Wayne Dalton 8000/8100/8200 Extension Standard Lift garage door Installation Instructions And Owner’s Manual

Below you will find brief information for garage door 8000/8100/8200 Extension Standard Lift. This manual provides step-by-step instructions for installing your new garage door. It also covers important safety instructions, tools required, package contents, door section identification, removing an existing door, preparing the opening, parts breakdown, installation, optional installation, maintenance, cleaning your garage door, painting your garage door, maintaining the finish on your garage door, operating and maintaining your garage door, and warranty information.

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M anual

T a b l e O f C o n t e n t s

Pre-Installation 2

Important Safety Instructions

Tools Required

Package Contents

Door Section Identification

Removing an Existing Door

Preparing the Opening

Parts Breakdown 5

Installation 6

Optional Installation 14

Inside Lock

Pull Down Rope

Maintenance 15

Cleaning Your Garage Door

Painting Your Garage Door

Maintaining The Finish On Your Garage Door

Operation And Maintenance

Warranty 16

PLEASE DO NOT RETURN THIS PRODUCT

TO THE STORE

Please Do Not Return This Product To The

Store. Please call 1-866-569-3799 (Press

Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have.

IMPORTANT NOTICES!

Wayne Dalton highly recommends that you read and fully understand the Installation Instructions and Owner’s Manual before you attempt this installation.

To avoid possible injury, read the enclosed instructions carefully before installing and operating the garage door. Pay close attention to all warnings and notes. After installation is complete, fasten this manual near garage door for easy reference.

DEFINITION OF DOOR HEIGHTS:

1. Door Heights less than or equal to 8’0” (< = 8’0”) are considered

Standard Lift Applications.

The complete Installation Instructions and Owner’s Manual are available at no charge from:

Wayne Dalton, a Division Of Overhead Door Corporation,

P.O. Box 67, Mt. Hope, OH., 44660, Or Online At

www.Wayne-Dalton.com.

Part Number 346745 REV5_06/04/2015

Pre-Installation

Important Safety Instructions

DEFINITION OF KEY WORDS USED IN THIS MANUAL:

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.

READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING INSTALLATION. IF IN QUES-

TION 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.

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

It is always recommended to wear eye protection when using tools, otherwise 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 over 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.

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

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, fasteners, counterbalance lift 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.

17. This door may not meet the building code wind load requirements in your area. For your safety, you will need to check with your local building official for wind load code requirements and building permit information.

After installation is complete, fasten this manual near the garage door.

IMPORTANT: STAINLESS STEEL OR PT2000 COATED LAG SCREWS MUST BE USED WHEN

INSTALLING CENTER BEARING BRACKETS, END BRACKETS, JAMB BRACKETS, DRAWBAR

OPERATOR MOUNTING SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED

LUMBER (PRESERVATIVE-TREATED). STAINLESS STEEL OR PT2000 LAG SCREWS ARE NOT

NECESSARY WHEN INSTALLING PRODUCTS ON UN-TREATED LUMBER.

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

IMPORTANT: WHEN INSTALLING 5/16” LAG SCREWS USING AN ELECTRIC DRILL/ DRIVER,

THE DRILL/ DRIVERS CLUTCH MUST BE SET TO DELIVER NO MORE THAN 200 IN-LBS OF

TORQUE. FASTENER FAILURE COULD OCCUR AT HIGHER SETTINGS.

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

LOOKING OUT.

Tools Required

Power drill

Drill bits: 1/8”, 3/16”, 9/32”,

7/16”, 1/2”

Ratchet wrench

Socket driver: 7/16”

Sockets: 7/16”, 1/2”, 9/16”,

5/8”

Socket extension: 3”

Phillips head screwdriver

Flat tip screwdriver

Pliers / Wire cutters

Needle nose pliers

Locking pliers

(2) Vice clamps

Wrenches: 7/16”, 1/2”, 9/16”,

5/8”

Hammer

Tape measure

Step ladder

Level

Pencil

Saw horses

Leather gloves

Safety glasses

Package Contents

NOTE: Depending on the door model, some parts listed will not be supplied if not required.

Rear Back Hangs may not be included with your door.

Door sections (as required)

Extension Springs

Quick Install flag angles RH/LH (as required) Fully Adjustable flag angles RH/LH (as required)

Riveted vertical track assemblies RH/LH (as required)

Vertical tracks RH/LH (as required)

Horizontal tracks RH/LH (as required)

(2) Horizontal track angles (as required)

Angle mount vertical track assemblies RH/LH (as required)

Q.I. jamb brackets

(as required)

F.A. jamb brackets

(as required)

Strut (U-bar)

(if included)

Weather seals & nails (If included)

(2) Top fixture assemblies

Roller spacers

Track rollers

(as required)

Bottom corner brackets

RH/LH

(1) Step plate

(as required)

(2) Step plates

(as required)

PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS, EN-

SURE 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.

Graduated hinges (as required)

Pull down rope

(if included)

(2) Lift handles

& Spacers

(1) Step plate

(as required)

(2) 5/16”-18 x 3-3/4”

Eye bolts

2

The BOTTOM SECTION can be identified by the factory attached bottom astragal, the factory attached bottom corner brackets, and by the bottom corner bracket warning labels on each end stile.

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

(2) Front cable lift sheaves

(2) Rear cable lift sheaves

3 Hole clips

(as required)

S-hooks

(as required)

(2) Sheave forks

(as required)

Counterbalance lift cables Safety cables (2) 5/16”-18 Hex nuts (2) 3/8”- 16 Hex nuts

1/4”- 20 Flanged hex nuts (as required)

(2) 1/4” - 20

Hex nuts

(lift handles)

1/4”-14 x 5/8” Self tapping screws (as required)

(2) 3/8”-16 x 3/4”

Truss head bolts

Warning label

Intermediate I section

18” or

21”

Bottom corner bracket warning labels

Bottom weather seal

Bottom section

Section side view illustration

Removing an Existing Door

IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE

ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.

1/4”-20 x 7/8” Self drilling screws (as required)

(2) 1/4” - 20 x 5/8”

Tamper resistant screws

1/4”-20 x 11/16” Self drilling screws (as required)

1/4”-20 x 9/16”

Track bolts (as required)

(2) #8 x 1-5/8”

Self tapping screws (step plate)

3/8” - 16 x 1-1/4” Hex head bolts (as required)

5/16” x 1-5/8” Hex head lag screws

(as required)

(2) 1/4”-20 x 2-1/2” Carriage bolts (lift handles)

(2) 1/4” x 2-3/4” Carriage bolts (lift handles)

Door Section Identification

Door Height

7’0”

7’6”

7’9”

8’0”

6’0”

6’3”

6’6”

6’9”

Bottom

21”

18”

21”

18”

21”

Door Section Identification

Lock (second)

Intermediate

I (third)

18”

21”

18”

21”

18”

21”

18”

Intermediate

II (fourth)

18”

Top

21”

18”

21”

18”

21”

18”

When installing your door you must use sections of the appropriate height in the right stacking order. What section heights you need to use in what order depends on the height of your door.

Unless your door is five sections in height, you will not receive an Intermediate II section.

3

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 not supplied with the door, but are available at no charge from Wayne Dalton, A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope,

OH., 44660, or at

www.Wayne-Dalton.com.

Preparing the Opening

IMPORTANT: 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 ® 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.

