Wayne-dalton Thermomark 5255 User manual

The complete Installation Instructions and Owner’s Manual are available at no

charge from:

- Your local Wayne Dalton Sales Center, or

- Online at www.Wayne-Dalton.com, or

- By mailing to: Wayne Dalton, a division of Overhead Door Corporation,

P.O. Box 67, Mt. Hope, OH., 44660

Table Of Contents

353364

PLEASE DO NOT RETURN THIS PRODUCT

TO THE STORE

If you need assistance, please call 1-866-

569-3799 (press Option 1) and follow the

prompts to contact a customer service

representative. They will be happy to handle

any questions that you may have.

Pre-Installation 2

Important Safety Instructions 2

Removing an Existing Door and Preparing the Opening 2

Breakdown Of Parts 3

Door Installation Instructions 4

Counterbalance Installation Instructions 7

Maintenance 14

Cleaning Your Garage Door 14

Painting Your Garage Door 14

Operation And Maintenance 14

Warranty 15

Wayne Dalton, a division of Overhead Door Corporation

Models

ThermoMark™5150 /

5155 / 5200 / 5255

To r s i o n

Quick sTarT Guide

commercial

sTandard lifT

Windload

This Quick Start Guide is only meant to be used as an aid and

/ or introduction to garage door installation, and does not replace the

complete Installation Instructions and Owner’s manual available on the

web at www.Wayne-Dalton.com. Wayne Dalton highly recommends

that you read and fully understand the Installation Instructions and

Owner’s Manual before you attempt this installation.

To avoid possible injury, read and fully understand 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.

QUICK START GUIDE IMPORTANT NOTICES!

Important Safety Instructions

DEFINITION OF KEY WORDS USED IN THIS MANUAL:

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 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. It is 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

causing severe or fatal injury.

5. Doors 12’-0” wide and over should be installed by two persons, to avoid possible

injury.

6. Operate door only when it is properly adjusted and free from obstructions.

7. If a door becomes hard to operate, inoperative or is damaged, immediately have

necessary 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

alteration to any part of the door, especially to springs, spring brackets, bottom corner

brackets, fasteners, counterbalance lift cables or supports. To avoid possible severe or

fatal injury, have any such work performed by a trained door systems technician using

proper tools and instructions.

12. On electrically operated doors, pull down ropes must be removed and locks must be

removed or made inoperative in the open (unlocked) position.

13. Top section of door may need to be reinforced when attaching an electric opener.

Check door and/ or opener manufacturer’s instructions.

14. Visually inspect door and hardware monthly for worn and or broken parts. Check to

ensure door operates freely.

15. Test electric opener’s safety features monthly, following opener manufacturer’s instruc-

tions.

16. NEVER hang tools, bicycles, hoses, clothing or anything else from horizontal tracks.

Track systems are not intended or designed to support extra weight.

17. This door may not meet the building code wind load requirements in your area. For

your safety, you will need to check with your local building ofﬁcial for wind load code

requirements and building permit information.

18. For windloaded doors, the wind performance is achieved via the entire door system

and component substitution is not authorized without express permission by Wayne

Dalton.

NOTE: It is recommended that 5/16” lag screws are pilot drilled using a 3/16” drill bit, prior

to fastening.

CAUTION

IF ANY PART OF THE DOOR IS TO BE INSTALLED ONTO PRESERVATIVE-

TREATED WOOD, PTFE-COATED OR STAINLESS STEEL FASTENERS MUST BE

OBTAINED AND USED. REPLACEMENT FASTENERS MUST BE OF AT LEAST

EQUAL STRENGTH AND SIZE AS ORIGINAL FASTENERS. IF THE ORIGINAL

FASTENER WAS RED-HEAD, THE REPLACEMENT FASTENER MUST BE RED-

HEAD ALSO. CONTACT WAYNE DALTON FOR FASTENER STRENGTH VALUES IF

NEEDED.

WARNING

IMPACT GUNS ARE NOT RECOMMENDED. 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.

IMPORTANT: RIGHT AND LEFT HAND IS DETERMINED INSIDE THE BUILDING LOOKING OUT.

Potential Hazard Effect Prevention

Moving door

WARNING

Could result in Death or Serious

Injury

Keep people clear of opening

while Door is moving.

Do NOT allow children to play

with the Door Opener.

Do NOT operate a Door that

jams or one that has a broken

spring.

High tension spring

WARNING

Could result in Death or Serious

Injury

Do NOT try to remove, install,

repair or adjust springs or

anything to which door spring

parts are fastened, such as,

wood blocks, steel brackets,

cables or other like items.

Installations, repairs and

adjustments must be done by

a trained door system techni-

cian using proper tools and

instructions.

Removing an Existing Door

and Preparing the Opening

IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE

ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.

WARNING

A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE

SEVERE OR FATAL INJURY. TO AVOID INJURY, HAVE A TRAINED DOOR

SYSTEMS TECHNICIAN, USING PROPER TOOLS AND INSTRUCTIONS,

RELEASE THE SPRING TENSION.

To avoid possible injury and to insure proper installation, it's highly recommended that you

read and fully understand the complete instructions on removing an Existing Door & Prepar-

ing the Opening. These are available for download at www.Wayne-Dalton.com or at your

local Wayne Dalton Sales Center.

WEATHERSTRIPS (MAY NOT BE INCLUDED):

Depending on the size of your door, you may have to cut or trim the weatherstrips (if neces-

sary) to properly ﬁt into the header and jambs.

NOTE: If nailing product at 40°F or below, pre-drilling is required.

NOTE: Do not permanently attach weatherstrips to the header and jambs at this time.

For the header, align the weatherstrip 1/8” to 1/4” inside the header edge, and temporarily

secure it to the header with equally spaced nails. Starting at either side of the jamb, ﬁt the

weatherstrip up tight against the temporarily attached weatherstrip in the header and 1/8”

to 1/4” inside the jamb edge. Temporarily secure the weatherstrip with equally spaced nails.

Repeat for other side. This will keep the bottom section from falling out of the opening during

installation. Equally space nails approximately 12” to 18” apart.

Pre-Installation

A. FLAG ANGLES (AS REQUIRED):

A1. Fully Adjustable (F.A.) Flag Angles

B. JAMB BRACKETS (AS REQUIRED):

B1. Fully Adjustable (F.A.) Jamb Brackets / B2. Windload Jamb Brackets

C. TRACK ROLLERS (AS REQUIRED):

C1. Short Stem Track Rollers / C2. Long Stem Track Rollers

D. GRADUATED END HINGES:

D1. Single Graduated End Hinges (S.E.H.), Industry Standard

D2. Double Graduated End Hinges (D.E.H.), Industry Standard

D3. Half Center Hinges (As Required)

E. STACKED SECTIONS:

E1. Top Section

E2. Intermediate Section (s)

E3. Lock Section / E4. Bottom Section

F. TOP FIXTURES:

F1. Top Fixture Bases / F2. Top Fixture Slides

F3. Top Fixture Assemblies (As Required)

G. STRUT(S) (AS REQUIRED):

G1. Strut (2” U-shaped) / G2. Strut (3” U-shaped) / G3. Girt(s)

H. TRACKS (AS REQUIRED):

H1. Left Hand and Right Hand Horizontal Track Assemblies

H2. Left Hand and Right Hand Vertical Tracks

H3. Left Hand and Right Hand Vertical Track Assemblies

H4. Left Hand and Right Hand Wall Angle Track Assemblies

I. TORSION SPRING ASSEMBLY (AS REQUIRED):

I1. Center Bracket(s) With Center Bracket Bearing(s) (As Required)

I2. Torsion Shaft / Torsion Keyed Shaft (As Required)

I3. Torsion Keyed Shafts (As Required)

I4. Keys (As Required)

I5. Center Coupler Assembly (As Required)

I6. Left Hand And Right Hand End Bearing Brackets

I7. Left Hand And Right Hand Cable Drums

I8. Left Hand and Right Hand Torsion Springs (As Required)

I9. Counterbalance Lift Cables

J. REAR BACK HANGS:

J1. Left and Right Hand Rear Back Hangs Assemblies

J2. Left and Right Hand Rear Center Back Hang Assemblies (As Required)

J3. Left and Right Hand Rear Center Back Hang Assemblies (As Required)

K. BOTTOM CORNER BRACKETS (AS REQUIRED):

K1. Left Hand and Right Hand Bottom Corner Brackets

L. CABLE KEEPERS (AS REQUIRED):

L1. Cable Keepers

M. BROKEN CABLE SAFETY DEVICES (AS REQUIRED):

M1. Left Hand And Right Hand Broken Cable Safety Devices

N. TRACK ROLLER CARRIER’S (AS REQUIRED):

N1. Track Roller Carrier’s

O. BOTTOM WEATHER SEAL:

O1. Bottom Weather Seal (Door Width)

D3.

I4.

F1.

K1.

C1.

F1.

G1.

G2.

L1.

K1.

C2.

F2.

M1.

E4.

E3.

E2.

E1.

F2.

I5.

D2.

D1.

N1.

O1.

G3.

NOTE: The illustrations shown on this page are general

representations of the door parts. Each speciﬁc door

model may have unique variations.

H1.

J1.

I6.

I8.

I9.

I8.

I2.

J2.

I6.

I3.

I7.

I9.

J1.

I3.

J3.

NOTE: For Item (J2), The Center Back Hang Assemblies

are to be used for all doors over 11’0” door height and

over 14’0” door width. One Center Back Hang

Assembly, per side.

NOTE: For Item (J3), The Center Back Hang Assemblies

are to be used for all doors over 16’0” door height. Tw

Center Back Hang Assemblies, per side.

NOTE: Depending on your door weight and door height,

you may have bigger springs. The illustration shown

below is a typical example.

H1.

J2.

I1.

I8. I8.

H3.

H4.

H2.

B1.

A1.

A1. H4.

H2.

H3.

B1.

H3.

I4.

I7.

B2.

F3.

BREAKDOWN OF PARTS

DOOR INSTALLATION

INSTRUCTIONS

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.

IMPORTANT: IF THE DOOR WILL BE EXPOSED TO A SIGNIFICANT AMOUNT OF ROAD SALT,

PAINT THE BARE GALVANIZED BOTTOM WEATHER STEEL RETAINER TO INHIBIT RUSTING.

Attaching Flag Angles and Jamb Brackets To

Vertical Tracks

NOTE: If you have Riveted Track or Angle Mount Track, skip this step.

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.

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. Hand tighten jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20

ﬂange hex nut. Place the center jamb bracket over the lower hole of the hole/ slot pattern

that is centered between the bottom jamb bracket and ﬂag angle of the 2nd hole set. Hand

tighten jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 ﬂange hex nut.

If a top jamb bracket was included, hand tighten 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 the same process for right hand side.

Attaching (WL) Jamb Brackets To Vertical

Tracks

Measure the length of the vertical tracks. Using the Jamb Bracket Schedule (shown on the

Windload Speciﬁcation Sheet), determine the placement of the windload jamb brackets for

your door height. Loosely fasten the jamb bracket to the vertical track with (1) 1/4” - 20 x

9/16” track bolt and (1) 1/4” - 20 ﬂange hex nut. Repeat for other side.

