Instructions / Assembly

ManualsBrandsClopay ManualsKitchenGallery Collection 16 ft. x 7 ft. 18.4 R-Value Intellicore Insulated Ultra-Grain Medium Garage Door with SQ24 Window

I N S TA L L AT I O N

INSTRUCTIONS

RESIDENTIAL SECTIONAL INSULATED STEEL DOORS

CLOPAY CONSUMER SERVICES • 1-800-225-6729

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http://www.clopaydoor.com/owners-manuals

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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

STEP 10 Reinforce the Top Section for Garage Door Opener

...................................... 17–18

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

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Verify you have all parts and materials required for installation.

• Door Components (See Page 5).

If missing parts or damaged sections, call Clopay Consumer

Services Hotline 1-800-225-6729.

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Read instructions completely and/or watch installation video.

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HEADROOM: Verify appropriate amount of headroom to install door

(STEP 3).

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LOW HEADROOM: Special instructions and additional hardware may be

required (STEP 3, Table 3-B).

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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.

• Removing existing door will take approximately 1–3 hours.

• Typical installation time is 9–12 hours.

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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.

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AUTOMATIC DOOR OPENER: Installation of a reinforced mounting point

is required to avoid damage (STEP 10). Sold separately.

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DRILLING: Take care not to drill through outside steel skin unless

otherwise instructed.

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HIGH WIND AREAS: Doors installed in high windload regions (Florida

and other high wind-prone areas) may require additional reinforcement.

Refer to Supplemental Instructions for details if applicable.

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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.

STEP 1 - BEFORE YOU BEGIN TABLE OF CONTENTS

INSTALLATION VIDEO:

http://www.clopaydoor.com/residential/buyingguide/

residential-installation-videos

or scan the QR code on the right.

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

Summary of content (32 pages)

PAGE 1
RESIDENTIAL SECTIONAL INSULATED STEEL DOORS I N S TA L L AT I O N I NSTRUCTI O NS 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 D
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STEP 2 – READ THIS SAFETY INFORMATION - IMPORTANT! ! WARNING TO PROTECT YOURSELF FROM INJURY, YOU MUST CAREFULLY READ THE FOLLOWING SAFETY INFORMATION AND WARNINGS BEFORE YOU INSTALL OR USE YOUR NEW GARAGE DOOR! BEFORE INSTALLING YOUR DOOR ■ ■ ■ ■ ■ ■ ■ ■ You can install your new garage door yourself if: a) you have help (it may weigh up to 150 lbs.
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STEP 3 - CHECK HEADROOM, BACKROOM, SIDEROOM Headroom Requirement: ■ 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). ■ Refer to Table 3-A for standard headroom requirements. ■ Track radius can be determined by measuring dimension “R” (Fig. 3-B). Rough Opening = Door Size Backroom = Door Height Plus 18" Headroom Required • If “R” equals 11" to 12", it is a 12" radius track.
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STEP 4 - REVIEW COMPLETE DOOR ASSEMBLY AND VERIFY ALL HARDWARE IS PRESENT Typical InstallationIllustration Illustration TypicalGarage Garage Door Door Installation FINAL GARAGE DOOR ASSEMBLY Extension Spring System Shown onComplete Complete Door Extension Spring System Shown on Door EXTENSION SPRING SYSTEM SHOWN RearTrack TrackHanger Hanger Rear (NotIncluded) Included) (Not Containment Cable Cable Containment Extension ExtensionSpring Spring Stationary Sheave Sheave Stationary Sheave Sheave Door Jam
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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.
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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.
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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.
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STEP 6 - PREPARE THE OPENING Required Headroom 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 replace immediately. ■ Inside of door opening should be framed with 2" × 6" lumber. ■ Vertical jamb should extend past opening (Fig. 6-A) to match headroom required (Table 3-B). ■ Jambs should be plumb and header should be level. ■ Be sure bolts fastening jambs to wall are flush.
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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. Step 7-2: Attach Bottom Brackets ■ By hand, bend to break apart bottom brackets as shown (Fig. 7-B). Remove connecting tabs.
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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.
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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. ■ For 1-3/8" thick doors, cut stems on lift handle along ridge line using a hacksaw (Fig. 8A-A). LIFT HANDLE STEMS Step 8A-2: Bottom (First) Section ■ Fig.
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STEP 8 - INSTALL LIFT HANDLES STEP 8B: FOR COMPOSITE DOORS Step 8B-1: ■ 5-1/2" (Composite Overlay Doors) 5-1/4" (Composite Overlay Faux Wood Doors) 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.
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STEP 8 - INSTALL LIFT HANDLES STEP 8C: FOR STEEL CARRIAGE HOUSE GARAGE DOORS Step 8C-1: ■ Use supplemental templates provided in handle bag to determine handle configuration for your door size. ■ The top carriage bolt should also go through the top hole of the roll grip handle. ■ Attach bottom of roll grip handle with a #14 × 5/8" sheet metal screw into the backer plate (Fig. 8C-B). Step 8C-2: ■ Find the center of the distance between embosses on the front of the section.
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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 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.
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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. ■ 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).
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Step 9A-8: Prepare Last (Top) Section ■ 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. #14 x 5/8" Sheet Metal Screws 1/4" x 3/4" Self-Tapping Screws NOTE: If door was supplied with any struts (Table 7-A) attach using 1/4" × 3/4" self-tapping screws (Fig. 9A-F).
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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. ! WARNING DO NOT install the bracket supplied with opener. Failure to reinforce door, as illustrated, will void door warranty.
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STEP 10 - REINFORCE THE TOP SECTION FOR GARAGE DOOR OPENER STEP 10B: FOR COMPOSITE OVERLAY FAUX WOOD DOORS 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. 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.
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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. 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).
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■ 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.
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■ 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 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.
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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.
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STEP 15 - ATTACH AUTOMATIC GARAGE DOOR OPENER 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. Failure to reinforce door as illustrated will void door warranty. Step 15-1: Remove Pull Rope and Lock ■ If installed, remove pull rope and locks (or unlock).
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GENERAL MAINTENANCE FOR ALL NON-INSULATED GARAGE DOORS 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. Any missing, broken, loose, or malfunctioning door handles.
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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, HDPCC
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Gallery® Collection Window Frame and Retainer Retightening ■ 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. NOTE: You must remove any wax applied to the door before cleaning (doors are not waxed in the manufacturing process).
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CARE & MAINTENANCE FOR COMPOSITE OVERLAY FAUX WOOD GARAGE DOORS APPLIES TO THE FOLLOWING MODELS Composite Overlay Faux Wood Doors CAN, CRM, GLN, GLM CLEANING & PRESERVING THE DOOR Window Cleaning 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.
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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 If you have ordered your door without factory pre-finish, it is necessary to finish the door prior to installation.
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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.
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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. Pretesting Paint All paints are not created equal.
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LIMITED WARRANTY Subject to the terms of this Limited Warranty (“Warranty”) and any warranty policies and procedures in effect at the time a notice of a claim is received, Clopay Corporation (“Clopay”, “we”, or “our”) will repair or replace (at our sole discretion) any garage door sections/section components, hardware, or springs/spring components (collectively, “Replacement Parts”) that we determine to be defective in material or workmanship so long as timely written notice is provided within the applicabl