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8800 Aluminum Full View
Torsion Spring
Installation Instructions and Owner’s Manual
Portland Source Plant
IMPORTANT NOTICE!
Read these instructions carefully before
attempting installation. If in question about
Wayne-Dalton Corp. any of the procedures, do not perform the
P.O. Box 67
work. Instead, have a qualified door agency
Mt. Hope, OH 44660
do the installation or repairs.
www.wayne-dalton.com
2009 Wayne-Dalton Corp. Part No. 338303 REV1 08/03/2009
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waRNiNg Table of Contents Important Safety Instructions ............................................ 2 ReaD TheSe iNSTR ucTioNS Package Contents ..........................................................3-4 caReFully beFoRe a TTemPTiNg Door Section Identification ................................................ 4 Tools Required .................................................................. 5 iNSTalla TioN. iF iN queSTioN abouT aNy oF The PRoceDuReS, Do Pre-Installation ..
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NoTe: DEPENDING ON ThE DOOR MODEL, SOME PARTS LISTED WILL NOT BE SUPPLIED IF NOT NECESSARY. REAR Package contents SUPPORTS MAY OR MAY NOT BE INCLUDED WITh YOUR DOOR. (2) hORIzONTAL TRACK WITh ATTAChED hORIzONTAL ANGLE Rh/Lh (1) TORSION TUBE DOOR SECTIONS (AS REqUIRED) (2) WALL ANGLES RIGhT AND LEFT #6 SCREW EYE AND (2) VERTICAL BOTTOM BRACKETS PULL ROPE (AS REqUIRED) Rh/Lh TRACK (AS REqUIRED) TOP BRACKET (2) FULLY ADjUSTABLE ROLLERS jAMB BRACKETS ASSEMBLY Rh/Lh FLAGANGLE (AS REqUIRED) (AS
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Package contents continued... 3/8”- 16 hEx NUTS (2) 1/4”- 20 hEx NUTS 1/4”- 20 FLANGE hEx (AS REqUIRED) NUTS (AS REqUIRED) (2) 1/4”- 20 x 5/8” TAMPER 1/4”- 20 x 5/8” 1/4”- 20 x 7/8” SELF DRILLING 3/8”- 16 x 3/4” hEx hEAD BOLTS RESISTANT SCREWS CARRIAGE BOLTS SCREWS (AS REqUIRED) (AS REqUIRED) (AS REqUIRED) (2) 3/8”- 16 x 1-1/2” hEx hEAD BOLTS 5/16” x 2” TAMPER RESISTANT LAG SCREWS 5/16” x 2” hEx hEAD LAG SCREWS (AS REqUIRED) (AS REqUIRED) (2) 1/4” x 2-1/2” CARRIAGE BOLTS Door Section identifi
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Tools Required PENCIL RATChET WRENCh VICE GRIPS GLOVES 3/8”, 7/16” SOCKET POWER DRILL DRIVER PhILLIPS hEAD SAFETY GLASSES 1/4”, 3/8”, 7/16”, 1/2” & hAMMER 7/16”, 1/2” & 9/32”, 1/2”, 3/16” & 1/8” SCREWDRIVER 9/16” WRENChES 9/16” SOCKET DRILL BITS NEEDLE NOSE TAPE MEASURE VICE CLAMPS LEVEL PLIERS SAWhORSE FLAT TIP SCREWDRIVER 1/4” TORx BIT APPROVED WINDING BARS STEP LADDER Removing an old Door P1 Counterbalance spring tension must always be released before any attempt is made to start removing
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SUITABLE MOUNTING SURFACE 2” x 6” hEADER BOARD Preparing the opening LUMBER MINIMUM 2” x 6” LUMBER P2 RECOMMENDED Tools Needed: waRNiNg FAILURE TO SECURELY ATTACh A SUITABLE DOOR hEIGhT Tape Measure MOUNTING PAD TO STRUCTURALLY SOUND LEVEL hEADER FRAMING COULD CAUSE SPRINGS TO VIOLENTLY PULL MOUNTING PAD FROM WALL, PLUMB jAMBS RESULTING IN SEVERE OR FATAL INjURY. If you just removed your existing door or you are installing a new door, complete all steps in PREPARING ThE OPENING. DOOR W
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Preparing the opening continued...... 2” x 6” jAMB IS SEE SIDEROOM RECOMMENDED REqUIREMENTS 5/16 x 2” ChART LAG SCREW SiDeRooom RaDiuS TRack FLUSh (Requirements) wooD JambS 12” R 4-1/2” 2” TRack 1-1/2” 14”R 4-1/2” 3.5 LhR REAR 9” 3.5 LhR FRONT 4-1/2” 4-3/16” 1/2”- 5/8” SiDeRoom RequiRemeNTS installation Begin the installation of the door by checking the opening. It must be the same size as the door. Vertical jambs must be plumb and level with header. imPoRTaNT: STAINLESS STEEL OR PT 200