Attaching Bottom Weather Seal

NOTE: Reference Package Contents or Breakdown Of Parts, to determine if a bottom weather

seal was supplied. If a bottom weather seal was supplied, complete this step.

Place the bottom section face down on a couple of sawhorses or ﬂat clean/ smooth surface.

Position the bottom weather seal up against the bottom of the bottom section with the long

lip on the inside surface of the bottom section. From inside the door, attach the bottom

weather seal to the bottom section with 1/4” - 20 x 11/16” self drilling screws, placing one

6” in from each end of the bottom section and one every 18” (maximum) in between, as

shown.

NOTE: Verify bottom weather seal is aligned with bottom section. If there is more than 1/2”

excess weather seal on either side, trim weather seal even with bottom section.

Attaching Bottom Corner Brackets

NOTE: Refer to door section identiﬁcation, located in the pre-installation section of this

manual or refer to Breakdown of Parts.

With the bottom section facing down from the previous step, uncoil the counterbalance lift

cables.

NOTE: Refer to Package Contents / Breakdown of Parts, to determine which bottom corner

brackets you have.

Locate the left hand bottom corner bracket.Secure the cable loop to the clevis pin and bot-

tom corner bracket using a ﬂat washer and a cotter pin. Repeat for right hand bottom corner

bracket.

WARNING

ENSURE TIGHT FIT OF CABLE LOOP OVER PIN TO PREVENT

COUNTERBALANCE LIFT CABLE FROM COMING OFF THE PIN, WHICH

COULD ALLOW THE DOOR TO FALL AND RESULT IN SEVERE OR FATAL

INJURY.

NOTE: Prior to installing the bottom corner brackets onto the bottom section, you may

have to slit the bottom weather seal at both ends to allow the bottom corner brackets to be

adhered to the bottom section unobstructed by the bottom weather seal.

IMPORTANT: DO NOT INSTALL BOTTOM CORNER BRACKETS OVER THE BOTTOM WEATHER

SEAL.

NOTE: Refer to the Windload Speciﬁcation Sheet for the strutting schedule to determine if

your bottom section requires a strut at this time. Depending on your windload option code,

either your strut may need to be attached to the bottom section on top of the bottom corner

brackets or above the bottom corner brackets.

TO ATTACH BOTTOM CORNER BRACKETS WITHOUT A STRUT: Starting on the left hand

side, attach the left hand bottom corner bracket to the left corner of the bottom section, mak-

ing sure it is seated to the edges of the end cap, using 1/4” - 14 x 7/8” self drilling screws.

Repeat for right hand bottom corner bracket.

TO ATTACH BOTTOM CORNER BRACKETS WITH A STRUT: Starting on the left hand side,

position the left hand bottom corner bracket to the left corner of the bottom section, making

sure it is seated against the edges of the end stile. Repeat for other side. Next, position the

strut over the bottom corner brackets and center the strut side to side on the bottom section.

Attach the bottom corner bracket and the strut into the end stile using 1/4” - 14 x 7/8” self

drilling screws. Repeat for other side. Finish securing the strut to the bottom section using

(2) 1/4” - 14 x 7/8” self drilling screws at each center hinge location(s) and in between each

hinge locations.

TO ATTACH A STRUT ABOVE THE BOTTOM CORNER BRACKETS: Starting on the left

hand side, attach the left hand bottom corner bracket to the left corner of the bottom section,

making sure it is seated to the edges of the end cap, using 1/4” - 14 x 7/8” self drilling

screws. Repeat for right hand bottom corner bracket. Next, position the strut above the

bottom corner brackets and center the strut side to side on the bottom section. Secure the

strut to the end stile using 1/4” - 14 x 7/8” self drilling screws. Repeat for other side. Finish

securing the strut to the bottom section using (2) 1/4” - 14 x 7/8” self drilling screws at each

center hinge location(s) and in between each hinge locations.

NOTE: If you have broken cable safety devices, only install the top (4) 1/4” - 14 x 7/8” self

drilling screws to secure the bottom corner bracket to the bottom section. Reference Step

Broken Cable Safety Devices.

NOTE: If you did not receive Track Roller Carriers or Cable Keepers, then insert a short stem

track roller into each of the bottom corner brackets.

Attaching Track Roller Carrier’s

NOTE: If you don’t have track roller carriers, then skip this step. Refer to Package Contents /

Breakdown of Parts, to determine if a track roller carrier was supplied with your door.

NOTE: If your door came with two track roller carriers, then one track roller carrier, short

stem track roller and spacer are required for each side.

NOTE: If your door came with four track roller carriers, then two track roller carriers, long

stem track roller and spacer are required for each side.

Starting on left hand side of the bottom section, position the track roller carrier with the

stamp “STD” facing UP to the bottom corner bracket and aligning the four holes of the track

roller carrier with the four holes in the bottom corner bracket. Secure the track roller carrier

to the bottom corner bracket with (4) 1/4” - 20 x 7/8” self drilling screws. Repeat the same

process for other track roller carrier(s). Insert the appropriate stem track roller and spacer

into the inner holes of the track roller carrier(s).

NOTE: The track roller carrier’s inner holes are used on doors with 2” track applications; the

outer holes are used on doors with 3” track applications.

Attaching Cable Keepers

NOTE: If you don’t have cable keepers, then skip this step. Refer to Package Contents /

Breakdown of Parts, to determine if a cable keeper was supplied with your door.

NOTE: Cable keepers are right hand and left hand.

NOTE: Cable keepers are color coded, black for right hand side and red for left hand side.

Locate the left hand cable keeper. Starting on the left hand side of bottom section, position

the left hand cable keeper in between the roller carrier tabs. Insert a short stem track roller

with roller spacer through the holes in the tabs and through the cable keeper. Repeat the

same process for the right hand side.

Attaching Broken Cable Safety Devices

NOTE: If you don’t have broken cable safety devices, then skip this step. Refer to Package

Contents / Breakdown of Parts, to determine if a broken cable safety device was supplied

with your door.

Starting on left hand side of the bottom section, position the left hand broken cable safety

device to the bottom corner bracket by aligning the four holes of the bottom corner bracket

with the four holes in the broken cable safety device. Secure the broken cable safety device

to the bottom corner bracket with (5) 1/4” - 20 x 11/16” self drilling screws. Rotate the cam

arm upward and slide the counterbalance lift cable through the arm, as shown. Repeat the

same process for the right hand side.

Attaching Hinges To Sections

NOTE: Refer to the Door Section Identiﬁcation, Graduated End Hinge Schedule, to determine

the appropriate hinges needed to be installed onto your section(s).

NOTE: The graduated hinges can be identiﬁed by the number stamped onto their lower hinge

leaf. The graduated end hinge sequence is dependent on your track size (2” or 3”). Refer to

Graduated End Hinge Schedule.

NOTE: Refer to the illustrations below or refer to your Windload Speciﬁcation Sheet to deter-

mine if you have single end stiles or double end stiles.

Graduated End Hinge Schedule

Section Type Graduated End Hinge Number

2” Track 3” Track (< = 9 Sec-

tions High)

3” Track (> 9 Sec-

tions High)

Intermediate X N/A N/A #8

Intermediate IX N/A N/A #8

Intermediate VIII N/A N/A #7

Intermediate VII #9 N/A #7

Intermediate VI #8 #10 #6

Intermediate V #7 #9 #6

Intermediate IV #6 #8 #5

Intermediate III #5 #7 #5

Intermediate II #4 #6 #4

Intermediate I #3 #5 #4

Lock #2 #4 #3

Bottom #1 #3 #3

IF YOU HAVE SINGLE END STILES: Starting with the bottom section, align the lower hinge

leaf of the appropriate graduated end hinges over the holes at the top of the end caps of the

bottom section. Secure the graduated end and center hinges to the section each using (2)

1/4” - 14 x 7/8” self drilling screws.

IF YOU HAVE DOUBLE END STILES: Starting with the bottom section, align the lower hinge

leafs of the appropriate graduated end hinges over the holes at the top of the end caps of the

bottom section. Secure the graduated end and center hinges to the section each using (2)

1/4” - 14 x 7/8” self drilling screws.

TO INSTALL CENTER HINGES: Align the lower hinge leaf of the #1 center hinge(s) with the

dimples at the intermediate / center locations at the top of the bottom section. Secure the

center hinge(s) to the section each using (2) 1/4” - 14 x 7/8” self drilling.

NOTE: Refer to your Windload Speciﬁcation Sheet to determine if an additional 1/4” - 14 x

7/8” self drilling screw is required to be installed on the lower hinge leaf of the graduate end

hinge, as shown.

IMPORTANT: ONCE THE 1/4” - 14 X 7/8” SELF DRILLING SCREWS ARE SNUG AGAINST THE

LOWER HINGE LEAFS, TIGHTEN AN ADDITIONAL 1/4 TO 1/2 TURN TO RECEIVE MAXIMUM

DESIGN HOLDING POWER.

FOR SINGLE END STILES: Insert a short stem track roller into the hinge tube of the gradu-

ated end hinge, as shown.

FOR DOUBLE END STILES: Insert a long stem track roller into the hinge tubes of the gradu-

ated end hinges, as shown.

IMPORTANT: PRIOR TO INSERTING THE LONG STEM TRACK ROLLER INTO THE INNER HINGE

TUBE OF THE GRADUATED END HINGE A PUSH NUT MAY NEED TO BE INSTALLED, REFER TO

YOUR WINDLOAD SPECIFICATION SHEET.

IMPORTANT: WHEN PLACING SHORT STEM / LONG STEM TRACK ROLLERS INTO THE #2

GRADUATED END HINGES AND HIGHER, THE SHORT STEM / LONG STEM TRACK ROLLER

GOES INTO HINGE TUBE FURTHEST AWAY FROM SECTION.

Repeat the same process for graduated hinge attachment using the appropriate graduated

end hinges for all remaining sections, except the top section.

Attaching Top Fixtures To Top Section

NOTE: Depending on your door, you may have Top Fixture Bases and Top Fixture Slides or

you may have Top Fixture Assemblies. Refer to Package Contents / Breakdown Of Parts, to

determine which Top Fixtures you have.

NOTE: Refer to the Windload Speciﬁcation Sheet to determine if a strut is required to be

installed on your top section.

IF YOU HAVE TOP FIXTURE ASSEMBLIES: Starting on the left hand side of the top section,

place the top edge of the top ﬁxture assembly 3” down from the top section edge and even

with the side edge of the section. Once the top ﬁxture assembly is properly positioned, as

shown, secure the top ﬁxture assembly to the top section using (4) 1/4” - 14 x 7/8” self-

drilling screws, one in each corner of the top ﬁxture base. Next, loosen the 5/16” - 18 hex

nut on the 5/16” - 18 x 5/8” carriage bolt. Repeat the same process for the right hand side.

The top ﬁxtures will be tightened and adjusted later, in step, Adjusting Top Fixture.

Locate and center the strut (if applicable) onto the top portion of the top section, as shown.