For TorqueMaster ® counterbalance systems, a suitable mounting surface (2” x 6”) must be firmly attached to the wall, above the header at the center of the opening.

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

WEATHERSTRIPS (MAY NOT BE INCLUDED):

Depending on the size of your door, you may have to cut or trim the weatherstrips (if necessary) to properly fit into the header and jambs.

NOTE: If nailing product at 40°F or below, pre-drilling is required.

NOTE: Do not permanently attach weatherstrips to the header and jambs at this time.

For Quick Install track: For the header, align the weatherstrip with the inside edge of the header and temporarily secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and flush with the inside edge of the jamb. Temporarily secure the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart.

For Fully Adjustable track: For the header, align the weatherstrip 1/8” to 1/4” inside the header edge, and temporarily secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and 1/8” to 1/4” inside the jamb edge. Temporarily secure the weatherstrip with

equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart.

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” low headroom conversion kit is available for 12” 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.

BACKROOM REQUIREMENTS

DOOR HEIGHT TRACK MANUAL LIFT MOTOR OPERATED

6’0” to 7’0”

7’1” to 8’0”

12”,15” Radius

102” (2591 mm)

114” (2896 mm)

125” (3175 mm)

137” (3480 mm)

HEADROOM REQUIREMENTS

TRACK TYPE

15” Radius track

12” Radius track

6” LHR KIT

SPACE NEEDED

14-1/2” (368 mm)

11” (279 mm)

6” (152 mm)

Suitable mounting surface

2”x 6” lumber minimum

Header board 2”x 6” lumber preferred

Headroom

Min. Side room

Clearance is 3 1/2”

Backroom

Nail

Min. Side room

Clearance is 3 1/2”

Level header

Weatherstrips

Finished

Door

Height

Plumb jambs

Finished

Door width

Jambs

Weatherstrips

Jamb

Quick Install track

Jamb

Other track systems

1/8” to 1/4”

Weatherstrips

4

NOTE: The illustrations shown on this page are general representations of the door parts. Each specific door models may have unique variations.

PARTS BREAKDOWN

A1.

J3.

J6.

J5.

C1.

A2.

F2.

J5.

F1.

A1.

F3.

E1.

A2.

J5.

J3.

F2.

C1.

F1.

E2.

J9.

J5.

J6.

J4.

J7.

D4.

J1.

D3.

J8.

D2.

B1.

C2.

D1.

B2.

C1.

I4.

I3.

I2.

L1.

A. FLAG ANGLES (AS REQUIRED):

A1. Fully Adjustable (F.A.) Flag Angles

A2. Quick Install (Q.I.) Flag Angles

B. JAMB BRACKETS (AS REQUIRED):

B1. Fully Adjustable (F.A.) Jamb Brackets

B2. Quick Install (Q.I.) Jamb Brackets

C. TRACK ROLLERS:

C1. Short Stem Track Rollers

C2. Long Stem Track Rollers

D. GRADUATED END HINGES:

D1. Single Graduated End Hinges (S.E.H.), Anti-Pinch

D2. Single Graduated End Hinges (S.E.H.), Industry Standard

D3. Double Graduated End Hinges (D.E.H.), Anti-Pinch

D4. Double Graduated End Hinges (D.E.H.), Industry Standard

E. STACKED SECTIONS:

E1. Top Section

E2. Intermediate(s) Section

E3. Lock Section

E4. Bottom Section

F. TOP FIXTURES (AS REQUIRED):

F1. Top Fixture Bases - (L - Shaped)

F2. Top Fixture Slides - (L - Shaped)

F3. Top Fixture Assemblies

G. STRUT(S) (AS REQUIRED):

K1.

E3.

F3.

B2.

B1.

I1.

J4.

J7.

G1.

G2.

H2.

J9.

H1.

Top of vertical track

3rd hole set

J2.

J1.

K1.

J8.

J5.

Top of vertical track

B1. (Fully

Adjustable

Feature)

E4.

J2.

I2.

I1.

L1.

I3.

I4.

2nd hole set

J5.

B2. (Quick

Install

Feature)

3rd hole set

2nd hole set

1st hole set

Top hole

Middle hole

Bottom hole

1st hole set

Lower hole of hole/ slot pattern

5

G1. Strut (U - shaped) / G2. Strut (A - symmetrical)

H. DRAWBAR OPERATOR BRACKET (FOR TROLLEY OPERATED DOORS):

H1. Drawbar Operator Bracket - For Models 9600/9405/9100/5145/5120

H2. Drawbar Operator Bracket - For Models 9700/9800

I. TRACKS (AS REQUIRED):

I1. Left Hand and Right Hand Horizontal Track Assemblies

I3. Left Hand and Right Hand Vertical Tracks

I3. Left Hand and Right Hand Riveted Vertical Track Assemblies

I4. Left Hand and Right Hand Angle Mount Vertical Track Assemblies

J. EXTENSION SPRING ASSEMBLY (AS REQUIRED):

J1. Extension Springs

J2. Safety Cables

J3. Front Cable Lift Sheaves

J4. Rear Cable Lift Sheaves

J5. 3 Hole Clips (As Required)

J6. S-Hooks (As Required)

J7. Sheave Forks (As Required)

J8. 5/16” - 18 x 3-3/4” Eye Bolts (As Required)

J9. Counterbalance Lift Cables

J10. 5/16” - 18 Hex Nuts (As Required)

K. REAR BACK HANGS:

K1. Left Hand And Right Hand Rear Back Hang Assemblies

L. BOTTOM CORNER BRACKETS (AS REQUIRED):

L1. Left Hand And Right Hand Bottom Corner Brackets

INSTALLATION

Before installing your door, be certain that you have read and followed all of the instructions covered in the pre-installation section of this manual. Failure to do so may result in an improperly installed door.

NOTE: Reference TDS 160 for general garage door terminology at www.dasma.com.

Quick Install Flag Angles

Tools Required: Safety glasses, Leather gloves

NOTE: If you have Fully Adjustable Flag Angles, Riveted Track or Angle Mount Track, skip this step.

NOTE: Flag angles are right and left handed.

Place the lower Quick Install tab of the left hand flag angle in the Quick Install feature of the left hand vertical track. Give the flag angle 1/4 turn to lock in place. Repeat for other side.

Flag angle

1/4 Turn

Vertical track

Lower Quick

Install tab

Quick Install feature

Fully Adjustable Flag Angles

Tools Required: Safety glasses, Leather gloves

NOTE: If you have Quick Install flag angles, Riveted Track or Angle Mount Track, skip this step.

NOTE: Flag angles are right and left handed.

If you have Quick Install vertical tracks, hand tighten the left hand flag angle to the left hand vertical track using (1) stud plate and (2) 1/4” - 20 flange hex nuts. Repeat for the other side.

If you have Fully Adjustable vertical tracks, hand tighten the left hand flag angle to the left hand vertical track using (2) 1/4” - 20 x 9/16” track bolts and (2) 1/4” - 20 flange hex nuts.

Repeat for other side. Flange nuts will be secured after flag angle spacing is completed in step, Top Section.

Flag angle

1/4”-20

Flange hex nuts

Flag angle

1/4”-20

Flange hex nuts

Stud plate

Quick Install vertical track

Fully Adjustable vertical track

Horizontal Track Angles

Tools Required: Hammer, Safety glasses, Leather gloves

1/4”- 20 x 9/16”

Track bolts

NOTE: For larger doors, a full length horizontal track angle may not already be spot welded to the horizontal track. If the horizontal track angle is not welded, the horizontal track angle will be installed, as shown.

