Composite Garage Doors Installation Instructions FOR PROFESSIONAL GARAGE DOOR INSTALLERS Tools required Screwdriver Claw Hammer Locking Pliers Power Drill Level with a 3/32" Drill Bit Utility Knife 9/16", 3/8", 7/16" 9/16", 3/8" and 1/2" Wrench and 7/16" Pliers 2 (1/2" x 18") Bars (Torsion Hdwr. Only) Socket Wrench Step Ladder
Installation Instructions 2" x 6" CENTER PAD REQUIRED FOR TORSION SPRING HEAD ROOM DANGER High Spring Tension can cause severe injury or death. Do not attempt to remove, repair or adjust torsion or extension spring assemblies, red-coated fasteners, or the hardware to which the red-coated fasteners are attached. Removal, adjustment or repair must be made by a professional door repair person. JAMB FASTENERS FLUSH WITH SURFACE OPENING HEIGHT DOOR HEIGHT HEADER OPENING WIDTH DOOR WIDTH 2" x 6" JAMB ATTENTION Failure to comply with these instructions invalidates the warranty. SHIM FIGURE 1 BOTTOM SECTION LEVEL NAIL Before you begin the installations, be sure to read and understand all of the instructions. Installation and/or repair of garage doors should be performed by a qualified garage door installer. We recommend that installation be performed by a team of two individuals. Garage doors are heavy, awkward and may be difficult to handle. Installing a garage door without assistance could result in injuries. Both one and two-car doors are installed in the same manner. Damage to a garage door due to an improperly installed or adjusted electric opener is not covered by JELD-WEN s warranty. Disconnect and/or remove all locks and pull ropes when you install an electric operator. Attempting to use the operator while the door is locked may damage your door. Number of door sections and number of panels may vary from illustrations. Be sure all warning labels and tags are affixed to door. 3-3/4" SIDEROOM 7-1/2" MIN. CENTER POST DOOR FIGURE 2 STOP SUPPLIED BY INSTALLER Notice to Architects and Designers: Architects and designers should consider when designing a building the forces a garage door system transmits to the building structure openings, such as the jambs, anchor pads, headers, and horizontal track. Since the forces vary, load information may be obtained by contacting JELD-WEN s Garage Door Manufacturing Plant (1-800-606-7380). Step 1: The inside of the garage door opening should be framed with 2" x 6" wood jambs. Jambs should be plumb and square and extend to the top of the minimum headroom required (see Table 1 & Fig. 1 & 2). All jamb fasteners should be flush with jambs and securely anchored to the wall. Step 2: Nail door stops (supplied by installer) temporarily to the edge of the jambs flush with surface (Fig. 3). Step 3: Lay bottom section on sawhorses face down. Attach bottom bracket flush with bottom section using 3 (1/4" x 1") red lag bolts (Fig. 4A). Next slide the full length of astragal into the aluminum retainer until both ends are flush with each end of the retainer. Trim the astragal to length if necessary but do not stretch the astragal once in the retainer. Then crimp the edges 1/2" from the ends. Secure the retainer with lag bolts starting in the center and working your way towards the edges. When securing the retainer to the edges a lag bolt should extend through the retainer then through the pre-drilled hole at the bottom of the bottom bracket. Attach the looped end of the steel cables to the bottom bracket using the small bolt and cotter pin. Note: Use 3/32" drill bit to start pilot holes for fasteners where pre-drilled holes are not provided. The bottom of each section will have the groove and the top of each section will have the tongue. Step 4: Struts must be attached according to (Fig. 8 & 10). See strut schedule (Table 2) for location of struts. Install lift handle on bottom rail of bottom section and second section using 2 (1/4" x 1") lags (Fig. 4B). Lift handles to be installed in accordance with DASMA 116. BOTTOM CORNER BRACKET RIGHT HAND ALUMINUM BOTTOM RETAINER 1/4" x 1" RED LAG BOLT LIFTING STUD STEEL CABLE FIGURE 3 NOTE: SLOTTED HOLE IS ON TOP HALF OF HINGE FIGURE 4A Page 2 FIGURE 4B LIFT HANDLES
Installation Instructions STRUTS AS REQUIRED TOP SECTION #4 TRACK HANGERS SUPPLIED BY INSTALLER TOP FIXTURE #3 #2 HINGE #1 BOTTOM SECTION #1 BOTTOM CORNER BRACKET FIGURE 5 Step 5: Hinges have numbers stamped on them and their placement on the door is important (Fig. 5). Hinge numbers are on the bottom half of the hinge and slotted hole is on the top half. All hinges are fastened with 1/4" x 1" lag bolts (Fig. 6). Starting with the bottom section, attach the bottom of the #1 hinge to the pre-drilled holes at the top of the section. Attach all #1 hinges to all center stile locations. Note: When using 3" track numbers on the end hinges may vary. Use #1 hinges on the bottom and attach remaining end hinges in numerical order. FIGURE 6 INTERMEDIATE SECTION Step 6: With hardware in place, place bottom section