Center the strut side to side. Secure strut to the top section using (2) 1/4” - 14 x 7/8” self

drilling screws at each ends. Next, secure the strut to the top section surface using (2) 1/4”

- 14 x 7/8” self drilling screws at each center hinge location(s) and in between each hinge

locations.

IF YOU HAVE TOP FIXTURE BASES AND TOP FIXTURE SLIDES: Loosely secure each of

the top ﬁxture slide to the top ﬁxture base using (1) 5/16” - 18 x 3/4” carriage bolt and (1)

5/16” - 18 hex nut. Starting on the left hand side, align the lip of the top ﬁxture base on top

of the corner of the top section and even with the edge of the top section. Fasten each top

ﬁxture base to the top section using (2) 1/4” - 14 x 7/8” self drilling screws. Repeat for other

side, then repeat the same process for the right hand side.

Next, locate and center the strut onto the top portion of the top section and on top of the top

ﬁxture bases, as shown. Center the strut side to side. Secure strut to the top section using

(2) 1/4” - 14 x 7/8” self drilling screws at each ends. Next, secure the strut to the top section

surface using (2) 1/4” - 14 x 7/8” self drilling screws at each center hinge location(s) and in

between each hinge locations. The top ﬁxtures will be tightened and adjusted later, in step,

Adjusting Top Fixture.

Attaching Strut To Sections

NOTE: Refer to door section identiﬁcation, located in the pre-installation section of this

manual to determine what size sections you need to use as your bottom (ﬁrst) section, lock

(second) section, intermediate (third) section, intermediate (fourth) section, intermediate (ﬁfth)

section, intermediate (sixth) section, intermediate (seventh) section and intermediate (eighth)

section. Measure your sections to make sure they are the correct height as indicated on the

chart.

NOTE: Refer to the Windload Speciﬁcation Sheet to determine the placement of the struts

and their position on each section.

Place the sections face down on a couple of sawhorses or ﬂat clean / smooth surface. Butt

the sections together in the proper stack sequence and ﬂip up the hinges. Position the strut

onto the section and center the strut side to side on the section. Fasten the strut to the

section surface using (2) 1/4” - 14 x 7/8” self drilling screws at each end stile. Next, secure

the strut to the section surface using (2) 1/4” - 14 x 7/8” self drilling screws at each center

hinge location(s) and in between each hinge locations.

Attaching Top Head Seal

NOTE: If you don’t have a top head seal, then skip this step. Refer to Package Contents /

Breakdown of Parts, to determine if you have a top head seal.

Using sawhorses, lay the top section on a ﬂat smooth surface. Position the top head seal on

the top section, making sure the straight portion of the head seal is facing the outside of the

section and is pointing upward, as shown.

NOTE: Since the top head seal will tend to want to slip off the tongue of the top section prior

to securing, it is advisable to have someone hold the top section and another person holding

the top head seal in position, while securing it to the top section.

While holding the top head seal in position, use the #6 - 20 x 1/2” screws to secure the head

seal to the tongue of the top section, as shown. Screws should be installed at each end and

at 18” intervals.

Positioning Bottom Section

Center the bottom section in the door opening. Level the section using wooden shims (if

necessary) under the bottom section. When the bottom section is leveled, temporarily hold it

in place by driving a nail into the jamb and bending it over the edge of the bottom section on

both sides.

NOTE: For wider size doors, more than two wooden shims (shown in illustration) might be

needed to level the bottom section.

Attaching Wall Angle Seals

NOTE: If you don’t have wall angle seals, then skip this step. Refer to Package Contents and

or illustrations below, to determine which wall angle seals you have received.

Starting with the left hand wall angle, align the proﬁle of the wall angle seal with the inside

edge of wall angle. Next, slide wall angle seal over the inside edge of wall angle until seal

is ﬂush up against the edge of wall angle, as shown. Repeat the same process for the right

hand side wall angle.

Attaching Vertical Tracks To Jambs

NOTE: Depending on your door, you may have Fully Adjustable Flag Angles, Riveted Vertical

Track Assemblies or you may have Angle Mount Vertical Track Assemblies. Refer to Package

Contents / Breakdown of Parts, to determine which Flag Angles / Vertical Track Assemblies

you have.

IMPORTANT: IF YOUR DOOR IS TO BE INSTALLED PRIOR TO A FINISHING CONSTRUCTION

OF THE BUILDING’S FLOOR, THE VERTICAL TRACKS AND THE DOOR BOTTOM SECTION

ASSEMBLY SHOULD BE INSTALLED SUCH THAT WHEN THE FLOOR IS CONSTRUCTED, NO

DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION.

IMPORTANT: THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE.

IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT, THE VERTICAL TRACK ON THE

SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM.

NOTE: Make sure the counterbalance lift cable is located between the track rollers and the

door jamb.

Starting on the left hand side of the bottom section, remove the nail. Position the left hand

vertical track assembly over the track rollers of the bottom section and install, as shown. Drill

3/16” pilot holes into the door jamb for the lag screws.

LOOSELY FASTEN WALL ANGLES TO ONE OF THE FOLLOWING SCENARIOS LISTED

BELOW:

Wood jambs, using 5/16” x 1-5/8” lag screws. Drill 3/16” pilot holes into the wood

jamb for the lag screws.

Steel jambs, using 5/16” x 1” self drilling screws.

Pre-cast concrete, using 3/8” x 3” sleeve anchor (not supplied).

NOTE: Products being installed to pre-cast or block must use a 3/8” x 3” sleeve anchor

to attach the wall angle to the building, as shown. Use the slots in the wall angle as a drill

template and drill a 3/8” hole (3-1/2” deep) and secure to anchor.

WARNING

DO NOT USE SLEEVE ANCHORS ON HOLLOW BLOCK.

FOR 2” TRACK: Tighten fasteners, securing the bottom jamb bracket in the vertical track

assemblies / bottom slot in the wall angle to jamb, maintain 3/8” to 5/8” spacing, between

the bottom section and vertical track.

FOR 3” TRACK: Tighten fasteners, securing the bottom jamb bracket in the vertical track

assemblies / bottom slot in the wall angle to jamb, maintain 1/2” to 3/4” spacing, between

the bottom section and vertical track.

Allow proper clearance as shown and use the values as illustrated in the Side Room Require-

ments (Minimum Distance Required), located in the pre-installation section of this manual.

Hang counterbalance lift cable over ﬂag angle / angle mount. Repeat same process for other

side.

Stacking Sections

NOTE: Refer to door section identiﬁcation, located in the pre-installation section of this

manual to determine what size sections you need to use as your lock (second) section, inter-

mediate (third) section, intermediate (fourth) section, intermediate (ﬁfth) section, intermediate

(sixth) section, intermediate (seventh) section, intermediate (eighth) section and top section.

Measure your sections to make sure they are the correct height as indicated on the chart.

NOTE: Make sure graduated end and center hinges are ﬂipped down, when stacking another

section on top.

Place appropriate stem 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.

NOTE: Make sure graduated end and center hinges are ﬂipped down, when stacking another

section on top.

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 7/8” self-drilling screws. Repeat same process for

other sections, except top section.

IMPORTANT: PUSH & HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE

SECURING WITH 1/4” - 14 X 7/8” 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 Lock.

Stacking Top Section

Place the top section in the opening. Install a nail to prevent the top section from falling back-

wards. Now, ﬂip up the 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 OR ANGLE MOUNT FROM THE EDGE OF THE DOOR:

FOR 2” TRACK APPLICATIONS: 1-11/16” (43 mm) to 1-3/4” (44 mm) for smooth, safe

door operation.

FOR 3” TRACK APPLICATIONS: 2-3/16” (56 mm) to 2-1/4” (57 mm) for smooth, safe door

operation

Tighten the bottom lag screw. Flag angles / Angle mount must be parallel to the door sec-

tions. Repeat for other side.

FOR 2” TRACK APPLICATIONS: Door width plus 3-3/8” (86mm) to 3-1/2” (89 mm) for

smooth, safe door operation.

FOR 3” TRACK APPLICATIONS: Door width plus 4-7/8” (124mm) to 5” (127 mm) for

smooth, safe door operation.

Complete the vertical track installation by securing the fasteners to the jamb. Push the verti-

cal 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.

Attaching Drawbar Operator Bracket

NOTE: If you don’t have a drawbar operator bracket, then skip this step. Refer to Illustrations

shown below, Package Contents or Breakdown of Parts, to determine which drawbar operator

bracket you have.

NOTE: If you’re installing a drawbar operator, the drawbar operator bracket must be mounted

and secured prior to installing top section.

IMPORTANT: WHEN CONNECTING A TROLLEY TYPE GARAGE DOOR OPENER TO THIS DOOR,

A WAYNE DALTON OPERATOR / TROLLEY BRACKET MUST BE SECURELY ATTACHED TO

THE TOP SECTION OF THE DOOR IF ONE HAS BEEN PROVIDED, ALONG WITH ANY STRUTS

PROVIDED WITH THE DOOR (IF A WAYNE DALTON OPERATOR / TROLLEY BRACKET WAS NOT

PROVIDED WITH YOUR DOOR, THAN USE THE ONE PROVIDED BY YOUR OPERATOR MANU-

FACTURER). THE INSTALLATION OF THE OPERATOR MUST BE ACCORDING TO MANUFAC-

TURER’S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED PROPERLY.

NOTE: For retro ﬁt applications, the drawbar operator bracket must be aligned with an exist-

ing operator.

NOTE: Refer to illustrations to determine which drawbar operator bracket was supplied with

your door.

Place the bottom half of drawbar operator bracket inside the top half of drawbar operator

bracket and ﬂush against the inside surface of the top section. Adjust both the top and bot-

tom halves out as far apart as possible on the section surface, as shown. Secure the bottom

half drawbar operator bracket and the top half drawbar operator bracket together using (4)

5/16” - 18 x 1/2” carriage bolts and (4) 5/16” - 18 ﬂange hex nuts.

NOTE: Install the 5/16” - 18 x 1/2” carriage bolts and the 5/16” - 18 ﬂange hex nuts as far

apart as possible, prior to securing both top and bottom halves together.

Now, 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.

Slide the upper half of the drawbar operator bracket under the strut (if applicable), keeping

the drawbar operator bracket aligned with the center line. Remove the strut’s screws, if nec-

essary and attach to the top section (through strut if necessary) using 1/4” - 20 x 7/8” self

drilling screws. Attach the lower half of the drawbar operator bracket to the section surface

using 1/4” - 20 x 7/8” self drilling screws.

NOTE: When attaching drawbar operator bracket to top section with strut, apply additional

pressure to thread into the strut.

NOTE: Depending on your door width, it may be required that the rectangular drawbar

operator bracket be mounted off center so the drawbar operator bracket mounts to the hinge

points.

Now, locate the center of the top section and align the drawbar operator bracket assembly

with the top section center line. Align the drawbar operator bracket assembly vertically and

horizontally. Secure the drawbar operator bracket to the top section surface using 1/4” - 20 x

7/8” self drilling screws, as shown. Next, if applicable and using 1/4” - 20 x 7/8” self drilling

screws, secure the rectangular drawbar operator bracket to the Strut / C Channels, as shown.

