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How to Cut the Hinge to Fit
A. Keep hinge in “door closed” position
(Fig. 1).
B. Determine whether this will be a right-
hand or left-hand installation.
IMPORTANT: Cut only one end of hinge.
Cut end will be installed at the bottom. Keep
original templated six-hole pattern at top
end of hinge.
C. Using a metal-cutting saw, begin the
cut through the gear cap first.
NOTE: DO NOT cut through a set screw
bearing.
D. Loosen set screw from side of door leaf
cover with 5/64" Allen wrench (Fig. 1).
E. Remove door leaf cover by sliding it o
uncut end of hinge.
F. Reinstall any set screw bearing that
may have been cut o.
A. Attach Hinge to Frame
NOTE: Remove door leaf cover if not
already removed. See step D above.
1. Shim hinge to 1/8" below the header to
allow for door clearance.
2. Hold hinge in “door open” position (Fig.
2) making sure frame leaf alignment
flange is tight against frame rabbet.
3. Mark (or centerpunch) two holes at top
and two holes at bottom of frame leaf.
NOTE: TF screws and wood screws require
pilot holes at marked locations. SDTF
screws do not require pilot holes.
4. If using SDTF screws, go to Step 5. If
using TF or wood screws, drill holes at
marked locations.
QMetal frame: Use #13 (.185") bit or
3/16" (.188") bit
QWood frame: Use a 5/32" (.156") bit
5. Fasten frame leaf to door frame using
two screws at the top and two screws
at the bottom.
QMetal frame : Use #12-24 TF flathead
screws provided, or use #12-24
SDTF flathead screws (provided on
request)
QWood frame: Use #12 flathead wood
screws (provided on request)
B. Prepare Door
6. Shim door into opening to provide
required hinge clearances.
IMPORTANT: Top end of the hinge must be
flush with the top of the door.
IMPORTANT: A 13/16" gap between
door edge and a frame without a stop is
necessary for the SL77 safety feature to be
eective.
See illustration on other side.
7. Mark locations for the four SDTF
panhead screws on the door using
7/32" center punch.
8. With #3 Phillips drive, temporarily
attach door leaf to door through the
four locator holes with SDTF panhead
screws provided.
9. Remove shims and check door
clearances, alignment and operation.
NOTE: Door may sag slightly when
shims are removed. Note the amount of
adjustment needed to bring door back into
alignment.
DO NOT PROCEED UNTIL DOOR
OPERATES PROPERLY.
10. Mark locations for barrel nuts on the
door using 3/8" center punch.
11. Remove door and lay it flat. Use
3/8" drill bit to drill holes at marked
locations.
NOTE: Be sure to drill squarely through
door.
C. Attach Door to Hinge
12. Fasten door to door leaf with the barrel
nuts and 1/4-20 shoulder screws.
NOTE: Always install shoulder screws on
the secured side of the door (Fig. 3).
13. Mark (or centerpunch) remaining frame
leaf hole locations. Drill holes in frame
through the frame leaf and secure with
flathead screws.
14. Secure door to door leaf with barrel
nuts and 1/4-20 shoulder screws.
NOTE: Always install shoulder screws on
the secured side of the door (Fig. 3).
D. Install Leaf Cover
15. Align leaf cover with top edge of hinge.
16. Starting from the top and working
downward, apply pressure to leaf cover
to snap it into place (Fig. 3).
NOTE: If you use a hammer to tap cover
into place, be sure to protect the surface of
the cover from damage.
17. Tighten set screws with 5/64" Allen
wrench.
Tools Needed
QMetal-cutting saw
QTape measure
Q#13 or 3/16" drill bit & 3/8" drill bit
Q5/32" drill bit (wood frames only)
Q#3 Phillips drive
Q5/64" Allen wrench
QHammer
QShims
Parts Supplied
Q#12-24 self-drilling, thread-forming
(SDTF) 410 SS Phillips undercut
flathead screws
Q#12-24 self-drilling, thread-forming
(SDTF) 410 SS Phillips undercut
panhead screws
Q1/4-20 barrel nuts (through bolts)
Q1/4-20 shoulder screws
Q7/32" center punch
Q3/8" center punch
QSet screws
Optional Parts
Q#12 410 SS Phillips undercut
flathead wood screws
Q#12-24 thread-forming (TF)
410 SS Phillips undercut flathead
screws
QLong barrel nuts for doors
2"—2-1/4" thick
QProtective gloves are
recommended
Gear Cap
Frame
Leaf
Door
Leaf
Frame
Door
Set
Screw
Fig. 1 Door Closed Position
Gear
Cap
Frame
Leaf
Door
Leaf
Frame
Door
Fig. 2 Door Open 90˚
Gear Cap Door Leaf
Cover
Frame
Door
Set Screw
Shoulder Screw
SECURED SIDE, OUTSWING
Barrel Nut
(not to
scale)
NOTE: For inswing applications, reverse
position of barrel nut and shoulder
screw so that the shoulder screw is
on the secured side of the door.
Fig. 2 Leaf Cover Installation