Position the left hand horizontal track angle, as shown. Place the Quick Install tabs of the horizontal track angle in the key slot of the left hand horizontal track. Using a hammer, tap the horizontal track angle towards the curved end of the track until the alignment hole in the track and angle are aligned. Repeat for other side. Set tracks aside.

Quick

Install tabs

Horizontal track angle

Alignment hole

Key slots

Horizontal track

Quick Install tabs in place

Horizontal track angle

Quick

Install tabs

Quick

Install tabs

Key slots

Quick Install tabs in place

Horizontal track

Quick Install Jamb Brackets

Tools Required: Tape measure, Safety glasses, Leather gloves

NOTE: If you have Fully Adjustable jamb brackets, Riveted Track or Angle Mount Track, skip this step.

Measure the length of the vertical tracks. Using the jamb bracket schedule, determine the placement of the jamb brackets for your door height and track length. To install the jamb brackets, align the Quick Install tab on the Quick Install jamb bracket with the Quick Install feature in the vertical track and turn the bracket perpendicular to the track so the mounting flange is toward the back (flat) leg of the track. Repeat for other side.

JAMB BRACKET SCHEDULE

DOOR

HEIGHT

6’0”

3RD SET

6’3”

6’6”

6’9”

7’0”

7’6”

7’9”

8’0”

73”

(1854 mm)

76”

(1930 mm)

82”

(2083 mm)

85”

(2159 mm)

88”

TRACK

LENGTH

64”

(1626 mm)

67”

(1702 mm)

70”

(1778 mm)

1ST SET

2ND SET

9 T 10 M

B= BOTTOM HOLE, M= MIDDLE HOLE, T= TOP HOLE

1st hole set 2nd hole set

Vertical track Top of track

3rd hole set

Bottom hole

Middle hole

Top hole

Q.I. tab

Q.I. jamb bracket

Jamb bracket in place

Mounting flange

6 Fully Adjustable Jamb Brackets

Tools Required: Tape measure, Safety glasses, Leather gloves

NOTE: If you have Quick Install jamb brackets, Riveted Track or Angle Mount Track, skip this step.

NOTE: The bottom jamb bracket is always the shortest bracket, while the center jamb bracket is the next tallest. If three jamb brackets per side are included with your door, you will have received a top jamb bracket, which is the tallest.

To attach the bottom jamb bracket, locate lower hole of the hole/ slot pattern of the 1st hole set on the vertical track. Align the slot in the jamb bracket with the lower hole of the hole/ slot pattern. Secure jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side.

Place the center jamb bracket over the lower hole of the hole/ slot pattern that is centered between the bottom jamb bracket and flag angle of the 2nd hole set. Secure jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side.

If a top jamb bracket was included, secure it to vertical track using the lower hole of the hole/ slot pattern in the 3rd hole set and (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side.

Vertical track Top of track

1st hole set 2nd hole set 3rd hole set

Lower hole of hole/ slot pattern

1/4”- 20

Flange hex nut

1/4”- 20 x 9/16”

Track bolt

Jamb bracket in place

F.A. jamb bracket

Graduated Hinge Attachment

Tools Required: Power drill, 7/16” Socket driver, Step ladder, Tape measure,

Safety glasses, Leather gloves

NOTE: Refer to door section identification, located in the pre-installation section of this manual.

NOTE: The graduated hinges can be identified by the number stamped on the lower hinge leaf.

NOTE: The #1 graduated end hinges serves as end hinges on the bottom section. The #1 graduated end hinges also serves as center hinges on all sections, except for the top section.

NOTE: The #2 graduated end hinges serves as end hinges on the Lock section.

NOTE: The #3 graduated end hinges serves as end hinges on the Intermediate I section.

NOTE: The #4 graduated end hinges serves as end hinges on the Intermediate II section

(used only on the fourth section of a five section high door).

Starting on the left hand side of the bottom section, align the lower hinge leaf of the #1 graduated end hinge over the holes, located at the top of the end caps. Attach lower leaf to the end caps with (2) 1/4” - 14 x 5/8” self tapping screws. Repeat for other side. Next, align the lower hinge leaf of the #1 center hinges with the pre-punched holes at each center stile location(s), located at the top of the bottom section. Attach lower hinge leaf to the center stile with (2) 1/4” - 14 x 5/8” self tapping screws. Insert a short stem track roller into the hinge tube of the #1 graduated end hinges.

IMPORTANT: ONCE THE 1/4” - 14 X 5/8” SELF TAPPING SCREWS ARE SNUG AGAINST THE

LOWER HINGE LEAFS, TIGHTEN AN ADDITIONAL 1/4 TO 1/2 TURN TO RECEIVE MAXIMUM

DESIGN HOLDING POWER.

Repeat graduated hinge attachment using the appropriate graduated end hinges for all remaining sections except the top section.

IMPORTANT: WHEN PLACING SHORT STEM TRACK ROLLERS INTO THE #2 GRADUATED

END HINGES AND HIGHER, THE SHORT STEM TRACK ROLLER GOES INTO HINGE TUBE

FURTHEST AWAY FROM SECTION.

IMPORTANT: ONCE THE 1/4” - 14 X 5/8” SELF TAPPING SCREW IS SNUG AGAINST THE

LOWER HINGE LEAF, TIGHTEN AN ADDITIONAL 1/4 TO 1/2 TURN TO RECEIVE MAXIMUM

DESIGN HOLDING POWER.

Short stem track roller

#1 Graduated end hinge

#1Center hinge(s)

Lower hinge leaf

1/4”-14 x 5/8” Self tapping screw locations

End stile

#2 Graduated end hinge

(short stem track roller inserted into tube furthest from section)

Center stile(s) End stile

Strut (U-shaped)

Tools Required: Power drill, 7/16” Socket driver, Step ladder, Tape measure,

Safety glasses, Leather gloves

NOTE: Refer to door section identification, located in the pre-installation section of this manual or refer to Parts Breakdown.

Using the strut schedule, determine the placement of the struts for your door width and door height.

INSTALLATION ON THE TOP SECTION:

Locate and center the strut at the top of the top section surface. Secure strut to top section using (2) 1/4” - 20 x 7/8” self drilling screws at each end and at each center stile locations.

INSTALLATION ON ALL OTHER SECTIONS:

NOTE: All struts are placed at the top of the sections and up against the bottom of the graduated hinges, for the intermediate, lock and bottom sections.

Locate and center the strut onto the section surface and up against the bottom of the hinges.

Center the strut side to side. Secure strut to the section using (2) 1/4” - 20 x 7/8” self drilling screws at each end and center stile locations.

