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8000 Series, Model 46
®
TorqueMaster Plus - 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 trained door systems
Mt. Hope, OH 44660
technician do the installation or repairs.
www.wayne-dalton.com
Copyright 2009 Wayne-Dalton Corp. Part No. 328739 REV
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wARNINg Table of Contents Important Safety Instructions ............................................ 2 TO AvOID POSSIblE INjUR y, READ ThESE Package Contents ..........................................................3-4 INSTRUCTIONS CAREFUlly bEFORE Door Section Identification ................................................ 4 ATTEMPTINg INSTAllATION. IF IN qUESTION Tools Required .................................................................. 5 AbOUT ANy OF
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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 TRACkS WITh ATTAChED hORIzONTAL ANGLE Rh/Lh ® (1) TORquEMASTER SPRING TuBE DOOR SECTIONS (AS REquIRED) jAMB BRACkETS RIGhT & LEfT (1) LOOSE WINDING ShAfT RIGhT AND LEfT CABLE (AS REquIRED) DRuM WRAPS (SINGLE SPRING ONLy) DRuM ASSEMBLIES 8000 Series, Model 46 ® T orqueMaster - Single and Double Spring Installation I
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Package Contents Continued... 5/16”- 18 hEX NuTS (2) 3/8”- 16 1/4”- 20 fLANGED hEX 1/4”- 20 hEX NuTS (2) 1/4”- 20 X 5/8” TAMPER- (AS REquIRED) NuTS (AS REquIRED) hEX NuTS (LIfT hANDLE) RESISTANT SCREWS 1/4”- 14 X 5/8” SELf T APPING (2) 3/8”- 16 X 3/4” 1/4”- 20 X 5/8” CARRIAGE 1/4”- 20 X 5/8” CARRIAGE SCREWS (AS REquIRED) hEX hEAD BOLTS BOLTS (AS REquIRED) BOLTS (AS REquIRED) 1/4”-20 X 11/16” SELf DRILLING 1/4”- 20 X 7/8” SELf DRILLING 5/16” X 2” hEX hEAD LAG SCREWS (AS REquIRED) SCREWS (AS
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Tools Required POWER DRILL PENCIL RATChET WRENCh PLIERS/WIRE CuTTERS 7/16”, 1/2” SOCkET GLOVES LEVEL DRIVER hAMMER 1/4”, 3/8”, 7/16”, 1/2” & TORX BIT PhILLIPS hEAD 1/2”, 9/16”, 5/8” 1/8”, 3/16”, 9/32”, VICE GRIPS 9/16” WRENChES SCREWDRIVER & SOCkET 5/16”, 1/2” DRILL BITS hACkSAW TAPE MEASuRE (2) VICE CLAMPS 3” EXTENSION fLAT TIP SCREWDRIVER SAfETy GLASSES (2) SAWhORSES STEP LADDER Removing an Existing Door Counterbalance spring tension must always be released before any attempt is made to start
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SuITABLE MOuNTING hEADER BOARD SuRf ACE 2” X 6” 2” X 6” LuMBER Preparing the Opening LuMBER MINIMuM PREfERRED Tools Needed: fAILuRE TO DOOR hEIGhT wARNINg SECuRELy ATTACh A Recommended LEVEL hEADER SuITABLE MOuNTING PAD TO STRuCTuRALLy tools from page 5 SOuND fRAMING COuLD CAuSE SPRINGS TO 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 DOOR new door, complete all steps in PREPARI
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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 the header level. Side clearance, from edge of door to wall, must be minimum of 3-1/2” (89 mm) on each side. IMPORTANT: STAINLESS STEEL OR PT 2000 COATED LAG SCREWS MuST BE uSED WhEN INSTALLING CENTER BEARING BRACkETS, END BRACkETS, jAMB BRACkETS, OPERATOR MOuNTING/SuPPORT BRACkETS AND DISCONNECT BRACkETS ON TREATED LuMBER (PRESERVATIVE-TREATED). STAINLESS STEEL LAG
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Cutting vertical Track and Installing Fully Adjustable jamb 1 Horizontal brackets track Tools Needed: NOTE: If you have riveted track, skip this step. 12” Tape Measure Stamped 12” radius hacksaw Vertical track must be cut to the proper Power Drill length prior to installation. 5/16” Drill Bit IMPORTANT: DOORS ThAT ARE 7’-0” OR 8’-0” IN hEIGhT DO NOT REquIRE vertical Track Cutting Chart CuTTING ThE VERTICAL TRACk. Vertical Track Cut Length Horizontal Vertical Track Cut Length Determine th
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Attaching Fully Adjustable fuLL y ADjuSTABLE fLAGANGLE Flagangle to vertical Track 2 Tools Needed: NOTE: If you have riveted track, skip this step. None hand tighten the flagangle to the vertical track using (2) 1/4”- 20 x 5/8” carriage bolts and (2) 1/4”- 20 flange hex nuts. Repeat for opposite side. The flange nuts will be tightened after flagangle spacing is complete (Step 14). (2) 1/4”- 20 fLANGE hEX (2) 1/4”- 20 X 5/8” NuTS CARRIAGE BOLTS VERTICAL TRACk bottom bracket 3 LEfT hAN
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Drums 4 IMPORTANT: RIGhT AND LEfT hAND IS Tools Needed: LEfT hAND ALWAyS DETERMINED fROM INSIDE ThE ® TORquEMASTER PLuS None GARAGE LOOkING OuT. COuNTERBALANCE DRuM NOTE: f or door section identification see page 4. ® TorqueMaster Plus 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 milford pin of the right hand bottom corner bracket. Place the left hand cable loop on the milf
