Wayne-Dalton 5120, 5140 User Manual

Page 1

5120 AND 5140

TorqueMaster® - Single and Double Spring

Installation Instructions and Owner’s Manual

Wayne-Dalton Corp. P.O. Box 67 Mt. Hope, OH 44660 www.wayne-dalton.com

Read these instructions carefully before attempting installation. If in question about any of the procedures, do not perform the work. Instead, have a qualiﬁed door agency do the installation or repairs.

IMPORTANT NOTICE!

Page 2

Table of Contents

Important Safety Instructions .................................................. 2

Package Contents ................................................................... 3

Door Section Identiﬁcation ...................................................... 4

Tools Required ........................................................................ 5

WARNING

READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING INSTALLATION. IF IN QUESTION ABOUT ANY OF THE

Pre-Installation ..................................................................5-10

Removing The Old Door .......................................5-9

Preparing The Opening ......................................... 10

Installation ......................................................................11-30

Optional Installations .......................................................31-35

Side Lock (Sold Separately) ..................................31

Doormaster

Step Plate (Sold Separately) .................................. 32

Pull Rope .............................................................. 32

Trolley Instructions For Standard Lift ..................... 33

Trolley Instructions For Low Headroom ................. 34

Trolley Operator .................................................... 35

Maintenance ....................................................................36-37

Cleaning ............................................................... 36

Painting Instructions ........................................36-37

Warranty ............................................................................... 38

Customer Service Number .................................................... 38

Bracket ......................................... 31

Deﬁnition of key words used in this manual:

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN SEVERE OR FATAL INJURY.

CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT FROM FAILURE TO FOLLOW INSTRUCTIONS.

IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER DOOR OPERATION.

NOTE: Information assuring proper installation of the door.

PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A QUALIFIED DOOR AGENCY 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 wider 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, red colored fasteners, 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 instructions.

16. NEVER hang tools, bicycles, hoses, clothing or anything else from horizontal tracks. Track systems are not intended or designed to support extra weight.

After installation is complete, fasten this manual

near garage door.

To find your Wayne-Dalton dealer; refer to your local yellow pages / business listings or go to Find a dealer area online at www.wayne-dalton.com

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer.

Page 3

(2) HORIZONTAL ANGLES

T o rqueMaster® - Single and Double Spring

Installation Instructions and Owner’s Manual

9100, 9600, 5120, 5140

IMPORTANT NOTICE! Read these instructions carefully before attempting installation. If in question about any of the procedures, do not perform the work. Instead, hav e a q ua liﬁ ed door age nc y do the installation or repairs.

(21-15/16” OR 80”)

(AS REQUIRED)

Package Contents

NOTE: DEPENDING ON THE DOOR MODEL, SOME PARTS LISTED WILL NOT BE SUPPLIED IF NOT

NECESSARY. REAR SUPPORTS MAY OR MAY NOT BE INCLUDED WITH YOUR DOOR.

DOOR SECTIONS (AS REQUIRED)

(1)TORQUEMASTER® SPRING TUBE

ASYMMETRICAL U-BAR

(IF INCLUDED)

RIGHT & LEFT DRUM WRAPS

RIGHT & LEFT

END BRACKETS

(2) QUICK INSTALL RH/LH

FLAGANGLE (AS REQUIRED)

U-BAR

(IF INCLUDED)

Q.I. JAMB BRACKETS

(AS REQUIRED)

36 TOOTH WORM GEAR

(AS REQUIRED)

IDRIVE® OPERATOR

(SOLD SEPARATELY)

(1) OPERATOR BRACKET

COUNTER COVERS

(AS REQUIRED)

(2) HORIZONTAL TRACKS RH/LH

(2) TOP BRACKET SLIDES

(2) TOP BRACKET BASES

COUNTER GEARS

(AS REQUIRED)

RIGHT AND LEFT CABLE

DRUM ASSEMBLIES

WEATHER SEALS & NAILS

(IF INCLUDED)

ROLLERS

(1) CENTER BRACKET

(AS REQUIRED)

(2) VERTICAL

TRACKS RH/LH

ASSEMBLY

MANUAL 1/4”- 20 FLANGED HEX

5/16” X 1 5/8” HEX HEAD LAG SCREWS

(AS REQUIRED)

(4) 1/4”-20 X 5/8”

CARRIAGE BOLTS

LUBRICATING OIL

(AS REQUIRED)

3/8”- 16 X 3/4” HEX HEAD

BOLTS (IF INCLUDED)

1/4”-14 X 5/8” SELF TAPPING

SCREWS (AS REQUIRED)

PULL ROPE

(IF INCLUDED)

(2) #12 X 1/2” PHILLIPS

HEAD SCREWS

(1) LOOSE WINDING SHAFT

(SINGLE SPRING ONLY)

(2) #10 PHILLIPS

HEAD SCREWS

(2) 3/8”-16 X 3/4”

TRUSS HEAD BOLTS

CLEVIS PIN

(2) 3/8”- 16 HEX NUTS

NUTS (AS REQUIRED)

1/4”-20 X 11/16” SELF DRILLING

SCREWS (AS REQUIRED)

(1) COTTER PIN(1) 5/16” X 1-1/4”

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Page 4

Door Section Identification

Tools Needed:

NOTE: This provides an alternative method for identifying your door sections/stack position.

Hinges are always pre-attached at the top of each section (except top section) and the hinges are stamped for identiﬁcation, #1, #2, #3, and #4 (#4 only on ﬁve section doors). See view below. The stamp identiﬁes the stacking sequence of the section. The sequence is always determined by #1 being the bottom section to #3 or #4 being the highest intermediate section. See views to the right. If the stamp on the end hinge is illegible, refer to the section side view illustration to the right.

The section side view illustration shows the end hinge proﬁle of all the sections, and can also be used in conjunction with identifying each sections.

The BOTTOM SECTION can be identiﬁed by a #1 end hinge, the factory attached bottom astragal, or by the bottom bracket warning labels on each end stile.

The LOCK SECTION can be identiﬁed by a #2 end hinge.

ASTRAGAL

WARNING LABEL

TOP SECTION

END STILES

WARNING LABELS

INTERMEDIATE SECTION

LOCK SECTION

BOTTOM BRACKET

WARNING LABELS

BOTTOM SECTION

The INTERMEDIATE SECTION can be identiﬁed by a #3 end hinge. Some sections may have a warning label attached to either the right or left hand end stile of the section. NOTE: #4 End hinges are used on the fourth section of ﬁve section doors.

The TOP SECTION can be identiﬁed by no pre-installed hinges on the section and the warning label attached in the center of the section.

7/8”

#1 END HINGE

BOT.

BOTTOM BRACKET

SECTION SIDE VIEW

1 1/8”

#2 END HINGE

LOCK

1 3/8”

#3 END HINGE

INT.

1 19/32”

#4 END HINGE

INT.

(USED ONLY

ON FIVE

SECTIONS)

TYPICAL HINGE STAMPING LOCATION

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ASTRAGAL

Page 5

Tools Required

POWER DRILL RATCHET WRENCH PLIERS/WIRE CUTTERS

PHILLIPS HEAD SCREWDRIVER PENCIL

7/16”, 1/2”, 9/16”

SOCKETS

HAMMER

FLAT TIP SCREWDRIVER

7/16” SOCKET DRIVER

VICE GRIPS VICE CLAMPS

3/8”, 7/16”, 1/2”, 9/16”

WRENCHES

Removing An Old Door

TAPE MEASURE

NEEDLE NOSE PLIERS

SAFETY GLASSES

(2) SAW HORSES

1/8”, 3/16” DRILL BITS

PRE-INSTALLATION

GLOVES

STEP LADDER

WARNING

IF YOUR COUNTERBALANCE SYSTEM IS OTHER THAN THOSE MENTIONED IN SECTIONS P1, P2 AND P3, DO NOT ATTEMPT TO WORK ON IT, BUT HAVE A QUALIFIED DOOR AGENCY PERFORM THE WORK. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.

WARNING

DISCONNECT AND REMOVE ANY ELECTRIC OPENER PRIOR TO REMOVAL OF COUNTERBALANCE SYSTEMS TO PREVENT UNINTENDED DOOR OPERATION. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.

WARNING

COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.

WARNING

IF YOU HAVE BACK PROBLEMS DO NOT ATTEMPT THIS, OR SEVERE INJURY COULD RESULT

WARNING

REMOVING AN EXISTING DOOR CAN BE DANGEROUS. FOLLOW INSTRUCTIONS ON PAGES 6-10 “REMOVING AN OLD DOOR/PREPARING THE OPENING” CAREFULLY, OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.

If you have an existing door, follow the instructions to identify which counterbalance removal is necessary. The process of removing an existing door begins by identifying it’s counterbalance system. If you are not removing an existing door, proceed to PREPARING THE OPENING on page 10. Generally, you will ﬁnd three (3) types of counterbalance systems: Torsion spring counterbalance systems, WayneDalton® exclusive TorqueMaster® and Extension Spring counterbalance systems. For more technical information regarding the opening preparation, installation and use of your garage door and opener, you can go to www.dasma.com and click on Publications and then Technical Data Sheets Number 156, 161 and 164.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer.

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Page 6

Torsion Spring Removal

For Standard Lift

SET SCREWS

Tools Needed:

Recommended

tools from

page 5

WARNING

FAILURE TO USE APPROVED WINDING BARS CAN CAUSE SPRING ENERGY TO BE RELEASED SUDDENLY, RESULTING IN SEVERE OR FATAL INJURY.

WARNING

COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.