Door Width

Strut Schedule

4 Section High Door 5 Section High Door

8’0” – 13’11”

14’0” – 16’0”

16’1” – 18’0”

18’1” – 20’0”

N/A

(1) Strut Top Section

(3) Struts Top, Lock and Bottom

Sections

(4) Struts All Sections

N/A

(2) Struts Top and Bottom

Sections

(3) Struts Top, Intermediate I and Bottom Section

(5) Struts, All Sections

Strut installation for top section

1/4”-20 x 7/8” Self drilling screws

Graduated end hinges

Center hinge(s)

Strut installation for other sections

Strut

1/4”-20 x 7/8” Self drilling screws Typical graduated lower hinge leaf

Strut

Strut installation at top of top section

Strut installation for other sections

Top Fixtures

Tools Required: Power drill, 7/16” Socket driver, Step ladder, Safety glasses,

Leather gloves

Align the upper-center hole of top fixture base with the hole in the end stile of the top section, as shown. Ensure the top fixture base is level and aligned with edge of the top section. Secure with (4) 1/4” - 20 x 7/8” self drilling screws, one in each corner of the top fixture base.

Insert short stem track roller into top fixture slide. Repeat for other side.

NOTE: If needed, ensure the top fixture slides are able to slide back and forth along the top fixture bases. If needed, loosen the (2) 1/4” - 20 flange hex nuts.

7

Top section

Hole

Top fixture base

End cap

Upper center slotted hole

Cable Drum Assemblies and Track Rollers

Tools Required: Power drill, 7/16” Drill bit, Tape measure, Safety glasses,

Leather gloves

NOTE: Refer to door section identification, located in the pre-installation section of this manual or refer to Parts Breakdown.

Starting on the left hand side, attach left hand bottom corner bracket to the left corner of the bottom section, making sure it is seated to the edges of the end cap, using (2) 1/4” - 20 x

11/16” self drilling screws (1) 1/4” - 20 x 5/8” tamper resistant screw. Repeat for other side.

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

NOTE: Cable drum assemblies are marked right and left hand.

FAILURE TO ENSURE TIGHT FIT OF CABLE LOOP OVER MILFORD PIN

COULD RESULT IN COUNTERBALANCE LIFT CABLE COMING OFF THE PIN,

ALLOWING THE DOOR TO FALL, POSSIBLY RESULTING IN SEVERE OR

FATAL INJURY.

Uncoil the counterbalance lift cables. Starting on the left hand side, place the left hand cable loop on the left hand milford pin of the bottom corner bracket.

NOTE: Check to ensure cable loops fits tightly over the milford pins.

Insert a short stem track roller with a roller spacer into each of the bottom corner brackets.

NOTE: Larger doors will use long stem track rollers with double graduated end hinges.

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

End cap n

Bottom weather seal

Bottom sectio

Counterbalance lift cable loop

Milford pin

(2) 1/4” - 14 x 7/8”

Self drilling screws

Short stem track roller

Roller spacer

Bottom corner bracket

(1) 1/4” - 20 x 5/8”

Tamper resistant screw

Step Plate

Tools Required: Power drill, 9/32”/1/2” Drill bits, 7/16” Wrench, Phillips head screwdriver, Tape measure, Safety glasses, Leather gloves

NOTE: Depending on your door, you may have two different kinds of Step Plates or two of the same kind of Step Plates. Refer to Package Contents, to determine which Step Plates you have.

IF YOU HAVE TWO OF THE SAME KINDS OF STEP PLATES: Locate the center most center stile of the bottom section of the door. On the inside of the door, center the step plate on the center most stile no higher than 6” from the bottom of the door. Using the step plate holes as a template, drill a 5/16” dia. hole along each side of the center stile, through the face of the door. Drill through insulation and door’s face on an insulated door.

IMPORTANT: BE EXTREMELY CAREFUL TO KEEP DRILL STRAIGHT.

Mount the inside step plate and the outside step plate back to back, straddling the center stile. Secure with (2) 1/4” - 20 x 2-3/4” carriage bolts and 1/4” - 20 hex nuts.

IMPORTANT: DO NOT MOUNT THE STEP PLATE HIGHER THAN 6” FROM THE BOTTOM OF

THE SECTION.

Bottom section inside

Bottom section outside

6” Max.

mounting height

Inside step plate

(2) 5/16” Dia. drilled holes

Outside step plate

(2) 1/4”-20 x 2 3/4”

Carriage bolts

(2) 1/4”-20 x 2 3/4”

Carriage bolts

Inside step plate

Bottom section inside

(2) 1/4”-20 Nuts

IF YOU HAVE TWO DIFFERENT KINDS OF STEP PLATES: Locate the center most center stile on the bottom section of the door. On the inside of the door and using the pre-punched holes at the bottom of the center 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” dia. and assemble the outside and inside step 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.

NOTE: After completing this step, continue with Step Lift Handles.

Inside of bottom section

Center stile

(2) 7/32”

Diameter holes

Inside step plate

Outside of bottom section

Outside step plate

(2) #8 x 1-5/8” Self tapping screws

(2) 7/16”

Diameter holes

Lift Handle

Tools Required: Power drill, 9/32”/1/2” Drill bits, 1/4” Wrench, Tape measure,

Safety glasses, Leather gloves

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

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 lock (2nd) section.

IMPORTANT: THE DISTANCE BETWEEN THE STEP PLATE AND THE MIDDLE OF THE LIFT

HANDLE MUST BE 20” MINIMUM TO 30” MAXIMUM. IF NECESSARY REPOSITION THE UPPER

LIFT HANDLE TO STAY WITHIN THE REQUIRED DIMENSION.

Using the lift handle holes as a template, drill (2) 9/32” dia. holes through the lock section.

Enlarge the holes from the outside the door to 1/2” dia.

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

Assemble the outside and inside lift handles to the lock section using (2) spacers, (2) 1/4” -

20 x 2-1/2” carriage bolts and (2) 1/4” - 20 hex nuts.

(2) 9/32”

Diameter holes

Center stile

Inside lift handle

(2) Spacers

Outside lift handle

Inside of lock section

4”

(2) 1/4”-20

Hex Nuts

Outside of lock section

(2) 1/2”

Diameter holes

(2) 1/4”-20 x 2-1/2”

Carriage bolts

Outside lift handle

Outside of lock section

20” Minimum to

30” Maximum

Outside of bottom section

Outside step plate

8 Bottom Section

Tools Required: Tape measure, Level, Wooden shims (if necessary), Safety glasses, Leather gloves

Center the bottom section in the door opening. Level the section using wooden shims (if necessary) under the bottom section. When the bottom section is leveled, temporarily hold it in place by driving a nail into the jamb and bending it over the edge of the bottom section on both sides.

Weather seal (If applicable)

Level

Stacking Sections

Tools Required: Power drill, 7/16” Socket driver, Tape measure, Level, Step ladder, Safety glasses, Leather gloves

NOTE: Refer to door section identification, located in the pre-installation section of this manual.

NOTE: The sections can be identified by the graduation of the installed graduated end hinges.

The smallest graduated end hinge on section should be stacked on top of the bottom section, with each graduated end hinge increasing as the sections are stacked, see Parts Breakdown.

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

Place track rollers into graduated end hinges of remaining sections.

NOTE: Larger doors will use long stem track rollers with double graduated end hinges.

With assistance, lift second section and guide the track rollers into the vertical tracks. Lower section until it is seated against bottom section. Flip hinges up. Fasten center hinge(s) first; then end hinges last using 1/4” - 20 x 7/8” self-drilling screws.

Repeat same process for other sections, except top section.

IMPOTANT: PUSH & HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE

SECURING WITH 1/4” - 20 X 7/8” SELF-DRILLING SCREWS. THERE SHOULD BE NO GAP

BETWEEN THE HINGE LEAFS AND THE SECTIONS.

NOTE: Install lock at this time (sold separately). See optional installation step, Side Lock.

