■
Use back of the template to find your door configuration.
6
■
Using the template, drill the holes in your second section.
3
5
Step 8C-6:
Fig. 8C-A
■
Find the center of the distance between embosses and the middle of the
section height on the front of the section.
■
Use template included with handle to line up the center lines and the
bottom section.
■
Drill the indicated 1/2" holes through the section and insulation.
8
6
Step 8C-7: Two Outside Spade Handles
4
For one handle, skip to STEP 8C-8.
5
1
3
■
Line up holes in handle backer plate with holes drilled in previous step.
■
7
Attach handle backer plate to back of door with (2) #14 × 5/8" sheet
metal screws through inside roll grip handle and into the inside skin
(Fig. 8C-A).
5
■
Slide (2) 1/4" black head carriage bolts through the vertical spade handle,
4
the handle spacers, door section and through the backer plate.
■
Secure on the inside with 1/4" flange nuts. Do this for each handle
(Fig. 8C-A). Skip to STEP 9.
Step 8C-8: One Outside Spade Handle
5
2
3
■
Slide (2) 1/4" black head carriage bolts through vertical handle, handle
spacers, door section and through backer plate.
6
Fig. 8C-B
13
STEP 9 - INSTALL DOOR SECTIONS
STEP 9A: FOR INSULATED GARAGE DOORS & STEEL CARRIAGE HOUSE GARAGE DOORS
NOTE: For Composite Doors proceed to STEP 9B.
Step 9A-1: Place and Secure First (Bottom) Section
■
Place First Section in opening against stop molding and center it from
Stop Molding
side to side.
■
Place a level on section. If necessary, use wood shim under one end to
make section level (Fig. 9A-A).
■
Once section is level, remove level and drive a 10d 3" nail in jambs at
each section end. Bend over edge to hold section in place (Fig. 9A-B).
Step 9A-2: Determine Stacking Order for Remaining Sections
Using Table 9A-A or 9A-B Below
NOTE: If a lock assembly was ordered with door, holes for lock may be
predrilled. Lock templates are included in lock instructions for doors
without predrilled holes.
Fig. 9A-A
Table 9A-A:
SECTION ORDER FOR INSULATED STEEL GARAGE DOORS
1st
(Bottom)
Section
2nd
(Lock)
Section
Door
Height
3rd
Section*
4th
Section
5th
Section
6'0"
6'3"
6'6"
6'9"
7'0"
7'6"
7'9"
8'0"
18"
18"
21"
21"
21"
18"
18"
21"
18"
18"
18"
21"
21"
18"
18"
18"
18"
18"
18"
18"
21"
18"
18"
18"
18"
21"
21"
21"
21"
18"
18"
18"
–
–
–
–
–
Fig. 9A-B
18"
21"
21"
* Section with general safety label.
Table 9A-B:
SECTION ORDER FOR STEEL CARRIAGE HOUSE GARAGE DOORS
1st
2nd
Door
Height
(Bottom)
Section
(Lock)
Section
3rd
Section*
4th
Section
6'0"
6'3"
6'6"
6'9"
7'0"
7'3"
7'6"
7'9"
8'0"
24"
18"
21"
21"
21"
21"
24"
24"
24"
24"
18"
18"
21"
21"
21"
21"
24"
24"
24"
18"
18"
18"
21"
21"
21"
21"
24"
–
21"
21"
21"
21"
24"
24"
24"
24"
* Section with general safety label.
14
Step 9A-3: Prepare Second (Lock) Section
NOTE: If door is predrilled for a lock, this section will be the one with
holes in the center of panel face.
#14 x 5/8" Sheet
Metal Screws
■
Place Second Section face down on covered sawhorses.
■
Attach a #2 hinge to each end at top edge using (2) #14 × 5/8" sheet
metal screws. Attach a #1 hinge to all other prepunched holes using (2)
#14 × 5/8" sheet metal screws (Fig. 9A-C).
#1 Hinge
Step 9A-4: Keyed Lock/Lift Handle Installation
■
If you wish to install a keyed lock, begin lock installation now according
to supplemental instructions included with lock hardware.
■
If door did not come with a keyed lock, install lift handle (Fig. 8A-B).
! CAUTION
Take care not to bend or twist sections with glass as this may cause
glass to break, which may result in personal injury.
#2 Hinge
Bottom Edge
Fig. 9A-C
End Stile
Step 9A-5: Place and Secure Second (Lock) Section
■
Place Second Section in opening on top of First Section.
■
Drive a 10d 3" nail in jambs at each section end. Bend over edge to hold
section in place.
Safety
Label
■
Attach hinges from top of First Section to bottom of Second Section using
(2) #14 × 5/8" sheet metal screws for each hinge (Fig. 9A-D).
Step 9A-6: Prepare Next (Third) Section
Third Section has the general safety label applied (Fig. 9A-D).
■
Place section face down on covered sawhorses.
Fig. 9A-D
Fig. 9-D
■
Attach a #3 hinge to each end at top edge using (2) #14 × 5/8" sheet
metal screws for each hinge. Attach a #1 hinge to all other prepunched
holes using (2) #14 × 5/8" sheet metal screws (Fig. 9A-E).
NOTE: If door has more than 1 strut, consult Table 7-A or 7-C. Attach
using 1/4" × 3/4" self-tapping screws (Fig. 9A-E). When predrilled
holes do not line up with hinge, drill (2) 3/16" pilot holes through strut,
hinge and door at each location or use impact wrench with 7/16"
socket and self-tapping screws.
#14 x 5/8" Sheet
Metal Screws
#1 Hinge
Step 9A-7: Place and Secure Next (Third) Section
■
Place section in opening on top of previously installed section.
■
Drive a 10d 3" nail in jambs at each section end. Bend over edge to hold
#3 Hinge
End Stile
section in place.
Bottom Edge
■
Attach hinges from top of previous section to bottom of this section using
Fig. 9A-E
Fi. 9
(2) #14 × 5/8" sheet metal screws for each hinge (Fig. 9A-E).
NOTE: If you have two sections left, repeat STEP 9A-6 to 9A-7 using
#4 hinges on the end of the top edge and #1 hinges to all other stiles
along the top edge.
! WARNING
DO NOT install top section unless you are able to immediately continue
through to STEP 9A-10 installing vertical track as this may cause
sections to fall.
! WARNING
DO NOT install top section if there are high wind conditions as this may
cause sections to fall. Failure to follow these warnings could result in
serious injury, death or property damage.
15
Step 9A-8: Prepare Last (Top) Section
#14 x 5/8"
Sheet Metal
Screws
1/4" x 3/4"
Self-Tapping
Screws
■
Place Last Section face down on covered sawhorses.
■
Place top roller brackets 3-1/4" from the top of the section, aligning the
middle hole in top of bracket with the bottom hinge hole/indentation.
■
Attach top bracket using (3) #14 × 5/8" sheet metal screws.
NOTE: If door was supplied with any struts (Table 7-A) attach using
1/4" × 3/4" self-tapping screws (Fig. 9A-F). When predrilled holes do
not line up with hinge holes, drill (2) 3/16" pilot holes through strut
and door at each hinge hole location (or use impact wrench with 7/16"
socket and self-tapping screws (Fig. 9A-F).
Strut (If required)
Step 9A-9: Place and Secure Last (Top) Section
Top Bracket
End Stile
■
Fig. 9A-F
Bottom Bracket
Place top section in opening on top of previous section.
■
Drive a 10d 3" nail in the jambs at each section end. Bend over edge to
hold section in place.
