Overhead door 321 Series User manual

410440-0001
7/14/06 © OVERHEAD DOOR CORPORATION
Contents
Warnings and Safety Information . . . . . . . . . . . . . . . . . . . . . 2
HowtoUsetheseInstructions.......................3
GeneralNotes,ToolsNeeded........................4
Parts Identification and . . . . 5
Preparing for Installation
1. AssembleTrack...............................6
2. Pre-assemble Spring System . . . . . . . . . . . . . . . . . . . . 7
3. Pre-assemble the Sections . . . . . . . . . . . . . . . . . . . . 8-9
4. PreparingtheOpening.........................10
Door Section Installation
5. StackSectionsinOpening......................11
6. InstallVerticalTrack...........................12
8. InstallCounterbalance.........................13
9. InstallBackhang.............................20
10. FinalAdjustments ...........................21
Installing Optional Accessories
Drawbar Plate, Locks and Step Plate . . . . . . . . . . . . . 22-28
TrackAngleSupport.............................29
LowHeadroomTrack .........................29-30
Key Drawings (Door, Sections)
7. InstallHorizontalTrack ........................12
ExtensionSprings.........................14-15
TorsionSprings...........................16-19
Warranty.......................................31
READ THIS MANUAL CAREFULLY AND OBSERVE ALL
WARNINGS WHEN INSTALLING, OPERATING OR
MAINTAINING YOUR GARAGE DOOR.
RESIDENTIAL
SECTIONAL GARAGE DOOR
INSTALLATION INSTRUCTIONS
SERIES 321, 323, 327, 329

WARNINGS & SAFETY INFORMATION
2
SAFETY INFORMATION
POTENTIAL HAZARD EFFECT PREVENTION
MOVING DOOR
HIGH SPRING TENSION
WARNING
Could result in death
or serious injury
Keep people clear of opening while Door is moving.
Do Not allow children to
play with the Door operator.
Do Not operate a Door that jams or one
that has a broken spring.
Do Not try to remove, repair or adjust
springs or anything to which Door spring
parts are fastened, such as wood blocks,
steel brackets, cables or other like items.
Repairs and adjustments must be made
by a trained door system technician using proper
tools and instructions.
Overhead doors are large, heavy objects that move with the help of springs under high tension and electric motors.
Since moving objects, springs under tension, and electric motors can cause injuries, your safety and the safety of others
depend on you reading the information in this manual. If you have questions or do not understand the information
presented, call your nearest service representative.
In this Section and those that follow, the words Danger, Warning, and Caution are used to emphasize important safety
information. The word:
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in injury or property damage.
The word NOTE is used to indicate important steps to be followed or important considerations.
OVERVIEW OF POTENTIAL HAZARDS
WARNING
Could result in death
or serious injury
WARNING
Could result in death
or serious injury
Turn off power before removing operator cover.
When replacing cover, make sure wires are not
pinching or near moving parts.
Operator must be properly grounded.
ELECTRICAL SHOCK
1. Read manual and warnings carefully.
2. Make sure support angles are strong enough to support door in horizontal position.
3. Check distance between horizontal tracks before raising door.

INSTALLATION INSTRUCTIONS
HOW TO USE THESE INSTRUCTIONS
These instructions have been designed to aid installation of a Residential Sectional Garage Door. You should
have the tools necessary for this installation and be skilled in their use. It is very important that you read and
understand these instructions and WARNINGS before attempting to install your door. If you do not
understand an instruction or have a question, call your nearest Overhead Door Distributor at 1-800-929-DOOR
1. Use “KEY DRAWINGS” on page 5 and 6 to
locate and identify specific terminology.
2. These instructions show the step-by-step
procedures required to install the following:
DOORS
Non Insulated - 321, 327
Insulated -
TRACK
Standard 2“ residential
COUNTERBALANCE SPRINGS
Extension
Torsion
Use only those instructions applicable to your
particular installation.
3. Each “STEP” will include:
a. A brief statement of the procedure to be
performed.
b. Illustrations showing procedure in specific
detail.
c. Hardware and fasteners required.
323, 329
DOOR JAMB REQUIREMENTS
1. Jambs should be plumb and flush.
2. Floor should be flat and level.
3. Opening should be the same width as the
length of the door section.
4. Standard headroom - 12 inches
Minimum headroom - 10-1/2 inches
(Additional headroom required for door
operator)
5. Minimum sideroom - 1-1/2 inches
6. MASONRY WALLS:
HEADER - should be cased with a wood 2 x
4 or 2 x 6.
JAMB - should be cased with wood 2 x 4’s
or 2 x 6’s which extend 12 inches above
header.
NOTE: Casings should be flush with opening
and secured with masonry anchors.
DEFINITIONS OF TERMS USED
HEADROOM - distance from top of door opening to ceiling. CLINCH SCREW - Screw driven through End Stile into door jambs to temporarily
NOTE: Door-to-ceiling clearance may be different than “headroom” if hold door sections in mounting position. See General Note 4, page 4.
door overlaps top of opening.
CLEARANCE HOLE - hole drilled through material and large enough to allow easy
SIDEROOM - distance from side of door opening to sidewall. passage of a bolt or fastener being used.
PLUMB - perpendicular to floor of structure. Measured with a plumb line. PILOT HOLE - pre-drilled hole in material in which a screw is used. May be step to
obtaining larger hole in thin material.
CASE - attachment of wood 2 x 4’s or 2 x 6’s around the inside face (header &
jambs) of door opening on masonry walls
3