Do not release the torsion spring tension unless you’re a qualiﬁed and experienced door technician, but have a professional door agency release the tension.

Step 1: Close the door and place vice clamps to the back legs on both vertical tracks, above the third roller to prevent the door from lifting as you unwind the springs. Use only approved winding bars available from your dealer. Do not use undersized steel rods, screw drivers or anything else to unwind the springs. Position the ladder just off to the side of the winding cone. The winding cone should be easy to reach without putting your body directly in front of it.

Step 2: Insert a winding bar into one of the holes in the winding cone. Exert upward pressure. Using caution, loosen the two (2) set screws in the winding cone. Be prepared to support the full torsional force of the spring when the set screws are loosened.

Step 3: Once set screws are loose, slowly and carefully lower the winding rod until it rests against the door. Insert other winding bar into the upper hole. Push up and remove lower bar. Carefully lower upper winding bar, one 1/4 turn at a time, until it rests against the door. Repeat process until all tension is relieved. If your door is equipped with two (2) torsion springs, follow the same procedure to relieve tension on the second spring.

Step 4: Remove vice clamps from tracks, unbolt entire torsion assembly and remove from work area.

FIRMLY HOLD WINDING

BAR AND CAUTIOUSLY LOOSEN SET SCREWS

WINDING CONE

TORSION ASSEMBLY

APPROVED WINDING BARS

NOTE: Continue with “P4” on page 9 after completing this step.

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Page 7

TorqueMaster® Spring Removal

LOOSEN LOCK NUT

COUNTER

GEAR/ COVER

Tools Needed:

Recommended

tools from

page 5

A TorqueMaster® spring system can be identiﬁed by the end brackets. For single spring applications, the right hand end bracket will always have a drive gear, counter gear, counter cover, and a winding bolt head. The left hand end bracket will have no gears, counter cover, or winding bolt head. The hole for the winding bolt head will be plugged.

For double springs, both the right hand and left hand end brackets will always have a drive gear, counter gear, counter cover and a winding bolt head.

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

Step 1: If you have a black counter cover:

Place a mark on the drive gear tooth and an adjacent mark on the right hand end bracket (Fig. 1). Loosen the lock nut 1/4 turn using a 7/16” wrench and continue with Step 2. If you have a gray counter cover: Loosen the lock nut 1/4 turn using a 7/16” wrench and continue with Step 2.

Step 2: Using an electric drill (High torque / gear reduced to 1300 rpm preferred) with a 7/16” hex head driver, unwind the right hand winding bolt head counterclockwise (Fig. 2) and count the number of turns the mark on the drive gear passes the adjacent mark on the end bracket. Referencing the chart below, by door height, stop unwinding the spring once the counted turns have reached the listed number of turns. 6’-0” Door Height = 14 turns 6’-3” Door Height = 14 1/2 turns 6’-5” Door Height = 15 turns 6’-6” Door Height = 15 turns 6’-8” Door Height = 15 1/2 turns 6’-9” Door Height = 15 1/2 turns 7’-0” Door Height = 16 turns 7’-3” Door Height = 16 1/2 turns 7’-6” Door Height = 17 turns 7’-9” Door Height = 17 1/2 turns 8’-0” Door Height = 18 turns

CAUTION:

DO NOT USE IMPACT GUN TO

UNWIND SPRINGS.

IMPORTANT: DO NOT REFERENCE THE COUNTER COVER WHEN COUNTING THE NUMBER OF TURNS BEING UNWOUND ON TH E SP R I N G, BU T FO L L O W THE INSTRUCTIONS ABOVE.

Step 3: Verify that spring tension has been released by pulling the counterbalance cable on the right hand cable drum away from the header (Fig. 3). If spring tension has been released, the cable will be loose. In addition, the TorqueMaster® spring tube

should be free to rotate in either direction.

RIGHT HAND

CABLE DRUM

TORQUEMASTER®

SPRING TUBE

PRY COUNTER GEAR

AND COUNTER COVER

FROM END BRACKET

USING FLAT TIP

SCREWDRIVER

Fig. 1

Fig. 2

Fig. 3

Fig. 4

RIGHT HAND

END BRACKET

PRE-INSTALLATION

PLACE MARK ON END BRACKET

AND DRIVE GEAR TOOTH

BEFORE UNWINDING SPRINGS

END BRACKET

RIGHT HAND

WINDING BOLT HEAD

ELECTRIC DRILL WITH 7/16” HEX DRIVER (DO NOT

USE IMPACT

GUN)

CHECK CABLE

TENSION

COUNTER

GEAR

COUNTER

COVER

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Page 8

TorqueMaster® Spring

Removal continued...

Tools Needed:

If the counterbalance cable is still taut and the TorqueMaster® spring tube is difﬁcult

Recommended

tools from

page 5

to rotate, that is an indication that spring tension still exists on the left hand spring. Repeat Steps 1 and 2 for releasing spring tension on the left hand side.

Step 4: Using a ﬂat tip screwdriver, pry the counter gear and counter cover from the right hand end bracket (Fig. 4 on previous page). Discard the counter gear and counter cover. On double spring applications, repeat for left hand side.

REMOVE TOP

LAG SCREW

Fig. 5

USE LOCKING PLIERS

TO HOLD END BRACKET

Step 5: Remove the upper 5/16” x 1-5/8” lag screw from the right hand end bracket (Fig. 5). Attach locking pliers to the upper portion of the end bracket and hold the housing steady while removing the lower 5/16” x 1-5/8” lag screw and #10 x 1/2” phillips head screw from the end bracket (Fig. 6).

Step 6: Holding the right hand end bracket steady with locking pliers, carefully pry the end bracket and drive gear off the winding shaft using a ﬂat tip screwdriver (Fig. 7).

CAUTION: THE WINDING SHAFT MAY

REMOVE

BOTTOM LAG

SCREW

Fig. 6

ROTATE WHEN REMOVING THE END BRACKET AND DRIVE GEAR.

Step 7: Repeat Step 4 for the left hand side. Holding the left hand end bracket

END BRACKET

STEADY WITH

LOCKING PLIERS

steady with locking pliers, carefully pry the end bracket off the winding shaft using a ﬂat tip screwdriver (Fig. 7).

Step 8: Remove the two (2) lag bolts attaching the center bracket assembly to the header board (Fig. 8).

Step 9: Lift the right hand side of the TorqueMaster

spring tube and slide the

PRY END BRACKET FROM WINDING

SHAFT USING A FLAT TIP SCREW

DRIVER AND LOCKING PLIERS

cable drum off. Realign the groove in the winding shaft with the round notch in the ﬂagangle and drape the counterbalance cable with drum over the ﬂagangle. Lift the left hand side of the TorqueMaster® spring tube and slide the cable drum and winding shaft off (Fig. 9). Drape the

CENTER

BRACKET

ASSEMBLY

Fig. 7

REMOVE CABLE DRUM AND

WINDING SHAFT

counterbalance cable with drum over the ﬂagangle. Lift the TorqueMaster® spring assembly off the ﬂagangles and out of the doorway. Unhook the counterbalance cables from the bottom brackets and remove all parts from the work area.

NOTE: The cable drums may be difﬁcult to remove. If so, twist the cable drum to aid in removal.

NOTE: Continue with “P4” on page 9 after completing this step.

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(2) 5/16” X 1-5/8”

HEX HEAD LAG

SCREWS

Fig. 8

DRAPE CABLE

ACROSS

TOP OF

FLAGANGLE

TORQUEMASTER

SPRING TUBE

OFF FLAGANGLE

Fig. 9

REMOVE #10

PHILLIPS

HEAD SCREW

HOLD THE

LIFT

Page 9

Tools Needed:

Recommended

tools from

page 5

Extension Spring Removal

Step 1: Raise the door to the fully open

position and place vice clamps to the back legs of both vertical tracks, below the bottom rollers to prevent the door from falling. By opening the door you release most of the spring tension. Carefully unfasten the S-hook from the horizontal angle. Remove cable, sheave and extension spring. Repeat for the other side. If safety cables are running through the extension springs, remove them also. Remove parts from work area.

Step 2: Holding door in the open position, remove the vice clamps, be prepared to support the entire weight of the door. Garage doors can weigh 200-400 pounds.

With assistance, carefully lower the door, by grasping the door ﬁrmly by it’s lift handles. Do not place ﬁngers or hands near joints, between sections, or between bottom of door and ﬂoor. Otherwise, severe injury could result.

REMOVE LAG SCREW

FROM SAFETY CABLE (IF

INSTALLED). REPEAT FOR

OPPOSITE SIDE.

BOTTOM SECTION

(DOOR OPEN)

PRE-INSTALLATION

CAREFULLY REMOVE “S”

HOOK AND COUNTREBALANCE

CABLE (REPEAT FOR THE

OPPOSITE SIDE)

HORIZONTAL ANGLE

Tools Needed:

Recommended

tools from

page 5

NOTE: Continue with “P4” on page 9 after completing this step.

Removing the Old Door

Having removed the counterbalance system, the door can now be disassembled.

Start by ﬁrst removing the top row of hinge(s).

With assistance, hold the top section to keep it from falling and remove the top brackets. With assistance, lift the top section out of the opening and remove it from the work area. Repeat for all remaining sections.

After door is disassembled, unbolt both track assemblies from the jambs and remove all material from the work area. You can neatly dispose of the old door by placing it in the carton of your new door.

TOP BRACKET

HORIZONTAL TRACK

HINGES

Clean up area and complete “Preparing the Opening” “P5” on page 10 before installing the new door.

