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Wayne-Dalton 5500 Garage Door Opener User Manual

1. Lock section Lift handles Pull handle A Bottom section 20 Minimum to 30 Maximum Typical placement of lift handles referenced on double wide doors Lift handles dd ha Bottom Lock section section 20 Mini to 30 Maxi Pull handle a S E Pull handle cS y Pull Handles Tools Tape Measure Pencil Power Drill 1 16 Drill Bit Locate and mark the horizontal and vertical center on the bottom rail of the bottom section on single car doors Center the pull handle using the vertical and horizontal lines as referenced on the bottom section rail Using the pull handle as a template mark the two hole locations in the pull handle onto the horizontal line of the bottom section rail Drill 1 16 pilot holes at the marked hole locations Fasten pull handle s using 2 10 X 5 8 pan head self tapping screws f your door came with two pull handles locate them directly below the lift handles and repeat the installation process Center stile i Bottom section r Z l PSr 2 10 X 5 8 Pan head self tapping screws j Pull handle Bottom rail l Typical placement of pull hand
2. 30 To 36 Long leg Strut A symmetrical side view eae Short leg Drawbar Operator Bracket Tools Power drill 7 16 Socket driver Flat head screwdriver 7 16 Wrench Tape measure Pencil IMPORTANT WHEN CONNECTING A DRAWBAR OPERATOR TYPE GARAGE DOOR OPENER TO THIS DOOR A WAYNE DALTON OPERATOR DRAWBAR OPERATOR BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR ALONG WITH ANY STRUT PROVIDED WITH THE DOOR THE INSTALLATION OF THE DRAWBAR OPERATOR MUST BE AC CORDING TO MANUFACTURER S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED PROPERLY Position the drawbar operator bracket arm inside the top portion of the top half of drawbar operator bracket and flush against the back of the top half of drawbar operator bracket Adjust the top holes in the drawbar operator bracket arm with the two upper holes in the top half of drawbar operator bracket Fasten both the drawbar operator bracket arm and the top half of drawbar operator bracket ogether using 2 1 4 20 x 9 16 track bolts and 2 1 4 20 flange hex nuts Slide the bottom half of drawbar operator bracket inside the top half of drawbar operator bracket Adjust the both the top and bottom halves of drawbar operator brackets out against he top and bottom rib of the top section Loosely fasten both the top and bottom halves of drawbar operator brackets toget
3. Fully Adjustable Flag Angles Tools None NOTE If you have Quick Install flag angles skip this step NOTE If you have riveted track skip this step NOTE Flag angles are right and left handed f you have Quick Install vertical tracks hand tighten the left hand flag angle to the left hand vertical track using 1 stud plate and 2 1 4 20 flange hex nuts Repeat for the other side 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 Flag angle 1 4 20 1 4 20 Flange hex nuts Flange hex nuts Z Stud Z GZ plate W 1 4 20 x 9 16 Quick Install Fully Adjustable Track bolts vertical vertical track track Quick Install Jamb Brackets Tools None NOTE If you have Fully Adjustable jamb brackets skip this step NOTE If you have riveted track skip this step Measure the length of the vertical tracks Using the jamb bracket schedule determine the placement of the jamb brackets for your door height and track length To install the jamb brackets align the Quick Install tab on the Quick Install jamb bracket with the Quick Install feature in the vertical track and
4. Door sections as required TorqueMaster spring tube zE Ss a EZ En J T 7 A CYT TEE 2 VV N WY D N N VSS Quick Install flag angles RH LH Fully Adjustable flag angles RH LH as required as required zoe 00 woe leas ome T Too y Vertical tracks RH LH HE jo Horizontal tracks RH LH 0 lt y Y lt L Quick instal jamb Fully Adjustable jamb Center bracket brackets as required brackets as required End brackets RH LH bushing assembly GZ 2 Top fixtures o i Loose winding shaft single spring only Cable drum assemblies RH LH X S gt of Drum urapa RH LH as O hed down ibi Weenen S amp nails Track rollers Strut A sae as required if include included rope if included s S E e Top half drawbar Serre half drawbar Drawbar operator Stud Plate operator bracket operator bracket bracket arm as required 1 4 20 panged hex nuts as required g 2 5 16 Washers 2 3 8 16 Hex nuts 2 5 16 18 Hex nuts 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 5 16 x 1 5 8 Hex head lag screws 1 4 20
5. NOTE If you have Fully Adjustable flag angles complete this step To install horizontal track place the top rail end over the top track roller of the top section Align the bottom rail end of the horizontal track with the top of the vertical track If you have Quick Install horizontal track tighten the bottom rail of the horizontal track to the flag angle with 1 stud plate and 2 1 4 20 flange hex nuts If you have Universal horizontal track tighten the bottom rail of the horizontal track to the flag angle with 2 1 4 20 x 9 16 track bolts and 2 1 4 20 flange hex nuts 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 and bolt the top rail of the horizontal track to the encoun tered slot in the flag angle using 1 1 4 20 x 9 16 track bolt 1 1 4 20 flange hex nut and 1 5 16 washer 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 NOTE If an idrive opener will be installed position horizontal tracks slightly above level Bottom rail Bottom rail Full ou 1 4 20 x 9 16 Quick Ins
6. 20 x9 16 Track bolts T and 2 1 4 20 Flange hex nuts 1 quadrex pan head To Drawbar operator bracket arm patton bracket section surface a 1 4 20 x9 16 Track bolts nd 4 1 4 20 Flange hex nuts Bottom half of drawbar h operator bracket Bottom rib Top half of drawbar operator bracket Drawbar operator bracket arm 1 4 20 X 11 16 Top rib Self drilling screws Top half of drawbar operator ake Top section surface Bottom half of drawbar operator bracket Quadrex pan head screw Bottom rib 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 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 Position flag angle between 1 11 16 43 mm to 1 3 4 44 mm from the edge of the door tighten the bottom lag screw Flag angles must be parallel to the door sections Repeat same process for other side IMPORTANT THE DIMENSION BETWEEN THE FLAG ANGLES MUST BE DOOR WIDTH PLUS 3 3 8 86MM TO 3 1 2 89 MM FO
7. AS REQUIRED A1 Fully Adjustable F A Flag Angles A2 Quick Install Q 1 Flag Angles B JAMB BRACKETS AS REQUIRED B1 Fully Adjustable F A Jamb Brackets B2 Quick Install Q 1 Jamb Brackets C TRACK ROLLERS C1 Short Stem Track Rollers C2 Long Stem Track Rollers D GRADUATED END HINGES D1 Single Graduated End Hinges S E H Anti Pinch D2 Single Graduated End Hinges S E H Industry Standard D3 Double Graduated End Hinges D E H Anti Pinch D4 Double Graduated End Hinges D E H Industry Standard E STACKED SECTIONS E1 Top Section E2 Intermediate s Section E3 Lock Section E4 Bottom Section F TOP FIXTURES F1 Top Fixture Assemblies G STRUT S G1 Strut U shaped G2 Strut A symmetrical A2 Fully Adjustable eature Lower hole of hole slot pattern Top of vertical Top of vertical track track 3rd hole N N amp st g R 14 i 3rd R Be Quick hole set Feature ald S it ole set RI R i 0 Q 2nd Q hole set s i i i To hole 1st hole S Middle S set 5 hole jj it i Bottom hole set hole H DRAWBAR OPERATOR BRACKET FOR TROLLEY OPERATED DOORS H1 Top Half Drawbar Operator Bracket H2 Bottom Half Drawbar Operator Bracket H3 Drawbar Operator Bracket Arm I TRACKS 11 Left Hand Horizontal Trac