GENERAL NOTES
1. Nuts, bolts and screws should be hand
tools to prevent thread stripping.
NOTE: Use care with power tool on steel door, do not
exceed 100 in/lbs of torque.
2. All required items are furnished except those noted.
Additionally you will need:
2x4 or 2x6 wood framing material.
Lag screws for attaching ceiling angle to ceiling joists.
5/16“ hex bolts, nuts & lockwashers used to secure
hanging angles, sway braces & track.
#8 x 3.5” Wood Screws or 16p Nails.
The following items are available from your OHD
representative:

Stop Molding Nails. OHD P/N 607614
3. Stop molding (not furnished) is required to correctly
install this door. It must be installed inside door opening
on jambs and header.
tightened using
Hanging Angle OHD P/N 607055
Stop molding. OHD P/N 407624
5. Hanging angle fasteners shown in the details below are
not supplied with your door. You will need
approximately 6 feet of hanging angle to complete this
project.
4. When stacking door sections in mounting position on
door opening, temporarily “HOLD” sections to jamb
using #8 x 3.5” wood screws or nails(not provided).
Place the screw through the end stile and fasten into
the door jamb until the section is held vertical but still
has a little play in the horizontal direction. Do not
overtighten, this could cause installation problems or
damage the door section.
TOOLS NEEDED
You will need the following tools to perform this
installation:
Safety Glasses
Tape Measure
Stud Finder
Winding Bar, OHD P/N 409152-0001 (Call your
nearest Overhead Door representative) For
Torsion Springs Only
Chalk
Electric or Cordless Drill and Bits
1/8” Drill Bit, 7/16” Socket with Drive
5/16” Allen Hex Bit (Armortite only)
Carpenter Level
Step Ladder
Saw Horses
Hack Saw
Locking Pliers (2)
Hammer
Slotted Screwdriver
Wrenches
3/8”, 7/16”, 1/2”, 9/16”
3/16” Allen Hex Wrench (Armortite only)
4
Jamb
Stop Molding
Do not set nails initially.
1/4" Initially, install 1/4" inside jamb.
CEILING ANGLE
SWAY BRACE
HANGING ANGLE
NUT
5/16-18 x 5/8"
BOLT
LOCK
WASHER
HORIZONTAL TRACK
LW
NUT

PARTS IDENTIFICATION
5
494
2
0
5-
5494
2
0
5-
5
The Parts shown below are Scaled 1:1.
The Parts shown below are NOT to Scale.
Roller Holder Brackets
(P/N 409554-0002(Shown),-0003, & -0004)
409554-0005 (Not Shown - For 5 section high door)
Leaf Spring Roller
(P/N 608672-0000)
Top Fixture
(P/N 410123-XXXX)
Set Screw
(for torsion counterbalance drums)
(P/N 080299-2416)
Hex Nut (3/8”)
(Torsion Spring Assembly)
(P/N 080352-0616)
Lag Screw (5/16” x 1-3/4”)
(used for mounting track brackets)
(P/N 605574-0001)
Lag Screw (5/16” x 2-1/2”)
(used for mounting center support bracket)
(P/N 605574-0002)
P/N 605911-0001 or -0002 Red Head for Bottom Fixtures)
AB Point Screw (1/4”)
(Track Bolt (1/4” x 5/8”)
(P/N 080019-0006)
Track Nut (1/4”)
(P/N 086480-1620)
Hex Head Bolt (3/8” x 1-1/2”)
(Torsion Spring Assembly)
(P/N 080105-0612)
Bottom Fixture
(P/N 410427-0001, -0002)
(Right hand Shown)
Decorative Hardware
Hinges and Handles
P/N 410094-0015
P/N 410094-0012
P/N 410094-0014
P/N 410094-0016
P/N 405964-XXXX
P/N 410094-0013
P/N 410437-XXXX
White Vinyl Cap P/N 608769-XXXX
Sheetmetal Screw
P/N 410094-0011
Track Brackets
P/N 046450-XXXX