Attaching Horizontal Tracks

NOTE: Depending on your door, you may have Fully Adjustable Flag Angles, Riveted Vertical

Track Assemblies or you may have Angle Mount Vertical Track Assemblies. Refer to Package

Contents / Breakdown of Parts, to determine which Flag Angles / Vertical Track Assemblies

you have.

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.

IMPORTANT: PRIOR TO INSTALLING THE HORIZONTAL TRACKS, USE CABLES OR CHAINS TO

TEMPORARILY SUSPEND THE REAR PORTION OF HORIZONTAL TRACKS.

WARNING

DO NOT USE ROPES, SINCE EDGES OF HORIZONTAL TRACKS AND

ANGLES ARE VERY SHARP.

IF YOU HAVE FLAG ANGLES: To install horizontal track, place the curved end over the top

track roller of the top section. Align the bottom of the horizontal track with the top of the verti-

cal track. Tighten 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.

IF YOU HAVE ANGLE MOUNT: To install horizontal track, place the curved end over the

top track roller of the top section. Align the bottom of the horizontal track with the top of the

vertical track. Tighten the horizontal track to the angle mount with (2) 1/4” - 20 x 9/16” track

bolts and (2) 1/4” - 20 ﬂange hex nuts.

Next level the horizontal track assembly and bolt the horizontal track angle to the ﬁrst

encountered slot in the ﬂag angle / angle mount using (1) 3/8” - 16 x 3/4” truss head bolt

and (1) 3/8” - 16 hex nut. Repeat for other side. Remove nail that was temporally holding the

top section in position.

IMPORTANT: FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD

CAUSE PERMANENT DAMAGE TO TOP SECTION.

Adjusting Top Fixtures

NOTE: Depending on your door, you may have Top Fixture Bases and Top Fixture Slides or

you may have Top Fixture Assemblies. Refer to Package Contents / Breakdown Of Parts, to

determine which Top Fixtures you have.

With horizontal tracks installed, you can now adjust the top ﬁxtures. Vertically align the top

section of the door with the lower sections. Once aligned, position the top ﬁxture slide, out

against the horizontal track. Maintaining the slide’s position, tighten the 5/16” - 18 hex nuts

to secure the top ﬁxture slide to the top ﬁxture base. Repeat for other side.

Next remove the nail(s) that was temporarily holding the top section in place, installed in step,

Top Section.

IMPORTANT: FAILURE TO REMOVE NAIL(S) BEFORE ATTEMPTING TO RAISE DOOR COULD

CAUSE PERMANENT DAMAGE TO TOP SECTION.

Depending on which top ﬁxture was supplied with your door, lock the top ﬁxture slide to

the top ﬁxture base using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 ﬂange hex nut

through any two aligning holes in the top ﬁxture slide / top ﬁxture base. Repeat for other side.

NOTE: Refer to your windload speciﬁcation sheet to determine if pushnuts are required.

Install the pushnuts by placing a pushnut onto the end of each track roller stem and sliding

it toward the graduated end hinge or top ﬁxture. Leave at least 1/4” of space between the

pushnut and top ﬁxture.

COUNTERBALANCE

INSTALLATION INSTRUCTIONS

Attaching End Bearing Brackets

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING

LOOKING OUT.

WARNING

INSTALL END BEARING BRACKETS TO SOLID STRUCTURAL MEMBERS

ONLY. DO NOT INSTALL OVER DRY WALL OR PANELING. FAILURE TO

INSTALL END BEARING BRACKETS TO SOLID STRUCTURAL MEMBERS

CAN CAUSE SEVERE OR FATAL INJURY.

WARNING

FAILURE TO USE PROPER NUMBER OF FASTENERS CAN RESULT IN

SUDDEN SPRING TENSION RELEASE, CAUSING SEVERE OR FATAL

INJURY.

NOTE: Spring pads must be securely anchored before proceeding, as shown. The pads must

be ﬂush with the jambs.

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING

LOOKING OUT.

NOTE: End bearing brackets are right hand and left hand.

Attach the left hand end bearing bracket through either the end bearing bracket’s upper or

lower slots to the left hand horizontal track angle using (2) 3/8” - 16 x 3/4" truss head bolts

and (2) 3/8” - 16 nuts.

IMPORTANT: THE END BEARING BRACKET’S LOWER SLOTS ARE USED ON DOORS WITH

12” RADIUS TRACK; THE UPPER SLOTS ARE USED ON DOORS WITH 15” RADIUS TRACK.

SECURE THE END BEARING BRACKET TO THE JAMB USING ONE OF THE FOLLOWING

SCENARIOS LISTED BELOW:

For wood jambs, using (3) 5/16” x 1-5/8” lag screws.

NOTE: Prior to fastening end bearing brackets into the door jamb, pilot drill using a

3/16” drill bit.

For steel jambs, using (3) 5/16” x 1” self drilling screws.

For pre-cast concrete, using (3) 3/8” x 3” sleeve anchors (not supplied).

NOTE: Products being installed to pre-cast or block must use a 3/8” x 3” sleeve anchor to

attach the end bearing brackets to the building, as shown. Use the slots in the end bearing

bracket as a drill template and drill a 3/8” hole (3-1/2” deep) and secure to anchor.

WARNING

DO NOT USE SLEEVE ANCHORS ON HOLLOW BLOCK.

Repeat the same process for the right hand side.

(2) 3/8”-16

Hex nuts

(2) 3/8”-16 x 3/4”

Truss head bolts

Left end

bracket

Upper slot

Lower slots

Horizontal

track angle

(3) 5/16” x 1-5/8”

Lag screws

Wall

angle

NOTE: This illustration shows 15” radius track with lag screws to Wood Jambs.

(2) 3/8”-16

Hex nuts

(2) 3/8”-16 x 3/4”

Truss head bolts

Left end

bracket

Upper

slot

Lower slots

Horizontal

track angle

(3) (Steel Jambs)

5/16” x 1”

Self drilling screws

NOTE: This illustration shows 15” radius track with self drilling screws to Steel.

Wall

angle

(3) (Pre-cast

concrete) 3/8” x 4”

Sleeve anchors (not

supplied)

NOTE: This illustration shows 15” radius track with anchors to Concrete.

(2) 3/8”-16

Hex nuts

(2) 3/8”-16 x 3/4”

Truss head bolts

Left end

bracket

Upper slot

Lower slots

Horizontal

track angle

Wall

angle

Attaching Center Bracket to Wall

NOTE: Refer to Package Contents / Breakdown of Parts, to determine which Center

Bracket(s) came with your door.

NOTE: When attaching the center bracket(s) to the spring pads, it has to be at the same

elevation as the bearing in the end bearing brackets.

NOTE: Additional center brackets may be required for doors with coupler assembly. Refer to

Package Contents / Breakdown of Parts, to determine if you have a coupler assembly.

NOTE: If your door came with (4) or more springs, each of the outer springs mounting

surface will need to be a minimum of 3” wide.

NOTE: If needed, measure the diameter of your springs. If you have a one piece shaft with

3-3/4” or larger diameter springs, they do not share center brackets and do not have a

coupler assembly.

First, locate the center of the door. Mark a vertical pencil line on the mounting surface above

the door, at the center. Measure from the center of the bearing, in one of the end bearing

brackets, downwards, to the top the door. Using that measurement, measure that distance

upwards from the top of the door to the mounting surface and mark a horizontal pencil line

which intersects the vertical pencil line.

NOTE: On some single spring doors, the spring can be longer than half the opening width. If

your spring is longer, then the center bracket must be mounted off center for the spring to ﬁt

properly. Measure spring length adding room for spring growth during winding, to determine

appropriate center bracket location.

NOTE: Depending on the construction, different fasteners must be used.

FOR WOOD CONSTRUCTION: Align the edge of the center bracket with the vertical pencil

line and the center of the center bracket with the horizontal pencil line; this is to ensure the

torsion shaft is level between the center and end bearing brackets. Attach the center bracket

to the mounting surface, using 5/16” x 1-5/8” lag screws.

NOTE: Drill 3/16” pilot holes into header for the lag screws.

FOR STEEL CONSTRUCTION: Secure each center bracket using (4) 5/16” x 1” self-drilling

and tapping screws, as shown.

FOR PRE-CAST CONSTRUCTION: Secure each center bracket using (2) 1/2” x 3” sleeve

anchors (by others). This installation will require the 1/2” anchors to be secured to the build-

ing and then secure the brackets to the anchors, as shown.

NOTE: Pre-Drill 1/2” pilot holes into the pre-cast for the 1/2” x 3” sleeve anchors.

FOR BLOCK CONSTRUCTION: Attach perforated angle 18” long to center bracket(s) using

(2) 3/8” x 1-1/4” bolts and (2) 3/8”nuts. Chamfer angle to clear top section high arc. Secure

center bracket(s) and perforated angle to block using (4) 3/8” x 2-1/2” sleeve anchors, as

shown.

WARNING

DO NOT USE SLEEVE ANCHORS ON HOLLOW BLOCK.

Vertical line

Spring mounting pad (2”

X 6“) White Pine or

denser. Secured with a

minimum of (4) 5/16” x

4” lag bolts into header.

Horizontal

line

Center

bracket

5/16” x 1-5/8” Hex

head lag screws

Wood

NOTE:

Actual center bracket may

vary, see breakdown of parts.

(2) 3/8” x 1-1/4”

Hex bolts

Center bracket

(2) 3/8”

Hex nuts

Chamfered to clear

door high-arc. Sleeve anchors (3/8” x

2-1/2”) positioned in

the top and bottom slot

of center bracket.

(18” length) Perforated

angle

Concrete

Blocks

NOTE: All (4) sleeve anchors (3/8” x 2-1/2”) must

be positioned a minimum of 1” from block edge.

NOTE: Actual center

bracket may vary, see

breakdown of parts.

Center

bracket

(Steel Jambs) (4) 5/16” x 1”

Self drilling screws

Steel Pre-Cast

Center

bracket

(Pre-cast) (2) 1/2” x 4”

Sleeve anchors

NOTE: Must secure

sleeve anchors ﬁrst, then

attach center brackets to

sleeve anchors.

NOTE: Actual center bracket may vary, see breakdown of parts.

12”

Center

brackets

Mounting

surface

17”

Minimum

NOTE: Actual center bracket may

vary, see breakdown of parts.

FOR ALTERNATE STEEL SPRING PAD APPLICATIONS:

IMPORTANT: DO NOT BOLT TWO 3-3/4” OR LARGER DIAMETER SPRINGS TO ONE CENTER

BRACKET.

WARNING

THESE SPRING MOUNTING TECHNIQUES ARE NOT SUPPORTED FOR 800-

32 CABLE DRUMS. THESE INSTRUCTIONS ARE ALSO NOT APPLICABLE

FOR 5750-120 CABLE DRUMS WITH 72” OR MORE HIGH-LIFT.

WARNING

MAXIMUM SPACING FOR DIMENSION “Y” IS 84” (7 FT.) THESE

INSTRUCTIONS ARE NOT APPLICABLE FOR A SPAN GREATER THAN 84”..

Maximum Door Size 9’0” x 9’0” (Maximum Door Weight 210 lb.)

