the right hand torsion spring assembly.
Torsion
keyed
shaft
Center bracket
bearing
Coupler
half
Center bearing
brackets
Left hand end
bearing bracket
Right
hand end
bearing
bracket
Torsion
keyed
shaft
Right wound, red
winding cone (left
hand side)
Center
bracket
bearing
Center bracket
Torsion keyed shafts
Right hand end
bearing bracket
Left hand end
bearing bracket
NOTE:
Position both torsion keyed shafts so that equal amounts of the shafts extend from
each end bearing brackets.
Attaching Springs to Center Bracket
17
NOTE:
Refer to Package Contents / Breakdown of Parts, to determine which Center
Bracket(s) came with your door.
NOTE:
Refer to Package Contents / Breakdown of Parts, to determine if your door came with
a coupler assembly.
IMPORTANT:
THE SPRING WARNING TAG(S) SUPPLIED MUST BE SECURELY ATTACHED
TO THE STATIONARY SPRING CONE(S) IN PLAIN VIEW. SHOULD A REPLACEMENT SPRING
WARNING TAG BE REQUIRED, CONTACT WAYNE DALTON FOR FREE REPLACEMENTS.
NOTE:
Measure the diameter of your springs. If your spring diameter is 3-3/4”, the springs
do not share center brackets. If your spring diameter is either 2” or 2-5/8”, then two springs
will share the same center bracket, unless a coupler assembly is provided.
IF YOU DON’T HAVE A COUPLER ASSEMBLY:
Slide center bracket bearing into the spring.
Align the stationary spring cone(s) with the holes in the center bracket. Secure the torsion
spring(s) to the center bracket with (2) 3/8” - 16 x 1-1/2” hex head bolts and (2) 3/8” - 16
nuts.
IMPORTANT:
NEVER USE MORE THAN ONE BEARING WHEN ATTACHING TWO SPRINGS TO
ONE CENTER BRACKET.
IF YOU HAVE A COUPLER ASSEMBLY:
Slide center bracket bearing into the spring. Align
the stationary spring cone with the holes in the center bracket. Secure the torsion spring to
the center bracket with (2) 3/8” - 16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts. Repeat
the same process for the other center bearing bracket.
At the middle of the two center bearing brackets, re-assemble the coupler assembly by
loosely fastening the coupler halves together using the (3) 3/8” - 16 x 1-1/2” hex head
screws, (6) 3/8” washers, (3) 3/8” lock washers and the (3) 3/8” - 16 hex nuts, previously
removed.
NOTE:
Ensure both torsion keyed shafts have equal amounts of the shafts extending from
each end bearing bracket.
Typical center
bracket bearing
Stationary
spring cone
Typical center
bracket
Stationary
spring cone
Torsion spring
Spring
warning tags
Torsion spring
Typical center
bracket
Stationary spring cone
(2) 3/8”-16 x 1-1/2”
Hex head bolts
(2) 3/8”-16
Nuts
Torsion
spring
Torsion
spring
Stationary
spring cone
Coupler halves
Coupler
assembly
(3) 3/8” - 16 x 1-3/4”
hex head screws and
(3) 3/8” - 16 Hex nuts
Stationary
spring cone
Torsion
spring
(2) 3/8”-16 x 1-1/2” Hex head
bolts and (2) 3/8”-16 Hex nuts
Torsion
spring
Center bracket
Center
bracket
Attaching Counterbalance Lift Cables
18
Starting on the left hand side, thread the counterbalance lift cable up and around the front
side of the left hand cable drum.
IMPORTANT:
VERIFY THAT THERE ARE NO OBSTRUCTIONS IN THE TRAVEL PATH OF THE
DOOR SECTIONS OR COUNTERBALANCE LIFT CABLES.
NOTE:
Always assemble the left hand cable and cable drum first to help maintain equal cable
tension on both sides of the door.
Hook the counterbalance lift cable into the left hand cable drum. Slide the left hand cable
drum up against the left hand end bearing bracket. Counterbalance lift cable should termi-
nate at the 3 o’clock position.
NOTE:
If you have torsion keyed shaft(s), insert (1) key into the slot of both the cable drum
and the slot in the torsion keyed shaft, as shown.
Rotate the left hand drum and torsion shaft until counterbalance lift cable is taut. Now attach
locking pliers to the torsion shaft and brace locking pliers up against jamb to keep counter-
balance lift cable taut. Tighten the set screws in the drum to 14-15 ft-lbs of torque (once set
screws contact the torsion shaft, tighten screws an additional 1/2 turn for solid shaft and one
full turn for tubular shaft). Repeat for right hand side.
IMPORTANT:
INSPECT EACH COUNTERBALANCE LIFT CABLE MAKING SURE IT IS SEATED
PROPERLY ONTO THE CABLE DRUM AND THAT BOTH COUNTERBALANCE LIFT CABLES HAVE
EQUAL TENSION.
CHECK COUNTERBALANCE LIFT CABLES FOR EQUAL TENSION:
1. Attach locking pliers to track above top roller.
2. Grasp cable at approximate mid-door height location.
3. Draw cable toward you about 1/2” to 1” and release, noting the response of the cable.
4. Repeat above steps for other cable.
5. Adjust cable tension as needed until right and left cables both respond the same.
Once the counterbalance cables are set and if applicable tighten the coupler assembly
together by tightening the (3) 3/8” - 16 nylon hex nuts to secure the coupler halves together.
Counterbalance lift cable hooked in cable
drum
Counterbalance
lift cable
Typicall left hand
cable drum
Torsion shaft /
Torsion keyed shaft
Typicall left hand
end bearing bracket
15
Summary of Contents for Flush 42
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