6
PREPARING FOR INSTALLATION
KEY DRAWINGS
NO TRIATHALON HINGE
FIGURE 1 FIGURE 2
NOTE: Refer to Key Drawing during installation for
placement of hardware.
1. Identify the Sections by referring to Figure 1. Right
and Left will be identified by looking at the door from
the inside of the garage looking out. (See Figure 2)
LEFT
RIGHT
TOP SECTION
BOTTOM SECTION
INTERMEDIATE SECTION
KEY DRAWING
WEATHERSEAL
INSIDE GARAGE
TM
1. TRACK ASSEMBLY 405964-XXXX
(Third slot from the top)
Bottom of Track
FIGURE 1-3
FIGURE 1-2
1. Attach jamb brackets to the vertical track using track bolt and
nut.(See Figure 1-1)
NOTE: Locate the jamb bracket(405964-XXXX) on the first
slot hole from the bottom of track and the other jamb bracket
on the third slot from the top.
2. Assemble the flag Bracket to the transition curve using track bolts
and nuts from the inside of the track and through a slot on the flag
bracket.(See Figure 1-2)
3. Install the transitional curve and flag bracket assembly on the
vertical track assembly by sliding the vertical track into the
swedged end of the curve track.(See Figure 1-3)
4. Assemble the Vertical tracks for the other side the same way and
then set the tracks to the side while you get the door in place.
FIGURE 1-1
405964-XXXX
(First slot from the bottom)
TRACK BOLT AND
NUT IS OPTIONAL
TRACK BOLTS
AND NUTS

FIGURE 2-1 FIGURE 2-2
PREPARING FOR INSTALLATION
For Torsion Springs, Use the Drawing to the Right as a
guide for assembly of the components to the shaft. The
drawing shows all components required to install single
and dual torsion springs. Use only those parts supplied
with your door.
1) Secure anchor plug(s) to anchor bracket.
NOTE:
Single torsion spring: If spring is “Left” wound it
should be located on the right side of the anchor
bracket. If spring is “Right” wound it should be
located on left of anchor bracket. See Figures 2-1
and 2-2 to determine if you have a right wound or left
wound spring.
Dual torsion springs: “Left” wound spring on right side
of bracket and “Right” wound spring on left side.
2) Slide torsion spring assembly onto the
counterbalance shaft.
3) Install cable drums on shaft. Make sure left and right
drums are on correct ends.
NOTE: Drums are marked “R” for right and “L” for left.
4) Set the spring assembly aside and move on to Step 3.
2. SPRING SYSTEM ASSEMBLY
LEFT
SPRING
ANCHOR
BRACKET
RIGHT
SPRING
ANCHOR
PLUG
WARNING TAG
408622-0001
ANCHOR
BRACKET
051070-0000
WARNING TAG
408622-0001
ANCHOR PLUG
"RED" WINDING PLUG/
SPRING ASSEMBLY
"BLACK" WINDING PLUG/
SPRING ASSEMBLY
COUNTERBALANCE
SHAFT
080918-XXXX
LIFT CABLE
LIFT CABLE
LEFT
CABLE DRUM
RIGHT
CABLE DRUM
SET SCREW
3/8-16 x 1"
(TWO PER DRUM)
SET SCREW
3/8-16 x 1"
(TWO PER DRUM)
SET SCREW
3/8-16 x 1"
(TWO PER PLUG)
SET SCREW
3/8-16 x 1"
(TWO PER PLUG)
NUT
LOCKWASHER
NYLON BEARING
605881-0001
ANCHOR PLUG
HEX HEAD BOLT
3/8-16 x 1-1/2"
TORSION SPRING PRE-ASSEMBLY
For Extension Springs, No pre-assembly is
needed.
TORSION SPRING
7
RIGHT WOUND LEFT WOUND
Wind Direction
End View End View
RED LAG SCREWS
5/16" x 2 ½"
P/N 605574-0002

PREPARE BOTTOM SECTION
CABLE ASSEMBLY FULLY SEATED BOTTOM FIXTURE
FIGURE 3-1
NOTE: Refer to Key Drawing during installation for
placement of hardware.
8
1. Attach one of the lift cables(P/N 409950-XXXX)
to the Right Hand bottom fixture(P/N 410427-
0002).(See Figure 3-1)
2. Place the Right hand bottom fixture on the
bottom right hand side of the section. See
Figure 3-2.
3. Fasten the bottom fixture to the bottom section
with two AB Point screws(P/N 605911-0002,
Figure 3-3) provided. Install the AB Point
Screws(See Figure 3-4) into the Bottom Fixture
until it is flush up against the end stile.
4. Repeat Steps 1-3 for Left hand bottom
fixture(P/N 410427-0001).
5. Place Rollers into the Left and Right hand
bottom fixtures.(See Figure 3-5)
NOTE: Pinch leading springs down when
inserting rollers into the holders. (See Figure 3-
6)
FIGURE 3-4
FIGURE 3-6
FIGURE 3-3
FIGURE 3-2
1. Stage the sections on sawhorses and insert
roller holders(Part #’s 409554-xxxx) into the
sections. Start with the -0002 roller holder on
the top of the bottom section and working up
from there. With the 1st intermediate section
receiving the -0003 roller holder and so forth.
Slide Roller holders down into the tabs on the
end stile and snap the holder into place.
2. Secure the Roller Holders to the End Stile
using two AB Point Screws provided. The
holes on the roller holder will line up with the
holes on the end stile.(See Figure 3-8)
3. Insert Rollers into the roller holders just
installed. Remember to pinch the springs when
inserting the rollers. FIGURE 3-7
ROLLER HOLDER INSERTION
Snap Roller Holder
down into Tabs
FIGURE 3-8
(PART NUMBER LOCATION)
EXAMPLE: 409554 -0002
AB POINT
SCREWS
3. DOOR SECTION PRE- ASSEMBLY
AB POINT SCREW 1/4-14 x 5/8“
FIGURE 3-5
AB POINT
SCREWS