Cut perforated angle (1-5/8” x 2-3/8” x 11 GA.) to Dim “Y”. Thru-bolt top and bottom of

angle to each girt using (4) 3/8” x 1-1/4” bolts and (4) 3/8”nuts. Thru-bolt center bracket to

perforated angle using (3) 3/8” x 1-1/4” bolts and (3) 3/8” nuts, as shown.

(3) 3/8” x 1-1/4”

Hex bolts

Center bracket

(3) 3/8”

Hex nuts

Heavy perforated angle

(1-5/8” x 2-3/8” x 11ga.)

Girt

(2) 3/8” x 1-1/4”

Hex bolts and (2)

3/8” Hex nuts

“Y” (< 7 FT.)

(2) 3/8” x 1-1/4”

Hex bolts and (2) 3/8” Hex nuts

NOTE: Actual center

bracket may vary, see

parts breakdown.

Maximum Door Size 14’0” x 12’0” (Maximum Door Weight 400 lb.)

Cut (2) perforated angle (1-5/8” x 2-3/8” x 11 GA.) to Dim “Y”. Thru-bolt top and bottom of

each angle to each girt using (4) 3/8” x 1-1/4” bolts and (4) 3/8” nuts. Thru-bolt each center

bracket to perforated angle using (3) 3/8” x 1-1/4” bolts and (3) 3/8” nuts, as shown.

(3) 3/8” x 1-1/4”

Hex bolts

Center

brackets

(3) 3/8”

Hex nuts

Heavy perforated angles

(1-5/8” x 2-3/8” x 11ga.)

Girt

(2) 3/8” x 1-1/4”

Hex bolts and (2)

3/8” Hex nuts

“Y” (< 7 FT.)

(2) 3/8” x 1-1/4”

Hex bolts and (2) 3/8” Hex nuts

Space center brackets 12” apart

on applications requiring center

coupler assembly

NOTE: Actual

center brackets

may vary, see

breakdown of

parts.

Maximum Door Size 14’-2” x 12’-1” (Maximum Door Weight 800 lb.)

Cut (2) pieces of perforated angle (1-5/8” x 2-3/8” x 11 GA.) to Dim “Y” and (2) more pieces

at Dim “Y” minus 3”. Bolt the angles together into a “Z” shape using (4) 3/8” x 1-1/4” bolts

and (4) 3/8” nuts. Thru-bolt top and bottom of each “Z” shaped angle to each girt using (4)

3/8” x 1-1/4” bolts and (4) 3/8” nuts. Thru-bolt each center bracket to perforated angle as-

sembly using (3) 3/8” x 1-1/4” bolts and (3) 3/8” nuts, as shown.

(3) 3/8” x 1-1/4”

Hex bolts

Center

brackets

(3) 3/8”

Hex nuts

Heavy perforated angles

(1-5/8” x 2-3/8” x 11ga.)

Girt

(2) 3/8” x 1-1/4”

Hex bolts and (2)

3/8” Hex nuts

“Y” (< 7 FT.)

(2) 3/8” x 1-1/4”

Hex bolts and (2) 3/8” Hex nuts

Space center brackets 12” apart

on applications requiring center

coupler assembly

(2) 3/8” x 1-1/4”

Hex bolts and (2)

3/8” Hex nuts

NOTE: Actual

center brackets

may vary, see

breakdown of

parts.

Torsion Spring Assembly

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING

LOOKING OUT.

NOTE: Torsion spring assemblies can be of several conﬁgurations depending on your door

size and door weight.

IMPORTANT: ON SINGLE SPRING APPLICATIONS, ONLY A LEFT HAND WOUND (BLACK

WINDING CONE), WHICH GOES ON THE RIGHT HAND SIDE IS REQUIRED.

NOTE: Identify the torsion springs provided as either right hand wound (red winding cone),

which goes on the LEFT HAND SIDE or left hand wound (black winding cone), which goes on

the RIGHT HAND SIDE.

Facing the inside of the door and referencing the illustrations shown, lay the torsion shaft /

torsion keyed shaft(s) on the ﬂoor.

NOTE: If your door came with (2) torsion keyed shafts, one torsion keyed shaft should be on

the left hand side of the ﬂoor and the other torsion keyed shaft should be on the right hand

side of the ﬂoor.

Lay the torsion spring(s) with the black winding cone and the black cable drum at the right

end of the torsion shaft / torsion keyed shaft(s). Lay the torsion spring(s) with the red winding

cone and the red cable drum at the left end of the torsion shaft / torsion keyed shaft(s).

NOTE: The set screws used on all torsion winding cones and cable drums are colored red.

DO NOT identify right and left hand by the set screw color.

IF YOUR DOOR CAME WITH A COUPLER ASSEMBLY: Disassemble the coupler assembly

by removing the (3) 3/8” - 16 x 1-3/4” hex head screws and the (3) 3/8” - 16 nylon hex

lock nuts from the coupler halves. Loosen the set screws. Slide the ﬂat edge of the coupler

half ﬂush with the side edge of the torsion keyed shaft. Insert (1) key into the slot of both

the coupler halves and the slot in the torsion keyed shaft. Tighten the (2) set screws and the

locking nut to secure the coupler half to the torsion keyed shaft, as shown. Repeat the same

processes for the other coupler half.

NOTE: Tighten the set screws to 14 - 15 ft. lbs. of torque (once set screws contact the shaft,

tighten set screws one full turn).

IMPORTANT: THE COUPLER HALVES, CENTER BEARING(S), TORSION SPRINGS, AND CABLE

DRUMS MUST BE POSITIONED, AS SHOWN IN THE ILLUSTRATIONS.

Torsion shaft

Right wound, red

winding cone (left hand

side) (If applicable)

Left wound, black

winding cone

(right hand side)

Right hand

cable drum,

black

Left hand cable

drum, red

IMPORTANT: ON SINGLE

SPRING APPLICATIONS,

ONLY ONE SPRING IS

SUPPLIED WHICH IS

POSITIONED PER THE

INDICATED COLOR CODING.

Center bearing

Single Spring Or Double Springs Applications,

1 Piece Shaft, Up To 2-5/8” Springs

Torsion

shaft

Right wound, red

winding cone (left hand

side) (If applicable)

Right wound, red

winding cone (left

hand side)

Right

hand

cable

drum,

black

Left

hand

cable

drum,

red

Center

bearing

Left wound, black

winding cone (right

hand side)

Left wound, black

winding cone (right

hand side)

Center

bearing

Center

bearing

Double Springs Applications, Two Or Four

Springs, 1 Piece Shaft, Up To 2-5/8” Springs

Torsion shaft /

Torsion keyed

shaft(s)

Right wound, red winding cone

(left hand side) (if applicable)

Right hand cable

drum, black

Left hand

cable

drum, red

Left wound, black

winding cone (right

hand side)

Single Spring Or Double Springs Applications,

1 Piece Shaft, 3-3/4” and 6” Springs

Flange

bearings

IMPORTANT: ON SINGLE SPRING

APPLICATIONS, ONLY ONE SPRING IS

SUPPLIED WHICH IS POSITIONED PER

THE INDICATED COLOR CODING.

Coupler halves

(If applicable,

for two outer

springs)

orsion

keyed

shaft

Red cable drum

(left hand side)

Black cable drum

(right hand side)

Center

bearing

Center

coupler

assembly

(3) 3/8” - 16 x 1-3/4” Hex head screws

and (3) 3/8” - 16 Nylon hex lock nut

Set screws

and Lock

nut

Coupler halves

Set screws

and Lock nut

Key

Torsion

keyed

shaft

Right wound, red

winding cone

(left hand side)

Left wound,

black

winding cone (right

hand side)

Center

bearing

Double Springs Applications, 2 Piece Shafts, Two or 4 springs, up to 6” Springs.

Center

bearing

IF YOUR DOOR DOESN’T HAVE A COUPLER ASSEMBLY: With assistance, pick up the tor-

sion spring assembly and slide one end of the torsion shaft / torsion keyed shaft through one

end bearing bracket. Lay the middle of the torsion shaft / torsion keyed shaft into the center

bracket. Slide the other end of the torsion shaft / torsion keyed shaft into the other end bear-

ing bracket. Position the torsion shaft / torsion keyed shaft so that equal amounts of the shaft

extend from each of the end bearing brackets.

Left hand end

bearing bracket Right hand end

bearing bracket

Center

bracket

bearing

Center bracket

Torsion shaft /

Torsion keyed shaft

NOTE: Position the torsion shaft so that equal amounts of the shaft extend from each end

bearing bracket.

IF YOUR DOOR HAS A COUPLER ASSEMBLY: With assistance and starting on the left hand

side of door, pick up the left hand torsion spring assembly and slide one end of the torsion

keyed shaft through the end bearing bracket. Lay the other side of the torsion keyed shaft

into the center bracket. Repeat the same process for the right hand torsion spring assembly.

Position both torsion keyed shafts so that equal amounts of the shafts extend from each of

the end bearing brackets.

Torsion

keyed

shaft

Center

bearing

Coupler

half

Center bearing

brackets

Left hand end

bearing bracket

Equal

spacing

Right

hand end

bearing

bracket

Equal

spacing

Torsion

keyed

shaft

Right wound, red

winding cone (left

hand side)

Drum spacer (as required)

Right hand end

bearing bracket with

dodge bearing

(optional)

Drum

spacer

Torsion keyed

shaft

Attaching Springs to Center Bracket

NOTE: Refer to Package Contents / Breakdown of Parts, to determine which Center

Bracket(s) came with your door.

NOTE: Refer to Package Contents / Breakdown of Parts, to determine if your door came with

a coupler assembly.

IMPORTANT: THE SPRING WARNING TAG(S) SUPPLIED MUST BE SECURELY ATTACHED

TO THE STATIONARY SPRING CONE(S) IN PLAIN VIEW. SHOULD A REPLACEMENT SPRING

WARNING TAG BE REQUIRED, CONTACT WAYNE DALTON FOR FREE REPLACEMENTS.

NOTE: Measure the diameter of your springs. If your spring diameter is 3-3/4”, the springs

do not share center brackets. If your spring diameter is either 2” or 2-5/8”, then two springs

will share the same center bracket, unless a coupler assembly is provided.

IF YOU DON’T HAVE A COUPLER ASSEMBLY: Slide center bracket bearing into the spring.

Align the stationary spring cone(s) with the holes in the center bracket. Secure the torsion

spring(s) to the center bracket with (2) 3/8” - 16 x 1-1/2” hex head bolts and (2) 3/8” - 16

nuts.

IMPORTANT: NEVER USE MORE THAN ONE BEARING WHEN ATTACHING TWO SPRINGS TO

ONE CENTER BRACKET.

IF YOU HAVE A COUPLER ASSEMBLY: Slide center bracket bearing into the spring. Align

the stationary spring cone with the holes in the center bracket. Secure the torsion spring to

the center bracket with (2) 3/8” - 16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts. Repeat

the same process for the other center bearing bracket.

At the middle of the two center bearing brackets, re-assemble the coupler assembly by

loosely fastening the coupler halves together using the (3) 3/8” - 16 x 1-1/2” hex head

screws, (6) 3/8” washers, (3) 3/8” lock washers and the (3) 3/8” - 16 hex nuts, previously

removed.