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Page 10

Tools Needed:

Recommended

tools from

page 5

Preparing the Opening

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 TorqueMaster 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 TorqueMaster counterbalance systems, a suitable mounting surface (2” x 4”) 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. Weather Seal (May Not Be Included): Cut or trim the weather seal (if necessary) to the header and jambs. For quick install track: Align the header seal with the inside edge of the header and temporarily secure it to the header with equally spaced nails. Next, ﬁt the jamb seals up tight against the header seal and ﬂush with the inside edge of the jamb. Temporarily secure the jamb seals with equally space nails approximately 12” to 18” apart. This will keep the bottom section from falling out of the opening during installation. For fully adjustable track: Align the header seal 1/8” to 1/4” inside the header and temporarily secure it to the header with equally spaced nails. Next, ﬁt the jamb seals up tight against the header seal and 1/8” to 1/4” inside the jamb. Temporarily secure the jamb seals with equally space nails approximately 12” to 18” apart. This will keep the bottom section from falling out of the opening during installation. NOTE: Do not permanently attach weather seal to the jamb at this time. 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” LHR 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.

HEADER BOARD 2” X 6” LUMBER

PREFERRED

LEVEL HEADER

PLUMB JAMBS

DOOR

WIDTH

HEADROOM

HEADER

WEATHER SEAL

JAMB

HEADROOM REQUIREMENT

TRACK TYPE TorqueMaster

12” Radius track 11” (279 mm)

6” LHR Kit

†

BACKROOM REQUIREMENT

DOOR HEIGHT TRACK

7’0” 12” Radius

8’0” 12” Radius

SUITABLE MOUNTING

SURFACE 2” X 6”

LUMBER MINIMUM

DOOR

HEIGHT

BACKROOM

JAMB

QUICK INSTALL TRACK

6” (152 mm)

MANUAL

LIFT

98”

(2489 mm)

110”

(2794 mm)

MOTOR

OPERATED

(3175 mm)

(3480 mm)

WEATHER

SEAL

125”

137”

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Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer.

Page 11

Installation

IMPORTANT: READ INSTRUCTIONS TITLED “P4” “REMOVING THE OLD DOOR” ON PAGE 9 AND “P5” “PREPARING THE OPENING” ON

PAGE 10 BEFORE ATTEMPTING DOOR INSTALLATION.

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

NOTE: It is recommended that 5/16” x 1-5/8” lag screws be pilot drilled using a 3/16” drill bit, and 1/4” x 2” lag screws and 1/4” x 1-1/2” lag screws be pilot drilled using a 1/8” drill bit, prior to fastening.

INSTALLATION

Tools Needed:

None

Attaching Quick Install Flag

Angle to Vertical Track

NOTE: If you have riveted track, skip this

step.

Place the lower quick install tab of the ﬂagangle in the quick install feature of the vertical track. Give the ﬂagangle 1/4 turn to lock in place. Repeat for other side.

QUICK INSTALL TAB UNLOCKED QUICK INSTALL TAB LOCKED

FLAGANGLE

VERTICAL

TRACK

VERTICAL

TRACK

LEFT HAND TRACK AND FLAGANGLE

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RIGHT HAND TRACK AND FLAGANGLE

Page 12

Horizontal Angle

HOLE

TABS

HORIZONTAL

ANGLE

KEY SLOT

Tools Needed:

Hammer

Position the horizontal angle as shown. Place tabs of horizontal angle in the key slot of horizontal track. Using a hammer, tap the horizontal angle towards the curved end of the track until the holes in track and angle are aligned. Set tracks aside.

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

HORIZONTAL ANGLE

HORIZONTAL TRACK

HORIZONTAL

TRACK

HAMMER

HOLE

HORIZONTAL

TRACK

HORIZONTAL

ANGLE

HORIZONTAL

TRACK

TABS

Installing Q.I. Jamb Brackets

Tools Needed:

None

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NOTE: If you have riveted 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 type. To install the jamb brackets, align the twistlock tab on the quick install jamb bracket with the quick install feature in the track and turn the bracket perpendicular to the track so the mounting ﬂange is toward the back (ﬂat) leg of the track.

TWISTLOCK TAB

Q.I. JAMB BRACKET

JAMB BRACKET SCHEDULE

DOOR

HEIGHT

7’0”

76” TRACK (1930 mm)

8’0”

88” TRACK (2235 mm)

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1ST SET 2ND SET 3RD SET

JAMB BKT POSITION JAMB BKT POSITION JAMB BKT POSITION

QIJB - 3 BOTTOM QIJB - 7 TOP NOT APPLICABLE

QIJB - 3 MIDDLE QIJB - 6 TOP QIJB - 7 MIDDLE

LEFT SIDE SHOWN

TOP HOLE

MIDDLE HOLE

BOTTOM HOLE

QUICK INSTALL FEATURE

RIGHT SIDE SHOWN

3RD SET HOLES

2ND SET HOLES

1ST SET HOLES

Page 13

Drums

LEFT HAND TORQUEMASTER®

COUNTERBALANCE DRUM

#1 END HINGE

(HINGE TUBE)

Tools Needed:

None

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

NOTE: For door section identiﬁcation see page 4.

TorqueMaster® counterbalance drums are marked right and left hand. Uncoil the counterbalance cables and make sure you place the right hand cable loop on the right hand milford pin and place the left hand cable loop on the left hand milford pin. Insert a roller into bottom bracket of the bottom section and insert another roller at #1 end hinge at the top of the bottom section. Repeat for other side.

NOTE: Verify astragal (bottom seal) is aligned with door section. If there is more than 1/2” excess astragal on either side, trim astragal even with door section.

ASTRAGAL

BOTTOM SECTION

COUNTERBALANCE

CABLE

MILFORD PIN

BOTTOM SECTION

ROLLERS

BOTTOM BRACKET

BOTTOM SECTION

INSTALLATION

Tools Needed:

Level

Bottom Section

Before installing the bottom section, the weather seal (may not be included) must be installed (see PREPARING THE OPENING on page 10)

Center the bottom section in the door opening. Level section using wooden shims (if necessary) under the bottom section.

WEATHER SEAL

DOOR OPENING

LEVEL

BOTTOM SECTION

WOODEN SHIMS

(IF NECESSARY)

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Page 14

Vertical Track

CABLE DRUM

FLAGANGLE

VERTICAL TRACK

BOTTOM SECTION

Tools Needed:

3/16” Drill Bit

Power Drill

7/16” Socket

Driver

Tape Measure

Level

IMPORTANT: THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE. IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT. THE VERTICAL TRACK ON THE SHIMMED SIDE, MUST BE RAISED THE HEIGHT OF THE SHIM.

Position the left hand vertical track assembly over the rollers of the bottom section. Make sure the counterbalance cable is located between the rollers and the door jamb. Drill 3/16” pilot holes for the lag screws. Loosely fasten jamb brackets and ﬂagangle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screw securing bottom jamb bracket to jamb, to maintain 5/8” spacing. Hang cable drum over ﬂagangle. Repeat for the right hand side.

CABLE

JAMB

BRACKET

5/16” X 1-5/8”

LAG SCREWS

VERTICAL

TRACK

ASSEMBLY

BOTTOM SECTION

ROLLER

5/8”

LAG

SCREW

LOCATIONS

12R QI FLAGANGLE

QUICK INSTALL

JAMB BRACKET

LAG

SCREW

Tools Needed:

Power Drill

7/16” Socket

Driver

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NOTE: For door section identiﬁcation see

page 4. NOTE: Make sure hinge leafs are ﬂipped down, when stacking another section on top.

Place rollers in hinge tubes of the second section (lock section). With assistance, lift second section and guide rollers into the vertical tracks. Keep sections aligned and fasten hinges to connect the sections using 1/4”-14 x 5/8” self tapping screws. Repeat for other section(s) except top section.

IMPORTANT: PUSH & HOLD THE HINGE LEAFS AGAINST SECTION WHILE SECURING WITH 1/4”-14 X 5/8” SELF TAPPING SCREWS. END HINGES HAVE (2) SCREWS AND INTERMEDIATE HINGES HAVE (3) SCREWS.

NOTE: Install lock at this time (sold separately) see instructions in OPTIONAL SIDE LOCK INSTALLATION on page 31.

Stacking Sections

LOCK SECTION

(3) 1/4”-14 X 5/8” SELF TAPPING

(2) 1/4”-14 X 5/8”

SELF TAPPING SCREWS

END HINGES (LEFT HAND SHOWN, RIGHT

HINGE SYMMETRICALLY OPPOSITE)

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SCREWS

INTERMEDIATE HINGES

Page 15

Tools Needed:

Power Drill

7/16” Socket

Driver

Top Brackets

To install the L-shaped top brackets, align the top holes in the top bracket base with the second set of holes in the endcap.

Fasten using (4) 1/4” - 14 x 5/8” self tapping screws. Secure the top bracket slide to the bracket base loosely using (2) 1/4” - 20 x 5/8” carriage bolts and (2) 1/4” - 20 ﬂanged hex nuts. The bracket will be tightened and adjusted in Step 14. Insert rollers into top bracket slide. Repeat for other side.

TOP SECTION

2ND SET

TOP BRACKET BASE

TOP BRACKET SLIDE

OPERATOR BRACKET

(INSTALLED IN THE STEP 11)

U-BAR

TOP DOOR SECTION

6”

(2) 1/4”-14 X 5/8”

SELF TAPPING

SCREWS

INSTALLATION

NOTE: After completing this step,

continue with Step 11.

ATTACHING CENTER OF U-BAR ATTACHING ENDS OF U-BAR

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Page 16

Tools Needed:

Power Drill

7/16” Socket

Driver

U-Bar - Asymmetrical

NOTE: If a 3” u-bar was installed in Step

9, skip this step.