TOP FIXTURE INSTALLATION
9
3. DOOR SECTION PRE- ASSEMBLY (con’t)
1. Secure the Top Fixture Assembly to the End
Stile using AB Point Screws provided.
STRUT INSTALLATION
While working on door sections, lay sections flat on sawhorses.
Position sawhorses approximately 2-3 ft. from the ends of the door
section.
DO NOT LAY SECTIONS FLAT IF SUPPORT LOCATION IS NOT
BETWEEN TWO TO THREE FEET AWAY FROM EACH END.
NOTE: Steel door sections, 16 and 18 ft. long, must be carried
vertically (on edge).
For 18 ft. Doors, Struts are to be installed on bottom, 1st Intermediate(4
section high) or 2nd Int.(5 high), and top sections.
For 16 ft. Doors, Strut should be attached to top section only. Attach Struts
to Intermediate and bottom sections if supplied.
Strut Installation
1. Position the Strut on the section using the drawings below as a guide to
determine the correct location. (See Figure 3-13)


2. Attach ends of strut to end stiles with 1/4-14 x 5/8“ AB Point screws(P/N
605911).
3. Attach the strut to the center stiles using the 1/4-14 x 5/8“ AB Point
screws(P/N 605911).
2 - 3 FEET
1/4-14 x 5/8“
HEX HEAD AB POINT SCREWS
1/2“
END STILE
CENTER STILE
STRUT
THIS END UP
WHEN CARRYING
THE SECTIONS
ATTACH STRUT APPROXIMATELY ½”
FROM THE END OF THE STILE
TOP
1ST OR 2ND
INTERMEDIATE BOTTOM
FIGURE 3-10
STRUT LOCATIONS
7“
7-1/4“
2-1/2“
FIGURE 3-12
1/2”
FIGURE 3-13
FIGURE 3-11
FIGURE 3-9
AB POINT SCREWS

4. PREPARING THE OPENING
On the inside of the garage the door opening should be framed with wood jambs, 2 x 4’s or 2 x 6’s. The jambs should
extend 12 inches above the header. If you have just removed an old door, the jambs should be inspected for the
condition of the wood. If the wood is rotten it should be replaced now. The jambs should be plumb and the header level.
If there are any bolts fastening the jambs to the wall, the heads should be flush so they don’t interfere with the
installation of the new door.
NOTE: Opening width = Door Width
10
TORSION SPRINGS
If the door has a torsion spring assembly, YOU MUST MAKE SURE THAT THE TORSION
SPRING ANCHOR BRACKET WILL BE SECURELY FASTENED TO THE GARAGE WALL.
Anchor into wood stud or structurally sound member. Failure to securely fasten the
anchor bracket could allow the springs to break loose from the garage wall and cause
severe personal injury.
Check Headroom
Headroom is the space needed above the top of the door opening for the door, the overhead tracks and the
springs. Measure to check that there are no obstructions in your garage within that space. The standard
headroom is 12 inches and the minimum headroom space requirement is 10- inches. If the Door overlaps the
top of the opening, then measure the door-to-ceiling clearance. This should be a minimum of 10-1/2 inches.
The backroom distance is measured from the back of the door into the garage, and should be at least 18 inches
more than the height of the door.
A minimum sideroom of 1- inches should be available on each side of the door.
NOTE: About three inches of additional headroom height at the center plus additional backroom is needed to
install an automatic garage door opener. Check door opener instructions.
Low Headroom- If you have restricted headroom, several remedies are available. For the correct product,
contact your nearest Overhead Door distributor.
½
½
OPENING WIDTH = DOOR WIDTH
OPENING
HEIGHT
12" STANDARD
HEADROOM
1-1/2" MIN.
SIDEROOM
2X4 OR 2X6 JAMB
2X4 OR 2X6 HEADER
WOOD STUD OR STRUCTURALLY SOUND MEMBER
FOR TORSION SPRING ANCHOR BRACKET ATTACHMENT
BACKROOM =
OPENING HEIGHT + 18“
Jamb
Stop Molding
Do not set nails initially.
1/4" Initially, install 1/4" inside jamb.
FIGURE 4-1 FIGURE 4-2
FIGURE 4-3
STOP MOLDING INSTALLATION
1. Stop molding is required to correctly install this
door. It must be installed inside door opening on
jambs and header. Refer to Figure 4-3 on proper
location of the stop molding in reference to the
jamb.
NOTE: Stop Molding and nails are not included in
the standard door kit. Contact your nearest
Overhead Door distributor for these parts.
1-1/2”
SIDEROOM