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cutting vertical Track Horizontal 1 track NoTe: If you have riveted track, skip this Tools Needed: step. 12” Stamped 12” Vertical track must be cut to the proper radius None length prior to installation. imPoRTaNT: DOORS ThAT ARE 7’-0” OR 8’-0” IN hEIGhT DO NOT REqUIRE CUTTING ThE VERTICAL TRACK. Determine the radius of your horizontal track. vertical Track cutting chart Vertical Track NoTe: All Portland tracks have the radius Horizontal Vertical Track Cut Length Cut Length stamped on t
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attaching wall angle to vertical WALL ANGLE Track and installing wall angle 3 NoTe: If you have riveted track, skip this step. Tools Needed: If your door has fully adjustable flagangle to None vertical track, skip this step and go to step 2. hand tighten the wall angle to the vertical track using 1/4”- 20 x 5/8” carriage bolts and 1/4”- 20 flange hex nuts. 1/4”- 20 x 5/8” CARRIAGE BOLTS 1/4”- 20 FLANGE hEx NUTS VERTICAL TRACK installing Fully adjustable Jamb FULLY ADjUSTABLE brackets
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COUNTERBALANCE attaching counterbalance cables CABLE to bottom brackets 5 imPoRTaNT: RIGhT AND LEFT hAND IS Tools Needed: BOTTOM ALWAYS DETERMINED FROM INSIDE ThE BRACKET GARAGE LOOKING OUT. Pliers NoTe: For door section identification see page BOTTOM 4. BRACKET Locate the right and left hand bottom brackets. Uncoil the counterbalance cables. Slide the clevis pin through the left hand bottom bracket and counterbalance cable. Insert a cotter pin in the end of the clevis pin, and bend t
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hinges 7 NoTe: For door section identification see page 4. Tools Needed: Locate the bottom section, using #1 end hinges for Power Drill the end stiles; depending on the width of your door (2) 1/4” x 7/8” enough #1 half hinges for each of the pre-drilled SELF DRILLING 7/16” Socket locations along the reinforcing fin. SCREWS Driver end hinges: Place (1) #1 end hinge at the top left hand corner of the bottom section. Vertically align the slot/hole ROLLER of the lower (numbered) leaf with
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1-3/4” DOWN Top bracket FROM EDGE OF TOP SECTION 8 TOP SECTION NoTe: Top brackets are attached 1-3/4” down from the Tools Needed: TOP BRACKET top edge of the top section.. BASE Power Drill For single top brackets: (4) 1/4” x 7/8” SELF Place a top bracket onto the top left hand corner of the 7/16” Socket DRILLING SCREWS top section and down 1-3/4”. Align the edge of the END STILE Driver top bracket with the edge of the section, and secure using (2) 1/4” x 7/8” self drilling screws in the
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bottom Section 10 Tools Needed: Center the bottom section in the door opening. Level section using wooden shims jAMB hammer (if necessary) under the bottom section. hEADER Wood Shims WEAThER SEAL LEVEL jAMB BOTTOM SECTION WOODEN ShIMS VERTICAL TRACK vertical Track and wall angle installation 3/8 - 11 5/8” FLAGANGLE imPoRTaNT: ThE TOPS OF ThE VERTICAL Tools Needed: TRACKS MUST BE LEVEL FROM SIDE TO SIDE. IF ThE BOTTOM SECTION WAS 3/16” Drill Bit ShIMMED TO LEVEL IT. ThE VERTICAL 5/16 x