NOTE: Model 5120 or 5140 glazed top doors 13’-0” wide or greater will be supplied with a 3” asymmetrical u-bar for the top section.

Place the 3” asymmetrical u-bar over the top rib of the top section. Fasten each end of the u-bar to the endcap with (2) 1/4”- 20 x 11/16” self drilling screws.

Fasten center of the u-bar as shown to the rib using (2) 1/4”-14 x 5/8” self tapping screws 6” off the center of the door section.

Fasten the u-bar as shown using (2) 1/4”-14 x 5/8” self tapping screws every 30 - 36 inches. (Approximately 18 self tapping screws per 18’ u-bar)

30” TO 36”

(2) 1/4”-20 X 11/16”

SELF DRILLING

SCREWS

OPERATOR BRACKET

(INSTALLED IN THE STEP 11)

(2) 1/4”- 14 X 5/8” SELF

TAPPING SCREWS

TOP DOOR SECTION

U-BAR

6”

(2) 1/4”-14 X 5/8”

SELF TAPPING

6”

SCREWS

ATTACHING CENTER OF U-BAR

ALIGN CENTER OF BOTH TABS WITH

Operator Bracket

CENTER LINE OF TOP SECTION

Tools Needed:

Power Drill

7/16” Socket

Driver

Vice Clamps

Phillips Head

Screwdriver

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NOTE: Operator bracket must be mounted

and secured prior to installing top section.

IMPORTANT: WHEN CONNECTING A

TROLLEY TYPE GARAGE DOOR OPENER TO THIS DOOR, A WAYNE-DALTON OPENER/TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR, ALONG WITH ANY U-BARS PROVIDED WITH THE DOOR. THE INSTALLATION OF THE OPENER MUST BE ACCORDING TO MANUFACTURER’S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED PROPERLY.

Prior to installing top section, locate the center of the top section and seat the operator bracket on male part of the top section. For retro ﬁt applications, the operator bracket must be aligned with an existing operator and positioned on the top section, as shown in FIG. 1.1 and 1.2.

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TOP SECTION WITH OR

WITHOUT

U-BAR

OPPOSITE SIDE OF

OPERATOR BRACKET

FIG. 1.3

FIG. 1.1

OPERATOR

BRACKET

(2) #12 X 1/2”

PHILLIPS HEAD

SCREWS

ATTACHING INTERMEDIATES OF U-BAR

MALE PART OF

TOP SECTION

U-BAR

VICE CLAMP

NOTE: NOT REQUIRED

FOR J-STRUTS.

OPERATOR

BRACKET

TOP

SECTION

FIG. 1.2

OPERATOR BRACKET

U-BAR

FIG. 1.4

Page 17

Operator Bracket Continued...

OPERATOR

BRACKET

(2) 1/4” - 14 X 5/8”

SELF-TAPPING

SCREWS

Tools Needed:

Install (2) #12 x 1/2” phillips head screws on the opposite side of operator bracket, as shown in FIG. 1.3. Clamp

operator bracket to u-bar (if furnished),

as shown in FIG. 1.4. First attach (3) 1/4” - 14 x 5/8” self-tapping screws to the operator bracket, as shown in FIG.

1.5. Then attach (2) 1/4” - 14 x 5/8” self-tapping screws to the operator bracket, as shown in FIG. 1.6. Remove

vice clamps.

NOTE: If you have a 5120 door, use (2) of the 1/4” - 20 x 11/16” self-drilling screws to attach the u-bar instead of (2) 1/4” - 14 x 5/8” self-tapping screws

when attaching operator bracket to ubar, as shown in FIG. 1.6.

NOTE: When attaching operator bracket to top section with u-bar, apply additional pressure to thread into the u-bar. NOTE: See FIG. 1.7 for installing operator

bracket on top section without u-bars.

(3) 1/4” - 14 X 5/8”

SELF-TAPPING

SCREWS

FIG. 1.5

OPERATOR

BRACKET

U-BAR

(2) 1/4” - 20 X 11/16”

SELF-DRILLING SCREWS

FIG. 1.6

(5) 1/4” - 14 X 5/8”

SELF-TAPPING

SCREWS

OPERATOR

BRACKET

INSTALLATION

FIG. 1.7

Tools Needed:

Hammer

Top Section

Place the top section in the opening and vertically align with lower sections. 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 hinge leafs, hold them tight against section and fasten center hinges ﬁrst and end hinges last. (Refer to Step 7). When installing a door with a TorqueMaster® counterbalance system, vertical track alignment is critical. Position ﬂagangle between 111/16” (43 mm) to 1-3/4” (44 mm) from the edge of the door. Flagangles must be parallel to the door sections. Now complete the vertical track installation by securing the center jamb bracket and tightening the other lag screws. Repeat for other side. IMPORTANT: THE DIMENSION BETWEEN THE FLAGANGLES MUST BE DOORWIDTH PLUS 3-3/8” (86 MM) TO 3-1/2” (89 MM) FOR SMOOTH, SAFE DOOR OPERATION.

NAIL

FLAGANGLE

DOOR WIDTH

+3-3/8” TO 3-1/2”

1-11/16”

TO 1-3/4”

TOP

SECTION

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Page 18

Attaching Horizontal Track

to Quick Install Flagangle

FLAGANGLE

Tools Needed:

9/16” Socket

Ratchet Wrench

9/16” Wrench

Level

To install horizontal track, place the curved end over the top roller. Align key slot of the horizontal track with the quick install tab of the ﬂagangle. Push curved portion of horizontal track down to lock in place. Level the horizontal track assembly and bolt the horizontal angle to the slot in the ﬂagangle using (1) 3/8” - 16 x 3/4” truss head bolt and (1) 3/8” - 16 hex nut. Repeat for other side. Remove the nail that was temporarily holding the top section in place, installed in Step 12.

IMPORTANT: FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION.

WARNING

DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SE CURED AT REAR, AS OUTLINED IN STEP 32, OR DOOR COULD FALL FROM OVERHEAD POSI TION CAUSING SEVERE OR FATAL INJURY.

NOTE: If an idrive® opener will be installed, position horizontal tracks slightly

above level.

HORIZONTAL TRACK

QUICK

INSTALL

TAB

VERTICAL

TRACK

3/8” - 16 X 3/4”

TRUSS HEAD BOLT

KEY SLOT

QUICK

INSTALL

TAB

HORIZONTAL TRACK

KEY SLOT

VERTICAL

TRACK

3/8” - 16 HEX NUT

HORIZONTAL ANGLE

HORIZONTAL TRACK

Tools Needed:

7/16” Wrench

Adjusting Top Brackets

With horizontal tracks installed, you can now adjust the top brackets.

Vertically align the top section of the door with the lower sections. Once aligned, position the top bracket slide, out against the horizontal track.

Maintaining the slide’s position, tighten the (2) 1/4” - 20 ﬂange hex nuts to secure the top roller slide to the top bracket base.

SECTION

CORRECT

SECTION

TOP

HORIZONTAL

TRACK

TOP

SECTION

TOP

BRACKET

SLIDE

(2) 1/4” - 20 FLANGE HEX

NUTS

INCORRECT

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Page 19

TorqueMaster® Spring Tube

Tools Needed:

None

TorqueMaster® springs come lubricated and pre-assembled inside the TorqueMaster® spring tube. To install, lay the TorqueMaster® spring tube on the ﬂoor (inside garage) in front of the door with the labeled end to the left.

TORQUEMASTER®

SPRING TUBE

LABELED END

INSTALLATION

Tools Needed:

None

Center Bracket Bushing

NOTE: If you are installing the idrive®

opener on your garage door, skip this step and continue with Step 17.

NOTE: If you are not installing an idrive® opener on your garage door, you must install the center bracket bushing assembly. Follow these instructions for non-idrive® operated garage doors.

NOTE: If you are installing a DoorMaster™ opener, see optional DoorMaster™ Bracket installations on page 31, Figure A.

Being cam shaped the center bracket bushing only ﬁts one way. Slide the center bracket assembly towards the center of the TorqueMaster® spring tube, from the right side as shown.

NOTE: Upon completion of this step, continue with Step 18.

TORQUEMASTER

SPRING TUBE

CENTER

BRACKET

ASSEMBLY

TORQUEMASTER®

SPRING TUBE

CENTER

BRACKET

BUSHING

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Page 20

idrive® Installation

Tools Needed:

None

NOTE: See idrive® main installation and owners manual for idrive® parts.

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

Lay the TorqueMaster® spring tube on the floor (inside garage) in front of the door with the labeled end to the left.

Look into the opener’s left side to ensure the left hand bearing and the internal (black) sleeve are aligned with the TorqueMaster® spring tube profile.

IMPORTANT: HOLD OPENER BY THE MAIN BODY. DO NOT HOLD BY THE MOTOR.

NOTE: Opener will not slide over the TorqueMaster® spring tube label. Attempting to slide opener over the left end of the TorqueMaster® spring tube can damage the internal electronics.

Once aligned, slide the opener onto the right hand end of the TorqueMaster® spring tube. As the right end of the TorqueMaster® spring tube enters the internal (black) sleeve, rotate the opener back and forth slightly to help aid alignment.

Continue sliding the opener onto the TorqueMaster® spring tube. Align the right hand bearing with the TorqueMaster® spring tube and slide the opener completely onto the TorqueMaster® spring tube until the TorqueMaster® spring tube exits the opener right hand bearing.