Bottom section

Wooden shims (If necessary)

Vertical Tracks

Tools Required: Power Drill, 3/16” Drill bit, 7/16” Socket driver, Tape measure,

Level, Step ladder, Safety glasses, Leather gloves

NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable Flag

Angles or you may have Riveted Vertical Track Assemblies. Refer to Package Contents / Parts

Breakdown, to determine which Flag Angles / Vertical Track Assemblies you have.

IMPORTANT: IF YOUR DOOR IS TO BE INSTALLED PRIOR TO A FINISHING CONSTRUCTION

OF THE BUILDING’S FLOOR, THE VERTICAL TRACKS AND THE DOOR BOTTOM SECTION

ASSEMBLY SHOULD BE INSTALLED SUCH THAT WHEN THE FLOOR IS CONSTRUCTED, NO

DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION.

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.

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

For Quick Install Flag Angles, Fully Adjustable Flag Angles or Riveted Vertical Track Assemblies: Loosely fasten jamb brackets and flag angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spacing, between the bottom section and vertical track. Hang counterbalance lift cable over flag angle. Repeat same process for other side.

Flag angle

Vertical track assembly

Jamb bracket

Bottom section

5/16” x 1-5/8”

Lag screws

Track rollers

Floor

12R FA 15R FA 12R QI 15R QI

Flag angle lag screw locations

3/8” to 5/8”

Spacing

Bottom section

Vertical track

Track roller

Vertical tracks

Lock section

1/4”-20 x 7/8” Self drilling screw locations

Left graduated end hinge with short stem track roller

Center hinge(s)

Right graduated end hinge with short stem track roller

Top Section

Tools Required: Power drill, 7/16” Socket driver, 7/16” Wrench, Step ladder,

Tape measure, Safety glasses, Leather gloves

Place the top section in the opening. 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 leaves, hold tight against section, and fasten center hinges first and end hinges last

(refer to step, Stacking Sections). Vertical track alignment is critical. Position flag angle or wall angle between 1-11/16” (43 mm) to 1-3/4” (44 mm) from the edge of the door; tighten the bottom lag screw. Flag angles must be parallel to the door sections. Repeat for other side.

IMPORTANT: THE DIMENSION BETWEEN THE FLAG ANGLES OR WALL ANGLES MUST BE

DOOR WIDTH PLUS 3-3/8” (86MM) TO 3-1/2” (89 MM) FOR SMOOTH, SAFE DOOR OPERA-

TION.

FOR QUICK INSTALL TRACK: Complete the vertical track installation by securing the jamb bracket(s) and tightening the other lag screws. Repeat for other side.

For Fully Adjustable track or Riveted Track: Complete the vertical track installation by securing the jamb bracket(s) and tightening the other lag screws. Push the vertical track against the track rollers so that the track rollers are touching the deepest part of the curved side of the track; tighten all the track bolts and nuts. Repeat for other side.

9

Flag angle

1-11/16” to 1-3/4”

Door width

+ 3-3/8” to 3-1/2”

Nail

Top section

Flag angle

Top section

Vertical track against track rollers

Horizontal Tracks

Tools Required: Ratchet wrench, 9/16” 7/16” Socket, 9/16” 7/16” Wrench, Step ladder, Tape measure, Safety glasses, Leather gloves

NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable Flag

Angles or you may have Riveted Vertical Track Assemblies. Refer to Package Contents / Parts

Breakdown, to determine which Flag Angles / Vertical Track Assemblies you have.

Adjusting Top Fixtures

Tools Required: 7/16” Wrench, Step ladder, Tape measure, Safety glasses,

Leather gloves

ADJUSTING TOP FIXTURE SLIDE:

With horizontal tracks installed, you can now adjust the top fixtures. Vertically align the top section of the door with the lower sections. Once aligned, position the top fixture slide, out against the horizontal track. Maintaining the slide’s position, tighten the (2) 1/4”-20 flange hex nuts to secure the top fixture slide to the top fixture base. Repeat for other side.

REVERSING THE TOP FIXTURE SLIDE, IF NEEDED:

NOTE: Depending on your application, you may have to reverse the top fixture slide for more adjustability, prior to securing it to the top fixture base.

Remove the top fixture slide by removing the (2) 1/4”-20 flanged hex nuts and the (2) 1/4”-

20 x 5/8” carriage bolts. Remove the track roller from the top fixture slide and flip the top fixture slide in the opposite direction. Re-insert the track roller back into the top fixture slide and loosely fasten the top fixture slide to the top fixture base by re-using the (2) 1/4”-20 x

5/8” carriage bolts and (2) 1/4”-20 flange hex nuts. Repeat same process for other side.

Now follow the instructions at the top of this step “Adjusting top fixture slide(s)”.

Short stem track roller

Horizontal track

Top section

(2) 1/4”-20

Flange hex nuts

Rear Back Hangs

Tools Required: Ratchet wrench, Socket: 1/2” 5/8”, Wrench: 1/2” 5/8”, (2) Vice clamps, Tape measure, Level, Step ladder, Safety glasses, Leather gloves

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

WARNING

RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE

SEVERE OR FATAL INJURY.

Clamp a pair of vice clamps onto the vertical tracks just above the second track roller on one side, and just below the second track roller on the other side. This will prevent the door from raising or lowering while installing the rear back hangs.

Attach the horizontal tracks to the rear back hangs with 5/16” - 18 x 1” hex bolts and nuts

(may not be supplied).

NOTE: Doors heights over 8’0” or door widths over 11’0”, require an additional set of rear center back hangs to be installed and located at the middle of the horizontal tracks, see parts breakdown.

Using the chart (Perforated Angle Gauge Weight Limitations) below, use the appropriate perforated angle (may not be supplied), (2) 5/16” x 1-5/8” hex head lag screws and (3) 5/16” bolts with nuts (may not be supplied), fabricate rear center back hangs for the middle of the horizontal tracks. Attach the rear center back hangs to the horizontal tracks with (1) 3/8” truss head bolt and (1) 3/8” nut (may not be supplied).

Horizontal tracks must be level and parallel with door within 3/4” to 7/8” maximum of door edge.

EXCEEDING THE RECOMMENDED LISTED DOOR WEIGHT LIMITATIONS OF

SPECIFIC GAUGE PERFORATED ANGLES MAY RESULT IN DOOR FALLING

WHEN RAISED, CAUSING SEVERE OR FATAL INJURY.

10

WARNING

VERIFY PERFORATED BACK HANG ANGLE LOAD RATINGS WITH BACK

HANG ANGLE SUPPLIER.

Perforated Angle Gauge Weight Limitations:

Perforated Angle Gauge

2” x 2” x 12 Gauge

Door Weight

Door Weight Less Than 800 lbs.

1-1/4” x 1-1/4” x 13 Gauge

1-1/4” x 1-1/4” x 15 Gauge

1-1/4” x 1-1/4” x 16 Gauge

Door Weight Less Than 305 lbs.

Door Weight Less Than 220 lbs.

Door Weight Less Than 175 lbs.

NOTE: If an opener is installed, position horizontal tracks one hole above level when securing it to the rear back hangs.

KEEP HORIZONTAL TRACKS PARALLEL AND WITHIN 3/4” TO 7/8” MAXI-

MUM OF DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING IN

SEVERE OR FATAL INJURY.

