Wayne-dalton 44 double flush 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

347777

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 13

Cleaning Your Garage Door 13

Painting Your Garage Door 14

Maintaining The Finish On Your Garage Door 14

Operation And Maintenance 14

Warranty 15

Wayne Dalton, a division of Overhead Door Corporation

Model 44, Double

Flush

TO R S I O N

QUICK START GUIDE

RESIDENTIAL AND LIGHT COMMERCIAL

REAR MOUNT LOW HEADROOM

OUTSIDE HOOKUP

DEFINITION OF LIGHT COMMERCIAL:

1. Door Heights less than or equal to 8’0” (< = 8’0”) are considered

Residential Applications.

2. Door Heights greater than 8’0” (> 8’0”) are considered Light

Commercial Applications.

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

C. TRACK ROLLERS (AS REQUIRED):

C1. Short Stem Track Rollers

C2. Long Stem Track Rollers

C3. Short Stem Tandem Track Rollers

C4. Long Stem Tandem 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(s) Section / E3. Bottom Section

F. TOP FIXTURES (AS REQUIRED):

F1. Top Fixtures

G. STRUT(S) (AS REQUIRED):

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

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 Riveted Vertical Track Assemblies

H4. Left Hand and Right Hand Angle Mount Vertical Track Assemblies

I. TORSION SPRING ASSEMBLY (AS REQUIRED):

I1. Left Hand and Right Hand Torsion Springs (As Required)

I2. Counterbalance Lift Cables

I3. Left Hand and Right Hand Cable Drum

I4. Center Bracket (As Required)

I5. Center Bracket Bearing (As Required)

I6. Torsion Shaft / Torsion Keyed Shaft (As Required)

I7. Torsion Keyed Shafts (As Required)

I8. Keys (As Required)

I9. Center Coupler Assembly (As Required)

I10. Cable Sheaves

I11. Oval bearings (As Required)

I12. Cable sheave saddles

J. REAR BACK HANGS:

J1. Left Hand And Right Hand Rear Back Hang 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. BOTTOM WEATHER SEAL (AS REQUIRED):

L1. Bottom Weather Seal (Door Width), (Nails Not Supplied)

M. TRACK ROLLER CARRIERS (AS REQUIRED):

M1. Track Roller Carriers

C1.

E4.

E1.

E2.

E3.

F1.

NOTE: The illustrations shown on this page are general

representations of the door parts. Each speciﬁc door

models may have unique variations.

F1.

K1.

B1.

H2.

J1.

H3.

H4.

A1.

H2.

J1.

H3.

H4.

A1.

L1.

M1.

G1.

G2.

C3.

C4.

C2.

D1. D2.

C1.

D3.

J2.

J3.

NOTE: For Item (J2), The Rear Center Back Hang Assemblies are to used for

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

Back Hang Assembly, per side.

NOTE: For Item (J3), The Rear Center Back Hang Assemblies are to used for

all doors over 16’0” door height. Two Rear Center Back Hang Assemblies,

per side.

J2.

I10.

I12.

I1.

B1.

I2.

I3.

I8.

I10.

I2.

I3. I8.

K1.

I6. I7.

I9.

I8.

I11.

I4.

I8.

I11.

I5.

I4.

I5.

I7.

I1.

I12.

H1.

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: WOOD DOORS MUST BE COMPLETELY FINISHED (3 TOTAL COATS, INCLUDING

PRIMER COAT) PRIOR TO INSTALLATION, TO ENSURE THAT THE INTERIOR AND EXTERIOR

SURFACES, AS WELL AS ALL EDGES OF THE DOORS ARE PROPERLY PROTECTED AGAINST

MOISTURE OR OTHER CONTAMINANTS. WOOD DOORS, IN A NON-FINISHED CONDITION,

MUST BE TRANSPORTED AND STORED SO THE WOOD SURFACES ARE NOT EXPOSED

TO MOISTURE OR OTHER CONTAMINANTS. IMPROPER TRANSPORTATION, STORAGE OR

DELAYS IN FINISHING, THAT ALLOWS EXPOSURE OF THE WOOD DOOR SURFACES TO MOIS-

TURE OR OTHER CONTAMINANTS WILL RESULT IN THE WARRANTY BEING VOIDED.

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 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.

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

manual to determine what size section you need to use as your bottom (ﬁrst) section. Mea-

sure your section to make sure it is the correct height as indicated on the chart.

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

Align the bottom weather seal with the ﬂap pointing towards the outside surface of the

bottom section. Starting at one end of the door, measure inward 1” and attach the bottom

weather seal to the bottom of the bottom section with 3/4” long galvanized rooﬁng nails

(not supplied). Now stretch the bottom weather seal slightly and nail the rest of the bottom

weather seal to the bottom of the bottom section every 6”. Once the bottom weather seal is

fastened cut off any extra material so that the bottom weather seal is even with both ends of

the bottom section.

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

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

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.

Bottom weather seal

Cable loopCable loop

Counterbalance

lift cable Counterbalance

lift cable

Bottom section

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

brackets you have.

Secure the cable loop to the clevis pin and bottom corner bracket using a ﬂat washer and a

cotter pin. Repeat for other 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.

Counterbalance

lift cable

Cotter pin

Clevis pin

(inserted through

cotter pin and

bent into place)

Washer

Left hand

bottom

corner

bracket

Left hand

bottom corner

bracket

Cotter

Washer

Locate the left hand bottom corner bracket.Align the bottom corner bracket horizontally with

the bottom edge of the bottom section and align the bottom corner bracket vertically with the

left bottom edge of the bottom section.

Mark and pre-drill 9/32” diameter holes through the bottom section. Attach the bottom

corner bracket to the bottom section using 1/4” - 20 x 2-1/2” carriage bolts, (3) 1/4” - 20

RED HEAD ﬂange hex nuts and a 1/4” - 20 ﬂange hex nut. Repeat the same process for the

right hand side.

IMPORTANT: THE CARRIAGE BOLTS AND THE 1/4” - 20 RED HEAD FLANGE HEX NUTS

MUST BE MUST BE INSTALLED ON THE BOTTOM CORNER BRACKETS, AS SHOWN.

Typical left hand

bottom corner bracket Bottom

section

(4) 1/4” - 20 x 2-1/2”

Carriage bolts

Bottom

weather seal

(3) 1/4” - 20 Flange

hex nuts (RED HEAD)

1/4” - 20

Flange hex nut

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.

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” - 14 x 1” lag screws.

NOTE: Prior to fastening the track roller carrier to the bottom section, pilot drill using a 1/8”

drill bit.

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Insert a short stem track roller and spacer into the bottom corner bracket. Repeat the same

process for the right hand side.

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

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

Attaching Hinges and Strut To Bottom Section

Lay a SHORT STRUT onto the bottom rail of the bottom section. Position the bottom of the

strut 3/4” up from the bottom edge of the bottom section. Center the short strut from side

to side on the section surface. Drill pilot holes, 1” deep into the bottom section using a 1/8”

drill bit.

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Attach the strut using (1) 1/4” - 14 x 1” lag screw at each pre-drilled hole.

NOTE: Refer to the Bottom Section Graduated End Hinge Schedule below, to determine the

appropriate hinges for your bottom section.

Bottom Section Graduated End Hinge Schedule

Door Height Section Type Track Graduated End

Hinge Number

3 Through 8 Section

High Doors

Bottom 2” #1

3” #3

NOTE: Center hinge(s) use #1 graduated end hinges at each pre-drilled or vertical stile loca-

tion. The pre-drilled locations are located at the top rails on the inside of the section surface.

NOTE: Some struts also may or may not have holes in them. If they don’t, then prior to

installing the strut and hinge to the section surface, you may have to drill a 3/16” hole for the

appropriate fastener on one or both sides of the strut legs.