LEFT HAND SIDE

TORQUEMASTER

AND BEARING PROFILES ALIGNED

RIGHT HAND END

OF TORQUEMASTER

SPRING TUBE

MOTOR

RIGHT HAND SIDE TORQUEMASTER

SPRING TUBE AND

BEARING PROFILES

ALIGNED

NOTE: Do not force the opener onto the TorqueMaster® spring tube if misalignment occurs.

Continue sliding the opener to the center of the TorqueMaster® spring tube.

PLUG-IN MOTOR

POWER CORD

Plug the motor power cord into the opener.

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Page 21

Cable Drum Installation

TORQUEMASTER®

SPRING TUBE

GROOVE

COUNTERBALANCE

CABLE

Tools Needed:

None

Shake the TorqueMaster® spring tube gently to extend the winding shafts out about 5" on each side. For single spring applications, there will be no left hand spring in the TorqueMaster® spring tube.

Lift the TorqueMaster

spring tube and rest it on the top of the flagangles. Orient TorqueMaster® spring tube so that back of opener is flat against header/mounting surface.

NOTE: Cable drums are marked right and left hand. Cable drums and

TorqueMaster

spring tube are cam

shaped to fit together only one way.

To install the cable drum, slide the correct cable drum over the winding shaft until the cable drum seats against

the TorqueMaster

spring tube. The winding shaft must extend past the cable drum far enough to expose the splines and the groove. Align the winding shaft groove with the round notch in the flagangle.

For Double Spring Applications:

Repeat for opposite side.

WINDING

SHAFT

SPLINES

TORQUEMASTER®

SPRING TUBE

RIGHT HAND

CABLE DRUM

FLAGANGLE

CABLE DRUM

FLAGANGLE

WINDING

SHAFT

GROOVE

ROUND

NOTCH

INSTALLATION

For Single Spring Applications: Insert

the loose winding shaft into the left hand cable drum prior to sliding the

cable drum over the TorqueMaster spring tube.

NOTE: On single spring applications, take care in handling the loose winding shaft (left side) so that it does not slide

back into the TorqueMaster

spring

tube.

TORQUEMASTER®

SPRING TUBE

Left Hand Side

Single Spring Application

LEFT HAND

CABLE DRUM

GROOVE

ROUND NOTCH

WINDING

SHAFT

TORQUEMASTER®

SPRING TUBE

LOOSE

WINDING

SHAFT

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Page 22

Tools Needed:

None

Drive Gear Installation

Beginning with the right hand side, lubricate entire circumference of the 36 tooth worm gear with the lubricating oil provided. Slide the 36 tooth worm gear onto the winding shaft splines until it touches the flagangle.

CABLE DRUM

WINDING

SHAFT

SPLINES

LUBRICATING

OIL

36 TOOTH

WORM GEAR

Tools Needed:

None

NOTE: On single spring applications, no 36 tooth worm gear is required on the left side.

NOTE: If additional lubricating oil is needed, use “Dura Lube® Engine Oil Treatment”.

End Brackets

IMPORTANT: WARNING TAGS MUST BE

SECURELY ATTACHED TO BOTH END BRACKETS.

FLAGANGLE

CABLE

DRUM

END BRACKET

36 TOOTH

WORM GEAR

WINDING

SHAFT

WARNING

TAG

Slide the right hand end bracket over the drive gear and fasten to the flagangle using a #10 self-tapping screw. Drill 3/16” pilot holes into jamb for the lag screws. Secure end bracket and the flagangle to the jamb using (2) 5/16” x 1-5/8" lag screws.

Repeat for left hand side.

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(2) 5/16” X 1-5/8”

LAG SCREWS

#10 PHILLIPS

HEAD

SCREW

Page 23

Tools Needed:

None

Counter Installation

Install the right side counter gear, with the missing tooth toward the outside and away from the end bracket. Press the counter gear onto the end bracket until snaps engage.

Select the right hand counter cover and align the hex of the counter cam with the end of the winding shaft. Also, align the “0” on the counter cover with the raised rib on the end bracket. Press the counter cover against the counter gear until it locks into place.

Repeat for left hand side for double spring applications.

NOTE: No 36 tooth worm gear, counter gear or counter cover is required on left hand side for single spring applications. Only an end bracket is needed.

WINDING

SHAFT INSIDE

END BRACKET

COUNTER

GEAR

MISSING

TOOTH

RAISED RIB

“0”

COUNTER

COVER

HEX OF THE

COUNTER CAM

Tools Needed:

Power Drill

1/8” Drill Bit

7/16” Socket

Driver

IMPORTANT: AT THIS TIME DO NOT WIND COUNTERBALANCE SPRINGS!

Securing Center Bracket

Assembly

NOTE: If you are installing an idrive

opener on your garage door, skip this step and continue with Step 23.

NOTE: If you are not installing an idrive® opener on your garage door, you must install the center bracket bushing assembly. Follow these instructions for non-idrive® operated garage doors.

NOTE: If you are installing a DoorMaster™ opener, see optional DoorMaster™ Bracket installations on page 32, Figure B.

To locate the center bracket, mark the header halfway between the ﬂagangles and level the TorqueMaster® spring tube. Drill 1/8” pilot holes into header for the lag screws. Fasten the metal bracket to the header using (2) 5/16” X 1-5/8” lag screws.

NOTE: Upon completion of this step, continue with Step 27.

INSTALLATION

CENTER BRACKET BUSHING

ASSEMBLY

(2) 5/16” X 1-5/8”

HEX HEAD LAG

SCREWS

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Page 24

Tools Needed:

Power Drill

1/8” Drill Bit

7/16” Socket

Driver

Positioning Support Bracket

NOTE: See idrive® main installation and

owners manual for idrive® parts.

NOTE: idrive® must be installed on a solid mounting surface.

Locate the mounting surface. Remove (2) 1/4”-20 flange nuts from bottom of opener.

TORQUEMASTER® SPRING TUBE

45 ANGLE

ANTENNA

WIRE

MOUNTING

SURFACE

NOTE: Do not discard flange nuts.

Place the support bracket underneath opener, to the right side of motor, centered on mounting surface. Using a tape measure, level the bottom of the TorqueMaster® spring tube to the top of the door section with the idrive® resting on the support bracket. Once TorqueMaster® spring tube is level, drill 1/8” pilot holes for the lag screws. Then secure support bracket to the mounting surface with (2) 1/4” x 1-1/2" lag screws.

IMPORTANT: TORQUEMASTER® SPRING TUBE MUST BE LEVEL AFTER SUPPORT BRACKET IS FASTENED TO MOUNTING SURFACE.

NOTE: If wood mounting surface is behind dry wall, use 1/4” x 2” lag screws.

Lift and slide the opener over the support bracket, aligning the mounting studs with the bracket slots. Loosely fasten to mounting studs with the (2) 1/4”-20 flange nuts.

(HEADER)

TOP OF DOOR

TORQUEMASTER SPRING TUBE

1/4” X 1-1/2”

LAG SCREWS

SUPPORT BRACKET

1/4” - 20

FLANGE NUTS

MOUNTING

STUDS

MOUNTING

STUDS

BRACKET

SLOTS

SUPPORT BRACKET

NOTE: Do not tighten 1/4”-20 flange nuts to opener studs at this time. You

(2) 1/4” - 20

FLANGE NUTS

will be instructed when to tighten them in the idrive® main installation and owners manual.

Remove the temporary orange label holding the antenna wire. Straighten antenna wire and angle it 45 degrees to the right.

“X”

NOTE: Do not coil the antenna wire. This will reduce the radio signal range.

USING A TAPE MEASURE, MAINTAIN AN EQUAL MEASUREMENT “X” (TOP OF DOOR TO BOTTOM OF TORQUEMASTER® TUBE) AT BOTH

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TOP SECTION

ENDS AND THE CENTER.

“X”

Page 25

6ft

Tools Needed:

Pliers

Attaching Disconnect Cables

NOTE: See idrive® main installation and

owners manual for idrive® parts.

Attach the loose disconnect cable (located in opener hardware bag) to the opener with the “S” hook. Close both ends of the “S” hook (with pliers) to lock assembly together.

Thread the disconnect cable (behind the counterbalance cable) through the hole in the right hand end bracket; remove all slack between opener and right end bracket.

RIGHT SIDE OF

END BRACKET

HOLE IN

END BRACKET

S-HOOK

DISCONNECT

CABLE

HOLE IN RIGHT

END BRACKET

CLOSE “S” HOOK

INSTALLATION

Tools Needed:

Pencil

Tape measure

1/8” Drill Bit

7/16” Socket

Driver

Power Drill

Mounting Disconnect

Handle Bracket

NOTE: See idrive® main installation and

owners manual for idrive® parts.

Mark a location on the right jamb, 6 feet above the floor to mount the disconnect handle bracket.

Drill 1/8” pilot holes for the lag screws.

Align top of the bracket with the mark. Fasten bracket to the jamb with (2) 1/4” x 1-1/2" lag screws.

(2) 1/4” X 1-1/2”

LAG SCREWS

DISCONNECT

HANDLE BRACKET

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Page 26

Attaching Disconnect Handle

Tools Needed:

Phillips head

screwdriver

Wire cutters

NOTE: See idrive® main installation and owners manual for idrive® parts.

NOTE: Bring motor to the down position by pulling the disconnect cable, insure opener disconnect teeth are engaged before installing disconnect handle.

Start the #6-20 x 1/2" screw into the disconnect handle. Thread the disconnect cable through the top of the disconnect handle bracket and then the disconnect handle.

Locate the disconnect handle in full upper position of disconnect handle bracket.

