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Wayne-Dalton 44 User's Manual

1. Top 1 Short Top Of Section op Intermediate IV Bottom Of section Intermediate III i Top Of Section Intermediate Intermediate II Bottom Of section Intermediate Top Of Section Bottom RAET Bottom Bottom Of section 6 Section High Door Top 4 Section High Strutting Schedule Intermediate IV E Type Of Strut EPE i ection Type ocation On Section Intermediate III yp gt Strut 3 Strut intent z 1 Short 1 Short Top Of Section op ntermediate 1 N A N A Bottom Of section Bottom z 1 Long 1 Long op Of Section Top Intermediate II N A N A om Of section ermediate V z A N A 1 Long op Of Section ntermediate IV Intermediate N A N A om Of section ermediate IIl N A N A Top Of Section ermediate Il Bottom 5 1 Short 1 Short om Of section Intermediate Bottom 5 Section High Strutting Schedule 7 Section High Door Type Of Strut Section Type Location On Section Intermediate V 2 Strut 3 Strut Intermediate IV x 1 Short 1 Short Top Of Section op Intermediate III A N A Bottom Of section Intermediate II Long Long Top Of Section Intermediate III Intermediate V A N A om Of section Bottom Long Top Of Section Intermediate II z Top Of section i Section Intermediate VI intermediate Intermediate V Intermediate IV Bottom Intermediate III Intermediate II 6 Section High Strutting Schedule Intermediate ee Type
2. Ss a i Bottom section Wooden shims If necessary Vertical Tracks Tools Power Drill 3 16 Drill bit 7 16 Socket driver Tape measure IMPORTANT IF YOUR DOOR IS TO BE INSTALLED PRIOR TO A FINISHING CONSTRUCTION OF THE BUILDING S FLOOR THE VERTICAL TRACKS AND THE DOOR BOTTOM SECTION ASSEMBLY SHOULD BE INSTALLED SUCH THAT WHEN THE FLOOR IS CONSTRUCTED NO DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION IMPORTANT THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT THE VERTICAL TRACK ON THE SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM Position the left hand vertical track assembly wall angle track assembly over the track rollers of the bottom section Make sure the counterbalance lift cable is located between the track rollers and the door jamb Drill 3 16 pilot holes into the door jamb for the lag screws FOR FLAG ANGLE TRACK ASSEMBLIES Loosely fasten jamb brackets and flag angle to the jamb using 5 16 x 1 5 8 lag screws as shown FOR WALL ANGLE TRACK ASSEMBLY Loosely fasten wall angle to the jamb using 5 16 x 1 5 8 lag screws as shown IF YOU HAVE 2 VERTICAL TRACKS Tighten lag screws securing the bottom jamb bracket bottom slot to jamb maintain 3 8 to 5 8 spacing between the bottom section and vertical track Please Do N
3. Repeat for other side i Flag angle Left hand top fixture s op 2 1 4 20 Flange hex nuts or 2 1 4 20 x 1 3 8 bolts f 2 1 4 14x 1 Horizontal rms Lag screws HE He Top section End Bearing Brackets Tools Step ladder Power drill 7 16 Socket driver NOTE Right and left hand is always determined from inside the garage looking out End bearing brackets are right and left hand Identify the end bearing brackets supplied with your door Align the bottom edge of left end bearing bracket with the top edge of the flag angle Main taining this alignment also align the right edge of the end bearing bracket with the right edge of the flag angle Secure the end bearing bracket to the jamb using 3 5 16 x 1 5 8 lag screws as shown Repeat same process for the other side Left end bearing Left end bearing bracke bracket 2 N b 3 5 16 x 1 5 8 i Lag Screws 0 NE Top edge of flag angle To op section section y Position the left hand end bearing bracket up against the jamb and the horizontal track as shown Fasten the left hand end bearing bracket to the horizontal track with 1 3 8 16 x 3 4 truss head bolt and 1 3 8 16 nut Secure the left hand end bearing bracket to the jamb using 3 5 16 x 1 5 8 lag screws Repeat same process for the other side 3 5 16 x
4. track position flag angle wall angle between 2 3 16 56 mm to 2 1 4 57 mm from the edge of the door tighten the bottom lag screw Flag angles wall angles must be parallel to the door sections Repeat same process for other side IMPORTANT THE DIMENSION BETWEEN THE FLAG ANGLES MUST BE FOR 2 TRACK APPLICATIONS DOOR WIDTH PLUS 3 3 8 86MM TO 3 1 2 89 MM FOR SMOOTH SAFE DOOR OPERATION FOR 3 TRACK APPLICATIONS DOOR WIDTH PLUS 4 7 8 124MM TO 5 127 MM FOR SMOOTH SAFE DOOR OPERATION Complete the vertical track installation by securing the jamb bracket s or slots in the wall angle and tightening the other lag screws Push the vertical track against the track rollers so that the track rollers are touching the deepest part of the curved side of the track tighten all the track bolts and nuts Repeat for other side Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com Door width 2 Track Door width 3 Track 3 3 8 to 3 1 2 4 7 8 to 5 Top of flag angle or F Top of wallangle assembly N Nail 2 Track Applications 1 11 16 to 1 3 4 Top section 3 Track Application
5. Torsion Keyed Shaft G4 Torsion Keyed Shafts G5 Key Shafts As Required G6 Left Hand End Bearing Bracket G7 Right Hand End Bearing Bracket G8 Center Coupler Assembly G9 Set Collars As Required G10 Left Hand Cable Drum G11 Right Hand Cable Drum G12 Left Hand and Right Hand Torsion Springs As Required G13 Counterbalance Lift Cables H REAR BACK HANGS H1 Left Hand and Right Hand Rear Back Hang Assemblies H2 Left Hand and Right Hand Rear Center Back Hang Assemblies As Required BOTTOM CORNER BRACKETS AS REQUIRED 11 Left Hand and Right Hand Bottom Corner Brackets J TRACK ROLLER CARRIERS AS REQUIRED J1 Track Roller Carriers K BOTTOM WEATHER SEAL AS REQUIRED K1 Bottom Weather Seal Door Width Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com Pre Installation amp Important Safety Instructions c DEFINITION OF KEY WORDS USED IN THIS MANUAL A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN SEVERE OR FATAL INJURY CAUTION PROPERTY DAMAGE OR INJURY CAN RESULT FROM FAILURE TO FOLLOW INSTRUCTIONS IMPORTANT REQUIRED STEP FOR SAFE AND PROPER DOOR OPERATION NOTE Information assuring proper installation of the door READ THESE INSTRUCTIONS CAREFULLY BEFO
6. to 10 0 15 Radius 138 3505 mm 168 4267 mm 10 1 to 12 0 15 Radius 162 4115 mm 3 HEADROOM REQUIREMENTS Track Type Space Needed 6 LHR 9 229 mm Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com Suitable mounting surface 2 x 6 lumber minimum Header board 2 x 6 lumber preferred PES Min side room clearance for 2 track is 3 1 2 89 Min side room clearance for 3 track is 4 1 2 114 mm Headroom Vg P Min side room clearance for 2 track is 3 1 2 89 mm Min side room clearance for 3 track is 4 1 2 114 mm Weather Jamb Js nps 1 8 to 1 4 Please Do Not Return This Product To The Store Contact you refer to your local yellow pages business listings or go r local Wayne Dalton dealer To find your local Wayne Dalton dealer o the Find a Dealer section online at www Wayne Dalton com INSTALLATION Before installing your door be certain that you have read and followed all of the instruc ions covered in the pre installation section of this manual Failure to do so may result in an improperly installed door IMPORTANT WOOD DOORS MUST BE
7. 1 5 8 Nert cal Lag screws Lag screws Horizontal line Horizontal line 1 5 16 X 2 or 1 5 16 x 1 5 8 Tamper resistant lag screw Mounting surface 17 Minimum i Vertical line 5 16 x 1 5 8 Lag screws 2 5 16 x 1 5 8 Lag screws Horizontal t 2 Center bearin line 1 5 16 brackets spaced 6 to 7 8 Tamper resistant apart from the center of lag screw the door LSA x1 Torsion Spring Assembly Tools Step Ladder NOTE Refer to the Package Contents and or Parts Breakdown to determine if your door came with a coupler assembly IMPORTANT RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT IMPORTANT ON SINGLE SPRING APPLICATIONS ONLY A RIGHT HAND WOUND RED WIND G CONE WHICH GOES ON THE RIGHT HAND SIDE IS REQUIRED OTE Identify the torsion springs provided as either right hand wound red winding cone hich goes on the RIGHT HAND SIDE or left hand wound black winding cone which goes on e LEFT HAND SIDE or Doors without Coupler Assembly acing the inside of the door lay the torsion shaft on the floor Lay the torsion spring with the ack winding cone and the red cable drum at the left end of the torsion shaft Lay the torsion pring with the red winding cone and the black cable drum at the right end of the torsion haft NOTE The set screws used on all torsion winding cones an
8. 1 5 8 r Left end bearing bracket N a 3 8 16 x 3 4 russ head bolt S Lag screws Upper slot Left end bearing bracket Pall i 1 3 8 16 ex nut Horizontal track Horizontal track Center Bracket Tools Step ladder Power drill 7 16 Socket driver 1 4 Torx bit Level NOTE Refer to the Package Contents and or Parts Breakdown to determine if your door came with a coupler assembly NOTE If your door came with a coupler assembly the mounting surface needs to be a mini mum of 17 wide The 2 center bearing brackets will need to be spaced 12 to 14 apart at the center of the door as shown Locate the center of the door If your door did not come with a coupler Mark a vertical pencil line on the mounting surface above the door at the center If your door did come with a coupler Mark a vertical pencil line on the mounting surface Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com above the door at the center Split the difference up and position the 2 center bearing brackets apart from each other Mark two vertical pencil lines one for each center bearing bracket onto the mounting surface ab
9. Find a Dealer section online at www Wayne Dalton com 3 Lubrication The door should open and close smoothly Ensure the door track rollers are rotating freely when opening and closing the door If track rollers do not rotate freely clean the door tracks removing dirt and any foreign substances Clean and lubricate use a non silicon based lubricant graduated end hinges steel track rollers spring s and bearings DO NOT lubri cate plastic idler bearings nylon track rollers door track DO NOT oil a cylinder lock if actuation is difficult use a graphite dust to lubricate Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com Warranty Limited warranty Double Flush Model 44 Subject to the terms and conditions contained in this Limited Warranty Wayne Dalton Manufacturer warrants the sections of the door against defects in material and workmanship for a period of ONE 1 YEAR from the time of delivery provided i i The interior and exterior surfaces as well as all edges of the wood door s are properly finished according to the Manufactures Maintenance and Painting Instructions and finish manufacturer s instructions All surfaces of the wood door s must be completely finished 3 total coats including primer coat prior to installati