Using the appropriate graduated end hinges for the ends and depending on the width of your

door, enough center hinge(s) for each pre-drilled hole location(s). Starting at the upper left

hand corner of the bottom section. Position the lower hinge leaf of the appropriate graduated

end hinge onto the upper corner of the bottom section. Align the slots of the lower hinge leaf

with the pre-drilled holes in the bottom section.

FOR GRADUATED END HINGES: Attach the upper slot of the graduated end hinge to the

bottom section using (1) 1/4” - 20 x 2-1/2” carriage bolt and (1) 1/4” - 20 ﬂange hex nut.

Next attach the bottom hole of the graduated end hinge to the bottom section using (1) 1/4” -

20 x 2-1/2” carriage bolt and (1) 1/4” - 20 ﬂange hex nut.

IF YOU HAVE DOUBLE GRADUATED END HINGES: Position the second graduated end

hinge next to the ﬁrst (single) graduated end hinge. Using the second graduated end hinge as

a template, drill pilot holes, 1” deep into the bottom section using a 1/8” drill bit.

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Secure the graduated end hinge to the bottom section using (2) 1/4” - 14 x 1” lag screws.

Repeat for other side.

FOR CENTER HINGES: Attach the upper slot of the graduated end hinge to the bottom

section using (1) 1/4” - 20 x 2-1/2” carriage bolt and (1) 1/4” - 20 ﬂange hex nut. Next

attach the bottom hole of the graduated end hinge to the bottom section using (1) 1/4” - 20 x

2-1/2” carriage bolt and (1) 1/4” - 20 ﬂange hex nut.

NOTE: If you don’t have half center hinges, then skip this part of the step. Refer to Package

Contents / Breakdown Of Parts, to determine if you have half center hinges.

Using a tape measure, position the half center hinges equally spaced in between the center

hinges and the graduated end hinges. Position the holes of the lower hinge leaf at the top rail

of the bottom section. Using the half center hinge as a template, drill pilot holes, 1” deep into

the bottom section with a 1/8” drill bit (if needed).

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Attach the lower hinge leaf of the center hinge to the bottom section using (2) 1/4” - 14 x 1”

lag screws. Repeat for other half center hinge(s).

If you have single graduated end hinges, insert a short stem track roller / short stem tandem

track roller (if included) into the hinge tube on each side.

If you have double graduated end hinges, insert a long stem track roller / short stem tandem

track roller (if included) into the hinge tubes on each side.

IMPORTANT: WHEN PLACING TRACK ROLLERS / TANDEM TRACK ROLLER (IF INCLUDED)

INTO GRADUATED END HINGES NUMBER 2 AND HIGHER, THE TRACK ROLLER / TANDEM

TRACK ROLLER (IF INCLUDED) GOES INTO TUBE FURTHEST AWAY FROM SECTION.

Attaching Hinges and Strut To Intermediate

Section(s)

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

manual to determine what size section you need to use as your intermediate I (second),

intermediate II (third), intermediate III (fourth), Intermediate IV (ﬁfth), Intermediate V (sixth) and

if applicable Intermediate VI (seventh). Measure your section to make sure it is the correct

height as indicated on the chart.

NOTE: Refer to the Graduated End Hinge Schedule below, to determine the appropriate

hinges for your Intermediate section(s).

3 Section High Graduated End Hinge Schedule

Door Height Track Section Type Graduated End Hinge

Number

3 Section High Door 2” Intermediate I #2

3” Intermediate I #4

4 Section High Graduated End Hinge Schedule

Door Height Track Section Type Graduated End Hinge

Number

4 Section High Door 2” Intermediate II #3

Intermediate I #2

3” Intermediate II #5

Intermediate I #4

5 Section High Graduated End Hinge Schedule

Door Height Track Section Type Graduated End Hinge

Number

5 Section High Door 2” Intermediate III #4

Intermediate II #3

Intermediate I #2

3” Intermediate III #6

Intermediate II #5

Intermediate I #4

6 Section High Graduated End Hinge Schedule

Door Height Track Section Type Graduated End Hinge

Number

6 Section High Door 2” Intermediate IV #5

Intermediate III #4

Intermediate II #3

Intermediate I #2

3” Intermediate IV #7

Intermediate III #6

Intermediate II #5

Intermediate I #4

7 Section High Graduated End Hinge Schedule

Door Height Track Section Type Graduated End Hinge

Number

7 Section High Door 2” Intermediate V #6

Intermediate IV #5

Intermediate III #4

Intermediate II #3

Intermediate I #2

3” Intermediate V #8

Intermediate IV #7

Intermediate III #6

Intermediate II #5

Intermediate I #4

8 Section High Graduated End Hinge Schedule

Door Height Track Section Type Graduated End Hinge

Number

8 Section High Door 2” Intermediate VI #7

Intermediate V #6

Intermediate IV #5

Intermediate III #4

Intermediate II #3

Intermediate I #2

3” Intermediate VI #9

Intermediate V #8

Intermediate IV #7

Intermediate III #6

Intermediate II #5

Intermediate I #4

NOTE: Refer to the Strutting Schedules below, to determine the appropriate strutting for your

Intermediate(s) section. Measure the height of the long strut(s) to determine if you have 2”

or 3”.

3 Section High Strutting Schedule

Section Type Type Of Strut Location On Section

2” 3”

Intermediate I (1) Long Top Of Section

4 Section High Strutting Schedule

Section Type Type Of Strut Location On Section

2” 3”

Intermediate II (1) Long Top Of Section

Intermediate I N/A (1) Long

5 Section High Strutting Schedule

Section Type Type Of Strut Location On Section

2” 3”

Intermediate III (1) Long Top Of Section

Intermediate II (1) Long

Intermediate I N/A (1) Long

6 Section High Strutting Schedule

Section Type Type Of Strut Location On Section

2” 3”

Intermediate IV (1) Long Top Of Section

Intermediate III (1) Long

Intermediate II (1) Long

Intermediate I N/A (1) Long

7 Section High Strutting Schedule

Section Type Type Of Strut Location On Section

2” 3”

Intermediate V (1) Long Top Of Section

Intermediate IV (1) Long

Intermediate III (1) Long

Intermediate II (1) Long

Intermediate I N/A (1) Long

8 Section High Strutting Schedule

Section Type Type Of Strut Location On Section

2” 3”

Intermediate VI (1) Long Top Of Section

Intermediate V (1) Long

Intermediate IV (1) Long

Intermediate III (1) Long

Intermediate II (1) Long

Intermediate I N/A (1) Long

NOTE: Center hinge(s) use #1 graduated end hinges at each pre-drilled or vertical stile loca-

tion. The pre-drilled locations are located at the top rails on the inside of the section surface.

NOTE: Some struts also may or may not have holes in them. If they don’t, then prior to

installing the strut and hinge to the section surface, you may have to drill a 3/16” hole for the

appropriate fastener on one or both sides of the strut legs.

Place the Intermediate I section face down on a couple of sawhorses or ﬂat clean/ smooth

surface. Using the appropriate graduated end hinges for the ends and depending on the

width of your door, enough center hinge(s) for each pre-drilled hole location(s). Starting at the

upper left hand corner of the Intermediate section. Position the lower hinge leaf of the appro-

priate graduated end hinge onto the upper corner of the Intermediate section. Align the slots

of the lower hinge leaf with the pre-drilled holes in the Intermediate section. If applicable, lay

a long strut over the lower hinge leaf and over the top rail of the Intermediate section. Center

the long strut from side to side.

FOR GRADUATED END HINGES WITHOUT A LONG STRUT: Attach the upper slot of the

graduated end hinge to the Intermediate section using (1) 1/4” - 20 x 2-1/2” carriage bolt

and (1) 1/4” - 20 ﬂange hex nut. Secure the lower hole of the graduated end hinge to the

Intermediate section using (1) 1/4” - 20 x 2-1/2” carriage bolt and (1) 1/4” - 20 ﬂange hex

nut. Repeat for other side.