IMPORTANT: DO NOT SUPPORT THE WEIGHT OF THE DOOR ON ANY PART OF THE REAR

BACK HANGS THAT CANTILEVERS 4” OR MORE BEYOND A SOUND FRAMING MEMBER.

NOTE: If rear / center back hangs are to be installed over drywall, use (2) 5/16” x 2” hex head lag screws and make sure lag screws engage into solid structural lumber.

NOTE: 26” angle must be attached to sound framing members and nails should not be used.

Now, permanently attach the weatherstrips on both door jambs and header. The weatherstrips were temporarily attached in Preparing the Opening, in the pre-installation section of this manual.

NOTE: When permanently attaching the weatherstrips to the jambs, avoid pushing the weatherstrips too tightly against the face of door.

Horizontal track

5/16”-18 x 1-1/4”

Hex bolt must extend into the track to serve as a roller stop

Sound framing members

Perforated angle bolted using (2) 5/16” x 1-5/8” hex head lag screws to ceiling member and parallel to door

(3) 5/16” Bolts and nuts

Perforated angle

Sound framing members

Vice clamp

Horizontal tracks

2nd Track roller

Vice clamp

(3) 5/16”

Bolts and nuts

Horizontal track

Perforated angle

5/16”-18 x 1-1/4”

Hex bolt must extend into the track to serve as a roller stop

3/4” To 7/8”

Door edges

Horizontal tracks

Perforated angle bolted using (2) 5/16” x 1-5/8” hex head lag screws to ceiling member and parallel to door

3/4” To 7/8”

11

Horizontal track

Rear center back hang

(1) 3/8” Truss head bolt

(may not be supplied)

Horizontal track

(1) 3/8” Nut

(may not be supplied)

Drill 3/8” diameter hole

Center of the horizontal track

Attaching Front Cable Lift Sheaves

Tools Required: Wrench: 9/16”, (2) Vice clamps, Tape measure, Level, Step ladder, Safety glasses, Leather gloves

IF YOU HAVE 3” FRONT CABLE LIFT SHEAVE AND A 12” RADIUS HORIZONTAL TRACK:

STARTING ON THE LEFT HAND SIDE AND USING (1) 3/8” - 16 HEX NUT, secure the front cable lift sheave to the 13/32” hole near the top of the flag angle, as shown.

IF YOU HAVE 3” OR 4” FRONT CABLE LIFT SHEAVE AND A 15” RADIUS HORIZONTAL

TRACK: Starting on the left hand side and using (1) 3/8” - 16 hex nut, secure the front cable lift sheave to the first 13/32” hole in the horizontal angle, as shown.

Repeat the same process for the right hand side. Remove the locking pliers from the vertical tracks. With assistance, raise the door slowly into the open position making sure the door travels smoothly through the tracks. Clamp locking pliers to the back leg of both horizontal tracks, below the bottom track rollers to keep the door from lowering.

12” Radius horizontal track with 3” front cable lift sheave hole location

Front cable lift sheave

3/8”-16

Hex nut

15” Radius horizontal track with 3” or 4” front cable lift sheave hole location

Spring safety cable

Rear back hang

Special knot

3 Hole clip

Horizontal track

(1) 5/16”-18 x 3-3/4”

Extension spring loop

Eye bolt

3 Hole clip

(1) 5/16” x 1-5/8”

Lag screw

Spring safety cable

(1) 5/16”-18

Hex nut

3 Hole clip

Extension spring

Front view Back view

Special knot

Spring safety cable

Extension spring

Rear back hang

Extension spring

Spring safety cable

Extension spring loop

Eye bolt

Extension spring loop

5/16” x 1-5/8” Lag Bolt

Spring safety cable

Extension spring loop

3 Hole clip

3” Or 4”

Front cable lift sheave

Flag angle

Horizontal track angle

Horizontal track

Attaching Extension Springs

Tools Required: Wrench: 9/16”, Tape measure, Level, Step ladder, Safety glasses, Leather gloves

FAILURE TO INSTALL SPRING SAFETY CABLES CAN RESULT IN SEVERE

OR FATAL INJURY IN CASE OF SPRING BREAKAGE.

Position (1) 5/16” - 18 x 3-3/4” eye bolt and (1) 5/16” - 18 hex nut into the rear back hang,

6” to 8” above the horizontal track, as shown. Feed the spring safety cable through the rear back hang and tie the special knot around the “room side” of the 3 hole clip, as shown.

Secure the eye bolt and 3 hole clip to the rear back hang using (1) 5/16” - 18 hex nut. Hook one end of the extension spring onto the eye bolt. Feed the spring safety cable through the rear extension spring loop and center of the extension spring then front spring loop, pull the spring safety cable taut and tie the special knot around the “jamb side” of the 3 hole clip.

Attach the “jamb side” 3 hole clip to the jamb near the flag angle using (1) 5/16” x 1-5/8” lag bolt. Repeat the same process for the other side.

IMPORTANT: SPRING SAFETY CABLES MUST BE TAUT.

(1) 5/16”-18 x 3-3/4”

Eye bolt

Horizontal track angle

Horizontal track

Rear back hangs

Attaching Spring Sheaves

Tools Required: Wrench: 9/16”, Tape measure, Level, Step ladder, Safety glasses, Leather gloves

Hook the sheave fork through the front loop of the extension spring and attach the sheave fork to the rear cable lift sheave using (1) 3/8” - 16 x 1-1/4” hex head bolt and (1) 3/8” - 16 hex nut. Thread the counterbalance lift cable over the front cable lift sheave and around the rear cable lift sheave and tie the special knot around the “horizontal angle” using a 3 hole clip, as shown.

Insert one end of the large “S” hook into the “horizontal angle” with the 3 hole clip and the other end into the second slot of the horizontal angle, as shown.

Repeat for the other side.

IMPORTANT: CLOSE “S” HOOKS AND EYE BOLTS TO PREVENT SPRINGS FROM COMING

LOOSE.

FAILURE TO CLOSE “S” HOOKS AND EYE BOLTS CAN RESULT IN SEVER

OR FATAL INJURY IF SPRINGS COME LOOSE.

NOTE: Some larger doors feature 2 pairs of extension springs. A spring safety cable must be installed through each spring.

(1) 5/16”-18

Hex nut

6”-8”

Rear back hang

(Perforated angle)

Horizontal track

12

Extension spring

Sheave fork

Spring safety cable

Rear cable lift sheave

Extension spring loop

(1) 3/8” - 16

Hex nut

(1) 3/8”-16 x 1-1/4”

Hex head bolt

Horizontal track

(1) 3/8” - 16

Hex nut

Sheave fork

Front cable lift sheave

Horizontal track

Counterbalance lift cable

Rear cable lift sheave

Counterbalance lift cable

Extension spring

3 Hole clip

Counterbalance lift cable

Special knot

Horizontal track angle

Second slot

“S” Hook

Counterbalance lift cable

Rear cable lift sheave

Hook plate

Front cable lift sheave

Counterbalance lift cable

Spring safety cable

Final Adjustments

Tools Required: Tape measure, Level, Step ladder, Safety glasses, Leather gloves

Now lift the door and check its balance. If the door is hard to pull down or lifts by itself, adjust extension spring length by moving the “S” hook backward (towards the rear back hangs) to a different hole in the horizontal angle.