#1 Hinge
■
Attach hinges from top of previous section to bottom of the this section
using (2) #14 × 5/8" sheet metal screws for each hinge (Fig. 9A-E).
NOTE: If your door is to be used with an electric operator, you must
reinforce the top section before placing it in the opening. Proceed to
STEP 10 prior to completing this step.
#2, 3 or 4 Hinge
Top Bracket
Step 9A-10: Place Rollers
■
Place a roller in the top and bottom bracket and in the tubes in each of
the hinges at the ends of each installed section.
NOTE: In hinges with two tubes, placer roller in tube farthest from door
face (Fig. 9A-G).
Fig. 9A-G
Fig9-G
STEP 9 - INSTALL DOOR SECTIONS
STEP 9B: FOR COMPOSITE DOORS
Composite Overlay Faux Wood Doors and Composite Overlay Doors are
custom assembled one door at a time. It is important matching sections stay
together and sections are stacked in the correct order.
ꢂꢃꢃR ꢀꢂ ꢆ:
SEꢄTꢀꢃꢁ ꢆ:
ꢂoor ꢀꢂ
Laꢅel
9723-01
Step 9B-1: Stack Composite Door Sections
ꢀꢁSꢀꢂE ꢃF SEꢄTꢀꢃꢁS
■
Door sections are labeled on the inside upper left hand corner of the
section (Fig. 9A-H).
■
All sections for each door have the same four digit identification number.
■
Sections should be stacked in sequence, with #01 being the bottom
section, the next section being #02 and so on.
■
Use the Alignment Label between joining sections to ensure proper
alignment of the door sections.
ꢇlignment Laꢅel
Fig. 9A-H
16
STEP 10 - REINFORCE THE TOP SECTION FOR GARAGE DOOR OPENER
STEP 10A: FOR INSULATED GARAGE DOORS & STEEL CARRIAGE HOUSE GARAGE DOORS
To avoid damage to door, you MUST reinforce top section of door in order to
provide a mounting point for opener to be attached.
NOTE: An opener bracket kit specifically designed for opener
attachment may be included or purchased (silver galvanized or white
powder coated). Instructions are provided with the kit.
! WARNING
DO NOT install the bracket supplied with opener. Failure to reinforce door,
NOTE: Operator may be attached up to 2 feet off center. (Doors with
as illustrated, will void door warranty.
torsion springs only.)
Step 10A-1: Reinforce Top Section
■
You will need (1) or (3) pieces of 1-1/4" × 1-1/4" minimum punched
angle at least 13 gauge or 3/32" thick.
■
Determine how punched angle is to be affixed to your door size
(Fig. 10A-A through 10A-D). Angle iron may need to be trimmed
depending on door section height and distance between center stiles.
10'0'' up to 14'10'' Wide Doors
2''
8'0'' up to 9'0'' Wide Doors
27'' or 50''
18'' or 21''
Vertical Punched Angle
18" or 21" Long
Notch Cut
on Vertical Angle
Punched Angle
for Operator Draw
Bar Attachment
18'' or 21''
Punched Angle –
One 27'' long piece
(12' wide doors require one 50'' long piece) and
two 18'' or 21'' pieces (measure top section height).
Fig. 10A-C
Fig.10A-A
Required Materials
Required Materials
(1) 18" or 21" length of angle iron (4) #14 × 5/8" sheet metal screws
(2) 18" or 21" lengths of angle iron (2) 1/4" lock washers
(1) 27" or 50" lengths of angle iron (2) 1/4" nuts
(2) 1/4" × 1" bolts
(8) #14 × 5/8" sheet metal screws
16'0'' up to 18'0'' Wide
Doors with Strut
15'0'' up to 15'10'' and
19'0'' up to 20'0'' Wide Doors
with Strut
5''
5''
Notch Cut
on Vertical Angle
Notch Cut
on Vertical Angle
Punched Angle for
Operator Draw
Bar Attachment
Strut
Strut
18'' or 21''
18'' or 21''
Punched Angle –
Two 18'' or 21'' pieces
(measure top section height)
Fig. 10A-D
Fig. 10A-B
Required Materials
Required Materials
(2) 18" or 21" lengths of angle iron (2) 1/4" nuts
(1) 18" or 21" length of angle iron (2) 1/4" × 3/4" self-tapping screws
(2) #14 × 5/8" sheet metal screws
(2) 1/4" × 1" bolts
(4) #14 × 5/8" sheet metal screws
(4) 1/4" × 3/4" self-tapping screws
(2) 1/4" lock washers
17
STEP 10 - REINFORCE THE TOP SECTION FOR GARAGE DOOR OPENER
STEP 10B: FOR COMPOSITE OVERLAY FAUX WOOD DOORS
Step 10B: Remove Pull Rope and Lock
IMPORTANT: To avoid damage to door, you MUST reinforce top section
of door in order to provide a mounting point for opener to be attached.
Refer to STEP 10A – Reinforcing the Top Section.
■
Figures 10B-A through 10B-C show installation of operator reinforcement
corresponding to a specific door width.
Failure to reinforce door as illustrated will void door warranty.
■
At locations where the bracket is attached to the hinge, the hinge screws
must be removed, the bracket installed and the hinge screws then
replaced.
IMPORTANT: When installing an automatic garage door operator, follow
manufacturer’s installation and safety instructions carefully.
! WARNING
To avoid risk of strangulation or personal injury, if door has a pull rope,
you must remove pull rope when you install an automatic garage door
opener.
! CAUTION
If you have installed a door lock, unlock or remove at this time.
Failure to do so may cause damage to the door and void the warranty.
Fig. 10B-A
Fig. 10B-B
Required Materials
Required Materials
(1) operator reinforcement bracket (2) 1/4" × 3/4" self-tapping screws
(2) operator reinforcement bracket (2) 1/4" lock washers
(2) 2" pieces of 1-1/4" 1-1/4"
×
(2) 1/4" nuts
punched angle
(2) 1/4" × 1" bolts
(4) 1/4" × 3/4" self-tapping screws
Fig. 10B-C
Required Materials
(1) operator reinforcement bracket (2) 1/4" × 3/4" self-tapping screws
18
STEP 11 - ASSEMBLE AND INSTALL THE TRACK
Before assembling brackets to vertical track, be sure to read STEP 11-1 and
11-2. Refer to Fig.11-C for placement of brackets on track.
1/4" Flange
Nut
Wall
Side
NOTE: Brackets may already be riveted in place. If additional
adjustment is required, rivets can be drilled out and brackets
reattached with track bolts and flange nuts (available through toll-free
Consumer Service Hotline, see front).
! WARNING
Failure to use the track provided with new door may cause installation
problems or the door to fall which could result in serious injury or
property damage.
1/4" x 5/8"
Track Bolt
Top View
Left Side
Note: Use One
Track Bolt in Slot.
Fig. 11-A
! WARNING
DO NOT attach any brackets directly to drywall. All track brackets, flag
brackets and spring brackets should be attached directly only to wood
bucks.
1/4" Flange
Nut
1-3/8" and 1-1/2"
Thick Door
Use These
Step 11-1: Assemble Track Brackets to Vertical Track
2" Thick Door
Use These
Two Holes
Two Holes
■
There are two sizes of track brackets for 7' tall doors and 3 sizes for 8'
tall doors. Each bracket should be installed with flange facing flat side of
track and flat side toward wall (Fig. 11-A).