temporarily in the opening against stops and center it. Level section using shims if necessary and drive nails into jambs and bend them over section on each end to hold in place (Fig. 1). TABLE 1 - HEADROOM Minimum Track Headroom Type of Spring Radius Required Torsion 12" 12" Torsion 15" 15" TABLE 2 - STRUT SCHEDULE Width of Door Traditional Series Carriage House & Estate Series 8'0" & 9'0" 2-1/4" - 22 ga. Strut per section 2-1/4" - 22 ga. Strut per section 10'0" Not Available 2-1/4" - 22 ga. Strut per section 16'0" & 18'0" 2-1/4" - 22 ga. Strut per section 3" - 20 ga. Strut per section FIGURE 7 SLIDE TOP FIXTURE TOP SECTION - NO STRUT TABLE 3 - SECTION HEIGHT AND # CHART Section Qty Bottom 2nd 3rd 4th 5th Total Ft-In 4 20 20 20 24 7'0" 4 24 20 20 24 7'4" 4 24 24 20 24 7'8" 4 24 24 24 24 8'0" 5 20 20 20 20 20 8'4" 5 20 20 20 20 24 8'8" 5 24 20 20 20 24 9'0" 5 24 24 24 24 24 10'0" Stacking chart is for Carriage House and Estate Series Doors only. Traditional panels are ordered by sections and can be stacked out in any order. STRUT AS REQUIRED TOP FIXTURE STRUT ON TOP SECTION TOP FIXTURE USE HOLES FIGURE 8 Page 3
Installation Instructions CENTER STILE END STILE Step 7: Place second section on sawhorses face down and attach #2 end stile hinges to section. Install remaining hinges and struts to the section and to all intermediate sections making sure hinges are in numerical order (Fig. 5). Refer to Table 2 and Fig. 10 for location of struts and installation. SLOTTED HOLES Step 8: Place top section on sawhorses face down. Install strut to top section (Fig. 8). Place top fixture (with sliding portion to the top) near top of section below strut with 3 (1/4" x 1") lag bolts. If top section has no glass install strut at center of top section (Fig. 10). Step 9: Stack each section (one at a time) with all hinges, fixtures and brackets attached (and struts required) in the opening and onto the previous section. Index - line up each section from the exterior. Be sure to drive nail into jamb and bend over to each section to hold section in place. On each section, fold hinges up and fasten to bottom of next section with 2 (1/4" x 1") lag bolts. Step 10: Place rollers in all end hinges, bottom corner brackets and top fixtures. Be sure rollers are inserted in the hinge tube which is farthest from door surface when more than one tube is provided (Fig. 11). Step 11: ASSEMBLING TRACK (MAY BE WELDED) Install jamb bracket to straight-vertical track using 1/4" x 5/8" (for 7'0" doors) track splice bolts and 1/4" nuts. 1/4" nuts always go on outside of track curve. Install brackets in numerical order. Place shorter bracket towards bottom end of track with short side of bracket and track facing towards the jamb. Hand tighten (Fig. 12). 1/4" X 1" LAG BOLTS STRUT 1/4" X 1" LAG BOLTS FIGURE 10 BOTTOM CORNER BRACKET TOP FIXTURE #2, 3, 4, ETC. HINGE FIGURE 11 1/4" NUT OR WELD FLAG BRACKET Step 12: Attach lag bracket to top of track with 2 (1/4" x 5/8") track splice bolts and 1/4" nuts with flat side of flag and track facing towards the jamb. Hand tighten (Fig. 12). Step 13: Hook the straight vertical track over rollers on door. Maintain 3/8" space between door edge and vertical track (Fig. 15). Tops of vertical track must be level with each other. To determine, measure from top of tracks to top of door on each side. If not level, raise lower track but not higher than lowest roller. Vertical tracks must be plumb. When properly aligned, securely fasten jamb brackets and flag bracket to jambs with 5/16" x 1-5/8" lag bolts (Fig. 13). Pre-drill 3/16" hole to prevent splitting. Step 14: Install horizontal angle to horizontal track using 1/4" x 5/8" track splice bolts and nuts (if not already done). Place horizontal track assembly in position using a temporary rope or wire support from trusses to support back end. Slip curved end of horizontal track over top roller and attach it to flag bracket using 2 (1/4" x 5/8") track splice bolts (Fig. 13). Attach end of horizontal angle to top of flag bracket with 1 (3/8" x 3/4") LSC bolt and 3/8" nut (Fig. 13). Step 15: Replace support rope or wire with metal angle hangers (supplied by installer - minimum 14 ga.) Make sure track is square with opening. Make sure distance between tracks is the same at the bottom of the vertical, at the curve of horizontal and back of horizontal. Adjustment of track position may need to be made later, after the door is open to maintain proper spacing. CAUTION: Keep horizontal tracks close to the door so door will not fall out of track. LOCATE STRUT CENTER SECTION 1/4" NUT OR WELD TRACK SPLICE BOLT JAMB BRACKETS VERTICAL TRACK LEFT HAND VERTICAL TRACK RIGHT HAND TRACK SPLICE BOLT FIGURE 12 - VERTICAL TRACK ASSEMBLY TEMPORARY ROPE SUPPORT HORIZONTAL ANGLE TRACK SPLICE BOLT 1-5/8" LAG BOLT FIGURE 13 3/8" x 3/4" BOLT 3/8" NUT FLAG BRACKET 1/4" NUT Page 4
