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8000 Series, Model 46
®
TorqueMaster - Single and Double 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
© Copyright 2009 Wayne-Dalton Corp. Part No. 323295 REV2 08/03/2009
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wARNINg Table of Contents Important Safety Instructions ............................................ 2 READ ThESE INSTRUCTIONS Package Contents ..........................................................3-4 CAREFUlly bEFORE ATTEMPTINg Door Section Identification ................................................ 4 Tools Required .................................................................. 5 INSTAllATION. IF IN qUESTION AbOUT ANy OF ThE PROCEDURES, DO Pre-Ins
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Package Contents NOTE: DEPENDING ON ThE DOOR MODEL, SOME PARTS LISTED WILL NOT BE SuPPLIED If NOT NECESSAR y. REAR SuPPORTS MAy OR MAy NOT BE INCLuDED WITh yOuR DOOR. (2) hORIzONTAL TRACk WITh ATTAChED hORIzONTAL ANGLE Rh/Lh ® (1) TORquEMASTER SPRING TuBE (2) fuLL y ADjuSTABLE Rh/Lh fLAGANGLES DOOR SECTIONS (AS REquIRED) jAMB BRACkETS LuBRCIATING OIL RIGhT AND LEfT DRIVE GEARS (AS REquIRED) (AS REquRED) BOTTOM BRACkETS (AS REquIRED) (2) VERTICAL RIGhT & LEfT (1) LOOSE WINDING ShAfT RIGhT AND
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Package Contents Continued... (2) 3/8”- 16 1/4”- 20 fLANGED hEx (2) #10 PhILLIPS 1/4”- 20 hEx NuTS 1/4”- 14 x 5/8” SELf T APPING (2) 1/4”- 20 x 5/8” NuTS (AS REquIRED) hEAD SCREWS hEx NuTS (LIfT hANDLE) SCREWS (AS REquIRED) TAMPER-RESISTANT SCREWS (2) 3/8”- 16 x 3/4” 1/4”- 20 x 5/8” 1/4”- 20 x 7/8” SELf DRILLING 5/16” x 2” hEx hEAD LAG SCREWS hEx hEAD BOLTS CARRIAGE BOLTS SCREWS (AS REquIRED) (AS REquIRED) (AS REquIRED) (2) #8 x 1-5/8” SELf TAPPING SCREWS (2) 1/4” x 2-1/2” CARRIAGE BOLTS
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Tools Required 3/8”, 7/16” SOCkET POWER DRILL PENCIL RATChET WRENCh PLIERS/WIRE CuTTERS GLOVES DRIVER 1/2” & 9/16” PhILLIPS hEAD VICE GRIPS 1/4”, 3/8”, 7/16”, 1/2” & hAMMER 9/32”, 1/2”, 5/16”, SOCkET SCREWDRIVER 9/16” WRENChES 3/16” & 1/8” DRILL BITS LEVEL TAPE MEASuRE (2) VICE CLAMPS (2) SAWhORSES fLAT TIP SCREWDRIVER SAfETy GLASSES STEP LADDER Removing An Old Door wARNINg If yOuR COuNTERBALANCE SySTEM IS OThER ThAN ThOSE MENTIONED, DO NOT ATTEMPT TO WORk ON IT, BuT hAVE A quALIfIED DOOR A
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Torsion Spring Removal P1 For Standard lift Tools Needed: wARNINg TORSION SPRING ASSEMBLy fAILuRE TO uSE APPROVED Recommended WINDING BARS CAN CAuSE SPRING tools from ENERGy TO BE RELEASED page 5 SuDDENLy, RESuLTING IN SEVERE OR f ATAL INjuR y. wARNINg COuNTERBALANCE SPRING TENSION MuST BE RELIEVED BEfORE REMOVING ANy hARDWARE. A WINDING CONE POWERfuL SPRING RELEASING IT’S ENERGy SuDDENLy CAN CAuSE SEVERE OR f ATAL INjuR y. Do not release the torsion spring tension unless you are a q
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LOOSEN LOCk COuNTER ® TorqueMaster Spring Removal NuT GEAR/ COVER P2 ® A TorqueMaster spring system can be Tools Needed: identified by the end brackets. f or single spring applications, the right hand end RIGhT hAND Recommended bracket will always have a drive gear, END BRACkET tools from counter gear, counter cover, and a winding bolt head. The left hand end bracket will page 5 have no gears, counter cover, or winding bolt head. The hole for the winding bolt head will be plugged. f