Remove all disconnect cable slack between the opener and the top of the disconnect handle bracket. Tighten #6-20 x 1/2" screw into the disconnect handle until snug, and then tighten screw an additional 1 to 1-1/2 turns to secure disconnect cable to the disconnect handle. Trim off excess cable from bottom of the disconnect handle.

CAUTION: PULL CABLE ONLY TAUT ENOUGH TO REMOVE THE CABLE SLACK. PULLING THE CABLE MORE COULD CAUSE OPENER TO DISCONNECT FROM THE TORQUEMASTER® SPRING TUBE.

UPPER POSITION

#6-20 X 1/2”

SCREW

HANDLE

DISCONNECT

CABLE

DISCONNECT

HANDLE

BRACKET

MANUAL OPERATED POSITION

EMERGENCY DISCONNECT

LABEL

MOTOR OPERATED POSITION

Apply emergency disconnect label next to the mounted bracket. Use mechanical fasteners if adhesive will not adhere.

Using the emergency disconnect, pull disconnect handle downwards and place it in the manual door operated position (Use disconnect label for reference). Motor will be rotated 90° from its packaged position.

If motor does not pivot 90°, see troubleshooting section in the main installation and owners manual of your idrive® opener

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Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer.

Page 27

Securing Door

for Spring Winding

Tools Needed:

Vice Clamp

WARNING

FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY.

Place vice clamps onto both vertical tracks just above the third roller. This is to prevent the garage door from raising while winding counterbalance springs.

IMPORTANT: DO NOT USE IMPACT GUN TO WIND SPRING(S).

PLACE VICE

CLAMPS ABOVE

3RD ROLLER

VICE CLAMPS ATTACHED TO

INNER RAIL

OF TRACK

TRACK

INSTALLATION

Tools Needed:

Locking Pliers

Flat Tip

Screwdriver

Cable Adjustments

Rotate the cable drum until the set screw faces directly away from the header. TorqueMaster® spring tube cam peak should be pointing straight up.

Beginning with the right side, loosen the set screw approximately 2 turns, to adjust cable. Using locking pliers, pull on the end of the cable to remove all cable slack.

Check to ensure the cable is aligned and seated in the first groove of the cable drum. Snug the set screw, then tighten an additional 1-1/2 turns. Cut excess cable.

COUNTERBALANCE

CABLE

DRUM

CAM PEAK

STRAIGHT UP

SET SCREW

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Page 28

15.5

Tools Needed:

Power Drill

7/16" Socket

Driver

Winding Bolt Rotation

See chart in Step 30 for proper spring tension setting.

Beginning with the right hand side, ensure the cable is in the first groove of the cable drum. Apply light pressure to the canoe clip on counter cover while winding springs.

Using a power drill (high torque/gear reduced to 1300 RPM preferred) with a 7/16" socket, carefully rotate right hand winding bolt clockwise, until counter shows 2-3 turns.

This will keep the counterbalance cable taut while adjusting the left hand side counterbalance cable. Adjust left hand counterbalance cable tension. (refer to Step 28)

NOTE: Single spring applications require no spring winding on left hand side, but need cable tension adjusted.

NOTE: Ensure counterbalance cable tension is equal for both sides prior to fully winding spring(s) to appropriate number of turns. If cable tension is unequal refer to Step 28.

WARNING

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.

WINDING

BOLT

CANOE CLIP

Setting Spring Tension

Tools Needed:

Power Drill

7/16” Socket

Driver

7/16" Wrench

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NOTE: Apply light pressure to the canoe clip on the

counter cover while winding spring(s). See the Spring Turn chart. For SINGLE SPRING applications, return to the right hand side and carefully rotate the winding bolt head clockwise until the counter shows the correct number of turns for your door. For DOUBLE SPRING applications, remain on the left hand side and carefully rotate the winding bolt head clockwise until the counter shows the correct number of turns for your door. Then return to the right hand side and wind the right hand spring to the required number of turns. IMPORTANT: DO NOT OVERWIND. After spring is wound, hold the lock nut (in back of end bracket) stationary on the right hand side with a 7/16” wrench while rotating the winding bolt clockwise until snug. Tightening of the lock nut prevents spring from unwinding. Repeat for opposite side for double spring TorqueMaster® systems. IMPORTANT: CAUTIOUSLY REMOVE VICE CLAMPS FROM VERTICAL TRACKS. ADJUSTMENTS TO THE RECOMMENDED NUMBER OF TURNS MAY BE REQUIRED. AFTER REAR SUPPORT ASSEMBLY IS COMPLETE (STEP

32), CHECK DOOR BALANCE. IF DOOR RAISES OFF FLOOR UNDER SPRING TENSION ALONE, REDUCE SPRING TENSION UNTIL DOOR RESTS ON THE FLOOR. IF THE DOOR IS HARD TO RAISE OR DRIFTS DOWN ON ITS OWN, ADD SPRING TENSION. AN UNBALANCED DOOR SUCH AS THIS CAN CAUSE IDRIVE® OPERATION PROBLEMS.

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SPRING TENSION

SAMPLE SETTING

LOCK NUT

NOTE: For 7’ high doors, 8’, 9’, 10’, 16’ or 18’ wide with

windows, the recommended number of spring turns is 15.

RECOMMENDED SPRING TURNS

Operated

idrive

Door Height

7’-0” 15-1/2 16

8’-0” 17-1/2 18

Doors 11’-11”

Wide or Less

Manually Operated Door,

and idrive

Doors 12’ Wide or Greater

7/16”

WRENCH

Operated

Page 29

Drum Wrap Installation

DRUM WRAP

Tools Needed:

None

Drum wraps are identified as right and left hand.

To install, place the drum wrap over the cable drum and under the idrive® disconnect cable (right hand side). Align the outside flange over the outside edge of the cable drum and push the drum wrap down onto the cable drum. Repeat for left hand side.

NOTE: Drum wraps must be installed to prevent cable from becoming tangled.

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

CABLE

DRUM

CABLE

DRUM

WRAP

OUTSIDE

FLANGE

INSTALLATION

Tools Needed:

Ratchet Wrench

1/2” Socket

1/2” Wrench

(2) Vice Clamps

Tape Measure

Level

Hammer

Rear Support

WARNING

KEEP HORIZONTAL TRACK PARALLEL AND WITHIN 3/4” MAXIMUM OF DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING IN SEVERE INJURY OR DEATH. Raise the door until the top section and half of the next section are in a horizontal position. Do not raise door any further since the horizontal tracks are not yet supported at the rear.

WARNING

RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE SEVERE INJURY OR DEATH. Clamp a pair of vice clamps on the vertical tracks just above the second roller on one side, just below the second roller on the other side. This will prevent the door from raising or lowering while installing the rear support. Fabricate rear support for horizontal tracks, using perforated angle, 5/16” x 1-5/8” hex head lag screws and 5/16” bolts with nuts (may not be supplied). Attach horizontal tracks to the rear supports with 5/16”-18 x 1-1/4” hex bolts and nuts (may not be

DOOR IN THE

UP POSITION

3/4”

VICE

CLAMPS

DOOR EDGE

VERTICAL

TRACK

HORIZONTAL

TRACK

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Page 30

ANGLE BOLTED TO CEILING

MEMBER AND PARALLEL TO

DOOR

HORIZONTAL

TRACK

Tools Needed:

Rear Support Continued...

supplied). Horizontal tracks must be level and parallel with door. NOTE: If perforated angle is installed

PERFORATED ANGLE

(3) 5/16” NUTS

over drywall, use 5/16” x 2” hex head lag screws. Adjust weather seal (if necessary) and now permanently attach the weather

(3) 5/16” BOLTS

seal or door stop to both door jambs and header. (They were temporarily attached to the jambs in PREPARING THE OPENING on page 10.) Avoid pushing weather seal or door stop too tightly against face of door. NOTE: If an idrive® opener will be installed, position horizontal tracks one

SOUND FRAMING MEMBERS

BOLT MUST EXTEND INTO

THE TRACK TO SERVE AS

A ROLLER STOP

hole above level when securing it to rear supports. Now, lift door and check it’s balance.

PERFORATED

ANGLE

WARNING

Adjust, if door lifts by itself (hard to pull down) or if door is difﬁcult to lift (easy to pull down). Anytime spring adjustments are made you must loosen the lock nuts

HORIZONTAL TRACK

SOUND FRAMING MEMBERS

and retighten both lock nuts afterwards. To adjust spring(s), only add or remove 1/4 turn on the counter at a time. Adjust both sides equally.

IMPORTANT: DO NOT ADD OR REMOVE

MORE THAN 1 SPRING TURN FROM SPECIFIED AMOUNT. IF THE DOOR STILL DOES NOT OPERATE EASILY, LOWER THE DOOR INTO THE CLOSED POSITION, UNWIND SPRING(S) TO ZERO, AND RECHECK THE FOLLOWING ITEMS:

1.) Check the door for level.

2.) Check the TorqueMaster® spring tube and ﬂagangles for level and plumb.

3.) Check the distance between the ﬂagangles - must be door width plus 3-3/8” to 3-1/2”.

HORIZONTAL

TRACK

BOLT MUST EXTEND INTO THE TRACK

TO SERVE AS A ROLLER STOP

PERFORATED ANGLE

4.) Check the counterbalance cables for equal tension - adjust if necessary.

5.) Rewind the spring(s).

6.) Make sure door isn’t rubbing on jambs.

NOTE: As a safety feature, the right hand

end bracket cannot be disassembled for service until the spring is completely unwound and the counter cover reads zero. After door installation is completed, refer to the idrive® owner’s manual.

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Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer.

