Wayne-Dalton 46 Installation Instructions And Owner's Manual

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Page 1

8000 Series, Model 46

TorqueMaster® - Single and Double Spring

Installation Instructions and Owner’s Manual

Portland Source Plant

Wayne-Dalton Corp. P.O. Box 67 Mt. Hope, OH 44660 www.wayne-dalton.com

IMPORTANT NOTICE! Read these instructions carefully before attempting installation. If in question about any of the procedures, do not perform the work. Instead, have a qualiﬁed door agency do the installation or repairs.

Page 2

Table of Contents

Important Safety Instructions ............................................ 2

Package Contents ..........................................................3-4

Door Section Identiﬁcation ................................................ 4

Tools Required .................................................................. 5

WARNING

READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING INSTALLATION. IF IN QUESTION

Pre-Installation ............................................................5-10

Removing The Old Door .................................5-9

Preparing The Opening ................................... 10

Installation ................................................................11-32

Optional Installations .................................................33-35

Side Lock .......................................................33

DoorMaster

Alternative Step Plate ..................................... 34

Pull Rope ........................................................ 34

Trolley Operator .............................................. 35

Maintenance ................................................................... 36

Cleaning ......................................................... 36

Painting Instructions ....................................... 36

Warranty ......................................................................... 37

Dealer Locator Information.............................................. 38

Bracket .................................... 33

Deﬁnition of key words used in this manual:

WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN SEVERE OR FATAL INJURY.

CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT FROM FAILURE TO FOLLOW INSTRUCTIONS.

IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER DOOR OPERATION.

NOTE: Information assuring proper installation of the door.

ABOUT ANY OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A QUALIFIED DOOR AGENCY DO THE INSTALLATION OR REPAIRS.

1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

2. Wear protective gloves during installation to avoid possible cuts from sharp metal edges.

3. It is always recommended to wear eye protection when using tools, otherwise severe or fatal eye injury could result.

4. Avoid installing your new door on windy days. Door could fall during the instazllation causing severe or fatal injury.

5. Doors 12’-0” wide and wider should be installed by two persons, to avoid possible injury.

6. Operate door ONLY when it is properly adjusted and free from obstructions.

7. If a door becomes hard to operate, inoperative or is damaged, immediately have necessary adjustments and/or repairs made by a trained door system technician using proper tools and instructions.

8. DO NOT stand or walk under a moving door, or permit anybody to stand or walk under an electrically operated door.

9. DO NOT place ﬁngers or hands into open section joints when closing a door. Use lift handles/gripping points when operating door manually.

10. DO NOT permit children to operate garage door or door controls. Severe or fatal injury could result, should the child become entrapped between the door and the ﬂoor.

11. Due to constant extreme spring tension, DO NOT attempt any adjustment, repair or alteration to any part of the door, especially to springs, spring brackets, bottom corner brackets, red colored fasteners, cables or supports. To avoid possible severe or fatal injury, have any such work performed by a trained door systems technician using proper tools and instructions.

12. On electrically operated doors, pull down ropes must be removed and locks must be removed or made inoperative in the open (unlocked) position.

13. Top section of door may need to be reinforced when attaching an electric opener. Check door and/or opener manufacturer’s instructions.

14. VISUALLY inspect door and hardware monthly for worn and or broken parts. Check to ensure door operates freely.

15. Test electric opener’s safety features monthly, following opener manufacturer’s instructions.

16. NEVER hang tools, bicycles, hoses, clothing or anything else from horizontal tracks. Track systems are not intended or designed to support extra weight.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

After installation is complete, fasten this manual

near garage door.

Page 3

Package Contents

8000 Series, Model 46

TorqueMaster® - Single and Double Spring

Installation Instructions and Owner’s Manual

Portland Source Plant

(2) HORIZONTAL TRACK WITH ATTACHED HORIZONTAL ANGLE RH/LH

JAMB BRACKETS

(AS REQUIRED)

NOTE: DEPENDING ON THE DOOR MODEL, SOME PARTS LISTED WILL NOT BE SUPPLIED IF NOT NECESSARY.

REAR SUPPORTS MAY OR MAY NOT BE INCLUDED WITH YOUR DOOR.

(1) TORQUEMASTER® SPRING TUBE

(2) FULLY ADJUSTABLE

RH/LH FLAGANGLES

DOOR SECTIONS (AS REQUIRED)

LUBRCIATING OIL

(AS REQURED)

RIGHT AND LEFT

BOTTOM BRACKETS

DRIVE GEARS

(AS REQUIRED)

(1) LOOSE WINDING SHAFT

(SINGLE SPRING ONLY)

(2) TOP BRACKET

BASES

(2) TOP BRACKET

SLIDES

#1, #2, #3 & #4

HINGES (AS REQURED)

RIGHT & LEFT DRUM WRAPS

MANUAL

RIGHT & LEFT

END BRACKETS

(1) STEP PLATE

OUTSIDE

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

RIGHT AND LEFT CABLE

DRUM ASSEMBLIES

ROLLERS

(AS REQUIRED)

U-BAR

(AS REQUIRED)

COUNTER GEAR(S)

(AS REQUIRED)

COUNTER COVER(S)

(AS REQUIRED)

(1) CENTER BRACKET

ASSEMBLY

(2) LIFT HANDLES

& SPACERS

#6 SCREW EYE AND PULL

ROPE (IF INCLUDED)

(2) VERTICAL

RH/LH TRACK

IDRIVE

OPERATOR

(SOLD SEPARATELY)

WEATHER SEAL &

NAILS (IF INCLUDED)

(1) STEP PLATE

INSIDE

Page 4

Package Contents Continued...

(2) 3/8”- 16

HEX NUTS

1/4”- 20 X 5/8”

CARRIAGE BOLTS

(AS REQUIRED)

1/4”-20 X 11/16” SELF DRILLING

SCREWS (AS REQUIRED)

1/4”- 20 HEX NUTS

(LIFT HANDLE)

1/4”- 20 X 7/8” SELF DRILLING

Door Section Identification

1/4”- 20 FLANGED HEX

NUTS (AS REQUIRED)

SCREWS (AS REQUIRED)

(2) 1/4” X 2-1/2” CARRIAGE BOLTS (LIFT HANDLE)

(2) #10 PHILLIPS

HEAD SCREWS

(2) 3/8”- 16 X 3/4”

HEX HEAD BOLTS

1/4”- 14 X 5/8” SELF TAPPING

SCREWS (AS REQUIRED)

5/16” X 2” HEX HEAD LAG SCREWS

(AS REQUIRED)

(2) #8 X 1-5/8” SELF TAPPING SCREWS

(2) 1/4”- 20 X 5/8”

TAMPER-RESISTANT

SCREWS

(STEP PLATE)

Tools Needed:

The BOTTOM SECTION can be identiﬁed by the factory attached bottom astragal and the bottom bracket warning labels on each end stile. This section is always the 1st section on four and ﬁve section doors.

The LOCK SECTION may have a yellow and black warning label on the right side of the section. This section is always the 2nd section on four and ﬁve section doors.

The INTERMEDIATE I SECTION may have a warning label attached to either right or left hand endstile of the section. This section is always the 3rd section from the bottom of the door.

The INTERMEDIATE II SECTION is always the 4th section on ﬁve section door.

The TOP SECTION is always the 4th section on four section door and the 5th section on ﬁve section door.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

TOP SECTION

INTERMEDIATE II SECTION (5 SECTION DOORS ONLY)

WARNING LABEL

INTERMEDIATE I SECTION

LOCK SECTION

BOTTOM BRACKET

WARNING LABELS

ASTRAGAL

BOTTOM SECTION

Page 5

Tools Required

PHILLIPS HEAD SCREWDRIVER

(2) SAWHORSES

PENCIL

1/2” & 9/16”

SOCKET

9/32”, 1/2”, 5/16”,

3/16” & 1/8” DRILL BITS

Removing An Old Door

PLIERS/WIRE CUTTERSRATCHET WRENCHPOWER DRILL

TAPE MEASURELEVEL (2) VICE CLAMPS

SAFETY GLASSESFLAT TIP SCREWDRIVER

3/8”, 7/16” SOCKET

DRIVER

1/4”, 3/8”, 7/16”, 1/2” &

9/16” WRENCHES

GLOVES

PRE-INSTALLATION

HAMMERVICE GRIPS

STEP LADDER

WARNING

IF YOUR COUNTERBALANCE SYSTEM IS OTHER THAN THOSE MENTIONED, DO NOT ATTEMPT TO WORK ON IT, BUT HAVE A QUALIFIED DOOR AGENCY PERFORM THE WORK. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.

WARNING

DISCONNECT AND REMOVE ANY ELECTRIC OPENER PRIOR TO REMOVAL OF COUNTERBALANCE SYSTEMS TO PREVENT UNINTENDED DOOR OPERATION. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.

WARNING

COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.

WARNING

IF YOU HAVE BACK PROBLEMS DO NOT ATTEMPT THIS, OR SEVERE INJURY COULD RESULT

WARNING

REMOVING AN EXISTING DOOR CAN BE DANGEROUS. FOLLOW INSTRUCTIONS ON PAGES 6-10 “REMOVING AN OLD DOOR/PREPARING THE OPENING” CAREFULLY, OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.

If you have an existing door, follow the instructions below to identify which counterbalance removal is necessary. The process of

removing an existing door begins by identifying it’s counterbalance system. If you are not removing an existing door, proceed to

PREPARING THE OPENING on page 10. Generally, you will ﬁnd three (3) types of counterbalance systems: Extension Spring,

Wayne-Dalton® exclusive TorqueMaster® and Torsion counterbalance system, see pages 6-9.

For more technical information regarding the opening preparation, installation and use of your garage door and opener, you can go to

www.dasma.com and click on Publications and then Technical Data Sheet.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Page 6

Torsion Spring Removal

For Standard Lift

Tools Needed:

Recommended

tools from

page 5

WARNING

FAILURE TO USE APPROVED WINDING BARS CAN CAUSE SPRING ENERGY TO BE RELEASED SUDDENLY, RESULTING IN SEVERE OR FATAL INJURY.