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® TorqueMaster Spring Removal continued... (Spring Tube should be free to rotate in Tools Needed: either direction.) If the counterbalance ® cable is still taut and the TorqueMaster Recommended Spring Tube is difficult to rotate, that is an tools from indication that spring tension still exists page 5 on the left hand spring. Repeat Steps 1 and 2 for releasing spring tension on the left hand side. REMOVE TOP LAG SCREW Step 4: using a flat tip screwdriver, pry the counter gear and cou
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REMOVE LAG SCREW fROM SAfETy CABLE (If Extension Spring Removal INSTALLED). REPEAT fOR P3 OPPOSITE SIDE. Step 1: Raise the door to the fully open Tools Needed: position and place vice clamps to the back Recommended legs of both vertical tracks, below the tools from bottom rollers to prevent the door from page 5 falling. By opening the door you release most of the spring tension. Carefully BOTTOM SECTION unfasten the S-hook from the horizontal (DOOR OPEN) angle. Remove cable, sheave and
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SuITABLE MOuNTING hEADER BOARD SuRf ACE 2” x 6” 2” x 6” LuMBER Preparing the Opening LuMBER MINIMuM PREfERRED P5 fAILuRE TO Tools Needed: wARNINg DOOR hEIGhT SECuRELy ATTACh A Recommended SuITABLE MOuNTING PAD TO STRuCTuRALLy LEVEL hEADER tools from SOuND fRAMING COuLD CAuSE SPRINGS TO page 5 PLuMB jAMBS VIOLENTLy PuLL MOuNTING PAD fROM WALL, RESuLTING IN SEVERE OR f ATAL INjuR y. If you just removed your existing door or you are installing a new door, complete all steps in PREPARING
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IMPORTANT: READ INSTRuCTIONS TITLED “P4” “DOOR REMOVAL” ON PAGE 9 AND “P5” “PREPARING ThE OPENING” ON PAGE 10 BEfORE ATTEMPTING DOOR INSTALLATION. IMPORTANT: STAINLESS STEEL OR PT 2000 COATED LAG SCREWS MuST BE uSED WhEN INSTALLING CENTER BEARING BRACkETS, END BEARING BRACkETS, jAMB BRACkETS, OPERATOR MOuNTING/SuPPORT BRACkETS AND DISCONNECT BRACkETS ON TREATED LuMBER (PRESERVATIVE-TREATED). STAINLESS STEEL LAG SCREWS ARE NOT NECESSARy WhEN INSTALLING PRODuCTS ON uNTREATED LuMBER. NOTE: It
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Installing Fully Adjustable Jamb fuLL y ADjuSTABLE brackets 2 jAMB BRACkET Tools Needed: NOTE: If you have riveted track, skip this step. None 3RD SET To attach the bottom jamb bracket, jB-2, locate the first set of quick install features of the vertical track. Align jAMB BRACkET the slot in the jamb bracket with the SLOT slot above the quick install features in the vertical track. The long side of the (1) 1/4”- 20 x 5/8” bracket is placed against the track. CARRIAGE BOLT f asten the
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Drums LEfT hAND 4 ® TORquEMASTER COuNTERBALANCE DRuM IMPORTANT: RIGhT AND LEfT hAND IS Tools Needed: ALWAyS DETERMINED fROM INSIDE ThE None GARAGE LOOkING OuT. NOTE: f or door section identification see page 4. ® TorqueMaster counterbalance drums are marked right and left hand. uncoil the counterbalance cables and BOTTOM SECTION make sure you place the right hand cable loop on the right hand milford pin and place the left hand cable loop on the left hand milford pin. Insert a roller i
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1 hinges 2 5 3 Locate the lower (numbered) leaf of Tools Needed: 4 5 the #1 end hinges and required center Power Drill 6 hinges over the #1 and #4 holes in the end stiles for the end hinges and the 7/16” Socket pre-punched holes in the center stile(s) Driver for the center hinges at the top of the ROLLER section. 7 PLACEMENT NOTE: The #1 hinges serve as end hinges on the bottom section. The #1 #1 hINGE #2 END hINGE hinges also serve as center hinges at all center hinge locations.
