Roller Replacement
Replacing worn or damaged rollers on sectional overhead doors per DASMA guidelines
Warnings
Never remove the bottom bracket rollers — they are under spring tension and can cause serious injury. Only a trained technician with proper spring tools should service bottom brackets.
Work with the door in the closed position. Use vise grips on the track above the bottom roller as a safety stop.
Do not bend the track to remove rollers unless absolutely necessary. Most rollers can be replaced by tilting the hinge after removing the hinge bolts.
Required PPE
- Safety glasses
- Leather gloves
- Steel-toed boots
Tools Required
- Replacement rollers (match stem length and roller diameter)
- Socket set (7/16", 1/2")
- Pliers
- Pry bar (flat)
- Stepladder
- Lubricant (white lithium grease for steel rollers)
Procedure — 5 Steps
Disconnect the operator and secure the door
Disconnect power to the automatic operator. Pull the emergency release to disengage the trolley. Close the door fully. Clamp vise grips on both vertical tracks just above the bottom roller as a safety stop.
Start with the top section hinges
Begin replacing rollers from the top section and work downward. Remove the bolts from the hinge that holds the roller you are replacing. Tilt the hinge outward to free the roller stem from the track. Pull the old roller out.
⚠ Never remove the bottom bracket rollers (the ones at the very bottom of the door on each side). These are under extreme spring tension.
Install the new roller
Insert the new roller stem into the hinge. Slide the roller back into the track. Re-seat the hinge and tighten the bolts. The roller should spin freely in the track without binding.
Repeat for each roller
Work through each hinge on the door, one at a time. Replace all rollers that show wear, flat spots, or cracking. For nylon rollers, check for chips or cracks. For steel rollers, check for worn bearings or rough spinning.
Lubricate and test
Apply a light coat of lubricant to the roller stems (not nylon roller surfaces). Reconnect the operator and cycle the door 3–4 times. Listen for smooth, quiet operation. Check that the door tracks evenly on both sides.
Training Videos
Disclaimer: These videos are produced by third-party YouTube channels and are not affiliated with Doorbot. Video content may not align exactly with the procedures above, may depict techniques that differ from DASMA or manufacturer recommendations, and may show tasks that are dangerous if performed without proper training and equipment. Always follow the written procedure, your company's safety policies, and applicable industry standards. Use these videos as supplementary reference only.