IF YOU HAVE DOUBLE GRADUATED END HINGES WITHOUT A LONG STRUT: Position the

second graduated end hinge next to the ﬁrst (single) graduated end hinge. Using the second

graduated end hinge as a template, drill pilot holes, 1” deep into the bottom section using a

1/8” drill bit.

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Secure the graduated end hinge to the Intermediate section using (2) 1/4” - 14 x 1” lag

screws. Repeat for other side.

FOR GRADUATED END HINGES WITH A LONG STRUT: Attach the upper leg of the strut, (1)

strut clip to the upper slot of the graduated end hinge to the Intermediate section using (1)

1/4” - 20 x 2-1/2” carriage bolt and (1) 1/4” - 20 ﬂange hex nut. Secure the lower leg of the

strut, (1) strut clip to the lower hole of the graduated end hinge to the Intermediate section

using (1) 1/4” - 20 x 2-1/2” carriage bolt and (1) 1/4” - 20 ﬂange hex nut. Repeat for other

side.

IF YOU HAVE DOUBLE GRADUATED END HINGES WITH A LONG STRUT: Position the

second graduated end hinge next to the ﬁrst (single) graduated end hinge. Using the second

graduated end hinge as a template, drill pilot holes, 1” deep into the bottom section using a

1/8” drill bit.

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Secure the strut and the graduated end hinge to the Intermediate section using (2) 1/4” - 14

x 1” lag screws. Repeat for other side.

FOR CENTER HINGES WITHOUT A LONG STRUT: Attach the upper slot of the center hinge

to the Intermediate section using (1) 1/4” - 20 x 2-1/2” carriage bolt and (1) 1/4” - 20 ﬂange

hex nut. Secure the lower hole of the center hinge to the Intermediate section using (1) 1/4” -

20 x 2-1/2” carriage bolt and (1) 1/4” - 20 ﬂange hex nut. Repeat for other center hinge(s).

FOR CENTER HINGES WITH A LONG STRUT: Attach the upper leg of the strut, (1) strut clip

to the upper slot of the center hinge to the Intermediate section using (1) 1/4” - 20 x 2-1/2”

carriage bolt and (1) 1/4” - 20 ﬂange hex nut. Secure the lower leg of the strut, (1) strut clip

to the lower hole of the center hinge to the Intermediate section using (1) 1/4” - 20 x 2-1/2”

carriage bolt and (1) 1/4” - 20 ﬂange hex nut. Repeat for other center hinge(s).

NOTE: If you don’t have half center hinges, then skip this part of the step. Refer to Package

Contents / Breakdown Of Parts, to determine if you have half center hinges.

Using a tape measure, position the half center hinges equally spaced in between the center

hinges and the graduated end hinges. Position the holes of the lower hinge leaf at the top

rail of the Intermediate section. Using the half center hinge as a template, drill pilot holes, 1”

deep into the Intermediate section with a 1/8” drill bit (if needed).

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Attach the lower hinge leaf of the center hinge to the Intermediate section using (2) 1/4” - 14

x 1” lag screws. Repeat for other half center hinge(s).

If you have single graduated end hinges, insert a short stem track roller / short stem tandem

track roller (if included) into the hinge tube on each side.

If you have double graduated end hinges, insert a long stem track roller / short stem tandem

track roller (if included) into the hinge tubes on each side.

IMPORTANT: WHEN PLACING TRACK ROLLERS / TANDEM TRACK ROLLER (IF INCLUDED)

INTO GRADUATED END HINGES NUMBER 2 AND HIGHER, THE TRACK ROLLER / TANDEM

TRACK ROLLER (IF INCLUDED) GOES INTO TUBE FURTHEST AWAY FROM SECTION.

If applicable, repeat the same process for the other Intermediate sections, except for the top

section.

Attaching Top Fixtures And Strut To Top Sec-

tion

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

manual to determine what size section you need to use as your top section. Measure your

section to make sure it is the correct height as indicated on the chart.

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

Lay a SHORT STRUT onto the top rail of the top section. Position the top of the strut 3/4”

downward from the top edge of the top section. Center the short strut from side to side on

the section surface. Drill pilot holes, 1” deep into the top section using a 1/8” drill bit.

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Attach the strut using (1) 1/4” - 14 x 1” lag screw at each pre-drilled hole.

NOTE: If your door came with two top ﬁxtures, then one top ﬁxture and a short stem track

roller are required for each side.

NOTE: If your door came with four top ﬁxtures, then two top ﬁxtures and a long stem track

roller are required for each side.

Starting on the left hand side, align the edge of the top ﬁxture parallel to the top section

edge. Using the top ﬁxture base as a template, mark and pre-drill (2) 9/32” diameter holes

through the top section. Loosely attach the top ﬁxture base to the top section using (2) 1/4”

- 20 x 2-1/2” carriage bolts and (2) 1/4” - 20 ﬂange hex nuts. Repeat the same process for

the right hand side.

IF YOU HAVE FOUR TOP FIXTURE ASSEMBLIES: Position the second top ﬁxture assembly

next to the ﬁrst installed top ﬁxture assembly. Using the top ﬁxture base as a template, drill

pilot holes, 1” deep into the top section with a 1/8” drill bit (if needed).

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Loosely attach the top ﬁxture base to the top section using (2) 1/4” - 14 x 1” lag screws.

Repeat the same process for the right hand side.

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.

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, remove the nail holding the bottom section to jamb. Position

the left hand vertical track assembly / angle mount assembly over the track rollers of the bot-

tom section. Make sure the counterbalance lift cable is located between the track rollers and

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

vertical track assembly / angle mount assembly to the jamb using 5/16” x 1-5/8” lag screws.

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

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

the bottom section and vertical track.

Stacking Sections

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

manual to determine what size section you need to use as your intermediate I (second),

intermediate II (third), intermediate III (fourth), Intermediate IV (ﬁfth), Intermediate V (sixth) and

if applicable Intermediate VI (seventh). Measure your section to make sure it is 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.

With assistance, lift second section and guide the track rollers into the vertical tracks. Keep-

ing the sections vertically aligned, lower section until it is seated against bottom section.

FOR CENTER HINGE(S): Starting with a center hinge, ﬂip the upper hinge leaf up. If needed

use it as a template, mark and pre-drill (2) 9/32” diameter holes through the section. Attach

the upper hinge leaf to the section using (2) 1/4” - 20 x 2-1/2” carriage bolts and (2) 1/4” -

20 ﬂange hex nuts. Repeat same process for the other Center Hinges.

FOR HALF CENTER HINGE(S): Flip a upper hinge leaf up and use it as a template. Mark and

pre-drill (2) 1/8” pilot holes, 1” deep into the section with a 1/8” drill bit.

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Attach the center hinge upper leaf to the section using (2) 1/4” - 14 x 1” lag screws. Repeat

same process for other half center hinge(s).

FOR GRADUATED END HINGES: Starting with the outer graduated end hinges, ﬂip the up-

per hinge leaf up. If needed use it as a template, mark and pre-drill (2) 9/32” diameter holes

through the section. Attach the upper hinge leaf to the section using (2) 1/4” - 20 x 2-1/2”

carriage bolts and (2) 1/4” - 20 ﬂange hex nuts. Repeat same process for the other side.

IF YOU HAVE DOUBLE GRADUATED END HINGES: Flip the inner upper hinge leaf up and

use it as a template. Mark and pre-drill (2) 1/8” pilot holes, 1” deep into the section with a

1/8” drill bit.

IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”

DEEP.

Attach the inner upper hinge leaf to the section using (2) 1/4” - 14 x 1” lag screws. Repeat

same process for the other side.

Repeat same process for other sections, except top section.