WARNING

COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.

Do not release the torsion spring tension unless you are a qualiﬁed and experienced door technician. Instead have a professional door agency release the tension.

Step 1: Close the door and place vice clamps on the back legs of both vertical tracks, above the third roller to prevent the door from lifting as you unwind the springs. Use only approved winding bars available from your dealer. Do not use undersized steel rods, screw drivers or anything else to unwind the springs. Position the ladder just off to the side of the winding cone. The winding cone should be easy to reach without putting your body directly in front of it.

TORSION SPRING ASSEMBLY

WINDING CONE

APPROVED WINDING BAR

Step 2: Insert a winding bar into one of the holes in the winding cone. Exert upward pressure. Using caution, loosen the two (2) set screws in the winding cone. Be prepared to support the full torsional force of the spring when the set screws are loosened.

Step 3: Once set screws are loose, slowly and carefully lower the winding rod until it rests against the door. Insert other winding bar into the upper hole. Push up and remove lower bar. Carefully lower upper winding bar, 1/4 turns at a time until it rests against the door. Repeat process until all tension is relieved. If your door is equipped with two (2) torsion springs, follow the same procedure to relieve tension on the second spring.

Step 4: Remove vice clamps from tracks, unbolt torsion shaft assembly and remove from work area.

NOTE: Continue with “P4” on page 9 after completing this step.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

SET SCREWS

FIRMLY HOLD WINDING BARS AND

CAUTIOUSLY LOOSEN SET SCREWS

Page 7

TorqueMaster® Spring Removal

LOOSEN LOCK

NUT

COUNTER

GEAR/ COVER

Tools Needed:

A TorqueMaster® spring system can be identiﬁed by the end brackets. For single spring applications, the right hand end

Recommended

tools from

page 5

bracket will always have a drive gear, counter gear, counter cover, and a winding bolt head. The left hand end bracket will have no gears, counter cover, or winding bolt head. The hole for the winding bolt head will be plugged.

For double springs, both the right hand and left hand end brackets will always have a drive gear, counter gear, counter cover and a winding bolt head.

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT.

Step 1: If you have a black counter cover:

Place a mark on the drive gear tooth and an adjacent mark on the right hand end bracket (Fig. 1). Loosen the lock nut using a 7/16” wrench and continue with step 2. If you have a gray counter cover: Loosen the lock nut using a 7/16” wrench and continue with step 2.

Step 2: Using an electric drill (High torque / gear reduced to 1300 rpm preferred) with a 7/16” hex head driver, unwind the right hand winding bolt head counterclockwise (Fig. 2) and count the number of turns the mark on the drive gear passes the adjacent mark on the end bracket. Referencing the chart below, by door height, stop unwinding the spring once the counted turns have reached the listed number of turns.

6’-0” Door Height = 14 turns 6’-3” Door Height = 14 1/2 turns 6’-5” Door Height = 15 turns 6’-6” Door Height = 15 turns 6’-8” Door Height = 15 1/2 turns 6’-9” Door Height = 15 1/2 turns 7’-0” Door Height = 16 turns 7’-3” Door Height = 16 1/2 turns 7’-6” Door Height = 17 turns 7’-9” Door Height = 17 1/2 turns 8’-0” Door Height = 18 turns

CAUTION:

DO NOT USE IMPACT GUN TO

UNWIND SPRINGS.

IMPORTANT: DO NOT REFERENCE THE COUNTER COVER WHEN COUNTING THE NUMBER OF TURNS BEING UNWOUND ON TH E SP R I N G, BU T F O L L O W THE INSTRUCTIONS ABOVE.

Step 3: Verify that spring tension has been released by pulling the counterbalance cable on the right hand cable drum away from the header (Fig. 3). If spring tension has been released, the cable will be loose. In addition, the TorqueMaster® Spring Tube should be free to rotate in either direction.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

RIGHT HAND

CABLE DRUM

TORQUEMASTER®

SPRING TUBE

PRY COUNTER GEAR

AND COUNTER COVER

FROM END BRACKET

USING FLAT TIP

SCREWDRIVER

Fig. 1

Fig. 2

Fig. 3

Fig. 4

RIGHT HAND

END BRACKET

PRE-INSTALLATION

PLACE MARK ON END BRACKET

AND DRIVE GEAR TOOTH

BEFORE UNWINDING SPRINGS

END BRACKET

RIGHT HAND

WINDING BOLT HEAD

ELECTRIC DRILL WITH 7/16” HEX

DRIVER (DO NOT

USE IMPACT

GUN)

CHECK CABLE

TENSION

COUNTER

GEAR

COUNTER

COVER

Page 8

TorqueMaster® Spring

Removal continued...

Tools Needed:

(Spring Tube should be free to rotate in either direction.) If the counterbalance

Recommended

tools from

page 5

cable is still taut and the TorqueMaster® Spring Tube is difﬁcult to rotate, that is an indication that spring tension still exists on the left hand spring. Repeat Steps 1 and 2 for releasing spring tension on the left hand side.

Step 4: Using a ﬂat tip screwdriver, pry the counter gear and counter cover from the right hand end bracket (Fig. 4 on previous page). Discard the counter gear and counter cover. On double spring applications, repeat for left hand side.

Step 5: Remove the upper 5/16” x 1-5/8” lag screw from the right hand end bracket (Fig. 5). Attach locking pliers to the upper portion of the end bracket and hold the housing steady while removing the lower 5/16” x 1-5/8” lag screw and #10 x 1/2” phillips head screw from the end bracket (Fig. 6).

Step 6: Holding the right hand end bracket steady with locking pliers, carefully pry the end bracket and drive gear off the winding shaft using a ﬂat tip screwdriver (Fig. 7).

CAUTION: THE WINDING SHAFT MAY ROTATE WHEN REMOVING THE END BRACKET AND DRIVE GEAR.

Step 7: Repeat Step 4 for the left hand side. Holding the left hand end bracket steady with locking pliers, carefully pry the end bracket off the winding shaft using a ﬂat tip screwdriver (Fig. 7).

Step 8: Remove the two (2) lag bolts attaching the center bracket assembly to the header board (Fig. 8).

Step 9: Lift the right hand side of the TorqueMaster

Spring Tube and slide the cable drum off. Realign the groove in the winding shaft with the round notch in the ﬂagangle and drape the counterbalance cable with drum over the ﬂagangle. Lift the left hand side of the TorqueMaster® Spring Tube and slide the cable drum and winding shaft off (Fig. 9). Drape the counterbalance cable with drum over the ﬂagangle. Lift the TorqueMaster® spring assembly off the ﬂagangles and out of the doorway. Unhook the counterbalance cables from the bottom brackets and remove all parts from the work area.

NOTE: The cable drums may be difﬁcult to remove. If so, twist the cable drum to aid in removal.

NOTE: Continue with “P4” on page 9 after completing this step.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

REMOVE TOP

LAG SCREW

REMOVE

BOTTOM LAG

SCREW

CENTER

BRACKET

ASSEMBLY

(2) 5/16” X 1-5/8”

HEX HEAD LAG

SCREWS

Fig. 8

Fig. 5

USE LOCKING PLIERS

TO HOLD END BRACKET

REMOVE #10

PHILLIPS HEAD

SCREW

Fig. 6

HOLD THE

END BRACKET

STEADY WITH

LOCKING PLIERS

PRY END BRACKET FROM WINDING

SHAFT USING A FLAT TIP SCREW

DRIVER AND LOCKING PLIERS

Fig. 7

REMOVE CABLE DRUM AND

WINDING SHAFT

LIFT

TORQUEMASTER®

SPRING TUBE

OFF FLAGANGLE

DRAPE CABLE ACROSS

TOP OF FLAGANGLE

Fig. 9

Page 9

Tools Needed:

Recommended

tools from

page 5

Extension Spring Removal

Step 1: Raise the door to the fully open

position and place vice clamps to the back legs of both vertical tracks, below the bottom rollers to prevent the door from falling. By opening the door you release most of the spring tension. Carefully unfasten the S-hook from the horizontal angle. Remove cable, sheave and extension spring. Repeat for the other side. If safety cables are running through the extension springs, remove them also. Remove parts from work area.

Step 2: Holding door in the open position, remove the vice clamps, be prepared to support the entire weight of the door. Garage doors can weigh 200-400 pounds.

With assistance, carefully lower the door, by grasping the door ﬁrmly by it’s lift handles. Do not place ﬁngers or hands near joints, between sections, or between bottom of door and ﬂoor. Otherwise, severe injury could result.

REMOVE LAG SCREW

FROM SAFETY CABLE (IF

INSTALLED). REPEAT FOR

OPPOSITE SIDE.

BOTTOM SECTION

(DOOR OPEN)

PRE-INSTALLATION

CAREFULLY REMOVE “S”

HOOK AND COUNTREBALANCE

CABLE (REPEAT FOR THE

OPPOSITE SIDE)

HORIZONTAL ANGLE

Tools Needed:

Recommended

tools from

page 5

NOTE: Continue with “P4” on page 9 after completing this step.

Removing the Old Door

Having removed the counterbalance system, the door can now be disassembled.

Start by ﬁrst removing the top row of hinges.

With assistance, hold the top section to keep it from falling and remove the top brackets. With assistance, lift the top section out of the opening and remove it from the work area. Repeat for all remaining sections.

After door is disassembled, unbolt both track assemblies from the jambs and remove all material from the work area. You can neatly dispose of the old door by placing it in the carton of your new door.

TOP BRACKET

HORIZONTAL TRACK

HINGES

Clean up area and complete “Preparing the Opening” “P5” on page 10 before installing the new door.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Page 10

Preparing the Opening

HEADER BOARD 2” X 6” LUMBER

PREFERRED

SUITABLE MOUNTING

SURFACE 2” X 6”

LUMBER MINIMUM

Tools Needed:

Recommended

tools from

page 5

WARNING

FAILURE TO

SECURELY ATTACH A SUITABLE MOUNTING PAD TO STRUCTURALLY SOUND FRAMING COULD CAUSE SPRINGS TO VIOLENTLY PULL MOUNTING PAD FROM WALL, 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.