■
Loosely fasten horizontal slot of track brackets to vertical track using (1)
Flag Bracket
1/4" × 5/8" track bolt and (1) 1/4" flange nut. Head of bolt faces inside
track. Brackets should be installed on vertical track as follows (Fig. 11-C):
• Shortest pair — 10" from bottom of track
1/4" x 5/8"
Track Bolt
• Next longest pair — centered on track
Fig. 11-B1
• For 8' tall doors — install remaining pair 10" from top of track
Step 11-2A: Assemble Flag Brackets to Vertical Track
FOR STEEL AND STEEL CARRIAGE HOUSE DOORS
Use these holes to splice
Horiꢀontal and ꢁertical Tracꢂs
■
Determine proper holes in flag bracket for door thickness (Fig. 11-B1).
■
Loosely attach flag bracket to top of track with (2) 1/4" × 5/8" track bolts
and 1/4" flange nuts. Head of bolts face inside track.
Fig. 11-B2
NOTE: If additional adjustment is required, horizontal slots in flag
brackets can be used for attachment to vertical track.
Step 11-2B: Assemble Flag Brackets to Vertical Track
FOR COMPOSITE OVERLAY DOORS
Top
Flag Bracket
Left-Hand
Vertical Track
Assembly
■
Due to overall door thickness of most non-insulated Composite Overlay
Door models, a commercial style flag bracket is used to splice the vertical
and horizontal tracks together (Fig. 11-B2).
Right-Hand
Vertical
Track
Step 11-3: Place Vertical Track into Position
Assembly
Longer
Track
■
Place track over rollers on door.
■
Move track close to door so rollers are all the way into hinges leaving
Bracket
Shorter
about 1/2" between edge of door and edge of track.
Track
Bracket
NOTE: Do not force track too tightly or door will bind.
Bottom
Figi.111-C
Finished Track Assembly
■
Lift track about 1/2" from floor and mark jamb for each lag screw
position.
NOTE: Do not raise vertical track beyond bottom rollers on bottom
section of door.
19
■
■
Drill 3/16" pilot holes at each lag screw location. Fasten flag bracket to
jamb using (3) 5/16" × 1-5/8" lag screws, one in each of top, middle and
bottom holes. Repeat on opposite side.
Once flag brackets are securely fastened to jamb, tighten track bolts and
flange nuts connecting flag brackets to tracks (Fig. 11-D).
NOTE: The tops of vertical tracks must be level with each other. Check
this by measuring from top of door sections to top of track on both
sides. If they are not equal, cut material off bottom of one track to
lower it or raise other track.
NOTE: Pressure-treated lumber purchased after January 2004 is
treated with chemicals that have highly corrosive effects on metal
fasteners. Fasteners provided with door are intended for use with
standard lumber (not pressure-treated) only. If installing door
into an opening framed with pressure-treated lumber, it is highly
recommended that 5/16" × 1-5/8" lag screws with a minimum
galvanization equivalent of G185 be purchased for this application.
Fig. 11-D
Horizontal Angle
Step 11-4: Assemble Flag Brackets to Vertical Track
NOTE: On some doors this angle may be 82" long and will require (3)
additional fasteners per side. If angle has been preassembled, skip
STEP 11-4 and proceed with STEP 11-5.
■
Fasten horizontal angle to horizontal (curved) track using
Horizontal Track
(2) 1/4" × 5/8" track bolts and (2) 1/4" flange nuts.
Head of bolt faces inside track (Fig.11-E).
Step 11-5: Support Rear End of Track
Fig. 11-E
■
Temporarily support rear end of track with a rope tied to trusses overhead
in garage or resting on tall ladder (Fig. 11-F).
Step 11-6: Assemble Horizontal Track to Flag Bracket
Rope
Flag Bracket
■
Place curved end of horizontal track over roller in top bracket.
■
Horizontal Angle Bracket
Attach track to flag bracket using (2) 1/4" × 5/8" track bolts and
(2) 1/4" flange nuts. Head of bolt faces inside track.
NOTE: Horizontal and vertical track must join together to form a
Horizontal
Track
continuous channel for rollers.
■
Attach end of horizontal angle to top of flag bracket with a
Vertical
Track
3/8" × 3/4" carriage bolt and 3/8" hex nut (Fig. 11-G).
• For 15" radius track use top set of slots
• For 12" radius track use middle set of slots
• For low headroom track use bottom set of slots
Fig. 11-F
Step 11-7: Assemble Rear Track Hangers
3/8" x 3/4"
Carriage
Bolt
NOTE: Rear track hangers are not provided with standard hardware
and will need to be made at this time. They are used to attach rear
horizontal track to ceiling joist and must be strong enough to hold full
weight of door.
Horizontal
Angle
! WARNING
Sway braces must be used to prevent tracks from spreading and allowing
door to fall, which could cause serious injury. Bolts placed in end of each
track (Fig. 11-H) must be at least 1" long to prevent top section from
exiting track.
Horizontal
Track
Fig. 11-G
20
■
■
Use 1-1/4" × 1-1/4" punched angle, at least 13 gauge or 3/32" steel to
make two rear track hangers with sway braces (Fig. 11-H).
Attach to track using at least 1" long bolts (Fig. 11-H).
Step 11-8: Placement of Rear Track Hangers
3/8" x 1"
Bolts and Nuts
(4 places)
Placement of rear track hangers is critical for door to operate properly. They
should not be mounted any farther than 6" from end of horizontal track and
should hold horizontal track level and square to door.
Sway Brace
Bolt Blocks
■
Squareness should be measured by comparing two diagonal distances
(Fig. 11-I):
Door Travel
1) From top left-hand corner of door to rear of right-hand
horizontal track.
Fig. 11-H
Fig11-H
2) From top right-hand corner of door to rear of left-hand
horizontal track.
■
Squareness distances should be within 1/2" of each other. Horizontal
track can be out of level up to 1" from front jamb to rear track hanger
(Fig. 11-I).
■
With track square and level with opening, track hangers can be fastened
permanently to ceiling trusses using (3) 5/16" × 1-1/2" lag screws. Drill
3/16" pilot holes before installing 5/16" lag screws.
! WARNING
To prevent door from falling and causing serious injury, be sure rear track
hangers are properly secured to trusses with adequate length screws.
Step 11-9: Adjust Top Section
Fig. 11-I
Fg. 11-I
■
With track installed, top door section can now be properly adjusted.
■
Loosen slide on top bracket and push top of door against stop molding or
door jamb. Pull roller toward you so it is tight against the groove in track.
■
Tighten slide bolts (Fig. 11-J).
■
Remove all 10d 3" nails holding all sections in place.
Slide
Bolts
Slide
Top Roller
Bracket
Fig. 11-J
21
STEP 12 - INSTALL LOCK (IF INCLUDED)
If a lock is included with door, follow appropriate instructions below.
#14 x 5/8" Sheet Metal Screw or 1/4" x 1" Lag Screw
Exterior Keyed Lock:
■
If door has an exterior keyed lock, complete installation of lock at this
time. Follow instructions provided with lock hardware.
Interior Slide Lock:
■
Use track as a guide to achieve proper alignment.
■
Position slide bolt against top of one of rectangular engaging slots in
vertical track.
NOTE: It may be necessary to knock out slug in vertical track to open
slot for lock engagement. Remove slug by striking with a hammer from
outside of track.
Fig. 12-A
■
Install inside slide bolt on the end stile of second section.
Use (4) #14 × 5/8" hex head sheet metal screws (steel doors)
or (4) 1/4" × 1" lag screws (Fig. 12-A).
NOTE: 3/16" holes may need predrilled before installing screws.
IMPORTANT: If door is going to be equipped with an automatic garage
door opener, make sure that door is always unlocked when opener is
being used. This will avoid damage to door.