10. If you have a wall angle track assembly or if you already have jamb brackets pre attached to the vertical tracks skip this step Refer to Package Contents Parts Breakdown to determine if you have jamb brackets NOTE The bottom jamb bracket is always the shortest bracket while the center jamb bracket is the next tallest If three jamb brackets per side are included with your door you will have received a top jamb bracket which is the tallest To attach the bottom jamb bracket locate lower hole of the hole slot pattern of the 1st hole set on the vertical track Align the slot in the jamb bracket with the lower hole of the hole slot pattern Secure jamb bracket using 1 1 4 20 x 9 16 track bolt and 1 1 4 20 flange hex nut Repeat for other side Place the center jamb bracket over the lower hole of the hole slot pattern that is centered between the bottom jamb bracket and flag angle of the 2nd hole set Secure jamb bracket using 1 1 4 20 x 9 16 track bolt and 1 1 4 20 flange hex nut Repeat for other side a top jamb bracket was included secure it to vertical track using the lower hole of the hole slot pattern in the 3rd hole set and 1 1 4 20 x 9 16 track bolt and 1 1 4 20 flange hex nut Repeat for other side Vertical track Top of track ist hole set 2nd hole set 3rd hole set ae JO 00
11. Of Strut meie Baian ection Type n Location On Section 8 Section High Door 2 Strut 3 Strut Top R 1 Short 1 Short Top Of Section n 0 Intermediate VI p VA VA Bottom Of secti Intermediate V Top 0 Intermediate IV Intermediate IV Bottom Intermediate III z op 0 Intermediate II Intermediate III Bottom Intermediate op 0 Intermediate II Bottom NOTE Center hinge s use 1 graduated end hinges at each pre drilled vertical stile location Top 0 The pre drilled locations are located at the top and or bottom rails on the inside of the section Intermediate surface Bottom NOTE Some doors will receive half center hinge s These will be installed in between the center Bottom Top 0 hinge s and graduated end hinge s Bottom 0 STRUT IDENTIFICATION Identify your struts to determine which ones are long strut s or short strut s Type Of Strut Short Strut s are typically installed along the top rail of the top section and or along the bottom Section Type Recanonm ntSection rail of the bottom section 2 Strut 3 Strut Long Strut s are typically installed along the top and or bottom rails of sections Measure the 1 Short 1 Short Top Of Section height of the long strut s to determine if you have 2 or 3 Top WA WA Bottom OF section NOTE Some struts also may or may not have holes in them If they don t then prior to installing the strut and hinge to the section surfa
12. coef ece eae Jomo 0 00 eae O00 2 l Lower hole of N hole slot pattern 1 4 Hange l fiex nut Jamb bracket x ANJ in place amp 1 4 20 x i 9 16 FA jamb Track bolt bracket Bottom Weather Seal Tools Hammer Tape Measure Saw Horses NOTE If a bottom weather seal is supplied complete this step NOTE Refer to Door Section Identification Parts Breakdown Place the bottom section face down on a couple of sawhorses or flat clean smooth surface S Align the bottom weather seal wi tom section Starting at one end of the door measure inward 1 and attach the bottom weather seal to the bottom of the bottom section with 3 4 long galvanized roofing nails not supplied Now stretch the bottom weather seal slightly and nail the rest of the bottom weather seal to the bottom of the bottom section every 6 he flap pointing towards the outside surface of the bot Once the bottom weather seal is fastened cut off any extra material so that the bottom weather seal is even with both ends of the bottom section NOTE Verify bottom weather seal is aligned with bottom section If there is more than 1 2 excess weather seal on either side trim weather seal even with bottom section i Lo ve Bottom bottom Bottom eather pasz mn SS section weather seal Flap I 1 6 6 3 4 Long galvanized roofing
13. nails not supplied Bottom Corner Brackets Tools Power Drill 9 32 Drill Bit Socket Driver 7 16 Wrench 7 16 NOTE Refer to Door Section Identification Parts Breakdown to determine which bottom corner brackets were supplied with your door WARNING FAILURE TO ENSURE TIGHT FIT OF CABLE LOOP OVER COTTER PIN COULD RESULT IN COUNTERBALANCE LIFT CABLE COMING OFF THE PIN AL LOWING THE DOOR TO FALL POSSIBLY RESULTING IN SEVERE OR FATAL INJURY With the bottom section facing down from the previous step uncoil the counterbalance lift cables Starting on the left hand side place the cable loop into position between the two holes on the side of the left hand bottom bracket Slide a clevis pin through the innermost hole cable loop and outermost hole of the bottom bracket Slide a washer onto the clevis pin and secure in place by inserting a cotter pin into the hole of the clevis pin Bend the ends of the cotter pin outwards to secure it in place Repeat for other side A Left B Left hand hand Counterbalance bottom corner bottom S ift cable bracket corner i bracket o Washer Clevis pin 8 0 O inserted through rd cotter pin an bent into place vq y lt A Washer o S Cotter o pin Cotter pin Locate the left hand bottom corner bracket Align the bottom corner bracket horizontally with the bottom edge of the bottom section and also align t
14. o Bottom corner bracket 1 4 14x 1 Lag screws or 3 4 Starting on the left hand side attach the upper slot of the graduated end hinge to the bottom section using 1 1 4 20 x 2 1 2 carriage bolt and 1 1 4 20 flange hex nut Next secure the lower slot of the graduated end hinge to the bottom section using 1 1 4 20 x 2 1 2 carriage bolt and 1 1 4 20 flange hex nut as shown Repeat same process for other side FOR SINGLE GRADUATED END HINGES WITH A STRUT IF APPLICABLE Starting on the left hand side attach the upper slot of the graduated end hinge 1 strut clip and the upper leg of strut to the bottom section using 1 1 4 20 x 2 1 2 carriage bolt and 1 1 4 20 flange hex nut Next secure the bottom leg of strut the lower slot of the gradu ated end hinge to the bottom section 1 1 4 20 x 2 1 2 carriage bolt and 1 1 4 20 flange hex nut as shown Repeat same process for other side FOR DOORS WITH DOUBLE GRADUATED END HINGES Position the second graduated end hinge next to the first single graduated end hinge Using the second graduated end hinge as a template drill pilot holes 1 deep into the bottom section with a 1 8 drill bit IMPORTANT BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION ONLY DRILL 1 DEEP Attach the upper leg of strut if applicable to the upper slot of the graduated end hinge to the bot
15. rod while carefully loose ng add garage door operator operation problems Apply vice grips to track above third track rol er ng ning THE ust spring tension 1 4 turn Retighten both se nding cone and repeat for the other side Recheck door balance DO NOT ADJUST MORE THAI OF TURNS If door still does not balance correctly contact a qualified door agency If the door still does not operate easily lower the door into the closed position UNWIND THE SPRING S FULLY Reference the insert Removing The Old Door Preparing The Opening section on torsion spring removal and recheck the following the items 1 Check the door for level Check the torsion shaft for level Check the track spacing Check the counterbalance lift cables for equal tension Check the track for potential obstruction of the track rollers 6 Clamp locking pliers onto track and rewind springs IMPORTANT IF DOOR STILL DOES NOT OPERATE PROPERLY THEN CONTACT A TRAINED DOOR SYSTEM TECHNICIAN 1 2 TURN FROM THE RECOMMENDED NUMBER Horizontal tracks Horizontal track 5 16 18 x 1 1 4 Hex bolts must extend into the track to serve as a roller stop A eboob ocooo ooccoococoocoo g using 2 5 16 x 1 5 8 hex head lag screws to ceiling
16. s for each pre drilled hole location Starting at the upper left hand corner of the bottom section Position the lower hinge leaf of the appropriate graduated end hinge onto the upper corner of the bottom section Align the slots of the lower hinge leaf with the pre drilled holes or the factory installed threads in the bottom section Next lay a long strut if applicable over the lower hinge leaf and over the top rail of the bottom section Center the long strut from side to side as shown FOR SINGLE GRADUATED END HINGES WITHOUT A STRUT O L 1 Strut clip 1 Strut clip if applicable Long strut if applicable Long edge if applicable Typical section Short edge shown f you have single graduated end hinges insert a short stem track roller short stem tandem track roller if included into the hinge tube on each side f you have double graduated end hinges insert a long stem track roller short stem tandem track roller if included into the hinge tubes on each side IMPORTANT WHEN PLACING TRACK ROLLERS TANDEM TRACK ROLLER IF INCLUDED NTO GRADUATED END HINGES NUMBER 2 AND HIGHER THE TRACK ROLLER TANDEM TRACK ROLLER IF INCLUDED GOES INTO TUBE FURTHEST AWAY FROM SECTION Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to t
17. side IF YOU HAVE HALF CENTER HINGES Flip the upper hinge leaf up and use it as a template Mark and pre drill 2 1 8 pilot holes 1 deep into the section using a 1 8 drill bit Attach the upper hinge leaf to the section using 2 1 4 14 x 1 lag screws Repeat same process for other half center hinges IMPORTANT BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION ONLY DRILL 1 DEEP IMPORTANT PUSH amp HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE SECURING WITH 1 4 20 X 2 1 2 CARRIAGE BOLTS AND 1 4 20 FLANGE HEX NUTS THERE SHOULD BE NO GAP BETWEEN THE HINGE LEAFS AND THE SECTIONS 2 1 4 14 x 1 Iy screws Upper hinge leaf s Typical sections shown Half center hinge O Q Long strut if applicable Top Section Tools Hammer Step ladder Tape measure Place the top section in the opening Temporarily secure the top section by driving a nail into the header near the center of the door and bending it over the top section Now flip up the graduated end hinge and center hinge leaves hold tight against section and fasten center hinges first and end hinges last refer to step Stacking Sections Vertical track alignment is Critical For 2 track position flag angle wall angle between 1 11 16 43 mm to 1 3 4 44 mm from the edge of the door tighten the bottom lag screw For 3
18. with your door Door sections as required Torsion shaft Torsion keyed shaft as required Torsion keyed shafts as required FX 5 AES 8 Fully Adjustable jamb brackets RH LH as required MP Ful angles RH ly Adjustable flag LH as required a T A Sor Vertical tracks RH LH as required S 5 A M Vertical track assemblies RH LH as required 5 LH as required gt 2 2 Rivited vertical track assemblies RH wile aLI Fez z z r 7 z tf z Wall angle track assemblies RH LH as required Horizontal tracks RH LH as required Horizontal tracks RH LH as required lt L NA D 16 Track Roller Lanen Tandem track rollers 2 Spacers as required if included aS rollers fl Ai D j Top fixtures Bottom corner j corner as required Strut if included brackets as required brackets as required r local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go o the Find a Dealer section online at www Wayne Dalton com The BOTTOM SECTION can be identified by 1 The INTER
