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Wayne-Dalton Model 451/452 User's Manual

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1. H 16 X 1 DRILLING ers ANCHO an 5 SLEEVE ANCHOR TAPPING SCREW gio ird Da eed dbi Bg 1 OVERLAP ORI 1 2 5 8 1 2 5 8 111 1 1 2 5 8 ES E rh mE ik amje gt amp gt 22 5 E Sw 9 60 1 1 2 TO y d EET lt gt co 88 4 3 16 y 4 4 2 a 43 6 E OPTIONAL OPTIONAL P 3 8 X 3 MIN MOUNTING MOUNTING 4 3 16 SLEEVE ANCHOR BRACKET ES BRACKET PRECAST WALL WITH CORNER ANGLE PRECAST WALL WITHOUT CORNER ANGLE STEEL JAMBS 2 TRACK 2 TRACK 2 TRACK 3 8 X 3 MIN 5 16 X 1 DRILLING SLEEVE ANCHOR FLUSH TAPPING SCREW 1 OVERLAP 1 OVERLAP i ip 1 2 5 8 1 2 5 8 n 1 2 5 8 11 1 zo 1 H z HE Sz mmm 1 2 A 5214 ry a RI a 2S 5 16X1 5 8 ERE p zc LAG SCREW Sve y vA y E 1 2 a 1 2 H a m 4 15 16 4e 1 1 2 Y OPTIONAL 2 X 6 JAMB IS e boss OPTIONAL 1
2. LOCK SECTION SLIDE RIGHT ENDHINGE AND ROLLER DOWN VERTICAL TRACK AND OVER LOCK SECTION FIG I TOP BRACKETS TOP SECTION Align upper center hole of top bracket with vertical groove on the end stile and ensure top bracket is level and aligned with edge of top section Secure with 4 1 4 20 x 7 8 self drilling Screws one in each corner of the top bracket as shown in FIG J Loosely fasten top bracket slide with 1 5 16 x 3 4 carriage bolt and flange hex nut Insert roller into slide Repeat for other side If your door has double end stiles then it will require 2 top brackets as shown in FIG K in which case an additional top bracket will be installed in the same manner next to the first top bracket with one roller being placed through both top bracket slides 2 reinforcement brackets will then be installed under the 2 top brackets and secured to the section with 2 1 4 20 X 7 8 self drilling screws If your door is trolley operated it is recommended that an optional strut be installed on the top rail Now stack the top section take care to ensure it is aligned properly with the other sections TOP BRACKET BASE 4 TOP SECTION 1 5 16 X 3 4 Hr pe CARRIAGE BOLT sag TOP SECTION Pa 4 1 4 26 X 7 8 SELF
3. APPLY LOCKING PLIERS TO VERTICAL TRACK ABOVE AND BELOW BOTTOM ROLLERS ON EACH SIDE TO SECURE WHILE ATTACHING BACK HANGERS Uu Co Cm INTERMEDIATE HANGERS BACK HANGERS 3 4 7 8 CC Ob ul USEAS X3M s 3 8 DIA BOLT SHOULD TRUSS BOLT FOR ww PROTRUDE INTO TRACK TO ROLLER CLEARANCE 5 SERVEASAROLLER STOP FIG R 13 SPRING ADJUSTMENTS Release the locking pliers from vertical tracks and check the door s counterbalance Adjust springs if necessary If door does not balance properly verify that all supplied components such as struts are installed Verify quantity wire diameter spring size amp drums to the spring tag Check Cable length Add or subtract up to one turn on the springs Contact Wayne Dalton Corp if problem persists FINAL ADJUSTMENTS Vertical tracks can now receive final adjustments Open and close the door a few times checking and adjusting side clearance if necessary Tighten jamb fasteners lags self drilling or anchors to permanently secure verticals Adjust door in or out from jamb by loosening the track to obtain proper seal Permanently tighten all track bolts Lubricate springs rollers and bearing with oil DO NOT GREASE THE INSIDE OF THE TRACK ALTERNATE STEEL SPRING PAD APPLICATIONS Contact
4. Model 451 452 Aluminum FullView COMMERCIAL GARAGE DOOR INSTALLATION INSTRUCTIONS AND OWNER S MANUAL Read these instructions carefully before attempting installation If in question about any of the procedures do not perform the work Instead have a trained door systems technician do the installation or repairs IMPORTANT SAFETY NOTICES An overhead door is a large heavy object that moves with the help of springs under high tension Moving objects and springs under tension can cause injuries For your safety and the safety of others follow these instructions Wear protective gloves during installation to avoid possible cuts from sharp metal edges Itis always recommended to wear eye protection when using tools other wise serious eye injury could result Operate door ONLY when properly adjusted and free of obstructions Keep door in full view while operating it Watch the door open or close completely before leaving the area 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 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 To prevent serious injury or death avoid standing in the open doorway or walking through the doorway while the door is moving
5. 5 16 X 1 5 8 LAG S SCREW FOR USE ON WOOD JAMBS FIG H 1 Y 5 16 X 1 SELF DRILLING amp TAPPING SCREW FOR USE ON STEEL JAMBS 5 FIG 2 3 8 X 3 SLEEVE ANCHOR BY OTHERS FOR USE ON PRE CAST CONCRETE DRILL A 3 8 X 3 1 2 DEEP HOLE FIG H 3 STACK THE SECTION INTO POSITION BY HOOKING THE LEFT zz HAND ROLLER INTO 222 THE VERTICAL TRACK AND REPEATING FOR C 7 THE RIGHT HAND SIDE FIG H 4 FIG H STACKING SECTIONS Locate the Lock Section the second section and insert a roller into the left end hinge Stack this section into the opening by hooking the roller into the left hand vertical track and lowering the section onto the bottom section as shown in FIG I Insert a roller into the proper uninstalled right hand end hinge and place the roller into the right hand vertical track Lower the roller and hinge into the proper position over the section and attach to the section in the same manner the left hand end hinge was attached as described on page 5 Verify section alignment and flip up the upper hinge leaf s from the bottom section and secure to the lock section using 1 4 20 x 7 8 self drilling screws Continue to stack the remaining sections in the proper sequence except for the top section HOOK LEFT HAND ROLLER INTO TRACK b
6. _ NN EIN 800 32 WIND SPRINGS TOWARD CEILING STANDARD LIFT APPLICATIONS 88 2 2 Tas os Le ES Dt mE EE 6 25 75 7 625 8 125 REAR SUPPORTS After spring s are wound cautiously remove locking pliers from vertical tracks while pushing downward on door to prevent it from raising unexpectedly in case spring s were over wound Carefully and slowly raise door until one and a half sections are in the horizontal tracks Lock door in this position using locking pliers attached to vertical tracks above bottom roller on one side and below bottom roller on other side of door Space the horizontal tracks 3 4 7 8 from section edge and level Using 1 5 8 x 2 3 8 x 12 Ga angle fabricate back hangers and attach them to building as shown in FIG R using 3 8 bolts and nuts Laterally brace all drop angles once proper spacing is achieved Doors over 11 ft high and over 14 ft wide must have 1 intermediate drop hanger as shown in FIG R Doors over 16 high must have 2 intermediate drop hangers as shown in FIG R INTERMEDIATE HANGERS FOR ALL DOORS OVER 11 HIGH AND OVER 14 WIDE POSITIONED HALF WAY BETWEEN JAMB AND BACK HANGER LATERAL BRACE ALL HANGER ANGLES 7 DOORS OVER 16 HIGH USE 2 INTERMEDIATE HANGERS d 3 Y S 3 USE 12 GA MINIMUM ANGLE 1 5 8 X 2 3 8
7. 1 hinges attached to the top corners of the bottom section 3 track applications begin with 3 hinges attached to the top corners of the bottom section To install center hinges on doors without integral ribs place the center hinge over the center stile s using the center line of the stile s as a guide and secure to the section using 2 1 4 x 7 8 self drilling screws as shown in FIG G To install center hinges on doors with integral ribs seat the bottom half of the half hinge s onto the integral rib above the center stile s and over the punch marks of each section and secure to the rib with 2 1 4 20 x 5 8 carriage bolts and 2 1 4 x 20 flange hex nuts as shown in FIG G Repeat for all remaining sections except top section END STILE END STILE PUNCH MARKS CENTER LINE DOUBLE ATTACHED HINGE END STILE ATTACHED HINGE 4 7 8 SELF DRILLING SCREWS 1 4 X 7 8 SELF DRILLING SCREWS 2 FIG E FIG F SECTIONS WITH INTEGRAL RIBS SECTIONS WITHOUT INTEGRAL RIBS 1 4 X 7 8 SELF DRILLING SCREWS INTEGRAL RIB 2 g HALF HINGE PUNCH MARKS CENTER LINE 2 1 4 20 X 5 8 ENDHINGE CHART CARRIAGE BOLTS 2 1 4 X 20 FLANGE HEX 86 6 Hinges are stamped wi
8. END STILE DRILLING SCREWS FLANGE HEX NUT BRACKET BASE FIG J p d z di TOP SECTION pz 2 1 4 20 X 7 8 SELF P4 DRILLING SCREWS OY 8 1 4 20 X 7 8 SELF P 2 REINFORCEMENT ae BRACKETS FIG K VERTICAL TRACK ADJUSTMENT Adjust the spacing of the vertical tracks from 3 8 5 8 spacing at the bottom section to 3 4 7 8 spacing at the top section refer to page 3 Permanently secure each vertical track to the jambs HORIZONTAL TRACKS ADJUSTING TOP BRACKET Use chain or cable to temporarily suspend the rear of the horizontal track assembly Align the curved end of the horizontal track assembly with the top of the vertical track Secure the horizontal track to the splice plate or flagangle using 2 1 4 x 9 16 track bolts and hex flange nuts as shown in FIG L 4 Secure the horizontal reinforcing angle to the wall angle using 1 3 8 x 3 4 truss bolt and nut as shown in FIG L 3 ignore the counterbalance hardware in this illustration this hardware will be installed in the next step With tracks installed you can adjust the top brackets Starting on one side slide the top bracket roller s out against the horizontal track Maintaining the slide s position tighten the 5 16 x 3 4 carriage bolt s and flange hex nut s to secure the top bracket slide s to the top bracket base Repeat for other side COUNTERBALANCE A WARNING INSTALL SUPPORT BRACKETS TO SOLID STRUCTURAL MEMBERS ONLY DO NOT INSTALL OVE
9. These instructions are not applicable for a span greater than 84 in p Pd HEAVY PERFORATED ANGLE Ca 1 5 8 X 2 3 8 X 11 GA 4 P d A CENTER SPRING BRACKET WS 7 SS B S d 7 2 3 8 X 1 1 4 BOLTS TO 6 di p di d e Jo 9 9 9 A AA o 9 o 9 9 E SECURE BRACKET TO ANGLE 2 3 8 X 1 1 4 BOLTS amp NUTS TOP amp BOTTOM p 74 SPACE CENTER BRACKETS 12 14 ps BRACKETS 12 14 lt ON APPLICATIONS 22 gt APART ON APPLICATIONS REQUIRING COUPLERS p ty REQUIRING COUPLERS HEAVY PERFORATED ANGLE al Fat zoe X2 X11 GAJ 1 5 8 X 2 3 8 X 11 GA uum CENTER SPRING Pd NS gt BOLT Z SHAPED ASSEMBLY USING 4 2 3 8 X 1 1 4 2 T 3 8 X 1 1 4 BOLTS BOLTS TO SECURE sl EK AND NUTS E BRACKET TO ANGLE a E d 2 3 8 X 1 1 4 BOLTS TO SECURE 2 3 8 X 1 1 4 BOLTS amp AN BRACKET TO ANGLE GIRT NUTS TOP amp BOTTOM 2 3 8 X 1 1 4 BOLTS amp NUTS TOP amp BOTTOM FIG T FIG U INSIDE SIDE LOCK INSTALLATION Install lock on second section of door Secure the lock to the section with 4 1 4 20 X 5 8 self drilling screws as shown in FIG V The s
10. 1 2 di 2 DOUBLE WIDE COUNTER SUNK BOLT BOTTOM RAIL CABLE KEEPER INSTALLATION Place cable keeper between roller carrier tabs Insert roller through holes in the tabs and through cable keeper Rotate arm up and hook around cable letting cable keeper arm pull against the counterbalance cable keeping it taut as shown in FIG Y NOTE Cable keepers are color coded black for right hand and red for left hand IMPORTANT Cable keepers are intended to keep cables from coming off drums on manually operated doors CABLE Q a KEEPER P 0 a ROLLER KEEPER FIG Y CHAIN HOIST INSTALLATION STANDARD LIFT APPLICATIONS Chain Hoists and JackShaft Operators are limited to 1 Standard Lift Doors with roof pitch track 2 12 or greater 2 High Lift track greater than or equal to 24 3 High Lift track 12 thru 24 with roof pitch track 1 12 If your door is to be trolley operated it is recommended that an optional strut be installed on the top section Wayne Dalton recommends the use of a trolley rail s and auxiliary shaft for standard or high lift doors below these limits Cable Keepers are recommended for all chain hoist or jackshafts operators Install the chain hoist or sprocket as close to the end bearing bracket as possible to minimize torsion shaft deflection as shown in FIG Z Chain tensioners are recommended for door over 144 sq ft
11. 8 2 2 gt CAM ARM MAINTENANCE AND FINISHING INSTRUCTIONS MAINTENANCE An occasional light cleaning will also help maintain an aesthetically pleasing appearance The only regular maintenance necessary is that of annual washing Mild solutions of detergents or household ammonia will aid in the removal of most dirt and the following are recommended levels One cup of Tide or other common detergents which contain less than 0 5 phosphate dissolved into five gallons of warm water NOTE The use of detergents containing greater than 0 5 phosphate is not recommended for use in general cleaning of garage doors NEVER BLEND CLEANSERS OR DETERGENTS WITH BLEACH ACRYLIC GLAZING CLEANING INSTRUCTIONS 1 To clean acrylic glazing wash with plenty of nonabrasive soap or detergent and water Use the bare hand to feel and dislodge any caked dirt or mud A soft grit free cloth sponge or chamois may be used to wipe the surface Do not use hard or rough cloth that will scratch the acrylic glazing Dry with a clean damp chamois 2 Grease and oil may be removed with kerosene or a good grade of naphtha No aromatic content Users of these solvents should become familiar with their proper ties to handle them safely 3 Do not use Window cleaning fluids scouring compounds gritty cloths leaded or ethyl gasoline or solvents such as alcohol acetone carbon tetrachloride etc 19 20 Limited Warranty Model 451 452 am
12. door opening to the ceiling or underside of joists Refer To Headroom Chart Backroom required distance from door opening header to the furthest back point to which the door track or operator unit and their brackets will extend Refer to Backroom Chart Verify the operating zone dimensions 1 Exact size of finished daylight opening Do you have the correct door size 2 Sideroom requirements for track and spring shaft Refer to sideroom chart 3 Headroom requirements Refer to headroom chart for standard lift track 4 Backroom depth into room Manual lift 2 Door height plus 18 Operators Door height plus 48 Standard Lift 5 Jambs must be plumb and solidly attached to the building Floor must be level or exact gradeline established before you start Shipping tags show important information door size track size and type spring size and hardware type Verify that all material is present and correct before attempting installation EXTEND JAMBS TO OPENING HEIGHT 8 PLUS DIM Y PLUS 1 1 2 MINIMUM LENGTH EXT N OA A WALL ANGLES CUT 3 OFF MINIMUM HEADROOM 4 FOR 12 RADIUS APPLICATIONS REQUIRED REFER TO HEADROOM CHART oe DIM Y HEADER V TO SHAFT CENTERLINE AZ 7 TORSION SHAFTS REQUIRE
13. m MOUNTING 4 RECOMMENDED SLEEVE ANCHOR MOUNTING BRACKET WOOD JAMBS PRECAST WALL WITH CORNER ANGLE PRECAST WALL WITHOUT CORNER ANGLE 2 TRACK 3 TRACK 3 TRACK 5 16 X 1 DRILLING FLUSH 1 OVERLAP TAPPING SCREW 1 2 5 8 1 2 5 8 E v z i i a i 8 16 11 5 8 rp S LAGSCREW SIDE ROOM 5 A C 2 e 1 ga m lt lt 4 15 16 2 X 6 4 15 16 IS RECOMMENDED STEEL JAMBS WOOD JAMBS 3 TRACK 3 TRACK COUNTERBALANCE CABLES BOTTOM BRACKETS For doors using the broken cable safety device see page 19 For Model 451 doors with the bottom bracket shown in FIG A locate the bottom section and the left and right hand bottom brackets Secure the counterbalance cables to the brackets using clevis pin washer and cotter key as shown in FIG A Secure bottom brackets to bottom section using 5 1 4 x 7 8 self drilling screws as shown in FIG B Insert a roller into the bottom brackets as shown in FIG C For Model 451 doors with the bottom bracket shown in FIG D Secure the counterbalance cables in the same manner as described above Attach the bracket to the section with 5 1 4 X 7 8 self drilling screws Attach the roller carrier to the bottom bracket with 4 1 4 X 7 8 self drilling screws Insert a roller and 3 16 roller spacer into the roller carrier the inner holes of the roller carrier are for 2 track th
14. with jackshaft operators Wayne Dalton recommends the use of a trolley rail s coupled to an auxiliary shaft that is powered by a side mount type chain hoist as shown in FIG Z 9 of extra headroom are required for these installations Assemble the trolley rail as per the manufactures installation instructions Secure the trolley header bracket to the building using the appropriate fasteners 2 5 16 X 1 5 8 lags for wood 2 5 16 X 1 self drilling and tapping screws for steel and 2 3 8 2 1 2 sleeve anchors for masonry Back hang the trolley using angles center hang supports are required for doors over 14 wide and 12 high Attach the trolley arm to the bracket Secure the auxiliary shaft to the building with bearing brackets and couple the shaft to the trolley rail Assemble the chain hoist and secure to the auxiliary shaft 17 1 2 X 3 MIN SLEEVE ANCHOR BY OTHERS 5 16 X 1 SELF DRILLING AND TAPPING SCREW OR 5 16 X 1 5 8 LAG BOLT 22 2 oe COUPLING NOTE Install Sprocket or chain hoist as close to track as possible minimum of 3 4 to minimize shaft deflection Cy Pusher Spring Installation 5 MIN EXTRA HEADROOM REQUIRED 1 2 X 3 MIN SLEEVE ANCHOR BY OTHERS 5 16 X 1 SELF DRILLIN
15. 10 OF SIDEROOM FOR SOLID SHAFTS AND 5 OF SIDEROOM FOR TUBULAR SHAFTS 8 FOR 2 TRACK 12 FOR 3 TRACK Pa Y o HEADROOM CHART For Standard Lift Track Minimum Distance Required 3 TRACK 15 2 TRACK 15 2 TRACK DIM B MANUAL DEPTH DIM A RADIUS RADIUS 12 RADIUS INTO ROOM SIDEROOM TRACK SIDEROOM TORSION SHAFT 400 8 HEADROOM 15 1 2 14 1 2 12 1 2 aa et A HEADROOM 19 18 15 DIMY 14 1 2 13 1 2 10 1 2 DOOR HEIGHT PLUS 18 DIMY 16 1 2 15 12 1 2 DOOR HEIGHT Dim Y INDICATES THE DISTANCE FROM THE HEADER TO THE CENTER LINE OF TE eel ee TORSION SHAFT NOTE 2 1 2 OF ADDITIONAL HEADROOM IS REQUIRED FOR SINGLE TROLLEY OPERATOR INSTALLATIONS NOTE HEADROOM CAN BE REDUCED 2 1 2 BY USING THE QUICK CLOSING TOP FIXTURE OR BY SHORTENING THE VERTICAL TRACKS BY 3 MAX SIDEROOM REQUIREMENTS
16. AL ANGLE TO FLAG ANGLE 1 4 X 9 16 TRACK BOLTS AND NUTS 55 5 CENTER SUPPORT BRACKET SLEEVE ANCHOR POSITIONED IN BOTTOM SLOT OF SUPPORT BRACKET PERFORATED ANGLE TRIMMED TO CLEAR DOOR HIGH ARC 4 3 8 x 2 1 2 SLEEVE ANCHOR NOTE ALL ANCHORS MUST BE POSITIONED A MINIMUM OF 1 FROM BLOCK EDGE 2 3 8 X 1 1 4 HEX HEAD BOLTS AND NUTS x 2 S o SECOND MUST BELOW SUPPORT BRACKET SPRING MOUNTING PAD 2 X 6 WHITE PINE OR DENSER SECURED WITH MIN 4 5 16 X 4 LAG BOLTS INTO HEADER e TOP PLATE ds HEADER 2 3 8 X 1 1 2 BOLTS 2 3 8 NUTS 5 16 X 1 5 8 LAG SCREWS PERIMETER SEAL FIG M 1 2 1 2 X 3 SLEEVE ANCHOR PRE CAST 3 5 16 X 1 SELF DRILLING AND TAPPING SCREWS NOTE MUST SECURE SLEEVE ANCHORS TO BUILDING FIRST THEN ATTACH BRACKETS TO ANCHORS ONE or TWO SPRINGS 2 or 2 5 8 ONLY 3 MINIMUM SPRING PAD WIDTH 6 IF FOR TROLLEY OPERATOR RIGHT HAND DRUM amp BLACK WINDING CONE BLACK WINDING CONE LEFT HAND DRUM E RIGHT HAND DRUM BLACK WINDING CONE BLACK WINDING CONE RED LEFT HAND DRUM 9 MINIMUM SPRING PAD WIDTH NOTE 6 SPRINGS UTILIZE SOLID SHAFTS 10 TWO MORE SPRINGS 2 5 8 or 3 3 4 SPLIT SOLID SHAFT RIGHT HAND DRUM 17 MINIMUM SPRING PAD WIDT
17. G AND TAPPING SCREW OR 5 16 X 1 5 8 LAG BOLT SINGLE TROLLEY OPERATOR BRACKET IS DOOR SIZE DEPENDENT TROLLEY OPERATOR BRACKET IS SUPPLIED BY OTHERS 24 o 5 1 TOP SECTION 2 3 8 DIAMETER HOLES PUSHER SPRING 2 2 3 8 X 1 1 4 HEX HEAD BOLTS AND NUTS Raise door until bottom section is 3 4 below header Align pusher spring with the top corner of the top section Compress against the top bracket flange Drill 2 3 8 holes in each track and secure using 2 3 8 x 1 1 4 hex head bolts and nuts bolt may extend into track 18 FIG Z Broken Cable Safety Device Installation 1 Attach the broken cable safety device with cable attached to the section using 8 1 4 20 X 5 8 self drilling screws 2 Place the bottom section in the opening 3 Install the verticals over the rollers 4 Follow the rest of the door installation per the instruction manual 5 After the door installation is complete rotate the cam arm up and connect the cable arm to the cam arm with the bolt and locking nut 6 Operate the door to verify that there is clearance between the track and section for the cable arm 7 Adjust the track as needed ia CABLE ARM p CABLE ARM BROKEN CABLE 10 X 1 1 2 LP SAFETY DEVICE BOLT W LOCK NUT 5 8 X 20 SELF oe Aa SES DRILLING SCREWS
18. H 3 MINIMUM SPRING PAD WIDTH lt WINDING W BLACK COUPLING WINDING CONE RED TWO OR MORE SPRINGS 6 SPLIT SOLID SHAFT d 17 MINIMUM SPRING S PAD WIDTH 5 SO SA SIN D N SSO SRA SORT SY SO SR A SSN SON SSN SS WINDING CONE SN Ton 3 MINIMUM SPRING BLACK PAD WIDTH EN SS SOON SS COUPLING Sy SON SS VR SR N NN SON Se SA SSO SORTI inna 2 3 8 X 1 GRADE 5 BOLT AND NUT WITH 2 FLAT td N M RRN WASHERS EACH AND 1 E amp LOCK WASHER EACH PER Zs NND D DSB WALL ANGLE AND E oa S SONI ANN N SN IF PROVIDED SSN Sh SN SPRING PLATE DEO NOS LQ SA SSN Se SS SPRING PLATE WINDING SSN SN SS p SONA TUM RED SA SA LEFT HAND DRUM e DSB WALL ANGLE So SSA Sy RED x AND 11 WINDING SPRINGS A WARNING APPLY LOCKING PLIERS TO THE TRACKS ABOVE THE THIRD ROLLER OR LOCK DOOR IF APPLICABLE BEFORE WINDING THE SPRING S TO PREVENT DOOR FROM RISING UNEXPECTEDLY POSSIBLY RESULTING IN SEVERE OR FATAL INJURY A WARNING WINDING BARS MUST FIT SNUGGLY INTO HOLES IN SPRING WINDING CONES ATTEMPTING TO WIND SPRINGS WITH LOOSELY FITTING RODS SCREWDRIVERS OR OTHER IMPROPER TOOLS CAN RESULT IN SEVERE OR FATAL INJURY Feed the cable attached to the left hand bottom bracket up the vertical track behind the rollers and secure to the left hand drum Push th
19. Manufacturer For Applications Not Covered Below Maximum Door Size 9 x 9 Maximum Door Weight 210 Ib Cut perforated angle 1 5 8 x 2 3 8 x 11 GA to Dim Y Thru bolt top and bottom of angle to each girt using 4 3 8 x 1 1 4 bolts and nuts Thru bolt center bracket to perforated angle using 2 3 8 x 1 1 4 bolts and nuts See FIG S Maximum Door Size 14 x 12 Maximum Door Weight 400 Ib Cut 2 perforated angle 1 5 8 x 2 3 8 x 11 GA to Dim Y Thru bolt top and bottom of each angle to each girt using 4 3 8 x 1 1 4 bolts and nuts Thru bolt each center bracket to perforated angle using 2 3 8 x 1 1 4 bolts and nuts See FIG T Maximum Door Size 14 2 x 12 1 Maximum Door Weight 800 Ib Cut 2 pieces of perforated angle 1 5 8 x 2 3 8 x 11 GA to Dim Y and 2 more pieces at Dim Y minus 3 Bolt the angles together into a Z shape using 4 3 8 x 1 1 4 bolts and nuts Thru bolt top and bottom of each Z shaped angle to each girt using 4 3 8 x 1 1 4 bolts and nuts Thru bolt each center bracket to perforated angle assembly using 2 3 8 x 1 1 4 bolts and nuts See FIG U NOTE Do NOT Bolt 2 3 3 4 Torsion Springs To ONE Center Bracket NOTE These spring mounting techniques are not supported for 800 32 6375 164 1100 18 1350 28 amp 800 120 drums These instructions are also not applicable for 5750 120 drums with 72 Or more high lift NOTE Maximum spacing for dimension Y is 84 in 7 ft
20. R DRY WALL OR PANELING FAILURE TO INSTALL SUPPORT BRACKETS TO SOLID STRUCTURAL MEMBERS CAN CAUSE SEVERE OR FATAL INJURY A WARNING FAILURE TO USE PROPER NUMBER OF FASTENERS CAN RESULT IN SUDDEN SPRING TENSION RELEASE CAUSING SEVERE OR FATAL INJURY NOTE Spring pads must be securely anchored before proceeding as shown in FIG M 2 The pads must by flush with the jambs Attach the EBF s end bearing brackets to the horizontal reinforcing angles using 2 3 8 x 3 4 truss bolts and nuts as shown in FIG L1 L2 L3 Attach the EBF s to the jambs using 2 5 16 x 1 5 8 lags wood 2 5 16 x 1 self drilling and tapping screws steel or 2 3 8 x 3 sleeve anchors precast anchors by others Install the Center Support Bracket s to the spring pads at the same elevation as the bearing in the EBF s Depending on the construction different fasteners must be used Steel Secure each center support bracket using 3 5 16 x 1 self drilling and tapping screws as detailed in FIG M 3 Pre Cast Secure each center support bracket using 2 1 2 x 3 sleeve anchors by others This installation will require the 1 2 anchors to be secured to the building then securing the brackets to the anchors as detailed in FIG M 4 Block Construction Attach perforated angle 18 long to center support bracket s using 2 3 8 x 1 1 4 bolts and nuts Chamfer angle to clear top section high arc Secure center support bracket s and perforated angle to block us
21. Use lift handles step plate when manually operating the door DO NOT place fingers into section joints when operating the door Remove pull rope if door is operated by an electric opener 0 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 BRACKETS should be performed ONLY by qualified door service people 11 Check door and its hardware monthly for loose worn or broken parts Have any repairs or adjustments made by a qualified door agency 12 Have the door professionally inspected once a year 13 Lubricate hinges springs and rollers once a year This manual MUST be attached to the wall in close proximity to the door Copyright 2008 Wayne Dalton Corp Part No 338306 New 5 27 2008 OPERATING ZONE You Can Save Time And Effort If You First Establish All The Facts About The Operating Zone The Operating Zone is the area surrounding the door opening extending upward and backward as far as the door will travel We call it the Operating Zone because it is the area that the door will have to operate within and the dimensions are critical and must be known in advance of a door and operator installation Daylight Opening Exact size of finished opening Sideroom required distance from the door opening to a wall or any obstruction Refer To Sideroom Requirements Headroom required distance from top of
22. ade at all At the Manufacturer s option pursuant to the dealer having notified the Manufacturer of a warranty claim a service representative may inspect the product on site or Buyer may be required to return the product to the Manufacturer at Buyer s expense Buyer agrees to cooperate with any representative of the Manufacturer and to give such representative full access to the product with the claimed defect and full access to the location of its installation If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty the Manufacturer will cause the defective product to be repaired or replaced The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer subject to applicable law THE REMEDY WILL COVER ONLY MATERIAL THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES SUCH AS FIELD SERVICE LABOR FOR REMOVAL INSTALLATION PAINTING SHIPPING ETC Any repairs or replacements arranged by Manufacturer will be covered by and subject to the terms conditions limitations and exceptions of this Limited Warranty provided however that the installation date for the repaired or replaced product will be deemed to be the date the original product was installed and this Limited Warranty will expire at the same time as if there had been no defect If a claim under this Limited Warranty is resolved in a manner other than described in the immediately preceding paragraph then
23. e drum up against the end bearing bracket and secure to the shaft by tightening the set screws solid shafts use 1 4 key s and set screws to secure drums Rotate drum and shaft until cable is taut then apply locking pliers to torsion shaft with end resting against header This will hold cable taut and on drum There must be at least 1 2 wrap of cable on the drum If not contact Wayne Dalton for proper length cables Attach other cable to right hand drum Push drum against end bearing bracket and rotate drum until cable is taut Secure drum to shaft by tightening the set screws Cable tension must be equal on both drums on single shaft applications On split shaft applications apply locking pliers to both torsion shafts and secure bolts in coupling after springs are fully wound Carefully following spring winding instructions detailed in FIG Q wind spring s using the appropriate 1 2 5 8 or 3 4 diameter winding rods of sufficient length wind spring 1 4 turn at a time to the number of complete revolutions recommended on the spring turn chart When the proper number of turns is reached tighten the set screws on the winding cone Release the locking pliers from the spring shaft s Adjust the coupler on split solid shafts until drums are in line check door level and tighten coupler NOTE Coupling used on solid shaft only Tighten connecting bolts after winding springs SPRING TURN CHART Ed 459 sme 1 1 Lm pue pes
24. e outer holes of the roller carrier are for 3 track T COUNTERBALANCE CABLE BOTTOM BOTTOM BRACKET SECTION SECTION 5 1 4 X 7 8 SELF ATTACHED DRILLING SCREWS DOTIOM BRACKET WASHER 1 BOTTOM BRACKET P D ASSEMBLY CLEVIS PIN g COTTER KEY 1 FIG A FIG B d 4 1 4 X 7 8 SELF DRILLING SCREWS 5 1 4 X 7 8 SELF DRILLING SCREWS ROLLER CARRIER p 1 o FIG C 0 3 16 ROLLER SPACER OUTER HOLES FOR 3 TRACK INNER HOLES FOR 2 TRACK FIG D HINGES NOTE Top sections do not require hinges Use the ENDHINGE CHART to determine the proper endhinges for the proper section Install only the left hand end hinge as the right hand end hinge will need to be installed when the sections are stacked Align the proper left hand end hinges to the proper sections using the center line of the endstile as a guide and the 2 punch marks in the endstile to locate the placement of the end hinge Secure using 2 1 4 x 7 8 self drilling screws as shown in FIG E Sections with double end stiles require 2 end hinges per side on each section as shown in FIG F The end hinge sequence is dependent on track size 2 or 3 2 track applications begin with
25. ide lock should be spaced approximately 1 8 from the section edge Ensure that lock is square with section and lock bolt aligns with lock hole in vertical track VERTICAL TRACK ALIGN WITH SLOT IN TRACK 4 1 4 20 X 5 8 SELF DRILLING SELF DRILLING SCREWS STEP PLATE INSTALLATION Position your step plate on the inside of the door over the bottom section end stile on the side of the door containing the side lock Secure step plate to endstile with 1 4 20 x 7 8 Self drilling screws as shown in FIG W For doors ordered with non keyed locks a second step plate is provided Install the second step plate in the same manner as the first on the lock section second section below the side lock IF SECOND STEP PLATE WAS RECEIVED FOR DOORS ORDERED WITH NON KEYED LOCKS INSTALL IT BELOW THE SIDE LOCK LOCK SECTION END STILE STEP PLATE BOTTOM SECTION 2 1 4 20 X 7 8 SELF DRILLING SCREWS EXHAUST PORT INSTALLATION Install the exhaust port using 3 10 x 1 1 2 counter sunk bolts and nuts as shown in FIG X Exhaust port goes on the inside of bottom section and can be installed into the aluminum panel or a double wide bottom rail OUTSIDE TRIM RING ALUMINUM PANEL 3 10 HEX NUTS EXHAUST PORT P GASKET 21 6 ASKET 3 10 X 1
26. ing 4 3 8 x 2 1 2 sleeve anchors as detailed in FIG M 1 For 6 Springs Attach DSB wall angle s to the spring pads Fasten the spring plate to the wall angle bracket as shown in FIG P NOTE 1 GRADE 5 bolts are provided and must be used with the flat and locking washers to fasten the spring plate to the DSB wall angle NOTE Additional center support brackets are not required for coupler support Torsion spring assemblies Torsion spring assemblies can be of several configurations depending on door size and weight Left or right hand spring s must be identified by the color of the winding cone Refer to FIG 0 and P Ensure that spring warning tags are securely wired to all stationary spring cones NOTE All red winding cone springs will be on the left side and all black winding cone springs will be on the right side NOTE All set screws on drums and winding cones are painted red Locate torsion shaft and lay it in front of door on garage floor Assemble torsion shaft assembly components according to spring and torsion shaft type as shown in FIG N 0 and For 2 or 2 5 8 Spring s Tubular Shaft Only Install the loose steel bearing onto shaft 1 per spring s and insert into stationary cone For 2 5 8 solid shaft with coupler 1 spring per bracket or 3 3 4 springs Install the loose steel bearing onto shaft 1 per spring and insert into the stationary cone NOTE Additional center support brackets are not required for coupler
27. l be governed by the laws of the State of Ohio USA to the extent permitted by law This Limited Warranty gives you specific legal rights and you may also have other rights which may vary from State to State
28. neither this Limited Warranty nor any other warranty from the Manufacturer will cover the repaired or replaced portion of the product THE REMEDIES FOR THE BUYER DESCRIBED IN THIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy The liability of the Manufacturer whether in contract or tort under warranty product liability or otherwise will not go beyond the Manufacturer s obligation to repair or replace at its option as described above THE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES including but not limited to damage or loss of other property or equipment personal injury loss of profits or revenues business or service interruptions cost of capital cost of purchase or replacement of other goods or claims of third parties for any of the foregoing Some States do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you No employee distributor dealer representative or other person has the authority to modify any term or condition contained in this Limited Warranty or to grant any other warranty on behalf of or binding on the Manufacturer and anyone s attempt to do so will be null and void Buyer should be prepared to verify the date of installation to the satisfaction of the Manufacturer The rights and obligations of the Manufacturer and Buyer under this Limited Warranty wil
29. p K AL Subject to the terms and conditions contained in this Limited Warranty Wayne Dalton Corp Manufacturer warrants the sections of the door for FIVE 5 YEARS with the exception of the following items These items will be warranted for a period of ONE 1 YEAR from the date of installation against i Fading cracking or chipping of the anodized or powder coated finish 1 Fogging or condensation forming inside of the insulated glass unit Chipping cracking scratching breaking or discoloration of the glass due to defects in material or workmanship The Manufacture will not be responsible for glass chipping breaking or cracking resulting from any circumstances beyond the direct control of the manufacture The Manufacturer warrants the garage door hardware except springs and the tracks of the above described door for a period of FIVE 5 YEARS from the date of installation against defects in material and workmanship subject to all the terms and conditions below The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Limited Warranty against defects in material and workmanship for a period of ONE 1 YEAR from the date of installation This Limited Warranty is extended only to the original purchaser property owner where the door is installed This Limited Warranty is not transferable nor does it extend benefits to any other buyer even when the property is sold As a re
30. sult this Limited Warranty does NOT apply to any person who purchases the product from someone other than an authorized Wayne Dalton dealer or distributor The Manufacturer will not be responsible for any damage attributable to improper storage improper installation or any alteration of the door or its components abuse damage from corrosive fumes or substances salt spray or saltwater air fire Acts of God failure to properly maintain the door or attempt to use the door its components or related products for other than its intended purpose and its customary usage This Limited Warranty does not cover ordinary wear This Limited Warranty will be voided if any holes are drilled into the door other than those specified by the Manufacturer THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON MOSS ACT NO WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WILL EXTEND BEYOND THE TIME PERIOD SET FORTH IN UNDERSCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY ABOVE Some States do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you Any claim under this Limited Warranty must be made in writing within the applicable warranty period to the dealer from which the product was purchased Unless the dealer is no longer in business a written claim to the Manufacturer will be the same as if no claim had been m
31. support Lift the torsion shaft assembly into place by placing one end of the shaft into the end bearing bracket followed by the other end Make sure the torsion shaft assembly and it s components are positioned properly with respect to the end and center support brackets as shown in FIG 0 and P The torsion shaft should be level and held in place by the end and center support bracket s Secure the spring stationary cone s dead end to the center support bracket s using 3 8 bolts and nuts Keep spring warning tags clearly visible NOTE The center support brackets require 2 fasteners in the lower slot and hole then 1 fastener in the top slot NOTE Each 3 3 4 6 and Duplex spring is secured to a separate center support bracket DO NOT attach two springs of this size to one center support bracket FIG L 1 L 2 amp L 3 THIS ILLUSTRATION SHOWS 15 RADIUS TRACK W CONCRETE ANCHOR THIS ILLUSTRATION SHOWS 12 RADIUS TRACK W LAG BOLT TO WOOD EBF CUT OFF 3 OF WALL ue ANGLE 12 RADIUS N APPLICATIONS ONLY THIS ILLUSTRATION SHOW 15 RADIUS TRACK W SELF 3 3 8 X 3 4 TRUSS BOLTS AND NUTS 2 FOR SECURING END BRACKET 1 FOR SECURING HORIZONT
32. th their identification 5 BOTTOM SECTION VERTICAL TRACK Center and level or support to a known grade level the bottom section in the opening using shims if necessary as seen in FIG Temporarily attach the wall angles to the jambs with the appropriate lag screws as shown in FIG H 1 FIG H 2 and FIG H 3 Allow 1 2 clearance between the section and the vertical tracks as illustrated in the sidereoom requirements illustrations on page 3 It is important that the top of each track is on the same plane NOTE Products being installed to precast or block must use a 3 8 x 3 sleeve anchor to attach the wall angle to the building as shown in FIG H 3 Use the slots in the wall angle as a drill template and drill a 3 8 hole 3 1 2 deep and secure to anchor Stack the bottom section into position by hooking the left hand roller into the left hand vertical track as shown in FIG H 4 Insert a roller into the proper uninstalled right hand end hinge and place the roller into the right hand vertical track Lower the roller and hinge into the proper position over the section and attach to the section in the same manner the left hand end hinge was attached as described on page 5 lt WALL ANGLE N 27 lt VERTICAL TRACK 24 E i NOTE TYPICAL FASTENER SPACING WALL ANGLE

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