®
®
5150, 5155, 5200 & 5255
LIMITED WARRANTY
The Manufacturer warrants that its door and its hardware fittings will be free from defect in workmanship and material. Should any defects in workmanship or material appear
within ONEYEAR of delivery, manufacture shall, upon notification, correct such nonconformity at its option, by repairing or replacing any defective part or parts. See maintenance
and painting instructions for prepainted steel doors listed below or contact Wayne-Dalton Distributor for a copy of the maintenance and finishing instructions for prepainted steel doors.
™
The Manufacturer warrants the steel skin of the THERMOMARK Series insulated garage door for a period of 10 YEARS, from the time of delivery against cracking, splitting or
deterioration due to rust-through. Other conditions and exceptions as contained herein apply.
™
The Manufacturer warrants the steel skin of the THERMOMARK Series insulated garage door for a period of 7 YEARS, from the time of delivery against separation of the
ThermoMark 5150, 5155, 5200 & 5255
COMMERCIAL GARAGE DOOR
INSTALLATION INSTRUCTIONS AND
OWNERS MANUAL
polyurethane foam from the steel skin of the panel. Other conditions and exceptions as contained herein apply.
NO EMPLOYEE, DISTRIBUTER, OR REPRESENTATIVE ISAUTHORIZED TO CHANGE THE FOREGOING WARRANTIES INANYWAYOR GRANTANYOTHER
WARRANTYON BEHALF OF MANUFACTURER.
The Manufacturer shall not be responsible for any damage resulting to or caused by its products by reason of installation (the warranty becomes null and void if other than
Manufacturer’s specified holes are drilled), improper storage, unauthorized service, alteration of products, neglect or abuse, or attempt to use the products for other than the customary
usage or for their intended purposes. The above warranty does not cover normal wear or any damage beyond Manufacturer’s control or replacement labor.
THIS WARRANTY COVERS A COMMERCIAL PRODUCT. THE FORGOING WARRANTIES ARE LIEU OF ALL OTHER WARRANTIES AND NO REPRESENTA-
TIONS, GUARANTEES, OR WARRANTIES, EXPRESSED OR IMPLIED, (INCLUDING, BUT NOT LIMITED TO, THE WARRANTYOF MERCHANTABILITYOR FIT-
NESS FORA PARTICULAR PURPOSE),ARE MADE BY MANUFACTURE IN CONNECTION WITH TH MANUFACTURE OR SALE OF ITS PRODUCTS.
Claims for defects in material and workmanship covered by this warranty shall be made in writing to the dealer from whom the product was purchased within the warranty period.
Manufacturer may either send a service representative or have the product returned to the Manufacturer at Buyer’s expense for inspection. If judged by Manufacturer to be defective
in material or workmanship, the product will be replaced or repaired at the option of Manufacturer, free from all charges except authorized transportation and replacement labor.
THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER REMEDIES. THE LIABILITY OF MANUFACTURER,
WHETHER IN CONTRACT, TORT, UNDER ANYWARRANTY, OR OTHERWISE, SHALL NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR REPLACE, AT
ITS OPTION,ANYPRODUCT OR PART FOUND BYMANUFACTURER TO BE DEFECTIVE IN MATERIALORWORKMANSHIP. MANUFACTURER SHALLNOTBE
LIABLE FOR COST OF REMOVAL OR INSTALLATION OR SHALL NOT BE RESPONSIBLE FORANY DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIALDAM-
AGES OFANYNATURE.
Read these instructions carefully before attempting installation.
If in question about any of the procedures,
This warranty gives you specific legal rights, which may vary from state to state. However, some states do not allow limitations on how long an implied warranty lasts or the
exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you.
Yearly maintenance as described in the Maintenance and Painting Instructions for Prepainted Steel Doors is required. Should you need an additional copy, contact your local
Do Not perform the work.
Instead have a qualified door agency do the installation or repairs.
authorized Wayne-Dalton distributor.
CONTENTS
IMPORTANT
MAINTENANCE AND FINISHING INSTRUCTIONS
MAINTENANCE
SAFETY NOTICES
n Operating Zone
While factory-applied finishes for steel garage doors are so durable that they will last many years longer than ordinary paints, it is desirable to clean them thoroughly on a routine basis.
Apparent discoloration of the paint may occur when it has been exposed in dirt-laden atmospheres for long periods of time. Slight chalking may also cause some change in appearance
in areas of strong sunlight. A good cleaning will generally restore the appearance of these coatings and render repainting unnecessary. An occasional light cleaning will also help maintain
an aesthetically pleasing appearance. To maintain the original finish of the garage doors, 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.
SURFACE PREPARATION FOR PAINTING
Wax on the surface must be removed or paint peeling/flaking will result. To remove this wax, it will be necessary to lightly scuff the surface with a gray (not green!) 3M ScotchBrite
pad saturated with soapy water.A final wipe and rinse should be done with clean water only, to remove any loose dust or soap film.
Surface scratches, which have not exposed the metal substrate, can be lightly buffed or sanded with 0000 steel wool or No. 400 sand paper to create a smoother surface. Care must be
taken to not expose the substrate under the paint (see Note No. 2). Once this exposed condition exists, the likelihood for rusting is greatly increased. See the following paragraph if the
metal substrate is observed.
Exposed substrate must be treated to prevent rust from forming (see Note No. 2). Sand the exposed area lightly and paint with high quality metal primer to protect from corrosion.
Follow drying time on primer can label before applying topcoat.
The surface to be recoated must not be to smooth or the repaint material will not adhere to it (see Note No. 2). It is advisable to test a representative area to evaluate adhesion. If poor
adhesion is observed, the surface must be abraded by sanding or buffing using grades mentioned above. Care must be taken to not expose the substrate under the paint.
PAINTING
After the surface has been properly prepared it must be allowed to dry thoroughly, then coated immediately with a premium quality latex house paint. Follow the paint label directions
explicitly. Oil base paint is not recommended. Please note that if substrate is exposed, painting with latex paint may cause accelerated rusting of steel.
NOTES:
1. Repainting of finish painted steel doors cannot be warranted as this condition is totally beyond door manufacturer’s control.
2. If the steel door surface has a finish painted textured surface representing wood grain, stucco, etc., this step should not be attempted as danger of exposing substrate is
greatly increased.
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:
1. Wear protective gloves during installation to avoid possible
cuts from sharp metal edges.
2. It is always recommended to wear eye protection when
using tools, otherwise serious eye injury could result.
3. Operate door ONLY when properly adjusted and free of
n Door Preparation
n Leveling Door
n Installing Door Sections
obstructions.
4. Keep door in full view while operating it. Watch the door
open or close completely before leaving the area.
5. Should the door become hard to operate or completely
inoperative, a qualified door agency should correct the problem
n Installing Track
to prevent damage to
the door or serious personal injury.
6. 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.
7. To prevent serious injury or death, avoid standing in the
open doorway or walking through the doorway while the door is
moving.
8. Use lift handles/step plate when manually operating the
door. DO NOT place fingers into section joints when operating
the door.
9. Remove pull rope if door is operated by an electric opener.
10. 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.
n Torsion Springs
n Chain Hoist
3. Consult a professional coatings contractor if in doubt about any of the above directions.
4. Follow directions explicitly on the paint and solvent container labels for proper applications of coatings and disposal of containers. Pay particular attention to those
directions involving acceptable conditions in which to paint.
n Trolley Operator
ACRYLIC GLAZINGCLEANINGINSTRUCTIONS:
n Auxiliary Components
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 properties to
handle them safely.
WARNING: It is recommended that installation,
repairs, or adjustments of this product be made
by a qualified door agency.
3. Do not use: Window cleaning fluids, scouring compounds, gritty cloths, leaded or ethyl gasolines, or solvents such as alcohol, acetone, carbon tetrachloride, etc.
12. Have the door professionally inspected once a year.
© Copyright 2001 Wayne-Dalton Corporation
© Copyright 2001 Wayne-Dalton Corp.
Rev.6 01/2002
PART # 295276
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EXTEND JAMBS TO OPENING HEIGHT plus
STEP 13: Operator Trolley Bracket Installation: Attach the operator trolley bracket as illustrated in Fig. AA. This trolley
bracket is limited to doors 14’2” X 10’ (5 Sections high and smaller).
DIM Y plus 1 1/2” (MINIMUM LENGTH)
For doors 14’2” X over 10’ (5 sections) and 14’3” thru 20’2” by all heights see Fig. BB.
For doors over 20’2” by all heights see Fig. CC.
(3) 1/4-20 X 7/8” SELF
DRILLING TEK SCREWS
MINIMUM
HEADROOM
REQUIRED
(REFER TO
HEADROOM
CHART)
U-BAR
DIM Y
HEADER TO
SHAFT
CENTERLINE
MODELS 5150, 5155, 5200, &5255
PART NUMBER 107319
DOORS UP TO 14 ft 2 in WIDE X 10’
(5 SECTIONS HIGH)
NOTE: TROLLEY BRACKET TO BE
INSTALLED OFFSET FOR ODD PANELS
TORSION SHAFTS REQUIRE 10” OF
SIDEROOM FOR SOLID SHAFTS and
5” OF SIDEROOM FOR TUBULAR
SHAFTS
OPERATOR BRACKET
(4) 1/4-20 X 5/8” SELF
DRILLING TEK SCREWS
8” for 2” TRACK
12” for 3” TRACK
Fig. AA
NOTE: HEADROOM CAN BE REDUCED 2-1/2” BY
USING THE QUICK CLOSING TOP FIXTURE OR
BY SHORTENING THE VERTICAL TRACKS BY
3” MAX.
(6) 1/4-20 X 7/8” SELF
DRILLING TEK SCREWS
U-BAR
SIDEROOM REQUIREMENTS
2 inch TRACK
5/16 X 1”
DRILLING /
TAPPING
SCREW
OPERATOR BRACKET
(4) 1/4-20 X 5/8” SELF
DRILLING TEK SCREWS
3/8 X 3” MIN.
SLEEVE
ANCHOR
3/8 X 3” MIN.
SLEEVE
ANCHOR
FLUSH
1” OVERLAP
1” OVERLAP
1” OVERLAP
1/2”- 5/8”
1/2”- 5/8”
MODELS 5150, 5155, 5200, & 5255
PART NUMBER 295689
1/2”- 5/8”
1/2”- 5/8”
2 1/2” MIN.
SIDE ROOM
2 1/2” MIN.
SIDE ROOM
4 3/4”
2 1/2” MIN.
SIDE ROOM
3 1/2” MIN.
SIDE ROOM
(4) 1/4-20 X 7/8” SELF
4 3/4”
THIS DESIGN IS FOR DOORS UP TO
1 1/2”
3 1/2”
DRILLING TEK SCREWS
14’ 2” WIDE AND OVER
5/16 X 1 5/8”
LAG SCREW
1 1/2”
3 1/2”
5/16 X 1”
DRILLING /
TAPPING
SCREW
1 1/2”
3 1/2”
1 1/2”
3 1/2”
THROUGH OPERATOR
BRACKET INTO GIRT
10’ (5 SECTIONS HIGH) AND
14’3” THRU 20’2” BY ALL HEIGHTS
NOTE: TROLLEY BRACKET TO BE
INSTALLED OFFSET FOR ODD
2” X 6” JAMB IS
RECOMENDED
OPTIONAL
MOUNTING
BRACKET
OPTIONAL
MOUNTING
BRACKET
Fig. BB
PRECAST WALL WITHOUT
CORNER ANGLE
2” TRACK
PRECAST WALL WITH
CORNER ANGLE
2” TRACK
STEEL JAMBS
2” TRACK
WOOD JAMBS
2” TRACK
PANELS
6” GIRT
3 inch TRACK
(12) 1/4-20 X 7/8” SELF
DRILLING TEK SCREWS
5/16 X 1”
DRILLING /
TAPPING
SCREW
MODELS 5155 & 5255
OPERATOR
3/8 X 3” MIN.
SLEEVE
ANCHOR
PART NUMBER 293009 38in WIDE X 19 5/8 in HIGH FOR 24 in TOP SECTION
BRACKET
3/8 X 3” MIN.
SLEEVE
ANCHOR
PART NUMBER 293010 38in WIDE X 16 7/16 in HIGH FOR 21 in TOP SECTION
ATTACH USING (12) PRE DRILLED HOLES
FLUSH
1” OVERLAP
1/2”- 5/8”
1” OVERLAP
1” OVERLAP
1/2”- 5/8”
1/2”- 5/8”
1/2”- 5/8”
MODELS 5150 & 5200
3” MIN.
SIDE ROOM
3” MIN.
SIDE ROOM
3” MIN.
SIDE ROOM
PART NUMBER 295687 50 in WIDE X 17 1/4 in HIGH FOR 24 in TOP SECTION
PART NUMBER 295686 50 in WIDE X 14 in HIGH FOR 21 in TOP SECTION
MOUNT BRACKET OVER HINGES IN CENTER OF SECTION, DRILL (2) 9/32”
HOLES IN EACH CORNER AND SECURE USING (12) 14-20” X 7/8” SELF
DRILLING TEK SCREWS (SEE NOTE BELOW)
5” MIN.
SIDE ROOM
5”
4 3/4”
1”
4”
1”
4”
5/16 X 1 5/8”
LAG SCREW
1”
4”
1”
4”
5/16 X 1”
DRILLING /
TAPPING
SCREW
2” X 6” JAMB IS
RECOMENDED
OPTIONAL
MOUNTING
BRACKET
OPTIONAL
MOUNTING
BRACKET
THIS RECTANGULAR DESIGN IS FOR DOORS OVER 20 ft. 2 in. WIDE.
Fig. CC
NOTE: MODEL 5150 & 5200 DOORS BETWEEN 20 ft 2 in AND 24 ft 2 in
REQUIRE THAT THE OPERATOR BE MOUNTED OFF CENTER SO THE
OPERATOR BRACKET MOUNTS TO THE HINGE POINTS.
PG. 14
PRECAST WALL WITH
CORNER ANGLE
3” TRACK
PRECAST WALL WITHOUT
CORNER ANGLE
3” TRACK
STEEL JAMBS
3” TRACK
WOOD JAMBS
3” TRACK
PG. 3
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Intermediate hangers for all
doors over 11’ high and over
14’ wide. Positioned half way
between jamb and rear
hanger.
NOTE: Use a chalk line or line level to ensure
all bearing brackets are in line. (± 1/8”)
1/4” GRADUATION
8 SECTIONS HIGH OR LESS
FIG. F
Lateral brace all hanger
angles.
#5 HINGE (2in. Track)
#7 HINGE (3in. Track)
#4 HINGE (2in. Track)
#6 HINGE (3in. Track)
#3 HINGE (2in. Track)
#5 HINGE (3in. Track)
#2 HINGE (2in. Track)
#4 HINGE (3in. Track)
#1 HINGE (2in. Track)
#3 HINGE (3in. Track)
3/8” dia. Bolt should
protrude into track to
serve as a roller stop.
Single Wide 2”
& 3” secure
using 5 screws
Double Wide 2”
& 3” secure
FIG. G
using 10 screws
Single Wide
2” secure
using 5 screws
Use a 3/8” X 3/4”
truss bolt for roller
clearence.
3/4”
FIG.D
Secure Bracket
using (5) screws.
(No Spacer)
2” use 3/16”
spacer
3” use 3/16”
Doors 16’ to 18’ use 2 inter-
mediate hangers.
Over 18’ use hangers at 6’
18” o.c.
FIG.H
Use 12 ga. minimum angle
(1-5/8” X 2-3/8”)
spacer
FIG.B
FIG.C
max. centers
5” to 8”
Refer to Fig R Page 12.
5200 & 5255
Single Wide
2” & 3”
secure using
5 screws
FIG.A
Apply locking pliers to
secure while attaching
hangers.
5150 & 5155
Single Wide
2” secure
1/8” GRADUATION
OVER 8 SECTIONS HIGH
using 5 screws
NOTE: For doors over 8
sections high and using
3 in. track, start with
(2) # 3 hinges, (2) #4 hinges,
(2) # 5 hinges, etc...
Inside Side Lock Installation (See Fig. T Page 15)
FIG.E
Secure Bracket
using (5) screws.
2” use 3/16”
spacer
3” use 1/2”
spacer
Install lock on second section of door. Secure the lock to the section with (4) 5/8” x 20 self-drilling TEK screws. The side 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.
#5 HINGE (3in. Track)
#4 HINGE (3in. Track)
#4 HINGE (3in. Track)
Step Plate Installation 5150/5155 (See Fig. U Page 15)
At the desired location (typically below the lock) make two measurements from bottom of section and mark at
1-3/16” and 3-3/8”. Drill 3/16” hole thru section at each mark. From the outside enlarge both holes to 7/16” without drilling thru
the inner skin of door.
Secure to 5150/5155 section with (2) 1” x #8 self-tapping screws and (2) washers..
#3 HINGE (3in. Track)
#3 HINGE (3in. Track)
Step Plate Installation 5200/5255 (See Fig. V Page 15)
Install outside step in pre-cut opening and bolt together with inside step plate using (2) 1/4” x 1” carriage bolts and nuts.
If your door does not have the pre-cut opening you can cut a 7-5/8” wide by 3’ high opening 3” from the bottom edge of the
bottom section. This will need to be in vertical alignment with your lock.
STEP 3. Locate the bottom section, attach bottom seal using 1/4” self drilling and tapping screws as shown in Fig. A .
Locate the left and right hand bottom brackets, secure the counterbalance cable using clevis pin, washer and cotter key shown
in Fig. C
Locate the left and right hand bottom brackets, secure the counterbalance cable over the large milford pin shown in Fig. D
Secure bottom bracket to section using 1/4” drilling and tapping screws shown in Fig. E (for doors over 18’2” wide use
doublewide bottom brackets as shown in Fig. H)
Short Lock Bar Installation (See Fig. W Page 15)
Install lock on second section of door. Make two measurements from the bottom rib and mark at 4” and 8-1/4”. These marks
must be 12-1/2” from section edge. Drill 1/4” hole thru section at each mark. From the outside enlarge the bottom hole to 7/8”
without drilling thru the inner skin of door. Enlarge this hole in inner skin to 7/16”. Enlarge top hole to 1-1/4” all the way thru
door section. Align inside lock plate with two holes in section and drill (2) 3/8” holes thru door section above and below 7/16”
hole, using lock plate as template. Install outside handle to section with (2) #10 pan head screws and proper spacer. From inside
secure the rim cylinder to the section with (2) #12 pan head screws, broken to correct length. Secure the night latch to the lock
plate with (4) 3/4” x #8 screws. Attach spring to section with (1) 1/2” x #12 screw. Secure the inside “T” handle over square
shank of outside handle with push nut. (See note)
(For doors using Broken Cable Safety Device Refer to Fig. B and page 12 Fig. R.)
Align the appropriate end hinge to the pre-punched holes in the endstile and secure using (2) 1/4” x 5/8” self drilling and
tapping screws per hinge leaf. Products 14’2” wide and less require (1) end hinge (Fig. G) and doors over 14’2” wide require
double end hinges. (Fig. F)
NOTE: Use a short piece of 7/16” to 1/2” ID steel pipe to tap push nut onto square shank.
The end hinge sequence is dependent on track size (2” or 3”).
2” track applications begin with a number 1 hinge attached to the top corners of the bottom section.
3” track applications begin with a number 3 hinge attached to the top corners of the bottom section.
Exhaust Port Installation (See Fig. X Page 12)
Install the exhaust port using (3) #10 x 1-1/2” counter sunk bolts and nuts. Exhaust port goes on the inside of bottom section.
( Refer to the illustrations matching your track size)
PG. 4
PG. 13
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STEP 4. MODEL 5150 & 5200 U-bars & struts to be secured to the section using (2) 1/4 - 20 x 7/8” TEK screws at each end.
Additional 1/4 - 20 x 7/8” TEK screws will need to be used at each hinge location.
U-bars and struts are to be mounted at the top of section under hinges and across top brackets, as seen in Fig. K. Refer to
STRUTTING SCHEDULE for strut placement.
NOTE: Strut clips used at top bracket. If strutting is required for a raised panel, glazed section, place
U-bar over hinge leaf and attach with 1/4” self-drilling/tapping screws and strut clips.
STEP 4. MODEL 5155 & 5255 U-bars are to be secured to the sections using 1/4 - 20 x 7/8” TEK screws and strut clips. Mount
U-bars at top of section, across hinge leafs and top brackets.
SPRING TURN CHART
DOOR HEIGHT 400-8
400-12
7 1/2
7 7/8
8 1/2
8 7/8
9 1/4
9 1/2
10 1/8
10 1/2
11
5250-18
800-32
DOOR HEIGHT 400-8
400-12
5250-18
10 1/2
10 7/8
11 1/4
11 1/2
11 7/8
12 1/4
12 1/2
12 7/8
13 1/4
13 1/2
800-32
7
6’6"
7’0"
7 1/2
7 7/8
8 1/2
8 7/8
13’6"
14’0"
14’6"
15’0"
15’6"
16’0"
16’6"
17’0"
17’6"
18’0"
18’6"
19’0"
19’6"
20’0"
7 3/8
7 1/2
7 5/8
8
7’6"
8’0"
6 3/4
7 1/8
7 3/8
7 3/4
8 1/8
8 3/8
8 7/8
9 1/8
9 1/2
9 7/8
10 1/4
5150 & 5155 Strutting Schedule
8’6"
Standard Section Reinforcement
Non-Brown Doors
9’0"
8 1/8
8 1/4
8 5/8
8 7/8
9
Top bracket installation illustration.
Door Widths
Strutting
Secure each bracket using (4) 1/4” - 20 x 7/8”
self-drilling/tapping screws and (2)strut clips.
Doors over 14’2” wide require double top
brackets.
9’6"
8’ 0" - 10’ 2" None
10’ 3" - 14’ 2" (1) 2" U-Bar
10’0"
10’6"
11’0"
11’6"
12’0"
12’6"
13’0"
5 3/8
5 5/8
5 7/8
6
(1) 3" U-Bar
14’ 3" - 16’ 2"
Every Other Section
(Top Section Shown)
(1) 3" U-Bar (20 Ga.)
Eve ry S e cti on
16’ 3" - 18’ 2"
18’ 3" - 20’ 2"
20’ 3" - 26’ 2"
11 1/2
12
(1) 3" U-Bar (16 Ga.)
Every Section Plus 1
(1) 6" Girt
9 1/4
9 1/2
9 3/4
9 7/8
Strut clips are
required, on
raised panel,
glazed sections
12 1/2
6 1/4
6 1/2
6 3/4
Place (2) 1/4 - 20 x 7/8”
self-drilling/tapping screws
at each hinge location.
Every Other Section
Brown Doors
Door Widths
Strutting
8’ 0" - 10’ 2" None
10’ 3" - 12’ 2" (1) 2" U-Bar
3” U-Bar
(1) 3" U-Bar
12’ 3" - 16’ 2"
Every Section Plus 1
(1) 3" U-Bar (20 Ga.)
Eve ry S e cti on
16’ 3" - 18’ 2"
18’ 3" - 20’ 2"
20’ 3" - 26’ 2"
Fasten using (2) 1/4 - 20 x 7/8”
self-drilling/tapping screws at each
hinge location.
(1) 3" U-Bar (16 Ga.)
Every Section Plus 1
(1) 6" Girt
Every Other Section
5150/5200
Girt Attachment
5200 & 5255 Strutting Schedule
Standard Section Reinforcement
Non-Brown Doors
Fasten using (2) 1/4 - 20 x 7/8”
self-drilling/tapping screws at each
hinge location.
Door Widths
Strutting
8’ 0" - 12’ 2" None
6” Girt
12’ 3" - 14’ 2" (1) 2" U-Bar
(1) 2" U-Bar
14’ 3" - 16’ 2"
Every Other Section
(1) 3" U-Bar
Fasten using (4) 1/4-20 x 7/8”
16’ 3" - 18’ 2"
18’ 3" - 20’ 2"
20’ 3" - 26’ 2"
Every Section Plus 1
(1) 3" U-Bar (20 Ga.)
Every Section Plus 1
(1) 6" Girt
self-drilling/tapping screws.
(1) Attach the broken cable safety device, with cable attached, to the section
using (8) 1/4”-20 X 5/8” self-drilling TEK screws (as seen in Fig. R.).
(2) Place the bottom section in the opening.
Fasten using (5) 1/4 - 20 x 7/8”
self-drilling/tapping screws and
(1) “L” Bracket at each hinge location.
Broken Cable Safety Device Installation
Every Other Section
Brown Doors
(3) Install the verticals over the rollers.
Door Widths
Strutting
(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 clevis and cotter pins.
(6) Operate the door to verify that there is clearance between the track and section
for the cable arm.
8’ 0" - 10’ 2" None
5155/5255
Girt Attachment
10’ 3" - 12’ 2" (1) 2" U-Bar
Fasten using (2) 1/4-20 x 7/8”
self-drilling/tapping screws and
(1) 2" U-Bar
12’ 3" - 16’ 2"
Every Other Section Plus 1
(1) “L” Bracket at each hinge location.
Install “L” Bracket over lower hinge leaf.
(1) 3" U-Bar
16’ 3" - 18’ 2"
18’ 3" - 20’ 2"
20’ 3" - 26’ 2"
(1) 1/4-20 x 7/8”
self-drilling/
Every Other Section Plus 1
(1) 3" U-Bar (20 Ga.)
Every Section Plus 1
(1) 6" Girt
(7) Adjust the track as needed.
tapping screws.
Broken Cable Safety
Device (SES)
6” Girt
Attach Girt at end of section
using (4) 1/4-20 x 7/8”
Every Other Section
#10 Hex Nuts (3)
Fig. K
(Top (2) Section Shown)
self-drilling/tapping screws.
Cable Arm
Cam Arm
Cable Arm
Outside Trim Ring
Gasket
STEP 5. Center and level (or support to a known grade level) the bottom section in the opening, as seen in Fig. K. Temporarily
attach the vertical tracks to the jambs. Allow 1/2” clearance between the section and the track as illustrated in the sideroom
illustrations (page 3).
Gasket
Exhaust Port
1-1/2” X #10 Counter
Sunk Bolt (3)
5/8” X 20 self-drilling
TEK screw (8)
It is important that the top of each track is at the same level. (shim if necessary)
Products being installed to precast or block must use a 3/8 x 3” long sleeve anchor to attach the verticals to the building. Use the
#10 X 1-1/2” BOLT
W/LOCK NUT
Fig. X
slots in the wall angle as a drill template, drill a 3/8” hole (3-1/2” deep) and secure to anchor.
Fig. R Cam Arm
PG. 12
PG. 5
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Spring mounting pad. 2 X 6 White
Pine or denser. Secured with min.
(4) 5/16” x 4” lag bolts into header.
Steel
Pre-Cast
STEP 6. Secure the end hinges, (one side only) center hinges, and strutting ( if applicable) as previously illustrated. Locate the
Lock Section (usually the second section) and insert a roller into the end hinge. Stack this section into the opening by hooking the
roller in the vertical track and lowering it onto the bottom section. Insert a roller into the appropriate end hinge and insert roller
into vertical track on the opposite end. Secure end hinge to the section using the self-drilling and tapping screws. Align the
section edges, flip up the upper hinge leafs and secure to the lock section using the self-drilling and tapping screws. Continue to
hardware and stack the remaining sections in the proper sequence. Attach the top brackets to the upper corners, of the top
section, using self drilling and tapping screws as shown in Fig. J.
Top plate
Header
(2) 3/8” Nuts
and Washers
NOTE : Top section maybe installed now or may wait until the last step (installer preference)
STEP 7. Adjust the vertical track from 1/2” spacing at the bottom section to 3/4” at the top section. Refer to page 3. Permanently
secure each vertical to the jambs using the following fasteners:
Steel Jambs: 5/16” x 1” self drilling and tapping screw.
Wood Jambs: 5/16” x 1-5/8” lag screw.
5/16” x 1” Self-drilling and
tapping screw
5/16” x 1-5/8”
Lag Screws
(2) 3/8” x 1” or
1-1/2” Bolts
1/2” x 3” Sleeve anchor
NOTE: Must secure sleeve
anchors to building first ,
then attach brackets to
anchors.
Precast or Block: 3/8” x 3” sleeve anchor.
Perimeter seal
The left hand vertical track assembly indicates the standard fastener spacing (Fig. K page 7).
STEP 8: Use chain or cable to temporarily suspend the rear of the horizontal tracks. Secure the horizontal reinforcing angle to
the wall angle using (1) 3/8” x 3/4” truss bolt and nut, then secure the horizontal track to the splice plate or flagangle using (2)
track bolts and hex flange nuts.
STEP 9: 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. L and pages 8-10)
Assemble torsion spring system components to applicable configuration shown on pages 8-10. Ensure that spring warning tags
are securely wired to all stationary spring cones.
WARNING: Install support brackets to solid structural members only. Do not install over dry wall or paneling.
NOTE: Use a chalk line or line level to ensure all support brackets are in line.
Bearing Bracket
Sleeve anchor positioned in
bottom slot of bearing bracket
Perforated Angle
3/8” X 1-1/4” Hex Head
Bolt and Nut (2)
Second anchor from bottom
must be below bearing
bracket
(Trimmed to clear door high-arc)
Sleeve Anchor (4)
NOTE: All anchors must be positioned a
minimum of 1” from block edge.
STEP 10: Position shaft(s) with spring system components to proper elevation, level and secure each end bracket to the horizontal
reinforcing angle using (2) 3/8” x 3/4” truss bolts and nuts. Anchor the wall mounting flange of the end bracket to the jamb
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).
Fig. N
Alternate Steel Spring Pad Applications
Contact Manufacturer For Applications Not Covered Below
NOTE: Spring pads must be securely anchored before proceeding. The pads must by flush with the jambs.
Attach the spring support brackets to the pad(s) using the following fasteners:
Space Center Brackets 12” - 14”
Apart On Applications Requiring
Couplers
Pre-Cast: Secure each spring support bracket using (2) 1/2” x 3” sleeve anchors. 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. N Page 11.
Girt
Girt
Heavy Perforated Angle
(1-5/8 x 2-3/8” x 11 GA.)
Heavy Perforated Angle
(1-5/8 x 2-3/8” x 11 GA.)
Steel: Secure each spring support bracket using (3) 5/16” x 1” self-drilling and tapping screws as detailed in Fig. N Page 11.
Block Construction: Attach perforated angle 18” long to support bracket(s) using (2) 3/8” x 1-1/4” bolts and nuts. Chamfer angle
to clear top section high arc. Secure support brackets and perforated angle to block using (4) 3/8” x 2-1/2” sleeve anchors as
detailed in Fig. N Page 11.
Center Spring Bracket
Center Spring Bracket
Secure the stationary cone(s) (dead end) to the spring support bracket(s) using 3/8” bolts and nuts. Keep spring warning tags
clearly visible.
(2) 3/8” x 1-1/4” Bolts To
Secure Bracket To Angle
(2) 3/8” x 1-1/4” Bolts To
Secure Bracket To Angle
“Y”
(< 7 ft.)
“Y”
(< 7 ft.)
NOTE: The coupler support brackets only require (2) fasteners. The spring support brackets require (2) fasteners in the lower
slot and hole, then (1) fastener in the top slot.
(2) 3/8” x 1-1/4” Bolts & Nuts
Top & Bottom
(2) 3/8” x 1-1/4” Bolts & Nuts
Top & Bottom
Girt
Girt
Fig. BB
WARNING: Failure to use proper number of fasteners can result in sudden spring tension release, causing severe injury or death.
Fig. AA
Space Center Brackets 12” - 14”
Apart On Applications Requiring
Couplers
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 support bracket.
Girt
NOTE: Do Not Bolt (2) 3-3/4” Torsion Springs to One
Center Bracket
STEP 11: Feed the cable attached to the left hand bottom bracket up the vertical track, behind the roller shafts and secure to the
left hand drum. Push the 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 vice grips to 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 vice grips to both shafts and secure bolts in coupling after springs are fully wound.
Heavy Perforated Angle
(1-5/8 x 2-3/8” x 11 GA.)
NOTE: These Spring Mounting Techniques Are Not
Supported For 800-32, 6375-164, 1100-18, 1350-28,
& 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.) These Instructions Are Not
Applicable For A Span Greater Than 84 in.
Center Spring Bracket
Bolt “Z” Shaped Assembly Using (4)
3/8” x 1-1/4” Bolts And Nuts
(2) 3/8” x 1-1/4” Bolts To
Secure Bracket To Angle
“Y”
(< 7 ft.)
If top section is not installed, do so now, before winding springs. Make sure hardware is securely attached to all sections.
(2) 3/8” x 1-1/4” Bolts & Nuts
Top & Bottom
Carefully following spring winding instructions detailed in Fig. M on Page 10, wind spring(s), using the appropriate 1/2”, 5/8” or
3/4” diameter winding rods of sufficient length.
Girt
Fig. CC
Maximum Door Size 9’ x 9’ (Maximum Door Weight 210 lb.) Fig AA: 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. N-2).
STEP 12: 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.
Maximum Door Size 14’ x 12’ (Maximum Door Weight 400 lb.) Fig BB: 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. N-3).
Maximum Door Size 14’-2” x 12’-1” (Maximum Door Weight 800 lb.) Fig CC: 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. N-4).
Space the horizontal tracks 3/4” 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. S on Page 13 using 3/8” bolts and nuts. Laterally brace all drop angles once proper
PG. 6
NOTE: Do NOT Bolt (2) 3-3/4” Torsion Springs To ONE Center Bracket
PG. 11
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spacing is achieved.
Doors over 11 ft. high and over 14ft. wide must have (1) intermediate drop hanger as shown in Fig. S on Page 13.
Doors between 16’ and 18’ high must have (2) intermediate drop hangers as shown in Fig. S on Page 13.
24” MINIMUM SPRING PAD
WIDTH
Doors over 18’ high must have intermediate drop hangers placed on 6’ centers.
TWO SPRINGS
(6”)
SPLIT SOLID
SHAFT
20”
13”
STEP 13: Release the locking pliers from vertical track and check the door’s counterbalance.
Adjust springs if necessary.
RIGHT HAND DRUM
BLACK
STPE 14: 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, teks, 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. Adjust top bracket roller carrier so
WINDING CONE
BLACK
COUPLING (SEE NOTE * )
that the top section is sealed against header.
EXTRA SUPPORT BRACKET USED WITH SPLIT SHAFT
STEP 15: Lubricate springs, rollers, and bearing with oil.
DO NOT GREASE THE INSIDE OF THE TRACKS.
WINDING CONE
RED
LEFT HAND DRUM
RED
5/16” X 1” Self drilling & tapping screw
for use on steel jambs.
RIGHT HAND DRUM
BLACK
8” MIN.
SPRING
PAD
Reverse angle
5/16” X 1 5/8” Lag
(steel or precast/block)
screw for use on
7”
FOUR SPRINGS
(6”)
SPLIT SOLID
wood jambs.
12” MIN.
PAD
WIDTH
WINDING CONE BLACK
13”
Angle out (wood
SHAFT
WINDING CONE BLACK
jambs)
3/8” X 3” Sleeve anchor for use on
pre-cast concrete.
( Drill a 3/8” x 3-1/2” deep hole)
WINDING CONE RED
COUPLING (SEE NOTE * )
EXTRA SUPPORT BRACKET USED
WITH SPLIT SHAFT
13”
30”or
18”
RED WINDING CONES ALWAYS POINT TO THE LEFT
SIDE
BLACK (OR PLAIN) WINDING CONES ALWAYS POINT THE
RIGHT SIDE,
Install hardware onto left side of
section, install roller into vertical
track, rotate the section into
position and stack, align sections
and secure right hand hardware.
STANDING INSIDE OF THE BUILDING, LOOKING OUT.
WINDING CONE RED
24”
24”
RED DRUMS GO ON THE LEFT SIDE
BLACK DRUMS GO ON THE RIGHT SIDE
LEFT HAND DRUM
RED
*NOTE: COUPLING USED ON SOLID SHAFT ONLY. TIGHTEN CONNECTING BOLTS AFTER
WINDING SPRING.
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 sever injury or death.
Wind springs toward ceiling.
24”
10”
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
injury or death.
(Standard lift applications)
NOTE: Typical
fastener spacing.
Fig. L
Wind spring 1/4 turn at a time to the number of complete revolutions
recommended on the spring tag. Wind up as shown Fig. M. When the
proper number of turns is reached, tighten the set screws on the
winding cone. Release the vice grips from the spring shaft(s). Adjust
the coupler on split solid shafts until drums are in time (check door
Fig. M
level) and tighten coupler.
PG. 10
PG. 7
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This illustration shows
15” radius track
W/TEK Screw to Steel
TWO SPRINGS
(3) 3/8” x 3/4” truss bolts and nuts.
(2) for securing end bracket
(1) for securing horizontal angle
(3-3/4”)
This illustration shows
TUBULAR OR 1 PIECE
12” radius track
W/Lag Bolt to Wood.
3-1/2”
RIGHT HAND DRUM
SOLID SHAFT
This illustration shows
15” radius track
BLACK
W/Concrete Anchor
Extra 3/8” truss bolt and nut
BLACK
WINDING CONE
BLACK
WINDING CONE
RED
Intermediate hangers for all doors over
11’ high and over 14’ wide. Positioned
half way between jamb and rear hanger.
BLACK
Laterial brace all
hanger angles.
9” MINIMUM SPRING PAD
WIDTH
RED
RED
LEFT HAND DRUM
RED
1/4” x 9/16”
track bolt and nut.
NOTE: 6” SPRINGS UTILIZE SOLID SHAFTS
Doors 16’ to 18’ high use 2
intermediate hangers.
Doors over 18’ use hangers at
6’ max. centers
24” MINIMUM SPRING PAD
WIDTH
20”
RIGHT SIDE ILLUSTRATES
DOUBLE ENDCAPS AND
HARDWARE
TWO SPRINGS
13”
RIGHT HAND DRUM
BLACK
(3-3/4”)
SPLIT SOLID
SHAFT
WINDING CONE
BLACK
LEFT SIDE ILLUSTRATES
SINGLE ENDCAPS AND
HARDWARE
COUPLING (SEE NOTE * )
EXTRA SUPPORT BRACKET USED WITH SPLIT SHAFT
SINGLE SPRING
WINDING CONE
RED
RIGHT HAND DRUM
BLACK
WINDING CONE
BLACK
RIGHT HAND DRUM
BLACK
8” MIN.
SPRING
PAD
LEFT HAND DRUM
RED
3-1/2”
FOUR SPRINGS
12” MIN.
PAD
WIDTH
3” MINIMUM SPRING PAD WIDTH
(6” IF FOR TROLLEY OPERATOR)
(3-3/4”)
WINDING CONE BLACK
SPLIT SOLID
13”
LEFT HAND DRUM
RED
SHAFT
WINDING CONE BLACK
WINDING CONE RED
COUPLING (SEE NOTE * )
EXTRA SUPPORT BRACKET USED
WITH SPLIT SHAFT
RIGHT HAND DRUM
BLACK
WINDING CONE
TWO SPRINGS
(2” ONLY)
BLACK
WINDING CONE
RED
WINDING CONE RED
LEFT HAND DRUM RED
LEFT HAND DRUM
RED
* NOTE: COUPLING USED ON SOLID SHAFT ONLY. TIGHTEN CONNECTING BOLTS AFTER WINDING SPRINGS.
PG. 9
PG. 8
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