Installation Instructions Step 16: Tighten the slide on the top fixture by pushing the top section tightly against the opening and lightly pulling the slide towards the inside of the garage. Tighten nuts. Step 17: If lock bar used: Locate and fasten the lock bar guide(s) with 2 (1/4" x 1") lag bolts so that lock bar(s) enter the hole(s) in the track without obstruction but as close to the top of the hole as possible. LOCK AND PULL ROPE SHOULD BE REMOVED AND/OR DISENGAGED IF ELECTRIC OPERATOR IS USED. Step 18: Lock the door in the down position using locking pliers. This must be done to prevent the door from prematurely opening. Step 19: Slip the springs onto the torsion shaft followed by the cable drums. If your on the inside looking out the red winding cone spring goes on the left, the black on the right. The set screws on the drums face in towards the springs. Step 20: Fasten the end bearing plates to the horizontal angle using 2 long hex bolts and nuts. Use the bottom 2 slots for 12" radius track and the upper slots for 15" radius. Step 21: Lift the complete torsion assembly and slide the ends into the end bearing plates. With the torsion shaft level mount the center bearing plate to the anchor pad using the long lag, red headed screws. Step 22: Place the end of the cable into the notch in the cable drum. Turn the cable drum and slide it up tight to the end bearing plate to remove any slack in the cable. Tighten the set screws using a 3/8" box wrench while keeping the cable taut. Repeat on opposite side. Step 23: Insert 2 winding bars all the way into the winding cone and wind the springs 1/4 turn at a time in an upward direction. Consult manufacturer if unsure on how many turns. Step 24: Remove locking pliers. Slowly raise the door and prop it about halfway open. Check spacing of door and track. Make sure there is approximately 3/8" spacing along entire vertical and horizontal track. If adjustments are necessary the door must be locked in the closed position. INSTALL POWER UNIT IN ACCORDANCE WITH POWER UNIT INSTRUCTIONS. Step 25: Close door from outside and permanently nail stop moulding for a snug fit so that the stop does not bind the door. Wax inside edge of stop moulding to prevent binding. Step 26: FINAL ADJUSTMENT 1. Re-adjust spring tension if necessary. Refer to spring power unit instructions. 2. Make sure door is square with opening. 3. If the door doesn t work easily, re-check installation to make sure spacing of track is correct and that door is not binding. DAMAGE TO THE GARAGE DOOR DUE TO AN IMPROPERLY INSTALLED OR ADJUSTED OPERATOR IS NOT COVERED BY JELD-WEN S WARRANTY. Leave these instructions by the door for future reference. Be sure all warning labels and tags are properly affixed to door shown on back of warranty and that the Home Owner Information Bag is posted on the door jamb and warranty information is filled out. TRACK HANGERS SUPPLIED BY INSTALLER FIGURE 14 FIGURE 15 3/8" Painting composite doors 1. A waterborne all-acrylic exterior latex finish with a U.V. inhibitor is most compatible with our primer and is our recommended finish. 2. Be sure to select a finish coating specifically intended for the job, derived from a reputable coatings manufacturer. 3. Follow the recommendation on the paint manufacturer s label. Avoid painting in hot, humid weather or when the temperature is below 50 degrees F. Two coats of paint are recommended. These are only general instructions and in no way cover all aspects of painting composite doors. INSTALLATION INSTRUCTION SUMMARY 1. Nail door stop 2. Attach hardware 3. Stack sections in opening 4. Fasten hardware between sections 5. Install track 6. Install power unit 7. Check operator and balance Page 5
The JELD-WEN Web site is your ultimate resource for learning about our reliable windows and doors. It has all the product information and design advice you need. Visit us at www.jeld-wen.com today. JELD-WEN Interior Rail & Stile s (16' and 8' Carriage House Sections Shown For Example) End Stile Intermediate Stile Center Stile Rail End Stile Center Stile Rail Traditional Series Doors - 19-1/4", 21" and 24" Sections Door Size End Stiles Intermediate Stiles Center Stiles Rails 8' & 9' 2-7/8" 3-1/8" 2" 16' 6" 3-1/8" 3-1/8" 2" 18' 6" 3-1/8" 3-1/8" 2" Carriage House and Estate Series Doors - 20" and 24" Sections Door Size End Stiles Intermediate Stiles Center Stiles Rails 8' & 9' 2-7/8" 3-1/8" 2" 10' 2-7/8" 3-1/8" 3-1/8" 2" 16' 6" 3-1/8" 6-1/4" 2" 18' 6" 3-1/8" 6-1/4" 2" Official window, door and millwork provider of the PGA TOUR and Champions Tour 2003 JELD-WEN, inc. JELD-WEN and Reliability for real life are registered trademarks of JELD-WEN, inc., Oregon, USA. All other trademarks are the property of their respective owners. JELD-WEN reserves the right to change product specifications without notice. Please check our Web site www.jeld-wen.com for current information. Individual door designs are protected under U.S. copyright laws. SB 525 03/08 10-535