(3) 5/16” BOLTS

& NUTS

PERFORATED ANGLE - BOLTED

USING (2) 5/16” X 1-5/8” HEX HEAD

LAG SCREWS TO CEILING MEMBER

AND PARALLEL TO WIDTH OF DOOR.

SPACE LAG SCREWS NO FURTHER

THAN 24” APART.

BOLT MUST EXTEND INTO THE TRACK

TO SERVE AS A ROLLER STOP

PERFORATED ANGLE

PERFORATED ANGLE -BOLTED USING

(2) 5/16” X 1-5/8” HEX HEAD LAG

SCREWS TO CEILING MEMBERS

AND PARALLEL TO WIDTH OF DOOR.

ATTACH VERTICAL PERFORATED ANGLE

BETWEEN THE (2) 5/16” X 1-5/8”

HEX HEAD LAG SCREWS, SECURING

PERFORATED ANGLE TO CEILING

MEMBERS.

WEATHER

JAMB

PERMANENTLY ATTACHED

WEATHER SEAL

ANGLE

VERTICAL

ANGLE

SEAL

Page 31

Side Lock (Sold Separately)

�

1/8”

Tools Needed:

Power Drill

7/16” Socket

Driver

Install the side 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 side lock should be spaced in approximately 1/8” from the section edge.

IMPORTANT: SIDE LOCKS MUST BE REMOVED OR MADE INOPERATIVE IN THE UNLOCKED POSITION IF AN OPERATOR IS INSTALLED ON THE DOOR.

NOTE: After completing this step, continue with Step 8 on page 15.

(4) 1/4”- 20 X 11/16”

SELF DRILLING SCREWS

INSTALLATION

Tools Needed:

None

Tools Needed:

Power Drill

1/8” Drill Bit

7/16” Socket

Driver

DoorMasterTM Bracket/Gear

(Supplied With Doormaster™)

NOTE: When installing a DoorMasterTM

operator use the center bracket and drive gear supplied with your operator (located in DoorMasterTM package).

Slide the DoorMaster gear assembly onto the TorqueMaster® spring tube, so that the drive gear/center bracket assembly are in the center of the TorqueMaster® spring tube.

NOTE: After completing this step, continue with Step 18 on page 22.

bracket/drive

CENTER

BRACKET

BUSHING

ASSEMBLY

DOORMASTER

DRIVE GEAR ASSEMBLY

TORQUEMASTER® TUBE

BRACKET/

NOTE: After completing this step, continue with Step 27 on page 28.

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(2) 1/4” X 1-1/2”

HEX HEAD LAG

SCREWS

Page 32

Step Plate (Sold Seperately)

�

STEP PLATE OUTSIDE

Tools Needed:

7/16” Drill Bit

Power Drill

7/16" Wrench

Make one mark 1” (25 mm) up from the center of bottom edge of the bottom section and another mark 2-3/16” (56 mm) up from the ﬁrst mark.

Drill a 7/16” (11 mm) hole through the section at each mark and insert the outside step plate.

Loosely fasten step plate slide to base with (1) 1/4” - 20 x 5/8” carriage bolt and nut.

Align inside step plate holes and fasten from inside using the #8 screws provided. Install one #8 x 3/4” screw in the bottom step plate hole. The screw in the top hole varies with door models.

Use the screw size shown below for your model door.

a) #8 x 3/4” screw for Model 5120 b) #8 x 1” screw for Model 5140

Tighten 1/4” - 20 carriage bolt and nut.

2 3/16” (56mm)

1” (25mm)

1/4” - 20 X 5/8” CARRIAGE BOLT

STEP PLATE

SLIDE

STEP PLATE

BASE

HEX NUT

STEP PLATE INSIDE

ASSEMBLED

STEP PLATE

(2) #8 SCREWS

Tools Needed:

Power Drill

1/8” Drill Bit

Pull Rope

WARNING

DO NOT INSTALL PULL ROPES ON DOORS WITH ELECTRIC 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 door. Drill 1/8” pilot hole for No. 6 screw eye. Tie the pull rope to the No. 6 screw

eye and to the bottom bracket as shown.

NO. 6 SCEW EYE

PULL ROPE

BOTTOM BRACKET

PULL ROPE

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Page 33

Trolley Installation for

�

Standard Lift

DETERMINE THE WAYNE-DALTON

TRACK RADIUS BEING USED:

LEVEL

HIGH ARC

Measure the curved ends of the horizontal track to determine if you have a 12” or 15” radius horizontal track, as shown

in FIG. 2.1. Determine center line of door. Mark vertical line

at this point, on the header wall. Raise the door slightly until the top section reaches the highest point of travel (high arc).

HORIZONTAL

TRACK

12” OR 15”

TOP

SECTION

Using a level, mark this high arc point of travel on the header wall, intersecting the vertical center line, as shown in FIG.

2.2 through 2.3. Hold the wall bracket’s bottom edge to the

appropriate 1/2” - 1” (room permitting) above of the high arc line and centered on the vertical line, as shown in FIG.

2.3. Spot the wall brackets mounting holes on the header

wall and then refer to your garage door operator manual for

pre-drilling and securing the wall bracket to header. Using the

FIG. 2.1

TYPICAL 1/2” - 1” ABOVE HIGH ARC

HIGH ARC LINE

TORQUEMASTER

COUNTERBALANCE

FIG. 2.2

STRAIGHT

OPERATOR HOOK-UP CHARTS, refer to referenced illustrations in FIG. 2.4 through FIG. 2.5 for correct arm hook-up from trolley to operator bracket.

NOTE: Refer to your operator manual for speciﬁc details on how to assembly the curved and straight arm, as shown in FIG. 2.4 through FIG. 2.5.

NOTE: Depending on your setup, you may or may not have to

FROM STEP 11

VERTICAL CENTER LINE

HEADER

FIG. 2.3

CURVED

ARM

FIG. 2.4

CUT STRAIGHT

ARM TO

ACCOMPLISH

TROLLEY SETTING

cut straight arm to accomplish trolley settings, as shown in FIG. 2.4 through FIG. 2.5.

Align hole in the appropriate arm with holes in operator bracket tabs, as shown in FIG. 2.6. Insert 5/16” x 1-1/4” clevis pin, making sure hole in clevis pin is outside of second

STRAIGHT

ARM

CURVED

ARM

tab of operator bracket. Insert hairpin cotter into clevis pin hole and spread hairpin cotter to ensure it will secure assembly, as shown in FIG. 2.6 and FIG. 2.7.

CUT STRAIGHT

ARM TO

ACCOMPLISH

TROLLEY

SETTING

FIG. 2.5

Hairpin Cotter

Door

FIG. 2.6

top view

Hairpin Cotter

(outsiDe of operator

BraCket taB)

operator BraCket

taBs

OPERATOR HOOK-UP CHART STANDARD LIFT FOR 12” RADIUS

OPERATOR MODELS TYPE OF ARM BEING USED

Quantum/ClassiC CurveD / straigHt FIG. 2.5

linear straigHt / CurveD FIG. 2.4

liftmaster

(sears)

genie CurveD / straigHt FIG. 2.5

OPERATOR HOOK-UP CHART STANDARD LIFT FOR 15” RADIUS

OPERATOR MODELS TYPE OF ARM BEING USED

Quantum/ClassiC CurveD / straigHt FIG. 2.5

linear straigHt / CurveD FIG. 2.4

liftmaster

(sears)

genie CurveD / straigHt FIG. 2.5

CurveD / straigHt FIG. 2.5

REF. ILLUSTRATIONS

ABOVE

REF. ILLUSTRATIONS

ABOVE

operator BraCket

operator

BraCket taBs

5/16” x 1-1/4”

Clevis pin

5/16” x 1-1/4”

Clevis pin

Door arm

FIG. 2.7

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ARM

arm

OPTIONAL INSTALLATION

Page 34

Trolley Installation for

�

Low Headroom

Determine center line of door. Mark vertical line at this point, on the header wall. Raise the door slightly until the top section reaches the highest point of travel (high arc). Using a level, mark this high arc point of travel on the header wall, intersecting the vertical center line, as shown in FIG.

3.1 through 3.2. Hold the wall bracket’s bottom edge to the

appropriate 1/2” - 1” (room permitting) above of the high arc line and centered on the vertical line, as shown in FIG.

3.2. Spot the wall brackets mounting holes on the header

wall and then refer to your garage door operator manual for

pre-drilling and securing the wall bracket to header. Using the OPERATOR HOOK-UP CHARTS, refer to referenced illustrations in FIG. 3.3 through FIG. 3.4 for correct arm hook-up from trolley to operator bracket.

NOTE: Refer to your operator manual for speciﬁc details on how to assembly the curved and straight arm, as shown in FIG. 3.3 through FIG. 3.4.

NOTE: Depending on your setup, you may or may not have to cut straight arm to accomplish trolley settings, as shown in FIG. 3.3 through FIG. 3.4.

Align hole in the appropriate arm with holes in operator bracket tabs, as shown in FIG. 3.5. Insert 5/16” x 1-1/4” clevis pin, making sure hole in clevis pin is outside of second tab of operator bracket. Insert hairpin cotter into clevis pin hole and spread hairpin cotter to ensure it will secure assembly, as shown in FIG. 3.5 and FIG. 3.6.

