GARAGE DOORS & OPENERS Models: 40, 42, 43, 45, 47 To r s i o n Standard Lift MH installation instructions and owner’s manual Ta b l e O f C o n t e n t s Parts Breakdown Pre-Installation Important Safety Instructions Tools Required Package Contents Door Section Identification Graduated End Hinge And Strut Identification Removing an Existing Door Preparing the Opening Installation Optional Installation Door Arm Hookup Lift Handles Pull Down Rope Maintenance Cleaning Your Garage Door Painting Your Garag
Parts Breakdown G10. NOTE: The illustrations shown on this page are general representations of the door parts. Each specific door models may have unique variations. G9. H3. G8. G7. G2. G2. F1. G3. G1. A1. G7. G10. H2. G4. G8. G5. G4. A2. D3. E1. E2. G6. C1. G5. A1. F6. C2. D1. F2. A2. F4. H3. F3. C2. F6. F1. F7. I1. G9. F4. C3. B3. B2. J1. A2. B1. A4. K1. A1. A3. H1. F7. J1. F5. F2. F3. F5. I1. A. Track Rollers (As Required): A1. Short Stem Track Rollers A2.
Pre-Installation Important Safety Instructions Tools Required Definition of key words used in this manual: • Power drill • Drill bits: 1/8”, 3/16”, 9/32”, 7/16”, 1/2” • Ratchet wrench • Socket driver: 7/16” • Sockets: 7/16”, 1/2”, 9/16”, 5/8” 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.
Track roller carriers (as required) Keys (as required) The INTERMEDIATE I SECTION can be identified by #2. The INTERMEDIATE II SECTION can be identified by #3, for a 4 section high door only. The INTERMEDIATE III SECTION can be identified by #4, for a 5 section high door only. The INTERMEDIATE IV SECTION can be identified by #5, for a 6 section high door only. The INTERMEDIATE V SECTION can be identified by #6, for a 7 section high door only.
Graduated End Hinge Schedule Top 2” Intermediate IV 5# Intermediate III 4# Intermediate II 3# Intermediate I 2# Bottom 1# 6 Section High Door 3” 2” Top N/A Intermediate IV 7# Intermediate III 6# Intermediate II 5# Intermediate I 4# Bottom 3# Top N/A Intermediate V 6# Intermediate IV 5# Intermediate III 4# Intermediate II Intermediate I 7 Section High Door 3” 2” 1# Top N/A Intermediate V 8# 7# Intermediate III 6# Intermediate II 5# Intermediate I 4# Bottom 3#
Door Height 2” Strut 3” Strut Short strut Lower hinge leaf Hinges are stamped for identification 2 1 Center hinge(s) (as required) 1 Track Motor Operated 98” (2489 mm) 125” (3175 mm) 7’1” to 8’0” 110” (2794 mm) 137” (3480 mm) 8’1” to 9’0” Long strut Upper hinge leaf Manual Lift 6’0” to 7’0” 126” (3200 mm) 168” (4267 mm) 9’1” to 10’0” 138” (3505 mm) 168” (4267 mm) 10’1” to 12’0” 162” (4115 mm) * 12” Or 15” Radius Headroom Requirements Half center hinge(s) (as required) Removing
Tools: Hammer, Tape Measure, Saw Horses Note: If a bottom weather seal is supplied, complete this step. Note: Refer to Door Section Identification / Parts Breakdown. 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.
Bottom section Side view of track roller carrier(s) Bottom weather seal Outer holes (3” Track) (3) 1/4” - 20 x 1 7/8” Carriage bolts and (3) 1/4” - 20 Flange hex nuts (1) 1/4” - 14 x 1” Tamper resistant lag screw Typical left hand bottom corner bracket Inner holes (2” Track) Bottom section 6 Bottom weather seal (3) 1/4” - 20 x 1 7/8” Carriage bolts and (3) 1/4” - 20 Flange hex nuts Short stem track roller Spacer Bottom section (1) 1/4” - 14 x 1” Tamper resistant lag screw Cable loop Short stem
Double graduated end hinge with long stem track roller Lower hinge Long strut leaf(s) (if applicable) Single graduated end hinge with short stem track roller Hinge Short tube(s) edge (1) Strut clip (if applicable) Half center hinge Equally spaced Center hinge Typical section shown Lower hinge leaf Long edge (1) Strut clip (if applicable) (2) 1/4” - 14 x 1” Lag screws (2) 1/4” - 20 x 1 7/8” Carriage bolts and (2) 1/4” - 20 Flange hex nuts Short edge Hinge tube(s) Tandem roller Short edge (1) Stru
If you have 3” vertical tracks: Tighten lag screws, securing the bottom jamb bracket/bottom slot to jamb, maintain 1/2” to 3/4” spacing, between the bottom section and vertical track. Hang counterbalance lift cable over flag angle/wall angle. Repeat same process for other side. Strutting For Top Section Tools: Power drill, 7/16” Socket driver NOTE: Refer to the Door Section Identification and Strut Identification, to determine if the top section requires a short strut to be installed.
Door width (2” Track) + 3-3/8” to 3-1/2” Top of flag angle or Top of wallangle assembly Typical graduated end hinge with typical long stem tandem track roller Left double graduated end hinge with typical long stem track roller Vertical tracks Top section (2) 1/4”-14 x 1” Lag screws Typical sections shown Center hinge(s) Flag angle or wallangle assembly Horizontal Tracks 15 Right single graduated end hinge with typical short stem track roller Tools: Ratchet wrench, 7/16” Socket, 9/16” Socket, 9/1
Top section (2) 1/4”-20 Flange hex nut(s) Top section Left end bracket Typical top fixture slide Typical top fixture slide (1)1/4”-20 x 9/16” Track bolt Upper slot 18 Top fixture slide Top fixture base (2) 1/4”-20 x 1/2” Carriage bolts End Bearing Brackets Tools: Step ladder, Power drill, 7/16” Socket driver IMPORTANT: Right and left hand is always determined from inside the building looking out. NOTE: End brackets are right and left hand.
Center bracket bushing assembly (2) 5/16” x 1-5/8” Lag screws Mounting surface Vertical line Mounting surface Vertical line Equal spacing Center bracket bushing Left hand end bearing bracket (2) 5/16” x 1-5/8” Lag screws Torsion shaft Or Torsion keyed shaft Horizontal line Right hand end bearing bracket Center bracket Drum spacers (as required) Horizontal line (1) 5/16” X 2” or (1) 5/16” x 1-5/8” Tamper-resistant lag screw Center of door Mounting surface (17” Minimum) † If you have a Coupler
and the slot in the torsion keyed shaft, as shown. Rotate the left hand drum and torsion shaft until counterbalance lift cable is taut. Now attach locking pliers to the torsion shaft and brace locking pliers up against jamb to keep counterbalance lift cable taut. Repeat for right hand side. IMPORTANT: Inspect each counterbalance lift cables making sure they are seated properly onto the cable drums and that both counterbalance lift cables have equal tension.
WARNING Raising door further can result in door falling and cause severe or fatal injury. Vice clamps above third track roller on both sides of door Clamp a pair of vice clamps onto the vertical tracks just above the second track roller on one side, and just below the second track roller on the other side. This will prevent the door from raising or lowering while installing the rear back hangs.
3/4” To 7/8” 3/4” To 7/8” Door edges Horizontal tracks Horizontal tracks Vice clamp Vice clamp 2nd Track roller Rear center back hang Horizontal track (1) 3/8” Truss head bolt (may not be supplied) (1) 3/8” Nut (may not be supplied) Horizontal track Drill 3/8” diameter hole Sound framing members Center of the horizontal track 25 Tools: Step Ladder IMPORTANT: Using the illustration, attach the appropriate labels to the appropriate location on the section, as shown.
Optional Installation WARNING Door Arm Hookup Tools: Needle nose pliers Do not install pull down rope on doors with operators. Children may become entangled in the rope causing severe or fatal injury. At the center of the top section, measure horizontally from the top of center hinge to the bottom of strut. Using that dimension, measure and cut (2) pieces of perforated angles. Assemble the (2) pieces together using (2) 3/8” bolts and nuts (supplied by others).
Maintenance Before you begin, read all warning labels affixed to the door and the installation instructions and owner’s manual. When correctly installed, your Wayne-Dalton door will operate smoothly. Always operate your door with controlled movements. Do not slam your door or throw your door into the open position, this may cause damage to the door or its components. If your door has an electric opener, refer to the owner’s manual to disconnect the opener before performing manual door operation below.
3. Lubrication: The door should open and close smoothly. Ensure the door track rollers are rotating freely when opening and closing the door. If track rollers do not rotate freely, clean the door tracks, removing dirt and any foreign substances. Clean and lubricate (use a non-silicon based lubricant) graduated end hinges, steel track rollers, spring(s) and bearings. DO NOT lubricate plastic idler bearings, nylon track rollers, door track.
Warranty Limited warranty Models: 40, 42, 43, 45, 47 Subject to the terms and conditions contained in this Limited Warranty, Wayne-Dalton (“Manufacturer”) warrants the sections of the door, against defects in material and workmanship, for a period of ONE (1) YEAR from the time of delivery provided: i) (i) The interior and exterior surfaces, as well as all edges of the wood door(s) are properly finished according to the Manufactures Maintenance and Painting Instructions and finish manufacturer’s instructions
Covered by one or more of the following Patents; 5,408,724; 5,409,051; 5,419,010; 5,495,640; 5,522,446; 5,562,141; 5,566,740; 5,568,672; 5,718,533; 6,019,269; 6,089,304; 6,644,378; 6,374,567; 6,561,256; 6,527,037; 6,640,872; 6,672,362; 6,725,898; 6,843,300; 6,915,573; 6,951,237; 7,014,386; 7,036,548; 7,059,380; 7,121,317; 7,128,123; 7,134,471; 7,134,472; 7,219,392; 7,254,868. Canadian: 2,384,936; 2,477,445; 2,495,175; 2,507,590; 2,530,701; 2,530,74; 2, 2,532,824. Other US and Foreign Patents pending.