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VERTICAL TRACK WALL ANGLE vertical Track and wall angle installation continued.... 3/8 - 5/8” Position the left hand vertical track assembly Tools Needed: over the rollers of the bottom section. Make sure the counterbalance cable is located between the rollers and the door jamb. Drill ROLLER 3/16” pilot holes for the lag screws. Loosely fasten the vertical track assembly to the jamb WALL using 5/16” x 2” lag screws. Tighten ANGLE bottom lag screw securing vertical track 5/16 x 2” LAG
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Top Section 13 Place the top section in the opening and DOOR WIDTh vertically align with lower sections. hammer +3-3/8” TO 3-1/2” Temporarily secure the top section by driving a nail in the header near the center of the door Nail and bending it over the top section. Power Drill Now flip up hinge leaf against section, fastening center hinges first, and end hinges last. (Refer 7/16 Socket to Step 7). Driver When installing a door with a torsion counterbalance system, vertical track alignme
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attaching horizontal Track to adjustable Flagangle and wall 14 FLAGANGLE angle To install horizontal track, place the curved Tools Needed: hORIzONTAL end over the top roller. Align the bottom of the TRACK horizontal track with the vertical track. hand 9/16” Socket tighten the horizontal track to the flagangle/wall angle with (2) 1/4”- 20 x 5/8” carriage bolts 7/16” Socket and (2) 1/4”- 20 flange hex nuts. (2) 1/4” x 5/8” CARRIAGE Ratchet Wrench Level the horizontal track assembly and b
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LEFT END BEARING Torsion end bearing brackets BRACKET 16 Tools Needed: imPoRTaNT: RIGhT AND LEFT hAND IS ALWAYS DETERMINED FROM INSIDE Power Drill ThE GARAGE LOOKING OUT. 7/16” Socket End bearing brackets are right and left. Driver Using the upper slots in the end bearing bracket, position above the flagangle and secure the end bearing bracket to the 9/16” Socket horizontal angle using hORIzONTAL ANGLE (2) 3/8”- 16 x 3/4” hex head bolts and (2) Ratchet Wrench 3/8”- 16 hex nuts. 9/16”
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RIGhT hAND CABLE Torsion Spring assembly DRUM BLACK 18 imPoRTaNT: RIGhT AND LEFT hAND IS Tools Needed: ALWAYS DETERMINED FROM INSIDE ThE GARAGE LOOKING OUT. none NoTe: Identify the springs provided as either right hand wound (red winding cone), which goes on the LEFT hAND SIDE or left hand wound (black winding cone), which goes on LEFT hAND TORSION the RIGhT hAND SIDE. CABLE DRUM TUBE RED Facing the inside of the door, lay the torsion tube on the floor. Lay the spring with the black
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Nylon center bushing 19 Slide the nylon center bushing into the Tools Needed: TORSION stationary spring cone at the end of the spring SPRING and align the stationary spring cone(s) with 9/16” Socket STATIONARY the holes in the center bearing bracket. SPRING CONE Secure the spring(s) to the center bearing Ratchet Wrench bracket with (2) 3/8”- 16 x 1-1/2” hex head CENTER BEARING bolts and (2) 3/8”- 16 hex nuts. BRACKET 9/16” Wrench imPoRTaNT: SPRINGS UNDER TENSION Step Ladder CAN BE DAN
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counterbalance cables LEFT CABLE 20 DRUM Release the vice grips from the ends of the Tools Needed: cables and thread the counterbalance cables CABLE around the back side of the cable drums and Vice Grips verify that there are no cable obstructions. hook the cables into the drums. Slide the left hand 3/8” Wrench CABLE cable drum against the left hand end bearing hOOKED IN bracket and tighten the set screws in the drum CABLE DRUM Step Ladder to 14-15 ft. lbs. of torque (Once set screws
