INSTALLATION INSTRUCTIONS FOR … will adjust to minor irregularities. door/opening height Read and...

INSTALLATIONINSTRUCTIONS

FORCOMMERCIAL

STEELGARAGE DOORS

Read and be sure that you completely understand all of the steps and warnings as outlined prior to beginning installation.Page 1

Door Basics

torsion spring

drum

horizontaltrack

#3 section

vertical track(clip angle shown)

center hinge

bottom fixture

end bearing

spring support

end hinge

top fixture

top section

#2 section

bottom section

warning label

warning label

springwarning tag

rear track support

These instructions will show you how to install a C.H.I. Commercial door. They are for the mechanicallyexperienced person who has proper tools to perform the job. They are not meant to infringe upon orsupersede any State or County building codes or safety regulations.

C.H.I. COMMERCIAL OVERHEAD DOORINSTALLATION INSTRUCTIONS

Included in this booklet are instructions for installing Standard Lift, High Lift, Vertical Lift and LowHeadroom doors mounted on Wood or Steel Jambs.


If you plan to use an existing door opener, check it for current safety features. This is the time to update youroperator to assure yourself of the safest door system possible.

Warning! If you are removing an existing door, only an experienced person should release the springtension. The spring is the most dangerous part of your door. It is charged with force at all times andthis force must be properly and safely released before removing any part of your existing door. Seriousinjury or death may result if you attempt to loosen or remove any part of the spring system whether it isattached to the door or to the wall before releasing all of this spring force.

Read and be sure that you completely understand all of the steps and warnings as outlined prior tobeginning installation!

Safety First. Safety warnings are clearly marked with a Warning! symbol. Observe all guidelines andwarnings given in the instructions during installation and then review and post Maintenance and Warnings atback of booklet near the door for future reference.

Copyright 2002 C.H.I. Overhead Doors 12/02

Warning! Strong winds or gusts can cause a partially installed door to fall.

Warning! Wear protective gloves and eye wear when working on your door.

Before You Begin...

Before You Begin...Opening PreparationInstalling Your New Door Sections and Hardware Struts Track SpringsLow Headroom DetailsSupplemental Instructions Adjustable End Bearings Incline Track Spring Bumper Bottom Fixtures Double Lock BarMaintenanceWarranty

Table of Contents

this pagepage 3

page 6page 8page 11page 17page 25

page 30page 31page 32page 33page 34page 37page 38

trackmounting

Sample Hardware Carton Label

Opening Preparation

door width + 8" (2" track)door width + 10" (3" track)

bracket mount


Check opening size and door size.Door size and type are marked on the hardware carton label and spring tag. Check this information andcompare it with the actual opening size. Also check side room, headroom and back depth dimensions.

Opening Requirements

Side room Requirements(for low headroom see page 25)

Whenever possible allow more side room for ease of installation.

openingheight

same as door height

openingwidth

opening width

door width

same as door width

reverse angle

angle mount

door width minus 2"

same as door width same as door height

same as door height

door width

opening width1" 1"

door width + 3-1/2" (2" track)door width + 5" (3" track)

Bracket Mounted TrackAngle Mounted Track: Leg Out

(Wood Jambs Shown)

Reverse Angle Track: Leg In(Steel Jambs Shown)

TOR SPG AUXindicates auxiliary shaftsupports. Refer to instructionson pages 5 and 19.

(5) 2" STRUTS

3285505801

16 x 7STEEL

TOR. SPRING

ModelOrder #

Door SizeInsulation TypeSpring Type

12 IN.Track Rad.

Track Type

Strut Amount


Minimum values shown. Whenever possible allow more headroom for ease of installation.Add 2-1/2" to headroom if you are using a door opener.

Headroom and Back depth Requirements for Standard Lift Doors(for low headroom see page 25)

headroom

door height + 22"

door/openingheight

(door height + 30") - high lift

headroom

door/openingheight

22"

door height + 20"

door height + 6"

door/openingheight

Headroom and Back depth Requirementsfor High Lift Doors

drum

hl-164

hl-120

hl-54

n/a

13-1/2"

11-1/2"

11-1/2"

11-1/2"1-3/4"

3-3/4"

2-5/8"

8-32

5-18

6"

all

hl + 10"

hl + 8"

hl + 6"

shaft center

17"

n/a

15"

15"

15"

14-1/2"

16-1/2"

12-1/2"

12-1/2"

12-1/2"

hl + 13"

hl + 16"

hl + 10"

headroom

18"

21"

16"

16"

16"

9-1/2"

9-1/2"

11"

11"

9-1/2"

9-1/2"

shaft center

1-3/4"4-8

1-3/4"

2-5/8"

3-3/4"

3-3/4"

2-5/8"

4-12

spring iddrum

15" radius

12-1/2"12"

12"

14"

12"

14"

12"

12-1/2"

12-1/2"

12-1/2"

12-1/2"

12-1/2"

headroom

12" radius

shaft center

15"

15"

15"

15"

15"

15"

headroom

Headroom and Back depth Requirementsfor Vertical Lift Doors

highlift

add 1" to shaftcenter and headroomfor 3" track.

Floor: Start by checking that thefloor is level and smooth. The doorhas a weather seal on the bottomthat will adjust to minorirregularities.

door/openingheight


After you have checked that the door will fit, prepare the opening.It is very important that the opening is correctly prepared before installing tracks and springs. All mountingsurfaces must be structural components and not covered with drywall, paneling or any other buildingmaterial. The materials listed here are not supplied with the door.