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TOP BRACkET Top bracket #6 hOLE BASE TOP SECTION 6 Align upper-center hole of top bracket Tools Needed: base with #6 hole in the end stile (See end Power Drill stile hole layout). Loosely secure with (1) 1/4”- 20 x 7/8” self drilling screw. END STILE (4) 1/4-20 x 7/8” SELf 7/16” Socket DRILLING SCREW Driver Ensure top bracket is level and aligned with edge of section. Secure with (1) 1/4”- 20 (4) 1/4”- 20 x 7/8” self drilling screws, fLANGE hEx one in each corner of the top bracket
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u-BAR PLACEMENT fOR TOP SECTION U-bar 8 NOTE: f or door section identification see Tools Needed: page 4. Power Drill INSTAllATION ON ThE TOP SECTION: 7/16” Socket Driver Doors 14’0” wide and over, locate u-Bar above top bracket and secure with u-BAR u-BAR (2) 1/4”-20 x 7/8” self drilling screws at each end and center stile location. TOP NOTE: 3” u-Bars are now supplied with (2) 1/4”- 20 x 7/8” SECTION SELf DRILLING all glazed doors starting at 14’0” width. SCREWS TOP INSTAllATION ON All
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LOCk LOCk SECTION lift handle SECTION 9 LIfT hANDLE Tools Needed: NOTE: Doors with a keyed lock do not require this lift handle. Tape Measure 4” NOTE: f or door section identification see page 4. Pencil (2) SPACERS Locate the inside center stile or the desired lift handle Power Drill location on the lock (2nd) section of the door. Position LIfT (2) 1/4” x 2-1/2” 9/32” Drill Bit the lower hole in the lift handle 4” from the bottom of hANDLE BOTTOM CARRIAGE BOLTS the second section. SECT
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VERTICAL TRACk vertical Track 11 5/8” IMPORTANT: ThE TOPS Of ThE VERTICAL Tools Needed: fLAGANGLE 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 2” hEx TRACk ON ThE ShIMMED SIDE, MuST BE Power Drill ROLLER hEAD LAG RAISED ThE hEIGhT Of ThE ShIM. SCREWS 7/16” Socket Position the left hand vertical track Driver assembly over the rollers of the bottom section. Make sure the counterbalance Tape Measure VERTICAL
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DOOR WIDTh Top Section NAIL +3-3/8” TO 3-1/2” 13 Tools Needed: Place the top section in the opening and vertically align with lower sections. hammer Temporarily secure the top section by Nail driving a nail in the header near the center of the door and bending it over Power Drill the top section. 7/16 Socket Now flip up the hinge leaf against Driver section, fastening center hinges first and end hinges last. vertical Track 14 Tools Needed: When installing a door with a ® TorqueMaster co
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fLAGANGLE horizontal Track 15 Tools Needed: To install horizontal track, place the curved end over the top roller. Align the bottom of the horizontal track 9/16” Socket with the vertical track. hand tighten the horizontal (2) 1/4”- 20 x 5/8” CARRIAGE BOLTS track to the flagangle with (2) 1/4”-20 x 5/8” carriage Ratchet Wrench bolts and (2) 1/4”-20 flange hex nuts. 9/16” Wrench Level the horizontal track assembly and bolt the Level horizontal angle to the slot in the flagangle using (2) 1