5. INSTALLING DOOR SECTIONS
1. Position assembled bottom door section in the
opening. Center the section in the opening, the
section should line-up with the edge of the jamb
on the left and right side. Level the bottom
section in the doorway. Use shims if required to
level the section. See Figure 5-1
2. Secure the section in place by inserting clinch
screws or nails (Not Provided, #8 x 3-1/2“ wood
screws recommended) through the pre-drilled
holes in the end stile into the jamb as shown in
Figure 5-2.
3. Position an Intermediate section on top of
the bottom section, verify that the upper
section end stiles are on the outside of the
bottom section end stiles on each end and
that both the steel upper hinge half and
lower Triathlon™hinge are aligned. Refer to
Figure 5-3)
4. Snap the Intermediate section hinges into the
bottom section hinges starting at one end and
working your way across till all the hinges are in
place.(See Figures 5-4 and 5-5) Push down on
the bottom rail at the end stile or use vise grips
to snap the hinges together.
11
Header
Jamb Jamb
CARPENTER'S LEVEL
CLINCH SCREW CLINCH SCREW
Floor
Stile
Clinch Screw
Jamb
Molding
Upper Tab
(Must be located on
the outside of the Lower Tab)
Lower Tab
FIGURE 5-1
FIGURE 5-5
FIGURE 5-2
FIGURE 5-3
FIGURE 5-4
FIGURE 5-6
5. Rotate the entire section 90 degrees
inward(See Figure 5-6) to insure that the
sections are properly connected.
6. Secure the section in place by inserting #8 x 3-
1/2“ wood screws though the end stile into the
jamb as shown in Figure 5-2.
7. Repeat Steps 3 through 6 for the remaining
sections.
Fully Seated Triathlon™Hinge
Rotate the Section 90 degrees to fully seat the hinges
Start at one end and Work your Way across snapping
sections into place

12
6. INSTALLING VERTICAL TRACK
FIGURE 6-1
1. Identify the side of the door which has the bottom
section touching the floor after leveling the bottom
section.
Position Vertical Track Assembly over the Rollers.
NOTE: When positioning vertical track over rollers,
space the track approximately 1” away from the end of
the door.(See Figure 6-1)
3. Adjust the flag bracket such that it rests against the
jamb. Secure it to the wall with lag screws and tighten
the track bolts and nuts on the flag bracket. Make
sure the track and curve are aligned vertically.
NOTE: If the door was shimmed to level the section,
then the track must be shimmed the same amount.
2.
4. Adjust the position of the jamb brackets starting with
the lowest one such that they are against the jamb
and the track is touching the floor. Secure the jamb
brackets to the jamb with the lag screws provided.
5. Repeat Steps 2 - 4 for the vertical track and flag
bracket on the other side of the door.
1”
LAG SCREW
5/16” x 1-3/4”
STOP MOLDING
(Not Furnished)
DOOR SECTION
BOTTOM FIXTURE
TRACK
3/16” DIA
PILOT HOLE
1. Take one of the straight tracks to use for a horizontal.
Position the end of the track in the swedged end of the
transition curve nesting the u shape side of the track
with the curve swedged end.(See Figure 7-1)
2. Push the track into the swedged end of the curve until
the track is fully seated in the swedged end.(See
Figure 7-2)
3. Secure the track and the curve using a track bolt and
nut. (See Figure 7-2)
4. Repeat Steps 1-3 for the horizontal track on the other
side of the door.
5. If the Door requires angle on the track refer to the
section for installing Track Angle Support on page 29.
7. INSTALLING HORIZONTAL TRACK
FIGURE 7-1
FIGURE 7-2
FIGURE 7-3
HORIZONTAL TRACK SHOULD BE FULLY SEATED
AND SECURE WITH TRACK BOLT AND NUT
SLIDE HORIZONTAL TRACK INTO THE CURVE
(HORIZONTAL TRACK PIECES DO NOT HAVE
1” X 1-1/2” LOCK HOLES)
TRACK BOLT AND
NUT IS REQUIRED