NOTE: Ensure both torsion keyed shafts have equal amounts of the shafts extending from

each end bearing bracket.

Typical center

bracket bearing

Stationary

spring cone

Typical center

bracket

Stationary

spring cone

Torsion spring

Spring

warning tags

Torsion spring

Typical center

bracket

Stationary spring cone (2) 3/8”-16 x 1-1/2”

Hex head bolts

(2) 3/8”-16

Nuts

Torsion

spring

Torsion

spring

Stationary

spring cone

Coupler halves

Coupler

assembly

(3) 3/8” - 16 x 1-3/4”

hex head screws and

(3) 3/8” - 16 Hex nuts

Stationary

spring cone

Torsion

spring (2) 3/8”-16 x 1-1/2” Hex head

bolts and (2) 3/8”-16 Hex nuts

Torsion

spring

Center bracket

Center

bracket

NOTE: Refer to Package Contents / Breakdown of Parts, to determine which Center

Bracket(s) came with your door.

NOTE: Refer to Package Contents / Breakdown of Parts, to determine if your door came with

a coupler assembly.

IMPORTANT: THE SPRING WARNING TAG(S) SUPPLIED MUST BE SECURELY ATTACHED

TO THE STATIONARY SPRING CONE(S) IN PLAIN VIEW. SHOULD A REPLACEMENT SPRING

WARNING TAG BE REQUIRED, CONTACT WAYNE DALTON FOR FREE REPLACEMENTS.

FOR SPRINGS UP TO 3-3/4” ID AND IF YOU DON’T HAVE A COUPLER ASSEMBLY: Slide

center bearing into the spring (if applicable). Align the stationary spring cone(s) with the holes

in the center bracket assembly. Secure the torsion spring(s) to the center bracket assembly

with (2) 3/8” - 16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts.

IF YOU HAVE A COUPLER ASSEMBLY: Slide the center bearing into the spring. Align the

stationary spring cone with the holes in the center bearing bracket.

NOTE: Prior to attaching the torsion spring(s) to the center bracket(s), the torsion shaft /

torsion keyed shafts have to be at the same elevation as the bearing in the end bearing

brackets. Slide the torsion shaft / torsion keyed shafts out to the correct shaft centerline from

the jambs before tightening the spring assembly fasteners.

FOR SPRINGS UP TO 3-3/4” ID: Secure the torsion spring to the center bracket with (2)

3/8” - 16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts. Repeat the same process for the

other center bearing bracket.

FOR 6” AND DUPLEX SPRINGS: Secure the torsion spring and the ﬂange bearing to the

center bracket using (2) 3/8” - 16 x 1” Hex head bolts, as shown.

WARNING

FOR DUPLEX SPRINGS, YOU MUST ENSURE THE ASSEMBLY BOLTS

GO THROUGH THE CENTER BRACKET AND INNER SPRING CONE AND

THREAD INTO THE OUTER SPRING CONE AS SHOWN. FAILURE TO

ENSURE THE BOLTS ARE SECURING BOTH THE INNER AND OUTER

SPRING CONES TO THE CENTER BRACKET CAN RESULT IN SUDDEN

SPRING TENSION RELEASE, CAUSING SEVERE OR FATAL INJURY.

At the middle of the two center bearing brackets, loosely re-assemble the coupler assembly

by fastening the coupler halves together using the (3) 3/8” - 16 x 1-3/4” hex head screws

and the (3) 3/8” - 16 nylon hex lock nuts, as shown.

NOTE: Ensure both torsion keyed shafts have equal amounts of the shafts extending from

each end bearing brackets.

Coupler

halves

Coupler

assembly

End bearing

bracket

Torsion shaft or

Torsion keyed shafts

orsion

spring

Cable

drum

Center

bracket

Surface

Torsion shaft(s)

centerline

Coupler halves

Coupler

assembly

(3) 3/8” - 16 x 1-3/4” hex head

screws and (3) 3/8” - 16 Hex nuts

Stationary

spring cone

Torsion

spring (2) 3/8”-16 x 1-1/2”

Hex head bolts and (2)

3/8”-16 Hex nuts

Torsion

spring

Center bracket

Center

bracket

Up To 3-3/4” Springs Applications

Torsion shaft /

Torsion keyed

shaft(s)

3/8” - 16 x 1”

Hex head

screws

Outer torsion

spring assembly

Center bracket

Outer torsion

spring assembly

Flange bearing

Center bracket

6” ID Springs

NOTE: This type of torsion spring

assembly has just an outer spring,

no inner spring assembly.

6” Springs Applications

Outer torsion

spring assembly Bolt hole for

outer spring cone

Inner torsion

spring

assembly

Bolt hole

for inner

spring

cone

NOTE: Prior to securing the center bracket to the torsion spring, ensure The bolt goes through

the inner spring cone and threads into the outer spring cone.

Bolt holes for outer spring cone

and inner spring cone aligned

Outer torsion

spring assembly

Inner torsion

spring assembly

Inner torsion

spring assembly

Bolt hole for inner

spring cone

Bolt hole

for outer

spring cone

6” Duplex Springs Applications

3/8” - 16 x 1”

Hex head

screws

Outer torsion

spring assembly

Center bracket

Center

bracket

Torsion shaft / Torsion

keyed shaft(s)

Inner torsion

spring assembly

Flange

bearing

Duplex

springs

NOTE: This type of torsion spring assembly has both an outer spring and an inner spring

assembly.

Duplex

springs

6” Duplex Springs Applications

Attaching Counterbalance Lift Cables

Starting on the left hand side, thread the counterbalance lift cable up and around the front

side of the left hand cable drum.

IMPORTANT: VERIFY THAT THERE ARE NO OBSTRUCTIONS IN THE TRAVEL PATH OF THE

DOOR SECTIONS OR COUNTERBALANCE LIFT CABLES.

NOTE: Always assemble the left hand cable and cable drum ﬁrst to help maintain equal cable

tension on both sides of the door.

Hook the counterbalance lift cable into the left hand cable drum. Slide the left hand cable

drum up against the left hand end bearing bracket / spacer. Counterbalance lift cable should

terminate at the 3 o’clock position.

NOTE: If you have torsion keyed shaft(s), insert (1) key into the slot of both the cable drum

and the slot in the torsion keyed shaft, as shown.

FOR SPRINGS UP TO 3-3/4” ID: Tighten the (2) set screws in the drum to 14 - 15 ft. lbs. of

torque (once set screws contact the shaft, tighten screws one full turn).

FOR 6” AND DUPLEX SPRINGS: Tighten the (4) set screws in the drum to 25 ft. lbs. of

torque (once set screws contact the shaft, tighten screws 1/2 to 1 full turn).

At the middle of the two center bearing brackets, loosen the (3) 3/8” - 16 x 1-3/4” hex head

screws and the (3) 3/8” - 16 nylon hex lock nuts from the coupler assembly (if applicable).

Rotate the left hand drum and torsion shaft until counterbalance lift cable is taut. Now attach

locking pliers to the torsion shaft and brace locking pliers up against jamb to keep counter-

balance lift cable taut. Repeat for right hand side.

At the middle of the two center bearing brackets, tighten the (3) 3/8” - 16 x 1-3/4” hex head

screws and the (3) 3/8” - 16 nylon hex lock nuts from the coupler assembly (if applicable).

IMPORTANT: INSPECT EACH COUNTERBALANCE LIFT CABLE MAKING SURE IT IS SEATED

PROPERLY ONTO THE CABLE DRUM AND THAT BOTH COUNTERBALANCE LIFT CABLES HAVE

EQUAL TENSION.

CHECK COUNTERBALANCE LIFT CABLES FOR EQUAL TENSION:

1. Attach locking pliers to track above top roller.

2. Grasp cable at approximate mid-door height location.

3. Draw cable toward you about 1/2” to 1” and release, noting the response of the cable.

4. Repeat above steps for other cable.

5. Adjust cable tension as needed until right and left cables both respond the same.

Once the counterbalance cables are set and if applicable tighten the coupler assembly

together by tightening the (3) 3/8” - 16 nylon hex nuts to secure the coupler halves together.

Left cable drum

Counterbalance cable hooked in cable drum

Left cable drum

Counterbalance lift cable

Locking pliers

Set screws

Jamb

Left end

bearing bracket

Torsion keyed

shaft

Key

Counterbalance lift cable

Locking pliers

Set screws

Jamb

Key

Typical left hand

cable drum

Torsion shaft /

Torsion keyed shaft(s)

Left hand end

bearing bracket

with dodge

bearing (optional)

Drum spacer

NOTE: Prior to securing the

cable drum to the torsion shaft

/ torsion keyed shaft, position

the cable drum tight up

against the drum spacer.

Chalking Torsion Spring(s)

NOTE: If your springs have stenciling, then skip this step.

Draw a chalk line horizontally along the center of the torsion spring coil(s). As the torsion

spring is wound, the chalk line will create a spiral. This spiral can be used to count and

determine the number of turns that are applied on the torsion spring.

Draw horizontal chalk line prior to

winding

Spirals created after winding

Torsion spring

coils

Securing Door for Spring Winding

With the door in the fully closed position, place locking pliers onto both vertical tracks just

above the third track roller. This is to prevent the garage door from rising while winding

springs.

NOTE: Check the following before attempting to wind torsion spring(s):

a. Counterbalance lift cables are secured at bottom corner brackets.

b. Counterbalance lift cables are routed unobstructed to cable drums.

c. Counterbalance lift cables are correctly installed and wound onto cable lift drums.

d. Counterbalance lift cables are taut and have equal tension on both sides.

e. Cable lift drums are against end bearing brackets and set screws are tight.

f. Torsion spring or springs are installed correctly.

g. Review the label attached to the spring warning tag, to determine number of spring turns

required.

NOTE: Door MUST be closed and locked when winding or making any adjustments to the

torsion spring(s).

WARNING

FAILURE TO ENSURE DOOR IS IN A CLOSED POSITION AND TO PLACE

LOCKING PLIERS ONTO VERTICAL TRACK CAN ALLOW DOOR TO RISE

AND CAUSE SEVERE OR FATAL INJURY.

Winding Bars

(Steel Rods)

Size Of Winding Bar

(Inches)

Spring Inner

Diameter Used On

1/2” dia. x 18”

5/8” dia. x 24”

2” and 2-5/8”

3-3/4”

Locking pliers above

third track roller on

both sides of door

Bottom section

Lock

section

Locking pliers attached

to crown leg of vertical

track

Intermediate section

Vertical

track

Vertical

track

Winding Spring(s)

WARNING

WINDING SPRING IS AN EXTREMELY DANGEROUS PROCEDURE

AND SHOULD BE PERFORMED ONLY BY A TRAINED DOOR SYSTEM

TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.

WARNING

USE ONLY SPECIFIED WINDING BARS, AS STATED IN STEP

SECURING DOOR FOR SPRING WINDING. DO NOT SUBSTITUTE WITH

SCREWDRIVERS, PIPE, ETC. OTHER TOOLS MAY FAIL OR RELEASE FROM

THE SPRING CONE AND CAUSE SEVERE OR FATAL INJURY.

