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GARAGE DOORS & OPENERS
T a b l e O f C o n t e n t s
Models: 40, 42,
Parts Breakdown 2
Pre-Installation 3
43, 45, 47
Important Safety Instructions 3
Tools Required 3
t o r s i o n
Package Contents 3
Door Section Identification 4
6” Fontr Mount Low HM ooeadr
Graduated End Hinge And Strut Identification 4
Removing an Existing Door 6
Preparing the Opening 6
Installation 7
Optional Installation 17
MH
Door Arm Hookup 17
instaLLation instructions and owner ’s ManuaL
Lift Handles 17
Pull Down Rope 17
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Parts Breakdown G5. NOTE: The illustrations shown on this page are general G11. representations of the door parts. Each specific door G7. models may have unique variations. H2. G9. G12. F1. G2. H1. A1. G1. G3. D1. D1. G12. G4. G6. A2. G5. G9. E1. G5. G10. G8. G5. C1. G4. D1. D1. F6. A1. C2. A2. F4. H2. F3. F6. C2. F1. G13. F7. F2. C3. F4. B3. B2. A2. I1. B1. J1. A4. H1. F7. A1. K1. A3. F5. F5. J1. F2. G13. F3. I1. A. TRACk ROLLERS (AS REquIRED): F7. Left Hand and Right Hand Fully Adjustable (F.
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Pre-Installation Important Safety Instructions Tools Required DEFINITION OF kEy WORDS uSED IN THIS MANuAL: • Power drill • Phillips head • Hammer screwdriver • Drill bits: 1/8”, 3/16”, • Tape measure W WARNING ARNING 9/32”, 7/16”, 1/2” • Locking Pliers • Step Ladder • Ratchet wrench • (2) Vice clamps INDICATES A POTENTIALLy HAzARDOuS SITuATION WHICH; IF NOT A vOIDED, • Level COuLD RESuLT IN SEvERE OR FATAL INJuR y. • Socket driver: 7/16” • Wrenches: 3/8”, • Pencil 7/16”, 1/2”, 9/16”, CAuTI
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The BOTTOM SECTION can be identified by #1. The INTERMEDIATE I SECTION can be identified by #2. The INTERMEDIATE II SECTION can be identified by #3, for a 4 section high door only. The INTERMEDIATE III SECTION can be identified by #4, for a 5 section high door only. 5/16” x 1-1/4” Cotter pin Clevis pin (as required) (as required) Cable drums RH/LH Torsion springs RH/LH The INTERMEDIATE Iv SECTION can be identified by #5, for a 6 section high door only. The INTERMEDIATE v SECTION can be identifie
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Graduated End Hinge Schedule 3 Section High Strutting Schedule Top N/A (1) Short Top Of Section Top N/A Bottom Of section Intermediate IV 5# (1) Long Top Of Section Intermediate III 4# 2” Intermediate I Intermediate II 3# N/A Bottom Of section Intermediate I 2# N/A Top Of Section Bottom Bottom 1# (1) Short Bottom Of section 6 Section High Door Top N/A 4 Section High Strutting Schedule Intermediate IV 7# Section Type Type Of Strut Location On Section Intermediate III 6# (1) Short Top Of Section 3
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Backroom Door Height Track Manual Lift Motor Operated 6’0” to 7’0” 102” (2591 mm) 125” (3175 mm) 7’1” to 8’0” 114” (2896 mm) 137” (3480 mm) 2” Strut 3” Strut 8’1” to 9’0” 12” Or 15” Radius 126” (3200 mm) 168” (4267 mm) 9’1” to 10’0” 138” (3505 mm) 168” (4267 mm) Long strut 10’1” to 12’0” 162” (4115 mm) * Short strut Center hinge(s) Upper hinge (as required) leaf HEADROOM REquIREMENTS Track Type Space Needed Hinges are stamped for Lower hinge identification leaf 6” LHR 9” (229 mm) Half center
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Bottom Weather Seal Tools: Hammer, Tape Measure, Saw Horses 3 InstallatIon NOTE: If a bottom weather seal is supplied, complete this step. Before installing your door, be certain that you have read and followed all of the instruc- NOTE: Refer to Door Section Identification / Parts Breakdown. tions covered in the pre-installation section of this manual. Failure to do so may result in an improperly installed door. Place the bottom section face down on a couple of sawhorses or flat clean/ smoot
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Short Bottom (3) 1/4” - 20 strut section Flange hex nuts (3) 1/4” - 20 x 1-7/8” Bottom Carriage bolts Bottom corner section bracket Typical left hand bottom corner bracket (1) 1/4” - 10 x 1” Tamper resistant lag screw 1/4” - 14 x 1” 3/4” Lag screws (3) 1/4” - 20 Graduated End And Center Hinges Flange hex nuts (3) 1/4” - 20 x 1-7/8” Bottom Carriage bolts Tools: Power Drill, 1/8”/9/32” Drill Bit, Socket Driver 7/16”, Tape 7 section Typical left hand bottom corner bracket NOTE:
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the upper leg of strut to the bottom section using (1) 1/4”-20 x 1-7/8” carriage bolt and (2) 1/4” - 20 x 1 7/8” (1) 1/4”–20 flange hex nut. Next secure the bottom leg of strut, the lower slot of the center Carriage bolts hinge to the bottom section (1) 1/4”-20 x 1-7/8” carriage bolt and (1) 1/4”–20 flange hex nut, as shown. Repeat same process for other center hinges. Short Center hinge (2) 1/4” - 20 edge Flange hex nuts (1) Strut clip (2) 1/4” - 20 x 1 7/8” Carriage bolts (if applicable
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Stacking Sections Tools: Power drill,7/16” Socket driver 13 NOTE: Make sure graduated end and center hinges are flipped down, when stacking another Weather seal section on top. With assistance, lift intermediate I (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
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side. Adjusting Top Fixtures IMPORTANT: THE DIMENSION BETWEEN THE FLAG ANGLES MuST BE: Tools: 7/16” Wrench, Step ladder 16 FOR 2” TRACK APPLICATIONS: DOOR WIDTH PLuS 3-3/8” (86MM) TO 3-1/2” (89 MM) FOR SMOOTH, SAFE DOOR OPERATION. With horizontal tracks installed, you can now adjust the top fixtures. FOR 3” TRACK APPLICATIONS: DOOR WIDTH PLuS 4-7/8” (124MM) TO 5” (127 MM) FOR SMOOTH, SAFE DOOR OPERATION. NOTE: If your door came with two top fixtures, then one top fixture is required to be a
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NOTE: Identify the torsion springs provided as either right hand wound (red winding cone), Center Bracket which goes on the RIGHT HAND SIDE or left hand wound (black winding cone), which goes on the LEFT HAND SIDE. Tools: Step ladder, Power drill, 7/16” Socket driver, 1/4” Torx bit, Level, 18 For Doors without Coupler Assembly: Facing the inside of the door lay the torsion shaft on the floor. Lay the torsion spring with the NOTE: Refer to the Package Contents and or Parts Breakdown to det
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Black cable drum Coupler Set screws Center bearing bracket(s) Torsion (right hand side) and Lock halves spring nut Coupler assembly Center Torsion Center coupler keyed Set bearing assembly shaft collar Center bearing inside Coupler Right hand wound, torsion spring (3) 3/8” - 16 x 1-3/4” Hex head screws halves red winding cone and (3) 3/8” - 16 Nylon hex lock nut Torsion Center (right hand side) keyed bearing shaft Key Red cable drum Set screws (left hand side) and Lock nut (2)
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Center bearing brackets (3) 3/8” - 16 Winding Springs nylon hex lock Coupler nuts assembly Tools: Step Ladder, Approved winding bars, 3/8” Wrench Torsion 24 keyed Set screws shaft 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. Torsion IMPORTANT: CHECK THE LABEL ATTACHED TO THE SPRING WARNING TAG FOR THE Lock nuts keyed REquIRED NuMBER OF COMPLETE TuRNS TO BALANCE YOuR
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W WARNING ARNING 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 Horizontal tracks 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” an
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3/4” To 7/8” 3/4” To 7/8” Door edges Horizontal tracks Rear center back hang Horizontal (1) 3/8” Truss head bolt track (may not be supplied) (1) 3/8” Nut (may not be supplied) Horizontal track Drill 3/8” diameter hole Center of the horizontal track Label Placement Tools: Step Ladder 26 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: Becau
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optional Installation Door Arm Hookup W WARNING ARNING Tools: Needle nose pliers DO NOT INSTALL PuLL DOWN ROPE ON DOORS WITH OPERATORS. CHILDREN MAy BECOME ENTANGLED IN THE ROPE CAuSING SEvERE OR FATAL INJuR y. At the center of the top section, measure horizontally from the top of center hinge to the bottom of strut. using that dimension, measure and cut (2) pieces of perforated angles. Assemble the Measure and mark the jamb approximately 48” to 50” (1220 to 1270 mm) from floor on the (2)
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Maintenance 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 Cleaning Your Garage Door 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 per
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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 difficu
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w arranty Limited warranty Models: 40, 42, 43, 45, 47 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
