Wayne-Dalton EXTENSION 44, Quick Start Manual

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DOOR INSTALLATION
INSTRUCTIONS
Before installing your door, be certain that you have read and followed all of the instruc-
tions 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 .
IMPORTANT:
WOOD DOORS MUST BE COMPLETELY FINISHED (3 TOTAL COATS, INCLUDING
PRIMER COAT) PRIOR TO INSTALLATION, TO ENSURE THAT THE INTERIOR AND EXTERIOR
SURFACES, AS WELL AS ALL EDGES OF THE DOORS ARE PROPERLY PROTECTED AGAINST
MOISTURE OR OTHER CONTAMINANTS. WOOD DOORS, IN A NON-FINISHED CONDITION,
MUST BE TRANSPORTED AND STORED SO THE WOOD SURFACES ARE NOT EXPOSED
TO MOISTURE OR OTHER CONTAMINANTS. IMPROPER TRANSPORTATION, STORAGE OR
DELAYS IN FINISHING, THAT ALLOWS EXPOSURE OF THE WOOD DOOR SURFACES TO MOIS-
TURE OR OTHER CONTAMINANTS WILL RESULT IN THE WARRANTY BEING VOIDED.
Attaching Flag Angles and Jamb Brackets To
Vertical Tracks
1
NOTE: If you have Riveted Track or Angle Mount Track, skip this step.
Hand tighten the left hand flag angle to the left hand vertical track using (2) 1/4” - 20 x 9/16”
track bolts and (2) 1/4” - 20 flange hex nuts.
NOTE: The bottom jamb bracket is always the shortest bracket, while the center jamb
bracket is the next tallest. If three jamb brackets per side are included with your door, you will
have received a top jamb bracket, which is the tallest.
To attach the bottom jamb bracket, locate lower hole of the hole/ slot pattern of the 1st hole
set on the vertical track. Align the slot in the jamb bracket with the lower hole of the hole/ slot
pattern. Hand tighten jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” – 20
flange hex nut.
Place the center jamb bracket over the lower hole of the hole/ slot pattern that is centered
between the bottom jamb bracket and flag angle of the 2nd hole set. Hand tighten jamb
bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 flange hex nut.
If a top jamb bracket was included, hand tighten it to vertical track using the lower hole of the
hole/ slot pattern in the 3rd hole set and (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20
flange hex nut.
Repeat the same process for right hand side.
Attaching Bottom Weather Seal
2
NOTE:
Reference Package Contents or Breakdown Of Parts, to determine if a bottom weather
seal was supplied. If a bottom weather seal was supplied, complete this step.
NOTE: Refer to door section identification, located in the pre-installation section of this
manual to determine what size section you need to use as your bottom (first) section. Mea-
sure your section to make sure it is the correct height as indicated on the chart.
Place the bottom section face down on a couple of sawhorses or flat clean/ smooth surface.
Align the bottom weather seal with the flap pointing towards the outside surface of the
bottom section. Starting at one end of the door, measure inward 1” and attach the bottom
weather seal to the bottom of the bottom section with 3/4” long galvanized roofing nails
(not supplied). Now stretch the bottom weather seal slightly and nail the rest of the bottom
weather seal to the bottom of the bottom section every 6”. Once the bottom weather seal is
fastened cut off any extra material so that the bottom weather seal is even with both ends of
the bottom section.
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.
Attaching Bottom Corner Brackets
3
NOTE:
Refer to door section identification, located in the pre-installation section of this
manual or refer to Breakdown of Parts.
With the bottom section facing down from the previous step, uncoil the counterbalance lift
cables.
Bottom weather seal
Cable loop Cable loop
Counterbalance
lift cable
Counterbalance
lift cable
Bottom section
NOTE:
Refer to Package Contents / Breakdown of Parts, to determine which bottom corner
brackets you have.
Depending on which bottom corner brackets you have, slip the loop at the ends of the coun-
terbalance lift cable over the milford pin of the bottom corner bracket or secure the cable
loop to the clevis pin and bottom corner bracket using a flat washer and a cotter pin. Repeat
for other bottom corner bracket.
WARNING
ENSURE TIGHT FIT OF CABLE LOOP OVER PIN TO PREVENT
COUNTERBALANCE LIFT CABLE FROM COMING OFF THE PIN, WHICH
COULD ALLOW THE DOOR TO FALL AND RESULT IN SEVERE OR FATAL
INJURY.
Counterbalance lift cable loop
Cotter pin (attached into
place from opposite side
of bottom corner bracket)
Clevis pin (inserted through cotter pin
and bent into place)
Washer
Left hand bottom
corner bracket
Locate the left hand bottom corner bracket
.
Align the bottom corner bracket horizontally with
the bottom edge of the bottom section and align the bottom corner bracket vertically with the
left bottom edge of the bottom section.
Mark and pre-drill 9/32” diameter holes through the bottom section. Attach the bottom
corner bracket to the bottom section using 1/4” - 20 x 2-1/2” carriage bolts, (3) 1/4” - 20
RED HEAD flange hex nuts and 1/4” - 20 flange hex nut(s). Repeat the same process for the
right hand side.
IMPORTANT:
THE CARRIAGE BOLTS AND THE 1/4” - 20 RED HEAD FLANGE HEX NUTS
MUST BE MUST BE INSTALLED ON THE BOTTOM CORNER BRACKETS, AS SHOWN.
If applicable, insert a short stem track roller and roller spacer into each of the bottom corner
brackets.
Typical left hand
bottom corner bracket
Bottom section
Short stem track roller
Roller
spacer
(3) 1/4” - 20
Flange hex nuts
Bottom
weather
seal
Counterbalance
lift cable
(6) 1/4” - 20 x 2-1/2”
Carriage bolts
(3) 1/4” - 20 Flange hex nuts (RED HEAD)
Cable
loop
Bottom corner
bracket
Milford
pin
Left hand bottom
corner bracket
Bottom
section
(4) 1/4” - 20 x 2-1/2”
Carriage bolts
Short stem
track roller
Spacer
Bottom
weather seal
(3) 1/4” - 20 Flange
hex nuts (RED HEAD)
(1) 1/4” - 20
Flange hex nut
Left hand bottom
corner bracket
Bottom
section
(4) 1/4” - 20 x 2-1/2”
Carriage bolts
(1) 1/4” - 20
Flange hex nut
(3) 1/4” - 20 Flange
hex nuts (RED HEAD)
Bottom
weather seal
4