Wayne-Dalton 6600 User Manual

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6600

t o r S i o n

Standard Lift and

L i g h t C o m m e r C i a L

inStaLLation inStruCtionS and owner’S manuaL

T a b l e O f C o n t e n t s

Pre-Installation 2

Important Safety Instructions 2 Tools Required 2 Package Contents 2 Door Section Identiﬁcation 3 Removing an Existing Door 3 Preparing the Opening 3

Parts Breakdown 5 Installation 6 Optional Installation 18

Door Arm Hookup 18 Inside Lock 18 Pull Down Rope 18 Interior Lite Caulking 18

Maintenance 19

Cleaning Your Garage Door 19 Painting Your Garage Door 19 Operation And Maintenance 20

Warranty 21

PLEASE DO NOT RETURN THIS PRODUCT

TO THE STORE

Please Do Not Return This Product To The Store. Please call 1-866-569-3799 (Press Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have.

Wayne-Dalton, a Division Of Overhead Door Corporation

IMPORTANT NOTICES!

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 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.

DEFINITION OF DOOR HEIGHTS:

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

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

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

Wayne-Dalton, a Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, Or Online At www.Wayne-Dalton.com

Part Number NEW 04/26/2013

351725

Pre-Installation

Important Safety Instructions

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

DEFINITION OF KEY WORDS USED IN THIS MANUAL:

WARNINGWARNING

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.

After installation is complete, fasten this manual near the garage door. IMPORTANT: STAINLESS STEEL OR PT2000 COATED LAG SCREWS MUST BE USED WHEN

INSTALLING CENTER BEARING BRACKETS, END BRACKETS, JAMB BRACKETS, DRAWBAR OPERATOR MOUNTING/ SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER (PRESERVATIVE-TREATED). STAINLESS STEEL OR PT2000 LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN-TREATED LUMBER.

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

IMPORTANT: 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.

Tools Required

• 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”

• Phillips head screwdriver

• Locking Pliers

• (2) Vice clamps

• Wrenches: 3/8”, 7/16”, 1/2”, 9/16”, 5/8”

• 1/4” Torx bit

• Approved winding rods

• Hammer

• Tape measure

• Step Ladder

• Level

• Pencil

• Leather gloves

• Safety glasses

Package Contents

NOTE: Depending on the door model, some parts listed will not be supplied if not required. Rear Back Hangs may not be included with your door.

Door sections (as required)

Torsion shaft / Torsion keyed shaft (as required)

Torsion keyed shafts (as required)

Q.I. ﬂag angles RH/LH (as required)

(2) Horizontal angles (as required)

Q.I. jamb brackets

(as required)

Top ﬁxture assemblies

(as required)

F.A. jamb brackets

Angle mount vertical track assemblies RH/LH (as required)

Riveted vertical track assemblies RH/LH (as required)

(as required)

(2) Top ﬁxture bases

Weather seals & nails

(as required)

F.A. ﬂag angles RH/LH (as required)

Vertical tracks RH/LH (as required)

Horizontal tracks RH/LH (as required)

(If included)

(2) Top ﬁxture slides

(as required)

Drawbar operator

bracket (if included)

Bottom corner brackets

RH/LH (as required)

WARNINGWARNING

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.

Bottom corner brackets

RH/LH (as required)

Track rollers (as required)

Graduated hinges

(as required)

Strut (U-shaped)

(if included)

Pull down rope

(if included)

End bearing bracket RH/LH (as required)

Torsion

springs RH/LH

Inside lift handles

Center bracket (as required)

Pull handles

Counterbalance lift cables

Lift handles

Cable drums RH/LH

Center bracket

bushing (as required)

Keys

(as required)

# Of Sections Door Height Bottom

7’ 0” 20.8” 20.8” 20.8” N/A 20.8”

5 9’ 0” 20.8” 20.8” 20.8” 20.8” 24”

7’ 6” 24” 20.8” 20.8” N/A 24”

8’ 0” 24” 24” 24” N/A 24”

Lock (sec-

ond)

Int I (third)

Int II

(fourth)

Top

When installing your door you must use sections of the appropriate height in the right stacking order. What sections heights you need to use in what order depends on the height of your door.

Unless your door is six sections in height, you will not receive an Intermediate III section. The BOTTOM SECTION can be identiﬁed by the factory attached bottom astragal and by the

bottom bracket warning labels on each end stile. The INTERMEDIATE I SECTION may have a warning label attached to either right or left

hand end stile of the section. This section is always the 3rd section from the bottom of the door.

Warning labels

Center coupler

assembly (as required)

1/4”- 20 Flanged

hex nuts (as required)

1/4”-20 x 9/16”

Track bolts (as required)

(2) 3/8”-16 x 3/4”

Truss head bolts

(2) Roller spacers

(as required)

Stud plate

(as required)

5/16”- 18 Flanged

hex nuts (as required)

5/16”-18 x 1/2”

Carriage bolts (as required)

3/8” Washer (as required)

1/4”-20 x 2-1/2” Carriage bolts (as required)

5/16” x 1 5/8” Hex head lag screws

Door Section Identiﬁcation

(2) 3/8”- 16 Hex nuts(2) 5/16”-18 Hex nuts

1/4”-20 x 7/8” Self

drilling screws (as required)

1/4”-14 x 5/8”

Tamper resistant Self

drilling screws (as required)

1/4”-20 x 11/16” Self

drilling screws (as required)

Backer plates (as required)

(as required)

3/8”-16 x 1-1/2” Hex bolts

5/16”-18 x 3-1/2” Hex bolts

Intermediate I section

Section

height

Bottom corner bracket warning labels

Bottom weather seal

Bottom section

Section side view

Removing an Existing Door

IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.

WARNINGWARNING

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.

For detailed information see supplemental instructions “Removing an Existing Door/ Preparing the Opening”. These instructions are not supplied with the door, but 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.

Preparing the Opening

IMPORTANT: IF YOU JUST REMOVED YOUR EXISTING DOOR OR YOU ARE INSTALLING A NEW DOOR, COMPLETE ALL STEPS IN PREPARING THE OPENING.

To ensure secure mounting of track brackets, side and center brackets, or steel angles to new or retro-ﬁt construction, it is recommended to follow the procedures outlined in DASMA technical data sheets #156, #161 and #164 at www.dasma.com.

The inside perimeter of your garage door opening should be framed with wood jamb and header material. The jambs and header must be securely fastened to sound framing members. It is recommended that 2” x 6” lumber be used. The jambs must be plumb and the header level. The jambs should extend a minimum of 12” (305 mm) above the top of the opening for Torsion counterbalance systems. For low headroom applications, the jambs should extend to the ceiling height. Minimum side clearance required, from the opening to the wall, is 3-1/2” (89 mm).

IMPORTANT: CLOSELY INSPECT JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD FOUND NOT TO BE SOUND, MUST BE REPLACED.

For Torsion counterbalance systems, a suitable mounting surface (2” x 6”) must be ﬁrmly attached to the wall, above the header at the center of the opening.

NOTE: Drill a 3/16” pilot hole in the mounting surface to avoid splitting the lumber. Do not attach the mounting surface with nails.

WEATHERSTRIPS (MAY NOT BE INCLUDED):

Depending on the size of your door, you may have to cut or trim the weatherstrips (if necessary) to properly ﬁt into the header and jambs.

NOTE: If nailing product at 40°F or below, pre-drilling is required. NOTE: Allow the weatherstrips to return to room temperature prior to nailing to jambs. NOTE: Do not permanently attach weatherstrips to the header and jambs at this time.

For Quick Install track: For the header, align the weatherstrip with the inside edge of the header 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 ﬂush with the inside edge of the jamb. 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.

For Fully Adjustable track: 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.

Headroom requirement: Headroom is deﬁned as the space needed above the top of the door for tracks, springs, etc. to allow the door to open properly. If the door is to be motor operated, 2-1/2” (64 mm) of additional headroom is required.

NOTE: 6” low headroom conversion kit is available for 12” radius only. Contact your local Wayne-Dalton dealer.

Backroom requirement: Backroom is deﬁned as the distance needed from the opening back into the garage to allow the door to open fully.

BACKROOM REQUIREMENTS

Door Height Track Manual Lift Motor Operated

6’0” to 7’0” 12”, 15” Radius 102” (2591 mm) 125” (3175 mm)

7’1” to 8’0” 12”, 15” Radius 114” (2896 mm) 137” (3480 mm)

8’1” to 9’0” 12”, 15” Radius 126” (3200 mm) 168” (4267 mm)

HEADROOM REQUIREMENTS

Track Type Space Needed

12” Radius 13-1/2” (343 mm)

15” Radius 14 1/2” (368 mm)

Suitable mounting surface 2”x 6” lumber minimum

Header board 2”x 6” lumber preferred

Min. Side room Clearance is 3 1/2”

Plumb jambs

Level header

Weatherstrips

Finished

Door width

Jambs

Headroom

Finished

Door

Height

Min. Side room Clearance is 3 1/2”

Nail

Jamb

Quick Install track

Jamb

Fully Adjustable track

Backroom

1/8” to 1/4”

Weatherstrips

PARTS BREAKDOWN

NOTE: The illustrations shown on this page are general representations of the door parts. Each speciﬁc door models may have unique variations.

J11.

J9.

J11.

J3.

J5.

J3.

A2.

A1.

J2.

D1.

B2.

B1.

I3.

I4.

C1.

I2.

C1.

J8.

J9.

J6.

J7.

J1.

F3.

F1.

D2.

C2.

L1.

J13.

J6.

F2.

J10.

J1.

E1.

E2.

E3.

J1.