8. INSTALLING THE SPRING SYSTEM
13
Refer to the following Figures 8-1, 8-2 for the type of
spring system being installed on this door.
For Extension Springs (Figure 8-1) go to page 20 to
install the backhang, then proceed to page 14.
For Torsion Springs (Figure 8-2) go to page 16.
EXTENSION SPRING
TORSION SPRING
FIGURE 8-2
FIGURE 8-1
ANCHOR
BRACKET
051070-0000
WARNING TAG
408622-0001
RED LAG SCREWS
5/16" x 2 ½”
P/N 605574-0002
ANCHOR PLUG
"RED" WINDING PLUG/
SPRING ASSEMBLY
"BLACK" WINDING PLUG/
SPRING ASSEMBLY
COUNTERBALANCE
SHAFT
080918-XXXX
LIFT CABLE
LIFT CABLE
LEFT
CABLE DRUM
RIGHT
CABLE DRUM
SET SCREW
3/8-16 x 1"
(TWO PER DRUM)
SET SCREW
3/8-16 x 1"
(TWO PER DRUM)
SET SCREW
3/8-16 x 1"
(TWO PER PLUG)
SET SCREW
3/8-16 x 1"
(TWO PER PLUG)
NUT
LOCKWASHER
NYLON BEARING
605881-0001
ANCHOR PLUG
HEX HEAD BOLT
3/8-16 x 1-1/2"
Track
Sway Brace
Stud Pulley
Headplate
Lift Cable
Safety
Retaining
Cable
Clevis
Pulley
Extension
Spring
Ceiling
Angle
1/4-20 x 5/8
Track Bolt (1)
Hanging
Angle

EXTENSION SPRING COUNTERBALANCE INSTRUCTIONS
14
Figure C. Stud Pulley Assembly
Headplate
3/8-16 x 1-1/2
Hex Head Bolt
Falling door can cause serious injury.
Before attempting to raise door:
Check distance between tracks. If tracks are
too far apart, door could fall.
Put long track bolts through holes at end of
each track to stop travel.
Get help to raise door. Door is very heavy.
Raise door slowly.
The drawing at right shows all components required to
install left side extension springs. Right side will be
similar.
Follow the step sequence for assembly, installation
and adjustment.
The complete door must be raised into horizontal
tracks before attaching lift cables to extension springs.
Backhangs must be attached before raising the door.
Proceed to page 20 to attach the backhangs before
installing the extension springs.
Step 1. Stud Pulleys
A. Install Stud pulleys on headplates. See Figure C. Stud
Pulley
Double Spring Assembly With Yoke
Figure A. Single Spring Assembly
Track
Spring
Yoke
Sway Brace
Stud Pulley
Headplate
Lift Cable
Figure B. Double Spring Assembly
Safety
Retaining
Cable
Clevis
Pulley
Extension
Spring
Ceiling
Angle
Extension
Springs
Safety
Retaining
Cables
Clevis
Pulley
1/4-20 x 5/8
Track Bolt (1)
Hanging
Angle

Figure G
Figure E
Figure F
EXTENSION SPRING INSTRUCTIONS
15
Step 4. Attaching the Spring
A. Hook one end of each extension spring into each
hanging angle.
B. Install clevis pulleys on opposite ends of springs.
C. For double extension spring installation, refer to
Extension Spring Counterbalance Assembly Drawing
(page 14).
Step 5. Retainer Cable Installation
NOTE: Proper installation of safety retainer cables is
important. These cables help prevent personal injury or
property damage by retaining the broken piece of the
spring in cases of extension spring failure.
A. Attach looped end of safety retainer cables to
hanging angles and thread cables thru springs.
B. Remove slack from retainer cables and secure to
appropriate holes in headplate.
C. See Extension Spring Counterbalance Assembly
Drawing, page 14.
Step 3. Raise door
A. Raise door and install locking pliers to flat portion of
track just below door to prevent door from
accidentally closing.
D. Remove Locking pliers from tracks.
E. Test door operation and re-adjust spring tension if
necessary.
F. Too much spring tension will not allow door to stay on
floor when closed.
G. Insufficient spring tension will make the door hard to
open.
H. Lightly lift cables using 30 wt. Oil. Wipe off excess
oil.
I. If door is painted after installation, extension springs
will have to be readjusted to compensate for the
added weight.
Go to Section 10, page 21.
Step 2. Sway Brace Installation
A. Raise door slowly. Watch top track rollers and
horizontal tracks.
B. Check spacing between ends of door and tracks.
Maintain approximately 1” clearance.
C. If tracks are set too far apart, lower door and make
necessary adjustments.
D. Cut sway braces from perforated angle (not
supplied) and install using hex head bolts (not
supplied).
Step 6. Cable Installation
A. Route lift cables over stud pulleys, around clevis
pulleys to holes in headplates.
B. Pull equal tension on both springs and secure lift
cables to headplates.
C. See Extension Spring Counterbalance Assembly
Drawing, page 14.
Track
Radius
Hanging
Angle
JAMB
BOTTOM
DOOR
SECTION
Extension
Spring
BOTTOM
FIXTURE
EACH SIDE SHOULD
BE EQUAL DISTANCE
FROM FLOOR
HANGING
ANGLE
LOCKING
PLIERS
TRACK
EXTENSION
SPRING
HORIZONTAL
TRACK
CLEVIS
PULLEY
Lift Cable
Lift
Cable
Horizontal
Track
Headplate
Stud Pulley
Figure H
Figure D
HORIZONTAL
TRACK
CEILING
ANGLE
1/4 - 20 X 5/8
BOLT
HANGING
ANGLE
NUT
LW
SWAY
BRACE
NUT LW
1/4-20 X 5/8
BOLT

TORSION SPRING INSTRUCTIONS
16
The drawing above shows all components required to install single and
dual torsion springs. Use only those parts supplied with your door.
Follow the step sequence below for assembly, installation and adjustment.
Installation of the Torsion Spring System can be extremely
dangerous. All instructions must be strictly followed.
ANCHOR
BRACKET
051070-0000
WARNING TAG
408622-0001
ANCHOR PLUG
"RED" WINDING PLUG/
SPRING ASSEMBLY
"BLACK" WINDING PLUG/
SPRING ASSEMBLY
COUNTERBALANCE
SHAFT
080918-XXXX
LIFT CABLE
LIFT CABLE
LEFT
CABLE DRUM
RIGHT
CABLE DRUM
SET SCREW
3/8-16 x 1"
(TWO PER DRUM)
SET SCREW
3/8-16 x 1"
(TWO PER DRUM)
SET SCREW
3/8-16 x 1"
(TWO PER PLUG)
SET SCREW
3/8-16 x 1"
(TWO PER PLUG)
NUT
LOCKWASHER
NYLON BEARING
605881-0001
ANCHOR PLUG
HEX HEAD BOLT
3/8-16 x 1-1/2"
Figure A
RIGHT WOUND LEFT WOUND
Anchor
Plug
Anchor
Bracket
Right
Wound
Spring
Left
Wound
Spring
Wind Direction
End View End View
Step 1. Torsion Spring Pre-assembly
A. Secure anchor plug(s) to anchor bracket.
NOTE:
•Single torsion spring: If spring is “Left” wound it should
be located on the right side of the anchor bracket. If
spring is “Right” wound it should be located on the left
side of the anchor bracket. See Figure A To determine if
you have a right wound or left wound spring.
•Dual torsion springs: “Left” wound spring on right side
of bracket and “Right” wound spring on left side.
RED LAG SCREWS
5/16" x 2 ½"
P/N 605574-0002

TORSION SPRING INSTRUCTIONS
17
Step 2. Installing Torsion Shaft
A. Slide torsion spring assembly onto counterbalance
shaft.
B. Install cable drums on shaft. Make sure left and right
drums are on correct ends.
NOTE: Drums are marked “R” for right and “L” for left.
C. Do not secure setscrews at this time.
D. Lay counterbalance shaft assembly on the top edge
of the headplate, then insert one end thru the
headplate with largest amount of sideroom.
CAUTION: Do not insert shaft far enough to pull
opposite end off its horizontal angle. Go to opposite
end and insert shaft through remaining headplate. For
double wide doors two people are recommended.
Step 3. Anchor Bracket Installation
A. Raise anchor bracket up to header until
counterbalance shaft is level or slightly above.
NOTE: Anchor bracket must be mounted so that center
of shaft does not sag below level.
•SINGLE SPRINGS - Locate winding plug near
centerline of door.
•DUAL SPRINGS - Locate anchor bracket near
centerline of door.
Anchor brackets will be under high spring tension and
must be securely fastened to a structurally sound wood
member or the bracket can break loose and cause
severe personal injury.
Anchor into wood stud or structurally sound member.
For wood studs on top of masonry or steel jambs, use
1-3/4” lags.
B. Secure anchor bracket to stud using 5/16 x 2-1/2”
screws in 3/16” pilot holes.
Wood Stud
Figure C
Left Wound
Centerline of Door
Winding Plug
Left Wound
Right Wound
Right Wound
Anchor Bracket
Wood Stud
Wood Stud
Figure B-2
Drum is Flush
to Headplate
Headplate
Shaft
Shaft is Fully Inserted
Figure B-1
Insert Shaft here

Figure E
TORSION SPRING INSTRUCTIONS
18
Step 5. Cable Attachment - Right Side
A. Route right side lift cable up to cable drum and insert
into cable slot.
B. Wind lift cable onto cable drum until all slack is
removed.
C. Position right cable drum against right headplate.
D. Tighten set screws on drum into shaft.
Step 6.
A. Check the following before attempting to wind torsion
springs:
•Fasteners secure on bottom fixtures.
•Lift cables secure at bottom fixtures.
•Lift cables routed unobstructed to cable drums.
•Lift cables correctly installed and wound onto cable
drums.
•Lift cables are taut.
•Cable drums are against headplates and setscrews
are tight.
•Torsion spring(s) are installed correctly.
NOTE: Clamp locking pliers to flat portion of door track
just above door. This will prevent the door from rising
quickly once torsion spring winding is complete.
Step 4. Cable Attachment - Left Side
A. Route left side lift cable up to cable drum and insert
into cable slot.
B. Wind lift cable onto cable drum until all slack is
removed.
C. Position left cable drum against left headplate.
D. Tighten set screws on drum into shaft and install
locking pliers on shaft with handles against ceiling or
header.
Winding torsion springs is an EXTREMELY DANGEROUS
procedure and should be performed by a trained
technician or a mechanically experienced person using
proper tools and following these instructions.
Should you elect to perform this procedure:
1. Read winding instructions thoroughly.
2. Make sure you understand the procedure.
3. Follow the instructions carefully.
4. Wear safety glasses.
5. Use only winding bars described in the “Tools
Needed” section on page 4. DO NOT SUBSTITUTE
with screwdrivers, pipe, etc. Other tools may fail
and cause serious personal injury.
6. Door must be closed when winding or making any
adjustments to torsion spring(s).
7. Sound footing is required. Before attempting to
wind torsion spring(s) make sure stepladder is
sturdy and positioned correctly.
Lift cable
Headplate
Set Screws
Door Track
Shaft
Cable Drum
Figure D
Lift cable
Headplate
Locking Pliers
Door Track
Shaft
Cable Drum
Set Screws

Figure F
Figure G
TORSION SPRING INSTRUCTIONS
19
Step 8.
A. Insert winding bar into winding plug and rotate plug
1/4 turn upward.
B. Insert second winding bar into plug, take up torque
load and remove first winding bar.
Step 9.
A. After winding spring, keep winding bar fully seated in
plug.
B. Secure winding plug setscrews and remove winding
bar.
C. Remove locking pliers from counterbalance shaft.
D. If dual torsion springs are used, wind remaining
spring the same as first.
E. Remove locking pliers from door track.
C. Continue winding torsion spring until spring is wound
the required number of turns.
6 Foot high doors - 7-1/8 turns
7 Foot high doors - 8-1/4 turns
8 Foot high doors - 9-1/8 turns
Step 7.
A. Draw a chalk line horizontally along the center of the
spring coil. As spring is wound, chalk mark will
create a spiral. These can be counted to determine
the number of turns on the spring.
DO NOT remove a winding bar from winding plug until a
second bar has been fully seated in plug and torque load
has been assumed.
Original Chalk Mark
before winding
Set Screws
Spirals created by chalk
mark after winding
WIND UP
Winding Plug
Anchor Plug

INSTALLING SWAY BRACES
20
Dimension "B" should be 1" less
than dimension "A".
10. Check spacing between ends of door and tracks.
Maintain 1” clearance.
11. If tracks are set too far apart, lower door and make
necessary adjustments.
12. Cut sway braces from perforated angle (not
supplied) and install using hex head bolts (not
supplied). (See Figure 9-4)
TRACK SLOPES UP
FRONT HORIZONTAL TRACK BACK
B
A
HEADER
1. Raise the Door slowly until it is halfway into the
opening. Watch the top track rollers and horizontal
tracks.
2. Clamp the door in place using vise grips.
3. Check the spacing between ends of door and
tracks. Maintain a 1” clearance when setting the
backhang.
CEILING
JOISTS
SHEET ROCK
CEILING
ANGLE
DOOR DOOR
CEILING JOIST
Perpendicular to door.
CEILING JOIST
Parallel to door.
FIGURE 9-2
FIGURE 9-1
FIGURE 9-4
4. Using a stud finder, locate ceiling joists nearest rear
end of horizontal tracks. NOTE: Figure 9-1 should
help to locate ceiling joists.
5. Cut two lengths as appropriate of perforated angle
for ceiling angles (not supplied).
6. Secure ceiling angles to ceiling joists using lag
screws (not supplied).
If horizontal tracks are set too far apart at rear,
door may fall from tracks resulting in serious
personal injury. Raise door slowly so that
distance between tracks can be checked.
WARNING
FIGURE 9-3
7. Measure distance from ceiling to horizontal tracks at
front and rear.
NOTE: Rear of tracks should be elevated 1" higher
than front. (See Figure 9-2)
8. Cut vertical hanging angles to length required from
perforated angle (not supplied).
9. Secure hanging angles to ceiling angles and track
using hex head bolts (not supplied). (See Figure 9-3)
DO NOT install sway braces at this time. Go to the
next step first.
9. INSTALLING THE BACKHANG
INSTALLING CEILING ANGLE
INSTALLING VERTICAL ANGLE
CEILING
HORIZONTAL
TRACK
CEILING
ANGLE
NUT
NUT
LW
LW
1/4 - 20 X 5/8
BOLT
HANGING
ANGLE
1/4-20 X 5/8
BOLT
HORIZONTAL
TRACK
CEILING
ANGLE
1/4 - 20 X 5/8
BOLT
HANGING
ANGLE
NUT
LW
SWAY
BRACE
NUT LW
1/4-20 X 5/8
BOLT