Warning! Attachment of the jamb plates, header plate and torsion spring mounting area to buildingframework must provide adequate support to sustain the weight of the door, track and springassemblies as well as resistance to wind load forces and vibration caused by door operation.

Torsion Spring Mounting Area iswhere the torsion springs will mount.It must be at least 10" wide x 10" high.Where shaft couplings are used,18" wide x 10" high.

Header Plate provides a surface forthe door to seal against. It must belevel and flush with the jamb plates.

Jamb Plates support the door tracks.Make sure that they are plumb andsquare with the header plate.

Recommended Wood Framing Sizes

Wood Framing should be Southern Pineor better structural species,grade2/better, free of cracks, splitsand knots.

opening width10"

Auxiliary Shaft Support MountingArea is used to provide extra shaftsupport on large doors. see labelon page 3.

2 x 10spring mount

aux. shaft support

header plate

jamb plate

2 x 6

2 x 6

2 x 8

1/4 x 10

Recommended Steel Framing Sizes

Reinforce torsion spring mounting areato a structural member with (4) 5/16" x4" wood lags.

aux. shaft support

spring mount

1/4 x 6

Seeheadroomchart

on Page 4for

top ofjambs

Sections and Hardware

STEP 4

STEP 3

The door is raised and lowered by lift cables.Attach cables to bottom fixtures (one mounted oneach side of the bottom section). Additionalbottom fixture details located on page 33.

The Door is held in the track with rollers. Insertrollers into bottom fixtures and end hinges.

Attach hardware to bottom section.The bottom section has weather seal attached to it. Set it on saw horses face down (the face is the outsideof the door). Apply hardware as shown below. Refer to tag on the hardware carton to see if this door willhave struts. If so, review pages 8 and 9.

Warning! Fasteners used to attachbottom fixtures must be painted red.

Install inside step plate on an intermediate stileusing 1/4" sheet metal screws.

Sections are attached to each other with hinges.Fasten hinges marked #1 to top of bottom sectionat each stile using (2) 1/4" sheet metal screwsper hinge. Make sure that the two slots are attop of hinge. This allows for adjustment whenstacking sections. Attach each bottom fixturewith (4) red 1/4" sheet metal screws.

STEP 2

STEP 1

auxiliary roller carrier(if double end stile)

fixed pin bottom fixture

end hinge.#1 for first joint,#2 for second joint...etc.review pages 7 & 12.

the end hinges on 3" track start with the #3hinges on the bottom section (there will not be #1or #2 end hinges). Additional bottom fixturedetails located on page 33.

special note for 3" track

auxiliary end hinge(if double end stile)

bottom fixture


(additional bottomfixture details locatedon page 33)

For low headroom doors see differences in bottom fixture design on page 26.

End Hinge progression.To allow door to 'breakaway' from jambs, the vertical tracks areangled out from the wall. Review page 12 for end hingeplacement. End hinges are designed to match the angle of thetrack. As hinge numbers increase so will the distance from hingetube to roller carrier.


rollercarrier

hingetube

If a strut is required on this section,install it now (see pages 8 and 9).

If the door will be electricallyoperated, the operator must attach to astructural part of the section. Use thecenter stile for this purpose. Whenthere is an odd number of panels acenter stile is factory attached to thetop section.

Selecting a top section.Use a 24" high section when available.

Prepare remaining sections for stacking.Apply #1 center hinges to intermediate stiles.If a strut is required, install it now (see pages8 and 9).

center stile

intermediatestile

top section

intermediatesection

intermediatestile

Sandwich type doors with an oddnumber of panels will not have acenter stile; an operator mounting platemust be used. This mounting plate isnot supplied with the door. Contactyour C.H.I. door supplier.

Struts. (refer to page 9 for model 3214)Struts provide reinforcement of larger commercial doors. Not all doors will have struts. However, the topsection of a trolley operated door must include one. Struts are fastened at the same time as hinges. Warning! Installing a trolley operator without a top section reinforcing strut will void warranty.


Two struts.Install one strut on top section. Installthe second strut on an intermediatesection approximately half way up door.

Three struts.Install one strut on top section. Installthe second strut on an intermediatesection approximately half way up door.Install third strut on hinge line at top ofbottom section.

* Stiles not visible on model 3285. Stile location and strut attachment is the same as shown.

One strut per door: use on top section.Locate edge of strut approximately 1"down from section shoulder. Use 1/4"self drilling screws and strut clips toattach strut to intermediate stiles. Use1/4" self drilling screws to attach strut toend stiles. Top fixtures will be attachedafter horizontal tracks are in place.

intermediatestiles

strutclip

strut

end stile

strut

top section

intermediatesection

1/4" self drilling screw

strapping

truss bridge

turnbuckle

strut

The turnbuckle is used to apply tensionto the strut. Tighten until the straps aretaut. Be careful not to over tighten theturnbuckle or the section will begin tobow and not set in the opening properly.

Trussed struts.Very large doors may need extrasupport. This is done by addingtrussing to the strut. The truss bridgewill fit on top of the strut and attachesto the outermost intermediate stiles.Each set of trussing consists of two trussbridges, one turnbuckle and two lengthsof strapping.