STEP 13 - INSTALL PULL ROPE (MANUALLY OPERATED DOORS ONLY)
NOTE: Rope is only intended for use on manually operated doors.
DO NOT install pull rope if using an automatic garage door opener.
Step 13-1: Install Pull Rope for Manually Operated Doors
■
Install the pull rope by attaching to roller shaft in bottom bracket of door
(Fig. 13-A).
Pull Rope
Fig. 13-A
STEP 14 - INSTALL SPRINGS
Step 14-1: Install Springs
■
Proceed to springing instructions that came with spring hardware.
22
STEP 15 - ATTACH AUTOMATIC GARAGE DOOR OPENER
Step 15-1: Remove Pull Rope and Lock
IMPORTANT: To avoid damage to door, you MUST reinforce top section
of door in order to provide a mounting point for opener to be attached.
Refer to STEP 10 – Reinforcing the Top Section.
■
If installed, remove pull rope and locks (or unlock).
Step 15-2: Install Opener Head and Rail
Failure to reinforce door as illustrated will void door warranty.
IMPORTANT: When installing an automatic garage door operator, follow
manufacturer’s installation and safety instructions carefully.
! WARNING
To avoid risk of strangulation or personal injury, if door has a pull rope,
you must remove pull rope when you install an automatic garage door
opener.
■
To prevent top of door from bending, opener rail should be mounted no
less than 2" and no greater than 5" from face of door in open position
(Fig. 15-A).
■
Follow operator manufacturer’s instructions.
! CAUTION
If you have installed a door lock, disable or remove at this time.
Failure to do so may cause damage to the door and void the warranty.
Step 15-3: Attach Opener Arm to Door
■
Attach opener arm to vertical reinforcement (Fig.15-B through 15-D).
■
Attachment should be roughly same height as top roller of door.
■
When door is in down position, door should be at angle of approximately
60 degrees from vertical operator bracket (Fig. 15-B).
Opnr RiMouning Ditne
Opener Rail Mounting Distance
Ceiling
Clevis
Pin
Opener Rail
Horizontal Track
60°
Keep Clearance at 2"–5"
Fig. 15-A
Fig. 15-B (Doors with supplied reinforcement bracket and stile in center of door)
Opener Arm Attachment to Horizontal Angle or Strut
Opener Arm Attachment to Vertical Angle
Opener Arm
Horizontal
Punched
Angle
3/8" x
1-1/2"
Hex Bolt
3/8"
Hex Nut
Punched
Vertical
Punched
Angle
Opener Arm
Angle
Horizontal Angle
or Strut
Front View (assembled)
Opener Arm
Top View
(assembled)
Mounting
Surface of Door
Punched
Angle
Lock These Nuts
Together Securely
Vertical Punched
Angle
Horizontal
Angle
Leave
Clearance
Lock These
Nuts Together
Securely
or Strut
Opener
Arm
Fig. 15-C (Doors with odd number of panels)
Fig. 15-D (Doors with angle iron reinforcement bracket and stile in center of door)
Fig. 15-D (Doors with angle iron reinforcement bracket and stile in center of door)
23
THIS PAGE
INTENTIONALLY
LEFT BLANK
GENERAL MAINTENANCE
FOR ALL NON-INSULATED GARAGE DOORS
ˆ
Your door will need regular inspection, lubrication and cleaning. The
following checklists will help keep your door and its parts in good working
order and help protect it from the elements
Tears or gaps in the bottom weather seal or perimeter seal.
Any covered, ripped, damaged, or missing warning labels.
ˆ
ˆ
Any missing, broken, loose, or malfunctioning door handles. There
should be two lifting points on the outside and two on the inside of the
garage door.
! WARNING
A sectional garage door is a large, heavy object that moves with the
help of springs under high tension. Springs, bottom brackets, cables
and associated hardware are under high tension and can cause death,
serious injuries, or damage to the door if not properly handled. For your
safety and the safety of others, follow these instructions:
DOOR OPERATION CHECKLIST
We recommend that at least twice per year after you have
visually inspected the door and all of its components. Scan
the QR code to the right or visit: https://vimeo.com/
106430735
■
DO NOT loosen or remove bottom bracket with the spring tension
engaged.
ˆ
Check the balance of the door.
■
DO NOT operate door with a broken spring.
1. With the door in the down position, detach the opener (if applicable)
by pulling down on the red manual release handle.
■
DO NOT manually operate door if handles are not installed or
functioning properly.
2. Next lift the door manually up to the halfway point and gently
release the door. A balanced door should hang in place and not
raise or lower. If the door does not stay in place contact your Clopay
Dealer for adjustment.
■
DO NOT operate door if it is too difficult to move, opens too quickly,
or the rollers come out of the track.
■
DO NOT operate the door if glass or interior window retainer
appears to be loose, cracked, or warped. DO NOT remove screws on
inside retainer.
ˆ
Check the door operation.
■
Once you have determined your door is in balance, lift the door up
■
For assistance with these maintenance steps, repair
or replacement of any parts, please contact your
professional installing Clopay Dealer:
and down to ensure smooth operation. The door should be easily
controlled when lifting and lowering.
■
Note: Be sure to reattach the opener once you confirm the door is
operating properly.
ˆ
Safety feature for doors with automatic operators:
VISUAL INSPECTION CHECKLIST
■
Make sure any door locks are disabled or removed if an automatic
operator is installed.
Monthly inspection of the door and all of its components is recommended.
If something seems out of balance or adjustment, or you note any of the
following, please contact your Clopay Dealer or Clopay Customer Service at
800-225-6729.
■
Retest following opener manufacturer's instructions.
Visually inspect the door when in the down position for:
LUBRICATE THE DOOR
ˆ
Loose or bent hinges.
At least twice per year lubricate all moving parts of the door with Clopay
Garage Door Pro Lube or a synthetic lubricant:
ˆ
Broken wheels, bent shafts or worn out bearings on rollers.
ˆ
Lift cables at bottom bracket button.
ˆ
Loose or missing bolts, screws, or other fasteners on the door or track.
ˆ
Lock hardware where surfaces turn or slide.
ˆ
Creases or bends in the track.
ˆ
Full length of torsion spring to reduce friction between coils.
ˆ
Cracking or fatigue of the door panels.
ˆ
Rollers at the bearing (but not the tire)
ˆ
Damaged or broken springs or spring components. If the spring looks
broken it will need replaced.
ˆ
Hinges
ˆ
Standard extension springs that run alongside the
door should include a safety containment cable. To
see a visual of the safety containment cable scan the
QR code to the right or visit: http://clopaypdfs.com/
pdf_files/SUP-0137180_EN.pdf
ˆ
Worn or frayed cables.
ˆ
Loose, cracked, or warped glass panels or inside glass retainers. Inside
the door, the plastic retainer and holding the glass and its fasteners
should appear secure.
