Wayne-Dalton WAYNEWOOD DOORS 40 User Manual

START HERE

IMPORTANT! READ IMPORTANT SAFETY NOTICES AND REFER TO INSERT SHEET INSTRUC-

TIONS TITLED “REMOVING THE OLD DOOR/PREPARING THE OPENING”. IF THE INSERT SHEET
INSTRUCTIONS ARE NOT INCLUDED, CONTACT WAYNE-DALTON CORP. FOR A FREE COPY. If remov­ing an existing door, carefully follow the directions given on the insert sheet instruction in the portion titled “Removing
the Old Door”.

WARNING!

REMOVAL OF AN EXISTING DOOR CAN BE DANGEROUS. FOLLOW INSERT SHEET INSTRUCTIONS
CAREFULLY, OTHERWISE SERIOUS INJURY OR DEATH COULD OCCUR.

Begin the installation of the door by checking the opening. It must be the same size as the door. Vertical jambs must
be plumb and the header level. Side clearance, from edge of door to wall, must be minimum of 3-1/2” (89 mm) on each
side. For proper opening preparation refer to the portion of the insert sheet instructions titled “Preparing the
Opening”. Follow the steps below. The steps correspond to the illustrations on the garage door layout.

NOTE: It is recommended that 5/16” x 1-5/8” and 2” lag screws be pilot drilled using a 3/16” (5mm) drill bit, and

1/4” x 1” lag screws be pilot drilled using 1/8” (3mm) drill bit, prior to fastening.

1A

Fully adjustable track: Secure the vertical to the lower slot in the flagangle using (1) stud plate and (2) whiz nuts.

NOTE: Some “bolt on track” will have (2) track bolts (k) instead of a stud plate.

Q.I. Track: Put the lower Twistlock tab on the flagangle into the Twistlock hole in the vertical track. Give the

flagangle 1/4 turn to lock in place. Repeat for other side.

1B-1C

Fully adjustable track: To attach the bottom (short) jamb bracket, locate the lower hole/slot pattern in the vertical
track. Align the slot in the jamb bracket with the lower hole of the hole/slot pattern in the vertical track. Secure jamb
bracket with (1) 1/4-20 x 9/16” track bolt and nut. Place the center (long) jamb bracket over the hole/slot pattern
nearest to the center of the track. Loosely fasten the bracket onto the track with (1) 1/4-20 x 9/16” track bolt and nut.

NOTE: Doors over 7’3” high get (3) set of jamb brackets. Install the center and top jamb brackets so that they are

equally spaced in between the flagangle and bottom jamb bracket.

1D

Q.I. Track: Using the
the jamb brackets for your door height. Align the Twistlock™ wings on each jamb bracket with the correct butterfly
hole in the track and turn the jamb bracket perpendicular to the track so the mounting flange is toward the back leg of
the track.

2A

Bottom brackets are right and left. Before attaching the bottom brackets, secure the counterbalance cables to the
brackets by placing the looped end of the cables over the milford pin. Attach the bottom brackets to the bottom
corners of the sections, aligning the bottom of the bracket with the bottom of the section. Using the bracket as a
template, drill (3) 9/32” (7mm) dia. holes through the section. Secure the bracket to the section with
(3) 1/4-20 x 1-7/8” carriage bolts and hex nuts each. NOTE: Double car doors get (5) carriage bolts and nuts per
bottom bracket (see 2C). Now install a 1/4” x 1” tamper-resistant lag screw into each bottom bracket (Pilot drilling a
1/8” (3mm) dia. hole into the section.

IMPORTANT! When pre-drilling 1/8” hole for tamper-resistant lag be sure NOT to drill through the section).
IMPORTANT! Right and left hand is always determined from inside the building looking out.

Strut Installation (if necessary): Wood doors are provided with short struts and long struts. Center the short strut

on the bottom of the bottom section in between the two bottom brackets. The strut should be at least 3/4” (19mm)
from the bottom of the section. Secure strut using (2) 1” lag screws on each end and center stile (alligned with hinges)
locations.

2B

Align the bottom seal (may not be provided) with the angled extension to the outside of the door (see 2B). Starting at
one end of the door, attach the seal to the bottom of the section with 3/4” long galvanized roofing nails (not supplied).
Stretch the seal slightly and nail the seal to the bottom of the door every 6”.

3A-3B

Locate the lower leaf of the No. 1 end hinges and required No.1 center hinges over the predrilled holes in the end stiles
and center stiles at the top of the bottom section (for strut installation, see below). Secure the hinges to the sections
using (2) 1/4-20 x 1-7/8” carriage bolts and hex nuts each. Insert (1) roller in each end hinge. Repeat using No. 2 end
hinges for second (lock) section and No. 3/No.4 hinges for the third/forth (intermediate) section(s).

IMPORTANT! Do NOT over tighten hex nuts.
IMPORTANT! When placing rollers into end hinges No. 2 and higher, the roller must be inserted into the tube

furthest away from section. See 3B.

Strut Installation (if necessary): Place a long strut over the lower hinge leafs of the section and secure the hinges

and strut together to the sections using (2) strut clips and (2) 1/4-20 x 1-7/8” carriage bolts and hex nuts each.
(See Fig 22 this page and Strutting Schedules on reverse side of this manual.)

4A-4B

Standard Flush doors are predrilled for hinges and lift handles. Lift handles may be offset from center of section.
Align lift handle with predrilled holes and assemble the outside and inside lift handle back to back with
(2) 1/4” x 2-1/2” (64 mm) carriage bolts and nuts.

5A-5B

Before installing the bottom section, measure and cut the vinyl jamb weather-stripping or wood door stops (weather­stripping or wooden stops may or may not be supplied) for entire garage door opening. Vinyl weather seal must be
installed prior to door installation when utilizing fully adjustable track. Attach the weather seal to the jamb
1/8” to 1/4” (3-6mm) past door jamb using the nails supplied with strip. This will help hold the bottom door section
in place. Now, center the bottom section in the door opening. Level it using wooden shims under the bottom seal as
needed. Once the bottom section is level, all the other components will automatically align. Hold the section in the
opening while attaching vertical tracks.

NOTE: In the event that the bottom section was shimmed to level it, then the vertical track on that same side of the

section must be raised the thickness of the shim(s). The tops of the vertical track must be level.

6A-6B

Position the first vertical track over the rollers of the bottom section. Make sure the counterbalance cable is located
between the rollers and the door jamb. Secure jamb brackets and flagangles to the jamb using 5/16” x 1-5/8” lag screws.
Install the other vertical track the same way. Hang counterbalance cables over flagangles.

IMPORTANT! The tops of the vertical tracks must be level from side to side. If the bottom section was shimmed

to level it. The vertical track on the shimmed side, must be raised the height of the shim.

7A

Make sure the top leaves of all hinges on the bottom section are folded down. With assistance lift second section and
place rollers over the tops of the vertical tracks. Install by guiding rollers into the vertical track on both sides and
gently lowering the section onto the bottom section. Keeping the ends of the sections aligned, install remaining
section(s), except top section, in same manner. Fasten all hinges to connect the sections by flipping up the hinge leaf
and securing with (2) 1/4-20 x 1-7/8” carriage bolts and nuts.

NOTE: To install lock, see lock instructions included in the lock assembly bag.

Quick Install Jamb Bracket Schedule (located on the reverse side), determine the placement of

11A

6

a

a

1B

a

2A

8

WayneWood Doors Models: 40,42,43,45,47

Torsion Spring Installation Instructions Layout

18A

d

b

a

10

ALIGN
HOLES

h

OPTIONAL SELF­DRILLING SCREW

11B

15” RAD.

12” RAD.

e

b

12

d

INSERT COUNTER-BALANCE CABLE

16

BEND

9

1-11/16”
(43 mm)

1A

h

e

g

j

3-1/4”

p

18B

8

1C

k

k

1D

g

g

g

LEFT HAND BOTTOM
BRACKET

OUTSIDE

p

p

i

p

j

g

7A

p

p

2B

ANGLED
EXTENSION

2C

3/4”
ROOFING
NAIL

p

LEFT HAND BOTTOM
BRACKET

g

p

p

LEVEL

i

p

p

j

5A

JAMB

1/8”-1/4”

WEATHER
SEAL

DOOR

e

e

3A

g

p

3B

m

m

5B

13

e

q

e

14

RED

BLACK

n

n

15

b

b

17

21

CENTER
STILE

22

STRUT
CLIP

20

4B

p

m

4A

p

p

2-1/2” (64 mm)

m

p

Identify the supplied top brackets. Measure down from the top of the section 3-1/4” (83mm) and mark location. Align
the top holes on the top bracket with the mark and align the edge of the bracket with the edge of the section. Using the
top bracket as a template, drill (4) 9/32” (7mm) holes through the section. Secure the brackets using (4) 1/4-20 x 1-7/8”
carriage bolts and hex nuts each. Insert a roller into each top bracket and loosen the bolt in the adjustable slides. Proper
adjustment will be required once the track is installed.
Strut Installation (if necessary): Center the short strut onto the top of the top section in between the two top
brackets. The strut should be at least 3/4” (19mm) from the top of the section. Secure strut using (2) 1” lag screws on
each end and center stile (alligned with hinges) locations.

Place the top section in the door opening. Keeping the ends of the sections aligned, secure it temporarily by driving a nail
into the header near the center of the door and bending it over the section. Once section is secure, fold the upper leaves
of the hinges from the section below to the top section and secure with (2) 1/4-20 x 1-7/8” carriage bolts and nuts.

9

Position flagangle 1-11/16” (43 mm) from the edge of the door. Tighten the first lag screw then secure the flagangle to the
jamb with (2) more 5/16” x 1-5/8” lag screws. Now complete the vertical track installation on both sides by securing the
center jamb brackets and tightening other lag screws.

IMPORTANT! Vertical tracks must be secured so that the rollers are touching the deepest part of the curved side of the

track.

10

Align the Slidelock™ tabs on the applicable horizontal angle with key slots in the horizontal track. Push the parts
together. Using a hammer, tap the horizontal angle towards the curved end of the track until the hole in track and angle
are aligned.

NOTE: For large size doors, a full length horizontal angle is already spot welded to the horizontal track.

11A-11B

To install horizontal track, place the curved end over the top roller. Align the bottom of the horizontal track with the top
of the vertical track. Fully adjustable track: Secure the track to the flagangle with (1) stud plate and nuts.

NOTE: For “bolt on” track, secure the horizontal track to the flagangle with (2) 1/4-20 track bolts and nuts.)

Q.I. Track: Align the key slot in the track with the quick install tabs on the flagangle. Push the curved portion of the

horizontal track downward to lock into place.

Level horizontal track and bolt the horizontal angle to the slot in the flagangle using (1) 3/8-16 x 3/4” truss head bolt and
nut. Repeat for other side. Remove nail which is temporarily holding the top section.

With tracks installed you can adjust the top brackets. Vertically align the top section with the lower sections. Once
aligned, position top roller in adjustable slide against horizontal track, maintain position and tighten nut(s).
Add a 1/4-20 x 11/16” self-drilling screw into the slide to lock the slide in place (see 11B). Repeat for other side.

IMPORTANT! Failure to remove nail before attempting to raise door could cause permanent damage to top section.

WARNING! DO NOT ATTEMPT TO RAISE DOOR AT THIS TIME.

12

End bearing brackets are right and left. Locate the end bearing bracket above the flagangle and secure the bracket to the
horizontal angle using (2) 3/8-16 x 3/4” truss head bolts and nuts. Once the bracket is secured to the horizontal angle,
secure the top of the bracket to the jamb using (1) 5/16” x 1-5/8” lag screw.

IMPORTANT! End bearing brackets must be attached through the lower slots on 12” radius track and through the upper

slots on 15” radius track.

13

Locate the center of the door and mark a vertical pencil line on the spring pad. Then measure the distance from the center
of the mounting hole (hole where tube fits into) in the end bearing bracket to the top of the door. Using that same distance,
mark a horizontal line on the spring pad, measuring up from the top of the door. Align the center bearing bracket edge
along the vertical pencil line on the spring pad as shown. In addition, position the center bearing bracket halfway over the
horizontal pencil line. This will level the torsion tube through the end bearing brackets when installed. Attach the center
bearing bracket to the spring pad using (2) 5/16” x 1-5/8” lag screws and (1) 5/16” x 2” tamper-resistant lag screw.

IMPORTANT! Use the 5/16” x 1-5/8” tamper-resistant lag screw ONLY if spring pad is mounted over masonry.

IMPORTANT! Tamper-resistant lag screw MUST be attached through the bottom hole of the center bearing bracket.

14

Facing the inside of the door, lay the torsion tube on the floor. Lay the black color coded winding cone with spring and
cable drum on the floor at the right end of the tube. Then lay the red color coded winding cone with spring and cable drum
on the floor at the left end of the tube.

NOTE: Right and left hand is always determined from inside the building looking out.

NOTE: Some lighter weight doors are provided with only (1) torsion spring. Identify the spring(s) provided as either

right hand wound (red winding cone), which goes on the LEFT HAND SIDE or left hand wound (black winding cone),
which goes on the RIGHT HAND SIDE.

NOTE: The set screws used on all Torsion Counterbalance cable drums and winding cones are now painted red.

DO NOT identify right and left hand side by the set screws.

Slide the nylon center bushing onto the torsion tube followed by the spring(s) and cable drums. The nylon center
bushing, spring(s), and cable drums must be positioned as shown in the illustrations. With assistance, pick up the torsion
tube assembly and slide one end the of tube through one end bearing bracket. Lay the torsion tube into the center bearing
bracket and slide the other end of the tube into the opposite end bearing bracket. Position the torsion tube so that equal
amounts of the tube extend from each end bearing bracket.

15

Slide the nylon center bushing into the end of (1) stationary spring cone and align the cone(s) with the holes in the center
bearing bracket. Secure the spring(s) to the center bearing bracket with (2) 3/8-16 x 1-1/2” bolts and nuts.

IMPORTANT! Springs under tension can be dangerous. Spring warning tag must be attached to center bearing bracket

in obvious sight. If this tag is missing, contact Wayne-Dalton Corp. for free replacements.

Clamp locking pliers onto both vertical tracks just above the third roller. This is to prevent door from raising while
winding the spring(s).

WARNING!

FAILURE TO CLAMP TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE INJURY OR DEATH.

16

Thread the counterbalance cables around the back side of the cable drums and verify that there is no cable obstructions.
Before hooking cables into drums, slide the loose cable buttons against the crimped buttons and with a pliers bend a 90
degree angle in the cable as illustrated.

NOTE: Some cable assemblies only have the crimped cable button.

Hook the cables into the drums. Slide the left hand cable drum against the end bearing bracket and tighten the set screws
in the drum to 14-15 ft lbs. of torque (Once set screws contact the tube, tighten screws one full turn). Rotate the left hand
drum and torsion tube until cable is taut. Attach locking pliers to torsion tube and brace locking pliers against jamb to
keep cable taut. Slide the right hand cable drum against the end bearing bracket and rotate drum until cable is taut. Tighten
set screws in right hand cable drum.

Clamp locking pliers onto the torsion tube, to keep it from rotating.

CAUTION! Check each cable, making sure both are seated properly on the cable drums and have equal cable tension.

CONTINUE INSTALLATION INSTRUCTIONS ON REVERSE SIDE.

(1) Pliers

(1) 7/16” Wrench

(1) Hammer

(2) Locking Pliers

1/4”-20 Flanged Hex Nut

a

#100279

3/8”-16 Hex Nut

b

#100313

1/4”-20 x 5/8”

c

Carriage Bolt
#262617

Required Tools

(1) Screw Driver
(Phillips Blade)

(1) Screw Driver
(Standard Blade)

(1) Level (2’ Minimum Length)

(1) Electric Drill
with Clutch

7/16” Drill Bit (Step Plate)
9/32” Drill Bit

3/8”-16 x 3/4” Truss Head Bolt

d

#154531

Stud Plate

h

#266102

Gloves

Safety Glasses

(50) 1-1/2”
Common Nail

(1) 7/16” Hex
Head Driver

(2 or 3) Saw Horses or other supports for
placing sections on while assembling

1/4”-20 x 1-7/8” Carriage Bolt

g

#102843

5/16” x 1-5/8” Hex Head Lag Screw

e

#100292

Track Bolt

k

#200527

(1) Step Ladder

(1) Tape Measure

(1) Ratchet with 7/16”,
1/2”, 9/16” sockets

5/16” x 1-5/8” Tamper-Resistant Lag Screw

f

#107801

1/4” x 1” Tamper-Resistant Lag

i

Screw
#141887

1/4” x 1” Lag screw

j

#296575

1/4”-20 x 2-1/2” Carriage Bolt

m

#107687

n

5/16” x 2” Tamper-Resistant Lag Screw

q

#141888

p

3/8” x 1-1/2” Hex Head Bolt
#107645 (Torsion Springs)

1/4”-20 Hex Nut
#107703

Wayne-Dalton Corp.

P.O. Box 67

Mt. Hope, Ohio 44660

IMPORTIMPORT

IMPORT

IMPORTIMPORT

SAFETY NOTICESSAFETY NOTICES

SAFETY NOTICES

SAFETY NOTICESSAFETY NOTICES

ANTANT

ANT

ANTANT

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.

1. Wear protective gloves during installation to avoid possible cuts from sharp metal edges.

2. It is always recommended to wear eye protection when using tools, otherwise serious eye injury could
result.

3. Avoid installing your new door on windy days. Door could fall during the installation and cause damage
and personal injury.

4. If the door is to be electrically operated at any time, all pull ropes MUST be removed to prevent injury or
death to children who may become entangled in the rope. The locking mechanism MUST also be disen­gaged.

5. Operate door ONLY when properly adjusted and free of obstructions.

6. Should the door become hard to operate or completely inoperative, a qualified door agency should
correct the problem to prevent damage to the door or serious personal injury.

7. DO NOT PERMIT children to play with the garage door or the electrical controls. Fatal injury could
result, should the child become entrapped between the door and the floor.

8. To prevent serious injury or death, avoid standing in the open doorway or walking through the doorway
while the door is moving.

9. Door is constantly under EXTREME SPRING TENSION. To prevent possible serious injury or death,
adjustments, repairs, removal or installation, ESPECIALLY of SPRING ASSEMBLIES, CABLES or
BOTTOM CORNER BRACKETS, should be performed ONLY by qualified door service people.

10. If your existing garage door opener does not have a reversing mechanism, you should consider
purchasing one that has up to date safety features. These features can prevent opener related property
damage or personal injury.

11. Check all bolted connections monthly during the lifetime of the door to prevent damage or personal
injury caused by loose connections.

12. Definition of key words used in this manual:

WARNING! -- Indicates a potentially hazardous situation which, if not avoided, could result

in serious injury or death.

IMPORTANT! -- Required step for safe and proper door operation.

NOTE: -- Information assuring proper installation of the door.

Copyright 2003 Wayne-Dalton Corp.

©

Maintenance and Painting Instructions for All Wood Doors

These instructions apply to all Wood Doors produced and sold by Wayne-Dalton Corp. The interior
and exterior surfaces, as well as all edges must be properly primed, 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 (3 top coats) 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. IMPROPER STORAGE,
TRANSPORTATION OR DELAY IN FINISHING, THAT EXPOSE WOOD DOOR SURFACES TO
MOISTURE OR OTHER CONTAMINANTS, WILL RESULT IN THE WARRANTY BEING VOIDED.

Surface Preparation

All surfaces must be clean, free of dust and dirt and any other contamination. Any scarring or stains
that occur during transportation, handling and storage must be re-sanded to the original condition.

Painted Finishes

When painting a door, the finish coat base must be the same as the primer coat base. A latex based
finish paint is recommended for use over a latex based primer, and an oil based finish paint is
recommended for use over an oil based primer. Prime the interior and exterior surfaces, as well as all
edges, using paint approved for use on the specific species of wood substrate being finished. (Note:
Some species of wood, such as cedar, require special primers and finishes to prevent tannin stains from
appearing. Consult with your paint supplier.) If the door is factory primed by Wayne-Dalton Corp., the
priming step is not required, unless touch-up is needed due to surface preparation and re-sanding.
(Note: Wayne-Dalton Corp. uses a latex primer, so latex finish paint is required.) Finish paint the interior
and exterior surfaces, as well as all edges with at least 2 coats of finish paint over the primer. Follow
paint manufacture’s label directions completely for all coatings.

Clear or Stained Finishes

If staining, apply an exterior grade stain, approved for use on each species of wood substrate being
finished, to the interior and exterior surfaces, as well as all edges, following stain manufacturer’s label
directions. The stain selected must be compatible with the urethane finish that will be used to finish the
door. After proper drying time for the stain (or if stain in not being applied), apply 1 coat of urethane
finish to the interior and exterior surfaces, as well as all edges. After recommended drying time of 1
coating, sand with a fine grit (320) sandpaper. Clean all surfaces of sanding dust and apply a 2nd coat of
the urethane coating to the interior and exterior surfaces, as well as all edges,. After 2nd coat is dry,
sand with a fine grit (320) sandpaper again. Clean all surfaces of sanding dust and apply a final 3
coat. Three urethane finish coats are required for proper finish. Follow the finish manufacturer’s label
directions completely for each coating applied. (NOTE: Do not stain MDO plywood, apply paint only.
Only a urethane finish is an approved top coat for stained or natural doors. Other types of top coat
finishes, including deck sealers, are not acceptable and if used, will void the warranty.

Maintenance and Refinishing

Yearly inspection of all the 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).

Copyright 2003 Wayne-Dalton Corp.

©

st

rd

Rev 04/15/2003

Parts List

PART NO. 307327

plied if not necessary.

NOTE: Depending on the door model, some parts listed will not be sup-

(W) 60” PULL ROPE # 274884
(V) # 6 SCREW EYE # 100362
(U) REAR SUPPORT SOLD SEPARATELY
(T) STRUTS AS REQUIRED
(S) TORSION SPRING(S) AS REQUIRED
(R) NYLON CENTER BUSHING # 103336
(Q) CENTER BEARING BRACKET # 100298
(P2) END BEARING BRACKET (LH) # 279134
(P1) END BEARING BRACKET (RH) # 103415
(O) COUNTERBALANCE CABLES 1 PAIR
(N2) CABLE DRUM (LEFT) # 284654
(N1) CABLE DRUM (RIGHT) # 284653
(M) TORSION TUBE AS REQUIRED
(L3) 80-5/8” QI HORIZ. ANGLE (LEFT) # 292540
(L2) 80-5/8” QI HORIZ. ANGLE (RIGHT) # 292541
(L1) 23-3/32” HORIZ. ANGLE # 292537
(K2) R 15” UNIV. FLAGANGLE (RIGHT, 19-7/16”) # 285215
(K1) R 15” UNIV. FLAGANGLE (LEFT, 19-7/16”) # 285214
(J2) R 12” UNIV. FLAGANGLE (RIGHT, 18-1/16”) # 285207
(J1) R 12” UNIV. FLAGANGLE (LEFT, 18-1/16”) # 285206
(H2) R 12” Q.I. FLAGANGLE (RIGHT, 18-1/2”) # 292533
(H1) R 12” Q.I. FLAGANGLE (LEFT, 18-1/2”) # 292532
(G) HORIZONTAL TRACK 1 PAIR
(F2) ST-1 JAMB BRACKET (LONG) # 270345
(F1) ST-0 JAMB BRACKET (SHORT) # 287665
(E3) QIJB - 8 JAMB BRACKET # 297927
(E2) QIJB - 7 JAMB BRACKET # 297926
(E1) QIJB - 6 JAMB BRACKET # 297925
(D) VERTICAL TRACK 1 PAIR
(C) ROLLER # 100269
(B2) BOTTOM BRACKET (LEFT) # 295762
(B1) BOTTOM BRACKET (RIGHT) # 295763
(A2) TOP BRACKET (SLIDE) # 270344
(A1) TOP BRACKET (BASE) # 270343

U

W

V

D

J2

B1

C

O

A2

T

A1

N1

Q

S

B2

F1

F2

G

M

J1

L1

N2

© Copyright 2003 Wayne-Dalton Corp.

www.wayne-dalton.com

Installation Instructions and Owners Manual

Models: 40,42,43,45,47

WayneWood - Torsion Spring

17

Position a ladder slightly to the side of spring so that the winding cone is easily accessible, yet your body is not in the path
of the winding bars. Check the tag(s) attached to the spring(s) for the number of required spring turns.

6’0” Door Height = Approx. 6-3/4 Turns
6’3” Door Height = Approx. 7 Turns
6’6” Door Height = Approx. 7-1/4 Turns
6’9” Door Height = Approx. 7-1/2 Turns
7’0” Door Height = Approx. 7-3/4 Turns
7’3” Door Height = Approx. 8 Turns
7’6” Door Height = Approx. 8-1/4 Turns
7’9” Door Height = Approx. 8-1/2 Turns
8’0” Door Height = Approx. 8-3/4 Turns

Inserting winding bars into holes of winding cone, one after the other, rotate winding cone upward toward ceiling 1/4 turn
at a time until correct number of turns for your door height is achieved. As the last 1/4 turn is achieved, securely hold
winding bar while tightening both set screws in winding cone to 14-15 ft-lbs of torque (Once set screws contact the tube,
tighten screws one full turn). Carefully remove winding bar from winding cone. If required, repeat for other side.

While holding the door down to prevent it from rising unexpectedly, in the event the spring(s) were overwound. Carefully
remove the locking pliers from the vertical tracks and torsion tube. 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 rear of horizontal track is not yet supported.

WARNING!

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

Now clamp a pair of locking pliers to the vertical tracks just above the second roller on one side, and just below the second
roller on the other side. This will prevent the door from raising or lowering while installing the rear support.

18A-18B

Using perforated angle, fabricate rear support for horizontal tracks as shown.

IMPORTANT! Using 5/16” x 2” lag screws, make sure that support is fastened into ceiling joist, or adequate framing

members to hold the weight of the door. Keeping the horizontal track parallel to the edge of the door sections, raise the
horizontal track to a level position and bolt it to the rear support structure using (1) 5/16” hex bolt and nut on each side.
Track must be secured and braced to prevent movement. The bolt should extend into the track to act as a roller stop.
Repeat for other side. Remove locking pliers and close door.

WARNING! KEEP HORIZONTAL TRACK PARALLEL AND WITHIN 3/4” OF DOOR EDGE,

OTHERWISE DOOR COULD FALL FROM TRACKS, RESULTING IN SERIOUS INJURY OR DEATH.

19 (Not illustrated)

Permanently attach the vinyl weather stripping (or wood door stops) to both door jambs and the header. Now lift the door
and check it’s balance. Unwind spring(s) if door lifts by itself or if it is hard to pull down. Wind spring(s) if door is difficult
to lift or too easy to pull down.

To adjust spring tension, fully close door. Apply locking pliers to track above third roller. Insert a winding bar into the
winding cone. Push upward on the winding bar 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.

NOTE: On doors utilizing one spring, it will be necessary to clamp the torsion tube with locking pliers to keep

counterbalance cables on cable drums BEFORE loosening set screws.

Carefully adjust spring tension 1/4 turn. Retighten both set screws in the winding cone and if required, repeat for the other
side. Recheck door balance DO NOT ADJUST MORE THAN 1/2 TURN FROM THE RECOMMENDED NUMBER
OF TURNS. If door still does not balance correctly, contact a qualified door agency.

If the door still does not operate easily, lower the door into the closed position, UNWIND THE SPRING(S) FULLY
(Reference the insert sheet “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 tube for level.

3.) Check the track spacing.

4.) Check the counterbalance cables for equal tension.

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

6.) Clamp locking pliers onto track and rewind spring(s).

IMPORTANT! If door still does not operate properly, then contact a qualified door agency.

20

Twist the No. 6 screw eye into the wood jamb approximately 48” to 50” (1220 to 1270 mm) from the floor. Tie the pull
rope to the screw eye and to the bottom bracket as shown.

WARNING! DO NOT INSTALL PULL ROPES ON DOORS WITH ELECTRIC OPERATORS.

CHILDREN MAY BECOME ENTANGLED IN THE ROPE CAUSING INJURY OR DEATH.

21

If you are installing an electric operator on your door, the following information is provided to ensure proper function of
your door/operator installation. See fig. 21 (on reverse side) for a typical operator arm installation.

1. Follow the installation instructions supplied with your operator.

2. Reinforce top section per manufacturer’s recommendation prior to attaching operator.

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

4. 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).

5. The operator bracket must be mounted to the operator stile on the top section so it bridges the transition point in section
thickness.

6. Attach operator rail to spring pad (vertical wood support above center of header).

7. Attach operator to ceiling using perforated angle.

8. IMPORTANT! Angle(s) must be attached to framing memeber(s).

TYPICAL OPERATOR INSTALLATION

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 INJURY OR DEATH.
IF YOUR OPERATOR IS EQUIPPED
WITH PHOTOELECTRIC SYSTEM,
THEN THIS MUST BE TESTED AT THE
SAME TIME TO ENSURE THAT DOOR
DOES NOT CLOSE AND A CLOSING
DOOR OPENS IF SYSTEMS IS OB­STRUCTED. FAILURE TO MAKE AD­JUSTMENTS, IF NECESSARY, CAN RE­SULT IN SEVERE INJURY OR DEATH.

ATTACH OPERATOR

RAIL SECURELY TO
SPRING PAD

IMPORTANT! ANGLE MUST BE

ATTACHED TO FRAMING MEMBERS

INSTALL FRONT OF TROLLEY RAIL
1/2” TO 1-1/2” (13 - 38mm) ABOVE
HIGH-ARC OF SECTIONS

Strutting Schedule: Doors 8 ft. high and below

tcudorP

74,54,34,24,04ledoMsraB-U"2)3(**sraB-U"2)3(**sraB-U"3)3(**

** (2) SHORT U-BARS AND THE REST LONG U-BARS WITH HOLES

htdiWrooD

"2-'21ot"0-'8

Strutting Schedule: Doors greater than 8 ft. high

tcudorP

74,54,34,24,04ledoM

** (2) SHORT U-BARS AND THE REST LONG U-BARS WITH HOLES

htdiWrooD

"2-'01ot"0-'8

raB-U"2)1(**

noitcesrep

Quick Install Jamb Bracket Schedule

Residential Wood Panel

htdiWrooD

"0-'61ot"3-'21

htdiWrooD

"0-'81ot"1-'61

The Manufacturer warrants Wood Doors will be free from defects in material and workmanship for a
period of ONE YEAR from the time of delivery, provided the interior and exterior surfaces, as well as all
edges of the wood doors are properly finished according to Wayne-Dalton Corp.’s Maintenance and

LIMITED WARRANTY

Fully Adjustable Track Jamb Bracket Schedule

INSTALL THE SHORTEST JAMB BRACKET ON THE
BOTTOM HOLE/SLOT PATTERN. THE CENTER JAMB
BRACKET(S) IS/ARE CENTERED BETWEEN THE BOTTOM
JAMB BRACKET AND FLAGANGLE.

CENTER JAMB
BRACKET
(LONGEST)

Painting Instructions and the finish manufacturer’s instructions. All surfaces of wood doors must be
protected with three(3) coats of paint, including primer, or three(3) coats of urethane finish, whether
wood is stained or left natural, prior to any exposure of the doors to moisture. Non-finished doors must
be protected from exposure to moisture during transportation and storage. Sections should not be
installed until they have been finish painted or stained and sealed with urethane finish. IMPROPER
STORAGE, TRANSPORTATION OR DELAYS IN FINISHING THAT EXPOSE WOOD SURFACES TO
MOISTURE OR OTHER CONTAMINANTS, WILL RESULT IN THIS WARRANTY BEING VOIDED.

The Manufacturer warrants the garage door hardware, track, and springs against defects in workmanship

htdiWrooD

"0-'61ot"3-'01

raB-U"2)1(**

noitcesrep

htdiWrooD

"0-'81ot"1-'61

repraB-U"3)1(**

noitces

or material for a period of ONE YEAR from time of installation.

Manufacturer shall, upon notification, correct such nonconformity at its option, by repairing or replacing
any defective part(s). This warranty covers material only and excludes all other charges incurred.

NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THE FOREGOING

rooD

thgieH

"6-'6

"0-'7

"6-'7

"0-'8

teSts1teSdn2teSdr3

7-BJIQ

POT

7-BJIQ

POT

6-BJIQ

POT

6-BJIQ

POT

DIM

DIM

TOB

TOB

8-BJIQ

8-BJIQ

7-BJIQ

7-BJIQ

A/N

A/N

8-BJIQ

TOB

8-BJIQ

TOB

WARRANTIES IN ANY WAY OR GRANT ANY OTHER WARRANTY ON BEHALF OF MANUFACTURER.

The Manufacturer shall not be responsible for any damage resulting to or caused by its products by
reason of installation, improper storage, unauthorized service, alteration of products, neglect or abuse, or
attempt to use the products for other than the customary usage or for their intended purposes. The above
warranty becomes null and void if holes are drilled other than those specified by the Manufacturer. This
warranty does not cover the product due to circumstances such as normal wear, damage from corrosive
fumes or substances, fire, condensation, vandalism, acts of God, or other causes beyond Manufacturer’s
control, nor replacement or repair labor.

NOTE: Jamb brackets are stamped for identification.

3RD

SET

2ND

SET

1ST
SET

NOTE: DOORS OVER 7’3” HIGH GET

(3) SETS OF JAMB BRACKETS.
INSTALL THE CENTER AND TOP
JAMB BRACKETS SO THAT THEY
ARE EQUALLY SPACED IN BETWEEN
THE FLAGANGLE AND BOTTOM
JAMB BRACKET.

NOTE: THE BOTTOM JAMB

BRACKET IS THE SHORTEST
IS LENGTH. IT DOES NOT
NECESSARILY MEAN THE
“SHORT” (ST-0) JAMB
BRACKET.

CENTER JAMB
BRACKET

BOTTOM JAMB
BRACKET
(SHORTEST)

NOTE: Jamb brackets are stamped for identification.

IF THIS WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON-MOSS
WARRANTY ACT, NO WARRANTIES, EXPRESSED OR IMPLIED, (INCLUDING, BUT NOT LIMITED
TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), SHALL
EXTEND BEYOND THE APPLICABLE TIME PERIOD STATED IN BOLD FACE TYPE ABOVE.

Claims for defects in material and workmanship covered by this warranty shall be made in writing to the
dealer from whom the product was purchased within the warranty period. Manufacturer may either send a
service representative or have the product returned to the Manufacturer at Buyer’s expense for inspection.
If judged by Manufacturer to be defective in material or workmanship, the product will be replaced or
repaired at the option of Manufacturer, free from all charges except authorized transportation and replacement
labor.

THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER
REMEDIES. THE LIABILITY OF MANUFACTURER, WHETHER IN CONTRACT, TORT, UNDER ANY
WARRANTY, OR OTHERWISE, SHALL NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR
REPLACE, AT ITS OPTION, ANY PRODUCT OR PART FOUND BY MANUFACTURER TO BE DEFECTIVE
IN MATERIAL OR WORKMANSHIP. MANUFACTURER SHALL NOT BE LIABLE FOR COST OF
REMOVAL OR INSTALLATION OR SHALL NOT BE RESPONSIBLE FOR ANY DIRECT, INDIRECT,
SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE.

This warranty gives you specific legal rights, and you may also have other rights, which may vary from
state to state. However, some states do not allow limitations on how long an implied warranty lasts or the
exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may
not apply to you.

Copyright 2003 Wayne-Dalton Corp.

©