More than three struts.Install one strut on the top and bottomsections. Space remaining struts asevenly as possible.


turnbuckle

truss bridge

strapping

strut

strut

1/4" self drilling screw

end stile

strut

1/4" self drilling screwused to anchor strutto each end of section

3-3/4"

Struts. Model 3214 onlyStruts provide reinforcement of larger commercial doors. Not all doors will have struts. However, the topsection of a trolley operated door must include one. Struts are fastened at the same time as hinges. Warning! Installing a trolley operator without a top section reinforcing strut will void warranty.

backer plate

backer plate3-3/4"

top section

intermediatesection

More than three struts.Install one strut on the top and bottomsections. Space remaining struts asevenly as possible.

The turnbuckle is used to apply tensionto the strut. Tighten until the straps aretaut. Be careful not to over tighten theturnbuckle or the section will begin tobow and not set in the opening properly.

Trussed struts.Very large doors may need extrasupport. This is done by addingtrussing to the strut. The truss bridgewill fit on top of the strut and attachesapproximately 4' from the section end.Each set of trussing consists of two trussbridges, one turnbuckle and two lengthsof strapping.

Three struts.Install one strut on top section. Installthe second strut on an intermediatesection approximately half way up door.Install third strut on hinge line at top ofbottom section.

Two struts.Install one strut on top section. Installthe second strut on an intermediatesection approximately half way up door.

One strut per door: use on top section.Locate edge of strut approximately 1"down from section shoulder. This willinsure contact with the 3-3/4" horizontalbacker plate. Use 1/4" self drillingscrews and strut clips to attach strut.Top fixtures will be attached afterhorizontal tracks are in place.

CENTER SECTION IN OPENING

reference line

STEP 5

STEP 6

STEP 7

Place bottom section in the opening and mark reference lines for tracks.

Measure down from the referenceline 8" (14" for low head room) andmark a level reference lineacross both jambs. This is wherethe lower vertical and upperhorizontal tracks will meet.

After section is leveled, measureup from bottom rail (do notmeasure from the vinyl weatherseal) same distance as door heightand mark a line on the jamb.

Center and level bottom section inopening. If there is a gap on oneend at the floor then the trackwill not rest on the floor by thesame amount. Check this whenvertical tracks are in place.

DOORHEIGHT

8"

LEVEL SECTION

reference line


If you have stop molding or clip-on seal, attach it to the jambs or track as shown.

steel jamb

clip-on seal

vinyl stop molding(nail on 6" centers)

1/8" - 1/4"


Always place heads of bolts to inside of the track. This willprevent rollers from striking bolts.

The flag angle mounts to the top of the track with (2)1/4" x 5/8" track bolts and nuts. This bracket joins thevertical and horizontal tracks as well as the angleattached to the horizontal track. Leave bolts loose atthis time. You will adjust the track after it isinstalled to the jambs.

The top of the vertical track must pitch back from thejamb for the door to seal properly. This spacing is setby use of graduated track brackets. Attach but do notfully tighten brackets to track with 1/4" x 5/8" trackbolts and nuts.

Prepare the field bolted vertical tracks.

STEP 2

STEP 1

nut

5.5

6

Track Installation

Install vertical tracks.Bring cables up behind roller shafts. This will save you from having to thread them after the track isinstalled. Wood jambs shown. Use 1/4" jamb teks for steel jambs.

Install right hand tracksame way as left hand track.

Continue to fasten trackassembly to jamb withwood lags.

Now loosen top of track andplumb it with the bottom.Check to make sure that thespacing at the bottom didnot change. Attach flagangle to the jamb with(3) 5/16" x 1-5/8" wood lags.

STEP 6

STEP 5

Position top of vertical trackeven with the reference linethat you marked on the jambs.Temporarily fasten track tojamb to keep it at correctheight. You will need to beable to plumb the track oncethe spacing at the bottom isset.

Space bottom of track leaving1/2" to 3/4" opening betweentrack and bottom section.Fasten bottom track bracketto jamb with 5/16" x 1-5/8"wood lag (always drill 3/16"pilot holes for wood lags).

STEP 3

Slip left hand vertical trackover rollers with a twistingmotion.

STEP 2

STEP 1 STEP 4

lag

reference line(step 7 page 10)

two trackbracketsshown. Yourdoor may havemore dependingon door height.

Stack the sections in the opening.

Stack an intermediate section on top ofthe bottom (#1) section. This is shown asthe #2 section.

STEP 1

Bring up lift cables so they are betweenedge of door and track.

STEP 2

Slip roller stem into #2 end hinge usinghinge tube that will be farthest from door(see detail below). Insert roller intotrack. Attach end hinge (make sure thetwo slots are at the top of the hinge) totop of #2 section with 1/4" sheet metalscrews. Repeat at other end of section.

STEP 3

With #2 section held in place by rollersand end hinges, flip up hinges from bottomsection and attach them to the #2 sectionwith 1/4" sheet metal screws.

STEP 4

For each section added you will usedifferent end hinges. The #3 section willuse #3 end hinges, the #4 section will use#4 hinges and so on.

STEP 5

STEP 6

Continue to stack sections in openinguntil you come to the top section.Secure top section in opening with lockingpliers clamped to the track. Flip uphinges from section below and attachthem to the top section.