A. FLAG ANGLES (AS REQUIRED):

A1. Quick Install (Q.I.) Flag Angles A2. Fully Adjustable (F.A.) Flag Angles

B. JAMB BRACKETS (AS REQUIRED):

B1. Quick Install (Q.I.) Jamb Brackets B2. Fully Adjustable (F.A.) Jamb Brackets

C. TRACK ROLLERS:

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

D. GRADUATED END HINGES:

D1. Double Graduated End Hinges (D.E.H.), Anti-Pinch D2. Double Graduated End Hinges (D.E.H.), Industry Standard

E. STACKED SECTIONS:

E1. Top Section E2. Intermediate(s) Section E3. Lock Section E4. Bottom Section

F. TOP FIXTURES (AS REQUIRED):

F1. Top Fixture Assemblies F2. Top Fixture Bases - (L-Shaped) F3. Top Fixture Slides

G. STRUT(S) (AS REQUIRED):

G1. Strut (U-shaped)

H. DRAWBAR OPERATOR BRACKET (FOR TROLLEY OPERATED DOORS):

J11.

J2.

J5.

F2.

E4.

I1.

J4.

B1.

B2.

A1.

A2.

I1.

H1.

G1.

H2.

Top of vertical track

3rd hole set

B1. (Quick

Install

2nd hole set

I4.

I3.

1st hole set

Feature)

Top

hole

Middle

hole

Bottom

hole

K1.

Top of vertical track

3rd hole set

2nd hole set

1st hole set

B2. (Fully

Adjustable

Feature)

Lower hole of hole/ slot pattern

J4.

C1.

F1.

F3.

I2.

L1.

H1. Top Half Drawbar Operator Bracket H2. Bottom Half Drawbar Operator Bracket

I. TRACKS (AS REQUIRED):

I1. Left Hand and Right Hand Horizontal Track Assembly I2. Left Hand and Right Hand Vertical Tracks I3. Left Hand and Right Hand Riveted Vertical Track Assembly I4. Left Hand and Right Hand Angle Mount Vertical Track Assembly

J. TORSION SPRING ASSEMBLY (AS REQUIRED):

J1. Left Hand and Right Hand Torsion Springs (As Required) J2. Counterbalance Lift Cables J3. Left Hand End Bearing Bracket (As Required) J4. Right Hand End Bearing Bracket (As Required) J5. Left Hand and Right Hand Cable Drums J6. Center Bracket (As Required) J7. Center Bracket Bushing (As Required) J8. Center Bearing Bracket (As Required) J9. Torsion Shaft / Torsion Keyed Shaft (As Required) J10. Torsion Keyed Shafts (As Required) J11. Keys (As Required) J12. Center Coupler Assembly (As Required)

K. REAR BACK HANGS:

K1. Left Hand and Right Hand Rear Back Hang Assemblies

L. BOTTOM CORNER BRACKETS (AS REQUIRED):

L1. Left Hand and Right Hand Bottom Corner Brackets

INSTALLATION

Quick Install tabs

Horizontal track angle

Before installing your door, be certain that you have read and followed all of the instructions 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.

Quick Install Flag Angles

NOTE: If you have Fully Adjustable Flag Angles, Riveted Track or Angle Mount Track, skip this step.

NOTE: Flag angles are right and left handed. Place the lower Quick Install tab of the left hand ﬂag angle in the Quick Install feature of the

left hand vertical track. Give the ﬂag angle 1/4 turn to lock in place. Repeat for other side.

Tools Required: None

Flag angle

Vertical track

Lower Quick Install tab

Quick Install feature

1/4 Turn

Fully Adjustable Flag Angles

NOTE: If you have Quick Install ﬂag angles, Riveted Track or Angle Mount Track, skip this step.

NOTE: Flag angles are right and left handed. If you have Quick Install vertical tracks, hand tighten the left hand ﬂag angle to the left hand

vertical track using (1) stud plate and (2) 1/4” - 20 ﬂange hex nuts. Repeat for the other side. 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. Flange nuts will be secured after ﬂag angle spacing is completed in step, Top Section.

Flag angle

1/4”-20 Flange hex nuts

Quick Install vertical track

Tools Required: None

Stud plate

Flag angle

1/4”-20 Flange hex nuts

Fully Adjustable vertical track

1/4”- 20 x 9/16” Track bolts

Alignment hole

Quick

Install tabs

Horizontal

Horizontal track

angle

track

Key slots

Horizontal

Quick

Install tabs

track

Quick Install tabs in place

Horizontal track

angle

Quick Install tabs

in place

Quick Install Jamb Brackets

TRACK

LENGTH

76” (1930

mm)

82” (2083

mm)

88” (2235

mm)

1st hole set

Q.I. tab

Q.I. jamb

bracket

Tools Required: None

JAMB BRACKET SCHEDULE

1ST SET 2ND SET 3RD SET

9 M 10 B NA

9 T 10 M 11 M

B= BOTTOM HOLE, M= MIDDLE HOLE, T= TOP HOLE

Vertical track

2nd hole set 3rd hole set

Jamb bracket in place

Mounting ﬂange

Top of track

NOTE: If you have Fully Adjustable Flag Angles, Riveted Track or Angle Mount Track, skip this step.

Measure the length of the vertical tracks. Using the jamb bracket schedule, determine the placement of the jamb brackets for your door height and track length. To install the jamb brackets, align the Quick Install tab on the Quick Install jamb bracket with the Quick Install feature in the vertical track and turn the bracket perpendicular to the track so the mounting ﬂange is toward the back (ﬂat) leg of the track. Repeat for other side.

DOOR HEIGHT

7’0”

7’6”

8’0”

Bottom hole Middle hole Top hole

Horizontal Track Angles

NOTE: For larger doors, a full length horizontal track angle may not already be spot welded to the horizontal track. If the horizontal track angle is not welded, the horizontal track angle will be installed, as shown.

Position the left hand horizontal track angle, as shown. Place the Quick Install tabs of the horizontal track angle in the key slot of the left hand horizontal track. Using a hammer, tap the horizontal track angle towards the curved end of the track until the alignment hole in the track and angle are aligned. Repeat for other side. Set tracks aside.

Tools Required: Hammer

Fully Adjustable Jamb Brackets

NOTE: If you have Quick Install jamb brackets, Riveted Track or Angle Mount Track, skip this step.

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

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

If a top jamb bracket was included, secure it to vertical track using the lower hole of the hole/

Tools Required: None

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 for other side.

1st hole set

Vertical track

2nd hole set 3rd hole set

Top of track

End cap

Counterbalance

lift cable

(4) 1/4”-20 x 11/16” Self drilling screws

Lower hole of hole/ slot pattern

1/4”- 20 Flange hex nut

F.A. jamb

bracket

1/4”- 20 x 9/16” Track bolt

Jamb bracket in place

Bottom Corner brackets

NOTE: Refer to door section identiﬁcation, located in the pre-installation section of this manual. Refer to Package Contents / Parts Breakdown, to determine which bottom corner brackets you received.

NOTE: Bottom corner brackets are right and left hand.

Tools Required: Power Drill, 7/16” Socket driver, Tape Measure

WARNINGWARNING

FAILURE TO ENSURE TIGHT FIT OF CABLE LOOP OVER MILFORD PIN COULD RESULT IN COUNTERBALANCE LIFT CABLE COMING OFF THE PIN, ALLOWING THE DOOR TO FALL, POSSIBLY RESULTING IN SEVERE OR FATAL INJURY.

Starting on the left hand side, attach the left hand bottom bracket to the left corner of the bottom section, making sure it is seated to the edges of the end cap with 1/4” - 20 x 11/16” self drilling screws and (1) 1/4” - 14 x 5/8” tamper resistant self drilling screw, as shown. Next, uncoil the counterbalance lift cables and place the cable loop on the left hand milford pin of the bottom corner bracket. Insert a short stem track roller with roller spacer into the bottom corner bracket. Repeat for other side.

NOTE: All doors are provided with the tamper resistant fastener for the bottom corner brackets. However, the professional installer is most likely to have the proper tool to install this fastener. If the homeowner does not have the proper tool to install the tamper resistant fastener, use a regular 1/4” - 20 x 11/16” self drilling screw in its place.

NOTE: Check to ensure cable loops ﬁts tightly over the milford pins. 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.

Counterbalance

Short stem track roller

Counterbalance

lift cable

End cap

cable loop

Milford pin

Roller spacer

Bottom corner bracket

Bottom weather

seal

Bottom section

(2) 1/4”-20 x 11/16” Self drilling screws

1/4”-14 x 5/8” Tamper resistant self drilling screw

Bottom section

Counterbalance

Short stem track roller

cable loop

Milford pin

Roller spacer

Bottom corner bracket

Bottom weather

seal

1/4”-14 x 5/8” Tamper resistant self drilling screw

Graduated Hinge / Strut Attachment

NOTE: Refer to door section identiﬁcation, located in the pre-installation section of this manual to determine what size sections you need to use as your bottom section, lock (second) section, intermediate I (third) section, intermediate II (fourth section on a ﬁve section door) and top section.

Measure your sections to make sure they are the correct size as indicated on the chart. Using sawhorses lay sections together on a ﬂat smooth surface.

NOTE: Hinges can be identiﬁed by the number stamped onto their lower hinge leaf. NOTE: The #1 graduated end hinges serves as end hinges on the bottom section. The #1

graduated end hinges also serves as center hinges on all sections, except for the top section.

NOTE: The #2 graduated end hinges serves as end hinges on the Lock section. NOTE: The #3 graduated end hinges serves as end hinges on the Intermediate I section. NOTE: The #4 graduated end hinges serves as end hinges on the Intermediate II section. NOTE: Depending on your door, single end hinges and short shaft rollers MAY be required on

each end of the bottom, lock and intermediate(s) sections. NOTE: Depending on your door, double end hinges and long shaft rollers MAY be required on

each end of the bottom, lock and intermediate(s) sections. Starting on the left hand side of the bottom section, position the lower hinge leaf of the #1

graduated end hinge over the holes, located at the top of the end caps. Next, align the lower hinge leaf of the #1 center hinges with the dimples at each center location(s), located at the top of the bottom section.

