INSTALLATION INSTRUCTIONSSingle Track Low Headroom Supplemental Instructions

Single Track Low HeadRoom SupplementalInstallation InstructionsThese instructions are to be used in conjunctionwith your standard installation manual. Followthe standard manual up to “Preparing BottomSection”. Use this supplemental instructions forinstalling bottom bracket and then continue usingstandard manual up to “Preparing Top Section”.Use this supplement to install top brackets andthen continue following the standard manual for“Assembling & Installing the Track” – exceptreplace horizontal track with Single Track LowHead Room (STLHR).

Please read and understand these instructionscompletely before proceeding with the instal-lation of the Single Track Low Head Roomsystem. Carefully follow these instructions toavoid personal injury or property damage.

Single Track Low Head Room can be used for allresidential low head room applications.

Tools Needed• Socket wrench kit• 9/16" box wrench• 9/16" diameter deep well socket• Hammer

In the interest of safety this symbol meansWARNING or CAUTION. Personal injuryand/or property damage may occur unlessinstructions are followed carefully.

All References To Left Hand And Right Hand Are Made AssumingThat You Are Inside The Garage Looking Out (ISLO).

Covered by one or more of U.S. Patent Numbers D337,042; 5,240,216; 5,404,927; 6,047,761 and patents pending.

Consumer Hotline1-800-225-6729

2

Parts ListSTD. EXT.

& TORSION, EZ-SETEZ-SET EXT. TORSION

DESCRIPTION QTY. QTY.

TOPBRACKETLOW HEADROOM

TOP ROLLERLINKAGEASSEMBLY

PUSH NUT

SHEAVEBRACKET

3/8" - 16 x 3/4"CARRIAGEBOLT

3" OR 4"SHEAVE

2

2

2

2

0

0

2

2

2

2

6

2

STD. EXT. & TORSION, EZ-SETEZ-SET EXT. TORSION

DESCRIPTION QTY. QTY.

3/8" x 3/4" HEXHEAD BOLT

3/8" x 16FLANGE NUT

3/8" - 16 x 11/2"PAN HEADSHEAVEBOLT

SINGLETRACK LOWHEAD ROOMASSEMBLY(LH/RH)

LOW HEADROOM BTMBRACKET(LH/RH)

0

0

0

2

2

0

4

10

2

2

2

2Note: Depending on spring configuration tobe used, all parts required may not be shownabove. Consult your standard installationmanual for detailed list.

Identify which spring system is to be usedwith Single Track Low Head Room (STLHR)System and refer to table A below to see ifyou meet minimum head room and side roomrequirements.

Available Springing Systems with STLHR – Table A

Minimum Minimum Sheave/ Low Head Room Head Room Side Room Sheave Brkt. Bottom Bracket

Spring System Required Required Required Required

Extension Spring Low Head Room 51/2" 33/4" Yes YesTorsion Spring Low Head Room Front Mount 91/2" 33/4" Yes YesTorsion Spring Low Head Room Rear Mount 51/2" 33/4" Yes YesEZ-Set Torsion Spring Low Head Room 91/2" 33/4" No *NoEZ-Set Extension Spring Low Head Room 51/2" 7" Yes Yes

*EZ-Set Torsion Spring uses standard bottom bracket

Note: Consult your standard manual under “Check Headroom/ Backroom/ Sideroom” for description.

SPACER**

**Use only with extension spring on doors with horizontalangle 82" or longer

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Fig. 1B

Fig. 1A

Attaching Low Head RoomBottom Bracket(s) To DoorStep 1For steel doors, insert low head room bottombracket locking tabs into end stile key slot bypushing inward and then up. The “L” and “R”letters on the bracket designate left hand andright hand brackets. Attach brackets to door using#14 x 5/8" sheet metal screws. (FIG. 1A)

Failure to properly engage locking tabs onbottom bracket into key slots can result insevere injury when spring tension is applied.

For wood doors or steel doors weighting inexcess of 250# use bottom bracket as shown inFigure 1C (call the consumer hotline to verify doorweight). If door is wood, attach bottom bracketusing 1/4" x 17/8" carriage bolt and nut as shownin Figure 1C. If using low head room safety bottombracket, loop end of lift cable around button asshown. For residential bottom bracket, insert loopthru clevis pin. Insert cotter pin into clevis pin holeand bend out to secure into place.

If using EZ-Set Extension Spring System, do notattach loop end of lifting cable to bottom bracketat this time. (FIG. 1A)

Step 2Proceed with stacking sections and attachingvertical track to jamb as detailed in your standardinstallation manual. Do not install STLHRhorizontal system at this time.

Loop End Of Cable

BottomDoor

Section

Low HeadroomSafety BottomBracket (RightHand Shown)

Button

“R” DesignatesRight HandBracket “R” IsAt Bottom OfBracket

End Stile

Key Slots

Locking TabsLHR Safety Bottom Bracket

Fig. 1C

5/16" Washer

Low Head Room Bottom Bracket(Right Hand Shown)

Wood DoorSection

Loop End Of Cable

Low Head RoomBottom Bracket

Cotter Pin

Clevis Pin

Ear

4

Preparing the Top SectionStep 3If top section requires a strut, place section onsawhorses (exterior faced side down) and positionstrut 1" below top edge of door. Fasten using pre-punched holes in stiles and strut. If pre punchedholes not provided, at each end and center stilelocation drill 5/32" diameter pilot hole through strutand stiles. Be careful not to drill completelythrough section. At all center stile locationsonly, attach strut to door section using #14 x 5/8"sheet metal screws. If strut clips are provided,use with sheet metal screws. For wood doors, use1/4" x 1" lag screw instead of sheet metal screwsto fasten strut to door.

Do not attach strut at either end stile locationat this time. Stack top section in opening.Make sure top section is securely in placeand will not fall out of opening. It may benecessary to temporarily secure top sectionto vertical jamb using 3" long nail. Referto standard installation manual. (FIG. 2)

Installing Single Track LowHead Room Horizontal TrackStep 4Before attaching left hand and right hand STLHRhorizontal track, bend short radius piece down-ward until gaps close as shown in Figure 3. PlaceSTLHR on top of vertical track and temporarilysupport the rear end of the track with a rope fromthe trusses overhead or a tall ladder.

Fig 3Attach the curved end of the horizontal track tothe flag bracket using two 1/4" x 5/8" track bolts and1/4" flange nuts. Fasten short radius piece andhorizontal angle to flag bracket by using 3/8" x 3/4"carriage bolts and 3/8" flange nuts as shown inFigure 4. Repeat Step 4 for other side.

Fig. 2

TopSection

STLHRHorizontal

Track

Fig. 3

ShortRadius

Piece

Horizontal Track

Fig. 4

Horizontal Angle

FlagBracket

Short Radius Piece

3/8" x 3/4"CarriageBolt

5

Top Roller Linkage AssemblyStep 5To assemble, place roller on flat surface such asa wood block with roller stem pointed in up-rightposition. Slide linkage onto stem. Make surelinkage is placed in the direction as shown inFigure 5A. Place push nut onto roller stem andforce downward using 9/16" diameter deep wellsocket and hammer. (FIG. 5B) Force push nutdownward as far as it can go. Then using closedend of 9/16" box wrench slide onto roller stem andcontinue forcing downward until it contacts linkageand will not travel any further. (FIG. 5C) Linkage tobe positioned firmly against shoulder of roller asshown in Figure 6. Repeat Step 5 for other side.

Fig. 5C

Push Nut

Roller

Top RollerLinkage Assembly

9/16" DiameterDeep Well

Socket (To HelpInstall Push Nut)

PushNut

RollerStem

9/16" BoxWrench (UseClosed End)

Block

Fig. 6

Fig. 5B

Fig. 5A

6

Installing Top Roller BracketWith Linkage AssemblyStep 6Install linkage assembly into short radius piece bytilting slightly and then rotating upward. Make suretop roller linkage assembly is fully engaged intrack as shown in Figure 7. Slide low head roomtop roller bracket onto roller stem of linkageassembly. Position top bracket at very top of doorsection. If pre-punched holes do not exist on endstile, use both slots in top bracket as template anddrill 5/32" pilot hole. Attach top bracket to end stileusing two #14 x 5/8" sheet metal screws. For wooddoors, use fasteners provided.

If a top strut is installed the top roller bracket will gobetween the strut and section with the roller abovethe strut. If pre-punch holes are not available, usestrut clips as shown in Figure 8A. For doors with-out a strut refer to Figure 8B.

Repeat Step 6 for other side. Make sure placementof left hand and right hand top roller bracket are inline with each other.

After springing system is installed, top bracket canbe adjusted by sliding it slightly up or down inorder to position the top section correctly.

Fig. 7

TopSection

Top RollerBracketWithLinkageAssemblyShownBeforeRotation

ShortRadius

Piece

Fig. 8A

Top RollerLinkageAssembly

Top RollerBracket

ShortRadius

Piece

#14 x 5/8" SheetMetal Screw Strut Clip

Fig. 8B

Top RollerLinkageAssembly

Top RollerBracket

ShortRadius

Piece

#14 x 5/8"Sheet MetalScrew

Strut

ILLUSTRATION WITH STRUT

ILLUSTRATION WITHOUT STRUT

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Sheave Bracket AssemblyStep 7The sheave bracket is designed to work witheither 3" or 4" diameter sheave. Locate sheaveprovided and fasten to sheave bracket withone 3/8" x 11/2" pan head sheave bolt and one3/8" flange nut. Make sure sheave bolt and nut areinstalled in same orientation as shown in Figure 9.Securely fasten bolt and nut. Repeat Step 7 forother side.

Install Sheave Bracket ToSTLHR Horizontal TrackStep 8Taking assembled sheave bracket, place abovecut out in horizontal angle and slide downwardinto position. Make sure sheave is in up positionas shown in Figure 10A. Fasten bracket assemblyto horizontal angle using two 3/8" x 3/4" hex headbolt and 3/8" flange nut. For 3" sheave, make surebolts are placed in holes marked with “3”. If 4"diameter sheave is used, make sure to placebolts in holes marked with “4”. Securely fastenall bolts and nuts. Repeat Step 8 for other side.(FIG. 10B & 10C)

Once spring tension is applied, do not removesheave and/or sheave bracket. Personal injuryand/or property damage may occur if removedunder spring tension.

You Are Now Ready ToAttach The SpringingSystem To Your Door• For Extension Spring Low Head Room go to

section 2A.• For Torsion Spring Low Head Room Front Mount

go to section 2B.• For Torsion Spring Low Head Room Rear Mount

go to section 2C.• For EZ-Set Extension Spring Low Head Room

go to section 2D.• For EZ-Set Torsion Spring Low Head Room go

to section 2E.

Fig. 9

3" Or 4" Diameter Sheave

SheaveBracket

3/8 - 16 x 11/2" Pan Head Sheave Bolt

3/8" Flange Nut

Fig. 10A

3/8" x 3/4" Hex Head Bolt

Cut-OutArea InHorizontalAngle

3/8" Flange Nut

Horizontal Track

HorizontalAngle

Fig. 10B

Bolt Hole(s)Identification Number

NOTE: If Using 3" Diameter Sheave,Must Use Bolt Holes Identified WithNumber 3. For 4" Sheave, Must UseHoles With Number 4.

Fig. 10C

Flag Bracket

1/4" x 5/8" Track BoltWith 1/4" Flange Nut

8

Section 2AExtension SpringLow Head RoomStep 1Complete steps 1 and 3 thru 6 (skip Step 2) in thestandard manual for extension spring installation.If horizontal angle 82" or longer, a spacer is usedto provide clearance between the sheave fork andhorizontal angle. The spacer is attached to thesheave fork as shown in FIG 11C. Make sure theextension spring is attached to the sheave forkbefore assembling. Repeat same assemblyoperation for other side.

Step 2Tie the cable end to the three hole adjustingclip as shown in Figure 11A. Make sure cable issecurely tied to clip as shown. Hook the cableand clip to the sheave bracket using the “S” hook.(FIG. 11B)

Step 3Follow instruction in standard manual for installingextension spring. If spacer is used, make sure it issitting on top of horizontal angle or riding ingroove as shown in FIG 11D. The groove locationworks best on doors with duel (two) extensionspring set-up per side. For this springingconfiguration, make sure the rear track hangeris extended 1" to 2" below the track to providesufficient space for locating the lower springunder the horizontal angle.

Step 4Complete installing safety containment kitinstallation instruction in the standard manualfor extension spring installation.

Garage door extension springs can causeserious injury and property damage if theybreak under tension and are not secured withsafety cables.

Fig. 11A

Cable

Cable

3 Hole Clip

“S” Hook

Cable FromSheave To

BottomBracket

Fig. 11B

3 Hole Clip

“S” Hook

Cable

Fig. 11C

SheaveHook

Sheave

Spacer

Note: Spacer NotchIn-line with Sheave Fork

Fig. 11D

Horizontal Angle

Spacer On Top OfHorizontal Angle

ExtensionSpring

Note: Lift andSafety CablesNot Shown

SpacerGroove On

Side OfHorizontal

Angle

Hex Head Bolt

Spacer

SheaveSheave

ForkHexNut

Note: Bolt Head Fits Into HexRecess Area Inside Spacer

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Section 2BTorsion Spring Low HeadRoom Front Mount

Torsion springs can be very dangerous if theyare improperly installed or mishandled. Donot attempt to install them yourself unless1) you have the right tools and reasonablemechanical aptitude or experience and2) you follow these instructions very carefully.

Step 1Compete Step 1 in the standard manual fortorsion spring installation.

Step 2Attach end bearing plate as shown in Figure 12.Fasten end bearing plate to horizontal anglefollowing Step 3 in standard manual for torsionspring installation. In place of the 3/8" x 3/4" hexhead bolts, use 3/8" x 3/4" carriage head bolts.Repeat Step 2 for other side.

Step 3For installation of springs, shaft and cable drumsaccording see Step 4 in standard installationinstructions. Refer to Figure 13 for assemblyillustration.

Step 4For each side, loop lift cable from bottom bracketaround sheave and attach to cable drum. (FIG. 13)

Fig. 12

Cable

SheaveBracketWithSheave

Cable

Drum

EndBearing

Plate

Fig. 13

Spring With RedWinding Cone

Black CableDrum

Spring Anchor Pad

Spring With BlackWinding Cone

Red Cable Drum

Center Bearing Plate Attached ToStationary Torsion Spring Cones

With 3/8" x 1" Long Hex Head Bolts(For Single Spring) And 15/8" Long(For Double Springs) And 3/8" Nuts

For Torsion Spring Low Head Room FrontMount, the cable drums are placed outside ofthe end bearing plates with the set screwsfacing out. Also note that the “Red” drum andspring with the “Black” winding cone are onthe left side (ISLO). The “Black” drum andspring with “Red” winding cone are on theright side (ISLO).

Step 5Once both sides are assembled, follow Steps 6,7 and 8 in the standard manual on torsion springinstallation with the exception that the torsionsprings are wound downward as shown inFigure 13.

Springs AreTo Be Wound Down

10

As shown in Figure 14, both bolts attach the endbearing plate to the rear track hanger with thelower bolt also securing the horizontal track.

Step 2Rear mount torsion spring doors will require thatsprings to be placed at rear of track and a centersupport hanger(s) be provided that is strongenough to withstand the torque of the springs.For both sides, loop cable from bottom bracketto sheave to cable drum. End of horizontal tracksmust be securely fastened to the rear trackhanger before springs are wound or door is lifted.

Horizontal tracks should be level and backhung.Install springs and wind all springs in down-ward directions. (FIG. 14)

The “Red” drum and spring with the “Black”winding cone are on the left side (ISLO). The“Black” drum and spring with “Red” windingcone are on the right side (ISLO).

Section 2CTorsion Spring Low HeadRoom Rear Mount

Torsion springs can be very dangerous if theyare improperly installed or mishandled. Do notattempt to install them yourself unless 1) youhave the right tools and reasonable mechani-cal aptitude or experience and 2) you followthese instructions very carefully.

Step 1Attach horizontal track to flag bracket using 1/4" x5/8" track bolts and 1/4" flange nuts. Attach horizon-tal angle to flag bracket using 3/8" x 3/4" carriagebolts and 3/8" flange nut. The end bearing plateattaches to the track and rear track hanger usingtwo 3/8" x 3/4" hex head bolts and 3/8" flange nuts.

Fig. 14

RH HorizontalTrack

Rear TrackHangerBracket(NotSupplied)

VIEW INSIDE LOOKING OUT AT REAR OF TRACK

A Center Hanger Bracket Is RequiredThat Is Strong Enough To Withstand TheTorque Of The Spring(s). (Not Supplied)

BlackCableDrum

Center Bearing PlateAttached To Stationary

Torsion Spring Cones With(2) 3/8"-16 x 11/2" Lg. Hex

Head Bolts And Nuts. PlateAttaches To Center Hanger

WIth (2) 3/8"-16 x 11/2" Lg.Hex Head Bolts And Nuts

End Bearing Plates Attached ToTrack With (2) 3/8"-16 x 3/4" Lg.Hex Head Bolts And Hex Nuts

Torsion Shaft

Spring With Red Winding Cone

Nylon Bearing

Spring With Black WInding Cone

LH HorizontalTrack

Lift Cable

Red Cable DrumSet Screws Away

From Track

To Sheave

ToSheave

11

Section 2DEZ-Set Extension SpringLow Head Room

Do not use EZ-Set Extension Springs on doorsweighing over 280 lbs.

Step 1Refer to EZ-Set Extension Spring standardinstallation manual and follow Step 1.

Step 2Remove the spring system housing from thepackage. Locate the housing bracket with thepre-attached sheave. Detach the sheave from thehousing bracket by unscrewing the 3/8" nut andremoving the bolt. (FIG. 15A) Slide the SpringSystem housing onto the housing bracket asshown in Figure 15B. Repeat for both sides.

Step 3Attach housing bracket to sheave bracket asshown in Figure 16A. Using slots in upper part ofhousing bracket, fasten to sheave bracket usingtwo 3/8" x 3/4" hex head bolts and 3/8" flange nuts.(FIG. 16B)

Step 4Follow steps 4 thru 11 in EZ-Set ExtensionSystem installation instruction to completeassembly.

Fig. 15A

3/8" Hex Head Bolt

HousingBracketPlate

Sheave

HousingBracket

Fig. 15B

Fig. 16A

CableEZ-Set ExtensionBracket And Unit

Sheave Bracket

Fig. 16B

3/8" x 3/4" HexHead BoltsAnd 3/8" Nuts(Not Shown)

EZ-Set ExtensionBracket And Unit

Horizontal AngleSheave Bracket

12

©2002 CBPC P/N 0135070 STLHR SUPP - 10/02

Section 2EEZ-Set Torsion SpringLow Head Room

Use standard lift bottom brackets. Do not uselow head room bottom bracket for EZ-SetTorsion Spring Low Head Room.

Step 1Fasten EZ-Set Torsion Spring Low Head Roombracket to horizontal angle and flag bracket asshown in Figure 17. Follow Step 1 as called outin EZ-Set Torsion System standard installationmanual. Use slots labeled “STD MOUNTING” tofasten to flag bracket and horizontal angle.

Step 2Follow Steps 2 thru 11 in EZ-Set Torsion Systeminstallation instruction to complete assembly.(FIG. 17)

Fig. 17

STLHR HorizontalTrack

EZ-Set Torsion Bracket

Horizontal Angle

Flag Bracket

LEFT SIDE SHOWN