*Special Note for 3" TrackThe end hinges on 3" track start with #3end hinges on the bottom section (therewill not be #1 or #2 end hinges). The #2section will have #4 end hinges, the #3section will have #5 end hinges and so on.


bottomsection

locking pliers

#1 endhinge

#1 center hinge

#2 endhinge

#3 endhinge

#2section

#3section

topsection

track(shown with

track brackets)

STEP 3

hinge tube

roller stem

Identify the type of upper track to be used.The first step is to look at what type of upper track attaches to your vertical tracks. Review the illustrationson page 4 to see what installation instructions you need to follow.


Standard lift track installation.Standard lift doors will have a pair of horizontal curve tracks that will mount to the vertical track assembly.

Fasten angle (attached tohorizontal curve track) toflag angle with 3/8" x 3/4"carriage bolt and nut.Always place heads of boltson same side as the doorsections. This will preventdoor from striking bolts.

Use rope as a temporarysupport for the back of thehorizontal curve track. Alignrope with vertical track.Attach it to a structuraloverhead member.

STEP 1

Fasten horizontal curvetrack to flag angle with (2)1/4" x 5/8" track bolts andnuts. Always place heads ofbolts to inside of the track.This will prevent rollersfrom striking bolts.

STEP 2 STEP 3

1/4" nut

verticaltrack

flag angle

3/8" nut

horizontalcurve track

rope

STEP 1

to structuraloverhead member

STEP 3

STEP 2

Warning! Rope, structural overheadmember, attachment and loop, must becapable of safely supporting four timesthe door weight.

High Lift: page 14Vertical Lift: page 15

Standard Lift: shown below

Low Headroom: page 26


High lift track installation.High lift doors with 24" or more of lift have an additional straight piece of track (see detail below). Highlift doors with less than 24" of lift have an extended vertical track and will install the same as standard lifttrack. Review page 13.

STEP 1

Fasten bottom of adder to flagbracket or mounting angle with (1) 1/4"x 5/8" track bolt and nut. Place bolthead on same side as door. This willprevent rollers from striking againstthe bolt. Attach adder to wall with5/16" x 1-5/8" wood lags or metalscrews (always drill 3/16" pilot holesfor wood lags).

Use rope as a temporary support forback of horizontal curve track. Alignrope with vertical track. Attach itto a structural overhead member.

STEP 2

Fasten horizontal curve track with(2) 1/4" x 5/8" track bolts and nuts.Always place heads of bolts to insideof track. This will prevent rollersfrom striking bolts.

STEP 3

Fasten angle (attached to horizontalcurve track) to wall angle with 3/8"x 3/4" carriage bolt and nut.Always place heads of bolts on sameside as door sections. This willprevent door from striking bolts.

STEP 4

ropetostructuraloverheadmember.

STEP 2

vertical track(shown withmounting angle)

two 1/4" nuts

1/4" nut

3/8" nut

STEP 1

STEP 3

STEP 4

horizontalcurve track

Warning! Rope, structuraloverhead member, attachmentand loop, must be capable ofsafely supporting four timesthe door weight.

7" less thanamount

of high lift


Vertical lift track installation.Vertical lift doors do not have a horizontal track.The upper track is straight, similar to the verticaltrack, and is mounted to a wall angle. A horizontalangle connects the track to the top of the wall angle.

STEP 1

Fasten upper track to flag bracketor mounting angle with (2) 1/4" x 5/8"track bolts and nuts. Always placeheads of bolts on same side as door.This will help prevent rollers fromstriking against the bolts.

Plumb upper tracks with verticaltracks and attach to wall with 5/16"x 1-5/8" wood lags or metal screws(always drill 3/16" pilot holes forwood lags).

STEP 2

1/4" nuts

vertical track(shown with

mounting angle)

uppertrack


1/4"sheet metalscrew

Loosen adjustment bolt in top fixture.Slip roller stem into roller carrier.Insert a roller into the track. Positiontop fixture about 1" from section top.Holes in fixture will line up with holes inend stiles. Attach top fixture with1/4" sheet metal screws. Adjust topfixture roller carrier so door sealsfirmly against stop molding.

Attach top fixtures and rollers.(for low headroom doors see page 27)

Finish applying door hardware by attaching top fixtures and rollers to the top section.Review pages 8 and 9 if your door includes a top strut.

rope

to structuraloverhead member.

roller

topfixture

vertical track(shown with mounting angle)

Warning! If this door is to be electrically operated, do not install the pull rope. The use of a pull ropeon a non-manually operated door can cause serious injury.

For manually operated doors attach an eye screw to the jamb at about 50" from the floor. Tie one end of pullrope to roller stem on bottom fixture between the two tabs that hold the roller. Tie other end of the rope toeye screw.

Inspect the work which you have done for missing parts or loose fasteners.Before moving on, check that all of the fasteners used in the track system are in place and tight. Also checkthat applied hardware is in place and securely fastened.

Attach the pull rope.

Warning! Rope, structuraloverhead member, attachmentand loop, must be capable ofsafely supporting four timesthe door weight.

auxiliary top fixture(if double end stile)


End Bearing Plates: End bearing plates support the spring shaft and allow it to rotate freely while door ismoving.

Spring systems will vary according to the door model, size and options. While you are assembling the springline, take time to study the parts and identify them.