25
CARE & MAINTENANCE
FOR STEEL GARAGE DOORS
APPLIES TO THE FOLLOWING MODELS
Carriage House Steel Doors GR2SU, GR2LU, GR1SU, GR1LU, GR2SP, GR2LP, GR1SP, GR1LP, GD2SU, GD2LU, GD1SU, GD1LU, GD2SP, GD2LP, GD1SP, GD1LP,
AR2SU, AR2LU, AR1SU, AR1LU, AR2SP, AR2LP, AR1SP, AR1LP // Classic Steel Doors HDP20, HDPL20, HDP13, HDPL13, 9200, 9203, 9130, 9133, 7200, 7203,
7130, 7133, HDG, HDGL, 2050, 2053, 4300, 4310, 4050, 4053, 6200, 6203, 6130, 6133 // Contemporary Steel Doors HDPC20, HDPC13, HDPF20, HDPF13,
HDPCC2, HDPCC1, HDPR20, HDPRC2, HDPRC1, 9202, 9132, 9201, 9131, 9208, 9138, 9205, 9209, 9139, 7202, 7132, 7201, 7131, 7208, 7138, 7205, 7209, 7139,
HDGC, 2132, HDGF, 2051, HDGCC, 2138, HDGR, HDGRC, 4302, 4132, 4301, 4051, 4308, 4138, 4305, 4309, 6202, 6132, 6201, 6131, 6208, 6138, 6205, 6209
CLEANING & PRESERVING THE DOOR
WINDOW CARE
Doors must be cleaned and waxed at least twice a year or four times a
year for harsh environments (such as coastal regions, areas with high road
salt, etc.). Failure to do so may result in loss of warranty coverage. For
further questions about the requirements, refer to the warranty page at
the end of this manual or contact Clopay Consumer Services.
Snap-In Decorative Inserts
■
Decorative inserts are designed to snap in and out of the window frame
and may be installed on the inside or outside of the window.
NOTE: DO NOT REMOVE SCREWS from the window frame.
Cleaning & Waxing
Removing Decorative Inserts for Cleaning & Painting Purposes
■
Help prevent damage (rusting) caused by foreign matter or salt adhering
■
The insert has tabs on each end of each leg.
to the door.
■
To remove pull the center of the insert firmly out of the window.
■
Assist to restore the look of factory-applied finish by
■
Replacing the insert is the reversal of the process described for removal.
removing dirt and chalking.
The four tabs must be pressed under the lip in the window frame.
■
For how-to video scan the QR code to the right
or visit: https://vimeo.com/106434183
Window Cleaning
■
Clean glass with a mild solution of a dishwashing detergent and a soft
cloth.
Cleaning the Door
Working from top to bottom of the door sections, use a well soaked cloth,
sponge or soft bristle brush with either of the following solutions:
• For acrylic impact or decorative windows: These windows CAN
ONLY be washed using a clean, soft sponge or cloth with a mild dish
soap and lukewarm water. Dry with soft cloth or chamois to prevent
spotting.
One cup of Simple Green® or other non-toxic biodegradable cleaner (less
■
than 0.5% phosphate) into two gallons of warm water -OR-
Household liquid dishwashing detergent such as Dawn®.
■
• DO NOT use any ammoniated, abrasive or solvent-based cleaners of
any kind. DO NOT brush, scrub or scrape these windows.
■
DO NOT use scouring powders or solvents when cleaning the door.
If preparing to paint, see cleaning instructions under "Painting" in
this manual.
■
After cleaning, rinse thoroughly.
■
Rinse door with clean water to complete cleaning and allow to dry.
! CAUTION
Use care when handling decorative windows to avoid scraping or
scratching the surface.
NOTE: Be sure to clean behind stop molding on the sides and top of
the door. Refer to "Window Care" for detail on window cleaning on the
next page. DO NOT use a pressure washer on the door.
Glass Replacement
! WARNING
Waxing the Door
To avoid injury, use extreme caution in handling glass window pane.
When frame is removed, exposed steel edge of door may be sharp.
Avoid contact with steel edges. Always wear safety glasses and gloves.
After cleaning, use liquid car wax (not paste) to preserve the door’s finish.
This is especially important in coastal and harsh environments. Be sure to
wax any surface that may be exposed to elements such as salt, including
the interior of the bottom section of the door.
■
If the door is equipped with windows, and glass should need
replacement, follow the steps below:
■
To apply the wax, follow the manufacturer’s instructions.
1) With someone holding the outside frame, remove screws from the
inside frame retainer.
NOTE: Be careful not to get wax on decorative hardware as this may
cause discoloration.
2) Pull inside frame out of door. Carefully remove broken or old glass.
3) Insert new glass.
4) With someone holding outside frame, reinsert screws into inside
frame, securing glass.
26
Gallery® Collection Window Frame and Retainer Retightening
NOTE: You must remove any wax applied to the door before cleaning
(doors are not waxed in the manufacturing process). Using moderate
pressure, wipe the door surface with a rag saturated with xylene
(xylol). Xylene is a flammable substance, be sure to follow instructions
when using. DO NOT allow it to sit on door for extended time. Damage
to your door’s paint system can occur if overexposed to this or other
solvents.
■
Using drill loosen screw by turning it counter-clockwise one to two turns
- do not unscrew any farther.
■
Retighten screw turning it clockwise the total turns unscrewed plus
another turn or two. Do not over tighten the screw.
■
Tighten one screw location at a time. Repeat steps for remaining screws.
PAINTING THE DOOR
Pretesting Paint
Read these instructions completely prior to painting your door.
All paints are not created equal. The following test must be performed prior
to application on the entire door:
! CAUTION
■
Apply paint on a small area of door (following instructions on paint
Failure to follow these instructions may cause damage to your door,
which will result in loss of warranty.
container).
■
Allow paint to dry and evaluate for any blistering or peeling.
Required Paint
■
Perform adherence test by applying strip of masking tape over painted
■
Your garage door can be painted with high quality 100% acrylic latex
area and peel back tape. Check to see that paint adheres to door and not
to tape.
(flat, satin or semi-gloss) exterior grade paint.
■
DO NOT use any type of oil-based paint or alkyd modified paint.
NOTE: If paint shows signs of poor adherence (blistering or peeling)
there may be a problem with the paint or surface preparation.
DO NOT PROCEED! A new paint or further preparation of surface is
called for.
These paints will void the warranty of your door.
■
We strongly recommend all doors are painted with solar reflective paint
when available, especially when using darker colors and when the door is
in direct sunlight or a high heat/high UV environment. These paints help
reflect more sunlight keeping the surface of the door cooler.
Applying Paint
■
For more information and a list of pre-approved paints,
call the consumer hotline at 800-225-6729, scan the
QR code to the right or visit info.garagedoors.com/lrv
Follow directions on paint container and apply to door. Be sure to allow
adequate drying time should you wish to apply a second coat.
NOTE: DO NOT apply paint when door surface temperature is different
from manufacturer’s suggested temperature range for application.
Preparing the Surface
Before painting, the door, window frames and inserts must be free of dirt,
oil, caulk, waxes and mildew. To prepare window grilles and window frames:
Paint Repair
Should door’s paint finish become damaged, exposing bare metal, it will
become necessary to repair this area to prevent rust from forming.
■
Lightly scuff the entire exposed surface of window grilles and window
frames with medium sandpaper (grit 60-100).
■
Damaged area should be lightly sanded with medium to fine sandpaper,
NOTE: Sanding could remove rust-inhibiting compounds from the steel
portion of the door, therefore, sanding should be done only to damaged
areas where bare metal has been exposed. Refer to “Paint Repair” for
details on repair on the next page.
making sure to remove all visible red and white rust.
■
Wipe this area with dry, clean rag.
■
Coat sanded area with high quality, rust inhibiting, zinc enriched primer.
This can be found at most paint or hardware stores and should be labeled
for covering bare and galvanized steel.
Cleaning the Door for Painting Only
■
Make a solution of trisodium phosphate, also known as TSP, using 1/3
cup of powder to 1-1/2 to 2 gallons of water. NEVER BLEND CLEANERS
OR AMMONIA WITH BLEACH.
■
Wait time specified on the primer’s instructions before proceeding with
painting door.
NOTE: DO NOT use this if you are not planning to paint the door.
■
Saturate cleaning pad (3M synthetic steel wool–gray not green) and rub
with even pressure to lightly scuff surface while applying the cleaning
solution over all surfaces to be painted.
■
Rinse with clean water and sponge, changing water often.
■
A final wipe and rinse with clean water and sponge should be done to
remove any loose material.
27
CARE & MAINTENANCE
FOR COMPOSITE OVERLAY FAUX WOOD GARAGE DOORS
APPLIES TO THE FOLLOWING MODELS
Composite Overlay Faux Wood Doors CAN, CRM, GLN, GLM
Window Cleaning
CLEANING & PRESERVING THE DOOR
■
Clean glass with a mild solution of a dishwashing detergent and a soft
cloth.
These garage door models contain both Limited Edition Series doors that
consist of composite cladding and overlays and Ultra-Grain® Series doors
which consist of composite overlays and Ultra-Grain® steel.
• For acrylic impact or decorative windows: These windows CAN
ONLY be washed using a clean, soft sponge or cloth with a mild dish
soap and lukewarm water. Dry with soft cloth or chamois to prevent
spotting.
Both the Ultra-Grain® steel portion of the door and the inside steel surface of
the door should be periodically cleaned and waxed at least twice a year or
four times a year for harsh environments (such as coastal regions, high road
salts, etc.). Failure to do so may result in loss of warranty coverage. For
further questions about the requirements, refer to the warranty page at
the end of this manual or contact Clopay Consumer Services.
• DO NOT use any ammoniated, abrasive or solvent-based cleaners
of any kind. DO NOT brush, scrub or scrape these windows.
■
After cleaning, rinse thoroughly.
Cleaning the Door
! CAUTION
Working from top to bottom of the door sections, use a well soaked cloth,
sponge or soft bristle brush with either of the following solutions:
Use care when handling decorative windows to avoid scraping or
scratching the surface.
One cup of Simple Green® or other non-toxic biodegradable cleaner (less
■
Glass Replacement
than 0.5% phosphate) into two gallons of warm water -OR-
Household liquid dishwashing detergent such as Dawn®.
■
! WARNING
To avoid injury, use extreme caution in handling glass window pane.
When frame is removed, exposed steel edge of door may be sharp.
Avoid contact with steel edges. Always wear safety glasses and gloves.
■
DO NOT use scouring powders or solvents when cleaning the door.
If preparing to paint, see cleaning instructions under "Painting" in
this manual.
■
If the door is equipped with windows, and glass should need
■
Rinse door with clean water to complete cleaning and allow to dry.
replacement, follow the steps below:
NOTE: Be sure to clean behind stop molding on the sides and top of the
door.
1) With someone holding the outside frame, remove screws from the
inside frame retainer.
2) Pull inside frame out of door. Carefully remove broken or old glass.
3) Insert new glass.
Waxing the Door
After cleaning, use liquid car wax (not paste) to preserve the Ultra-Grain®
finish and the interior steel surface between cleanings. This is especially
important in coastal and harsh environments.
4) With someone holding outside frame, reinsert screws into inside
frame, securing glass.
WINDOW CARE
MAINTAINING YOUR COMPOSITE OVERLAY FAUX WOOD
GARAGE DOOR
Proper care and maintenance are imperative for long-term appearance and
performance of doors. Periodic inspection and maintenance of the composite
cladding and overlays as well as regular inspection, lubrication and cleaning
are required. The following information will help keep your door and its parts
in good working order and help protect it from the elements.
= Clips in these locations
Window Grille Removal
Decorative window grilles on your door can be removed for cleaning or
painting purposes. The grille is held in place with plastic clips located at the
bottom of the vertical grille sticks and the ends of the horizontal grille sticks.
To remove grille:
■
Squeeze the clips and slide them towards the center of the window
(see figure above).
■
Rotate bottom of grille out from the door and remove from top notches.
■
Reverse the process to re-install grilles.
28
FINISHING INFORMATION
REPAIR AND RE-FINISH
Composite Overlay Faux Wood Garage Doors come pre-finished from the
factory unless “No-Finish” has been specified.
Should your door’s composite wood overlay or cladding become damaged or
discolored, they can be repaired using the following instructions.
No-Finish Limited Edition Doors
NOTE: DO NOT apply recoat or re-finish when door surface temperature
is different from manufacturer’s suggested temperature range.
If you have ordered your door without factory pre-finish, it is necessary to
finish the door prior to installation.
■
First, fill any gaps or voids in the composite surface with
Recommended finish: Minwax® gel stain or high quality exterior grade
a paintable wood putty or urethane caulk and let dry
completely.
■
latex paint.
■
■
Surface preparation: Before finishing your door, the overlay and cladding
For a how-to video scan the QR Code to the right or visit
surfaces must be prepared and cleaned.
• Clean with a mild store-bought paint surface preparation cleaner.
• Rinse with clean water and sponge, changing water often.
NOTE: For Ultra-Grain® Series doors, mask off the steel surface using
painter's tape.
• A final wipe and rinse with clean water and sponge should be done to
remove any loose material.
■
To bring out light and dark highlights of the composite texture, two coats
are needed (a lighter base coat and a darker top coat). This
can be accomplished one of two ways, a combination of
paint and gel stain, or two coats of paint.
• Allow to dry.
■
Pre-test paint: All paints are not created equal, the following test needs
■
to be performed:
For a how-to video scan the QR Code to the right or visit
• Apply paint on small area of door (following instructions on paint
container).
NOTE: Be sure to follow the Pre-test Paint instructions to ensure proper
adhesion, then follow the directions on the container to apply to the
door.
• Allow paint to dry and evaluate for any blistering or peeling.
• Perform adherence test by applying strip of masking tape over painted
area and peel back tape. Check to see that paint adheres to door and
not to tape.
■
Exterior grade 100% acrylic latex paint bottom coat with darker gel stain
top coat.
NOTE: If paint shows signs of poor adherence there may be a problem
with the paint or surface preparation. DO NOT PROCEED!
A new paint or further preparation of surface is needed.
• Brush lighter base coat of paint completely into composite texture for
full coverage. Allow to dry overnight.
• Brush darker top coat gel stain onto the door thoroughly; BEFORE THE
GEL STAIN DRIES, use a cloth rag to wipe off a little or a lot of the
stain (depending on your preference) to reveal areas of base coat. Use
paint brush to even out coat. Allow to dry overnight.
NOTE: DO NOT apply paint when door surface temperature is different
from manufacturer’s suggested temperature range.
■
Exterior grade 100% acrylic latex paint base coat and top coat.
! CAUTION
• Brush lighter base coat paint completely into the composite texture for
full coverage. Allow to dry overnight.
Do not use any type of oil-based paint or alkyd modified paint.
These paints will void the warranty of your door.
• Brush darker top coat paint onto the door; BEFORE THE TOP
COAT DRIES, use a cloth rag to wipe off a little or a lot of top coat
(depending on your preference) to reveal areas of base coat.
■
Finishing: Follow directions on the paint or stain container and apply to
the door. Be sure to allow adequate drying time between coats and prior
to installation.
• Once finish coats are dried, apply layer of exterior grade, UV resistant,
clear protective top coat (such as Minwax® Clear Shield™ or Minwax®
Helmsman® Spar Urethane). Allow to dry. (Required for gel stain top
coat, optional for paint top coat). Use brush to even coat out. Allow to
dry overnight.
Factory Pre-Finish Limited Edition and Ultra Grain® Doors
Unless you purchased the door with “No-Finish”, your door has been factory
pre-finished. Limited Edition Series doors consist of composite cladding and
overlays that must have periodic maintenance performed to the finish. Ultra-
Grain® Series doors consist of composite overlays that must have periodic
maintenance performed to the finish and Ultra-Grain® steel that does not
require this finish maintenance other than periodic cleaning (see CLEANING
AND PRESERVING THE DOOR).
NOTE: Remove painters tape AFTER clear coat.
■
Annual inspection: Inspect the finish for discoloration and coating
delamination every 12 months and more frequently if exposed to direct
sunlight or harsh environmental conditions.
■
Maintenance coat: The composite portions must be recoated at least
every two years for maximum longevity with an exterior grade, UV
resistant, clear protective top coat. In locations of severe weather
exposure, more frequent maintenance may be required.
• Recommended finish: Minwax® Helmsman® Spar Urethane or
Minwax® Clear Shield™. (Use painter’s tape to mask off the Ultra-
Grain® steel from the overlays.)
29
CARE & MAINTENANCE
FOR COMPOSITE OVERLAY GARAGE DOORS
APPLIES TO THE FOLLOWING MODELS
Composite Overlay Doors CXU, CX, CF, CGU, CG, CD, SXU, SX, SF
CLEANING & PRESERVING THE DOOR
PAINTING THE DOOR
Both the exterior steel of the door and the inside steel surface of the door
should be periodically cleaned and waxed at least twice a year or four times
a year for harsh environments (such as coastal regions and areas with high
road salt, etc.). Failure to do so may result in loss of warranty coverage. For
further questions about the requirements, refer to the warranty page at
the end of this manual or contact Clopay Consumer Services.
Read these instructions completely prior to painting your door.
! CAUTION
Failure to follow these instructions may cause damage to your door,
which will result in loss of warranty.
Required Paint
Cleaning & Waxing
■
Your garage door can be painted with high quality 100% acrylic latex
(flat, satin or semi-gloss) exterior grade paint.
■
Help prevent damage (rusting) caused by foreign matter or salt adhering
to the door.
■
DO NOT use any type of oil-based paint or alkyd modified paint.
These paints will void the warranty of your door.
■
Assist to restore the look of factory-applied finish by
removing dirt and chalking.
■
We strongly recommend all doors are painted with solar reflective paint
when available, especially when using darker colors and when the door is
in direct sunlight or a high heat/high UV environment. These paints help
reflect more sunlight keeping the surface of the door cooler.
■
For how-to video scan the QR code to the right
or visit: https://vimeo.com/106434183
Cleaning the Door
! CAUTION
Working from top to bottom of the door sections, use a well soaked cloth,
sponge or soft bristle brush with either of the following solutions:
For your Composite Overlay Garage Door, you must check the Light
Reflectance Value (LRV) of the paint color. If the desired color has an LRV
less than 38, only a pre-approved solar reflective paint can be used.
One cup of Simple Green® or other non-toxic biodegradable cleaner (less
■
than 0.5% phosphate) into two gallons of warm water -OR-
■
For more information and a list of pre-approved paints,
Household liquid dishwashing detergent such as Dawn®.
■
call the consumer hotline at 800-225-6729, scan the
QR code to the right or visit info.garagedoors.com/lrv
■
DO NOT use scouring powders or solvents when cleaning the door.
If preparing to paint, see cleaning instructions under "Painting" in
this manual.
Preparing the Surface for Painting
Before painting, the door, window frames and inserts must be free of dirt,
oil, caulk, waxes and mildew. To prepare window grilles and window frames:
■
Rinse door with clean water to complete cleaning and allow to dry.
NOTE: Be sure to clean behind stop molding on the sides and top of the
door.
■
Lightly scuff the entire exposed surface of window grilles and window
frames with medium sandpaper (grit 60-100).
Waxing the Door
NOTE: Sanding could remove rust-inhibiting compounds from the steel
portion of the door, therefore, sanding should be done only to damaged
areas where bare metal has been exposed. Refer to “Paint Repair” for
details on repair.
After cleaning, use liquid car wax (not paste) to preserve the door’s finish.
This is especially important in coastal and harsh environments. Be sure to
wax any surface that may be exposed to elements such as salt, including
the interior of the bottom section of the door.
Cleaning the Door for Painting Only
■
To apply the wax, follow the manufacturer’s instructions.
■
Make a solution of trisodium phosphate, also known as TSP, using 1/3
NOTE: Be careful not to get wax on decorative hardware as this may
cup of powder to 1-1/2 to 2 gallons of water. NEVER BLEND CLEANERS
cause discoloration.
OR AMMONIA WITH BLEACH.
NOTE: DO NOT use this if you are not planning to paint the door.
■
Saturate cleaning pad (3M synthetic steel wool–gray not green) and rub
with even pressure to lightly scuff surface while applying the cleaning
solution over all surfaces to be painted.
■
Rinse with clean water and sponge, changing water often.
■
A final wipe and rinse with clean water and sponge should be done to
remove any loose material.
30
NOTE: You must remove any wax applied to the door before cleaning
(doors are not waxed in the manufacturing process). Using moderate
pressure, wipe the door surface with a rag saturated with xylene
(xylol). Xylene is a flammable substance, be sure to follow instructions
when using. DO NOT allow it to sit on door for extended time. Damage
to your door’s paint system can occur if overexposed to this or other
solvents.
PAINT REPAIR
Should the door’s paint finish become damaged, exposing bare metal, it will
become necessary to repair this area to prevent rust from forming.
■
Damaged area should be lightly sanded with medium to fine sandpaper,
making sure to remove all visible red and white rust.
■
Wipe this area with dry, clean rag.
■
Coat sanded area with high quality, rust inhibiting, zinc enriched primer.
Pretesting Paint
This can be found at most paint or hardware stores and should be labeled
for covering bare and galvanized steel.
All paints are not created equal. The following test must be performed prior
to application on the entire door:
■
Wait time specified on the primer’s instructions before proceeding with
painting door.
■
Apply paint on a small area of door (following instructions on paint
container).
■
Allow paint to dry and evaluate for any blistering or peeling.
■
Perform adherence test by applying strip of masking tape over painted
area and peel back tape. Check to see that paint adheres to door and not
to tape.
NOTE: If paint shows signs of poor adherence (blistering or peeling)
there may be a problem with the paint or surface preparation.
DO NOT PROCEED! A new paint or further preparation of surface is
called for.
Applying Paint
Follow directions on paint container and apply to door. Be sure to allow
adequate drying time should you wish to apply a second coat.
NOTE: DO NOT apply paint when door surface temperature is different
from manufacturer’s suggested temperature range for application.
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LIMITED WARRANTY
Subject to the terms of this Limited Warranty (“Warranty”) and any warranty policies and procedures in effect at the time a notice of a claim is received, Clopay Corporation (“Clopay”, “we”, or “our”) will repair
or replace (at our sole discretion) any garage door sections/section components, hardware, or springs/spring components (collectively, “Replacement Parts”) that we determine to be defective in material or
workmanship so long as timely written notice is provided within the applicable limited warranty periods provided below. This Warranty shall apply and benefit only the original purchase of a Clopay garage
door product and is non-transferable, and does not apply to decorative hardware or to any commercial, industrial or other non-residential application/installation.
The warranty period begins from the date of delivery or installation, up to a maximum of one (1) year from the date of purchase. Proof of purchase is required. Once we have verified any defect(s) with your
product through persons authorized by Clopay, we will provide – at no cost to you – Replacement Parts to the extent necessary to repair or replace any such defective sections, hardware, or springs/spring
components. We reserve the right to inspect and/or verify any claimed defect, as well as the right to replace product(s) with a similar or like product, all within the sole discretion of Clopay. All labor costs
associated with any warranty claim (including removal, reinstallation, installation, and/or finishing) will be your responsibility.
The applicable Warranty periods are as follows:
SECTIONS/
DELAMINATION
MODEL NUMBER
PAINT FINISH
WINDOWS
HARDWARE/SPRINGS
Single Family*–Lifetime
Other**–10 Years
COMPOSITE OVERLAY GARAGE DOORS:
CGU, CG, CD, CXU, CX, CF, SXU, SX, SF
Color Blast® –5 Years
Hardware: 5 Years
5 Layer–5 Years
10 Years
(insulated glass)
Springs:
Torsion – 5 Years
Extension – 3 Years
5 Years
4 Layer:
Overlay–5 Years
Steel Paint–Lifetime
COMPOSITE OVERLAY FAUX WOOD GARAGE DOORS:
CAN, CRM, GLN, GLM
Color Blast® –5 Years
INSULATED STEEL GARAGE DOORS:
4050, 4051, 4053, 4132, 4138, 4300, 4301, 4302, 4305, 4308, 4309, 4310, HDG,
HDGL, HDGF, HDGC, HDGCC, HDGR, HDGRC, 2050, 2053, 2051, 2132, 2138, 6200,
6203, 6130, 6133, 6202, 6132, 6201, 6131, 6208, 6138, 6205, 6209
9130, 9131, 9132, 9133, 9134, 9135, 9138, 9139, 9200, 9201, 9202, 9203, 9204,
9205, 9208, 9209, HDPCC1, HDPRC1, HDPCC2, HDPRC2, HDP20, HDPL20, HDPF20,
HDPC20, HDPR20, HDP13, HDPL13, HDPF13, HDPC13, HDPR13, 7200, 7203, 7130,
7133, 7202, 7132, 7201, 7131, 7208, 7138, 7205, 7209, 7139
Single Family*–Lifetime
Other**–10 Years
5 Years
10 Years
3 Years
Color Blast® – 5 Years
GD1LU, GD1SU , GD2LU, GD2SU, GR2LU, GR2SU, GR1LU, GR1SU, GD1LP, GD1SP,
GD2LP, GD2SP, GR1LP, GR1SP, GR2LP, GR2SP, AR2SU, AR2LU, AR2SP, AR2LP, AR1SU,
AR1LU, AR1SP, AR1LP
Terms and limitations of the limited warranty are further detailed below:
*
Applies to residential single family installations.
** “Other” refers to all other residential installations (including installations on facilities owned in common by condominium associations or similar organizations).
ADDITIONAL INFORMATION REGARDING YOUR WARRANTY
Clopay warrants the sections of the Models listed above against the paint finish cracking, checking or peeling (i.e. losing adhesion).We warrant our rust prevention system against rust through for perforation(s)
caused by corrosion originating at the steel layer. Failure to properly clean and maintain your door (particularly in, but not limited to, high-salt or acidic environments) or damage to the door such as scratching,
may result in surface rust, a coating that forms on the surface when exposed to moisture, which – if left untreated – may result in loss of warranty coverage. Surface rust is not covered under this warranty.
For more information about our rust prevention system and how to care for your door visit: info.garagedoors.com/maintenance.
Window components such as frames, grilles, inserts, and clear acrylic are warranted for ten (10) years from manufacturing defects and excessive yellowing. Insulated windows are warranted for ten (10) years
for material obstruction of vision resulting from film formation or dust or moisture collection between the interior surface of the insulating glass. No warranty is available for single pane glass. No warranty is
available for decorative hardware.
EXCLUSIONS TO COVERAGE
This warranty shall not extend to damages or defects caused by any of the following:
Paint or Stain Not Applied per Manufacturer
Specifications after Delivery of Door
Failure to Follow All Installation Instructions
Failure to Follow Maintenance Instructions
Faulty or Defective Installation(s)
Fire
Radiation (UV or Other)
Vandalism
Foreign Substances
Act(s) of God
Accident or Casualty
Harmful Fumes
Physical Damage
Salt Spray or Exposure
Operation Beyond Rated Capacity
Normal Wear and Tear
Improper Use or Abuse
Chemical Action
Abrasive Materials
Improper Installation or Handling
Exposure to Coastal Weather Conditions
Alteration, Modification or Use of Non-OEM/
Clopay-Approved Parts or Products
Other Painted Parts Not Part of a Door Section
(such as stop mold)
Normal Fading or Discoloration from Usage,
Age or UV Exposure
Thermal bow as described in DASMA
If you make any repair or alteration without first providing notice to and receiving authorization from us, or use any parts, accessories, or attachments other than authorized by Clopay for use in its products,
you will be solely responsible for any such repairs or parts and you may void this Warranty. Routine maintenance and related items, as well as minor adjustments or damage caused by your installer either
during delivery or installation, are excluded from this Warranty. For purposes of this Warranty, minor scratches will not be considered a defect.
If you would like to submit a Warranty claim, notify Clopay Customer Service promptly after discovery of the defect by sending an email to [email protected] or calling 800-225-6729. Please be prepared
to send us a proof of purchase and complete description with photographs of any issues. YOU MUST REPORT ANY MANUFACTURING DEFECTS THAT ARE IMMEDIATELY OBVIOUS OR VISIBLE AT THE TIME OF
INSTALLATION (SUCH AS INCORRECT OR INCONSISTENT PAINT COLOR, MANUFACTURING DEFECTS (E.G. SURFACE CONTAMINANT(S) OR SMUDGES), VISIBLE PHYSICAL DAMAGE, OR MAJOR SCRATCHES)
WITHIN FORTY FIVE (45) DAYS FROM DELIVERY OR YOUR CLAIM MAY BE BARRED. Additional copies of our installation and maintenance instructions may be obtained by calling 800-225-6729.
UNDER NO CIRCUMSTANCES SHALL WE BE LIABLE FOR ANY CONSEQUENTIAL OR SPECIAL DAMAGES WHICH ANY PERSON OR ENTITY MAY INCUR OR CLAIM TO INCUR AS A RESULT OF ANY DEFECT IN
THE PRODUCT OR IN ANY CORRECTION OR ALTERATION THEREOF MADE OR FURNISHED BY US OR OTHERS. OUR MAXIMUM LIABILITY UNDER THIS WARRANTY SHALL BE THE PURCHASE PRICE PAID TO US
WITH RESPECT TO THE GARAGE DOOR TO WHICH SUCH WARRANTY IS CLAIMED. THE LIMITATION OF LIABILITY PROVISIONS HEREIN SHALL APPLY TO ANY AND ALL CLAIMS OR SUITS BROUGHT AGAINST
US, INCLUDING ANY CLAIM BASED UPON NEGLIGENCE, BREACH OF CONTRACT, BREACH OF WARRANTY, STRICT LIABILITY OR ANY OTHER THEORIES UPON WHICH LIABILITY MAY BE ASSERTED AGAINST US.
This warranty constitutes our entire and exclusive warranty as to the Replacement Parts and is the sole and exclusive remedy for product defects in material and workmanship. We do not assume (and have
not authorized any other person to assume on its behalf) any other warranty or liability in connection with any product covered by this warranty. 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.
If warranty is provided in multiple languages, the English language version governs.
© 2019 Clopay Corporation. All rights reserved.
MOD 0137320-R08-1119 / 0137398-R04-1119 / C31-R11-1119 / C35-R08-1119
© 2020 Clopay Corporation. All rights reserved.
4150077-R01-0120
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