19. 4 truss head bolts and 2 3 8 16 hex nuts Now secure he top rail of the horizontal track to the wall angle using 1 1 4 20 x 9 16 track bolt 1 washer and 1 1 4 20 flange hex nut Repeat for other side Remove the nail that was temporarily holding the top section in place installed in step Top Section IMPORTANT FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION 1 1 4 20 Flange hex nut 2 3 8 16 Hex nuts Washer a 3 8 16 x 3 4 russ head bolts Flange hex nut Top rail of horizontal track Top rail of horizontal track 1 1 4 20 x 9 16 1 1 4 20 x 9 16 2 Track bolt Track bolt Flag angle Wall angle l Wal Adjusting Top Fixtures Tools 7 16 Wrench Step ladder With horizontal tracks installed you can now adjust the top fixtures NOTE If your door came with two top fixtures then one top fixture is required to be adjusted for each side NOTE If your door came with four top fixtures then two top fixtures are required to be adjusted for each side Starting on the left hand side vertically align the top section of the door with the lower sec tions Maintaining the top fixture s position tighten the 1 4 20 flange hex nuts or 1 4 20 x 1 3 8 bolts and or 1 4 14 x 1 lag screws to secure the top fixture s to the top section
20. COMPLETELY FINISHED 3 TOTAL COATS INCLUDING PRIMER COAT PRIOR TO INSTALLATION TO ENSURE THAT THE INTERIOR AND EXTERIOR SURFACES AS WELL AS ALL EDGES OF THE DOORS ARE PROPERLY PROTECTED AGAINST OISTURE OR OTHER CONTAMINANTS WOOD DOORS IN A NON FINISHED CONDITION UST BE TRANSPORTED AND STORED SO THE WOOD SURFACES ARE NOT EXPOSED TO MOISTURE OR OTHER CONTAMINANTS IMPROPER TRANSPORTATION STORAGE O DELAYS IN FINISHING THAT ALLOWS EXPOSURE OF THE WOOD DOOR SURFACES TO MOIS TURE OR OTHER CONTAMINANTS WILL RESULT IN THE WARRANTY BEING VOIDED NOTE Reference TDS 160 for general garage door terminology at www dasma com Fully Adjustable Flag Angles Tools None NOTE If you have a wall angle track assembly or if you already have flag angles pre attached to the vertical tracks skip this step Refer to Package Contents Parts Breakdown 0 determine if you have flag angles NOTE Flag angles are right and left handed f you have Fully Adjustable vertical tracks hand tighten the left hand flag angle to the left hand vertical track using 2 1 4 20 x 9 16 track bolts and 2 1 4 20 flange hex nuts Repeat for other side Flange nuts will be secured after flag angle spacing is completed in step Top Section Flag angle 1 4 20 Flange hex nuts Zz W 1 4 20 x 9 16 Fully Adjustable Track bolts vertical track Fully Adjustable Jamb Brackets Tools None NOTE
21. CREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN TREATED LUMBER NOTE It is recommended that 5 16 lag screws are pilot drilled using a 3 16 drill bit prior to fastening IMPORTANT WHEN INSTALLING 5 16 LAG SCREWS USING AN ELECTRIC DRILL DRIVER THE DRILL DRIVERS CLUTCH MUST BE SET TO DELIVER NO MORE THAN 200 IN LBS OF TORQUE FASTENER FAILURE COULD OCCUR AT HIGHER SETTINGS A WARNING PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS ENSURE YOU RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTAL LATION INSTRUCTIONS OTHERWISE THE SPRING FITTINGS MAY RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND COULD RESULT IN SEVERE OR FATAL INJURY IMPORTANT RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT building official for wind load code require Please Do Not Return This Product To The Store Contact you Tools Required e Power drill e Phillips head e Hammer e Drill bits 1 8 3 16 screwdriver e Tape measure 9 32 7 16 1 2 e Locking Pliers e Step Ladder e Ratchet wrench e 2 Vice clamps Level e Socket driver 7 16 e Wrenches 3 8 Pencil e Sockets 7 16 1 2 716 1 2 9 16 9 16 5 8 5 8 e Leather gloves e 1 4 Torx bit e Safety glasses e Approved winding rods Package Contents NOTE Depending on the door model some parts listed will not be supplied if not required Rear Back Hangs may not be included
22. Doors heights over 8 0 or door widths over 11 0 require an additional set of rear center back hangs to be installed and located at the middle of the horizontal tracks see parts breakdown Using perforated angle may not be supplied 2 5 16 x 1 5 8 hex head lag screws and 3 5 16 bolts with nuts may not be supplied fabricate rear center back hangs for the horizon tal tracks Measure and drill a 3 8 diameter hole through the center length of the horizontal track as shown Attach the rear center back hangs to the horizontal tracks with 1 3 8 truss head bolt and 1 3 8 nut may not be supplied Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com A WARNING KEEP HORIZONTAL TRACKS PARALLEL AND WITHIN 3 4 TO 7 8 MAXI MUM OF DOOR EDGE OTHERWISE DOOR COULD FALL RESULTING IN SEVERE OR FATAL INJURY IMPORTANT DO NOT SUPPORT THE WEIGHT OF THE DOOR ON ANY PART OF THE REAR BACK HANGS THAT CANTILEVERS 4 OR MORE BEYOND A SOUND FRAMING MEMBER NOTE If rear back hangs are to be installed over drywall use 2 5 16 x 2 hex head lag screws and make sure lag screws engage into solid structural lumber NOTE 26 angle must be attached to sound framing members and nails should not be used Now pe
23. INGS OIL OR ALKYD PAINTS VINYL ACETATE PVA VINYL ACRYLIC OR VINYL ACETATE ACRYLIC CO POLYMER PAINTS Clear Or Stained Finishes If staining select an exterior grade stain approved for use on the species of wood substrates being finished and compatible with Alkyd varnishes FOR BEST RESULTS DO NOT USE A DARK STAIN HIGH HEAT ABSORPTION CAN CAUSE EXCESSIVE BOWING AND CRACKING OF THE WOOD Apply the stain to the interior and exterior surfaces as well as all edges following stain manufacturer s label directions After proper drying time for the stain or if wood is being left natural apply 1 coat of waterproof exterior Alkyd varnish marine type varnish to the interior and exterior surfaces as well as all edges After recommended drying time of 1st coat sand all surfaces with fine grit 20 sandpaper Clean all surfaces of sanding dust and apply a 2nd coat of the Alkyd varnish to the interior and exterior surfaces as well as all edges After 2nd coat is dry sand all surfaces again with fine grit 320 sandpaper Clean all surfaces of sanding dust and apply a final 3rd coat of the Alkyd varnish to all surfaces Three finish coats of waterproof exterior Alkyd varnish are required to properly finish a stained or natural wood door Follow the finish manufacturer s label directions explicitly for each coat applied NOTE Do not stain MDO plywood apply paint only Only a waterproof exterior Alkyd varnish top coat finish is approved for st
24. MEDIATE SECTION can be identified by 2 The INTERMEDIATE II SECTION can be identified by 3 for a 4 section high door only Q 5 16 x 1 1 4 Cotter pin N N The INTERMEDIATE III SECTION can be identified by 4 for a 5 section high door only Glevis pin fas required _ as required _ Cable drums RH LH Torsion pl RH LH The INTERMEDIATE IV SECTION can be identified by 5 for a 6 section high door only The INTERMEDIATE V SECTION can be identified by 6 for a 7 section high door only The INTERMEDIATE III SECTION can be identified by 7 for a 8 section high door only gt The TOP SECTION can be identified by a being the highest section n gt bearing bracket Center bracket bushin Top rail assembly as required assembly as required Typical design option Outside surface o HC door sections shown OD Outside Inside 3 Top surface su face RR o End bearing brackets RH LH as required ZY End bearin brackets RH LI as required Center en Key shafts Set collars section assembly as required as required as required Counterbalance lift cables A Typical O th roel 3 stamp ing jocation H y cw PETR Intermediate it Strut clips Half Center Weather seals sec
25. RE ATTEMPTING INSTALLATION IF IN QUESTION ABOUT ANY OF THE PROCEDURES DO NOT PERFORM THE WORK INSTEAD HAVE A TRAINED DOOR SYSTEMS TECHNICIAN DO THE INSTALLATION OR REPAIRS 1 READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS 2 Wear protective gloves during installation to avoid possible cuts from sharp metal edges 3 Itis always recommended to wear eye protection when using tools otherwise eye injury could result 4 Avoid installing your new door on windy days Door could fall during the installation caus ing severe or fatal injury 5 Doors 12 0 wide and over should be installed by two persons to avoid possible injury 6 Operate door only when it is properly adjusted and free from obstructions 7 If a door becomes hard to operate inoperative or is damaged immediately have neces sary adjustments and or repairs made by a trained door system technician using proper tools and instructions 8 DO NOT stand or walk under a moving door or permit anybody to stand or walk under an electrically operated door 9 DO NOT place fingers or hands into open section joints when closing a door Use lift handles gripping points when operating door manually 10 DO NOT permit children to operate garage door or door controls Severe or fatal injury could result should the child become entrapped between the door and the floor 11 Due to constant extreme spring tension do not attempt any adjustment repair or altera tion to any part o
26. Repeat the same process for he right hand side NOTE The track roller carrier s inner holes are used on doors with 2 track applications the outer holes are used on doors with 3 track applications Bottom corner Bottom corner bracket bracket 2 STD Short stem mange Short iF track roller Bottom corner stem Bottom corner bracket track track bracket track roller carrier roller roller carrier Spacer Spacer cas 4 1 4 20x7 8 a Self drilling screws 4 1 4 20 x 7 8 re elf drilling screws Side view of track roller carrier s Outer holes o Tak d F 2 Track Strutting Tools Power Drill 1 8 Drill Bit Socket Driver 7 16 Tape Measure NOTE Refer to the Door Section Identification and Strut Identification to determine if the bottom section requires a short strut to be installed Lay the short strut onto the bottom rail of the bottom section Position the bottom of the strut 3 4 up from the bottom edge of the bottom section Center the short strut from side to side on the section surface Drill pilot holes 1 deep into the bottom section using a 1 8 drill bit IMPORTANT BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION ONLY DRILL 1 DEEP Attach the strut using 2 1 4 14 x 1 lag screws at each on each end and center stile aligned with hinges locations Bottom Short section strut
27. Wayne Dalton GARAGE DOORS amp OPENERS Table Of Contents Parts Breakdown Pre Installation Important Safety Instructions Tools Required Package Contents Door Section Identification Graduated End Hinge And Strut Identification Removing an Existing Door Preparing the Opening Installation Optional Installation Door Arm Hookup Lift Handles Pull Down Rope Maintenance Cleaning Your Garage Door Painting Your Garage Door Clear Or Stained Finishes Operation and Maintenance Warranty Dealer Locator Information ODnnmnF FSF WWWWHD NINA Soe So aS Se O O O O O C amp C CO CO Oo IMPORTANT NOTICES Wayne Dalton highly recommends that you read and fully under stand the Installation Instructions and Owner s Manual before you attempt this installation To avoid possible injury read the enclosed instructions carefully before installing and operating the garage door Pay close attention to all warnings and notes After installation is complete fasten this manual near garage door for easy reference The complete Installation Instructions and Owner s Manual are available at no charge from Wayne Dalton a Division Of Overhead Door Corporation P O Box 67 Mt Hope OH 44660 Or Online At www Wayne Dalton com Part No 347617 REV1 03 08 2012 i FS NOTE The illustrations shown on this page are general representations of the door parts Each specific door models may have unique var
28. Y A TRAINED DOOR SYSTEMS TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS TorqueMaster Plus Springs Pawl knob s located on the TorqueMaster end brackets above the door should be engaged to prevent the door from rapidly descending in case of spring failure or forceful manual operation Torsion Springs The torsion springs located above the door should only be adjusted by a trained door systems technician DO NOT attempt to repair or adjust torsion springs yourself Extension Springs A restraining cable or other device should be installed on the extension spring located above the horizontal tracks to help contain the spring if it breaks 2 Door Balance Periodically test the balance of your door If you have a garage door drawbar operator use the release mechanism so you can operate the door by hand when doing this test Start with the door in the fully closed position Lift the door to check its balance Adjust TorqueMaster or Extension spring s if door lifts by itself hard to pull down or if door is difficult to lift easy to pull down DO NOT attempt to repair or adjust Torsion Springs yourself To adjust TorqueMaster or Extension spring s refer to your installation instructions and owner s manual If in question about any of the procedures do not perform the work Instead have it adjusted by a trained door systems technician r local Wayne Dalton dealer To find your local Wayne Dalton dealer o the
29. a Coupler Assembly Disassemble the coupler assembly by removing the 3 3 8 16 x 1 3 4 hex head screws and the 3 3 8 16 nylon hex lock nuts from the coupler halves Loosen the set screws Set the components aside Facing the inside of the door lay the 2 torsion keyed shafts on the floor One torsion keyed shaft on the left hand side and the other torsion keyed shaft on the right hand side Starting on the left hand side lay one of the coupler halves center bearing the torsion spring with the black winding cone one set collar and the red cable drum at the left end of the tor sion keyed shaft Next on the right hand side lay the other coupler halve center bearing the torsion spring with the red winding cone one set collar and the black cable drum at the right end of the torsion keyed shaft NOTE The set screws used on all torsion winding cones and cable drums are now colored red DO NOT identify right and left hand by the set screw color Slide the coupler halve the center bearing onto the torsion keyed shaft followed by the tor sion spring and the set collar IMPORTANT THE COUPLER HALVES CENTER BEARINGS TORSION SPRINGS AND THE SET COLLARS MUST BE POSITIONED AS SHOWN Slide the flat edge of the couple halve flush with the side edge of the torsion keyed shaft Tighten the 2 set screws and the locking nut to secure the coupler halve to the torsion keyed shaft NOTE Tighten the set screws to 14 15 ft Ibs of t
30. ained or natural wood doors Other types of top coat finishes including deck sealers are not acceptable and if used will void the warranty amp Operation and Maintenance OPERATING YOUR GARAGE DOOR 1 Please Do Not Return This Product To The Store Contact you refer to your local yellow pages business listings or go Before you begin read all warning labels affixed to the door and the installation instructions and owner s manual When correctly installed your Wayne Dalton door will operate smoothly Always operate your door with controlled movements Do not slam your door or throw your door into the open position this may cause damage to the door or its components If your door has an electric opener refer to the owner s manual to disconnect the opener before performing manual door operation below Manual door operation For additional information on manual garage door operations go to www dasma com and reference TDS 165 IMPORTANT DO NOT PLACE FINGERS OR HANDS INTO SECTION JOINTS WHEN OPENING AND OR CLOSING A DOOR ALWAYS USE LIFT HANDLES SUITABLE GRIPPING POINTS WHEN OPERATING THE DOOR MANUALLY Opening a Door Make sure the lock s are in the unlocked position Lift the door by using the lift handles suitable gripping points only Door should open with little resistance Closing a Door From inside the garage pull door downward using lift handles gripping point only or a high frictio
31. and 1 1 4 20 flange hex nut Next secure the ower slot of the center hinge to the bottom section using 1 1 4 20 x 2 1 2 carriage bolt and 1 1 4 20 flange hex nut as shown Repeat same process for other center hinges FOR CENTER HINGES WITH A STRUT IF APPLICABLE Starting on the left hand side attach the upper slot of the center hinge 1 strut clip and the upper leg of strut to the bottom section using 1 1 4 20 x 2 1 2 carriage bolt and 1 1 4 20 flange hex nut Next secure the bottom leg of strut the lower slot of the center hinge to the bottom section 1 1 4 20 x 2 1 2 carriage bolt and 1 1 4 20 flange hex nut as shown Repeat same process for other center hinges Short 0 Center hinge age 2 1 4 20 x 2 1 2 Carriage bolts i StL BB and 2 1 4 20 Flange hex nuts _ if applicable 1 Strut cli i Jatt oip 1 Strut cli i peat Longedge E ut Lower hinge leaf Zz Graduated End And Center Hinges Tools Power Drill 1 8 9 32 Drill Bit Socket Driver 7 16 Tape NOTE Refer to the Door Section Identification Graduated End Hinge and Strut Identification to determine the appropriate hinges and or struts for your sections Using the appropriate graduated end hinges for the ends and depending on the width of your door enough center hinge
32. are available at no charge from Wayne Dalton A Division Of Overhead Door Corporation P O Box 67 Mt Hope OH 44660 or at www wayne dalton com For additional information on garage door operator maintenance go to www dasma com and reference TDS 151 167 and 179 Monthly Inspections 1 Visual Inspection Closely inspect jambs header and mounting surface Any wood found not to be structurally sound must be replaced Inspect the springs counterbalance lift cables track rollers pulleys rear back hangs and other door hardware for signs of worn or broken parts Tighten any loose screws and or bolts Check exterior surface of the door sections for any minor cracks Verify door has not shifted right or left in the opening If you suspect problems have a trained door system technician make the repairs A WARNING GARAGE DOOR SPRINGS COUNTERBALANCE LIFT CABLES BRACKETS AND OTHER HARDWARE ATTACHED TO THE SPRINGS ARE UNDER EXTREME TEN SION AND IF HANDLED IMPROPERLY CAN CAUSE SEVERE OR FATAL INJURY ONLY A TRAINED DOOR SYSTEMS TECHNICIAN SHOULD ADJUST THEM BY CAREFULLY FOLLOWING THE MANUFACTURER S INSTRUCTIONS A WARNING NEVER REMOVE ADJUST OR LOOSEN THE BOLTS SCREWS AND OR LAG SCREWS ON THE COUNTERBALANCE END OR CENTER BEARING BRACKETS SYSTEM OR BOTTOM CORNER BRACKETS OF THE DOOR THESE BRACKETS ARE CONNECTED TO THE SPRING S AND ARE UNDER EXTREME TENSION TO AVOID POSSIBLE SEVERE OR FATAL INJURY HAVE ANY SUCH WORK PER FORMED B
33. ce you may have to drill a 3 16 hole for the appropriate TEN 1 Long 1 Long Top Of Section fastener on one or both sides of the strut legs z N A N A Bottom Of section 3 Section High Strutting Schedule Section Type Type Of Strut Location On Section Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com 7 Section High Strutting Schedule 1 Long Top Of Section 1 Long Intermediate IV Bottom Of section Top Of Section Intermediate III Bottom Of section Top Of Section Intermediate Il Bottom Of section Top Of Section Bottom Of section Top Of Section Bottom Of section Intermediate Bottom 8 Section High Strutting Schedule Type Of Strut Section Type Location On Section 2 Strut 3 Strut 1 Short 1 Short N A N A Bottom Of section Top Of Section Top 1 Long 1 Long Top Of Section N A N A Bottom Of section 1 Long 1 Long N A N A Bottom Of section 1 Long N A N A Bottom Of section 1 Long Top Of Section N A N A Bottom Of section 1 Long 1 Long Top Of Section N A N A Bottom Of section N A 1 Long Top Of Section N A N A Bottom Of section N A N A 1 Short Intermediate VI Top Of Section Intermediate V 1 L
34. chamois NOTE Do not use any window cleaning fluids scouring compounds gritty cloths or solvent based cleaners of any kind Clean all surfaces of dust dirt and any other contaminants Any scarring or stains that occur during transportation handling or storage must be re sanded to the original condition J Painting Your Garage Door A high quality exterior 100 Acrylic Latex based finish paint is recommended for painting your wood door FOR BEST RESULTS DO NOT USE A DARK COLOR PAINT HIGH HEAT ABSORPTION CAN CAUSE EXCESSIVE BOWING AND CRACKING OF THE WOOD If priming is necessary prime the interior and exterior surfaces as well as all edges using a primer compatible with the selected finish paint and for the specific species of wood substrate being finished NOTE Some species of wood such as cedar require special primers and finishes to prevent tannin stains from appearing Consult with your paint supplier If the door is factory primed by Wayne Dalton the priming step is not required except if touch up is needed due to surface preparation and re sanding NOTE Wayne Dalton uses a latex primer Finish paint the interior and exterior surfaces as well as all edges with at least 2 coats of a high quality exterior 100 Acrylic Latex finish paint over the primer Follow paint manufacture s label directions explicitly for all coatings IMPORTANT THE FOLLOWING TOP COATS ARE NOT RECOMMENDED SHAKE AND SHINGLE PAINTS CLEAR COAT
35. cket Left hand cable drum Key Set Collars Tools Step Ladder 3 8 Wrench NOTE If your door did not come with set collars then skip this step Slide each of the set collars up against the inside surface of the end bearing brackets with he set screw facing directly away from the header Tighten the set screw in each of the set collars to the torsion shaft to 14 15 ft Ibs of torque once set screw contacts the shaft ighten set screw one full turn IMPORTANT PRIOR TO TIGHTENING THE SET SCREWS IN THE SET COLLARS AVOID PLAC NG THE SET SCREWS IN THE KEYWAYS OF TORSION KEYED SHAFT S End Right End beari bearin hand nd bearing Berke cable bracket J Counterbalance liftcable oe Torsion keyed shaft Securing Door For Spring Winding s Tools Vice Clamps With the door in the fully closed position place vice clamps onto both vertical tracks just above the third track roller This is to prevent the garage door from rising while winding springs A WARNING FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY Sa o Vice clamps above third track roller on both sides of door Bottom section Vice clamps attached to inner and outer rail of vertical track Winding S
36. ckets Center l 1 I i if 1 bearing I I i Torsion i eyed Coupler shat i Torsion halve I Right hand end ibearing bracket i Equal spacing Left hand wound black winding cone left hand side Left hand end bearing bracket Torsion Spring Attachment Tools Step Ladder 1 2 Wrench If your door came with a Center Bracket Bushing Slide the center bracket bushing into the center bracket Align the stationary spring cone s with the holes in the center bracket bushing assembly f your door came with a Center Bearing Bracket s ide the center bearing into the spring Align the stationary spring cone with the holes in the enter bearing bracket Qn ime ecure the torsion spring to the center bracket bushing assembly or the center bearing racket assembly with 2 3 8 16 x 1 1 2 hex head bolts and 2 3 8 16 nuts Repeat for others if applicable IMPORTANT THE SPRING WARNING TAG S SUPPLIED MUST BE SECURELY ATTACHED TO THE STATIONARY SPRING CONE S IN PLAIN VIEW SHOULD A REPLACEMENT SPRING WARNING TAG BE REQUIRED CONTACT WAYNE DALTON FOR FREE REPLACEMENTS For Doors with a Coupler Assembly At the middle of the two center bearing brackets re assemble the coupler assembly by loosely fastening the coupler halves together using the 3 3 8 16 x 1 3 4 hex head screws and the 3 3 8 16 nylon hex lock nuts as shown NOTE Ensure both torsion keyed shafts have equa
37. d cable drums are now colored red DO NOT identify right and left hand by the set screw color Slide the center bracket bushing or center bearing onto the torsion shaft followed by the torsion springs IMPORTANT THE CENTER BRACKET BUSHING OR CENTER BEARING AND TORSION Sez anon n SPRINGS MUST BE POSITIONED AS SHOWN With assistance pick up the torsion spring assembly and slide one end of the torsion shaft through one end bearing bracket Lay the middle of the torsion shaft into the center bracket Slide the other end of the torsion shaft into the other end bearing bracket Position the torsion shaft so that equal amounts of the shaft extend from each end bearing brackets r Black cable drum right hand side Right hand wound red winding cone right hand side Red cable drum left hand side Torsion shaft or Torsion keyed shaft Left hand wound black winding cone left hand side Equal spacing Center F Left hand end s Right hand end i bearing bracket pracke i bearing bracket i H jim iam j Torsion shaft L Center bracket o o For Doors with
38. e middle of the top lift handle If needed reposition the lift handle to stay within the Minimum and Maximum dimensions as stated above Using the lift handle as a template mark the hole locations and drill 2 9 32 dia holes through the section On the outside of the door insert 2 1 4 20 x 2 1 2 carriage bolts black head into the outside lift handle and insert the assembly into the 2 pre drilled holes in the section From the inside slide the 2 holes in the inside lift handle over the stems of the carriage bolts Secure the outside and inside lift handle to the section with 2 1 4 20 flange hex nuts 2 1 4 20 x 2 1 2 i a Carriage bolts and 2 1 4 20 Intermediate andie Flange hex nuts section Center i hinge Bottom 1 section Lift l handle 2 1 4 20 x 2 1 2 Carriage bolts and 2 1 4 20 Strut 1 Flange hex nuts Z ya Pull Down Rope Tools Power drill 1 8 Drill bit Tape measure Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com Maintenance amp Cleanin
39. eatherstrips to the header and jambs at this time For the header align the weatherstrip 1 8 to 1 4 inside the header edge and temporarily secure it to the header with equally spaced nails Starting at either side of the jamb fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and 1 8 to 1 4 inside the jamb edge Temporarily secure the weatherstrip with equally spaced nails Repeat for other side This will keep the bottom section from falling out of the opening during installation Equally space nails approximately 12 to 18 apart Backroom requirement Backroom is defined as the distance needed from the opening back into the garage to allow the door to open fully NOTE For door heights from 10 1 to 12 0 refer to your operator manufacture installation instructions for appropriate depth into room Headroom requirement Headroom is defined as the space needed above the top of the door for tracks springs etc to allow the door to open properly If the door is to be motor operated 2 1 2 64 mm of additional headroom is required Preparing the Opening BACKROOM REQUIREMENTS Door Height Track Manual Lift Motor Operated 6 0 to 70 15 Radius 102 2591 mm 125 3175 mm 7 1 to 8 0 15 Radius 114 2896 mm 137 3480 mm 8 1 to 9 0 15 Radius 126 3200 mm 168 4267 mm 9 1
40. ed center Cener hinge Typical section Mge 70 Lower hinge leaf shown i AYJ L Long strut 2 1 4 14 x 1 Lag screws if applicable Top Fixtures Tools Power drill 7 16 Socket driver NOTE If your door came with two top fixtures A then one top fixture and a short stem track roller are required for each side NOTE If your door came with four top fixtures B then two top fixtures and a long stem track roller are required for each side NOTE Refer to Door Section Identification Parts Breakdown Place the top section face down on a couple of sawhorses or flat clean smooth surface NOTE Depending on your door refer to illustrations A or B to determine how to install the top fixtures Follow the corresponding steps below A Starting on the left hand side align the edge of the top fixture parallel to the top section edge Using the top fixture as a template mark and pre drill 3 9 32 diameter holes through he top section Loosely attach the top fixture to the top section using 2 1 4 20 x 2 1 2 carriage bolts and 2 1 4 20 flange hex nuts Insert a short stem track roller into the top ixture slide Repeat the same process for the right hand side 2 1 4 20 x 2 1 2 Carriage bolts a TN 2 1 4 20 Flange hex nuts z Top section C Left hand Short stem top fixture track roller B Position t
41. er THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON MOSS ACT NO WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WILL EXTEND BE YOND THE TIME PERIOD SET FORTH IN UNDERSCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY ABOVE e e Some States do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you Any claim under this Limited Warranty must be made in writing within the applicable warranty period to the dealer from which the product was purchased Un less the dealer is no longer in business a written claim to the Manufacturer will be the same as if no claim had been made at all At the Manufacturer s option pursuant to the dealer having notified the Manufacturer of a warranty claim a service representative may inspect the product on site or Buyer may be required to return the product to the Manufacturer at Buyer s expense Buyer agrees to cooperate with any representative of the Manufacturer and to give such representative full access to the product with the claimed defect and full access to the location of its installation If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty the Manufacturer will cause the defective product to be repaired or replaced The decision about the manner in which the defect will be remedied will be at the discretion of t
42. f perforated angles Assemble the easure and mark the jamb approximately 48 to 50 1220 to 1270 mm from floor on the 2 pieces together using 2 3 8 bolts and nuts supplied by others Now secure to the top right or left side of jamb Drill 1 8 pilot hole for no 6 screw eye Tie the pull down rope to the section using carriage bolts and nuts supplied by others thru bolt both the perforated angles to no 6 screw eye and to the bottom corner bracket as shown he top section as shown ign the door arm with hole with one of the holes in the perforated angles Secure the door rm to the perforated angle using 1 5 16 18 x 1 hex head bolt and 1 5 16 18 lock nut supplied by others as shown o 6 Screw eye A N Typical bottom corner bracket ob 2 3 8 Hex bot Top 516 Hex bolt M and lock nut 23 Section Carriage bolt A and lock nut hen EQ D supplied by others 3 and nuts supplied by others 48 to 50 Pull dow j W up led by From floor a 2 Perforated __ f 7 others angles BE Pull _ __ down rope El Center hinge Typical door arm Lift Handles Tools Power drill 1 8 Drill bit Tape measure NOTE Lift handles must be lined up vertically Bottom Section Locate the exterior center stile or center most stile on the bottom section NOTE For
43. f the door especially to springs spring brackets bottom corner brackets fasteners counterbalance lift cables or supports To avoid possible severe or fatal injury have any such work performed by a trained door systems technician using proper tools and instructions 12 On electrically operated doors pull down ropes must be removed and locks must be removed or made inoperative in the open unlocked position 13 Top section of door may need to be reinforced when attaching an electric opener Check door and or opener manufacturer s instructions 14 Visually inspect door and hardware monthly for worn and or broken parts Check to ensure door operates freely 15 Test electric opener s safety features monthly following opener manufacturer s instruc tions 16 NEVER hang tools bicycles hoses clothing or anything else from horizontal tracks Track systems are not intended or designed to support extra weight 17 This door may not meet the building code wind load requirements in your area For your safety you will need to check with your local ments and building permit information After installation is complete fasten this manual near the garage door IMPORTANT STAINLESS STEEL OR PT2000 COATED LAG SCREWS MUST BE USED WHEN INSTALLING CENTER BEARING BRACKETS END BRACKETS JAMB BRACKETS DRAWBAR OP ERATOR MOUNTING SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER PRESERVATIVE TREATED STAINLESS STEEL OR PT2000 LAG S
44. flush doors find the center most stile by locating the center most hinge Using the bottom hole of the lift handle measure up 3 from the bottom of bottom section Mark the hole locations and drill 2 9 32 dia holes through the bottom section On the outside of the door insert 2 1 4 20 x 2 1 2 carriage bolts black head into the outside lift handle and insert the assembly into the 2 pre drilled holes in the bottom section From the inside slide the 2 holes in the inside lift handle over the stems of the carriage bolts Secure the outside and inside lift handle to the bottom section with 2 1 4 20 flange hex nuts Intermediate Section Locate the exterior center stile or center most stile on the Intermediate section Mark a vertical line on the section at that point NOTE Some Garage Doors may require both lift handles to be installed on bottom section If your bottom section height is 28 or 29 install both lift handles onto the bottom section Install bottom lift handle per above instructions then install the second lift handle a Minimum of 20 and a Maximum of 30 above the bottom lift handle Measure up 4 from the bottom of the Intermediate section Using this measurement as a guide position the bottom hole of the lift handle bottom at the mark Make a mark at the top hole of the lift handle This should give you a Minimum of 20 and a Maximum of 30 between the lower lift handle and th
45. g Your Garage Door IMPORTANT DO NOT USE A PRESSURE WASHER ON YOUR GARAGE DOOR An annual inspection of all the surfaces of your garage door s will reveal the extent of weather ing and the possible need for refinishing When the finish becomes eroded or thin clean and prime any areas showing deterioration Then completely refinish the door according to the directions listed below or the manufacturer s label directions Proper finishing of the wood substrates to protect your door s from the effects of moisture and sunlight is vital in extending the service life and beautifying your garage door s The interior and exterior surfaces as well as all edges must be properly primed painted and maintained to protect and beautify your door These finishing instructions are intended to achieve both objectives for your wood doors s NOTE Be sure to clean behind weatherstrips on both sides and top of door CAUTION NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH GLASS CLEANING INSTRUCTIONS Clean with a mild detergent solution same as above and a soft cloth After cleaning rinse thoroughly ACRYLIC CLEANING INSTRUCTIONS Clean acrylic glazing with nonabrasive soap or detergent and plenty of water Use your bare hands to feel and dislodge any caked on particles A soft grit free cloth sponge or chamois may be used to wipe the surface Do not use hard or rough cloths that will scratch the acrylic glazing Dry glazing with a clean damp
46. he Find a Dealer section online at www Wayne Dalton com Half Center Hinges Tools Power drill 7 16 Socket driver Tape measure NOTE If you don t have half center hinges then skip this step Refer to Package Contents Parts Breakdown to determine if you have half center hinges Using a tape measure position the half center hinges equally spaced in between the center inges and equally spaced in between the center hinges and the graduated end hinges osition the holes of the lower hinge leaf onto the bottom section surface as shown Using he half center hinge as a template drill pilot holes 1 deep into the bottom section using a 8 drill bit r MPORTANT BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION ONLY DRILL 1 DEEP Attach the lower hinge leaf of the center hinge to the bottom section using 2 1 4 14 x 1 ag screws Repeat for other half center hinge s Set the bottom section aside Place the Intermediate section face down on a couple of sawhorses or flat clean smooth surface Reference step Graduated End And Center Hinges and this step to attach the long ruts if applicable and hinges to the top rail of the sections in the same manner as was done for the bottom section Repeat the same process for the other Intermediate section s if applicable except top section n Half gt Equally spac
47. he Manufacturer subject to applicable law THE REMEDY WILL COVER ONLY MATERIAL THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES SUCH AS FIELD SERVICE LABOR FOR REMOVAL INSTALLATION PAINTING SHIPPING ETC Any repairs or replacements arranged by Manufacturer will be covered by and subject to the terms conditions limitations and exceptions of this Limited War ranty provided however that the installation date for the repaired or replaced product will be deemed to be the date the original product was installed and this Limited Warranty will expire at the same time as if there had been no defect If a claim under this Limited Warranty is resolved in a manner other than described in the immedi ately preceding paragraph then neither this Limited Warranty nor any other warranty from the Manufacturer will cover the repaired or replaced portion of the product THE REMEDIES FOR THE BUYER DESCRIBED IN THIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy The liability of the Manufac turer whether in contract or tort under warranty product liability or otherwise will not go beyond the Manufacturer s obligation to repair or replace at its option as described above THE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES including but not limited to damage or loss of other property or equipment personal injury loss of profits or revenues business or service interruption
48. he bottom corner bracket vertically with the left bottom edge of the bottom section Mark and pre drill 3 9 32 diameter holes through the bottom section and attach the bottom corner bracket to the bottom section using 3 1 4 20 x 2 1 2 carriage bolts and 3 1 4 20 flange hex nuts as shown 3 1 4 20 3 1 4 20x 2 1 2 Flange hex nuts Carriage bolts Bottom section Typical left hand i bottom corner bracket 1 1 4 10 x 1 Tamper resistant lag screw Track Roller Carriers Tools Power Drill 9 32 Drill Bit Socket Driver 7 16 Wrench 7 16 Starting on left hand side of the bottom section attach the track roller carrier with the stamp STD facing UP to the bottom corner bracket by aligning the four holes of the track roller carrier with the four holes in the bottom corner bracket Secure the track roller carrier to the bottom corner bracket with 4 1 4 20 x 7 8 self drilling screws or 4 1 4 14 x 1 lag Screws NOTE Depending on your door some track roller carriers will use 1 4 14 x 1 lag screws instead of the 1 4 20 x 7 8 self drilling screws to secure in place If this is the case mark and pre drill 4 1 8 diameter holes and secure the track roller carrier to the bottom corner bracket and bottom section using 4 1 4 14 x 1 lag screws Insert a short stem track roller and spacer into the inner holes
49. he second top fixture next to the first installed top fixture and loosely attach it with 2 1 4 14 x 1 lag screws Insert a long stem track roller into the top fixture slides Repeat the same process for the right hand side 2 To atures Top section Long stem trac A Sa e 2 1 4 14x1 Lag screws D Left hand top fixture Strutting For Top Section Tools Power drill 7 16 Socket driver NOTE Refer to the Door Section Identification and Strut Identification to determine if the top section requires a short strut to be installed Lay the short strut onto the top rail of the top section Position the top of the strut 3 4 down from the top edge of the top section Center the short strut from side to side on the section surface Drill pilot holes 1 deep into the top section using a 1 8 drill bit IMPORTANT BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION ONLY DRILL 1 DEEP Attach the strut using 2 1 4 14 x 1 lag screws at each on each end and center stile aligned with hinges locations Short strut Zz Top section Typical to rte i 1 4 14x 1 Lag screws Bottom Section Tools Level Wooden shims if necessary Center the bottom section in the door opening Level the section using wooden shims if necessary under the bottom section Weather seal aii
50. iations PARTS BREAKDOWN B Aa a 413 A TRACK ROLLERS AS REQUIRED A1 Short Stem Track Rollers A2 Long Stem Track Rollers A3 Short Stem Tandem Track Rollers A4 Long Stem Tandem Track Rollers B GRADUATED END HINGES B1 Single Graduated End Hinges S E H Industry Standard B2 Double Graduated End Hinges D E H Industry Standard B3 Half Center Hinges As Required C STACKED SECTIONS C1 Top Section C2 Intermediate s Section As Required C3 Bottom Section D TOP FIXTURES AS REQUIRED D1 Top Fixtures E STRUT S U SHAPED AS REQUIRED E1 Str t 2 And Or 3 F TRACKS AS REQUIRED F1 Le Hand and Right Hand Horizontal Track Assemblies F2 Le F3 Lefi F4 Lefi F5 Left Hand and Right Hand Riveted Track Assemblies As Required Hand and Right Hand Wall Angle Track Assemblies As Required Hand and Right Hand Vertical Track Assemblies As Required Hand and Right Hand Vertical Tracks As Required F6 Le Hand and Right Hand Fully Adjustable F A Flag Angles As Required G13 dt ay iil F Q 4 Q N F7 Left Hand and Right Hand Fully Adjustable F A Jamb Brackets As Required G TORSION SPRING ASSEMBLY AS REQUIRED G1 Center Bracket Bushing Assembly G2 Center Bearing Bracket Assembly G3 Torsion Shaft
51. l Placement Tools Step Ladder IMPORTANT USING THE ILLUSTRATION ATTACH THE APPROPRIATE LABELS TO THE AP PROPRIATE LOCATION ON THE SECTION AS SHOWN NOTE The Spring Warning tag s are factory attached one per spring NOTE Because of different configurations some labels may require minor relocations Torsion spring tag s one per spring Residential Dust label For California Residents Only i Residential warming label mi E AWARNING AWARNING _ Wood label important notice gS T Tm 38 gt Bottom section warning labels Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com Optional Installation Tote ee A WARNING Tools Needle nose pliers j A WARN I NG DO NOT INSTALL PULL DOWN ROPE ON DOORS WITH OPERATORS CHILDREN At the center of the top section measure horizontally from the top of center hinge to the bottom MAY BECOME ENTANGLED IN THE ROPE CAUSING SEVERE OR FATAL INJURY of strut Using that dimension measure and cut 2 pieces o
52. l amounts of the shafts extending from each end bearing brackets Stationary spring cone Typical center bracket Stationary spring cone Torsion spring g warning tags Center bearing bracket s Torsion Coupler spring assembly Center bearing Center bearing inside torsion spring Torsion keyed shaft Typical center bracket assembly Torsion Torsion spring spring 2 3 8 16 x 1 1 2 Hex head bolts Stationary spring cone Center bearing brackets Coupler assembly 3 3 8 16 nylon hex lock nuts Torsion Torsion keyed 5 shaft JA 3 3 8 16 x 1 3 4 Coupler hex head screws halves Counterbalance Lift Cables Tools Step Ladder Locking Pliers 3 8 Wrench Starting on the left hand side thread the counterbalance lift cable up and around the front side of the left hand cable drum IMPORTANT VERIFY THAT THERE ARE NO COUNTERBALANCE LIFT CABLE OBSTRUCTIONS Hook the counterbalance lift cable into the left hand cable drum Starting on the left hand side slide the left hand cable drum onto the torsion shaft and up against the left hand end bearing bracket Counterbalance lift cable should provide a minimum of 1 2 pre wrap on the cable drum Tighten the 2 set screws in the cable drum to 14 15 ft Ibs of torque once set screws contact the shaft tighten set screw
53. member and parallel to door 3 5 16 Bolts and nuts Perforated angle Vice clamp Micecamp 2nd Track roller pl e ra el a Sound framing j a members i wie ae gern a ar z SS 2i a AS 24 Perforated angle bolted 3 5 16 Bolts and nuts Horizontal track Perforated angle 5 16 18 x 1 1 4 Hex bolts must extend into the track to serve as a roller stop edoooopoooo pao 7 hzer p peee R Sound framing members Perforated angle bolted using 2 5 16 x 1 5 8 hex head lag screws to ceiling member and parallel to door Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com gt lt 3 4 To 7 8 3 4 To 7 8 gt lt _______ Door edges __ gt e Horizontal tracks _ gt gt l Rear center back hang ee 1 3 8 Truss head bolt may not be supplied 1 3 8 Nut may not be supplied 5 horizontal rac L k k 4 2 Drill 3 8 diameter hole ik Center of the horizontal track gt Labe
54. n area only If you are unable to reach the lift handles suitable gripping points only use pull down rope affixed to the side of door Door should close completely with little resistance Using an electric operator IMPORTANT PULL DOWN ROPES MUST BE REMOVED AND LOCKS MUST BE REMOVED OR MADE INOPERATIVE IN THE UNLOCKED POSITION When connecting a drawbar trolley type garage door operator to this door an drawbar opera tor and or drawbar operator bracket must be securely attached to the top section of the door along with any struts provided with the door Always use the drawbar operator and or drawbar operator bracket supplied with the door To avoid possible damage to your door Wayne Dalton recommends reinforcing the top section on models 8000 8100 8200 and 9100 doors with a strut may or may not be supplied The installation of the drawbar operator must be according to manufacturer s instructions and force settings must be adjusted properly Refer to the owner s manual supplied with your drawbar operator for complete details on installation operation maintenance and testing of the operator MAINTAINING YOUR GARAGE DOOR Before you begin read all warning labels affixed to the door and the installation instructions and owner s manual Perform routine maintenance steps once a month and have the door professionally inspected once a year Review your Installation Instructions and Owner s Manual for the garage door These instructions
55. nded to follow the procedures outlined in DASMA technical data sheets 156 161 and 164 at www dasma com The inside perimeter of your garage door opening should be framed with wood jamb and header material The jambs and header must be securely fastened to sound framing members It is recommended that 2 x 6 lumber be used The jambs must be plumb and the header level The jambs should extend a minimum of 12 305 mm above the top of the opening for Torsion counterbalance systems For low headroom applications the jambs should extend to the ceiling height Minimum side clearance required from the opening to the wall is 3 1 2 89 mm for 2 track Minimum side clearance required from the opening to the wall is 4 1 2 114 mm for 3 track IMPORTANT CLOSELY INSPECT JAMBS HEADER AND MOUNTING SURFACE ANY WOOD FOUND NOT TO BE SOUND MUST BE REPLACED For Torsion counterbalance systems a suitable mounting surface 2 x 6 must be firmly at tached to the wall above the header at the center of the opening NOTE Drill a 3 16 pilot hole in the mounting surface to avoid splitting the lumber Do not attach the mounting surface with nails WEATHERSTRIPS MAY NOT BE INCLUDED Depending on the size of your door you may have to cut or trim the weatherstrips if necessary to properly fit into the header and jambs NOTE If nailing product at 40 F or below pre drilling is required NOTE Do not permanently attach w
56. on to ensure that the interior and exterior surfaces as well as all edges of the doors are properly protected against moisture or other contaminants Wood doors in a non finished condition must be transported and stored so the wood surfaces are NOT exposed to moisture or other contaminants If the door s is not finished within TEN 10 DAYS of delivery this warranty shall only extend to defects in workmanship and materials that appear within ONE 1 MONTH IMPROPER TRANSPORTATION STORAGE OR DELAYS IN FINISHING THAT ALLOWS EXPOSURE OF THE WOOD DOOR SURFACES TO MOISTURE OR OTHER CON TAMINANTS WILL RESULT IN THE WARRANTY BEING VOIDED The Manufacturer warrants the garage door hardware tracks and springs of the above described door for a period of ONE 1 YEAR from the date of installa tion against defects in material and workmanship subject to all the terms and conditions below The Manufacturer will not be responsible for grain and color variations of natural wood These natural variations in grain and color are not product defects and therefore will not be considered under this Limited Warranty The Manufacturer uses high quality material for framework door skins overlays and panel materials Exposure of wood to the environment may cause bowing checking and or cracking of a door section regardless of efficiency of painting This is not considered a defect it is an uncontrollable characteristic of natural wood The dealer and the end user have
57. ong Top Of Section Intermediate IV 1 Long Intermediate III Intermediate Il Intermediate Top Of Section Bottom om Of section 2 Strut Long strut Upper hinge Short strut Center hinge s PP saf t as ar hinget 0 km Lower hinge ft Hinges are stamped for leaf y l identification ooo 2 1 Half center hinge s _ 2 as require amp Removing an Existing Door G IMPORTANT COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR A WARNING A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY TO AVOID INJURY HAVE A TRAINED DOOR SYSTEMS TECH NICIAN USING PROPER TOOLS AND INSTRUCTIONS RELEASE THE SPRING TENSION For detailed information see supplemental instructions Removing an Existing Door Preparing the Opening These instructions are not supplied with the door but are available at no charge from Wayne Dalton A Division Of Overhead Door Corporation P O Box 67 Mt Hope OH 44660 or at www Wayne Dalton com IMPORTANT IF YOU JUST REMOVED YOUR EXISTING DOOR OR YOU ARE INSTALLING A NEW DOOR COMPLETE ALL STEPS IN PREPARING THE OPENING To ensure secure mounting of track brackets side and center brackets or steel angles to new or retro fit construction it is recomme
58. orque once set screws contact the shaft tighten set screws one full turn Insert 1 key shaft into the slot of both the coupler halve and the slot in the torsion keyed shaft as shown Repeat the same process for the other side With assistance and starting on the left hand side of door pick up the left hand torsion spring assembly and slide one end of the torsion keyed shaft through the end bearing bracket Lay the other side of the torsion keyed shaft into the center bracket Repeat the same process for the right hand torsion spring assembly Position both torsion keyed shafts so that equal amounts of the shafts extend from each end bearing brackets Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com Black cable drum Coupler ll right hand side halves Cema Torsion coupler eye Set assembly shaft collar x Coupler Right hand wound 3 3 8 16 x 1 3 4 Hex head screws halves red winding cone and 3 3 8 16 Nylon hex lock nut right hand side Red cable drum left hand side Set screws and Lock nut bearing Left hand wound black winding cone left hand side Coupler halves assemblied Center bearing bra
59. ot Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com IF YOU HAVE 3 VERTICAL TRACKS Tighten lag screws securing the bottom jamb bracket bottom slot to jamb maintain 1 2 to Typical graduated end hinge with typical lon L stem tandem track roller i v Intermediate section be Oo Left double graduated m g end hinge with typical A long stem track roller Vertical tracks g O E i e Right double graduated Bottomisection end hinge with typical ong stem track roller 2 1 4 20 x 2 1 2 Carriage bolts and 2 1 4 20 Flange hex nuts 2 9 Left single m graduated end a Right single a kr hinge with graduated end hinge a typical short Center with typical short 5 stem track roller hinge s stem track roller 3 4 spacing between the bottom section and vertical track Hang counterbalance lift cable over flag angle wall angle Repeat same process for other side Wallangl j ane Riveted track assembly j flag angle gt snown e 0 Lag scre
60. ove the door Measure from the center of the bearing in one of the end bearing brackets downwards 0 the top the door Using that measurement measure that distance upwards from the top of the door to the mounting surface and mark a horizontal pencil line which intersects the vertical pencil line s Align the edge of the center bracket s with the vertical pencil line and he center of the center bracket s with the horizontal pencil line this is to ensure the torsion shaft is level between the center and end bearing brackets Attach the center bracket s to the mounting surface using 2 5 16 x 1 5 8 lag screws and 1 5 16 x 2 tamper resistant lag screw IMPORTANT USE A 5 16 X 1 5 8 TAMPER RESISTANT LAG SCREW INSTEAD OF THE 5 16 X 2 TAMPER RESISTANT LAG SCREW IF MOUNTING SURFACE IS MOUNTED OVER MASONRY TAMPER RESISTANT LAG SCREW MUST BE ATTACHED THROUGH THE BOTTOM HOLE OF THE CENTER BRACKET S i ountin Typical Center of typical a Hace canter gone bearing bracket bracket H fi i 4 Horizontal _ Vertical N line _ line Equal distance from top of door section to horizontal line Center of typical end bearing bracket L lo gt lounting _ Center bracket Vertical Mounting surface 1 bushing assembly line surface F 2 5 16 x 1 5 8 2 5 16 x
61. prings Tools Step Ladder Approved winding bars 3 8 Wrench Position a ladder slightly to the side of the spring so that the winding cone is easily acces sible and so your body is not directly in line with the winding bars IMPORTANT CHECK THE LABEL ATTACHED TO THE SPRING WARNING TAG FOR THE REQUIRED NUMBER OF COMPLETE TURNS TO BALANCE YOUR DOOR A WARNING PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS ENSURE YOU RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTAL LATION INSTRUCTIONS OTHERWISE THE SPRING FITTINGS MAY RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND COULD RESULT IN SEVERE OR FATAL INJURY Alternately inserting the winding rods into the holes of the springs winding cone rotate the winding cone downward toward the floor 1 4 turn at a time until the required number of complete turns for your door height is achieved As the last 1 8 to 1 4 turn is achieved securely hold the winding rod while tightening both set screws in the winding cone to 14 15 ft Ibs of torque once set screws contact the torsion shaft tighten screws one full turn Carefully remove winding rod from winding cone Repeat for the opposite spring While holding the door down to prevent it from raising unexpectedly in the event the spring s were over wound carefully remove the locking pliers from the torsion shaft and vertical tracks Adjustments to the number of turns stated may be necessary If door rises off floo
62. r under spring tension alone reduce spring tension until door rests on the floor If the door is hard to ise or drifts down on its own add spring tension NOTE An unbalanced door such as this can cause garage door opener operation problems Approved winding rods Winding cone Rear Back Hangs Tools Ratchet wrench Socket 1 2 5 8 Wrench 1 2 5 8 2 Vice IMPORTANT HOLD THE DOOR DOWN TO PREVENT IT FROM RISING UNEXPECTEDLY IN THE EVENT THE SPRING S WAS OVER WOUND AND CAUTIOUSLY REMOVE VICE CLAMPS FROM VERTICAL TRACKS Raise the door until the top section and half of the next section are in the horizontal track radius Do not raise door any further since rear of horizontal tracks are not yet supported A WARNING RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE SEVERE OR FATAL INJURY Clamp a pair of vice clamps onto the vertical tracks just above the second track roller on one side and just below the second track roller on the other side This will prevent the door from raising or lowering while installing the rear back hangs Using perforated angle may not be supplied 2 5 16 x 1 5 8 hex head lag screws and 3 5 16 bolts with nuts may not be supplied fabricate rear back hangs for the horizontal tracks Attach the horizontal tracks to the rear back hangs with 5 16 18 x 1 hex bolts and nuts may not be supplied NOTE