If the door is difficult to lift or too easy to pull down, adjust extension spring length by moving the “S” hook forward (towards the header) to a different hole in the horizontal angle.

IMPORTANT: WHENEVER ADJUSTING EXTENSION SPRING LENGTH FOR DOOR BALANCE,

ALWAYS OPEN THE DOOR TO THE FULLY OPEN POSITION AND RETURN THE LOCKING PLI-

ERS TO THE HORIZONTAL TRACKS BELOW THE BOTTOM TRACK ROLLERS.

If the door still does not operate easily, lower the door into the closed position and recheck the following items:

1.) Check the door for level.

2.) Check the distance between flag angles - must be door width plus 3-3/8” + 1/4” - 0”.

3.) Check the counterbalance lift cables for equal tension - adjust by re-tieing the special knot.

Counterbalance lift cable

Sheave fork

Horizontal track

This illustrations shows doors featuring (2) pairs of extension springs

Cable Adjustments

Tools Required: Wrench: 9/16”, Tape measure, Level, Step ladder, Safety glasses, Leather gloves

Adjust counterbalance lift cables to create about 1” to 2” (25 mm to 50 mm) of initial extension spring stretch, with the door in the fully opened position. Measure relaxed extension spring length for your door height and verify with the chart below. Spring length must be the same for both extension springs to allow even door balance. Carefully remove the locking pliers from the horizontal track and lower the door into the closed position. Once the door is closed, measure the extension spring length in tension for both sides. Using the chart, verify the spring length in tension, is correct with your door height.

NOTE: It may be necessary to adjust spring length for proper door balance.

DOOR HEIGHT SPRING LENGTH RELAXED

(DOOR OPEN)

SPRING LENGTH EXTENDED

(DOOR CLOSED)

6’0”

6’3”

6’6”

7’0”

7’6”

7’9”

8’0”

25” (635 mm)

27” (686 mm)

61” (1549 mm)

62-1/2” (1588 mm)

64” (1626 mm)

67” (1702 mm)

72” (1829 mm)

73-1/2” (1867 mm)

75” (1905 mm)

13 Optional Installation

Inside Lock

Install the inside 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 inside lock should be spaced approximately 1/8” away from the section edge.

IMPORTANT: INSIDE LOCK(S) MUST BE REMOVED OR MADE INOPERATIVE IN THE UN-

LOCKED POSITION IF AN OPERATOR IS INSTALLED ON THIS DOOR.

Square hole in vertical track

Second section

Side lock

(4) 1/4”-20 x 11/16”

Self drilling screws

1/8”

End stile

Pull Down Rope

WARNING

DO NOT INSTALL PULL DOWN ROPE ON DOORS WITH 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 jamb. Drill 1/8” pilot hole for no. 6 screw eye. Tie the pull down rope to the no. 6 screw eye and to the bottom corner bracket, as shown.

No. 6 Screw eye

Typical bottom corner bracket

48” to 50”

From floor

Pull down rope

14 Maintenance

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 weatherstrips on both sides and top of door.

or drawbar operator bracket supplied with the door. To avoid possible damage to your door,

Wayne-Dalton recommends reinforcing the top section on models 8000, 8100, 8200 and

9100 doors with a strut (may or may not be supplied). The installation of the drawbar operator must be according to manufacturer’s instructions and force settings must be adjusted properly. Refer to the owner’s manual supplied with your drawbar operator for complete details on installation, operation, maintenance and testing of the operator.

MAINTAINING YOUR GARAGE DOOR…

Before you begin, read all warning labels affixed to the door and the installation instructions and owner’s manual. Perform routine maintenance steps once a month, and have the door professionally inspected once a year. Review your Installation Instructions and Owner’s

Manual for the garage door. These instructions are available at no charge from Wayne-Dalton,

A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, or at

www.

wayne-dalton.com. For additional information on garage door/operator maintenance go to

www.dasma.com and reference TDS 151, 167 and 179.

Monthly Inspections:

1. Visual Inspection: Closely inspect jambs, header and mounting surface. Any wood found not to be structurally sound must be replaced. Inspect the springs, counterbalance lift cables, track rollers, pulleys, rear back hangs and other door hardware for signs of worn or broken parts. Tighten any loose screws and/or bolts. Check exterior surface of the door sections for any minor cracks. Verify door has not shifted right or left in the opening. If you suspect problems, have a trained door system technician make the repairs.

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 solventbased cleaners of any kind.

Painting Your Garage Door

Refer to Instruction Insert “

Field Painting and Finishing Fiberglass or Steel Door Sec-

tions”.

Maintaining The Finish

On Your Garage Door

If the factory finish is beginning to fade, the door may require a field applied top clear coat.

Depending on environment and usage, this may be necessary after 1 to 3 years of use. Refer to Instruction Insert “ Field Painting and Finishing Fiberglass Or Steel Door Sections”.

Operation And Maintenance

GARAGE DOOR SPRINGS, COUNTERBALANCE LIFT CABLES, BRACK-

ETS, AND OTHER HARDWARE ATTACHED TO THE SPRINGS ARE UNDER

EXTREME TENSION, AND IF HANDLED IMPROPERLY, CAN CAUSE SEVERE

OR FATAL INJURY. ONLY A TRAINED DOOR SYSTEMS TECHNICIAN

SHOULD ADJUST THEM, BY CAREFULLY FOLLOWING THE MANUFAC-

TURER’S INSTRUCTIONS.

OPERATING YOUR GARAGE DOOR…

Before you begin, read all warning labels affixed to the door and the installation instructions and owner’s manual. When correctly installed, your Wayne-Dalton door will operate smoothly.

Always operate your door with controlled movements. Do not slam your door or throw your door into the open position, this may cause damage to the door or its components. If your door has an electric opener, refer to the owner’s manual to disconnect the opener before performing manual door operation below.

Manual door operation:

For additional information on manual garage door operations go to

www.dasma.com and reference TDS 165.

IMPORTANT: DO NOT PLACE FINGERS OR HANDS INTO SECTION JOINTS WHEN OPENING

AND/OR CLOSING A DOOR. ALWAYS USE LIFT HANDLES / SUITABLE GRIPPING POINTS

WHEN OPERATING THE DOOR MANUALLY.

Opening a Door: Make sure the lock(s) are in the unlocked position. Lift the door by using the lift handles / suitable gripping points only. Door should open with little resistance.

Closing a Door: From inside the garage, pull door downward using lift handles / gripping point only or a high friction area only. If you are unable to reach the lift handles/ suitable gripping points only, use pull down rope affixed to the side of door. Door should close completely with little resistance.

Using an electric operator:

IMPORTANT: PULL DOWN ROPES MUST BE REMOVED AND LOCKS MUST BE REMOVED OR

MADE INOPERATIVE IN THE UNLOCKED POSITION.

When connecting a drawbar (trolley type) garage door operator to this door, an drawbar operator and or drawbar operator bracket must be securely attached to the top section of the door, along with any struts provided with the door. Always use the drawbar operator and

15

NEVER REMOVE, ADJUST, OR LOOSEN THE BOLTS, SCREWS AND/OR

LAG SCREWS ON THE COUNTERBALANCE (END OR CENTER BEARING

BRACKETS) SYSTEM OR BOTTOM CORNER BRACKETS OF THE DOOR.

