Wayne-Dalton TORQUEMASTER 46 User Manual

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

any of the procedures, do not perform the work. Instead, have a trained door systems technician do the installation or repairs.

Table of Contents

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

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

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

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

Preparing The Opening .....................................................6

Installation ..................................................................7-31

Optional Installations .................................................32-36

Side Lock .......................................................32

Alternative Step Plate ..................................... 33

Pull Rope ........................................................ 33

Trolley Operator .............................................. 34

Maintenance ................................................................... 35

Cleaning ......................................................... 35

Painting Instructions ....................................... 35

Warranty ......................................................................... 36

Dealer Locator Information.............................................. 36

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.

WARNING

TO AVOID POSSIBLE INJURY, READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING INSTALLATION. IF IN QUESTION ABOUT ANY OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A TRAINED DOOR SYSTEMS TECHNICIAN 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 installation 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.

After installation is complete, fasten this manual

near garage 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

Package Contents

Cable Drum

No space betw

een Ratchet

Pawl

and Cabl

e Drum

indicates engagem

ent

Cable Drum

Ratchet

Pawl

ENGA

GED SI

DE VIEW

No space betw

een

Ratchet

Pawl

and

Cable Drum

ENGA

GED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cabl

e Drum

non-indicates engagem

ent

Cable Drum

Ratchet Pawl

DISENGAGED

SIDE VIEW

No space betw

een

Ratchet

Pawl

and

DISENGA

GED U

NDERNEATH VIEW

UPPER

POSITION

LOWER POSI

TION

LOWER

POSITION

SIDE VIEW

UPPER

POSITION SIDE VIEW

Ratchet Pawl

in Low

er Position

Ratchet

Pawl in Upper Pos

ition

Use these Illustration

, in conjunction with

the Instructions on the other side of

this label.

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.

Ratchet

Pawl

ENGA

GED

SIDE VIEW

No space betw

een

NDERNE

ATH VIEW

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.

8000 Series, Model 46

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.

TorqueMaster® - Single and Double Spring

Installation Instructions and Owner’s Manual

Portland Source Plant

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.

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

(1) TORQUEMASTER® SPRING TUBE

DOOR SECTIONS (AS REQUIRED)

JAMB BRACKETS

(AS REQUIRED)

MANUAL

RIGHT & LEFT

END BRACKETS

RIGHT & LEFT DRUM WRAPS

RIGHT AND LEFT

BOTTOM BRACKETS

ROLLERS

(AS REQUIRED)

(1) LOOSE WINDING SHAFT

(SINGLE SPRING ONLY)

(1) CENTER BRACKET

ASSEMBLY

(2) STEP PLATES

RIGHT AND LEFT CABLE

DRUM ASSEMBLIES

U-BAR

(AS REQUIRED)

#1, #2, #3 & #4

HINGES (AS REQUIRED)

(2) FULLY ADJUSTABLE

RH/LH FLAGANGLES

(2) VERTICAL

RH/LH

TRACKS

(2) TOP BRACKET

BASES

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

(2) TOP BRACKET

SLIDES

(2) LIFT HANDLES

& SPACERS

WEATHER SEAL &

NAILS (IF INCLUDED)

#6 SCREW EYE AND PULL

ROPE (IF INCLUDED)

Package Contents Continued...

5/16”- 18 HEX NUTS

(AS REQUIRED)

1/4”- 20 X 5/8” CARRIAGE

BOLTS (AS REQUIRED)

1/4”-20 X 11/16” SELF DRILLING

SCREWS (AS REQUIRED)

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

Door Section Identification

(2) 3/8”- 16

HEX NUTS

1/4”- 20 X 5/8” CARRIAGE

BOLTS (AS REQUIRED)

1/4”- 20 X 7/8” SELF DRILLING

1/4”- 20 HEX NUTS

(LIFT HANDLE)

SCREWS (AS REQUIRED)

1/4”- 20 FLANGED HEX

NUTS (AS REQUIRED)

(2) 3/8”- 16 X 3/4”

HEX HEAD BOLTS

5/16” X 2” HEX HEAD LAG SCREWS (AS REQUIRED)

(2) 1/4” X 2-3/4” CARRIAGE BOLTS

(2) 1/4”- 20 X 5/8” TAMPER-

RESISTANT SCREWS

1/4”- 14 X 5/8” SELF TAPPING

SCREWS (AS REQUIRED)

Tools Needed:

The BOTTOM SECTION can be identiﬁed by the factory attached

TOP SECTION

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

INTERMEDIATE II SECTION (5 SECTION DOORS ONLY)

and black warning label on the right side of the section. This section is always the 2nd section from the bottom

WARNING LABEL

of the door.

The INTERMEDIATE I SECTION may

INTERMEDIATE I SECTION

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

LOCK SECTION

always the 4th section on a ﬁve section door.

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

BOTTOM BRACKET

WARNING LABELS

section on ﬁve section door.

ASTRAGAL

BOTTOM SECTION

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

Tools Required

PHILLIPS HEAD SCREWDRIVER

(2) SAWHORSES

PENCIL

1/2”, 9/16”, 5/8”

& SOCKET

1/8”, 3/16”, 9/32”,

5/16”, 1/2” DRILL BITS

HACKSAW

3” EXTENSION

Removing an Existing Door

PLIERS/WIRE CUTTERSRATCHET WRENCHPOWER DRILL

VICE GRIPS

TAPE MEASURE

DRIVER

1/4”, 3/8”, 7/16”, 1/2” &

9/16” WRENCHES

(2) VICE CLAMPS

SAFETY GLASSESFLAT TIP SCREWDRIVER

GLOVES7/16”, 1/2” SOCKET

TORX BIT

LEVEL

HAMMER

STEP LADDER

Counterbalance spring tension must always be released before any attempt is made to start removing an existing door.

WARNING

A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY. TO AVOID INJURY HAVE A TRAINED DOOR SYSTEMS TECHNICIAN, USING PROPER TOOLS AND INSTRUCTIONS, RELEASE THE SPRING TENSION.

For detailed information see supplemental instructions “removing an existing door/preparing the opening”. These instructions are available at no charge from Wayne-Dalton Corp., P.O. Box 67, Mt. Hope, OH 44660, or at www.wayne-dalton.com.

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

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

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.

To ensure secure mounting of track brackets, side and center brackets, or steel angles to new or retro-ﬁt construction, it is recommended to follow the procedures outlined in DASMA Technical Data Sheets #156, #161 and #164 at www.dasma.com.

The inside perimeter of your garage door opening should be framed with wood jamb and header material. The jambs and header must be securely fastened to sound framing members. 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® Plus counterbalance systems. 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” (89 mm).

IMPORTANT: Closely inspect jambs, header and mounting surface. Any wood found not to be sound, must be replaced.

FAILURE TO

DOOR HEIGHT

LEVEL HEADER

PLUMB JAMBS

DOOR

WIDTH

HEADROOM

BACKROOM

HEADER

JAMB

WEATHER SEAL

For TorqueMaster® Plus counterbalance systems, a suitable mounting pad (2” x 4”) must be ﬁrmly attached to the wall, above the header at the center of the opening.

NOTE: Drill 3/16” pilot holes in the mounting pad to avoid splitting the lumber, and attach mounting pad with lag screws of appropriate length. Do not attach the mounting pad with nails.

Weather Seal (May Not Be Included):

Cut or trim the weather seal (if necessary) to ﬁt the header and jambs.

JAMB

WEATHER SEAL

1/8” TO 1/4”

HEADROOM REQUIREMENT

For fully adjustable track: Align the header seal 1/8” to

1/4” inside the header and temporarily secure it to the header with equally spaced nails. Next, ﬁt the jamb seals up tight against the header seal and 1/8” to 1/4” inside the jamb. Temporarily secure the jamb seals with equally spaced nails. Equally space nails approximately 12” to 18” apart. This will keep the bottom section from falling out of the opening during installation. NOTE: Do not permanently attach weather seal to the jamb at this time.

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” track radius only. Contact your local Wayne-Dalton dealer.

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

HEIGHT

TRACK TYPE TorqueMaster® Plus

10”, 12” 10”

14” 12”

3-1/2” LHR 6”

LHR Kit 6 1/2”

BACKROOM REQUIREMENT

DOOR

6’5” 10”, 12”, 14” Radius 89” 125” 6’5” Low Headroom 101” 125” 6’6” 10”, 12”, 14” Radius 90” 125” 6’6” Low Headroom 102” 125” 7’0” 10”, 12”, 14” Radius 96” 125” 7’0” Low Headroom 108” 125” 7’6” 10”, 12”, 14” Radius 102” 137” 7’6” Low Headroom 114” 137” 8’0” 10”, 12”, 14” Radius 108” 137” 8’0” Low Headroom 120” 137”

TRACK

MANUAL

LIFT

MOTOR

OPERATED

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

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 SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UNTREATED LUMBER.

NOTE: It is recommended that 5/16” x 2” lag screws will be pilot drilled using a 3/16” drill bit, prior to fastening.

INSTALLATION

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

12”

Tools Needed:

Tape Measure

Hacksaw

Power Drill

5/16” Drill Bit

Cutting Vertical Track and

Installing Fully Adjustable Jamb

Brackets

NOTE: If you have riveted track, skip

this step.