NOTE: Depending on the size of your door, one or more sections may require a strut. Referring to the strutting schedule, determine how many struts your door needs and on what sections they are needed to be installed.

NOTE: Sections noted with “N/A” in the strutting schedule, do not require a strut. NOTE: All strut(s) are placed at the top of the section.

Starting with the bottom section, place the appropriate strut against top of section. Center the strut and align it horizontally with bottom section.

FOR ATTACHING GRADUATED END HINGES ONLY TO SECTION SURFACE: Attach graduated end hinges to the section using (2) 1/4” - 20 x 11/16” self drilling screws at each #1 graduated end hinge and at each #1 center stile locations, as shown.

FOR ATTACHING GRADUATED END HINGES AND STRUT TO SECTION SURFACE: Attach graduated end hinges, strut and strut clips to the section using (2) 1/4” - 20 x 7/8” self drilling screws at each #1 graduated end hinge and at each #1 center stile locations, as shown.

Repeat the same process for the graduated hinge attachment / strutting using the appropriate graduated end hinges / strutting for all remaining sections. Place the appropriate short or long stem track roller into each graduated end hinges.

IMPORTANT: When placing short stem track rollers into the #2 graduated end hinges and higher, the short stem track roller goes into hinge tube furthest away from section.

Repeat the same process for the graduated hinge attachment / strutting using the appropriate graduated end hinges / strutting for all remaining sections.

Tools Required: Power Drill, 7/16” Socket driver, Tape Measure

Door Height # Of Sections

7’0” - 8’0” 4

9’0” 5

Short stem track roller

#1 Graduated end hinge

Lower hinge leaf

(2) 1/4”-20 x 11/16” Self drilling screw locations

Endcaps

Long stem track roller

#1 Graduated end hinges

Lower hinge leafs

(2) 1/4”-20 x 11/16” Self drilling screw locations

Strutting Schedule

Solid Or

Glazed

Solid Or

8’0” - 9’0” 10’0”

Solid N/A

2” Strut, Top

Glazed

of top section

2” Strut, Top

Glazed

of top section

#1 Center

hinge(s)

#1 Center

hinge(s)

Door Width

12’0” -

14’0”

2” Strut, Top

of top section

2” Strut, Top

of top section

2” Strut, Top

of top section

#2 Graduated end hinge

(roller inserted into tube

2” Struts, Top

of Top, Lock

and Bottom

sections

2” Struts, Top

of Top, Lock

and Bottom

sections

2” Struts, Top

of Top, Lock

and Bottom

sections

furthest from section)

Short stem track roller

#2 Graduated

end hinges (roller

inserted into

tubes furthest

from section)

15’0” -

18’0”

2” Struts,

Top of Top,

Int., Lock

and Bottom

sections

2” Struts,

Top of Top,

Int., Lock

and Bottom

sections

3” Strut, Top

of top section

2” Struts, Top

of Int., Lock and Bottom

sections

Inside Lift Handles

NOTE: Refer to door section identiﬁcation, located in the pre-installation section of this manual to determine what size sections you need to use as your bottom section and lock (second) section.

Starting on the left hand side and on the inside portion of bottom section, position the inside lift handle on top of the end cap. Keeping the inside lift handle vertically aligned and center on the end cap, secure the lift handle to end cap using (2) 1/4” - 20 x 11/16” self-drilling screws, as shown.

Next, install the second inside lift handle in the same manner as the ﬁrst on the lock section (second section).

IMPORTANT: THE INSIDE LIFT HANDLES NEED TO BE VERTICALLY ALIGNED WITH EACH OTHER.

(2) 1/4”-20 x 11/16”

Self drilling screws

Tools Required: Power Drill, 7/16” Socket driver, Tape Measure

Lift handle

End cap

Bottom section

Lift handle

installed

End cap

Bottom and or

Lock section

Pull Handle(s)

NOTE: Refer to door section identiﬁcation, located in the pre-installation section of this manual to determine what size sections you need to use as your bottom section.

On the outside of bottom section, locate the bottom horizontal rail. Using the illustrations below, position and center the pull handle on the bottom section, as shown.

IMPORTANT: THE PULL HANDLE(S) NEEDS TO BE HORIZONTALLY ALIGNED WITH THE BOTTOM SECTION RAIL.

Using the holes in the pull handle as a template, mark the hole locations onto the section surface. Drill 1/4” diameter holes straight through the entire section at each marked location.

CAUTION: BE CAREFUL TO KEEP DRILL STRAIGHT WHEN PRE-DRILLING. SECTION DAMAGE CAN RESULT FROM FAILURE TO KEEPING THE DRILL STRAIGHT.

Assemble the pull handle to the bottom section using (2) 1/4” - 20 x 2-1/2” carriage bolts, (1) backer plate and (2) 1/4” - 20 ﬂange hex nuts. If applicable, repeat the same process for other pull handle.

NOTE: Prior to securing the pull handles to the section, caulk the top ﬂat edges of the pull handle, but leave the bottom un-caulked.

NOTE: Ensure the 1/4” - 20 x 2-1/2” carriage bolts is going through the pull handle ﬁrst and the backer plate and the 1/4” - 20 ﬂange hex nuts is on the inside surface of bottom section.

NOTE: You may need to cut off the protruding ends of the carriage bolts after securing the pull handle(s) to the section. If the carriage bolts are cut off, use a ﬁle to smooth rough edges.

Tools Required: Power drill, 1/4” Drill bit, 7/16” Wrench, Tape measure

Endcaps

Strut

(2) 1/4”-20 x 7/8” Self drilling screws

Strut installation at top of top section

Graduated end hinge

(2) 1/4”-20 x 7/8”

Self drilling screws

Strut clip

Strut installation at top of other sections

Strut

Long stem track roller

Center hinge

Strut clip

Strut

(2) 1/4”-20 x 7/8” Self drilling screws

CAUTION: FAILURE TO SMOOTH CARRIAGE BOLT ENDS MAY RESULT IN POSSIBLE INJURY.

Typical placement of pull

handle referenced on

single wide doors

Lift handles

Pull handle

Bottom section

Typical placement of pull handles referenced on double wide doors

Lift handles

Bottom section

Pull handle Pull handle

20” Minimum to 30” Maximum

Caulk

Lock

section

20” Minimum to

30” Maximum

Lock

section

Center rail

Bottom section

Bottom rail

Pull handle

(2) 1/4” x 2-1/2”

Carriage bolts

Backer

plate

(2) 1/4”- 20

Flange hex nuts

Lift Handle(s)

NOTE: Refer to door section identiﬁcation, located in the pre-installation section of this manual to determine what size sections you need to use as your lock (second) section.

On the outside of the lock (second) section, locate the vertical center stile. Using the illustrations below, position and center the lift handle on the lock (second) section, as shown.

IMPORTANT: THE LIFT HANDLE(S) NEEDS TO BE VERTICALLY ALIGNED WITH THE CENTER STILE.

IMPORTANT: THE DISTANCE BETWEEN THE LIFT HANDLE(S) AND THE MIDDLE OF THE PULL HANDLE(S) MUST BE 20” MINIMUM TO 30” MAXIMUM. IF NECESSARY REPOSITION THE UPPER LIFT HANDLE(S) TO STAY WITHIN THE REQUIRED DIMENSION.

Using the holes in the lift handle as a template, mark the hole locations onto the section surface. Drill 1/4” diameter holes straight through the entire section at each marked location.

CAUTION: BE CAREFUL TO KEEP DRILL STRAIGHT WHEN PRE-DRILLING. SECTION DAMAGE CAN RESULT FROM FAILURE TO KEEPING THE DRILL STRAIGHT.

Assemble the lift handle to the lock (second) section using (2) 1/4” - 20 x 2-1/2” carriage bolts, (1) backer plate and (2) 1/4” - 20 ﬂange hex nuts. If applicable, repeat the same process for other lift handle.

NOTE: Prior to securing the lift handles to the section, caulk the ﬂat edges of the lift handle. NOTE: Ensure the 1/4” - 20 x 2-1/2” carriage bolts is going through the lift handle ﬁrst and

the backer plate and the 1/4” - 20 ﬂange hex nuts is on the inside surface of lock (second) section.

IMPORTANT: THE LIFT HANDLE(S) AND THE PULL HANDLE(S) NEED TO BE VERTICALLY ALIGNED.

Tools Required: Power drill, 1/4” Drill bit, 7/16” Wrench, Tape measure

Center stileCenter stile

Vertical

line

3-7/8” 3-7/8”

Horizontal

Lift

line

Lift

handle

Center line Center line

Lock section Lock section

(2) 1/4” x 2-1/2”

Carriage bolts

Center

stile

handle

Vertical

line

(4) 1/4” x 2-1/2”

Carriage bolts

Lift

handle

Center stile

Horizontal

line

Backer

plate

(2) 1/4”- 20

Flange hex nuts

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.

Tools Required: Level, Wooden shims (if necessary)

Weather seal

WARNINGWARNING

TO AVOID POSSIBLE INJURY, LIFT HANDLES THAT ARE INSTALLED WITHIN 4 INCHES (102MM) OF A SECTION INTERFACE SHALL PROMOTE VERTICAL ORIENTATION OF THE HAND.

NOTE: You may need to cut off the protruding ends of the carriage bolts after securing the lift

handle(s) to the section. If the carriage bolts are cut off, use a ﬁle to smooth rough edges.

CAUTION: FAILURE TO SMOOTH CARRIAGE BOLT ENDS MAY RESULT IN POSSIBLE INJURY.

Typical placement of lift

handles referenced on

single wide doors

Lift handles

Pull handle

Bottom section

Typical placement of lift handles referenced on double wide doors

Lift handles

Bottom section

Pull handle Pull handle

20” Minimum to 30” Maximum

Caulk

Lock

section

20” Minimum to

30” Maximum

Lock

section

Level

Bottom section

Wooden shims

(If necessary)

Vertical Tracks

NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable Flag Angles, Riveted Vertical Track Assemblies or you may have Angle Mount Vertical Track Assemblies. Refer to Package Contents / Parts Breakdown, 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 TRACK ASSEMBLIES MUST BE LEVEL FROM SIDE TO SIDE. IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT, THE VERTICAL TRACK ASSEMBLY ON THE SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM.

