9700 T o r s i o n Rear Mount Low Headroom MH Installation Instructions And Owner s Manual Table Of Contents Pre-Installation 2 Important Safety Instructions 2 Tools Required 2 Package Contents 2 Door Section Identification 3 Removing an Existing Door 3 Preparing the Opening 3 Parts Breakdown 5 Installation 6 Optional Installation 16 Door Arm Hookup 16 Inside Lock 16 Pull Down Rope 16 Maintenance 17 Cleaning Your Garage Door 17 Painting Your Garage Door 17 Maintaining The Finish On Your Garage Door 17 Operation And Maintenance 17 Warranty 18 PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE Please Do Not Return This Product To The Store. Please call 1-866-569-3799 (Press Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have. IMPORTANT NOTICES! Wayne Dalton highly recommends that you read and fully understand the Installation Instructions and Owner s Manual before you attempt this installation. To avoid possible injury, read the enclosed instructions carefully before installing and operating the garage door. Pay close attention to all warnings and notes. After installation is complete, fasten this manual near garage door for easy reference. DEFINITION OF DOOR HEIGHTS: 1. Door Heights less than or equal to 8 0 (< = 8 0 ) are considered Standard Lift Applications. 2. Door Heights greater than 8 0 (> 8 0 ) are considered Light Commercial Applications. The complete Installation Instructions and Owner s Manual are available at no charge from: Wayne Dalton, a Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, Or Online At www.wayne-dalton.com. Copyright 2015 Wayne Dalton, a Division Of Overhead Door Corporation Part Number 345579 REV1_04/30/2015
Pre-Installation Important Safety Instructions DEFINITION OF KEY WORDS USED IN THIS MANUAL: INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH; IF NOT AVOIDED, COULD RESULT IN SEVERE OR FATAL INJURY. CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT FROM FAILURE TO FOLLOW INSTRUCTIONS. IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER DOOR OPERATION. NOTE: Information assuring proper installation of the door. READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING INSTALLATION. IF IN QUES- TION ABOUT ANY OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A TRAINED DOOR SYSTEMS TECHNICIAN DO THE INSTALLATION OR REPAIRS. 1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS. 2. Wear protective gloves during installation to avoid possible cuts from sharp metal edges. 3. It is always recommended to wear eye protection when using tools, otherwise eye injury could result. 4. Avoid installing your new door on windy days. Door could fall during the installation causing severe or fatal injury. 5. Doors 12-0 wide and over should be installed by two persons, to avoid possible injury. 6. Operate door only when it is properly adjusted and free from obstructions. 7. If a door becomes hard to operate, inoperative or is damaged, immediately have necessary adjustments and/ or repairs made by a trained door system technician using proper tools and instructions. 8. DO NOT stand or walk under a moving door, or permit anybody to stand or walk under an electrically operated door. 9. DO NOT place fingers or hands into open section joints when closing a door. Use lift handles/ gripping points when operating door manually. 10. DO NOT permit children to operate garage door or door controls. Severe or fatal injury could result should the child become entrapped between the door and the floor. 11. Due to constant extreme spring tension, do not attempt any adjustment, repair or alteration to any part of the door, especially to springs, spring s, bottom corner s, fasteners, counterbalance lift cables or supports. To avoid possible severe or fatal injury, have any such work performed by a trained door systems technician using proper tools and instructions. 12. On electrically operated doors, pull down ropes must be removed and locks must be removed or made inoperative in the open (unlocked) position. 13. Top section of door may need to be reinforced when attaching an electric opener. Check door and/ or opener manufacturer s instructions. 14. Visually inspect door and hardware monthly for worn and or broken parts. Check to ensure door operates freely. 15. Test electric opener s safety features monthly, following opener manufacturer s instructions. 16. NEVER hang tools, bicycles, hoses, clothing or anything else from horizontal s. Track systems are not intended or designed to support extra weight. 17. This door may not meet the building code wind load requirements in your area. For your safety, you will need to check with your local building official for wind load code requirements and building permit information. After installation is complete, fasten this manual near the garage door. IMPORTANT: STAINLESS STEEL OR PT2000 COATED LAG SCREWS MUST BE USED WHEN INSTALLING CENTER BEARING BRACKETS, END BRACKETS, JAMB BRACKETS, DRAWBAR OPERATOR MOUNTING/ SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER (PRESERVATIVE-TREATED). STAINLESS STEEL OR PT2000 LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN-TREATED LUMBER. NOTE: It is recommended that 5/16 lag screws are pilot drilled using a 3/16 drill bit, prior to fastening. IMPORTANT: WHEN INSTALLING 5/16 LAG SCREWS USING AN ELECTRIC DRILL/ DRIVER, THE DRILL/ DRIVERS CLUTCH MUST BE SET TO DELIVER NO MORE THAN 200 IN-LBS OF TORQUE. FASTENER FAILURE COULD OCCUR AT HIGHER SETTINGS. PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS, EN- SURE 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. IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT. Tools Required Power drill (2) Vice clamps Level Drill bits: 1/8, 3/16, 9/32, 7/16, 1/2 Wrenches: 3/8, 7/16, 1/2, 9/16, 5/8 Pencil Ratchet wrench 1/4 Torx bit Saw Horses Socket driver: 7/16 Approved winding rods Leather gloves Sockets: 7/16, 1/2, 9/16, 5/8 Phillips head screwdriver Locking Pliers Hammer Tape measure Step Ladder Package Contents Safety glasses NOTE: Depending on the door model, some parts listed will not be supplied if not required. Rear Back Hangs may not be included with your door. Door sections (as required) Torsion shaft Or Torsion keyed shaft Torsion keyed shafts (as required) Quick Install flag angles RH/LH (as required) Fully Adjustable flag angles RH/LH (as required) Q.I. Jamb s F.A. Jamb s (as required) (as required) Drawbar operator (if included) (2) Top fixtures Riveted vertical assemblies RH/LH (as required) s RH/LH (as required) Wall angle assemblies RH/LH (as required) Weather seals & Door stop & nails nails (If included) (If included) Track rollers Horizontal s RH/LH Pull down rope (if included) Strut (U-shaped) (if included) 2
