Wood-Core Series Retractable Screen Storm Door INSTALLATION INSTRUCTIONS Before You Get Started......................................................Page 1 Installation Instructions ....................................................Pages 2­7 Closure Installation Instructions .......................................Pages 6­7 Troubleshooting ................................................................Page 8 Warranties.........................................................................Page 5 General Care and Maintenance.........................................Page 9 Visit our web site at www.larsondoors.com Congratulations! You've purchased a quality-built wood core storm/screen door from Larson. Please take a moment to fill out and mail in your product warranty card for years of trouble-free service. See page 5 for warranty details. NOTE: Modification of door will void warranty. Retain instruction booklet and sales receipt for future reference. If you have any questions regarding the installation of your Larson storm door or need to order replacement parts, do not go back to the store, call our Homeowner's Helpline at 1-888-483-3768. Our staff of storm door experts are on hand to answer any questions you may have. Please have the following information on hand when you call: (1) Warranty Registration number--the number is on a decal located on the hinge z-bar (door must be open to view once installed) (2) Model of door (3) Size of the door (4) Color. FIGURE 1 TOP Z-BAR OR DRIP CAP PINCH PINCH PARTS IDENTIFICATION READ BEFORE BEGINNING INSTALLATION. 1. The door requires caution while installing and during its total operational life. 2. The door is heavy and requires two people to lift and install on your home or business. LATCH SIDE Z-BAR HINGE SIDE Z-BAR PINCH PINCH 3. Pinch points are indicated in the instructions by this symbol. Children should not be allowed to play with the door and should be made aware of the pinch points by the owner. Failure to properly instruct the user of this product could result in the loss of a finger or other injury. 4. Do not operate the storm door without closer(s) installed and adjusted to prevent door slamming. 5. Eye protection must be used during the installation to prevent damage from flying particles. PINCH PINCH PINCH 6. Do not modify or alter the installation and specified use of the door. 7. Read the complete installation instructions before proceeding with installation. NOTE: Larson Manufacturing Company is not responsible for accidents and injury resulting from the use or installation of this product. PINCH PINCH FRONT VIEW PINCH PINCH EXPANDER AND VINYL SWEEP TOOLS NEEDED Hammer Pencil Pliers Saw horses Small wood chisel Hole saw or spade bit - per hardware instructions Larson recommends having another person help you install your storm door. A cordless drill with a screw driver bit is recommended. Assembly may require shimming to fit existing opening (shims not included). 1. Power drill with assorted bits 2. Phillips head screwdriver, regular screwdriver 3. Hacksaw 4. Caulking gun with caulking 5. Tape measure 6.Square and level 7. 8. 9. 10. 11. 12. BEFORE YOU GET STARTED Verify opening size with size shown on the box label. All Larson doors are down sized to fit the opening. Remove hardware box from inside door carton. Remove the expander from the door (will be applied later). See Figure #1 Make sure house door trim is securely nailed to support your new storm door. Check box for any INSTRUCTION REVISIONS (printed on colored paper). Instruction revisions take precedence over printed manual. 202220586 LM 12/03 1 Determine Left or Right Hinge Side FIGURE 2 LEFT HAND HINGE RIGHT HAND HINGE Your Larson storm door is Reversa-HingeTM meaning that the door is designed for either right hand or left hand hinge installation. Looking at your door opening from the outside, determine which side you want the hinge on. (See Figure 2) IMPORTANT NOTICE: If you choose to have the storm door handle on the same side as your prime door hardware, you MUST verify that there will be NO interference between the two handles or hardware. Your storm door handle will be 39-3/4" down from the top of the opening. If the prime door hardware is at this height, it is likely to interfere with the storm door hardware. If this is the case, we recommend you hinge the storm door on the same side as your prime door hardware so the storm door handle is opposite your prime door handle. 