8800 Aluminum Full View Torsion 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 2009 Wayne-Dalton Corp. 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. Part No.
Table of Contents Important Safety Instructions............................................. 2 Package Contents...........................................................3-4 Door Section Identification................................................. 4 Tools Required................................................................... 5 Pre-Installation...............................................................5-7 Removing An Old Door....................................... 5 Preparing The Opening.........
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.
Package Contents Continued...
pencil power drill Phillips Head Screwdriver 7/16”, 1/2” & 9/16” Socket Needle Nose Pliers sawhorse P1 ratchet Wrench 9/32”, 1/2”, 3/16” & 1/8” drill bits level Flat Tip Screwdriver vice grips gloves 3/8”, 7/16” socket driver Safety Glasses hammer 1/4”, 3/8”, 7/16”, 1/2” & 9/16” Wrenches Tape Measure vice clamps 1/4” torx bit Approved Winding Bars PRE-INSTALLATION Tools Required Step Ladder Removing An Old Door Counterbalance spring tension must always be released before any attempt
P2 Tools Needed: Tape Measure Preparing the Opening suitable mounting surface 2” x 6” lumber minimum header board 2” x 6” lumber recommended 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. door height level header plumb jambs If you just removed your existing door or you are installing a new door, complete all steps in PREPARING THE OPENING.
Preparing the Opening Continued...... 2” X 6” JAMB IS RECOMMENDED RADIUS TRACK SIDEROOOM (Requirements) 12” R 14”R 3.5 LHR REAR 3.5 LHR FRONT 4-1/2” 4-1/2” 9” 4-1/2” See sideroom requirements chart 5/16 X 2” LAG SCREW FLUSH WOOD JAMBS 2” TRACK 1-1/2” 4-3/16” 1/2”- 5/8” INSTALLATION SIDEROOM requirements Installation Begin the installation of the door by checking the opening. It must be the same size as the door. Vertical jambs must be plumb and level with header.
1 Cutting Vertical Track Tools Needed: NOTE: If you have riveted track, skip this step. None Vertical track must be cut to the proper length prior to installation. Horizontal track 12” 12” Stamped radius IMPORTANT: Doors that are 7’-0” or 8’-0” in height do not require cutting the vertical track. Determine the radius of your horizontal track. Vertical Track Cutting Chart NOTE: All Portland tracks have the radius stamped on the side of the track.
3 Attaching Wall Angle to Vertical Track and Installing Wall Angle Tools Needed: NOTE: If you have riveted track, skip this step. None If your door has fully adjustable flagangle to vertical track, skip this step and go to step 2. Wall angle Hand tighten the wall angle to the vertical track using 1/4”- 20 x 5/8” carriage bolts and 1/4”- 20 flange hex nuts.
5 Tools Needed: Pliers Attaching Counterbalance Cables to Bottom Brackets counterbalance cable IMPORTANT: Right and left hand is always determined from inside the garage looking out. NOTE: For door section identification see page 4. bottom bracket Bottom Bracket Locate the right and left hand bottom brackets. Uncoil the counterbalance cables. Slide the clevis pin through the left hand bottom bracket and counterbalance cable.
Hinges Tools Needed: NOTE: For door section identification see page 4. Power Drill 7/16” Socket Driver Locate the bottom section, using #1 end hinges for the end stiles; depending on the width of your door enough #1 half hinges for each of the pre-drilled locations along the reinforcing fin. End Hinges: Place (1) #1 end hinge at the top left hand corner of the bottom section.
8 Top Bracket Tools Needed: NOTE: Top brackets are attached 1-3/4” down from the top edge of the top section.. Power Drill 7/16” Socket Driver For single top brackets: Place a top bracket onto the top left hand corner of the top section and down 1-3/4”. Align the edge of the top bracket with the edge of the section, and secure using (2) 1/4” x 7/8” self drilling screws in the top door section rail and (2) 1/4” x 7/8” self drilling screws into the stile as shown.
10 Tools Needed: Hammer Bottom Section Center the bottom section in the door opening. Level section using wooden shims (if necessary) under the bottom section. jamb header Wood Shims weather seal level INSTALLATION jamb bottom section Wooden Shims 11 Tools Needed: 3/16” Drill Bit Power Drill 7/16” Socket Driver Tape Measure Level Step Ladder vertical track Vertical Track and Wall Angle Installation IMPORTANT: The tops of the vertical tracks must be level from side to side.
Vertical Track and Wall Angle Installation Continued.... Tools Needed: 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. Loosely fasten the vertical track assembly to the jamb using 5/16” x 2” lag screws. Tighten bottom lag screw securing vertical track assembly to jamb, to maintain 5/8” spacing. Repeat for the right hand side.
13 Hammer Nail Power Drill 7/16 Socket Driver Tape Measure Step Ladder Top Section 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. door width +3-3/8” to 3-1/2” Now flip up hinge leaf against section, fastening center hinges first, and end hinges last. (Refer to Step 7).
14 Attaching Horizontal Track to Adjustable Flagangle and Wall Angle Tools Needed: 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/wall angle with (2) 1/4”- 20 x 5/8” carriage bolts and (2) 1/4”- 20 flange hex nuts.
16 Tools Needed: Power Drill 7/16” Socket Driver 9/16” Socket Ratchet Wrench 9/16” Wrench Step Ladder Left end bearing bracket Torsion End Bearing Brackets IMPORTANT: Right and left hand is always determined from inside the garage looking out. End bearing brackets are right and left. Using the upper slots in the end bearing bracket, position above the flagangle and secure the end bearing bracket to the horizontal angle using (2) 3/8”- 16 x 3/4” hex head bolts and (2) 3/8”- 16 hex nuts.
Tools Needed: none Right hand cable drum black Torsion Spring Assembly IMPORTANT: Right and left hand is always determined from inside the garage looking out. NOTE: Identify the springs provided as either right hand wound (red winding cone), which goes on the LEFT HAND SIDE or left hand wound (black winding cone), which goes on the RIGHT HAND SIDE. Facing the inside of the door, lay the torsion tube on the floor.
Tools Needed: 9/16” Socket Ratchet Wrench Nylon Center Bushing S lide the nylon center bushing into the stationary spring cone at the end of the spring and align the stationary spring cone(s) with the holes in the center bearing bracket. Secure the spring(s) to the center bearing bracket with (2) 3/8”- 16 x 1-1/2” hex head bolts and (2) 3/8”- 16 hex nuts. Torsion Spring Stationary Spring cone Center bearing bracket 9/16” Wrench Step Ladder IMPORTANT: Springs under tension can be dangerous.
Tools Needed: Vice Grips 3/8” Wrench Step Ladder Counterbalance Cables Left cable drum Release the vice grips from the ends of the cables and thread the counterbalance cables Cable around the back side of the cable drums and verify that there are no cable obstructions. Hook the cables into the drums. Slide the left hand cable drum against the left hand end bearing bracket and tighten the set screws in the drum to 14-15 ft. lbs.
22 Tools Needed: Power Drill 3/16” Drill Bit 7/16” Socket Driver Phillips Head Screwdriver Step Ladder Winding Torsion Spring(s) Position a ladder slightly to the side of spring so that the winding cone is easily accessible, yet your body is not in direct line with the winding bars. Check the label attached to the spring warning tag for the required number of complete turns to balance your door.
23 Tools Needed: Ratchet Wrench Rear Support DOOR IN THE UP POSITION WARNING Keep horizontal track parallel and within 3/4” 1/2” Socket maximum of door edge, otherwise door could fall, 1/2” Wrench resulting in severe injury or (2) Vice Clamps death. Step Ladder 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 rear of horizontal track is not yet supported.
Rear Support Continued... To adjust spring tension, fully close door. Apply locking pliers to track above third roller. Insert a winding bar into the winding cone. Push upward on the winding bar while carefully loosening the set screws in the winding cone.
� Tools Needed: Power Drill 7/16” Socket Driver Tape Measure Side Lock 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.
� Trolley Operator WARNING Step Ladder 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.
� 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.
Limited Warranty Model 8800 Subject to the terms and conditions contained in this Limited Warranty, Wayne-Dalton Corp. (“Manufacturer”) warrants the sections of the door for FIVE (5) YEARS with the exception of the items that follow which is described at the top of this page. These exceptions will be warranted for a period of ONE (1) YEAR from the date of installation against: (i) (ii) (iii) Fading, cracking or chipping of the anodized or powder coated finish.
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.