Bottom corner s RH/LH (as required) Cable drums RH/LH bushing (2) Cable assembly (as required) assembly (as required) lift sheaves coupler assembly (as required) Keys (as required) Oval Bearings (as required) Counterbalance lift cables The INTERMEDIATE SECTION can be identified by #3 graduated end hinges (Only on a 4 section high door). The section will have a warning label attached to either the right or left hand end stile. NOTE: #4 graduated end hinges are used on the fourth section of five section doors. The INTERMEDIATE SECTION II can be identified by #4 end hinges. The INTERMEDIATE SECTION III can be identified by #5 end hinges. The INTERMEDIATE SECTION IV can be identified by #6 end hinges. The TOP SECTION can be identified with no pre-installed graduated end or center hinges. Warning label Torsion springs RH/LH Clevis pins Cotter pins #6 Top section 2 #6 Graduated end hinge 1/4-14 x 5/8 Self tapping screws (as required) 1/4-20 x 9/16 Track bolts (as required) 1/4-20 x 7/8 Self drilling screws (as required) 1/4-20 x 5/8 Tamper resistant Self drilling screws (as required) 1/4-20 x 11/16 Self drilling screws (as required) 5/16-16 x 3/4 Carriage bolts #12 x 1/2 (as required) Phillips head screws #5 #4 #3 Intermediate IV section Intermediate III section Intermediate II section 1-7/8 #5 Graduated end hinge 1-5/8 #4 Graduated end hinge 1-3/8 #3 Graduated end hinge (2) 3/8-16 x 3/4 Truss head bolts 3/8-16 Hex nuts 5/16-16 Hex nut (as required) 1/4-20 Flanged hex nuts (as required) #2 Intermediate I section 1-1/8 #2 Graduated end hinge 5/16 x 1-5/8 Tamper-resistant hex head lag screw (as required) 5/16 Washers #1 Lock section 7/8 #1 Graduated end hinge 5/16 x 2 Tamper-resistant hex head lag screw (as required) Cable sheave saddles (as required) Bottom weather seal Bottom section Typical graduated end hinge stamping location Bottom corner Bottom weather seal Section side view illustration 5/16 x 1-5/8 Hex head lag screws (as required) 3/8-16 x 1-1/2 Hex head bolts (as required) Door Section Identification Graduated end and center hinges are always pre-attached at the top of each section (except top section) and the graduated end hinges are stamped for identification, #1, #2, #3, #4, #5 and #6. The stamp identifies the stacking sequence of the section. Depending on your door height, the sequence is always determined by #1 being the bottom section to #3, #4, #5 or #6 being the highest intermediate section. If the stamp on the graduated end hinge is illegible, refer to the section side view illustration. The section side view illustration shows the graduated end hinge profile of all sections, and can also be used to identify each section. The BOTTOM SECTION can be identified by #1 graduated end hinges, the factory attached bottom astragal, the factory attached bottom corner s and by the bottom corner warning labels on each end stile. The LOCK SECTION can be identified by #2 graduated end hinges on a 4 section high door and by #3 graduated end hinges on a 3 section high door. Also, on a 3 section door, the lock section will come with a warning label attached to the right or left endstile. Removing an Existing Door IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR. A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY. TO AVOID INJURY, HAVE A TRAINED DOOR SYSTEMS TECHNICIAN, USING PROPER TOOLS AND INSTRUCTIONS, RELEASE THE SPRING TENSION. For detailed information see supplemental instructions Removing an Existing Door/ Preparing the Opening. These instructions are not supplied with the door, but are available at no charge from Wayne Dalton, A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, or at www.wayne-dalton.com. Preparing the Opening IMPORTANT: IF YOU JUST REMOVED YOUR EXISTING DOOR OR YOU ARE INSTALLING A 3
NEW DOOR, COMPLETE ALL STEPS IN PREPARING THE OPENING. To ensure secure mounting of s, side and center s, or steel angles to new or retro-fit construction, it is recommended to follow the procedures outlined in DASMA technical data sheets #156, #161 and #164 at www.dasma.com. The inside perimeter of your garage door opening should be framed with wood jamb and header material. The jambs and header must be securely fastened to sound framing members. It is recommended that 2 x 6 lumber be used. The jambs must be plumb and the header level. The jambs should extend a minimum of 12 (305 mm) above the top of the opening for Torsion counterbalance systems. For low headroom applications, the jambs should extend to the ceiling height. Minimum side clearance required, from the opening to the wall, is 3-1/2 (89 mm). IMPORTANT: CLOSELY INSPECT JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD FOUND NOT TO BE SOUND, MUST BE REPLACED. For Torsion counterbalance systems, a suitable mounting surface (2 x 6 ) must be firmly attached to the wall, above the header at the center of the opening. NOTE: Drill a 3/16 pilot hole in the mounting surface to avoid splitting the lumber. Do not attach the mounting surface with nails. WEATHERSTRIPS (MAY NOT BE INCLUDED): Depending on the size of your door, you may have to cut or trim the weatherstrips (if necessary) to properly fit into the header and jambs. NOTE: If nailing product at 40 F or below, pre-drilling is required. NOTE: Do not permanently attach weatherstrips to the header and jambs at this time. For Quick Install : For the header, align the weatherstrip with the inside edge of the header and temporarily secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and flush with the inside edge of the jamb. Temporarily secure the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12 to 18 apart. For other systems: For the header, align the weatherstrip 1/8 to 1/4 inside the header edge, and temporarily secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and 1/8 to 1/4 inside the jamb edge. Temporarily secure the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12 to 18 apart. Headroom requirement: Headroom is defined as the space needed above the top of the door for s, 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. Backroom requirement: Backroom is defined as the distance needed from the opening back into the garage to allow the door to open fully. *NOTE: For door heights from 10 1 to 14 0, refer to your operator manufacture installation instructions for appropriate depth into room. BACKROOM REQUIREMENTS Door Height Track Manual Lift Motor Operated 6 0 to 7 0 Low Headroom 108-1/2 (2756 mm) 125 (3175 mm) 7 1 to 8 0 120-1/2 (3061 mm) 137 (3480 mm) 8 1 to 9 0 132-1/2 (3366 mm) 168 (4267 mm) 9 1 to 10 0 144-1/2 (3670 mm) 168 (4267 mm) 10 1 to 12 0 168-1/2 (4280 mm) See *NOTE 12 1 to 14 0 192-1/2 (4890 mm) See *NOTE Suitable mounting surface 2 x 6 lumber minimum Header board 2 x 6 lumber preferred Min. Side room Clearance is 3 1/2 Plumb jambs Level header Weatherstrips Jambs Headroom Finished Door width Finished Door Height Min. Side room Clearance is 3 1/2 Nail Jamb Quick Install Jamb Fully Adjustable Backroom 1/8 to 1/4 Weatherstrips Weatherstrips HEADROOM REQUIREMENTS Track Type Space Needed 6 Low Headroom 6 (152 mm) 4
PARTS BREAKDOWN NOTE: The illustrations shown on this page are general representations of the door parts. Each specific door models may have unique variations. A2. A1. I3. J12. A2. F1. C1. H1. J2. G1. I1. K1. E1. B1. K1. J4. J10. C1. F1. I1. E2. B2. J5. J8. J1. J9. A1. B1. B2. D1. J12. D2. E4. C2. E3. K1. J3. J10. L1. J2. I2. J9. I4. J6. J1. J7. J5. J11. J10. J10. J13. J7. J5. J13. C1. I3. I2. L1. I4. A. FLAG ANGLES (AS REQUIRED): A1. Quick Install (Q.I.) Flag Angles A2. Fully Adjustable (F.A.) Flag Angles B. JAMB BRACKETS (AS REQUIRED): B1. Quick Install (Q.I.) Jamb Brackets B2. Fully Adjustable (F.A.) Jamb Brackets C. TRACK ROLLERS (AS REQUIRED): C1. Short Stem Track Rollers C2. Long Stem Track Rollers D. GRADUATED END HINGES: D1. Single Graduated End Hinges (S.E.H.), Anti-Pinch D2. Double Graduated End Hinges (D.E.H.), Anti-Pinch E. STACKED SECTIONS: E1. Top Section E2. Intermediate(s) Section E3. Lock Section E4. Bottom Section F. TOP FIXTURE ASSEMBLIES: F1. Top Fixtures G. STRUT(S) (AS REQUIRED): G1. Strut (U-shaped) H. DRAWBAR OPERATOR BRACKET (FOR TROLLEY OPERATED DOORS): H1. Drawbar Operator Bracket I. TRACKS (AS REQUIRED): I1. Left Hand and Right Hand Horizontal Track Assembly I2. Left Hand and Right Hand Tracks I3. Left Hand and Right Hand Riveted Track Assembly I4. Left Hand and Right Hand Angle Mount Track Assembly J. TORSION SPRING ASSEMBLY (AS REQUIRED): J1. Left Hand and Right Hand Torsion Springs (As Required) J2. Counterbalance Lift Cables J3. Left Hand Cable Drum J4. Right Hand Cable Drum J5. Bracket (As Required) J6. Bracket Bushing (As Required) J7. Bearing (As Required) J8. Torsion Shaft / Torsion Keyed Shaft (As Required) J9. Torsion Keyed Shafts (As Required) J10. Keys (As Required) J11. Coupler Assembly (As Required) J12. Cable Lift Sheaves J13. Oval Bearings (As Required) K. REAR BACK HANGS: K1. Left Hand and Right Hand Rear Back Hang Assemblies L. BOTTOM CORNER BRACKETS (AS REQUIRED): L1. Left Hand and Right Hand Bottom Corner Brackets 5
INSTALLATION Before installing your door, be certain that you have read and followed all of the instructions covered in the pre-installation section of this manual. Failure to do so may result in an improperly installed door. NOTE: Reference TDS 160 for general garage door terminology at www.dasma.com. 1 Quick Install Flag Angles Tools Required: Safety glasses, Leather gloves NOTE: If you have Fully Adjustable Flag Angles, Riveted Track or Angle Mount Track, skip this step. NOTE: Flag angles are right and left handed. Place the lower Quick Install tab of the left hand flag angle in the Quick Install feature of the left hand vertical. Give the flag angle 1/4 turn to lock in place. Repeat for other side. Jamb Bracket Schedule 6 6 63.50 3 B 6 M - - 6 8 65.50 3 B 6 M - - 6 10 67.50 3 B 6 M - - 7 0 69.50 3 B 6 M - - 7 3 72.50 3 B 7 T 8 T 7 6 75.50 3 B 7 T 8 T 7 9 78.50 3 B 7 T 8 T 8 0 (4 Sec) 81.50 3 B 7 T 8 T 1st hole set B= BOTTOM HOLE, M= MIDDLE HOLE, T= TOP HOLE 2nd hole set 3rd hole set Top of 2 Flag angle Lower Quick Install tab Quick Install feature 1/4 Turn Fully Adjustable Flag Angles Tools Required: Safety glasses, Leather gloves NOTE: If you have Quick Install flag angles, Riveted Track or Angle Mount Track, skip this step. NOTE: Flag angles are right and left handed. If you have Quick Install vertical s, hand tighten the left hand flag angle to the left hand vertical using (1) stud plate and (2) 1/4-20 flange hex nuts. Repeat for the other side. If you have Fully Adjustable vertical s, hand tighten the left hand flag angle to the left hand vertical using (2) 1/4-20 x 9/16 bolts and (2) 1/4-20 flange hex nuts. Repeat for other side. Flange nuts will be secured after flag angle spacing is completed in step, Top Section. Flag angle 1/4-20 Flange hex nuts Stud plate Flag angle 1/4-20 Flange hex nuts Bottom hole Middle hole Top hole 4 Q.I. tab Q.I. jamb Jamb in place Mounting flange Fully Adjustable Jamb Brackets Tools Required: Tape measure, Safety glasses, Leather gloves NOTE: If you have Quick Install jamb s, Riveted Track or Angle Mount Track, skip this step. NOTE: The bottom jamb is always the shortest, while the center jamb is the next tallest. If three jamb s per side are included with your door, you will have received a top jamb, which is the tallest. To attach the bottom jamb, locate lower hole of the hole/ slot pattern of the 1st hole set on the vertical. Align the slot in the jamb with the lower hole of the hole/ slot pattern. Secure jamb using (1) 1/4-20 x 9/16 bolt and (1) 1/4-20 flange hex nut. Repeat for other side. Place the center jamb over the lower hole of the hole/ slot pattern that is centered between the bottom jamb and flag angle of the 2nd hole set. Secure jamb using (1) 1/4-20 x 9/16 bolt and (1) 1/4-20 flange hex nut. Repeat for other side. If a top jamb was included, secure it to vertical using the lower hole of the hole/ slot pattern in the 3rd hole set and (1) 1/4-20 x 9/16 bolt and (1) 1/4-20 flange hex nut. Repeat for other side. Top of 1st hole set 2nd hole set 3rd hole set Quick Install vertical 3 Fully Adjustable vertical Quick Install Jamb Brackets Tools Required: Tape measure, Safety glasses, Leather gloves 1/4-20 x 9/16 Track bolts Lower hole of hole/ slot pattern 1/4-20 Flange hex nut F.A. jamb 1/4-20 x 9/16 Track bolt Jamb in place NOTE: If you have Fully Adjustable jamb s, Riveted Track or Angle Mount Track, skip this step. Measure the length of the vertical s. Using the jamb schedule, determine the placement of the jamb s for your door height and length. To install the jamb s, align the Quick Install tab on the Quick Install jamb with the Quick Install feature in the vertical and turn the perpendicular to the so the mounting flange is toward the back (flat) leg of the. Repeat for other side. DOOR HEIGHT TRACK LENGTH JAMB BKT Jamb Bracket Schedule 1ST SET 2ND SET 3RD SET POSITION JAMB BKT POSITION JAMB BKT POSITION 6 0 57.50 5 M 8 B - - 5 Counterbalance Cables and Track Rollers Tools Required: Power drill, 7/16 Socket driver, Tape measure, Safety glasses, Leather gloves NOTE: The bottom section can be identified by the smallest graduated edge hinge of the factory installed graduated edge hinges, see Door Section Identification. Locate the left hand bottom corner. Align the bottom corner horizontally with the top edge of the factory attached bottom corner and align the bottom corner vertically with the left edge of the bottom section. Attach the bottom corner using (4) 1/4-20 x 11/16 self drilling screws and (1) 1/4-20 x 5/8 tamper proof screw, as shown. 6
FAILURE TO ENSURE A GOOD FIT OF CABLE LOOP OVER MILFORD PIN COULD RESULT IN COUNTERBALANCE LIFT CABLE COMING OFF THE PIN, ALLOWING THE DOOR TO FALL, POSSIBLY RESULTING IN SEVERE OR FATAL INJURY. Uncoil the counterbalance cables. Place clevis pin into the inside tab of the bottom corner and slide the cable loop of the counterbalance lift cable onto pin. Continue sliding clevis pin thru the outside tab of the. Place a washer onto mildford pin and secure in place using a cotter pin. Insert a short stem roller into the factory attached bottom corner s and another into the #1 graduated end hinges at the top of the bottom section, as shown. Repeat for other side. NOTE: Larger doors will use long stem rollers with double graduated end hinges. NOTE: Check to ensure cable loops fits over the milford pins. NOTE: Verify bottom weather seal is aligned with bottom section. If there is more than 1/2 excess weather seal on either side, trim weather seal even with bottom section. Left hand bottom corner (4) 1/4-20 x 11/16 Self drilling screws (1)1/4-20 x 5/8 Tamper resistant self drilling screw Single graduated end hinge (Hinge tube) Short stem roller Left hand bottom corner Counterbalance lift cable 3/8 Washer Short stem roller 6 End cap Clevis pin Cotter pin Factory attached bottom corner Bottom weather seal Long stem roller Bottom section Bottom weather seal Double graduated end hinge (Hinge tube) Cable loop End cap Bottom section Factory attached bottom corner Bottom corner Counterbalance lift cable Bottom Section Tools Required: Tape measure, Level, Wooden shims (if necessary), Safety glasses, Leather gloves 3/8 Washer Clevis pin Cotter pin the bottom section in the door opening. Level the section using wooden shims (if necessary) under the bottom section. When the bottom section is leveled, temporarily hold it in place by driving a nail into the jamb and bending it over the edge of the bottom section on both sides. 7 Weather seal (If applicable) Level Bottom section Wooden shims (If necessary) Tracks Tools Required: Power Drill, 3/16 Drill bit, 7/16 Socket driver, Tape measure, Level, Step ladder, Safety glasses, Leather gloves NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable Flag Angles, Riveted Track Assemblies or you may have Angle Mount Track Assemblies. Refer to Package Contents / Parts Breakdown, to determine which Flag Angles / Track Assemblies you have. IMPORTANT: IF YOUR DOOR IS TO BE INSTALLED PRIOR TO A FINISHING CONSTRUCTION OF THE BUILDING S FLOOR, THE VERTICAL TRACKS AND THE DOOR BOTTOM SECTION ASSEMBLY SHOULD BE INSTALLED SUCH THAT WHEN THE FLOOR IS CONSTRUCTED, NO DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION. IMPORTANT: THE TOPS OF THE VERTICAL TRACK ASSEMBLIES MUST BE LEVEL FROM SIDE TO SIDE. IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT, THE VERTICAL TRACK AS- SEMBLY ON THE SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM. Position the left hand vertical assembly over the rollers of the bottom section. Make sure the counterbalance lift cable is located between the rollers and the door jamb. Drill 3/16 pilot holes into the door jamb for the lag screws. FOR QUICK INSTALL FLAG ANGLES OR FULLY ADJUSTABLE FLAG ANGLES: Loosely fasten jamb s and flag angle to the jamb using 5/16 x 1-5/8 lag screws. Tighten lag screws, securing the bottom jamb to jamb, maintain 3/8 to 5/8 spacing, between the bottom section and vertical. Hang counterbalance lift cable over flag angle. Repeat same process for other side. Flag angle assembly Jamb Bottom section 5/16 x 1-5/8 Lag screws Track rollers Floor 12R FA 15R FA 12R QI 15R QI Flag angle lag screw locations 3/8 to 5/8 Spacing Bottom section Track roller FOR RIVETED VERTICAL TRACK ASSEMBLY: Loosely fasten jamb s and flag angle to the jamb using 5/16 x 1-5/8 lag screws. Tighten lag screws, securing the bottom jamb to jamb, maintain 3/8 to 5/8 spacing as shown between the bottom section and vertical. Hang counterbalance lift cable over flag angle. Repeat same process for other side. FOR ANGLE MOUNT VERTICAL TRACK ASSEMBLY: Loosely fasten the slots in the wall angle to the jamb using 5/16 x 1-5/8 lag screws. Tighten lag screws, securing the bottom slot in the wall angle, maintain 3/8 to 5/8 spacing as shown between the bottom section and vertical. Hang counterbalance lift cable over angle mount. Repeat same process for other side. 7
P/N # 327985 NEW 9-04-06 P/N # 327985 NEW 9-04-06 Wall angle Slot 8 Angle mount vertical assembly 5/16 x 1-5/8 Lag screws Bottom section Jamb Riveted vertical assembly Flag angle 5/16 x 1-5/8 Lag screws Bottom section 3/8 to 5/8 Spacing Bottom section Floor Flag angle lag screw locations Stacking Sections Tools Required: Power drill, 7/16 Socket driver, Tape measure, Level, Step ladder, Safety glasses, Leather gloves NOTE: The sections can be identified by the graduation of the factory installed graduated end hinges. The smallest graduated end hinge on section should be stacked on top of the bottom section, with each graduated end hinge increasing as the sections are stacked, see Door Section Identification / Parts Breakdown. NOTE: Make sure graduated end and center hinges are flipped down, when stacking another section on top. NOTE: Larger doors will use long stem rollers with double graduated end hinges. Place rollers into graduated end hinges of remaining sections. With assistance, lift second section and guide the rollers into the vertical s. Lower section until it is seated against bottom section. Align vertical marks in the upper alignment sticker, with the lower alignment sticker on right hand side, on the back of door. Keep sections aligned, flip hinges up. Fasten center hinge(s) first; then end hinges last using 1/4-14 x 5/8 self tapping screws. NOTE: To prevent center hinge leaf(s) from rotating, first secure the top middle hole of the center hinge leaf with one 1/4-14 x 5/8 self-tapping screw then secure the other two holes. NOTE: Larger doors with double graduated end hinges, fasten both hinges to connect the sections using 1/4-14 x 5/8 self-tapping screws. Repeat same process for other sections, except top section. IMPORTANT: PUSH & HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE SECURING WITH 1/4-14 X 5/8 SELF TAPPING SCREWS. THERE SHOULD BE NO GAP BETWEEN THE HINGE LEAFS AND THE SECTIONS. 9 Top Fixtures Tools Required: Power drill, 7/16 Socket driver, Level, Safety glasses, Leather gloves NOTE: The top fixtures come pre-assembled from the factory. Starting on the left hand side, locate the edge of the top section and seat the top fixture on male part of the top section, as shown. 1. Attach one 1/4-20 x 11/16 self-drilling screw to the top fixture assembly. 2. Attach two 1/4-20 x 11/16 self-drilling screws to the top fixture assembly. 3. Attach two #12 x 1/2 phillips head screws on the opposite side of top fixture assembly. Insert short stem roller into top fixture slide. Repeat for left hand side. 10 Top fixture slide Top fixture assembly 2. (2) 1/4-20 x 11/16 Self-drilling screws Short stem roller 3. (2) 12# x 1/2 Phillips head screws Top section 1. (1) 1/4-20 x 11/16 Self-drilling screw Drawbar Operator Bracket Tools Required: Power drill, 7/16 Socket driver, Step ladder, Tape measure, Safety glasses, Leather gloves NOTE: If you re installing a drawbar operator, the drawbar operator must be mounted and secured prior to installing top section. IMPORTANT: WHEN CONNECTING A DRAWBAR OPERATOR TYPE GARAGE DOOR OPENER TO THIS DOOR, A WAYNE DALTON OPERATOR/ DRAWBAR OPERATOR BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR, ALONG WITH ANY STRUT PROVIDED WITH THE DOOR. THE INSTALLATION OF THE DRAWBAR OPERATOR MUST BE AC- CORDING TO MANUFACTURER S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED PROPERLY. Remove, but retain (4-6) 1/4-20 x 7/8 self drilling screws from the center of the strut, allowing the drawbar operator to slide between the section and the strut. NOTE: For retro fit applications, the drawbar operator must be aligned with an existing drawbar operator. Locate the center of the top section and slide drawbar operator under strut till the drawbar operator is seated against the strut flange. NOTE: Prior to fastening drawbar operator to top section, ensure the top edge of drawbar operator is aligned with the top edge of the section, as shown. Attach the drawbar operator using (8) 1/4-20 x 11/16 self drilling screws (as shown). Finish re-attaching the strut using the self tapping screws removed previously. Top section Top section Drawbar operator Lock section Alignment sticker Strut Strut 1/4-20 x 7/8 Self-drilling screws Left double graduated end hinge with long stem roller s Right double graduated end hinge with long stem roller 1/4-14 x 5/8 Self tapping screw locations Secure top middle hole first Left graduated end hinge with short stem roller hinge(s) Alignment sticker Right graduated end hinge with short stem roller 11 Drawbar operator in place under strut (8) 1/4-20 x 11/16 Self-drilling screws Top Section Tools Required: Power drill, 7/16 Socket driver, 7/16 Wrench, Step ladder, Tape measure, Safety glasses, Leather gloves Place the top section in the opening. Temporarily secure the top section by driving a nail in the header near the center of the door and bending it over the top section. Now, flip up the hinge leaves, hold tight against section, and fasten center hinges first and end hinges last (refer to step, Stacking Sections). alignment is critical. Position flag angle or wall 8
angle between 1-11/16 (43 mm) to 1-3/4 (44 mm) from the edge of the door; tighten the bottom lag screw. Flag angles or wall angles must be parallel to the door sections. Repeat for other side. IMPORTANT: THE DIMENSION BETWEEN THE FLAG ANGLES OR WALL ANGLES MUST BE DOOR WIDTH PLUS 3-3/8 (86MM) TO 3-1/2 (89 MM) FOR SMOOTH, SAFE DOOR OPERA- TION. FOR QUICK INSTALL TRACK: Complete the vertical installation by securing the jamb (s) and tightening the other lag screws. Repeat for other side. FOR FULLY ADJUSTABLE TRACK OR RIVETED TRACK: Complete the vertical installation by securing the jamb (s) and tightening the other lag screws. Push the vertical against the rollers so that the rollers are touching the deepest part of the curved side of the ; tighten all the bolts and nuts. Repeat for other side. FOR ANGLE MOUNT TRACK: Complete the vertical installation by securing the jamb (s) and or tightening the other lag screws. Push the vertical against the rollers so that the rollers are touching the deepest part of the curved side of the vertical, as shown. Repeat for other side. Top of flag angle or Top of wallangle assembly Flag angle 12 1-11/16 to 1-3/4 Top section Door width + 3-3/8 to 3-1/2 Nail Flag angle or wallangle assembly Top section against rollers Horizontal Tracks Tools Required: Ratchet wrench, 9/16 7/16 Socket, 9/16 7/16 Wrench, Step ladder, Tape measure, Safety glasses, Leather gloves NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable Flag Angles, Riveted Track Assemblies or you may have Angle Mount Track Assemblies. Refer to Package Contents / Parts Breakdown, to determine which Flag Angles / Track Assemblies you have. DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT REAR, AS OUTLINED IN STEP, REAR BACK HANGS, OR DOOR COULD FALL FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY. IF YOU HAVE QUICK INSTALL FLAG ANGLES: To install horizontal, place the top rail end over the top roller of the top section. Align key slot of the bottom rail end of horizontal with the Quick Install tab of the flag angle. Push curved portion of horizontal down to lock in place. Flag angle Bottom rail of horizontal Quick Install tab Quick Install tab in place Tracks flush Key slot Flagangle 1/4-20 x 9/16 Track bolt Washer Top rail of horizontal 1/4-20 Flange hex nut IF YOU HAVE FULLY ADJUSTABLE FLAG ANGLES: To install horizontal, place the top rail end over the top roller of the top section. Align the bottom rail end of the horizontal with the top of the vertical. If you have Quick Install horizontal, tighten the bottom rail of the horizontal to the flag angle with (1) stud plate and (2) 1/4-20 flange hex nuts. If you have Universal horizontal, tighten the bottom rail of the horizontal to the flag angle with (2) 1/4-20 x 9/16 bolts and (2) 1/4-20 flange hex nuts. Bottom rail Quick Install Horizontal 1/4-20 Flange hex nuts Bottom rail Fully Adjustable Horizontal 1/4-20 Flange hex nuts Flagangle Flag angle Flag angle upper slot upper slot 1/4-20 Flange hex nut Stud plate 1/4-20 x 9/16 Track bolts 1/4-20 x 9/16 Track bolt Washer Top rail of horizontal IF YOU HAVE RIVETED TRACK ASSEMBLIES OR ANGLE MOUNT VERTICAL TRACK ASSEMBLIES: To install horizontal, place the curved end over the top roller of the top section. Align the bottom of the horizontal with the top of the vertical. Tighten the horizontal to the Flag Angle / Angle Mount with (2) 1/4-20 x 9/16 bolts and (2) 1/4-20 flange hex nuts. Bottom rail of horizontal (2) 1/4-20 Flange hex nuts (1) 1/4-20 Flange hex nut Washer Top rail of horizontal Rivited flag angle (2) 1/4-20 x 9/16 Track bolts (1) 1/4-20 x 9/16 Track bolt Rivited flag angle or Flag angle Bottom rail of horizontal (2) 1/4-20 Flange hex nuts Wall angle (2) 1/4-20 x 9/16 Track bolts (2) 3/8-16 Hex nuts (2) 3/8-16 x 3/4 (1) 1/4-20 Truss head bolts Flange hex nut Washer Top rail of horizontal (1) 1/4-20 x 9/16 Track bolt Wall angle Next level the horizontal assembly and bolt the top rail of the horizontal to the encountered slot in the flag angle using (1) 1/4-20 x 9/16 bolt, (1) 1/4-20 flange hex nut and (1) 5/16 washer. Repeat for other side. Repeat for other side. Next remove the nail that was temporarily holding the top section in place, installed in step, Top Section. IMPORTANT: FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION. 13 Adjusting Top Fixtures Tools Required: 7/16 Wrench, Safety glasses, Leather gloves ADJUSTING TOP FIXTURE SLIDE: With horizontal s installed, you can now adjust the top fixtures. ly align the top section of the door with the lower sections. Once aligned, position the top fixture slide, out against the horizontal. Maintaining the slide s position, tighten the (2) 1/4-20 flange hex nuts to secure the top fixture slide to the top fixture base. Repeat for other side. REVERSING THE TOP FIXTURE SLIDE (IF NEEDED): NOTE: Depending on your application, you may need to reverse the top fixture slide for more adjustment, if needed, prior to securing it to the top fixture base. Remove the top fixture slide by removing the two 1/4-20 x 5/8 carriage bolts, two retention washers and two 1/4-20 flanged hex nuts. Flip the top fixture slide in the opposite direction. Loosely fasten the top fixture slide to the using two 1/4-20 x 5/8 carriage bolts, two retention washers and two 1/4-20 flanged hex nuts, as shown. NOTE: The retention washers must be fully seated against the top fixture base to ensure the anti-twist feature on the top fixture slide engages in the slotted hole in the top fixture. Now follow the instructions at the top of this step Adjusting top fixture slide: Short stem roller Low headroom horizontal Top fixture slide Top fixture assembly (2) 1/4-20 Flange hex nuts Top section 9
14 (2) 1/4-20 Flange hex nuts Top fixture slide reversed Anti-twist feature Top fixture slide (2) Retention washers Slotted hole of top fixture base (2) 1/4-20 x 5/8 Carriage bolts Cable Lift Sheaves Tools Required: Ratchet wrench, 3/8 Socket, 3/8 Wrench, Step ladder, Tape measure, Safety glasses, Leather gloves NOTE: Using the illustrations below, identify which cable lift sheave assemblies were provided with your door. FOR CABLE SHEAVE ASSEMBLIES WITHOUT THE SHEAVE SADDLE: Place a 3/8-16 x 1-1/2 hex head bolt through the hole in the sheave plate. Next insert the sheave over the end of the bolt. Secure the sheave to the sheave plate with a 3/8-16 nut. Repeat the same process for the other side. Then loop the counterbalance cables over each sheave, as shown. Counterbalance lift cable Sheave Typical flagangle (1) 3/8-16 Nut Sheave plate Sheave plate Horizontal (1) 3/8-16 X 1-1/2 Hex head bolt Horizontal EXCEEDING THE RECOMMENDED LISTED DOOR WEIGHT LIMITATIONS OF SPECIFIC GAUGE PERFORATED ANGLES MAY RESULT IN DOOR FALLING WHEN RAISED, CAUSING SEVERE OR FATAL INJURY. VERIFY PERFORATED BACK HANG ANGLE LOAD RATINGS WITH BACK HANG ANGLE SUPPLIER. Perforated Angle Gauge Perforated Angle Gauge Weight Limitations: Door Weight 2 x 2 x 12 Gauge Door Weight Less Than 800 lbs. 1-1/4 x 1-1/4 x 13 Gauge Door Weight Less Than 305 lbs. 1-1/4 x 1-1/4 x 15 Gauge Door Weight Less Than 220 lbs. 1-1/4 x 1-1/4 x 16 Gauge Door Weight Less Than 175 lbs. NOTE: If an opener is installed, position horizontal s one hole above level when securing it to the rear back hangs. KEEP HORIZONTAL TRACKS PARALLEL AND WITHIN 3/4 TO 7/8 MAXI- MUM OF DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING IN SEVERE OR FATAL INJURY. IMPORTANT: DO NOT SUPPORT THE WEIGHT OF THE DOOR ON ANY PART OF THE REAR BACK HANGS THAT CANTILEVERS 4 OR MORE BEYOND A SOUND FRAMING MEMBER. NOTE: If rear back hangs are to be installed over drywall, use (2) 5/16 x 2 hex head lag screws and make sure lag screws engage into solid structural lumber. NOTE: 26 angle must be attached to sound framing members and nails should not be used. Now, permanently attach the weatherstrips on both door jambs and header. The weatherstrips were temporarily attached in Preparing the Opening, in the pre-installation section of this manual. NOTE: When permanently attaching the weatherstrips to the jambs, avoid pushing the weatherstrips too tightly against the face of door. Sheave Counterbalance lift cable FOR CABLE SHEAVE ASSEMBLIES WITH THE SHEAVE SADDLE: Position the sheave saddle over the 1 x 4 x 23 angle and align the slots in the sheave saddle with the corresponding holes in the 1 x 4 x 23 angle. While holding the sheave saddle in place, insert (1) 5/16-18 x 3/4 carriage bolt through each of the aligned holes and secure the assembly with 5/16-18 hex nuts. Repeat the same process for the other side. Then loop the counterbalance cables over each sheave, as shown. Typical wall angle 1 x 4 x 23 Angle Horizontal Sound framing members (2) 3/8-16 x 3/4 Truss head bolts and nuts Bolt must extend into the to serve as a roller stop End plate Sheave Sheave saddle (2) 5/16-18 X 3/4 Carriage bolts 15 Counterbalance lift cable Sheave saddle (2) 5/16-18 Hex nuts Horizontal Rear Back Hangs Tools Required: Ratchet wrench, Socket: 1/2 5/8, Wrench: 1/2 5/8, (2) Vice clamps, Tape measure, Level, Step ladder, Safety glasses, Leather gloves Using the chart (Perforated Angle Gauge Weight Limitations) below, use the appropriate perforated angle (may not be supplied), (2) 5/16 x 1-5/8 hex head lag screws and (3) 5/16 bolts with nuts (may not be supplied), fabricate rear back hangs for the horizontal s. Attach the horizontal s to the rear back hangs with 5/16-18 x 1 hex bolts and nuts (may not be supplied). Horizontal s must be level and parallel with door within 3/4 to 7/8 maximum of door edge. Horizontal Angle brace Perforated angle- Bolted using (2) 5/16 x 1-5/8 hex head lag screws to ceiling member and parallel to door End plate 10
Sound framing members One or Two springs, One piece shaft IMPORTANT: ON SINGLE SPRING APPLICATIONS, ONLY A RIGHT WOUND (RED WINDING CONE), WHICH GOES ON THE RIGHT HAND SIDE IS REQUIRED. Left wound, black winding cone (left hand side) Right wound, red winding cone (right hand side) Red cable drum (right hand side) Torsion shaft or Torsion keyed shaft Black cable drum (left hand side) Oval 16 Horizontal Angle brace Perforated angle- Bolted using (2) 5/16 x 1-5/8 hex head lag screws to ceiling member and parallel to door. End plate Torsion Spring Assembly Tools Required: 3/8 Wrench, 9/16 Wrench, Step ladder, Tape measure, Safety glasses, Leather gloves NOTE: Refer to Package Contents / Parts Breakdown, to determine if your door came with a coupler assembly. If your door came with a coupler assembly, the mounting surface needs to be a minimum of 17 wide. The two center s will need to be spaced 12 to 14 apart at the center of the door, as shown. IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT. IMPORTANT: IDENTIFY THE TORSION SPRINGS PROVIDED AS EITHER RIGHT WOUND (RED WINDING CONE), WHICH GOES ON THE RIGHT HAND SIDE OR LEFT WOUND (BLACK WIND- ING CONE), WHICH GOES ON THE LEFT HAND SIDE. IMPORTANT: ON SINGLE SPRING APPLICATIONS, ONLY A RIGHT WOUND (RED WINDING CONE), WHICH GOES ON THE RIGHT HAND SIDE IS REQUIRED. NOTE: On some single spring doors, the single spring can be longer than half the opening width. If your spring is longer, then the center must be mounted off center for the spring to fit properly. Measure spring length to determine appropriate center location. NOTE: If your door came with a center coupler assembly or if it utilizes 3-3/4 springs, the springs will not share a center. NOTE: If your door has (4) springs, split the distance between the center of the door and the end on each side to locate the intermediate center s. NOTE: The set screws used on all torsion winding cones and cable drums are now colored red. DO NOT identify right and left hand by the set screw color. IMPORTANT: REFERENCE THE ILLUSTRATIONS FOR PROPER SPRING POSITIONING WHEN MORE THAN 2 SPRINGS ARE PROVIDED. Facing the inside of the door, either lay the torsion shaft / torsion keyed shaft on the floor or lay the (2) torsion keyed shafts on the floor, one torsion keyed shaft on the left hand side and the other torsion keyed shaft on the right hand side. IMPORTANT: DEPENDING ON YOUR DOOR APPLICATION, USE ONE OF THE THREE ILLUS- TRATION S, SHOWN BELOW TO ASSEMBLE YOUR TORSION COUNTERBALANCE SYSTEM. 1. Lay the torsion spring with the black winding cone and the black cable drum at the left end of the torsion shaft or the torsion keyed shaft. Lay the torsion spring with the red winding cone and the red cable drum at the right end of the torsion shaft or the torsion keyed shaft. Next, lay the center, the center or the oval at the center of the torsion shaft / torsion keyed shaft. 2. Lay the torsion spring with the red winding cone at the left end of the torsion shaft / torsion keyed shaft. Next, lay the torsion spring with the black winding cone at the left end of the torsion shaft / torsion keyed shaft. Lay the torsion spring with the black winding cone at the right end of the torsion shaft / torsion keyed shaft. Next, lay the torsion spring with the red winding cone at the right end of the torsion shaft/torsion keyed shaft. Next, lay the center, the center or the oval at the center of the torsion shaft / torsion keyed shaft. Four springs, One piece shaft Right wound, red winding cone (right hand side) Right wound, red winding cone (left hand side) Left wound, black winding cone (left hand side) Torsion shaft or Torsion keyed shaft Black cable drum (left hand side) Left wound, black winding cone (right hand side) Red cable drum (right hand side) 3. Starting on the left hand torsion keyed shaft, lay the torsion spring with the red winding cone at the right end of the torsion keyed shaft. Next, lay the torsion spring with the black winding cone at the left end of the torsion keyed shaft. Next, starting on the right hand torsion keyed shaft, lay the torsion spring with the black winding cone at the left end of the torsion keyed shaft. Next, lay the torsion spring with the red winding cone at the right end of the torsion keyed shaft. Next, lay either the center s or the oval s in between the two torsion keyed shafts. Two or Four springs, Two piece shafts Torsion keyed shaft Right wound, red winding cone (left hand side) Left wound, black winding cone (left hand side) Torsion keyed shaft Coupler halves Left wound, black winding cone (right hand side) s Red cable drum (right hand side) Right wound, red winding cone (right hand side) Black cable drum (left hand side) Oval s Disassemble the coupler assembly by removing the hex head screws, the lock washers, the flat washers and the hex nuts from the coupler halves. Loosen the set screws. Set the components aside. Next, slide the flat edge of the couple half flush with the side edge of the torsion keyed shaft. Insert (1) keyed shaft into the slot of both the coupler half and the slot in the torsion keyed shaft, as shown. Tighten the (2) set screws and the locking nut to secure the coupler half to the torsion keyed shaft. NOTE: Tighten the set screws to 14-15 ft. lbs. of torque (once set screws contact the shaft, tighten set screws one full turn). Repeat the same process for the other side. 11
Coupler half Coupler half (6) Flat washers (3) Lock washers (3) Hex nuts Adequate framing members Key (3) Hex head screws (4) Set screws and (2) Lock nuts Torsion keyed shaft Key Torsion Coupler keyed halves shaft s Slide either the center or the center (s) or the oval (s) onto the torsion shaft / torsion keyed shaft(s) followed by the torsion spring(s). IMPORTANT: THE CENTER BEARING BRACKET, THE CENTER BEARING(S), THE OVAL BEARING(S), THE COUPLER HALF S AND THE TORSION SPRINGS, MUST BE POSITIONED, AS SHOWN. (4) 5/16 x 2 Lag screws Horizontal Oval CENTER BEARING BRACKETS WITH SPRINGS MUST BE SECURELY FASTENED INTO SOLID STRUCTURAL MEMBERS ONLY AND MUST BE ADEQUATELY REINFORCED TO HOLD THE LOAD OF TORSION SPRING ASSEMBLIES. FAILURE TO DO SO CAN CA USE SEVERE OR FATAL INJURY. NOTE: It is recommended that 5/16 lag screws are pilot drilled using a 3/16 drill bit, prior to fastening. NOTE: On some single spring doors, the single spring can be longer than half the opening width. If your spring is longer, then the center must be mounted off center for the spring to fit properly. Measure spring length to determine appropriate center location. NOTE: If your door came with a coupler assembly, the (2) center s will need to be spaced 12 to 14 apart, at the center of the opening width. Referring to Step, Rear Back Hangs either secure the center (s) to the ceiling using perforated angle at the center of the opening width using 3/8-16 x 3/4 hex head bolts and nuts (not supplied) or to wood blocking (adequate framing member(s)) at the center of the opening width using (4) 5/16 x 2 lag screws. IMPORTANT: USE A 5/16 X 1-5/8 TAMPER -RESISTANT LAG SCREW INSTEAD OF THE 5/16 X 2 TAMPER -RESISTANT LAG SCREW IF MOUNTING SURFACE IS MOUNTED OVER MASONRY. TAMPER-RESISTANT LAG SCREW MUST BE ATTACHED THROUGH THE BOTTOM HOLE OF THE CENTER BEARING BRACKET. Torsion shaft or Torsion keyed shaft End If you have two Torsion Keyed Shafts: With assistance, pick up the left hand torsion spring assembly and slide one end of the torsion keyed shaft through the end and loosely attach the oval to the center with (2) 3/8-16 x 1-1/2 hex head bolts and (2) 3/8-16 hex nuts, as shown. Repeat for others, if needed. Repeat the same process for the right hand torsion spring assembly. Horizontal Horizontal Oval Torsion keyed shafts End Torsion shaft or Torsion keyed shaft Adequate framing member End End End End Coupler half Oval Coupler half Oval Adequate framing members Adequate framing member Torsion shaft / Torsion keyed shaft s Torsion keyed shafts (4) 5/16 x 2 Lag screws (2) 3/8-16 x 1-1/2 Hex head nolts of opening width Torsion shaft / Torsion Keyed shaft 12 (2) s spaced 6 to 7 apart from the center of opening width. If you have a Torsion Shaft or a Torsion Keyed Shaft: With assistance, pick up the torsion spring assembly and slide one end of the shaft through the end. Extend the shaft through the until the opposite end of the shaft can be inserted into the other end. Lay the middle of the shaft into the center (if applicable). If your door came with oval (s), loosely attach the oval to the center with (2) 3/8-16 x 1-1/2 hex head bolts and (2) 3/8-16 hex nuts, as shown. Repeat for others, if needed. 12 (2) 3/8-16 Hex nuts Oval (4) 5/16 x 2 Lag screws
Adequate framing member (2) 3/8-16 x 1-1/2 Hex head bolts Torsion spring Torsion shaft / Torsion Keyed shaft (4) 5/16 x 2 Lag screws (2) 3/8-16 Hex nuts IMPORTANT: RIGHT AND LEFT AND IS ALWAYS DETERMINED FROM INSIDE THE GARAGE LOOKING OUT. Slide the black cable drum against the left hand end. Thread the counterbalance lift cable up and over the cable sheave. Position the cable drum and counterbalance lift cable, as shown. Hook the cable into the drum. NOTE: For doors with a torsion keyed shaft, insert (1) key into the slot of both the black cable drum and the slot in the torsion keyed shaft, as shown. Tighten the set screws in the black cable drum to 14-15 ft. lbs. of torque (once set screws contact the shaft, tighten screws one full turn). Slide the red cable drum against the right hand end. Rotate the left hand drum and torsion shaft until counterbalance lift cable is taut. Now attach locking pliers to the torsion shaft and brace locking pliers against the perforated angle of the rear back hangs to keep counterbalance lift cable taut. On the right hand side, thread the counterbalance lift cable up and over the red cable drum and position the cable drum and counterbalance lift cable, as shown. Hook the cable into the drum. NOTE: For doors with a torsion keyed shaft, insert (1) key shaft into the slot of both the red cable drum and the slot in the torsion keyed shaft, as shown. Tighten the set screws in the red cable drum to 14-15 ft. lbs. of torque (once set screws contact the tube, tighten screws one full turn). IMPORTANT: CHECK EACH COUNTERBALANCE LIFT CABLE, MAKING SURE BOTH ARE SEATED PROPERLY ON THE SHEAVES, CABLE DRUMS, ARE SECURELY ATTACHED TO THE BOTTOM CORNER BRACKETS AND BOTH SIDES HAVE EQUAL COUNTERBALANCE LIFT TENSION. Now, secure the coupler assembly by tightening the (3) hex head screws and the (3) hex nuts. 17 Torsion Spring Attachment Tools Required: Step ladder, Ratchet Wrench, 9/16 Socket, 9/16 Wrench, Tape measure, Safety glasses, Leather gloves FOR DOORS WITHOUT COUPLER ASSEMBLY: Equalize the amount that the torsion shaft / torsion keyed shaft protrudes on each side. Align the stationary cone(s) of the torsion springs with the slots in the end s and secure using (2) 3/8-16 x 1-1/2 hex head bolts and nuts. FOR DOORS WITH A COUPLER ASSEMBLY: At the middle of the two center s, re-assemble the coupler assembly by loosely fastening the coupler halves together reusing the hex head screws, the lock washers, the flat washers and the hex nuts, as shown. NOTE: Ensure both torsion keyed shafts have equal amounts of the shafts extending from each end s. Next, align the stationary cone(s) of the torsion springs with the slots in the center s and secure using (2) 3/8-16 x 1-1/2 hex head bolts and nuts. Repeat for opposite side. Secure all oval (s), to the center with (2) 3/8-16 x 1-1/2 hex head bolts and (2) 3/8-16 hex nuts. Insert (s) into stationary cone and attach center (s) to the torsion spring(s) using (2) 3/8-16 x 1-1/2 bolts and (2) 3/8-16 hex nuts. Repeat for others. Rear back hang assembly Perforated angle Shaft Locking Pliers Winding cone Horizontal Horizontal End Torsion shaft equalized on both sides Stationary cone 3/8-16 x 1-1/2 Hex head bolts and 3/8-16 nuts Spring Counterbalance lift cable End Torsion shaft Torsion warning tag Spring Coupler half Coupler half Set screws on cable drum 18 Coupler assembly Coupler halves (6) Flat washers (3) Hex nuts (3) Lock washers (3) Hex head screws Counterbalance Lift Cables Tools Required: Step ladder, Locking pliers, 3/8 Wrench, Tape measure, Safety glasses, Leather gloves 19 Left hand end Key Torsion keyed shaft(s) Chalking Torsion Spring(s) Tools Required: Step ladder, Chalk, Safety glasses, Leather gloves Left hand cable drum Torsion spring NOTE: If your spring(s) have stenciling, then skip this step. Draw a chalk line horizontally along the center of the torsion spring coil(s). As the torsion spring is wound, the chalk line will create a spiral. This spiral can be used to count and determine the number of turns that are applied on the torsion spring. 13