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GARAGE DOORS & OPENERS
T a b l e O f C o n t e n t s
Double Flush,
Parts Breakdown 2
Pre-Installation 3
Model 44
Important Safety Instructions 3
Tools Required 3
t o r s i o n
Package Contents 3
Door Section Identification 4
ExtEnsion
Graduated End Hinge And Strut Identification 4
Removing an Existing Door 5
Preparing the Opening 5
Installation 6
Optional Installation 14
MH
Door Arm Hookup 14
installation instructions and ownEr ’s Manual
Lift Handles 14
Pull Down Rope 14
Maintenance 15
Cleaning
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Parts BreakDown NOTE: The illustrations shown on this page are general G3. representations of the door parts. Each specific door F2. G6. models may have unique variations. G5. F1. D1. A1. H2. G4. D2. G7. G10. D3. G8. G5. G9. A2. C1. G2. D1. E1. E2. G1. G10. G5. D2. A1. D3. F6. A2. C2. F4. G3. G9. F3. F6. C2. G5. F1. G2. F7. G6. I1. I1. G4. F4. C3. G7. G1. B3. G8. B2. A2. J1. G10. G5. H1. B1. A4. G10. K1. F7. A1. A3. J1. F5. F5. F2. F3. I1. A. TRACk ROLLERS (AS REquIRED): F4. Left Hand and Righ
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Pre-Installation Important Safety Instructions Tools Required DEFINITION OF kEy WORDS uSED IN THIS MANuAL: • Power drill • Phillips head • Tape Measure screwdriver • Drill bits: 1/8”, 3/16”, Step Ladder W WARNING ARNING 9/32”, 7/16”, 1/2” • Locking Pliers • Level • Ratchet wrench • (2) Vice clamps INDICATES A POTENTIALLy HAzARDOuS SITuATION WHICH; IF NOT A vOIDED, • Pencil COuLD RESuLT IN SEvERE OR FATAL INJuR y. • Socket driver: 7/16” • Wrenches: 3/8”, • Leather gloves 7/16”, 1/2”, 9/16”,
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Top rail Typical design option “Outside surface of door sections shown” Bottom corner brackets Weather seals Pull down rope Strut clips (as required) & nails (If included) (if included) (as required) Outside Inside 3. Top surface surface section Typical stamping 2. location (2) 5/16”-18 x Counterbalance # # 1 Intermediate Lift handles (as required) 3-3/4” Eye bolts lift cables Snubber cables section(s) Bottom Bottom rail rail Side views of sections 1. Bottom Top Intermediate(s) Bottom s
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Backroom 3 Section High Strutting Schedule Section Type Type Of Strut Location On Section Preparing the Opening (1) Short Top Of Section Top IMPORTANT: IF YOU JUST REMOVED YOUR ExISTING DOOR OR YOU ARE INSTALLING A NEW N/A Bottom Of section DOOR, COMPLETE ALL STEPS IN PREPARING THE OPENING. (1) Long Top Of Section To ensure secure mounting of track brackets, side and center brackets, or steel angles to new or Intermediate I N/A Bottom Of section retro-fit construction, it is recommended to fol
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Bottom Weather Seal Tools: Hammer, Tape Measure, Saw Horses 3 InstallatIon NOTE: If a bottom weather seal is supplied, complete this step. Before installing your door, be certain that you have read and followed all of the instruc- NOTE: Refer to Door Section Identification / Parts Breakdown. tions covered in the pre-installation section of this manual. Failure to do so may result in an improperly installed door. Place the bottom section face down on a couple of sawhorses or flat clean/ smoot
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Bottom section Side view of track roller carrier(s) Outer holes Bottom weather (3” Track) seal (3) 1/4” - 20 x 2 1/2” Carriage bolts and (3) 1/4” - 20 Flange hex nuts (1) 1/4” - 14 x 1” Tamper Typical left hand resistant lag screw bottom corner bracket Inner holes (2” Track) Bottom section Strutting Bottom weather 6 Tools: Power Drill, 1/8” Drill Bit, Socket Driver 7/16”, Tape Measure seal NOTE: Refer to the Door Section Identification and Strut Identification, to determine if the (3)
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Double graduated end hinge Single graduated end hinge Equally spaced Half with long stem track roller Center with short stem track roller center hinge Lower hinge hinge Hinge Long strut Typical section Short leaf(s) Lower hinge leaf tube(s) (if applicable) shown edge (1) Strut clip (if applicable) Long edge Long strut (2) 1/4” - 14 x 1” Lag screws Typical (if applicable) (1) Strut clip (2) 1/4” - 14 x 1” section (if applicable) Lag screws shown Top Fixtures (2) 1/4” - 20 x 2 1/2” Carr
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surface. Drill pilot holes, 1” deep into the top section using a 1/8” drill bit. Wallangle Riveted track track IMPORTANT: BE ExTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1” flag angle assembly DEEP. shown Attach the strut using (2) 1/4”-14 x 1” lag screws at each on each end and center stile Lag (aligned with hinges) locations. screw locations Short strut Top section 5/16” x 1-5/8” Lag screws 3/4” Typical top fixture assembly Jamb bracket 1/4” - 14 x 1” Flag Fully Adjus
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Door width (2” Track) Door width (3” Track) + 3-3/8” to 3-1/2” + 4-7/8” to 5” Top of flag angle or Top of wallangle assembly Nail Typical graduated end 2” Track Applications: hinge with typical long Top section 1-11/16” to 1-3/4” stem tandem track roller 3” Track Applications: 2-3/16” to 2-1/4” Intermediate I section Left double graduated end hinge with typical long stem track roller Flag angle or wallangle assembly Vertical Top tracks section Vertical track against rollers Bottom sec
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Sound framing members Top fixture slide(s) Horizontal track 5/16”-18 Track roller Hex nut(s) Rear Back Hangs Tools: Ratchet wrench, Socket: 1/2” 5/8”, Wrench: 1/2” 5/8”, (2) Vice 17 Perforated angle bolted using (2) 5/16” x 1-5/8” hex head lag screws to Raise the door until the top section and half of the next section are in a horizontal position. ceiling member and Do not raise door any further since rear of horizontal tracks are not yet supported. parallel to door Horizontal track W
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TRACk: 3 Hole clip Front view Back view Bolt the front cable lift sheave to the first 13/32” hole in the horizontal track angle, using (1) (1) 5/16” x 1-5/8” 3/8”-16 hex nut, as shown. Special Lag screw knot 3 Hole Repeat the same process for right hand side. clip Special Remove the locking pliers from the vertical tracks. With assistance, raise the door slowly into knot the open position making sure the door travels smoothly through the tracks. Clamp locking pliers to the back leg of bot
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knot. Special knot 3 Hole Front cable Label Placement clip lift sheave Tools: Step Ladder 23 Horizontal Counterbalance Counterbalance lift cable track lift cable angle IMPORTANT: USING THE ILLUSTRATION, ATTACH THE APPROPRIATE LABELS TO THE AP- Second slot PROPRIATE LOCATION ON THE SECTION, AS SHOWN. NOTE: The Spring Warning tag(s) are factory attached (one per spring). “S” Hook “S” Hook NOTE: Because of different configurations, some labels may require minor relocations. Rear Torsion spri
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optional Installation Door Arm Hookup W WARNING ARNING Tools: Needle nose pliers DO NOT INSTALL PuLL DOWN ROPE ON DOORS WITH OPERATORS. CHILDREN MAy BECOME ENTANGLED IN THE ROPE CAuSING SEvERE OR FATAL INJuR y. At the center of the top section, measure horizontally from the top of center hinge to the bottom of strut. Using that dimension, measure and cut (2) pieces of perforated angles. Assemble the Measure and mark the jamb approximately 48” to 50” (1220 to 1270 mm) from floor on the (2)
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Maintenance Before you begin, read all warning labels affixed to the door and the installation instructions and owner’s manual. When correctly installed, your Wayne-Dalton door will operate smoothly. Always Cleaning Your Garage Door operate your door with controlled movements. Do not slam your door or throw your door into the open position, this may cause damage to the door or its components. If your door has an electric opener, refer to the owner’s manual to disconnect the opener before per
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3. Lubrication: The door should open and close smoothly. Ensure the door track rollers are rotating freely when opening and closing the door. If track rollers do not rotate freely, clean the door tracks, removing dirt and any foreign substances. Clean and lubricate (use a non-silicon based lubricant) graduated end hinges, steel track rollers, spring(s) and bearings. DO NOT lubri- cate plastic idler bearings, nylon track rollers, door track. DO NOT oil a cylinder lock, if actuation is difficu
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w arranty Limited warranty Double Flush, Model 44 Subject to the terms and conditions contained in this Limited Warranty, Wayne-Dalton (“Manufacturer”) warrants the sections of the door, against defects in material and workmanship, for a period of ONE (1) yEAR from the time of delivery provided: i) (i) The interior and exterior surfaces, as well as all edges of the wood door(s) are properly finished according to the Manufactures Maintenance and Painting Instructions and finish manufacturer’s i
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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
