Garaga Door Installation User Manual

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.  
Fig. 5-B  
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  
Fig. 9-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)  
Fig. 15-C (Doors with odd number of panels)  
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  
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 manufacturers 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 Shieldor 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  
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 manufacturers 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.  
31  
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 PaintLifetime  
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 WARRANTYAS 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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