8. HAVE A QUALIFIED DOOR SYSTEMS TECHNICIAN RESET THE SYSTEM A WARNING TO AVOID SEVERE OR FATAL INJURY DO NOT STAND OR WALK UNDER A Ratchet Ww wrench qe Pawl knob in lower position MOVING DOOR OR PERMIT ANYONE TO STAND OR WALK UNDER AN ELECTRI CALLY OPERATED DOOR This door is equipped with a TorqueMaster plus system a safety feature which prevents the raul A door from rapidly descending in case of spring failure or forceful manual operation If the system End bracket Heat engages with the door in the open position personal items that are left unattended in the garage Ratchet wheel pper p or home are at risk to theft To ensure the safekeeping of these items close the garage door TorqueMaster Plus p Typical signs of an engaged system reset instructions tag 5 8 socket Single spring system Visually inspect the TorqueMaster Plus right hand end bracket to con firm that the system has engaged see illustration If the system is engaged then the door will not close If the drawbar operator force settings were properly set during the initial installation the door will not open If the drawbar operator can physically overcome the weight of the door and lift it to the open position then the counterbalance lift cables will be slack If the system is engaged DO NOT attempt to make the repairs Instead have a trained door system technician Align hole in the door arm wi
9. a second and third vertical line parallel to the previously made center line mark low measure the height of the panel Divide that measurement in half and mark a horizontal line intersecting the vertical line s previously marked Measure up 3 7 8 from the intersect ing line s and mark another horizontal line Use the point s where the top horizontal line intersects the vertical line s to locate the top hole of the lift handle s Using the lift handle as a template mark this location onto the center stile Keeping the lift handle aligned with the vertical line mark the lower lift handle hole onto the center stile Drill 1 16 pilot holes at the marked hole locations Fasten both lift handles to the center stile using 10 X 5 8 pan head self tapping screws f the door came with two sets of lift handles repeat the same process for the other lift handles Center stile Center stile Vertical line L o L 3 7 8 Ve ne Be 3 7 8 l qa line Horizontal 1 Horizontal Center line Ine Center line as iine T Lock section Lock section L ie T 9 10X5 8 Pan 2 10 X 5 8 Pan ii head self tapping head self tapping screws screws NS W nd s h vd handle andle i Center Center stile N Lift l N stile handle Typical placement of lift handles referenced on single wide doors
10. Loose winding shaft End Brackets Tools Power drill 7 16 Socket driver 1 2 Wrench Step ladder IMPORTANT WARNING TAGS MUST BE SECURELY ATTACHED TO BOTH END BRACKETS End brackets are right and left hand You can identify the right hand end bracket by the disconnect cable guide hole located at the top of the end bracket Beginning with the right hand side slide the end bracket onto the winding shaft so that the splines in the ratchet wheel fit onto the winding shaft grooves Attach the end bracket to the flag angle using 1 5 16 18 x 3 4 carriage bolt 1 5 16 washer and 1 5 16 18 hex nut Then secure the end bracket to the jamb using 1 5 16 x 1 5 8 lag screw Repeat same process for left hand end bracket NOTE If ratchet wheel falls out of end bracket refer to illustration for proper insertion orientation NOTE On single spring applications no ratchet wheel is required on the left hand side Grooves Windin Disconnect cable guide hole m Warning tag Right hand 5 16 Hex nut end bracket Ratchet wheel teeth pointing upwards Lag screw RQ 5 16 18 x 3 4 Washer Carriage bolt Flag angle Black tooth Securing Center Bracket Bushing Assembly Tools Power drill 3 16 Drill bit 7 16 Socket driver Step ladder Level IMPORTANT TORQUEMASTER SPRING TUBE MUST BE LEVEL BEFORE SECURING C
11. 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 permanently 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 to the jambs avoid pushing the weath erstrips too tightly against the face of door 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 member and parallel to door 3 5 16 Bolts and nuts Perforated angle Vice clamp Micecamp 2nd Track roller el e ra el a Sound framing j ae members ots eal gern a a z SS 2i a woe 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 z bze p peee
12. 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 Noo Please Do Not Return This Product To The Store Contact you e Power drill e Drill bits 1 8 3 16 7 16 e Ratchet wrench e Socket driver 7 16 e Sockets 7 16 1 2 9 16 5 8 e Socket extension 3 Tools Required e Phillips head screwdriver e Flat tip screwdriver e Pliers Wire cutters e Needle nose pliers e Locking Pliers e 2 Vice clamps e Hammer e Tape measure Step Ladder e Level e Pencil e Leather gloves e Safety glasses e Wrenches 7 16 1 2 9 16 5 8 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 with your door
13. 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 Cleaning Your Garage Door IMPORTANT DO NOT USE A PRESSURE WASHER ON YOUR GARAGE DOOR While factory applied finishes on garage doors are durable it is desirable to clean them on a routine basis Some discoloration of the finish may occur when a door has been exposed to dirt laden atmosphere for a period of time Slight chalking may also occur as a result of direct exposure to sunlight Cleaning the door will generally restore the appearance of the finish To maintain an aesthetically pleasing finish of the garage door a periodic washing of the garage door is recommended THE FOLLOWING CLEANING SOLUTION IS RECOMMENDED A mild detergent solution consisting of one cup detergent with less than 0 5 phosphate dis solved into five gallons of warm water will aid in the removal of most dirt NOTE The use of detergents containing greater than 0 5 phosphate is not recommended for use in general cleaning of garage doors 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 thoroug
14. REMOVE A MAXIMUM OF 3 10 OF RATCHET WHEEL AT A TIME BOTH SIDES NEED TO BE DOUBLE SPRING DOORS ade 0 Il tighten counter clockwise on the righ Place the ratch down to add 3 10 of a turn ee clicks ension place a reg jeve p ra ed upward 10 teeth To add spring tension ensure t hand side h 5 8 socket and 3 socket Watch as three teeth of the et wrench wi lar 5 8 wrench onto the essure between the pawl and the ratchet chet wheel teeth to pass by the pawl as you by the spring tension release the pawl to E SPRING THAN 1 SPRING TURNS 1 SPRING TURN THE RECOMMENDED NUMBER OF TURNS items ube and flag angles for level and plumb ag angles which must be door width plus 3 3 8 to es for equal tension adjust if necessary ed and you have completed this step refer to the idrive Installation Instructions and Owner s Manual to complete your idrive installation Ratchet wrench End bracket Ratchet wheel Pawl knob in lower position Pawl knob in upper position 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 TorqueMaster Plus Reset Instructions
15. 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 and bolt the top rail of the horizontal track to the encoun tered slot in the flag angle using 1 1 4 20 x 9 16 track bolt 1 1 4 20 flange hex nut and 1 5 16 washer 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 NOTE If an idrive opener will be installed position horizontal tracks slightly above level 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 Flagangle Af 1 4 20 x 9 16 Track bolt Flag angle Bottom rail g of horizontal Quick Install O track tab in place 6 A 2 Quick i ca a Top rail of Install Tracks flush horizontal tab key slot n track 1 4 20 Flange hex Vertical Vertical nyt track track Horizontal Tracks F A Flag Angles Tools Ratchet wrench 7 16 Socket 9 16 Socket 9 16 Wrench level Step ladder Flat tip screwdriver