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1 hinges 2 5 3 Position the lower (numbered) leaf of the Tools Needed: 4 5 #1 end hinge over the #1 and #4 holes in Power Drill 6 the top of the end stiles, and secure to the end stiles by 1/4”-14 x 5/8” self tapping 7/16” Socket screws. Position and secure #1 center Driver hinge(s) with 1/4”-14 x 5/8” self tapping ROLLER screws using the pre-punched holes in 7 PLACEMENT the top of the center stile(s). NOTE: The #1 hinges serve as end hinges #1 hINGE #2 END hINGE on the bottom sectio
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Top bracket #6 hOLE TOP BRACkET TOP SECTION 6 BASE Align upper-center hole of top bracket Tools Needed: base with #6 hole in the end stile (See end Power Drill stile hole layout). 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 Ensuring top bracket is level and aligned DRILLING SCREW Driver with edge of section. Permanently fasten top bracket with (4) 1/4”- 20 x 7/8” self (1) 1/4”- 20 fLANGE hEX drilling screws, one in each corner of
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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 NOTE: Doors with a keyed lock do not require this lift Tools Needed: handle. Tape Measure NOTE: f or door section identification see page 4. Pencil LIfT hANDLE Locate the inside center stile or the desired lift handle (2) SPACERS Power Drill 4” location on the lock (2nd) section of the door. Position MAX. the lower hole in the lift handle 4” from the bottom of (2) 1/4” X 2-1/2” 9/32” Drill Bit BOTTOM CARRIAGE BOLTS the second section
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VERTICAL TRACk vertical Track 11 5/8” IMPORTANT: ThE TOPS Of ThE VERTICAL Tools Needed: TRACkS MuST BE LEVEL fROM SIDE TO SIDE. fLAGANGLE If ThE BOTTOM SECTION WAS ShIMMED 3/16” Drill Bit TO LEVEL IT, ThE VERTICAL TRACk ON ThE 5/16 X 2” hEX ShIMMED SIDE MuST BE RAISED ThE hEIGhT Power Drill ROLLER hEAD LAG Of ThE ShIM. SCREWS 7/16” Socket Position the left hand vertical track assembly Driver over the rollers of the bottom section. Make sure the counterbalance cable is located Tape M
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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 hinge(s) first and end hinges last. 7/16” Wrench Tape Measure vertical Track Alignment 14 Tools Needed: When inst
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horizontal Track 15 To install horizontal track, place the curved end over the Tools Needed: top roller. Align the bottom of the horizontal track with (2) 1/4”- 20 X 5/8” 9/16” Socket the vertical track. hand tighten the horizontal track to CARRIAGE BOLTS the flagangle with (2) 1/4”-20 x 5/8” carriage bolts and 7/16” Socket (2) 1/4”-20 flange hex nuts. Ratchet Wrench Level the horizontal track assembly and bolt the horizontal angle to the slot in the flagangle using (1) 3/8”- 1
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® TorqueMaster Spring Tube 17 ® Tools Needed: TorqueMaster springs come lubricated and pre-assembled inside the None ® TorqueMaster spring tube. To install, lay ® the TorqueMaster spring tube on the floor (inside garage) in front of the door with the labeled end to the left. IMPORTANT: RIGhT AND LEfT hAND IS ALWAyS DETERMINED fROM INSIDE ThE GARAGE LOOkING OuT. ® TORquEMASTER SPRING TuBE LABELED END Center bracket bushing 18 CENTER BRACkET ® Tools Needed: NOTE: If you are installing t
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Drum wraps 19 IMPORTANT: RIGhT AND LEfT hAND Tools Needed: IS ALWAyS DETERMINED fROM INSIDE None ThE GARAGE LOOkING OuT. RIGhT hAND DR uM WRAP Drum wraps are identified as right and left. Slide the left hand drum wrap over the ® left side of the TorqueMaster spring LEfT hAND DRuM WRAP tube assembly with the tabs facing left. Continue sliding the left hand drum wrap towards the center of the ® TorqueMaster spring tube assembly. Slide the right hand drum wrap over the ® right side of the
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WARNING Rachet Bracket is under EXTREME SPRING TENSION. To avoid possible severe or fatal injury, DO NOT remove fasteners from ratchet bracket until spring(s) are fully wnwound. To safely unwind spring(s) read and follow the directions in the installation instructions/owners manual. DO NOT REMOVE THIS TAG. Use these Illustration, in conjunction with the Instructions on the other side of this label. ENGAGED SIDE VIEW Cable Drum ENGAGED UNDERNEATH VIEW Ratchet Pawl No space between Ratchet