Torsion Springs: Torsion springs supply the force to raise the weight of the door. Torsion springs are undertension and rotate about a shaft as they operate. Initial tension is loaded into springs using spring winding bars(not supplied). Torsion springs come in different coil diameters, wire sizes and lengths. Each torsion springhas a retainer and a winding plug mounted on the ends. The retainer holds one end of the spring stationary andis mounted to a spring bracket. The winding plug at the other end of the spring is fastened to the shaft with setscrews and transfers spring force to the spring shaft. See illustration on page 19.

Check all spring assembly instructions and parts.Warning! If there appears to be any parts missing stop here and contact your C.H.I. door supplier

immediately. Do not substitute parts.

Spring Bracket: Holds spring system to wall.

Secure door using the lock. If your door is notequipped with a lock, attach locking pliers toeach vertical track just above rollers at thesecond hinge line (from bottom of door).

Secure door in fully closed position. Warning! Securing door in the fully closed position will prevent any unexpected door movementwhile you are working on the spring system. Failure to do so could result in serious injury or death.

Cable Drums: Cable drums transfer spring force to the door by use of lift cables. Cable drums will differ indesign according to the upper track system and door weight.

Spring Shaft: The spring shaft transfers force from the springs to the cable drums. The shaft may come in oneor two pieces. The one piece will span the entire door width while the two piece will be coupled together at thecenter.

Torsion Spring Assembly Details

#2 section

end hinge

lockingpliers

vertical track(shown with mounting angle)

#3 section

Warning! Do not remove any factory applied spring tag or warning label! If any tags or labels aremissing or unreadable, contact your C.H.I. door supplier immediately.


3/8" x 3/4"carriage bolts

Attach end bearing plates tohorizontal angle using (2) 3/8" x 3/4"carriage bolts and nuts. Alwaysplace heads of bolts on same side asdoor sections. This will preventrollers from striking the bolts.

wall angle

end bearing plate

horizontal angle

"A"

"A"

Snap a chalk reference line acrossthe top of the end bearing platesonto the spring mounting area.

Attach spring supports to the spring mounting area.

STEP 1

Use the illustrations on pages 5, 19and 20 to help you determine wherethe spring brackets will be placed.Mark these locations on thereference line (allow 10" betweenbrackets when shaft couplings areused). Measure from the top of oneend bearing plate to the center ofthe bearing ("a"). Mark this samedistance "a" down from the referenceline where the spring brackets willbe located. This will indicate thecenter of the spring shaft.

STEP 2

Fasten each spring bracket (see pages19 and 20) to the spring mounting areausing (2) red 5/16" x 1-5/8" wood lagsor metal screws. If auxiliary shaftsupports were provided, locate them 10"in from each jamb. Position andattach in the same manner as thespring brackets.

STEP 3

right hand wound(red winding plug)

Springs are single or in pairs based on door design and track system. It is important to determine the 'wind'of a spring before installation. A 'right hand wound spring' will have a red winding plug. A 'left hand woundspring' will have a black winding plug. Cable drums are also color coded. The red drum will be on the leftside of the spring assembly and the black drum on the right side. Match color of winding plug on springwith drum.

left hand wound(black winding plug)

Spring wire is woundclockwise

Spring wire is woundcounterclockwise

Identify torsion springs. (for low headroom doors note differences in spring placement as shown on page 28)

refere

nce lin

e

springmounting

area

end bearingplate

(Install end bearing plates.(for low headroom doors note different end bearingplates as shown on page 27)

(supplemental end bearing instructions are on page 30)


Pre-assemble spring line and mount it to spring support.(for low headroom doors note differences in spring system layout as shown on pages 28 and 29)

Review spring assembly diagram andassemble all components on springshaft. If the springline has acoupling see page 20.

cable drum (red)set screwsfacing spring winding plug

(red)

For illustrative purposes, two springs are shown. Your door may have a single spring. If so, follow thedetails for that color of spring.

approximately 10" from jamb

Auxiliary Shaft Support Detail.(See hardware carton to determine if your doorhas Auxiliary Shaft Supports. A sample hardwarecarton tag is located on page 3.)

spring support

3/8" x 3/4"carriage boltwith hex nut

flange bearing


Review spring assembly diagram andassemble all components on springshaft. you may want to install oneshaft at a time and then connectthe coupling halves together.

cable drum (red)set screwsfacing spring winding plug

(red)

approximately 10" from jamb

Auxiliary Shaft Support Detail.(See hardware carton to determine if your doorhas Auxiliary Shaft Supports. A sample hardwarecarton tag is located on page 3.)

3/8" x 3/4"carriage boltwith hex nut

spring support

flange bearing

Pre-assemble spring line with shaft coupling.(for low headroom doors note differences in spring system layout as shown on pages 28 and 29)


Position right hand cabledrum (black) against endbearing plate. Insert cableinto slot on drum edge.Firmly seat cable lug indrum. Rotate drum to windup cable until it is taught.Tighten set screws snug. Donot exceed 30 foot pounds oftorque.

STEP 3

Both drums should now be positionedthe same. If not, check that torsionshaft is level with door sections.

Secure spring shaft and fasten cables to drums.(for low headroom doors note differences in spring system layout as shown on pages 28 and 29)

Position left hand cabledrum (red) against endbearing plate. Insert cableinto slot on drum edge.Firmly seat the cable lug inthe drum. Rotate drum towind up cable until it istaught. Tighten set screwssnug. Do not exceed 30 footpounds of torque.

STEP 1

Restrain spring shaft withlocking pliers to keep shaftfrom turning. Use wall tohold locking pliers in place.Movement of shaft maycause slack in cable.

STEP 2


Using two winding bars, insert one fully into winding plug and wind spring by pushing in an upwarddirection. Wind spring one quarter of a turn until second winding bar can be properly inserted. Now,insert second winding bar and push up while cautiously removing first winding bar. Repeat this procedureuntil the correct number of turns have been wound into spring. Stretch the spring the distance of twowire coils. Tighten set screws snug. Do not exceed 30 foot pounds of torque. Remove winding bars.

STEP 2

STEP 3

Carefully remove the lockingpliers from the shaft.

Warning! Use solid steel winding bars 1/2" in diameter and at least 18" long (not supplied). Be surethat the bar is inserted fully into the winding plug. Use of improper or undersized bars may result incomponent failure and cause serious personal injury or death. Never use screwdrivers or tubing.

Warning! From this point onward, the spring is under tension and extremely dangerous.

Warning! Keep your head and body out of line with the winding bars. Always maintain a securefooting and balance. Firmly grasp the winding bars and be braced to resist strong forces wheneverwinding springs.

Mark a chalk line along length of spring to count number of turns while winding. The approximatenumber of turns to wind each spring is on tag attached to spring assembly. Leave tag attached tospring assembly for future reference.

STEP 1

Wind torsion springs.(for low headroom doors see differences in spring winding as shown on pages 28 and 29)

Warning! Never exceed number of turns shown on spring tag by more than one-half turn.

Warning! When winding torsion springs, spring diameter will decrease and spring length willincrease. If this is not observed, stop immediately and check for proper spring placement.

Warning! Never place your fingers in or near section joints while the door is moving.

Warning! Spring adjustments from this point onward must be performed in accordance with allwarnings and directions as previously stated.

Warning! All spring component parts whether part of spring line, attached to door, or attached towall are now under tension and are extremely dangerous.

Warning! Do not raise the door to the fully opened position. The track backhangs and swaybracingmust first be set in place.

Remove track restraints and test the balance of the door on the floor.With door still secured, clamp an additional set of locking pliers to each track just below the rollers at thethird hingeline (from the bottom of the door). This will allow for testing of the door counterbalancewithout permitting the door to travel freely. Carefully remove the first set of constraints and slowly raisethe door.

If door does not lift off of the floor by itself, or does not roll back to the floor when not supported, it isproperly counterbalanced.If door lifts off of the floor by itself, the springs are too strong and less spring tension may be required (lessturns on the spring).If the door rolls back to the floor, the springs are too weak and more spring tension may be required (moreturns on the spring).

After determining the door is adequately balanced to avoid unexpected movement, remove all restraintsfrom the vertical tracks.


Install track hangs. Standard Lift and High Lift Doors.Standard Lift and High Lift track hang assemblies are the same. The high lift door assembly is shown.Materials and fasteners for track hangs and swaybraces are not provided with the door.

Attach rear of horizontal tracks tobackhangs and swaybraces with 5/16"bolts and nuts. Do not use bolts as astop for the door, this will damage thetop section. Anchor all bracing tostructural ceiling members using 5/16" x1-5/8" wood lags or metal screws. Doorsover 12' high will require additionalbackhangs at center of horizontaltracks.

STEP 2

Slowly raise door half-way and checkthat spacing between door edges andupper tracks is approximately 1/2"-3/4"per side (avoid crowding the track withtoo small of a spacing). Horizontaltracks should be pitched slightly upwardinto building (about 1/8" of rise per 12"of run).

STEP 1

Minimum angle size is1-1/4" x 1-1/4" x 13 ga.

High lift doorsuse springbumpers shownon page 32.

More than one-half turn added or released from a spring may indicate that the installed door weight isdifferent from the calculated spring weight. Check if all the options and hardware were installed. Consultyour C.H.I. door supplier if door remains inoperable.

Warning! Never add more than one-half turn of tension to any spring.

Warning! Failure to securely support and brace the upper track assembly can cause the door to fallfrom the overhead position and result in serious personal injury or death.

Upper tracks must be plumb and in-line withvertical tracks. Attach sway bracing to top ofupper tracks with 5/16" bolts and nuts. Do notuse bolts as a stop for the door, this willdamage the top section. Anchor all bracing tostructural members with 5/16" x 1-5/8" wood lagsor metal screws.


Operate the door through one full cycle. Check door stops and top fixtures for proper seal.

If door is not functioning correctly check for binding against the jamb, header or tracks. If no obstructionsare observed, attempt to correct the situation by adjusting the spring tension.

Complete installation of stop molding on jambs and header where applicable.

Install track hangs. Vertical Lift Doors

Finalize the track and spring adjustments.

2" track

track type


Installation of low headroom doors is basically the same as standard lift doors. Certain differences dohowever require additional details. All low headroom doors will have a pair of double horizontal curve tracks(see detail below). The upper track is used for the low headroom-top fixture rollers. All other rollers travelin the lower track. This allows the top section to 'turn over' quickly and requires less headroom.

Sideroom Requirementsfor Low Headroom Doors

door width + 6"

at bottom of door

door width + 12"

at torsion shaft

Low Headroom Details

3" track door width + 9-1/2" door width + 14"

torsion springsfront mount

torsion springsrear mount

"B"

door height+ 22"

door height+ 22"

door height+ 28"

door height+ 28"

See page 29 for rear torsion spring mounting area.

2" track

Headroom and Back depth Requirementsfor Low Headroom Doors

over12' springs

rear 6"

springsfront

springmount

springsrear

springsfront

up to12'

9"

11"

6"

"a"dimension

door height+ 22"

door height+ 28"

8"

door height+ 22"

door height+ 28"

"b"dimension

"A"

"a"dimension

"b"dimension

11"

14"

8"

3" track


Bottom fixture attachment for low headroom doors.

Low headroom horizontal curve track installation.Low Headroom doors have double-horizontal tracks that mount to the vertical track assembly andflag bracket.

Warning! Fasteners used to attachbottom fixtures must be painted red.

STEP 2

STEP 3

Fasten horizontal curve track toflag bracket with (2) 1/4" x 5/8"track bolts and nuts. Always placeheads of bolts to inside of track.This will prevent rollers fromstriking bolts.

Fasten pulley plate to flag bracketwith a 3/8" x 3/4" carriage bolt andnut.

STEP 1

Temporarily secure back ofhorizontal curve tracks. See page13 for instructions and warnings.

3/8" x 3/4"carriage bolt

red 1/4" sheet metal screw

bottom fixture

roller

Top fixture attachment for low headroom doors.

End bearing plates for front mounted springs.


End bearing plates for rear mounted springs are factory attached to end of curve track.

Low Headroom Torsion Spring Assembly Details

3/8" nut

Attach low headroom end bearingplate to track with (2) 3/8" x 3/4"carriage bolts and nuts. Flange ofbearing must face outside of track.Where headroom permits, mountbearing plate using lower set ofslots. This will raise the springline as high as possible

end bearing flange

top fixture

1/4" x 3/4"sheet metal screw

Insert a roller into the track.Slip roller stem into top fixture.Attach top fixture with 1/4" x 3/4"sheet metal screws.

torsion shaft mustbe level with door

Front mounted low headroom torsion springs.


Low headroom spring installations do not follow the standard rules for spring placement and winding. Themain differences are:

1) Cable drums are on the outside of the track.2) The right hand wound spring (painted red) will face the right hand drum (painted black) and the left handwound spring (painted black) will face the left hand drum (painted red).3) Springs are wound down instead of up.4) Lift cables spool off the back of cable drums.

liftcable

set screwslift

cable

lift cable

cable drum

cable drum(red)

Low headroom torsion springs assemblies.

two 3/8" x 1-1/2"hex bolts and nuts

winding plug(black)

Warning! Attachment of the torsion spring mounting area to building framework must provideadequate support to sustain the weight of the spring assembly as well as resistance to vibration caused bydoor operation.


Warning! Attachment of the torsion spring mounting area to building framework must provideadequate support to sustain the weight of the spring assembly as well as resistance to vibration caused bydoor operation.

Torsion Spring Mounting Area minimumsize is 10" x 10". Secure to astructural member with (4) 5/16" x 4"wood lags for wood jambs. Steeljambs should be a minimum of 1/4" thickstructural material

door height + 24"

lift cable

pulley

cable drum

torsion springmounting area

Rear mounted low headroom torsion springs.

liftcable

liftcable


(left side shown right side opposite)

Wood Jamb Assembly

flange bearing

hex nut carriagebolt

endbearing plate

endbearing plate

hex nut

flange bearing

carriagebolt


Steel Jamb Assembly

Adjustable End Bearing Assembly

Supplemental Instructions


Shown below is a typical standard-lift incline-track layout. A field-installed splice angleconnects the horizontal track to the wall angle / flag angle. This allows job siteadjustment of the track pitch. Incline track installations will require additional time andmaterial.

Incline horizontal track

Headroomsee chart A Spring Center

see chart A

Standard vertical track

Spring line and splice angle arefield located to allow job siteadjustment of the track pitch.

Flange Bearing omitted for clarity.

2" Track over 6:12 pitch

Spring CenterDrum Type

4-8 / 4-12

5-18w/ 6" springs

Chart A

10-1/2"

5-18

14"

12"

17"

15"

13"

2" Track up to 6:12 pitch

Spring Center Headroom Headroom

3" Track

18-1/2"

14-1/2"

15"

12"

13" 16" 14"

13"

16"

Headroom Spring Center

19-1/2"

15-1/2"

17"

8-32 17-1/2" 22"N/A N/A N/A N/A


Incline Track Installation Details


3/8" x 1" BOLTAND HEX NUT TYP.

DRILL TWO7/16" HOLES

rear of horizontal curve track


Spring Bumper Assembly



(right side shown right side opposite)

Loose PinBottom Fixture

(right side shown left side opposite)

3" TrackBottom Fixture

Clevis, Cotter Pin and Cableattach same as the Loose pinbottom fixture shown above.

Additional Bottom Fixture Details



1-3/4" screws(packaged withCylinder Lock)

1-3/4" Screws

Lift Handle

Cylinder Lock

Locate the stile that the lock will beinstalled in.

Using the Lift Handle holes on the stiledrill one 1/2" hole and two 1/4" holesthru the outside face of the section.