For detailed technical information regarding the opening preparation, refer to the DASMA Technical Data Sheet TDS #161 Connecting Garage Door Jambs to Building. Framing located at www.dasma.com.

The inside of your garage door opening should be framed with wood jambs and header. It is recommended that 2” x 6” lumber be used. The jambs must be plumb and the header level. The jambs should extend a minimum of 12” (305 mm) above the top of the opening for TorqueMaster For low headroom applications, the jambs should extend to the ceiling height. Minimum side clearance required, from the opening to the wall, is 3-1/2”.

IMPORTANT: CLOSELY INSPECT JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD FOUND NOT TO BE SOUND, MUST BE REPLACED.

The jambs and header must be securely fastened to sound framing members. Do not place jambs and header over drywall, paneling, etc. Heads of fasteners must be ﬂush or below jamb and header surface, so they do not interfere with installation or operation of new door.

TorqueMaster surface must be ﬁrmly attached to the wall, above the header at the center of the opening.

counterbalance systems, a suitable mounting

counterbalance systems.

HEADER

DOOR HEIGHT

LEVEL HEADER

PLUMB JAMBS

DOOR

WIDTH

HEADROOM

BACKROOM

JAMB

WEATHER SEAL

JAMB

The mounting surface must be 2” x 6” lumber minimum (Select southern yellow pine lumber. Do not use lumber marked as spruce-pine-fur or SPF).

The mounting surface must be securely attached to block or concrete wall with four (4) 3/8” masonry anchors or four (4) 5/16” x 4” lag screws for a wood structure.

NOTE: Drill a 3/16” pilot hole in the mounting surface to avoid splitting the lumber. Do not attach the mounting surface with nails.

WEATHER SEAL: Fit weather seal (may not be included) to ﬁt the jambs and header. Align the edge of the weather seals an 1/8” to 1/4” inside the edge of the opening. Temporarily nail the weather seal to the jambs to keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart. NOTE: Do not permanently attach weather seal to the jambs at this time. Permanent installation will be done in Step 34.

HEADROOM REQUIREMENT: Headroom is deﬁned as the space needed above the top of the door for tracks, springs, etc. to allow the door to open properly. If the door is to be motor operated, 2-1/2” (64 mm) of additional headroom is required.

NOTE: 6” LHR Conversion Kit is available for 12” Radius only. Contact your local Wayne-Dalton

BACKROOM REQUIREMENT: Backroom is deﬁned as the distance needed from the opening back into the garage to allow the door to open fully.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

dealer.

JAMB

1/8” TO 1/4”

HEADROOM REQUIREMENT

TRACK TYPE

10”, 12” 10”

14” 12”

3-1/2” LHR 6”

LHR Kit 6 1/2”

TorqueMaster

BACKROOM REQUIREMENT

DOOR

HEIGHT

6’5” 10”, 12”, 14” Radius 89” 120” 6’5” Low Headroom 101” 120” 6’6” 10”, 12”, 14” Radius 90” 120” 6’6” Low Headroom 102” 120” 7’0” 10”, 12”, 14” Radius 96” 120” 7’0” Low Headroom 108” 120” 7’6” 10”, 12”, 14” Radius 102” 132” 7’6” Low Headroom 114” 132” 8’0” 10”, 12”, 14” Radius 108” 132” 8’0” Low Headroom 120” 132”

TRACK

MANUAL

LIFT

MOTOR

OPERATED

WEATHER

SEAL

Page 11

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 is recommended that 5/16 x 2” lag screws be pilot drilled using a 3/16” drill bit, and 1/4 x 2” lag screws and 1/4 x 1-1/2” lag screws be pilot drilled using a 1/8” drill bit, prior to fastening.

INSTALLATION

Tools Needed:

None

Attaching Fully Adjustable Flagangle to Vertical Track

NOTE: If you have riveted track, skip

this step.

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. Secure the ﬂange nuts after ﬂagangle spacing is complete (Step 14).

FULLY ADJUSTABLE

FLAGANGLE

(2) 1/4”- 20 X 5/8”

CARRIAGE BOLTS

(2) 1/4”- 20

FLANGE HEX

NUTS

VERTICAL

TRACK

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Page 12

Installing Fully Adjustable Jamb

Brackets

FULLY ADJUSTABLE

JAMB BRACKET

Tools Needed:

None

NOTE: If you have riveted track, skip this step.

To attach the bottom jamb bracket, JB-2, locate the ﬁrst set of quick install features of the vertical track. Align the slot in the jamb bracket with the slot above the quick install features in the vertical track. The long side of the bracket is placed against the track. Fasten the jamb bracket ﬁnger tight, using (1) 1/4”- 20 x 5/8” carriage bolt and (1) 1/4”- 20 ﬂange hex nut.

To attach the top jamb bracket, JB-3, locate the third set of quick install features of the vertical track. Align the slot in the jamb bracket with the slot above the quick install features in the vertical track. The long side of the bracket is placed against the track. Fasten the jamb bracket ﬁnger tight, using (1) 1/4”- 20 x 5/8” carriage bolt and (1) 1/4”- 20 ﬂange hex nut.

JAMB BRACKET

(1) 1/4”-20

FLANGE

HEX NUT

JAMB BRACKET

QUICK INSTALL

SLOT

QUICK INSTALL

FEATURE

3RD SET

(1) 1/4”- 20 X 5/8”

CARRIAGE BOLT

VERTICAL

TRACK

1ST SET

VERTICAL

TRACK

Bottom Bracket

Tools Needed:

Power Drill

7/16” Socket

Driver

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NOTE: For door section identiﬁcation see page 4.

Align the center hole of bottom bracket with hole #3 in the end stile of bottom section. Fasten with (2) 1/4”-20 x 11/16” self drilling screws and (1) 1/4”-20 x 5/8” tamper-proof self drilling screw as shown.

Repeat for other side.

NOTE: Only doors provided to professional installers, who have required tools will be supplied with a tamper-resistant fastener. Use a 1/4”-20 x 11/16” self drilling screw in the bottom bracket, if not provided with a tamper-resistant screw.

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2 1

END STILE HOLE

PATTERN

(LEFT SIDE IS SHOWN.

RIGHT SIDE IS

OPPOSITE.)

LEFT HAND

BOTTOM BRACKET

#3 HOLE

BOTTOM BRACKET

CENTER HOLE

BOTTOM BRACKET

(2) 1/4”-20 X 11/16”

SELF DRILLING

SCREWS

(1) 1/4”- 20 X 5/8”

TAMPER-RESISTANT

SELF DRILLING

SCREW

WARNING

LABEL

BOTTOM SECTION

Page 13

Tools Needed:

None

Drums

IMPORTANT: RIGHT AND LEFT HAND IS

ALWAYS DETERMINED FROM INSIDE THE GARAGE LOOKING OUT.

NOTE: For door section identiﬁcation see page 4.

TorqueMaster® counterbalance drums are marked right and left hand.

Uncoil the counterbalance cables and 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 into bottom bracket of the bottom section.

LEFT HAND

TORQUEMASTER®

COUNTERBALANCE DRUM

BOTTOM SECTION

Repeat for other side.

NOTE: Verify astragal (bottom seal) is aligned with door section. If there is more than 1/2” excess astragal on either side, trim astragal even with door section.

MILFORD PIN

INSTALLATION

COUNTERBALANCE

CABLE

BOTTOM

BRACKET

MILFORD PIN

ROLLER

HINGE TUBE

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BOTTOM SECTION

ASTRAGAL

Page 14

Hinges

Tools Needed:

Power Drill

7/16” Socket

Driver

Locate the lower (numbered) leaf of the #1 end hinges and required center hinges over the #1 and #4 holes in the end stiles for the end hinges and the pre-punched holes in the center stile(s) for the center hinges at the top of the section.

NOTE: The #1 hinges serve as end hinges on the bottom section. The #1 hinges also serve as center hinges at all center hinge locations.

Secure the hinges to the section using (2) 1/4”-14 x 5/8” self tapping screws on each hinge leaf.

Insert roller into appropriate hinge tube.

Repeat for all other sections using the #2 end hinges on the second (lock section) and the #3 end hinges on the third section (intermediate section).

NOTE: #4 End hinges are used on fourth section of ﬁve section doors.

END STILE HOLE

PATTERN

(LEFT SIDE IS SHOWN.

RIGHT SIDE IS

OPPOSITE.)

CENTER STILE

HOLE PATTERN

ROLLER

PLACEMENT

#1 HINGE #2 END HINGE

ROLLER

PLACEMENT

ROLLER

PLACEMENT

#3 END HINGE #4 END HINGE

IMPORTANT: WHEN PLACING ROLLERS INTO END HINGES NUMBER 2 AND HIGHER, THE ROLLER GOES INTO THE TUBE FURTHEST AWAY FROM SECTION.

IMPORTANT: ONCE FASTENER IS SNUG AGAINST HINGE LEAF, TIGHTEN AN ADDITIONAL 1/4 TO 1/2 TURN TO RECEIVE MAXIMUM DESIGN HOLDING POWER.

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#1 HOLE

#4 HOLE

END STILE

END HINGE PLACEMENT

CENTER STILE

CENTER HINGE PLACEMENT

HINGE

(2) 1/4”-14 X 5/8”

SELF TAPPING

SCREWS

HINGE

(2) 1/4”-14 X 5/8”

SELF TAPPING

SCREWS

Page 15

Top Bracket

#6 HOLE

TOP BRACKET

BASE

TOP SECTION

Tools Needed:

Power Drill

7/16” Socket

Driver

Align upper-center hole of top bracket base with #6 hole in the end stile (See end stile hole layout). Loosely secure with (1) 1/4”- 20 x 7/8” self drilling screw.