LEVEL

TOP

SECTION

HIGH ARC

FIG. 3.1

FIG. 3.3

LOW

HEADROOM

TRACK

STRAIGHT

ARM

TYPICAL 1/2” - 1” ABOVE HIGH ARC

HIGH ARC LINE

FROM STEP 11

top view

TORQUEMASTER

COUNTERBALANCE

VERTICAL CENTER LINE

FIG. 3.2

CURVED

ARM

CUT STRAIGHT

ACCOMPLISH

FIG. 3.4

HEADER

ARM TO

TROLLEY

SETTING

operator BraCket

5/16” x 1-1/4”

Clevis pin

operator

BraCket taBs

Hairpin Cotter

FIG. 3.5

OPERATOR MODELS

Quantum/ClassiC

linear straigHt FIG. 3.3 n/a N/A

liftmaster

(sears)

genie

5/16” x 1-1/4”

Clevis pin

Door

arm

OPERATOR HOOK-UP CHART FOR LOW HEADROOM

TYPE OF ARM BEING USED

PREFERRED

HOOKUP

CurveD / straigHt

REF. ILLUSTRA-

TIONS ABOVE

FIG. 3.4 straigHt FIG. 3.3

Door arm

OPTIONAL

HOOKUP

Hairpin Cotter

(outsiDe of operator

BraCket taB)

operator BraCket

taBs

FIG. 3.6

REF. ILLUSTRATIONS

ABOVE

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Page 35

Tools Needed:

�

Trolley Operator

WARNING

OPERATOR MUST BE TESTED AT TIME OF INSTALLATION AND MONTHLY THEREAFTER TO ENSURE THAT DOOR REVERSES ON CONTACT WITH 2 X 4 BOARD LAID FLAT UNDER THE DOOR. FAILURE TO ADJUST OPERATOR, IF NECESSARY, CAN RESULT IN SEVERE OR FATAL INJURY. IF YOUR OPERATOR IS EQUIPPED WITH A PHOTOELECTRIC EYE SYSTEM, THEN THIS MUST BE TESTED AT THE SAME TIME TO ENSURE THAT DOOR DOES NOT CLOSE AND A CLOSING DOOR OPENS IF PHOTOELECTRIC EYE SYSTEM IS OBSTRUCTED. FAILURE TO MAKE ADJUSTMENTS, IF NECESSARY, CAN RESULT IN SEVERE OR FATAL INJURY.

1. Install operator rail 1/2” to 1-1/2” (13 - 38 mm) above high arc of top section of the door.

SUITABLE MOUNTING

SURFACE (2” X 6”)

LUMBER MINIMUM

HEADER

OPERATOR

RAIL

OPERATOR RAIL

DOOR ARM TO

OPERATOR

BRACKET

PERFORATED

ANGLE

2. Mount operator to ceiling so that 1” to 1-1/2” (25 - 38 mm) clearance is maintained between trolley rail and top section when door is fully open (trolley rail will slope down towards rear).

3. Attach door arm to operator bracket installed in Step 12.

4. Attach operator to a suitable mounting surface (2” x 6”) lumber minimum.

5. Attach operator to ceiling using perforated angle.

IMPORTANT: ANGLES MUST BE SECURELY ATTACHED TO SOUND FRAMING MEMBER(S).

FRAMING MEMBERS

PERFORATED ANGLE

OPERATOR

OPTIONAL INSTALLATION

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Page 36

Cleaning

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 weather stripping on both sides and top of door. CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.

GLASS CLEANING INSTRUCTIONS

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

ACRYLIC CLEANING INSTRUCTIONS

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

NOTE: DO NOT USE any window cleaning ﬂuids, scouring compounds, gritty cloths or solvent-based cleaners of any kind.

Painting

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.

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Page 37

Painting Continued....

Painting

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. Repainting 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.

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MAINTENANCE

Page 38

Limited Warranty

Models 5120 And 5140

Subject to the terms and conditions contained in this Limited Warranty, Wayne-Dalton Corp. (“Manufacturer”) warrants the sections of the door, which is described at the top of this page, for a period of TEN (10) YEARS from the date of installation against: (i) The door becoming inoperable due to rust-through of the steel skin from the core of the door 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. (ii) Peeling of the original paint on the door as a result of a defect in the original paint or in the application of the original paint coating, in cases where the door sections and the original paint: (a) have not been subjected to adverse atmospheric conditions or contaminates (such as salt water or other marine environment, or to toxic or abrasive substances, including those in the air); (b) have been maintained in compliance with Manufacturer’s recommendations; and (c) have not been subject to physical abrasion, impacted by a hard object, or punctured (including without limitation “paint rub” occurring in metal to metal contact and movement). The Manufacturer warrants the garage door hardware (except springs) and the tracks of the above-described door, for a period of TEN (10) YEARS from the date of installation, against defects in material and workmanship, subject to all the terms and conditions below. The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Limited Warranty against defects in material and workmanship for a period of ONE (1) YEAR from the date of installation. The Manufacturer warrants the factory-applied ﬁnish and the factory attached stiles against fading and cosmetic changes from the time of installation for TWO (2) YEARS. If the door is re-stained or re-painted, the TWO (2) YEARS warranty for the factory-applied ﬁnish is void. The Model 5140 factory attached stiles (if applicable) are warranted against peeling, cracking, chalking, or delamination from the time of installation for TWO (2) YEARS. This Limited Warranty is extended only to the person who purchased the product and continues to own the premises (where the door is installed) as his/her primary residence (“Buyer”). This Limited Warranty does not apply to residences other than primary, or to commercial or industrial installations, or to installations on rental property (even when used by a tenant as a residence). This Limited Warranty is not transferable to any other person (even when the premises is sold), nor does it extend beneﬁts to any other person. The Manufacturer will not be responsible for any damage attributable to improper storage, improper installation, or any alteration of the door or its components, abuse, damage from corrosive fumes or substances, salt spray or saltwater air, ﬁre, Acts of God, failure to properly maintain the door, or attempt to use the door, its components or related products for other than its intended purpose and its customary usage. This Limited Warranty does not cover ordinary wear. This Limited Warranty will be voided if the original ﬁnish is painted over, unless Manufacturer’s preparation and painting instructions are followed explicitly. This Limited Warranty will be voided if any holes are drilled into the door, other than those speciﬁed by the Manufacturer. THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON-MOSS ACT. NO WARRANTIES, EXPRESS OR IMPLIED (INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE) WILL EXTEND BEYOND THE TIME PERIOD SET FORTH IN UNDER- SCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY, ABOVE.

 • SomeStatesdonotallowlimitationsonhowlonganimpliedwarrantylasts,sotheabovelimitationsmaynotapplytoyou.

Any claim under this Limited Warranty must be made in writing, within the applicable warranty period, to the dealer from which the product was purchased. Unless the dealer is no longer in business, a written claim to the Manufacturer will be the same as if no claim had been made at all. At the Manufacturer’s option, a service representative may inspect the product on site, or Buyer may be required to return the product to the Manufacturer at Buyer’s expense. Buyer agrees to cooperate with any representative of the Manufacturer and to give such representative full access to the product with the claimed defect and full access to the location of its installation. If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty, the Manufacturer will repair or replace the defective product. The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer, subject to applicable law. THE REMEDY WILL COVER ONLY MATERIAL. THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES, SUCH AS FIELD SERVICE LABOR FOR REMOVAL, INSTALLATION, PAINTING, SHIPPING, ETC. Any repairs or replacements arranged by Manufacturer will be covered by (and subject to) the terms, conditions, limitations and exceptions of this Limited Warranty; provided, however, that the installation date for the repaired or replaced product will be deemed to be the date the original product was installed, and this Limited Warranty will expire at the same time as if there had been no defect. If a claim under this Limited Warranty is resolved in a manner other than described in the immediately preceding paragraph, then neither this Limited Warranty nor any other warranty from the Manufacturer will cover the repaired or replaced portion of the product. THE REMEDIES FOR THE BUYER DESCRIBED IN THIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy. The liability of the Manufacturer, whether in contract or tort, under warranty, product liability, or otherwise, will not go beyond the Manufacturer’s obligation to repair or replace, at its option, as described above. THE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, including (but not limited to) damage or loss of other property or equipment, personal injury, loss of proﬁts or revenues, business or service interruptions, cost of capital , cost of purchase or replacement of other goods, or claims of third parties for any of the foregoing.

 • 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. No employee, distributor, dealer, representative, or other person has the authority to modify any term or condition contained in this Limited Warranty or to grant any other warranty on behalf of or binding on the Manufacturer, and anyone’s attempt to do so will be null and void. Buyer should be prepared to verify the date of installation to the satisfaction of the Manufacturer. The rights and obligations of the Manufacturer and Buyer under this Limited Warranty will be governed by the laws of the State of Ohio, USA, to the extent permitted by law.

 • ThisLimitedWarrantygivesyouspeciclegalrightsandyoumayalsohaveotherrights,whichmayvaryfromStatetoState.

Thank you for your purchase

www.wayne-dalton.com

Covered by one or more of the following Patents; 5,408,724; 5,409,051; 5,419,010; 5,495,640; 5,522,446; 5,562,141; 5,566,740; 5,568,672; 5,718,533; 6,019,269; 6,089,304; 6,644,378; 6,374,567; 6,561,256; 6,527,037; 6,640,872; 6,672,362; 6,725,898; 6,843,300; 6,915,573; 6,951,237; 7,014,386; 7,036,548; 7,059,380; 7,121,317; 7,128,123; 7,134,471; 7,134,472; 7,219,392; 7,254,868. Canadian: 2,384,936; 2,477,445; 2,495,175; 2,507,590; 2,530,701; 2,530,74; 2, 2,532,824. Other US and Foreign Patents pending

To find your Wayne-Dalton dealer; refer to your local yellow pages / business listings or go to Find a dealer area online at www.wayne-dalton.com

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer.

Wayne-Dalton 5120, 5140 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual