RESIDENTIAL STEEL DOORS
Garage Door Installation Instructions
STANDARD LIFT 12” & 15” RADIUS TORSION
SPRING HARDWARE
WARNING: Installing, adjusting, and servicing of a garage door can be DANGEROUS.
Read instructions thoroughly before you begin. If you are unsure, SEEK PROFESSIONAL HELP.
ALL WARNING LABELS AND SAFETY ITEMS MUST BE INSTALLED
SL REV 1.0 JAN 2011
SL REV 1.0 JAN 2011
1
TOOLS REQUIRED
IMPORTANT!
Hammer, level, measuring tape, drill & bits,
1/2” x 24” round cold rolled steel winding bars,
socket set, screw drivers, wrenches, hacksaw,
vise-grips, utility knife, pliers, ladder, and
saw horses.
CONSTRUCTION
can
ADDITIONAL MATERIAL
Figure “A”
10’ x 1-1/4” x 1-1/4” Pre-punched angle, wood or
vinyl door stop, 3 1/2” common nails,
2 1/4” galvanized finishing nails,
5/16” x 3/4” hex head bolts & 5/16” flange nuts, and
5/16” x 1-1/2” lag screws. (Prepunched angle and
vinyl weather seal may be included if ordered as an option)
OPENING PREPARATION
Measure the opening. It must be 1” to 2“
smaller than the door width and 0” to 1” less
than door height.Vertical jambs must be plumb and
header must be level for a square opening. Note
vertical jamb extension above opening. Minimum
side clearance is 4 ½”. 2x6 bucks are recommended
for a mounting surface.
HEAD
ROOM
CL
2X6
2X6
HEIGHT
HEADROOM REQUIRED:
LEVEL
TORSION SPRING 12” Radius = 13”
15” Radius = 15“
Note: If door is to be motor operated,
an approximate 2 ½” additional
headroom will be required.
See clearance requirements
2x6
provided with your garage
2x4
BUCK
door opener for exact
HEADER
measurements.
WIDTH
Figure “A”
HEADER
DOOR
STOP
Figure “B”
PAGE 1
SL REV 1.0 JAN 2011
Figure “C”
VINYL
WEATHER
SEAL
INSTALLING DOOR STOP
Using 2-1/4” galvanized finish nails,
TEMPORARILY tack door stop around edge
of opening. See Figure “C”. Drive nails
only part way in. Weather Seal should
be flush with jambs.
2-1/4”
GALVANIZED
BOTTOM SECTION ASSEMBLY
If you have sections of different heights, choose the larger
of the sections for the bottom section. Lay the
bottom section face down on sawhorses or other
flat smooth surface. See Figure “J” & “I” PAGE 3 to
determine the interior (face) side of door. BE SURE TO
PROTECT THE FACE OF THE DOOR FROM DAMAGE.
If not pre-installed, slide the full length of astragal into
aluminum retainer until both ends of astragal are flush with
each end of the retainer.Trim the astragal to length if necessary,
however the astragal MUST NOT be stretched once
in the retainer. Then crimp as shown in FIgure “D”.
Place the retainer and astragal assembly on the back
side and bottom of the bottom section.The retainer/astragal assembly
should be flush with each end of bottom section. Secure the
retainer/astragal assembly with the self-drillingTEK screws at
each center stile location. See figures “E” and “I”. Do not install
screws at end stiles yet.
SELF
DRILLING
TEK
SCREW
SHEET
METAL
SCREW
”
ALUMINUM
RETAINER
ASTRAGAL
Figure “D”
END STILE
RETAINER
ASTRAGAL
ASSEMBLY
BOTTOM
SECTION
Figure “E”
Figure ”F”
Figure “F”
PAGE 2
SL REV 1.0 JAN 2011
(Continued)
BOTTOM SECTION ASSEMBLY
Position the bottom bracket on the back side of the bottom of the bottom section 3/4” from the bottom using the
mark on the bottom bracket as a guide. Using one sheet metal screw attach the bottom bracket through
the hole shown and slightly tighten only. See Figure “G1”. Then slide the bottom bracket forward.
See Figure “G2”. The fastener head will then be positioned between the two safety tabs. DO NOT REMOVE
TABS. These tabs are a safety device that will prevent accidental removal after the door is operational. See
Figure “G3”. Then insert two more sheet metal screws in the holes shown and securely tighten screws.
SHEET METAL
SCREW
SHEET METAL
SCREWS
SAFETY TABS
BOTTOM
BRACKET
Figure “G1”
Figure “G2”
Figure “G3”
Figure “H ”
*NOTE: Some door models start with a #2 hinge on the end stiles of the bottom section, and upper sections
increment to #3, #4, #5 etc. Check the end panel of your hardware carton for the appropriate starting end hinge.
Figure “H”
Insert
rollers
here
SHEET
METAL
SCREWS
d
.
Insert
rollers
here
*SEE NOTE
Figure “I”
Figure “H”
”
CABLE
ASSEMBLY
Figure “J”
”
and
I and “M”.
EXTERIOR
OF
GARAGE
DOOR
TONGUE AND
SHIPLAP
JOINT
Figure “J”
ROLLER
PAGE 3
SL REV 1.0 JAN 2011
(Continued)
BOTTOM SECTION ASSEMBLY
Check your packing list to see if the door you are
installing requires reinforcement struts. If you do not have
struts, continue to next step. If you have only one (1) strut,
it will be installed later on the top section. If you have multiple
struts, you must install one of them on the bottom
section using self-drilling TEK screws or
sheet metal screws. Attach the strut, centered
horizontally just above the bottom brackets.
Secure at top and bottom of the strut on
STRUT
each center stile and end stiles. See Figure “M”
If you have been supplied with three (3) or
more struts, one strut is secured to the top section,
one strut on the bottom section and the remaining
struts should be distributed evenly up and down
the door. When you later install these struts on
the intermediate sections, attach them in the center of the appropriate section(s).
If your door has an electric opener or windows in the top section, then install
the strut at the top edge of the top section. See Step “4”.
Figure “M”
INTERMEDIATE AND TOP SECTION ASSEMBLY
NOTE: See Step “5” for instructions on stacking the door sections in the door opening.
Depending on your door height, the number of intermediate sections you have will vary. As previously noted
the larger of the sections is used for the bottom. If you have an additional large section, it will be used as the
top section. If you have more large sections, they will be distributed as evenly as possible up and down the
door. After choosing the order of the intermediate sections, take intermediate section #2 and lay face down on
a flat smooth surface. At the top of the section install the required hinges with sheet metal screws. The end
stiles require #2 hinges (or #3 hinges for some models) and the center stile or stiles #1 hinges.
See Figure “N” (Page 5).
*NOTE: Some door models start with a #2 hinge on the end stiles of the bottom section, and upper sections
increment to #3, #4, #5 etc. Check the end panel of your hardware carton for the appropriate starting end hinge.
If the door will be electrically operated and is not supplied with a keyed manual locking assembly, you MUST
also install lift handles on intermediate section #2. If you will be installing a keyed lock assembly, the lift
handles are not required on intermediate section #2. Refer to separate lock installation instructions if provided.
PAGE 4
SL REV 1.0 JAN 2011
(Continued)
NOTE: See Step “5” for
stacking instructions.
INTERMEDIATE AND TOP SECTION ASSEMBLY
TOP
FIXTURE
”
*NOTE: Some door models start with a #2 hinge
on the end stiles of the bottom section, and upper TOP SECTION
sections increment to #3, #4, #5 etc. Check the
INTERMEDIATE
end panel of your hardware carton for the
appropriate starting end hinge.
*SEE
NOTE
INTERMEDIATE
BOTTOM
SECTION
LIFT
HANDLES
*SEE NOTE
Figure “N”
”
TEK
SCREWS
”
Figure “0”
Figure “N” & “O”
STACKING THE DOOR
LEVEL
Place the bottom section in the
opening so it is centered and
level. If not level, place a shim
3 ” Common Nail
3 ” Common Nail
under one end to level it. The
BOTTOM SECTION MUST BE
LEVEL. See Figure “P”.
SHIM
FLOOR
Drive 3 ” Common Nails part of
the way into the jamb along both
ends of the section as shown in Figure “P”. Bend nails over the ends
of the section to hold the section in place. See FIgure “Q”
WEATHER SEAL
Next stack intermediate section #2 on top of the bottom section.
Hold it in position with 3 ” Common Nails just like the bottom section,
JAMB
then secure the upper half of the hinges with sheet metal screws.
DOOR
Continue stacking the remaining sections in the correct order as
shown in Figure “N”. Each time each section is stacked, be sure to
secure it with 3 ” Common Nails and attach the upper half of the hinges.
Once you have completed stacking the door, MAKE SURE THE
3 ” Common Nail
TOP SECTION IS LEVEL. If not, disassemble the door and repeat
the stacking procedure until all sections are level.
Figure “P”
Figure “Q”
PAGE 5
SL REV 1.0 JAN 2011
(Continued)
correctly into the hinges, the top fixtures,
and the bottom brackets.
TOP FIXTURE
GRADUATED
HINGE
Figure “R”
Figure “R”
TRACK ASSEMBLY
for standard height doors (7ft, 8ft, etc.). If
’-6”
FLAG
BRACKET
’-6” you
”.
Be sure to cut vertical tracks off the bottom ends
”x 5/8 ”
1/4”
1/4”X 5/8”
CARRIAGE
BOLTS
Figure “S”
1/4” HEX
FLANGE
NUTS
Figure “T”.
JAMB
BRACKET
(Or #8 for 2” thick doors)
VERTICAL TRACK ASSEMBLY
Figure “T”
IMPORTANT
JAMB
BRACKET
#4 (J4)
(Or #6 for
2” thick doors)
1/4”X 5/8”
CARRIAGE
BOLT
VERTICAL
TRACK
1/4” HEX
FLANGE
NUT
shown)
Figure “S”
NOTE: If your door is 8’ tall, the 3rd jamb
bracket is a #8 (J8)
PAGE 6
SL REV 1.0 JAN 2011
(Continued)
TRACK ASSEMBLY
Leaving 1/2” clearance between the track and the edge of the door,
fasten the vertical track to the jambs with 5/16” x 1 1/2” lag screws.
See Figure “U”. Drill 3/16” pilot holes 1 1/2” deep, before inserting the
lag screws. The vertical tracks and the flag brackets must be plumb
and parallel with the edges of the door, allowing the 1/2” space.
The rollers should be in the tracks. Assemble the horizontal angle and
track with 1/4” X 5/8” carriage bolts and nuts.
Lift the horizontal track assemblies into position. Suspend the
rear of the track with a rope temporarily. Position the curved
portion of the tracks over the top roller as shown in Figure “X”. Attach the
horizontal track to the flag bracket using two 1/4” x 5/8” track bolts
and 1/4” hex flange nuts per side, thumb tighten only. Heads of the bolts
must be on the inside of the track.Using one 3/8”x 3/4” carriage bolt, and
a 3/8” hex nut per side, attach the horizontal track angle to upper slots
in the flag brackets. If you have 15” radius track use the upper most slots.
If 12” radius use the next set of slots down. Finger tighten only.
5/16”X 1 1/2” HEX
Figure “U”
3/8”
3/8”
”
CARRIAGE BOLT
HORIZONTAL TRACK ANGLE
STRUCTURAL MEMBER
HORIZONTAL
TRACK
”
1/4” X 5/8” TRACK
BOLTS
ROPE
(15” radius
LEVEL
TRACK
1/4” HEX
VERTICAL TRACK
Figure “V”
Figure “W”
Figure “W”
Push the sections against the jamb and pull the verticle tracks back against
as you do this.
the rollers. T
SLIDE
TOP
FIXTURE
”
Note: reajustments of the top fixtures may be necessary once
the springs have been wound.
Figure “X”
PAGE 7
SL REV 1.0 JAN 2011
NYLON
BUSHING
RIGHT
HAND
CABLE
DRUM
(Black)
SPRING
ANCHOR
BRACKET
LEFT HAND
RIGHT HAND
Measure the length of the 1 inch diameter
torsion tube included. It must be at least 10
inches longer than the door’s width.
WINDING
Next slide the bushing, torsion springs and
LEFT WINDING
SPRING
PLUG
the cable drums onto the torsion tube as
HAND PLUG
(Black)
(Red)
shown in Figure “Y”. The cable drums and
CABLE
torsion springs must be in the correct location DRUM
and are color coded for easy identification.
(Red)
The cable drums are also stamped on the
interior rim “LH” or “RH” for identification.
The wind of the springs can also be identified
by Figure “Z”. In some cases you may have
only one spring rather than two. If so, identify
which wind torsion spring it is and locate it on
RIGHT HAND
LEFT HAND
the torsion tube according to Figure “Y”.
Insert the black nylon bushing into the spring
anchor end of one of the springs. The exposed portion
of the bushing has a collar that fits inside the slot
in the spring anchor bracket. See Figure “AA”.
SPRING SLEEVE
Then attach the spring or springs to the spring
anchor bracket with the 3/8” x 1 1/2” hex head bolts
SPRING
WARNING LABEL
and the 3/8” hex nuts, finger tighten only.
ANCHOR
G
IN
Once assembled the spring anchor bracket should
BRACKET
RN EME
A
R
W T
ER
be at mid point or centered on the torsion tube.
EX ANG
Figure “Y”
Figure “Z”
D
IMPORTANT
:
Install Warning Sleeve on Spring
Assembly as shown
3/8”
”
WARNING
”
BOLTS
Figure “AA”
Figure “AB”
PLATE
LEFT HAND
PLATE
RIGHT HAND
Figure “AB”
PAGE 8
SL REV 1.0 JAN 2011
(Continued)
PLATE
Attach the end bearing plates to each
horizontal track angle using two 3/8” x 3/4”
carriage bolts and 3/8” hex nuts, finger
tighten only. Then drill a 3/16” diameter
pilot hole, 2 1/2“ deep, and
secure the top of the end bearing plate to
the jamb with a 5/16” x 2 1/2“ lag screw.
See Figure “AC”. After the lag screws are
tight, finish tightening the 3/8” bolts and
nuts attaching the end bearing plates to
the horizontal track angles.
5/16” X 2 1/2“
3/8”
”
CARRIAGE
BOLTS
FLAG
BRACKET
3/8”
HORIZONTAL
TRACK ANGLE
NUTS
12”
Next, lift the complete spring and torsion tube
assembly into place. Slide the ends of the torsion
tube into the end bearing plates evenly. With the torsion
tube level and straight you can now secure the
spring anchor bracket to the header. Using the top
and bottom slotted holes, drill 3/16” diameter pilot
holes into the header. Then secure the spring anchor
bracket with two red head 5/16” x 2 1/2” lags directly
to the solid wood blocking.
Figure “AC”
Figure “B”
r and the header. Then fully tighten the 3/8” hex head nuts.
‘
See Figure
“AA”. Remove all 3 ” common nails holding the door sections against the jamb.
t hits the torsion tube.
prevent
Figure “AE”
the
the
PAGE 9
SL REV 1.0 JAN 2011
(Continued)
NOTCH
CABLE
Figure “AE”
WARNING:
you
Figure “AF”.
”
IMPORTANT
winding.
“
CHALK
LINE
.
1/2”
”
WINDING
BARS
WINDING CONE
Figure “AF”
Remove the winding bars from the spring(s) and
remove the vice-grip from the torsion tube.
6’-0”
6’-6”
7’-0”
7’-6”
8’-0”
full turns
full turns
full turns
full turns
full turns
PAGE 10
SL REV 1.0 JAN 2011
1/2”
Back hangs are required for support of
the horizontal tracks. Generally the angle
and fasteners required for the back hang
PREPUNCHED
and sway brace assembly are not included
ANGLE
with the door. The distance between the
5/16” STOP BOLT
horizontal track and the overhead structure
will determine how much angle will be required.
If the ceiling trusses are exposed, usually the back hangs
can be installed as in Figure “AG”. If the truss locations are
not correct or you have concealed trusses, refer to Figure “AH”
There should be 1/2” clearance between the door and the horizontal
track. The sway braces should be 18” to 24” from the end of the horizontal track,
and the horizontal track should be level. See Figure “AG”.
The angle should be attached to the structural members
with 5/16”x1-1/2” lag screws. Use longer lag screws
when going through sheet rock as required. Holes
should be pilot drilled before inserting lag screws.
The angle that you attach to the horizontal track
should drop straight down from the structural member
and should be attached to the track with a 5/16”x1”
PREPUNCHED
carriage bolt and 5/16” flange nut. If an existing slot or
ANGLE
hole does not lineup you must first drill
a 5/16” diameter hole at the appropriate location in the
horizontal track. An additional piece of angle must
be attached to this vertical angle, diagonally, to resist
any movement of the track. Attach the angle to the angle
with 5/16”x 1” bolts and hex head nuts.
STRUCTURAL
MEMBER
TOP
SECTION
Figure “AG”
Figure “AH”
STRUCTURAL
MEMBERS
HORIZONTAL
TRACK
IMPORTANT
Insert a 5/16”x 1” bolt with nut at the back of the
track which acts as a stop for the door to prevent the top section from exiting the track.
FINAL ASSEMBLY & ADJUSTMENT
Remove vise-grip from track and raise the door. Check track alignment, the door should raise
evenly and not bind. The door should not be able to be moved side to side more than 1/4”, if so re-adjust
the tracks as required. Then check that the track bolts of the vertical and horizontal track are tight.
Operate the door up and down, if the door is difficult to open and tends to close by itself,
more spring tension is required. If the door opens by itself and is difficult to close, less
spring tension is required. Always adjust torsion springs with the door closed, locked
down, and with a vise-grip on the torsion tube to prevent the shaft from turning.
IMPORTANT
PAGE 11
SL REV 1.0 JAN 2011
ARE
1.
2.
3.
4.
Bottom Brackets with Safety Tabs
Spring Warning Sleeve
Lifting Handles
Pull Rope
PAGE 12
SL REV 1.0 JAN 2011