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Models 42 and 45,
Flush
T
O R S I O N
R
L
ESIDENTIAL AND
IGHT
S
L
TANDARD
IFT
I
I
NSTALLATION
NSTRUCTIONS
M
ANUAL
DEFINITION OF LIGHT COMMERCIAL:
1. Door Heights less than or equal to 8'0" (< = 8'0") are considered
Residential Applications.
2. Door Heights greater than 8'0" (> 8'0") are considered Light
Commercial Applications.
PLEASE DO NOT RETURN THIS PRODUCT
TO THE STORE
If you need assistance, please call 1-866-
569-3799 (press Option 1) and follow the
prompts to contact a customer service
representative. They will be happy to handle
any questions that you may have.
©Copyright 2021
Wayne Dalton, a division of Overhead Door Corporation
C
OMMERCIAL
A
O
'
ND
WNER
S
T a b l e O f C o n t e n t s
IMPORTANT NOTICES!
To avoid possible injury, read and fully understand 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.
This Installation document is available at no charge from:
- Your local Wayne Dalton Sales Center, or
- Online at www.Wayne-Dalton.com, or
- By mailing to: Wayne Dalton, a division of Overhead Door Corporation, P.O. Box
67, Mt. Hope, OH., 44660
Part Number
345862
2
2
2
3
4
4
5
6
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19
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22
REV11_01/06/2021
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Table of Contents
Related Manuals for Wayne-Dalton Flush 42
Summary of Contents for Wayne-Dalton Flush 42
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Page 1: Table Of Contents
This Installation document is available at no charge from: - Your local Wayne Dalton Sales Center, or - Online at www.Wayne-Dalton.com, or - By mailing to: Wayne Dalton, a division of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660... -
Page 2: Pre-Installation
Existing Door & Prepar- NEVER hang tools, bicycles, hoses, clothing or anything else from horizontal tracks. ing the Opening. These are available for download at www.Wayne-Dalton.com or at your Track systems are not intended or designed to support extra weight. -
Page 3: Package Contents
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 neces- sary) to properly fit into the header and jambs. -
Page 4: Door Section Identification
Sections are stamped for identification, #1, #2, #3, #4, #5, #6, #7, and #8. The stamp, located on each side of the sections identifies the stacking sequence. The sequence is always determined by #1 being the bottom section to #7 or #8 being the highest top section. If the stamp on the section is illegible, refer to the section side view illustration. -
Page 5: Breakdown Of Parts
BREAKDOWN OF PARTS NOTE: The illustrations shown on this page are general representations of the door parts. Each specific door models may have unique variations. J10. NOTE: For Item (K2), The Rear Center Back Hang Assemblies are to used for all doors over 11’0” door height and over 14’0”... -
Page 6: Door Installation Instructions
sure your section to make sure it is the correct height as indicated on the chart. DOOR INSTALLATION Place the bottom section face down on a couple of sawhorses or flat clean/ smooth surface. INSTRUCTIONS Align the bottom weather seal with the flap pointing towards the outside surface of the bottom section. - Page 7 (4) 1/4” - 20 x 1-7/8” Carriage bolts Side view of track roller carrier(s) Outer holes Bottom section (3” Track) Counterbalance lift cable Cable Bottom loop weather seal (1) 1/4” - 20 Inner holes Flange hex nut (2” Track) Milford (3) 1/4”...
- Page 8 6 Section High Graduated End Hinge Schedule Center hinge Door Height Track Section Type Graduated End (2) 1/4” - 20 x 1-7/8” Carriage bolts Hinge Number and (2) 1/4” - 20 Flange hex nuts 6 Section High Door 2” Intermediate IV Bottom Intermediate III section...
- Page 9 IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1” 6 Section High Strutting Schedule DEEP. Section Type Type Of Strut Location On Section Secure the strut and the graduated end hinge to the Intermediate section using (2) 1/4” - 14 x 1”...
- Page 10 NOTE: If the “L” reinforcement bracket(s) was not supplied with your door, then only pre-drill INTO GRADUATED END HINGES NUMBER 2 AND HIGHER, THE TRACK ROLLER / TANDEM TRACK ROLLER (IF INCLUDED) GOES INTO TUBE FURTHEST AWAY FROM SECTION. (2) 1/8” diameter holes drilled holes are needed. If applicable, repeat the same process for the other Intermediate sections, except for the top Attach the top fixture base to the top section using 1/4”...
- Page 11 DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION. With assistance, lift second section and guide the track rollers into the vertical tracks. Keep- ing the sections vertically aligned, lower section until it is seated against bottom section. IMPORTANT: THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE. IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT, THE VERTICAL TRACK ON THE SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM.
- Page 12 Horizontal 12” Radius track angle track (2) 1/4” - 20 x 1-7/8” Carriage bolts and (2) 1/4” - 20 Flange hex nuts 1/4”-20 x 9/16” (2) 1/4” - 14 x 1” 1/4”-20 Flange Track bolts Lag screws hex nuts Single graduated Flag angle 15”...
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Page 13: Counterbalance Installation Instructions
Horizontal track Attaching Center Bracket to Wall Track roller (1)1/4”-20 x 9/16” Bolt(s) and (1) section 1/4”-20 flange hex NOTE: Refer to Package Contents / Breakdown of Parts, to determine which Center nut(s) Bracket(s) came with your door. Top fixture slide(s) NOTE: Drill 3/16”... - Page 14 IMPORTANT: USE A 5/16” X 2-1/2” RED HEAD LAG SCREW INSTEAD OF THE 5/16” X (3) 3/8” - 16 hex nuts from the coupler halves. Loosen the set screws. Set the components 1-5/8” RED HEAD LAG SCREW IF MOUNTING SURFACE IS COVERED BY DRYWALL. THE LAG aside.
- Page 15 the right hand torsion spring assembly. Stationary spring cone Center bearing brackets Torsion Center bracket Torsion spring bearing spring Coupler half Torsion keyed shaft (2) 3/8”-16 Nuts Typical center bracket Right wound, red (2) 3/8”-16 x 1-1/2” Torsion winding cone (left Stationary spring cone Hex head bolts keyed...
- Page 16 Winding Bars Size Of Winding Bar Spring Inner (Steel Rods) (Inches) Diameter Used On Jamb 1/2” dia. x 18” 2” and 2-5/8” 5/8” dia. x 24” 3-3/4” Locking pliers Intermediate section Typicall left hand end bearing bracket Locking pliers attached Vertical Vertical to crown leg of vertical...
- Page 17 Torsion spring(s) should be wound in the direction the end coil points. 90° Torsion spring(s) Spring coils Perforated HIGH SPRING TENSION CAN CAUSE SERIOUS INJURY OR DEATH. angle DO NOT adjust, repair or remove springs or parts to which springs are connected, such as steel brack- ets, cables, wood blocks, fasteners or other parts of the counterbalance system.
- Page 18 Wayne Dalton 2501 S. State Hwy 121 Bus., Suite 200 Lewisville, TX 75067 For service, call (800) 827-3667 www.Wayne-Dalton.com SAFETY INSTRUCTIONS 1. Operate door ONLY when it is properly adjusted and free of obstructions. Residential warning label, The warning label will 2.
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Page 19: Optional Installation
Optional Installation WARNING Door Arm Hookup DO NOT INSTALL PULL DOWN ROPE ON DOORS WITH OPERATORS. CHILDREN MAY BECOME ENTANGLED IN THE ROPE CAUSING SEVERE OR FATAL INJURY. At the center of the top section, measure horizontally from the top of center hinge to the bottom of strut. -
Page 20: Maintenance
When the finish becomes eroded or thin, clean 67, Mt. Hope, OH., 44660, or at www.Wayne-Dalton.com. For additional information on and prime any areas showing deterioration. Then completely refinish the door, according to garage door/operator maintenance go to www.dasma.com and reference TDS 151, 167... - Page 21 Wayne Dalton 2501 S. State Hwy 121 Bus., Suite 200 Lewisville, TX 75067 For service, call (800) 827-3667 www.Wayne-Dalton.com SAFETY INSTRUCTIONS 1. Operate door ONLY when it is properly adjusted and free of obstructions. Residential warning label, The warning label will 2.
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Page 22: Warranty
Warranty Models 42, 44, and 45 Limited Warranty Wayne Dalton, a division of Overhead Door Corporation ("Seller") warrants to the original purchaser of the Models 42, 44, and 45 (“Product”), subject to all of the terms and conditions hereof, that the Product and all components thereof will be free from defects in materials and workmanship for a period of One (1) year, measured from the date of installation:... - Page 24 Thank you for your purchase. PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE If you need assistance, please call 1-866-569-3799 (press Option 1) and follow the prompts to contact a customer service representative. They will be happy to handle any questions that you may have.