16. area from corrosion Follow the drying time on primer can label before applying topcoat The surface of the factory applied finish that is being painted must not be too smooth or the paint will not adhere to it It is advisable to test in an inconspicuous area to evaluate adhesion If poor adhesion is observed surface preparation for painting thefactory applied finish must be repeated until desired results are achieved Again care must be taken to not expose the substrate under the paint Steel Painting After surface has been properly prepared it must be allowed to dry thoroughly then coated immediately with a premium quality latex house paint Follow paint label directions explicitly Oil base or solvent base paints are not recommended Please note that if substrate is exposed and not properly primed painting with latex paint may cause accelerated rusting of the steel in the exposed area NOTES 1 Repainting of finish painted steel doors cannot be warranted as this condition is totally beyond the door manufacturer s control 2 Consult a professional coatings contractor if in doubt about any of the above directions 3 Follow directions explicitly on the paint container labels for proper applications of coatings and disposal of containers Pay particular attention to acceptable weather and temperature condi tions in which to paint Wood Preparation and Painting These instructions apply to all Wood Doors produced and sold
17. lumber minimum is 3 1 2 Header board 2 x 6 lumber preferred Min Side room Clearance is 3 1 2 jambs q Weather strips Jamb N 5 Quick Install track NS ys iy Weather yo Jan strips i T Fully Adjustable track 4 8 to 1 4 Please Do Not Return This Product To The Store Contact you 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 INSTALLATION Before installing your door be certain that you have read and followed all of the instruc tions covered in the pre installation section of this manual Failure to do so may result in an improperly installed door NOTE Reference TDS 160 for general garage door terminology at www dasma com Quick Install Flag Angles Tools None NOTE If you have Fully Adjustable flag angles skip this step NOTE If you have riveted track skip this step NOTE Flag angles are right and left handed Place the lower Quick Install tab of the left hand flag angle in the Quick Install feature of the left hand vertical track Give the flag angle 1 4 turn to lock in place Repeat for other side 1 4 Turn Flag angg g fe Vertical Lower track Quick Install tab Quick Install feature
18. s have tension the door will need to be balanced refer to step Balancing Door to do this If no spring tension is present contact a Inside lock qualified trained door system technician to replace the spring s IMPORTANT TO AVOID POSSIBLE INJURY HAVE A TRAINED DOOR SYSTEMS TECHNICIAN MAKE ADJUSTMENTS REPAIRS TO COUNTERBALANCE LIFT CABLES SPRING ASSEMBLIES AND OTHER HARDWARE Second section Square hole in vertical track 4 1 4 20 x 11 16 elf drilling screws End cap 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 Pull Down Rope Tools Power drill 1 8 Drill bit Tape measure A WARNING DO NOT INSTALL PULL DOWN ROPE ON DOORS WITH OPERATORS CHILDREN MAY BECOME ENTANGLED IN THE ROPE CAUSING SEVERE OR FATAL INJURY 1220 to 1270 mm from floor on the Tie the pull down rope to the Measure and mark the jamb approximately 48 to 50 t or left side of jamb Drill 1 8 pilot hole for no 6 screw eye 1 righ no 6 screw eye and to the bottom corner bracket as shown lo 6 Screw eye Pull down rope 48 to 50 From floor ___ Bottom corner bracket Pull down rope
19. 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 Doors 12 0 wide and over should be installed by two persons to avoid possible injury Operate door only when it is properly adjusted and free from obstructions 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 of the door especially to springs spring brackets bottom corner brackets fasteners counterbalance lift cables or suppor
20. CHART DOOR HEIGHT SPRING TURNS 6 0 14 6 3 14 1 2 6 5 6 6 6 8 Pawl knob in upper position Securing Drum Wraps Tools Step ladder NOTE If you don t have drum wraps then skip this step Refer to Package Contents Parts Breakdown to determine if you have drum wraps Starting on the left hand side position the left hand drum wrap as shown Slide the left hand drum wrap over the cable drum assembly IMPORTANT PULL THE COUNTERBALANCE LIFT CABLE AWAY FROM THE HEADER TO CLEAR THE LATCH WHILE SIMULTANEOUSLY SLIDING THE DRUM WRAP AGAINST THE LAST RIB UNTIL THE THREE CATCHES ENGAGE THE 3RD RIB Secure the hinge latch by rotating upward until a distinct snap is felt Confirm the catch is fully engaged by lightly tugging on it Repeat the same process for right hand 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 Last rib Drum wrap 3catches 3rd rib Cable 3rd rib A 3 Re engage X hinged latch Rear Back Hangs Tools Ratchet wrench Socket 1 2 5 8 Wrench 1 2 5 8 2 Vice clamps Tape measure Level Hammer Step Ladder lift cable Pull to Clear latch IMPORTANT HOLD THE DOOR DOWN TO PREVENT IT
21. EMBLY 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 F 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 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 Loosely fasten jamb brackets and flag angle to the jamb using 5 16 x 1 5 8 lag screws Tighten lag screws securing the bottom jamb bracket to jamb maintain 3 8 to 5 8 spac ing as shown between the bottom section and vertical track Hang cable drum assembly over lag angle Repeat same process for other side gt p P S ol Fla i oo am GCN angle Vertical track 5 16 x 1 5 8 z T 5 assembly Lag screws se l Lies ie kad ae 4 J 12RFA 15RFA 12RQI 15RA Flag angle lag screw locations ae 5 8 ES H acing Kea Bottom _Track i i section rollers Bottom section IN i Vertical track Track roller Floor Stacking Sections Tools Power drill 7 16 Socket d
22. ENTER BRACKET BUSHING ASSEMBLY TO HEADER To locate the center bracket bushing assembly mark the header halfway between the flag angles and level the TorqueMaster spring tube Drill 3 16 pilot holes into header for the lag screws Fasten the center bracket bushing assembly to the header using 2 5 16 x 1 5 8 ag screws TorqueMaster Center bracket spring tube bushing assembly 2 5 16 x 1 5 8 Lag screws o Securing Door For Winding Spring 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 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 Sl J Vice clamps above third track roller on both sides of door Bottom section Vice clamps attached to inner and outer rail of vertical track NOTE Single spring applications require no spring winding on the left hand side but lift cable tension needs to be a
23. 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 Horizontal tracks must be level and parallel with door within 3 4 to 7 8 maximum of door edge NOTE If an idrive opener is installed position horizontal tracks one hole above level when securing it to the rear back hangs 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
24. ING A DOOR From inside the garage pull door downward using lift handles gripping point only or a high friction area only If you are unable to reach the lift handles suitable gripping points only use pull rope affixed to the side of door Door should close completely with little resistance USING AN ELECTRIC OPENER IMPORTANT PULL ROPES MUST BE REMOVED AND LOCKS MUST BE REMOVED OR MADE INOPERATIVE IN THE UNLOCKED POSITION When connecting a trolley type garage door opener to this door an opener and or trolley bracket must be securely attached to the top section of the door along with any u bars provided with the door Always use the opener and or trolley 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 u bar may or may not be supplied The installation of the opener must be according to manufacturer s instructions and force settings must be adjusted properly Refer to the owner s manual supplied with your electric opener for complete details on installation operation maintenance and testing of the opener 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 fo
25. IONS 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 Preparing the Opening 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 recommended 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 TorqueMas ter counterbalance systems For low headroom applications the jambs should extend to the ceiling height Minimum side clearance required mm from the opening to the wall is 3 1 2 89 IMPORTANT CLOSELY INSPECT JAMBS HEADER AND MOUNTING SURFACE ANY WOOD FOUND NOT TO BE SOUND MUST BE REPLACED For TorqueMaster cou
26. Lock ta Lock section B 8b T a ay Left double graduated A end hinge with long Vertical stem track roller tracks b a 5 _ _al Right double graduated end hinge with lo stem track roller 1 4 14 x 5 8 Self tapping screw locations Q e io Secure top Ta middle hole first Center p gt Right graduated end hinge hingele with short stem track roller Olke L_ Left graduated end hinge with short stem track roller Top Fixtures Tools Power drill 7 16 Socket driver Phillips screwdriver NOTE The top low headroom brackets come pre assembled from the factory To install the low headroom top brackets align the edge of top bracket assembly with side edge of top section 1 Attach one 1 4 14 x 5 8 self tapping screw to the top bracket assembly 2 Attach two more 1 4 20 x 11 16 self drilling screws to the top bracket assembly 3 Attach two 12 x 1 2 phillips head screws on the opposite side of top bracket assembly The bracket will be adjusted later in step Adjusting Top Brackets Insert a roller into the top bracket slide as shown Repeat the same process f
27. ON NECTED TO THE SPRING S AND ARE UNDER EXTREME TENSION TO AVOID POSSIBLE SEVERE OR FATAL INJURY HAVE ANY SUCH WORK PERFORMED BY A TRAINED DOOR SYSTEMS TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS TORQUEMASTER PLUS SPRINGS Paw 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 opener 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 traine
28. 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 lt 3 4 To 7 8 lt __ _______ Door edges __ gt e Horizontal tracks _ gt gt 3 4 To 7 8 gt l Balancing Door 5 8 2 Vice clamps Tape NOTE Windows will cause the sections Wayne Dalton attemp sudden door acceleration between the top and doors with windows Doors with Remove any vice clamps Lift th itself hard to pull down or if door is difficult to e door an op section to be significantly heavier than t s to balance the door at the top and bottom Tools Ratchet wrench Socket 5 8 3 Socket extension Wrench measure Level Step Ladder he remaining To prevent any bottom we recommend motor operating all windows in the top section should not be manually operated d check its balance Adjust spring s if door lifts by lift easy to pull down Anytime spring adjust ments ca Close rol are made ratchet pawl k
29. R SMOOTH SAFE DOOR OPERATION FOR QUICK INSTALL TRACK Complete the vertical track installation by securing the jamb bracket s other lag screws Repeat for other side FOR FULLY ADJUSTABLE TRACK Complete the vertical track installation by securing the jamb bracket s 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 o nd tightening the Door widt 3 3 8 to 3 1 2 ine i Nail Top section 1 11 16 to 1 3 4 ap Gx a a Flai angle 00 Top E section gt Vertical track against track rollers Horizontal Tracks Q Flag Angles Tools Ratchet wrench 9 16 Socket 9 16 Wrench level Step ladder NOTE If you have Quick Install flag angles complete this step To install horizontal track place the top rail end over the top track roller of the top section Align key slot of the bottom rail end of horizontal track with the Quick Install tab of the flag angle Push curved portion of horizontal track down to lock in place A WARNING DO NOT RAISE DOOR UNTIL HORIZONTAL
30. Ratchet gt Cable Cable Tools Ratchet wrench 5 8 Socket 3 Socket extension 5 8 Wrench f pawi rum rum Vice clamps Step ladder side J C iE KA IMPORTANT THE DRAWBAR OPERATOR FORCE SETTINGS MUST BE ADJUSTED ACCORDING pum Sbe Drum n TO THE MANUFACTURER S INSTRUCTIONS SOME LIGHTER WEIGHT DOORS ARE DESIGNED p L p B TO OPERATE WITH A SINGLE COUNTERBALANCE SPRING IF THAT COUNTERBALANCE SPRING l BREAKS AND THE DRAWBAR OPERATOR S FORCE SETTINGS ARE NOT ADJUSTED ACCORDING TO THE MANUFACTURER S SPECIFICATIONS THE DRAWBAR OPERATOR MAY THEN HAVE THE No space between drum pawl and Space between drum pawl and cable CAPABILITY OF LIFTING THE DOOR TO THE OPEN POSITION DESPITE THE BROKEN COUNTER cable drum indicates engagement drum indicates non engagement BALANCE SPRING THIS SCENARIO WILL CAUSE THE COUNTERBALANCE LIFT CABLES TO GO SLACK AND ENGAGE THE TORQUEMASTER PLUS SAFETY SYSTEM IF A PERSON IS UNAWARE OF THE SLACK COUNTERBALANCE LIFT CABLES AND THE ENGAGED TORQUEMASTER PLUS SAFETY SYSTEM AND ACTIVATES THE MISADJUSTED DRAWBAR OPERATOR DAMAGE WILL LIKELY OCCUR TO THE DOOR AND DRAWBAR OPERATOR THE POTENTIAL ALSO EXISTS THAT rate THE PERSON ACTIVATING THE DRAWBAR OPERATOR UNDER THIS SCENARIO COULD BE SEVERELY INJURED A WARNING L__ READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO RESET THE Drum wrai TORQUEMASTER PLUS SYSTEM IF IN QUESTION ABOUT ANY OF THE PRO if applicable CEDURES DO NOT PERFORM THE WORK INSTEAD
31. The retention washers must be fully seated against the top bracket base to ensure the anti twist feature on the top bracket slide engages in the slotted hole in the top bracket base Roller Low headroom A 2 1 4 20 horizontal track Go lange hex nuts A ZO Top bracket SS Ca slide r Top section Fa Top bracket assembly Top bracket slide y 2 Retention washers Slotted hole of top bracket base 2 1 4 20 x 5 8 arriage bolts p 1 4 20 lange hex nuts Anti twist feature Top bracket slide reversed TorqueMaster Spring Tube Tools None TorqueMaster springs come lubricated and pre assembled inside the TorqueMaster spring tube To prepare for install lay the spring tube assembly on the floor inside garage in front of the door and with the labeled end to the left TorqueMaster spring tube Center Bracket Bushing Assembly Tools None NOTE If you are installing the idrive opener with your garage door skip this step and go to your idrive Installation Instructions and Owner s Manual After completing the steps up to and including Drum Wrap Installation of your idrive Installation Instructions and Owner s Manual continue with Step Rear Back Hangs of this door Installation Instructions and Owner s Manual NOTE If you are not installing the idrive opener on your garage door you must install the cen
32. Wayne Dalton GARAGE DOORS amp OPENERS Table Of Contents Parts Breakdown Pre Installation Important Safety Instructions Tools Required Package Contents Door Section Identification Removing an Existing Door Preparing the Opening Installation Optional Installation TorqueMaster Plus Reset Instructions Door Arm Hookup Inside Lock Pull Down Rope Maintenance Cleaning Your Garage Door Painting Your Garage Door Operation and Maintenance Warranty Dealer Locator Information OFF BWW WWD Be Sb Sh Sk See CON WNW N OUTDO 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 346805 REV6 03 01 2012 PARTS BREAKDOWN NOTE The illustrations shown on this page are general representations of the door parts Each specific door models may have unique variations A FLAG ANGLES
33. al tracks just below the bottom track roller on both sides e Tools Power drill 7 16 Socket driver Tape measure 5 Now is a good time to remove vehicles or personal items from garage to provide clear access to end brackets 6 Flip the ratchet pawl knob on both end brackets to the upper position see illustration Install the inside lock on the second section of the door Secure the lock to the section with 4 1 4 20 x 11 16 self drilling screws Square the lock assembly with the door section and align 7 Raise door 2 3 and then lower door Repeat this process until the system resets see with the square hole in the vertical track The inside lock should be spaced approximately 1 8 disengaged system illustrations away from the section edge IMPORTANT BE PREPARED TO SUPPORT THE TOTAL WEIGHT OF THE DOOR IMPORTANT INSIDE LOCK S MUST BE REMOVED OR MADE INOPERATIVE IN THE UNLOCKED 8 Cautiously remove the vice clamps from the vertical tracks With assistance lower door POSITION IF AN OPERATOR IS INSTALLED ON THIS DOOR Checking springs for tension 9 Starting on the right hand side place a ratchet wrench 5 8 socket and a 3 extension on the TorqueMaster Plus winding shaft see illustration Ensure ratchet is set so that it will tighten counter clockwise on the right hand side and clockwise on the left hand side If tension is pres ent remove the ratchet and check the left hand side If spring