Ensure top bracket is level and aligned with edge of section. Secure with (4) 1/4”- 20 x 7/8” self drilling screws, one in each corner of the top bracket base.

Remove the 1/4”- 20 x 7/8” self drilling screw installed in the upper-center hole of the top bracket base.

Loosely hand tighten top bracket slide with (1) 1/4”- 20 x 5/8” carriage bolts and (1) 1/4”- 20 ﬂange hex nuts. Insert roller and repeat for other side.

NOTE: For doors with a glazed top section (windows). Top strut may be mounted between #2 and #6 holes before top bracket is installed. See Step 8 for U-Bar installation

END STILE

(1) 1/4”- 20 X 5/8”

CARRIAGE BOLT

(4) 1/4-20 X 7/8” SELF

DRILLING SCREW

(1) 1/4”- 20

FLANGE HEX

NUT

TOP

BRACKET

SLIDE

TOP SECTION

TOP

BRACKET

BASE

TOP

BRACKET

ASSEMBLY

TOP SECTION

INSTALLATION

Step Plate

Tools Needed:

Pencil

Power Drill

5/16” Drill Bit

Phillips

Screwdriver

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NOTE: For alternative step/ lift plate installation, see “Step Plate” in the optional installations on page 34.

Locate the center most stile on the bottom section of the door. Using the pre-punched holes at the bottom of the stile as a template, drill (2) 7/32” dia. holes through the section. Using the previously drilled holes as a guide, enlarge the holes from outside the door to 7/16” diameter. Assemble the outside and inside step/lift plates to the section using (2) #8 x 1-5/8” screws.

NOTE: Do not drill through or enlarge holes on the inside of the door.

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BOTTOM SECTION

INSIDE STEP

PLATE

(2) #8 X 1-5/8” SELF

TAPPING SCREWS

OUTSIDE

STEP PLATE

STEP PLATE OUTSIDE

BOTTOM SECTION

OUTSIDE

STEP PLATE

BOTTOM SECTION

INSIDE STEP

PLATE

STEP PLATE INSIDE

Page 16

U-BAR PLACEMENT FOR TOP SECTION

U-Bar

Tools Needed:

Power Drill

7/16” Socket

Driver

NOTE: For door section identiﬁcation see page 4.

INSTALLATION ON THE TOP SECTION:

Doors 14’0” wide and over, locate U-Bar above top bracket and secure with (2) 1/4”-20 x 7/8” self drilling screws at each end and center stile location.

NOTE: 3” U-Bars are now supplied with all glazed doors starting at 14’0” width.

INSTALLATION ON ALL OTHER SECTIONS:

NOTE: All U-Bars are placed at the top

of the section, against the bottom of the hinges, for the intermediate, lock and bottom sections.

NOTE: For doors 16’1” to 18’0” that have a glazed intermediate section, the U-bar needs to be placed on the glazed intermediate section.

NOTE: All WayneMark™ 8200 doors 14’0” to 16’0” wide, 6’0” to 7’0” high (4 section high only) are now supplied with a 2” U-Bar for the top of the bottom section.

Place the U-Bar on the section against the bottom of the hinges. Center the U-Bar side to side on the section at the location shown, and secure to the section using (2) 1/4”-20 x 7/8” self drilling screws at each end and center stile location.

U-BAR

(2) 1/4”- 20 X 7/8”

SELF DRILLING

SCREWS

TOP

SECTION

SIDE PROFILE

DOOR

SECTION

U-BAR PLACEMENT FOR BOTTOM, LOCK AND INTERMEDIATE SECTIONS

HINGE

U-BAR

BOTTOM SECTION

U-BAR

U-BAR PLACEMENT FOR TOP SECTION

TOP SECTION

U-BAR

TOP

BRACKET

ASSEMBLY

HINGE

U-BAR

TOP

SECTION

U-BAR

Model 46 U-Bar Schedule

Door Width 4 Section 5 Section

8’-0” to 14’-11” N/A N/A

15’-0” to 16’-0” (1) 2” U-Bar (1) 2” U-Bar

16’-1” to 18’-0” (3) 2” U-Bar (3) 2” U-Bar

8000 Series U-Bar Schedule

Door Width 4 Section 5 Section

8’-0” to 13’-11” N/A N/A

14’-0” to 14’-11” (1) 2” U-Bar (1) 2” U-Bar

15’-0” to 16’-0” (1) 2” U-Bar (1) 2” U-Bar

16’-0” to 18’-0” (3) 2” U-Bar (3) 2” U-Bar

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(2) 1/4”- 20 X 7/8”

SELF DRILLING

SCREWS

ATTACHING END STILE

BOTTOM SECTION

ATTACHING CENTER STILE

(2) 1/4”- 20 X 7/8”

SELF DRILLING

SCREWS

Page 17

Tools Needed:

Tape Measure

Pencil

Lift Handle

NOTE: Doors with a Keyed lock do not require this lift

handle.

NOTE: For door section identiﬁcation see page 4.

LOCK

SECTION

LIFT

HANDLE

4”

LOCK

SECTION

Power Drill

9/32” Drill Bit

1/2” Drill Bit

1/4” Wrench

Locate the inside center stile or the desired lift handle location on the lock (2nd) section of the door. Position the lower hole in the lift handle 4” from the bottom of the second section.

IMPORTANT: The distance between the step/lift plate and the middle of the lift handle must be 20” minimum to 30” maximum. If needed reposition upper lift handle to stay within the required dimension.

Drill (2) 9/32” dia. holes through section. Enlarge the holes from outside the door to 1/2” dia.

Assemble the outside and inside lift handle to the section using (2) 1/4” x 2-1/2” carriage bolts, ( 2) 1/4”- 20 hex nuts and (2) spacers.

NOTE: Do not drill through or enlarge holes on the inside of the door.

Bottom Section

(2) SPACERS

BOTTOM SECTION

LIFT HANDLE OUTSIDE

LIFT HANDLE INSIDE

(2) 1/4” X 2-1/2”

CARRIAGE BOLTS

LOCK

SECTION

LIFT

HANDLE

BOTTOM SECTION

(2) 1/4”-20

HEX NUT

LIFT

HANDLE

20” TO 30”

BOTTOM SECTION

INSTALLATION

Tools Needed:

Level

Wood Shims

Before installing the bottom section, the weather seal (may not be included) must be installed (see PREPARING THE OPENING on page 10)

Center the bottom section in the door opening. Level section using wooden shims under the bottom astragal if necessary. Hold the section in the opening while attaching vertical tracks.

JAMB

HEADER

WEATHER

SEAL

LEVEL

JAMB

BOTTOM SECTION

WOODEN

SHIMS

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Page 18

VERTICAL TRACK

Tools Needed:

3/16” Drill Bit

Power Drill

7/16” Socket

Driver

Tape Measure

Level

Vertical Track

IMPORTANT: THE TOPS OF THE VERTICAL

TRACKS MUST BE LEVEL FROM SIDE TO SIDE. IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT, THE VERTICAL TRACK ON THE SHIMMED SIDE, MUST BE RAISED THE HEIGHT OF THE SHIM.

Position the left hand vertical track assembly over the rollers of the bottom section. Make sure the counterbalance cable is located between the rollers and the door jamb. Drill 3/16” pilot holes for the lag screws.

If installing an idrive® opener: Raise the track so that the bottom of the track is 1” higher than the bottom of the door.

For non-idrive® operated garage doors:

Install the track so that it is aligned with the bottom of the door.

Loosely fasten jamb brackets and ﬂagangle to the jamb using 5/16” x 1-5/8” hex head lag screws. Tighten bottom jamb bracket lag screw securely to the jamb to maintain 5/8” spacing. Hang cable drum over ﬂagangle. Repeat for the right side.

JAMB

BRACKET

FLAGANGLE

VERTICAL

TRACK

ASSEMBLY

BOTTOM SECTION

5/16 X 2” HEX

HEAD LAG

SCREWS

5/8”

ROLLER

FLAGANGLE HOLE

SELECTION

JAMB BRACKET

5/16” X 2”

HEX HEAD

LAG SCREW

Tools Needed:

Power Drill

7/16” Socket

Driver

Stacking Sections

NOTE: For door section identiﬁcation

see page 4.

NOTE: Make sure hinges are ﬂipped down, when stacking another section on top.

LOCK SECTION

With assistance, lift second section and guide rollers into the vertical tracks. Keeping the ends of the sections aligned, install remaining section(s), except top section, in same manner. Now ﬂip up hinge leaf, and fastening center hinges ﬁrst, and end hinges last, using (2) 1/4”- 14 x 5/8” self tapping screws. Repeat for other section(s) except top section.

NOTE: Install lock at this time (sold separately) See instructions in OPTIONAL SIDELOCK INSTALLATION on page 33.

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Page 19

Top Section

NAIL

DOOR WIDTH

+3-3/8” TO 3-1/2”

Tools Needed:

Hammer

Nail

Power Drill

7/16 Socket

Driver

Place the top section in the opening and vertically align with lower sections.

Temporarily secure the top section by driving a nail in the header near the center of the door and bending it over the top section.

Now ﬂip up the hinge leaf against section, fastening center hinges ﬁrst and end hinges last.

INSTALLATION

Tools Needed:

Power Drill

7/16 Socket

Driver

Tape Measure

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When installing a door with a TorqueMaster® counterbalance system, vertical track alignment is critical. Position ﬂagangle between 1-11/16” (43 mm) to 1-3/4” (44 mm) from the edge of the door. Tighten the bottom lag screw. Flagangles must be parallel to the door sections. Repeat for opposite side.

IMPORTANT: THE DIMENSION BETWEEN THE FLAGANGLES MUST BE DOOR WIDTH PLUS 3-3/8” (86MM) TO 3-1/2” (89 MM) FOR SMOOTH, SAFE DOOR OPERATION.

Complete the vertical track installation by securing the center jamb bracket(s) and tightening the other lag screws. Push the vertical track against the rollers so that the rollers are touching the deepest part of the curved side of the track (see illustration). Tighten all the track bolts and nuts. Repeat for opposite side.

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Vertical Track

VERTICAL TRACK

FLAGANGLE

ROLLER

ROLLER AGAINST VERTICAL TRACK

1-11/16” TO 1-3/4”

TOP SECTION

Page 20

FLAGANGLE

Horizontal Track

Tools Needed:

9/16” Socket

Ratchet Wrench

9/16” Wrench

Level

To install horizontal track, place the curved end over the top roller. Align the bottom of the horizontal track with the vertical track. Hand tighten the horizontal track to the ﬂagangle with (2) 1/4”-20 x 5/8” carriage bolts and (2) 1/4”-20 ﬂange hex nuts.

Level the horizontal track assembly and bolt the horizontal angle to the slot in the ﬂagangle using (1) 3/8”- 16 x 3/4” hex head bolt and (1) 3/8”-16 hex nut. Repeat for other side. Remove the nail that was temporarily holding the top section in place, installed in Step 13.

IMPORTANT: FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION.

WARNING

DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SE CURED AT REAR, AS OUTLINED IN STEP 34, OR DOOR COULD FALL FROM OVERHEAD POSI TION CAUSING SEVERE OR FATAL INJURY.

NOTE: If an idrive® opener will be installed, position horizontal tracks slightly above level.

(2) 1/4”- 20 X 5/8”

CARRIAGE BOLTS

(2) 1/4”-20 FLANGE

HEX NUTS

(1) 3/8-16 X 3/4”

HEX HEAD BOLT

FLAGANGLE

(1) 3/8”-16

HEX NUT

HORIZONTAL

ANGLE

Tools Needed:

7/16” Wrench

Adjusting Top Brackets

With horizontal tracks installed you can adjust the top brackets.

Vertically align the top section with the lower sections. Once aligned, position the top roller in the top bracket slide out against the horizontal track. Maintaining the slide’s position, tighten 1/4”- 20 ﬂange hex nut to secure the top bracket slide to the top bracket base.

Repeat for other side.

SECTION

CORRECT

SECTION

TOP

HORIZONTAL

TRACK

TOP ROLLER

TOP BRACKET

SLIDE

TOP

SECTION

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INCORRECT

Page 21

TorqueMaster® Spring Tube

Tools Needed:

None

TorqueMaster® springs come lubricated and pre-assembled inside the TorqueMaster 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.

spring tube. To install, lay

TORQUEMASTER®

SPRING TUBE

LABELED END

INSTALLATION

Tools Needed:

None

Center Bracket Bushing

NOTE: If you are installing an idrive®

opener on your garage door, skip this step and continue with Step 19.

NOTE: If you are not installing an idrive® opener on your garage door, you must install the center bracket bushing assembly. Follow these instructions for non-idrive® operated garage doors.

NOTE: If you are installing a DoorMaster™ opener, see optional DoorMaster™ Bracket installations on page 33, ﬁgure A.

Being cam shaped the center bracket bushing only ﬁts one way.

Slide the center bracket assembly towards the center of the torque tube, from the right side as shown.

NOTE: Upon completion of this step, continue with Step 20.

TORQUEMASTER

SPRING TUBE

CENTER

BRACKET

ASSEMBLY

TORQUEMASTER®

SPRING TUBE

CENTER BRACKET BUSHING

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Page 22

idrive® Installation

Tools Needed:

None

NOTE: See idrive® main installation and owner’s manual for idrive® parts.

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE GARAGE LOOKING OUT.

Lay the TorqueMaster® spring tube on the floor (inside garage) in front of the door with the labeled end to the left.

Look into the opener’s left side to ensure the left hand bearing and the internal (black) sleeve are aligned with the TorqueMaster® spring tube profile.

IMPORTANT: HOLD OPENER BY THE MAIN BODY. DO NOT HOLD BY THE MOTOR.

NOTE: Opener will not slide over the TorqueMaster® spring tube label. Attempting to slide opener over the left end of the TorqueMaster® spring tube can damage the internal electronics.

Once aligned, slide the opener onto the right hand end of the TorqueMaster® spring tube. As the right end of the TorqueMaster® spring tube enters the internal (black) sleeve, rotate the opener back and forth slightly to help aid alignment.

Continue sliding the opener onto the TorqueMaster® spring tube. Align the right hand bearing with the TorqueMaster® spring tube and slide the opener completely onto the TorqueMaster® spring tube until the TorqueMaster® spring tube exits the opener right hand bearing.

LEFT HAND SIDE

TORQUEMASTER

AND BEARING PROFILES ALIGNED

RIGHT HAND END

OF TORQUEMASTER

SPRING TUBE

MOTOR

RIGHT HAND SIDE TORQUEMASTER

SPRING TUBE AND

BEARING PROFILES

ALIGNED

NOTE: Do not force the opener onto the TorqueMaster® spring tube if misalignment occurs.

Continue sliding the opener to the center of the TorqueMaster® spring tube.

Plug the motor power cord into the opener.

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PLUG-IN MOTOR

POWER CORD

Page 23

Cable Drum Installation

GROOVE

Tools Needed:

None

Shake the TorqueMaster® spring tube gently to extend the winding shafts out about 5" on each side.

NOTE: For single spring applications, there will be no left hand spring in the TorqueMaster® spring tube.

Lift the TorqueMaster® spring tube and rest it on the top of the flagangles.

For idrive® operated doors: Orient TorqueMaster® spring tube so that back of opener is flat against header/ mounting surface.

NOTE: Cable drums are marked right and left hand. Cable drums and TorqueMaster® spring tube are cam shaped to fit together only one way.

To install the cable drum, slide the correct cable drum over the winding shaft until the cable drum seats against the TorqueMaster® spring tube. The winding shaft must extend past the cable drum far enough to expose the splines and the groove.

TORQUEMASTER

SPRING TUBE

WINDING

SHAFT

TORQUEMASTER

SPRING TUBE

SPLINES

RIGHT HAND

CABLE DRUM

RIGHT HAND

CABLE DRUM

FLAGANGLE

COUNTERBALANCE

CABLE

FLAGANGLE

WINDING

SHAFT GROOVE

ROUND

NOTCH

INSTALLATION

Align the winding shaft groove with the round notch in the flagangle.

For double spring applications: Repeat for opposite side.

For single spring applications: Insert the loose winding shaft into the left hand cable drum prior to sliding the cable drum over the TorqueMaster® spring tube.

NOTE: On single spring applications, take care in handling the loose winding shaft (left side) so that it does not slide back into the TorqueMaster® spring tube.

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TORQUEMASTER®

SPRING TUBE

RIGHT HAND

CABLE DRUM

Left Hand Side

Single Spring Application

LOOSE

WINDING

SHAFT

LEFT HAND

CABLE DRUM

GROOVE

ROUND

NOTCH

WINDING

SHAFT

TORQUEMASTER®

SPRING TUBE

ROUND NOTCH

Page 24

Tools Needed:

Drive Gear Installation

Beginning with the right hand side, lubricate entire circumference of the drive gear with the lubricating oil provided. Slide the drive gear onto the winding shaft splines until it touches the flagangle.

NOTE: On single spring applications, no drive gear is required on the left side.

FLAGANGLE

CABLE DRUM

WINDING

SHAFT

SPLINES

LUBRICATING

OIL

DRIVE

GEAR

Tools Needed:

Power Drill

3/16” Drill Bit

7/16”

Socket Driver

Phillips Head

Screwdriver

NOTE: If additional lubricating oil is needed, use “Dura Lube® Engine Oil Treatment”.

End Brackets

IMPORTANT: WARNING TAGS MUST BE

SECURELY ATTACHED TO BOTH END BRACKETS.

Slide the right hand end bracket over the drive gear and fasten to the flagangle using a #10 phillips head screw.

Drill 3/16” pilot holes into jamb for the lag screws. Secure end bracket and the flagangle to the jamb using (2) 5/16” x 2" hex head lag screws.

(2) 5/16” X 2”

HEX HEAD LAG

SCREWS

CABLE DRUM

END BRACKET

DRIVE GEAR

WINDING

SHAFT

WARNING

TAG

#10 PHILLIPS

HEAD

SCREW

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Page 25

Counter Installation

WINDING SHAFT INSIDE END BRACKET

Tools Needed:

None

Install the right side counter gear, with the missing tooth toward the outside and away from the end bracket. Press the counter gear onto the end bracket until snaps engage.

Select the right hand counter cover and align the hex of the counter cam with the end of the winding shaft. Also, align the “0” on the counter cover with the raised rib on the end bracket. Press the counter cover against the counter gear until it locks into place.

Repeat on left hand side for double spring applications.

NOTE: No drive gear, counter gear or counter cover is required on left hand side for single spring applications. Only an end bracket is needed.

IMPORTANT: AT THIS TIME DO NOT WIND COUNTERBALANCE SPRINGS!

RAISED RIB

HEX OF THE

COUNTER CAM

COUNTER

GEAR

MISSING

TOOTH

COUNTER

COVER

INSTALLATION

Tools Needed:

Power Drill

3/16” Drill Bit

7/16” Socket

Driver

Securing Center Bracket Bushing

NOTE: If you are installing an idrive® opener on your

garage door, skip this step and continue with Step 25.

NOTE: If you are not installing an idrive® opener on your garage door, you must install the center bracket bushing assembly. Follow these instructions for non-idrive® operated garage doors.

NOTE: If you are installing a DoorMaster™ opener, see optional DoorMaster™ Bracket installations on page 33, Figure B.

IMPORTANT: TORQUEMASTER® SPRING TUBE MUST BE LEVEL AFTER CENTER BRACKET ASSEMBLY IS FASTENED TO HEADER.

To locate the center bracket, mark the header halfway between the ﬂagangles and level the TorqueMaster® spring tube. Drill pilot holes into header for the lag screws. Fasten the metal bracket to the header using (2) 5/16” X 2” hex head lag screws.

