Wayne-Dalton EXTENSION 44, Quick Start Manual

Page: 5 / 14

Left hand bottom
corner bracket
Bottom
section
(7) 1/4” - 20 x 2-1/2”
Carriage bolts
(4) 1/4” - 20
Flange hex nuts
Bottom
weather seal
(3) 1/4” - 20 Flange
hex nuts (RED HEAD)
Attaching Track Roller Carrier’s
4
NOTE:
If you don’t have track roller carriers, then skip this step. Refer to Package Contents /
Breakdown of Parts, to determine if a track roller carrier was supplied with your door.
NOTE: If your door came with two track roller carriers, then one track roller carrier, short
stem track roller and spacer are required for each side.
NOTE: If your door came with four track roller carriers, then two track roller carriers, long
stem track roller and spacer are required for each side.
Starting on left hand side of the bottom section, position the track roller carrier with the
stamp “STD” facing UP to the bottom corner bracket and aligning the four holes of the track
roller carrier with the four holes in the bottom corner bracket. Secure the track roller carrier
to the bottom corner bracket with (4) 1/4” - 14 x 1” lag screws.
NOTE: Prior to fastening the track roller carrier to the bottom section, pilot drill using a 1/8”
drill bit.
IMPORTANT:
BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”
DEEP.
Repeat the same process for other track roller carrier(s). Insert the appropriate stem track
roller and spacer into the inner holes of the track roller carrier(s).
NOTE: The track roller carrier’s inner holes are used on doors with 2” track applications; the
outer holes are used on doors with 3” track applications.
Attaching Hinges and Strut To Bottom Section
5
Lay a SHORT STRUT onto the bottom rail of the bottom section. Position the bottom of the
strut 3/4” up from the bottom edge of the bottom section. Center the short strut from side
to side on the section surface. Drill pilot holes, 1” deep into the bottom section using a 1/8”
drill bit.
IMPORTANT:
BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”
DEEP.
Attach the strut using (1) 1/4” - 14 x 1” lag screw at each pre-drilled hole.
NOTE: Refer to the Bottom Section Graduated End Hinge Schedule below, to determine the
appropriate hinges for your bottom section.
Bottom Section Graduated End Hinge Schedule
Door Height Section Type Track Graduated End
Hinge Number
3 Through 5 Section
High Doors
Bottom 2” #1
3” #3
NOTE: Center hinge(s) use #1 graduated end hinges at each pre-drilled or vertical stile loca-
tion. The pre-drilled locations are located at the top rails on the inside of the section surface.
NOTE:
Some struts also may or may not have holes in them. If they don’t, then prior to
installing the strut and hinge to the section surface, you may have to drill a 3/16” hole for the
appropriate fastener on one or both sides of the strut legs.
Using the appropriate graduated end hinges for the ends and depending on the width of your
door, enough center hinge(s) for each pre-drilled hole location(s). Starting at the upper left
hand corner of the bottom section. Position the lower hinge leaf of the appropriate graduated
end hinge onto the upper corner of the bottom section. Align the slots of the lower hinge leaf
with the pre-drilled holes in the bottom section.
FOR GRADUATED END HINGES:
Attach the upper slot of the graduated end hinge to the
bottom section using (1) 1/4” - 20 x 2-1/2” carriage bolt and (1) 1/4” - 20 flange hex nut.
Next attach the bottom hole of the graduated end hinge to the bottom section using (1) 1/4” -
20 x 2-1/2” carriage bolt and (1) 1/4” - 20 flange hex nut.
IF YOU HAVE DOUBLE GRADUATED END HINGES: Position the second graduated end
hinge next to the first (single) graduated end hinge. Using the second graduated end hinge as
a template, drill pilot holes, 1” deep into the bottom section using a 1/8” drill bit.
IMPORTANT: BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”
DEEP.
Secure the graduated end hinge to the bottom section using (2) 1/4” - 14 x 1” lag screws.
Repeat for other side.
FOR CENTER HINGES:
Attach the upper slot of the graduated end hinge to the bottom
section using (1) 1/4” - 20 x 2-1/2” carriage bolt and (1) 1/4” - 20 flange hex nut. Next
attach the bottom hole of the graduated end hinge to the bottom section using (1) 1/4” - 20 x
2-1/2” carriage bolt and (1) 1/4” - 20 flange hex nut.
NOTE: If you don’t have half center hinges, then skip this part of the step. Refer to Package
Contents / Breakdown Of Parts, to determine if you have half center hinges.
Using a tape measure, position the half center hinges equally spaced in between the center
hinges and the graduated end hinges. Position the holes of the lower hinge leaf at the top rail
of the bottom section. Using the half center hinge as a template, drill pilot holes, 1” deep into
the bottom section with a 1/8” drill bit (if needed).
IMPORTANT:
BE EXTREMELY CAREFUL NOT TO DRILL THRU THE SECTION. ONLY DRILL 1”
DEEP.
Attach the lower hinge leaf of the center hinge to the bottom section using (2) 1/4” - 14 x 1”
lag screws. Repeat for other half center hinge(s).
If you have single graduated end hinges, insert a short stem track roller / short stem tandem
track roller (if included) into the hinge tube on each side.
If you have double graduated end hinges, insert a long stem track roller / short stem tandem
track roller (if included) into the hinge tubes on each side.
IMPORTANT: WHEN PLACING TRACK ROLLERS / TANDEM TRACK ROLLER (IF INCLUDED)
INTO GRADUATED END HINGES NUMBER 2 AND HIGHER, THE TRACK ROLLER / TANDEM
TRACK ROLLER (IF INCLUDED) GOES INTO TUBE FURTHEST AWAY FROM SECTION.
Attaching Hinges and Strut To Intermediate
Section(s)
6
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 intermediate I (second),
intermediate II (third), intermediate III (fourth), Intermediate IV (fifth), Intermediate V (sixth) and
if applicable Intermediate VI (seventh). Measure your section to make sure it is the correct
height as indicated on the chart.
NOTE:
Refer to the Graduated End Hinge Schedule below, to determine the appropriate
hinges for your Intermediate section(s).
3 Section High Graduated End Hinge Schedule
Door Height Track Section Type Graduated End Hinge
Number
3 Section High Door 2” Intermediate I #2
3” Intermediate I #4
4 Section High Graduated End Hinge Schedule
Door Height Track Section Type Graduated End Hinge
Number
4 Section High Door 2” Intermediate II #3
Intermediate I #2
3” Intermediate II #5
Intermediate I #4
5 Section High Graduated End Hinge Schedule
Door Height Track Section Type Graduated End Hinge
Number
5 Section High Door 2” Intermediate III #4
Intermediate II #3
Intermediate I #2
3” Intermediate III #6
Intermediate II #5
Intermediate I #4
NOTE: Refer to the Strutting Schedules below, to determine the appropriate strutting for your
Intermediate(s) section. Measure the height of the long strut(s) to determine if you have 2”
or 3”.
3 Section High Strutting Schedule
Section Type Type Of Strut Location On Section
2” 3”
Intermediate I (1) Long Top Of Section
4 Section High Strutting Schedule
Section Type Type Of Strut Location On Section
2” 3”
5