2 Install Hinge on Door FIGURE 3 The "hinged Z-bar assembly" (or hinged door frame) is packaged unattached. It can be mounted to either side of the door. Lay the door flat on saw horses (outer front face of door facing up). To verify outside from inside of your door. . .glass and screen inserts are removed and installed from the inside. Place the "hinge Z-bar assembly" on the edge of the door as shown with each hinge leaf turned down (see Figure 3). Check to see that the aluminum Z-bar is orientated as shown in illustrations (Figure 5, for a left-hand hinged door), or (Figure 6, for a righthand hinged door). Move "hinge Z-bar assembly" up or down until the top of the z-bar hangs over the top edge of the door 1/16"­1/8". (See Figure 4) Mark the top hole of the top hinge and drill an 1/8" pilot hole. Install one #8x1" unpainted pan head screw. The top end of the Z-bar MUST overhang the top of the door 1/16" to 1/8". The bottom end will be cut to length later. Align each hinge leaf along the edge of the door, drill 1/8" pilot holes, and complete the attachment of each hinge to the door using the remaining #8x1" unpainted pan head screws. NOTE: Hinged Z-bar must swing after securing hinges to the door. START OUTER FRONT FACE OF DOOR ­ UP TOP OF DOOR HINGE LEAF TURNED DOWN ROTATE INSTALLED POSITION END VIEW FIGURE 4 1/16"-1/8" Rotate per Figure 3. TOP OF DOOR HINGE Z-BAR #8 x 1" PAN HEAD SCREW FIGURE 5 FIGURE 6 1/8" PILOT HOLE NEEDED OU FA TER CE ­F OF RO DO NT OR 1/8" PILOT HOLE NEEDED LEFT EDGE OF DOOR RIGHT EDGE OF DOOR T ON FR OR R­ DO TE F OU CE O FA TOP OF DOOR TOP OF DOOR FIGURE #3 END VIEW 2 202220586 RETRACTABLE WOOD-CORE 3 FIGURE 7 Measure the Opening Height Facing the house from the outside, measure the height of the opening as illustrated in Figure 7. This measurement is taken from the top of the door opening (underside of the trim board) down to the bottom threshold. Take two measurements (A and B) as shown to determine the threshold angle to cut the Z-bar. B 4 Cut Hinge-Side Z-Bar to Length A The top of the z-bar should be at the correct position--1/16" to 1/8" above the door. The bottom of the z-bar must be cut to the correct length (opening height), taking into account the angle of the threshold. See Figure 8. Using the measurements taken in step 3, determine the angle to cut the z-bar. Transfer this measurement to the z-bar, then make a cut 1/16" less than your measurement to allow room for top drip cap. Save the z-bar cut-off scrap for steps 6 and 10. FIGURE 8 TOP OF Z-BAR A B OPENING HEIGHT FIGURE 9 EXPANDER CUT LINE DOUBLE SWEEP 5 Install Expander Sweeps CRIMP (INNER LEG) NOTE: This does NOT apply to models with vinyl expanders. Vinyl expanders have integrated sweeps. Remove the expander from the door if you haven't already. Some models come with a single sweep, others come with a double sweep. To install the sweep, simply thread the sweep into the channel of the expander. With the sweep installed, crimp both ends of the expander channel with a pliers. NOTE: For best results crimp the inner leg of the channel­only, at both ends of the expander (see Figure 9). FOR THE DOUBLE SWEEP ONLY: You must bend the rubber sweep out of the way while crimping. EXPANDER SINGLE SWEEP CRIMP (INNER LEG) RETRACTABLE WOOD-CORE 202220586 3 6 Secure Door to Opening 7 Secure Hinge-Side Z-Bar Place the door in the opening with the hinge- FIGURE 10 side Z-bar tight against the door trim or wood frame. Temporarily install just two of the painted #8 x 1" pan head screws (Figure 10) on the front of the hinge-side Z-bar. Install one #8 x 1" PAN HEAD SCREW screw next to the top hinge and one next to the bottom hinge. Be sure not to over tighten the screws and crush down the Z-bar. Set the cut-off scrap piece of Z-bar from step 4 in place between the door and up against the wood trim on the latch side of the door as shown in Figure 11. From the outside of the house with the door closed, check the distance between the side of your Larson storm door and the scrap Z-bar. If this distance is greater than 1/4", a wood spacer can be placed between the hinge-side or latch-side Z-bar and the wood jamb. (Figure 12) If a wood spacer is needed, remove the door, add the spacer behind the hinge side z-bar and reinstall. Spacer thickness should not exceed 1/4" and longer screws should be used to properly secure the door to the jamb. (A wood spacer can also be used on the latch side Z-bar.) NOTE: Wood spacers and longer screws are not included. With the door properly fit in the opening, open the door to expose the hinges. You will see two (2) pre-punched holes at each hinge plate. Using eight (8) #8x1" flat head screws (Figure 13), attach each hinge plate to the wood jamb. Screw heads must be flush with the hinge surface. Install the remaining #8x1" painted pan head screws (Figure 14) in the outside of the hinge-side Z-bar. FIGURE 13 FIGURE 14 #8 x 1" FLAT ZINC PLATED #8 x 1" PAN HEAD PAINTED 8 Install the Drip Cap The drip cap goes above the door and z-bars. Place the top drip cap into position as shown in Figure 15. Close the door. From outside the door, the gap between the top of the door and the drip cap should be 1/16" to 1/8" as shown in Figure 15. Attach the drip cap with #8x1" painted pan head screws provided. Caulk along the edge of drip cap. FIGURE 15 FIGURE 11 FRONT VIEW CAULK SCRAP Z-BAR 1/16" ­ 1/8" GAP TOP OF DOOR (1/8" is ideal) If greater than 1/4" a spacer may be needed or slide latch z-bar over to reduce gap Z-BAR FIGURE 12 INSTALLED POSITION WOOD SPACER *Wood Spacer NOT included 4 202220586 RETRACTABLE WOOD-CORE 9 Install Latch Side Z-Bar Determine Top: First, determine which end of the Z-bar is top and mark it with a piece of tape. Bottom Cut: Cut the Z-bar to length (use the same procedure used to cut the hinge side Z-bar back in Step 4, page 3). Installation: Set the z-bar in place between the door and the wood jamb. Allow a gap of approximately 1/8" between the door and the latch-side z-bar. Make sure the door closes freely without hitting the z-bar, but also makes good contact with woolpile weather-stripping. Fasten z-bar using #8x1" painted panhead screws through the predrilled holes provided in z-bar. Larson offers three types of z-bars. The style will vary based on the handle set of your model. · Surface-mount Figure 16 · Mortise with deadbolt Figure 17 · Mortise without deadbolt Figure 18 FIGURE 16 SURFACE MOUNT FIGURE 17 MORTISE WITH DEADBOLT FIGURE 18 MORTISE WITHOUT DEADBOLT MORTISE HOLE COVER OPENING HEIGHT OPENING HEIGHT OPENING HEIGHT Install the Mortise Hole Cover on the hinge-side edge of door to cover up hole. CUT LINE CUT LINE CUT LINE CUT BOTTOM OF Z-BAR ONLY. LEFT HINGE APPLICATION SHOWN. CAULKING may be applied, although not always necessary. Apply caulking behind the latch, hinge and top Z-bars, or along the front edge of Z-bar. 10 Install Latch Hardware Refer to separate instructions packaged in the hardwarebox. *CAUTION: Be sure to install storm door hardware at a height that will not interfere with the prime door hardware. 11 Install/Adjust Bottom Expander Install expander at the bottom of the door with the slotted holes to the inside. Adjust the bottom expander so that the vinyl sweeps touch the door threshold. Centrally locate the two #6x3/8" pan head screws (Figure 19) in the slot to allow for future adjustments. FIGURE 19 Drill 3/32" diameter pilot holes for the screws, being careful not to drill all the way through to the front face of the door, then install screws. #6 x 3/8" PAN HEAD STAINLESS RETRACTABLE WOOD-CORE 202220586 5 Wood-Core Series Retractable Screen Storm Door 1 CLOSER INSTRUCTIONS Closer Installation (Some models have two closers and others have one closer.) NOTE: Be sure door opens and closes freely before installing the closer. CLOSER ASSEMBLY PREPARATION 1. Slide hold-open washer onto closer rod as shown. Pull rod out of closer so that there is a approximately 1/4" gap per Figure 1 (insert small screwdriver in rod hole to provide pulling grip). Position washer behind flanges and against the closer. Remove screwdriver. This will give proper tension for installation. (Do not change until installation is complete.) See Figure 1. 2. Attach brackets to closer as shown in Figure 2. Attach front hole in closer to door bracket (long connecting pin). Attach closer rod to side jamb bracket (short connecting pi ...