CENTER

BRACKET

ASSEMBLY

(2) 5/16” X 2” HEX

HEAD LAG SCREWS

NOTE: Upon completion of this step, continue with Step 29.

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Page 26

Positioning Support Bracket

Tools Needed:

Power Drill

1/8” Drill Bit

7/16” Socket

Driver

Tape Measure

NOTE: See idrive® main installation and owners manual for idrive® parts.

NOTE: idrive® must be installed on a solid mounting surface.

Locate the mounting surface. The mounting surface is a vertical board running directly above the center of the door. Remove (2) 1/4”-20 flange nuts from bottom of opener.

NOTE: Do not discard flange nuts.

Place the support bracket underneath opener, to the right side of motor, centered on mounting surface. Using a tape measure, level the bottom of the TorqueMaster® spring tube to the top of the door section with the idrive® resting on the support bracket. Once TorqueMaster® spring tube is level, drill 1/8” pilot holes for the lag screws. Then secure support bracket to the mounting surface with (2) 1/4” x 1-1/2" hex had lag screws.

IMPORTANT: TORQUEMASTER® SPRING TUBE MUST BE LEVEL AFTER SUPPORT BRACKET IS FASTENED TO MOUNTING SURFACE.

(HEADER)

45° ANGLE

1/4 X 1-1/2”

HEX HEAD

SCREWS

TOP OF DOOR

LAG

ANTENNA WIRE

1/4” - 20

FLANGE

NUTS

MOUNTING

STUDS

MOUNTING

SURFACE

TORQUEMASTER®

SPRING TUBE

SUPPORT BRACKET

STUDS

BRACKET

SLOTS

NOTE: If wood mounting surface is behind dry wall, use 1/4” x 2” lag screws.

Lift and slide the opener over the support bracket, aligning the mounting studs with the bracket slots. Loosely fasten to mounting studs with the (2) 1/4”-20 flange nuts.

NOTE: Do not tighten 1/4”-20 flange nuts to opener studs at this time. Remove the temporary orange label holding the antenna wire. Straighten antenna wire and angle it 45 degrees to the right.

NOTE: Do not coil the antenna wire. This will reduce the radio signal range.

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TORQUEMASTER®

SPRING TUBE

(2) 1/4”-20

FLANGE NUTS

“X”

TOP SECTION

USING A TAPE MEASURE, MAINTAIN AN EQUAL MEASUREMENT “X” (TOP OF DOOR

TO BOTTOM OF TORQUEMASTER® TUBE) AT BOTH ENDS AND THE CENTER.

“X”

SUPPORT BRACKET

“X”

Page 27

6ft

Tools Needed:

Pliers

Attaching Disconnect Cables

NOTE: See idrive® main installation and

owners manual for idrive® parts.

Attach the loose disconnect cable (located in opener hardware bag) to the opener with the “S” hook. Close both ends of the “S” hook to lock assembly together with pliers.

Thread the disconnect cable (behind the counterbalance cable) through the hole in the right hand end bracket, and remove all slack between opener and right end bracket.

S-HOOK

DISCONNECT

CABLE

HOLE IN RIGHT

END BRACKET

RIGHT SIDE OF

END BRACKET

Tools Needed:

Pencil

Tape Measure

1/8” Drill Bit

7/16” Socket

Driver

Power Drill

Mounting Disconnect

Handle Bracket

NOTE: See idrive® main installation and

owners manual for idrive® parts.

Mark a location on the right jamb, 6 feet above the floor to mount the disconnect handle bracket.

Drill 1/8” pilot holes for the lag screws.

Align top of the bracket with the mark. Fasten bracket to the jamb with (2) 1/4” x 1-1/2" hex head lag screws.

HOLE IN

END BRACKET

CLOSE “S” HOOK

INSTALLATION

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(2) 1/4 x 1-1/2"

HEX HEAD LAG

SCREWS

DISCONNECT

HANDLE BRACKET

Page 28

Attaching Disconnect Handle

Tools Needed:

Phillips Head

Screwdriver

Wire cutters

NOTE: See idrive® main installation and owners manual for idrive® parts.

NOTE: Bring motor to the down position by pulling the disconnect cable, insure opener disconnect teeth are engaged before installing disconnect handle.

Start the #6-20 x 1/2" screw into the disconnect handle. Thread the disconnect cable through the top of the disconnect handle bracket and then the disconnect handle.

Locate the disconnect handle in full upper position of disconnect handle bracket.

Remove all disconnect cable slack between the opener and the top of the disconnect handle bracket. Tighten #6-20 x 1/2" screw into the disconnect handle until snug, and then tighten screw an additional 1 to 1-1/2 turns to secure disconnect cable to the disconnect handle. Trim off excess cable from bottom of the disconnect handle.

CAUTION: PULL CABLE ONLY TAUT ENOUGH TO REMOVE THE CABLE SLACK. PULLING THE CABLE MORE COULD CAUSE OPENER TO DISCONNECT FROM THE TORQUEMASTER® SPRING TUBE.

UPPER POSITION

#6-20 X 1/2”

SCREW

HANDLE

DISCONNECT

CABLE

DISCONNECT

HANDLE

BRACKET

MANUAL OPERATED POSITION

EMERGENCY DISCONNECT

LABEL

MOTOR OPERATED POSITION

Apply emergency disconnect label next to the mounted bracket. Use mechanical fasteners if adhesive will not adhere.

Using the emergency disconnect, pull disconnect handle downwards and place it in the manual door operated position (Use disconnect label for reference). Motor will be rotated 90° from its packaged position.

If motor does not pivot 90°, see troubleshooting section in the main installation and owners manual of your idrive® opener

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Page 29

Securing Door

for Spring Winding

Tools Needed:

(2) Vice Clamps

Place vice clamps onto both vertical tracks just above the third roller. This is to prevent the garage door from raising while winding counterbalance spring(s).

WARNING

FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY.

IMPORTANT: DO NOT USE IMPACT GUN TO WIND SPRING(S).

PLACE VICE

CLAMPS ABOVE

3RD ROLLER

VICE CLAMPS ATTACHED TO

INNER RAIL

OF TRACK

TRACK

INSTALLATION

Tools Needed:

Locking Pliers

Flat Tip

Screwdriver

Wire Cutters

Cable Adjustments

Rotate the cable drum until the set screw faces directly away from the header. TorqueMaster peak should be pointing straight up.

Beginning with the right side, loosen the set screw approximately two turns, to adjust cable. Using locking pliers, pull on the end of the cable to remove all cable slack.

Check to ensure the cable is aligned and seated in the first groove of the cable drum. Snug the set screw, then tighten an additional 1-1/2 turns. Cut excess cable.

spring tube cam

COUNTERBALANCE

CABLE

CABLE DRUM

CAM PEAK

STRAIGHT UP

SET SCREW

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Page 30

15.5

Tools Needed:

Power Drill

7/16" Socket

Driver

Winding Bolt Rotation

See chart in Step 32 for proper spring tension setting.

Beginning with the right hand side, ensure the cable is in the first groove of the cable drum. Apply light pressure to the canoe clip on counter cover while winding springs.

Using a power drill (high torque/gear reduced to 1300 RPM preferred) with a 7/16" socket, carefully rotate right hand winding bolt clockwise, until counter shows 2-3 turns.

This will keep the counterbalance cable taut while adjusting the left hand side counterbalance cable. Adjust left hand counterbalance cable tension. (refer to Step 30)

NOTE: Single spring applications require no spring winding on left hand side, but need cable tension adjusted.

NOTE: Ensure counterbalance cable tension is equal for both sides prior to fully winding spring(s) to appropriate number of turns. If cable tension is unequal refer to Step 30.

WARNING

ING ADJUSTMENTS TO THE SPRINGS, ENSURE YOU’RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTALLATION INSTRUCTIONS. OTHERWISE, THE SPRING FITTINGS MAY RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND COULD RESULT IN SEVERE OR FATAL INJURY.

CANOE CLIP

WINDING

BOLT

PRIOR TO WINDING OR MAK-

Tools Needed:

Power Drill

7/16” Socket

Driver

7/16" Wrench

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NOTE: Apply light pressure to the canoe clip on the counter cover while winding spring(s). See the Spring Turn chart.

For SINGLE SPRING applications, return to the right hand side and carefully rotate the winding bolt head clockwise until the counter shows the correct number of turns for

your door.

For DOUBLE SPRING applications, remain on the left hand side and carefully rotate the winding bolt head clockwise until the counter shows the correct number of turns for your door. Then return to the right hand side and wind the

right hand spring to the required number of turns. IMPORTANT: DO NOT OVERWIND.

After spring is wound, hold the lock nut (in back of end bracket) stationary on the right hand side with a 7/16” wrench while rotating the winding bolt clockwise until snug. Tightening of the lock nut prevents spring from unwinding. Repeat for opposite side for double spring TorqueMaster® systems.

IMPORTANT: CAUTIOUSLY REMOVE VICE CLAMPS FROM VERTICAL TRACKS. ADJUSTMENTS TO THE RECOMMENDED NUMBER OF TURNS MAY BE REQUIRED. AFTER REAR SUPPORT ASSEMBLY IS COMPLETE (STEP

39), CHECK DOOR BALANCE. IF DOOR RAISES OFF FLOOR UNDER SPRING TENSION ALONE, REDUCE SPRING TENSION UNTIL DOOR RESTS ON THE FLOOR. IF THE DOOR IS HARD TO RAISE OR DRIFTS DOWN ON ITS OWN, ADD SPRING TENSION. AN UNBALANCED DOOR SUCH AS THIS CAN CAUSE IDRIVE® OPERATION PROBLEMS.

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Setting Spring Tension

SPRING

TENSION

SAMPLE SETTING

NOTE: For 7’ high doors, 8’, 9’, 10’, 16’ or 18’ wide with

windows, the recommended number of spring turns is 15.