Stacking Top Section

Place the top section in the opening. Temporarily secure the top section by driving a nail into

the header near the center of the door and bending it over the top section. Now, ﬂip up the

graduated end hinge and center hinge leaves, hold tight against section, and fasten center

hinges ﬁrst and end hinges last (refer to step, Stacking Sections). Vertical track alignment is

critical. For 2” track, position ﬂag angle / wall angle between 1-11/16” (43 mm) to 1-3/4”

(44 mm) from the edge of the door; tighten the bottom lag screw. For 3” track, position ﬂag

angle / wall angle between 2-3/16” (56 mm) to 2-1/4” (57 mm) from the edge of the door;

tighten the bottom lag screw.

Flag angles / wall angles must be parallel to the door sections. Repeat same process for

other side.

IMPORTANT: THE DIMENSION BETWEEN THE FLAG ANGLES MUST BE:

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

smooth, safe door operation.

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

smooth, safe door operation.

Complete the vertical track installation by securing the jamb bracket(s) or slots in the wall

angle and tightening the other lag screws. Push the vertical track against the track rollers so

that the track rollers are touching the deepest part of the curved side of the track; tighten all

the track bolts and nuts. Repeat for other side.

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.

IF YOU HAVE FULLY ADJUSTABLE FLAG ANGLES OR RIVETED TRACK ASSEMBLIES:

To install horizontal track, place the top rail end over the top track roller of the top section.

Align the bottom rail end of the horizontal track with the top of the vertical track. Tighten the

bottom rail of the horizontal track to the ﬂag angle with (2) 1/4” - 20 x 9/16” track bolts and

(2) 1/4” - 20 ﬂange hex nuts.

IF YOU HAVE ANGLE MOUNT VERTICAL TRACK ASSEMBLIES: To install horizontal track,

place the top rail end over the top track roller of the top section. Align the bottom rail end of

the horizontal track with the top of the vertical track. Tighten the bottom rail of 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 top rail of the horizontal track to the

encountered slot in the ﬂag angle / angle mount using (1) 1/4” - 20 x 9/16” track bolt, (1)

1/4” - 20 ﬂange hex nut and (1) 5/16” washer.

NOTE: If you have angle mount, bolt the top rail of the horizontal track to the encountered

slots in the angle mount using (2) 3/8” - 16 x 3/4” truss head bolts, (2) 3/8” - 16 hex nuts.

Repeat for other side.

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

Top Section.

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

CAUSE PERMANENT DAMAGE TO TOP SECTION.

Adjusting Top Fixtures

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

Assemblies 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(s), out

against the horizontal track. Maintaining the slide’s position, tighten the 1/4” - 20 ﬂange hex

nuts to secure each of the top ﬁxtures.

COUNTERBALANCE

INSTALLATION INSTRUCTIONS

Attaching Cable Lift Sheaves

NOTE: Using the illustrations below, identify which cable lift sheave assemblies were provided

with your door.

FOR 3” OR 4” SHEAVES, WITH NO SHEAVE SADDLE: Place a 3/8” - 16 x 1-1/2” hex head

bolt through the hole in the sheave plate. Next insert the sheave over the end of the bolt.

Secure the sheave to the sheave plate with a 3/8” - 16 nut. Repeat the same process for the

other side. Then loop the counterbalance cables over each sheave, as shown.

Sheave

plate hole

Sheave

3/8” - 16 x 1-1/2”

Truss head bolt

Horizontal

track

3/8” - 16

Hex nut

Sheave

Counterbalance lift cable

NOTE: Repeat the same

process for the other side.

Then loop the counterbalance

lift cables over each sheave.

FOR 5” SHEAVES, WITH SHEAVE SADDLE: Position the sheave saddle over the 1” x 4” x

23” angle and align the slots in the sheave saddle with the corresponding holes in the 1” x 4”

x 23” angle. While holding the sheave saddle in place, insert (1) 5/16” - 18 x 3/4” carriage

bolt through each of the aligned holes and secure the assembly with 5/16” - 18 hex nuts.

Repeat the same process for the other side. Then loop the counterbalance cables over each

sheave, as shown.

Counterbalance

lift cable

NOTE: Repeat the same

process for the other side.

Then loop the counterbalance

lift cables over each sheave.

Flag

angle

Horizontal

track

5/16” - 18 X 3/4”

Square neck

carriage bolt

5/16” - 18

Hex nut

Sheave

saddle

Sheave saddle

Sheave

Attaching Rear Back Hangs

NOTE: Temporarily support the horizontal track with rear back hangs as shown in illustra-

tions, without lifting door.

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 800 lbs. to 1600 lbs.

1-1/4” x 1-1/4” x 13 Gauge 305 lbs. to 610 lbs.

1-1/4” x 1-1/4” x 15 Gauge 220 lbs. to 440 lbs.

1-1/4” x 1-1/4” x 16 Gauge 175 lbs. to 350 lbs.

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

them to the rear back hangs.

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.

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 nuts

5/16”-18 x 1-1/4”

Hex bolts

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”

Torsion Spring Assembly

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

coupler assembly. If your door came with a coupler assembly, the mounting surface needs to

be a minimum of 17” wide. The two center bearing brackets will need to be spaced 12” to

14” apart at the center of the door, as shown.

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

LOOKING OUT.

IMPORTANT: IDENTIFY THE TORSION SPRINGS PROVIDED AS EITHER RIGHT WOUND (RED

WINDING CONE) OR LEFT WOUND (BLACK WINDING CONE).

NOTE: On some single spring doors, the single 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 to determine appropriate center bracket location.

NOTE: If your door came with a center coupler assembly or if it utilizes 3-3/4” springs, the

springs will not share a center bracket.

NOTE: If your door has (4) springs, split the distance between the center of the door and the

end bracket on each side to locate the intermediate center brackets.

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

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

IMPORTANT: REFERENCE THE ILLUSTRATIONS FOR PROPER SPRING POSITIONING WHEN

MORE THAN 2 SPRINGS ARE PROVIDED.

IMPORTANT: IN APPLICATIONS WHERE MORE THAN ONE SPRING SHARES A CENTER

BRACKET, USE ONLY 1 BEARING IN THE SPRING. ATTEMPTING TO USE 2 BEARINGS CAN

DAMAGE THE BEARINGS AND / OR SPRING CONES.

Facing the inside of the door, either lay the torsion shaft / torsion keyed shaft on the ﬂoor or

lay the (2) torsion keyed shafts on the ﬂoor, one torsion keyed shaft on the left hand side and

the other torsion keyed shaft on the right hand side.

IMPORTANT: DEPENDING ON YOUR DOOR APPLICATION, USE ONE OF THE THREE ILLUS-

TRATION’S, SHOWN BELOW TO ASSEMBLE YOUR TORSION COUNTERBALANCE SYSTEM.

IF YOU HAVE ONE OR TWO TORSION SPRINGS AND ONE PIECE TORSION SHAFT:

Torsion shaft

Torsion keyed shaft

Left wound, black winding

cone (left hand side)

Right wound, red winding

cone (right hand side)

One or Two springs, One piece shaft

Oval

bearing

IMPORTANT: ON SINGLE SPRING

APPLICATIONS, ONLY A RIGHT WOUND

(RED WINDING CONE), WHICH GOES ON

THE RIGHT HAND SIDE IS REQUIRED.

IF YOU HAVE FOUR TORSION SPRINGS AND ONE PIECE TORSION SHAFT / TORSION

KEYED SHAFT:

Torsion shaft

Torsion keyed

shaft

Right wound, red

winding cone (left

hand side)

Left wound, black

winding cone (left

hand side)

Right wound, red winding cone

(right hand side)

Left wound, black

winding cone (right

hand side)

Center

bearing

Four springs, One piece shaft

IF YOU HAVE TWO OR FOUR TORSION SPRINGS AND TWO PIECE TORSION KEYED

SHAFTS:

Torsion

keyed

shaft

Right wound, red

winding cone (left

hand side)

Left wound, black

winding cone (left

hand side) Right wound, red

winding cone (right

hand side)

Left wound, black

winding cone (right

hand side)

Coupler

halves

Torsion keyed shaft

Center bearings

Two or Four springs, Two piece shafts

Oval

bearings

Disassemble the coupler assembly by removing 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 from the coupler

halves. Loosen the set screws. Set the components aside. Next, slide the ﬂat edge of the

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

slot of both the coupler half and the slot in the torsion keyed shaft, as shown. Tighten the (2)

set screws and the locking nut to secure the coupler half to the torsion keyed shaft.

