Wayne-Dalton WAYNEWOOD DOORS 40 - Manual

WayneWood Doors
Models: 40,42,43,45,47
Torsion Spring Installation Instructions Layout
1A
1C
1B 1D
LEFT HAND BOTTOM
BRACKET
2B
5B
5A
3A
g WEATHER
SEAL
JAMB
DOOR
6
3B
3-1/4”
10
14
17
15
3/4”
ROOFING
NAIL
LEVEL
12
13
16
a
h
a
a
k
k
p
p
p
g
i
e
e
p
p
p
m
m
p
p
g
g
p
j
INSERT COUNTER-BALANCE CABLE
BEND
20
b
d
b
d
e
e
e
n
b
b
n
p
p
m
m
21
j
2-1/2” (64 mm)
4B
ALIGN
HOLES
15” RAD.
12” RAD.
RED
BLACK
11B
q
ANGLED
EXTENSION
OUTSIDE
18B
18A
1/8”-1/4”
OPTIONAL SELF-
DRILLING SCREW
2A
g
g
7A
8
11A
CENTER
STILE
4A-4B
4A
22
STRUT
CLIP
9
1-11/16”
(43 mm)
e
h
a
g
p
p
LEFT HAND BOTTOM
BRACKET
2C
i
p
j
p
p
Fully adjustable track: Secure the vertical to the lower slot in the flagangle using (1) stud plate and (2) whiz nuts.
NOTE: Some “bolt on track” will have (2) track bolts (k) instead of a stud plate.
Q.I. Track: Put the lower Twistlock tab on the flagangle into the Twistlock hole in the vertical track. Give the
flagangle 1/4 turn to lock in place. Repeat for other side.
Q.I. Track: Using the Quick Install Jamb Bracket Schedule (located on the reverse side), determine the placement of
the jamb brackets for your door height. Align the Twistlock™ wings on each jamb bracket with the correct butterfly
hole in the track and turn the jamb bracket perpendicular to the track so the mounting flange is toward the back leg of
the track.
Bottom brackets are right and left. Before attaching the bottom brackets, secure the counterbalance cables to the
brackets by placing the looped end of the cables over the milford pin. Attach the bottom brackets to the bottom
corners of the sections, aligning the bottom of the bracket with the bottom of the section. Using the bracket as a
template, drill (3) 9/32” (7mm) dia. holes through the section. Secure the bracket to the section with
(3) 1/4-20 x 1-7/8” carriage bolts and hex nuts each.
NOTE: Double car doors get (5) carriage bolts and nuts per
bottom bracket (see 2C). Now install a 1/4” x 1” tamper-resistant lag screw into each bottom bracket (Pilot drilling a
1/8” (3mm) dia. hole into the section.
IMPORTANT! When pre-drilling 1/8” hole for tamper-resistant lag be sure NOT to drill through the section).
IMPORTANT! Right and left hand is always determined from inside the building looking out.
START HERE
IMPORTANT!
READ IMPORTANT SAFETY NOTICES AND REFER TO INSERT SHEET INSTRUC-
TIONS TITLED “REMOVING THE OLD DOOR/PREPARING THE OPENING”. IF THE INSERT SHEET
INSTRUCTIONS ARE NOT INCLUDED, CONTACT WAYNE-DALTON CORP. FOR A FREE COPY. If remov-
ing an existing door, carefully follow the directions given on the insert sheet instruction in the portion titled “Removing
the Old Door”.
WARNING!
REMOVAL OF AN EXISTING DOOR CAN BE DANGEROUS. FOLLOW INSERT SHEET INSTRUCTIONS
CAREFULLY, OTHERWISE SERIOUS INJURY OR DEATH COULD OCCUR.
Begin the installation of the door by checking the opening. It must be the same size as the door. Vertical jambs must
be plumb and the header level. Side clearance, from edge of door to wall, must be minimum of 3-1/2” (89 mm) on each
side. For proper opening preparation refer to the portion of the insert sheet instructions titled “Preparing the
Opening”. Follow the steps below. The steps correspond to the illustrations on the garage door layout.
NOTE: It is recommended that 5/16” x 1-5/8” and 2” lag screws be pilot drilled using a 3/16” (5mm) drill bit, and
1/4” x 1” lag screws be pilot drilled using 1/8” (3mm) drill bit, prior to fastening.
CONTINUE INSTALLATION INSTRUCTIONS ON REVERSE SIDE.
Fully adjustable track: To attach the bottom (short) jamb bracket, locate the lower hole/slot pattern in the vertical
track. Align the slot in the jamb bracket with the lower hole of the hole/slot pattern in the vertical track. Secure jamb
bracket with (1) 1/4-20 x 9/16” track bolt and nut. Place the center (long) jamb bracket over the hole/slot pattern
nearest to the center of the track. Loosely fasten the bracket onto the track with (1) 1/4-20 x 9/16” track bolt and nut.
NOTE: Doors over 7’3” high get (3) set of jamb brackets. Install the center and top jamb brackets so that they are
equally spaced in between the flagangle and bottom jamb bracket.
1B-1C
Align the bottom seal (may not be provided) with the angled extension to the outside of the door (see 2B). Starting at
one end of the door, attach the seal to the bottom of the section with 3/4” long galvanized roofing nails (not supplied).
Stretch the seal slightly and nail the seal to the bottom of the door every 6”.
2B
Locate the lower leaf of the No. 1 end hinges and required No.1 center hinges over the predrilled holes in the end stiles
and center stiles at the top of the bottom section (for strut installation, see below). Secure the hinges to the sections
using (2) 1/4-20 x 1-7/8” carriage bolts and hex nuts each. Insert (1) roller in each end hinge. Repeat using No. 2 end
hinges for second (lock) section and No. 3/No.4 hinges for the third/forth (intermediate) section(s).
IMPORTANT! Do NOT over tighten hex nuts.
IMPORTANT! When placing rollers into end hinges No. 2 and higher, the roller must be inserted into the tube
furthest away from section. See 3B.
Strut Installation (if necessary): Place a long strut over the lower hinge leafs of the section and secure the hinges
and strut together to the sections using (2) strut clips and (2) 1/4-20 x 1-7/8” carriage bolts and hex nuts each.
(See Fig 22 this page and Strutting Schedules on reverse side of this manual.)
Standard Flush doors are predrilled for hinges and lift handles. Lift handles may be offset from center of section.
Align lift handle with predrilled holes and assemble the outside and inside lift handle back to back with
(2) 1/4” x 2-1/2” (64 mm) carriage bolts and nuts.
Before installing the bottom section, measure and cut the vinyl jamb weather-stripping or wood door stops (weather-
stripping or wooden stops may or may not be supplied) for entire garage door opening. Vinyl weather seal must be
installed prior to door installation when utilizing fully adjustable track. Attach the weather seal to the jamb
1/8” to 1/4” (3-6mm) past door jamb using the nails supplied with strip. This will help hold the bottom door section
in place. Now, center the bottom section in the door opening. Level it using wooden shims under the bottom seal as
needed. Once the bottom section is level, all the other components will automatically align. Hold the section in the
opening while attaching vertical tracks.
NOTE: In the event that the bottom section was shimmed to level it, then the vertical track on that same side of the
section must be raised the thickness of the shim(s). The tops of the vertical track must be level.
Position the first vertical track over the rollers of the bottom section. Make sure the counterbalance cable is located
between the rollers and the door jamb. Secure jamb brackets and flagangles to the jamb using 5/16” x 1-5/8” lag screws.
Install the other vertical track the same way. Hang counterbalance cables over flagangles.
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.
6A-6B
Make sure the top leaves of all hinges on the bottom section are folded down. With assistance lift second section and
place rollers over the tops of the vertical tracks. Install by guiding rollers into the vertical track on both sides and
gently lowering the section onto the bottom section. Keeping the ends of the sections aligned, install remaining
section(s), except top section, in same manner. Fasten all hinges to connect the sections by flipping up the hinge leaf
and securing with (2) 1/4-20 x 1-7/8” carriage bolts and nuts.
NOTE: To install lock, see lock instructions included in the lock assembly bag.
Identify the supplied top brackets. Measure down from the top of the section 3-1/4” (83mm) and mark location. Align
the top holes on the top bracket with the mark and align the edge of the bracket with the edge of the section. Using the
top bracket as a template, drill (4) 9/32” (7mm) holes through the section. Secure the brackets using (4) 1/4-20 x 1-7/8”
carriage bolts and hex nuts each. Insert a roller into each top bracket and loosen the bolt in the adjustable slides. Proper
adjustment will be required once the track is installed.
Strut Installation (if necessary): Center the short strut onto the top of the top section in between the two top
brackets. The strut should be at least 3/4” (19mm) from the top of the section. Secure strut using (2) 1” lag screws on
each end and center stile (alligned with hinges) locations.
Place the top section in the door opening. Keeping the ends of the sections aligned, secure it temporarily by driving a nail
into the header near the center of the door and bending it over the section. Once section is secure, fold the upper leaves
of the hinges from the section below to the top section and secure with (2) 1/4-20 x 1-7/8” carriage bolts and nuts.
Align the Slidelock™ tabs on the applicable horizontal angle with key slots in the horizontal track. Push the parts
together. Using a hammer, tap the horizontal angle towards the curved end of the track until the hole in track and angle
are aligned.
NOTE: For large size doors, a full length horizontal angle is already spot welded to the horizontal track.
Position flagangle 1-11/16” (43 mm) from the edge of the door. Tighten the first lag screw then secure the flagangle to the
jamb with (2) more 5/16” x 1-5/8” lag screws. Now complete the vertical track installation on both sides by securing the
center jamb brackets and tightening other lag screws.
IMPORTANT! Vertical tracks must be secured so that the rollers are touching the deepest part of the curved side of the
track.
To install horizontal track, place the curved end over the top roller. Align the bottom of the horizontal track with the top
of the vertical track. Fully adjustable track: Secure the track to the flagangle with (1) stud plate and nuts.
NOTE: For “bolt on” track, secure the horizontal track to the flagangle with (2) 1/4-20 track bolts and nuts.)
Q.I. Track: Align the key slot in the track with the quick install tabs on the flagangle. Push the curved portion of the
horizontal track downward to lock into place.
Level horizontal track and bolt the horizontal angle to the slot in the flagangle using (1) 3/8-16 x 3/4” truss head bolt and
nut. Repeat for other side. Remove nail which is temporarily holding the top section.
With tracks installed you can adjust the top brackets. Vertically align the top section with the lower sections. Once
aligned, position top roller in adjustable slide against horizontal track, maintain position and tighten nut(s).
Add a 1/4-20 x 11/16” self-drilling screw into the slide to lock the slide in place (see 11B). Repeat for other side.
IMPORTANT! Failure to remove nail before attempting to raise door could cause permanent damage to top section.
WARNING!
DO NOT ATTEMPT TO RAISE DOOR AT THIS TIME.
11A-11B
End bearing brackets are right and left. Locate the end bearing bracket above the flagangle and secure the bracket to the
horizontal angle using (2) 3/8-16 x 3/4” truss head bolts and nuts. Once the bracket is secured to the horizontal angle,
secure the top of the bracket to the jamb using (1) 5/16” x 1-5/8” lag screw.
IMPORTANT! End bearing brackets must be attached through the lower slots on 12” radius track and through the upper
slots on 15” radius track.
12
Locate the center of the door and mark a vertical pencil line on the spring pad. Then measure the distance from the center
of the mounting hole (hole where tube fits into) in the end bearing bracket to the top of the door. Using that same distance,
mark a horizontal line on the spring pad, measuring up from the top of the door. Align the center bearing bracket edge
along the vertical pencil line on the spring pad as shown. In addition, position the center bearing bracket halfway over the
horizontal pencil line. This will level the torsion tube through the end bearing brackets when installed. Attach the center
bearing bracket to the spring pad using (2) 5/16” x 1-5/8” lag screws and (1) 5/16” x 2” tamper-resistant lag screw.
IMPORTANT! Use the 5/16” x 1-5/8” tamper-resistant lag screw ONLY if spring pad is mounted over masonry.
IMPORTANT! Tamper-resistant lag screw MUST be attached through the bottom hole of the center bearing bracket.
13
Facing the inside of the door, lay the torsion tube on the floor. Lay the black color coded winding cone with spring and
cable drum on the floor at the right end of the tube. Then lay the red color coded winding cone with spring and cable drum
on the floor at the left end of the tube.
NOTE: Right and left hand is always determined from inside the building looking out.
NOTE: Some lighter weight doors are provided with only (1) torsion spring. Identify the spring(s) 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.
NOTE: The set screws used on all Torsion Counterbalance cable drums and winding cones are now painted red.
DO NOT identify right and left hand side by the set screws.
Slide the nylon center bushing onto the torsion tube followed by the spring(s) and cable drums. The nylon center
bushing, spring(s), and cable drums must be positioned as shown in the illustrations. With assistance, pick up the torsion
tube assembly and slide one end the of tube through one end bearing bracket. Lay the torsion tube into the center bearing
bracket and slide the other end of the tube into the opposite end bearing bracket. Position the torsion tube so that equal
amounts of the tube extend from each end bearing bracket.
14
Slide the nylon center bushing into the end of (1) stationary spring cone and align the cone(s) with the holes in the center
bearing bracket. Secure the spring(s) to the center bearing bracket with (2) 3/8-16 x 1-1/2” bolts and nuts.
IMPORTANT! Springs under tension can be dangerous. Spring warning tag must be attached to center bearing bracket
in obvious sight. If this tag is missing, contact Wayne-Dalton Corp. for free replacements.
Clamp locking pliers onto both vertical tracks just above the third roller. This is to prevent door from raising while
winding the spring(s).
WARNING!
FAILURE TO CLAMP TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE INJURY OR DEATH.
15
Thread the counterbalance cables around the back side of the cable drums and verify that there is no cable obstructions.
Before hooking cables into drums, slide the loose cable buttons against the crimped buttons and with a pliers bend a 90
degree angle in the cable as illustrated.
NOTE: Some cable assemblies only have the crimped cable button.
Hook the cables into the drums. Slide the left hand cable drum against the end bearing bracket and tighten the set screws
in the drum to 14-15 ft lbs. of torque (Once set screws contact the tube, tighten screws one full turn). Rotate the left hand
drum and torsion tube until cable is taut. Attach locking pliers to torsion tube and brace locking pliers against jamb to
keep cable taut. Slide the right hand cable drum against the end bearing bracket and rotate drum until cable is taut. Tighten
set screws in right hand cable drum.
Clamp locking pliers onto the torsion tube, to keep it from rotating.
CAUTION! Check each cable, making sure both are seated properly on the cable drums and have equal cable tension.
16
1A
2A
3A-3B
Strut Installation (if necessary): Wood doors are provided with short struts and long struts. Center the short strut
on the bottom of the bottom section in between the two bottom brackets. The strut should be at least 3/4” (19mm)
from the bottom of the section. Secure strut using (2) 1” lag screws on each end and center stile (alligned with hinges)
locations.
5A-5B
10
7A
1D
9
8