RECOMMENDED SPRING TURNS

Operated

idrive

Door

Height

6’-0” 13-1/2 14

6’-3” 14 14-1/2

6’-5” 14-1/2 15

6’-6” 14-1/2 15

6’-8” 15 15-1/2

6’-9” 15 15-1/2

7’-0” 15-1/2 16

7’-3” 16 16-1/2

7’-6” 16-1/2 17

7’-9” 17 17-1/2

8’-0” 17-1/2 18

Doors 11’-11”

Wide or Less

LOCK NUT

Manually Operated Door,

and idrive

Doors 12’ Wide or Greater

Operated

7/16”

WRENCH

Page 31

Drum Wrap Installation

DRUM

WRAP

Tools Needed:

None

Drum wraps are identified as right and left hand.

To install, place the drum wrap over the cable drum and under the idrive® disconnect cable (right hand side). Align the outside flange over the outside edge of the cable drum and push the drum wrap down onto the cable drum. Repeat for left hand side.

NOTE: Drum wraps must be installed to prevent cable from becoming tangled.

IMPORTANT: RIGHT AND LEFT HAND ARE ALWAYS DETERMINED FROM INSIDE THE GARAGE LOOKING OUT.

CABLE

DRUM

CABLE

DRUM

OUTSIDE

FLANGE

DRUM

WRAP

INSTALLATION

Tools Needed:

Ratchet Wrench

1/2” Socket

1/2” Wrench

(2) Vice Clamps

Tape Measure

Level

Hammer

Rear Support

WARNING

KEEP HORIZONTAL TRACK PARALLEL AND WITHIN 3/4” MAXIMUM OF DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING IN SEVERE INJURY OR DEATH.

Raise the door until the top section and half of the next section are in a horizontal position. Do not raise door any further since the horizontal tracks are not yet supported at the rear.

WARNING

RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE SEVERE INJURY OR DEATH.

Clamp a pair of vice clamps on the vertical tracks just above the second roller on one side and below the second roller on the other side. This will prevent the door from raising or lowering while installing the rear support. Using perforated angle, 5/16” x 1-5/8” hex head lag screws and 5/16” bolts with nuts (may not be supplied), fabricate rear support for horizontal tracks. Attach

DOOR IN THE UP POSITION

DOOR EDGE

HORIZONTAL TRACK

3/4”

VICE

CLAMPS

VERTICAL

TRACK

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Page 32

Rear Support Continued...

Tools Needed:

horizontal tracks to the rear supports with 5/16”-18 x 1-1/4” hex head bolts and nuts (may not be supplied). Horizontal tracks must be level and parallel with door. NOTE: If rear supports are to be installed over drywall, use 5/16” x 2” hex head lag screws. NOTE: If an idrive® opener will be installed, position horizontal tracks one hole above level when securing it to rear supports. Adjust weather seal (if necessary). Now permanently attach the weather seal to both door jambs and header. (Temporarily attached in PREPARING THE OPENING on page 10.) Avoid pushing weather seal too tightly against face of door.

WARNING

PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS, ENSURE YOU’RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTALLATION INSTRUCTIONS. OTHERWISE, THE SPRING FITTINGS MAY RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND COULD RESULT IN SEVERE OR FATAL INJURY.

Now, lift door and check it’s balance. Adjust, if door lifts by itself (hard to pull down) or if door is difﬁcult to lift (easy to pull down). Anytime spring adjustments are made you must loosen the lock nuts to begin with and retighten both lock nuts afterwards. To adjust spring(s), only add or remove 1/4 turn on the counter at a time. Adjust both sides equally.

IMPORTANT: DO NOT ADD OR REMOVE

MORE THAN 1 SPRING TURN FROM SPECIFIED AMOUNT. IF THE DOOR STILL DOES NOT OPERATE EASILY, LOWER THE DOOR INTO THE CLOSED POSITION, UNWIND SPRING(S) TO ZERO, AND RECHECK THE FOLLOWING ITEMS:

1. Check the door for level.

2. Check the TorqueMaster® Spring

Tube and ﬂagangles for level and

plumb.

3. Check the distance between the ﬂagangles - must be door width plus 3-3/8” to 3-1/2”.

4. Check the counterbalance cables for equal tension - adjust if necessary.

5. Rewind the spring(s).

6. Make sure door isn’t rubbing on jambs.

NOTE: As a safety feature, the right hand

end bracket cannot be disassembled for service until the spring is completely unwound and the counter cover reads zero. After door installation is completed, refer to the idrive® owner’s manual.

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PERFERATED

BRACE

HORIZONTAL TRACK

(3) 5/16” BOLTS & NUTS

SOUND FRAMING MEMBERS

ANGLE BRACE

PERFORATED ANGLE

PERFERATED ANGLE -

BOLTED USING (2) 5/16” X 1-5/8” HEX HEAD LAG SCREWS TO CEILING MEMBER AND

PARALLEL TO WIDTH OF

DOOR

BOLT MUST EXTEND INTO

THE TRACK TO SERVE AS

A ROLLER STOP

PERFERATED ANGLE -

BOLTED USING (2) 5/16” X 1-5/8” HEX HEAD LAG SCREWS TO CEILING MEMBER AND

PARALLEL TO WIDTH OF

DOOR

BOLT MUST EXTEND INTO

THE TRACK TO SERVE AS

A ROLLER STOP

WEATHER

SEAL

JAMB

PERMANENTLY ATTACHED

WEATHER SEAL

Page 33

�

Side Lock

Tools Needed:

Power Drill

7/16” Socket

Driver

Tape Measure

Install the side lock on the second section of the door. Secure the lock to the section with (4) 1/4”- 20 x 11/16” self drilling screws. Square the lock assembly with the door section and align with the square hole in the vertical track. The side lock should be spaced in approximately 1/8” from the section edge.

IMPORTANT: SIDE LOCKS MUST BE REMOVED OR MADE INOPERATIVE IN THE UNLOCKED POSITION IF AN OPERATOR IS INSTALLED ON THE DOOR.

NOTE: After completing this step, continue with Step 13 on page 19.

(4) 1/4”- 20 X 11/16”

SELF DRILLING SCREWS

1/8”

Tools Needed:

Power Drill

1/8” Drill Bit

7/16” Socket

Driver

Tape Measure

Level

DoorMasterTM Bracket

NOTE: When installing a DoorMasterTM

operator use the center bracket and drive gear supplied with your operator (located in DoorMasterTM package).

Slide the DoorMaster gear assembly onto the TorqueMaster® spring tube, so that the drive gear/center bracket assembly are in the center of the TorqueMaster® spring tube.

NOTE: After completing this step, continue with step 20 on page 23.

bracket/drive

Locate the center bracket, mark the header halfway between the ﬂagangles and level the TorqueMaster® spring tube. Drill 1/8” pilot holes for the lag screws. Fasten the metal bracket to the header using (2) 1/4” x 1-1/2” hex head lag screws.

NOTE: After completing this step, continue with step 29 on page 29.

DOORMASTER BRACKET/ DRIVE GEAR ASSEMBLY

DOORMASTER

DRIVE GEAR ASSEMBLY

TORQUEMASTER® TUBE

BRACKET/

OPTIONAL INSTALLATION

(2) 1/4” X 1-1/2” HEX

HEAD LAG SCREWS

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Page 34

�

Step Plate

BOTTOM SECTION

Tools Needed:

Pencil

1/4” Wrench

Locate the center stile on the bottom section of the door.

On the outside of the door, position step plate directly above astragal retainer. Using the step plate as a template, mark hole locations for mounting on door face.

Drill (2) 5/16” dia. holes through the door face and insulation, if necessary, at marked locations, being careful to keep drill straight.

Mount step plates back to back, straddling stile. Secure with (2) 1/4 x 2-3/4” carriage bolts and 1/4”20 ﬂange hex nuts.

NOTE: After completing this step, continue with Step 13 on page 18.

STEP PLATE

(2) 1/4”-20 FLANGE HEX NUT

INSIDE STEP PLATE INSTALLATION

BOTTOM SECTION

STEP PLATE

(2) 1/4 X 2-3/4”

CARRIAGE BOLTS

OUTSIDE STEP PLATE INSTALLATION

BOTTOM SECTION

STEP PLATE

ASSEMBLY

BOTTOM SECTION

STEP PLATE ASSEMBLY

Tools Needed:

Power Drill

Drill Bit

Pull Rope

WARNING

DO NOT INSTALL PULL ROPES ON DOORS WITH ELECTRIC OPERATORS. CHILDREN MAY BECOME ENTANGLED IN THE ROPE CAUSING SEVERE OR FATAL INJURY.

Measure and mark the jamb approximately 48” to 50” (1220 to 1270 mm) from floor on the right or left side of door. Drill 1/8” pilot hole for No. 6 screw eye. Tie the pull rope to the No. 6 screw eye and to the bottom bracket as shown.

NO. 6 SCREW EYE

PULL ROPE

BOTTOM BRACKET

PULL ROPE

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Page 35

�

Trolley Operator

OPERATOR RAIL

Tools Needed:

Tape Measure

Power Drill

7/16” Socket

Driver

WARNING

OPERATOR MUST BE TESTED AT TIME OF INSTALLATION AND MONTHLY THEREAFTER TO ENSURE THAT DOOR REVERSES ON CONTACT WITH 2 X 4 BOARD LAID FLAT UNDER THE DOOR. FAILURE TO ADJUST OPERATOR, IF NECESSARY, CAN RESULT IN SEVERE OR FATAL INJURY. IF YOUR OPERATOR IS EQUIPPED WITH A PHOTOELECTRIC EYE SYSTEM, THEN THIS MUST BE TESTED AT THE SAME TIME TO ENSURE THAT DOOR DOES NOT CLOSE AND A CLOSING DOOR OPENS IF PHOTOELECTRIC EYE SYSTEM IS OBSTRUCTED. FAILURE TO MAKE ADJUSTMENTS, IF NECESSARY, CAN RESULT IN SEVERE OR FATAL INJURY.