THESE BRACKETS ARE CONNECTED TO THE SPRING(S) AND ARE UNDER

EXTREME TENSION. TO AVOID POSSIBLE SEVERE OR FATAL INJURY,

HAVE ANY SUCH WORK PERFORMED BY A TRAINED DOOR SYSTEMS

TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.

TorqueMaster

Plus Springs: Pawl knob(s) (located on the TorqueMaster

end brackets above the door) should be engaged to prevent the door from rapidly descending in case of spring failure or forceful manual operation.

Torsion Springs: The torsion springs (located above the door) should only be adjusted by a trained door systems technician. DO NOT attempt to repair or adjust torsion springs yourself.

Extension Springs: A restraining cable or other device should be installed on the extension spring (located above the horizontal tracks) to help contain the spring if it breaks.

2. Door Balance: Periodically test the balance of your door. If you have a garage door drawbar operator, use the release mechanism so you can operate the door by hand when doing this test. Start with the door in the fully closed position. Lift the door to check its balance.

Adjust TorqueMaster

or Extension spring(s), if door lifts by itself (hard to pull down) or if door is difficult to lift (easy to pull down). DO NOT attempt to repair or adjust Torsion Springs yourself. To adjust TorqueMaster

or Extension spring(s), refer to your installation instructions and owner’s manual. If in question about any of the procedures, do not perform the work.

Instead, have it adjusted by a trained door systems technician.

Warranty

Limited Warranty

Models 8000, 8100 and 8200

Wayne Dalton, a division of Overhead Door Corporation (“Seller”) warrants to the original purchaser of the Models 8000, 8100, 8200 (“Product”), subject to all of the terms and conditions hereof, that the Product and all components thereof will be free from defects in materials and workmanship for the following period(s) of time, measured from the date of installation:

TEN (10) YEARS from the date of installation against:

• The Product becoming inoperable due to rust - through of the steel skin from the core of the Product 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.

• Peeling of the original paint as a result of a defect in the original paint or in the application of the original paint coating.

TEN (10) YEARS on Product hardware and tracks (except springs).

ONE (1) YEAR on all other component and parts.

Seller’s obligation under this warranty is specifically limited to repairing or replacing, at its option, any part which is determined by Seller to be defective during the applicable warranty period. Any labor charges are excluded and will be the responsibility of the purchaser.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. This warranty is made to the original purchaser of the Product only, and is not transferable or assignable. This warranty applies only to Product installed in a residential or other non-commercial application. It does not cover any Product installed in commercial or industrial building applications. This warranty does not apply to any unauthorized alteration or repair of the Product, or to any Product or component which has been damaged or deteriorated due to misuse, neglect, accident, failure to provide necessary maintenance, normal wear and tear, acts of God, or any other cause beyond the reasonable control of Seller or as a result of having been exposed to toxic or abrasive environments, including blowing sand, salt water, salt spray and toxic chemicals and fumes.

ALL EXPRESS AND IMPLIED WARRANTIES FOR THE PRODUCT, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS

FOR A PARTICULAR PURPOSE, ARE LIMITED IN TIME TO THE APPLICABLE WARRANTY PERIOD REFLECTED ABOVE. NO WARRANTIES, WHETHER EXPRESS OR IMPLIED,

WILL APPLY AFTER THE LIMITED WARRANTY PERIOD HAS EXPIRED. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

IN NO EVENT SHALL SELLER BE RESPONSIBLE FOR, OR LIABLE TO ANYONE FOR, SPECIAL, INDIRECT, COLLATERAL, PUNITIVE, INCIDENTAL OR CONSEQUENTIAL

DAMAGES, even if Seller has been advised of the possibility of such damages. Such excluded damages include, but are not limited to, loss of use, cost of any substitute product, or other similar indirect financial loss. 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.

Claims under this warranty must be made promptly after discovery, within the applicable warranty period, and in writing to the authorized distributor or installer whose name and address appear below. The purchaser must allow Seller a reasonable opportunity to inspect any Product claimed to be defective prior to removal or any alteration of its condition. Proof of the purchase and/or installation date, and identification as the original purchaser, may be required. There are no established informal dispute resolution procedures of the type described in the Magnuson-Moss Warranty Act.

• SELLER: _______________________________________________________________________

• SELLER’S ADDRESS: _______________________________________________________________________

_______________________________________________________________________

16 Thank you for your purchase.

PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE

Please Do Not Return This Product To The Store. Please call 1-866-569-3799 (Press Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have.

AFTER INSTALLATION IS COMPLETE, FASTEN THIS

MANUAL NEAR GARAGE DOOR FOR EASY REFERENCE.

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Key features

Step-by-step installation instructions
Important safety instructions
Tools required for installation
Door section identification
Removing an existing door
Preparing the opening
Parts breakdown
Optional installation features
Maintenance tips
Warranty information

Frequently asked questions

The minimum side clearance required, from the opening to the wall, is 3-1/2” (89 mm).

The headroom requirement 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.

Quick Install track systems are designed for faster, easier installation using tabs and slots, while Fully Adjustable track systems allow for more precise alignment and adjustments using track bolts and nuts.

Refer to the Strut Schedule in the installation instructions, which determines the placement of the struts based on your door width and height.

The distance between the step plate and the middle of the lift handle must be 20” minimum to 30” maximum.

E s

l

MH

T a b l e O f C o n t e n t s

PLEASE DO NOT RETURN THIS PRODUCT

TO THE STORE

Please Do Not Return This Product To The

Store. Please call 1-866-569-3799 (Press

Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have.

IMPORTANT NOTICES!

Wayne Dalton highly recommends that you read and fully understand the Installation Instructions and Owner’s Manual before you attempt this installation.

To avoid possible injury, read the enclosed instructions carefully before installing and operating the garage door. Pay close attention to all warnings and notes. After installation is complete, fasten this manual near garage door for easy reference.

DEFINITION OF DOOR HEIGHTS:

1. Door Heights less than or equal to 8’0” (< = 8’0”) are considered

Standard Lift Applications.

Pre-Installation

Important Safety Instructions

Tools Required

Package Contents

2

Removing an Existing Door

Door Section Identification

3

Preparing the Opening

4

PARTS BREAKDOWN

5

INSTALLATION

Quick Install Flag Angles

Fully Adjustable Flag Angles

Horizontal Track Angles

Quick Install Jamb Brackets

6

Fully Adjustable Jamb Brackets

Graduated Hinge Attachment

Strut (U-shaped)

Top Fixtures

7

Cable Drum Assemblies and Track Rollers

Step Plate

Lift Handle

8

Bottom Section

Stacking Sections

Vertical Tracks

Top Section

9

Horizontal Tracks

Adjusting Top Fixtures

Rear Back Hangs

10

11

Attaching Front Cable Lift Sheaves

Attaching Extension Springs

Attaching Spring Sheaves

12

Final Adjustments

Cable Adjustments

13

Optional Installation

Inside Lock

Pull Down Rope

14

Maintenance

Cleaning Your Garage Door

Painting Your Garage Door

Maintaining The Finish

On Your Garage Door

Operation And Maintenance

15

Warranty

Limited Warranty

Models 8000, 8100 and 8200

16

Thank you for your purchase.

PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE

Please Do Not Return This Product To The Store. Please call 1-866-569-3799 (Press Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have.

AFTER INSTALLATION IS COMPLETE, FASTEN THIS

MANUAL NEAR GARAGE DOOR FOR EASY REFERENCE.

What is the minimum side clearance required for the door?