34. ating in cases where the door sections and the original paint a have not been subjected to adverse atmospheric conditions or contaminates such as salt water or other marine environment or to toxic or abrasive substances including those in the air b have been maintained in compliance with Manufacturer s recommendations and c have not been subject to physical abrasion impacted by a hard object or punctured including without limitation paint rub occurring in metal to metal contact and movement The Manufacturer warrants the factory applied wood overlay of the above described door against defects in material and workmanship for a period of ONE 1 YEAR from the date of installation provided all exterior surfaces and edges of the wood overlay are properly painted according to Wayne Dalton s Maintenance and Painting Instructions found in your Installations Instructions and Owner s Manual Bowing checking and or cracking of the door overlay components is not considered a defect but is an uncontrollable characteristic of wood The Manufacturer warrants the garage door hardware except springs and the tracks of the above described door for as long as you own the door against defects in material and workmanship subject to all the terms and conditions below The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Lifetime Limited Warranty against defects in material and workmanship
35. ating the drum until the set screw faces directly away from the header The position of the cam peak on the TorqueMas ter spring tube should be pointing straight up Loosen the set screw no more than 1 2 turn Ensure counterbalance lift cable is aligned and seated in the first and second grooves of the cable drum Pull on the end of the cable to remove all cable slack Snug the set screw and then tighten an additional 1 1 2 turns Measure approximately 6 of cable and cut off excess cable Insert end of the cable into the hole of cable drum Repeat for left hand cable drum assembly IMPORTANT ENSURE THE COUNTERBALANCE LIFT CABLE IS ALIGNED AND SEATED IN THE FIRST AND SECOND GROOVES OF THE CABLE DRUM PRIOR TO WINDING SPRINGS NOTE Illustration shows the right hand cable drum assembly left hand cable drum assembly is symmetrically opposite First and second grooves Cam peak pointing straight up PAN 4 Re Cut cable here Set screw TorqueMaster 6 spring tube o g Insert cable here Counterbalance i lift cable Winding Springs Tools Ratchet wrench 5 8 Socket 3 Socket extension Pliers Wire cutters Flat tip screwdriver Step ladder A WARNING IT IS RECOMMENDED THAT LEATHER GLOVES BE WORN WHILE WINDING SPRINGS FAILURE TO WEAR GLOVES MAY CAUSE INJURY TO HANDS Double check to ensure the counterbalance lift cable is aligned in the first and second grooves of t
36. 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 the original finish is painted over unless Manufacturer s preparation and painting instructions are followed explicitly This Limited Warranty will be voided if any holes are drilled into the door other than those specified by the Manufacturer THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON MOSS ACT NO WARRANTIES EXPRESS OR IMPLIED INCLUD ING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WILL EXTEND BEYOND THE TIME PERIOD SET FORTH IN UNDERSCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY ABOVE 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
37. by Wayne Dalton The exterior surfaces as well as all edges must be properly painted and maintained if satisfactory perfor mance is to be achieved The purpose for painting is to both protect and beautify the substrates These requirements for finishing are intended to achieve both functions for reasonable service life of wood doors Wood doors must be completely finished prior to installation 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 not be trans ported or stored where the wood surfaces can be exposed to moisture or other contaminants Wood Surface Preparation All surfaces must be clean free of dust and dirt and any other con amination 1 Please Do Not Return This Product To The Store Contact you refer to your local yellow pages business listings or go Wood Painting Using painter s tape tape off all metal surfaces A premium quality latex house based finish paint is recommended for use over the factory latex based primer Painting the wood surfaces with at least 2 coats of finish paint over the primer Follow paint manufacture s label directions completely for all coatings Once finished remove painter s tape and touch up where necessary Wood Maintenance and Refinishing Yearly inspection of all the wood surfaces of the garage door s will reveal the
38. d door systems technician 3 LUBRICATION The door should open and close smoothly Ensure the door rollers are rotating freely when opening and closing the door If rollers do not rotate freely clean the door tracks re moving dirt and any foreign substances Clean and lubricate use a non silicon based lubricant hinges steel rollers and bearings DO NOT lubricate plastic idler bearings nylon 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 Lifetime Limited Warranty Model 6100 Subject to the terms and conditions contained in this Lifetime Limited Warranty Wayne Dalton Manufacturer warrants the steel sections of the door which is described at the top of this page for as long as you own the door against i The door becoming inoperable due to rust through of the steel skin from the core of the door section due to cracking splitting or other deterioration of the steel skin or due to structural failure caused by separation or degradation of the foam insulation ii Peeling of the original paint on the door as a result of a defect in the original paint or in the application of the original paint co
39. djusted IMPORTANT COUNTERBALANCE LIFT CABLE TENSION MUST BE EQUAL ON BOTH SIDES PRIOR TO FULLY WINDING SPRINGS See the Winding Spring Turn Chart for the required number of winding turns FOR SINGLE SPRING APPLICATIONS Return to the right hand end bracket and continue winding the spring to the required number of turns for your door Place pawl knob in lower position FOR DOUBLE SPRING APPLICATIONS Either use the black tooth on the ratchet wheel for winding reference or place a mark on the winding shaft and end bracket Place the ratchet wrench with 5 8 socket and a 3 extension onto the left hand winding shaft end To wind the spring rotate the winding shaft clockwise while watching the black tooth on the ratchet wheel or the mark on the winding shaft Rotate the winding shaft to the required number of winding turns for your door Then return to the right hand side and wind the right hand spring to the required number of turns Place pawl knob in lower position on both sides IMPORTANT MARK THE NUMBER OF SPRING TURNS ONTO THE END BRACKET WARNING TAG NOTE Since total turns to balance door can deviate from winding spring turn chart values by 1 2 turn adjustments to the recommended number of turns may be required after rear Lift Cable Adjustments Tools Locking pliers Flat tip screwdriver Step ladder Tape measure Pliers Wire cutters Starting on the right side adjust the cable drum assembly by rot
40. ease 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 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
41. eplaced 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 interruptions cost of capital cost of purchase or replacement of other goods or claims of third parties for any of the foregoing 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 Pl
42. et 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 sing 1 1 4 20 x 9 16 track bolt and 1 1 4 20 flange hex nut Repeat for other side f 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 exe Jec e e 920 0 co C00 Lower hole of hole slot pattern 1 4 20 Flange hex nut ENN Jamb bracket x Z in place Vig 1 4 20 x 9 16 Track bolt FA jamb bracket Lift Handles Tools Tape Measure Pencil Power Drill 1 16 Drill Bit NOTE Refer to door section identification located in the pre installation section of this manual or refer to Parts Breakdown on page 2 Starting with the lock section measure the width of the center stile which will receive the lift handle s Divide that measurement in half and mark a vertical line onto the center of the stile NOTE If you are installing two lift handles on the center stile you will need to measure from the edge of the center stile to the center line mark Divide that measurement in half and draw
43. extent of weather ing and the need for refinishing When the finish becomes eroded or thin clean and prime the areas of deterioration Follow up with a complete refinishing of the door s according to the above directions as well as the manufacturer s label directions Protecting the door s from prolonged exposure to moisture and sunlight is vital in extending the service life of your garage door s O Operation and Maintenance OPERATING YOUR GARAGE DOOR 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 refer ence 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 CLOS
44. for a period of ONE 1 YEAR from the date of installation The Manufacturer warrants the factory applied finish and the factory attached Decatrim against fading and cosmetic changes from the time of installation for TWO 2 YEARS If the sectional steel portion of door is re stained or re painted the TWO 2 YEARS warranty for the factory applied finish is void The Model 6100 factory attached Decatrim is warranted against warping peeling chalking or delamination from the time of installation for TWO 2 YEARS After a period of TWENTY 20 YEARS from time of installation replacement of Lifetime Limited Warranty materials will be pro rated at 50 per cent of Manufac turer s published list pricing at time of claim and you must pay this amount 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
45. he cable drum see step Lift Cable Adjustments There are two methods for counting the spring turns as you wind One method is to identify the black tooth on the ratchet wheel inside of the end bracket When the wheel makes one revolution and the tooth returns to its starting point one turn has been made The other method is to make a mark on the winding shaft or socket and end bracket and count your turns in this manner Starting on the right hand side turn the paw knob on the end bracket to the upper position Using a ratchet wrench with a 5 8 socket and a 3 extension wind the spring by rotating the winding shaft counter clockwise while watching either the black tooth on the ratchet wheel or the mark on the winding shaft NOTE A 3 extension is recommended for added clearance from the horizontal track angle IMPORTANT PAWL KNOB MUST BE IN UPPER POSITION TO ADD REMOVE REQUIRED NUMBER OF SPRING TURNS After 2 to 3 turns remove the ratchet wrench and adjust the counterbalance lift cable on the left side Ensure counterbalance lift cables are in the first and second grooves of the cable drums as shown in step Lift Cable Adjustments back hangs are installed End bracket a Ww C Pawl knob in CG lower position Ratchet 5 8 wrench Socket Black tooth on ratchet wheel Mark the number of spring turns onto the end bracket warning tag WINDING SPRING TURN
46. her using 4 1 4 20 x 9 16 track bolts and 4 1 4 20 lange hex nuts NOTE Install the 1 4 20 x 9 16 track bolts and the 1 4 20 flange hex nuts as far apart as possible when positioning both the top and bottom halves of drawbar operator brackets ogether NOTE For retro fit applications the drawbar operator bracket assembly must be aligned with an existing drawbar operator ow locate the center of the top section and align the center of the holes in the drawbar op erator bracket assembly with the top section center line Align the drawbar operator bracket assembly vertically First secure the back of the drawbar operator bracket assembly to the top section inside surface using 2 1 4 20 x 11 16 self drilling screws Next secure the drawbar operator bracket assembly to the top and bottom ribs of the top section using 8 1 4 20 x 11 16 self drilling screws Now tighten all previously installed 1 4 20 x 9 16 track bolts and 1 4 20 flange hex nuts Secure the drawbar operator bracket assembly to the top section using screw NOTE If you have 7 0 door height and your door width is less than or equal to 16 0 use 1 8 x 1 21 32 quadrex pan head screw NOTE If you have 7 0 door height and your door width is greater than 16 0 use 1 8 x 1 13 32 quadrex pan head screw NOTE For door heights greater than 7 0 use 1 8 x 1 13 32 quadrex pan head screw 2 1 4
47. hly 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 chamois NOTE Do not use any window cleaning fluids scouring compounds gritty cloths or solvent based cleaners of any kind amp Painting Your Garage Door amp Painting Instructions For Steel and Wood Doors Steel Surface Preparation for Painting Wax on the surface must be removed or paint peeling flaking will result To remove this wax it will be necessary to lightly scuff the surface with a fine steel wool pad saturated with soapy water A final wipe and rinse should be done with clean water only to remove any loose particles and any soapy film residue Surface scratches which have not exposed the metal substrate can be lightly buffed or sanded with 0000 steel wool or No 400 sand paper to create a smoother surface Care must be taken to not expose the substrate under the paint Once the substrate is exposed the likelihood for rusting is greatly increased If substrate is exposed it must be treated to prevent rust from forming Sand the exposed area lightly and paint with a high quality metal primer specifically intended for galvanized surfaces to protect the
48. k Assembly 12 Right Hand Horizontal Track Assembly 13 Left Hand Vertical Track 14 Right Hand Vertical Track J TORQUEMASTER PLUS SPRING ASSEMBLY J1 Center Bracket Bushing Assembly J2 TorqueMaster Spring Tube Single Or Double Springs J3 Left Hand End Bracket J4 Right Hand End Bracket Disconnect Cable Guide J5 Left Hand Cable Drum Assembly J6 Right Hand Cable Drum Assembly J7 Loose Winding Shaft Single Spring Only J8 Left Hand Drum Wrap As Required J9 Right Hand Drum Wrap As Required K REAR BACK HANGS K1 Left Hand Rear Back Hang Assemblies K2 Right Hand Rear Back Hang Assemblies 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 BEFORE ATTEMPTING INSTALLATION IF IN QUESTION ABOUT ANY OF THE PROCEDURES DO NOT PERFORM THE WORK INSTEAD HAVE
49. le referenced on single wide doors Lock section Lift handles Pull handle ae Bottom section 20 Minimum to 30 Maximum Typical placement of pull handles referenced on double wide Lift handles Bottom Lock section f section 20 Minimum to 30 Maximum Pull handle ie Pull handle 5 i i Cable Drum Assemblies and Track Rollers Tools None NOTE Refer to door section identification located in the pre installation section of this manual or refer to Parts Breakdown on page 2 NOTE Cable drum assemblies are marked right and left hand A WARNING FAILURE TO ENSURE TIGHT FIT OF CABLE LOOP OVER MILFORD PIN COULD RESULT IN COUNTERBALANCE LIFT CABLE COMING OFF THE PIN AL LOWING THE DOOR TO FALL POSSIBLY RESULTING IN SEVERE OR FATAL INJURY Uncoil the counterbalance lift cables from the cable drum assemblies making sure you place the left hand cable loop on the left hand milford pin of the bottom corner bracket and the right hand cable loop on the right hand milford pin of the bottom corner bracket NOTE Check to ensure cable loops fits tightly over the milford pins Insert a short stem track roller into the bottom corner brackets and another into the 1 graduated end hinges at the top of the bottom section NOTE Larger doors will use long stem track rollers with double graduated end hinges NOTE Verify bottom weather seal is aligned with bottom section If
50. n attached to the wall abo NOTE Drill a 3 16 pilot the mounting surface wi erbalance systems a su itable mounting surface 2 x 6 must be firmly ve the header at the center of the opening hole in the mounting surface to avoid splitting h nails the lumber Do not attach WEATHERSTRIPS MAY NOT BE INCLUDED Depending on the size o to properly fit into the header and jambs your door you may have to cut or trim the weatherstrips if necessary NOTE If nailing product at 40 F or below pre drilling is required NOTE Do not permanently attach weatherstrips to the header and jambs at this time For Quick Install track For the header align the weatherstrip with the inside edge of the header and temporarily secure it to the header with equally spaced nails Starting at either side of the 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 jamb fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and flush with the inside edge of the jamb 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 For Fully Adju
51. nob idrive or TorqueMaster he door and place vice c er This is to prevent se Plus operation problems amps on he garage door must be in the upper position An unbalanced door can o both vertical tracks just above the third track rom rising while adjusting the counterbalance spring s IMPORTANT TO ADJUST SPRI A TURN THREE TEETH ON THE ADJUSTED EQUALLY ON Add spring tension The ratchet w the ratchet and socket is set so that and clockwise on the left hand side extension onto the winding shaft pu ratchet wheel pass over the pawl creating th Remove spring tension To remove spring winding shaft Pull down on the wrench to rel wheel Push in on the pawl to allow the three carefully allow the wrench to be rota allow it to engage with the ratchet wheel IMPORTANT BE PREPARED TO HO IMPORTANT DO NOT ADD OR RE EQUALS 10 TEETH ON RATCHET WHEEL FRO SHOWN ON THE WI If the door still does not operate easi spring s completely and recheck the following Check the door for level Check the TorqueMaster spring Check the distance between the f 1 2 Check the counterbalance lift cab Rewind the spring s Make sure door isn t rubbing on jambs NOTE If an idrive opener was instal heel is m it wi a LD THE FULL TENSION OF TH OVE MORE DING SPRING TURN CHART y lower the door into the closed position unwind GS ONLY ADD OR
52. or the other side 1 1 1 4 14 x 5 8 Roller Self tapping screw 9 a 12 x 1 2 Phillips head screws Top bracket slide Top bracket assembly 2 2 1 4 20 x 11 16 Self drilling screws Strut A symmetrical Tools Power drill 7 16 Socket driver Tape measure NOTE If an a symmetrical strut is supplied complete this step Place the a symmetrical strut over the top rib of the top door section Fasten each end of 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 the a symmetrical strut to the end cap with 2 1 4 20 x 11 16 self drilling screws Fasten both wall and the long leg of the a symmetrical strut as shown using 2 1 4 14 x 5 8 self tapping screws every 30 36 inches Approximately 18 self tapping screws per 18 a symmetrical strut IMPORTANT WHEN SECURING THE A SYMMETRICAL STRUT TO THE TOP SECTION IT S RECOMMENDED NOT TO INSTALL ANY FASTENERS INTO THE SHORT LEG OF THE A SYMMETRICAL STRUT 2 1 4 20 x 11 16 elf drilling screws 2 1 4 14 x 5 8 elf tapping screws 2 1 4 14 x 5 8 2 1 4 20 x 11 16 elf tapping screws Self drilling screws Strut A symmetrical End cap attached to top rib z
53. r the garage door These instructions 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 For additional information on garage door opener 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 cables rollers pulleys 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 and or left in the opening If you suspect problems have a trained door system technician make the repairs A WARNING GARAGE DOOR SPRINGS CABLES BRACKETS AND OTHER HARDWARE AT TACHED TO THE SPRINGS ARE UNDER EXTREME TENSION 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 r local Wayne Dalton dealer To find your local Wayne Dalton dealer o the Find a Dealer section online at www Wayne Dalton com 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 BRACKETS OF THE DOOR THESE BRACKETS ARE C
54. river NOTE Refer to door section identification located in the pre installation section of this manual NOTE The sections can be identified by the graduation of the factory installed graduated end hinges The smallest graduated end hinge on section should be stacked on top of the bottom section with each graduated end hinge increasing as the sections are stacked see Parts Breakdown on page 2 NOTE Make sure end and center hinges are flipped down when stacking another section on top Place track rollers into graduated end hinges of remaining sections NOTE Larger doors will use long stem track rollers with double graduated end hinges With assistance lift second section and guide the track rollers into the vertical tracks Lower section until it is seated against bottom section Flip hinges up Fasten center hinge s first then end hinges last using 1 4 14 x 5 8 self tapping screws NOTE To prevent center hinge leaf s from rotating first secure the top middle hole of the center hinge leaf with one 1 4 14 x 5 8 self tapping screw then secure the other two holes Repeat same process for other sections except top section IMPORTANT PUSH amp HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE SECURING WITH 1 4 14 X 5 8 SELF TAPPING SCREWS THERE SHOULD BE NO GAP BETWEEN THE HINGE LEAFS AND THE SECTIONS NOTE Install lock at this time sold separately See optional installation step Side
55. stable track 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 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 NOTE 6 low headroom conversion kit is available for 12 radius only Contact your local Wayne Dalton dealer Backroom requirement Backroom is defined as the distance needed from the opening back into the garage to allow the door to open fully 9 BACKROOM REQUIREMENTS Door Height Track Manual Lift Motor Operated 6 0 to 70 6 Low Headroom 102 2591 mm 125 3175 mm 7 1 to 8 0 6 Low Headroom 114 2896 mm 137 3480 mm HEADROOM REQUIREMENTS Track Type Space Needed 6 Low Headroom 6 152 mm Min Side i room Suitable mounting surface Headroom Clearance 2 x 6
56. t on top of the flag angles NOTE Cable drum assemblies are marked right and left hand Cable drums and TorqueMas ter spring tube assembly is cam shaped to fit together only one way Starting on the right hand side pre wrap the cable drum with the counterbalance lift cable 1 1 2 wraps as shown Position the TorqueMaster spring tube assembly so the cam peak is pointing straight up Slide the cable drum over the winding shaft until the cable drum seats against the Torque Master spring tube assembly The winding shaft must extend past the cable drum far enough to expose the splines and the grooves Align the winding shaft grooves with the round notch in the flag angle FOR DOUBLE SPRING APPLICATIONS Repeat for left hand side FOR SINGLE SPRING APPLICATIONS Pre wrap the left hand cable drum with the counter balance lift cable 1 1 2 wraps and insert the loose winding shaft into the cable drum prior to sliding the cable drum over the TorqueMaster spring tube assembly NOTE On single spring applications take care in handling the loose winding shaft left hand side so that it does not slide back into the TorqueMaster spring tube assembly Winding shaft Counterbalance lift cable Cable drum Cam peak 1 1 2 wraps straight Grooves Windin sha 5 TorqueMaster sprin tube assembly ee Round notch ace Splines LK Right cable drum
57. tall Adjustable Flagangle Me Track bolt Horizontal Horizontal gf track track BN A z i wa N sx a ange hex Washer nu nuts 68 a Washer amp Top rail of D horizontal Flag angle Flag angle D track upper slot upper slot 1 4 20 Vertical Vertical Flange hex track track nut Stud plate 1 4 20 x 9 16 Track bolts Adjusting Top Fixtures Tools 7 16 Wrench Step ladder With horizontal tracks installed you can now adjust the LHR top brackets NOTE Depending on your application you may need to reverse the top bracket slide for more adjustment if needed prior to securing it to the top bracket base TO ADJUST THE TOP BRACKET SLIDES Loosen the 2 1 4 20 flange hex nuts if neces sary and vertically align the top section of the door with the lower sections Once aligned position the top bracket slide out against the horizontal track Maintaining the slide s posi tion tighten the 2 1 4 20 flange hex nuts to secure the top bracket slide to the top bracket base Repeat for other side TO REVERSE THE TOP BRACKET SLIDES IF NEEDED Remove the two 1 4 20 x 5 8 carriage bolts two retention washers and two 1 4 20 flanged hex nuts Flip the top bracket slide in the opposite direction Loosely fasten the top bracket slide to the bracket using two 1 4 20 x 5 8 carriage bolts two retention washers and two 1 4 20 flanged hex nuts as shown NOTE
58. ter bracket bushing assembly Follow these instructions for non idrive operated garage doors Being cam shaped the center bushing only fits one way Slide the center bracket bushing as sembly towards the center of the TorqueMaster spring tube from the right side as shown TorqueMaster spring tube Center bracket bushing assembly 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 Drum Wraps Tools None NOTE If you don t have drum wraps then skip this step Refer to Package Contents Parts Breakdown to determine if you have drum wraps Drum wraps are marked right and left hand Beginning with the left hand side slide the left hand drum wrap onto the TorqueMaster spring tube Repeat for the right hand side The drum wrap will be secured later in Step Securing Drum Wraps Right hand drum wrap Left hand ____ drum wrap TorqueMaster spring tube Cable Drum Assemblies Tools Tape measure Step ladder Shake the TorqueMaster spring tube assembly gently to extend the winding shafts out about 5 on each side For single spring applications there will be no left hand spring in the TorqueMaster spring tube assembly Lift the TorqueMaster spring tube assembly and rest i
59. th holes in drawbar operator bracket tabs as shown Insert 5 16 make the necessary repairs to counterbalance lift cables spring assemblies and other hardware x 1 1 4 clevis pin making sure hole in clevis pin is outside of second tab of drawbar operator Double spring system Visually inspect the TorqueMaster Plus end brackets to confirm bracket Insert hairpin cotter into clevis pin hole and spread hairpin cotter to secure assembly that the system has engaged see illustration Door will open but will not close Door makes a as shown Door Arm Hookup Tools Needle nose pliers distinct clicking noise upon being opened If the system is engaged carefully follow the reset instructions below or refer to the reset tag attached to right hand end bracket to reset the Door arm TorqueMaster Plus system Sense Clevis pin Resetting an engaged TorqueMaster Plus double spring system only 5 16 x 1 1 4 pin 1 First locate and visually inspect the TorqueMaster plus end brackets to confirm that the Clevis pin J system has engaged see illustration Drawbar operator 2 Disengage the drawbar operator if installed by pulling or placing the emergency disconnect Drawbar bracket tabs Spread cotter pin in the manually operated position operator bracket 3 With assistance raise the door to the fully open position Inside Lock 4 Place vice clamps onto both vertic
60. the Manufacturer s option 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 repair or replace the defective product The decision about the manner in which the defect will be remedied will be at the discretion of the 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 r
61. the bottom corner bracket warning labels on each end stile The LOCK SECTION can be identified by 2 graduated end hinges The INTERMEDIATE SECTION can be identified by 3 graduated end hinges The section will have a warning label attached to either the right or left hand end stile NOTE 4 graduated end hinges are used on the fourth section of five section doors The TOP SECTION can be identified with no pre installed graduated end or center hinges 1 TF 1 9 16 Warning label 4 Graduated Top section end hinge 1 3 8 3 3 Graduated Warning label end hinge Intermediate section ii 2 E Ai 2 f z 2 Graduated end hinge Lock section 7 8 1 amp I F 1 Graduated f i Bottom corner bracket warning labels ZN end hinge r Bottom corner Astragal Bottom section fae Typical graduated end hinge samping Section side view illustration location amp Removing an Existing Door 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 INSTRUCT
62. there is more than 1 2 excess weather seal on either side trim weather seal even with bottom section Left hand cable drum assembly 1 Single graduated end hinge A g Hinge tube 3 L Long stem 2 r x track roller KQ ene graduated Short stem track roller X end hinge Hinge 7 tube xt Counterbalance lift cable Bottom section Bottom corner bracket warning label Cable loop Bottom weather seal Bottom corner Milford pin bracket ei stem track roller 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 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 Bottom section T Wooden shims If necessary Vertical Tracks Tools Power Drill 3 16 Drill bit 7 16 Socket driver Tape measure Level Step ladder 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 ASS
63. ts 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 building official for wind load code require 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 SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN TREATED LUMBER
64. turn the bracket perpendicular to the track so the mounting flange is toward the back flat leg of the track Repeat for other side Vertical track Top of track ist hole set 2nd hole set 3rd hole set eae ome Jomef omef Jomt 000 eae 000 r l Bottom hole Middle hole Top hole S N ES Jamb bracket Q I tab in place Mounting flange Q I jamb bracket JAMB BRACKET SCHEDULE TRACK LENGTH 69 50 1765mm 81 50 2070mm B BOTTOM HOLE M MIDDLE HOLE T TOP HOLE Fully Adjustable Jamb Brackets Tools None DOOR HEIGHT 1ST SET 2ND SET 70 Y M 8 B NOTE If you have Quick Install jamb brackets skip this step NOTE If you have riveted track skip this step 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 brack
65. x 11 16 Self as required drilling screws as required 1 4 20 x 9 16 Track bolts as required 2 5 16 18 x 3 4 Carriage bolts russ nead bots 16 x 3 4 1 4 14 x 5 8 Self tappin russ head bolts screws as WS aS required O E 5 16 x 1 1 4 Clevis pin Cotter pin 9 10 x 5 8 Cm7 Phillips pan head screws Pull handles as required Lift handles as required black painted heads Hite Hre 8 x 1 21 32 Quadrex pan head screws 8 x 1 13 32 Quadrex pan head screws amp Door Section Identification amp Graduated end and center hinges are always pre attached at the top of each section except top section and the graduated end hinges are stamped for identification 1 2 3 and 4 4 only on five section doors The stamp identifies the stacking sequence of the section The sequence is always determined by 1 being the bottom section to 3 or 4 being the highest intermediate section If the stamp on the graduated end hinge is illegible refer to the section side view illustration The section side view illustration shows the graduated end hinge profile of all sections and can also be used to identify each section The BOTTOM SECTION can be identified by 1 graduated end hinges the factory attached bottom astragal the factory attached bottom corner brackets and by

Wayne-Dalton 5500 Garage Door Opener User Manual

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