NOTE: Tighten the set screws to 14-15 ft-lbs (Once set screws contact the shaft, tighten

screws an additional 1/2 turn).

Repeat the same process for the other side.

Torsion

keyed

shaft Coupler

halves

(6) Set screws

and (2) Lock nuts

orsion

keyed

shaft

Key

Coupler assembly

(3) 3/8” - 16 x 1-1/2”

hex head screws

(3) 3/8” - 16

Hex nuts

(3) 3/8”

Washers

(3) 3/8”

Washers

(3) 3/8”

Lock

washers

Coupler halves

Set screws

Slide either the center bearing bracket or the center bearing(s) or the oval bearing(s) onto the

torsion shaft / torsion keyed shaft(s) followed by the torsion spring(s).

IMPORTANT: THE CENTER BEARING BRACKET, THE CENTER BEARING(S), THE OVAL

BEARING(S), THE COUPLER HALF’S AND THE TORSION SPRINGS, MUST BE POSITIONED, AS

SHOWN.

WARNING

CENTER BEARING BRACKETS WITH SPRINGS MUST BE SECURELY

FASTENED INTO SOLID STRUCTURAL MEMBERS ONLY AND MUST BE

ADEQUATELY REINFORCED TO HOLD THE LOAD OF TORSION SPRING

ASSEMBLIES. FAILURE TO DO SO CAN CAUSE SEVERE OR FATAL INJURY.

NOTE: If applicable, it is recommended that 5/16” lag screws are pilot drilled using a 3/16”

drill bit, prior to fastening the center bracket to the ceiling.

Referring to Step, Rear Back Hangs either secure the center bearing bracket(s) to the ceiling

using perforated angle at the center of the opening width using 3/8” - 16 x 3/4” hex head

bolts and nuts (not supplied) or to wood blocking (adequate framing member(s)) at the center

of the opening width using 5/16” x 1-5/8” RED HEAD hex head lag screws.

IMPORTANT: THE 5/16” RED HEAD LAG SCREWS MUST BE ATTACHED TO THE CENTER

BRACKET(S).

IMPORTANT: USE A 5/16” X 2-1/2” RED HEAD LAG SCREW INSTEAD OF THE 5/16” X

1-5/8” RED HEAD LAG SCREW IF MOUNTING SURFACE IS COVERED BY DRYWALL. THE LAG

SCREW MUST BE ATTACHED THROUGH THE BOTTOM HOLE OF THE CENTER BRACKET(S).

Center

bracket

Adequate

framing

member

Torsion shaft /

Torsion keyed

shaft

Adequate framing

members

Center

brackets

Torsion

keyed

shafts

† (2) Center bearing brackets spaced

6” to 7” apart from the center of

opening width.

Center of

opening

width

†12”

5/16” x 1-5/8” Hex head

lag screws (RED HEAD)

5/16” x 1-5/8” Hex head lag screw (RED HEAD) or

5/16” x 2-1/2” Hex head lag screw (RED HEAD)

Adequate framing

members

Center

brackets

5/16” x 1-5/8” Hex head

lag screws (RED HEAD)

5/16” x 1-5/8” Hex head

lag screws (RED HEAD)

5/16” x 1-5/8” Hex head

lag screw (RED HEAD) or

5/16” x 2-1/2” Hex head

lag screw (RED HEAD)

5/16” x 1-5/8” Hex head lag screw

(RED HEAD) or 5/16” x 2-1/2” Hex

head lag screw (RED HEAD)

IF YOU HAVE A TORSION SHAFT OR A TORSION KEYED SHAFT: With assistance, pick up

the torsion spring assembly and slide one end of the shaft through the rear support bracket.

Extend the shaft through the bearing until the opposite end of the shaft can be inserted into

the other rear support bracket. If your door came with oval bearing(s), loosely attach the oval

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

hex nuts, as shown. Repeat for others, if needed.

Torsion shaft

or Torsion

keyed shaft

Horizontal

track

Oval

bearing

Rear support

bracket

Rear support

bracket

One or Two springs

Torsion shaft or

Torsion keyed shaft

Horizontal

track

Center

bearing

Center

bearing

Center

bearing Rear support

bracket

Rear support

bracket

Four springs

IF YOU HAVE TWO TORSION KEYED SHAFTS: With assistance, pick up the left hand

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

bracket and loosely attach the oval bearing to the center bracket with (2) 3/8” - 16 x 1-1/2”

hex head bolts and (2) 3/8” - 16 hex nuts, as shown. Repeat for others, if needed.

Repeat the same process for the right hand torsion spring assembly.

Torsion

keyed shafts

Horizontal

track

Center bracket assembly

(See image below)

Center

bracket

Center bearing

((4) Springs)

Oval bearing ((2) Springs)

Coupler half

Coupler

half

Rear support

bracket

Rear support

bracket

Two or Four springs

Oval bearing (See

image below)

Center bracket

(See image below)

(2) 3/8” - 16

Hex nuts

Center bracket

Center

bearing

(2) 3/8” - 16 x 1-1/2”

Hex head bolts

Adequate framing member

Torsion shaft /

Torsion keyed shaft

Torsion spring

Four

springs

5/16” x 1-5/8” Hex head

lag screws (RED HEAD)

5/16” x 1-5/8” Hex head lag screw

(RED HEAD) or 5/16” x 2-1/2” Hex

head lag screw (RED HEAD)

(2) 3/8” - 16

Hex nuts

Center bracket

Oval

bearing

(2) 3/8” - 16 x 1-1/2”

Hex head bolts

Adequate framing member

Torsion shaft /

Torsion Keyed shaft

One or two springs

5/16” x 1-5/8” Hex head

lag screws (RED HEAD)

5/16” x 1-5/8” Hex head

lag screw (RED HEAD) or

5/16” x 2-1/2” Hex head

lag screw (RED HEAD)

Attaching Torsion Spring

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

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

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

FOR DOORS WITHOUT COUPLER ASSEMBLY: Equalize the amount that the torsion shaft /

torsion keyed shaft protrudes on each side. Align the stationary cone(s) of the torsion springs

with the slots in the rear support bracket and secure using (2) 3/8” - 16 x 1-1/2” truss head

bolts and (2) 3/8” - 16 hex nuts.

FOR DOORS WITH A COUPLER ASSEMBLY: At the middle of the two center bearing

brackets, re-assemble the coupler assembly by loosely fastening the coupler halves together

re-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, as shown.

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

each rear support bracket.

Next, align the stationary cone(s) of the torsion springs with the slots in the rear support

brackets and secure using (2) 3/8” - 16 x 1-1/2” truss head bolts and (2) 3/8” - 16 hex nuts.

Repeat for opposite side. Secure all oval bearing(s), to the center bracket with (2) 3/8” - 16 x

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

NOTE: If you have 4 springs, 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.

3/8”-16 x 1-1/2”

Truss head bolts

and 3/8” - 16 nuts

Spring

Horizontal track

Rear support

bracket

Torsion shaft

equalized on

both sides

Stationary cone

Winding

cone

Torsion

keyed

shafts

Center

brackets

Keys

Torsion

spring

Torsion

spring

(3) 3/8” - 16 x 1-1/2”

hex head screws

(3) 3/8” - 16

Hex nuts

(3) 3/8”

Washers

(3) 3/8”

Washers

(3) 3/8” Lock

washers

Coupler halves

Set screws

Four springs shown

Attaching Counterbalance Lift Cables

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

LOOKING OUT.

Slide the black cable drum against the left hand rear support bracket. Thread the counterbal-

ance lift cable up and over the cable sheave. Position the cable drum and counterbalance lift

cable, as shown. Hook the cable into the drum.

NOTE: For doors with a torsion keyed shaft, insert (1) key into the slot of both the black cable

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

Tighten the set screws in the black cable drum to 14-15 ft-lbs of torque (once set screws

contact the torsion shaft, tighten screws an additional 1/2 turn for solid shaft and one full

turn for tubular shaft).

Torsion spring, Left wound,

black winding cone

(left hand side)

Horizontal track

Rear

support

bracket

Torsion warning tag

Counterbalance

lift cable taut

Tighten set screws

on cable drum

Torsion shaft

Black cable drum

(left hand side)

Horizontal track

Left hand end bearing bracket

Key

Torsion

keyed

shaft(s) Torsion spring, Left wound,

black winding cone

(left hand side)

Tighten set screws on cable drum

Black cable drum

(left hand side)

Counterbalance lift cable taut

Torsion warning tag

Slide the red cable drum against the right hand rear support bracket. Rotate the left hand

drum and torsion shaft until counterbalance lift cable is taut. Now attach locking pliers to the

torsion shaft and brace locking pliers against the perforated angle of the rear back hangs

to keep counterbalance lift cable taut. On the right hand side, thread the counterbalance lift

cable up and over the red cable drum and position the cable drum and counterbalance lift

cable, as shown. Hook the cable into the drum.

NOTE: For doors with a torsion keyed shaft, insert (1) key shaft into the slot of both the red

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

Tighten the set screws in the red cable drum to 14-15 ft-lbs of torque (once set screws

contact the torsion shaft, tighten screws an additional 1/2 turn for solid shaft and one full

turn for tubular shaft).

Secure locking pliers

to adequate framing

member / ceiling

Torsion shaft

Center

bracket

Horizontal track

Rear

support

bracket

Torsion warning tag

Counterbalance

lift cable taut

Torsion shaft

Red cable drum

(right hand side)

Torsion spring, Right wound,

red winding cone

(right hand side)

Tighten set screws to

14-15 ft. lbs. of torque

Right hand end bearing bracket

Key

Torsion

keyed

shaft(s)

Torsion spring, Right wound,

red winding cone

(right hand side)

Tighten set screws on cable drum

Red cable drum

(right hand side)

Counterbalance lift cable taut

Torsion warning tag

Horizontal track

IMPORTANT: CHECK EACH COUNTERBALANCE LIFT CABLE, MAKING SURE BOTH ARE

SEATED PROPERLY ON THE SHEAVES, CABLE DRUMS, ARE SECURELY ATTACHED TO THE

BOTTOM CORNER BRACKETS AND BOTH SIDES HAVE EQUAL COUNTERBALANCE LIFT

TENSION.

Now, secure the coupler assembly (if applicable) by tightening the (3) 3/8” - 16 hex nuts.

Torsion

keyed

shafts Center

brackets

Tighten (3) 3/8” - 16

hex nuts.

Torsion

spring

Torsion

spring

Coupler

assembly

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 (E7). 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.

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.

IMPORTANT: AFTER WINDING THE SPRING(S), TIGHTEN THE SET SCREWS IN THE WINDING

CONE TO 14-15 FT-LBS OF TORQUE (ONCE SET SCREWS CONTACT THE TORSION SHAFT,

TIGHTEN SCREWS AN ADDITIONAL 1/2 TURN FOR SOLID SHAFT AND ONE FULL TURN FOR

TUBULAR SHAFT).

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

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

Approved

winding rod

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

Spring

coils

Finish installing Rear Back Hangs

NOTE: Complete Step Rear Back Hangs now to secure the Rear Back Hangs, then proceed

to next Step.

Attaching Weather Seal

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.

Weather seals

Nail

Weather

seal

Jamb Weather seal

installed

Jamb

Header

Jamb

Nail

NOTE: Door not shown for clarity.

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 E5. 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 level and plumb?

3.) Does the distance between the ﬂag angles 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.

Label Placement

IMPORTANT: USING THE ILLUSTRATION, ATTACH THE APPROPRIATE LABELS TO THE AP-

PROPRIATE LOCATION ON THE SECTION, AS SHOWN.

NOTE: The Spring Warning tag(s) are factory attached (one per spring).

NOTE: Because of different conﬁgurations, some labels may require minor relocations.

HIGHSPRING TENSION CA NCAUSE

SERIOUSINJURY OR DEAT H.

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 ONLY be 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 REV2 06/24/2010

DONOT REMOVE, COVER OR PAINT OVER

THISLABEL. PRODUCT USER SHOULD

INSPECTTHIS LABEL PERIODICALLY FOR

LEGIBILITYAND SHOULD ORDER A

REPLACEMENTFROM THE DOOR

MANUFACTURERAS NEEDED.

346214 NEW 11/19/2010

CALIFORNIAHEALTH AND SAFETY

CODESECTION 25249.6

DRILLING,SAWING, SANDING OR

MACHININGWOOD PRODUCTS GENERATES

WOODDUST, A SUBSTANCE KNOWN TO THE

STATEOF CALIFORNIA TO CAUSE CANCER.

AVOIDINHALING WOOD DUST OR USE A

RESPIRATOR OR OTHER SAFEGUARDS FOR

PERSONALPROTECTION.

WARNING

THISWOOD PRODUCT REQUIRES PROPER

FINISHING PRIORTO ANY DOOR HARDWARE BEING

APPLIED.BOTH INNER AND OUTER FA CESOF THE

SECTION(S),AS WELL AS ALL EDGE SURFACES

MUST BE PREPAREDAND FINISHED IN STRICT

ACC0RDANCETO THE DIRECTIONS GIVEN IN THE

INSTALLATIONINSTRUCTIONS AND OWNER’S

MANUAL UNDER “MAINTENANCE AND PAINTING

INSTRUCTIONS FOR ALLWOOD DOORS”.

IMPROPER STORAGE, IMPROPER TRANSPORTATION

AND/OR DELAYIN FINISHING, THAT ALLOWS FOR

THE EXPOSURE OFTHIS WOOD PRODUCT TO

MOISTUREAND/OR OTHER CONTAMINANTS, VOIDS

THE LIMITED WARRANTY.

IMPORTANT

316986

WARNING

Lift handles/gripping points are required

on this door, located as spelled out in the

installation instructions, even if the door

is motor operated.

Failure to install and use these lift handles/

gripping points on this door can result in

serious injury to ﬁngers and/or hands, if

placed in the opening between sections,

when the door is operated manually.

The adjacent bottom corner bracket and

all cable retention features including

milford pins, cotter pins, & clevis pins are

under HIGH SPRING TENSION.

Adjustments and repairs must only be

made by a trained door systems

technician, using proper tools and

instructions.

DO NOT REMOVE, COVER OR PAINT OVER

THIS LABEL.PRODUCT USER SHOULD

INSPECT THIS LABEL PERIODICALLY FOR

LEGIBILITY AND SHOULD ORDER A

REPLACEMENT FROM THE DOOR

MANUFACTURER AS NEEDED.

325304 REV3 06/26/12

OverheadDoor Corporation

WARNING

Lift handles/gripping points are required

on this door,located as spelled out in the

installation instructions, even if the door

is motor operated.

Failure to install and use these lift handles/

gripping points on this door can result in

serious injury to ﬁngers and/or hands, if

placed in the opening between sections,

when the door is operated manually.

The adjacent bottom corner bracket and

all cable retention features including

milford pins, cotter pins, & clevis pins are

under HIGH SPRING TENSION.

Adjustments and repairs must only be

made by a trained door systems

technician, using proper tools and

instructions.

DO NOT REMOVE, COVER OR PAINT OVER

THIS LABEL.PRODUCT USER SHOULD

INSPECT THIS LABEL PERIODICALLYFOR

LEGIBILITY AND SHOULD ORDER A

REPLACEMENT FROM THE DOOR

MANUFACTURER AS NEEDED.

325304 REV3 06/26/12

OverheadDoor Corporation

SAFETYINSTRUCTIONS

1. Operatedoor ONLY when it is properly

adjustedandfree of obstructions.

2. Ifa door becomes hard to operate,

inoperativeoris damaged, immediately

havenecessaryadjustments and/or repairs

madebya trained door system technician

usingpropertools and instructions.

3. DONOT stand or walk under a moving door,

orpermitanybody to stand or walk under

anelectricallyoperated door.

4. DONOT place ﬁngers or hands into open

sectionjointswhen closing a door. Use lift

handles/grippingpointswhen operating

doormanually.

5. DONOT permit children to operate garage

doorordoor controls.

6. Dueto constant extreme spring tension,

DONOTattempt any adjustment, repair or

alterationtoany part of the door,

especiallytosprings, spring brackets,

bottomcornerbrackets, red colored

fasteners,cablesor supports. To avoid

possiblesevereor fatal injury, have any

suchworkperformed by a trained door

systemtechnicianusing proper tools and

instructions.

7. Onelectrically operated doors, pull down

ropesmustbe removed and locks must be

removedormade inoperative in the open

(unlocked)position.

8. Topsection of door may need to be

reinforcedwhenattaching an electric

opener. Check door and/or opener

manufacturer’s instructions.

9. VISUALLYinspect door and hardware

monthly for worn and/or broken parts.

Check to ensure door operates freely.

10.Te stelectricopener’s safety features

monthly, following opener manufacturer’s

instructions.

11.NEVER hang tools,bicycles, hoses, clothing

or anything else from horizontal tracks.

Track systems are not intended or designed

to support such extra weight.

Placelabel at a readable height on door. DO NOT

remove,cover or paint over this label. Product

usershould inspect this label periodically for

legibilityand should order a replacement label

fromthe door manufacturer as needed.

324100 REV7 09/16/2013

Qualitygarage doors since 1954

WayneDalton

2501S. State Hwy 121 Bus., Suite 200

Lewisville,TX 75067

Forservice, call (800) 827-3667

www.Wayne-Dalton.com

DivisionofOverheadDoor Corp.

Residential warning label, The warning label will

either be on the right or the left end stile.

Bottom section warning labels

Residential Dust label

(For California Residents Only)

Wood label

important notice

Torsion spring tag(s)

(one per spring)

MAINTENANCE

Cleaning Your Garage Door

IMPORTANT: DO NOT USE A PRESSURE WASHER ON YOUR GARAGE DOOR!

An annual inspection of all the surfaces of your garage door(s) will reveal the extent of weath-

ering and the possible need for reﬁnishing. When the ﬁnish becomes eroded or thin, clean

and prime any areas showing deterioration. Then completely reﬁnish the door, according to

the directions, listed below, or the manufacturer’s label directions. Proper ﬁnishing of the

wood substrates to protect your door(s) from the effects of moisture and sunlight is vital in

extending the service life and beautifying your garage door(s).

The interior and exterior surfaces, as well as all edges must be properly primed, painted and

maintained, to protect and beautify your door. These ﬁnishing instructions are intended to

achieve both objectives for your wood doors(s).

NOTE: Be sure to clean behind weatherstrips on both sides and top of door.

CAUTION

NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.

GLASS CLEANING INSTRUCTIONS

Clean with a mild detergent solution (same as above) and a soft cloth. After cleaning, rinse

thoroughly.

ACRYLIC CLEANING INSTRUCTIONS

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

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

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

glazing. Dry glazing with a clean damp chamois.

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

based cleaners of any kind.

Painting Your Garage Door

Refer to Instruction Insert “Field Painting Wood Door Sections”.

Maintaining The Finish On

Your Garage Door

If the ﬁnish is beginning to fade, the door may require a ﬁeld applied top clear coat. Depend-

ing on environment and usage, this may be necessary after 1 to 3 years of use. Refer to

Instruction Insert “Field Painting Wood Door Sections”.

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 move-

ments. Do not slam your door or throw your door into the open position, this may cause dam-

age 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.

WARNING

DO NOT PLACE FINGERS OR HANDS INTO SECTION JOINTS WHEN

OPENING AND/OR CLOSING A DOOR. ALWAYS USE LIFT HANDLES /

SUITABLE GRIPPING POINTS WHEN OPERATING THE DOOR MANUALLY.

OPENING A DOOR: Make sure the lock(s) are in the unlocked position. Lift the door by using

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

CLOSING A DOOR: From inside the garage, pull door downward using lift handles / gripping

point only. If you are unable to reach the lift handles/ suitable gripping points only, use pull

down rope afﬁxed to the side of door. Door should close completely with little resistance.

USING AN ELECTRIC OPERATOR:

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

MADE INOPERATIVE IN THE UNLOCKED POSITION.

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

tor 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 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 installa-

tion, operation, maintenance and testing of the operator.

MAINTAINING YOUR GARAGE DOOR: Before you begin, read all warning labels afﬁxed to

the door and the installation instructions and owner’s manual. Perform routine maintenance

steps once a month, and have the door professionally inspected once a year. Review your

Installation Instructions and Owner’s Manual for the garage door. These instructions 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 material

found not to be structurally sound must be replaced. It may be necessary to uninstall part

or all of the door assembly in order to replace defective material. Refer to the supplemental

instructions “Removing an Existing Door / Preparing the Opening” at www.Wayne-Dalton.

com. Inspect the spring(s), 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, except on bottom corner brackets or on the counterbalance assembly. 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, contact a trained door system technician.

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 BEARING BRACKETS, DRUMS

OR SPRING 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.

TORQUEMASTER®PLUS SPRINGS: Pawl knob(s) (located on the TorqueMaster®end brack-

ets above the door) should be engaged to prevent the door from rapidly descending in case

of spring failure or forceful manual operation.

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

doing this test. Start with the door in the fully closed position. Using handles or suitable grip-

ping points, lift the door to check its balance. Adjust TorqueMaster® or Extension spring(s),

if door lifts by itself (hard to pull down) or if door is difﬁcult to lift (easy to pull down). DO NOT

attempt to repair or adjust Torsion Springs yourself. To adjust TorqueMaster® or Extension

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

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

systems technician.

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 hinges, steel track rollers, bearings and

torsion springs (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.

CHECK FOR PRESENCE OF SAFETY LABELS:

HIGHSPRING TENSION CA NCAUSE

SERIOUSINJURY OR DEAT H.

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 ONLY be 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 REV2 06/24/2010

DONOT REMOVE, COVER OR PAINT OVER

THISLABEL. PRODUCT USER SHOULD

INSPECTTHIS LABEL PERIODICALLY FOR

LEGIBILITYAND SHOULD ORDER A

REPLACEMENTFROM THE DOOR

MANUFACTURERAS NEEDED.

346214 NEW 11/19/2010

CALIFORNIAHEALTH AND SAFETY

CODESECTION 25249.6

DRILLING,SAWING, SANDING OR

MACHININGWOOD PRODUCTS GENERATES

WOODDUST, A SUBSTANCE KNOWN TO THE

STATEOF CALIFORNIA TO CAUSE CANCER.

AVOIDINHALING WOOD DUST OR USE A

RESPIRATOR OR OTHER SAFEGUARDS FOR

PERSONALPROTECTION.

WARNING

THISWOOD PRODUCT REQUIRES PROPER

FINISHING PRIORTO ANY DOOR HARDWARE BEING

APPLIED.BOTH INNER AND OUTER FA CESOF THE

SECTION(S),AS WELL AS ALL EDGE SURFACES

MUST BE PREPAREDAND FINISHED IN STRICT

ACC0RDANCETO THE DIRECTIONS GIVEN IN THE

INSTALLATIONINSTRUCTIONS AND OWNER’S

MANUAL UNDER “MAINTENANCE AND PAINTING

INSTRUCTIONS FOR ALLWOOD DOORS”.

IMPROPER STORAGE, IMPROPER TRANSPORTATION

AND/OR DELAYIN FINISHING, THAT ALLOWS FOR

THE EXPOSURE OFTHIS WOOD PRODUCT TO

MOISTUREAND/OR OTHER CONTAMINANTS, VOIDS

THE LIMITED WARRANTY.

IMPORTANT

316986

WARNING

Lift handles/gripping points are required

on this door, located as spelled out in the

installation instructions, even if the door

is motor operated.

Failure to install and use these lift handles/

gripping points on this door can result in

serious injury to ﬁngers and/or hands, if

placed in the opening between sections,

when the door is operated manually.

The adjacent bottom corner bracket and

all cable retention features including

milford pins, cotter pins, & clevis pins are

under HIGH SPRING TENSION.

Adjustments and repairs must only be

made by a trained door systems

technician, using proper tools and

instructions.

DO NOT REMOVE, COVER OR PAINT OVER

THIS LABEL.PRODUCT USER SHOULD

INSPECT THIS LABEL PERIODICALLY FOR

LEGIBILITY AND SHOULD ORDER A

REPLACEMENT FROM THE DOOR

MANUFACTURER AS NEEDED.

325304 REV3 06/26/12

OverheadDoor Corporation

WARNING

Lift handles/gripping points are required

on this door,located as spelled out in the

installation instructions, even if the door

is motor operated.

Failure to install and use these lift handles/

gripping points on this door can result in

serious injury to ﬁngers and/or hands, if

placed in the opening between sections,

when the door is operated manually.

The adjacent bottom corner bracket and

all cable retention features including

milford pins, cotter pins, & clevis pins are

under HIGH SPRING TENSION.

Adjustments and repairs must only be

made by a trained door systems

technician, using proper tools and

instructions.

DO NOT REMOVE, COVER OR PAINT OVER

THIS LABEL.PRODUCT USER SHOULD

INSPECT THIS LABEL PERIODICALLYFOR

LEGIBILITY AND SHOULD ORDER A

REPLACEMENT FROM THE DOOR

MANUFACTURER AS NEEDED.

325304 REV3 06/26/12

OverheadDoor Corporation

SAFETYINSTRUCTIONS

1. Operatedoor ONLY when it is properly

adjusted and free of obstructions.

2. Ifa 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.

3. DONOT stand or walk under a moving door,

or permit anybody to stand or walk under

an electrically operated door.

4. DONOT place ﬁngers or hands into open

section joints when closing a door. Use lift

handles/gripping points when operating

door manually.

5. DONOT permit children to operate garage

door or door controls.

6. Dueto 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, red colored

fasteners, cables or supports.To avoid

possible severe or fatal injury, have any

such work performed by a trained door

system technician using proper tools and

instructions.

7. Onelectrically operated doors, pull down

ropes must be removed and locks must be

removed or made inoperative in the open

(unlocked) position.

8. Topsection of door may need to be

reinforced when attaching an electric

opener. Check door and/or opener

manufacturer’s instructions.

9. VISUALLYinspect door and hardware

monthly for worn and/or broken parts.

Check to ensure door operates freely.

10.Te stelectricopener’s safety features

monthly, following opener manufacturer’s

instructions.

11.NEVER hang tools,bicycles, hoses, clothing

or anything else from horizontal tracks.

Track systems are not intended or designed

to support such extra weight.

Placelabel at a readable height on door. DO NOT

remove,cover or paint over this label. Product

usershould inspect this label periodically for

legibilityand should order a replacement label

fromthe door manufacturer as needed.

324100 REV7 09/16/2013

Qualitygarage doors since 1954

WayneDalton

2501S. State Hwy 121 Bus., Suite 200

Lewisville,TX 75067

Forservice, call (800) 827-3667

www.Wayne-Dalton.com

DivisionofOverheadDoor Corp.

Residential warning label, The warning label will

either be on the right or the left end stile.

Bottom section warning labels

Residential Dust label

(For California Residents Only)

Wood label

important notice

Torsion spring tag(s)

(one per spring)

Warranty

Rev. 08.2014

Models 42, 44, and 45

Limited Warranty

Wayne Dalton, a division of Overhead Door Corporation ("Seller") warrants to the original purchaser of the Models 42, 44,

and 45 (“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 a period of One (1) year, measured from the date of installation:

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 defective during the applicable warranty period. Any labor charges are excluded and will be the

responsibility of the purchaser.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. This

warranty is made to the original purchaser of the Product only, and is not transferable or assignable. This warranty applies

only to Product installed in a residential or other non-commercial application. It does not cover any Product installed in

commercial or industrial building applications. This warranty does not apply to any unauthorized alteration or repair of the

Product, or to any Product or component which has been damaged or deteriorated due to misuse, neglect, accident,

puncture, drilling of holes (other than as directed by Seller), incorrect installation of hardware, fire, failure to provide

necessary maintenance, normal wear and tear, exposure to salt or other corrosive environments, or acts of God or any other

cause beyond the reasonable control of Seller. This warranty also specifically excludes all refinishing costs and any

inconsistencies or occurrences related to the characteristics or attributes of natural wood, including but not limited to: (i)

variations in the color or grain of Product sections, (ii) the emission or secretion of tannins from the Product sections which

may stain or alter the color of a painted Product, and (iii) cracking, checking, lifting wood grain or cracking due to natural

expansion and contraction of the Product sections.

SPECIAL PAINTING REQUIREMENTS: This warranty shall be void if the Product sections are not painted or sealed in

accordance with DASMA TDS 162 (available at www.dasma.com) on all sides, including all edges with one (1) coat of

exterior grade primer (or stain) and two (2) coats of high quality acrylic latex exterior grade finish paint (or sealer), applied in

accordance with the paint or Sealer manufacturer’s instructions and Seller’s painting and maintenance instructions. Sections

must be finished within five (5) days of receipt and prior to installation. Damage caused by exposure of the product to water,

moisture, sun or other conditions prior to completion of painting (or Sealing) is excluded. This warranty shall also be void if

the Product is painted a dark color, including but not limited to black, dark grey, dark green and dark brown*. IMPROPER

TRANSPORTATION, STORAGE OR DELAYS IN FINISHING, THAT ALLOWS EXPOSURE OF THE WOOD DOOR

SURFACES TO MOISTURE OR OTHER CONTAMINANTS WILL RESULT IN THE WARRANTY BEING VOIDED.

ALL EXPRESS AND IMPLIED WARRANTIES FOR THE PRODUCT, INCLUDING BUT NOT LIMITED TO ANY

IMPLIEDWARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN TIME

TO THE APPLICABLE WARRANTY PERIOD REFLECTED ABOVE. NO WARRANTIES, WHETHER EXPRESS OR

IMPLIED, WILL APPLY AFTER THE LIMITED WARRANTY PERIOD HAS EXPIRED. Some states do not allow limitations

on how long an implied warranty lasts, so the above limitation may not apply to you.

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. Some states do not allow the exclusion or limitation of incidental or

consequential damages, so the above limitation or exclusion may not apply to you.

Claims under this warranty must be made promptly after discovery, within the applicable warranty period, and in writing to

the Seller 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. There are no established informal dispute resolution

procedures of the type described in the Magnuson-Moss Warranty Act.

* Dark colors shall mean colors as dark as or darker than any of the following Sherwin-Williams Exterior Colors: 7069 Iron

Ore (dark grey), 6447 Evergreens (dark green) or 7510 Chateau Brown (dark brown).

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.

PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE

After installation is complete, leave this Installation

Instructions And Owner’s Manual with the homeowner, or

fasten it near garage door for easy reference.

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