Vertical track must be cut to the proper length prior to installation.

IMPORTANT: DOORS THAT ARE 7’-0” OR 8’-0” IN HEIGHT DO NOT REQUIRE CUTTING THE VERTICAL TRACK.

Determine the radius of your horizontal track. Using this measurement, refer to the vertical track cutting chart to determine the length of the vertical track. Cut the track off at the TOP.

Now, two holes must be drilled into the top of the cut vertical track. Refer to the illustration shown for hole locations. Use a 5/16” drill bit.

Repeat for other vertical track.

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.

Horizontal track

Vertical Track Cutting Chart

Horizontal Track Radius

10”, 12” Door Height Minus 10”

14” Door Height Minus 8”

3-1/2” LHR Door Height Minus 15”

6-1/2” LHR Door Height Minus 12”

5/8”

FULLY ADJUSTABLE

JAMB BRACKET

Vertical Track Cut Length

1/2”

5/8”

5/16”

Stamped radius

Vertical Track Cut Length

Cut vertical track here

To attach the top jamb bracket, JB-3, locate the third set of quick install

3RD SET

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

JAMB BRACKET

SLOT

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.

Repeat for other vertical track.

(1) 1/4”-20

FLANGE

HEX NUT

JAMB BRACKET

QUICK INSTALL

FEATURE

QUICK INSTALL

FEATURE

(1) 1/4”- 20 X 5/8”

CARRIAGE BOLT

VERTICAL

TRACK

1ST SET

VERTICAL

TRACK

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

Attaching Fully Adjustable

Flagangle to Vertical Track

FULLY ADJUSTABLE

FLAGANGLE

Tools Needed:

None

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.

Repeat for opposite side.

The ﬂange nuts will be tightened after ﬂagangle spacing is complete (Step 14).

(2) 1/4”- 20

FLANGE HEX

NUTS

VERTICAL

TRACK

(2) 1/4”- 20 X 5/8”

CARRIAGE BOLTS

INSTALLATION

Tools Needed:

Power Drill

7/16” Socket

Driver

Torx Bit

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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-resistant self drilling screw as shown.

Repeat for other side.

NOTE: All doors are provided with the tamper resistant fastener for the bottom brackets. However, the professional installer is most likely to have the proper tool to install this fastener. If the homeowner does not have the proper tool to install the tamper resistant fastener, use a regular 1/4 – 20 x 7/8” self drilling screw in its place.

END STILE HOLE

(LEFT SIDE IS SHOWN.

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

2 1

PATTERN

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

Bottom Bracket

Drums

Tools Needed:

None

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

NOTE: For door section identiﬁcation see page 4.

TorqueMaster® Plus counterbalance drums are marked right and left hand.

Uncoil the counterbalance cables and 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 milford pin of the left hand bottom corner bracket.

Insert a roller into each bottom bracket of the bottom section.

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.

LEFT HAND

TORQUEMASTER® PLUS

COUNTERBALANCE DRUM

BOTTOM SECTION

MILFORD PIN

COUNTERBALANCE

CABLE

BOTTOM

BRACKET

MILFORD PIN

ROLLER

HINGE TUBE

BOTTOM SECTION

ASTRAGAL

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Hinges

Tools Needed:

Power Drill

7/16” Socket

Driver

Position the lower (numbered) leaf of the #1 end hinge over the #1 and #4 holes in the top of the end stiles, and secure to the end stiles by 1/4”-14 x 5/8” self tapping screws. Position and secure #1 center hinge(s) with 1/4”-14 x 5/8” self tapping screws using the pre-punched holes in the top of the center stile(s).

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.

Insert roller into appropriate hinge tubes.

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.

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

END STILE HOLE

PATTERN

(LEFT SIDE IS SHOWN.

RIGHT SIDE IS

OPPOSITE.)

CENTER STILE

HOLE PATTERN

PLACEMENT

#1 HINGE #2 END HINGE

ROLLER

PLACEMENT

ROLLER

PLACEMENT

#3 END HINGE

#4 END HINGE

ROLLER

INSTALLATION

IMPORTANT: ONCE FASTENER ARE

SNUG AGAINST HINGE LEAF, TIGHTEN AN ADDITIONAL 1/4 TO 1/2 TURN TO RECEIVE

#1 HOLE

HINGE

MAXIMUM DESIGN HOLDING POWER.

#4 HOLE

END STILE

END HINGE PLACEMENT

CENTER STILE

CENTER HINGE PLACEMENT

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

(2) 1/4”-14 X 5/8”

SELF TAPPING

SCREWS

HINGE

(2) 1/4”-14 X 5/8”

SELF TAPPING

SCREWS

+ 25 hidden pages