Position the left hand vertical track assembly over the track rollers of the bottom 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.

FOR QUICK INSTALL FLAG ANGLES OR FULLY ADJUSTABLE FLAG ANGLES: Loosely fasten jamb brackets and ﬂag angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spacing, between the bottom section and vertical track. Hang counterbalance lift cable over ﬂag angle. Repeat same process for other side.

Tools Required: Power Drill, 3/16” Drill bit, 7/16” Socket driver, Tape measure, Level, Step ladder

Flag angle

Lock section

Alignment sticker

P/N # 327985 NEW 9-04-06P/N # 327985 NEW 9-04-06

Vertical

track

assembly

Jamb bracket

Bottom section

5/16” x 1-5/8” Lag screws

Track rollers

Floor

12R FA

15R FA 15R QI12R QI

Flag angle lag screw locations

3/8” to 5/8”

Spacing

Bottom section

Vertical track

Track roller

FOR RIVETED VERTICAL TRACK ASSEMBLY: Loosely fasten jamb brackets and ﬂag angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spacing as shown between the bottom section and vertical track. Hang counterbalance lift cable over ﬂag angle. Repeat same process for other side.

FOR ANGLE MOUNT VERTICAL TRACK ASSEMBLY: Loosely fasten the slots in the wall angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screws, securing the bottom slot in the wall angle, maintain 3/8” to 5/8” spacing as shown between the bottom section and vertical track. Hang counterbalance lift cable over angle mount. Repeat same process for other side.

Wall

angle

Slot

Angle mount vertical track

assembly

5/16” x 1-5/8”

Lag screws

Vertical

track

Bottom section

Vertical

track

Jamb

bracket

Riveted

vertical track

assembly

Flag

angle

5/16” x 1-5/8”

Lag screws

Bottom section

Vertical track Floor

3/8” to 5/8”

Spacing

Flag angle lag screw

locations

Stacking Sections

NOTE: Refer to door section identiﬁcation. NOTE: Make sure hinges are ﬂipped down, when stacking another section on top. NOTE: When stacking sections on top of another and prior to securing the hinges to the sec-

tions, ensure the exterior face of the sections are aligned with each other by visually checking from the outside of the garage. The alignment stickers on the door interior are only meant as a rough alignment starting point.

With assistance, lift second section and guide rollers into the vertical tracks. Lower section until it is seated against bottom section. Keeping sections aligned, ﬂip hinges up and fasten center hinge(s) ﬁrst, then graduated end hinges, using 1/4” - 20 x 11/16” self drilling screws, as shown. Repeat for other sections, except top section.

IMPORTANT: PUSH & HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE SECURING WITH 1/4” - 20 X 11/16” SELF DRILLING SCREWS. THERE SHOULD BE NO GAP BETWEEN THE HINGE LEAFS AND THE SECTIONS.

NOTE: Install lock at this time (sold separately). See optional installation step, Side Lock.

Tools Required: Power Drill, 7/16” Socket driver

Vertical tracks

Left end hinge

Single end

hinges

Alignment sticker

1/4”-20 x 11/16” Self drilling screw locations

Upper

hinge

leafs

Double end

hinges

Center hinge(s)

Double end

hinges

Right

end hinge

Single end

hinges

Top Fixtures

NOTE: Depending on your door, you may have Top Fixture Bases and Top Fixture Slides or you may have Top Fixture Assemblies. Refer to Package Contents / Parts Breakdown, to determine which Top Fixtures you have.

IF YOU HAVE TOP FIXTURE ASSEMBLIES:

Align the top ﬁxture base 3” down from the top section or below strut and even with the edge of the top section. The slotted half of the top ﬁxture base should be facing upwards. Fasten to section through end cap using (4) 1/4” - 20 x 11/16” self drilling screws. Insert short stem track roller into top ﬁxture slide. Repeat for other side.

NOTE: If needed, ensure the top ﬁxture slides are able to slide back and forth along the top ﬁxture base. If needed, loosen the (2) 1/4” - 20 ﬂange hex nuts.

The ﬁxture will be tightened and adjusted later, in step, Adjusting Top Fixtures.

Top section

3”

Top ﬁxture

slide

Top ﬁxture

base

IF YOU HAVE TOP FIXTURE BASES AND TOP FIXTURE SLIDES:

Starting on the left hand side of the top section. align the top ﬁxture base on top of corner of the top section and even with the edge of the section. Fasten to section through end cap using (4) 1/4” - 20 x 11/16” self drilling screws. Loosely secure the top ﬁxture slide to the ﬁxture base using (1) 5/16” - 18 x 3/4” carriage bolt and (1) 5/16” - 18 hex nut.

Insert short stem track roller into top ﬁxture slide. Repeat for other side. The ﬁxture will be tightened and adjusted later, in step, Adjusting Top Fixtures.

Tools Required: Power Drill, 7/16” Socket driver

(1) 1/4”-20 x 11/16”

Self drilling screw

(2) 1/4”-20 Flange

(4) 1/4”-20 x 11/16”

Self drilling screws

End

Short stem track roller

cap

hex nuts

Top section

End cap

Strut

section

(4) 1/4”-20 x 11/16”

Self drilling screws

Top

Short stem

Quick Install

track roller

(4) 1/4”-20 x 11/16”

Self drilling screws

Top ﬁxture

base

5/16”-18

Hex nut

Top Section

Tools Required: Hammer, Step ladder, Tape measure

End cap

Top section

5/16”-18 x 3/4”

Carriage bolt

Top ﬁxture

slide

existing operator. Slide the top half of the operator bracket under the strut, keeping the operator bracket

aligned with the center line. Remove the struts screws if necessary and attach to the top section (through strut if necessary) using (3) 1/4” - 20 x 7/8” self drilling screws.

NOTE: If your door lacks a strut on the top section, ignore the previous paragraph. Attach the bottom half of the operator bracket to the section surface (center hinge if neces-

sary) using (2) 1/4” - 20 x 11/16” self drilling screws. NOTE: When attaching operator bracket to top section with strut, apply additional pressure to

thread into the strut.

(3) 1/4”- 20 x 7/8” Self-drilling screws

(4) 5/16”- 18 x 1/2” Carriage bolts and (4) 5/16”- 18 ﬂange

Upper half

hex nuts

Place the top section in the opening. Temporarily secure the top section by driving a nail in the header near the center of the door and bending it over the top section. Now, ﬂip up the hinge leaves, hold tight against section, and fasten center hinges ﬁrst and end hinges last (refer to step, Stacking Sections). Vertical track alignment is critical. Position ﬂag angle or 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. Flag angles or wall angles must be parallel to the door sections. Repeat for other side.

IMPORTANT: THE DIMENSION BETWEEN THE FLAG ANGLES OR WALL ANGLES MUST BE DOOR WIDTH PLUS 3-3/8” (86MM) TO 3-1/2” (89 MM) FOR SMOOTH, SAFE DOOR OPERATION.

FOR QUICK INSTALL TRACK: Complete the vertical track installation by securing the jamb bracket(s) and tightening the other lag screws. Repeat for other side.

FOR FULLY ADJUSTABLE TRACK OR RIVETED TRACK: Complete the vertical track installation by securing the jamb bracket(s) 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.

FOR ANGLE MOUNT TRACK: Complete the vertical track installation by securing the jamb bracket(s) and or 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 vertical track, as shown. Repeat for other side.

Door width + 3-3/8” to 3-1/2”

Top of ﬂag angle or Top of wallangle assembly

Nail

Top section

1-11/16” to 1-3/4”

Flag angle

Top section

Flag angle or wallangle assembly

Vertical track against track rollers

Strut

Lower half

Center hinge

Drawbar

operator bracket

(2) 1/4”- 20 x 11/16” Self-drilling screws

Horizontal Tracks

Tools Required: Ratchet wrench, 9/16” Socket, 9/16” Wrench, level, Step ladder

WARNINGWARNING

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 QUICK INSTALL FLAG ANGLES: To install horizontal track, place the curved

end over the top track roller of the top section. Align key slot of the horizontal track with the Quick Install tab of the ﬂag angle. Push curved portion of horizontal track down to lock in place.

Flag angle

3/8”-16

Flag angle Horizontal

track Quick

Install tab

Quick Install tab in place

Tracks ﬂush

Key slot

Hex nut

Horizontal track angle

Operator Bracket

IMPORTANT: WHEN CONNECTING A TROLLEY TYPE GARAGE DOOR OPENER TO THIS DOOR, A WAYNE-DALTON OPERATOR/ TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR IF ONE HAS BEEN PROVIDED, ALONG WITH ANY U-BARS PROVIDED WITH THE DOOR (IF A WAYNE-DALTON OPERATOR/ TROLLEY BRACKET WAS NOT PROVIDED WITH YOUR DOOR, THAN USE THE ONE PROVIDED BY YOUR OPERATOR MANUFACTURER). THE INSTALLATION OF THE OPERATOR MUST BE ACCORDING TO MANUFACTURER’S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED PROPERLY.

Place the bottom half inside the top half and ﬂush against the inside surface of the top section. Adjust both the top and bottom halves out as far apart as possible on the section surface. Secure the bottom half and the top halves together using (4) 5/16” - 18 x 1/2” carriage bolts and (4) 5/16” - 18 ﬂange hex nuts.

NOTE: Install the 5/16” - 18 x 1/2” carriage bolts and the 5/16” - 18 ﬂange hex nuts as far apart as possible, prior to securing both top and bottom halves together.

Now, locate the center of the top section and align the center of the holes in the adjustable operator bracket assembly with the top section center line. Align the adjustable operator bracket assembly vertically.

NOTE: For retro ﬁt applications, the adjustable operator bracket must be aligned with an

Tools Required: Level, Power drill, 7/16” Socket driver, Tape measure

3/8”-16 x 3/4” Truss head bolt

IF YOU HAVE FULLY ADJUSTABLE FLAG ANGLES: To install horizontal track, place the curved end over the top track roller of the top section. Align the bottom of the horizontal track with the top of the vertical track. If you have Quick Install horizontal track, tighten the horizontal track to the ﬂag angle with a stud plate and (2) 1/4” - 20 ﬂange hex nuts. If you have Universal horizontal track, tighten the horizontal track to the ﬂag angle with (2) 1/4” - 20 x 9/16” track bolts and (2) 1/4” - 20 ﬂange hex nuts.

horizontal

track

1/4”-20 Flange hex nuts

Flag angle upper slot

IF YOU HAVE RIVETED TRACK ASSEMBLIES OR ANGLE MOUNT VERTICAL TRACK ASSEMBLIES: To install horizontal track, place the curved end over the top roller of the top

Fully Adjustable horizontal track

1/4”-20 Flange hex nuts

Flag angle upper slot

Stud plate

Horizontal track angle

1/4”-20 x 9/16” Track bolts

3/8”-16 Hex nut

3/8”-16 x 3/4” Truss head bolt

section. Align the bottom of the horizontal track with the top of the vertical track. Tighten the horizontal track to the Flag Angle / Angle Mount with (2) 1/4” - 20 x 9/16” track bolts and (2) 1/4” - 20 ﬂange hex nuts.

Horizontal

track

1/4”-20

Flange hex

nuts

Flag angle

Horizontal track

1/4”-20 Flange hex nuts

Rivited ﬂag angle upper slot

1/4”-20 x 9/16” Track bolts

1/4”-20 Flange hex nuts

1/4”-20 x 9/16”

Track bolts

Rivited ﬂag angle

3/8”-16 Hex nut

Horizontal

track

Angle

mount

1/4”-20 x 9/16”

Track bolts

Horizontal

track angle

Horizontal

track

3/8”-16 x 3/4” Truss head bolt

3/8”-16 Hex nut

3/8”-16 x 3/4” Truss head bolt

Horizontal track angle

Angle

mount

Next level the horizontal track assembly and bolt the horizontal track angle to the ﬁrst encountered slot in the ﬂag angle / angle mount using (1) 3/8” - 16 x 3/4” truss head bolt and (1) 3/8” - 16 hex nut. Repeat for other side. 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

Tools Required: 7/16” Wrench, Step ladder

NOTE: Depending on your door’s conﬁguration you may have to break the end bearing brackets apart.

NOTE: End bearing brackets are right and left hand. Attach the left hand end bearing bracket through either the end bearing bracket’s upper or

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

IMPORTANT: THE END BEARING BRACKET’S LOWER SLOTS ARE USED ON DOORS WITH 12” RADIUS TRACK; THE UPPER SLOTS ARE USED ON DOORS WITH 15” RADIUS TRACK.

Secure the top of the end bearing bracket to the jamb using 5/16” x 1-5/8” lag screw(s). Repeat the same process for right hand side.

(2) 3/8”-16 Hex nuts

(2) 3/8”-16

Hex nuts

Left end bracket

(2) 3/8”-16 x 3/4” Truss head bolts

Upper slots Lower slots

Bend back and fourth to

seperate the (2) end

bearing brackets

Left end bracket

(2) 3/8”-16 x 3/4”

Truss head bolts

Upper

slot

Lower slots

(1) 5/16” x 1-5/8” Lag screw

Horizontal track angle

(3) 5/16” x 1-5/8”

Lag screws

Horizontal

track angle

IF YOU HAVE TOP FIXTURE ASSEMBLIES: With horizontal tracks installed, you can now adjust the top ﬁxtures. Vertically align the top section of the door with the lower sections. Once aligned, position the top ﬁxture slide, out against the horizontal track. Maintaining the slide’s position, tighten the (2) 1/4” - 20 ﬂange hex nuts to secure the top ﬁxture slide to the top ﬁxture base. Repeat for other side.

Short stem track

roller

Horizontal track

Top section

(2) 1/4”-20 Flange hex nuts

Top ﬁxture slide

IF YOU HAVE TOP FIXTURE BASES AND TOP FIXTURE SLIDES: With horizontal tracks installed, you can now adjust the top ﬁxtures. Vertically align the top section of the door with the lower sections. Once aligned, position the top ﬁxture slide, out against the horizontal track. Maintaining the top ﬁxture slide position, tighten the (1) 5/16” - 18 nut to secure the slide to the top ﬁxture. Repeat for other side.

Top section

Top

ﬁxture

Horizontal

track

Short stem track roller

slide

5/16”-18

Hex nut

End Bearing Brackets

Tools Required: Step ladder, Power drill, 3/16” Drill bit, Ratchet wrench, 7/16” Socket driver, 9/16” Socket, 9/16” Wrench

Center Bracket

NOTE: Refer to Package Contents / Parts Breakdown, to determine which Center Bracket(s) came with your door.

NOTE: Prior to fastening center bracket(s) into the door jamb, pilot drill using a 3/16” drill bit. 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.

NOTE: If your door came with (4) springs, each of the outer springs mounting surface will need to be a minimum of 3” wide.

NOTE: If needed, measure the diameter of your springs. If you have a one piece shaft with 3-3/4” diameter springs, they do not share center brackets and do not have a coupler assembly.

First, locate the center of the door. Mark a vertical pencil line on the mounting surface above the door, at the center. Measure from the center of the bearing, in one of the end bearing brackets, downwards, to the top the door. Using that measurement, measure that distance upwards from the top of the door to the mounting surface and mark a horizontal pencil line which intersects the vertical pencil line.

Tools Required: Step ladder, Power drill, 7/16” Socket driver, 3/16” Drill bit, 1/4” Torx bit, Level, Tape measure, Pencil

NOTE: Refer to Package Contents / Parts Breakdown, to determine which End Bearing Brackets you have.

NOTE: Prior to fastening end bearing brackets into the door jamb, pilot drill using a 3/16” drill bit.

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

Typicall center bracket

Typicall center of end bearing bracket

Mounting surface

Vertical line

Horizontal line

Equal distance (top of door section to horizontal line)

IF YOUR DOOR DID NOT COME WITH A CENTER COUPLER ASSEMBLY AND USES TORSION SPRINGS LESS THAN 3-3/4” ID: Mark a vertical pencil line on the mounting surface

above the door, at the center. Align the edge of the center bracket with the vertical pencil line and the center of the center bracket with the horizontal pencil line; this is to ensure the torsion shaft is level between the center and end bearing brackets.

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.

Horizontal

line

Mounting surface

(3” Minimum)

(2) 5/16” x 1-5/8”

Lag screws

Center bearing bracket

assembly

Mounting

surface

(3” Minimum)

Vertical

line

Horizontal

line

Center bracket

bushing assembly

(2) 5/16” x 1-5/8”

Lag screws

(1) 5/16” X 2” or (1) 5/16” x 1-5/8” Tamper-resistant lag screw

Vertical

line

IF YOUR DOOR DID COME WITH A CENTER COUPLER ASSEMBLY AND USES 3-3/4” ID TORSION SPRINGS: Mark a vertical pencil line on the mounting surface above the door,

at the center. Split the difference up and position the (2) center bearing brackets apart from each other. Mark two vertical pencil lines, one for each center bearing bracket onto the mounting surface above the door.

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.

Attach each of the center bracket(s) to the mounting surface, using (2) 5/16” x 1-5/8” lag screws and (1) 5/16” x 2” tamper-resistant lag screw.

IMPORTANT: USE A 5/16” X 1-5/8” TAMPER-RESISTANT LAG SCREW INSTEAD OF THE 5/16” X 2” TAMPER-RESISTANT LAG SCREW IF MOUNTING SURFACE IS MOUNTED OVER MASONRY. TAMPER-RESISTANT LAG SCREW MUST BE ATTACHED THROUGH THE BOTTOM HOLE OF THE CENTER BRACKET(S).

Mounting surface

(17” Minimum)

Vertical

line

(2) 5/16” x 1-5/8”

Lag screws

Horizontal

line

Center

door

(1) 5/16” X 2” or (1) 5/16”

x 1-5/8” Tamper-resistant

Torsion Spring Assembly

Tools Required: 3/8” Wrench, 9/16” Wrench, Step Ladder

†

lag screw

Vertical line

(2) 5/16” x 1-5/8”

Lag screws

† (2) Center bearing

brackets spaced 6” to 7”

apart from the center of

the door.

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

IMPORTANT: Identify the torsion springs provided as either right hand wound (red winding cone), which goes on the LEFT HAND SIDE or left hand wound (black winding cone), which goes on the RIGHT HAND SIDE.

IMPORTANT: ON SINGLE SPRING APPLICATIONS, ONLY A LEFT HAND WOUND (BLACK WINDING CONE), WHICH GOES ON THE RIGHT HAND SIDE IS REQUIRED.

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.

IF YOU DON’T HAVE A COUPLER ASSEMBLY:

Facing the inside of the door, lay the torsion shaft / torsion keyed shaft on the ﬂoor. Lay the torsion spring with the black winding cone and the black cable drum at the right end of the torsion shaft / torsion keyed shaft. Lay the torsion spring with the red winding cone and the red cable drum at the left end of the torsion shaft / torsion keyed shaft.

Slide the center bracket bearing / center bracket bushing onto the torsion shaft / torsion keyed shaft followed by the torsion springs and cable drums.

IMPORTANT: THE CENTER BRACKET BEARING / CENTER BRACKET BUSHING, TORSION SPRINGS, AND CABLE DRUMS MUST BE POSITIONED, AS SHOWN.

Right hand

cable drum,

black

Left hand cable drum, red

Torsion shaft

Right hand wound, red winding cone (left hand side)

Center bearing

Left hand wound,

black winding cone

(right hand side)

IMPORTANT: ON SINGLE

SPRING APPLICATIONS,

ONLY A LEFT HAND WOUND

(BLACK WINDING CONE),

WHICH GOES ON THE RIGHT

HAND SIDE IS REQUIRED.

With assistance, pick up the torsion spring assembly and slide one end of the torsion shaft / torsion keyed shaft through one end bearing bracket. Lay the middle of the torsion shaft / torsion keyed shaft into the center bracket. Slide the other end of the torsion shaft / torsion keyed shaft into the other end bearing bracket. Position the torsion shaft / torsion keyed shaft so that equal amounts of the shaft extend from each end bearing bracket.

Left hand end bearing bracket

Torsion shaft

Equal spacing

Center

bracket

bushing

Center bracket

Right hand end bearing bracket

IF YOU HAVE A COUPLER ASSEMBLY:

Disassemble the coupler assembly by removing the (3) 3/8” - 16 x 1-3/4” hex head screws and the (3) 3/8”-16 nylon hex lock nuts from the coupler halves. Loosen the set screws. Set the components aside. Facing the inside of the door, 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. Starting on the left hand side, lay one of the coupler halves, the center bearing, torsion spring with the red winding cone and the red cable drum at the left end of the torsion keyed shaft. Next on the right hand side, lay the other coupler half, center bearing, the torsion spring with the black winding cone, and the black cable drum at the right end of the torsion keyed shaft.

Slide the coupler halves, center bearings onto the torsion keyed shafts followed by the torsion springs and the cable drums, as shown.

IMPORTANT: THE COUPLER HALVES, CENTER BEARINGS, TORSION SPRINGS, CABLE DRUMS MUST BE POSITIONED, AS SHOWN.

Slide the ﬂat edge of the couple half ﬂush with the side edge of the torsion keyed shaft. Insert (1) key into the slot of both the coupler half and the slot in the torsion keyed shaft. Tighten the (2) set screws and the locking nut to secure the coupler half to the torsion keyed shaft, as shown.

NOTE: Tighten the set screws to 14-15 ft. lbs. of torque (once set screws contact the shaft, tighten set screws one full turn). Repeat the same process for the other coupler half.

NOTE: Refer to the Package Contents and or Parts Breakdown to determine if your door came with a coupler assembly.

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

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)

Center bearing

Torsion keyed shaft

Coupler

halves

Right hand wound, red winding cone (left hand side)

Coupler

halves

Right hand wound, red winding cone (left hand side)

Center

bearing

Center

bearing

Torsion

keyed

shaft

Coupler

halves

Center

bearing

Coupler

halves

Black cable drum

(right hand side)

Set screws

and Lock nut

Key

Black cable drum

(right hand side) Torsion keyed shaft

Set screws

and Lock nut

Key

Center

bearing

Left hand wound,

black winding cone

(right hand side)

Key

Coupler halves

assembled

Left hand wound,

black winding cone

(right hand side)

Key

Coupler halves

assembled

With assistance and starting on the left hand side of door, pick up the left hand torsion spring assembly and slide one end of the torsion keyed shaft through the end bearing bracket. Lay the other side of the torsion keyed shaft into the center bracket. Repeat the same process for the right hand torsion spring assembly. Position both torsion keyed shafts so that equal amounts of the shafts extend from each end bearing brackets.

Equal spacing

Equal

spacing

Torsion

keyed

shaft

Right

hand end

bearing bracket

Left hand end

bearing bracket

Left hand end bearing bracket

Torsion keyed shafts

Center bearing

brackets

Center

bearing

Right hand wound, red winding cone (left hand side)

Equal spacing

Center

bracket

bushing

Center bracket

Torsion

keyed

shaft

Right hand end bearing bracket

Coupler

half

Torsion Spring Attachment

NOTE: Refer to Package Contents / Parts Breakdown, to determine which Center Bracket(s) came with your door.

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

Tools Required: Step Ladder, Ratchet Wrench, 9/16” Socket, 9/16” Wrench

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

TO THE STATIONARY SPRING CONE(S) IN PLAIN VIEW. SHOULD A REPLACEMENT SPRING WARNING TAG BE REQUIRED, CONTACT WAYNE-DALTON FOR FREE REPLACEMENTS.

NOTE: Measure the diameter of your springs. If your spring diameter is 3-3/4”, the springs do not share center brackets. If your spring diameter is either 2” or 2-5/8”, then two springs will share the same center bracket, unless a coupler assembly is provided.

IF YOU DON’T HAVE A COUPLER ASSEMBLY:

Slide center bracket bushing into the spring. Align the stationary spring cone(s) with the holes in the center bracket bushing assembly. Secure the torsion spring(s) to the center bracket bushing assembly with (2) 3/8” - 16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts.

Stationary spring cone

Typical center bracket

Stationary spring cone

Torsion spring

Stationary spring cone

(2) 3/8”-16 Nuts

Typical center bracket bushing

(2) 3/8”-16 x 1-1/2” Hex head bolts

Spring warning tags

Typical center bracket assembly

Torsion spring

IF YOU HAVE A COUPLER ASSEMBLY:

Slide center bracket bushing into the spring. Align the stationary spring cone with the holes in the center bracket. Secure the torsion spring to the center bracket with (2) 3/8”-16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts. Repeat the same process for the other center bearing bracket.

At the middle of the two center bearing brackets, re-assemble the coupler assembly by loosely fastening the coupler halves together using the (3) 3/8” - 16 x 1-3/4” hex head screws and the (3) 3/8” - 16 nylon hex lock nuts, as shown.

NOTE: Ensure both torsion keyed shafts have equal amounts of the shafts extending from each end bearing bracket.

(3) 3/8” - 16 x 1-3/4”

hex head screws and

(3) 3/8” - 16 Hex nuts

Stationary

spring cone

Center bracket

Torsion

spring

Coupler halves

(2) 3/8”-16 x 1-1/2”

Hex head bolts and (2)

3/8”-16 Hex nuts

Coupler

assembly

Torsion

spring

Center

bracket

Counterbalance Lift Cables

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

IMPORTANT: VERIFY THAT THERE ARE NO COUNTERBALANCE LIFT CABLE OBSTRUCTIONS. NOTE: Always assemble the left hand cable and cable drum ﬁrst to help maintain equal cable

tension on both sides of the door. Hook the counterbalance lift cable into the left hand cable drum. Slide the left hand cable

drum up against the left hand end bearing bracket. Counterbalance lift cable should terminate at the 3 o’clock position. Tighten the (2) set screws in the drum to 14-15 ft. lbs. of torque (once set screws contact the shaft, tighten screws one full turn).

Tools Required: Step Ladder, Locking Pliers, 3/8” Wrench

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

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 CABLE MAKING SURE THEY ARE SEATED PROPERLY ONTO THE CABLE DRUMS AND THAT BOTH COUNTERBALANCE LIFT CABLES HAVE EQUAL TENSION.

Once the counterbalance cables are set and if applicable tighten the coupler assembly together by tightening the (3) 3/8” - 16 nylon hex lock nuts to secure the coupler halves together.

Typicall left hand end bearing bracket

Typicall left hand cable drum

Torsion shaft / Torsion keyed shaft

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).

WARNINGWARNING

FAILURE TO ENSURE DOOR IS IN A CLOSED POSITION AND TO PLACE VICE CLAMP ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY.

Locking pliers

Counterbalance lift cable

Typicall left hand cable drum

Set screws

Counterbalance

lift cable

Counterbalance lift cable hooked in cable

drum

Jamb

Typicall left hand end bearing bracket

Key

Winding Bars

(Steel Rods)

C-Clamps

Vice clamps / C-Clamps attached to inner

Size Of Winding Bar

(Inches) 1/2” dia. x 18” 5/8” dia. x 24”

Typical sections

and outer rail of vertical track

Spring Diameter

Used On

2” and 2-5/8”

3-3/4”

Vice clamps above third

track roller on both sides of

door

Bottom section

Winding Spring(s)

Tools Required: Step Ladder, Approved winding bars, 3/8” Wrench, Leather gloves, Safety glasses

WARNINGWARNING

WINDING TORSION SPRING(S) IS AN EXTREMELY DANGEROUS PROCEDURE AND SHOULD BE PERFORMED ONLY BY A TRAINED DOOR SYSTEM TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.

Torsion shaft / Torsion keyed shaft(s)

Chalking Torsion Spring(s)

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.

Torsion

shaft

Tools Required: Step Ladder, Chalk

Center

bracket

Original horizontal chalk line, prior

Torsion

spring coils

to winding

Winding

cone

Spirals created after winding

Securing Door for Spring Winding

With the door in the fully closed position, place vice clamps / c-clamps 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.

Tools Required: Vice Clamps

WARNINGWARNING

USE ONLY SPECIFIED WINDING BARS, AS STATED IN STEP SECURING DOOR FOR SPRING WINDING. DO NOT SUBSTITUTE WITH SCREWDRIVERS, PIPE, ETC. OTHER TOOLS MAY FAIL OR RELEASE FROM THE SPRING CONE AND CAUSE SERIOUS PERSONAL INJURY.

WARNINGWARNING

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.

Position a ladder slightly to the side of the spring so that the winding cone is easily accessible, and so your body is not directly in line with the winding bars.

Check the label attached to the spring warning tag for the required number of complete turns to balance your door.

Door Height Approximate Spring Turns

6’0” 6-7/8

6’3” 7-1/8

6’6” 7-1/4

6’8” 7-3/8

6’9” 7-1/2

7’0” 7-5/8

7’3” 7-7/8

7’6” 8

7’9” 8-1/4

8’0” 8-3/4

Alternately inserting the winding rods into the holes of the spring winding cone, rotate the winding cone upward toward the ceiling, 1/4 turn at a time, until the required number of complete turns for your door height is achieved. As the last 1/8 to 1/4 turn is achieved, securely hold the winding rod and carefully stretch the torsion spring 1/8” - 1/4”. Next while still securely holding the winding rod, tighten both set screws in the winding cone to 14-15 ft. lbs. of torque (once set screws contact the torsion shaft, tighten screws one full turn).

Carefully remove winding rod from winding cone. Repeat for the opposite spring. While holding the door down to prevent it from raising unexpectedly in the event the spring(s) were over-wound, carefully remove the locking pliers from the torsion shaft and vertical tracks.

Adjustments to the number of turns stated may be necessary. If door rises off ﬂoor under spring tension alone, reduce spring tension until door rests on the ﬂoor. If the door is hard to rise or drifts down on its own, add spring tension.

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

Torsion

spring(s)

Perforated Angle Gauge Weight Limitations:

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

NOTE: If an opener is installed, position horizontal tracks one hole above level when securing it to the rear back hangs.

WARNINGWARNING

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.

NOTE: 26” angle must be attached to sound framing members and nails should not be used.

Now, 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 weatherstrips too tightly against the face of door.

Approved

winding

rod

Winding

cone

Torsion shaft

Spring

coils

Set screws

Approved winding rod

IMPORTANT: CHECK THE WARNING

TAG(S) ATTACHED TO THE SPRING(S)

FOR THE REQUIRED NUMBER OF COMPLETE TURNS, TO BALANCE

HIGH SPRING TENSION CAN CAUSE SERIOUS INJURY OR DEATH.

DO NOT adjust, repair or remove springs or parts to

which springs are connected, such as steel brackets, cables, wood blocks, fasteners or other parts of the counterbalance system.

Adjustments or repairs must ONLY be made by a trained door systems technician using proper tools and instructions.

DO NOT remove, cover or paint over this tag. Product user should inspect this tag periodically for legibility and should order a replacement tag from the door manufacturer, as needed.

102081 REV2 06/24/2010

YOUR DOOR.

HIGH SPRING TENSION CAN CAUSE SERIOUS INJURY OR DEATH.

DO NOT adjust, repair or remove springs or parts to

which springs are connected, such as steel brackets, cables, wood blocks, fasteners or other parts of the counterbalance system.

Adjustments or repairs must ONLY be made by a trained door systems technician using proper tools and instructions.

DO NOT remove, cover or paint over this tag. Product user should inspect this tag periodically for legibility and should order a replacement tag from the door manufacturer, as needed.

102081 REV2 06/24/2010

Warning

tag(s)

Rear Back Hangs

IMPORTANT: HOLD THE DOOR DOWN TO PREVENT IT FROM RISING UNEXPECTEDLY IN THE EVENT THE SPRING(S) WAS OVER-WOUND AND CAUTIOUSLY REMOVE VICE CLAMPS FROM VERTICAL TRACKS.

Raise the door until the top section and half of the next section are in the horizontal track radius. Do not raise door any further since rear of horizontal tracks are not yet supported.

Tools Required: Ratchet wrench, Socket: 1/2” 5/8”, Wrench: 1/2” 5/8”, (2) Vice clamps, Tape measure, Level, Hammer, Step Ladder

WARNINGWARNING

RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE SEVERE OR FATAL INJURY.

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.

Using the chart (Perforated Angle Gauge Weight Limitations) below, use the appropriate perforated angle (may not be supplied), (2) 5/16” x 1-5/8” hex head lag screws and (3) 5/16” bolts with nuts (may not be supplied), fabricate rear back hangs for the horizontal tracks. Attach the horizontal tracks to the rear back hangs with 5/16” - 18 x 1” hex bolts and nuts (may not be supplied). Horizontal tracks must be level and parallel with door within 3/4” to 7/8” maximum of door edge.

WARNINGWARNING

Now, lift door and check its balance. Adjustments to the required number of spring turns stated may be necessary. If door rises off ﬂoor under spring tension alone, reduce spring tension until door rests on the ﬂoor. If the door is hard to rise or drifts down on its own, add spring tension. A poorly balanced door can cause garage door operator operation problems.

To adjust spring tension, fully close door. Apply vice grips to track above third track roller. Insert a winding rod into the winding cone. On single spring doors, counterbalance lift cable tension must be maintained by placing vice grips on torsion shaft before loosening set screws in the winding cone. Push upward on the winding rod while carefully loosening the set screws in the winding cone. 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 in the winding cone and repeat for the other side. Recheck door balance. DO NOT ADJUST MORE THAN 1/2 TURN FROM THE RECOMMENDED NUMBER OF TURNS.

If the door still does not operate easily, lower the door into the closed position, UNWIND THE SPRING(S) FULLY (Reference the insert “Removing The Old Door / Preparing The Opening” section on torsion spring removal) and recheck the following the items:

1.) Check the door for level.

2.) Check the torsion shaft for level.

3.) Check the track spacing.

4.) Check the counterbalance cables for equal tension and proper wrap onto the cable drums.

5.) Check the track for potential obstruction of the track rollers.

6.) Clamp locking pliers onto track and rewind springs. IMPORTANT: IF DOOR STILL DOES NOT OPERATE PROPERLY, THEN CONTACT A TRAINED

DOOR SYSTEM TECHNICIAN.

WARNINGWARNING

EXCEEDING THE RECOMMENDED LISTED DOOR WEIGHT LIMITATIONS OF SPECIFIC GAUGE PERFORATED ANGLES MAY RESULT IN DOOR FALLING WHEN RAISED, CAUSING SEVERE OR FATAL INJURY.

WARNINGWARNING

VERIFY PERFORATED BACK HANG ANGLE LOAD RATINGS WITH BACK HANG ANGLE SUPPLIER.

Perforated Angle Gauge Weight Limitations:

Perforated Angle Gauge Door Weight

2” x 2” x 12 Gauge Door Weight Less Than 800 lbs.

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

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

Horizontal tracks

Vice clamp

3/4” To 7/8”

Door edges

Horizontal tracks

3/4” To 7/8”

Vice clamp

Horizontal

track

Hex bolt must extend into the

track to serve as a roller stop

5/16”-18 x 1-1/4”

Sound framing members

2nd Track roller

Perforated angle bolted using (2) 5/16” x 1-5/8” hex head lag screws to ceiling member and parallel to door

(3) 5/16” Bolts and nuts

Perforated angle

(3) 5/16”

Bolts and nuts

Horizontal

track

Perforated angle

Hex bolt must extend into the

track to serve as a roller stop

5/16”-18 x 1-1/4”

Sound framing members

Perforated angle bolted using (2) 5/16” x 1-5/8” hex head lag screws to ceiling member and parallel to door

Optional Installation

Door Arm Hookup

Align hole in the door arm with holes in operator bracket tabs, as shown. Attach with 5/16” x 1-3/4” cotter pin and cotter ring, as shown.

Drawbar operator

bracket tabs

5/16” x 1-3/4”

Clevis pin

Cotter ring

5/16” x 1-3/4”

Clevis pin

Door arm

Cotter ring

Inside Lock

Install the inside lock on the second section of the door. Secure the lock to the section with (4) 1/4” - 20 x 11/16” self drilling screws. Square the lock assembly with the door section, and align with the square hole in the vertical track. The inside lock should be spaced approximately 1/8” away from the section edge.

Important : Inside lock(s) must be removed or made inoperative in the unlocked position if an operator is installed on this door.

Square hole in vertical track

Second section

(4) 1/4”-20 x 11/16”

Inside lock

Self drilling screws

1/8”

Not caulking the inside of the lite frames in these applications can subject the door to high amounts of moisture on the interior and may damage the door. Use acrylic latex plus silicone caulk.

First, caulk the perimeter of the inside of the lite frames to the glass located in the top section. Next, caulk the lite frames to the top section surface at the horizontal top edge only.

IMPORTANT: NOT CAULKING YOUR DOOR MAY VOID THE WARRANTY.

Top section

Caulk

Typical lite frames shown

Caulk

End stile

Pull Down Rope

WARNINGWARNING

DO NOT INSTALL PULL DOWN ROPE ON DOORS WITH OPERATORS. CHILDREN MAY BECOME ENTANGLED IN THE ROPE CAUSING SEVERE OR FATAL INJURY.

Measure and mark the jamb approximately 48” to 50” (1220 to 1270 mm) from ﬂoor on the right or left side of jamb. Drill 1/8” pilot hole for no. 6 screw eye. Tie the pull down rope to the no. 6 screw eye and to the bottom corner bracket, as shown.

No. 6 Screw eye

Typical bottom corner bracket

48” to 50” From ﬂoor

Pull down rope

Interior Lite Caulking

NOTE: After your door is installed, ﬁeld caulking is required for lited sections in applica-

tions subjected to heavy frost and or condensation forming on the inside of the windows.

Maintenance

Cleaning Your Garage Door

IMPORTANT: DO NOT USE A PRESSURE WASHER ON YOUR GARAGE DOOR! While factory-applied ﬁnishes on garage doors are durable, it is desirable to clean them on

a routine basis. Some discoloration of the ﬁnish may occur when a door has been exposed to dirt-laden atmosphere for a period of time. Slight chalking may also occur as a result of direct exposure to sunlight.

Cleaning the door will generally restore the appearance of the ﬁnish. To maintain an aesthetically pleasing ﬁnish of the garage door, a periodic washing of the garage door is recommended.

THE FOLLOWING CLEANING SOLUTION IS RECOMMENDED:

A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate) dissolved into ﬁve gallons of warm water will aid in the removal of most dirt.

NOTE: The use of detergents containing greater than 0.5% phosphate is not recommended for use in general cleaning of garage doors.

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

CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.

GLASS CLEANING INSTRUCTIONS

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

ACRYLIC CLEANING INSTRUCTIONS

Clean acrylic glazing with nonabrasive soap or detergent and plenty of water. Use your bare hands to feel and dislodge any caked on particles. A soft, grit-free cloth, sponge or chamois may be used to wipe the surface. Do not use hard or rough cloths that will scratch the acrylic glazing. Dry glazing with a clean damp chamois.