Flip the section over and drill 5/16"holes thru the 1/4" holes approximately1" deep. Also drill the 1-1/4" holedimensioned below.

Install the cylinder lock and lift Handleas shown.

3/4" 2 PL

1-1/4" Dia.

5/16" Dia. 2 PL

1/2" Dia.

2-1/8"

Lift Handle Hole


Double Lock Bar Assembly page 1 of 2


Slide Lock

Lock Bar Guide

Attach slide lock to stile usingtwo 1/4" Tec screws.

Connect lock bar rods to theslide lock with supplied boltsand nuts.

Position the lock bar guide oneach end stile to place the lockbar rod in-line with the verticaltrack slot.

Attach lock bar guides with two1/4" Tec screws.

Lock Bar Rod

Double Lock Bar Assembly


page 2 of 2


Notes

Repainting the Door: Wash surface thoroughly with a solution of trisodium phosphate (commonly calledTSP). Buff surface lightly with an extra-fine-grade steel wool. Repair any rust or bare metal areas and coatwith a zinc-based primer. Paint with premium-quality oil-base or latex exterior paint. Avoid use of solvents(mineral spirits can be used). Apply paint to small area of door to test for adhesion. If new paint does notchip, crack or bubble, apply to remainder of door. If in doubt about the correct paint system to use, contact apainting professional.

Warning! Do not remove red bolts attaching bottom bracket or spring supports while springs areunder tension.

Warning! Fasteners used to attach bottom brackets and spring supports must be painted red.

Warning! Never place your fingers in or near section joints while the door is moving.

Thank You for choosing C.H.I.

Warning! If door is now or later becomes electrically operated, pull rope and lock must be removed.

Warning! No person should ever stand directly in path of door in its downward travel or walkthrough doorway while door is moving.

Warning! All spring component parts whether part of spring line, attached to door, or attached towall are under tension and extremely dangerous. Remove all spring tension prior to any repair oradjustment.

Warning! Adjustments or repairs to door should be performed only by mechanically experiencedindividuals who have the proper tools, instructions and a thorough understanding of the entire doorassembly and its operation.


Check moving parts for signs of wear.

Check for loose or missing fasteners.

Check that all safety warning labels and tags are in place.

Check for proper seal against jambs, header and floor.

Check balance of door (if electrically operated, disconnect operator first).

Check door and track supports for proper spacing and alignment.

Lubricate all moving parts and coat torsion springs with regular grade machine oil.

POST INSTRUCTION SHEETS NEAR EDGE OF DOOR.

This door is constructed utilizing high quality materials and workmanship. To insure proper operation, thefollowing maintenance should be performed twice a year.

Periodic Cleaning: Use a mild detergent to wash your door; do not use abrasive cleansers. Check forscratches that can be reasonably repaired. If bare metal is exposed, treat with zinc-based primer. Avoidexcessive touch-up; post-applied painting will not match original factory finish.

Door Maintenance


Commercial applications are covered for ten (10) years from the date of manufacture.

Door Size: ______ x _______

To insure proper identification of this door please complete the information below.

C.H.I. SHALL NOT BE RESPONSIBLE FOR ANY INCIDENTAL OR CONSEQUENTIALDAMAGES ARISING OUT OF ANY BREACH OF THIS EXPRESS LIMITED WARRANTY,including but not limited to any damage to buildings, other property, or for injuries or damages sustainedby any persons whomsoever, or the recovery of any direct or indirect costs such as shipping, installationlabor charges, paint or painting, or other building materials.

This Limited Warranty applies only to C.H.I. doors and excludes (1) rust caused by damages or scratches;(2) damages resulting from exposure to corrosive chemicals, corrosive fumes, condensation, or fire; (3)damage caused by accident, improper use, negligent operation, improper installation or impropermaintenance (4) labor to replace parts; (5) performance of coatings used to finish the door (6) damagesresulting from causes beyond the manufacturer's control.

After notification, C.H.I. shall then be permitted to inspect the doors within a reasonable time, and uponverification of a defect will repair or replace, at its option, the defective part(s).

In the event the doors are defective, a claim in writing must be submitted to C.H.I. Overhead Doors,P.O. Box 260, Arthur, IL 61911. Such notice must be made within fifteen (15) days of the discovery ofthe suspected defect.

The wood grain film on the Iron Wood series is warranted against delamination and appreciable fadingfor ten (10) years.

Residential applications are covered for as long as the original purchaser/homeowner owns the buildingthe doors were installed in.

C.H.I. hereby warrants their steel garage door sections against splitting, cracking and rusting through.

Residential 26 gauge pan doors are warranted for three (3) years.

Commercial door applications are warranted for one (1) year.

This warranty is non-transferable and supersedes all warranties prior to December 2, 2002.

C.H.I. warrants springs for one (1) year in all commercial applications.

Residential 24 gauge pan and sandwich doors are warranted for six (6) years.

Door Model: _______________

C.H.I. warrants all other components except springs as follows:

Installation Date: _______________

_________________________________________

_________________________________________

Installed By:

C.H.I. LIMITED WARRANTYResidential (lifetime) · Commercial (10 year)

C.H.I. warrants springs in residential applications as follows:

Three (3) years for residential applications up to (8) eight feet high.One (1) year for residential applications over (8) eight feet high.

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