63. rmanently attach the weatherstrips on both door jambs and header The weather strips were temporarily attached in Preparing the Opening in the pre installation section of this manual NOTE When permanently attaching the weatherstrips erstrips too tightly against the face of door A WARNING PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS ENSURE YOU RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTAL LATION INSTRUCTIONS OTHERWISE THE SPRING FITTINGS MAY RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND COULD RESULT IN SEVERE OR FATAL INJURY ow lift door and check its balance Adjustments to the required number of spring turns o the jambs avoid pushing the weath state sprin set s the s cable d may be necessary tension until door rests on g tension A poorly bal To adj Insert a winding rod into ension must be main st spring tension crews in the winding u he winding con tained by placing vice cone Push upward on REPARED TO SUPPORT THE FULL FORCE OF door rises ofi ly close door et screws in the winding cone BE PI TORSION SPRING ONCE TI H screws in the wi E SET SCREWS floor un he floor If the door is anced door can cause e On sin ARE LOOSE Carefully adj der spring tension alone reduce spri hard to rise or drifts down on its own gle spring doors counterbalance lift grips on torsion shaft before looseni he winding
64. s 2 3 16 to 2 1 4 4 p l af Fla angie or n wallangle assembly A op 7 m section Y g A Vertical track against rollers Horizontal Tracks Tools Ratchet wrench 7 16 Socket 9 16 Socket 9 16 Wrench To install horizontal track place the curved end over the top track roller of the top section Align the bottom rail of the horizontal track with the top of the vertical track Tighten the bot om rail of the horizontal track to the flag angle or wall angle with 2 1 4 20 x 9 16 track bolts and 2 1 4 20 flange hex nuts Wall angle Bottom rail of Flag angle horizontal track Bottom rail of horizontal track Ge 2 1 4 20 2 1 4 20 ridge hex nuts S Fange hex nuts Vertical i track 2 1 4 20 x 9 16 ae 2 1 4 20 x 9 16 Track bolts Track bolts A WARNING DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT REAR AS OUTLINED IN STEP REAR BACK HANGS OR DOOR COULD FALL FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY Level the horizontal track assembly For riveted track assembly bolt the top rail of the horizontal track to the first encountered slot in the flag angle using 1 1 4 20 x 9 16 track bolt 1 washer and 1 1 4 20 flange hex nut For wall angle track assembly first bolt the angle of the horizontal track to the slots in the wall angle using 2 3 8 16 x 3
65. s cost of capital cost of purchase or replacement of other goods or claims of third parties for any of the foregoing e e Some States do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you No employee distributor dealer representative or other person has the authority to modify any term or condition contained in this Limited Warranty or to grant any other warranty on behalf of or binding on the Manufacturer and anyone s attempt to do so will be null and void Buyer should be prepared to verify the date of installation to the satisfaction of the Manufacturer The rights and obligations of the Manufacturer and Buyer under this Limited Warranty will be governed by the laws of the State of Ohio USA to the extent permitted by law e e This Limited Warranty gives you specific legal rights and you may also have other rights which may vary from State to State NOTE Variations in color or graining of natural wood is not considered a product defect and therefore not covered under the limited warranty Grain and color variations are inherent to natural wood These natural variations in grain and color are not product defects and therefore will not be considered under Wayne Dalton s limited warranty Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages bu
66. s one full turn NOTE For doors with a torsion keyed shaft insert 1 key shaft into the slot of both the cable drum and the slot in the torsion keyed shaft as shown Rotate the left hand drum and torsion shaft until counterbalance lift cable is taut Now attach locking pliers to the torsion shaft and brace locking pliers against the jamb to keep counter balance lift cable taut Repeat the same process for right hand side Now secure the coupler assembly by tightening the 3 3 8 16 x 1 3 4 hex head screws and the 3 3 8 16 hex nuts IMPORTANT INSPECT EACH COUNTERBALANCE LIFT CABLES MAKING SURE THEY ARE SEATED PROPERLY ONTO THE CABLE DRUMS AND THAT BOTH COUNTERBALANCE LIFT CABLES HAVE EQUAL TENSION Left hand end bearing bracket Counterbalance lift cable installed Cable drum set screws Counterbalance lift cable Left hand cable drum Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com Center bearing brackets 3 3 8 16 Coupler nylon hex lock assembly Torsion nuts Torsion keyed shaft jy 3 8 16 x 1 3 4 3 hex head screws Coupler halves Left hand end Torsion spring bearing bra
67. siness listings or go to the Find a Dealer section online at www Wayne Dalton com Covered by one or more of the following Patents 5 408 724 5 409 051 5 419 010 5 495 640 5 522 446 5 562 141 5 566 740 5 568 672 5 718 533 6 019 269 6 089 304 6 644 378 6 374 567 6 561 256 6 527 037 6 640 872 6 672 362 6 725 898 6 843 300 6 915 573 6 951 237 7 014 386 7 036 548 7 059 380 7 121 317 7 128 123 7 134 471 7 134 472 7 219 392 7 254 868 Canadian 2 384 936 2 477 445 2 495 175 2 507 590 2 530 701 2 530 74 2 2 532 824 Other US and Foreign Patents pending Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com AFTER INSTALLATION IS COMPLETE FASTEN THIS MANUAL NEAR THE GARAGE DOOR
68. the responsibility to select the type of material and or door which will offer the best results and longevity for the climate and or environ mental condition in which they will use the product This Limited Warranty is extended only to the person who purchased the product and continues to own the premises where the door is installed as his her primary residence Buyer This Limited Warranty does not apply to residences other than primary or to commercial or industrial installations or to installations on rental property even when used by a tenant as a residence This Limited Warranty is not transferable to any other person even when the premises is sold nor does it extend benefits to any other person As a result this Limited Warranty does NOT apply to any person who purchases the product from someone other than an authorized Wayne Dalton dealer or distributor The Manufacturer will not be responsible for any damage attributable to improper storage improper installation or any alteration of the door or its components abuse damage from corrosive fumes or substances salt spray or saltwater air fire Acts of God failure to properly maintain the door or attempt to use the door its components or related products for other than its intended purpose and its customary usage This Limited Warranty does not cover ordinary wear This Limited Warranty will be voided if any holes are drilled into the door other than those specified by the Manufactur
69. tion s Bottom Bottom as required Hinges hinges as required amp nails If included rail rail lt 1 i 1 Side views of sections Bottom Top Intermediate s Bottom section section section Bottom weather seal with A od es Pull down rope 1 4 20 x 9 16 NOTE 3 Section high doors does not have 3 4 nails as required as required if included Track bolts as required an Intermediate II Section Graduated End Hinge And Strut Identification 1 4 14x1 Graduated End Hinge Schedule Lag screws as required H 2 3 8 16 x 3 4 russ head bolts Graduated End Hinge Number 2 3 8 16 Hex nuts Door Height Track Section Type Intermediate istant hex head intermediate as required 5 16 x 2 Tamper resi lag screw Bottom 3 Section High Door Top Intermedia Bottom Top 5 16 x 1 5 8 Hex head lag screws 4 20 Flanged z as required hex nuts as requited Intermedia Intermedia Bottom 4 Section High Door Top 1 4 10 x 1 Tamper resistant hex head lag screw as required 3 8 16 x 1 1 2 Hex bolts Intermediai Intermedia Bottom WA WA WA WA WA Top 1 4 20 x 2 1 2 Carriage bolts as required Intermediate III Intermediate II Intermediate ee Bottom 5 Section High Door J 1 4 20 x 7 8 Self U 5 16
70. tom section using 1 1 4 14 x 1 lag screw Next secure the bottom leg of strut if ap plicable to the lower slot of the graduated end hinge to the bottom section using 1 1 4 14 x 1 lag screw as shown Repeat same process for other side Single graduated end hinge i Double graduated end hinge with Shit Siem track roller A Y with ion stem track roller Hinge A Lower hinge __ Long strut Shot tunes TIO ot eats if applicable 1 Strut clip i if applicable o Typical 2 1 4 14x1 c Lag screws section shown 2 1 4 20 x 2 1 2 Carriage bolts and 2 1 4 20 Flange hex nuts Hinge Single graduated end hinge with short stem tandem roller 1 Strut cli i S icab B Short edge a A tube s Double graduated end hinge ven Sy q Q with ion stem tandem roller Short n Lowerhinge _ Long strut y U leaf s if applicable 1 Strut cli i NS ij int N 0 LAO O 2 1 4 14x1 Typical Lag screws section shown 2 1 4 20 x 2 1 2 Carriage bolts and 2 1 4 20 Flange hex nuts FOR CENTER HINGES WITHOUT A STRUT Starting on the left hand side attach the upper slot of the center hinge to the bottom section sing 1 1 4 20 x 2 1 2 carriage bolt
71. w a L locations P iP 5 16 x 1 5 8 H Lag screws S T A INI Jamb Ne ye bracket Ba Fuy Adjustable Riveted 4 angle flag angle flag angle R potom 2 Vertical track Bottom spacing 3 8 to 5 8 section Cc K Track _3 Vertical track rollers spacing 1 2 to 3 4 as Floor Track roller Vertical track assembly Stacking Sections Tools Power drill 7 16 Socket driver NOTE Make sure graduated end and center hinges are flipped down when stacking another section on top With assistance lift intermediate second section and guide the track rollers tandem rollers into the vertical tracks Lower section until it is seated against bottom section Keep sections aligned Repeat same process for other sections except top section FOR GRADUATED END HINGES AND CENTER HINGES Starting with the outer graduated end hinges flip the upper hinge leaf up and secure to the section using 2 1 4 20 x 2 1 2 carriage bolts and 2 1 4 20 flange hex nuts Repeat same process for the center hinges If you have double graduated end hinges flip the inner upper hinge leaf up and use it as a template Mark and pre drill 2 1 8 pilot holes 1 deep into the section using a 1 8 drill bit Attach the upper hinge leaf to the section using 2 1 4 14 x 1 lag screws Repeat same process for other
72. x 1 5 8 Hex head lag screws Top drilling screws as required as required Intermediate III 7 Orne Inte diate amp Door Section Identification When installing your door you must use sections of the appropriate height in the right stacking location Determine what sections you need to use in what order depends on the design of your door Sections are stamped for identification 1 2 3 4 5 6 7 and 8 The stamp located on each side of the sections identifies the stacking sequence The sequence is always deter mined by 1 being the bottom section to 7 or 8 being the highest top section If the stamp on the section is illegible refer to the section side view illustration The section side view illustration shows the section profile of all sections and can also be used to identify each section Intermediate Bottom Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com Graduated End Hinge Schedule 3 Section High Strutting Schedule

Wayne-Dalton 44 User's Manual

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