1. Install operator rail 1/2” to 1-1/2” (13 - 38 mm) above high arc of top section of the door.

SUITABLE MOUNTING

SURFACE 2X6

LUMBER MINIMUM

HEADER

OPERATOR BRACKET

OPERATOR

RAIL

DOOR ARM TO

PERFORATED

ANGLE

OPERATOR

2. Mount operator to ceiling so that 1” to 1-1/2” (25 - 38 mm) clearance is maintained between trolley rail and top section when door is fully open (trolley rail will slope down towards rear).

3. Attach door arm to operator bracket.

4. Attach operator rail to suitable mounting surface 2x6 lumber minimum.

5. Attach operator to ceiling using perforated angle.

IMPORTANT: PERFORATED ANGLES MUST BE SECURELY ATTACHED TO SOUND FRAMING MEMBER(S).

FRAMING MEMBERS

PERFORATED ANGLE

OPTIONAL INSTALLATION

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Page 36

�

Cleaning

Cleaning Your Garage Door

IMPORTANT: DO NOT USE A PRESSURE WASHER ON YOUR GARAGE DOOR!

While factory-applied ﬁnishes on garage doors are durable, it is desirable to clean them on a routine basis. Some discoloration of the ﬁnish may occur when a door has been exposed to dirt-laden atmosphere for a period of time. Slight chalking may also occur as a result of direct exposure to sunlight.

Cleaning the door will generally restore the appearance of the ﬁnish. To maintain an aesthetically pleasing ﬁnish of the garage door, a periodic washing of the garage door is recommended.

The following cleaning solution is recommended

A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate) dissolved into ﬁve gallons of warm water will aid in the removal of most dirt.

NOTE: The use of detergents containing greater than 0.5% phosphate is not recommended for use in general cleaning of garage doors.

NOTE: Be sure to clean behind weather stripping on both sides and top of door.

CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.

GLASS CLEANING INSTRUCTIONS

Clean with a mild detergent solution (same as above) and a soft cloth. After cleaning, rinse thoroughly.

ACRYLIC CLEANING INSTRUCTIONS

Clean acrylic glazing with nonabrasive soap or detergent and plenty of water. Use your bare hands to feel and dislodge any caked on particles. A soft, grit-free cloth, sponge or chamois may be used to wipe the surface. Do not use hard or rough cloths that will scratch the acrylic glazing. Dry glazing with a clean damp chamois.

NOTE: DO NOT USE any window cleaning ﬂuids, scouring compounds, gritty cloths or solvent-based cleaners of any kind.

Painting

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 ﬁne steel wool pad, saturated with soapy water. A ﬁnal wipe and rinse should be done with clean water only, to remove any loose particles and any soapy ﬁlm residue.

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. Once the substrate is exposed, the likelihood for rusting is greatly increased.

If substrate is exposed, it must be treated to prevent rust from forming. Sand the exposed area lightly and paint with a high quality metal primer, speciﬁcally intended for galvanized surfaces, to protect the area from corrosion. Allow for drying time on primer can label before applying topcoat. The surface of the factory-applied ﬁnish, that is being painted, must not be too smooth, or the paint will not adhere to it. It is advisable to test in an inconspicuous area, to evaluate adhesion. If poor adhesion is observed, surface preparation for painting the factory-applied ﬁnish must be repeated until desired results are achieved. Again, care must be taken to not expose the substrate under the paint.

Painting

After surface has been properly prepared, it must be allowed to dry thoroughly, and then coated immediately with premium quality latex house paint. Follow paint label directions explicitly. Oil base or solvent base paints are not recommended. Please note that if substrate is exposed and not properly primed, painting with latex paint may cause accelerated rusting of the steel in the exposed area.

NOTES:

1. Repainting of ﬁnish painted steel doors cannot be warranted, as this condition is totally beyond the door manufacturer’s control.

2. Consult a professional coatings contractor if in doubt about any of the above directions.

3. Follow directions explicitly on the paint container labels for proper applications of coatings and disposal of containers. Pay particular

attention to acceptable weather and temperature conditions in which to paint.

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Page 37

Limited Warranty

Models 8000, 8100, 8200 and 46

Subject to the terms and conditions contained in this Limited Warranty, Wayne-Dalton Corp. (“Manufacturer”) warrants the sections of the door, which is described at the top of this page, for a period of TEN (10) YEARS from the date of installation against: (i) The door becoming inoperable due to rust-through of the steel skin from the core of the door section, due to cracking, splitting, or other deterioration of the steel skin, or due to structural failure caused by separation or degradation of the foam insulation. (ii) Peeling of the original paint on the door as a result of a defect in the original paint or in the application of the original paint coating, in cases where the door sections and the original paint: (a) have not been subjected to adverse atmospheric conditions or contaminates (such as salt water or other marine environment, or to toxic or abrasive substances, including those in the air); (b) have been maintained in compliance with Manufacturer’s recommendations; and (c) have not been subject to physical abrasion, impacted by a hard object, or punctured (including without limitation “paint rub” occurring in metal to metal contact and movement). The Manufacturer warrants the garage door hardware (except springs) and the tracks of the above-described door, for a period of TEN (10) YEARS from the date of installation, against defects in material and workmanship, subject to all the terms and conditions below. The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Limited Warranty against defects in material and workmanship for a period of ONE (1) YEAR from the date of installation. This Limited Warranty is extended only to the person who purchased the product and continues to own the premises (where the door is installed) as his/her primary residence (“Buyer”). This Limited Warranty does not apply to residences other than primary, or to commercial or industrial installations, or to installations on rental property (even when used by a tenant as a residence). This Limited Warranty is not transferable to any other person (even when the premises is sold), nor does it extend beneﬁts to any other person. The Manufacturer will not be responsible for any damage attributable to improper storage, improper installation, or any alteration of the door or its components, abuse, damage from corrosive fumes or substances, salt spray or saltwater air, ﬁre, Acts of God, failure to properly maintain the door, or attempt to use the door, its components or related products for other than its intended purpose and its customary usage. This Limited Warranty does not cover ordinary wear. This Limited Warranty will be voided if the original ﬁnish is painted over, unless Manufacturer’s preparation and painting instructions are followed explicitly. This Limited Warranty will be voided if any holes are drilled into the door, other than those speciﬁed by the Manufacturer. THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON-MOSS ACT. NO WARRANTIES, EXPRESS OR IMPLIED (INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE) WILL EXTEND BEYOND THE TIME PERIOD SET FORTH IN UNDERSCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY, ABOVE.

   • SomeStatesdonotallowlimitationsonhowlonganimpliedwarrantylasts,sotheabovelimitationsmaynotapplytoyou.

Any claim under this Limited Warranty must be made in writing, within the applicable warranty period, to the dealer from which the product was purchased. Unless the dealer is no longer in business, a written claim to the Manufacturer will be the same as if no claim had been made at all. At the Manufacturer’s option, a service representative may inspect the product on site, or Buyer may be required to return the product to the Manufacturer at Buyer’s expense. Buyer agrees to cooperate with any representative of the Manufacturer and to give such representative full access to the product with the claimed defect and full access to the location of its installation. If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty, the Manufacturer will repair or replace the defective product. The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer, subject to applicable law. THE REMEDY WILL COVER ONLY MATERIAL. THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES, SUCH AS FIELD SERVICE LABOR FOR REMOVAL, INSTALLATION, PAINTING, SHIPPING, ETC. Any repairs or replacements arranged by Manufacturer will be covered by (and subject to) the terms, conditions, limitations and exceptions of this Limited Warranty; provided, however, that the installation date for the repaired or replaced product will be deemed to be the date the original product was installed, and this Limited Warranty will expire at the same time as if there had been no defect. If a claim under this Limited Warranty is resolved in a manner other than described in the immediately preceding paragraph, then neither this Limited Warranty nor any other warranty from the Manufacturer will cover the repaired or replaced portion of the product. THE REMEDIES FOR THE BUYER DESCRIBED IN THIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy. The liability of the Manufacturer, whether in contract or tort, under warranty, product liability, or otherwise, will not go beyond the Manufacturer’s obligation to repair or replace, at its option, as described above. THE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, including (but not limited to) damage or loss of other property or equipment, personal injury, loss of proﬁts or revenues, business or service interruptions, cost of capital , cost of purchase or replacement of other goods, or claims of third parties for any of the foregoing.

   • SomeStatesdonotallowtheexclusionorlimitationofincidentalorconsequentialdamages,sotheabovelimitationor  

exclusion may not apply to you. No employee, distributor, dealer, representative, or other person has the authority to modify any term or condition contained in this Limited Warranty or to grant any other warranty on behalf of or binding on the Manufacturer, and anyone’s attempt to do so will be null and void. Buyer should be prepared to verify the date of installation to the satisfaction of the Manufacturer. The rights and obligations of the Manufacturer and Buyer under this Limited Warranty will be governed by the laws of the State of Ohio, USA, to the extent permitted by law.

   • ThisLimitedWarrantygivesyouspeciclegalrightsandyoumayalsohaveotherrights,whichmayvaryfromStatetoState.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Page 38

Covered by one or more of the following Patents; 5,408,724; 5,409,051; 5,419,010; 5,495,640; 5,522,446; 5,562,141; 5,566,740; 5,568,672; 5,718,533; 6,019,269; 6,089,304; 6,644,378; 6,374,567; 6,561,256; 6,527,037; 6,640,872; 6,672,362; 6,725,898; 6,843,300; 6,915,573; 6,951,237; 7,014,386; 7,036,548; 7,059,380; 7,121,317; 7,128,123; 7,134,471; 7,134,472; 7,219,392; 7,254,868. Canadian: 2,384,936; 2,477,445; 2,495,175; 2,507,590; 2,530,701; 2,530,74; 2, 2,532,824. Other US and Foreign Patents pending

Please Do Not Return This Product To The Store

Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local yellow pages business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Thank you for your purchase

Wayne-Dalton 46 Installation Instructions And Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual