INSTALLATION & MAINTENANCE Wood Residential Garage Door Instructions Model: Size: Serial No.: (Provided on label on interior door surface) Homeowners Should Retain This Booklet for Future Reference This Manual Contains Important Safety Information Installed By: CONSUMER HOTLINE y 1-800-621-3667 Hours of Operation (Central Time): Mon. – Fri., 8:00 AM – 5.
IDEAL DOOR® Limited Warranty Information Wood Door Limited Warranty Information We will repair or replace (at our option) any garage door section or hardware that is defective in material or workmanship pursuant to the terms of this limited warranty. This warranty extends to and benefits only the original purchaser of the garage door. This warranty does not apply to commercial, industrial or any other non-residential installation.
Table of Contents Introduction and Opening Preparation STEP 1 – Things to Know Before You Begin.................................................................................................... 3 STEP 2 – Read Safety Information .................................................................................................................. 4 STEP 3 – Check Headroom, Backroom, Sideroom..........................................................................................
STEP 2 – READ THIS SAFETY INFORMATION IMPORTANT! To Protect Yourself From Injury You Must Carefully Read The Following Safety Information and Warnings Before You Install Or Use Your New Garage Door You can install your new garage door yourself IF… • a) you have help (it may weigh up to 500 lbs.); b) you have the right tools and reasonable mechanical aptitude or experience; and c) you follow these instructions very carefully. Garage doors use springs to balance them.
STEP 3 – Check Headroom/ Backroom/ Sideroom Rough Opening = Door Size Backroom = Door Height Plus 18" Headroom is the space needed above the top of the door for the door, the overhead tracks, and the springs. Measure to check that there are no obstructions in your garage within that space. The normal headroom space requirement is shown in Table 3-A. The backroom distance is measured from the back of the door into the garage, and should be at least 18" more than the height of the garage door.
STEP 4 – Removing the Existing Door Springs WARNING Garage doors use springs to balance the door weight. There are two types of springs used — extension and torsion. Each of these is available in either a standard or EZ-SetTM assembly option. Please look at the drawings on page 8 to see which springs your old door has installed. If your present door uses standard torsion springs, do not attempt to remove the door or the springs yourself. They should be removed by a qualified door service professional.
STEP 5 - Removing Door Sections & Track Step 5-1: The door can now be disassembled. Starting with the top section, remove the hardware and unstack the sections one at a time. (FIG. 5-A) Step 5-2: After all sections have been removed from the opening, detach all remaining track and hardware from the jambs.
Typical Garage Door Installation Illustration Extension Spring System Shown on Complete Door Rear Track Hanger (Not Included) Stationary Sheave Extension Spring Sheave Door Jamb Panel Door Shown Section #4 Short Strut Flag Bracket Top Bracket Operator Label Vertical Track Vertical Track #1 Hinge #3 Hinge #3 Hinge General Safety Label Section #3 #2 Hinge Long Strut #2 Hinge Long Track Bracket Section #2 #1 Hinge Lift Handles #1 Hinge #1 Hinge Bottom Bracket Warning Label Serial Number L
Hardware Components 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. All Doors Will Receive (2) Of These Items: Track Bracket (Longer) 3/8"-18 x 3/4" Lg.
IMPORTANT: It is required that the door sections be finished prior to installation. Failure to properly and completely finish door section surfaces, including the sides, back, bottom, face, and joints, will void the warranty on the door. See page 19 for finishing instructions. Terms Used On Door Sections Section Height Holes For Hinges Top Rail STEP 7 – Preparing Bottom Door Section NOTE: FIG. 7-A illustrates common terms used in this manual.
Step 7-6: Hinges are identified by a number 1, 2, 3, or sometimes 4 (5 section doors only) stamped on the bottom leaf. Using 1/4” x 1-7/8” carriage bolts and 1/4” hex nuts (panel doors) or 1/4” x 1” lag screws (flush doors), attach a number 1 hinge to each stile using the pre-drilled holes along the top edge of the section (FIG. 7-F). Step 7-7: If your door was supplied with struts, there are three total, one long and two short. A short strut should be installed at this time.
Step 9 – Installing Door Sections Step 9-1: Place the bottom section in the opening so that it is against the stop molding and centered from side to side. Place a level on the section and use a piece of wood under one end or the other (if necessary) to make the section level. (FIG. 9-A) Step 9-2: Remove the level and drive a 3” nail into the jambs at each end and bend it over the edge of the section to hold the section in place. (FIG.
Step 9 – Installing Door Sections (Continued) Step 9-6: Place the third section on the sawhorses. Attach #3 hinges to the ends at the top edge and #1 hinges to all other sites along the top edge using 1/4” x 1-7/8” carriage bolts (panel doors) or 1/4” x 1” lag screws (flush doors). (FIG. 9-E) Safety Label Step 9-7: If your door was supplied with struts, attach the long strut as shown in the illustration. The bottom edge of the strut should be 4” from the bottom of the section.
Step 10 – Reinforcing the Top Section For Opener Attachment WARNING To avoid risk of strangulation or personal injury to children, you must remove the pull down rope when you install an automatic garage door opener. IMPORTANT: When installing an automatic garage door opener, make sure to follow the manufacturer’s installation and safety instructions carefully. Do not install the pull down rope when attaching an automatic opener. The lock should be removed or disengaged to prevent damage to the door.
STEP 11 – Assembling and Installing the Track Before assembling brackets to vertical track be sure to read Step 11-1 and Step 11-2. Refer to illustration for placement of brackets on track. NOTE: Brackets may already be riveted in place. If additional adjustment is required, the rivets can be drilled out and the brackets can be reattached with track bolts and flange nuts (available through the toll-free Consumer Services number, see outside cover).
STEP 11 - Assembling and Installing the Track (Continued) NOTE: Pressure-treated lumber purchased after January 2004 is treated with chemicals that have highly corrosive effects on metal fasteners. The fasteners provided with your door are intended for use with standard lumber (not pressure-treated) only.
Step 11- 8, Continued: Adjust the position of the tracks if the squareness distances are not 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) When the track is square and level with the opening, the track hangers can be fastened permanently to the ceiling trusses. Three 5/16" x 1-1/2" lag screws are recommended. Be sure 3/16" pilot holes are drilled before installing 5/16" lag screws.
STEP 15 – Attaching an Automatic Opener IMPORTANT: To avoid damage to your door, you must reinforce the top section of the door in order to provide a mounting point for the opener to be attached. Refer to the section of this manual titled Reinforcing the Top Section on page 14 for specific instructions. Failure to reinforce the door as illustrated will void the warranty on your door.
Finishing (Painting or Staining) Instructions: NOTE: Differences in grain and color variations are indicative of natural wood. These are not considered product defects. Some variations in stain penetration may occur between materials from which the door is constructed (i.e. plywood panel vs. wood frame). Preparation Work Important information: Wood products can absorb moisture during shipping and storage. Do not leave or store unfinished doors outside.
Maintaining Your Painted or Stained Door The two major contributing factors to the breakdown of the door’s finish (ultimately resulting in rotting and warpage) are sun and moisture. Annually examine your door for any signs of paint finish cracking or peeling or for any cracks in the wood door section. If the door is painted, the manufacturer recommends that it be repainted every 1-2 years to protect or seal the door against the elements. Failure to do so will result in voiding of the warranty.
