GARAGE DOORS & OPENERS Models: 40, 42, 43, 45, 47 To r s i o n 6” Front Mount Low Headroom 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 Paint
Parts Breakdown NOTE: The illustrations shown on this page are general representations of the door parts. Each specific door models may have unique variations. G5. G11. G7. H2. G9. G12. F1. G2. G1. G5. G3. G12. G6. H1. A1. G4. G9. D1. D1. A2. E1. G5. G10. G8. G4. D1. G5. C1. D1. A1. A2. F6. C2. F4. H2. F3. C2. F1. G13. F7. F2. C3. B3. F6. F4. B2. A2. B1. I1. A4. H1. A1. J1. F7. K1. A3. F3. G13. F5. J1. F2. F5. I1. A. Track Rollers (As Required): A1.
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.
5/16” x 1-1/4” Clevis pin (as required) Cotter pin (as required) The BOTTOM SECTION can be identified by #1. The INTERMEDIATE I SECTION can be identified by #2. The INTERMEDIATE II SECTION can be identified by #3, for a 4 section high door only. The INTERMEDIATE III SECTION can be identified by #4, for a 5 section high door only. 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 102” (2591 mm) 125” (3175 mm) 7’1” to 8’0” 114” (2896 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) Removin
Fully Adjustable Flag Angles Tools: None NOTE: If you have a wall angle track assembly or if you already have flag angles preattached to the vertical tracks, skip this step. Refer to Package Contents / Parts Breakdown, to determine if you have flag angles. Note: Flag angles are right and left handed. If you have Fully Adjustable vertical tracks, 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. Repeat for other side.
(3) 1/4” - 20 x 1-7/8” Carriage bolts (3) 1/4” - 20 Flange hex nuts Bottom section Bottom section Short strut Bottom corner bracket Typical left hand bottom corner bracket (1) 1/4” - 10 x 1” Tamper resistant lag screw 1/4” - 14 x 1” Lag screws 3/4” (3) 1/4” - 20 x 1-7/8” Carriage bolts (3) 1/4” - 20 Flange hex nuts Typical left hand bottom corner bracket Track Roller Carriers Tools: Power Drill, 9/32” Drill Bit, Socket Driver 7/16”, Wrench 7/16” Starting on left hand side of the bottom section,
the upper leg of strut to the bottom section using (1) 1/4”-20 x 1-7/8” carriage bolt and (1) 1/4”–20 flange hex nut. Next secure the bottom leg of strut, the lower slot of the center hinge to the bottom section (1) 1/4”-20 x 1-7/8” carriage bolt and (1) 1/4”–20 flange hex nut, as shown. Repeat same process for other center hinges.
13 Level Bottom section Wooden shims (If necessary) Vertical Tracks Tools: Power Drill, 3/16” Drill bit, 7/16” Socket driver, Tape measure, 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.
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.
18 NOTE: Identify the torsion springs provided as either right hand wound (red winding cone), which goes on the RIGHT HAND SIDE or left hand wound (black winding cone), which goes on the LEFT HAND SIDE. For Doors without Coupler Assembly: Facing the inside of the door lay the torsion shaft on the floor. Lay the torsion spring with the black winding cone and the red cable drum at the left end of the torsion shaft.
Black cable drum (right hand side) Coupler halves Set screws and Lock nut Center coupler assembly (3) 3/8” - 16 x 1-3/4” Hex head screws and (3) 3/8” - 16 Nylon hex lock nut Red cable drum (left hand side) Torsion keyed shaft Coupler halves Center bearing bracket(s) Coupler assembly Center bearing Set collar Right hand wound, red winding cone Center (right hand side) bearing Key Center bearing inside torsion spring Set screws and Lock nut Center bearing Left hand wound, black winding cone Set col
Center bearing brackets Coupler assembly Set screws Torsion keyed shaft Torsion keyed shaft (3) 3/8” - 16 nylon hex lock nuts 24 Coupler halves WARNING Torsion spring Left hand end bearing bracket Key Prior to winding or making adjustments to the springs, ensure you’re winding in the proper direction as stated in the Installation Instructions. Otherwise the spring fittings may release from spring if not wound in the proper direction and could result in severe or fatal injury.
WARNING Keep horizontal tracks parallel and within 3/4” to 7/8” maximum of door edge, otherwise door could fall, resulting in severe or fatal injury. Important: Do not support the weight of the door on any part of the rear 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.
3/4” To 7/8” 3/4” To 7/8” Door edges Horizontal tracks 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 Center of the horizontal track 26 Label Placement Tools: Step Ladder IMPORTANT: Using the illustration, attach the appropriate labels to the appropriate location on the section, as shown. NOTE: The Spring Warning tag(s) are factory attached (one per spring).
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.