NOTE: Do not use any window cleaning ﬂuids, scouring compounds, gritty cloths or solventbased cleaners of any kind.

Painting Your Garage Door

SURFACE PREPARATION FOR PAINTING

Wax on the surface must be removed or paint peeling/ ﬂaking will result. To remove this wax, it will be necessary to lightly scuff the surface with a ﬁne steel wool pad saturated with soapy water. A ﬁnal wipe and rinse should be done with clean water only to remove any loose particles and any soapy ﬁlm residue.

Surface scratches, which have not exposed the metal substrate, can be lightly buffed or sanded with 0000 steel wool or no. 400 sand paper to create a smoother surface. Care must be taken to not expose the substrate under the paint. Once the substrate is exposed, the likelihood for rusting is greatly increased.

If substrate is exposed, it must be treated to prevent rust from forming. Sand the exposed area lightly and paint with a high quality metal primer speciﬁcally intended for galvanized surfaces to protect the area from corrosion. Allow for drying time on primer can label before applying topcoat.

The surface of the factory-applied ﬁnish, that is being painted, must not be too smooth, or the paint will not adhere to it. It is advisable to test in an inconspicuous area, to evaluate adhesion. If poor adhesion is observed, surface preparation for painting the factory-applied ﬁnish must be repeated until desired results are achieved. Again, care must be taken to not expose the substrate under the paint.

CAULKING: NOTE: After SURFACE has been properly prepared use acrylic latex plus silicone caulk. Fol-

low caulking label directions explicitly. It must be allowed to dry thoroughly prior to painting.

1. Caulk the top edge of all horizontal stiles to the section (Top, Intermediate(s), Lock and Bottom sections) surface.

CAUTION: DO NOT CAULK BOTTOM EDGE OF ANY HORIZONTAL STILES.

CAUTION: DO NOT CAULK VERTICAL OR DIAGONAL STILES.

2. Caulk exterior overlay to glass in all lite cutouts for lited sections.

PAINTING: NOTE: When painting the section, the paint must not seal the bottom edge of any stiles to

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

coated immediately with premium quality latex house paint. Follow paint label directions explicitly. Oil base or solvent base paints are not recommended. Please note that if substrate is exposed and not properly primed, painting with latex paint may cause accelerated rusting of the steel in the exposed area.

NOTES:

1. Re-painting of ﬁnish painted steel doors cannot be warranted, as this condition is totally beyond the door manufacturer’s control.

2. Consult a professional coatings contractor if in doubt about any of the above directions.

3. Follow directions explicitly on the paint container labels for proper applications of coatings and disposal of containers. Pay particular attention to acceptable weather and temperature conditions in which to paint.

Wood (Preparation and Painting) These instructions apply to all Wood Doors produced and sold by Wayne-Dalton. The exterior

surfaces, as well as all edges must be properly painted and maintained if satisfactory performance is to be achieved. The purpose for painting is to both protect and beautify the substrates. These requirements for ﬁnishing are intended to achieve both functions for reasonable service life of wood doors. Wood doors must be completely ﬁnished 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 not be transported or stored where the wood surfaces can be exposed to moisture or other contaminants.

Wood (Surface Preparation) All surfaces must be clean, free of dust and dirt and any other contamination. Wood (Painting) Using painter’s tape, tape off all metal surfaces. A premium quality latex house based ﬁnish

paint is recommended for use over the factory latex based primer Painting the wood surfaces with at least 2 coats of ﬁnish paint over the primer. Follow paint

manufacture’s label directions completely for all coatings. Once ﬁnished, remove painter’s tape and touch up where necessary.

Wood (Maintenance and Reﬁnishing) Yearly inspection of all the wood surfaces of the garage door(s) will reveal the extent of

weathering and the need for reﬁnishing. When the ﬁnish becomes eroded or thin, clean and prime the areas of deterioration. Follow up with a complete reﬁnishing of the door(s), according to the above directions, as well as the manufacturer’s label directions. Protecting the door(s) from prolonged exposure to moisture and sunlight is vital in extending the service life of your garage door(s).

Operation And Maintenance

OPERATING YOUR GARAGE DOOR:

Before you begin, read all warning labels afﬁxed to the door and the installation instructions and owner’s manual. When correctly installed, your Wayne-Dalton door will operate smoothly. Always operate your door with controlled movements. Do not slam your door or throw your door into the open position, this may cause damage to the door or its components. If your door has an electric opener, refer to the owner’s manual to disconnect the opener before performing manual door operation below.

Manual door operation:

For additional information on manual garage door operations go to www.dasma.com and reference TDS 165.

IMPORTANT: DO NOT PLACE FINGERS OR HANDS INTO SECTION JOINTS WHEN OPENING AND/OR CLOSING A DOOR. ALWAYS USE LIFT HANDLES / SUITABLE GRIPPING POINTS WHEN OPERATING THE DOOR MANUALLY.

Opening a Door: Make sure the lock(s) are in the unlocked position. Lift the door by using the lift handles / suitable gripping points only. Door should open with little resistance.

Closing a Door: From inside the garage, pull door downward using lift handles / gripping point only or a high friction area only. If you are unable to reach the lift handles/ suitable gripping points only, use pull down rope afﬁxed to the side of door. Door should close 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, an drawbar

opener and/or drawbar operator bracket must be securely attached to the top section of the door, along with any struts provided with the door. Always use the drawbar operator and or drawbar operator bracket supplied with the door. To avoid possible damage to your door, Wayne-Dalton recommends reinforcing the top section on models 8000, 8100, 8200 and 9100 doors with a u-bar (may or may not be supplied). The installation of the drawbar operator must be according to manufacturer’s instructions and force settings must be adjusted properly. Refer to the owner’s manual supplied with your drawbar operator for complete details on installation, operation, maintenance and testing of the operator.

Maintaining Your Garage Door: Before you begin, read all warning labels afﬁxed to the door and the installation instruc-

tions and owner’s manual. Perform routine maintenance steps once a month, and have the door professionally inspected once a year. Review your Installation Instructions and Owner’s Manual for the garage door. These instructions are available at no charge from Wayne-Dalton, A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, or at www.

wayne-dalton.com. For additional information on garage door/operator maintenance go to www.dasma.com and reference TDS 151, 167 and 179.

Monthly Inspections:

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

not to be structurally sound must be replaced. Inspect the springs, counterbalance lift cables, track rollers, pulleys, rear back hangs and other door hardware for signs of worn or broken parts. Tighten any loose screws and/or bolts. Check exterior surface of the door sections for any minor cracks. Verify door has not shifted right or left in the opening. If you suspect problems, have a trained door system technician make the repairs.

WARNINGWARNING

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.

WARNINGWARNING

NEVER REMOVE, ADJUST, OR LOOSEN THE BOLTS, SCREWS AND/OR LAG SCREWS ON THE COUNTERBALANCE (END OR CENTER BEARING BRACKETS) SYSTEM OR BOTTOM CORNER BRACKETS OF THE DOOR. THESE BRACKETS ARE CONNECTED TO THE SPRING(S) AND ARE UNDER EXTREME TENSION. TO AVOID POSSIBLE SEVERE OR FATAL INJURY, HAVE ANY SUCH WORK PERFORMED BY A TRAINED DOOR SYSTEMS TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.

TorqueMaster® Plus Springs: Pawl knob(s) (located on the TorqueMaster® end brackets above the door) should be engaged to prevent the door from rapidly descending in case of spring failure or forceful manual operation.

Torsion Springs: The torsion springs (located above the door) should only be adjusted by a trained door systems technician. DO NOT attempt to repair or adjust torsion springs yourself.

Extension Springs: A restraining cable or other device should be installed on the extension 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. 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 hinge(s), steel track rollers, bearings and torsion spring(s) (torsion spring coil surfaces). DO NOT lubricate plastic idler bearings, nylon track rollers, door track. DO NOT oil a cylinder lock, if actuation is difﬁcult use a graphite dust to lubricate.

Warranty

Limited Lifetime warranty

Model 6600

Wayne Dalton, a division of Overhead Door Corporation (“Seller”) warrants to the original purchaser of the Model 6600 (“Product”), subject to all of the terms and conditions hereof, that the Product and all components thereof will be free from defects in materials and workmanship for the following period(s) of time, measured from the date of installation:

Limited Lifetime Warranty* on the Product sections against:

• The Product becoming inoperable due to rust-through of the steel skin from the core of the Product section, due to cracking, splitting, or other deterioration of the steel skin, or due to structural failure caused by separation or degradation of the foam insulation.

• Peeling of the original paint as a result of a defect in the original paint or in the application of the original paint coating.

• The Product hardware and tracks (except springs).

TWO (2) YEARS on factory attached overlay material against peeling, cracking, chalking, fading or delamination. ONE (1) YEAR on those component parts of the Product not covered by the preceding provisions of this Warranty.

*Limited Lifetime shall mean as long as the original purchaser owns the house in which the Product is originally installed. 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, failure to provide necessary maintenance, normal wear and tear, acts of God or as a result of having been exposed to toxic or abrasive environments, including blowing sand, salt water, salt spray and toxic chemicals and fumes.

ALL EXPRESS AND IMPLIED WARRANTIES FOR THE PRODUCT, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES 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 authorized distributor or installer whose name and address appear below. The purchaser must allow Seller a reasonable opportunity to inspect any Product claimed to be defective prior to removal or any alteration of its condition. Proof of the purchase and/or installation date, and identiﬁcation as the original purchaser, may be required. There are no established informal dispute resolution procedures of the type described in the Magnuson-Moss Warranty Act.

• SELLER: _______________________________________________________________________

• SELLER’S ADDRESS: _______________________________________________________________________

_______________________________________________________________________

Thank you for your purchase.

PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE

AFTER INSTALLATION IS COMPLETE, FASTEN THIS

MANUAL NEAR GARAGE DOOR FOR EASY REFERENCE.

Wayne-Dalton 6600 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual