How To Install a Wayne Dalton Garage Door – Easy To Follow DIY Video Tutorial

by kory972@yahoo.com
Installing a Wayne Dalton DIY Instructions

How To Install a Wayne Dalton Garage Door

Introduction

You bought a new Wayne Dalton garage door from Lowe’s. Now it’s time to tackle installation. In this video, we will walk you through the installation of your new purchase. Always remember, before attempting any installation, read the instructions and follow all steps as directed, paying close attention to all safety warnings. Always wear appropriate personal protective equipment, including leather gloves and eye protection.

Some steps in this video have been altered to make DIY installation easier, but should only be considered as supplemental information to the provided instructions.

Prep

As you begin, inspect all contents of your purchase to verify all parts are included in the package. Gain familiarity with these parts, as some are specific to left and right-hand placement.

To install your new garage door, you’ll need the following tools;

tools needed to install Wayne Dalton garage door
Tools needed to install a Wayne Dalton Garage Door
tools needed to install Wayne Dalton garage door 2
Tools needed to install a Wayne Dalton Garage Door

Track Preparation

The next step is preparing the track. Find the left-hand vertical track and flag angle. Place the lower Quick Install tab of the left-hand flag angle in the Quick Install feature of the lefthand vertical track. Then give the flag angle one four turns to lock in place. Measure the length of the vertical tracks. Use the jam bracket schedule found in the package instructions to determine the placement of the jam brackets for your door height. All jam brackets come in different lengths.

The bottom will be the shortest, and the top will be the longest. To install the jam brackets, align the Quick Install tab on the jam bracket with the Quick Install feature in the vertical track. Turn the bracket perpendicular to the track so the mounting flange is toward the back flat leg of the track. Repeat for the other side. Find the left-hand horizontal track and horizontal track angle.

Place the Quick Install tabs of the horizontal track angle in the key slot of the left-hand horizontal track. Using a hammer or mallet, tap the horizontal track angle towards the curved end of the track until the alignment hole in the track and angle are aligned. Repeat for the other side and set tracks aside. Find the bottom section and the left-hand cable drum. Place the left-hand cable loop of the counterbalance lift cables on the Milford pin of the bottom section corner bracket.

Ensure a tight fit to prevent injury. Then insert track rollers into the bottom corner bracket and graduated N hinges. Repeat for the right-hand side. Now that the tracks are assembled, the sections can be added.

Sections

All sections can be identified by the number shown on the hinges.

Center the bottom section of the door in the door opening and level the section using shims if necessary under the bottom section. Once leveled, temporarily hold it in place by driving a nail into the jam and bending it over the edge of the bottom section or inserting a screw at an angle on both sides. Flip hinges down after adding each section, and place the vertical tracks over the track rollers on the bottom section. Pre-drill 316-inch pilot holes and loosely secure the vertical tracks on the wall by adding 516 by one and five eight-inch lag screws to the bottom jam bracket.

These will be tightened later with each section. Always be sure that the counterbalance lift cable is behind the rollers before connecting the remaining middle sections. Place track rollers into the graduated end hinges of the remaining sections. List the second section marked with the number two and guide the track rollers into the vertical tracks. Lower the section until it is seated against the bottom section, and then add a temporary nail or screw on both sides.

Ensure panels are lined up and loosely secure the second jam bracket with the same 516 x one and five eight-inch lag screws. There should be some movement as this will be fully tightened later. Then flip the hinges up and fasten using seven one four by five eight-inch self-tapping screws. Always secure the center hinge first, then fasten the end hinges last. Be sure to push and hold the hinge leave firmly against the sections while securing the screws.

There should be no gap between the hinge leaves and the sections. Repeat the same process for the third section. Prior to installing, you need to prepare the top section. Find the top section center and seat the drawbar operator bracket on top. Install 212 x one two-inch Phillips head screws on the back side of the drawbar operator bracket.

Use the vise clamp placed in the center to clamp the drawbar operator bracket to the Strut predrill 316-inch pilot holes and attach six 1420 by 1116-inch self-drilling screws to the drawbar operator bracket. When complete, remove the vise clamps. To install the top fixtures, align the top holes in the top fixture base with the second set of holes in the end cap of the top section. Fasten the top fixture base to section using four one four by five eight-inch self-tapping screws. Secure the top fixture slide to the fixture base loosely using two 1420 by five eight-inch carriage bolts and two 1420-inch flange hex nuts.

Insert the track roller into the top fixture slide. The top fixture slide will be tightened and adjusted later, so ensure it is able to move along the top fixture base if needed, and loosen the hex nuts. Repeat the same process for the other side. Finally, you can install the top section. Place the top section in the opening.

Install a nail or screw on each side to prevent the top section from falling backward. Now flip up the hinge leaves, hold them tight against a section and fasten the center hinges first and the end hinges last, just like the previous step. Repeat for the other side.

Track Installation

Now it’s time to install and secure the horizontal and vertical tracks. To install the horizontal tracks, ensure the cable is hanging over the top roller and use the existing hardware to attach the horizontal track to the rear back hangs.

Then place the curved ends over the top track rollers of the top section. Align the key slot of the horizontal track with the Quick Install tab of the flag angle. Push the curved portion of the horizontal track down to lock it in place. Next, bolt the horizontal track angle to the first encountered slot in the flag angle using one 3816 x three-quarter inch truss head bolt and one 3816 inch hex nut. Repeat for the other side.

Do not raise a door until flag angles are secured against the jam. Next, you can secure the vertical tracks to the door opening. First, double-check that the counterbalance lift cable is located between the track rollers and the door jam and make sure the tops of the vertical tracks are level within a one-four-inch allowance. Vertical track alignment is critical and requires a slight outward angle from the door sections. Ensure there is a tight fit of three eight-inch to five eight-inch spacing between the bottom section and the vertical track.

Tighten the bottom jam bracket’s lag screw, then position the flag angle between one and 1116 inches to one and three four-inch from the edge of the top section. Refer to instructions for flag angle lag screw placement and secure to jam with 3516 by one and five eight-inch lag screws. While maintaining required spacing, remember to temporarily remove each screw or nail, securing the sections in place as you go. Once all left-hand vertical track lag screws are in place, hang the counterbalance lift cable over the flag angle. Repeat the process for the other side to adjust the top fixtures.

Position the top fixture slide out against the horizontal track. Tighten the two flange hex nuts to maintain the slide’s position to secure the top fixture. Slide to the top fixture base. The door should be stable and secure, but still have some room for movement. Repeat for either side.

Installing the Torquemaster Plus

The next step is to install the Torquemaster Plus, Wayne Dalton’s exclusive counterbalance system that encloses springs safely inside a steel tube and features an anti-drop device to prepare for installation. Lay the spring tube assembly on the floor in front of the garage door with a labeled end to the left. Find the center bracket bushing assembly and slide it toward the center of the spring tube from the right side. Now shake the spring tube assembly gently to extend the winding shaft out about five inches on the right side. Move the cable drums off the flag angles to hang on the track rollers as done in a previous step.

Then grab your ladder to rest the torque master on as the cable drums are installed. Starting on the right-hand side, slide the cable drum over the winding shaft until the cable drum seats against the spring tube assembly. The winding shaft must extend past the cable drum far enough to expose the splines in the grooves. Repeat for the other side and then insert the idler bracket into the left-hand cable drum. It is important to lightly press the idler bracket into the cable drum until two distinct clicks are heard so the idler bracket does not come back out.

Ensure the idler bracket extends past the cable drum far enough to expose the groove. Finally, use your ladder to bring the torque master to the tops of the flag angles. Drop in the right side first and then align the Adler bracket notch with the round notch in the flag angle. Ensure the spring tube assembly is positioned so the cam peak is pointing straight up. Next, confirm the left-hand cable drum bearing is all the way to the left and up against the flag angle.

If the cable drum is pulled away from the flag angle, then the idler bracket can rub against the cable drum, causing the noise. Attach the idler bracket to the flag angle using a 516 18 x three four-inch carriage bolt washer and hex nut. Then secure the idler bracket to the jam using 1516 by one and five eight-inch lag screws. Find the ratchet wheel, then remove the shipping tie, keeping your hand positioned so the ratchet gear does not fall out on the right-hand side, slide the ratchet wheel with the flange outward onto the winding shaft so that the splines in the ratchet wheel fit onto the winding shaft grooves. Attach the M bracket to the flag angle using a 516 18 by three-quarters inch carriage bolt washer and hex nut.

Then predrill a pilot hole and secure the M bracket to the jam using a 516 x one and five eight-inch lag screw. Warning tags must be securely attached to the end bracket and visible. Lift the center bracket so it’s holding the spring tube. Level the spring tube assembly and predrill 316-inch pilot holes into the header. Then fasten the center bracket bushing assembly to the header using 2516 x one and 58-inch lag screws.

With the door fully closed, place locking pliers onto both vertical tracks just above a track roller, preventing the garage door from rising while winding the spring. Now loosen the set screw in the cable drum. Use locking pliers to pull on the end of the cable to remove all cable slack. Turn the spring tube assembly until the counterbalance lift cable is aligned and seated in the first and second grooves of the cable, drawing a one-and-a-half turn. Then ensure the cable is taut and tighten the set screw to prevent cable movement.

Wrap the excess cable around the spring tube and insert the cable’s end into the cable drum’s hole. Repeat for the left-hand cable drum assembly before attempting to wind the spring. Be sure to check the following cam on the spring tube assembly is pointed up. There is a one-and-a-half wrap on the cable drum, and the slot on the drum is pointed outward. Counterbalanced lift cables should be secure at the bottom corner brackets.

Lift cables are routed unobstructed to the cable drums. Lift cables are correctly installed and wound onto the cable drums. The torque master plus spring tube is installed correctly. Locking pliers are installed above a roller on each side of the door to prevent the door from rising during spring winding. Check the label attached to the spring warning tag or the winding spring turn chart for the required number of complete turns to balance your door.

The door shown in this video requires 16 complete turns. Starting on the right-hand side, turn the pawl knob on the end bracket to the upper position to adjust spring tension. Be careful not to touch the notch that releases cable tension. Using a ratchet wrench and a five-eight-inch socket, wind the spring by rotating the winding shaft counterclockwise. Do not use an impact drill as it will not wind the spring accurately.

Ensure the counterbalance lift cables are correctly seated in the first groove of the cable drums and that both cables have equal tension. Check the lift cable tension as it may need to be adjusted. Once spring winding is complete, place a Paul knob in the lower position.

Balancing The Door

Finally, the door is installed, and all that is left to do is balance the door. This is an important step, as an unbalanced door can cause torque master, operation problems, and potential injury.

Cautiously remove the locking pliers from the vertical tracks and check that all screws or nails previously holding the sections in place have been removed. Lift the door approximately 3ft to check the balance. Adjust the springs if the door lifts by itself or if the door drifts down, using locking pliers to prevent the garage door from rising while adjusting the springs. Remember, any time spring adjustments are made, the ratchet pole knob must be in the upper position. All steps are complete and you can now enjoy your new Wayne Dalton Garage Door from Lowe’s.

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