WARNING

PRIOR TO WINDING THE SPRING, ENSURE YOU’RE WINDING IN THE

PROPER DIRECTION AS SHOWN BELOW. OTHERWISE THE SPRING

FITTING MAY RELEASE FROM SPRING AND RESULT IN SEVERE OR FATAL

INJURY.

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.

Check the label attached to the spring warning tag for the required number of complete turns

to balance your door.

HOW TO WIND TORSION SPRINGS:

1. Insert one winding rod snugly into winding cone, to full socket depth

2. Maintaining a tight grip on the winding rod rotate it slowly in the proper direction, as

shown below.

3. If there is any slippage of the winding rod in the winding cone socket, reverse the direction

of winding and return the cone to its original position. Remove the winding rod from the

winding cone socket. Reseat the winding rod in the socket. Start over at Step #1.

4. When the winding rod is vertical above the winding cone, insert another winding rod into

one of the other sockets, being careful to seat it snugly and at full socket depth.

5. Hold the spring with the second winding bar, and remove the ﬁrst.

6. Repeat Steps #2 through #5 until the complete turns have been applied.

FOR SPRINGS UP TO 3-3/4” ID: Securely hold the winding rod while tightening the 2 set

screws in the winding cone to 14 - 15 ft. lbs. of torque (once set screws contact the torsion

shaft, tighten screws one full turn).

HIGH SPRING TENSION CAN CAUSE

SERIOUS INJURY OR DEATH.

DONOTadjust, repair or remove springs or parts to

whichsprings are connected, such as steel brack-

ets,cables, wood blocks, fasteners or other parts of

thecounterbalance system.

Adjustmentsor repairs must ONLYbe made by a

traineddoor systems technician using proper tools

andinstructions.

DONOTremove, cover or paint over this tag. Prod-

uctuser should inspect this tag periodically for

legibilityand should order a replacement tag from

thedoor manufacturer, as needed.

102081 REV206/24/2010

HIGH SPRING TENSION CAN CAUSE

SERIOUS INJURY OR DEATH.

DONOTadjust, repair or remove springs or parts to

whichsprings are connected, such as steel brack-

ets,cables, wood blocks, fasteners or other parts of

thecounterbalance system.

Adjustmentsor repairs must ONLYbe made by a

traineddoor systems technician using proper tools

andinstructions.

DONOTremove, cover or paint over this tag. Prod-

uctuser should inspect this tag periodically for

legibilityand should order a replacement tag from

thedoor manufacturer, as needed.

102081 REV206/24/2010

Torsion shaft

Winding

cone

Torsion

spring(s)

Approved

winding

rod

Set screws

IMPORTANT: CHECK THE WARNING

TAG(S) ATTACHED TO

THE SPRING(S)

FOR THE REQUIRED NUMBER OF

COMPLETE TURNS, TO BALANCE

YOUR DOOR.

Warning

tag(s)

Approved winding rod

Torsion spring(s) should be wound in the direction the end coil points.

Spring

coils

FOR 6” AND DUPLEX SPRINGS: Securely hold the winding rod while tightening the 4 set

screws in the winding cone to 25 ft. lbs. of torque (once set screws contact the torsion keyed

shaft, tighten screws 1/2 to 1 full turn).

IMPORTANT: IF YOU HAVE TORSION KEYED SHAFT(S), ONE OF THE SET SCREWS WILL

NEED TO BE TIGHTENED INTO THE KEYWAY OF THE TORSION KEYED SHAFT(S).

HIGH SPRING TENSION CAN CAUSE

SERIOUS INJURY OR DEATH.

DONOTadjust, repair or remove springs or parts to

whichsprings are connected, such as steel brack-

ets,cables, wood blocks, fasteners or other parts of

thecounterbalance system.

Adjustmentsor repairs must ONLYbe made by a

traineddoor systems technician using proper tools

andinstructions.

DONOTremove, cover or paint over this tag. Prod-

uctuser should inspect this tag periodically for

legibilityand should order a replacement tag from

thedoor manufacturer, as needed.

102081 REV206/24/2010

Torsion

keyed

shaft(s)

Winding

cone

Torsion

spring(s)

Set screws

IMPORTANT: CHECK THE WARNING

TAG(S) ATTACHED TO

THE SPRING(S)

FOR THE REQUIRED NUMBER OF

COMPLETE TURNS, TO BALANCE

YOUR DOOR.

Warning

tag(s)

Approved winding rod

Approved

winding rod

Set screws

IMPORTANT: ONE SET SCREW BE

DRIVEN INTO THE KEYWAY OF

SOLID KEYED SHAFT.

Winding cone

Keyway

Torsion

keyed shaft

After the torsion spring is secure, use the winding rod to apply pressure in the opposite direc-

tion to ensure the set screws are securely ﬁxed to the torsion shaft.

Carefully remove winding rod from winding cone. Repeat for remaining springs, if applicable.

While holding the door down to prevent it from raising unexpectedly in the event the spring(s)

were over-wound, carefully remove the locking pliers from the torsion shaft and vertical

tracks.

NOTE: If you have a coupler assembly, it may be necessary to loosen and retighten the (3)

3/8” - 16 x 1-3/4” hex head screws and the (3) 3/8” - 16 nylon hex lock nuts assembly bolts

to equalize the cable tension on both sides of the door.

Adjustments to the number of turns stated may be necessary. If door rises off ﬂoor under

spring tension alone, reduce spring tension until door rests on the ﬂoor. If the door is hard to

rise or drifts down on its own, add spring tension.

NOTE: An unbalanced door such as this can cause garage door opener operation problems.

WARNING

DO NOT OPEN DOOR UNTIL STEP REAR BACK HANGS IS COMPLETED.

Attaching Rear Back Hangs

IMPORTANT: HOLD THE DOOR DOWN TO PREVENT IT FROM RISING UNEXPECTEDLY IN THE

EVENT THE SPRING(S) WERE OVER-WOUND AND CAUTIOUSLY REMOVE LOCKING PLIERS

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.

WARNING

RAISING DOOR INTO THE LOOSE HORIZONTAL TRACKS CAN RESULT IN

DOOR FALLING AND CAUSE SEVERE OR FATAL INJURY.

Clamp a pair of locking pliers 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 the chart below, select the appropriate perforated angle (may not be supplied). Fabri-

cate and install rear back hangs, as shown.

Perforated Angle Gauge Weight Limitations:

Perforated Angle Gauge Door Balance Weight

2” x 2” x 12 Gauge Less Than 800 lbs.

1-1/4” x 1-1/4” x 13 Gauge Less Than 305 lbs.

1-1/4” x 1-1/4” x 15 Gauge Less Than 220 lbs.

1-1/4” x 1-1/4” x 16 Gauge Less Than 175 lbs.

NOTE: If an opener is installed, position horizontal tracks one hole above level when securing

it to the rear back hangs.

WARNING

MAKE SURE BACK HANGS ARE BRACED SUFFICIENTLY TO RESIST ANY

MOTION DURING SPRING APPLICATION AND DOOR TRAVEL. IF BACK

HANGS PIVOT OR DEFLECT, ADD REINFORCEMENT UNTIL THEY REMAIN

FIRM AND STATIONARY. ANY BACK HANG THAT IS BENT MUST BE

REPLACED.

WARNING

KEEP HORIZONTAL TRACKS PARALLEL AND WITHIN 3/4” TO 7/8” FROM

DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING IN SEVERE OR

FATAL INJURY.

NOTE: Doors heights over 8’0” or door widths over 11’0”, require an additional set of rear

center back hangs to be installed and located at the middle of the horizontal tracks, see

breakdown of parts.

Based on your door width and door heights and using perforated angle (may not be supplied),

(2) 5/16” x 1-5/8” hex head lag screws and (3) 5/16” bolts with nuts (may not be supplied),

fabricate rear center back hangs for the horizontal tracks, for the following:

FOR ITEM J2, (SEE BREAKDOWN OF PARTS): The Rear Center Back Hang Assemblies are

to be used for all doors over 11’0” door height and over 14’0” door width. One Rear Center

Back Hang Assembly, per side.

FOR ITEM J3, (SEE BREAKDOWN OF PARTS): The Rear Center Back Hang Assemblies are

to be used for all doors over 16’0” door height. Two Rear Center Back Hang Assemblies, per

side.

Measure and drill a 3/8” diameter hole through the center length of the horizontal track, as

shown. Attach the rear center back hangs to the horizontal tracks with (1) 3/8” Truss head

bolt and (1) 3/8” nut (may not be supplied).

IMPORTANT: DO NOT SUPPORT THE WEIGHT OF THE DOOR ON ANY PART OF THE REAR

BACK HANGS THAT CANTILEVERS 4” OR MORE BEYOND A SOUND FRAMING MEMBER.

NOTE: If rear back hangs are to be installed over drywall, use (2) 5/16” x 2” hex head lag

screws and make sure lag screws engage into solid structural lumber.

WARNING

FAILURE TO ASSEMBLE AND ATTACH REAR BACK HANGS PROPERLY

ACCORDING TO THE ABOVE INSTRUCTIONS MAY RESULT IN DOOR

FALLING WHEN RAISED, CAUSING SEVERE OR FATAL INJURY.

NOTE: Perforated angle must be attached to sound framing members and nails should not

be used.

90°

(3) 5/16”

Bolts and nuts

(3) 5/16” Bolts and

(3) 5/16” nuts

Perforated

angle

5/16” Hex nut

5/16”-18 x 1-1/4”

Hex bolt

Perforated angle bolted

using (2) 5/16” x 1-5/8”

hex head lag screws to

ceiling member and

parallel to door

Horizontal track

NOTE: Repeat the same

process for right hand side.

Horizontal tracks

Door edges

3/4” To 7/8”

Center back

hang

Horizontal

track

(1) 3/8” Truss head bolt

(may not be supplied)

Center of the horizontal track

Drill 3/8”

diameter hole

Horizontal

track

(1) 3/8” Nut

(may not be supplied)

Cable Keepers

NOTE: If you don’t have cable keepers, then skip this step. Refer to Step 4 Attaching Cable

Keepers, to determine if you have cable keepers installed.

IMPORTANT: CABLE KEEPERS ARE INTENDED TO HELP PREVENT COUNTERBALANCE LIFT

CABLES FROM COMING OFF CABLE DRUMS ON MANUALLY OPERATED DOORS. ADDITION-

AL CABLE TENSIONING PROVISIONS MAY BE REQUIRED FOR MOTOR OPERATED DOORS.

Rotate arm up and hook around counterbalance lift cable, letting the cable keeper arm pull

against the counterbalance lift cable, keeping it taut, as shown. Next, close the hook to

prevent the counterbalance lift cables from coming out.

Bottom

section

Arm

Counterbalance

lift cable

Left hand

cable keeper

Typical left hand

bottom corner

bracket

NOTE: Roller omitted for clarity.

Attaching Weather Seal

NOTE: If you don’t have weather seals, then skip this step. Refer to Package Contents /

Breakdown of Parts, to determine if you have weather seals.

Permanently attach the weatherstrips on both door jambs and header. The weatherstrips

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.

Balancing Door

Remove locking pliers. Lift door and check its balance. Adjustments to the required number

of spring turns stated may be necessary. If door rises off ﬂoor more than 2 ft. under spring

tension alone, reduce spring tension. If the door is hard to rise or drifts down on its own, add

spring tension. A poorly balanced door can cause garage door operator problems.

To adjust spring tension, fully close door. Apply locking pliers to track above third track roller.

Place locking pliers on torsion shaft, as shown in Step Attaching Counterbalance Lift Cables.

Insert a winding rod into the winding cone. Push upward on the winding rod slightly while

carefully loosening the set screws in the winding cone.

IMPORTANT: BE PREPARED TO SUPPORT THE FULL FORCE OF THE TORSION SPRING ONCE

THE SET SCREWS ARE LOOSE.

Carefully adjust spring tension 1/4 turn. Retighten both set screws to 14-15 ft. lbs. of torque

in the winding cone and repeat for the other side. Recheck door balance and re-adjust spring

tension if needed.

IMPORTANT: DO NOT ADJUST MORE THAN 1 TURN FROM THE RECOMMENDED NUMBER

OF TURNS.

If the door still does not operate easily, lower the door into the closed position, unwind

spring(s) completely, and recheck the following items:

1.) Is the door level?

2.) Are the torsion shaft and ﬂag angles / angle mount level and plumb?

3.) Does the distance between the ﬂag angles / angle mount equal door width plus 3-3/8” to

3-1/2”?

4.) Do the counterbalance lift cables have equal tension? Adjust if necessary.

5.) Rewind the spring(s).

6.) Make sure door is not rubbing on jambs.

IMPORTANT: IF DOOR STILL DOES NOT BALANCE PROPERLY, THEN CONTACT A TRAINED

DOOR SYSTEM TECHNICIAN.

MAINTENANCE

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 aestheti-

cally pleasing ﬁnish of the garage door, a periodic washing of the garage door is recom-

mended.

THE FOLLOWING CLEANING SOLUTION IS RECOMMENDED:

A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate)

dissolved 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

thoroughly.

ACRYLIC CLEANING INSTRUCTIONS

Clean acrylic glazing with nonabrasive soap or detergent and plenty of water. Use your bare

hands to feel and dislodge any caked on particles. A soft, grit-free cloth, sponge or chamois

may be used to wipe the surface. Do not use hard or rough cloths that will scratch the acrylic

glazing. Dry glazing with a clean damp chamois.

NOTE: Do not use any window cleaning ﬂuids, scouring compounds, gritty cloths or solvent-

based cleaners of any kind.

Painting Your Garage Door

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 area from corrosion. Allow for 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 the factory-applied

ﬁnish must be repeated until desired results are achieved. Again, care must be taken to not

expose the substrate under the paint.

PAINTING:

After surface has been properly prepared, it must be allowed to dry thoroughly, and then

coated immediately with 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. Re-painting 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

conditions in which to paint.

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

reference TDS 165.

IMPORTANT: DO NOT PLACE FINGERS OR HANDS INTO SECTION JOINTS WHEN OPENING

AND/OR CLOSING A DOOR. ALWAYS USE LIFT HANDLES / SUITABLE GRIPPING POINTS

WHEN OPERATING THE DOOR MANUALLY.

Opening a Door: Make sure the lock(s) are in the unlocked position. Lift the door by using the

lift handles / suitable gripping points only. Door should open with little resistance.

Closing a Door: From inside the garage, pull door downward using lift handles / gripping

points only or a high friction area only. If you are unable to reach the lift handles/ suitable

gripping points only, use pull down rope afﬁxed to the side of door. Door should close com-

pletely with little resistance.

USING AN ELECTRIC OPERATOR:

IMPORTANT: PULL DOWN ROPES MUST BE REMOVED AND LOCKS MUST BE REMOVED OR

MADE INOPERATIVE IN THE UNLOCKED POSITION.

When connecting a drawbar (trolley type) garage door operator to this door, a drawbar opera-

tor and or drawbar operator bracket must be securely attached to the top section of the door,

along with any struts provided with the door. Always use the drawbar operator and or draw-

bar operator bracket supplied with the door. To avoid possible damage to your door, Wayne

Dalton recommends reinforcing the top section with a strut (may or may not be supplied).

The installation of the drawbar operator must be according to manufacturer’s instructions

and force settings must be adjusted properly. Refer to the owner’s manual supplied with your

drawbar operator for complete details on installation, operation, maintenance and testing of

the operator.

MAINTAINING YOUR GARAGE DOOR:

Before you begin, read all warning labels afﬁxed to the door and the installation instruc-

tions and owner’s manual. Perform routine maintenance steps once a month, and have the

door professionally inspected once a year. Review your Installation Instructions and Owner’s

Manual for the garage door. These instructions are available at no charge from Wayne Dalton,

a division of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, or at www.

Wayne-Dalton.com. For additional information on garage door/operator maintenance go to

www.dasma.com and reference TDS 151, 167 and 179.

MONTHLY INSPECTIONS:

1. Visual Inspection: Closely inspect jambs, header and mounting surface. Any wood found

not to be structurally sound must be replaced. Inspect the springs, counterbalance lift cables,

track rollers, pulleys, rear back hangs and other door hardware for signs of worn or broken

parts. Tighten any loose screws and/or bolts. Check exterior surface of the door sections

for any minor cracks. Verify door has not shifted right or left in the opening. If you suspect

problems, have a trained door system technician make the repairs.

WARNING

GARAGE DOOR SPRINGS, COUNTERBALANCE LIFT CABLES, BRACKETS,

AND OTHER HARDWARE ATTACHED 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.

WARNING

NEVER REMOVE, ADJUST, OR LOOSEN THE BOLTS, SCREWS AND/OR

LAG SCREWS ON THE COUNTERBALANCE (END OR CENTER BEARING

BRACKETS) SYSTEM OR BOTTOM CORNER BRACKETS OF THE DOOR.

THESE BRACKETS ARE CONNECTED TO THE SPRING(S) AND ARE UNDER

EXTREME TENSION. TO AVOID POSSIBLE SEVERE OR FATAL INJURY,

HAVE ANY SUCH WORK PERFORMED BY A TRAINED DOOR SYSTEMS

TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.

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 exten-

sion spring (located above the horizontal tracks) to help contain the spring if it breaks.

2. Door Balance: Periodically test the balance of your door. If you have a garage door

drawbar operator, use the release mechanism so you can operate the door by hand when do-

ing this test. Start with the door in the fully closed position. Lift the door to check its balance.

Adjust 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

Extension spring(s), refer to your installation instructions and owner’s manual. If in question

about any of the procedures, do not perform the work. Instead, have it adjusted by a trained

door systems technician.

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, center hinge(s), steel track rollers,

bearings and torsion spring(s) (torsion spring coil surfaces). DO NOT lubricate plastic idler

bearings, nylon track rollers, door track. DO NOT oil a cylinder lock, if actuation is difﬁcult use

a graphite dust to lubricate.

WARRANTY

Limited Warranty

Models: 5150, 5155, 5200 and 5255

Wayne Dalton, a division of Overhead Door Corporation (“Seller”) war-

rants to the original purchaser of the ThermoMark™Models 5150, 5155, 5200

and 5255 (“Product”), subject to all of the terms and conditions hereof, that

the Product and all components thereof will be free from defects in materials

and workmanship for the following period(s) of time, measured from the date

of installation:

• TEN (10) YEARS against cracking, splitting, rust deterioration and

delamination.

• ONE (1) YEAR against defects in materials and workmanship.

• TWO (2) YEARS against peeling or color fade of ﬁnish on Product sec-

tions with Black ﬁnish or Walnut or Golden Oak wood grain ﬁnish which

materially alters the color of the Product and cannot be remedied by

cleaning with the recommended solution.

Seller’s obligation under this warranty is speciﬁcally limited to repairing

or replacing, at its option, any part which is determined by Seller to be defec-

tive during the applicable warranty period. Any labor charges are excluded and

will be the responsibility of the purchaser.

This warranty is made to the original purchaser of the Product only, and

is not transferable or assignable. This warranty does not apply to any unauthor-

ized alteration or repair of the Product, or to any Product or component which

has been damaged or deteriorated due to misuse, neglect, accident, failure

to provide necessary maintenance, normal wear and tear, acts of God, or any

other cause beyond the reasonable control of Seller or as a result of having

been exposed to toxic or abrasive environments, including blowing sand, salt

water, salt spray and toxic chemicals and fumes.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY OTHER WARRAN-

TIES, EITHE

R EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED

WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

IN NO EVENT SHALL SELLER BE RESPONSIBLE FOR, OR LIABLE TO

ANYONE FOR, SPECIAL, INDIRECT, COLLATERAL, PUNITIVE, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, even if Seller has been advised of the possibility

of such damages. Such excluded damages include, but are not limited to, loss

of use, cost of any substitute product, or other similar indirect ﬁnancial loss.

Claims under this warranty must be made promptly after discovery,

within the applicable warranty period, and in writing to the authorized dealer

or installer whose name and address appear below. The purchaser must allow

Seller a reasonable opportunity to inspect any Product claimed to be defective

prior to removal or any alteration of its condition. Proof of the purchase and/or

installation date, and identiﬁcation as the original purchaser, may be required.

• SELLER: __________________________________

_____________________________________

• SELLER’S ADDRESS: __________________________________

_____________________________________

__________________________________

_____________________________________

If you need assistance, please call 1-866-569-3799 (press Option 1) and follow the prompts to

contact a customer service representative. They will be happy to handle any questions that you

may have.

Thank you for your purchase.

After installation is complete, leave this Installation

Instructions And Owner’s Manual with the homeowner, or

fasten it near garage door for easy reference.

This manual suits for next models

Table of contents

Popular Door manuals by other brands

Sterling Plumbing

Sterling Plumbing Frameless Bypass Shower Door SP5465-45 Specification sheet

KitchenAid

KitchenAid KBAU181V Installation instructions and use and care guide

Sterling

Sterling Designer Pivot Shower Doors 1500D Specifications

Avalon

Avalon DVS Bungalow 95200135 installation guide

Albany

Albany RapidRoll 670 owner's manual

raumplus

raumplus AIR-A S1200 Assembly & installation

KitchenAid

KitchenAid KBAU482TSS00 parts list

Ives

Ives Security Surface Bolt 454 installation instructions

Pella

Pella 35123 Owner's guide and installation manual

Pella

Pella 818T0101 installation instructions

Ives

Ives 495 installation instructions

Sterling

Sterling BATH CLASSICS 5900 Specifications

Grizzly

Grizzly GS45A Specifications

American Standard

American Standard Acrylux Framed By-Pass Shower Specifications

Pella

Pella 801V0101 installation instructions

Heat & Glo

Heat & Glo SL-550 Series installation instructions

Ives

Ives Flush Bolt 265 installation instructions

Honeywell

Honeywell RCWL100A user manual

Wayne-Dalton ThermoMark 5255 User manual

Popular Door manuals by other brands